Thermal oil heaters for industrial high-temperature process heat

efficient, safe and durable

Thermal oil heaters have been the main source of heat in almost all industrial processes for many decades. They reliably generate high temperatures and supply production facilities with uniform and precisely controllable process heat. CAW develops, designs and manufactures customised, robust and durable thermal oil heaters for demanding industrial applications – designed for maximum efficiency, permanently safe operation and long service life.

With our proven KONTAKTOMAT® thermal oil heaters, we cover a wide range of outputs from 100 kW to > 25,000 kW in a single unit and enable process heat supply up to 400 °C. The systems are manufactured and equipped in accordance with international regulations and are used worldwide.

How does a thermal oil heater work?

In a thermal oil heater – either fossil-fuelled with conventional combustion gases and heating oils or with hydrogen or special/waste fuels such as low-calorific gases, landfill and digester gases, solvent residues, etc. – a liquid heat transfer oil is heated and fed into a closed circuit. Circulation pumps transport the thermal oil to the connected consumers, such as reactors, distillation plants, evaporators, process and baking ovens, presses and drying plants. In the aforementioned plant components, the heat is transferred to the respective consumers by means of heat exchangers, and the cooled thermal oil then flows back to the heater.

Structure and process steps

Firing / burner system: Generates the required heat through the controlled combustion of the available fuels.
Combustion chamber and heating surfaces: The heat from combustion is transferred to the heat transfer oil via radiation and convection heating surfaces. CAW uses single, double and triple pass designs.
Circulation pump: Circulates the required oil volume flow through the heater to the consumers and ensures even heat distribution.
Thermal oil circuit: The hot heat transfer oil flows to the heat consumers, where it releases the required heat and then flows back to the heater in a cooled state.
Control and safety technology: The firing, flow temperature and oil flow are continuously monitored and controlled.

Technical features of CAW thermal oil heaters

Temperature ranges up to 400 °C depending on the heat transfer medium.
Efficiency levels up to > 95% thanks to optimised heating surfaces, optional combustion air preheaters and special downstream heating surfaces for residual heat utilisation.
Design and configuration of combustion chambers and heating surfaces for low film temperatures with low NOX formation.
Use of all common heat transfer media: mineral and synthetic thermal oils, warm and hot water, and water-glycol mixtures.
Special designs are also suitable for operation with molten salts at temperatures up to 550 °C.
Manufactured in accordance with DGRL 2014/68/EU, ASME Code Sec. I (“S-Stamp”) and Sec. VIII (“U-Stamp”), ML and other classifications and certifications depending on the target market.

Where are thermal oil heaters used?

Thermal oil heaters are used as the central heat source and thus as the “heart” of production in almost all industrial processes and plants. CAW develops customised systems for power ranges from 100 to > 25,000 kW – depending on the process, available fuels and temperature requirements.

Typical system types and operating environments

Thermal oil-heated production lines

Drying plants, presses, reactors, extrusion and calendering plants, thermal processing and baking ovens, and coating plants.

Combination with waste heat recovery systems

Utilisation of waste heat from production and combustion plants.

Heated heat exchangers

Steam, water or hot gas production via secondary media circuits.

Electrically heated systems

For locations without traditional fuel supplies or with a focus on renewable energy.

Large-scale plants with multiple heaters and consumers

Central supply of entire production sites via a heating plant, including load management.

Use as an integral part of process plants

In combination with TRO systems for heat recovery.
In incinerators for the provision of process heat without direct contact between combustion/hot gases and the product.
In ORC systems as a constant heat source for electricity generation.
In steam generation and hot water systems as an indirect heat source.

Industries in which thermal oil heaters are used

Thermal oil heaters are used wherever high temperatures, stable heat supply and individually precise controllability are required. The technology is versatile and established across a wide range of industries.