A new generation of air-to-air heat exchangers: Ecoonex and Jansen are setting new standards in efficiency, corrosion protection and operational reliability with their innovative PolyMore technology.
The next generation of air-to-air (flue gas – flue gas) heat exchangers: an innovative development by Ecoonex and Jansen
The optimisation of industrial combustion plants and refineries faces a twofold challenge today: maximising heat recovery to reduce CO₂ emissions whilst simultaneously providing protection against aggressive dew point corrosion.
A close development partnership between the Dutch technology company Ecoonex B.V. and the Swiss profile specialist Jansen AG has resulted in a groundbreaking solution: a bespoke multi-chamber profile made from the high-performance material PolyMore, which serves as the core component in modern air preheaters (APH).
The challenge at the ‘cold end’
At the cold air inlet of industrial air preheaters, the surfaces of the heat exchanger cool down so much that gaseous acids condense into liquid form. In conventional metal structures, this condensation leads to severe corrosion and costly, unplanned downtime within a very short time.
Previous solutions, such as the use of air-water heat exchangers (combined circulation systems), are structurally complex. They require additional pipework, pumps and intermediate media, which increases the complexity of the system and leads to additional heat loss and maintenance risks (leaks).
The technological breakthrough: Direct air-to-air design made from PolyMore
Ecoonex’s innovative system concept for a highly efficient air-to-air heat exchanger offering maximum corrosion resistance, combined with Jansen’s in-depth expertise in materials and geometry, has resulted in a bespoke PolyMore system solution.
The four pillars of PolyMore profile technology
The joint material and design development by Ecoonex and Jansen combines four key physical and chemical advantages that make this air-to-air system so unique:
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Extreme resistance to damage: Unlike many conventional engineering plastics or brittle protective coatings, PolyMore is extremely durable and boasts high material toughness. It withstands mechanical stress with ease and is therefore resistant to sudden temperature changes. This virtually eliminates the risk of invisible hairline cracks, which can form in brittle materials as a result of component movement or cleaning cycles and lead to catastrophic leaks.
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Chemical resistance: Highly resistant to sulphuric acid (H₂SO₄), hydrofluoric acid (HF), hydrochloric acid (HCl) and ammonium bisulphate (ABS). This is what makes it possible to operate right in the heart of the condensation zone, where metallic materials would fail within a very short time.
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High temperature resistance: Despite its flexible and corrosion-resistant properties, the PolyMore multi-chamber profile is designed to withstand flue gas temperatures of up to 280 °C, thereby offering considerable thermal safety margins during operation.
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Intelligent hybrid design: In the systems installed, the flexible PolyMore profile is positioned precisely in the critical, cold section at the cold air inlet. The hot section, which is subject to higher thermal loads but is corrosion-free, continues to be constructed from metal. This combination of materials ensures the optimal balance between maximum mechanical strength and uncompromising corrosion protection.
A wide range of applications in industrial practice
The jointly developed system demonstrates its strengths wherever highly corrosive gases, aggressive vapours or humid exhaust air streams push conventional metal structures to their limits. As a highly efficient air-to-air heat exchanger and robust air preheater (APH), PolyMore technology caters to a wide range of demanding industrial sectors.
Typical applications include thermal drying processes in the chemical and pharmaceutical industries, protection against acid condensation in conventional acid plants, and intensive exhaust air purification and heat recovery in electroplating and powder coating facilities. The system also ensures permanently maintenance-free operation in demanding drying applications in battery production, material recovery in recycling plants, and the utilisation of hydrogen process exhaust gases.
Even in harsh environments, such as tunnel exhaust air or sewage sludge heat recovery, the innovative profile design ensures maximum energy efficiency and reliable corrosion protection right at the heart of the condensation zone.
Collaborative engineering put to the test
The most recent practical application of the air-to-air heat exchanger demonstrates the precise operation of the entire system. All performance targets were met immediately. Furthermore, the ease of installation and commissioning of the new system design has left a lasting impression on everyone involved in the project, making this concept the clear favourite for future installations. Thanks to the precise performance data, operators can control the target parameters with pinpoint accuracy. This ensures maximum efficiency and an optimal reduction in CO₂ emissions.
Are you looking for a turnkey, corrosion-free heat exchanger solution for your combustion plant?
Find out more about the PolyMore systems directly from our partner Ecoonex.
Do you have your own product idea, or do you need bespoke profiles made from innovative plastics?
Get in touch with the team of experts at Jansen AG. Together, we’ll develop the solution for tomorrow.
