Thermic Fluid Systems
Part I - Thermic Fluids
G. S. Deshpande
16/05/25 Thermic Fluid Systems 1
BASIC CIRCUIT of THERMIC FLUID HEATING SYSTEM
Expn Tank
Heater Process
T F Pump
TF Pump is required to take care of friction in circuit
Expansion Tank is required to accommodate thermal expansion
16/05/25 Thermic Fluid Systems 2
THERMIC FLUID V/S STEAM HEATING
1600
1500
1400
1300
SYSTEM PRESSURE P.S.I.G.
1200
1100
1000
900
800
700
600 SATURATED STEAM / WATER
500
400
300 THERMIC FLUID
200
100
0
50 100 150 200 250 300
TEMPERATURE OC
16/05/25 Thermic Fluid Systems 3
ADVANTAGES OF INDIRECT HEATING
•LOCAL OVERHEATING OF THE PRODUCT IS AVOIDED
•THE TEMPERATURE OF THE PRODUCT IS CONTROLLED VERY ACCURATELY AND
UNIFORMLY
•FIRING SYSTEM IN THE IMMEDIATE NEIGHBOURHOOD OF THE CONSUMER IS NOT
REQUIRED
•THE HEATER IS ARRANGED CENTRALLY AND THE HEAT TRANSFERRED THROUGH THE HEAT
CARRIER CONSUMER POINTS
•THE EFFICIENCY OF THE CENTRALLY HEATED PLANT IS HIGHER
•THE HEAT TRANSFER CONDITIONS ARE OPTIMIZED AT THE CONSUMER
•FUEL FEEDING TO EACH FIRING POINT AND INSTALLATION OF FLUE GAS CHIMNEYS
AVOIDED
•HEATING AND COOLING PROCESS CAN BE CARRIED OUT WITH THE SAME HEAT CARRIER
•STORAGE OF ENERGY IS POSSIBLE
•TRANSFORMATION OF HOT THERMIC FLUID TO HOT WATER, STEAM IS POSSIBLE
•CONVERSION OF FUEL FIRING SYSTEM IS EASY
16/05/25 Thermic Fluid Systems 4
HEATING MEDIA AND TEMPERATURE LIMITS
1. WATER AND STEAM : 250 to 300 °C (PRESSURISED)
2. HEAT CARRIERS ON MINERAL OIL BASE (PRESSURE –LESS) 300°C
3. SYNTHETIC ORGANIC HEAT CARRIERS (PRESSURE –LESS) 350°C
4. SYNTHETIC ORGANIC HEAT CARRIERS, LIQUID & VAPOUROUS 400°C
5. SALT –MELTS (PRESSURE –LESS) 400- 550°C
6. LIQUID METALS (PRESSURE –LESS) (500 TO 800°C)
16/05/25 Thermic Fluid Systems 5
TYPES of HEATING FLUIDS
Mineral Oils Synthetic Oils
Mix of : Mix of :
Paraffins Aromatics
Naphthenes Toluene
Diphenyl
Diphenyl Oxide
< 280 Deg C > 300 Deg C
Molten Salt - > 400 Deg C
16/05/25 Thermic Fluid Systems 6
THERMIC FLUID IDEAL PROPERTIES
High thermal stability
Good transport and heat transfer properties
Optimum material tolerance
Low safety risks
Low sensitivity to oxidation
16/05/25 Thermic Fluid Systems 7
CHARACTERISTICS OF A THERMIC
FLUID
Viscocity - Resistance to flow
• Unit - Poise or Cpoise
• Higher viscosity -More starting
load on pump
Specific Gravity
Unit - Dimensionless
• Normally around 0.9 at ambient temperature.
• Reduces with increase in temperature.
16/05/25 Thermic Fluid Systems 8
CHARACTERISTICS OF A THERMIC
FLUID
Specific Heat -
Quantity of heat required to heat unit weight through unit temp.
difference, at a given temp.
About 0.45 at 30oC., 0.7 at 300oC.
Unit : Kcal/Kg /oC
• Flash Point
• Temperature when thermic fluid flashes – leaves liquid surface and
goes into atmosphere
• Value – 200 to 215 deg C for good Oil.
• Fire Point
• Temperature when thermic fluid cathes fire in presence of spark or
fire
• Value – flash Point + 30 deg C
16/05/25 Thermic Fluid Systems 9
CHARACTERISTICS OF A THERMIC
FLUID
Boiling Point
Temp. at which change of phase takes place.
330o to 370oC
Boiling point varies from 330o to 370oC
16/05/25 Thermic Fluid Systems 10
DISCARD CRITERIA for MINERAL
OILS
Flash point : < 170 C o
Insoluble :>1%
Acidity(mg of KOH / gm of oil): > 1.5
Viscosity index : < 95
16/05/25 Thermic Fluid Systems 11
THERMIC FLUID ANALYSIS
REPORT
Analysis Present
Appearance Dark
Specific gravity at 15oC 0.897
Insoluble in Hexane % (By wt.) 4.36
Insoluble % (By wt.) 2.09
Neutralisation no. (mg of KOH/gm oil) 0.026
Water content % (By Vol.) Nil
Viscosity at 40oC (100oF) (Redwood No. 1 Sec.) - Cst 220-
56.43
Viscosity at 100oC (210oF) (Redwood No. 1 Sec.) - Cst 48-8.92
Viscosity index + 133
Flash point (COC) oC 162/163
Fire Point oC 200
16/05/25 Thermic Fluid Systems 12
FLUID TEMPERATURE ZONES
TUBE WALL TEMP
FILM TEMP
BULK TEMP
16/05/25 Thermic Fluid Systems 13
CONCEPT OF FILM TEMPERATURE
16/05/25 Thermic Fluid Systems 14
FLUID DEGRADATION - MAJOR
FACTORS
Oxidation - Exposure to air
Coking - High film temperature
Formation of low boilers
Thermal cracking - Mineral oils
Dehydrogenation - gas formation
Reaction with foreign matter
16/05/25 Thermic Fluid Systems 15
TYPES OF
FOULING
Particulate fouling :
Deposition of suspended matter
Reaction fouling :
Cracking, coking, polymerisation
Solubility fouling :
Deposition of Dissolved solids
16/05/25 Thermic Fluid Systems 16
Problems from TF Fouling
Lower efficiency - heat loss
More pump power consumed
Process fouled - production loss
System cleaning needed
Downtime, production loss
Coil replacement
Downtime, coil cost, fire
16/05/25 Thermic Fluid Systems 17
THERMIC FLUIDS BRANDS AVAILABLE
IN INDIA
Brand Manufacturer Bulk Temp
Shell Thermia Plus Bharat Shell 280oC
•Hytherm 500 H.P.C.L. 280oC
•Hytherm 600 H.P.C.L 290oC
•Servotherm Medium I.O.C. L 260oC
•Servotherm Special I.O.C.L 280oC
•Servotherm Super I.O.C.L 280oC
Therminol 66 Solutia 330oC
Dowtherm A Dow Chemicals 380o
16/05/25 Thermic Fluid Systems 18
END of PART I
16/05/25 Thermic Fluid Systems 19
Thermic Fluid Systems
Part II - Applications
G. S. Deshpande
16/05/25 Thermic Fluid Systems 20
PROCESS HEATING
In industry, heat requirement is large,
unlike in making a cup of tea.
Heat is generated at one point and carried
to the point of use, using a heating medium
/ carrier.
16/05/25 Thermic Fluid Systems 21
TF In
VESSEL WITH
JACKET
TF Out
16/05/25 Thermic Fluid Systems 22
VESSEL WITH
LIMPET COIL
16/05/25 Thermic Fluid Systems 23
VESSEL WITH
INLET INTERNAL COIL
OUTLET
16/05/25 Thermic Fluid Systems 24
TANK WITH IMMERSED COIL
16/05/25 Thermic Fluid Systems 25
THERMAL OIL HEATING
FLUE GASES
PROCESS
VESSEL
FIRED HEATER
16/05/25 Thermic Fluid Systems 26
VESSEL WITH
JACKET
(FOR THERMAL OIL)
SPIRAL BAFFLES
16/05/25 Thermic Fluid Systems 27
HEATING OF PLATTEN PRESSES
Platten Press
TF Heater
16/05/25 Thermic Fluid Systems 28
Circulating Pump
METAL PRE-TREATMENT HEATING SYSTEM
Expansion Cum
Deaerator Tank
Heating Tanks
THERMOPAC
TF Heater
16/05/25 Thermic Fluid Systems 29
Circulating Pump
HEATING OF STORAGE TANK
Expansion Cum
Deaerator Tank
Heavy Oil
Storage Tank
280 0c
250 0c
THERMOPAC
TF Heater
16/05/25 Circulating Pump Thermic Fluid Systems 30
APPLICATIONS
TEXTILE PROCESSING HOUSE
3 CHAMBER STENTER M/C
EXPANSION
TANK
DEAERATOR
BOOSTER PUMP
TF HEATER
5 CHAMBER STENTER M/C
CURING M/C
CIRCULATING PUMPS
CALICO CURING
M/C
16/05/25 Thermic Fluid Systems 31
HEATING OF BAKING & DRYING OVEN
Expansion cum
Deaerator Tank
Oil to Air
Hot Air
Heat
Supply Duct
Exchanger
Air
Damper
Blower
Return
Air Duct
2800C
2500C
Baking & Drying
Oven
THERMOPAC
TF Heater
Circulating
16/05/25 Pump Thermic Fluid Systems 32
Expansion cum
Deaerator Tank
Reaction Kettle
Open
Bath
THERMOPAC
TF Heater
Circulating
16/05/25 Pump MULTIPLE
Thermic Fluid Systems APPLICATIONS OF HEATING33
Expansion Expansion
Tank Tank
Deaerator
Tank
Deaerator
Tank
Reaction
Kettle
TF Heater
Heat Exchanger
Booster Pump
Water
Circulating Supply
Pump
16/05/25 Thermic Fluid Systems
HEATING & COOLING 34
OF REACTION KETTLES
16/05/25 Thermic Fluid Systems 35
Tips for Application Study
• Identify dominant mode of heat transfer
• Simplify the process and model it
• Estimate peak and average heat load.
• Estimate Maximum process temp
• Select appropriate heating equipement –
boiler or thermal oil heater or air heater or
hot water heater etc.
16/05/25 Thermic Fluid Systems 36
Application Industry
Industry Temp Medium
Polyester 300 - Syn TF Liquid, Indo Rama, Reliance
400 Vapour
Laminate <250 Mineral Oil, Hot Century, Greenply, Merino
Water
Plywood <200 Mineral Oil, Hot Century, Greenlam
Water, Steam
Textiles < 250 Mineral OIl
Chemicals < 280 Mineral Oil
Pharma > 300 Synthetic Oil
Rubber Gloves < 250 Mineral OIl Oven & Tank Heating
Automoiles < 250 Mineral OIl Oven & Tank Heating
Soda Ash, Potash >400 Molten Salt
16/05/25 Thermic Fluid Systems 37
Energy Source
• Oil & Gas • 40 %
• Coal • 25 %
• Bio mass • 30 %
• Waste Heat • 5%
Firing Mechanism & Design
Very similar to boiler design
16/05/25 Thermic Fluid Systems 38
END of PART II
16/05/25 Thermic Fluid Systems 39
