Thermal Fluid Heaters

Vertical, Horizontal and Electric

75,000 - 14,000,000 BTU/HR

a few of the

Features
Thermal Fluid vs. Steam
No corrosion or freezing High operating temperatures (up to 750F) with low system pressure Minimum maintenance burner, pump and controls Simple circuit, no blow-downs, steam traps or condensate return systems Fultons combination expansion/ deaerator/thermal buffer tank provides pipework simplification, protection of thermal fluid from oxidation and continuous deaeration of fluid avoiding pump cavitation Heaters are built and tested to ASME Code Section I or ASME Code Section VIII Div. I Fulton heaters are manufactured individually for maximum flexibility and to customer specifications Fulton heaters and accessory components (pumps, expansion tanks, control valves, etc.) can be skid mounted to save time and on site fabrication
SYSTEM PRESSURE P . S.I.G. 1500
SATURATED STEAM/WATER THERMAL FLUID

A thermal fluid (hot oil) system operates in a closed loop circulation system with minimal pressure. Fulton thermal fluid systems can reach 750F (345C) making them an ideal choice for many process heat applications.

1000

500 400 300 200 100 0 0C 50C 100C 150C 200C 250C 300C 343C 32F 122F 212F 302F 392F 482F 572F 650F SYSTEM FLUID TEMERATURE
*Saturated steam or pressurized water

The choice between a steam system or a thermal fluid system is governed by the process requirements. The range or process temperature is a deciding factor. If the systems required temperature is above the freezing point of water (32F) and below approximately 350F, the choice is usually steam. However, if the required temperature is below 32F or above 350F, thermal fluid may be a better solution.

Fulton Deaerator or Expansion Tank

Fulton Thermal Fluid Heater

Fulton SteamPac Fulton WaterPac

Storage Tank

Press, Mold, or Platten

a wide range of

Applications
Fulton heaters are used in a variety of applications throughout many industries. Food, plastic and chemical processing as well as pharmaceutical and bio-fuel production are only a few of the many existing applications using Fulton.
Adhesives Asphalt Autoclaves Bio-fuel Chemical reactors Deoderization Distillation Food processing (frying, baking, etc.) Inks & Dyes Laminating Laundry Marine heating and shipboard services Metal finishing Mining Ovens Paint and varnish manufacture Paper converting machinery Plastics Printing and packaging machinery Surface pretreatment and finishing Tank farms/pipe and pump tracing Textile machinery Unfired steam or hot water generation Uranium processing Waste treatment/dryers

Bath or Kettle

Rolls

Fryer

Reactor

Oven

features of the C-Model

Vertical Coil Design

Vertical 4-pass design Preheated combustion air is an integral part of the design Built and tested in accordance with ASME Code Section I or ASME Code Section VIII Div. I 800,000 BTU/hr to 14,000,000 BTU/hr output Operating temperatures to 750F Gas, oil or dual fuel burners; on/off or modulating Low emissions natural gas burners are available Minimal refractory results in low thermal inertia and prevents overheating of the fluid in the event of a pump or power failure High efficiencies Even heating Customized controls available The FT-0600-C shown below supplies 600F thermal fluid for a food processing application. The skid includes modulating valves to control fluid flow and a bypass valve to maintain flow throughout the heater at all times.

take a look

Inside
Operating Principle
The combustion air enters the burner fan inlet, travels upward between the inner and outer jacket, preheating the air before it enters the top mounted burner. Hot gases travel down the full length of the vessel creating the first (radiant) pass.

C B

The gases then travel back across the inner row of coils, creating the second (convection) pass. The third (convection) pass is created as the gases continue back down between the inner and outer coil. The last pass is upward between the outer coil and inner jacket to the flue outlet, creating the fourth (convection) pass.

Thermal fluid inlet

Top mounted burner

Thermal fluid outlet

Electrical control panel

Combustion fan

technical

Details
Specifications
Models
Heat Output 1000 BTU/HR 1000 KCAL/HR Thermal Fluid Content GAL LITERS Recommended Flow Rate GPM M3/HR GPH LPH FT3/HR M3/HR HP KW HP KW

(C-Model)

FT-C 0080
800 200 10 38 50 11.4 7.1 27 998 28.3 7.5 5.6 1.5 1.1

0120
1,200 300 21 80 75 17 10.7 40.6 1,498 42.4 10 7.5 3 2.2

0160
1,600 400 19 72 100 22.7 14.3 54.1 1,998 56.5 10 7.5 3 2.2

0240 0320 0400

2,400 600 31 116 150 34 21.4 81 2,999 84.9 15 11.2 3 2.2 3,200 800 68 258 250 56.8 28 108.8 4,000 113.2 20 14.9 7.5 5.6 4,000 1000 76 288 250 56.8 35.3 136 4,997 141.5 20 14.9 7.5 5.6

0600 0800 1000 1200 1400

6,000 1500 132 500 375 85.2 53 201 7,498 212.3 30 22.4 7.5 5.6 8,000 2000 171 648 500 113 10,000 12,000 14,000 2500 3000 3500 290 383 460 1097 1450 1741 615 730 800 139 167 182

Approximate Fuel Usage

Light Oil * Natural Gas * 69.7 87.1 104.5 122 263.7 329.6 395.5 461.5 9,997 12,496 14,998 17,500 283 353.8 424.6 495.5 40 29.8 15 11.2 50 37.3 20 14.9 50 37.3 20 14.9 60 45 25 33.3

Power
Typical Circulating Pump Motor Typical Burner Motor

Voltage 3 Phase for Burner and Pump - Each unit has an incorporated stepdown transformer. Fuel up to No. 6 Oil Available for Large Units. (FT-0600-C and larger) Efficiency up to 80% Minimum Based on High Heating Value of the Fuel (No. 2 Oil @ 140,000 BTU/GHHV; Natural Gas @ 1000 BTU/ft3HHV. Modulation 3 to 1 Turn Down Ratio. Optional on FT-0080, 0120, and 0160 - Standard on all others. Circulating pump motor sizes based on standard pressure (55 PSIG) and viscosity 1 cs, specific gravity 0.7, with 25-37 PSID available head for installation.

Dimensions
Models
Heater Inlet/Outlet Connections (A) Overall Height (B) Heater Diameter (C) Overall Depth (D) Flue Outlet Diameter Recommended Vertical Stack Diameter Approx. Dry Weight

FT-C 0080
IN MM IN MM IN MM IN MM IN MM IN MM LB KG 1.25 32 60 1,524 25 6,35 41 965 10 254 10 254 1,500 680

0120
1.25 32 76 1,930 34 8,65 56 1,422 10 254 12 304 2,100 953

0160
2 50 76 1,930 34 8,65 56 1,422 10 254 12 304 2,550 1,150

0240 0320 0400

2.5 65 86 2,184 40 1,015 62 1,525 12 304 14 356 3,400 1,550 3 80 101 2,559 49 1,252 80 2,030 14 356 18 457 5,300 2,400 3 80 108 2,793 49 1,245 70 1,780 14 356 18 457 5,300 2,400

0600 0800 1000 1200 1400

4 100 139 3,531 57 1,450 79 2,007 18 457 22 558 8,250 3,750 4 100 139 3,531 71 1,805 103 2,615 20 508 24 609 11,450 5,200 6 6 6 150 150 150 143.5 144 163 3,645 3,658 4,144 90 108 108 2,285 2,745 2,746 130 148.5 153 3,302 3,772 3,894 20 22 22 508 558 558 24 26 26 609 661 661 19,250 21,700 23,000 8,750 9,850 10,455

* Please consult factory for additional fuel options. Specifications and Dimensions are approximate. Consult factory for model specific electrical requirements. We reserve the right to change specifications and/or dimensions without notice. Operating specifications may change based on field conditions. Top View Models FT-0080-C through FT-0400-C

Top View Models FT-0600-C through FT-1400-C Front & Side Views Not Shown

D A C

Diagram for guidance purposes only. Comprehensive details of dimensions, connections, etc. for each model are given on product dimension data sheets available from Fulton.

features of the Combination Expansion/Deaerator / Thermal Buffer Tank

Designed to work as an open system where applicable, eliminating the expense of an inert gas blanket Continuous deaeration of steam and other non-condensibles Protects fluid from oxidation Ease of installation Simplification of pipework
Vent for Piping to Safe Catchment Expansion Tank

Expansion Volume

Liquid Level Switch Fluid In Hot Fluid Medium Fluid Cool Fluid Deaerator Section Gases (Steam)

Fluid Out

Drain

Thermal Buffer Section

Tank Sizing and Capacities

Models
Capacity Initial Fill Available for Expansion Max System Volume Dry Weight

FT-L
Gallons Gallons Gallons Gallons LBS KG

200
52 25 46 184 636 289

500
132 40 121 525 970 440

1000
264 80 232 1,000 1,350 612

1500
397 90 380 1,400 1,710 776

2000
528 145 444 1,700 2,550 1,134

3000
793 215 717 2,600 3,200 1,451

5000
1,310 300 1,168 4,600 5,300 1,637

features of the A-Model

Vertical Tubeless Design

Vertical annular design Built and tested in accordance with ASME Code Section I or ASME Code Section VIII Div. I 200,000 BTU/hr to 1,736,000 BTU/hr output Operating temperatures to 600F Gas or oil fired burners on/off or modulating Low emissions gas burners are available Customized controls available Pictured below is a skid mounted FT-0690-A with deaerator tank and two secondary loops for automatic heating and cooling of reactors.

Specifications
Models
Heat Output Thermal Fluid Content Recommended Flow Rate

FT-A
1000 BTU/HR 1000 KCAL/HR GAL LITERS GPM M3/HR GPH LPH FT3/HR M3/HR HP KW HP KW

0200
207 52 23 87 90 21

0380
348 88 38 144 90 21

0520
519 131 45 170 125 28

0690
693 175 65 246 125 28

1050
1,052 265 98 371 150 34

1740
1,736 437 117 443 200 46

Approximate Fuel Usage

Light Oil Natural Gas 2.2 8.3 259 7.2 3.2 11.9 435 12.2 4.7 17.8 649 18.4 6.7 25.4 866 24.2 9.4 35.6 1,315 36.8 15.8 60 2,170 60.8

Power
Typical Circulating Pump Motor Typical Burner Motor 10 7.5 .33 .248 10 7.5 .33 .248 15 11.2 .33 .248 15 11.2 .75 .56 15 11.2 .75 .56 20 14.9 1.5 1.1

Consult factory for model specific electrical requirements.

technical

Details
Dimensions
Models
Heater Inlet/Outlet Connections (A) Overall Height (B) Heater Diameter (C) Overall Depth (D) Flue Outlet Diameter Approx. Dry Weight

FT-A
IN MM IN MM IN MM IN MM IN MM LB KG

0200
1.5 38 69 1,752 26 660 43 1,092 6 152 1,850 840

0380
1.5 38 75 1,905 28 710 45.5 1,156 6 152 2,100 955

0520
2 51 85 2,159 30 760 46 1,168 8 203 2,300 1,045

0690
2 51 86 2,185 36 915 56 1,422 10 254 3,400 1,540

1050
2 51 86 2,185 44 1,120 64 1,626 12 305 4,400 1,995

1740
2.5 64 110 2,794 44 1,120 64 1,626 12 305 7,200 3,275

Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions without notice. Operating specifications may change based on field conditions.

Operating Principle
A
Top mounted burner

The top-mounted down fired burner delivers a spinning flame down the length of the furnace. As the flame swirls downward in a controlled flow pattern the fluid spirals upward in the pressure vessel. Hot gases from the flame are carried up the outside of the vessel in the secondary flue passage convection area. Convection fins welded along the full length of the vessel transmit the remaining heat through the outer side of the fluid vessel and into the fluid. The result is even heating of thermal fluids for optimum thermal efficiency.

Heater outlet

Electrical control panel

D
D
Convection fins

Heater inlet

High density, high temperature insulation

features of the N-Model

Vertical Electric Design

Compact vertical design Built and tested in accordance with ASME Code Section I or ASME Code Section VIII Div. I 75,000 BTU/hr to 1,719,000 BTU/hr output Operating temperatures to 650F Low watt density elements results in low film temperatures and long element life Customized controls available, including Class 1, Division 1 or 2 groups C&D of NEC code Customized heaters available FT-0640-N skid mounted with one main circulation pump, one FT-500-L expansion deaerator tank, one 200 gallon holding tank with drain/fill pump and two secondary loops. Each secondary loop consists of one circulation pump, one cooling heat exchanger and one automatic 3-way valve. This system was manufactured to provide heat to platens for the production of specialty papers.

Specifications
Models
Heat Input

FT-N 0075 0150 0225 0300 0375 0430 0640 0860 1070 1290 1500 1720
22 75 18.9 74 18.6 18 68 50 11.4 44 150 37.8 148 37.3 36 136 50 11.4 66 225 56.7 222 59.9 42 159 50 11.4 88 300 75.6 294 74.1 54 204 90 20.5 110 375 94.5 368 92.7 63 238 90 20.5 126 429 108 420 105.8 79 299 125 28.4 189 644 162 631 159 79 299 125 28.4 252 859 216 842 212.2 102 386 150 34 315 1,074 271 1,053 265.4 127 480 150 34 378 1,289 325 1,263 318.3 152 575 175 39.8 441 1,504 379 1,474 371.4 168 636 200 45.5 504 1,719 433 1,685 424.6 185 700 200 45.5

KW 1000 BTU/HR 1000 KCAL/HR Heat Output 1000 BTU/HR 1000 KCAL/HR Thermal Fluid Content GAL LITERS Recommended GPM Flow Rate M3/HR

Power
Typical Circulating Pump Motor Amps HP KW 208V 208V 480V 7.5 5.6 61 53 26 7.5 5.6 122 106 53 7.5 5.6 183 159 79 10 7.5 245 212 106 10 7.5 306 265 132 15 11.2 350 303 151 15 11.2 525 455 228 15 11.2 700 607 303 15 11.2 875 758 379 15 11.2 1,050 910 455 20 14.9 1,224 1,061 531 20 14.9 1,399 1,212 606

Consult factory for model specific electrical requirements.

take a look

Inside
Dimensions
Models
Heater Inlet (A) Overall Height (B) Heater Diameter (C) Overall Depth Approx. Dry Weight

FT-N 0075 0150 0225 0300 0375 0430 0640 0860 1070 1290 1500 1720
IN MM IN MM IN MM IN MM LB KG 1.5 38 70 1,778 20 508 37.5 953 1,060 481 1.5 38 70 1,778 26 660 43 1,092 1,220 555 1.5 38 70.5 1,791 28 711 43.5 1,105 1,400 636 1.5 38 70 1,778 32 813 47.5 1,207 1,540 700 1.5 38 70 1,778 32 813 47.5 1,207 1,660 756 2 51 90.5 2,299 32 813 47.5 1,207 2,040 927 2 51 90.4 2,296 32 813 49.5 1,257 2,200 1,000 2 51 90.8 2,306 38 965 53.8 1,365 2,370 1,077 2 51 89.8 2,281 44 1,118 58.4 1,257 2,650 1,205 2 51 91.2 2,317 50 1,270 65.7 1,669 2,950 1,341 2.5 64 93 2,362 54 1,372 71.8 1,823 2,950 1,341 2.5 64 93 2,362 58 1,473 75.7 1,993 3,600 1,636

Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions without notice. Operating specifications may change based on field conditions.

A B

Operating Principle
Even circulation of thermal fluid is created within the vessel. This unique circulation method (upward spiraling fluid) results in an even flow of thermal fluid across the multiple low watt density elements, uniformly heating the thermal fluid. This results in low film temperatures and assures long element life.

A B

Thermal fluid outlet

D C E

Top mounted, easily accessible elements

High density, high temperature insulation

Thermal fluid inlet

Electrical control panel

features of the HC-Model

Horizontal Coil Design

Compact horizontal 3 pass design 2,400,000 BTU/hr to 12,000,000 BTU/hr output Built and tested in accordance with ASME Code Section I or ASME Code Section VIII Div. I Operating temperatures to 650F Modulating gas, oil or dual fuel burners Open protocol burner Low profile design Customized controls available Shown here is a FT-0600-HC horizontal heater skid mounted with circulation pump and combination expansion/deaerator/thermal buffer tank, designed for barge cargo heating.

Specifications
Models
Heat Output Thermal Fluid Content Recommended Flow Rate

FT-HC
1000 BTU/HR 1000 KCAL/HR GAL LITERS GPM M3/HR GPH LPH FT3/HR M3/HR HP KW HP KW

0240
2,400 600 75 284 150 35

0400
4,000 1,000 115 435 300 69

0600
6,000 1,500 190 719 400 91

0800
8,000 2,000 264 998 600 137

1000
10,000 2,500 325 1,230 850 193

1200
12,000 3,000 508 1,921 1,000 227

Approximate Fuel Usage

Light Oil Natural Gas 23 88 3,200 91 39 148 5,340 152 58 220 8,000 227 77 292 10,700 304 96 364 13,340 378 115 436 16,000 454

Power
Typical Circulating Pump Motor Typical Burner Motor 15 11.2 2 1.5 25 18.7 5 3.7 30 22.5 7.5 5.6 50 37.3 10 7.5 60 45 15 11.2 75 56.3 15 11.2

Consult factory for model specific electrical requirements.

take a look

Inside
Dimensions
Models
Heater Inlet/Outlet Connections (A) Overall Height (B) Heater Diameter (C) Overall Depth (D) Flue Outlet Diameter Approx. Dry Weight

FT-HC
IN MM IN MM IN MM IN MM IN MM LB KG

0240
2.5 65 64 1,626 62 1,575 134 3,404 12 305 5,000 2,272

0400
3 80 68 1,727 62 1,575 136 3,455 14 356 7,500 3,409

0600
4 100 78 1,981 80 2,032 157 3,988 18 457 9,500 5,455

0800
4 100 98 2,489 92 2,337 157 3,988 20 508 12,500 5,682

1000
6 150 107 2,718 107 2,718 153 3,886 20 508 19,250 8,750

1200
6 150 125 3,175 124 3,150 170 4,318 22 559 21,700 9,864

Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions without notice. Operating specifications may change based on field conditions.

Operating Principle
The burner fires down the center of the coil. The hot gases return between the coils to the front end plate, then flow to the back of the heater, exiting out the flue.

Thermal fluid inlet

A E

Burner and air inlet

C
C
Thermal fluid outlet

D
D
Electrical control panel

High density, high temperature insulation

thermal fluid system

Accessories
Unfired steam generators
Vertical design 10HP to 100HP Horizontal design 70HP to 350 HP (Custom sizes are available) Standard designs 15 psig to 150 psig (custom operating pressures are available) Built and stamped to ASME Code Section VIII Div. I Complete with modulating thermal fluid control valve May be skid mounted with blowdown separators, return tanks, deaerator tanks, feedwater pumps, chemical tanks and water softeners

Unfired hot water generators

Custom designs available Carbon steel or stainless steel Built and stamped to ASME Code Section VIII Div. I Complete with modulating thermal fluid control valve Instantaneous hot water generation, or can be used with a storage tank

some examples of

Customized Skid Systems

This system includes two FT-0600-C thermal fluid heaters skid mounted with three circulating pumps (one pump acts as a backup for either heater), and one FT-5000-L expansion tank. These heaters are used to provide process heat for the manufacture of asphalt roofing shingles.

Shown here is a skid mounted FT-0600-C with heating and cooling loops which was manufactured for the printing industry for staggered heating and cooling of ink compounds.

This skid system includes one FT-0240-C thermal fluid heater with a skid mounted circulation pump and FT-500-L expansion tank. The system also includes two specialty heat exchangers. One exchanger uses thermal fluid to heat water, while the other heat exchanger is used to heat ethylene glycol.

The skid system shown here included one FT-0240-C heater, a circulating pump, expansion tank and a temperature control unit (TCU). This system was designed to provide thermal fluid and hot water to several dryers for a wastewater application.

Fulton Thermal Corporation, Inc.

972 Centerville Road Pulaski, NY 13142 Call: (315) 298-5121 Fax: (315) 298-6390
FTC BRO 053107 Printed in USA

www.fulton.com

Fulton is a global manufacturer of steam, hot water & thermal fluid heat transfer systems.