Tempco Blog articles

Thermoregulation in critical pharma application

We recently supplied a number of thermoregulating units to a leading pharmaceutical company, aimed to regulate temperature on a series of reactors employed in a strategic production process.
The production presents some very critical temperature regulation requirements.

Termoregolazione farmaceutico

The criticality is not depending on the temperature levels, as the thermoregulation unit works on a set-point between +15 and +75° C.
Working fluids are warm water coming from a boiler and from a chiller, already in use in the production facility for other technical purposes.
The specific pharma application is critical because the thermoregulation must be constant and ensured upon any circumstance. This mandatory requirement led to a special design with a double automatic stand-by pump, in order to ensure in any case the constant temperature regulation.

pharma temperature regulation Tempco

 

termoregolazione settore pharma Tempco

The system also features two modulating control valves managed by a thermoregulator, respectively employed on the cooling and heating circuit, maintaining a constant temperature in a range of +/-1°C referred to the current set-point.
After the setting phase, the production in series will start, also including an additional variant with electrical heating.

How to… correct commissioning of Thermoregulating units

The commissioning phase of a TREG Thermoregulating units employing diathermic oil as heat transfer fluid is the most delicate and critical step in the whole plant’s lifespan, as the most serious issues can happen here. That’s why is fundamental to carefully follow the right steps for the correct commissioning of a thermoregulating unit, avoiding problems such as cavitation and leaks.

commissioning centraline termoregolazione TREG olio diatermico

First step: checking of all the electrical and hydraulics connections, and the right filling of the plant. With the machine being cold, let’s turn on the oil recirculating pump, in order to verify the correct inlet pressure, that must be constant. Working pressure and power consumption, with cold machine, will naturally be higher compared to values at standard use.

Second step: very slowly warm up the oil, approx. at +30°C every hour. This is a crucial process in order to completely eliminate the presence of air and moisture in the hydraulic circuit, through the expansion tank. The process will avoid the creation of vapor pads, foaming and possible oil overflow due to excess of filling. These events happen violently and out of control, so that’s why is very important to slowly increase the oil temperature.

 

unità termoregolazione TREG avviamento

 

Third step: once reached the temperature of approx. 100-110° C, further slow down the temperature increase, allowing the complete draining of water vapor. Relief valves must in some cases be opened, especially where vapor bags can develop, in particular if cavitation or sudden inlet pressure variations occur.

 

commissioning circuito termoregolazione olio diatermicoFourth step: regulate the set-point of the thermoregulating unit in order to warm up the oil at approx. 200° C, maintaining oil circulation at this temperature for about 1-2 hours. It allows to:

  • Completely remove moisture in the circuit
  • Completely expel air bubbles from the hydraulic circuit
  • Checking possible leaks on the oil circuit

Finally, once the circuit has been turned off and the system has returned to the initial temperature, verify that all the seals and fastenings are correctly performing, fixing possible leaks.
The thermoregulating unit is finally ready to operate.

 

 

 

TREG units and heat transfer fluids, advantages and critical points

Among the many kind of heat transfer fluids employed in heating, cooling and thermoregulation applications, heat transfer fluids, such as diathermic oil, offer a wide range of advantages. Diathermic oil is widely employed today in industrial applications of Tempco’s TREG thermoregulating units, in substitution of water and vapor to better meet the needs of more advanced technologies and production methods, requiring a wider range of working temperatures.

olio diatermico termoregolazione

Heat transfer fluids are mineral or synthetic oils with special thermo-physical properties, compared to water and vapor, such as a high boiling point, approx 400-500° C, low vapor pressure and low pour point, reasons why they are widely used as a heat carrier in heat transfer systems.

The working life span of a diathermic oil and its performances are strictly depending on a number of factors, such as a proper engineering and sizing of the termoregulating unit, taking account of the peculiar chemical-physical properties of the specific heat transfer fluid involved. Other crucial elements are the selection of the correct materials, suitable for use with the heat transfer fluid, a correct filling and warm-up of the plant in the starting phase, and finally a careful maintenance.

termoregolazione fluidi termovettori

And here is a list of the main advantages achievable with diathermic oil in TREG thermoregulating units as a heat carrier:

High temperatures resistance
– Working at atmospheric pressure
– No PED compliance required (no pressurization)
– No chemicals and conditioning required
Low freezing point and no risk of piping breaking in case of extreme low temperatures
– System startup at low temperature
– No scaling nor corrosion, if properly used
– Common construction materials (carbon steel)

On the opposite, diathermic Oil in thermoregulation and heat transfer systems also entail some disadvantages to be accounted, such as:

– Low specific heat compared to water
– Flammability
– Need of a recirculating pump
– Higher costs, especially in case of high capacity volume plants
– Craking and contamination risks related to bad operations

 

Legionella, risk avoiding and prevention

Due to the sadly recurring news about further cases of Legionella infections, we return on the topic of how a proper maintenance of cooling plants is crucial aimed to the safeguard of public health.
The BN 111U product employed by Tempco for evaporative towers purification is a specific active bactericidal, antimicrobial and algae treatment for humidification and rain test chambers, cooling circuits and paper mill processes.

 

Legionella trattamento antibattericida Tempco BN111U
The product TC BN 111U by Tempco is particularly effective for the treatment of Legionella Pneumophila bacteria, both for use as initial antimicrobial Legionella treatment and in a successive prevention program.

The product can be employed in a starting shock dosage aimed to completely eliminate all the existing bacteria, to be repeated every 2-3 days until complete control of the bacterial proliferation. Further following shock dosages can be used as a prevention treatment. Also a continuous dosage treatment in the system can be adopted for legionella prevention.

 

battericida antilegionella BN111U Tempco

 

The product can be added manually or automatically, employing a timer-controlled dosing pump.
The technical sheet of the TC BN 111U product reports in details the correct employ mode and dosage informations both for eliminating existing Legionella bacteria and for an effective successive Legionella prevention.

Heat to electricity, the disruptive technology of Rectennas

Producing electricity harvesting heat with a device without moving parts could soon be a reality, thanks to several studies on development in laboratories all around the world on optical Rectennas. The Rectennas are a disruptive technology consisting in micro-antennas able to capture the electromagnetic waves at optical frequencies of infrared, produced by any object emitting heat, directly transforming thermal energy into electricity for efficient heat recovery.

Paul Davids Sandia National Laboratories Rectennas

A prototype of Rectenna has been recently announced by the physicist Paul Davids of Sandia National Laboratories in a publication featured on the Physical Review Applied. The micro-antenna developed, the size of a small finger nail, is made of aluminium in the upper side and by silicon doped with other several elements in the lower side, reflecting the infrared radiation. The addition on the lower face of a layer of 20 molecules of silicon dioxide works as a rectifier diode, capturing the alternating flow of electrons to create a current flow. The rectenna has been optimized and constructed employing materials of high availability and common use as much as possible, with methods allowing a production by actual semiconductors industries.

 

Rectenna thermal energy harvestingOptical rectennas thus represent a highly interesting alternative to thermoelectric generators, electrons generators from heat employed to power spacecrafts, requiring high temperature gaps in order to function, with high construction costs and offering low efficiency. Rectennas production could be cost-effective and practical, also at an industrial level and in bigger scale compared to the Davids’ prototype. This kind of device is also very reliable, and unlike electromagnetic generators doesn’t need to be in contact with the thermal energy source, thus less exposed to thermal stresses.

 

 

 

 

By capturing the infrared radiation, coming in continuous from the Sun and also dissipated by the Earth itself at night, the rectennas could operate as a sort of innovative photovoltaic technology producing electricity 24/7. At the moment Davids is looking forward to applications on harvesting heat from thermal plants, or to power devices such as spacecrafts that employ radioisotopes. Many years of further development are necessary in order to apply rectennas on harvesting sunlight and infrared radiation during the night time.

torri evaporative energia termica

Interesting advancements are anyway coming in several other laboratories around the world, such as the prototype of an optical rectenna aimed for sunlight harvesting developed by the Connecticut University, of the rectenna developed by Baratunde Cola in 2015 at the Georgia Tech Institute. The Cola’s rectenna is a carbon nanotubes antenna coupled with a diode composed by a layer of calcium, recently further enhanced settling a bilayer material composed of alumina and hafnium dioxide, increasing by 1.000 times the capacity, switching the current production from microvolts to millivolts range. According to Cola, optical rectennas could then be used to operate low-power sensors and powering IoT devices.

Legionella and cooling towers maintenance

Strictly related to cooling towers maintenance, as well as of HVAC and cooling equipments, the problem of legionella infections returned as an emergency last July in the north of Milan, in Bresso, with 11 persons hospitalized at the near Niguarda hospital. The Italian ISS, the Superior Institute for Healthcare, reports an increase by 17% of legionellosis in 2017 in Italy, compared to 1.700 cases occurred in 2016.

torri evaporative prevenzione legionella

Legionella is a group of bacteria commonly present in aquatic environments, that proliferates in presence of air and water at temperatures in a range between 25 and 50° C. The Legionella disease is transmitted by aerosol inhalation of a contaminated source, small droplets that are commonly found in HVAC and cooling machinery or with cooling and evaporative towers. A proper and correct maintenance of cooling towers is thus mandatory, in order to reduce the risk of infections.

legionella prevenzione

 

The measures are diverse, ranging from technical solutions such as the adoption of efficient drop separators, a construction of the plant that allows high accessibility for cleaning and service, avoiding stagnation points with proper drainage, and finally a water purification of the plant. Towers’ maintenance thus ensure not only maximum efficiency operating conditions of the cooling plant, but also a healthy environment where the evaporative tower is installed.

cooling towers legionella preventionThe IIS reports other cases of Legionella disease in the past: in 2016 in Parma a total of 42 cases of infections were related to a cooling tower of a local posts office. Many cases happened in Cesano Maderno, near Milan, from 2005 to 2008. The cause was not clearly identified, but infections stopped with the closing of many industries during 2008. At last, a Legionella epidemic happened in Rome in 2013, with 15 cases, due to a cooling tower of an important local commercial center.

 

 

 

 

Cooling in aluminium profile drawing

The aluminium profile drawing process involves cooling and thermal exchange operations combined with the treatment of the water employed for washing and cooling purposes.

trafilatura alluminio

The production of aluminium profiles is increasing globally, due to the growing demand of this kind of products more and more utilized in construction and building such as in several industrial applications.
Once the profiles are made, they have to be washed and cooled before going through the next production treatments.

raffreddamento trafilatura alluminio

Leggi »

Heat pumps and deep-water dimple jacket TCOIL

We gladly and with great satisfaction dedicate a new article to an interesting application of TCOIL dimple jacket heat exchangers employed in thermal energy dissipation of a heat pump. The TCOIL dimple jacket exchangers are one of the most flexible solutions for cooling and heating purposes, able to adapt themselves to a wide variety of contexts and process needs.

scambiatori dimple jacket TCOIL pompe di calore

This time, we have installed the TCOIL directly in the deep-water, near the Como Lake, at the depth of 20 meters. Properly sized, the dimple jacket exchanger allows to convey the water of the heat pump using high-resistance flexible pipes.

Leggi »

Eco-friendly and smart cooling

The concepts of green and eco-friendly stand for a variety of meanings. Usually, an eco-friendly plant is a system offering low or zero emissions.
But a plant can also produce emissions in the upstream of the process, so that the term eco-friendly can also be employed to indicate low energy consumption plants.

raffreddamento ecologico Tempco
Recent regulations are in particular promoting the adoption of EC electric motors, addressing and embracing the green trend in industrial machinery.
Tempco since a long time devotes big efforts to provide customers thermoregulation solutions, cooling and heating systems engineered in order to meet the heat exchange needs of their final applications, limiting the energy waste.

termoregolazione green Tempco

Several technical solutions are available to achieve this kind of goals:

inverters in ventilation groups
– inverters in pumping systems
– Modulating regulation systems using dedicated control valves
– Electric heating managed by static relays or SCR

termoregolazione intelligente ecologica TempcoThe integration of this kind of technologies allows to achieve huge and significant energy savings.
Thermoregulation units are usually conceived in order to offer high performances also in the most critical conditions. Thus, the units become redundant in case of average conditions or during advantageous environmental conditions.
The implementation of modulating systems able to adapt their operations to climatic conditions and to effective working needs (productions levels, temperature levels, etc…) allows to achieve a very efficient consumptions control.
These solutions can often require higher investments at first, but the advantages offered lead to a full ROI in a few months after the commissioning of the plant.

 

raffreddamento intelligente ecologico Tempco

Exhaust air treatment in textile facilities

The rameuses are machines employed in textile plants producing synthehic and technical fabrics in order to dry dryed fabrics or to hot fix them. This kind of machinery produces exhaust air that requires a proper treatment, but first of all it is necessary to decrease its temperature.

abbattimento fumi industria tessile

The application doesn’t require to achieve deep low temperature levels, as usually air temperatures of 40-45° C are sufficient.

Leggi »