LAUDA, the world market leader for constant temperature equipment and systems for precise temperature control, is steadily expanding its comprehensive portfolio. With the fully redeveloped, future-proof LAUDA Integral product line, the company presents a further milestone in the field of professional temperature control. The powerful Integral process thermostats have been a permanent feature of the LAUDA portfolio since 2000, and have become established as a reliable solution in all manner of applications and industries. Major areas of application include the temperature control of reactors in the chemical and pharmaceutical industry, temperature tests at test stations in the automotive industry, or space simulations in mechanical and electrical engineering. The company is now driving the further development of the process thermostats and bringing the models in the T and XT series into the digital age. As a result, the new generation of Integral process thermostats have a variety of new features, including a brand new, intuitive control concept using mobile devices, increased pump output and a modular, expandable interface concept.

LAUDA Integral T and XT: 20 years of success

LAUDA's new Integral T process thermostats ensure efficient control of external temperature control processes in the temperature range from -30 to 150°C. The devices have an adjustable heating and cooling capacity and small internal volume that enables rapid temperature changes. Thanks to the open hydraulic system, the device aerates quickly and without loss of function. This makes it ideal for temperature control processes with frequent changes in consumer or test object. Classic application areas include controlling reactions or climate simulations. A reliable, powerful submersible pump and an internal bypass to limit the pressure are part of the standard equipment of the Integral T.

The extremely dynamic, high-performance LAUDA Integral XT process thermostats, on the other hand, operate with a cold oil blanket according to the flow principle and make it possible to use just one temperature control medium across the expanded temperature range from -90 to 320°C. Thanks to an electronically controlled, magnetically coupled, eight-level LAUDA Vario pump, the flow rate can be optimally thermally set for the requirements of pressure-sensitive consumers, as well as applications with high hydraulic resistance. An internal bypass, another new standard feature of the XT models, also increases flexibility. It increases the flow rate inside the device when only low flow rates are possible externally, to optimize the temperature control process.

For the new Integral XT models, LAUDA offers an optional through-flow control unit, which is particularly indispensable in creating reproducible test processes. An excellent example of such use is in test processes in the field of electric mobility. In order to achieve a high level of quality in production, validated test processes in this field use a defined flow rate that must be complied with. The optimized hydraulics and speed control of the new Integral devices also improve the conveying capacity of the thermostats considerably. Operated with future-proof refrigerants – the process thermostats conform to the European F-gas regulation – the new Integral devices provide the usual rapid temperature control along with high operating safety. The proven Smart Cool System of LAUDA Integral XT devices is now also featured on the new Integral I models. Here, electronic injection valves control the cooling output of the devices for greater energy-efficiency.

Integral process thermostats – Ready for the digital future

With the new Integral devices, LAUDA is driving forward the networking of temperature control technology. As the first series device in the history of LAUDA, the process thermostats have an integrated web server. This allows the devices to be integrated in existing company networks and therefore monitored and controlled via PC, or with mobile devices like a tablet or smartphone, if desired. The devices can be installed and operated in separate locations, if required. This enables location-independent monitoring and control. The thermostats can also be easily controlled via a modern OLED display directly on the device.

Newinterface concept provides flexibility

The new Integral process thermostats enable maximum networking of user processes, thanks to their modular and future-proof interface concept. The devices feature interfaces such as Ethernet, USB and Pt 100 as standard. Further interfaces and communication protocols can easily be added via additional modules. This allows Integral thermostats to be flexibly integrated in different communication scenarios. In addition, all the three-phase devices in the LAUDA Integral series are equipped for operation with a mains frequency of 50 or 60 Hz (bifrequent) – a great benefit for users who want to use their devices flexibly in different locations worldwide.

Modular design for simplified maintenance

LAUDA Integral devices are available in three different casing sizes and with a cooling capacity of 1.5 to 18 kW. Whereas the operating unit for the smallest casing size is mounted on the top of the device for best ergonomic advantage, on the medium and large casings, it is located at eye level on the right hand side of the device. The electrical and hydraulic connections are located on the right hand side for all devices. This means they will be easy to operate and see. With the Command Touch, LAUDA offers an intuitive operating unit with a touch display and expanded range of functions as an accessory, which can be connected to the device via a cable.

LAUDA Integral – A new generation

The process thermostats from the Integral series have proven successful on the market for decades. The development of the next generation takes the proven strengths of the series and combines them with future-proof components. By doing so, LAUDA offers its customers a piece of constant temperature equipment that fulfills today's requirements for refrigeration technology and guarantees a seamless transition with maximum process reliability.

An important aspect in the development of the Integral series was the European F-gas regulation. This will gradually restrict the quantities of partially fluorinated hydrocarbons available on the market until 2030. Demand for future-proof constant temperature equipment that conforms to the F-gas regulation has risen considerably. “We have put a lot of thought and expertise into the development of the refrigeration technology,” explains Dr. Jürgen Dirscherl, Head of Research & Development at LAUDA, for “simply replacing the refrigerant would limit performance data” and jeopardize customer processes. The goal of the LAUDA experts was to develop a new generation of devices that can seamlessly replace older models of existing Integral devices. “This will ensure the reliability of our customers’ process,” says Dr. Dirscherl. The new Integral series retains many of the proven functions and technical solutions of the old one.

With the new generation of Integral devices, LAUDA has put forward a technically more advanced version of a tried-and-tested product line, explains the Head of Research & Development. The new LAUDA design may be the most obvious new feature of the new devices, but that’s not the only difference. “For example, the new design enables simplified maintenance, thanks to improved accessibility of the components without separating the hydraulic circuit from the application. Further powerful benefits of the new generation of Integral devices include the position of the connections, enhanced communication options with process control systems, the integrated web server, pumps with a higher output range and, above all, considerably higher flow rates,” says Dr. Dirscherl.

Example applications for LAUDA Integral process thermostats

LAUDA process thermostats reliably heat and cool in a wide range of applications in the most varied of industries. For example, the devices can be used for the temperature control of stirrer tanks as well as reactors in chemistry, pharmacy and biotechnology, and in temperature tests on test stations in the automotive industry, be it for climate simulations or performance and material tests. Integral process thermometers are also the ideal partner for material inspections. In microreactor technology, the devices are used for temperature control in scale-up processes. And in mechanical and electrical engineering, LAUDA Integral process thermostats are an elementary component of space simulations.

At the end of 2018, the world market leader for temperature control, LAUDA, announced the acquisition of the laboratory technology specialist GFL from Burgwedel. In order to ensure a smooth transition, the previous managing partners of GFL, Ulrike Mischel and Dieter Bubel, continued as managing directors until the end of June 2019. Now LAUDA has taken the next step towards successful integration into the LAUDA Group with the appointment of Andreas Degmayr as the new Managing Director of GFL.

At the end of June, Dr. Gunther Wobser, CEO and President of LAUDA and also CEO of the youngest subsidiary GFL, invited the two former shareholders Ulrike Mischel and Dieter Bubel to a farewell reception. He expressed his thanks for the trusting cooperation during the purchase initiation phase and above all as colleagues in the management during the intensive last six months.

A big responsibility for LAUDA
The staff paid tribute to both of them with an original gift and words of thanks from the chairman of the works council, Mike-Peter Klotz, for the decades of management of the successful, traditional company. Dr. Gunther Wobser is aware of his responsibility: "GFL is a proud family business with over 50 years of successful activity. The values and excellent reputation of the GFL brand fit well with LAUDA. The high-quality water baths, freezers and distillation plants are an excellent addition to the portfolio. I would like to thank the second generation and promise to continue the successful tradition within the LAUDA Group with now 500 temperature experts at two German locations". On 1 July, the experienced engineer Andreas Degmayr was appointed as an additional managing director 'on site'. Antje Peters, who has been with the company for many years, is responsible for the commercial area.

Germany has set ambitious goals for the energy revolution: The proportion of renewable energy relative to overall energy consumption should be 80 per cent by 2050. With the expansion of wind energy, photovoltaics and other regenerative energy sources as well as the increasing electrification of society, the world of business, politics and science are facing a major challenge: the efficient and sustainable storage of locally generated excess energy so that it can be fed into the energy grid during peak times. One highly promising energy efficiency concept is “Power to Gas”, whereby methane is obtained from wind or solar energy by way of electrolysis and methanation. Energy is then stored in gas form and recovered when required. Methanation could also accelerate the rise of gas-powered vehicles in the automotive sector, while the methane required to fuel the vehicles could be produced in an environmentally compatible way. Researchers all over the world are working at full speed to design a technology that is simpler and more relevant in terms of energy efficiency. The Max Planck Institute for Dynamics of Complex Technical Systems in Magdeburg is a leading organization that has already been active in this field of research for seven years. To carry out work in its pilot plant, the institute uses a LAUDA heat transfer system that must meet the very specific requirements of the researchers.

High-precision, rapid cooling required

LAUDA Heating and Cooling Systems, which is the industrial division of temperature equipment manufacturer LAUDA, plans and manufactures customized constant temperature systems exactly according to customer requirements. A type ITH 350 heat transfer system was developed for the Max Planck Institute. The system is used to control the temperature of a reactor. The LAUDA system must be able to provide cooling of 100 Kelvin per minute without falling below the end point. It must therefore cool down quickly but must not fall below a certain temperature point and endanger the actual process. This challenge also posed problems for the LAUDA engineers because heat transfer systems are usually designed for constant temperature control. The research carried out at the Max Planck Institute requires a system that cools extremely quickly.

Cooling from 340 °C to 150 °C in minutes – with extreme precision

The methanation reaction generates a great deal of heat and high temperatures that may damage the reactor, or more importantly, the catalyst. Up to now, this kind of process was typically started up slowly one time and then run constantly for several weeks. Project manager Jens Bremer explains what the researchers are aiming to achieve: "First we are attempting to identify how dynamically this process can be arranged and then develop some basic concepts for new operating strategies and reactor designs. We have already obtained some initial promising results based on computer-assisted calculations and now wish to use the pilot system to verify these results”. Temperature control requirements are correspondingly high. The LAUDA heat transfer system is more than capable of delivering the required precision. “The performance and dynamics of the reactor are primarily determined by the cooling of the reactor. Rapid temperature control enables a flexible response to external influences, such as a decrease in the hydrogen supply, without having to shut down the reactor”, explains Jens Bremer.

During the process, the reactor is heated electrically to 340 °C. Once a defined temperature is reached, an exothermic reaction is triggered and the system must then be rapidly cooled to 150 °C. An electronic valve used in normal situations that serves as a regulating device would be much too slow for this particular application. It may be possible to use the valve to adjust the cooling capacity, depending on the actuating signal. If the system is cooled with cooling water, the cooling capacity for normal cooling tasks is limited to preserve the materials in the event of significant temperature differences. In this case, a rapid opening is required to reach the necessary cooling speed without stressing the material too much. LAUDA engineers have therefore developed a pneumatic 3-way valve that opens in only 2 seconds to ensure that the heat carrier is cooled at more than 150 °C per minute.

The heat transfer system incorporates two thermostatic circuits. While the first circuit controls the temperature in a buffer vessel, the second circuit controls the temperature in the test setup of the Max Planck Institute. Both circuits use the same medium and are connected to one another via the media storage unit. One additional customer requirement for the system was that the heat carrier could be used at temperatures of up to 350 °C. LAUDA therefore selected a thermal oil capable of satisfying the demanding requirements of the material.

Specific customer requirements fulfilled

LAUDA developed and designed the special heat transfer system according to the requirements of the Max Planck Institute. The restricted spatial conditions were already taken into consideration during the development phase on the computer. The system had to be enclosed in a special safety dome, which made it necessary to mount the control cabinets on the side. As requested by the customer, some of the nozzles are located on the underside of the device. The LAUDA system was sent to Magdeburg for assembly in two parts, which were lifted into the safety glass enclosure by a crane.

The heat transfer system for methanation research was the second system LAUDA has delivered to the Max Planck Institute. The institute is more than satisfied with the services provided by the temperature control manufacturer: “We received outstanding consultation and customer care all the way from the initial concept design phase to final on-site installation. No other manufacturer was able to provide such flexibility for our specific situation”, explains project manager Jens Bremer.