THERMAL FLUID
HEATING SYSTEM

Introduction to Thermal Oil (HTF)

Process Heating Systems for
High Temperature Applications

General Principle
The diagram is an example of a thermal fluid heating system
according DIN 4754 - this one is for process air heating.

The above HEATERS in these systems are off course the main components. They are available in many designs, sizes and special features.


Some examples below :

The ThermoPack is a AB&CO heater including accessories, all skid-mounted
in a unit, operating unpressurised i.e. atmospheric, and with
operating temperatures up to 300°C

AB&CO electric thermal oil heater for 400°C
moderate pressurised thermal fluid.

AB&CO Container Solution
 

AB&CO Thermal Fluid Heating Systems are high temperature process heating systems, using a special appropriate oil-based thermal fluid, a  so-called Heat Transfer Fluid (HTF) as the circulating heat carrier.
 

These types of heating systems are used for high performance industrial processes - most often as an alternative to high pressure saturated steam.

For instance spray-drying systems often requires very high temperature to achieve maximum performance.

These heaters become an attractive alternative to the steam - mainly due to much higher operating temperatures on the heating media (HTF), able to maintain low system pressure (often atmospheric pressure).

In the temperature diagram below (bottom page), you can see the differences in this - between water/steam (vapour) and different kind of heat transfer fluids. As it appears here, the steam at high temperatures REQUIRES PRESSURIZED SYSTEMS, whereas thermal fluid (HTF) can be operated atmospheric up to above 300°C. When pressurised, the HTF can be operated even up to 400°C.

There are numerous other advantages for using this kind of heating, including significant less overall operation costs. But there are also disadvantages, See more at "COMPARE STEAM AND THERMAL FLUID".

Get more TECHNICAL DETAILS  here about thermal fluid heating.
 

WARNING ! Despite the simplicity understanding the thermal oil heating system, it requires experts with high skills to get all things right. Unforetunately a lot of unsafe and poor designed systems are seen, also that leads to severe and fatal situations. Being basically a hot oil, it eventually burns when it is not controlled 100%.
 

General Principle
in Fuel Oil- and Gas-fired Models


 

General Principle
in Electric Heated Models

General Principle
Heat Exchanger
(Process Air Heater)

AB&CO Large Package Solution

  Above in higher quality                    Properties Steam/Water                   Properties HTF (typically white mineral oil type)

The simple principle in thermal thermal fluid systems is heating by use of a special thermal oil - also called heat transfer fluids (HTF).

The HTF circulating through heaters (whether they are with burners, electrical elements or as flue gas recuperators).

Thereafter the HTF is led through a piping to one or several consumers, which can be for instance heat exchangers, air heaters, tanks. reactors, convectors, rollers etc.

 

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

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. They come with full documentation and easy readable instructions for handling, erecting, installation operation and maintenance.

SPECIAL SERVICE

The engineers of AB&CO 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.