Benefits of a Custom Fluid Filtration System
Thermal fluid filtration systems help protect equipment in numerous industrial processes, such as presses, heat exchangers, mixers, circulation heaters, reactor operations, and mold production. They are used to reliably and efficiently filter particulates that build up during thermal fluid or hot oil heating processes across a system.
As low pressure thermal fluid is pumped through the heater, the generated heat is used to heat various processes. The thermal fluid may need to be continuously filtered in order to prevent fluid degradation, which will ultimately affect the performance of the thermal heating system.
Thermal Fluid Filtration System Benefits
Thermal filtration systems require optimal fluid recirculation and performance in order to achieve cost-effective, high-temperature heat production. If the thermal fluid degrades, a wide range of potential issues could occur in various parts the system, thereby affecting performance.
Thermal fluid filtering is used by countless industries including plastics, textiles, petrochemical, laundry, food production, chemical, and more. From industrial coatings to sludge drying, there are an array of benefits to using fluid filtration systems, such as:
Operating & Maintenance Cost Savings
Fluid degradation can have a cascading effect on operating and maintenance costs throughout an entire thermal fluid heating system. By design, these systems remove solids and other particulate buildup that occurs as a result of the thermal fluid or oil heating process.
As the thermal fluid passes along system lines, suspended solids as small as 10 microns can degrade the performance of all of the system components involved, including pumps, tanks, heating and cooling loops, or valves. Keeping thermal fluids filtered helps prevent system downtime, increases cost savings and reduces the need for frequent equipment and fluid maintenance checks.
Fewer Pump Failures
Industrial thermal fluid heating systems operate at very low pressures, making it easy for pumps to circulate hot thermal fluids. However, fluid degradation can affect pump parts including impeller, bearings, housings and shaft seals. Contamination deposits from unfiltered, degraded thermal fluids can increase wear and tear on pump components—especially at higher temperatures.
Reduced Fluid Viscosity
If the viscosity of the pumped thermal fluid is too high, frictional heat in areas throughout the system can degrade seals and other parts of an industrial fluid heating system. If the thermal fluid’s temperature surpasses its performance specifications, it begins to boil and vaporize, ultimately increasing in thickness due to byproduct material buildup. By using fluid filtration, reduced particulates help keep fluid viscosity optimal and flowing with reduced stresses that could affect heating performance and/or fluid flow.
Reduced Fouling Heater and Users
During the heat exchange process, chemical reactions on heated thermal fluids can cause material deposits on various surfaces. Known as “bruised” fluid, thermal fluid can become oxidized, overheated, or contaminated. If the fluid’s molecular bonds break down from boiling, the fluid releases sooty carbon material. The filtration system helps maintain chemical purity by filtering bruised fluid and keeping it clean and ready for high-temperature, closed-loop systems.
Less Frequent Fluid Replacement
Thermal fluids degrade over time, leading to inevitable cracking, oxidation, and contamination. Fluid analysis is commonly performed to identify when fluid replacement is necessary. Through the use of a fluid filtration system, maintenance and replacement costs decrease. In addition, the filter itself helps identify when the thermal fluid should ultimately be replaced.
Types of Thermal Fluid
Choosing the right type of thermal fluid involves consideration for operational temperature ranges, pumpability, thermal efficiency, price, and environmental conditions. There are a wide range of thermal fluids available that are specifically tailored for different application requirements, such as:
- Mineral oil (synthetic or specialty)
- Shell Thermia
Innovative Fluid Filtering Systems
Thermal Fluid Systems, Inc. is a single-source provider of affordable, superior quality thermal fluid heating systems, providing a broad spectrum of supplies and services for industries nationwide. Backed by over 25 years of experience in highly specialized, industrial-grade process heating, we work with our clients to understand their needs and develop solutions that help keep systems running efficiently.