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Thermal Oil Heater
Elevating global standards with exceptional, unmatched Dutch craftsmanship in advanced industrial heat exchange.
A Thermal Oil Heater is a highly efficient industrial heating system that uses heat transfer oil as the circulating medium to deliver controlled heat to various process applications. Unlike steam-based systems, thermal oil heaters operate in a closed circuit at atmospheric pressure, achieving high service temperatures—often up to 300°C or higher—without the need for high-pressure vessels. The system includes a combustion chamber, helical coil or concentric coils, circulation pump, and an expansion tank to maintain safe operation.
Ideal for continuous operation across a wide range of industrial processes, these heaters provide superior thermal efficiency, reduce fuel consumption, and minimize maintenance costs. Whether powered by liquid fuels, gaseous fuels, or electric heating, thermal oil heaters are a reliable solution for precise, high-temperature heating.
Where Precision Meets Performance – The Inner Workings of a Thermal Oil Heater
Within the heart of every Thermal Oil Heater lies a carefully orchestrated system, purpose-built to deliver consistent, high-temperature heating to demanding industrial processes. These systems thrive in environments where thermal efficiency, continuous operation, and precise temperature control are non-negotiable.
The Heat Transfer Advantage
Unlike steam boilers, which require high pressures to achieve elevated temperatures, thermal oil systems utilize synthetic or mineral-based heat transfer fluids that can reach temperatures of up to 400°C at atmospheric pressure. This not only reduces the need for pressurized equipment, but also simplifies safety and regulatory compliance. Inside the combustion chamber, a burner flame heats a coil—often a helical coil—that houses the circulating oil. This design allows for efficient heat transfer, low fluid film temperatures, and minimized risk of thermal cracking or carbon deposits.
Built for Reliable, Economical Operation
A well-designed thermal oil system is more than just a heater—it’s a long-term investment in economic saving. The expansion tank, recirculation pump, and control panel work together to maintain proper fluid pressure, flow rate, and temperature. These systems are known for low maintenance costs, minimal fuel consumption, and extended fluid life due to reduced oxidation and degradation. Modern heaters include multiple passes per coil for improved heat transfer efficiency, and come equipped with auxiliary valves, globe valves, and control valves for fine-tuned operation.
For plants dealing with liquid fuels, gaseous fuel burners, or hybrid energy sources, the thermal oil heater adapts effortlessly. It integrates with preheaters, air heaters, or even heat recovery boilers, making it suitable for a variety of applications—from fluid film heating to the handling of acidic elements in exhaust gases.
Tailored for Today’s Demands
From the maximum operating temperature to characteristic film temperatures, every parameter is optimized for stability, precision, and energy efficiency. Whether deployed in a food production line, a chemical processing plant, or integrated with inline heat recovery, the thermal oil system stands as a robust, versatile heating solution that continues to power modern industrial production forward.
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Direct manufacturer benefits
Your unique needs are our command. We offer tailored heat exchanger solutions.
Lower total cost of ownership (TCO)
We go beyond performance with our heat exchangers, sculpting an unbeatable blend of.
Superior durability
Built from robust materials, our heat exchangers are a testament to resilience. They reduce maintenance
Engineered Heat, Delivered with Purpose — ICARUS Thermal Solutions
At ICARUS, we don’t just build heating systems—we craft high-performance thermal solutions that fuel industrial ambition. Our expertly engineered Thermal Oil Heaters are designed to meet the rigorous demands of modern production processes, delivering exceptional heat transfer efficiency, low operating costs, and seamless integration into your existing fluid systems.
Whether you’re working with gaseous fuels, liquid fuel burners, or transitioning to electric heating, our heaters offer unmatched control, stability, and safety. We pair cutting-edge design with time-tested durability—offering features like concentric coils, circulation pumps, control panels, and expansion oil tanks, all tailored to ensure continuous, cost-effective performance.
Reach out to ICARUS today and discover how our finned tube heat exchangers and thermal oil systems can empower your process with precision, power, and reliability—every degree of the way.
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With over 27 years in business, we’ve carved out a reputation for excellence and innovation.
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Our global presence is marked by a diverse clientele of over 120 customers worldwide.
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Moreover, our portfolio boasts more than 850 completed projects.
FAQs about Thermal Oil Heater
What is a Thermal Oil Heater used for?
A Thermal Oil Heater is used to deliver consistent, high-temperature heating in industrial processes without the need for high-pressure steam. It’s commonly applied in industries such as chemicals, food production, pharmaceuticals, and textiles—where thermal efficiency, fluid stability, and precise temperature control are essential.
How does a Thermal Oil Heater work?
The heater uses a combustion chamber or electric heating elements to heat thermal oil, which circulates in a closed circuit via a circulation pump. This heat is then transferred to process equipment through a heat exchanger or helical coil, allowing high service temperatures without pressurization.
What are the benefits of using a Thermal Oil Heater over steam systems?
Thermal oil heaters operate at high temperatures without requiring high operating pressures, reducing the risk of explosion and lowering maintenance costs. They also offer better thermal stability, lower fuel consumption, and more efficient heat transfer, especially in continuous, high-load applications.
What fuels can power a Thermal Oil Heater?
Thermal oil heaters can run on a variety of energy sources, including liquid fuels, gaseous fuels, and even electric heating. They are often paired with liquid fuel burners, gaseous fuel burners, or resistive elements, depending on site-specific needs and fuel efficiency goals.
What are the key components of a Thermal Oil Heater system?
Key components include the combustion chamber, coil tube (often in a helical or concentric arrangement), expansion tank, circulation pump, control panel, and various valves. These elements work in tandem to ensure smooth operation, proper flow rates, and optimal heat transfer fluid circuit performance.
How do I maintain a Thermal Oil Heater?
Routine maintenance includes monitoring fluid film temperatures, checking for carbon deposits, inspecting control valves, and testing fluid pressure. Using a suitable heat transfer fluid, controlling degradation rate, and keeping the expansion tank and pumps in good condition ensures long-term, efficient operation.
