Thermal fluid systems for industrial heat transfer
At Pirobloc, we specialize in the design, manufacture, and installation of thermal fluid systems for industrial heat transfer. Our thermal fluid heating systems are engineered to deliver superior energy efficiency, safety, and process precision for a broad range of industrial activities. Contact one of our sales engineers to get a customized proposal.
COMPREHENSIVE THERMAL FLUID HEATING SOLUTIONS
Pirobloc delivers fully integrated, turnkey thermal fluid heating systems. Our comprehensive scope covers everything from initial process analysis and custom engineering to equipment manufacturing, commissioning, and ongoing maintenance. This end-to-end approach ensures your installation is perfectly optimized for your specific application, maximizing productivity, reliability, and system longevity.
We design and manufacture thermal fluid heating systems entirely in-house, which allows us to have an absolute control over the quality, safety, and customizability of every thermal fluid boiler we deliver.
Our thermal fluid systems can operate with different heating transfer fluids, such as thermal oil, water, glycol, or specialty fluids.
The chosen fluid circulates inside closed-loop circuits to transfer heat indirectly to production equipment and processes. This process allows for precise temperature control without exposing materials to direct combustion or high-pressure steam.
We can manufacture gas-fired heaters or electric boilers to adapt to our customer’s preferred energy source:
- Our Gas-fired thermal fluid heaters offer lower emissions, excellent combustion stability and up to 10% fuel savings thanks to exhaust gas preheaters.
- Our electric thermal fluid heaters are emissions-free, reliable, and suitable for operations where the cost of electricity is lower than that of gas.
- Additionally, we manufacture secondary loops for processes requiring targeted temperature and flow control.
ADVANTATGES OF THERMAL FLUID SYSTEMS FOR INDUSTRIAL HEAT TRANSFER
Using a thermal fluid heating system for industrial heat transfer delivers a series of powerful advantages:
- High temperature, up to 400°C without high-pressure risks.
- Exceptional high energy efficiency, as they use 20% to 50% less energy than steam systems, with no condensate losses or blowdown.
- Lower maintenance costs due to the absence of scaling, corrosion, or water treatment needed.
- Compact and flexible systems that can be placed near heat consumers to minimize losses.
- Precise heat control: Uniform, stable temperature distribution ensures process quality.
- Thermal fluid systems reduce exhaust emissions. Additionally, electric heaters offer zero on-site emissions.
- One single unit can serve multiple zones or machines via indirect heat.
Our turnkey, customized thermal fluid solutions help clients reduce energy consumption, increase process reliability, and meet the highest safety and environmental standards.
OPERATION AND KEY COMPONENTS OF THERMAL FLUID HEATING SYSTEMS
A thermal fluid heating system transfers heat to industrial processes using a special heat transfer fluid instead of steam or water. The fluid is heated in a thermal oil heater—often through natural gas, diesel, or electricity—until it reaches the required temperature.
Once heated, the fluid circulates in a closed loop through insulated pipes, delivering consistent, precise heat to process equipment such as reactors, dryers, or heat exchangers. Because the system is pressurized only slightly, it can operate at high temperatures without the risks of high-pressure steam.
After transferring its heat, the thermal fluid returns to the heater to be reheated, ensuring continuous, efficient, and safe operation with minimal energy losses.
A typical thermal fluid system includes the following components:
- A heater (gas or electric).
- Circulation pumps.
- Preheater (for gas units).
- Expansion tank.
- Control valves.
- Instrumentation.
- All connected by carbon steel piping.
The thermal fluid is selected based on the specific temperature and performance needs of the process.
THERMAL FLUID SYSTEMS VS STEAM BASED SYSTEMS
When compared to steam systems, thermal fluid heating delivers significantly improved thermal efficiency and operational safety.
The higher efficiency of thermal fluid systems is achieved thanks to their ability to maintain extremely high operating temperatures without the need for high pressures. This is possible due to the absence of phase change in thermal oil, which eliminates pressure risks and maximizes heat transfer efficiency, and the use of a closed-loop system.
Steam-based systems typically achieve an efficiency of 65–70%, while thermal fluid systems can exceed 90%. This translates into less energy losses and a direct reduction in fuel consumption, which can reach up to 25% in many applications, resulting in both environmental and economic benefits.
COMMON APPLICATIONS OF THERMAL FLUID HEATING SYSTEMS
Pirobloc thermal fluid systems have deliver an excellent performance in a wide range of industries and applications, including:
- Food & Beverage: Fryers, ovens, snack production lines.
- Plastics & Rubber: Molding, extrusion.
- Chemicals & Petrochemicals: Reactors, distillation, synthesis.
- Oil & Gas: Refining, crude heating, recycling.
- Construction Materials: Kilns, heat presses.
- Asphalt: Hot-mix plants, roofing material processing.
- Converting & Printing: Laminating, printing, pressing.
- Die Casting: Precise mold temperature regulation.
- Plastics & Rubber: Press heating, molding, and extrusion.
- Storage tank eating in port terminals.
- Wood & Building Materials: Press heating for particleboard, MDF, and laminates.
- Adhesives and glues.
- Textile industry.
- Industrial laundries.
- Solar energy production.
- Wastewater treatment.
- Paper drying.
- Flexography and rotogravure.
- Hydraulic presses.
- …and many more.
