HOT OIL SYSTEM

By- Binoy Shah [GET]

1 TITLE
 Overview of Presentation

HOT OIL
1. Introduction to Hot Oil
2. Classification of Hot Oil
3. Commonly used oil’s in Chemical & Allied lndustries
4. Thermal Oil vs Steam- Selection
5. Selecting a Thermal Oil
i. Process Conditions
ii. Physical properties /Critical considerations

HOT OIL HEATER SYSTEM

1. Introduction
2. System Components
3. Advantages and Limitations
4. Key Points for Operation Consideration
5. Identifying and Analyzing Problems in Hot Oil System
6. Application’s of Hot Oil Systems

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 Introduction to Hot Oil

Commonly known as:- Heat Transfer Fluid (HTF); Thermic Fluid; Thermal Fluid; Hot Oil

Definition:- Any vapor or liquid specifically manufactured for the purpose of transmitting heat
from one system to another. It can either be used for heating, cooling or simultaneous purposes.

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 Classification of Hot Oil

HOT OIL

Types Mineral Oils Synthetics Silicones

Temp Range -50 to 310 ºC Pressurized:- 10 to 410 ºC -40 to 400 ºC

Non-Pressurized:- -50 to 340 ºC
*Given range is of bulk
temperature.
If required temperature is above this range.
Upto 500 ºC:- Molten Salts
Upto 650 ºC:- Liquid Sodium
Above 700 ºC:- Electrical Heating

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 Commonly used oil’s in CI & Al

Company Name Oil Name Range ºC Type

DOW Dowtherm; [biphenyl (C12H10) -80 to 400 Synthetic
and diphenyl oxide (C12H10O)]
DOW Slytherm -100 to 400 Silicone
Paratherm Paratherm HTF -88 to 343 Mineral; Synthetic
Bharat Petroleum MAK Thermic Fluids Upto 250 Mineral
Eastman Therminol HTF 115 to 400 Mineral; Synthetic
Hindustan Petroleum Hytherm Upto 300 Mineral

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 Thermal Oil vs Steam- Selection

Criterion for selecting Hot Oil over Steam

1. Process/ Operational Requirements

2. Efficiency
3. System pressure
4. Temperature control
5. Pressure control
6. Licensed operator
7. Design of system
8. Maintenance
9. Safety
10. System cost
11. Payback Period

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 Selecting a Thermal Oil

Provisioned by process / design engineer

Important decision for Operational Purpose

Selection differs based on understanding and experience

Systematic sequence should be followed for Oil selection

Major Selection Criteria

i. Process Conditions
ii. Physical properties /Critical considerations

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 Oil Selection

Process Conditions
{ Temperature, Pressure, Method }

Physical Properties
Critical Consideration
{ Viscosity, Density, Pour Point ,
{ HTC, Pumpability Point} Cost
Flash and Fire Point}

Ease of
Standard Specifications
Availability

Final Selection

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 Process Conditions

Temperature is a parameter to check

• Maximum operational temperature taken into consideration
• Overload conditions and Accidental overheating also considered
• Oil should perform optimally under the specified temperature range

Why Check?
Limiting temperature obtained

Problems caused by overheating

• Thermal Degradation/ Cracking
• Oxidation
• Coking

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 Maximum recommended bulk temperature
 System operation should never exceed the maximum bulk temperature of the fluid

Minimum operating temperature

 Is cooling required?

Minimum start-up temperature

 Outdoor or indoor application

Vapor pressure/boiling point

 Special construction requirements if the operating temperature exceeds the boiling point

Process Application
 If application requires zero contamination ( food ; pharma industry); then toxic HTF cannot be
used. Green oil has to be implemented

Disposal Criteria

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 Properties of Oil

Physical Property:- Property that is measurable, whose value describes a state of a physical
system. The changes in the physical properties of a system can be used to describe its
transformations or evolutions between its momentary states. Physical properties are often
referred to as observables.

Examples-
Density; Viscosity; surface tension, bulk modulus, vapor pressure

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 Critical Properties for Selection of Hot Oil

Viscosity
 Useful flow property
 Pumpability point decision
 Cold temperature application

Density
 Power requirement
 Cost

Flash & Fire point

 Obtained for hazard issues
 Safe operating level is decided

Pour Point
 Useful in low temperature or low climate applications

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 Heat Transfer Coefficient

 Known as HTC or film coefficient, or film effectiveness, is the proportionality constant

between the heat flux and the thermodynamic driving force for the flow of heat
 Important to consider in selection
 Obtained from co-relations between Dimensionless numbers
 Higher the HTC value; greater the oil’s ability to conduct and transfer heat
 Compared between two or more oil’s

 Synthetic oils have a significant advantage in heat transfer coefficient over hot oils from
150ºC to 260ºC.
 At higher temperature HTC difference is again reduced

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 Distillation Range
 Analyzing fluid composition for alteration caused by overheating.

Vapor Pressure
 The Red Herring
 Confusing parameter to check
 Important to know details as can increase operating cost

Life of Fluid
 Operational stability
 Maintenance
 Changeover

Cost of Fluid

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 IS 14745:1999 [Thermic Fluid Specification ]

 Ash Percentage
 Auto Ignition Temperature
 Conradson Carbon Residue
 Initial and Final Boiling point
 Copper Corrosion

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 Hot Oil Heater System

A liquid phase thermal fluid system uses a heater in which the heat transfer fluid is heated but no
vaporization takes place within the vessel.
 Closed loop systems which may be open or closed to the atmosphere
 Similar in concept to hot water boiler systems

 A thermal oil heater fires through a helical coil and generates energy from the hot products of
combustion by heating the coil through radiation and convection
 The coil heats thermal that is pumped through the thermal oil heater. The thermal oil heats
coils and jackets in various types of equipment's
 Unlike a water or steam boiler, this heating process does not heavily pressurize the system

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 System Components

A typical thermal fluid system is comprised of four main components:

i. Thermal fluid heater
ii. Thermal fluid circulating pump
iii. Expansion tank
iv. Process Equipment

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 Advantages and Limitations

Advantages of Hot Oil systems

• Non pressurized system

• No loss system/ Closed circuit
• Point of use location
• No water treatment or Chemical usage
• Less effluent disposal
• No freezing hazards
• Low maintenance cost
• Relatively simple design

Limitations

• Escaping vapors
• Overheating
• Leakage Ignitability

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 Key Points for Operation Consideration

 Thermal fluid system layout planning

 Selection of system components
 Thermal fluid safety consideration
 Practicing safe fluid handling
 Extension of oil and system life by good operating practices
 Sensible start-up and shut-down
 Regular fluid analysis
 Effective thermal fluid filters
 Periodic clean-up with flushing fluid
 Standard Operating Procedure (SOP) for trouble shooting
 Pump and proof of flow
 Fluid excess temperature protection
 Stack excess temperature limit
 Expansion tank design and fluid level

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 Identifying and Analyzing Problems in Hot Oil System

Problems like cracking, oxidation common in such systems

Problem Identification important for fluid and system longevity

Thermal Oil RCA

Objective:- To identify what happened, why it happened, and what can be done to prevent it from
happening again

Apply Pareto's Principle

Conclude from Analytical Tests

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 How to conclude?

Oil’s will show degradation

Specified range deviation given by manufactures or standard

Distillation Range [ <10%]

Kinematic Viscosity [<50%]
Flash Point [ lowers by 100 ºF ]

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 Application’s of Hot Oil System

• Chemical Plants
• Textile Manufacturing Facilities
• Food Processing
• Pharma
• Laundries
• Marine Applications
• Oil and Gas production
• Petrochemicals
• Wood Processing
• Plastic & rubber processing
• Metal, paper and cardboard processing
• Building Materials
• Paper and Pulp

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 Thank you

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