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Thermal Fluid Heating Systems

A thermal fluid system is more than just a heater, and all system components must work together in harmony for proper performance. Purchasing a complete system from Sigma Thermal will ensure that your industrial operation is reliable.

Exhaust Stack Exhaust Stack Responsible for removing the combustion gases from the heat exchangers. Thermal Fluid Heater Thermal Fluid Heater Indirect heating in which a liquid phase heat transfer medium is heated and circulated to one or more heat energy users within a closed loop system. Pump Skid Pump Skid A pump skid includes a pump and a driver such as an electric motor or diesel engine mounted on a common steel base. Expansion Tank Expansion Tank Vessel designed to contain thermal expansion within a closed loop thermal fuid system. expansion within a closed loop thermal fuid system. Heat Exchanger Heat Exchanger A system used to transfer heat between two or more fuids. Double Leg Drop Double Leg Drop A piping structure, consisting of a block and bypass valve, that forces a high volume fow rate through the expansion tank, to aid in deaeration during thermal oil cookout.
Thermal Fluid Heating

Thermal Fluid Heating

Thermal fluid heating is a type of indirect heating in which a liquid phase heat transfer medium is heated and circulated to one or more heat energy users within a closed-loop system. Thermal oil, glycol, and water are common heat transfer mediums for these systems.

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Thermal Fluid Heater Options

Pre-engineered and custom process heaters are available in gas-fired, oil-fired, electric and biomass-fired configurations. While the basic components of a complete thermal fluid system are the same, the heater designs vary considerably based on the fuel source. For detailed information on specific heater designs please select from one of the below heater options.

Do you know what you need? Submit an RFQ or contact a thermal fluid systems expert with questions.

HC1 Gas Fired Heaters
HC1 Gas Fired Heaters
HC2 Gas Fired Heaters
HC2 Gas Fired Heaters
SHOTS Electric Heaters
SHOTS Electric Heaters
Biomass Fired Heaters
Biomass Fired Heaters
Rendering of thermal Fluid Heating System Assembly on white background

Thermal Fluid System Components

Packaged components enhance efficiency, ensuring a good return on investment. Overall, Sigma Thermal's expertise enables the creation of solutions that effectively address diverse thermal fluid requirements.

Examples:
  • Expansion & Drain Tanks
  • Temp Control Skid Packages
  • Ladders & Access Platforms
  • Burner Management Controls
  • Tanks & Vessels
  • Secondary Loops
  • Exhaust Stacks

Typical Applications

  • Tank heating
  • Platen/Press heating
  • Indirect steam generators
  • Crude oil heating
  • Suction heating
  • Ovens and fryers
  • In line liquid heating
  • Calendar roll heating
  • Reactor vessel heating
  • Natural gas heating
  • In line gas heating
  • Building heaters
  • Process reboilers
  • Jacketed vessel heating
  • Heated molds or dies
  • Autoclaves
Thermal Fluid Heating Systems
Thermal Fluid Heating Systems
Thermal Fluid Heating Systems
Thermal Fluid Heating Systems
Thermal Fluid Heating Systems

Economizers

With the typical elevated operating temperatures associated with thermal oil systems, it can be difficult to obtain high efficiencies in the heater alone. Sigma Thermal offers a wide variety of economizers to fit your process requirements, increase your thermal efficiencies, and lower your operating costs.

Common Waste Heat Consumers:
  • Combustion Air Pre-heat
  • Steam Ejectors
  • ORC Generators
  • Wash Water Pre-heat
  • Boiler Feedwater
  • ORC Generators
  • Building Comfort Heat
  • General Process Heat

Thermal Fluid Options

  • Thermal Oil

    Thermal oil offers the user the capability of high-temperature operation (up to 600F with organic thermal oils and 800F with certain synthetics) at very low pressures. Due to the low operating pressure and properties of thermal oil, most heaters are built to ASME Section VIII, and a licensed boiler operator is not typically required.

    Many people around the world refer to these systems by different names. The phrases thermal oil heater, thermal oil system, thermal oil boiler, thermal fluid heater, thermal fluid system, thermal oil boiler, hot oil heater, hot oil system, and hot oil boiler generally all refer to the same type of closed-loop liquid phase heat transfer system. Note that many people use the terms thermal oil boiler or thermal fluid boiler even though most systems do not involve any type of vaporization.

  • Hot Water & Water-Glycol

    Due to its superior thermophysical properties, water is an ideal heat transfer medium. Closed loop liquid phase hot water or glycol solution systems are an excellent choice for indirect process heating up to approximately 300F. Because the water is used in a closed loop with no direct feed water source, heaters are typically built to ASME Section VIII and do not require a licensed boiler operator. Heaters can be built to ASME Section I when required.

    These thermal fluid systems are a great alternative to water bath heaters.

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