Thermal oil heaters for industrial high-temperature process heat

efficient, safe and durable

For many decades, thermal oil heaters have been the primary heat source in virtually all industrial processes. They reliably generate high temperatures and supply production facilities with consistent and precisely controllable process heat. CAW develops designs and custom-builds, robust, and durable thermal oil heaters for demanding industrial applications – designed for maximum efficiency, consistently safe operation, and a long service life.

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

How does a thermal oil heater work?

In a thermal oil heater – whether fueled by conventional fossil fuels such as combustion gases and heating oils, or by hydrogen or specialty/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-loop system. Circulation pumps transport thermal oil to the connected consumers, such as reactors, distillation plants, evaporators, process and baking ovens, presses and drying plants. In these plants and systems components, the heat is transferred to the respective consumers via heat exchangers, and the cooled thermal oil then flows back to the heater.

Design 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 of combustion is transferred to the heat transfer oil via radiant and convective 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 after cooling down.
Control and safety technology: The combustion / firing process, flow temperature, and oil flow rate 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 utilizing residual heat.
Design and configuration of combustion chambers and heating surfaces for low thermal oil film temperatures while minimizing NOX formation.
Compatibility with all common heat transfer media: mineral and synthetic thermal oils, warm and hot water, and water-glycol blends.
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 facilities. CAW develops custom-designed 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 systems, presses, reactors, extrusion and calendering systems, 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 sites without traditional fuel supply or with a focus on renewable energy.

Large-scale plants with multiple heaters and consumers

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

Use as an integral part of process plants

In combination with thermal oxidizers for heat recovery.
In combustion plants to provide process heat without direct contact between combustion / hot gases and the product.
In ORC systems as a constant heat source for electric power 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 precise, customized control are required. The technology is versatile and well-established across a wide range of industries.