Thermal Fluid Solutions & Industrial Heating
Consumes 20–50% Less Energy Than Steam
Thermal Fluid Engineering for Modern Industry
Steam boilers have long served many enterprises faithfully. But it must be acknowledged that steam as a heat carrier is expensive. Therefore, remaining loyal to steam boilers is not always a good decision.
The use of thermal oil, unlike steam, is more economical. Companies familiar with this technology are convinced of the advantages of using oil as a heat transfer medium.
In the middle of the last century, thermal oil technology was economically unprofitable due to the low efficiency of oil heating furnaces, which exceeded the cost of electric heating. Today, modern boilers are used that run on gaseous or liquid fuel with an efficiency of up to 92%. Thermal oil (also known as high-temperature organic heat transfer fluid, or HTF) is a product of deep oil refining followed by distillation.
Our Offers
Thermal Oil Boiler Design & Production
Babcock Wanson thermal fluid heaters with built-in gas, liquid fuel, or dual-fuel burners meet the needs of modern industry. When using thermal fluid as a heat transfer medium, users do not encounter the well-known problems of pressure, scale formation, corrosion, or freezing.
Industrial Boiler Design for Waste Heat Recovery
The EXT series is constructed using multiple concentric tubular coils with passages for gas flow between the coil rows, providing low pressure drop and high gas velocity for self-cleaning.
They can be used in vertical or horizontal configurations, and the exhaust gas bypass function can be integrated concentrically, internally or externally for maximum flexibility.
Thermal Oil Boiler Tuning & Steam Generation
Thermal oil systems may also require steam, hot water, or superheated water. Babcock Wanson supplies specialized heat exchangers tailored to industrial process requirements and designed to handle a variety of fluids. Fully modulating or simpler on/off control for smaller units is provided in accordance with process requirements.
The SOV series is designed for steam production at pressures up to 65 bar (gauge).
SOAS produces superheated water.
SOAC produces hot water.
Thermal fluid vs steam: Why Choose Thermal Oil?
Thermal oil heating systems have revolutionized industrial heating for most industries, making large, energy-intensive production facilities that require a large number of people a thing of the past. Thermal oil heating systems are compact, easy to use, and provide overall energy savings that are hard to beat.
Unlike steam systems, thermal oil systems do not change the state of the fluid, so there is no condensation and, therefore, no steam losses, blowdown or make-up water losses, and no water discharge. Thermal oil systems are completely protected from corrosion and freezing and do not require expensive chemical treatment. In addition, users do not encounter the well-known problems of high pressure to achieve high temperatures. All this leads to significant cost savings during operation.
Advantages of thermal fluid
VERY SAFE SYSTEM
• Pressureless system
• Simple automatic control without an operator
• No corrosion
• No risk of freezing
• No liquid drains are formed
ENERGY EFFICIENCY
• It typically consumes 20–50% less energy than steam
• Closed loop - lossless system
• No losses due to boiler blowdown
• No condensate losses
• High efficiency of fuel combustion and plant operation
ECONOMICAL AND LONG-LASTING
• Quick start and stop
• Very low operating costs
• No water treatment or chemicals required
• Minimum requirements for the premises
• ТExtended service life of equipment and fluids
THE BEST AVAILABLE TECHNOLOGIES
• Accurate and simple temperature control
• Heating and cooling are possible within a single system
• Easy to achieve temperature mixing in a single system
• Ability to operate at high temperatures (up to 350°C)
• Lower exhaust emissions
How Thermal Oil Heaters Function
Thermal oil heating is based on a principle similar to that of a simple hot water supply system. The system consists of a heater connected to carbon steel supply and return pipes and can simultaneously supply heat to one or more users or systems. Instead of water flowing through a closed pipe circuit, a heat transfer fluid that remains liquid throughout operation is used as the heat transfer medium. The heat of the fluid is transferred by turbulent flow at the heat exchange surface. The fluid then returns through a closed circuit to the heat transfer fluid heater for reheating, which occurs without further energy loss.
Application and Industry
Pressing, Curing and Moulding
• press heating and cooling
• moulding processes
• extruder heating and cooling
• laminating
• autoclave heating
• drying and forming
• furniture manufacture
• plastics moulding
• automative manufacturing
• composite materials
Tanks, Vessels and Cookers
• tank heating
• reactor heating
• bulk liquid storage
• food processing
• metal finishing
• anodising
• pharmaceutical
• refining and blending
• marine applications
• brewing industry
Printing, Coating, Laminating and Drying
• paper and foil coating
• stentoring
• textile transfer printing
• calendar setting and ironing
• sterilising
• printing and laminating
• batch and and continuous dryers
• waste treatment
• drying and curing
• packaging
Heating and Cooling Systems
• controlled and cooling systems
• exothermic chemical reaction control
• press and moulding processes
• multiple independent variable temperature processes
• chemical manufacture
• pharmaceutical manufacture
Services Offered
The operation of machinery such as presses, calenders, dryers, mixers, evaporators and so on requires thermal heating and/or cooling as part of the manufacturing process. This places various demands on the thermal oil system in terms of capacity, temperature, flow rate or pressure. All parameters are interrelated and require special attention to ensure a cost-effective, high-quality and sustainable system. Furthermore, specific regulatory requirements must be taken into account and incorporated into the planning.
Thermal fluid system design and Engineering Documentation
– we create a complete package of technical solutions for the efficient and safe operation of systems with organic heat transfer fluids. We take into account the specifics of production and customer requirements.
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Boiler Plant Engineering and Equipment Supply
- we manufacture and supply high-quality equipment that is ready for installation and operation. We provide complete sets in accordance with the project.
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Thermal oil boiler install and Plant Assembly
– we perform professional installation of equipment in compliance with all technical standards. We guarantee the accuracy and reliability of connections.
Thermal fluid commissioning and Systems Tuning
– we launch, test, and configure systems. We optimize equipment performance for maximum efficiency.
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