Tempco Blog articles

Pressurized and atmospheric TREG thermoregulation units

Let’s keep on talking about TREG thermoregulation units. In a previous video we spoke about the different kind of fluids that are employed with TREGs. So now let’s talk about the kind of thermoregulation unit based on the kind of fluid employed. Starting with thermoregulating units that employ water. Typically it’s possible to use thermoregulating units with an atmospheric circuit or with a pressurized circuit.

The first main difference is represented by the working temperature range. Up to 90° C it’s clearly possible to use an atmospheric thermoregulation unit. Beyond 90° C, due to the boiling point, it’s necessary to use thermoregulating units with pressurized water, which means thermoregulating units with a closed and sealed circuit in order to ensure pressure resistance. As if it was a sort of pressure cooker, clearly with a series of additional safety measures, but it can be a topic for another video.

Often, pressurized water thermoregulating units are also employed because they offer an advantage, enabling to be installed at any point of the plant without respecting the heights. Let explain: an atmospheric unit, having an open hydraulic circuit, requires to have the expansion tank at the top point of the plant, otherwise, due to the principle of communicating vessels, the system would empty.

A pressurized thermoregulating unit is basically a closed and sealed circuit, then the water is put into circulation and once the air is vented from the high points of the system the unit can work without problems.

Clearly, the most appropriated thermoregulating unit can be selected based on the kind of plant. Many times, the atmospheric unit offers advantaged compared to a pressurized one. The pressurized unit, as said, offers the advantage that, once the air is vented from the circuit, the circuit is full, water is circulating and there are no further problems. But there are some industrial processes involving very complex circuits presenting various points where air pockets can form that are difficult to vent and eliminate.

In this case, an atmospheric thermoregulating unit installed at the higher point of the plant could be a winning solution, because the pump remains under the tank head, and so always fed by water, and push the water inside the plant. Possible air bubbles won’t arrive to the pump but will be directly gathered to the expansion tank or inside the water collection tank, which is installed at the higher point of the plant, and thus being automatically vented, without problems. This allows the pump to operate with no issues, especially in the start-up phase of the plant.

Sustainable and eco-friendly materials in case of accidental oil spills

On the subject of sustainable infrastructures and environmental and health protection in the event of accidental spills of diathermic oil in thermoregulation units, an alternative and very interesting product, which combines innovation and sustainability, is FoamFlex, an ecological polymer developed to prevent and eliminate pollution from oils and hydrocarbons.

Specifically, it is a reusable sponge developed by Test1 Solutions, an innovative SME owned by CDP, which in a short time is able to absorb and recover large quantities of oil, bringing a radical change towards green and sustainability in the management of oils and waste.

Tempco FoamFlex T1 Solutions spugna ecologica recupero oli

FoamFlex is a high performance oleophilic and hydrophobic sponge that is reusable after squeezing. The innovative sustainable material developed by T1 is able to absorb industrial oils, fuels and dielectric oils, and can be squeezed and recycled up to 200 times, maintaining the same performance and reducing disposal costs for industry and infrastructures by 93% and the carbon footprint by 98%, thanks to a drastic waste reduction.

The material allows the recovery of oil only, 1 kg of material absorbs up to 5.000 kg of hydrocarbons, and not water, which is captured in a percentage of less than 5%. The squeezing process is simple and fast, and can be done with both manual and automated methods. The material is compatible with all types of oils and hydrocarbons, and the recovered oil can also be classified as used oil and returned as a resource in a circular perspective. Compared to traditional oil absorption methods, FoamFlex therefore reduces the CO2 emissions by over 99%, and can be reused without generating solid waste.

Tempco FoamFlex T1 Solutions spugna ecologica recupero sversamento olio diatermico fluidi dielettrici
FoamFlex thus represents a sustainable solution to mitigate the environmental impact, for example, of thermoregulation units using diathermic oil or dielectric fluids for cooling of transformers in the event of accidental oil spills. These, if not managed correctly, in addition to being harmful to the environment, represent a potential cause of accidents at work, such as slips, fires, fumes and skin irritations. Thus offering a valuable ecological solution in terms of safety, health and protection of the environment and biodiversity.

Diverse and various applications of thermoregulating units in test benches

One of the most interesting and usual applications we deploy in Tempco of TREG thermoregulating units is on test benches. This is an interesting topic as it finds always new and different applications.

TREGs have indeed a very wide kind of applications on test benches, for example when test benches are intended for testing of automotive components such as radiators, of engine parts, or even utilities related to the automotive industry, for example pumps for water circulation or electric pumps or anyway components that are subjected to high temperature variations both due to ambient temperature and the temperature of the fluid they are working with.

Well, it is very interesting to be able to test this equipments by introducing them inside climate chambers where we vary ambient temperature. Along with the variation of ambient temperature, is also interesting to vary the temperature of the fluid that feeds these elements or that they have to work with. Clearly, we follow the temperature of the climate chamber, thus a certain ambient temperature, or even in contrast with the ambient temperature in order to evaluate and validate the behaviour of these components under variating temperature conditions.

Similarly, mechanical parts of engines are tested inducing a variation of the temperature for example of the lubricating oil, depending on different working conditions. Instead of a full engine, it’s also possible to test single components even using very wide temperature range variations, from negative value temperatures up to extremely positive temperatures, for example from -20° C up to +130° C. That’s because we can have an engine installed in a parked vehicle exposed to very cold temperatures that gets started, causing the temperature to rise until it reaches normal conditions of use. And so we have a very wide temperature variation for example for the refrigerating oil.

All of these applications can be served by thermoregulating units that accurately simulate these ambient situations and these load situations.

Chiller at -30° C for high precision cooling in pharma production

In the pharmaceutical industry, precision cooling is essential to ensure the stability of chemical reactions and the quality of the finished product. Tempco recently supplied two water-cooled chillers, designed to operate with a water/glycol solution at -30°C, to cool reactors in a new pharmaceutical production line.

This supply, completed at the end of last year and completely commissioned in January with a positive on-site test, stood out for two key factors:

  • Performance and reliability: system designed to ensure 24/7 operational continuity.
  • Reduced delivery times: design, construction and testing completed on time, allowing the customer to start production without delays.

Tempco chiller -30 C controllo termico pharma

Below are the technical characteristics of the chillers supplied:

• Process fluid: 50% inhibited water/monoethylene glycol mixture
• Operating temperature: -30°C
• Cooling capacity: 75 kW per unit
• Water condensation with plate heat exchangers
• Indoor installation, in a safe area of ​​the production site
• Power supply voltage: 400V – 3F – 50Hz

The chillers have an integrated hydraulic circuit, and each unit is supplied complete with: circulation pump, with a prevalence of 2÷2.5 bar, ensuring a stable and constant flow to the reactors; accumulation tank, to optimize thermal management and reduce temperature fluctuations; thermostatic valves, for precise control of the refrigeration regulation; AISI 304 stainless steel tanks and pipes, with stainless steel sheet insulation and cladding, to ensure durability and optimal thermal insulation.

Tempco chiller -30 C controllo termico industria farmaceutica

Tempco chiller -30 C controllo termico processi farmaceutici

Finally, there are several advantages ensured by this system created for the customer:

  • Maximum energy efficiency – thanks to water condensation and the use of high-efficiency plate exchangers.
  • Precision in temperature control – essential for the stability of pharmaceutical chemical processes.
  • Operational reliability – designed to operate continuously without interruptions.
  • Plug & play installation – thanks to the complete integration of the hydraulic part, the system was immediately put into production after testing.

Tempco chiller -30 C controllo termico pharma installazione

This supply represents another example of how Tempco is able to develop advanced solutions for industrial cooling, with high efficiency and reduced delivery times. Thanks to our experience in the pharma sector, we were able to respond promptly to the customer’s needs, ensuring a high-performance and ready-to-use system.

Special brazed plate exchangers in hydrogen applications

In recent videos we often spoke about applications of PCHE heat exchangers, printed circuit heat exchangers, for use in the hydrogen industry and thus involving high temperature levels and high pressure. These are in fact very peculiar and challenging applications.

But for this same sector it’s also possible to employ brazed plate heat exchangers, which are for sure less expensive but they also have very lower working condition limits. Anyway, they still can be a very efficient and effective solution up to certain temperature and pressure levels. Clearly, these are particular brazed plate exchangers, not copper brazed plate but nickel brazed plate or even brazed plate exchangers using a stainless steel filler. Therefore, these have no contraindications where fluids involved in the heat transfer can react to copper ions. That means there are no chemical compatibility issues.

These brazed plate exchangers can offer very good performances for quite high temperatures, 200, 300 or 400° C and some models can even be suitable for higher temperatures. But they can work at very much lower pressure levels compared to PCHE exchangers, and thus they can be employed only in certain applications where the pressure limit allows the use of these kind of brazed plate heat exchangers.

Finally, even these kind of exchangers, being fully welded, offer the advantage of a high sealing capacity, which means the advantage of being guaranteed as leaking and mixing free.

TREG thermoregulation units in automotive and EV test benches

In the automotive sector and electric vehicles production, test benches are essential for the simulation of operating conditions in order to test the resistance and performance of key components. For this type of applications, TREG thermoregulation units are therefore fundamental, as they allow to ensure a reliable thermal control, essential for obtaining precise and repeatable data in testing and simulation of the devices.

There are therefore several main applications in which TREG thermoregulating units are used on test benches in the automotive and electric car sectors, including:

1. Tests on engines and transmissions: thermoregulation units offer the possibility of managing wide temperature ranges to conduct extreme tests, carrying out simulation tests in real operating conditions for combustion engines, transmissions and engine parts.

2. Evaluation of EV batteries: TREGs are used to perform thermal control during charging/discharging processes and battery life cycle simulation. Precisely ensuring thermal stability during these tests improves data reliability and helps prevent possible component damage and failure.

3. Tests on inverters and powertrain systems: thermoregulation units are used in this context to simulate the thermal behavior of inverters in a variety of operating conditions. This allows engineers to optimize the dedicated cooling systems.


Tempco centraline termoregolazione banchi prova automotive auto elettriche

In applications for test benches on components within the automotive industry and vehicles electrification, TREG units therefore offer a series of advantages:

  • Extended thermal ranges: perfect for testing at both very low and high temperatures, from -30°C and up to +300°C
  • Operational reliability: robustness even under conditions of prolonged stress
  • Adaptability: configurable for different test bench applications
  • Configurable and adaptable interfaces for data monitoring and recording

In conclusion, TREG solutions represent a reliable technological partner for companies in the automotive and electric powertrain sectors, providing high performance supporting technological innovation in the strive to achieve maximum efficiency and reliability of different types of powertrain.

 

Dielectric fluids in data center and electronics components cooling

Dieletric fluids, what are they and what are they meant to. We have already talked recently about dielectric fluids related to the cooling of PCB immersed in fluids, also referred to as liquid cooling. These are in fact usually employed in applications of free cooling for data centers where PCBs are directly immersed in a dielectric fluid and therefore a fluid that doesn’t conduct electricity.

These same dielectric fluids are as well employed for the testing of thermoregulation and cooling systems of data centers or for other electronics components, for example in the automotive industry, or also in the production of batteries for electric vehicles, in order to evaluate the performances of these components when the temperature varies.

On a construction perspective, the employ of these fluids involve very few changes on thermoregulating units because eventually dielectric fluids are very similar to oils both for their physics and thermodynamic characteristics. Therefore, the components used in the temperature control units that use these particular fluids are also quite the same.

 

PCHE heat exchanger in offshore Oil&Gas cooling applications

Microchannel Devices, Tempco partner for PCHE exchangers, has finally officially unveiled details related to an important order for the development of a large printed circuit PCHE heat exchanger for use in the oil & gas sector.

The project represents a fundamental milestone, marking the entry of PCHE heat exchangers into applications for the offshore oil & gas sector, in addition to the various solutions already developed in the green energy and renewables sector and in particular hydrogen. After the signing of the contract at the end of last October with Rosetti Marino, for the development and production of a PCHE printed circuit exchanger intended for hydrocarbon sour gas cooling in the new gas recovery module installed on an offshore platform off the coast of Libya, Microchannel Devices is now very pleased to announce the deployment of the project and to share more details about it.

Tempco Microchannel Devices scambiatore PCHE piattaforma offshore oil and gas

Rosetti Marino is among the most important EPC operators (Engineering, procurement & construction) active in the Oil&Gas sector for oil platforms. The company was looking for a manufacturer of large PCHE exchangers who would be able to create an exchanger compliant with the stringent requirements of the ASME standard for ‘lethal’ gas applications by mid-2025.

The order got underway thanks to the commercial support of Tempco, and the intense work of the MCD team led in a few weeks to defining a PCHE concept capable of satisfying all the requirements posed by the ASME regulation as well as by the end user ENI, by Saipem (main contractor) and RINA (third party inspection body). In this regard, the great support of ICIM‘s ASME representative has been also as precious.

Tempco Microchannel Devices scambiatore PCHE di grandi dimensioni piattaforma offshore oil and gas

Rendering of the large PCHE heat exchanger for an oil & gas offshore plant

MCD is therefore working to create its first PCHE exchanger for an offshore Oil & Gas plant, which will be over 3 meters long and weigh more than 8.000 kg. The exchanger will be made up of 5 blocks of photo-etched plates, welded using diffusion bonding technology with welding seams of specific geometry, specifically designed to allow 100% control using gamma rays.

The sizing of the exchanger was supported by thermo-fluid dynamic tests on dedicated specimens. The acceptance tests will involve the ability to test a vessel capable of containing hundreds of liters of gas or water, and of managing flow rates of 200.000 litres/hour. The machining and metal-working systems that MCD acquired in 2024 proved to be perfectly suited to the order, including a cutting machine and a five-axis machining center for the mechanical processing of the blocks, both capable of working large dimension components, and a second chemical etching line which in six weeks will allow to create all of the 2.600 channeled plates necessary for the construction of the exchanger.

Hydrogen, compact and efficient PCHE heat exchangers for green mobility

We dedicate another article to illustrate the advantages offered by printed circuit PCHE heat exchangers for use in hydrogen refueling stations. As already explained previously, this innovative type of plate heat exchangers, created using a special diffusion bonding process for the thermal transfer pack and employing chemical etching for the layout of microchannels on the plates, is used in hydrogen refueling station to cool the gas in its different compression phases.

The possibility to work with extremely high pressures, up to 700 bar, guaranteeing high energy efficiency thanks to the micro-channel structure of the plates, also giving high desing freedom in order to customize the heat transfer circuits of the exchanger for specific application needs, leads to great reliability and durability of this type of exchanger. Essential characteristics in extremely challenging applications in the hydrogen industry, making it a potentially very interesting market for PCHE heat exchangers.

Tempco vantaggi scambiatori PCHE stazioni rifornimento idrogeno

Therefore, here are some other advantages that PCHE heat exchangers offer in this type of applications:

  • Compactness: their compact structure saves space, an important factor in hydrogen refuelling stations where space is limited.
  • High thermal efficiency: the microchannel configuration offers a high heat transfer surface area, improving heat transfer efficiency.
  • Versatility: PCHE heat exchangers can be used for a variety of fluids and operating conditions, making them highly adaptable to different cooling and heating needs.

In conclusion, PCHE heat exchangers are vital components in hydrogen refueling stations, helping to ensure a safe and efficient operation. Their ability to handle the heat generated during hydrogen compression, combined with their compactness and reliability, makes them a preferred choice for this application. As hydrogen infrastructure expands, the importance of this innovative technology will continue to grow, supporting the development of more sustainable and green mobility.

Strength and resistance with thermoregulation in carbon fiber production

Let’s go on with a series of videos dedicated to thermoregulation units and temperature control. Another interesting application of thermoregulating units is referred to carbon fiber production processes, or anyway carbon fiber structures.

Maybe not everyone knows it, but when a carbon fiber structure is realized it has to be ‘cooked’ inside special industrial ovens, and even if the ‘cooked’ term is not technically appropriated, this is in fact the proper function of this part of the production process. Once the carbon fiber part is molded, the chassis, a part of the car body, any kind of component made with carbon fiber is inserted in an oven in order to stabilize the resin and the structure and position of the carbon fibers, aimed at achieving the strength and the resistance levels required by the project.

These structures are then ‘cooked’ inside special dedicated ovens, that are able to reach high temperatures required to stabilize the resins. All of these ovens require some cooling systems, or anyway thermoregulating solutions. Yes, indeed, because in addition to cooling, also a thermoregulation function is required to allow the resin to reach its final stability.

Thermoregulating units are therefore employed to maintain the right process temperatures in these ovens. Furthermore, they are also required to ensure the proper final cooling: once the cooking process of the carbon fiber components inside the oven is completed, everything has to be properly cooled to return to normal ambient temperatures. Finally, there are even some processes where these units have an emergency function, and so these are aimed at cooling the oven in case there is a reaction that causes a temperature rise up, exceeding safety levels.