Energy recovery Heat Exchangers
Energy Recovery
Energy recovery is now a central theme in the design of HVAC and industrial systems. While previously driven mainly by economic considerations, today it represents a concrete response to European regulatory requirements and, increasingly, a choice of environmental and ethical responsibility.
DBM has long been committed to energy recovery, actively working in both HVAC applications, through high-efficiency twin-coil/run-around systems and heat pipes, and in industrial applications, recovering heat from combustion flue gases or process exhaust air.
Energy recovery systems for HVAC
DBM designs and supplies high-efficiency twin-coil/run-around (RAC) systems that not only meet but often exceed European requirements for air handling units (AHUs) set by Directive 2009/125/EC (ErP) and Regulation (EU) 1253/2014. This regulation requires all bidirectional ventilation units (BVUs) to include a heat recovery system with a thermal bypass and variable-speed fans (VSD).
For RAC systems, minimum thermal efficiency thresholds are defined as:
From January 1, 2016 → ηₜ ≥ 63%
From January 1, 2018 → ηₜ ≥ 68%
Efficiencies are determined according to EN 308:2022, the reference standard for air-to-air heat recovery, while classification and performance declaration within AHUs follow UNI EN 13053:2022.
Tailored thermal management solutions for HVAC Energy Recovery
Achieving — and exceeding — ErP-required efficiency levels requires specific geometries, high-efficiency counterflow configurations, and dedicated selection software capable of optimizing fluid flow, balancing heat transfer, pressure drops, and flow regimes. Generic designs or standard configurations cannot guarantee the performance required by modern high-efficiency HVAC systems or full compliance with ErP.
DBM engineering and innovation for
high-efficiency systems
High-efficiency run-around battery systems
Economizers and flue gas heat recovery
Energy recovery from flue gases presents design challenges very different from HVAC applications. The gases often reach temperatures up to 450 °C and can be corrosive or contaminated, with particularly severe operating conditions.
Key challenges include proper fouling factor assessment, material selection for corrosion and high-temperature resistance, mechanical design to manage thermal stress and expansion, and compliance with PED 2014/68/EU, often applicable to higher risk categories (Cat. III or IV).
Tailored thermal management solutions for flue gas recovery
Over the years, DBM has designed, tested, and built hundreds of economizers with design temperatures up to 450 °C and operating pressures up to 110 bar(g), guaranteeing certified performance and full operational safety.
Depending on the operating temperature and required materials, we provide finned-tube, smooth-tube, or enhanced-tube heat exchangers, ensuring planned energy recovery, maximum operational reliability, and compliance with PED 2014/68/EU or other local regulations.
Mechanical design can be performed according to major international codes—including ASME VIII Div.1/2, VSR Collections, EN 13445, AD2000, and CODAP—with FEM analysis for complex structural verification if required. Quality control includes all standard production checks and Non-Destructive Testing (NDT) prescribed by the applicable code or client requirements.
DBM engineering and innovation for
high-efficiency systems
Finned-tube heat exchangers
Smooth-tube heat exchangers
Enhanced-tube heat exchangers
Quality and performance for every requirement
DBM thermal management solutions can be fully customized to meet the specific needs of any facility and operating condition, ensuring maximum efficiency and real energy savings.
Product and Process Certifications
Certification AHRI 410
Certification ISO 9001
DBM selection software
Every detail—from materials to brazing/welding procedures—is designed for maximum reliability. Correct thermal and mechanical sizing, combined with high-quality manufacturing and rigorous testing, ensures consistent performance and long service life.
DBM provides an advanced proprietary thermal sizing software free of charge. It performs fast, reliable thermofluid calculations using high-performance algorithms and the most advanced correlations from technical literature. Available as both stand-alone software and DLL library, it makes heat exchanger selection intuitive, precise, and seamlessly integrated into HVAC system design workflows.
DBM: your technical partner for
high-performance systems
Since 1981, DBM has been a trusted partner for reliable, high-performing, and sustainable HVAC solutions, combining engineering precision, efficiency, and continuous service.
Every DBM heat exchanger follows a fully integrated and controlled process:
01.
Thermal and mechanical design in co-engineering with the client
02.
Automated production using cutting-edge technologies
03.
Quality control at every production stage
04.
Laboratory testing in our in-house R&D center and wind tunnel
05.
Final testing and verification of compliance with sector standards (PED, AHRI 410, or other requirements)
Engineering and innovation for more efficient, reliable systems
and long-term air quality.