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We can supply three types of Air to Air Heat Exchangers:

  • Aluminium Air to Air Plate Heat Exchangers
  • Thermal Wheels
  • High Temperature Industrial Air to Air Heat Exchangers

Aluminium Air to Air Plate Heat Exchangers

Air to Air Plate Heat Exchangers, or Air Plates as they are also known, are an extremely effective and low-cost way of reducing the heating or cooling loads on the treatment of process air and air conditioning systems.

A reduced heating or cooling load means lower energy bills and carbon emissions.

Air Plates use the exhaust air to pre-heat or pre-cool the incoming supply air, without the two air streams ever mixing. The box-like construction of the heat exchanger is supplied with flanges that can be drilled through for connecting to adjacent ductwork or are suitable to be slid into an enclosure.

Applications:

  • Heat recovery from exhaust air for space heating for factories, offices and warehouses.
  • Pre-heating/cooling of incoming air for air-conditioning units using exhaust warm/cool air.
  • De-humidification of air streams.
  • Electrical equipment cooling.

Efficiency

Energy recovery can be as high as 85%, depending upon operating conditions.

Plate Types:

Corrugated plate surface types, for high efficiency and energy recovery.

Smooth surface plate types that can be easily cleaned for dirty air streams.

Cross-flow models for good efficiency (typical 50-60%) and low pressure drops.

Counter-flow type for high efficiency (typical 75-85%).

Materials

Aluminium - non-corrosive air streams - max 200c.

Epoxy coated aluminium - adds protection to the aluminium for air streams containing salts / chlorine.

Stainless steel - for ultimate corrosion protection - max 230c.

Thermal Wheels

Thermal Wheels are installed across hot and cold air ducts. As the Thermal Wheel rotates, the extended surface is heated by the hot air stream. When the rotation passes through the cold air duct, the wheel cools down, thereby transferring heat.

The following sizes are available:

 One Piece Diameter 500 mm to 2500 mm Air flows up to 50,000 m³/hr
 Segmented Diameter 1200 to 3800 mm Air flows up to 120,000 m³/hr

Applications Include:

  • Heat recovery
  • De-humidification of air streams

Features:

  • Higher efficiency than air plates
  • Take up less space than air plates - particularly for very large air flows
  • Max operating temperature of 60C
  • Up to 90% Efficiency depending on operating conditions
  • Removable access panels available

Rotor Materials:

  • Aluminium
  • Epoxy coated aluminium
  • Aluminium with Hygroscopic surface

High Temperature Air To Air Heat Exchangers

(a) Stainless Steel Plate Type Exchangers - Uninsulated

Applications include:

  • Oven Heat Recovery
  • Combustion Air Pre-heating
  • Fume Pre-heating
  • Catalytic Oxidisers
  • Process air cooling
  • Indirect process air heaters
  • Thermal oxidisers
  • Spray Dryers

Features:

  • Various grade stainless steels and exotic alloys available with fully welded design
  • Robust construction
  • Max operating temperature of 650C
  • Up to 70% Efficiency
  • Removable access panels available

(b) Stainless Steel Plate Type Exchangers - Insulated

Features:

  • All the features of the fully welded stainless steel plate type - with fully insulated casing

(c) Tubular Air to Air Exchangers

Applications include:

  • Oven Heat Recovery
  • Combustion Air Pre-heating
  • Fume Pre-heating
  • Catalytic Oxidisers
  • Process air cooling
  • Indirect process air heaters
  • Thermal oxidisers

Features:

  • Various grade stainless steels and exotic alloys available with fully welded design
  • Robust construction
  • Max operating temperature of 870C
  • Ideal for dusty / particulate environments as less susceptible to blocking
  • More resistance to corrosion than plate design
  • Removable access panels available
  • Insulation options available
  • Design incorporates internal thermal expansion

Counterflow Air-to-Air Plate Heatexchangers

The typical operating range for the counterflow plate heatexchanger (CPH) is where the ordinary crossflow plate heatexchanger would not bring sufficient efficiency - or become ridiculous large - and the rotating heatexchanger would either be too expensive, not airtight enough and/or not achieve targeted temperature exchange.

The PCF exchanger is a metal counterflow plate heatexchanger that is manufactured in a high spec. aluminum allowing a dry efficiency easily exceeding >80% under ordinary conditions - and >90% calculated under conditions with enhanced condensation.

Ordinary air volumes for not exceeding 150 Pa pressure drop in a single pass exchanger with a width of 1600mm ranges up to 5000 m3/h (~1.400 l/s). However, you may easily double or triple this (or more) by making multi pass arrangements or just by extending the width of the unit or allowing higher pressure drops.

Do note, that when coming up in larger air volumes you will reach a breaking point where you may consider the rotating heatexchanger as the more economical choice, compared at similar pressure drops.

As a summary you may conclude:

  • Higher temperature efficiency than both crossflow plate and rotating heatexchangers at similar pressure drop
  • More economical than rotating heat exchangers at lower air volumes (trusted breaking point between 5- and 10.000 m3/h)
  • Less cross contamination than with a rotating heatexchanger
  • All advantages of metal vs. plastic heat exchangers



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