THERMAL FLUID

HEATING
SOLUTIONS
Babcock Wanson offer a complete solution for compact,
easy to use and high efficiency thermal fluid systems
 The Practical Application
of Thermal Fluid Heating

WHY CHOOSE THERMAL FLUID HEATING SYSTEMS?

Steam Pressure Thermal Fluid Circulation
Thermal fluid systems have revolutionised process heating, making large, Curve Pump Pressure
energy hungry and heavily manned plant rooms a thing of the past for the
180
majority of industries. Thermal Fluid Heating systems are compact, easy to
use and offer an overall saving in energy that is hard to beat. 160

140
Unlike a steam system, there is no change of state of the fluid in thermal
120
fluid systems, so no condensate and therefore no flash steam losses, no

Pressure BAR
blow down losses or make up water and no effluent discharge. Thermal fluid 100
systems operate completely corrosion and frost free without the need for
80
expensive chemical treatment. Furthermore, users are not confronted with
the well-known problems of high pressure to reach high temperatures. It all 60

adds up to substantial savings for the operator. 40

20
Thermal fluids typically operate at up to 350°C at atmospheric pressure and
can remain pumpable down to minus 20°C and lower with special fluids, 0
which makes it a solution suitable for a wide range of applications. 100 200 300 400
Temperature °C

Typical Thermal Fluid Heating system configuration

Combined Deaerator Expansion Tank

Effective fluid expansion and deaeration
systems to remove dissolved gases are
critical for the good, long term operation Combined Flow Sustaining or
of a thermal fluid system. The Babcock System Pressure Relief Valve
Wanson combined tank system achieves all
requirements in a simple to fit single tank.

Thermal Fluid Heater

Babcock Wanson Thermal Fluid
Heaters are designed for stress-free Primary Circulating Pump
and unrestricted expansion of the The primary circulating pump group
heater coils for long life. They are provides the flow in the system to
available with integrated gas, oil or take the heat from the Thermal Fluid
dual fuel burners for high efficiency Heater and transfer it to the users.
operation. Heat losses are minimised and are
limited to a low level of radiated heat
from the well-insulated distribution
pipe work.
HOW DO THERMAL FLUID HEATERS WORK?
Thermal Fluid Heating is based on a similar principle to a simple hot water
system. It consists of a heater connected to carbon steel flow and return
pipework which can simultaneously provide heat to one or more users
or systems. Instead of water running through the closed loop pipework, a
thermal fluid which remains liquid throughout the operation is used as the
heat transfer medium. The heat is transferred by turbulent liquid flow at the
heat transfer surface. The fluid then passes in a closed circuit back to the
Thermal Fluid Heater for reheating without further loss of energy.

Different fluids – typically mineral and synthetic based fluids – can be

used to meet specific process heating requirements, making it a very
flexible system.

WHERE CAN THERMAL FLUID HEATERS BE USED?

Thermal Fluid Heaters have outpaced steam generation whilst there are too many to list here, on the following
in the majority of new process heating applications pages we look at some common solutions.
and, with their energy efficient operation, ease of use
and compact size, it’s not difficult to see why. There are If you have a process heating requirement, contact us for
numerous applications for Thermal Fluid Heating and further information and we can advise on a suitable solution.

BENEFITS OF THERMAL FLUID

VERY SAFE SYSTEM COST EFFECTIVE & HIGH DURABILITY

• Non pressurised system • Rapid start-up & shutdown
• Easy unattended automatic operation • Very low maintenance
• Corrosion free • No water treatment or chemicals required
• No freezing hazard • Minimal space requirements
• No liquid effluent produced • Long equipment & fluid life

ENERGY EFFICIENCY BEST AVAILABLE TECHNOLOGY

• Typically 20 - 50% less energy consumed • Precise constant temperature control
compared to steam • Heating & cooling possible in same system
• Closed circuit - no loss system • Mixed temperatures readily achieved in the
• No boiler blowdown losses same system
• No condensate losses • Ability to work at high temperatures (up to 350°C)
• High combustion & plant efficiency • Lower total exhaust emissions
• Point of use location
Pressing, Curing and Moulding

Autoclave Platen (Daylight) Press

Close temperature control from Babcock Wanson

systems for pressing, curing and moulding

Many processes involve changing the shape or form of material

using heat. Where steam, electricity or direct fuel firing have been
traditionally used, thermal fluid systems can offer greater control,
higher quality, lower cost and repeatability.

Design of the system flow characteristics to suit the process ensures

even heat distribution across the face of multi daylight presses without
the risk of condensate logging often associated with steam systems.

Simple and accurate temperature control is readily achieved using a

variety of techniques that have been developed and proven over
many years.

Steam, when required for direct contact with the process, can be easily
and safely generated as part of a thermal fluid system using one of our
Unfired Steam Boilers.

APPLICATIONS AND INDUSTRIES

• Press heating & cooling • Autoclave heating • Automative manufacturing

• Moulding processes • Drying & forming • Composite materials
• Extruder heating & cooling • Furniture manufacture
• Laminating • Plastics moulding
Tanks, Vessels and Cookers

Storage Tank Reactor Jacketed Vessel

Thermal Fluid Heating provides simple operation and

high accuracy temperature control for the process

Storage of product which must be maintained at any given temperature

is achieved at the lowest practicable cost when Thermal Fluid Heating
is used. Individual tanks or multi tank systems, such as can be found on
continuous metal treatment plants, demonstrate the flexible nature of
these systems with each tank controlled at the required temperature
using the simplest automated techniques.

Reactor and blending vessels for food, chemical and pharmaceutical

applications with and without differential temperature control are a
key application.

Secondary circuits can be readily incorporated to provide higher

fluid flow rates, different temperatures and very close control, all fed
from the primary circuit. This enables several different temperature
processes to be used on a single system.

Food grade thermal fluids are available when required.

APPLICATIONS AND INDUSTRIES

• Tank heating • Metal finishing • Marine applications

• Reactor heating • Anodising • Brewing industry
• Bulk liquid storage • Pharmaceutical
• Food processing • Refining & blending
Printing, Coating, Laminating and Drying

Calendar (Rolls) Screw Dryer Drying Tunnel

Flexible heating solutions and accurate control of multi

zone systems is simple with Thermal Fluid Heating

Roller heating, continuous drying and laminating is achieved with

the greatest accuracy and lowest operating cost with Thermal Fluid
Heating due to its advanced temperature control, simple automation
and unattended start/stop design. All this means the highest quality
products at the lowest production cost.

Multiple heaters can be installed on a single system and remotely

controlled to match the demands of production. Automation is simple
to apply with the latest controls able to provide remote monitoring of
the complete process.

Where required, Thermal Fluid Heating can be integrated into VOC

abatement technology from Babcock Wanson to offer a complete
energy and environmental solution.

APPLICATIONS AND INDUSTRIES

• Paper & foil coating • Sterilising • Drying & curing

• Stentoring • Printing& laminating • Packaging
• Textile transfer printing • Batch & continuous dryers
• Calendar setting & ironing • Waste treatment
Heating and Cooling Systems

Cooler or
Chiller

Controlled temperature heat exchanger Controlled temperature heat exchanger

(Heating Mode) (Cooling Mode)

Heating and cooling can be combined in a single

thermal fluid system

Combined simple, heating and cooling circuits operating independently

within the main system provide for special applications which demand
fast process times and very accurate control of temperature. Secondary
pumps and individual coolers working together with the primary
heating circuit at different temperatures can be installed to meet any
particular process requirement.

Proven system design provides combined heating and cooling on a

single system for exothermic reaction control or simply to maximise
the use of a plant. Babcock Wanson thermal fluid systems offer fully
integrated controls to ensure the process demand is met.

APPLICATIONS AND INDUSTRIES

• Controlled temperature • Press & moulding processes • Pharmaceutical

heating & cooling • Multiple independent variable manufacture
• Exothermic chemical temperature processes
reaction control • Chemical manufacture
 Thermal Fluid Heaters

Babcock Wanson Thermal Fluid Heaters with integrated gas, All Babcock Wanson Thermal Fluid Heaters are supplied
oil or dual fuel burners meet the needs of modern industry. complete with a fully matched burner and are factory tested
for simple site installation. The complete range is available
Our multi-pass fired Thermal Fluid Heaters have a long with all required ancillary equipment.
pedigree of both design and construction and are used
world-wide in a diverse range of industries and with a • TPC-B series from 116 to 6,978 kW output
wide variety of heat transfer fluids.
• TPC-LN series from 291 to 5,800 kW output

The overall design of our fired heater construction • EPC-ES series from 1,163 to 6,978 kW output
ensures stress free operation and ease of expansion
of the heater coil and, where fitted, integral • EPC-H series from 2,326 to 13,953 kW output
economiser; both key features for long equipment
life. Their exceptional efficiency provides substantial Contact us with your process heating needs.
environmental advantages and low overall emissions. We offer free expert advice.

SERVICES
After Boiler Maintenance Replacement
Sales Refurbishment Contracts Spare Parts
Our extensive team of We offer attractive We offer a complete We provide our customers
Service Engineers are fully refurbishment and upgrade range of preventive and with a stock of over
qualified and trained to services for all steam, hot corrective maintenance 30,000 spare parts and
respond to any service water and thermal fluid contracts that can be guarantee the repair
needs related to your boilers and all of your tailored to your needs. of all breakdowns with
boiler house. boiler house installation. minimum delay.

Locations & Contacts

UNITED KINGDOM POLAND
Phone: +44 208 953 7111 Phone: +48 32 230 6894
Email: info@babcock-wanson.com Email: info.pl@babcock-wanson.com

FRANCE ITALY
Phone: +33 1 49 78 44 00 Phone: +39 02 95 91 21
Email: commercial@babcock-wanson.fr Email: bwi@babcock-wanson.com

TUNISIA BELGIUM
Phone: +216 31 400 167 Phone: +32 14 45 08 31
Thermal Fluid Heating June 2021 – Issue 1

Email: bw.tunisie@gmail.com Email: info@maes-bvba.com

PORTUGAL NETHERLANDS
Phone: +351 229 999 490 Phone: +31 294 415 950
Email: bwc@babcock-wanson.com Email: info@reputabel.nl

SPAIN
Phone: +34 94 452 30 36 For more information, please visit our website:
Email: comercial@babcock-wanson.com www.babcock-wanson.com