Decarbonization and cost reduction in industrial heating systems with electric hot oil heaters
July 14 03:19:37, 2025
Electric thermal oil heaters have gained significant popularity in recent years, aligning with the global shift toward electrification and decarbonization across various industrial processes. Installing an electric hot oil boiler enables industries to reduce their carbon footprint by replacing traditional combustion-based heating systems.
The main drivers behind this transition are economic and environmental:
1. Electric boilers generally offer lower operational costs due to reduced maintenance requirements and the absence of handling hazardous fuels. When electricity is cheaper than natural gas, these savings become even more substantial.
2. Replacing combustion-based thermal fluid heaters with electric ones helps cut down greenhouse gas emissions. Fossil fuel boilers emit COâ‚‚ and other pollutants, while electric boilers eliminate direct emissions during the heating process.
However, the extent of decarbonization depends on the energy source used for the electric boilers. If the electricity comes from renewable sources, the environmental benefits are maximized. If it's still derived from fossil fuels, the emission reductions will be less impactful.
Combustion heaters are often retained in certain situations, such as:
- As a backup system for the electric boiler.
- To support operations during peak production times.
- When cost analysis suggests it's more economical.
**Additional Advantages of Electric Hot Oil Boilers**
Beyond cost and environmental benefits, electric thermal fluid boilers provide several other advantages:
- They are more efficient, requiring less energy to achieve the same heat output, thus reducing both energy use and emissions.
- Electric heaters avoid emitting pollutants like nitrogen oxides, particulates, and volatile organic compounds, which are common in combustion boilers.
- They occupy less space and don’t require fuel storage infrastructure, offering greater flexibility in installation.
- Electric boilers typically allow for better control and automation, enabling precise temperature adjustments that can enhance efficiency.
- Adopting electric boilers can help companies meet environmental regulations and avoid potential penalties.
**Key Considerations Before Replacement**
When evaluating the switch from a combustion thermal fluid boiler to an electric one, several factors should be considered:
- Ensure the new heater meets the required heat demand and capacity.
- The electric boiler should deliver similar or better energy-to-heat conversion performance.
- Analyze investment and operational costs, including electricity prices and maintenance.
- Assess the availability and sustainability of energy sources, especially if the goal is decarbonization.
- Check if the existing electrical infrastructure can handle the additional load without major upgrades.
- Understand the regulatory requirements for installing and operating electric boilers.
- Evaluate how the new system will integrate with existing processes and affect production capacity.
- Conduct a life cycle analysis to assess the environmental impact of both options.
Making the decision to replace a combustion boiler with an electric one requires a thorough assessment of these factors. It’s essential to work with experienced engineers and consultants who can provide expert guidance.
**Hybrid Systems with Parallel Heaters**
Hybrid or parallel systems combine both combustion and electric boilers to optimize efficiency, flexibility, and reliability. These systems leverage the strengths of each type of boiler, allowing for dynamic operation based on energy prices and demand.
Several reasons justify choosing a hybrid system:
- Cost optimization: Using the most economical energy source at any given time reduces overall operating expenses.
- Capacity management: Combustion boilers can handle high-demand periods, while electric boilers respond quickly to fluctuating loads.
- Enhanced flexibility: Both boilers can operate simultaneously when extra heat is needed.
- Decarbonization: A hybrid approach supports gradual emission reduction strategies.
- Improved reliability: Having two types of boilers provides backup, minimizing downtime risks.
To ensure optimal performance, a smart control system is crucial to coordinate the operation of both boilers efficiently.
**Smart Hybrid System Development**
Pirobloc’s R&D team is developing a smart hybrid system capable of accessing real-time data on gas and electricity prices. This system automatically selects the most cost-effective energy source at any moment.
Benefits of this system include:
- Cost efficiency through intelligent energy selection.
- Greater energy efficiency by using the most suitable power source.
- Flexibility to adapt to price fluctuations and changing demands.
- Support for decarbonization when clean energy is available.
- Automation that reduces manual intervention.
- Lower emissions by prioritizing cleaner energy sources.
**Case Study 1: Replacing Thermal Oil Boilers with Electric Ones**
A client sought to replace two 1.5 million kcal/h fuel oil thermal oil boilers with two electric units. The goal was to enable 24/7 operation to prevent asphalt tar from cooling and maintain stable temperatures. One existing boiler would be converted to diesel for backup, reducing emissions.
Key findings included:
- The new electric boilers were designed to maintain a flow rate of 110 m³/h.
- Pressure loss was optimized to 1.5 bar_g, improving efficiency.
- Each boiler required 600 kW of power, totaling 1,200 kW for both.
- The system was designed to handle both 1°C and 2°C temperature differences in the tanks.
This setup significantly reduced fuel consumption and improved operational stability.
**Case Study 2: Hybrid Installation with Electric and Thermal Oil Heaters**
Another case involved integrating an electric thermal fluid boiler with an existing natural gas-fired unit. The goal was to allow flexible operation based on energy prices.
The proposed solution included:
- A 700 kW electric boiler matching the existing system’s capacity.
- Upgraded pumps to handle a higher flow rate of 40 m³/h.
- A new 1,000-liter expansion tank to accommodate the increased volume.
- A control panel to manage the switching between the two systems.
This hybrid configuration offered operational flexibility and cost savings, making it ideal for varying energy prices.
**Author: Carles Ferrer**
Carles Ferrer is an industrial engineer from the University of Barcelona and the Sales Director at Pirobloc. With extensive experience in thermal fluid systems, he has contributed to projects in over 80 countries. His expertise lies in designing sustainable and efficient heating solutions for industrial applications.
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