Decarbonization and cost reduction in industrial heating systems with electric hot oil heaters
July 14 03:11:23, 2025
The adoption of electric thermal oil heaters has significantly increased in recent years, aligning with the global shift toward electrification and decarbonization across various industrial processes. Installing an electric hot oil boiler enables the decarbonization of heating systems that previously relied on thermal fluid.
This transition is driven by both economic and environmental factors:
1. Electric boilers typically have lower operational costs due to reduced maintenance and the absence of handling hazardous fuels. When electricity prices are lower than those of natural gas, these savings become even more significant.
2. Replacing combustion-based thermal fluid heaters with electric ones helps reduce carbon emissions. Boilers fueled by fossil fuels emit COâ‚‚ and other pollutants, while electric boilers avoid these direct emissions during operation.
However, the actual impact on decarbonization depends on the energy source used for the electric boiler. If powered by renewable energy, the benefits are substantial. If the electricity still comes from fossil fuels, the emission reduction will be less pronounced.
Combustion heaters are often maintained in the following situations:
- As a backup to the electric boiler.
- To support operations during peak production times.
- When energy cost analysis suggests it’s beneficial.
**Additional Advantages of Transitioning to Electric Hot Oil Boilers**
Beyond the economic and environmental benefits, electric thermal fluid boilers offer several other advantages:
- Electric heaters are more efficient, requiring less energy to produce the same amount of heat, thus reducing energy use 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 since they don’t require fuel storage infrastructure.
- They provide better control and automation, allowing for precise temperature adjustments and improved efficiency.
- Adopting electric boilers can help companies meet environmental regulations and avoid potential fines.
**Factors to Consider Before Replacement**
When replacing a combustion thermal fluid boiler with an electric one, it's crucial to evaluate several factors to ensure the process meets desired efficiency improvements:
- Ensure the new heater can efficiently meet the required heat demand and capacity.
- The electric boiler should match or exceed the performance of the current system in terms of energy-to-heat conversion.
- Analyze investment and operational costs, including electricity prices and maintenance.
- Consider the availability and source of different energy options, especially if the goal is to decarbonize.
- Check if the existing electrical infrastructure can handle the additional load without major upgrades.
- Understand the regulations related to installation and operation of electric boilers.
- Evaluate how the new system will integrate with existing processes and affect production capacity.
- Conduct a life cycle analysis to assess environmental impacts from manufacturing through decommissioning.
The decision to replace a combustion boiler should be based on a comprehensive evaluation of these factors to meet the company’s operational, economic, and environmental goals. Collaborating with specialized engineers and consultants is essential for a thorough assessment and guidance.
**Hybrid Systems with Parallel Heaters**
Hybrid systems combine both types of boilers to optimize efficiency, flexibility, and reliability. A detailed engineering analysis is necessary before implementation, considering boiler compatibility, electrical infrastructure, operating costs, and overall system efficiency. Proper design ensures optimal performance and supports decarbonization goals.
Reasons for choosing a hybrid system include:
- Cost optimization by using the cheaper energy source at any given time.
- Complementing capacity to meet varying heat demands, with combustion boilers handling peak loads and electric ones managing fluctuations.
- Greater operational flexibility, such as running both boilers simultaneously when extra heat is needed.
- Enhancing system reliability with backup in case of failure.
A robust control and automation system is essential to manage both boilers efficiently and cohesively.
**Smart Hybrid System**
Pirobloc’s R&D team is developing a smart system that uses a database of gas and electricity prices to decide which boiler to activate based on the most economical option. This approach offers several benefits:
- Cost optimization by selecting the cheapest energy source.
- Improved energy efficiency by using the most efficient option available.
- Flexibility to adapt to price fluctuations and changing demand.
- Decarbonization by prioritizing cleaner energy sources when available.
- Automation reduces the need for manual decisions.
- Emission reduction by utilizing cleaner energy sources where possible.
**Case Study 1: Replacing a Thermal Oil Boiler with Two Electric Boilers**
A client requested a study to replace two 1,500,000 kcal/h fuel oil thermal oil boilers with two electric boilers. The goal was to switch from 10-hour daily operation to continuous 24-hour operation to maintain the temperature of stored asphalt tar and prevent cooling. The client also wanted to keep one boiler as a backup but switch its fuel from oil to diesel.
The study found that maintaining a constant temperature would reduce boiler power needs. Flow analysis and pressure loss calculations led to the selection of two 600 kW electric boilers, ensuring proper flow rates and pressure losses. The system would operate 24 hours a day, significantly lowering average consumption.
**Case Study 2: Hybrid Installation Combining a Thermal Oil Heater with an Electric Heater**
This study evaluated the feasibility of installing an electric thermal fluid boiler alongside an existing natural gas-fired boiler. The client wanted the ability to switch between boilers depending on fuel prices.
The proposed solution included a 700 kW electric boiler, a new pump system, and updated expansion tanks. Electrical requirements were calculated, and the system was designed to work seamlessly with the existing setup. A boiler selector panel allowed the user to choose the most suitable boiler based on cost and availability.
**Author**
Carles Ferrer is an industrial engineer from the Universitat de Barcelona. As the sales director at Pirobloc, he has been involved in numerous thermal fluid projects across over 80 countries. His expertise lies in optimizing industrial heating solutions and promoting sustainable energy transitions.
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