Gas turbines are extremely sensitive to fluid conditions, in terms of temperature, fluid density, and thermal profile stability. In many industrial applications (power generation, oil and gas, LNG, hydrogen-ready plants), precise control of gas temperature is essential to improve efficiency, reduce operational instabilities, and protect the equipment during transient conditions. This is where the Gas Turbine Performance Heater is involved.

A Gas Turbine Performance Heater is essentially a heat exchanger designed for gas preheating (air, fuel gas, process gas), with a controlled ΔT, high reliability, and often undergoing high pressure and continuous service. Typical applications include fuel gas conditioning, intake air heating, and heat recovery systems from oil/hot water/waste heat recovery circuits.

Tempco proposes PCHE exchangers as particularly suited to this role, as they offer significant key advantages over traditional shell-and-tube solutions:

• Extremely compact
• Resistance to high pressures (tens/hundreds of bar)
• Perfect thermal stability even with rapid gradients
• Minimal fluid accumulation → safety + fast response
• Channel geometry optimizable upon the actual operating point

In performance-driven turbine applications, this makes the difference.

PCHE + Turbine: a smart technical marriage
As a performance heater, the PCHE allows:

• very precise control of the inlet gas temperature
• low pressure drops (if properly designed)
• easy integration into compact skids
• reliable operation even in:
  ◦ offshore environments
  ◦ frequent start/stop cycles
  ◦ severe conditions (H₂ blend, dry gases, LNG boil-off)

When the focus is performance + reliability, the PCHE is often the most engineered choice, not just the most compact.

A double advantage is therefore achieved when increased performance is achieved by implementing a heat recovery system, and this is where the application becomes very interesting, when the PCHE is served by:

• heat recovery circuits
• jacket water
• hot oil
• process waste heat

The result is an increase in the overall efficiency of the system, a reduction in auxiliary consumption, and improved operational control of the turbine.

Tempco therefore positions itself as a strategic technology partner for the development and implementation of this type of application, providing not only the technology but also support for the engineering, in defining the actual duty cycle and verifying turbine-side pressure drops – a highly critical issue – and then ensuring the integration of PCHEs into complete skids and technical dialogue with EPCs and turbine OEMs. The PCHE is not a standard component, but a solution tailored to the plant.

In conclusion, the use of PCHEs as Gas Turbine Performance Heaters represents a natural, highly innovative evolution of high-performance applications in the oil and gas sector, effectively addressing the needs for compactness, safety, and control. Representing a perfect example of applied thermal engineering as a special and customized, non-standard solution.

L'articolo PCHE as gas turbine performance heater in oil & gas applications proviene da Tempco Blog.

Tempco already has several applications of temperature control units designed to meet the specific thermoregulation needs of molding carbon fiber components. The unit pictured below is a temperature control unit we recently supplied to a company in the province of Bergamo, specializing in the production of custom carbon fiber components for high-performance vehicles as well as other applications.

Tempco’s TCUs have a wide range of applications in the automotive sector, supporting our clients in defining the design and engineering process using a DFM (Design for Manufacturing) approach, aimed at achieving an ideal balance and harmony on both fronts. Maximizing aesthetic appeal while simultaneously enhancing the mechanical and structural performance of the components.

L'articolo Thermoregulation for custom carbon fiber components proviene da Tempco Blog.

These activities are crucial for the future of sustainable mobility, essential for the development of more sustainable technologies for the future of the automotive industry. We therefore extend our sincere thanks to Giacomo Silvagni, PhD Assistant Professor at Alma Mater Studiorum – University of Bologna, responsible for these projects at the University Department, who provided us with detailed information on two of the ongoing research projects.

The first image, in the scheme below, shows the construction of a flow bench for experimental diesel and gasoline common rail GDI (Gasoline Direct Injection) injectors, aimed at hydraulic characterization of the injection system and the development of control-oriented models.

As Giacomo Silvagni explains, high-pressure injection systems are typically used in control strategies with multiple, closely spaced injections. These strategies generate dynamic pressure wave effects and electromagnetic interactions that induce deviations from the normal injector operation, causing imbalances in the torque delivered by the engine from cylinder to cylinder, resulting in reduced efficiency and increased pollutant emissions. Thanks to the flow bench, built within the laboratories of the Department of Industrial Engineering of the University of Bologna, it was possible to carry out ad hoc experimental campaigns to experimentally characterize the tested injection systems, both diesel (up to 1,800 bar) and gasoline (up to 700 bar), and to develop control-oriented physical models aimed at real-time compensation of these dynamic phenomena compatible with standard engine control units.

For this first application, the Tempco temperature control unit was a central component of the test system, used to regulate the fuel temperature within the injection systems. The TCU therefore allowed for precise control of the fluid temperature, which is crucial for ensuring the repeatability of the experimental tests, and simultaneously verified the impact of different fuel temperatures on the system’s hydraulic dynamics.

The other two images below relate to the study for converting a 1.3-liter multijet diesel engine to operate on compression-ignition gasoline, aimed at studying high-efficiency combustion modes.

The study of innovative, high-efficiency, low-emission combustion methods is part of the ongoing development of internal combustion engines for high-efficiency, low-emission applications. Innovative combustion methods still represent one of the most promising solutions, especially considering the advent of synthetic and sustainable fuels. To verify the benefits of these technologies, a small 1.3-liter multijet internal combustion engine, originally designed for diesel compression ignition, was converted to GCI (Gasoline Compression Ignition) operation in the laboratories of the Department of Industrial Engineering at the University of Bologna. This activity allowed to verify the benefits of this combustion method, both in terms of efficiency and pollutant emissions, compared to traditional diesel operation. The entire engine operating range was replicated while maintaining all internal engine components in their stock production configuration, thus verifying their full applicability to off-the-shelf hardware already on the market.

The Tempco temperature control unit, as Silvagni further explains, was a central element of the test system as it was used to regulate the temperature of the air drawn into the engine during start-up. Thanks to the Tempco temperature control unit and the use of a dedicated air-oil heat exchanger, it was possible to increase the temperature of the air drawn into the engine before it entered the combustion chamber, thus promoting spontaneous ignition of the gasoline. The precise control achieved by the Tempco system also allowed to verify the impact of different combustion air temperatures on combustion stability and engine performance in terms of torque/power output and pollutant emissions.

L'articolo Temperature control units in high-efficiency combustion engine test benches proviene da Tempco Blog.

Also for pharmaceutical applications, we recently supplied three TREG temperature control units for silicone fluids in glass-lined reactors. This is a classic mono-fluid temperature control application, equipped with heating via electric resistors and a low-temperature cooling section (-30°C) using brazed plate heat exchangers and mixing valves.

Temperature ramps control is achieved through dedicated electronic thermoregulators and thyristors (SCR), which allow the customer to drive the heating elements with modulating power. Finally, the thermal control units work with special pumps, featuring magnetic drive technology and a very wide temperature range of -30/+300° C.

L'articolo Temperature control units for reactors at -30° C in the pharma industry proviene da Tempco Blog.

With such a prestigious reference, Tempco is very proud to have contributed to ensuring the high performance of Dallara cars, thanks to the supply of a TREG HE temperature control unit employed for radiator test benches of Dallara Automobili’s racing cars. The unit is specifically designed to heat a thermal oil circuit, operating in a temperature range of +30°C to +180°C and transferring heat to the test fluid via a brazed plate heat exchanger. The flow rate range of the test fluid is between 5 and 80 l/min.

Test benches for these components are essential for laboratory simulation of the same track conditions that the cars will be subjected to during races. Tempco’s thermal control unit is therefore meticulously designed to ensure the simulation of the thermal conditions in which the Dallara supercar radiators will operate, precisely regulating the flow rates and temperatures of the test fluid with great stability and repeatability (temperature regulation accuracy ± 2°C).

Behind every tested radiator, there is thus a control unit that ensures that every degree truly counts in determining the maximum performance of Dallara racing cars. At the heart of the test bench, the TREG HE thermal control unit uses low-specific-power resistors, offering PID-controlled temperature regulation with proportional SCRs and integrated safety logic. An electro-pneumatic modulating valve ensures the necessary heat transfer stability even at low flow rates (5 l/min), maintaining the correct turbulent flow rate on the brazed exchanger.

Finally, the system was designed to always maintain maximum efficiency in regulating the temperature of the test fluid, taking into account the strong variability of the fluid’s viscosity as the temperature varies, together with the need to contain pressure drops.

L'articolo Thermal control unit for radiators test bench in Dallara Automobili proviene da Tempco Blog.

The installed TREG manages a temperature range from –5° C to +90° C, using glycol water as monofluid heat transfer. The unit delivers 24 kW of power in both the heating and cooling phases, allowing for extremely precise modulation of the operating conditions of the reactor’s double shell, depending on the different phases of the drug production process.

The full stainless steel construction and compact design facilitate cleaning and maintenance, ensuring full compliance with the sterile environment requirements of the pharmaceutical industry. Every detail, from components to electronics, is designed to offer reliability, repeatability, and safety in laboratory processes and small production batches for research activities of new active ingredients.

L'articolo Precise thermal control in pharmaceutical research proviene da Tempco Blog.

The choice to use stainless steel for the frame of our T REG HC E temperature control units is strategic, as it specifically meets the most stringent hygiene and durability requirements. This material guarantees excellent corrosion resistance, which is essential in environments requiring frequent cleaning and the use of sanitizing agents. Its smooth, non-porous surface prevents the accumulation of contaminants, making cleaning easier and ensuring superior sanitization, in full compliance with the stringent regulations to which the Pharma and Food sectors are subject.

T REG HC E control units are designed to deliver high-level performance, putting technology at the service of quality. They guarantee operating temperature precision of ±0.5°C thanks to advanced PID electronic control, essential for the stability and repeatability of production processes. Operating within a temperature range of +30° C to +300° C and managing fluids such as pressurized water (130°C) or diathermic oil (180°C or +300°C), they are suitable for a wide range of applications, from reactor heating to thermal control in pasteurization processes. Each component, from high-flow centrifugal pumps to high-efficiency plate heat exchangers, is selected to ensure reliability and consistent performance.

The applications of T REG HC E thermoregulation units are diverse, in addition to the customization options Tempco offers. Whether maintaining precise temperatures in mixing tanks or producing hot water for specific needs, the T REG HC E is the ideal solution. Tempco also offer a wide range of options upon request, allowing each unit to be customized with special pumps, increased cooling capacity, or communication interfaces for seamless integration into the user’s automation systems.

The Tempco T REG HC E stainless steel thermoregulation units are the perfect embodiment of Tempco’s commitment to offering cutting-edge temperature control solutions, combining precision with hygiene and reliability. Contact us to find out how our thermoregulation units can elevate the standards of your production processes in the pharmaceutical and food industries.

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During tempering, the chocolate is heated, cooled, and then reheated following a very precise thermal cycle (45°C, 27°C, and finally 31-32°C). This process is essential for stabilizing the cocoa butter crystals in their most stable form, which guarantees a shiny, crispy, and heat-resistant final product.

Here, once again, thermoregulation units play a crucial role, ensuring that each step occurs at the correct temperature and with optimal timing. Poorly executed tempering can cause aesthetic defects, such as dull surfaces or streaks, and compromise the chocolate’s consistency. Precise temperature control, on the other hand, allows for a visually appealing product that is pleasing to the palate.

In this sense, the tempering phase is truly the touch of class that makes the difference in chocolate production.

L'articolo Tempering and thermoregulation: the secret behind crisp and shiny chocolate proviene da Tempco Blog.

These compact units are designed with custom dimensions for integration into the customer’s machine structure. Each version is configured based on application specifications: electric heating with resistances from 3 to 24 kW, forced circulation via a submersible foot pump, and cooling via a submersible coil connected to an industrial water circuit or external chiller.

The circuit is atmospheric, with a stainless steel tank, designed to ensure maximum hygiene and ease of maintenance. The recommended operating temperature range is 0/75°C, ideal for washing, mixing, or thermal conditioning of process fluids.

Versions for both the pharmaceutical and food & beverage sectors feature materials and components compatible with wash-down environments and, upon request, sanitary clamp or DIN connections. Versions with remote control options via PLC, analogic signals, or fieldbus (Modbus, Profinet, EtherNet/IP) are also available.

These solutions offer OEMs the ability to easily integrate a complete, compact, and reliable thermoregulation system, reducing development times and ensuring an efficient thermal management of the production process. As always, each project begins with a technical consultation with the customer, to tailor dimensions, materials, power, and control logic to the specific needs of the system.

L'articolo Custom thermoregulation units for OEMs in the food & pharma sectors proviene da Tempco Blog.

Why preheat rolling rolls?

1. Thermal shock reduction. Rolling rolls are subject to rapid temperature changes when they come into contact with the red-hot metal. Adequate preheating reduces thermal stress, preventing cracks, deformations, and premature wear.
2. Increased dimensional stability. Temperature variations affect the expansion of the rolls, potentially causing misalignment and defects in the rolled product. Maintaining the rolls at a uniform temperature before starting the lamination process ensures more precise rolling and reduces production waste.
3. Product surface quality. A roll with uneven temperature can cause imperfections on the surface of rolled steel, such as marks or waviness. Preheating ensures more uniform contact and a high-quality finishing.
4. Optimized energy efficiency. Without preheating, the initial contact between the cold roll and the hot metal leads to heat dissipation and increased energy requirements to maintain the suitable operating temperatures. Preheating units reduce this heat loss, improving process efficiency.

Tempco Solutions: Electric Heating Units
Tempco designs and manufactures electric heating units specifically for preheating rolling mill rolls.
These systems offer:

• Precise temperature control, with automated adjustment
• Uniform heat distribution, avoiding temperature differences along the roll
• Reduced start-up times, increasing plant productivity
• Compact and efficient design, with customized solutions based on customer needs

The adoption of Tempco control units therefore represents a strategic investment for rolling mills aiming to improve reliability, product quality, and operational sustainability.

Steel, rolling, rollers, finishing, solid temperature, temperature control, automation, reliability, steel industry, heating, preheating, heating units, Tempco, surface quality, dimensional stability, energy efficiency, energy saving, operational efficiency,

Illustrative image of the steel rolling process where preheating of the rolls is essential.

Image showing a heating unit for preheating the rolls in steel rolling.
Image showing the connections in a heating unit for preheating the rolls in steel rolling.

L'articolo The importance of rolls preheating in steel rolling processes proviene da Tempco Blog.