Thermal Oil Heating Systems


Example of a thermal oil heating system according DIN 4754.
This is for process air heating.


AB&CO TT BOILERS thermal fluid systems are high temperature process heating systems, used for high performance industrial processes - most often as an alternative to high pressure steam. An attractive alternative due to much higher media operating temperatures at low pressure, but also because of significant less overall operation costs. See more at "Compare Steam and Thermal Fluids".

As it appears from above diagram, steam at high temperatures requires pressurised systems, whereas thermal oil can be operated atmospheric up to above 300C. When pressurised, the thermal oil it can be operated even up to 400C.

Read more about 'FACTS ABOUT' at ProcessHeating.BIZ.

TT BOILERS electric thermal oil heater for 400C moderate pressurised thermal fluid.


Data & Details :

'ThermoPack Units'


  Above in higher quality                    Properties Steam/Water                 Properties White Mineral Oil


                                       'ThermoPack' is a compact AB&CO Hot Oil System mounted as a skid-mounted unit
operating as a pressureless (atmospheric) System at 300C Operating Temperature.

AB&CO process air heat exchanger during
final inspection by customer from Germany.


The ThermoPack units comprise heater, main pump, heat exchangers, tanks for expansion, dearating / de-gassing and for buffer, emptying systems with pump and tank, special valves, strainers, compensators, safeties, controllers, auxiliary equipment, tubes, fittings, charge of thermal fluid and of course full documentation.

For these packages TT BOILERS deliver a complete program of customised oil-fired, gas-fired and electric thermal oil heaters. 

Environmental solutions are available in many alternative design - including mounting of economiser and thermal oil heated by utilising waste heat in, for instance, hot flue gas.

AB&CO TT BOILERS have specialised in ThermoPacks as skid-mounted units and containerised solutions.

See all the technical details of the heaters using this link :

TT BOILERS oil-fired heaters at bitumen plant

The simple principle in thermal thermal fluid systems is heating by use of a special thermal fluid (non-flammable oil) circulating the through heaters (with burners, electrical elements or flue gas recuperators) - and thereafter the fluid is led to one or several consumers, which can be for instance heat exchangers, air heaters, reactors, convectors, rollers etc.

These systems are all tailor-made and they are always delivered as complete packages for assembly on site, or as skid-mounted units when the size allows it - and with full documentation and easy readable instructions for handling, erecting, installation and maintenance.

View and print an example of the Complete Thermal Fluid Heating System (PI-diagram) in a pdf-format (e.g. Acrobat Reader).


The engineers of AB&CO TT BOILERS are able to assist in the operation of the thermal fluid heating system by frequently analysing samples of the circulating oil. From the analysis it is possible to guide for an optimum performance and long life time for both the oil and the plant.

For more extensive assistance in optimising new or existing systems, or for trouble shooting - consider our Consultant Services.



Important for a trouble-free service is to choose a high quality thermal fluid i.e. the heat transfer oil. It is recommended to use a non fouling, high temperature resistant 'White Mineral Oil' for the applications like AB&CO NF. This fluid is available on stock in Copenhagen.

The thermal fluid should be frequently tested by AB&CO TT BOILERS laboratories in order to ensure a optimum and low cost operation of the heating systems.

Do not compromise on this fluid - use the right thermal oil and check it frequently!

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