Electric Thermal Fluid Heaters

Advantages of Electric Thermal Oil Boiler;

• Clean, Smokeless, Silent, 0 emission, reliable hot oil is produced with a Switch.
• Chimney system, burner, fuel supply, storage are no longer needed, which saves money and reduces space requirements.
• Compared to a conventional boiler, they offer compact simple design, smaller footprint and weight.
• Simple installation and commissioning. There is no need for any ventilation.
• Flanged resistance heater in accordance with DIN standards is used.
• With the SSR system, the energy power is driven proportionally.
• High process reliability, remote control
• Conversion to thermal energy with an efficiency close to 100%.
• Low operating costs by using cheap or renewable electrical energy
• Its instantaneous response to peak traction with maximum power and its response to minimum utilisation with minimum power compared to conventional fossil fuel boilers is mainly an excellent efficiency.
• Faster cold start is possible,
• There are zero emissions of COx, NOx and SOx at the user site.
• Quiet operation with virtually no noise emissions
• Customer-specific software revision with our expert staff specific to your company.
• The boiler can be optionally equipped with a PLC with different communication protocols such as Modbus, Profibus, etc. and thus boiler integration into any industrial process can be provided.

For higher thermal oil demand or fluctuating heat loads, several thermal oil producers can be connected in series (modular). Multiple systems like this are the right and economical solution.

The development of industrial electric boilers has become essential to cope with current environmental pollution. The Paris Agreement clearly states that global warming should not exceed 1.5 degrees Celsius. For this reason, the energy sources used to generate electricity have evolved significantly over the last 10 years, with authorities in each country implementing policies aimed at encouraging and supporting a rapid energy transition. Electrically heated industrial boilers have become an indispensable tool to deal with the dual challenges of energy optimisation and decarbonisation. At a time when wind power, hydropower and nuclear power can provide electricity without producing CO2, NOx and SOx, electric boilers have become a good environmental option.

TSB ENERGY offers future-orientated, electricity-based system solutions for industrial boilers. The focus is on resource conservation, reducing CO2 emissions and increasing the use of climate-friendly technologies.

Working Principle: While the thermal oil in the circulation at continuous speeds of 1.5-2 m/sec passes through the pipes designed in a horizontal construction in such a way that there is no stagnant point in the turbulent flow, the temperature of the thermal oil is increased to the desired temperature range with the heat energy received from the electrical resistances and hot oil is obtained at the desired temperature.

Design: Our electric hot oil boilers are designed and manufactured in a horizontal construction in a pipe-lining-pipe form so that there is no stagnant point in turbulent flow according to DIN 4754, EN13445, Loyd rules, TRD, DIN, EN, PED 2014/68/EC and ASME Section VIII Div 1. All electrical components are UL labelled and wired in accordance with applicable National Electrical Code requirements.

The boiler is delivered ready for operation as a compact unit on a single chassis. The only action required is to connect the electric thermal oil boiler to the electricity and thermal oil installation.

All our resistance electric boilers are designed to allow over-voltage conditions up to 10% without adversely affecting the integrity of the circuit components, and these resistances are controlled by SSR systems both to increase the service life and to supply energy in a proportional manner. 70-75 wpsi Incoloy sheathed elements are used in the system.

Ease of Operation and Maintenance: User-friendly controls and easy access to components simplify operation and maintenance, minimising downtime and operating costs. Starting with a button, self-checking the device and stopping the system against possible errors, a panel with summary maintenance instructions with warnings according to the duration of use have become very reliable and understandable for the boiler operator.

All security devices are monitored by PLC. Necessary safety measures are taken in case of alarm. Hot oil boiler control is carried out by the boiler operator via HMI. Active alarms and past alarms are monitored via the same HMI. Alarm and running information is transmitted to other systems via digital contacts (dry contact). Remote data acquisition and boiler status information is available via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our electric thermal oil boilers are equipped with advanced safety features such as overpressure protection, in-line oil level and flow control protections, resistance surface temperature monitoring and emergency shutdown mechanisms.

Material: Our hot oil boilers are manufactured from P355GH boiler sheet in accordance with EN 10028-2, boiler and nozzle tubes are manufactured from P235GH or P265GH steel drawn boiler tubes in accordance with EN 10216-2. TSB ENERGY electric hot oil boilers are heated with at least AISI304 quality stainless steel resistances with seamless drawn tubes with a large heating surface.

Efficiency: The output of the heating elements is continuously regulated by means of solid state rollers. One of the energy efficiency advantages is the adjustment of the modulated electrical output on the fly according to the actual demand for heat energy during the operating cycle.

Since all of the incoming electrical energy is converted into heat energy (only small heat losses caused by surfaces are deducted), an efficiency close to 100% is achieved.

100mm thick high density front and rear door insulation provides low heat loss from radiation. The thermal insulation is covered with galvanised and painted DKP sheet with low lambda value, All insulation has low conductivity and high density materials.

Environmentally Friendly Design: Our zero emission Electric Thermal Oil Boilers offer a cleaner alternative to traditional fossil fuel systems, helping you reduce your carbon footprint and achieve your carbon neutral goals.

Customisation: We know that every production and process has its own individual differences, and based on the analysis of your process, we optimise and customise our proven devices for you.

With our expert staff, our company designs and manufactures the most efficient, least maintenance-intensive electric industrial heat devices suitable for all processes and supports them up to the maintenance services during operation. Electric boilers put you on a more climate-friendly path and provide a system solution for the future.
Our experts will be happy to help and support you with your projects. If you have any further questions, please do not hesitate to request an individual expert consultation. 
Our experts will go through your project requirements together with you in order to arrive at the ideal solution.

What is Electric Thermal Oil Boiler?

Closed pressurised vessels with thermal oil as a heat-receiving fluid on one side of their surfaces and heat-giving electrical resistance elements (resistance) on the other side are called electric hot oil boilers.

When to Use Electric Thermal Oil Boiler?

Electric hot oil boilers are used in areas where there is sufficient electrical energy or where it is not possible to remove exhaust gas from gas or diesel burners, where open ignition is prohibited or where fuels such as diesel or gas are not available.

In processes requiring high temperatures (max. 415 °C) in the industry, steam or superheated water can be used as heat carrier to reach these temperatures, but a high temperature of 350 °C can be reached at a pressure of 170 barg. Plants operating at very high pressures not only have high initial installation costs, but also high maintenance costs: the risk of destruction increases accordingly.

The use of thermal oils, which can remain intact up to 350/400 °C at atmospheric pressure, as heat carriers eliminates the above drawbacks and brings great advantages.

With the widespread use of solar panels and wind turbines, 0 emission heat generation devices are preferred by businesses.

Advantages of Thermal Oil Systems Compared to Other Heat Systems;

• It can reach temperatures up to 350 °C at atmospheric pressure. (In the system, there is only a pressure created by the circulation pump. This does not exceed a maximum of 10 bar).
• Thermal oil does not cause corrosion in the installation and boiler coil and collectors.
• In the boiler; there are no problems such as boiler stone, calcification.
• No treatment (conditioning) process is applied to thermal oil.
• There is no freezing in the installation under normal climatic conditions.
• Up to 415 °C, there is a wide adjustment range. However, if higher temperatures are required in steam boilers, you can never exceed the operating pressure.
• If necessary, hot water, boiling water, steam can be produced (indirectly) by means of hot oil.

Disadvantages of Thermal Oil Systems Compared to Other Heat Systems;

• The cost of thermal oil to be filled into the system is high.
• In case of any puncture or oil leakage in the boiler, there is a possibility of fire. (Thermal oil is a flammable substance.)
• Thermal oil in the system loses its natural properties by undergoing "cracking" at high temperatures. Bitumen (bitumen) parts adhere to the heating surfaces and reduce the heat transfer property. They can also endanger the boiler over time.
• As the temperature of the thermal oil rises, it starts to oxidise and lose its natural properties in contact with oxygen (air) and after a short time a layer of sediment accumulates on the heating surfaces.
• Over time, when the thermal oil begins to lose its natural properties, the oil in the system may need to be replaced.
• The heat absorption (mass transfer) capacity of thermal oil is not as high as water. As in water, natural circulation is not easy during heating.  In this respect, forced circulation is obligatory in hot oil boilers. There should be no stagnant point in the thermal oil in the boiler and a turbulent flow should occur. The thermal oil speed in the boiler is around 1,5 - 3 m/sec.
• Although there is no pressure in hot oil systems, the fittings (valves, check valves, safety valves, etc.) used must be cast steel in PN25 or higher class, and circulation pumps must also have cast steel bodies.

Areas of Use;

• Jacketed vessels for processes
• Autoclaves
• Chemical processes
• In the food industry (production of juice, pasta, cheese and dairy products as well as large bakeries) it is also used for sterilisation.
• Fertiliser industry
• Vulcanisation of rubber products
• In the pharmaceutical industry for sterilisation purposes
• Building materials industry
• Paper industry
• Refineries
• It is used in areas such as wood processing (wood shaping).
• Frost protection.