Process Temperature Control Systems

Thermostat Process

A Thermostat Process is a precision temperature control solution that circulates a heat transfer fluid through an external loop while continuously regulating heating and cooling output using closed-loop feedback, typically with PT100/RTD temperature sensors. This technology maintains accurate process temperatures for jacketed reactors, heat exchangers, condensers, pilot plants, and other thermal systems where consistent temperature control supports repeatable results and product quality.

How a Thermostat Process Operates

A Thermostat Process maintains stable temperatures through a continuous feedback cycle by:

1. Circulating a heat transfer fluid through an external system, such as a reactor jacket, heat exchanger, or processing tool.

2. Monitoring process temperature with high-accuracy PT100/RTD sensors.

3. Automatically adjusting heating and cooling capacity to maintain the programmed temperature setpoint.

4. Executing programmable ramp and soak profiles for multi-stage thermal processes.

This closed-loop control strategy delivers stable thermal performance under changing process conditions while minimizing temperature fluctuations and overshoot in externally controlled systems.

Common Applications

Thermostat Process systems are suitable for applications requiring continuous circulation and accurate temperature regulation, including:

• Jacketed reactor temperature control for chemical synthesis, polymerization, crystallization, and other thermally controlled reactions.

• Laboratory instrument cooling circuits, including Atomic Absorption Spectroscopy (AAS) systems and similar analytical equipment, to remove excess heat and maintain stable operating conditions.

• Pilot-scale processing systems, heat exchangers, condensers, and external circulation loops where consistent thermal media temperature improves process consistency.

Thermostat Process Product Families

The brochure includes several Thermostat Process product series designed for different heating and cooling requirements.

Heating Thermostat Process Systems

• Precision Heating Temperature Control System (50°C to 200°C) – QualiHeat™ PH Series
  Provides precise heating and controlled fluid circulation for reactor jackets, external loops, and process equipment. The touchscreen HMI supports temperature adjustment, monitoring, and trend visualization.

• Integrated Heating Temperature Control System (50°C to 300°C) – QualiHeat™ IH Series
  Delivers an extended heating range with an enclosed circulation system that supports continuous operation and efficient heat transfer during demanding thermal processes.

Cooling Circulator Thermostat Process Systems

• Integrated Cooling Circulator – QualiCC™ IC Series
  Supplies stable recirculating coolant for laboratory instruments, reactor jackets, condensers, heat exchangers, and other external thermal loads.

• QualiCC™ HCC Series
  Includes multiple cooling circulator models with various reservoir capacities and cooling performance, covering operating ranges from -5°C to 45°C and -25°C to 45°C, depending on the selected model.

Heating and Cooling Thermostat Process Systems

High-precision heating and cooling circulator systems provide accurate bidirectional temperature regulation for applications requiring programmable temperature profiles, continuous circulation, and closed-loop PT100 feedback.

Safety and Configuration Options

Selected high-capacity Thermostat Process systems include optional configurations such as:

• SUS 304 stainless steel construction

• ExdIIBT4 explosion-proof configuration

• ExdIICT4 explosion-proof configuration

• Positive-pressure explosion-proof systems (water-cooled models)

These options support installation in facilities with specialized environmental and safety requirements.

Factors to Consider When Selecting a Thermostat Process

When choosing a Thermostat Process system, compare the following specifications:

• Operating temperature range for heating, cooling, or combined heating and cooling

• Heating capacity and cooling performance at the required operating temperature

• Circulation flow rate and pump pressure for the connected process loop

• Connection sizes (DN ports) and facility utilities, including electrical power and cooling water or air-cooled operation

• Control features, including touchscreen HMI, trend recording, programmable temperature profiles, MODBUS, and RS-485 communication

• Safety features, including over-temperature protection, low-level protection, system interlocks, and explosion-proof configurations where required

Key Features Across the Product Range

Depending on the selected model, Thermostat Process systems may include:

• Closed-loop temperature regulation with PT100 feedback and selectable control points for media, outlet, or external sensors

• Touchscreen interface with real-time temperature monitoring, historical trend recording, and process verification

• Programmable multi-step temperature profiles with ramps, holds, and repeatable operating sequences

• Integrated protection functions, including overload protection, high-temperature alarms, low fluid level detection, and sensor fault diagnostics