Thermal oil plays an important role in industry, enabling efficient heat transfer and thermal stability in many technological processes. Thanks to its ability to reach high temperatures without increasing pressure, it is indispensable in industries ranging from chemicals to food. In this case study, we show how modern control systems can optimise the performance of thermal oil systems, ensuring safety and operational efficiency. Read on to discover what solutions we implemented for our heating business partner to modernise and improve the performance of thermal oil boilers. Check it out and find out how our technology can revolutionise your heating system!
Systems using thermal oil are commonly used in industry for heat transfer, especially in the construction of industrial boilers. This heating medium allows high temperatures to be reached and maintained while maintaining thermal stability, making thermal oil systems more efficient and safer to operate.
Thermal oil systems are used in a wide range of industries such as chemicals, petrochemicals, pharmaceuticals and plastics. They are used in components such as:
The main heat source in which thermal oil is heated to high temperatures.
Transfer heat from thermal oil to other fluids or processes, such as heating water, chemical solutions, etc.
Used in the chemical industry to maintain a constant temperature during chemical reactions.
Used in the food, textile, paper and metallurgical industries for drying and heat treatment of materials.
In the plastics and rubber industries, production lines use thermal oil for extrusion, moulding and lamination.
We were approached by a business partner representing a company in the heating industry that specialises in the design, manufacture and implementation of advanced heating systems for various industrial sectors. He was looking to upgrade his industrial control system used for thermal oil heating systems to meet growing market demands and improve operational efficiency and safety.
The system required an advanced control that could operate key components such as heaters, circulation pumps and various sensors. The client wanted the new system to be more flexible and efficient, to be able to accurately monitor and control temperature and other relevant parameters. It was also intended to improve safety , especially with regard to the risk of exceeding permissible heat carrier temperatures.
To meet these requirements, we proposed the implementation of a JUMO variTRON 500 automation system compliant with DIN EN 61131-3, which has functions and process visualisation in CODESYS. All key process values are visualised on the JUMO variTRON 10’ web panel, which enables easy monitoring and management of the entire heating process. The touch panel provides users with an intuitive interface for operating the system,
For the precise control of the temperature in the vicinity of the flow nozzle and in the flow at the outlet of the heater, we offered a temperature controller in accordance with DIN EN 14597, equipped with a reliable safety temperature limiter.
We also introduced advanced functional safety features. The system is equipped with an emergency stop function, circulation pump control and status messages that include burner fan, differential pressure and low oil level. In addition, it generates error messages for flow, flue gas, pipe monitoring and nitrogen levels, allowing a quick response to any abnormalities.
In addition, the PROFINET controller has been integrated with the SIRIUS 3SK safety relay, which ensures consistent and reliable communication in the safety system. This enables seamless data transfer between different devices and system components.
The entire process works as follows: the control system monitors key parameters such as temperature, pressure and flow using sensors connected to universal analogue and digital inputs. These values are processed by the PLC, which regulates the operation of the heaters, pumps and other system components based on PID algorithms. In emergency situations, such as exceeding the permissible temperature or pressure drop, the system automatically initiates emergency stop procedures and generates appropriate alarm messages.
Integration with a superordinate system via PROFINET ensures smooth operation of the entire system and enables remote management and monitoring of heating processes.
Upgrading and modernising the existing solution with JUMO compact controllers brought many benefits to our business partner. First of all, the new system offers a high degree of flexibility in programming and configuration, which allowed it to be adapted to the specific needs of each heating process. Network integration has enabled seamless communication between the various components of the system and with the overarching management system, increasing operational consistency and efficiency. Through the use of IoT technology, it is possible to remotely monitor and manage the system, which has greatly facilitated servicing and diagnosing problems. In addition, advanced data analysis functions allow for accurate tracking and optimisation of heating process parameters. This translates into energy savings and increased efficiency. All these aspects mean that upgrading the system with JUMO controllers brings real and tangible benefits to users in the daily operation of their heating systems.
My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.
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