How Do Electric Heating Thermal Oil Heater Manufacturers Know When to Replace Thermal Oil?

Electric heating thermal oil heaters https://8ruiyan.com/en/all-organic-heat-carrier-boilers/are vital in modern industry. Their core medium, thermal oil, directly impacts efficiency, safety, and lifespan. Under prolonged high temperatures, thermal oil degrades over time. Untreated degradation causes equipment failure, efficiency loss, or safety hazards.

Manufacturers must accurately determine replacement timing. This ensures safe, stable operations. Key factors include oil properties, degradation mechanisms, testing methods, and replacement criteria.

I. Thermal Oil Basics

Thermal oil transfers heat in industrial systems. It has high thermal stability and wide temperature tolerance.
Critical properties:

• Thermal stability (resists decomposition)
• Viscosity (affects flow/heat transfer)
• Flash point (safety indicator)
• Acid number (measures acidity)
• Impurity content

These properties degrade with use. Regular checks are essential.

II. Degradation Causes

Four main degradation processes:

1. Thermo-oxidation: Oil reacts with oxygen. Forms acids and sludge.
2. Thermal cracking: High heat breaks molecular chains. Creates carbon residue.
3. Moisture damage: Water accelerates oxidation.
4. Impurity buildup: Solids clog systems.

III. Replacement Indicators

Check these key values:

Indicator	Replacement Threshold
Acid number	>0.5-1.0 mgKOH/g above new oil
Viscosity change	>20% increase/decrease
Flash point drop	>10°C below new oil
Water content	>0.1%
Visual signs	Dark color, sludge, cloudiness

IV. Testing Methods

On-site tests:

• Acid number (titration)
• Viscosity (viscometer)
• Flash point (closed-cup)
• Water (Karl Fischer)

Lab analysis:

• FTIR spectroscopy
• Thermal stability tests
• Sediment measurement

Continuous monitoring: Real-time sensors.

V. Replacement Procedure

1. Prepare
   • Cool system
   • Get new oil
   • Clean internal parts
2. Drain & clean
   • Remove old oil completely
   • Flush pipelines
3. Refill
   • Add new oil slowly
   • Circulate to remove air
4. Verify
   • Check temperature/pressure
   • Test new oil quality

VI. Maintenance Tips

• Test oil every 3-6 months
• Never exceed temperature limits
• Seal systems against moisture
• Clean filters monthly
• Fix leaks immediately

Conclusion:

Monitor acid number, viscosity, flash point, water, and appearance. Replace oil if any indicator exceeds thresholds. Proper maintenance extends oil life by 30-50%. Regular testing prevents system failures.

For further consultation, please contact our technical team for expert advice.

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