Air-to-air heat exchanger

Type 1
Type 1C
Type 1P
Type 1S
Type 2 diagonal
Type 3

Double and triple

Large heat exhangers

Flue gas scrubbing

Supply air pre-heating

Mine shaft ventilation heating

Maintenance

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GUPEX Limited
Northpoint House,  52 High Street,  Knaphill
Woking,  Surrey GU21 2PY,  U.K.
Tel, office: +44 1483 799333
Mob, dir: +44 7771 745084           
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Industrial air-to-air heat exchangers

- 25 years of recovering energy from corrosive and dusty exhaust gasses

GUPEX air-to-air (gas/gas) crossflow plate heat exchanger for heat recovery  from wet aggressive industrial exhaust air made in corrosion resistant composite GUPEX® air-to-air crossflow heat exchangers, made of glass fiber reinforced plastic, are increasingly cost effective with the escalation of energy prices. Designed for heat recovery from polluted, moist and corrosive air and gas emissions and humid flue gas as as well as heat recovery from low to medium temperature air, which is a substantial energy area largely ignored up until now. Retro–fitting of air-to-air waste heat recovery and heat exchanger batteries in industrial processes has never been more cost effective.

GUPEX® air to air (gas to gas) plate heat exchanger unit are designed for exhaust air handling in dusty and humid environments without air filters to protect them from clogging up the plates. The GUPEX® technology is used for recovering heat and energy from many harsh, corrosive, wet, dusty and polluted industrial air and gas processes and environments, including:

 

 

Zinc plating air heat recovery
Combustion exhaust gas heat exchanger
Mining air extract heaters
Air-to-air heat recovery metallurgical processes
Exhaust gas scrubber processes
Exhaust air heat recovery from galvanizing process
Mine ventilation supply air heaters 
Welding workshop air-to-air extraction heat recovery 
Food processing humid air/air heater system 
Heat recovery - combustion air preheater 
Paper Factory ventilation pre-heater
Moist flue gas HVAC exhaust air energy recovery
Energy efficient dehumidification
Exhaust gas purification (wet scrubbing)
Spray drying heat recovery
Flue gas heat recovery

 


TYPE 1  Air-to-air heat exchanger

Plate module, fiberglass reinforced polyesterGUPEX® air-to-air (gas/gas) heat exchanger plate module made of corrosion resistant composite material

Type G1  Air-to-air (gas to gas) heat exchanger

Air plate module only, designed for connecting to, and building into an air handling and air duct system.  Low to medium temperature.

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material (plastic) which gives it a long economic life with low maintenance cost even under wet, corrosive or very hostile air conditions.  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

TECHNICAL DATA
Model GUPEX type 1
Type Plate type, air-to-air (gas-to-gas) crossflow
Material Glass fibre reinforced composite 
Width 250-5000 mm - depending on air flow volume
Height 1450 mm 
Depth 1450 mm
Plate size 1400x1400 mm
Thickness of plates Approx 1 mm
Plate distance Approx 15 mm
Pressure drop 150 Pa (at nominal air volume)

 


TYPE 1C  Air-to-air plate heat exchanger

Plate module, with sandwich foam core polyesterCasing for GUPEX® air-to-air (gas/gas) crossflow plate heat exchanger made of corrosion resistant composite material with composite side walls walls

Type G1  Air-to-air (gas to gas) heat exchanger

Air-to-air plate module with polyester sandwich walls, thermally insulated, designed for connecting to, and building into an air handling system. low to medium temperature.

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under humid, dusty and very hostile air conditions.  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

Casing walls are thermally insulating, directing the energy exactly where it is needed.

TECHNICAL DATA
Model GUPEX type 1C
Type Plate type, air-to-air (gas-to-gas) crossflow
Plate Material Glass fibre reinforced polyester 
Casing Material Polyester sandwich core foam with laminated glassfibre layers on both sides 
Width 250-5000 mm - depending on air flow volume
Height 1500 mm 
Depth 1500 mm
Plate size 1400x1400 mm
Thickness of plates Approx 1 mm
Plate distance Approx 15 mm
Pressure drop 150 Pa (at nominal air volume)

 


Type 1P   Gas-to-gas in industrial processes

Vinylester plate module in vinyl ester casingGUPEX® air-to-air (gas/gas) crossflow plate heat exchanger made of corrosion resistant vinylester composite material with vinylester casing and solid flanges

Type G1P  Gas-to-gas (air-to-air) heat exchanger

Heat exchanger plates and casing made of vinyl ester to operate in  and process gases up to 140°C. Can be used for combustion air preheating.

This heat exchanger has solid laminated flanges on every opening for connection into a gas and air process flow.   Low and medium temperature.

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under very hostile (moist, condensing, dusty) air conditions  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

TECHNICAL DATA
Model GUPEX type 1P
Type Plate type, air-to-air (gas-to-gas) crossflow
Material Glass fibre reinforced vinylester 
Width 250-5000 mm - depending on air flow volume
Height 1600 mm (approx.) excluding flanges
Depth 1600 mm (approx.) excluding flanges
Plate size 1400x1400 mm
Thickness of plates Approx 1 mm
Plate distance Approx 15 mm
Pressure drop 150 Pa (at nominal air volume)

 


Type 1S   Gas-to-gas heat exchanger for ventilation and flue gas heat recovery

Polyester plate module in galvanized steel casingGUPEX® air-to-air (gas/gas) crossflow plate heat exchanger made of corrosion resistant composite material with galvanized steel side panels and steel frame

Type G1S  Gas-to-gas (air-to-air) heat exchanger

Air/air heat exchanger plates and casing made of polyester to operate in wet, corrosive air flows with high concentration of particles and dust. 

The heat exchanger has air openings made of solid galvanized steel and with galvanized steel sheet side panels. 

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under very hostile air conditions.  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

TECHNICAL DATA
Model GUPEX type 1S
Type Plate type, air-to-air (gas-to-gas), crossflow
Plate Material Glass fibre reinforced vinylester 
Casing Material Galvanized steel
Width 250-5000 mm - depending on air flow volume
Height 1500 mm (approx.) excluding flanges
Depth 1500 mm (approx.) excluding flanges
Plate size 1400x1400 mm
Thickness of plates Approx 1 mm
Plate distance Approx 15 mm
Pressure drop 150 Pa (at nominal air volume)

 


TYPE 2  Diagonal air to air crossflow heat exchanger

Fiberglass reinforced polyester plates - diagonal configuration Diagonal air to air (gas/gas) composite glass fibre reinforced plate heat exchanger for corrosive and dusty air

Type G2  Air to air (gas to gas) heat exchanger.  Both gas or air stream enters into a plenum which has tapered walls defined by the diagonal walls of heat exchanger casing.  The air flows diagonally at an angle through the plates of the heat exchanger.

Diagonal plate heat exchangers may be advantageous in many plant layouts to minimize the number of bends in the air ducts and reduce the overall pressure drop and installation cost.  Low to medium temperature.

 

TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under very hostile air conditions like wet and condensing air containing particles and dust.  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

TECHNICAL DATA
Model GUPEX type 2
Type Plate type, air-to-air (gas-to-gas) crossflow
Material Glass fibre reinforced polyester 
Width 250-5000 mm - depending on air flow volume
Height 2000 mm 
Depth 2000 mm
Plate size 1400x1400 mm
Thickness of plates Approx 1 mm
Plate distance Approx 15 mm
Pressure drop 200 Pa (at nominal air volume)

 


TYPE 3  Air-to-air heat exchanger with two plenums

Air to air crossflow plate heat exchanger in fiberglass reinforced polyesterGlass fibre reinforced composite air to air crossflow plate heat exchanger for heat and energy recovery from dusty polluted and corrosive air flows with top and lower plenum

GUPEX® model 3  Air-to-air (gas to gas) heat exchanger.

Built for the most most extreme air atmosphere conditions, offering the advantages of low weight, high mechanical strength, high thermal insulation and high resistance to corrosive air and gas atmospheres. The surface finish of the air or gas heat transfer plates is smooth and easy to clean, making the heat exchanger practically maintenance free. 

The GUPEX® 3 type air heat exchanger body is supplied with plenums with large inspection doors for easy inspection and cleaning. The heat exchanger casing is made of insulated polyester sandwich material, limiting heat loss. The casing can also be made of other materials as an option. 

Any moisture condensing inside can automatically be drained away from a dedicated drain point at the lowest point in the lower plenum. 

 

 

GUPEX® type 3 air to air heat exchanger variant without top plenumGUPEX glass fibre reinforced composite gas-to-gas (air air) crossflow plate heat exchanger for heat and energy recovery from dusty polluted and corrosive air flows

Where ducting is not required and the air is being emitted straight to the atmosphere the GUPEX® type 3 air/air heat exchanger can be built without a top plenum.  This is less expensive and reduces pressure drop.

 

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under very hostile air conditions.  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

TECHNICAL DATA
Model GUPEX type 3
Type Plate type, air-to-air (gas-to-gas) crossflow
Material Glass fibre reinforced polyester 
Width 250-5000 mm - depending on air flow volume
Height 2900 mm 
Depth 1450 mm
Plate size 1400x1400 mm
Thickness of plates Approx 1 mm
Plate distance Approx 15 mm
Pressure drop 150 Pa (at nominal air volume)

 


Double and triple gas-to-gas heat exchangers

Double air-to-air plate heat exchangers for extra heat recovery3-step air/air heat exchanger for added heat recovery

Double configurations are chosen for when a higher degree of heat recovery is desired. or when there is a big difference between the hot and cold air flow volumes.  The overall thermal efficiency is higher when the hot and cold air is exchanged twice (or even three times).

With the GUPEX® air-to-air heat exchanger design you are totally flexible with regards to the positioning of the air and gas ducts. 

 

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under very hostile air conditions.   Double air/air heat exchanger in corrosion resistant composite material

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa at nominal air volumes excluding the air plenums.

 

 

 

 

 

TECHNICAL DATA
Model Based on GUPEX type 2 or 3 
Type Plate type, crossflow, air-to-air (gas-to-gas)
Material Glass fiber reinforced vinyl ester 
Casing Material Composite sandwich core construction
Width to fit the required design
Height to fit the required design
Depth to fit the required design
Plate size 1400x1400 mm
Thickness of plates Approx 1 mm
Plate distance Approx 15 mm
Pressure drop 150Pa through each plate module;
overall figure individually calculated

 


GUPEX gas-to-gas plate heat exchangers in gas scrubbing processes

Crossflow type fiberglass reinforced polyester air air heat exchanger

GUPEX gas/gas  heat exchanger in corrosive scrubbing processes The GUPEX® gas to gas plate heat exchangers are designed for medium-range temperature areas of flue gasses e.g coal fired power station processes. The air/air (gas gas) plate heat exchanger is a viable alternative to the rotating heat exchangers. And with no moving parts and with its excellent chemical resistance the plate heat exchanger improves efficiency and pay-back time and reduce the cost.

Untreated flue gas enters at 100 - 150°C and is cooled down to 70 - 100°C, which is below the acid dew point. The clean gas enters saturated with moisture at 45 - 50°C and is re-heated to typically 75 - 90°C to give the outlet gas the buoyancy required to lift it through the chimney. The flue gas at this stage typically contain fly ash, condensing acid, water with a high chlorine content, unbleached limestone, remnants of SO2 and SO3 etc. The use of a corrosion resistant high temperature resistant specialty composite plate heat exchanger can remove the need for large rotating heat exchangers which typically are made of coated or enameled steel.

GUPEX® gas-to-gas plate heat exchanger in FGD process

Since the GUPEX® gas to gas plate heat exchanger has no moving parts there will be no air leakage  caused by the design of the heat exchanger, so no cross contamination of gas flows will occur.

The GUPEX® gas to gas plate heat exchangers are scaleable to suit air and gas volumes from flue gasses in coal fired power stations (up to more than one  million m³ per hour, or more than 1 million CFM).

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under very wet and hostile air conditions.  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

 


Pre-heating of the supply air to drying processes

Hot exhaust air to pre-heat combustion (burner) airGUPEX heat exchanger for flue gas heat recovery to preheat combustion air in drying processes

Most drying processes use heat and air to remove moisture from a process.

The moisture is absorbed by the hot air. 

The hot and moist (and extremely energy-rich!) exhaust air is removed through exhaust gas ducts and chimneys and out into the atmosphere.

Very efficient drying indeed!  

Or is it?

Many companies are blowing tens of thousands of kWh of energy per year straight into the air.  

For example recovery of 100 kW of heat from exhaust air operating for 6000 hours per year will with an energy price of say, $0.02 per kWh, be equivalent to a loss of $12,000 per year.

This is a totally preventable loss.   With the installation of a GUPEX® exhaust gas-to-gas heat exchanger the cold supply air to the combustion process will be pre-heated directly by the outgoing exhaust gas.  And when the cold supply air is pre-heated this way, less energy is required to heat it further up the air to the required drying process.

 

KEY TECHNICAL POINTS  

Long Life:  GUPEX® air-to-air heat exchanger is made of corrosion resistant composite material which gives it a long economic life with low maintenance cost even under very hostile medium range temperature air conditions.  

Large plate distance:  A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

Low pressure drop:  A great advantage of the GUPEX® heat exchanger is very low pressure drop, only approx. 150 Pa excluding air chambers at nominal air volumes.  Low pressure drop reduces investment cost and saves energy.

 


Underground mine air pre-heating:  Heating the Supply Air to Deep Mine Ventilation Shafts

Frost-free mines: Air-to-air plate heat exchangers as pre-heaters of supply air to underground mine ventilation system.

Mine ventilation air heater system using heat from the energy-rich and moist mine extraction airIn arctic and other cold regions of the world (apart from deep mines where the mining horizon is above the permafrost) the supply air through the mines must be pre-heated prior to entry via the shaft, ventilation raise or adit during the frosty winter periods.  Air heating is typically done with large heater units or blowers burning propane, diesel, natural gas or oil, all of which consume large amounts of energy and add CO2 to the atmosphere. In addition, air-to-liquid fluid heat exchangers are sometimes used to recover some of the heat from the mine extract air but these installations have a very low inherent thermal efficiency since the exchange air-to-liquid has to take place twice.

The GUPEX® air-to-air crossflow plate heat exchanger, instead of a conventional mine heater, is a very cost-effective method of pre-heating the supply air to the mine shaft.  The incoming cold supply air is heated directly by the warm and moist mine extract air which contains vast amount of energy (which otherwise would be wasted) in a large plate heat exchanger with no moving parts.

The heat exchanger unit is built as part of the mine ventilation system to the required air flow, which can be up to several million m³/h (1m+ cfm), constructed with a housing connected to the air ducts and fan units.  Thousands of kW heat power is constantly transferred from the extract air to the cold supply air, saving large amounts of alternative energy used by combustion heater units.

The purpose of a mine ventilation shaft heater system is to raise the temperature of the mine intake air entering the decline portal to 2°C during the winter months. The basis for using a mine heater for keeping the air above freezing is to:

  • Prevent the mine services from freezing including compressed air (condensation), mine water and water discharge;
  • Keep decline roads and stopes free from ice;
  • Improve ergonomics and reduce cold related stress.

Gupex supply complete mine air pre-heater systems with heat exchanger unit, housing, ductwork, extract and supply air fan units, engineering and commissioning. 

These large GUPEX® heat exchangers are made of corrosion resistant material which withstand corrosion caused by condensing extracted mine air.  The heat exchanger plates are designed to give low pressure drop to minimize energy consumption of the fan units.

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Maintenance of GUPEX air-to-air heat exchanger

Rugged Design

GUPEX air-to-air heat exchanger systemsThe glass fibre reinforced plastic plates are so robust and mechanically strong that personnel can walk on the edges on top of the plates whilst inspecting, jet or steam spraying, scrubbing and washing and hosing the plates according to requirements.

The GUPEX plates are made of solid GRP which resists most corrosive and erosive air and gas flows. GUPEX therefore provide many years of operation where regular equipment replacements are the norm. 

When the the heat exchanger housing is included in our supply we provide suitable access openings for inspection maintenance and cleaning of the the plate section.
GUPEX air/air heat exchangers for heat energy recovery in corrosive environments

A 14mm gap between the heat conductive plates enable handling of very dusty air and particles without getting blocked. Air filters are therefore normally not needed.  If required, cleaning of plates is a very simple to carry out by e.g. water flushing.  

 

 

 

 

 

 

 


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