FHS-OCT23-PG22_Layout 1 13/10/2023 11:43 Page 22
boilers, pumps & valves
principle to a simple hot water system in that it features a heater connected to carbon steel flow and return pipework which can simultaneously provide heat to one or more users or systems. the big difference between the two systems is that water is replaced by a thermal fluid running through the pipework as the heat transfer medium. it is a closed loop system, with the fluid passing back to the thermal Fluid heater for reheating. Clearly, there has been a lot of r&D and technological advances made in thermal fluid heating over the years, but essentially the system is a simple one. thermal fluid systems have become
s
increasingly popular across a very wide range of industries where heat rather than actual steam is required. if you have yet to be swayed by thermal heating systems, here are eight good reasons you should reconsider:
EnErgy EFFiciEncy top of the list of benefits for many thermal fluid heating system users is their energy efficiency, especially when they come with an integral economiser which ensures very low fuel consumption even when operating at high fluid temperatures. 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 requirements for high efficiency. With lower energy input demand also comes lower total exhaust emissions, so there are also environmental benefits.
cost EFFEctivE one of the key factors in achieving very high levels of system energy efficiency 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 to a steam system this means no change of state of the fluid so no condensate and therefore no flash steam losses, no blow down losses or make up water required, no effluent discharge and completely corrosion free without the need for expensive chemical treatment. there is also no requirement for specialist plant rooms and distribution pipe work. it all adds up to substantial savings.
Easy to usE and maintain When you bear in mind the above, and the fact that it is a closed loop system, you can immediately see how much easier a thermal fluid system is to operate daily, and to maintain. it’s not quite a fit and forget system, but it is probably as close as you are going to get in process heating! Furthermore, these systems
ometimes, the simple things in life really are the best things. take thermal fluid process heating systems. their design and operation follows a similar
eight reasoNs to sWitCh to thermal FluiD proCess heatiNg
By Etienne Fourie, technical sales manager, Babcock Wanson
operate outside the pressure systems safety regulations as the fluid is not maintained in the liquid phase by pressure, so statutory inspections are eliminated.
saFEty the move away from water also has implications for safety. in a water system, pressure rises as a function of temperature: the higher the 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 not 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.
spacE thermal fluid heating systems are compact when compared to fire tube steam boilers, but the biggest gain here is that they do not require space for all the additional equipment that is required for a steam boiler to operate. a thermal fluid heater needs no specialist site work meaning it can usually be sited in the most convenient location, often close to the user.
EquipmEnt duraBility and longEvity a thermal fluid system should easily serve you 30 or more years without any reduction in productivity as it ages. a babcock Wanson thermal fluid heater will usually run for more than 100,000 hours, although we are still servicing heaters that are more than 40 years old. this exceptional longevity is a direct result of their passive nature (there are very few moving parts) and the swapping out of water for a thermal fluid as the heat transfer medium. unlike water and steam based systems, thermal fluid heaters are unaffected by
corrosion caused by water over time, or by ambient temperature where water freezing within pipes leads to costly failures. in fact, most thermal fluids are mineral oil based so are effectively lubricants that help keep the system components protected in use.
tEmpEraturE control For many industrial processes, maintaining a constant temperature is vital to the quality of the product being produced. Whilst a steam generator can be operated to maintain a constant temperature, it is much harder to do so – with temperature ramp up and cool down difficult to control – and is far more labour intensive; skilled operators are imperative, and they are in short supply. maintaining a constant temperature is much easier to achieve in a thermal fluid system, especially if it has been fitted with temperature control software. Composites manufacturer gurit has a babcock Wanson tpC450lN thermal fluid system in its multi mould production facility which features a unique menu driven software to allow up to 50 programmes to be created for the simultaneous heating and cooling system of multiple users. it provides absolute control over the process as well as flexibility in the temperature rise and cooling stages.
vErsatility Different fluids – typically mineral and synthetic based fluids – can be used to meet specific process heating requirements. thermal fluids typically operate at up to 350°C at atmospheric pressure and can remain pumpable down to minus 20°C and lower with special fluids, which makes thermal fluid systems incredibly versatile. they are used in numerous different industries and applications, with the most common being pressing, curing and moulding; tanks, vessels and cookers; printing, coating, laminating and drying; and heating and cooling systems.
Babcock Wanson
www.babcock-wanson.com
22 oCtober 2023 | FaCtorY&haNDliNgsolutioNs
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50
