The adoption of electric thermal oil heaters has seen significant growth in recent years, aligning with the global shift toward electrification and decarbonization across various industrial processes. Installing an electric hot oil boiler allows industries to transition away from fossil fuel-based heating systems, thereby reducing carbon emissions.
The primary motivations for this shift are economic and environmental:
1. Electric boilers generally have lower operational costs because they require less maintenance and eliminate the need for handling hazardous fuels. Additionally, when electricity is cheaper than natural gas, the cost savings become even more pronounced.
2. Replacing combustion-based thermal fluid heaters with electric ones helps reduce greenhouse gas emissions. Boilers powered by fossil fuels like oil or natural gas emit carbon dioxide and other pollutants, whereas electric boilers do not produce direct emissions during operation.
However, the actual impact on decarbonization depends on the source of the electricity used. If the power comes from renewable energy, the environmental benefits are substantial. Conversely, if the electricity is generated from fossil fuels, the reduction in emissions may be limited.
Combustion heaters are typically maintained in specific situations, such as:
- As a backup system for the electric boiler.
- To support operations during peak production periods.
- When energy costs make it more economical to use combustion.
**Additional Advantages of Electric Hot Oil Boilers**
Beyond economic and environmental benefits, electric thermal fluid boilers offer several other advantages:
- Electric heaters are more efficient, requiring less energy to achieve the same level of heat output, which reduces both energy consumption and emissions.
- They emit fewer pollutants compared to combustion boilers, which release nitrogen oxides, particulates, and volatile organic compounds.
- Electric boilers occupy less space and offer greater flexibility in placement, as they don’t require fuel storage infrastructure.
- They provide better control and automation, allowing for precise temperature adjustments that can improve efficiency.
- Adopting electric boilers can help companies meet environmental regulations and avoid potential fines.
**Factors to Consider Before Replacement**
When evaluating a switch from combustion to electric thermal fluid boilers, several factors should be considered:
- Ensure the new system meets the required heat demand and capacity efficiently.
- The electric boiler should perform well in terms of energy-to-heat conversion.
- Compare investment and operational costs, including electricity prices and maintenance.
- Assess the availability and source of energy, especially for decarbonization goals.
- Verify that the existing electrical infrastructure can handle the increased load without major upgrades.
- Understand the regulatory requirements for installation and operation.
- Evaluate how the new system will integrate with existing processes and affect production.
- Conduct a life cycle analysis to assess environmental impacts over time.
The decision to replace a combustion boiler with an electric one should be based on a thorough evaluation of these factors. It’s recommended to work with experienced engineers and consultants who can provide technical guidance and ensure a smooth transition.
**Hybrid Systems with Parallel Heaters**
Hybrid systems combine both combustion and electric boilers, offering a balance of efficiency, flexibility, and reliability. These systems allow for optimal use of each boiler type depending on energy costs and operational needs.
Key reasons for choosing a hybrid system include:
- Cost optimization by using the cheapest available energy source at any given time.
- Enhanced flexibility to meet varying heat demands, with one boiler operating during peak times and the other during off-peak hours.
- Improved system reliability through redundancy, ensuring continuous operation even if one boiler fails.
- Better decarbonization potential when electricity comes from clean sources.
Proper control and automation systems are essential to manage the interaction between the two types of boilers and ensure efficient operation.
**Smart Hybrid System**
Pirobloc's R&D team is developing a smart hybrid system that uses real-time data on gas and electricity prices to determine the most cost-effective boiler to activate. This system offers benefits such as:
- Cost savings by selecting the most economical energy source.
- Improved energy efficiency based on current demand.
- Greater flexibility in managing heat supply.
- Reduced emissions when using cleaner energy sources.
- Automation to minimize manual intervention.
- Lower overall emissions and environmental impact.
**Case Study 1: Replacing a Thermal Oil Boiler with Two Electric Boilers**
A client sought to replace two 1,500,000 kcal/h fuel oil boilers with two electric ones. The goal was to operate continuously to maintain asphalt tar temperatures and reduce fuel oil usage. One boiler would remain as a backup, but switched to diesel to reduce pollution.
After analyzing flow rates, pressure losses, and power requirements, it was determined that two 600 kW electric boilers would be sufficient. The study also included calculations for electrical consumption and suggested necessary infrastructure upgrades.
**Case Study 2: Hybrid Installation Combining a Thermal Oil Heater with an Electric Heater**
Another project involved integrating an electric boiler with an existing natural gas-powered thermal oil heater. This allowed the client to choose the most cost-effective energy source based on price fluctuations. The design included pump upgrades, expansion tank modifications, and control systems to manage both units effectively.
**Author: Carles Ferrer**
Carles Ferrer is an industrial engineer from the Universitat de Barcelona. As the sales director at Pirobloc, he has been instrumental in the development of numerous thermal fluid projects across more than 80 countries. His expertise spans the entire lifecycle of industrial heating systems, from design to implementation.
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