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ISO 9001:2015 Representatives About Sigma Thermal's Project Process Careers
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     * – HC2 Gas Fired
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     * Great For Use in:
         
         
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       * Molding & Extrusion
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       * Jacketed Reactor Heating & Cooling
       * Regeneration Gas Heating
       * Viscosity Reduction
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       * Edible Oil Deodorizers
   * Molten Salt Heating System
 * Applications
     
     
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     * Amine & Glycol Reboilers(old)
     * Regeneration Gas Heating
     * Jacketed Reactor Heating & Cooling
     * Viscosity Reduction
   * Other Applications:
       
       
     * Ammonia Heating
     * Calendar Rolls
     * Condensate Stabilizers
     * Dewpoint Heating
     * Dryers & Kilns
     * Edible Oil Deodorizers
     * Freeze Protection
     * Fuel Gas Conditioning
     * Indirect Steam Generators
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     * Liquid-Gas Vaporization
     * Molten Salts
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MenuMenu Get Heater Quote
 * Products
     
     
   * Thermal Fluid Heating Systems
       
       
     * Pre-Engineered Heaters
     * – HC2 Gas Fired
     * – SHOTS Electric
     * Refurbished Heaters
   * Electric Process Heaters
       
       
     * Circulation Heaters
     * Immersion Heaters
     * SHOTS Electric Thermal Fluid Systems
     * Great For Use in:
         
         
       * Jacketed Reactor Heating & Cooling
       * Molding & Extrusion
       * Molten Salts
   * Direct Fired Heaters
       
       
     * Great For Use In:
         
         
       * Regeneration Gas Heating
       * Viscosity Reduction
       * Process Air Heating
   * Process Bath Heaters
       
       
     * Great For Use In:
         
         
       * Dewpoint Heating
       * Viscosity Reduction
       * Amine & Glycol Reboilers
   * Automation Solutions
   * Biomass Energy Systems
       
       
     * Great For Use In:
         
         
       * Dryers & Kilns
       * Plant Utility Heating
       * Presses
   * Industrial Waste Heat Recovery Systems
       
       
     * Great For Use In:
         
         
       * Jacketed Reactor Heating & Cooling
       * Regeneration Gas Heating
       * Viscosity Reduction
   * High-Pressure Steam Generators
       
       
     * Great For Use In:
         
         
       * Edible Oil Deodorizers
   * Molten Salt Heating System
 * Applications
     
     
   * Featured Applications:
       
       
     * Amine & Glycol Reboilers
     * Regeneration Gas Heating
     * Jacketed Reactor Heating & Cooling
     * Viscosity Reduction
   * Other Applications:
       
       
     * Ammonia Heating
     * Calendar Rolls
     * Condensate Stabilizers
     * Dewpoint Heating
     * Dryers & Kilns
     * Edible Oil Deodorizers
     * Freeze Protection
     * Fuel Gas Conditioning
     * Indirect Steam Generators
     * Jacketed Vessels
     * Liquid-Gas Vaporization
     * Molten Salts
     * Molding & Extrusion
     * Ovens & Fryers
     * Plant Utility Heating
     * Process Air Heating
     * Presses
     * Steam Superheating
     * Seal Gas Heating
     * Tank & Suction Heating
     * Waste to Power
     * Process Heating for Wood Products
 * Industries
     
     
   * Featured Industries:
       
       
     * Gas Processing
     * Petro Chemical
     * Process Heating for the Power Generation Industry
     * Aerospace
   * Other Industries:
       
       
     * Agriculture
     * Asphalt & Roofing
     * Crude Oil Heating for Production & Processing
     * Custom Applications
     * Food & Beverage
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UNDERSTANDING THERMAL FLUIDS & THERMAL FLUID SYSTEMS

Posted by Nicole Laney on December 27, 2019 5:53 pm | Leave a Comment

Thermal Fluid Management • Advantages of Thermal Oil Heating Systems

Types of Thermal Fluid Heaters • Work With Sigma Thermal

--------------------------------------------------------------------------------


The demand for process heating and temperature control in the industry continues
to increase as manufacturers and industrial facilities grow, expand, and seek to
improve their existing operations. These process heating systems must perform
consistently, safely, and with minimal downtime over time.

Industrial facilities that use plant-wide distributed process systems typically
have one of two process systems: steam boilers or thermal fluid heating systems.
Boilers were often the default choice in the past, but thermal fluid heating
systems are a better solution for many applications, offering improved
flexibility, control, and reliability.



 
 


THERMAL FLUID MANAGEMENT

Thermal fluid heating systems operate in a closed-loop with the thermal fluid
(also referred to as heat transfer fluid) in constant circulation. This
continuous circulation at a constant supply temperature provides a heat source
that users can access as needed. Users can be controlled individually, and
thermal fluid temperature can be varied (user to user) through secondary control
loops. In most systems, the thermal fluid or heat transfer fluid stays in a
liquid state throughout the loop, although there are vapor phase fluids
available for some niche applications that can benefit from latent heat over
simple heat.




TYPES OF HEAT TRANSFER FLUIDS

Thermal oil, water, and water-glycol solutions are all commonly used in thermal
fluid heating systems. All of these heat transfer fluids offer various
advantages and disadvantages depending on the operating temperature and
performance requirements of a system. It is important to understand what each
fluid option is so a correct choice can be made for each application.

 * Hot water and water-glycol. Water is the best possible heat transfer medium
   available when considering thermophysical properties, but it also comes with
   a number of drawbacks. Principally that it can be corrosive, contain
   contaminants, boils at 212ºF and freezes at 32ºF. Adding glycol in solution
   with water both increases the boiling point and decreases the freezing point,
   although that comes with some reduction in heat capacity.
 * Thermal oil. Thermal oils tolerate higher temperatures than water-based
   formulas without boiling or unduly increasing system pressure. Natural oils
   can reach temperatures up to 600° F, while some synthetics allow oil-based
   systems to reach 800° F. These conditions allow oil-based heating systems to
   comply with ASME Section VIII, creating long-term savings since heat systems
   certified under ASME Section VIII don’t typically need a licensed boiler
   operator on site. Thermal oils are also typically non-corrosive and don’t
   need to be treated like water to prevent hard water deposits from forming in
   the system.



 
 


ADVANTAGES OF THERMAL FLUID HEATING SYSTEMS



 

Thermal fluid heating, and thermal oil systems, in particular, have several
advantages over their traditional boilers. These advantages include:


ACHIEVING HIGH TEMPERATURES AT LOW PRESSURES

Thermal fluid systems offer a greater range of temperatures and a higher maximum
temperature. These systems can reach temperatures of 0–750° F when using thermal
oil, whereas steam-based systems only operate up to 350° F before operating
pressures exceed 425 PSIG. Thermal fluid systems using water-glycol solutions
can also reach 32–350° F at somewhat lower pressures than steam, which still
offers significantly more flexibility than traditional systems.

While the temperature range is important, the low pressure is just as valuable.
Most hot oils operating below 600° F don’t require any vapor pressure, and the
maximum system pressure is only what is generated by the centrifugal circulation
pumps. Even high-temperature synthetics operating as high as 750° F require less
than 100 PSIG of vapor pressure. A steam system at 750° F would require over
3,200 PSIG of operating pressure.


MINIMAL MAINTENANCE



Aside from regular flashpoint tests, thermal fluid heating systems require
relatively little maintenance.

The circuits are simple and the fluid doesn’t require frequent adjustments or
additions provided it is cared for and tested periodically to identify any
potential issues. Also, thermal fluid systems don’t need blowdown, re-tubing,
steam trap maintenance, or water treatments like traditional boilers do.


NO ATTENDANT NEEDED

Due to the increased safety concerns regarding boilers near workers, more
industrial, state, and local regulations require the presence of a stationary
engineer in boiler rooms. Many plants across the country have to keep at least
one employee with specialized training in the boiler room during active periods
to monitor the boiler’s operation. This is most commonly required for
fire-steamed boilers.

Facilities that use thermal fluid heaters and an unfired steam generator often
don’t need a stationary attendant. This advantage depends on specific state and
local requirements.


OUTDOOR INSTALLATION

Thermal fluid systems create indirect heating power, which means they can be
installed in remote indoor locations or outdoors. Keeping the heater and primary
system components away from other key production areas helps to improve overall
plant safety.

Thermal fluid systems are easy to install outdoors, though there are additional
installation considerations. Cold start provisions must be considered when
sizing a circulation pump and motor. It may also be necessary to pour slabs,
weatherproof outdoor piping and equipment, and more.


UTILIZE CENTRAL PLANT HEATING

Larger or multi-purpose facilities may have high-temperature processes in
conjunction with open-loop steam injection requirements. Traditionally, these
facilities would need a thermal fluid heater and a steam boiler. Today, however,
these facilities can use heat exchangers and rely solely on the thermal fluid
heating system instead.

Certain types of heat exchangers coupled with a readily available hot oil can
produce near-instantaneous steam as thermal fluid flows into them. Operators may
use this steam for sterilization, wash downs, and other processes. The
advantages of a central plant heating system with a heat exchanger(s) include:

 * Lower maintenance
 * Fewer expenses (because there is no boiler)
 * A heat system that achieves high temperatures at low-pressure levels



 
 


TYPES OF THERMAL FLUID HEATERS


Thermal fluid heating systems are ideal for facilities that need to consistently
achieve high temperatures. Oil-based systems go by many names, but they all
refer to the same type of closed-loop oil-based heating system. Other common
names include:

 * Hot oil boiler
 * Hot oil heater
 * Hot oil system
 * Thermal fluid heater
 * Thermal fluid system
 * Thermal oil boiler
 * Thermal oil heater
 * Thermal oil system

Of note, thermal oil-based systems are still often referred to colloquially as
“boilers” even though they do not actually boil the process fluid. For
closed-loop indirect heating systems with lower process temperature
requirements, hot water and water-glycol mixtures are commonly used as heat
transfer fluids.


THERMAL FLUID HEATER OPTIONS

At Sigma Thermal, our range of systems includes the following:

 * SHOTS Electric Heater
   
   Thermal Fluid Heater
   
   HC-1 Thermal Fluid Systems: These systems come in horizontal, vertical
   up-fired, and vertical down-fired options and the sizes range from         
    1–100 MM Btu/hr. Custom heater designs are available to meet specific
   project needs.

 * HC-2 Thermal Fluid Systems: HC-2 systems are also available in horizontal,
   vertical up-fired, and vertical down-fired configurations. Sizes range from 1
   – 100 MM Btu/hour and custom designs are available.
 * SHOTS Electric Thermal Fluid System:  Sigma Hot Oil Transfer Systems (SHOTS)
   use electrical power for circulation heaters and low-watt density immersion
   bundles. This creates heat without requiring fuel sources such as natural
   gas, fuel oil, or biomass fuel. These systems provide power in configurations
   from 30kW–800kW. Custom units can be constructed to provide increased power
   ranges from 800kW–4MW or even higher.
 * Biomass Fired Thermal Fluid Heaters: These heaters achieve the same
   high-temperature, low-pressure heat of our most popular thermal fluid
   systems. Facilities can use these systems alongside other biomass energy
   systems to meet green energy benchmarks. Sigma Thermal provides installation,
   training, and equipment servicing to support these systems and help our
   customers meet their sustainability goals.



 
 


WORK WITH SIGMA FOR YOUR PROCESS HEATING NEEDS


Sigma Thermal is a leading provider of thermal fluid heating systems, parts, and
supporting services. We offer high-quality equipment that supports the energy,
heating, and process needs of our customers in a broad spectrum of industries.

 * Thermal fluid heating system installations
 * Retrofit services
 * Training
 * Maintenance
 * Part programs

Talk to our engineers and technicians today about your facility’s heating needs,
including maintenance, parts, and full systems. Request a quote today to get
your project started.

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