{"id":1137,"date":"2026-04-24T08:08:56","date_gmt":"2026-04-24T08:08:56","guid":{"rendered":"https:\/\/rtooxidizer.com\/?post_type=product&p=1137"},"modified":"2026-04-24T09:49:15","modified_gmt":"2026-04-24T09:49:15","slug":"gas-to-gas-heat-exchanger","status":"publish","type":"product","link":"https:\/\/rtooxidizer.com\/ta\/product\/gas-to-gas-heat-exchanger\/","title":{"rendered":"Gas-to-Gas Heat Exchanger"},"content":{"rendered":"
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Gas-to-Gas Heat Exchanger (GGH) \u2014 Fully-Welded Inflated Plate Design<\/p>\n

Built for Australian FGD systems, power plants and heavy industrial stacks. Corrosion-resistant, compact, and engineered to eliminate plume whitening while recovering flue-gas heat.<\/p>\n<\/div>\n

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\"Ever-power<\/div>\n
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What Is a Gas-to-Gas Heat Exchanger?<\/h2>\n

A gas to gas heat exchanger (commonly written as GGH) is a closed-loop thermal device that transfers heat from one flue-gas stream to another without mixing them. In a wet flue-gas desulfurisation (FGD) system, the GGH reheats the saturated, de-sulfurised flue gas using the heat of the raw, untreated flue gas upstream of the scrubber.<\/p>\n

The result: the stack plume disappears, downstream ductwork stays dry, and up to 8\u201312 % of waste flue-gas energy is returned to the process.<\/p>\n<\/div>\n<\/div>\n

How the Ever-power Inflated-Plate GGH Works<\/h2>\n

Instead of traditional shell-and-tube banks, the Ever-power GGH uses an inflated (pillow) plate pack<\/strong>. Each plate is produced by laser-welding two thin stainless sheets in a patterned grid, then hydro-forming the assembly under high pressure so that the unwelded zones bulge into a 3D honeycomb channel.<\/p>\n

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1. Hot-Side Flow<\/h3>\n

Raw flue gas (120\u2013180 \u00b0C) enters the hot side and releases sensible heat to the plate pack as it cools toward scrubber inlet temperature.<\/p>\n<\/div>\n

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2. Cold-Side Reheating<\/h3>\n

Saturated scrubbed gas (~50 \u00b0C) flows on the opposite side, absorbs the recovered heat and leaves the stack 20\u201335 \u00b0C warmer \u2014 enough to lift the plume above dew point.<\/p>\n<\/div>\n

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3. Self-Cleaning Geometry<\/h3>\n

Smooth pillow-plate surfaces and tuned plate spacing (typically 12\u201325 mm) resist fly-ash bridging and make sonic or steam soot-blowing highly effective.<\/p>\n<\/div>\n<\/div>\n

Key Advantages Over Tubular GGH and Rotary Regenerators<\/h2>\n
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Parameter<\/th>\nEver-power Inflated Plate GGH<\/th>\nTubular \/ Rotary Alternatives<\/th>\n<\/tr>\n<\/thead>\n
Heat-transfer coefficient<\/strong><\/td>\n45\u201375 W\/m\u00b2\u00b7K<\/td>\n20\u201335 W\/m\u00b2\u00b7K<\/td>\n<\/tr>\n
Footprint (same duty)<\/strong><\/td>\n40\u201355 % smaller<\/td>\nBaseline<\/td>\n<\/tr>\n
Cross-side leakage<\/strong><\/td>\nZero (fully welded, no seals)<\/td>\n1\u20135 % (rotary seals)<\/td>\n<\/tr>\n
Acid dew point defence<\/strong><\/td>\n316L \/ 2205 \/ C-276 cladding on cold end<\/td>\nOften glass-enamel or rubber lining<\/td>\n<\/tr>\n
Pressure drop<\/strong><\/td>\n600\u20131,200 Pa<\/td>\n1,200\u20132,500 Pa<\/td>\n<\/tr>\n
Maintenance cycle<\/strong><\/td>\nOnline soot-blowing; 3\u20135 yr overhaul<\/td>\nAnnual seal replacement<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Technical Specifications<\/h2>\n
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Item<\/th>\nStandard Range<\/th>\nCustom Option<\/th>\n<\/tr>\n<\/thead>\n
Gas flow capacity<\/td>\n5,000 \u2013 2,000,000 m3\/h<\/td>\nUp to 3.5 million m3\/h<\/td>\n<\/tr>\n
Design temperature<\/td>\nup to 350 \u00b0C<\/td>\nup to 550 \u00b0C (Inconel)<\/td>\n<\/tr>\n
Design pressure<\/td>\n-5 to +10 kPa (g)<\/td>\nup to 0.6 MPa<\/td>\n<\/tr>\n
Plate material<\/td>\n304 \/ 316L \/ 2205<\/td>\nC-276 \/ Inconel 625 \/ ND steel<\/td>\n<\/tr>\n
Plate thickness<\/td>\n1.0 \/ 1.2 \/ 1.5 mm<\/td>\n2.0 mm for high-ash streams<\/td>\n<\/tr>\n
Plate spacing<\/td>\n12 \/ 18 \/ 25 mm<\/td>\n30 mm for heavy fly-ash<\/td>\n<\/tr>\n
Heat recovery efficiency<\/td>\n75 \u2013 88 %<\/td>\nOptimised per duty sheet<\/td>\n<\/tr>\n
Applicable standards<\/td>\nAS 1210, ASME VIII Div.1<\/td>\nPED 2014\/68\/EU, GB 150<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Typical Applications in Australian Industry<\/h2>\n
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Coal & Biomass Power<\/h3>\n

Wet-FGD plume abatement and stack reheating at coastal power stations in NSW and QLD.<\/p>\n<\/div>\n

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Cement & Lime<\/h3>\n

Pre-heater tower flue-gas heat recovery for mills in Western Australia.<\/p>\n<\/div>\n

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Waste-to-Energy<\/h3>\n

Downstream of scrubbers in EfW plants to reheat cleaned gas above acid dew point.<\/p>\n<\/div>\n

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Petrochemical & Refining<\/h3>\n

SRU tail-gas reheating and FCC flue-gas energy recovery.<\/p>\n<\/div>\n

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Non-Ferrous Smelting<\/h3>\n

Copper, lead and zinc smelter stack conditioning for compliance with NEPM air-quality limits.<\/p>\n<\/div>\n

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Hazardous Waste Treatment<\/h3>\n

Integration with RTO and incinerator trains \u2014 see our complete thermal oxidation line-up<\/a>.<\/p>\n<\/div>\n<\/div>\n

Why Choose Ever-power<\/h2>\n
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\u25b6 18+ Years of Heat-Transfer Engineering<\/h3>\n

Over 600 GGH units delivered across Asia-Pacific, including turnkey scope to AS, ASME and PED codes.<\/p>\n<\/div>\n

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\u25b6 In-House Laser-Welding Lines<\/h3>\n

Four automated laser stations produce weld seams of consistent penetration \u2014 no sub-contracting, full traceability per heat number.<\/p>\n<\/div>\n

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\u25b6 CFD-Verified Thermal Design<\/h3>\n

Every GGH is simulated for flow distribution, temperature mapping and dust deposition before fabrication begins.<\/p>\n<\/div>\n

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\u25b6 Australian Compliance Ready<\/h3>\n

Design packages include AS 1210 calculations, WorkSafe-compliant lifting lugs, and documentation for local WTIA-certified site welding.<\/p>\n<\/div>\n

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\u25b6 Lifetime Technical Support<\/h3>\n

Remote performance audits, spare-plate stocking in Sydney, and a 24-month performance warranty. Learn more on our company profile<\/a>.<\/p>\n<\/div>\n

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\u25b6 Corrosion Allowance Engineered by Zone<\/h3>\n

Cold-end plates upgraded to 2205 duplex or C-276; hot-end optimised for cost. No one-material-fits-all shortcuts.<\/p>\n<\/div>\n<\/div>\n<\/div>\n

Australian Project Reference<\/h2>\n
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Hunter Valley Power Utility \u2014 2 \u00d7 660 MW Units<\/h3>\n

Challenge:<\/strong> Visible white plume after wet-FGD retrofit; community complaints and EPA attention.<\/p>\n

Ever-power Scope:<\/strong> Two parallel inflated-plate GGH modules, 1,850,000 m3\/h each, 2205 duplex cold-end plates, built to AS 1210 Cl. 3.<\/p>\n

Result:<\/strong> Stack plume eliminated at ambient temperatures above 5 \u00b0C; 34 \u00b0C reheating achieved; payback period under 2.1 years from recovered flue-gas energy and avoided social-licence costs.<\/p>\n<\/div>\n

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Melbourne Hazardous-Waste Treatment Centre<\/h3>\n

Challenge:<\/strong> Acid dew-point corrosion shortened previous tubular exchanger life to 14 months.<\/p>\n

Ever-power Scope:<\/strong> Compact GGH with Hastelloy C-276 cold-section pillow plates and online sonic soot-blowers.<\/p>\n

Result:<\/strong> Five-year continuous run with zero plate perforation; maintenance spend down 72 %.<\/p>\n<\/div>\n

Frequently Asked Questions<\/h2>\n
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Q1. How does a gas to gas heat exchanger differ from a rotary regenerator?<\/h3>\n

A rotary regenerator transfers heat through a rotating matrix and always has 1\u20135 % cross-leakage through seals. A fully-welded plate GGH has zero leakage because hot and cold sides are permanently sealed by laser-welded plate edges \u2014 critical where treated and untreated flue gas must not mix.<\/p>\n<\/div>\n

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Q2. What reheating temperature rise can I realistically expect?<\/h3>\n

For typical wet-FGD exit conditions (50 \u00b0C saturated) and raw flue gas of 130\u2013160 \u00b0C, Ever-power GGH units deliver 25\u201340 \u00b0C reheating \u2014 generally sufficient to defeat plume visibility above 0 \u00b0C ambient.<\/p>\n<\/div>\n

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Q3. How do you prevent low-temperature acid dew-point corrosion?<\/h3>\n

Three mechanisms: (1) selection of 2205 duplex, 904L or C-276 on the cold end, (2) controlled plate spacing and gas velocity to keep wall temperature above local acid dew point, and (3) condensate drain channels moulded into the pillow-plate geometry.<\/p>\n<\/div>\n

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Q4. What is the lead time for an Australian project?<\/h3>\n

Typical: 14\u201318 weeks from approved drawings to ex-works, plus 4\u20136 weeks sea freight to Sydney, Melbourne or Fremantle. Expedited production available for emergency replacements.<\/p>\n<\/div>\n

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Q5. Can the GGH be retrofitted into an existing duct layout?<\/h3>\n

Yes. Because the plate pack is 40\u201355 % smaller than an equivalent tubular exchanger, most retrofits require only local duct modifications. We supply laser-scan site surveys for Australian sites on request.<\/p>\n<\/div>\n

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Q6. Is online cleaning possible without shutdown?<\/h3>\n

Yes \u2014 we integrate steam soot-blowers, sonic horns, or low-pressure water washers depending on fly-ash characteristics. Cleaning cycles are typically programmed every 8\u201324 hours.<\/p>\n<\/div>\n

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Q7. What documentation do I receive at delivery?<\/h3>\n

Full QA\/QC dossier: material certificates (EN 10204 3.1 \/ 3.2), weld maps, PMI reports, hydro-test certificates, thermal-performance datasheet, and installation\/O&M manual in English.<\/p>\n<\/div>\n

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Request a No-Obligation GGH Sizing Study<\/h2>\n

Send us your flue-gas composition, flow and temperature profile. Within 48 hours you will receive a preliminary heat-transfer sizing, budget price and delivery schedule \u2014 backed by 18 years of inflated-plate engineering.<\/p>\n

\ud83d\udce7 sales@rtooxidizer.com<\/a>
\nContact Our Engineers \u25b6<\/a><\/p>\n<\/div>\n