The opportunity
A metal-finishing plant exhausted 18,000 m3/h of 160C air from curing ovens to atmosphere – pure lost energy. The brief was to recover it for winter make-up air heating and preheat a process water loop.
The solution
- A high-temperature plate air-to-air exchanger (stainless, rated to 200C+) transferred exhaust heat to incoming fresh air.
- A secondary air-to-water coil pulled surplus heat into the water buffer.
- Fouling-prone exhaust demanded a cleanable core and a maintenance plan from our cleaning guide.
Results
- Recovered ~520 kWth at peak.
- Gas boiler load cut ~35% in winter.
- Payback: 2.8 years.
Lessons
Capture heat in grade order – high-grade first (process water), low-grade last (ventilation). Match the core material to exhaust temperature and contaminants. See waste-heat recovery basics および standards overview before specifying.
Why capture at the source
The plant curing ovens rejected 160C air continuously, a high-grade, high-volume stream far more valuable than typical ventilation exhaust. Recovering it at the source, before it mixes with cooler building air, maximizes the temperature lift available to the incoming make-up air and the process-water loop. This grade-first logic is the backbone of any waste-heat strategy.
Material and contamination matching
At 160C and with curing by-products, a standard aluminum core would not survive. The stainless, high-temperature-rated plate exchanger was selected specifically for the exhaust condition, and the fouling-prone nature of the stream dictated a cleanable core plus a maintenance plan. Matching material and cleanability to the exhaust is what keeps the 520 kWth recovery stable year after year.
From one oven to a program
A single successful project often reveals more opportunities. The same approach, measure the stream, grade it, pick a core rated for the temperature and contaminants, then verify savings, scales to other process exhausts across the site. Tracking recovered energy against the boiler baseline proves the case for the next project and supports any efficiency-reporting requirement.
よくある質問
What did the industrial case recover?
About 520 kWth at peak from 18,000 cubic metres per hour of 160C oven exhaust, cutting boiler load about 35 percent in winter.
Why specify a stainless plate exchanger?
The exhaust at 160C and above, with curing by-products, needs a high-temperature-rated, cleanable material. Standard aluminum would not survive.
What was the payback?
About 2.8 years. The lesson is to capture high-grade heat first and match the core to the exhaust conditions.
How do I replicate this result?
Measure the stream, grade the heat, select a core rated for the temperature and contaminants, plan cleaning, and verify against the boiler baseline.
よくある質問
What did the industrial case recover?
About 520 kWth at peak from 18,000 cubic metres per hour of 160C oven exhaust, cutting boiler load about 35 percent in winter.
Why specify a stainless plate exchanger?
The exhaust at 160C and above, with curing by-products, needs a high-temperature-rated, cleanable material. Standard aluminum would not survive.
What was the payback?
About 2.8 years. The lesson is to capture high-grade heat first and match the core to the exhaust conditions.
How do I replicate this result?
Measure the stream, grade the heat, select a core rated for the temperature and contaminants, plan cleaning, and verify against the boiler baseline.
適切な熱交換器を選定
当社のエンジニアが風量、温度、圧力損失の予算に合わせてコアを設計し、用途に応じて板式・回転式・ヒートパイプ回収を選定します。以下をお読みください： 熱交換器ガイド 、または仕様についてお問い合わせください。
関連製品
HVAC および換気向けの板式・回転式・ヒートパイプ回収。
空気と液体用の大表面積固定コア。
大風量向け高効率エネルギー回収。
清浄用途向けの受動的・完全分離流。