Liquid-Gas Fired Thermal Oil Heater

Liquid - Gas Fired Thermal Oil Boiler Advantages;

• No conditioning, water treatment or chemicals are required for thermal oil.
• Designed in a horizontal or vertical position, it is suitable for almost any position.
• It does not freeze in the installation in winter under normal climatic conditions.
• Up to 420 °C, the desired temperature can be adjusted (specific equipment is used after 300 °C).
• It requires very little maintenance and its life is very long and corrosion-free,
• Closed circuit operation - lossless system
• High combustion and plant efficiency
• Compared to steam, 20 to 40 per cent less energy is consumed to transfer the same amount of heat
• Ability to ensure constant temperature control,
• Front boiler cover at touch temperature.
• Energy saving, clean energy supply
• Custom design according to customer requirements.
• Many years of experience in industrial/commercial boiler technology
• H2 ready
• Precise temperature control
• Low maintenance and service costs
• Easy user interface with Tsb Energy control system.
• Reduced operating cost with unattended operation from 24 hours to 720 hours
• Flow monitoring systems integrated into the heater design and included in all our devices ensure smooth and reliable operation.
• High process reliability, remote control is available.
• Optionally, to further increase the operating efficiency without affecting emissions, the combustion air is heated by the exhaust gas using a recovery unit (recuperator).
• Low NOx emissions are available.
• CO2 emissions are reduced by burning up to 100 per cent hydrogen.
• Customer-specific software revision specific to your company with our expert staff.
• The boiler can optionally be equipped with a PLC with different communication protocols such as Modbus, Profibus, etc. and thus boiler integration into any industrial process can be provided.

Working Principle of Liquid-Gas Fired Thermal Oil Boiler;

As the special mineral oils or synthetic based thermal oils circulating at continuous speeds of 1.5-2 m/sec pass through the pipes designed in a horizontal or vertical construction so 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 flame-smoke gases generated in the combustion chamber and hot oil is obtained at the desired temperature.

Different fluids can be used to meet specific process heating requirements, making it a very flexible system.

Design: Liquid - Gas fired thermal oil boilers are designed and manufactured according to DIN 4754, TS EN 13445, Loyd's rules, TRD, DIN, EN, PED 2014/68/EC and ASME Section VIII Div 1; in a horizontal or vertical construction, in the form of pipe-pipe-pipe or spiral consisting of intertwined pipe bundles. All electrical components are UL labelled and wired in accordance with applicable National Electrical Code requirements.

The boiler is delivered compactly on a single chassis ready for operation. All that is required is to connect it to electricity, feed water and hot oil users.

It offers unrivalled efficiency and safety, minimal carbon footprint, easy maintenance and long life with our university-supported R&D studies. The compact design achieves high  thermal performance and low film temperatures with high gas and fluid velocities.

TSB ENERGY Thermal Oil Boilers are designed for you to win while using, not buying.

Ease of Use and Maintenance: When using thermal fluid as the heat transfer medium, users do not encounter known problems such as pressure, scale formation, corrosion or freezing.

In contrast to a steam system, with Thermal Fluid Heaters there is no change in the state of the fluid and therefore no need for a condensate trap. Therefore, there are no flash steam losses, blow-off losses or make-up water demand, no wastewater discharge, no corrosion in the system and the systems do not require expensive chemical treatment. All these are significant savings for businesses.

User-friendly controls and easy access to components simplify operation and maintenance, minimising downtime and operating costs. Thanks to a control panel with one-button start-up, self-checking of the device to stop the system against possible errors, and summary maintenance instructions with warnings according to the duration of use, boiler operation has 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. 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 collection and boiler status information are available via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our boilers are equipped with advanced safety features such as overpressure protection, sequential temperature protections, flue temperature, oil temperature and oil safety temperatures monitoring and emergency boiler shutdown mechanisms.

Material: Envelopes and covers of our hot oil boilers are manufactured from P355GH boiler sheet in accordance with EN 10028-2, boiler pipes are manufactured from P235GH or P265GH steel drawn boiler pipes in accordance with EN 10216-2.

Efficiency: With the long-term studies of our R&D department, pipe diameters and spiral diameters of hot oil boilers have been redesigned with the support of analysis programmes and oil back pressures have been minimised. In this respect, both electrical energy is saved by using electric motors with lower power (KW) compared to standard boilers, and fuel is saved by discharging less NOx gas into the environment and high boiler efficiency is achieved.

There are three rows of insulation systems on the front door and the inferno door of our hot oil boilers, the first row is Hycast SS alumina reinforced fired concrete to trap the high heat in the inner wall, then the heat load from the concrete is prevented from passing to the boiler door with ceramic fibre blanket, and finally ceramic paper is adhered to the cover to keep the cover at touch temperature.

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.

During chlorine production and similar chemical processes, most of the hydrogen gas is released into the atmosphere without being used. This waste and difficult to store hydrogen can be used in our boilers by using suitable burners.

Environmentally Friendly Design: Our aim is a cleaner environment and for this we try to minimise emissions, In a clean combustion, NOx emissions in our gas-fired boilers: 70 mg/Nm3 in our gas fired boilers and 150 mg/Nm3 in our liquid fuelled boilers.

All of our TSB ENERGY industrial liquid-gas fuelled products can operate with 100% hydrogen by equipping them with a suitable burner that can operate with 100% hydrogen. Since the boiler structure and working principle are designed according to high-speed flame-smoke gases, NOx level remains far below the standards even in hydrogen fuel. At the same time, CO2 emissions are significantly reduced.

Customisation: We know that every manufacturing and process is unique to each business, and we customise our proven equipment based on hundreds of examples and analysis of your process to make it the most suitable and ideal for you. Designing and manufacturing our Svı-Gas fired boilers and more importantly providing the engineering support and personnel required for a successful installation requires exceptional expertise. You will not only buy a boiler from us, but also years of experience and know-how.

If you have any further questions, please do not hesitate to request an individual expert consultation.

Our customers are offered the following extensions for each boiler:

• Automation and control technology
• Reserve Tank, Expansion Tank and Complete System Deaerator
• Oil circulation pumps.
• System valves and controls.
• Pipework and chimney systems
• Very high efficiency and low emissions
• Micromodulation as standard
• Simple and easy maintenance
• Robust design for very long life
• Combustion air preheater
• Dual and mixed fuel ignition options
• O2 and CO trim options
• A fully integrated hot oil solution.

What is Liquid-Gas Fired Thermal Oil Boiler?

The thermal oil boiler is a forced circulation coil type thermal fluid heater circulating in a series of coils. The pump is custom sized to the flow rate and pressure drop requirements of each application, maintaining fluid volume and film temperature characteristics. Combustion air and fuel are controlled by PID control in response to the liquid outlet temperature. The small volume and high liquid velocity allow the thermal fluid heater to respond quickly to changing system output requirements.

When to Use Liquid-Gas Fired Thermal Oil Boiler?
Areas of Use;

• Oil heating systems
• Chemical processes
• Fertiliser industry
• Vulcanisation of rubber products
• Paper industry
• Refineries