In this module, you’ll be introduced to temperature control in industrial applications, its impact on production efficiency, reliability, and product quality, and the benefits of optimising your system. Let’s get started.

Temperature control includes heating, cooling, and refrigeration down to as low as -123 degrees Celsius. In industrial applications, it refers to regulating ambient temperatures, like cooling tunnels in abattoirs, as well as controlling the temperatures of specific substances, such as heating milk during pasteurisation.

The overall structure of temperature control systems is quite similar across applications. In every case, the pump is just one component within a larger system that includes condensors, evaporators, chiller units, pipes, valves, and cooling towers.

To optimise such systems, it’s necessary to look beyond the pump. International studies suggest that focusing on system optimisation can lead to energy savings of up to 30%, while focusing solely on pumps can result in energy reductions of just 10%.

But optimisation requires a long-term perspective. In temperature control, running costs outweigh capital investment by a factor of 20 to 1, meaning that focusing on total lifecycle costs can lead to significant savings over time. Because of this, selecting the right temperature control strategy becomes even more crucial.

There are three ways to control the transference of energy in a heating, cooling, or refrigeration system. The first and one of the most common methods is to use constant-speed pumps with throttling valves to regulate the amount of water entering the heat exchanger. But this is an inefficient strategy. When the valve closes, it generates substantial pressure, and pressure loss always leads to energy waste. Plus, it requires regular maintenance.

The second method is to add a frequency converter and a sensor that monitors and regulates the differential pressure. This demand-driven approach avoids high pressure at the valve, reducing pressure loss and energy waste. Although it lowers energy consumption, the system still relies on a regulating valve to control the flow of water to the heat exchanger.

Grundfos recommends the third method: creating demand-driven systems. By installing intelligent pumps equipped with temperature sensors that measure the outlet temperature, the pump can adjust its flow accordingly. This makes throttling valves redundant and ensures efficient operation at all times, regardless of the load profile.

To further minimise flow and pressure losses in the system, Grundfos recommends Distributed Pumping, which can save up to 50% of initial energy requirements.

Let’s recap.

• To achieve intelligent temperature control, you must look beyond the pump and focus on the system.

• To ensure an optimised system, focus on the total life cycle costs, not just capital investment.

• By designing demand-driven systems and using Distributed Pumping, you can simplify your system, cut maintenance costs, and increase efficiency.