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Direct Contact Heat Exchanger Design & Manufacture

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Maximise thermal efficiency and latent heat recovery with high-performance direct contact solutions. Graham Hart Process Technology engineers bespoke direct contact condensers and coolers designed for gas-to-liquid heat transfer in challenging, dust-laden environments.

Direct Contact Heat Exchangers and Condensers

By eliminating the physical barrier between fluids, Direct Contact Heat Exchangers and Condensers achieve superior heat transfer coefficients and closer temperature approaches than traditional surface exchangers. They are the ideal solution for recovering latent heat from gas streams and handling processes where fouling or dust contamination would compromise shell and tube designs.

Manufacturing of High-Integrity Heat Exchangers
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What is a Direct Contact Heat Exchanger?

A direct contact heat exchanger facilitates heat transfer by bringing two immiscible fluids (typically a hot gas and a cool liquid) into direct physical contact. Without the resistance of a tube wall, energy is exchanged through droplets, films, or sprays. This method is particularly effective for condensing water vapour from hot gas streams using water or oil as the cooling medium.

When should you use a Direct Contact Condenser?

Direct contact condensers are preferred when high efficiency and low capital cost are priorities, and where the two fluids can be safely mixed. They are uniquely suited to "dirty" gas streams because they act as a simultaneous scrubber—removing dust and particulates that would otherwise clog the narrow channels of a plate or shell and tube heat exchanger.

Technical Capabilities & Specifications

FeatureSpecification / Capability
Primary Function
Sensible cooling, vapour condensing, and latent heat recovery
Fluid Compatibility
Gas-to-liquid (water, oils, and other immiscible substances)
Contamination Handling
Integrated dust removal and tolerance for high-particulate streams
Efficiency
Ultra-close temperature approach compared to indirect exchangers
Design Codes
PD 5500, EN 13445, ASME VIII
Industries Served
CCUS, Hydrogen, Power Generation, Food & Drink, Petrochemical, and Waste-to-Energy

The Graham Hart Process Technology Difference

Many industrial processes lose significant energy through waste gas streams because traditional heat exchangers cannot handle the "triple threat" of latent heat, dust, and corrosive condensation.

At Graham Hart Process Technology, we move beyond standard fabrication to address the "Why" of thermal recovery. Our direct contact designs "unlock" the latent heat within gas streams by passing them through a precisely engineered shower of liquid. This doesn't just cool the gas; it scrubs it. By removing particulates during the heat exchange process, we provide a dual-purpose solution that protects downstream equipment while delivering best-in-class thermal efficiency.

Frequently Asked Questions

What are the main advantages of direct contact heat exchangers?

The primary advantages include significantly lower capital costs (due to simpler construction), higher heat transfer rates, and the ability to operate without the fouling or scaling risks associated with metal heat transfer surfaces. They also offer a much smaller physical footprint for the same thermal duty.

How is latent heat recovery achieved in these units?

By spraying a cool liquid directly into a hot gas stream, we induce phase changes. When water vapour in the gas condenses into the liquid spray, it releases a vast amount of latent heat that would otherwise be lost to the atmosphere, allowing it to be recycled back into the process.

Can Graham Hart Process Technology design units for corrosive gas streams?

Yes. Through our expertise in high-integrity materials and protective linings, we can engineer direct contact systems that withstand aggressive chemical environments, including those found in Carbon Capture (CCUS) and flue gas treatment.

Optimise Your Heat Recovery

Request a Technical Quote or Contact Our Thermal Engineers

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