A heat transfer oil is a gas or liquid specifically manufactured to transmit heat from one application to another. This branch of science and engineering involves the transfer of heat via a liquid or vapour — temperature, flow rate, phase transition, pressure, volume, and density all play an important role. It can also refer to coolants — fluids that flow through a device to prevent overheating. For example, we use water cooling to prevent car engines from overheating. Oil can also be referred to as thermal oil, thermal fluid, heat transfer fluid, thermic fluid, therm fluid or thermic oil.Why use heat transfer oil instead of water?What is the difference between synthetic and mineral fluids?How do I choose the right heat transfer oil for my application?What is the lifespan of a thermal oil?What are the causes of oil degradation?What are light ends?How can I remove light ends?How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

Steam heat transfer systems operate at very high operating pressures of about 85 bars or 8,500 kPa. If the steam reaches critical pressure and the system has no way to vent, it can cause pipes and valves to burst. In steam-based systems, manufacturers must also regularly maintain pipes to prevent corrosion which can result in downtime and loss of production. Thermal fluid systems are often better than steam-based systems because they are more efficient, safer and offer more precise temperature control. System availability is also reliable when condition monitoring and a preventative maintenance programme is applied.What is the difference between synthetic and mineral fluids?How do I choose the right heat transfer oil for my application?What is the lifespan of a thermal oil?What are the causes of oil degradation?What are light ends?How can I remove light ends?How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

The chemical composition of a thermal fluid can be organic or synthetic. Synthetic heat transfer fluids, such as a silicone or terphenyl, have a lower propensity to form carbon than mineral based oils, offering better heat transfer efficiency and thermal stability. They are also more resistant to fouling, which means they tend to form less coke on the internal pipework and heater.How do I choose the right heat transfer oil for my application?What is the lifespan of a thermal oil?What are the causes of oil degradation?What are light ends?How can I remove light ends?How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

Though all thermal fluids will degrade over time, matching the fluid choice to the system and the operating temperature can help to preserve fluid life. Heat transfer fluids are specifically designed to offer unique properties for specific applications. Important factors to consider when choosing a thermal oil include operating temperature — you should consider both the highest and lowest operating temperatures to ensure it operates effectively during start up and can maintain the required temperatures for long periods. The application can also dictate fluid choice, because many manufacturers need to adhere to industry specific regulations. For example, manufacturers in food, beverage and pharmaceutical processing should use a certified food-grade thermal oil.What is the lifespan of a thermal oil?What are the causes of oil degradation?What are light ends?How can I remove light ends?How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

All heat transfer fluids can provide good service over extended periods, even when operating at high temperatures, so long as routine testing and analysis and thermal fluid management is carried out.What are the causes of oil degradation?What are light ends?How can I remove light ends?How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

There are two main types of fluid degradation.Oxidation. A thermal oil oxidises when it reacts with oxygen in the air by a free radical mechanism, causing carbon to form. The rate of oxidation increases with temperature.Thermal degradation, also known as thermal cracking. When a thermal fluid is heated above the maximum film temperature specified by the manufacturer, it will start to degrade rapidly.  During cracking, the bonds between hydrocarbon chains start to break, producing shorter chained light ends. This leads to vaporisation and the formation of volatiles.The formation of carbon in thermal fluid also increases the viscosity. When the concentration of carbon reaches a certain level, it starts to form sludge on the insides of pipework, in a process known as fouling. The sludge accumulates, particularly in low flow areas such as reservoirs and expansion tanks, and reduces the efficiency of heat exchange.What are light ends?How can I remove light ends?How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

At high operating temperatures, fluids begin to degrade as a result of oxidation and thermal cracking. As hydrocarbon chain length decreases, so does the weight of the molecules, meaning less energy is required to accelerate them to a velocity where they will escape liquid phase. Hydrocarbon chains can also recombine to form heavy ends that usually cause fouling of the heat transfer system. Light ends will lower the flash point, or the ignition point, of the thermal oil. This increases the risk of fire, putting the workforce and facility at risk.How can I remove light ends?How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

Engineers can install a light ends removal kit (LERK) to remove volatile light ends. Hot thermal fluid flows through the distillation vessel and the gaseous light ends are collected in the liquid phase of the condenser. The light ends are either drained automatically or manually from the system. During the process, the system is not open to atmosphere as a hot expansion tank would be, which protects the oil against oxidation ageing.How do I maintain a thermal fluid?How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?

Implementing a continuous preventative maintenance programme, such as Thermocare from Global Heat Transfer, can help to slow degradation and improve efficiency. Regular fluid sampling and analysis enables engineers to get an accurate representation of the condition of the fluid in the system to anticipate what could happen in the near future. Engineers can then intervene and carry out maintenance tasks before thermal fluid degradation impacts production, reducing the risk of downtime while also maintaining safe operations.How do I sample and analyse a thermal oil?How do I know when to replace thermal oil?How do I replace a heat transfer oil?What regulations must I adhere to when working with thermal oil?Who can help with heat transfer oil maintenance?