High Performance Process Temperature Control System – QualiTCS™ HPPT Series
High Performance Process Temperature Control System (-60°C to 200°C)
Maintain accurate thermal regulation across demanding heating and cooling processes with the QualiTCS™ HPPT Series. This high-performance process temperature control system circulates heat-transfer fluid through reactor jackets, coils, and external heat exchangers while delivering precise temperature control from -60°C to 200°C.
Available in 10 models, the system supports a wide range of process capacities with circulating pump flow rates of up to 400 L/min. It delivers consistent temperature ramping, stable soak periods, and repeatable batch performance for research, pilot plants, and industrial production. Custom-built configurations are available to match specific heat-transfer fluids, piping layouts, and process safety requirements.
High Performance Process Temperature Control System – QualiTCS™ HPPT Series Applications
1. Reaction Still
Reaction still systems are used throughout the petroleum, chemical, rubber, pesticide, dye, pharmaceutical, food processing, and research industries. Typical processes include hydrolysis, neutralization, crystallization, distillation, evaporation, storage, hydrogenation, polymerization, condensation, and temperature-controlled mixing.
The QualiTCS™ HPPT Series delivers accurate temperature regulation for faster heating and cooling cycles while supporting continuous monitoring and recording of reaction temperatures throughout each processing stage. This helps improve process consistency, product quality, and repeatability.
2. Microchannel Reactor
Microchannel reactors are designed for demanding chemical processes, including highly exothermic reactions, liquid-phase processing, gas-liquid reactions, and absorption applications. Common reaction pathways include nitration, sulfonation, oxidation, peroxidation, alkylation, amination, photochemical reactions, and gasification processes.
With a broad operating temperature range and intelligent temperature regulation, the QualiTCS™ HPPT Series maintains stable process conditions using a single heat-transfer fluid across heating and cooling cycles. This minimizes thermal fluid changes during process development, scale-up, and fine chemical manufacturing while improving overall process efficiency.
Additional Applications of the High Performance Process Temperature Control System – QualiTCS™ HPPT Series (-60°C to 200°C)
- Reactor and Jacketed Vessel Temperature Control: Deliver precise heating and cooling for jacketed reactors and process vessels where temperature profiles directly influence product quality, yield, and viscosity. The system supports control based on either process media temperature through an external sensor or heat-transfer fluid outlet temperature to suit different process requirements.
- Microchannel and Continuous-Flow Systems: Provide accurate thermal regulation for microreactors and continuous-flow processing, where stable temperatures are essential for reaction efficiency and product consistency. High-flow circulation capabilities help maintain uniform inlet temperatures for compact heat exchangers.
- Distillation and Condensation Systems: Maintain accurate temperature control for condensers, receivers, and column jackets to improve separation performance and process repeatability. Built-in temperature monitoring and data logging support long-duration operation and process verification.
- Extraction and Crystallization Processes: Create controlled cooling profiles that support nucleation and crystal growth while improving batch consistency. Programmable multi-step temperature sequences deliver repeatable processing conditions across production cycles.
- Automotive, Pharmaceutical, Petrochemical, Electronics, and Aerospace Testing: Support controlled thermal cycling for component qualification, material characterization, research, and process validation. The QualiTCS™ HPPT Series is suitable for industries requiring reliable heating and cooling around laboratory and production equipment.
High Performance Process Temperature Control System – QualiTCS™ HPPT Series Key Features
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Wide Operating Temperature Range: Delivers reliable heating and cooling from -60°C to 200°C, supporting both deep sub-zero startup conditions and elevated process temperatures within a single system.
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Advanced PID Fuzzy Temperature Control: Intelligent PID fuzzy control continuously adjusts system output to maintain accurate and stable temperatures under changing process loads.
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Flexible Temperature Control Modes: Configure the system to regulate either process media temperature through an external sensor or heat-transfer fluid outlet temperature to suit different processing requirements.
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7-Inch Color Touchscreen Interface: View real-time temperature trends, operating status, alarms, and recorded process data on an intuitive touchscreen display for improved monitoring and traceability.
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Programmable Multi-Step Temperature Profiles: Store up to 5 process recipes with 30 programmable steps each, helping deliver consistent heating and cooling sequences across production batches.
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Three-Point PT100 Temperature Monitoring: Integrated PT100 sensors monitor internal fluid temperature, outlet temperature, and external process temperature for improved control accuracy and thermal consistency.
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MODBUS RTU Communication: RS-485 MODBUS RTU connectivity enables seamless integration with PLCs, SCADA platforms, automated processing systems, and production skids.
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Comprehensive Safety Protection: Multiple protection functions include overload protection, pressure monitoring, liquid level protection, over-temperature protection, sensor fault detection, and built-in system diagnostics for dependable operation.
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Sealed Fluid Circulation System: A sealed circulation design helps limit moisture ingress during low-temperature operation, reduces vapor formation at elevated temperatures, and maintains stable system pressure throughout the process.
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Custom Configuration Options: Project-specific configurations are available to match installation requirements, heat-transfer fluids, process layouts, communication interfaces, and safety specifications.
Theory and Method
The QualiTCS™ HPPT Series operates as a closed-loop process temperature control system that continuously circulates heat-transfer fluid through reactors, jacketed vessels, coils, or external heat exchangers before returning it to the unit for precise thermal conditioning.
Cooling is generated through a high-efficiency vapor-compression refrigeration system, while electric heating elements deliver rapid heat-up and stable temperature maintenance. Advanced PID fuzzy control processes feedback from multiple PT100 temperature sensors to regulate either the heat-transfer fluid outlet temperature or the process material temperature, depending on the selected operating mode. The system also supports differential temperature control between the process jacket and material, helping achieve smoother temperature transitions, improved process stability, and enhanced product consistency.
High Performanced Process Temperature Control System – QualiTCS™ HPPT Series Technical Specifications
| Spec |
QualiTCS™ HPPT25W-620 |
QualiTCS™ HPPT35-620 |
QualiTCS™ HPPT55-620 |
QualiTCS™ HPPT75-620 |
QualiTCS™ HPPT100W-620 |
QualiTCS™ HPPT150W-620 |
QualiTCS™ HPPT250W-620 |
QualiTCS™ HPPT380W-620 |
QualiTCS™ HPPT600W-620 |
QualiTCS™ HPPT950W-620 |
| Heating power |
2.5 kW |
3.5 kW |
5.5 kW |
7.5 kW |
10 kW |
15 kW |
25 kW |
38 kW |
60 kW |
95 kW |
| Cooling capacity @ 200°C |
2.5 kW |
3.5 kW |
5.5 kW |
7.5 kW |
10 kW |
15 kW |
25 kW |
38 kW |
60 kW |
95 kW |
| Cooling capacity @ 100°C |
2.5 kW |
3.5 kW |
5.5 kW |
7.5 kW |
10 kW |
15 kW |
25 kW |
38 kW |
60 kW |
95 kW |
| Cooling capacity @ 20°C |
2.5 kW |
3.5 kW |
5.5 kW |
7.5 kW |
10 kW |
15 kW |
25 kW |
38 kW |
60 kW |
95 kW |
| Cooling capacity @ -40°C |
0.95 kW |
1.45 kW |
2.3 kW |
3.1 kW |
4.8 kW |
7.75 kW |
18 kW |
22 kW |
30 kW |
45 kW |
| Cooling capacity @ -55°C |
0.25 kW |
0.5 kW |
0.75 kW |
0.9 kW |
1.5 kW |
2.8 kW |
6 kW |
7.5 kW |
11 kW |
15 kW |
| Pump max flow |
35 L/min |
35 L/min |
50 L/min |
60 L/min |
110 L/min |
150 L/min |
200 L/min |
250 L/min |
400 L/min |
400 L/min |
| Pump max pressure |
2 bar |
2.5 bar |
| Thermal interface size |
DN15 |
DN20 |
DN25 |
DN32 |
DN40 |
DN50 |
| Cooling water requirement @ 20°C |
1.2 m³/h |
1.5 m³/h |
1.8 m³/h |
2.6 m³/h |
3.2 m³/h |
7 m³/h |
10 m³/h |
14 m³/h |
20 m³/h |
30 m³/h |
| Cooling water pressure |
1.5–4 bar |
| Cooling water interface |
G1/2 |
G1/2 |
G3/4 |
G3/4 |
G1 |
G1 |
DN40 |
DN50 |
DN65 |
DN65 |
| Voltage |
AC 220V, 50 Hz (110V is also available) |
AC 380V, 50 Hz |
| Total power (max) |
5 kW |
7.5 kW |
10 kW |
14 kW |
8 kW |
26 kW |
38 kW |
58 kW |
85 kW |
130 kW |
| Compressor |
Embraco |
Emerson Copeland |
Turin / Bitzer / Fujijo (Italy) |
| Expansion valve |
Danfoss |
| Dimensions (Water-cooled) W×D×H (mm) |
400 × 600 × 1150 |
550 × 700 × 1350 |
550 × 700 × 1350 |
650 × 700 × 1650 |
700 × 800 × 1650 |
1000 × 950 × 1650* |
1250 × 950 × 1650 |
2000 × 1250 × 1750 |
2300 × 1450 × 1750 |
2300 × 1450 × 1750 |
| Dimensions (Air-cooled) W×D×H (mm) |
400 × 600 × 1250 |
550 × 700 × 1450 |
650 × 700 × 1650 |
650 × 700 × 1650 |
750 × 750 × 1800 |
750 × 750 × 1800 |
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| Weight (Water-cooled) |
170 kg |
185 kg |
265 kg |
305 kg |
340 kg |
380 kg |
980 kg |
1150 kg |
1380 kg |
1750 kg |
| Weight (Air-cooled) |
200 kg |
225 kg |
300 kg |
340 kg |
380 kg |
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Optional configurations: SUS 304 chassis; Ex d IIB T4 explosion-proof; Ex d IIC T4 explosion-proof; positive pressure explosion-proof (positive pressure explosion-proof is available for water-cooled models only).
