Understanding what’s driving thermal oil system performance

In many systems, performance, reliability, efficiency and emissions are impacted by one critical factor: how the thermal oil is heated.

Thermal oil systems are a critical part of many industrial processes.

While the wider system may often remain unchanged for years, the method used to heat the oil plays a central role in determining how the system performs.

In many installations, oil is heated using combustion-based systems such as gas or oil-fired heaters. These systems feel familiar to many operators, and can operate reliably, but over time they can also introduce limitations that impact:

Temperature control and responsiveness
Maintenance and uptime
Energy efficiency
Emissions
System complexity

These challenges are often then managed as part of normal operation, rather than addressed at source.

Common thermal oil system challenges and how they can be resolved through electric heat

Performance and Control

Combustion-based systems

In combustion-based systems, heat transfer is indirect and subject to variability from burner performance, fuel quality, and system condition.

This can lead to:

Reduced temperature stability
Slower system response
Localised hot spots
Ongoing performance drift

Electric systems

Electrically driven heating provides a different approach, delivering heat directly and with a high degree of control.

This allows for:

More precise and stable temperature regulation
Consistent system behaviour over time
Improved visibility through integrated control systems

Reliability and Uptime

Combustion-based systems

Fuel-fired systems require supporting infrastructure, including:

Burners
Fuel supply systems
Combustion air systems
Flues and exhaust handling

Each element introduces additional maintenance requirements and potential failure points.

Electric systems

By contrast, electric heating systems:

Remove combustion-related components
Reduce system complexity
Require less routine maintenance

This results in a simpler system that is inherently more predictable and easier to support.

Combustion-based heating produces direct (Scope 1) emissions at the point of use. Reducing these emissions while maintaining process conditions can be challenging with traditional systems. Electrification removes on-site combustion entirely.

This enables:
- Elimination of direct emissions from the heating process
- Alignment with site and corporate decarbonisation targets
- A clear pathway to lower-carbon operation, depending on electricity source
Importantly, these benefits can be achieved without compromising thermal performance.

Efficiency and Cost

Combustion-based systems

Combustion systems typically experience energy losses through:

Flue gases
Incomplete heat transfer
System inefficiencies that increase over time

These losses are not always visible, but they impact overall system efficiency and operating cost.

Electric systems

Electric heating systems convert energy to heat more directly, reducing losses within the heating process.

Combined with improved control, this can:

Reduce wasted energy
Support more efficient operation over time
Provide better data for ongoing optimisation

Risk and Integration

Combustion-based systems

The perceived risk of changing a thermal oil heating system is often the main barrier to improvement.

Key concerns include:

Integration with existing infrastructure
Maintaining process conditions
Compliance and safety requirements

Electric systems

Electric heating systems can be designed to integrate within existing thermal oil circuits and site constraints.

With the correct engineering approach, conversion can be:

Controlled and predictable
Fully compliant with industry standards
Aligned with existing process requirements

A practical shift in approach

For many thermal oil systems, the opportunity is not to replace the entire system, but to change how the oil is heated.

Moving from fuel-fired to electric heating can:

Improve control
More stable system performance
Reduce complexity
Fewer components and maintenance requirements
Eliminate combustion emissions
Remove Scope 1 emissons
Retain existing assets
Keep the existing thermal oil circuit

Specialist expertise in electric process heating

Electrifying a thermal oil system requires a detailed understanding of both process heating and electrical integration. Chromalox specialises in electric process heating for industrial applications, with extensive experience supporting operations in Oil & Gas, Chemical, and other demanding environments where reliability, performance and compliance are critical.
We combine deep knowledge of thermal oil systems with proven electric heating technologies and engineering expertise across the full lifecycle - from specification through to operation. This ensures solutions are correctly designed, fully integrated, and aligned with your process requirements.

Continuous process operations

High temperature systems

Hazardous and regulated environments

Medium-voltage heating with DirectConnect

Chromalox DirectConnect™ medium-voltage technology enables efficient, high-capacity electric heating.

This approach:

- Removes the need for step-down transformers at the heater
- Simplifies system architecture
- Reduces electrical losses
- Supports higher power applications

DirectConnect is proven across a large installed base of medium-voltage heating systems in industrial environments.

Start with a system assessment

Understanding whether your system is suitable for electric heating is the first step.

An assessment of your system provides:

- Evaluation of your current heating method and performance
- Identification of control, efficiency and reliability limitations
- Assessment of electrification feasibility
- Indicative view of potential performance and emissions improvements

- Guidance on practical next steps

This enables you to make informed decisions based on engineering insight, not assumptions. Conversion can be implemented using proven electric heating technologies designed for industrial-scale applications.

Request an electric conversion assessment from an expert

Our specialists work with you to evaluate your current thermal oil heating system and understand whether electric heating is a viable and beneficial option for your system.

Specialist expertise in electric process heating
Extensive experience in medium-voltage heating systems
Proven solutions in complex industrial and hazardous environments

Complete the form to arrange a call with one of our engineers.