Industrial operations depend on reliable, high-temperature heat to keep processes running safely, efficiently, and without interruption. From chemical processing and asphalt production to food manufacturing and energy applications, maintaining precise thermal control is critical to product quality, equipment longevity, and overall plant performance.
Industrial thermal fluid heating systems are specifically designed to meet these demands. By circulating thermal fluid through a closed-loop system, they deliver consistent, controllable heat at high temperatures, without the high pressures and operational challenges associated with steam. This makes thermal fluid systems an ideal solution for facilities that require dependable process heat with enhanced safety and efficiency.
At Enerquip Thermal Solutions, we specialize in direct-fired thermal fluid heating systems engineered for demanding industrial environments. Our systems are designed to optimize energy efficiency, maximize uptime, and provide long-term reliability across a wide range of applications and industries.
What Is an Industrial Thermal Fluid Heating System?
Industrial thermal fluid heating is the process of supplying controlled heat to industrial operations using heat transfer fluid. These systems are essential for maintaining production continuity, preventing freezing or temperature drops, and meeting precise process temperature requirements.
Compared to conventional steam systems, this heating method circulates a heat transfer liquid through a closed-loop network of pipes. This allows facilities to achieve high operating temperatures at atmospheric pressure, significantly improving safety and control.
A standard serpentine coil thermal fluid heating system from Enerquip consists of:
- Radiant heating coil
- Finned economizer section
- Burner
- Recirculation pump
- Fuel train
- Expansion tank
- Panels and controls
These key components work together to deliver reliable, efficient heat. Systems can be customized using different fuel sources and heat exchanger configurations to meet specific operating needs while optimizing energy efficiency and maintaining production performance.
Thermal Fluid Heaters / Hot Oil Heaters
Thermal fluid heaters, also known as hot oil heaters, are industrial systems designed to heat and circulate process fluids (e.g., oil, glycol, or water) within a closed-loop system. A gas-fired burner heats the thermal fluid, which is then circulated throughout the system to deliver a controlled, indirect source of high-temperature heat to downstream equipment.
Because these systems operate at atmospheric pressures, they eliminate many of the risks associated with steam systems. High-efficiency thermal fluid heaters offer industrial facilities several benefits:
- Ability to maintain stable process temperatures
- Reduced risk of corrosion
- Improved equipment longevity
- Lower operating costs and fuel consumption
- Minimized downtime and unplanned maintenance
Thermal fluid heaters utilize circulation pumps to deliver heated fluid to ancillary equipment, such as tank coils, steam generators, suction heaters, ovens, reactors, and presses. This precise and efficient heating method makes them ideal for industries that require a stable heat source for tasks such as refining, asphalt, paper manufacturing, and chemical processing.
Watch the video below to see this process in action.
Maintaining high temperatures at low pressure also helps prevent issues such as corrosion or coking, which can restrict flow and degrade performance in refining, manufacturing, asphalt plants, and petrochemical operations.
Available Configurations and Standard Features of Enerquip’s Thermal Fluid Heating Systems
- Burner Management System (BMS). Included with our high-efficiency gas-fired burners.
- Convection section. A built-in finned convection (economizer) section recovers waste heat, improving efficiency by 10%.
- Emissions options. Ultra Low NOx (<9 PPM), Low NOx (<30 ppm), or Standard (80 to 120 ppm).
- Expansion tank. The 1,000-gallon tank includes an optional nitrogen blanketing system.
- Fuel train. Pre-wired and pre-piped for alternate fuels and/or natural gas.
- NEMA 4 control panel. Features optional app connectivity for remote diagnostics, along with integrated alarms and safety features.
- Radiant section. Consists of a high-efficiency serpentine coil.
- Recirculation pump. Ensures continuous and consistent performance.
- Variety of sizes. Ranging from 1.3 MM BTU/hr. to 40 MM BTU/hr.
Steam Generators
Many facilities require steam for certain operations, but don’t have the necessary capital to invest in a large-scale boiler system. Thermal fluid steam generators from Enerquip offer unsurpassed efficiency, particularly when used in tandem with a hot oil heater and High-Pressure Condensate Receiver (HPR).
Advantages of Thermal Fluid Steam Generators Over Boilers
- Eliminates space constraints. The compact design requires less space than conventional boilers, which is ideal for confined areas.
- Enhances safety. Thermal fluid steam generators operate at lower pressures than boilers, minimizing the risk of explosion.
- Improves thermal efficiency. Thermal fluid steam generators feature higher thermal efficiency than traditional boilers, utilizing a closed-loop system that heats and circulates the thermal fluid, resulting in reduced energy losses and better heat transfer capabilities.
- Increases response times. These systems significantly improve operational efficiency, with faster startup and shutdown times.
- Lowers fuel consumption. Steam generators do not rely on a separate boiler. They produce steam by utilizing the heat generated from a thermal fluid system, significantly reducing emissions and fuel consumption.
- Maximizes temperature control. These systems provide accurate and consistent heating with precise temperature control, which is particularly important in applications that demand a certain temperature.
- Offers unsurpassed versatility. Thermal fluid steam generators utilize a broad range of heat sources, including plant steam or hot thermal oil.
- Reduces labor costs. Unlike conventional boilers that typically require an on-site licensed operator, thermal fluid steam generators require minimal oversight.
Helical Coil Heaters
Thermal fluid heaters featuring helically wound coils are manufactured using a coil that is wound into a spiral shape. Helical coil heaters are ideal for applications with reduced heat requirements. They are smaller in size and provide an affordable alternative to larger systems, delivering approximately 90% of the efficiency of our serpentine coil technology. While the primary purpose of helical coil systems is to heat thermal oil, they can also be used to directly warm fluids, such as water, oil, and other mixed fuels.
Low NOx Heaters
Low NOx industrial heaters are designed to significantly reduce nitrogen oxide (NOx) emissions by utilizing advanced combustion technology. Features such as premix burners and flue gas recirculation systems effectively minimize harmful gas emissions.
Asphalt Heaters
Asphalt heaters are an economical and efficient solution for heating asphalt used in roofing and road construction applications. These specialized heaters rely on radiant heat to soften the asphalt and heat it to its original mixing temperature, without burning the tar oils that are essential to the material’s flexibility.
Waste Heat Recovery Units
Waste heat recovery units, also known as waste heat economizers, capture heat energy from processes such as turbine operation or thermal oxidizers to reuse it within an industrial heating system. They can be either stand-alone equipment or attached to Enerquip’s serpentine coil thermal fluid heaters. The cost-effective solution allows facilities to reuse heat for other applications.
Shell and Tube Heat Exchangers
Shell and tube heat exchangers feature a pressure vessel or outer shell with a tube bundle connected inside. As one fluid flows through the tubes, another fluid flows through the shell around them, allowing efficient heat exchange between the two media. At Enerquip, we provide heat exchanger sizing to match our clients’ specific needs. These products are highly versatile and commonly used in high-heat and high-pressure applications, such as pharmaceuticals, food and beverage processing, oil refineries, and large-scale chemical processes.
Choose Enerquip for Your Next Thermal Fluid Heating System
Established in 1985, Enerquip Thermal Solutions is a trusted provider of Made in the USA industrial heating and cooling solutions. Our team of skilled experts is committed to delivering the highest quality of service, ensuring our clients receive a product that meets or exceeds their expectations, even under the toughest regulatory or operating conditions.
At Enerquip, we go above and beyond what is expected, integrating innovative safety strategies and best practices to maximize uptime and enhance performance capabilities. Our detailed approach to project management includes open communication through every step of the manufacturing process, from the initial design concept through delivery.
Contact us today to learn more about our thermal fluid heating systems and see how they can meet the demands of your next project. You can also request a quote for custom equipment.
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