Feature Energy management ‘Hard to beat’ energy savings


Thermal fluid heating systems have revolutionised process heating, making the large, energy hungry and heavily manned plant rooms a thing of the past for the majority of industries. Whereas a plant room based around mammoth fire tube steam boilers required lots of space for equipment and was relatively complex to use and maintain, thermal fluid heating systems are compact, easy to use and, offer an overall saving in energy that is hard to beat says Babcock Wanson MD Chis Horsley


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hermal fluid heating is based on a similar principle to a domestic hot water system. It consists of a heater connected to carbon steel flow and return pipework which can provide heat to one or more users or systems. Instead of water running through that pipework, a thermal fluid – most often a simple industrial oil – is used as the heat transfer medium.


One of the key factors in achieving very high levels of system energy effi- ciency is the ability of a thermal fluid system to work at high temperatures (up to 350°C in standard form) in a simple closed loop. When compared


with a steam system this means no change of state of the fluid so no con- densate and therefore no flash steam losses, no blow down losses or make up water required, no effluent dis- charge and completely corrosion free without the need for expensive chemical treatment. It all adds up to substantial savings for the operator. Using thermal fluid as opposed to water has other key benefits including removing the problems caused by scal- ing and changes to ambient tempera- tures, as well as improved safety. In a water system, pressure rises as a func- tion of temperature: the higher the


Thermal fluid heating systems are offering major energy savings in large heavily manned plant rooms


World class content for this year’s Energy Event S


hortlisted for the UK's Best Trade Show Award, this year’s Energy Event at the NEC in Birmingham on September 11th and 12th will help organisations optimise their energy use, comply with legislation and put in place sustainable energy efficiency and procurement solutions. Speakers include Philip Lowe, director general for Energy


at The European Commission, ITN journalist Daisy McAndrew, particle physicist and television presenter Professor Brian Cox, former New Labour director of communications and strategy Alastair Campbell and professor of forecasting and innovation James Woodhuysen. The Energy Event aims to provide a treasure trove of information and really make a difference in UK energy consumption. Set to host more sessions than last year, with more industry thought leaders, more interaction, more case studies and more vital debate, the show promises a programme of useful information that will be of value to anyone with an interest in energy. And, as the sessions are completely free to attend and Continuing Professional Developement (CPD) certified, it’s


a cost effective way to continue professional development too. Key industry associations that have all contributed to the conference programme are ESTA, MEUC, Energy Institute, GAMBICA, BCAS, Waterwise, BCIA and Water Technology List.


The event hosts over 150 exhibitors


including major UK energy suppliers, consultants and technology providers. It also hosts four theatres, each with a unique focus. The Energy Insight Conference is the central feature of the show which promises debate around the issues that are crucial to professionals who are respon- sible for energy purchasing, carbon reduction policies and practices within their organisations The Energy Information Theatre is a resource for energy managers, environment managers, facilities experts and property management specialists. It will feature case studies from energy users and practical advice for reducing energy consumption, tackling buildings efficiency, controls and benchmarking, organisational change and incentives. The Energy Services and Technology Association


seminars are designed with energy managers in mind to offer a basic understanding of principles, awareness of policy issues and effective implementation to produce savings. The Hosted Content Theatre will feature presentations hosted by Waterwise and npower among others. Seminars will include topics covering water efficiency, procurement strategies as well as a live energy debate. The Energy Event T: 020 7728 4681 www.theenergyevent.com/pr


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temperature, the greater the potential for problems within the system and the higher the system’s materials cost. Not so in a thermal fluid system as there is little relationship between temperature and cost so the fluid does- n’t have to be kept under pressure (other than the very small pressure of the circulating pump). This also brings significant advantages in the sizing and cost of heat exchangers. Size is another major factor in the uptake of this technology. A thermal fluid heater is very compact and needs no specialist site work meaning it can usually be sited in the most conve- nient location, often close to the user, meaning substantial savings in spe- cialist plant rooms and distribution pipe work. With Babcock Wanson’s TPC1000B thermal fluid heating system, for example, between 20-50 per cent energy savings can be made when compared to the transfer of the same amount of heat using traditional steam boilers. The system precisely matches fuel input to plant energy require- ments for high efficiency. With lower energy input demand also comes lower total exhaust emissions, so there are also environmental benefits. It’s also a very flexible system as dif- ferent thermal fluids can be used to meet specific process heating require- ments. Of course, not every industrial process is suited to thermal fluid heat- ing systems. There are a number appli- cations - most notably where both direct and indirect heating are required simultaneously - where steam generation is the only viable solution and the technology has advanced dra- matically to keep pace with changing requirements. However, thermal fluid heaters have outpaced steam genera- tion in the majority of process heating applications and, with their energy efficiency, ease of use and compact size, it’s not difficult to see why. Babcock Wanson


T: 020 89537111 Enter 302 www.babcock-wanson.co.uk Enter 301 JULY/AUGUST 2012 Factory Equipment


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