Heat transfer is referred to as the transfer of thermal energy from one individual system to another directly or indirectly. Heat transfer employs the movement of thermal energy between two physical systems of different temperatures to achieve an equilibrium of temperatures among them. We observe this phenomenon naturally all around us. Industrial applications, however, are much more advanced, in which it is used to add or remove heat from one place to elongate its lifecycle or mitigate the dangers of high temperatures.

What are Heat Transfer Systems?

Heat transfer systems rely on thermal oils, water, or a mixture of glycol and water as a transfer fluid for the process, depending upon the temperature requirements. In order to achieve a controlled and stable liquid flow, they are heated with electric mechanisms.

Heat transfer mechanisms can carry out both cooling and heating solutions efficiently and optimize the results. The machines used in this process consist of electric heating modules paired with a limit of one heat exchanger module.

How does Heat Transfer in a system work?

The process of repeatedly introducing or subtracting heat on demand helps boost productivity and provide a wider range of attained temperature readings for consistency in the output. This is possible due to a very systematic and organized approach methodology of breaking the process into smaller components.

• The Pump is tasked with providing a uniform pressurized fluid flow throughout the process. Centrifugal or positive displacement pumps are the most reliable for carrying out the process.
• The Heater focuses on providing thermal energy to the transfer fluid so that the heat transfer from one system to another can take place. Electric heaters are on the way to be the most ideal choice for the same.
• The Cooler is employed to mitigate the excessive temperature and help keep the system stable for improved performance and results. The most commonly used coolers are shell and tube exchangers, and brazed plate exchangers.
• The Control Valve is installed to meter the fluid utility throughout the process and a Thermocouple to measure and report the temperature of the fluid and regulation of temperature across the machine is equipped.

Selecting the appropriate transfer fluid

Water-glycol mixtures, minerals, molten salts, or even synthetic oils are used as a heat transfer medium. When provided with appropriate heat causing them to rise to a desired temperature, these media help achieve efficiency and accuracy in the process.

• Salts mixtures are used for temperatures far above 500°C and molten salts are suitable for temperatures reaching up to 630°C owing to their low viscosity and being able to be circulated without pressure.
• Oil and derivatives are called in for temperatures ranging between -50°C and 410°C. Industries rely on oil because of its low corrosive properties, and high stability while also maintaining low pressure.
• Water and glycol mixtures provide accurate operations between -50°C and 175°C. These fluids provide freeze protection, corrosion resistance, and efficient results in both cooling and heating environments.

What are the features offered by Heat Transfer Systems?

Heat transfer systems are available in a varying shape and sizes designed to cater to customer demands while also providing state-of-the-art results. These systems come equipped with a plethora of features that include some industry standards, and some optional features depending upon the brands, size and shape, and operations.

The Industry Standard features included are

• Heating Elements: the heating elements used in heat transfer systems offer low watt density that is paired with alloy sheaths. This combination not only improves the lifecycle of the system but also minimizes hazards from hot temperatures. The alloy sheaths reduce the degradation of thermal fluids while also providing a layer of protection from corrosion ensuring a smooth and efficient performance.
• Buffer Tank: The purpose of this tank is to provide better fluid utility and prevent thermal shock by isolating the hottest fluid in the system from the expansion tank. It assists in maintaining the stability of pressure and temperature throughout the process, minimizing operational costs.
• Heating Chambers: The Heating Chambers are installed with self-ventilating equipment that automatically removes and curbs trapped air and gases in the system. They help in getting rid of the unwanted air gaps created, these gaps are responsible for uneven heating and damage.
• Sealed Pump: The Mechanically Sealed Pumps, owing to their excellent leak-mitigation and resistance properties have preceded traditional ones. They ensure exceptional performance while guaranteeing no contaminants and exposure throughout the process.

Some Optional Features that can be added to your equipment are

• Backup Pump: a secondary pump is installed parallel in play with the primary pump to make room for an immediate and hassle-free switch so that if a problem arises leading to a faulty pump the operations can be switched over to backup and no downtime is recorded.
• Blanketing: the fluid in the expansion tank can be equipped with a blanket made of inert gas like nitrogen in order to keep stray contaminants at bay and prevent oxidation. This helps in the longevity of the fluid and output.
• Crash-cooling: the system can be paired with another exchanger for emergencies requiring immediate cooling and limiting exothermic reactions that can be a safety hazard for the users.

What are the applications of Heat Transfer systems?

Heat transfer systems employing thermal fluids systems have diverse and multifold uses in industries where precision and accurate temperature control are of utmost value. Chemical, power, food, and beverage industries are one of the key sectors.

• Chemical Processing: Heat transfer systems that are used in this industry heavily rely on thermal fluids to provide consistent temperatures for different processes to ensure total control over reactions and results. Thermal fluids make room for higher-temperature operations.
• Food and Beverage Industry: The food processing industry focuses on indirect heat and thermal fluids are exemplary for all the processes involved, by providing a contactless heat transfer at uniform temperature helps foods cook evenly and thoroughly while also maintaining the utmost hygiene and safety standards.
• Plastic and Rubber: Thermal fluids play an important role in maintaining temperature for injection and die molding. This is key for reducing warping and deformations among the product line while also assuring faster operations and exceptional dimensional accuracy.
• Power: Solar panels also rely upon these thermal fluids to absorb and transport heat collected on the collectors. The heat is then converted into electricity. Thermal fluids’ exceptional varying temperature operation while maintaining limited energy loss makes it one of the most viable methods. 

Conclusion

Heat transfer systems are a piece of vital process-based equipment that enable customers to achieve a precise and accurate temperature range for their varied purposes. This also makes room. Employing thermal fluids in this system has also helped deliver consistent results and due to the performance-enhancing features, these systems deliver consistent results with minimal maintenance.  As technology advances, their role in supporting sustainable, high-performance processes will only continue to grow.

Many industries use Wattco products to achieve their environmental, economic, and production goals. Contact us to discover which products will best help your application and how we can customize it to meet your needs.