Comparison of Thermal Fluid Heating
and Steam in Process Heating Applications
STEAM HEATING
Units above 100°C are classified as Pressure
Vessels
AS 2593 Compliance required
for unattended operation
AS 1228 Construction Required
Complex Controls System (AS 2593)
Annual inspections mandatory
Periodic INSPECTIONS MANDATORY
Unattended operation limited to 10 M.W
Output
Water Treatment Program Essential to
Minimise Corrosion In Vessel & Pipework
AS 3892 Compliant Boilerhouse
Required (Expensive)
Temperature Limitation Approx. 250°C
(AS 2593 Unattended Operation) limits design
options of process heat exchanger
Vessel and system volumes generally
larger, requiring system heat up times in
excess of 1 hour – with nil heat to process
System equipment must comply with relevant
pressure equipment standards and inspection
processes, adding to cost impact
System temperature control good
due
Maintenance requirements and therefore cost
generally more expensive due to the need for
condensate system etc.
System thermal losses are significant
including blow down losses, flash steam
losses from condensate systems, thermal
losses associated with deaerator systems and
feed water heating systems
THERMAL FLUID HEATING
Not Classified as a Pressure Vessel
9 Not Required
Manufactured to AS 1228, but not mandatory
Simplistic Control System (AS 3814)
9 Not Required
9 Not Required
9 Not Limited
Thermal Fluid (Oil) used as transfer medium
internal corrosion problems eliminated
Simple Weatherproof Housing required can be
externally located as an option
Temperatures above 250°C
Can be utilised to enable higher ∆ °T
options to be offered
Vessel and system volumes small by
comparison. system heat up of approximately
20 minutes likely reducing energy costs
9 Not Required
Generally Petrochemical Classified valving
and ancillary equipment utilised which reduces
cost impact while maintaining high level of
safety and integrity
System temperature control better
due to smaller system temperature differential
Maintenance requirements and
frequency required is less than
for steam systems
System thermal losses dramatically reduced
9 NIL BLOWDOWN
9 NIL CONDENSATE LOSSES
9 NIL PRE HEATING LOSSES