Chris Horsley explores the longevity of thermal fluid heaters
For a process heating equipment manufacturer, you might just say thermal fluid heaters are bad for business.They just go on and on and on, and maintenance and service requirements are low, in fact a fraction of the cost of maintaining an equivalent heat output steam plant.Wheres the repeat business?Wheres the big service contracts and money to be made replacing worn parts?Of course, for a customer, this is music to your ears!
Thermal fluid heaters frequently run for 20 years and often longer.Even when the heaters themselves might be at the end of their working life, the pipe work system and other plant is often as good as new, so upgrades are simple and cost effective to implement at any time.
Thermal fluid heating is based on a similar principle to a simple hot water system. It consists of a heater connected to carbon steel flow and return pipework that can provide heat to one or more users or systems.Instead of water running through the pipework, a thermal fluid typically a specialist mineral oil or synthetic based fluid is used as the heat transfer medium.Different fluids can be used to meet specific process heating requirements including high temperature operations and processes requiring heating and cooling thereby making it a very flexible system.
Thermal fluid heaters typically operate at up to 350C at atmospheric pressure and remain pumpable down to minus 20C and lower with special fluids, which makes it a solution suitable for a multitude of applications.
Thermal fluid heaters have rapidly grown in popularity across all industry sectors over the years.This is mainly due to their far-ranging benefits which include their ease of use, compact size, safer operation when compared to steam generators, precise heat control, low exhaust emissions and their energy efficiency.They also operate outside the Pressure Systems Safety Regulations as the fluid is not maintained in the liquid phase by pressure, so statutory inspections are eliminated.This further reduces operating costs and increases plant availability.
When it comes to flexibility in use, thermal fluid heaters often work at high temperatures in a simple closed loop.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 operation without the need for expensive chemical treatment.The savings thermal fluid heaters bring are very significant, often up to 50% of the overall cost of running a process heating system.
But one aspect that frequently gets overlooked is the longevity thermal fluid heaters enjoy, which should be a major point when deciding how to heat a process, especially in these uncertain times when many businesses are having to buckle belts that much tighter. With sustainability a key issue, plant longevity is not only about reducing capex, but also reducing wastage and equipment redundancy.
As mentioned, a thermal fluid system should easily serve you 20 or more years without any reduction in productivity as it ages.It would be difficult to find any equipment, process or otherwise, that can match this level of service.Take a car, for example.Assuming the car runs at an average 30mph and covers 200,000 miles before being scrapped it will operate for about 6000 hours in its total life.A Babcock Wanson thermal fluid heater, on the other hand, will usually run for more than 100,000 hours - or the equivalent of 3,000,000 miles with the minimum of service requirements! And thats just looking at heaters with a typical lifespan; Babcock Wanson is still servicing heaters that are more than 40 years old and working away every day quite happily!
Theres no secret elixir for long life when it comes to thermal fluid heaters.Their exceptional longevity is a direct result from 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.
However, not all thermal fluid heaters are equal, so it pays to do your homework.Heaters that will best stand the test of time are mostly designed for a downward fired configuration which ensures stress free and unrestricted expansion of the heater coils during normal operation.Also look for a heater that has been designed with a barrier between the hot combustion gases and the outer structure, as this will help provide long heater life as the higher pressure and cooler outer air helps prevent any escape of combustion gases as the plant ages over time.Babcock Wansons TPC and EPC range of thermal fluid heaters, for example, come with an integral, air-cooled outer case that provides this barrier, as well as acting as both a combustion air pre-heater/economiser.Lastly, ensure the heater is fully integrated and has a factory tested control system.
Another key factor is overall emissions. With higher process operating efficiency comes lower total emissions which provides savings in operating costs whilst being much better for the environment.
Its also vital that the thermal fluid heater you decide upon is correctly installed, commissioned and maintained.Thermal Fluid Systems - A Practical Guide for Safe Design, Operation and Maintenancefrom the Combustion Engineering Association (CEA) proffers excellent advice for designers, owners, managers and operators of new and existing thermal fluid heating systems to operate safe and efficient installations. It addresses system design considerations such as choice of fluid, heat source, expansion and deaeration, pumps and pipework, to installation and commissioning and operation and maintenance. Its important to understand how thermal fluid heaters work to ensure you get the most out of your investment, including long life.
With careful system design and careful choice of heater design a thermal fluid system will provide many years of trouble-free ownership, allowing the operator to concentrate on their process needs in the sure knowledge they are getting the best from their process heating investment.
Chris Horsley, is Process Engineering Director at Babcock Wanson
Link:
Longevity of thermal fluid heaters - Engineer Live
- I feel more alive than ever at 47 here's my 4-step routine - hellomagazine.com - April 14th, 2025
- Longevity Fitness: How to slow down aging and strategies to stay fit after middle age - Times of India - April 14th, 2025
- Living Longer and Better: The Rise of Longevity Clinics. But When Will They Be Accessible to Everyone? - Men's Health - April 14th, 2025
- Recent work suggests a connection between verbal factors and a longer lifespan. - Psychology Today - April 14th, 2025
- Aging In Place: Longevity In A Time Of Stress - CapeNews.net - April 14th, 2025
- Florida Wins National Title, a 101-Year-Olds Longevity Tips: What to Know TODAY - TODAY.com - April 14th, 2025
- Retirement could be bad for your health, says wellness expert: 'Powered by purpose' - Fox News - April 14th, 2025
- 101-Year-Old Nutrition Professor Shares 7 Tips For A Long Life - TODAY.com - April 14th, 2025
- Longevity and precision medicine driving the agenda at Abu Dhabi Global Health Week - PR Newswire - April 14th, 2025
- Sadhguru's 13 tips on right food habits that promote health and longevity - Times of India - April 14th, 2025
- Aging, regeneration and whole-body rejuvenation in long-lived planarians - Nature - April 14th, 2025
- Longevity expert says world's oldest people in Blue Zones 'never' drink this - Surrey Live - April 14th, 2025
- Technologies developed to clean up orbit and enhance satellite longevity - Space Daily - April 14th, 2025
- Longevity in theatre requires talent and skill and lucky timing - The Stage - April 14th, 2025
- FIBO 2025 opens with new longevity and wellness hall and conference - spaopportunities.com - April 14th, 2025
- What the Tech: Increasing your iPhone's longevity - KTBS - April 14th, 2025
- P90X trainer Tony Horton is in the best shape of his life at 66. Here are his top longevity tips. - Business Insider - April 14th, 2025
- This daily supplement can work wonders for longevity: Here's how to take it - Times of India - April 14th, 2025
- Is this longevity diet a magic pill for chronic diseases? Why Lancets planetary health diet can work for you - The Indian Express - April 14th, 2025
- Im a doctor why the French diet beats the Mediterranean diet for obesity, longevity and colon cancer - New York Post - April 14th, 2025
- So "Longevity Tea" Is A Thing & It's Easier To Make Than You'd Expect - MindBodyGreen - April 5th, 2025
- Longevity & Hospitality Summit: Transforming the future of hospitality - spaopportunities.com - April 5th, 2025
- Department of Health Abu Dhabi hosts inaugural Healthy Longevity Innovation Forum - MSN - April 5th, 2025
- Fat's surprising role in aging and longevity - WFTV - April 5th, 2025
- The creator of Kind Bars is now investing in longevity. Here's what his firm is betting on. - Business Insider - April 5th, 2025
- Try these moves tied to longevity and independence later in life - MSN - April 5th, 2025
- Longevity Beauty Brand Oneskin Launches Hair - The Business of Fashion - April 5th, 2025
- The science of brain longevity: The Magtein success story - NutraIngredients.com - April 5th, 2025
- Public invited to attend free conference on longevity: Focus Forward Long Live West Virginia - WV News - April 5th, 2025
- Dr Greger Reveals The 10 Blue Zones Food Guidelines To Lengthen Your Life - Plant Based News - April 5th, 2025
- NAD Supplements Promise to Improve Energy, Metabolism, and Longevity. Heres How Experts Recommend You Use Them - GQ - April 5th, 2025
- Longevity and Hyaluronic Acid, discover the novelties of LipoTrue at booth 1A80 - Cosmetics Business - April 5th, 2025
- The Longevity Superfood That Could Extend Your Life - Plant Based News - April 5th, 2025
- Nutritionist-approved 5 fruits that improve longevity and heart health - Times of India - April 5th, 2025
- Exclusive | 100-year-old NYC cabaret singer shares her secret to longevity: Everything about her is an inspiration - New York Post - April 5th, 2025
- The No. 1 Tip You Need To Live To 100, From A Longevity Expert - MindBodyGreen - April 5th, 2025
- I asked scientists about the best exercise for longevity - and they all said the same 3 workouts - Woman & Home - April 5th, 2025
- Longevity Is A Rich Man's Game. But What Does It Cost The Rest Of Us? - HuffPost UK - April 5th, 2025
- 'Fasting and the Longevity Revolution' Trailer Has Edward Norton Narrating Nutrition Doc - MovieWeb - April 5th, 2025
- The convergence of health, wealth and longevity Services - Deloitte - April 5th, 2025
- Longevity researcher shares secrets of the worlds blue zones - Fox News - March 19th, 2025
- Kyrgyzstan on the Threshold of an Aging Population: Government Develops Active Longevity Program - Times of Central Asia - March 19th, 2025
- Longevity dividend - Association of Health Care Journalists - March 19th, 2025
- Longevity: The cosmetics industry must rethink its approach to ageing - Premium beauty - March 19th, 2025
- Implantable biosensors get major longevity boost with coating technology that inhibits biofouling - Phys.org - March 19th, 2025
- Longevity vs. Metabolism: How Birds Cheat the Aging Process - SciTechDaily - March 19th, 2025
- Bon appetit, Cristiano Ronaldo! 'Unusual' dish behind 40-year-old's remarkable longevity - and where it can be bought - revealed - Goal.com - March 19th, 2025
- Secrets of the Greenland Sharks Longevity Revealed in New Study - The Brighter Side of News - March 19th, 2025
- Anthony Michael Hall Says Longevity Was Always His Goal As The Breakfast Club And Weird Science Turn 40 - Decider - March 19th, 2025
- LB Elandon Roberts' words on NFL longevity will have Raiders fans very excited to have him - Raiders Wire - March 19th, 2025
- Studies Undoubtedly Show This Vitamin Is Linked To LongevityHere's Why - mindbodygreen - March 19th, 2025
- 'Helps slow down ageing': Nutritionist names longevity foods that improve 'heart health and brain function' - GB News - March 19th, 2025
- Men With High-Quality Sperm May Have a Longer Life Expectancy - Everyday Health - March 19th, 2025
- Dr. Vonda Wright Shares the Longevity Habits Youre Not Thinking About (and That You Can Start Doing Today) - Maria Shriver's Sunday Paper - March 19th, 2025
- 99-Year-Old Dick Van Dyke Eats This Surprising Food Combo Every Day - Taste of Home - March 19th, 2025
- Climbing This Many Stairs A Week May Lead To A Longer Life - HuffPost UK - March 19th, 2025
- How to live longer: Supercentenarian who lived to 117 ate her go-to snack 3 times a day - GB News - March 19th, 2025
- Saudi Arabia Expands Regulatory Role To Shape The Future Of Health And Longevity - Citeline News & Insights - March 19th, 2025
- Crypto fans are obsessed with longevity and biohacking: Heres why - Cointelegraph - March 19th, 2025
- Unlocking the power of sleep: Longevity expert Dr Elie Abirached tells us how - Gulf Business - March 19th, 2025
- MST3K: Jonah Ray on Longevity, Evolution from Netflix to the Gizmoplex - Bleeding Cool News - November 27th, 2024
- Why Personal Health and Wellness Are Key to Business Longevity - Entrepreneur - November 27th, 2024
- How to live longer: 'I'm a doctor - adding two foods to your diet is the key to longevity' - GB News - November 27th, 2024
- The Best Talks of GSA 2024 - Lifespan.io News - November 27th, 2024
- Maren Tschinkel Shares Her 11 Healthy and Happy Habits - Bustle - November 27th, 2024
- Do blue zones, supposed havens of longevity, rest on shaky science? - Science - November 27th, 2024
- 2025 Longevity and Harmony coins recognize symbolism of birds - Coin World - November 27th, 2024
- The Hormonal Blueprint For Longevity And The Science Of Youthfulness - Forbes - November 27th, 2024
- How Has Life Expectancy Changed Throughout History? - Verywell Health - November 27th, 2024
- The key to a long life is avoiding the 'poisonous 5 P's,' says one of the world's top anti-aging experts - Fortune - November 27th, 2024
- Study unveils genetic secrets to longevity in Indian population - The Times of India - November 27th, 2024
- The Long Run: Behind The Song That Predicted Eagles Longevity - Dig! - November 27th, 2024
- Daily Walks Could Add More Than 10 Years to Your Life, New Study Says - Real Simple - November 27th, 2024
- The 5 best supplements for healthy aging, according to a longevity expert - Yahoo Finance - November 27th, 2024
- Longevity Burn-In Test: Updates And Results From 100 TVs - RTINGS.com - November 27th, 2024
- A 90-year-old comedian still does gigs and plays golf. She shared her secrets for staying fit and funny. - Business Insider - November 27th, 2024
- Longevity and Anti-senescence Therapy Global Market is set to reach $36.11 billion by 2028 at a CAGR of 6.4% - EIN News - November 27th, 2024
- Steinberg Hopes that the Runners Club Can Put Chatham on Course to 'Blue Zone' Longevity Status as Part of Mayor's Wellness - TAPinto.net - November 27th, 2024
- Why Brits are keen to go on wellness getaways for longevity in 2025 - Yahoo Lifestyle UK - November 27th, 2024
- 3 ancient foods are the staple of this blue zones longevity diet - Fortune - November 3rd, 2024