BEJO Steam Boiler and Thermal Oil Heater
Industrial heating systems play a critical role in modern manufacturing by providing reliable thermal energy for a wide range of production processes. Two of the most widely used technologies are Steam Boilers and Thermal Oil Heaters. While both systems are designed to transfer heat efficiently, they operate using different heat transfer media and are suited to different industrial applications.
What is a Steam Boiler?
A Steam Boiler is a closed pressure vessel designed to heat water and generate steam for industrial process heating, power generation, sterilization, and other thermal applications. Heat produced by a burner or electric heating elements is transferred to water inside the boiler until it reaches its boiling point, producing steam at a controlled pressure and temperature.
The generated steam is distributed through insulated piping systems to supply thermal energy to equipment such as:
- Heat Exchangers
- Chemical Reactors
- Dryers
- Sterilizers
- Food Processing Equipment
- Paper Machines
- Textile Machinery
- Steam Turbines
According to the United Nations Environment Programme (UNEP, 2006), a boiler is a closed vessel in which heat from fuel combustion is transferred to water to produce hot water or steam. Steam is widely used because it stores a large amount of thermal energy and efficiently transfers heat to industrial processes.
When water changes from liquid to steam, its volume expands by approximately 1,600 times, creating significant internal pressure. Consequently, steam boilers are classified as pressure vessels and must be designed, manufactured, operated, inspected, and maintained in accordance with recognized engineering standards and safety regulations.
Regular inspection, preventive maintenance, and proper water treatment are essential to ensure safe operation, maximize efficiency, and extend equipment service life.
What is a Thermal Oil Heater?
A Thermal Oil Heater, also known as a Thermal Fluid Heater or Hot Oil Heater, is an indirect heating system that uses heat transfer oil instead of water or steam as the heat transfer medium. The thermal oil circulates continuously through a closed-loop system, absorbing heat inside the heater and transferring it directly to industrial equipment.
Unlike steam boilers, Thermal Oil Heaters can achieve temperatures of up to 350°C while operating at low system pressure, eliminating many of the safety concerns associated with high-pressure steam systems.
Because thermal oil remains in the liquid phase throughout operation, there is no need for:
- Water treatment systems
- Steam traps
- Condensate recovery
- Blowdown systems
- High-pressure piping networks
This simplifies installation, reduces maintenance requirements, and lowers operating costs.
Steam Boiler vs. Thermal Oil Heater
| Steam Boiler | Thermal Oil Heater |
|---|---|
| Heat transfer medium: Water/Steam | Heat transfer medium: Thermal Oil |
| High-pressure operation | Low-pressure operation |
| Requires water treatment | No water treatment required |
| Steam traps and condensate return required | Closed-loop oil circulation |
| Temperature depends on steam pressure | Up to 350°C at low pressure |
| Higher maintenance costs | Lower maintenance costs |
| Potential scaling and corrosion | No scaling and minimal corrosion |
| Best for steam applications | Best for high-temperature process heating |
BEJO Industrial Heating Solutions
BEJO manufactures and supplies a complete range of industrial heating systems tailored to various production requirements, including:
- Steam Boilers
- Thermal Oil Heaters
- Electric Thermal Oil Heaters
- Hot Water Boilers
- Hot Air Generators
- Industrial Burners
- Heat Transfer Oil Systems
- Fuel Handling Systems
- Process Heating Packages
Our systems are engineered to deliver:
- High thermal efficiency
- Reliable continuous operation
- Precise temperature control
- Low fuel consumption
- Easy maintenance
- Long service life
- Compliance with industrial safety standards
Industrial Applications
BEJO Steam Boilers and Thermal Oil Heaters are widely used in:
- Food & Beverage Processing
- Chemical & Petrochemical Plants
- Pharmaceutical Manufacturing
- Palm Oil Processing (CPO)
- Plywood & Wood Processing
- Textile Industry
- Paper Mills
- Plastic Manufacturing
- Paint & Resin Production
- Asphalt Mixing Plants (AMP)
- Marine & Shipbuilding
- Rubber & Tire Manufacturing
- Printing & Packaging
- Mining
- Metal Processing
- Biofuel Production
- Waste Treatment Facilities
Definition of Thermal Oil Heater
A Thermal Oil Heater, also known as a Thermal Fluid Heater or Hot Oil Heater, is an indirect heating system that uses heat transfer oil as the heating medium instead of water or steam. The thermal oil circulates through a closed-loop piping system, carrying heat from the heater to industrial process equipment while remaining in the liquid phase.
One of the main advantages of a Thermal Oil Heater is its ability to provide process temperatures of up to 350°C while operating at low system pressure. Unlike steam boilers, thermal oil systems do not require water treatment, condensate recovery, steam traps, or blowdown systems, making them simpler to operate and maintain.
Thermal Oil Heaters are widely used in industries requiring precise and stable temperature control, including chemical processing, food and beverage manufacturing, pharmaceuticals, plastics, textiles, plywood, asphalt mixing plants, palm oil processing, marine heating, paper production, paint and resin manufacturing, and other high-temperature industrial applications.
Steam Boiler vs. Thermal Oil Heater
| Steam Boiler | Thermal Oil Heater |
|---|---|
| Uses water to generate steam | Uses heat transfer oil as the heating medium |
| Operates under high pressure | Operates at low pressure |
| Requires water treatment | No water treatment required |
| Requires steam traps and condensate recovery | Closed-loop oil circulation system |
| Maximum temperature depends on steam pressure | Can reach up to 350°C at low pressure |
| Higher maintenance requirements | Lower maintenance costs |
| Risk of scaling and corrosion | No scaling and minimal corrosion |
| Suitable for steam applications | Ideal for high-temperature process heating |
The boiler system consists of: feed water system, steam system and fuel system. The feed water system provides water to the boiler automatically according to steam requirements. Various faucets are provided for maintenance and repair purposes. The steam system collects and controls steam production in the boiler. Steam is routed through a piping system to the user point. In the whole system, steam pressure is regulated using a faucet and monitored by a pressure monitor.
The fuel system is all the equipment used to provide the fuel to generate the required heat. The equipment required for the fuel system depends on the type of fuel used in the system.
The water supplied to the boiler to be converted into steam is called feed water. The two sources of feed water are: (1) Condensate or condensed steam returning from the process and (2) Makeup water (treated raw water) which must be fed from outside the boiler room and process plant. To get a higher boiler efficiency, an economizer is used to preheat the feed water using the waste heat in the flue gas.
2.Thermal Oil Heater
Thermal Oil Heater is a heater using Thermal Oil Fluid as a heat conductor and can work up to a temperature of 300 degrees Celsius or more.
In contrast to steam which must use a pressure of up to 70 bar for the use of a temperature of 285 degrees Celsius, Thermal Oil Heater works only at the pressure of the circulation pump, so it is very safe and tools that require heating do not need to be designed with special construction.
The working life of the Thermal Oil Fluid used is generally more than 10 years and there is no need for any additions as long as there are no leaks in the pipes or heating equipment, and during that time no cleaning is needed because the inside of the heating coil is not crusty like in a Steam Boiler. Some of our Thermal Oil heater Units are still working well at the age of more than 20 years.
What are the advantages of Thermal Oil Heater compared to Steam Boiler?
• Working at high temperatures with atmospheric pressure
• Precise temperature control
• No need for water treatment etc. chemicals that require high costs
• No heat losses from condensate and blow down as in steam boilers
• No corrosion and crusting on the inside of the Boiler
• Very low maintenance costs
• Full Automatic and easy operation so it doesn’t require a special operator.
Design
Thermoblock Oil is generally supplied in Vertical construction which saves space and is very efficient because it uses an Integrated burner that utilizes exhaust gas for preheating combustion air so that the oil combustion is very complete. Heating Coil is made of Seamless Boiler Tube which is rolled continuously. Each weld joint is carefully checked with a Radiaography Test and a final pressure test using a pressure of up to 30 Bar. Thermal Oil flows inside the coil at a speed that is carefully designed to avoid overheating which can cause oil damage due to the formation of charcoal (coking).
The hot gas from the combustion heats the flow of thermal oil in the combustion chamber as radiant heat and then heats the oil in the convection coil through the gaps between the coils at a certain speed in 3 passes in the opposite direction to the direction of the thermal oil flow. The turbulence generated by the gas as it passes through the coil results in an increase in the efficiency of the heater and a coil cleaning effect of soot that may adhere to the outside of the coil. Scope of Delivery: Each unit is supplied complete with accessories, including:
• Heating Coil complete with cover
• Circulation Pump
• Expansion Tank & Deaerating Tank
• Control Panel
Design of BEJO Thermal Oil Heater – Case Study
Advanced Thermoblock Design for High-Efficiency Industrial Heating
BEJO Thermoblock Thermal Oil Heater is primarily manufactured in a vertical configuration, providing a compact footprint while maximizing thermal efficiency. The vertical design is ideal for industrial facilities with limited installation space and allows easier maintenance access.
The system incorporates an integrated high-efficiency burner that utilizes the heat contained in the exhaust gases to preheat the combustion air. This combustion air preheating process significantly improves combustion efficiency, resulting in lower fuel consumption, reduced emissions, and more stable heat output.
The heating coil is fabricated from high-quality seamless boiler tubes, continuously wound to ensure uniform heat transfer. Every welded connection undergoes rigorous Radiographic Testing (RT) and the complete pressure vessel is hydrostatically tested at pressures of up to 30 bar to ensure long-term reliability and safety.
The thermal oil flows through the coil at a carefully engineered velocity, preventing localized overheating that could degrade the heat transfer fluid through thermal cracking or coking.
Case Study: Resin Manufacturing Plant
Background
A resin manufacturing company required a heating system capable of maintaining a stable process temperature between 260°C and 280°C for its reactor vessels. The previous steam boiler system struggled to maintain consistent temperatures, resulting in variable product quality and increased production costs.
The company installed a BEJO Vertical Thermoblock Thermal Oil Heater equipped with an integrated gas burner and automatic temperature control.
Process Description
The burner generates high-temperature combustion gases that first transfer radiant heat to the thermal oil flowing through the radiant section of the heating coil.
The combustion gases then pass through the convection section in a three-pass heat exchange design, flowing opposite to the direction of the thermal oil. This counterflow configuration maximizes heat recovery while maintaining excellent thermal efficiency.
As the combustion gases pass through the narrow coil passages, controlled turbulence is created, increasing the heat transfer coefficient and reducing soot accumulation on the coil surface. This self-cleaning effect helps maintain consistent thermal performance over extended operating periods.
Results
After commissioning the BEJO Thermal Oil Heater, the plant achieved significant operational improvements:
- Stable reactor temperature between 260°C and 280°C.
- Improved resin quality and batch consistency.
- Reduced fuel consumption due to higher combustion efficiency.
- Lower maintenance costs because of reduced soot accumulation.
- Extended thermal oil service life by preventing overheating and coking.
- Increased production reliability with continuous 24-hour operation.
- Improved overall energy efficiency compared with the previous steam heating system.
Scope of Supply
Each BEJO Thermal Oil Heater is supplied as a complete package including:
- Thermal Oil Heating Coil with insulated casing
- High-efficiency Industrial Burner
- Hot Oil Circulation Pump
- Expansion Tank
- Deaeration Tank
- Digital Control Panel with automatic temperature control
- Safety Instrumentation
- Pressure and Temperature Gauges
- Chimney System
- Main Valves and Piping Connections
- Operation & Maintenance Manual
- Electrical Wiring Diagram
- Factory Testing Documentation
Conclusion
The BEJO Vertical Thermoblock Thermal Oil Heater is a high-performance industrial heating solution engineered to deliver safe, efficient, and reliable process heating at temperatures of up to 350°C. Its compact vertical design minimizes installation space while maximizing heat transfer efficiency through an advanced three-pass counterflow heat exchanger, seamless boiler tube coil, and high-efficiency integrated burner system.
Designed for continuous industrial operation, the system provides precise temperature control, low-pressure operation, and excellent fuel economy, helping manufacturers reduce operating costs while improving process stability and product quality. The optimized coil design also minimizes the risk of thermal oil degradation and coking, extending both fluid life and equipment service life.
With its robust construction, advanced safety features, and low maintenance requirements, the BEJO Thermal Oil Heater is the ideal choice for industries requiring dependable high-temperature heating, including chemical processing, food and beverage, pharmaceuticals, plastics, textiles, plywood, palm oil processing, asphalt mixing plants (AMP), paint and resin manufacturing, paper mills, marine heating, and many other industrial process applications.
Whether installed in a new production facility or integrated into an existing process line, the BEJO Vertical Thermoblock Thermal Oil Heater provides a long-term, energy-efficient heating solution that enhances productivity, reduces downtime, and supports sustainable industrial operations.
PT Indira Mitra Boiler
Industrial Heating System Specialist
Office:Emerald Residence Sepatan Ruko 8i, Kosambi Tangerang
Phone: (021) 352 95874
WhatsApp : +62 813-8866-6204 (Ratman Bejo)
Workshop : Tangerang – Indonesia
Website : www.indiramitraboiler.co.id
Website : www.burner.co.id
Email : info@indira.co.id | idmratman@gmail.com
YouTube : https://www.youtube.com/@Bejoburnerindonesia