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Typical applications of refrigeration heating temperature control system:
Dynamic constant temperature control of cold and heat sources of high-pressure reactor, dynamic constant temperature control of cold and heat sources of double-layer glass reactor, dynamic constant temperature control of cold and heat sources of double-layer reactor and constant temperature control of cold and heat sources of microchannel reactor; Small constant temperature control system, temperature control of steam saturation system, material low-temperature and high-temperature aging test, combined chemical cold and heat source constant temperature control, semiconductor equipment cooling and heating, vacuum chamber refrigeration and heating constant temperature control.
Structure and principle of Dynamic Temperature Control System:
Ultra high temperature cooling technology can directly cool from a high temperature of 300℃[because only the heat transfer medium in the expansion chamber contacts with oxygen in the air (and the temperature of the expansion tank is between normal temperature and 60℃), which can reduce the risk of heat transfer medium being oxidized and absorbing water in the air. At high temperature, no heat conducting medium evaporates, and continuous temperature control of - 80℃ ~ 190℃, - 70℃ ~ 220℃, - 88℃ ~ 170℃, - 55℃ ~ 250℃ and - 30℃ ~ 300℃ can be realized without pressurization.
Process Control Principle:
Change the control settings of the method, the response as soon as possible in the process of the system lags behind, be the smallest system overshoot.
Controlled by two PID(PID is a variable in each group control loop structure, known as the two sets of controlloops: the main circuit and from the circuit. the main control loopfrom the loop output as the setting.
System with feedforward with PV, the master PID loop operation results of the PV output and feedforward signals as the composite of the settings from the control loop, through such control of the temperaturegradient to ensure the accuracy of temperature control system.
| Model |
SUNDI -1035W |
SUNDI -1055W |
SUNDI -1075W |
SUNDI -10A10W |
SUNDI -10A15W |
SUNDI -10A25W |
SUNDI -10A38W |
SUNDI -10A60W |
SUNDI -10A80W |
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| Temp. range | -100℃～+135℃（the system add pressure 3bar) | |||||||||
| Control Mode | Feedback PID + Our special dynamic control calculation, PLC controller | |||||||||
| Temp. control | Process temp control and jacket temp control model | |||||||||
| Temp. difference | Set or control the temperature difference between jacket oil and raw material process | |||||||||
| Program Editor | 5 programs, each program can edit 40 steps. | |||||||||
| Communication Portocol | MODBUS RTU Protocol,RS485 interface | |||||||||
| Material temp. feedback | PT100 OR 4～20mA or communication（normal: PT100) | |||||||||
| Temp. feedback | The temp. of three points: the inlet and outlet of equipment, reactor material temp.(external temp. sensor) | |||||||||
| Medium temp. acccuracy | ±0.5℃ | |||||||||
| Material temp. accuracy | ±1℃ | |||||||||
| Heating power kW | 3.5 | 5.5 | 7.5 | 10 | 15 | 25 | 38 | 60 | 80 | |
| Cooling capacity kW at | 135℃ | 3.5 | 5.5 | 7.5 | 10 | 15 | 25 | 38 | 60 | 80 |
| 0℃ | 3.5 | 5.5 | 7.5 | 10 | 15 | 25 | 38 | 60 | 80 | |
| -60℃ | 2.8 | 5 | 6.2 | 8 | 9 | 15 | 23 | 38 | 52 | |
| -80℃ | 1.9 | 2.8 | 3.4 | 4.1 | 5 | 8 | 13 | 22 | 30 | |
| -90℃ | 0.7 | 1.2 | 1.6 | 2 | 3 | 4.8 | 7.5 | 12 | 16 | |
| -100℃ | 0.45 | 0.7 | 0.9 | 1.2 | 1.8 | 2.9 | 4.5 | 7.2 | 9.5 | |
|
Circulation pump max L/min bar |
35 | 35 | 50 | 60 | 110 | 150 | 200 | 400 | 400 | |
| 1.2 | 1.2 | 1.2 | 1.5 | 1.5 | 1.5 | 1.5 | 2.5 | 2.5 | ||
| Pump | Magnetic drive pump | |||||||||
| Compressor | Dorin semi-closed compressor | |||||||||
| Oil separator | EMERSON | |||||||||
| Expansion valve | Electronic expansion valve | |||||||||
| Evaporator | Plate heat exchanger | |||||||||
| Operation Panel | 7-inch touch screen，show temp curve\EXCEL data output | |||||||||
| Safety protection | Self-diagnosis function; freezer overload protection; high pressure switch, overload relay,thermal protection device, liquid low level protection, high temperature protection and temperature fault protection. | |||||||||
| Closed circulation system | The whole system is full closed circulation, there is no oil mist at high temperature and no water vapor at low temperature, pressure do not rise up when system is running. The system will supply oil automatically at low temperature. | |||||||||
| Refrigerant | R404A/R23/R14 | |||||||||
| Connection size | ZG3/4 | ZG3/4 | ZG1 | ZG1 | DN32 PN10 | DN32 PN10 | DN40 PN10 | DN65 PN10 | DN65 PN10 | |
| Water-cooled type W(cooling water@20℃) |
3500L/H 1.5bar ~4bar |
5000L/H 1.5bar ~4bar |
7000L/H 1.5bar ~4bar |
9000L/H 1.5bar ~4bar |
12m³/H 1.5bar ~4bar |
20m³/H 1.5bar ~4bar |
25m³/H 1.5bar ~4bar |
40m³/H 1.5bar ~4bar |
50m³/H 1.5bar ~4bar |
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| Dimension cm |
80 *120 *185 |
80 *120 *185 |
150 *100 *185 |
150 *100 *185 |
200 *145 *205 |
200 *145 *205 |
250 *160 *225 |
300 *160 *225 |
400 *160 *225 |
|
| Weight kg | 435 | 565 | 705 | 890 | 1250 | 1600 | 2100 | 2950 | 3350 | |
| Power 380V 50HZ |
11kW max |
16kW max |
20kW max |
26kW max |
38kW max |
58kW max |
82kW max |
135kW max |
200kW max |
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Displays Various Information：
1. Displays all the kind of process control temperatures.
2. Shows the liquid level of the heat conducting medium in the expansion vessel.
3. Shows indication for refrigeration system working.
4. Shows indication for heater working.
5. Shows indication for circulation pump working.
6. Displays the temp. control ( materials temp. control pattern, heat conducting medium temp. control ).
7. The temp. upper limit, lower limit control can be set.
8. The temp. difference between jacket & reactor material can be set.
9. Shows the alarm to add the liquid when it is empty.
10. The refrigeration compressor can be set to operate manuallyor automatically.
| Comparison between LNEYA SUNDI series and other systems on thermodynamic properties | ||
| LNEYA Dynamic temperature control system SUNDI series | General cooling circulator,heating oil furnace | |
| Whether it is closed system | Use patent closed liquid circulation system and expansion system, regardless of high or low temperature, the heat transfer oil inside the expansion tank will keep room temperature, So it can be used in a wide temperature range. You can safely use it if the boiling point of the heat conduction oil is within 10℃. | Generally open systems. The heat transfer oil will react with oxygen in the air at high temp. and turn brown even becomes deeper and darker in a short time with terrible smell. Because of open system at low temp., it can reach the target temp. for a few times, but accompanied by absorbing the moisture in the air, its viscosity will keep increasing and can't drop to the target temperature. |
| At low temperature, the heat conduction medium won't contact with or absorb the moisture in the air, this closed system can improve the stability of the cryogenic system. | There may be some closed loop systems, in the process of running, some medium inside the expansion tank will recycle, the above problems will appear. | |
| Whether the high-level heat transfersystem | The system adopts pipeline heating and cooling. There is lttle liquid participated in circulating. Plate heat exchanger is used in refrigeration, and pipeline flange heater is used in heating, the whole system volume is (The volume of plating heat exchange + The volume of pipeline heater+ The volume of circulating pump + The volume of circulation loop） | With open system, the same 10 kW heating or cooling ability, it can concert with 100L trough. This system loading is 100L + 25L jacket reactor + 100L material. The relative efficiency is much lower. |
| Such as to control a 100L reactor, choose model SUNDI-5A10W; heating power 10kW; cooling capacity 10kW;temperature -5℃. | They tend to use relatively small circulation pump, the heat transfer on reactor is even less. | |
| The volume of the whole system participated in the circulation is only 5.5L. Comparing with the 100L of reactor jacket + material, the 5.5L internal system volume is very small. | Some closed system: Because some liquid in expansion tank involved in circulation, the medium will be added. There is no heat preservation in expansion system, increase the heat dissipation and reduce the thermal efficiency. | |
| The 10kW heater is almost all used on reactor. | ||
| Use big flow circulation pump, heat transfer relies on circulation pump to transfer the liquid regardless of how large the outside storage tank is. | ||
| whether there has valve incirculatorysystem | The entire circulatory system without mechanical or electronic valve. This can avoid the broken of valve at high or low temp. for long time. | Use high and low temperature precooling control, system with mechanical or solenoid valve. Any mechanical or electronic valve will be broken easily after long time cold and hot shock. And a small amount of impurity in the system will cause valve broken.(we cannot avoid a small amount of impurity into the circulatory system in production and operation process) |
| Ultra high temperature cooling technology | Use ultra high temperature cooling technology, the system can directly start the compressor at max 300℃. | The general refrigeration cycle trough can't be cooled at high temperature or cool high temperature heat conduction medium to room temperature by circulation fan (this is often exchanged through the valve). After 2 ~ 3 months, the valve can't be tightly shut and cold energy loss is serious, the temperature can't drop down. |
| This system can easily take away heat when exothermic reaction taken place under high temperature. The unique temperature control system can always keep the system temperature maintain at moderate reactor's temperature. p Look at the control effect | Exothermic reaction at high temperature will often need people to pipe in low temperature liquid. Temperature control problems will take place easily for careless operation. Too much of the cryogenic liquid will lower the temperature of reaction system too much, which can't reach the reaction temperature. What's worse, the reaction kettle may be broken | |
| Temp.control system | The method of changing the control settings can response to the system delays as soon as possible, and gets the smallest system overshoot. The system consists of two PID (PID is changeable in each group) control loop structures. We call these two sets control loops the main circuit and from the circuit, the output of the Main loop as the set point of from loop. p The system with feed-forward PV, the master PID loop operation results of the PV output and feed-forward signals as the composite of the settings from the control loop. Through such control of the temperature gradient. | For example, reaction material reacts at 100℃. |
| To ensure the accuracy of temperature control. | Operators firstly set the temperature of thermal oil at 1350C or higher, this process will continue for a period of time, then operators will set heat conduction medium temperature at 105C according to their experience, to control the reaction temperature to about 100C. | |
| The specially designed lag forecasts ( special dynamic control calculation) create a dynamic signal yc(t) to replace the process variable y(t) to serve as the feedback signal. | This process with large temperature range, so skilled and responsible operators will be needed. No complete temperature curve record of the whole process. | |
| It sends an e (t) signal to the controller, the controller will predict whether the control function has large time delays. So the controller can always produce appropriate control signals. That is to say, even if there may be large time delays, the dynamic signal yc (t) can make the feedback loop keep working. | If just set the temperature of heat conduction medium at 1Ó5"C, there will be long time before the reaction material temperature reach 100*C. (Because the temperature difference between the jacket and material is too small). ý How about using temperature measuring points to directly sample the temperature of the reaction material? What's theresult? | |
| By taking sample at three temp. points (material temp., outlet and input temp. of the temp. control system), our special dynamic control calculation combine with the common resistance lag cascade algorithm. | Use common PID or simple cascade algorithm to control the process with significant time delays, the output of controller will keep increasing without getting appropriate feedback signal within the delay time, this will lead to large system response overshoot and even make the system out of control. | |
| Look at the control effect | Chemical reaction is often unpredictable, the 50L reactor is fixed, but the volume of the reaction materials will be different each time, and the hot hot melting will be different too, it can't be co controlled by PID self-tuning. | |
| LNEYA Dynamic temperature control system SUNDI series | General cooling circulator,heating oil furnace | |
| Repetitiv econtrol results | Based on advanced dynamic control system, each time it can achieve consistent control effect, it greatly improves the stability of the products. Look at the control effect | Because the operation with human intervention, It doesn't keep consistent in effect every time and influence the stability of produced products. |
| Control exothermic reaction | The material temperature is rising when testing of reactor. The system will rapid heat-up and cool-down temperature with good result to meet your demand. | Because jacketed reactor with large time delay. The heat conduction medium response time- delay, and the actual temperature is too high. |
| Based on the algorithm, make the right choice to maintain moderate heat conduction oil temperature; take away the released heat and maintain reaction system at required temperature. | Can' t be better controlled without human intervention. This system needs experienced operators, or the system temperature will be too low or too high, greatly affect the stability of the products. | |
| Look at the control effect | ||
| Smaller amplification effect | Based on precise control of reactor temperature,lt can control the process temperature. This is most important in process control with protecting thermostatically controlled environment. Look at the control effect | With small dose of laboratory experiment and higher yield. It has problems if it will be blew up. Need to grope for temperature process curve. It is high cost. No good result in extreme condition. |
| Safety protection | It can control and set the temperature of outlet temperature and material temperature. | Conventional protection: high temperature protection, refrigeration system high and low pressure protection, compressor circulating pump overheating protection, the high cooling water temperature protection, phase sequence protection, leakage circuit breaker, sensor fault protection, liquid level protection |
| Heating security protection, control protection, solid state relay power protection, independent temperaturelimiter. | ||
| Conventional protection: high temperature protection, refrigeration system high and low pressure protection, compressor circulating pump overheating protection, the high cooling water temperature protection, phase sequence protection, leakage circuit breaker, sensor fault protection, liquid level protection | ||
| Circulating pump | With magnetic resistance to high temp. and low temp. circulation, without shaft seal, no leakage problems for using 2 to 3 -years. | With shaft seal circulating pump, there will be leakage problems after being used for a long time. |
| Program Editor | It can edit 25 programs, each program can edit 45 steps. | With program Without program |
| Heat Conduction Medium | Use colorless and tasteless heat conduct medium, wide temperature range ( Look at the heat-conducting medium parameter table), with LNEYA temperature control system and the service life of more than 6 years. | In the process of using the color change, terrible smell of transfer fluid for a period of time. Firstly, the heat conduction medium itself has problems. Secondly, the system design has problems, lead to the oxidation of heat conduction oil at high temperature. |
| Display | Use 7-inch or 10-inch color touch screen. | With instrument display |
| Data recording | Clearly records material temp.,setting temp., inlet and outlet temp. of heat conduction medium and alarm record of -system. | Without data record ,only display |
| Temp. curve | With real time temperature curve record, it can record temperature curve of 18 months. | Without |
| Temp. data export | With U disk derived data curve, it can select the export time. | Without |
| Configuration software | It can be easily configured. You can install and record the picture of display on the computer. | Without |
| Communication | Adopt good Modbus RTU communication protocols, can easily communicate with other equipment like DCS. | without or no special communication protocol, poorscalability |
| Testing | All dynamic temp. control systems with load testing of 24 hours. Confirm and record the whole process of load testingprocess. | |
| Intellectualproperty | Wuxi Guanya Refrigeration Technology Co., Ltd, We have successfully applied for 10 patents in China. |
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