Applications by Sector
Cooling for Chemical Industry
Chillers and temperature controllers for chemical processes and classified areas
Cooling and thermal control systems for chemical industry. Temperature from -20°C to +150°C with ±0.5°C precision. Equipment for classified areas (Ex d/Ex e), 316L stainless steel corrosion-resistant materials. Solutions for exothermic reactions, distillation, crystallization and critical processes.
Talk to SpecialistTechnical Specifications
Process Requirements
Heat removal in polymerization, oxidation, neutralization and sulfonation reactions. Heat removal rate controls reaction rate and process safety.
Heat supply for energy-absorbing reactions such as cracking and dehydrogenation.
Condensers and reboilers for distillation columns. Precise control is essential for efficient component separation.
Cooling ramp control for uniform crystal formation. Cooling rate determines crystal size and purity.
Critical thermal control for molecular weight, distribution and polymer properties. Highly exothermic reactions require high cooling capacity.
Climate control of tanks and raw material warehouses to maintain stability and safety.
Climate-controlled environment for electronic equipment, SCADA systems and operators.
Controlled environment for physicochemical analyses and analytical instrumentation.
Technical Analysis
Thermal Engineering for Chemical Processes
The chemical industry presents some of the most complex challenges in industrial thermal control. Chemical reactions are often accompanied by the release or absorption of heat, and precise temperature control is critical for safety, product quality, and process efficiency.
Process Types and Thermal Requirements
Each type of chemical process has specific thermal control requirements:
| Process | Thermal Characteristic | Control Requirement |
|---|---|---|
| Polymerization | Highly Exothermic | Rapid heat removal, ±0.5°C |
| Neutralization | Exothermic | Maximum temperature control |
| Crystallization | Controlled cooling | Precise cooling ramp |
| Distillation | Heating and Condensation | Stable condenser temperature |
| Fermentation | Moderately Exothermic | Narrow temperature range |
Safety in Chemical Processes
Safety is an absolute priority in the chemical industry. Refrigeration systems for this industry must consider:
- Hazardous Locations: Ex d (explosion-proof) or Ex e (increased safety) certified equipment for areas with explosive atmospheres
- Runaway Reactions: Emergency cooling capacity to control uncontrolled reactions
- Compatible Materials: Selection of materials resistant to process chemicals
- Redundancy: Backup systems to ensure continuity of thermal control
- Interlocks: Integration with plant Safety Instrumented Systems (SIS)
Heat Transfer Fluids
The choice of heat transfer fluid depends on the temperature range and the process:
- Water: 5°C to 90°C - Higher efficiency, lower cost, ideal for most applications
- Water/Glycol: -20°C to 90°C - For temperatures below 5°C, with antifreeze protection
- Thermal Oil: -20°C to 350°C - For temperatures above 90°C or processes requiring heating and cooling
- Brine: -40°C to 0°C - For moderate cryogenic applications
System Sizing
Correct sizing considers multiple factors:
- Heat of reaction (kJ/mol or kW)
- Reaction rate and cycle time
- Heat exchange area available in the reactor
- Overall heat transfer coefficient (U)
- Log Mean Temperature Difference (LMTD)
- Safety margin for peak demand
Helioterm conducts detailed process studies for precise sizing, ensuring adequate capacity without oversizing.
Sector Challenges
Temperature control in chemical reactions that release intense heat. Cooling capacity must be sufficient to maintain temperature even at peak conditions, preventing runaway reactions.
Maintaining precise temperatures in distillation column condensers. Variations affect separation efficiency and product purity.
Thermal control for crystallization and precipitation processes. Cooling rate determines the size, shape and purity of formed crystals.
Reactor cooling with high precision for product quality control. Batch reactors require fast response; continuous reactors require stability.
Equipment must be certified for operation in potentially explosive atmospheres, meeting ATEX/IECEx standards.
Aggressive chemical environments require special materials such as 316L stainless steel, Hastelloy or special coatings.
Cooling systems must integrate with SIS (Safety Instrumented Systems) and respond to emergency commands.
Batch processes generate significant thermal load variations throughout the cycle, requiring responsive systems.
Our Solutions
Reactor and process cooling with high thermal capacity. N+1 redundancy configurations for continuous operation.
View ProductPrecise temperature control in reactors and tanks with heating and cooling. Range from -20°C to +150°C.
View ProductCombined heating and cooling for processes requiring temperature variation during the cycle.
View ProductHigh capacity for large chemical plants with continuous operation and low vibration.
View ProductClimate control for control rooms, laboratories and administrative areas with humidity control.
View ProductRegulations and Standards
Benefits for Your Business
Success Case
Specialty Polymers Plant - Bahia
Design and implementation of cooling system for 4 polymerization reactors of 20 m³ each. The solution included 2 chillers of 300 TR with redundancy, chilled water system at 5°C, individual temperature controllers for each reactor and integration with plant safety system.
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