Thermal Oil Heater
Function:
Industrial devices for heating thermal oil to high temperatures, facilitating heat transfer to various processes.
Types:
Available in horizontal or vertical designs, for capacities of up to 30 MW/unit, with operating temperatures from -100°C up to 450°C. Compatible with a range of fuels including heavy oil, diesel, natural gas, and biogas.
Features:
Constructed with a pipe coil through which the oil flows, surrounded by a shell where hot flue gases pass around the pipes creating efficient heat transfer.
Importance:
Vital for efficiency, productivity, and safety in industrial processes. Thermal oil heaters provide precise and reliable heat transfer, critical for numerous applications.
Maintenance:
Regular maintenance is crucial to mitigate risks and ensure the safe and efficient operation of thermal oil heaters. Monitoring oil flow, pressure, and temperatures prevents hazards such as overheating, which can lead to equipment damage, oil decomposition, and safety risks. Additionally, maintaining burner adjustments ensures proper combustion and optimizes performance, reducing the potential for accidents and operational disruptions.
Examples of Areas of Application:
Used in food, building materials, chemical, iron and steel, and textile industries for processes like frying, baking, steel forming, and chemical reactions.
Heat Exchanger
Function:
Heat exchangers help transfer thermal energy between two liquid or gaseous media without direct contact. They are used for heating or cooling and are crucial for temperature regulation in thermal oil systems.
Types:
Include shell and tube, plate, finned tube, and double pipe, each offering unique advantages.
Features:
Components like tubes, shells, headers, and baffles optimize heat transfer efficiency.
Operation:
One medium flows through the tubes while the other one goes around them in the shell. Heat moves from one medium to the other through the tube walls.
Maintenance:
Keep the heating surface clean! Regular inspections and cleaning prevent issues like fouling and corrosion, ensuring longevity and efficiency.
Importance:
Heat exchangers are vital in lots of industries. They are responsible for heating, cooling, and even power generation. Without them, many processes wouldn't work properly.
Sump Tank
Function:
Sump tanks are crucial reservoirs in thermal oil systems, collecting and storing thermal oil during maintenance or commissioning phases.
Types:
Available in vertical, horizontal, and customized designs tailored to specific system requirements.
Features:
Sump tanks are connected to the expansion tank, the fill and discharge pump, the atmosphere, and in certain cases to the Nitrogen of the Nitrogen blanketing.
Operation:
Sump tanks collect thermal oil from system components. According to DIN4754 the sump tank shall be big enough to take up the heat transfer fluid of the biggest separatable part of the system.
Maintenance:
Sump tanks don't require continuous maintenance as they are usually empty. They shall be checked when in use.
Importance:
Helpful for maintenance work where the heat transfer fluid must be temporarily drained from the system and acting as an overflow vessel for the expansion tank.
Chimney
Function:
The chimney is responsible for the safe expulsion of exhaust gases produced during the heating process.
Types:
Single-wall chimneys are typically used in standard applications, while double-wall chimneys provide added insulation and safety measures, often required for specific industrial settings.
Features:
Chimneys are constructed from durable materials such as stainless steel or other heat-resistant alloys. They may come as plug-in systems or are welded steel constructions with ladders, platforms, drain- and flue gas-measuring nozzles.
Operation:
As the thermal oil system operates, combustion gases are produced. These gases rise through the chimney due to natural draft or induced draft created by fans, facilitating the efficient removal of emissions.
Maintenance:
Regular inspection and maintenance of the chimney ensure optimal performance and safety. This includes checking for signs of corrosion, cracks, or blockages.
Importance:
The chimney plays a critical role in maintaining a safe and environmentally friendly thermal oil system by effectively venting combustion byproducts. Properly designed and maintained chimneys help prevent the buildup of harmful gases and ensure compliance with regulatory standards.
Expansion Tank
Function:
The expansion tank helps to accommodate the thermal expansion of the heat transfer fluid as it heats up during system operation.
Types:
Vertical and horizontal expansion tanks serve different installation needs. They are welded tanks from carbon steel or stainless steel.
Features:
The expansion tank is installed at the highest point of the thermal oil system to not only take up the expanding heat transfer fluid but also to ensure enough pressure on the inlet side of the thermal oil pump. It is equipped with a low-level switch to maintain a minimum filling level.
Operation:
As the heat transfer fluid heats up, it expands into the expansion tank. The temperature inside the expansion tank shall remain below 60 °C to reduce thermal degradation of the fluid; optionally Nitrogen blanketing may be installed which allows higher temperatures.
Maintenance:
The function of the low-level switch shall be checked regularly.
Importance:
The correct height and filling level of the expansion tank reduces the risk of cavitation in the thermal oil pumps. The right size allows thermal expansion of the complete volume of heat transfer fluid in the system.
Oil Sample Cooler
Function:
Facilitates safe and representative sampling of thermal oil systems.
Operation:
Allows sampling during hot system operation via a water-cooled sampling device.
Location:
In the main flow piping.
Benefits:
+ Prevents oil losses during sampling
+ Ensures accurate analysis by cooling samples below 60°C.
Importance:
Ensures reliable analysis, prevents falsified results, and supports proper system maintenance.
Why take oil samples every year and analyse them?:
+ Avoids unnecessary oil changes.
+ Reduces top-up frequency.
+ Extends thermal oil lifespan.
+ Maintains energy efficiency and reduces fire risk.
Thermal Oil Pumps
Function:
Thermal oil circulation pumps are responsible for circulating the hot thermal oil from the heater to the consumer and back to the heater for reheating.
Types:
Centrifugal Pumps: Commonly used for thermal oil systems due to their efficiency and reliability. Our preferred brands are KSB, Allweiler or Speck. Other types, less common: Gear pumps for high-pressure applications/precise flow control, and screw pumps for high-viscosity fluids.
Features:
Heat Resistance: Designed to handle high temperatures encountered in thermal oil systems. Corrosion Resistance: Constructed from materials resistant to thermal oil and its additives.
Sealing: Equipped with seals to prevent leakage and ensure system integrity. [link to mechanical seal blog post]
Operation:
The pump transports the cold thermal oil through the heater. The hot oil then circulates through the system's pipelines to the consumers, e.g., heat exchangers. After transferring heat, the cold oil returns back to the heater.
Location:
We install primary cycle pumps after the gas and derivate separator and before the thermal oil heater. The secondary cycle pumps we install closer to the consumer.
Maintenance:
Regular Inspections: Check for leaks, unusual noises, and signs of wear.
Lubrication: Ensure proper lubrication of bearings and moving parts.
Cleaning: Periodically clean the pump and its components to prevent buildup and corrosion.
Importance:
Efficient Heat Transfer: Ensures consistent and efficient heat transfer throughout the thermal oil system.
System Performance: Plays a crucial role in maintaining system pressure and temperature levels.
Reliability: Reliable pump operation is essential for uninterrupted process heating.
Fill and Discharge Pump
Function:
Fill and discharge pumps are used to transfer thermal oil from the drum or IBC into the system, as well as drain oil into the sump tank if required.
Types:
Fill and discharge pumps are generally gear pumps for one- or two-way operation and are selected based on flow rate, pressure requirements, and temperatures.
Features:
These pumps are designed with robust construction and materials to handle high temperatures and ensure reliable operation.
Maintenance:
Gear pumps are generally maintenance-free. Although periodic checks for leaks and pump functionality ensure readiness for operation.
N2 Blanketing
Function:
Nitrogen blanketing prevents oxidation of the heat transfer fluid in thermal oil systems by displacing oxygen and moisture with inert nitrogen gas.
Features:
N2 blanketing systems are typically installed at the sump tank of the system equipped with a pressure regulating valve, strainer, pressure gauge, and disc-check valve.
Operation:
Nitrogen gas is introduced to create an inert atmosphere, reducing the risk of corrosion and degradation.
Maintenance:
Regular checks ensure extended equipment lifespan and reduced risk of downtime. Checks include monitoring nitrogen levels and detecting leaks.
Safety Valve
Function:
A critical safety device installed at the highest point of the thermal oil system to prevent overpressure by automatically releasing excess pressure to maintain system integrity and safety.
Types:
The most commonly used safety valves are full-lift, spring-loaded with open or closed bonnet, designed for specific nominal pressures, and adjusted to the required set pressure.
Operation:
When the pressure within the thermal oil system exceeds the preset safety limit, the safety valve opens to release excess pressure and prevent potential damage or catastrophic failure of the system components.
Maintenance:
Regular inspection and testing of safety valves are essential to ensure they are in proper working condition. This includes checking for leaks, corrosion, and proper sealing to guarantee reliable operation when needed.
Gas Separator
Function:
The gas and derivative separator vessel is a critical component in thermal oil systems. By removing gases and derivatives from the thermal oil, the separator vessel prevents contamination and degradation of the oil, and minimizes the risk of cavitation maintaining the pumps' reliability.
Features:
The bottom nozzle extends slightly into the vessel to prevent the return flow of high boilers forced out to the shell, ensuring optimal separation. Additionally, sludge can be drained via a drain nozzle, closed by a gate or ball valve, allowing for easy removal.
Operation:
Thermal oil enters the vessel, where centrifugal force and gravity facilitate the separation of gases and derivatives. Low boilers can exit through the top nozzle, while centrifugal force directs high boilers towards the sides for collection. This process ensures the continuous circulation of clean thermal oil within the system.
Maintenance:
Regular inspections ensure the proper functioning of the separator vessel. This includes checking for any buildup or blockages and conducting regular cleaning to remove accumulated sludge.
Heat Up Valve
Function:
The heat-up valve allows hot oil from the thermal oil heater to enter the expansion tank during the commissioning phase, facilitating the removal of water content in the thermal oil.
Operation During Commissioning:
During commissioning, the heat-up valve is opened to allow hot oil to enter the expansion tank. This process effectively "cooks out" any water present in the system, ensuring optimal performance and preventing potential damage due to water contamination.
Operation After Commissioning:
Once commissioning is completed, the heat-up valve remains closed to prevent high-temperature oil from entering the expansion tank. This is crucial because prolonged exposure to high temperatures in the expansion tank can lead to thermal degradation of the oil, compromising its performance and lifespan.
Client Practice:
Many clients choose to lock the heat-up valve after commissioning to ensure that it remains closed permanently, mitigating the risk of thermal oil degradation and maintaining system integrity over time.
Importance:
The heat-up valve plays a critical role during the commissioning phase of thermal oil systems, facilitating the removal of water and ensuring system readiness. However, its proper closure afterward is equally important to prevent thermal oil degradation and maintain long-term system performance.
CONTACT
PT Maxxtec Teknologi Indonesia
ITC Permata Hijau, Lantai 3 C11 No. 16,
Jl. Arteri Permata Hijau, Kebayoran Lama,
12210 Jakarta Selatan
Indonesia
Telephone: +62-21-53670749
Service: +62-812-82506215
Email: teknologi@maxxtec.co.id