Disadvantages: Requires water supply & treatment (risk of scaling/corrosion).
Applications: High-capacity industrial systems.
3. Plate & Frame Coolers
Compact design with stacked metal plates for efficient heat transfer.
Advantages: High efficiency, easy maintenance.
Disadvantages: Limited to clean fluids (no particulates).
4. Shell & Tube Coolers
Robust design where thermal oil flows through tubes, and coolant flows around them.
Advantages: Handles high pressures/temperatures.
Disadvantages: Larger footprint, higher cost.
Key Benefits in Biogas & Industrial Applications
✔ Temperature Control – Maintains optimal thermal oil temperature for process stability. ✔ Energy Efficiency – Recovers waste heat for reuse (e.g., preheating biogas digesters). ✔ System Protection – Prevents overheating, extending equipment lifespan. ✔ Flexible Cooling – Can use air, water, or hybrid cooling methods.
Design Considerations
Flow Rate & Temperature Range – Must match system requirements.
Material Compatibility – Stainless steel for corrosive fluids (e.g., H₂S in biogas).
Fouling Resistance – Finned tubes or plate designs for dirty fluids.
Automation – Temperature sensors & control valves for precise cooling.
Applications
Biogas Plants – Cooling thermal oil from CHP units or gas cleaning systems.
Chemical Processing – Temperature regulation in reactors & distillation.
Food Industry – Cooling in edible oil processing.
Solar Thermal Plants – Heat dissipation in concentrated solar power (CSP).
Comparison with Other Cooling Systems
Feature
Thermic Fluid Cooler
Chiller
Cooling Tower
Cooling Medium
Air/Water
Refrigerant
Water (evaporative)
Temperature Range
50°C–400°C
-20°C–30°C
30°C–60°C
Best For
Thermal oil systems
Low-temp processes
Large water cooling
Installation Tips
Place downstream of the heat load (e.g., after a reactor or boiler).
Use corrosion-resistant materials if thermal oil contains contaminants.
Include bypass valves for maintenance without system shutdown.
