Another compelling aspect that further enhances the energy efficiency of liquid cooling solutions in data centers is the potential for implementing heat recovery systems. Because liquid absorbs heat more efficiently and in a more concentrated manner than air, the temperatures at the cooling system’s outlet are higher than those achieved with conventional air-based methods. This facilitates the adoption of highly advantageous energy recovery solutions, enabling the reused thermal energy to be applied to a variety of purposes—ranging from district heating and heat pumps to the heating of domestic hot water or the preheating of process fluids. In this way, the energy consumed by data centers—which would otherwise be dissipated as waste heat—is repurposed in line with circular economy principles, thanks to liquid cooling.

Tempco acts as a qualified system integrator for the implementation of liquid cooling skids for data centers, featuring brazed plate heat exchangers (BPHEs) as their technological core. There are various possible architectures for liquid cooling ecosystems in data centers (that often can also include chillers, free cooling and evaporative towers), and for each type, Tempco’s range of BPHEs offers the ideal solution to ensure maximum cooling efficiency and reduced energy consumption, thereby lowering the Power Usage Effectiveness (PUE) of computing facilities.

It is therefore worth examining the advantages—as well as some related drawbacks—associated with different liquid cooling options for servers and chips. Whether using cold plates (conductive metal plates placed in contact with electronic components to remove generated heat via a coolant circulating through microchannels) or direct immersion cooling (where servers are submerged in dielectric fluids), there are two primary operating modes for the thermal cycle: single-phase liquid cooling and two-phase liquid cooling. The former involves no phase change of the coolant—which could, for instance, be a 75% water-glycol mixture—offering the advantage of a simpler system design.

In two-phase liquid cooling, the coolant boils either within cold plates or upon direct contact with components submerged in cooling tanks. The transition to a vapor phase necessitates a more complex system to manage the vapor, requiring the inclusion of condensers as well as precise control over pressure and temperature levels. Conversely, two-phase liquid cooling enables the removal of large quantities of heat with significantly higher efficiency than single-phase methods.

Another aspect involves the comparison between cold plates and immersion liquid cooling. The use of cold plates requires pumping systems and piping to deliver coolant to the plates positioned on the components, which introduces a risk of leaks that must be carefully monitored. Immersion liquid cooling, by contrast, offers a more streamlined system architecture; it facilitates more uniform cooling and simplifies inspection and maintenance—essentially requiring only that the level of the coolant or dielectric fluid in the cooling tank be kept sufficient. On the other hand, despite its simpler system layout, immersion liquid cooling entails higher initial costs, driven by the high price of the specialized dielectric fluids required and the need for custom-built hardware, which must be constructed using materials compatible with immersion in special cooling liquids (requiring, for instance, careful selection of appropriate adhesives and gaskets).

L'articolo Liquid cooling and high efficiency heat recovery in data centers proviene da Tempco Blog.

Such applications in pharma productions highlight the added value of a pre-tested temperature control skid, starting with its compact design. Each TCU is engineered in 3D to maximize every available centimeter, with tolerances down to the millimeter.

Another major advantage is the “plug-and-play” quality achieved in the workshop: welding, wiring, and testing of the TCU are all performed in a controlled environment—rather than in the chaotic setting of a construction site or a potentially hazardous (ATEX) area. This ensures that on-site installation and commissioning of the TCU proceed without any unexpected issues.

This is ensured by the Factory Acceptance Test (FAT) of the TCU skid, through which the unit is tested at the workshop and therefore shipped in full working order. Once it arrives at the customer’s facility, only the connections to the utility lines (‘border line’ connections) are required; the system is then ready to start up within a few hours, eliminating downtime and last-minute unforeseen issues.

L'articolo Pre-tested skid-mounted temperature control units (TCUs) for pharma production proviene da Tempco Blog.

To meet this need, Tempco offers the new TCBS series of brazed plate heat exchangers made entirely of stainless steel and featuring brazing with a copper-free stainless steel alloy. These exchangers are therefore the ideal choice for a wide range of applications—from the hydrogen industry in fuel cells and electrolyzers, to semiconductor manufacturing, the food industry, the chemical and pharmaceutical sectors, and any processes requiring the handling of pure or demineralized water.

The absence of copper in the brazing of these heat exchangers eliminates the risk of copper ion contamination; such ions can be released upon contact with demineralized water through a process known as leaching, which can eventually lead to perforation of the heat exchanger. Compared to traditional gasketed plate heat exchangers, brazed models allow for stable operating pressures—standard versions rated at 10 bar (A) or 20 bar (B)—along with a wide operating temperature range and superior corrosion resistance. These factors contribute to high heat transfer efficiency, long service life, and an excellent cost-to-performance ratio. Their greater compactness compared to shell-and-tube solutions also makes the TCBS ideal for applications with limited space.

The Tempco TCBS series of all-stainless steel brazed plate heat exchangers is available in seven sizes to meet diverse production needs, ranging from low to high flow rates. Custom configurations and connection options are also available upon request. The TCBS series corresponds to the “S – All Stainless BPHE” series manufactured by Kaori Heat Treatment Co., Ltd. (Taiwan).

L'articolo All-stainless steel brazed plate heat exchangers for high water purity proviene da Tempco Blog.

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.

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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.

The simplest and least intrusive solution for this specific application was a stainless steel TCOIL heat exchanger immersed directly into the cutting oil tank. This solution required no machine modifications, allows for direct heat transfer with the oil, and can be supplied with water from a cooling tower, chiller, or well.

The solution proposed by Tempco therefore offers several advantages for this application:

• Minimal installation: the TCOIL immersion heat exchanger is placed directly into the cutting oil tank, requiring no machine modifications or additional process piping.
• Direct fluid contact: heat exchange occurs directly within the oil, eliminating the need for pumps or secondary circuits on the process side.
• Customized materials: AISI 304/316 stainless steel to withstand oil, emulsions, and harsh environments.
• Flexible supply: the coil can be fed with cooling tower water, chiller water, or well water; knowing the cooling water temperature and availability is crucial for sizing the unit.

Finally, the secret to a successful solution—ensuring maximum cooling effectiveness and efficiency—lies in the initial stage: measuring the actual thermal duty (volume, ΔT, operating hours) and sizing the system accordingly. To this end, before developing a proposal, Tempco’s technical team always conducts a site visit at the customer’s facility.

L'articolo Cutting oil cooling with immersion heat exchangers 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.

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.

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.