Analytical Process Control Trainer | ProzessiX PX-04

The Heat Exchanger Service Unit ThermoFlux – 7108 is a bench-mounted experimental control unit designed to provide hot and cold water circuits for the investigation and comparison of multiple heat exchanger types under parallel flow and counter flow conditions. This heat exchanger service unit is compatible with up to four interchangeable heat exchanger modules — plate type, concentric tube, shell and tube, and jacketed vessel — enabling systematic study of thermal energy transfer, mean heat transfer coefficients, and temperature curve plotting across different exchanger designs and flow configurations.

Product Overview

The Heat Exchanger Service Unit ThermoFlux – 7108 forms the central control and service element of a modular heat exchanger experimental system. The unit houses a stainless steel hot water tank of 50–60 litre capacity fitted with four electric heating resistances of 1.5 kW each (6 kW total), a PID digital temperature regulator, a K-type thermocouple for water temperature measurement, level switches to prevent dry-running of the heater, a stainless steel cover, and a draining valve. Hot water is circulated through the connected heat exchanger by a 0.75 HP centrifugal pump with a flow range of 0–29 litres per minute. Cold water is supplied from the laboratory mains or an optional chilling unit. Two flow meters — one for hot water and one for cold water — each cover a range of 1 to 7 litres per minute. A control valve regulates cold water flow, and a regulation pressure valve set at 0.6 bar prevents excess pressure in the exchanger. Four flexible connecting tubes allow rapid interchange of heat exchanger modules. The structural frame is constructed from anodised aluminium with an insulated HDF wood panel; all water-contact parts are manufactured from PVC, brass, copper, or stainless steel. A front panel diagram with laser-engraved labelling provides a schematic representation of the real unit layout. Temperature is monitored by one K-type thermocouple dedicated to the temperature controller (−100°C to 400°C) and six additional K-type thermocouples (−100°C to 400°C) distributed across the system. Measured values are displayed on digital indicators on the panel and can simultaneously be transmitted to a PC via USB/Ethernet when the DAQ option is selected. The heat exchanger service unit is designed to work exclusively as the service base; at least one heat exchanger module must be ordered separately to conduct experiments.

The Perfect Gas Law Apparatus ThermoFlux – 7077 is a small-scale bench-top unit designed for experimental investigation of the perfect gas law apparatus principles, covering the first law of thermodynamics and the pressure, volume, and temperature relationships for air. Two transparent vessels connected by a large-bore pipe and valve, together with an integral air pump, enable a range of gas expansion and compression experiments.

Air is used as the test gas. The pump can pressurize one vessel and evacuate the other simultaneously. Additional valves allow the vessels to be operated singly or in combination, including venting to atmosphere and controlled transfer between a pressurized vessel and an evacuated vessel.

Product Overview

The Perfect Gas Law Apparatus ThermoFlux – 7077 consists of two transparent vessels: a large vessel with an approximate volume of 18.5 litres and a smaller vessel with an approximate volume of 10.5 litres. The vessels are connected by a large-bore pipe and valve with an integral air pump. The pump pressurizes one vessel while evacuating the other.

Additional valves provide three operating configurations: vessels in isolation, venting to or from atmosphere, and a combined arrangement where the pressurized vessel vents into the evacuated vessel. This range of configurations enables direct observation of perfect gas law apparatus behaviour including transient pressure and temperature responses.

Fast-response thermocouple sensors are located in each vessel to record air temperatures. Individual pressure transducers record chamber pressures. Two pressure gauges, one per vessel, cover a range of -1 to 4 bar. Two temperature sensors, one per vessel, cover a range of -100 to 400°C. Pressure relief valves prevent over-pressurization in the pressurized vessel. Pressure switches limit operating pressures to safe levels.

The vessels and interconnecting pipework are constructed from impact-resistant plastic. A control box digitally displays air temperatures in both vessels. The unit supports optional continuous PC monitoring of pressure and temperature changes. The air pump is available in manual or optional computer-controlled versions.

The Small Steam Generator ThermoFlux-24 is a compact, variable-power laboratory heat reservoir designed to provide continuous steam at a constant temperature. This small steam generator boils 3/4 litre of water in ten minutes and delivers continuous steam output at up to 2.5 kg/h. Dual steam ports, a 1-litre water capacity, and variable power from 0 to 3,000 W make it a practical and flexible steam source for laboratory thermal experiments.

Product Overview

The ThermoFlux-24 is built for reliable, consistent steam supply in laboratory settings. It holds 1 litre of water and heats it using an internal electric heater, eliminating any open flame or exposed coil hazard. Variable power adjustment from 0 to 3,000 W allows the user to control steam flow rate to match experimental requirements. Continuous steam output reaches up to 2.5 kg/h.

Two steam ports allow the unit to supply two laboratory groups simultaneously from a single generator. A rubber stopper provides a tight seal and incorporates a safety pressure release function. A low water warning light alerts the user before the water level becomes critically low. An extra-wide base provides stability and resistance to tipping during operation. An included baster allows safe removal of hot water during experiments.

This small steam generator is suitable as a heat reservoir for use with compatible laboratory apparatus, including the Thermal Conductivity Apparatus ThermoFlux-25.

The Heat Transfer Service Unit ThermoFlux – 7049 is a fully instrumented bench-top service unit designed to power, control, and monitor the full range of ThermoFlux heat transfer modules. This heat transfer service unit provides regulated and adjustable DC power output, a 9-point Type K digital temperature indicator with a range of 0 to 800°C, PID-configurable heat controller, and digital meters for voltage and current. The modular design supports continuous expansion with compatible optional modules and an optional LABVIEW-based data acquisition system.

Product Overview

The ThermoFlux – 7049 serves as the central instrumentation and power platform for a range of optional heat transfer modules covering linear conduction, radial conduction, extended surface heat transfer, unsteady-state heat transfer, and radiation heat transfer. All instrumentation is standardised across modules, allowing the same service unit to power and monitor any connected module without reconfiguration.

The unit provides regulated and adjustable DC power suitable for all optional modules, with multiple auxiliary power outlets for additional equipment. A 9-point digital temperature indicator accepts Type K thermocouples and measures across a range of 0 to 800°C, with 10 temperature measurement channels each spanning -100 to 400°C. A heat controller is configurable in PID mode for precise thermal regulation. Digital meters cover voltage from 0 to 500 V and current from 0 to 20 A.

Internal electronic and mechanical safety devices are built into the unit, making it suitable for unsupervised student operation. An optional autonomous pilot unit with computerised control software is available for advanced operation. Optional DAQ software, developed in the National Instruments LABVIEW environment and compatible with any Windows operating system, enables detailed data collection and real-time monitoring. A set of electronic sensors is included when the software option is selected.

The unit is supplied with one set of thermocouples. Five optional modules are available: Linear Heat Conduction Module ThermoFlux – 7049/1, Radial Heat Conduction Module ThermoFlux – 7049/2, Radiation Heat Transfer Module ThermoFlux – 7049/3, Extended Surface Heat Transfer Module ThermoFlux – 7049/4, and Unsteady State Heat Transfer Module ThermoFlux – 7049/5.

The Bubble Point Calculation Unit ThermoFlux-27 is a standalone laboratory unit for studying and comparing the bubble point and dew point phenomena through direct experimentation. This bubble point calculation unit enables students to separate a solvent from a solution using both the bubble point method and the dew point method on the same apparatus. A coil condenser, glass and stainless steel feed and vapour separation tanks, and three temperature measurement channels provide a complete platform for comparative vapour-liquid equilibrium experiments.

Product Overview

The ThermoFlux-27 is designed as a self-contained unit for performing comparative experiments on bubble point and dew point behaviour. A boiler heats the feed solution, with heater temperature controlled by a dedicated temperature controller and heating power adjustable via a regulating knob across a range of 0 to 3 kW. Boiler vapour temperature and vapour separation temperature are each measured independently, with three temperature measurement channels covering -100 to 400°C.

The feed tank has a capacity of approximately 3 litres and is constructed from glass and stainless steel. The vapour separation tank has a capacity of approximately 0.5 litres, also in glass and stainless steel. A coil-type glass condenser, 780 mm in height, condenses the separated vapour back to liquid. Cooling water flow rate to the condenser is adjustable and measured within a range of 1 to 7 litres per minute. System pressure is monitored by a pressure gauge with a range of 0 to 4 bar.

The unit supports two structured experiments: solvent separation from a solution using the bubble point method and solvent separation using the dew point method. Both experiments are conducted on the same apparatus, enabling direct comparative analysis of the two separation approaches.

The Unsteady State Heat Transfer Module ThermoFlux – 7049/5 is a dedicated laboratory module designed for in-depth investigation of temperature variation over time and heat flow dynamics within solid shapes subjected to sudden surface heating. This unsteady state heat transfer module uses a 5-litre insulated stainless steel water bath, an integral flow duct, and an external circulating pump to maintain uniform bath temperature. Seven solid specimens in three geometric shapes, each with a built-in centre temperature sensor, enable direct transient thermal analysis across different materials and dimensions.

Product Overview

The ThermoFlux – 7049/5 centres on a 5-litre insulated stainless steel water bath fitted with a top plate and mounting for a solid shapes holder. An integral flow duct and external water circulating pump, controlled by a valve for flow rate adjustment, ensure uniform temperature distribution throughout the bath. A thermostat allows the bath to be set and maintained at a nominally constant temperature before experiments begin.

The heating element is rated at 300 W and incorporates internal thermal protection that automatically cuts power if the heater is activated without sufficient water coverage. Users should avoid repeated exposure of the heater to dry-run conditions to prevent premature component failure.

Seven solid specimens are supplied, made from brass and stainless steel, in three geometric forms: solid sphere, rectangular slab, and long solid cylinder. Each specimen has a built-in temperature sensor at its centre, enabling direct measurement of transient temperature response at the core of each shape.

The control panel integrates all necessary wiring, temperature measurement, and digital indicators for effective monitoring during experiments. The module requires the Heat Transfer Service Unit ThermoFlux – 7049/5 for operation.

This unsteady state heat transfer module supports experiments using analytical transient-temperature and heat flow charts, the Lumped Thermal Capacitance method, and comparative thermal conductivity analysis across materials and shapes.

The Cross Flow Heat Exchanger ThermoFlux – 7078 is a laboratory-grade unit designed to enable students to investigate heat transfer rates by free and forced convection. This cross flow heat exchanger provides hands-on experimentation with interchangeable heating elements, adjustable airflow, and digital measurement display, making it a precise tool for thermal engineering studies.

Product Overview

The Cross Flow Heat Exchanger ThermoFlux – 7078 consists of a vertical air duct through which air is drawn by a radial fan. Three interchangeable heater elements, a pipe, a pipe bundle, and a finned pipe bundle, dissipate heat directly into the airflow. Each heater element operates at 500W. The heating power is adjustable, and the air flow rate is variable, allowing systematic investigation across different conditions.

Electronic sensors measure temperature, differential pressure, and power. All measured values are displayed digitally on the front-mounted instrumentation unit. Data can also be transferred directly to a PC. The flow rate, Reynolds number, and Nusselt number are calculated from sensor data. The temperature-time relationship and the dependence of the Nusselt number on the Reynolds number can be demonstrated graphically.

The heater insert in the pipe bundle configuration can be repositioned across different pipe rows to investigate the effect of flow arrangement on heat transfer performance.

The Two Stage Air Compressor ThermoFlux – 7092 is a laboratory trainer designed to enable students to study the operating characteristics and thermal behaviour of a two-stage reciprocating compressor with intercooling. This two stage air compressor is equipped with a water-cooled intercooler, orifice-type flowmeter, pressure vessels, and digital instrumentation across both compression stages, providing a complete platform for compressor performance and efficiency analysis.

Product Overview

The Two Stage Air Compressor ThermoFlux – 7092 consists of a two-cylinder V-arrangement reciprocating compressor with a water-cooled intercooler between the first and second stages. Air is drawn from atmosphere into an intake vessel, which stabilizes the intake pressure. An orifice-type flowmeter at the intake measures the incoming airflow rate. After the first stage of compression, air passes through the water-cooled intercooler, which stabilizes pressure by controlling temperature before feeding into the second stage. The second stage compresses the air and delivers it to a final storage pressure vessel.

The compressor operates at a power consumption of 2.2 kW with a variable speed of 0 to 900 rpm and an intake capacity of 200 L/min. The operating pressure is 12 bar with a maximum of 20 bar. The pressure vessel has a capacity of 200 L, an operating pressure of 8 bar, and a maximum pressure of 12 bar. It is fitted with a safety valve, control valve, and outlet silencer.

Sensors measure pressures and temperatures across both stages as well as electric power consumption. All measured values are shown on digital displays. Analogue pressure gauges are also provided for direct visual reference. Measured values can be transmitted to a PC via USB (optional). Safety devices including pressure relief valves and pressure switches are fitted throughout the trainer. The optional software enables recording of compressor characteristics and representation of the compression process in a p-V diagram.

The Two Shaft Gas Turbine Study Apparatus ThermoFlux – 7087 is a laboratory-scale, wheeled training unit built for hands-on study of gas turbine operation in a two-shaft configuration. This two shaft gas turbine trainer replicates a real Joule-Brayton cycle at reduced scale, with a turbocharger assembly, power turbine, combustion chamber, and alternator mounted on a single base frame. Students gain direct exposure to gas turbine starting procedures, thermodynamic cycle analysis, and electrical power generation from turbine output.

Product Overview

The ThermoFlux – 7087 consists of a wheeled steel frame, a mimic diagram panel carrying all measurement instruments, and a base supporting the core components: combustion chamber, turbocharger assembly, power turbine, and alternator. Exhaust gases from combustion of compressed air and propane/butane LPG gas expand first through the turbocharger turbine, supplying energy to compress incoming air, and then through the power turbine. The power turbine, operating between 2,000 and 23,000 rpm, drives the alternator via a toothed belt. The alternator produces 1 kW at 3,300 rpm, and generated electrical energy is dissipated through a resistive load.

The turbocharger assembly operates between 30,000 and 90,000 rpm at a compression ratio of approximately 2:1. An auxiliary starting fan initiates the high-pressure turbine, and effective silencing at intake and exhaust makes the unit suitable for laboratory environments. The lubrication system includes a 20-litre oil tank, oil pump, oil filter, and a water/oil heat exchanger. Cooling water is supplied from laboratory mains.

The unit is available in two versions. The manual version uses digital meters, analog pressure gauges, and direct instrument displays on the mimic panel. The computerized version adds signal converters on all measurement instruments, a feeding and A/D conversion unit, a gas flow meter, a U-manometer, and data acquisition and analysis software. All sensors record data visualized on displays within the process schematic.

The optional ThermoFlux – 7087 DAQ software is developed in the National Instruments LABVIEW environment and is compatible with any Windows operating system.

The Exhaust Gas Calorimeter ThermoFlux – 7105 is a laboratory apparatus for determining the thermal exhaust gas losses of internal combustion engines using calorimetric measurement. The exhaust gas calorimeter achieves largely complete and loss-free heat exchange between the exhaust gas and a cooling water circuit, enabling accurate calculation of the engine energy balance.

The unit consists of an insulated stainless steel tank through which exhaust gas flows from bottom to top, transferring its heat to a looped finned pipe heat exchanger carrying cooling water. Four temperature sensors and a flow meter record all relevant parameters; values are displayed digitally via a measuring amplifier.

Product Overview

The Exhaust Gas Calorimeter ThermoFlux – 7105 determines the amount of heat contained in the exhaust gas from test engines. The calorimeter consists of a finned pipe heat exchanger housed in an insulated stainless steel tank. Exhaust gas enters at the bottom of the tank and flows upward, giving up its heat almost completely to cooling water circulating through the finned pipe.

The finned pipe is arranged in loops to maximise the heat exchange area. The heat exchange area on the exhaust gas side is 1.169 m². The heat exchange area on the water side is 0.164 m². This large ratio ensures thorough and near-complete heat transfer from the exhaust gas to the cooling medium, which is the core operating principle of the exhaust gas calorimeter.

Four temperature sensors record exhaust gas inlet and outlet temperatures and water inlet and outlet temperatures. A flow meter records the cooling water flow rate. All measured values are recorded electronically and displayed digitally using a measuring amplifier. The engine is connected to the calorimeter via an exhaust gas hose. The specific heat capacity of the exhaust gas can also be determined from the recorded data.

The Engine Test Bed ThermoFlux – 7080 is a self-contained, bench-mounting laboratory unit designed for the investigation of internal combustion engine performance, efficiency, and fuel consumption across multiple engine types. This engine test bed is supplied with three interchangeable engines as standard, a single-cylinder four-stroke gasoline engine, a single-cylinder four-stroke diesel engine, and a higher-capacity four-stroke diesel engine, along with an eddy current dynamometer, dual fuel tanks, air induction system, and full instrumentation for comprehensive engine testing.

Product Overview

The Engine Test Bed ThermoFlux – 7080 consists of an engine and dynamometer assembly mounted on a vibration-insulated solid steel base plate within a steel framework. The engine is connected to the dynamometer via an elastic claw coupling. The fuel system, incorporating two 5-litre fuel tanks with valves, and the air induction system are contained within the framework. The instrumentation and control panel are mounted on the front frame.

The eddy current dynamometer is rated at 10 kW generation power, 50 Nm braking torque, and a maximum speed of 13,000 rpm. Torque measurement accuracy is +0.2 to 0.3% FS and speed accuracy is +1 rpm. The dynamometer is water-cooled using tap water. The eddy current dynamometer controller operates in active mode with constant speed, constant torque, and constant power control modes. The controller uses a programmable PID with digital LCD panel display and 5 A output current. Protection covers engine stall, overload, and water.

The air inlet pipe has an internal diameter of 54.8 mm. The airflow meter measures 0 to 10 m/s. Air temperature range is 0 to 100°C and air consumption covers 20 to 350 L/min. Fuel temperature range is -100 to 400°C and fuel consumption is 0 to 60 cm³/min. A 10 kg weighing balance with 0.1 g graduation and a stopwatch are included for fuel consumption measurement.

Three engines are supplied as standard and are easily interchangeable for comparative testing. Two optional engines are also available: a variable compression ratio gasoline engine and a two-stroke gasoline engine. Optional accessories include a PV diagram system with cylinder head pressure transducer and crank angle encoder, an exhaust gas analysing unit, an exhaust gas calorimeter, and an electronic engine indicating system.

The Gas Turbine Jet Engine ThermoFlux – 7086 is a fully functioning, instrumented aero-derivative small turbojet engine test stand designed to enable students to study jet engine performance, energy balance, specific thrust, and specific fuel consumption across a thrust range of 10 to 100 N. This gas turbine jet engine unit features a single-shaft engine with centrifugal compressor, multi-injector combustion chamber, centrifugal turbine with ceramic bearings, electronic thrust measurement, and a full suite of temperature, pressure, speed, and force sensors displayed on a physical mimic panel and data acquisition system.

Product Overview

The Gas Turbine Jet Engine ThermoFlux – 7086 is mounted on a wheeled trolley for mobility. The engine assembly and air inlet unit are mounted on two sliding rails constrained by a linear thrust transducer for direct thrust measurement. The engine is a single-shaft design incorporating a single-stage centrifugal compressor, a combustion chamber fed by multiple fuel injectors, and a single-stage centrifugal turbine. A tailpipe ducts exhaust gas into a thrust-producing jet. Ceramic bearings in the turbine eliminate the need for lubricating oil. A protective grating is fitted over the jet engine.

Air is ducted into the engine via a calibrated nozzle for determination of air mass volume. Fuel is kerosene with a lubricant mix, pumped by a small electrically driven gear pump controlled precisely by the Engine Control Unit to directly regulate engine speed. Operator control is via a throttle lever. Starting is provided by a decoupling electric starter for fully automatic start-up. Maximum speed is 120,000 rpm with an idle speed of 32,000 rpm. Fuel consumption at maximum thrust is 550 ml/min. Full power pressure is slightly over 2 bar.

Temperature measurements are taken at five points: air inlet, fuel inlet, compressor outlet, combustion chamber outlet, and tailpipe stream. Pressure measurements cover ambient air pressure, air inlet differential pressure, and compressor outlet pressure. Thrust range is 10 to 100 N, measured electronically by a force sensor (0 to 200 N range). Speed is measured up to 120,000 rpm.

Measuring ranges cover differential pressure (-25 to 25 kPa), pressure (1x -1 to 1 bar, 4x 0 to 4 bar), temperature (3x 0 to 1200°C and 2x -100 to 400°C), speed (0 to 120,000 rpm), and force (0 to 200 N). A physical mimic diagram displays temperatures of the gas flow and engine pressure ratio. A data acquisition system records and displays all indications on screen. Optional LabVIEW-based DAQ software is available for PC-based data acquisition.

The Steam Power Plant with Steam Engine ThermoFlux – 7087 is a laboratory trainer that demonstrates the complete steam power cycle using a gas-fired boiler, a single-cylinder piston steam engine, a DC generator, and a water-cooled condenser. This steam power plant with steam engine enables students to study steam generation, mechanical energy conversion, electricity generation, condensation, and boiler efficiency through a fully instrumented and safety-monitored bench-scale unit.

Product Overview

The Steam Power Plant with Steam Engine ThermoFlux – 7087 contains all main components of a steam power plant: a gas-fired steam boiler, a single-cylinder piston steam engine with a crank mechanism, a DC generator, a water-cooled condenser, a feed water tank, and a feed water pump. The gas-fired boiler operates on NG or LPG, generates steam at a capacity of 6 kg/hr, and is protected by a safety valve rated at 4 bar.

Steam from the boiler is supplied to the single-cylinder piston steam engine, where a piston and crank mechanism convert vapour pressure into mechanical energy. The maximum steam engine power output is 5 W at a maximum speed of 1200 min⁻¹. A DC motor acting as a generator converts the mechanical power into electricity, rated at a maximum of 3.18 W at 6000 min⁻¹. Light bulbs serve as electrical energy consumers. The exhaust steam is condensed in a water-cooled condenser.

Safety devices include a digital electronic pressure switch and a mechanical pressure safety valve, both monitoring boiler operation. Sensors measure temperature across eight channels (-100 to 400°C), pressure (0 to 6 bar), gas flow rate (up to 5 LPM), and water flow rate (up to 7 LPM). Generator voltage (0 to 10 VDC) and current (0 to 250 mA) are also measured and displayed. All measured values are readable on displays integrated into the experimental unit. Optional DAQ software enables PC-based data acquisition in a LabVIEW environment.