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Total Cost of Ownership

Industrial Thermal Fluid Heaters

There are many factors that comprise the total cost of ownership for processes that utilize Thermal Fluid (Hot Oil) Heaters. While equipment purchase costs and system installation are initially focused on fuel cost is by far the greatest factor to consider over a 20 year operational period.

20 Year Total Cost of Ownership

Thermal Total Cost of Ownership

NOTE: Percentages may vary based on the application, system design and operating parameters.

Incorporating a high efficiency thermal fluid heater into the system design is a critical component for lowering of fuel costs. The rated efficiency of the thermal fluid heater along with it’s seasonal operating efficiency are important considerations to minimize operating fuel costs.

Industry-Leading Efficiencies

Fulton's C-Model Heaters (FT-C) provide energy saving features to maximize seasonal efficiency and achieve operating efficiencies greater than 87% LHV and 80% HHV.

Cost Over Time Coil Model Heater Cutaway

Factors Ensuring High Seasonal Efficiency and Low Operating Costs:

  • Low Stack Temperatures - This is a direct measurement of the amount of heat transfer achieved in the heater.
  • Burner Operates at Low O2 - The lower the Excess Air the less total volume of hot gases are exhausted via the heater chimney.
  • Low Standby Loss - Low heat losses both in Run and in Standby modes are key to high efficiency. Low surface temperatures and a small physical footprint also help to minimize standby losses.
  • Electronic Combustion Controls - Maintains optimum fuel / air ratio ensures efficient combustion as seasonal load changes.
  • Fully Closing Air Damper - Prevents draft loss while heater is in idle mode.
  • High Turn-Down Burners - Allows heater to seasonally match process load and prevent heater cycling.
  • Variable Speed Drive Motors - Reduce Electrical Consumption

Key Questions to Ask About Your Heater Efficiency:

  • What are the fluid operating temperatures and flue gas temperatures?
  • Are linkageless controls used to control fuel air ratio?
  • Is there a fully closing damper on the combustion air?
  • Are variable speed motors being used?

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