Tempco Blog articles

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.

Tempco presents the new site dedicated to the innovative PCHE heat exchangers

Tempco is very pleased to announce the launch of a new website exclusively dedicated to PCHE heat exchangers, printed circuit heat exchangers (https://pche.it/en/). The peculiarities of this type of plate heat exchangers are in fact such and unique that they deserve a space of their own where it is possible to illustrate and explore all the potential applications of this innovative heat transfer technology.

For some time now we have been talking about thermoregulation and temperature control solutions that Tempco has developed thanks to the use of PCHE exchangers: from hydrogen refueling stations for sustainable mobility, to temperature control in fuel cell technologies in hybrid powertrains of the most advanced zero-emission yachts. Up to pioneering applications that lie ahead in the oil and gas sector and safe nuclear energy field, with fourth generation reactors.

Illustrative image of Tempco's new website dedicated to PCHE printed circuit heat exchanger technology

The Fields of Application section of the site offers an overview of the cutting-edge industrial sectors where PCHE exchangers are already used. On the Features page of the website dedicated to Tempco PCHE heat exchangers it is possible to discover in detail the distinctive technical features of this exchangers technology, which, thanks to the solid state welding process called Diffusion Bonding, differ from traditional welded exchangers. Diffusion bonding in fact gives PCHEs exceptional mechanical and structural resistance, allowing them to be used in extreme operating conditions in terms of high pressures and temperatures.

The special technique of chemical etching of the plates, similar to that used in the electronics sector to create printed circuits, also allows to create customized layouts of the heat transfer circuits on the plates of these exchangers, with total design freedom to obtain high efficiency heat transfer circuits customized for individual applications. Furthermore, it offers the possibility of creating PCHE exchangers also in multistream mode, to manage different heat transfers simultaneously with different flow rates, pressure drops, pressure levels and temperatures.

We therefore invite you to discover and deploy together with Tempco the application potential offered by the new world of PCHE exchangers on the new dedicated page at https://pche.it/.

Silicone based fluids in thermoregulating units

Let’s go on speaking about thermoregulating units, and especially about a particular kind of heat transfer fluids, silicone based fluids. When they are employed?

First of all, let’s say these are highly expensive fluids. Compared to water or diathermic oil, they have a very higher cost. But there are some applications where it is necessary to employ them, because for example a process need to start from very low temperatures, where a mix of water and glicole becomes hard to handle because it becomes too much viscuous. Or even at too much high temperatures, where glicole water would start boiling and it’s not possible to pressurize the plant.

And so, we have to employ particular silicone based thermal transfer fluids, such as Therminol LT or Therminol D-12, that allow to work with very low temperatures and even with high temperatures, with atmospheric pressure circuits, and so not pressurized, but most of all, with a very low viscosity even at very low temperatures.

In fact, these heat transfer fluids keep a very smooth flowing at low temperatures allowing the use of pumps with relatively low power capacities and achieving an extremely efficient thermal transfer even at very low temperatures.

 

Happy Holidays from Tempco, Merry Christmas and Happy New 2025!

Happy Holidays from Tempco, for a Merry and Joyful Christmas and may everyone have a Happy and Prosperous New Year 2025!

 

Tempco will respect the following Christmas closure: from the 23rd of December to the 06th of January.

From the entire Tempco team, our warmest wishes for these holidays! See you in 2025!

 

Thermoregulation units, what determines the choice of carrier fluids in TCU

Let’s start a series of videos focused on the characteristics and peculiarities of thermoregulation units. First of all, what is a thermoregulation unit.

These are thermal machines, someone calls them boilers, others call them TCU, thermal control units. In fact these are equipments that include a circulating pump, a heating system and a cooling circuit system and an electrical panel with a PID controller that maintains a fluid at a certain controlled temperature. This fluid is then aimed at regulating the temperature of a downstream industrial process. Overall, TCU are utilities serving industrial production processes.

There are several kinds of thermoregulating units, as seen in other videos: in Tempco we engineer thermoregulating units with electric heating, with steam heating as well as using different kinds of cooling systems.

But here let’s focus more on the topic of the fluids employed as carrier fluids, in other words, on the topic of the monofluid. Based on the project temperature level at which they are design to operate with, these units can employ a wide range of different kind of fluids: water for example at ambient temperature, and therefore with not pressurized circulating systems; pressurized water, when temperatures involved are up to 130-140° C; water with anti freeze additives, such as glycol, mono ethylene or propylene glycol, in case the temperature range starts with temperatures under 0° C; silicone oils or special oils, when the temperature range start under 0° C but we have to reach very high temperatures, and we also have to guarantee and maintain a smooth flow, with a low viscosity; and eventually, when working temperatures rise up, we can switch to diathermic oils.

Using diathermic oil, there are two kind of units: a first one that enables to reach temperatures up to 180° C, typically realized using sophisticated components of a certain kind, such as pumps with mechanical seals; or otherwise diathermic oil for temperatures up to 300-320° C. In this case, components are even more sophisticated, using for example magnetic drive pumps.

What determines the selection of a carrier fluid instead of another? As already said, it depends on the design range of temperature. Which means, with low temperature, glycol and anti freeze, water in case of ambient temperatures, up to 130° C; extreme temperatures, which means from -20 or -30° C up to high temperatures, silicone fluids or special fluids, typically oils; and finally, for very high temperatures, up to 180-300° C, diathermic oils.

Cooling of burners in oxy-fuel cutting in steel mills

In the steel mill sector, industrial plants producing semi-finished steel products such as billets and slabs require the presence of a cutting system to fit the products within the standard shipping dimensions for the loads of ferrous materials.

Illustrative image of a steel plant with oxy-fuel cutting of slabs and billets, where the burner cooling system is crucial for safety, process efficiency, and component life.
Cooling systems on burners are crucial in slab and billet oxy-fuel cutting plants for a series of reasons:

  1. Prevention of overheating: burners operate at extremely high temperatures. Without a proper cooling, they could overheat, causing structural damages or failure.
  2. Maintain efficiency: a properly cooled burner operates more efficiently. Cooling prevents excessively high temperatures from altering performance, maintaining a precise and constant cut.
  3. Safety: cooling reduces the risk of fire or explosion due to overheating, improving the safety of the entire system.
  4. Component life extension: a regular and controlled cooling reduces wear on burner components, extending the life of the system and reducing maintenance costs.

Cooling of burners in oxi-fuel system employs water for obvious, with dissipation that can often be carried out using free-coolers, as the temperature levels are not particularly high.

 

PCHE heat exchangers Tempco in refueling stations in the Hydrogen Guide 2024

The technology of Tempco’s PCHE printed circuit exchangers is described in the new Hydrogen Guide 2024 of Hydrogen Fair, part of the EIOM circuit with mcTER and La Termotecnica, which offers many interesting insights into the evolution of the hydrogen sector in Italy.

PCHE exchangers offer an ideal application for cooling gas at very high pressure and temperature in the compression cycles of hydrogen refueling stations. Thanks to the diffusion bonding construction technique and the microchannel structure of the plates, obtained with a special chemical photo-etching process, these exchangers guarantee very high heat transfer efficiency, resistance to extreme working conditions with high pressure and temperatures and the necessary operational safety in hydrogen refueling stations.

A key technology for creating an adequate refueling infrastructure capable of supporting the growth of the hydrogen industry and the diffusion of fuel cell vehicles for the sustainable mobility of tomorrow.

On the Tempco page on the Fiera Idrogeno website you will find a collection of articles and applications developed for the hydrogen industry.

Here is the complete article on Tempco PCHE exchangers in hydrogen refueling stations featured in the new Hydrogen Guide 2024. Enjoy the reading!

Image showing the Tempco article's layout regarding the use of PCHE printed circuit heat exchangers in hydrogen refueling stations, featured in the 2024 Hydrogen Guide.

Image showing the second page of the Tempco article discussing the benefits of the innovative PCHE printed circuit heat exchangers technology in hydrogen refueling stations, featured in the 2024 Hydrogen Guide.

Image showing the cover of the 2024 Hydrogen Guide, which contains a Tempco article regarding PCHE heat exchangers used in hydrogen refueling stations.

Illustrative image of a hydrogen refueling station for green mobility, where Tempco PCHE heat exchangers are the ideal solution for multi-stage cooling in gas compression.

Role of PCHE heat exchangers in hydrogen refueling stations

One of the most interesting applications for printed circuit exchangers, or PCHE heat exchangers, is represented by hydrogen refueling stations. As already explained in other articles, this is an essential part for the commercial-scale development of sustainable mobility powered by hydrogen fuel cells.

Thanks to their ability to withstand extreme working pressures and temperatures, due to the special diffusion bonding construction process employed, in hydrogen refueling stations PCHE heat exchangers are essential for several reasons:

  1. Heat management during gas compression cycle: hydrogen must be compressed to very high pressures (up to 700 bar) before being transferred to vehicle tanks. This process generates a significant amount of heat. PCHE heat exchangers are used to cool compressed hydrogen, ensuring that the temperature remains within safe operational limits.
  2. Energy efficiency: the microchannel structure of PCHE allows for effective heat transfer with minimal energy loss. This helps improve the overall efficiency of the refueling station, reducing operating costs and environmental impact.
  3. Reliability and durability: PCHEs are built to withstand extreme operating conditions, including high pressures and variable temperatures. This durability is crucial for hydrogen refueling stations, which must operate continuously and safely.

Illustrative image of a hydrogen refueling station, an ideal application for Tempco’s innovative PCHE printed circuit heat exchanger technology for heat management during multi-stage gas compression cycles.

Compact thermoregulating units for wide temperature range in pharma labs

We have often talked about pharma production processes and about thermoregulating systems for the production processes of pharma products and APIs.

Clearly, before starting with industrial production, there are also pharma laboratories where new products and drugs are tested, let’s say produced in an early stage those same substances that later on will be produced in batch for an industrial consumption. Also pharma laboratories therefore require temperature control tasks.

At this purpose, there are very compact and small machinery which are employed in pharma laboratories, and they have to offer an extremely wide working range. That’s because a laboratory is where testing tasks are deployed, and very often the final temperature range is not yet defined, but it’s necessary to make several trials, in order to verify if at a certain temperature the expected reaction is going to take place, and then is necessary to find out at which temperature the product must be cooled in order to maintain the characteristics achieved at the high temperature level.

At this purpose, there are special and very flexible temperature regulation units that can be highly adapted to the varying needs of pharma labs.

Usually the heating cycle in these systems is carried out via an electrical system, since the powers required are very low. Same thing for the cooling section, which uses small refrigeration units with low power capacity but which allow to reach very low temperatures. Therefore, there are these systems that offer a wide range of working temperatures, offering for example the possibility of reaching -30° C and then up to +250° C, therefore a very extended temperature range to guarantee the possibility of carrying out all production tests, establishing the process parameters which will then be translated into industrial production.

Advantages and disadvantages of spiral heat exchangers

An interesting type of exchangers are spiral heat exchangers, particularly appreciated in many industrial applications thanks to their unique characteristics. These exchangers are often used in applications with sludge or very dirty fluids.

Below is a summary of the main advantages and disadvantages of spiral heat exchangers.

Advantages of spiral exchangers:

1. Compactness: spiral exchangers are designed to be very compact, which allows to save space compared to other types of exchangers.

2. Self-cleaning: the continuous flow configuration and spiral geometry creates turbulence which can help reduce the build-up of dirt and scale. This makes spiral exchangers more suitable for fluids with suspended or viscous solids.

3. Heat transfer efficiency: the spiral geometry guarantees a high thermal exchange surface area compared to the overall volume, improving thermal efficiency.

4. Resistance to clogging: thanks to their configuration, spiral heat exchangers are more resistant to clogging than shell and tube exchangers or plate exchangers, especially in applications with particularly dirty fluids.

5. Ease of maintenance: maintenance is generally simpler as opening the lid of a spiral exchanger allows easy access to the internal surface, making cleaning easier.

6. Versatility: Spiral exchangers can handle a wide range of fluids, including corrosive and dirty ones, and be used in applications requiring high pressures or temperatures.

Image showing a Tempco spiral heat exchanger, often used in heat transfer applications involving sludge or very dirty fluids.

Disadvantages of spiral exchangers:

1. Initial cost: spiral exchangers may have a higher initial cost than other types of exchangers, such as plate or shell-and-tube exchangers, especially for small-scale installations.

2. Manual cleaning: while they offer good resistance to clogging, when heavier fouling occurs, cleaning requires to open the unit, which can take time and resources.

3. Pressure limits: although they resist high pressures well, spiral exchangers still have a limit, especially when compared to shell and tube exchangers, which can handle much higher pressures in some critical applications.

4. Not suitable for all fluids: in applications with extremely viscous fluids or large solid particles, there may be increased resistance to flow, reducing heat transfer efficiency.

5. Less flexible design: once built, a spiral exchanger is less flexible than modular plate exchangers, which instead allow you to add or remove plates to increase the exchange capacity.

Image showing a side view of a Tempco spiral heat exchanger, a type of exchanger often used in heat transfer applications involving sludge or very dirty fluids.

Illustrative image of the internal circuits in a spiral heat exchanger, ideal for applications involving sludge or very dirty fluids, where they offer compactness, heat transfer efficiency, and resistance to clogging.

In conclusion, spiral heat exchangers are an excellent solution in applications where compactness, efficiency and resistance to clogging are critical, but they can be more expensive and less flexible than other solutions.