Thermal Oil Boilers
High-Temperature Heat Transfer Solutions Without High Pressure
Overview
Thermal Oil Boilers, also known as Thermal Oil Heaters or Hot Oil Systems, are designed to deliver high-temperature heat transfer (up to 350–400°C) while operating at low system pressure. Mechasol Thermal Oil Boiler systems provide a safe, stable, and energy-efficient alternative to steam boilers for processes requiring precise and continuous temperature control.
Unlike steam systems, thermal oil systems eliminate risks associated with high pressure and phase change, making them ideal for continuous industrial operations and temperature-sensitive processes.
Engineering Philosophy & Design Basis
Mechasol designs thermal oil boiler systems as closed-loop heat transfer systems, engineered specifically for the process requirements rather than standard boiler duty.
Key engineering parameters include:
Required supply and return oil temperature
Heat duty and load variation profile
Thermal oil type and degradation limits
Maximum allowable film temperature
System pressure drop and circulation flow
Expansion and inert gas blanketing philosophy
Each system is engineered to ensure uniform heat flux, avoiding localized overheating and thermal oil cracking.
Thermal Oil Boiler Types & Configurations
Coil Type Thermal Oil Boilers
The most commonly used configuration, utilizing a helical or serpentine coil arrangement.
Key Features
High heat transfer efficiency
Compact design
Uniform oil velocity and temperature distribution
Suitable for both horizontal and vertical layouts
Vertical Thermal Oil Boilers
Preferred where footprint is limited.
Advantages
Reduced installation space
Natural circulation support in some configurations
Easy integration into modular skids
Horizontal Thermal Oil Boilers
Used for higher capacities and easier maintenance access.
Advantages
Larger heating surface
Simplified inspection and coil replacement
Better suited for large industrial plants
Fuel Options & Combustion Systems
Mechasol Thermal Oil Boilers are designed for multiple fuel options, including:
Natural Gas
LPG
Diesel
Heavy Fuel Oil
Dual-fuel and multi-fuel configurations
Advanced burner systems ensure:
High turndown ratios
Stable flame characteristics
Low NOx emissions
Precise temperature control
Thermal Oil System Components
A complete Mechasol thermal oil system typically includes:
Thermal oil boiler (heater)
Circulation pumps (duty / standby)
Expansion tank
Nitrogen blanketing system
Air and safety valves
Oil filtration and drainage system
Control and automation panel
Optional systems include economizers, heat recovery units, and redundant safety instrumentation.
Automation, Control & Safety
Thermal oil systems require strict temperature monitoring and control. Mechasol systems include:
Continuous oil temperature and pressure monitoring
Burner modulation based on heat demand
Over-temperature and low-flow interlocks
Emergency shutdown systems
PLC-based automation with remote monitoring
Safety design complies with EN, ASME, PED, and relevant international standards.
Advantages Over Steam Systems
Thermal Oil Boilers offer several technical advantages compared to steam boilers:
High operating temperature at low pressure
No water treatment or blowdown required
No phase change losses
Stable and precise temperature control
Reduced corrosion and scaling risks
These benefits result in lower operating costs and higher system reliability.
Typical Applications
Thermal Oil Boiler systems are widely used in:
Chemical and petrochemical plants
Asphalt and bitumen processing facilities
Plastic, rubber, and polymer industries
Food processing (frying, drying, baking)
Textile and paper industries
Oil & gas process heating
They are particularly suitable where process stability and temperature accuracy are critical.
Modular & Skid-Mounted Solutions
Mechasol can deliver thermal oil systems as:
Skid-mounted modular packages
Containerized systems
Fully site-erected installations
This flexibility allows rapid installation, reduced civil works, and shorter commissioning time.
EPC & Turnkey Capability
Mechasol provides complete EPC services for thermal oil boiler projects, including:
Process and thermal design
Mechanical and electrical engineering
Manufacturing and factory testing
Installation and commissioning
Operator training and lifecycle support
Summary
Mechasol Thermal Oil Boilers deliver high-temperature, low-pressure thermal energy with exceptional safety, efficiency, and reliability. Engineered for demanding industrial environments, these systems provide a robust alternative to steam where process integrity and operational continuity are paramount.