Today, the rapid and continuous rise in heat amounts from chips renders traditional air-conditioning systems inadequate. Tempco BPHE brazed plate heat exchangers—also available in an all-stainless-steel version—are the technological heart of this shift to liquid cooling; they act as a key technological enabler that brings sustainability to data centers by reducing PUE (Power Usage Effectiveness) while simultaneously allowing for increased rack density.

The superior performance of liquid cooling stems primarily from the fact that liquids are more efficient than air at transferring heat, allowing for more effective heat dissipation and lower energy consumption for the same amounts of heat removed. This makes it possible to reliably manage the higher power densities typical of AI and HPC applications—delivering high performance in a more eco-friendly manner. Furthermore, liquid cooling allows for highly targeted and precise cooling, as liquids are easier to direct toward specific components than air. The cooling ecosystem is completed by free-cooling systems and chillers located outside the data center; these dissipate the heat extracted from the servers and conveyed outdoors via the BPHE exchangers.

Tempco supplies brazed plate heat exchangers (BPHEs) for data center liquid cooling, offering models and versions suitable for every type of liquid cooling method, regardless of the system architecture. Their highly compact design allows for easy integration into the Coolant Distribution Units (CDUs) found in liquid cooling systems, thereby saving space within the installation. Tempco’s process expertise and capability to manufacture integrated solutions—such as complete skid systems—offer a further advantage to data center manufacturers and operators, enabling the creation of compact, comprehensive solutions that are easy to install and integrate into computing infrastructures.

Tempco’s brazed plate exchangers are suitable for use in both cold plates and immersion cooling systems—the two main liquid cooling methods used in data centers. The product range covers a wide power spectrum, offering models from 5 to 200 kW for in-rack CDUs and units capable of handling 500 kW to 3 MW for stand-alone in-row CDUs.

Tempco’s range of brazed plate heat exchangers includes models designed for Direct-to-Chip (DTC) liquid cooling architectures that utilize cold plates. Cold plates technology employs conductive metal plates applied directly to high-power electronic components, such as GPUs and CPUs. The generated heat is absorbed by a coolant circulating through microchannel structures within the cold plates. In this liquid cooling system, the CDU acts as a hydraulic safety barrier: here, the overheated fluid arriving from the cold plates flows to the BPHE; once cooled, it is recirculated into the loop, remaining isolated from the external cooling water circuit (free cooler, chiller, and evaporative towers) and thereby protecting the IT equipment from potential contamination.

Tempco offers brazed plate heat exchangers for CDUs in liquid cooling solutions using cold plates for both “in-rack” architectures—where the exchangers’ compact size allows for easy CDU integration within server cabinets—and “in-row” setups, featuring standalone CDU cabinets separate from individual IT racks that can serve up to 10 servers simultaneously.

The product range also includes brazed plate heat exchangers (BPHEs) for immersion liquid cooling solutions. Unlike cold plates—which are applied directly to high-power chips and components, typically requiring hybrid solutions that rely on air cooling for other parts of the computing infrastructure—immersion liquid cooling involves submerging all hardware in dedicated tanks containing special dielectric fluids. This ensures uniform cooling across all components, thereby eliminating hot spots.

Finally, whether used with cold plates or immersion cooling,Tempco offers brazed plate exchangers optimized for single-phase liquid cooling systems, where the coolant (often a water-glycol mixture) remains in the liquid phase throughout the thermal cycle, as well as for two-phase cooling systems, where the coolant boils upon contact with the cold plate or the overheated servers. This two-phase approach offers superior cooling efficiency, making it ideal for high workloads and ultra-high-density racks; however, it requires a more complex cooling circuit to manage evaporation phases and ensure precise pressure and temperature control.

L'articolo Brazed plate heat exchangers for liquid cooling: high-efficiency computing density in data centers proviene da Tempco Blog.

In a previous post, we explored the challenges and solutions regarding temperature control in ATEX environments, focusing on the design of safe and efficient thermoregulation units. As previously mentioned, one of the most effective strategies for optimizing temperature control in these applications is to separate the control panel from the hazardous area by installing it in a safe zone. This configuration offers numerous advantages in terms of safety, reliability, and operational management.

Dual-configuration approach: ATEX TCU + Remote control
To ensure optimal temperature control in explosive hazard zones, temperature control units (TCUs) are frequently designed as two separate units:

• The TCU itself, installed within the ATEX area
• A remote control panel, positioned in a safe zone

This solution eliminates the need for complex electronic devices within the ATEX area, thereby reducing the risk of failure and simplifying maintenance.

The dual-configuration solution therefore comprises several key components:

1. Temperature Control Unit (TCU) in the ATEX zone
   The unit installed in the ATEX zone houses all components involved in the temperature control process, designed with appropriate protection measures:
   • Heat exchangers and thermal circuits constructed using materials and configurations compliant with ATEX standards.
   • Explosion-proof electric heating elements.
   • Intrinsically safe certified temperature sensors (PT100, thermocouples).
   • Actuators and valves with Ex d or Ex i protection for thermal flow control.
   • Special shielded and insulated wiring to prevent overheating and leakage.
2. Control panel in the safe zone
   The heart of the temperature control system is located in a non-hazardous area, allowing for the implementation of advanced electronics without ATEX constraints:• Industrial PLC for temperature management featuring advanced PID control.
   • Touchscreen HMI for monitoring and manually adjusting TCU parameters.
   • Data logging and reporting capabilities for thermal performance analysis.
   • Remote management via connection to SCADA or cloud systems.

Image showing a temperature control unit (TCU); for ATEX zone installations, a dual configuration with a separate control panel in a safe zone allows for the use of advanced electronics to ensure maximum efficiency and reliability.

L'articolo ATEX zone TCU temperature control units, maximum efficiency with control panel in safe area proviene da Tempco Blog.

Brazed plate heat exchangers consist of stainless steel plates joined via copper or nickel brazing. They offer maximum heat transfer efficiency within a compact footprint, making them ideal for heat transfer where space is limited. Furthermore, the brazing process creates a plate pack with superior mechanical strength, enabling operation at higher pressures and across wider temperature ranges.

Immediate availability applies to models with standard connections and ports up to 2″. By focusing on the most common sizes and configurations, Tempco can respond promptly to urgent needs, replacement requests, and equipment downtime. In such situations, the quick delivery of a heat exchanger makes the difference between getting a system back up and running immediately vs suffering costly shutdowns.

Let’s discuss your needs
If you have a system to complete, a machine that is down, or wish to get ahead of market price increases, please contact us with the required size and connection specifications; we will check immediate availability and shipping times together.

L'articolo Brazed plate heat exchangers: when immediate availability makes the difference proviene da Tempco Blog.

For a TCU (Temperature Control Unit), this entails rapid temperature ramps, continuous thermal shocks, and fluctuations in heat transfer fluid volume. In such cases, sizing based on standard rules is no more effective. A practical example is the design of the expansion vessel: in these chemical and pharmaceutical applications, the fluid undergoes massive expansion as temperatures shift from -15°C to over 140°C.

For instance, a theoretical calculation based on standard parameters suggested a 1.800-liter tank for a particular customer application; however, by analyzing the fluid’s actual transient dynamics, we optimized the size it to just 1.000 liters.

The result was impressive: a 44% space saving on the skid while maintaining maximum safety, even during the most extreme thermal peaks.

L'articolo Design upon ‘batch’: thermal duty changes the rules in pharma proviene da Tempco Blog.

In this specific case, the immersion plate heat exchanger arrays have been installed in the equalization tank, which receives the wastewater generated by the parboiling process—consisting primarily of water used to soak the paddy rice. The purpose of the custom immersion plate heat exchanger is to recover heat from the wastewater, yielding a dual benefit: first, the recovered heat preheats well water circulating within the plates to the highest possible temperature, resulting in significant energy savings by reducing steam consumption. Second, the heat transfer process cools the wastewater before it is sent to the purification plant, providing a substantial advantage for the biological treatment processes taking place there.

The system was implemented as custom and in retrofit, utilizing existing structures within the client’s equalization tank. Specifically, the existing agitators were leveraged to maintain a fluid velocity of ≥0.1 m/s, generating turbulence that enhances heat transfer efficiency. Furthermore, the immersion heat exchanger arrays were installed by anchoring them to decommissioned aeration pipes (2.0 x 2.6 m).

Overall, the system will enable significant energy savings for the client, recovering approximately 174 kW of heat (150,000 kcal/h) and saving 1,500–1,700 tonnes of steam per year. Material selection for the heat exchanger plates was also critical; AISI 316L stainless steel was chosen to ensure corrosion resistance (handling wastewater with a pH of 3.7–3.9 with no critical chloride levels). Fouling caused by starches in the wastewater was accounted for using a conservative fouling factor (4E-4 m²K/W). Finally, given the intermittent nature of the wastewater flow—process wastewater is discharged every two hours, though a minimum volume is always maintained in the tank—performance was calculated at 70% of the theoretical maximum to determine the system’s ROI.

L'articolo Wastewater heat recovery with custom immersion plate heat exchangers proviene da Tempco Blog.

A natural question arises: why not feed utility fluids (glycol, water, steam) directly into the reactor jacket? While this might seem like the simplest approach, for glass-lined reactors, it would be a perfect recipe for disaster. Glass linings are highly sensitive to sudden temperature fluctuations; injecting steam at 8 bar immediately after glycol at -15°C risks causing catastrophic cracking.

The solution lies in the adoption of the mono-fluid temperature control concept across an extended range: a single heat-transfer fluid circulates continuously within the jacket’s closed loop, while three utility fluids (glycol at -15° C, industrial water at 25° C, and steam at 8 bar) condition its temperature outside the reactor itself.

The resulting advantage is clear: the intermediate fluid acts as a thermal buffer, ensuring excellent temperature uniformity across the vessel wall, thermoregulation precision within a tenth of a degree, and the elimination of thermal shock to the glass lining.

L'articolo One fluid, many temperatures: how to regulate the temperature of a glass-lined reactor proviene da Tempco Blog.

In fact, as indicated in the documentation, just five of the listed data are necessary and sufficient: the ‘must-have’ data – essential for initiating the sizing process- are those required for the thermal calculation:

• Primary fluid inlet and outlet temperatures
• Primary fluid flow rate
• Secondary fluid inlet and outlet temperatures
• Secondary fluid flow rate
• Fluid pressure (crucial in the case of gases)

Capacity is another important factor for the thermal sizing of the exchanger; however, if the other five data are available, capacity can be calculated from them.

The other data listed under the heading “DATA FOR HEAT EXCHANGERS DESIGN AND CONSTRUCTION” are useful for a more precise and comprehensive design but are not essential for an initial thermal calculation:

• Fluid types
• Max. operating temperature
• Max. operating pressure
• Oversizing % (margin)
• Allowable pressure drops (primary and secondary)
• Fluid viscosity
• Fluid specific weight
• Heat transfer coefficient
• Fouling factor

In summary, to begin the sizing process, it is essential to provide at least five of the listed thermal parameters – including pressure if a gas is involved. The remaining data help refine the unit’s design specifications but are not required at the initial stage. It is important to note that for special fluids, you must contact Tempco directly, as specified in the document.

FIVE FINGERS RULE

L'articolo Five key data for heat exchangers sizing proviene da Tempco Blog.

There are applications involving aggressive cooling fluids or corrosive environments where standard copper tubing simply isn’t enough. Stainless steel coils are required to ensure durability and reliability, even under harsh conditions. In other instances, requirements are dictated by construction codes – such as ASME compliance – which are essential for systems destined for regulated sectors or markets where a certain certification is a mandatory requirement.

These are concrete examples of how dry coolers can be transformed into unique units, engineered to meet highly specific needs. This is precisely where Tempco’s philosophy comes into play: offering solutions that go beyond mere cooling to support the client, addressing specific requirements through a ‘tailor made’ approach.

A dry cooler, therefore, is never just a dry cooler. It can become a critical component for reliability, safety, and process performance when designed using materials and standards suited to its actual operating environment.

L'articolo Custom dry coolers: stainless steel, ASME, and bespoke solutions for critical processes proviene da Tempco Blog.

Temperature control units for use in food and beverage production lines must therefore meet stringent requirements in terms of materials and design, ensuring hygienic design of equipments. Thanks to an audit conducted by a notified body for the certification of the internal components of our TREG temperature control units, Tempco is therefore now able to provide IP55-certified temperature control units. The IP55 certification of a component specifically indicates the level of protection a device provides against the ingress of dust and liquids.

This is further important addition to Tempco’s range of temperature control solutions for the food and beverage industry, where it already boasts a wide range of important and interesting applications, from chocolate processing to pasta, candies and sweets, milk, wine, and beer, to name just a few. The ability to offer internal components for our TCU specifically designed with IP55 protection, to meet the needs of the food and beverage market which requires the ability to wash down equipment with water jets, therefore opens up a wide variety of new application opportunities for Tempco, to even better meet the temperature control needs of the food industry.

L'articolo IP55-certified temperature control units for food & beverage proviene da Tempco Blog.

A preventive check before summer is therefore essential to ensure production continuity, consistent performance, and controlled energy consumption.

A system that is not properly checked can encounter a series of interconnected problems during the summer months:

• Reduced cooling capacity, making it impossible to maintain the required process conditions
• Increased energy consumption, as the system operates unpredictably to compensate for inefficiencies
• Alarms and sudden shutdowns, often during peak production periods
• Loss of downstream process efficiency, with consequences for quality and productivity

To safely handle summer loads, a suitable best practice is to plan a systematic system check in advance. The main points to check are the followings:

Cleanliness and condition of heat exchangers. Heat transfer surfaces must be clean and free of deposits or fouling. Even a thin layer of fouling can significantly reduce the overall heat transfer coefficient (U), degrading the unit’s rated performance. The check must include both the process and service sides.

Water circuit and water quality. Pipe scaling, localized corrosion, and deterioration of cooling water quality are among the most common causes of problems during the summer season. It’s important to check the pH, hardness, and concentration of any inhibitors, as well as verify proper circulation within the circuits.

Ventilation and condensation components. In dry coolers and evaporative cooling towers, the condensation section is the first to be affected by high external temperatures. Checking that the fans are working properly, that the fins are clean, and that there are no obstructions to the airflow is essential to avoid compromising the unit’s capacity.

General functional check. The inspection must be completed with a comprehensive functional check: calibration of temperature and pressure controls, condition of control components, alarm management, and verification of the correct operating sequence under peak conditions.

Preventive maintenance conducted before summer allows for the identification and resolution of critical issues while there is still time to do so, avoiding emergency interventions during peak production periods.

L'articolo Cooling systems: what to check before summer to avoid machines downtime proviene da Tempco Blog.