Tempco Blog articles

Safety devices and alarms on thermoregulation units

20/06/2025

I wanted to close our video series dedicated to Tempco thermoregulating units with a new one dedicated to the safety systems on thermoregulation units. Thermoregulation units are a sort of boilers equipped with electric heating and a cooling section. These are in fact a quite simple kind of machines. They have very few components, heating electrical resistors, a circulation pump for water and typically a heat exchanger for the cooling task.

These components are very simple, and so are these units overall, and they are intended for a quite simple task as well, the regulation of a certain temperature and the task to maintain it. BUT, these units must have absolute safety systems. That’s because these machines, employing electrical resistors, whether they are working with oil, water or pressurized water, these machines involve some risks, due to the fact that if the electrical heating resistors remain turned on, without a proper water circulation, the temperature rises up to very high levels. And thus the pressure rises up as well, in case of pressurized water units, and the temperature inflammability point rises, in case of units working with oil. Therefore, all of these units are equipped with hardware safety devices.

It means that for sure on heating resistors we install safety thermostats, mechanical safety thermostats or thermal fuses that must be replaced after their intervention. And these safety devices are aimed at cutting off the functioning of the unit, they turn it off, by switching off the heating resistors and the circulating pump as well.

In case of lack of water, there are pressure switches, or flow meters or level switches that can block the unit, by switching off the resistors and the pump by signaling their intervention with an alarm.This is all aimed at avoiding problems. It is therefore very important that all of these safety devices are on and properly functioning and are not tampered with or bypassed. Because otherwise they can represent a potential source of risk.

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Special Tempco shell and tube exchangers for high temperature oil

13/06/2025

For our Tempco thermoregulating units, we manufacture internally special heat exchangers for high-temperature oil. Specifically, these are shell and tube exchangers that can work at temperatures of up to 300° C.

Due to the particularity of the application, shell and tube exchangers are used because brazed plate exchangers have a working temperature limit of 200° C. There are in fact also models that can work at higher temperatures, but they have costs and limitations in terms of cleaning and fouling that would compromise their use with diathermic oil in these extreme high-temperature conditions.

L'immagine mostra uno scambiatore a fascio tubiero per olio ad alta temperatura realizzato da Tempco per le centraline di termoregolazione

To ensure full control over the construction standards and the ready availability of these special TCFT HT shell and tube exchangers for high temperature oil, we have therefore decided to bring their construction in-house, and to market them to make available to the market a device that is difficult to find when the working conditions become so extreme.

The TCFT HT exchangers exist in a full stainless steel version and with the possibility of making the casing in carbon steel. The brochure below contains all the technical characteristics of these exchangers.

L'immagine mostra la brochure tecnica degli speciali scambiatori a fascio tubiero Tempco per olio ad alta temperatura

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Exchangers in cogeneration plant operating for over ten years

06/06/2025

In the images of this post you can see a cogeneration system realized by Tempco and that has been in operation since 2014, equipped with our heat exchangers.

Cogeneration plants involve different applications for heat exchangers, as they allow to further increase the efficiency of the process. The use of heat exhangers in cogeneration starts from the pre-treatment of the biogas, an operation aimed at eliminating the impurities and humidity present in the biofuel to preserve the engine, up to the heat recovery from the exhaust fumes of the engine itself using shell and tube exchangers, maximizing the amount of thermal energy that the system can generate.

Immagine che mostra un impianto di cogenerazione installato nel 2014 con scambiatori Tempco

In this case, the Tempco exchangers work both on the jackets, with a brazed plate exchanger, and on heat recovery from exhaust fumes, with a shell and tube exchanger.

Immagine che mostra il dettaglio di uno scambiatore a fascio tubiero di Tempco installato in impianto di cogenerazione

After 11 years of work, the customer then called us requiring a replacement of the gaskets on the flanges, which had worn out over time. At the time of installation, Tempco had supplied the exchangers, while the customer preferred to rely on another supplier for the gaskets, although to be fair, these are anyway components subject to wear and therefore requiring maintenance.

Immagine delle flange in impianto di cogenerazione realizzato da Tempco con scambiatori di calore in funzione dal 2014

Overall, we can say that we are very satisfied with the successful application realized for this customer.

Immagine che mostra la targhetta dell’installazione Tempco di due scambiatori di calore su un impianto di cogenerazione

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Preventive maintenance and the importance of alarms in thermoregulation

30/05/2025

Images of ordinary maintenance of thermoregulation systems… or rather, not exactly ordinary, luckily. In this case, it is true to say that we found ourselves in front of electric heaters that had literally ‘exploded’.

L'immagine mostra un riscaldatore elettrico scoppiato, durante intervento di manutenzione su un termoregolatore

This happened because the user had committed a serious imprudence: following the intervention of the high temperature safety thermostat, he had in fact ignored the alarm ‘bypassing’ it. The alarm was caused by poor oil circulation, for reasons related to fouling of the plant.

The scarce oil circulation therefore caused the intervention of the maximum temperature thermostat. By bypassing it, the customer caused the electrical resistances to break. Fortunately, everything was resolved with a shutdown of the thermoregulator, but the imprudence could have had even more serious consequences, for example if the oil had caught fire…

L'immagine mostra il dettaglio di un riscaldatore elettrico scoppiato, durante intervento di manutenzione su un termoregolatore

Preventive maintenance, evaluation of the manufacturer’s alarms, requesting the intervention of the service or telephone assistance, would have prevented everything.

L'immagine mostra il dettaglio di una resistenza elettrica scoppiata, durante intervento di manutenzione su un termoregolatore

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PCHE heat exchangers, multi-stream solution for interstage cooling

23/05/2025

Following with the series of articles on multi-stage compressors, PCHE (Printed Circuit Heat Exchangers) heat exchangers represent a cutting-edge solution for interstage cooling, capable of managing complex flows in a compact design. Their multi-stream structure allows indeed for the integration of multiple heat flows in a single device, reducing space and complexity.

Critical advantages of PCHEs:
1. High thermal efficiency:
◦ Microstructured channels that maximize heat transfer.
◦ Reduction of energy losses.
2. Compactness:
◦ Extremely compact design, ideal for systems with limited space.
3. Resistance to extreme conditions:
◦ Designed to handle high pressures and temperatures, making them perfect for applications with hydrogen and other technical gases.
4. Versatility:
◦ Possibility of integrating multiple heat flows in a single device, reducing the number of equipment required.

L'immagine mostra la struttura a microcanali delle piastre negli scambiatori PCHE ideali per applicazioni di raffreddamento multi-stream

Microchannels pattern in the plates of PCHE heat exchangers

Disadvantages:
• High initial cost:
◦ PCHEs require a higher initial investment compared to traditional solutions.
• Clean or filtered fluids:
◦ Cleaning of microstructured channels may require specific techniques, so it is preferable to have filtered or otherwise clean fluids

Why then choose PCHEs? Despite the disadvantages, PCHE exchangers represent a strategic choice for critical applications where efficiency, compactness and resistance are essential. In particular, in the hydrogen sector, PCHEs offer a competitive advantage in terms of performance and sustainability, becoming a key technology for the energy transition.

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Revamping and corrosion protection of cooling radiators in marine installation

16/05/2025

The images of a recent replacement and revamping intervention that we carried out in Tempco for a system installed in a marine climate speak for themselves: in a marine environment, with exposure to aggressive agents, the correct protection of the radiator fin pack is crucial to ensure the necessary duration and operational reliability of the cooling system.

The photos taken before the replacement intervention show very clearly the state of serious corrosion of the radiator thermal transfer pack fins.

L'immagine mostra radiatori installati in ambiente marino con corrosione del pacco alettato

L'immagine mostra in dettaglio lo stato dei radiatori installati in ambiente marino con corrosione del pacco alettato

L'immagine mostra radiatori di raffreddamento installati in ambiente marino con corrosione del pacco alettato

L'immagine mostra il sito di installazione in ambiente marino di radiatori di raffreddamento con corrosione del pacco alettato

We therefore proceeded to replace and revamp the system, installing thermal exchange batteries with a special ELECTROFIN treatment. The ElectroFin treatment is a special anti-corrosion protective coating that is applied by electrodeposition, which ensures the correct protection of the fin pack from the aggressive agents to which the systems and equipment are exposed in a saline/marine environment.

L'immagine mostra radiatori di raffreddamento con trattamento ElectroFin per protezione dalla corrosione del pacco alettato in ambiente marino
L'immagine mostra l'intervento di sostituzione e revamping di radiatori di raffreddamento con trattamento ElectroFin per protezione dalla corrosione del pacco alettato in ambiente marino

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Safe, reliable and efficient thermoregulation in ATEX Zone

09/05/2025

Temperature control units are essential to ensure precise temperature control in industrial processes. But what happens when these unitas must be installed in ATEX classified environments, where the risk of explosive atmospheres is real? In these cases, the design must meet stringent requirements to ensure safety, reliability and operational efficiency.

There are therefore several challenges for temperature control in ATEX environments:
1. Potentially explosive atmospheres
◦ Flammable dust, gases and vapours can trigger explosions when combined with sparks or overheating.
2. Regulatory compliance
◦ The temperature control units must comply with the ATEX directives (2014/34/EU) and have adequate certifications.
3. Protection from overtemperatures and overheating
◦ The design must avoid the risk of hotspots or ignition sources.

L'immagine mostra il pannello di controllo di una centralina di termoregolazione per ambiente Atex

The key design elements in this type of temperature control unit thus involve a series of elements:
– Safe materials and cases
• Watertight stainless steel or aluminum structures to prevent accumulation of dust and gas, in any case ‘certified’.
– Intrinsically Safe control systems
• Electronics and sensors designed to operate in Ex ia (intrinsically safe) regime.
• Use of components certified for ATEX Zone 1 or Zone 2.
– Explosion-proof components
• Use of certified ATEX electrical panels.
• Wiring and connections with special sheaths and certified flame-retardant cables.

Immagine che mostra una centralina di termoregolazione Tempco per ambienti Atex a rischio esplosivo

A properly designed ATEX control unit for use in potentially explosive environments therefore offers a series of advantages:

Guaranteed safety: elimination of ignition risks.
Energy efficiency: optimization of consumption and reduction of waste.
Operational reliability: continuity of operation in critical environments.
Regulatory compliance: compliance with ATEX directives and reduced legal risks.

In conclusion, thermoregulation in ATEX environments is a challenge that requires expertise and specialized technologies. An accurate design of the control units not only ensures maximum safety, but also contributes to improving the performance and durability of industrial plants.
Are you ready to optimize temperature control in your ATEX environments? Discover Tempco solutions for industrial thermoregulation.

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Different traditional and advanced solutions for interstage cooling in compressors

02/05/2025

We continue to talk about multistage compressors, following a first article in which we illustrated the main functions and applications in the production and treatment of technical gases, such as air and hydrogen. Another key point in this type of compressors concerns interstage cooling, a fundamental component in multistage compressors to keep the temperature under control and ensure optimal performances.

There are in particular different technological solutions for interstage cooling, each with specific characteristics and advantages.

The image shows an example of a plant for the production of technical gases where the interstage cooling of the compressors can be obtained with different types of exchangers

The most traditional solutions use different types of heat exchangers:
1. Shell and tube heat exchangers:
◦ Robust and suitable for managing large volumes of gas.
◦ Limited in terms of compactness and thermal efficiency.
2. Plate heat exchangers:
◦ Compact and offering high efficiency.
◦ Less suitable for high pressure applications.

Then there are new advanced solutions, which use innovative types of PCHE exchangers:
• PCHE (Printed Circuit Heat Exchangers) or microstructured exchangers:
◦ Innovative solutions that integrate multiple thermal flows, ideal for gases such as hydrogen.

Comparing these different exchangers technologies, when designing an optimal interstage cooling system with multistage compressors, is essential to choose the most suitable solution for each industrial application.

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Innovative solutions for the Hydrogen industry, from production to storage and distribution

24/04/2025

Visitors to the fourth edition of Hydrogen Expo, in Piacenza from 21 to 23 May 2025, will be able to see firsthand the technological developments that all major suppliers of components and systems are developing for the hydrogen economy. Hydrogen is a key resource for decarbonisation and the transition to a more efficient and sustainable green industry.

Electrolysers, fuel cells and hydrogen refueling stations impose very challenging requirements, new and special for the industrial sector, which depending on the operating principle of the different technologies may involve resistance to very high pressures, high temperatures and compatibility of the materials used with corrosive fluids.

L'immagine mostra il banner di presentazione della Hydrogen Expo di Piacenza, fiera dedicata alle tecnologie per l'industria dell'idrogeno

The hydrogen molecule in particular is very small, posing an unprecedented challenge to the sealing technologies and components of systems. Several companies have developed specific technologies for hydrogen technologies in their range of solutions. For example, Parker Hannifin has developed a range of sealing solutions designed to meet the special requirements of hydrogen electrolysers and fuel cells, in particular for the reliable sealing of bipolar plates, essential components of the units responsible for the chemical reaction. Here the bipolar plates act as connecting elements between the individual cells, not only to distribute and cool the unit, but also to seal it and protect it from the external environment.

Henkel, a well-known manufacturer of industrial adhesives, has also recently launched a new range of sealing fittings, specifically designed and optimized for the sealing of threaded fittings for hydrogen, able to guarantee the safety requirements and outstanding performance in critical environments such as hydrogen systems.

A range of innovative technologies and solutions that promote the development and expansion of the hydrogen economy, ensuring efficiency, operational reliability of systems throughout the supply chain, including production, distribution, storage and use of hydrogen. The latest innovations for the hydrogen industry will therefore be the focus of to the May appointment with Hydrogen Expo in Piacenza, an event in which Microchannel Devices, Tempco’s partner for PCHE heat exchangers technology, will also participate, showing the advantages of these exhangers for hydrogen applications at the company’s stand on Pad 1, B118.

L'immagine mostra il logo di Microchannel Devices, azienda partner di Tempco che porterà in mostra scambiatori PCHE per idrogeno alla fiera Hydrogen Expo di Piacenza

Tempco offers various specific plate heat exchangers solutions for hydrogen applications, both in the process area, with special brazed plate exchangers that can withstand operating pressures of up to 140 bar – also used for CO2 -; and in the distribution of hydrogen with the innovative PCHE exchangers, obtained by diffusion bonding technology and photoetching of the plates.

These special production techniques employed for printed circuit heat exchangers allow, in particular, to obtain a monolithic heat transfer pack with very high mechanical resistance and to realize customizable layouts of the thermal transfer microcircuits. This allows for the creation of PCHE even in multistream mode, ideal for cooling different gas streams in multi-stage compressors typically used at hydrogen fuelling stations.

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Thermoregulation in carbon fiber composite materials molding

18/04/2025

Carbon fiber reinforced composite materials are a high-performance material in terms of resistance combined with lightness and ductility that is widely used in the automotive sector, especially for parts and components in supercars and motorsport, as we have already often discussed in the past.

Even in this kind of production process, temperature control is a crucial step in the molding of composite materials such as carbon fiber, for a variety of fundamental reasons:

1. Product quality: temperature directly affects the quality of the final product. A correct temperature ensures that the resin used in the composite polymerizes uniformly, avoiding defects such as air bubbles, delaminations or weak points that could compromise the structural integrity of the component.

L'immagine mostra un esempio di componente in materiale composito con fibra di carbonio, la cui produzione richiede un controllo della temperatura molto fine

2. Production cycles: precise temperature control can optimize production cycles, reducing curing times and increasing efficiency. Too low temperatures will lengthen curing times, while too high temperatures can cause material degradation.

3. Mechanical properties: the mechanical properties of the composite, such as strength and stiffness, are highly dependent on the temperature profile during the molding process. Non-uniform temperatures can lead to an uneven distribution of mechanical properties in the finished part.

4. Operational safety: maintaining a tight and precise temperature control is also a safety issue, as excessive temperatures can cause thermal degradation of the resin or even trigger dangerous exothermic reactions.

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TEMPCO researches and develops systems and solutions for cooling, heating, control temperature and heat exchange in different industrial processes.

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