As industries worldwide seek more sustainable and efficient solutions for their production processes, the transition from gas heating systems to electric thermal oil heaters is gaining momentum. This change is particularly relevant in sectors like industrial laundry, where large-scale equipment such as ironers relies heavily on efficient heat generation. This article explores the case of a prominent manufacturer in the laundry industry, evaluating the replacement of their gas boilers with electric thermal oil boilers in collaboration with Pirobloc.
Use of thermal oil boilers to provide temperature for industrial ironers
Thermal oil heaters are a critical component in the operation of industrial ironers, as they are responsible for generating the high temperatures required to process large volumes of laundry efficiently.
Traditionally, these boilers have been gas-powered, integrated into the ironer’s chassis, offering a reliable and well-known energy source. However, as environmental regulations tighten and energy cost dynamics shift, many companies are exploring electrically-powered thermal oil systems.
Gas-powered ironers with thermal oil boilers have long been the preferred choice due to their ability to produce consistent heat at relatively low operational costs. However, these boilers also have significant disadvantages:
- Greenhouse gas emissions.
- Dependence on fossil fuels.
- Less reliable and consistent boiler performance.
- Occasionally complex installation and maintenance requirements.
The growing emphasis on sustainability and energy efficiency is leading many companies to consider electric thermal oil boilers as a viable alternative.
Replacing gas boilers with electric thermal oil heaters
Some companies have already undertaken this process, replacing their existing gas boilers with Pirobloc electric thermal oil boilers. The main reasons for considering this transition are:
- Optimize productivity.
- Reduce operational costs.
- Improve energy efficiency in their industrial operations.
- Reduce their environmental impact by lowering carbon emissions.
One of the primary considerations is the need to integrate the new electric boilers into existing ironer systems without requiring extensive modifications. This requires the electric boilers to match specific dimensions, ensuring they can seamlessly fit into the ironers already in use.
Electric thermal oil heaters offer several advantages over their gas counterparts:
- Electric thermal oil boilers achieve 100% efficiency, meaning almost all the electricity consumed is converted into heat. This represents a significant improvement over gas heaters, which, while efficient, lose energy in the combustion process.
- Electric oil heaters are easier to operate and require less maintenance than gas boilers.
- The need for fuel transport or storage at the customer’s facility is eliminated, reducing both space requirements and potential safety risks.
Technical considerations before transitioning to electric thermal oil boilers
The transition from a gas heating system to an electric-powered one is not without challenges in this project. The existing systems were designed with specific parameters in mind, including oil flow rates, temperature ranges, pressure limits, and physical dimensions. For the replacement to be successful, the new electric thermal oil boilers must meet these stringent requirements.
One of the specifications is that the electric boilers must have a diameter of no more than 1050 mm and a length not exceeding 2400 mm. These dimensions are crucial because the boilers are integrated into a broader machine system, and any deviation could interfere with the entire assembly.
Additionally, boilers of various power outputs (200 kW, 540 kW, and 750 kW) are required to meet quality and safety standards.
Pirobloc, with its extensive experience in designing and manufacturing custom thermal oil boilers for all types of applications, confirms its ability to meet these requirements with the highest guarantees. They offer a customized proposal, highlighting their flexibility to adapt standard designs to the specific needs of existing market equipment. This level of customization is essential in industrial applications where standard solutions are not always viable.
Other relevant factors
Beyond technical compatibility, a key variable to consider is the timing of the transition, as it is important that there are no operational interruptions during critical periods.
Another critical factor to consider is how operating costs are affected when replacing a gas-powered system with one where the energy source is electricity. While electric thermal oil boilers offer greater energy efficiency and reduce atmospheric emissions, operating costs can vary depending on geographic electricity prices compared to gas. This economic aspect plays a significant role in the final decision, along with the technical and environmental benefits.
A trending solution to heat industrial ironers
The transition from gas boilers to electric thermal oil boilers reflects a trend that has taken hold in the market, as demonstrated by the large number of such projects carried out by Pirobloc in recent years. The adoption of electric thermal oil boilers helps reduce costs, improve production capacity, optimize process sustainability, and ensure energy efficiency.
Although gas boilers have been a common solution in the industry for years, the growing demand for cleaner, more efficient energy solutions is driving companies to explore electric alternatives.
This success story highlights the importance of careful planning and close collaboration between client and manufacturer when making such transitions. It is essential to work with a provider that can offer customized solutions, such as Pirobloc, which can also ensure clients meet the most stringent technical requirements and provide extensive productivity and environmental benefits.
Future outlook on heating ironers in laundries
The use of thermal oil heaters for heating ironers in industrial laundries is becoming more common due to several key advantages they offer compared to other heating methods, such as steam or direct gas:
- Thermal oil boilers offer high energy efficiency, converting a higher proportion of consumed energy into useful heat. This is especially important in industrial applications like laundries, where consistent and uniform heat is required for the efficient operation of ironers. This reduces fuel consumption and, therefore, operating costs.
- Thermal oil allows for precise temperature control, keeping it stable and uniform, which is crucial for the ironing process in ironers. This is difficult to achieve with other heating methods, such as steam, which can fluctuate in temperature.
- Thermal oil allows the necessary temperatures to be reached without needing to operate at high pressures. This significantly reduces the risks associated with boiler operation, as no pressurized system is required, lowering the chance of accidents related to high pressure.
- Thermal oil heaters generally require less maintenance than steam boilers. There are no issues with corrosion, scaling, or fouling in thermal oil systems, which are common in steam systems. This translates to greater reliability and less downtime for maintenance.
- The thermal oil heating system is very versatile and can be used to heat different types of equipment in an industrial laundry, not just ironers. This allows industrial facilities to centralize their heating system, improving overall process efficiency.
- The use of thermal oil boilers allows for great adaptability in terms of design and configuration. Manufacturers can design systems that perfectly fit the specific needs of the facility, such as the dimensions of the ironer and heat flow requirements, ensuring a perfect fit and optimizing performance.
- In a context where sustainability is becoming increasingly important, thermal oil boilers can be easily integrated with renewable energy sources. For example, they can be powered by electricity generated from solar or wind sources, helping to reduce the carbon footprint of laundry operations.
