What Is a Thermal Oil Heating System?

A thermal oil heating system, also known as a thermal fluid heating system, uses synthetic or mineral thermal oils as the heat transfer medium. The oil is heated in a thermal oil heater and then circulated through pipelines to various pieces of heat-using equipment, such as:

• Rich oil heaters

• Coal tar heaters

• Final gas heaters

• Process tanks and distillation units

Unlike direct-fired equipment, thermal oil systems provide indirect, flame-free heating, which helps reduce emissions and the risk of localized overheating.

How Heat Exchangers Work Within the Thermal Oil System

In a typical configuration, thermal oil is pumped from the heater to several custom-designed heat exchangers. These exchangers transfer heat to process fluids—such as raw coal tar, ammonia-rich water, or light oil—without contaminating the fluids.

Main components include:

1. Thermal Oil Heater – Generates and maintains high-temperature oil (typically up to 350°C)

2. Circulation Pump – Drives the oil through the loop

3. Distribution Manifold – Sends oil to different heat exchangers

4. Heat Exchangers – Transfer heat to the process medium with high efficiency

5. Return Line and Expansion Tank – Collects used oil, balances pressure, and allows reheating

Why Match Heat Exchangers with Thermal Oil Systems?

Pairing thermal oil systems with heat exchangers brings several technical and operational advantages:

Application Across Industries

Thermal oil systems with matched heat exchangers are widely used in:

• Coking plants: for rich oil and coal tar preheating, and gas conditioning

• Coal chemical and refining: for stabilizing process temperatures

• Fine chemical production: for reactor heating and solvent recovery

• Petrochemical terminals: for bitumen, wax, or heavy oil storage tank heating

Booyo’s Expertise in Thermal Oil-Based Heat Exchangers

Booyo specializes in designing and manufacturing thermal oil-compatible heat exchangers for industrial applications. Our product range includes:

• Horizontal and vertical rich oil heaters

• Coal tar heaters with anti-coking designs

• Final gas heaters for coke oven gas treatment

• Shell-and-tube or spiral-type pressure vessels

In 2023 alone, Booyo delivered over 30 complete sets of thermal oil heat exchangers to coking and coal chemical customers, helping them significantly reduce emissions and improve energy performance.

Contact Us

Looking to optimize your heating system with safe, efficient, and environmentally compliant equipment?

Contact Booyo today to learn how our custom-designed thermal oil heat exchanger systems can support your industrial operations and meet regulatory standards.