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    • Thermal oil systems for industrial temperature control

    Precise, safe and cost-effective heat supply

    Numerous industrial processes require precise temperature control and reliable heat supply – whether for drying, heating, forming, or even chemical reactions. With a thermal oil system, you can provide your company with a modern and high-performance solution for generating and supplying process heat in the temperature range up to 400 °C: efficient, precise, safe, and flexible. CAW supplies custom-designed, complete thermal oil systems that are optimally tailored to your specific requirements.

    How does a thermal oil system work?

    A thermal oil system – also known as a thermal fluid heating system, heat transfer oil system or HTF / HTM / hot oil system – uses special temperature-resistant mineral (up to approx. 300 °C / 572 °F) and synthetic (up to 400 °C / 752 °F) thermal oils instead of water or steam as heat transfer media for the indirect temperature control of production processes and thermal processes.

    Basic principle

    • Oil or gas burner systems, electric heating elements or other mechanical combustion systems generate primary heat.
    • In a special heat exchanger – also known as a furnace or boiler, typically consisting of coiled heating surface systems in the form of concentric cylindrical tube coils – this heat is transferred to the thermal oil.
    • The heated thermal oil is conveyed through piping in a closed system to the heat consumers in the production processes. There, heat is transferred to secondary circuits and consumers. The cooled oil then flows back to the heater, and the cycle begins again.
    • Circulation pumps ensure the constant circulation of the thermal oil throughout all parts of the plant and system.
    • State-of-the-art control and regulation technology, compliant with industry standards, monitors the system’s temperature, flow rate, and safety.

    Technical features

    • Thermal oil allows for high flow temperatures of up to approximately 300 °C / 572 °F at near-atmospheric pressure; in systems specifically designed for this purpose, temperatures can even reach up to 400 °C/ 752 °F.
    • Since no significant vapor pressure is generated, many of the safety and maintenance complexities that are generally required for steam or other high-pressure systems are eliminated.
    • The permanently closed loop eliminates corrosion, minimizes heat loss, and ensures a stable and uniform heat supply even in complex system configurations, regardless of individual consumer temperatures and temperature spreads.

    Advantages of a thermal oil system

    High temperatures at low pressure

    Thermal oil enables process heat up to around 300 °C / 572 °F without significant vapor pressure – making it significantly simpler and safer than saturated and high-pressure steam.

    Efficient heat transfer and uniform temperature control

    Customized flow rates in closed loops ensure constant temperatures and uniform heat supply, making them ideal for all temperature-critical processes.

    Low maintenance requirements and long service life

    Unlike steam systems, thermal oil systems are not very susceptible – if at all – to corrosion and scaling.

    Flexible choice of fuel and heat sources

    In addition to fossil primary energy sources such as fuel gases and heating oils, electric heating and alternative energy sources are also possible.

    Centralized and reliable heat supply for multiple consumers

    A thermal oil system can centrally supply numerous heat consumers while accommodating different consumer temperatures, oil circulation rates, and temperature differentials.

    Good controllability and energy efficiency

    Modern systems with optimized heating surface systems and supplementary heating surfaces enable precise temperature control and minimize heat and waste heat losses, which reduces both energy consumption and operating costs.

    Industries and typical applications of thermal oil systems

    Thermal oil systems are particularly suitable for industrial companies that require a reliable, consistent and flexible heat supply. Typical industries and applications include:

    Chemical and pharmaceutical industry

    Heating for reactors and mixing tanks, spray and contact drying systems. Rectification / distillation, trace heating, etc.

    Plastics and rubber industry

    Heating of molding, extrusion, and lamination systems.

    Wood and wood processing

    Drying of sawn lumber, wood chips, wood fibers, and veneers; heating of single- and multi-daylight presses; heating of paper coating and resin production systems, thermal modification of sawn timber (ThermoWood®); heating of paint coating systems.

    Textile industry

    Heating of stenter frames as well as dyeing and drying processes that require very precise temperature control.

    Bitumen, asphalt and construction chemicals

    Heating of asphalt mixers, bitumen tanks, and similar products with specific temperature requirements.

    Semiconductor and circuit board manufacturing

    Drying printed circuit boards.

    Energy supply and plant engineering

    Centralized and decentralized heat supply, combined heat and power plants, waste heat recovery.

    Fuels and heat transfer fluids used

    A thermal oil system can utilize a wide variety of fuels and different thermal oils – depending on requirements, process conditions, and energy availability:

    Fuel options / Primary energy sources

    • Combustible gases such as natural gas, liquefied gases (LPG, LNG), low-grade / low-calorific gases, landfill gas, and biogas
    • Liquid fuels such as light, heavy and extra-heavy fuel oils, distillation residues, and solvent residues
    • Biomass, agricultural waste, and organic waste streams in liquid, solid and paste-like form, as well as alternative fuels such as RDF (depending on the design and configuration of grate systems, and combustion and burnout chambers)
    • Electric heating with absolutely no combustion or emissions, particularly suitable when no boiler room and / or no stable and secure fuel supply and / or storage is available, or when exceptional environmental regulations apply.

    Heat transfer oils / thermal oils / thermal fluids / HTF and HTM

    • Thermal oils generally exhibit high thermal stability while having negligible vapor pressures.
    • Depending on the operating temperature range, mineral (produced through the refining and processing of crude oils) or synthetic (consisting of a combination of refined base oils and targeted chemical modification) thermal oils are used:
      • At temperatures up to approx. 300 °C/ 572 °F, mineral thermal oils are significantly less expensive, but their application temperatures are limited.
      • For higher temperatures up to 400 °C/ 752 °F – and in exceptional cases even up to 430 °C / 806 °F – synthetic thermal oils offer considerably better thermal stability along with a much lower tendency to decompose.
    • A well-chosen, high-quality thermal oil ensures stable and uniform heat transfer, a long service life / operating time, and no risk of corrosion or scaling.

    Why CAW thermal oil systems are your best choice

    With a thermal oil system from CAW – professionally designed, installed and commissioned – you’ll receive a heat transfer oil system that meets the highest requirements for temperature, safety, efficiency, ease of maintenance, and service life. Thanks to decades of global experience in plant and equipment engineering across all industries, our solutions are always precisely tailored to your needs – regardless of your industry or process. Please feel free to contact us for a personalized consultation and a concept optimized for your specific requirements.

    References

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