Thermal oil heaters and heating systems provide reliable, precisely controlled heat for industrial manufacturing processes. They use thermal oil as a liquid heat transfer medium to transport thermal energy from a heat source to connected process consumers.
A thermal oil heating system consists of a heater, a closed circulation circuit, circulation pumps, piping, expansion equipment and the necessary control and safety devices.
The thermal oil heater is the heat-generating component within the system. It heats the circulating thermal oil to the required operating temperature. Depending on the selected heat transfer fluid and system design, thermal oil heating technology enables high process temperatures at comparatively low operating pressures.
AURA develops and manufactures customized industrial thermal oil heaters and complete thermal oil heating systems for a wide range of industrial applications.
Our expertise includes thermodynamic and hydraulic engineering, system design, manufacturing and integration into new or existing process heating installations.
Technology: Indirect industrial heat transfer using thermal oil
Heat transfer medium: Mineral or synthetic thermal oil and suitable specialized heat transfer fluids
Heat generation: Electric heating, fuel combustion or the utilization of existing thermal energy
Maximum operating temperature: Up to 450°C
Heating capacity: Depending on system type, from 75 kW to 25 MW
Applications: Industrial process heating
System design: Customized heating systems
Services: Engineering, design, manufacturing, commissioning and more
Typical heat consumers: Industrial presses, chemical reactors, dryers, industrial ovens and heat exchangers
A thermal oil heating system is an industrial process heating installation that transfers thermal energy from a heat source to one or more heat consumers using a circulating liquid heat transfer medium. The thermal oil is heated and transported through a closed piping circuit to connected production equipment. At the heat consumer, thermal energy is transferred to the industrial process. The cooled thermal oil then returns to the heater. This operating principle enables continuous and controlled heat transfer to industrial processes. Thermal oil heating systems are used in industries such as chemical manufacturing, food processing, plastics production, wood processing and industrial machinery.
Although the terms are sometimes used interchangeably, they describe different parts of an industrial process heating installation.
A thermal oil heating system refers to the complete installation, including the heater, circulation pumps, piping, control and safety equipment, and connected heat consumers.
A thermal oil heater is the component that transfers thermal energy to the circulating thermal oil. The heater can be electrically heated, fired or supplied with thermal energy from another heat source.
AURA develops both individual thermal oil heaters and complete industrial thermal oil heating systems.
The operating principle of a thermal oil heating system is based on a closed heat transfer circuit. Thermal energy is supplied to the circulating thermal oil, which transports the heat to connected industrial consumers. The process consists of four main steps.
1. Heat Generation
Thermal energy is supplied in the thermal oil heater. Depending on the technology, heat can be generated electrically, through the combustion of suitable fuels or by utilizing an existing heat source. In fired thermal oil heaters, gaseous or liquid fuels are burned under controlled conditions. The resulting heat is transferred to the circulating thermal oil through specially designed heat transfer surfaces.
2. Heating the Thermal Oil
The thermal oil absorbs the supplied thermal energy and is heated to the required operating temperature. The heating output is controlled according to the actual process heat demand.
3. Transporting Process Heat
A circulation pump transports the heated thermal oil through the piping system to the connected industrial heat consumers.
4. Heat Transfer and Return Flow
The thermal oil transfers its thermal energy to the production process and subsequently returns to the heater. This closed circulation circuit enables a continuous and controlled supply of industrial process heat. Modern measurement, control and safety systems ensure that the required thermal energy is supplied according to the current process demand.
The introduction of heat transfer systems or thermal oil heaters pays off for industrial and commercial companies in many ways. Compared to classic steam generators, thermal oil heaters operate almost without pressure, making the entire system technology simpler and requiring less maintenance. The use of thermal oil also means that corrosion does not occur, making the individual components very durable.
Another plus point is the high precision: Thanks to the sophisticated control technology, a thermal oil heater succeeds in providing process heat very reliably at the desired temperature level. From an economic point of view, it is also advantageous that thermal oil heaters are comparatively inexpensive both to purchase and to operate.
If you are thinking about introducing thermal oil heaters in your company, please feel free to contact us. As an experienced specialist for heat transfer systems, AURA is at your side from planning and design to implementation and operation.
Thermal oil heating systems differ primarily in how thermal energy is supplied to the heat transfer medium.
AURA develops and manufactures customized thermal oil heaters and complete thermal oil heating systems for industrial process heat. Our expertise covers thermodynamic and hydraulic engineering, mechanical design, manufacturing and integration of complete heat transfer systems. We consider not only the heater itself but also the entire thermal oil circuit, including pumps, piping, control systems, safety equipment and connected heat consumers. AURA develops different technologies to meet specific industrial requirements:
They are particularly relevant for industrial applications requiring high and continuous heating capacities.
Thermal oil heating technology offers several advantages for industrial applications requiring reliable and controlled process heat.
High Operating Temperatures: Suitable thermal oil systems enable heat transfer at elevated temperatures and can therefore be used for demanding industrial processes.
Comparatively Low Operating Pressure: Compared with high-temperature steam systems, suitable thermal oils can transfer heat at high temperatures while requiring comparatively low system pressures.
Precise Temperature Control: The heat supply can be regulated according to the requirements of individual industrial processes.
Centralized Process Heat Supply: A single thermal oil heating system can supply multiple industrial heat consumers.
Different Heat Sources: Thermal oil can be heated electrically, through fuel combustion or by utilizing existing thermal energy.
Integration into Existing Installations: Depending on the technical conditions, thermal oil systems can be integrated into, expanded or modernized within existing production facilities.
The advantages of thermal oil heating systems are closely related to the physical and chemical properties of the heat transfer fluid. On our technology page about low-pressure heat transfer with thermal oil, we explain the temperature and pressure characteristics of thermal oil, different heat transfer fluids and the comparison between thermal oil and steam.
Industrial thermal oil heaters are used wherever production processes require reliable and controlled heat transfer. Typical applications include:
Food Processing: Thermal oil heating systems can provide indirect heat for industrial baking ovens, frying equipment and other thermal food production processes.
Chemical Industry: Chemical reactors and stirred vessels require defined temperatures for different manufacturing processes. Thermal oil enables controlled indirect heating.
Plastics Processing: Extruders, presses and other manufacturing equipment require precise temperature control for processing different plastics.
Wood and Paper Industry: Industrial presses, calenders and drying systems depend on reliable heat supply to process materials under controlled conditions.
Industrial Machinery: Thermal oil heaters supply process heat to various industrial machines and production equipment.
Oil and Gas Industry: Thermal oil systems are used for applications such as crude oil processing, natural gas preheating and other thermal processes.
The appropriate heating system depends on the required heating capacity, operating temperatures and process conditions.
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The achievable operating temperature depends on the selected heat transfer fluid and system design.
Depending on the heating technology, AURA offers thermal oil heating systems for temperatures of up to 450°C.
Thermal oil heaters can be electrically heated, fired or supplied with heat from existing thermal energy sources. AURA also develops flue gas heated and steam heated thermal oil systems.
Yes. Depending on the condition and design of the existing installation, individual components or the heat generator can be replaced or upgraded.
Electrification, improved temperature control and waste heat recovery may also be possible. Find more information for retrofitting and modernization.
AURA provides thermal oil heating systems for different industrial requirements.
Depending on the technology, the portfolio includes compact systems starting at 75 kW and individually engineered fired systems with heating capacities of up to 25 MW.
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