Design & Supply of High Efficiency Thermal Fluid (Hot Oil, Dowtherm) Heating Systems

Thermal fluid heaters and hot oil systems are used in industrial applications for safe, consistent, and reliable indirect heating and cooling. In a closed-loop system, the thermal fluid circulates throughout the system, maintaining a steady supply of heat. Also sometimes referred to as hot oil heating system or a DOWTHERM™ heating system, these high-efficiency systems are found in a variety of applications in many industries, including:

  • Asphalt
  • Chemical
  • Food industry
  • Laundry
  • Petrochemical
  • Pharmaceuticals
  • Plastics
  • Process equipment
  • Specialty paper
  • Textiles
  • Wood

Thermal Fluid Heating System Design

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Design & Supply of High Efficiency Thermal Fluid (Hot Oil, Dowtherm) Heating Systems

At Thermal Fluid Systems, Inc., our high-efficiency thermal fluid heater design uses a three-pass configuration. Each carbon steel, high-efficiency thermal fluid heating system includes a three-pass dual helical coil heat exchanger, custom-designed isolation valves, a pump, strainer, a degasser, burner, expansion tank, temperature blocking vessel, and safety controls. You may also choose from additional options such as a drain tank and secondary heating and cooling controls.

We design each high-efficiency DOWTHERM heating system to customer specifications following rigorous quality standards, including:

  • American Society of Mechanical Engineers (ASME)
  • CSA/CGA
  • NEMA
  • NFPA
  • United States Coast Guard (USCG)
  • American Bureau of Shipping (ABS)

Based on the application and process needs, our thermal fluid heaters may be powered by:

  • Electricity
  • Natural gas
  • Propane
  • Biodiesel
  • Fuel oil numbers 2, 4, and 6
  • Bunker C oil
  • Waste liquid and gas products

A variety of NEMA ratings are also available, including 1, 3R, 4, 4X, 7, or 12.

Types of Thermal Fluid Heating Systems

Thermal fluid heating systems can operate on a variety of fuel sources. There are three main types of thermal fluid heating systems: gas (or liquid fuel), electric, and waste fuel. The right design for your application depends on factors such as:

  • Efficiency
  • Thermal stability over a range of temperatures
  • Equipment size
  • System adaptability
  • Physical properties such as the freezing, flash, and fire points; vapor pressure; viscosity; and rate of heat transfer

Each choice of thermal fluid system fuels has distinct advantages and disadvantages.

Gas Fired Systems

Since it burns efficiently, natural gas produces fewer harmful emissions. Gas operated heating systems also take less energy to run compared to the heat they produce, making them operationally efficient. However, natural gas prices can fluctuate widely, which sometimes results in a cost disadvantage.

Electric Systems

Electric systems can be used where natural gas is unavailable and may be cheaper to operate in areas with low cost electricity. They also convert almost all of the input energy directly to heat for the process.

A high-efficiency hot oil heating system design typically does not need an operator on-site, even though it can reach much higher temperatures than water. The disadvantage is performance and cost across the different temperature ranges.

Waste Fueled Systems

There are numerous advantages of using biomass energy for heating. Waste-fueled systems are efficient, less expensive to operate and eco-conscious. The energy is renewable and saves the waste from other processes from being dumped in a landfill. Waste fueled systems also help to reduce dependence on the electrical grid, further improving their sustainability benefits. These systems are ideal for helping businesses meet goals for green energy.

High-Efficiency Thermal Fluid Heating Systems from Thermal Fluid Systems, Inc.

For over a quarter of a century, Thermal Fluid Systems, Inc. has provided high-efficiency thermal fluid heating systems to process industries. Our process heaters can be operated indoors or outdoors. They have an output range of 0.5 to 50,000,000+ BTU/hour, as well as a lower heating value efficiency of up to 90% or more.

We are pleased to provide end-to-end service for high-efficiency Dowtherm heating systems, from design and engineering to fabrication and service. Our on-site technical service and support department is here to support all the equipment we manufacture.  To find out more about our capabilities or products, contact us or request a quote.

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High Efficiency Thermal Fluid Heating System Capabilities

Components

3 Pass Dual Helical Core

Fuel

Natural Gas
Propane
Biodiesel
#2 Fuel Oil

#4 Fuel Oil
#6 Fuel Oil
Bunker C
Waste Gas Product

Output

0.5 to 50,000,000+ BTU/hr

Efficiency

Up to 90%+ (LHV)

Services

Design
Supply
Maintenance Plan

Maintenance Inspection

Measure Burner Combustion
Check all Operating and Safety Controls
Check Heater Ancillary Equipment

Review Operating & Maintenance Procedures
Operator Training

Components

Heat Exchanger
Pump
Isolation Valves
Pump Strainer
Degasser

Temperature Blocking Vessel
Expansion Tank
Safety Controls
Burner

Options

Drain Tank
Explosion Proof
Secondary Heating Controls

Standards

API Standard 560
ASME
API

USCG
ABS

Operating Temperature

200 to 750°F

Design Temperature

To 800°F

Operating Pressure

Pumping Pressure (No Internal Pressure)

Design Pressure

Up to 150 psi

Thermal Fluid Type

Mineral Oil,Synthetic or Specialty
Calflo
Chevron
Dowtherm
Essotherm
Glycol
Marlotherm
Mobiltherm
Multitherm

Paratherm
Petrotherm
Shell Thermia
Syltherm
Texatherm
Therminol
Hot Water
Xceltherm
Others

Voltage

480 to 575 V

Phase

3

Frequency

50 to 60 Hz

Accuracy

+/- 1 °C

Configuration

Horizontal
Vertical

Location

Indoor
Outdoor

Mounting

Skids
Stand Alone

Class

General
Hose-Down

Class I
Class II

Division

I
II

NEMA Rating

1
3R
4

4X
7
12

Materials

Carbon Steel

Testing

Pressure
Function(Controls)

Additional Services

System Design
Maintenance & Repair
Field Service
Annual Inspections

Start Up
Engineering Consultation
Replacement Parts

Production Volume

Prototype to complete production system

Additional Information

Industry Focus

Plastics
Chemical
Food Industry
Laundry
Asphalt

Petrochemical
Pharmaceuticals
Process Equipment
Specialty Paper
Textiles

Intended Applications

Heated Rolls
Calendar Rolls
Press Platens
Process Skids
Wood Presses
Reactors
Heat Exchangers
Dryers
Evaporators
Mixers
Laminating Presses
Printing Machines
Coatings
Molding Presses
Edible Oils
Sludge Drying

Rubber Presses
Adhesives
Tank Heating
Fuel Heating
Ovens
Cargo Heating
Fluidized Beds
Fryers
Heat Tracing
Kilns
Dry Kilns
Chemicals
Wood Board Plants
Tenter Frames

Industry Standards

ASME
FM
ASI

File Formats

AutoCAD
Inventor

High Efficiency Thermal Fluid Heating Systems