Boilers for rubber, plastics and polymers
For this industry TIPO Kotlogradnja designs and manufactures: thermal oil boilers; steam generators, rapid steam boilers.
Each boiler is designed and manufactured to the required capacity, process requirements, fuel type and operating conditions of the plant.
The role of heat in rubber, plastics and polymer processing
Vulcanisation is the curing of elastomers by holding the compound at a set temperature, for a set time, under a set pressure; changing any one of the three changes the result. A stable heat supply is therefore a quality condition and not only an energy matter. Moulds and presses are heated by a fluid circulating through channels in the platens, while autoclaves use steam, which transfers heat better than air and, together with pressure, stops trapped bubbles from expanding.
In plastics processing, mould temperature influences warpage, sink marks, residual stress, melt flow and surface finish, so it must be held evenly across the whole mould. Extruder barrels are heated in zones, and indirect heating with hot oil is one common arrangement. The heat sources for such consumers are thermal oil boilers and steam generators. In multi-zone lines and co-extrusion, each zone and each material calls for independently controlled temperature.
Temperature uniformity, choice of fluid and safety
Evenness of temperature across the platen is the main argument for thermal oil on presses: technical sources describe oil systems as more uniform than electric or steam heating, with low pressure in the system. Steam, on the other hand, can suit rapid heating and cooling cycles, and where a boiler house already exists it may be cheaper to implement. For plastic moulds, water-type temperature controllers cover the lower range and oil-type controllers the higher range that engineering polymers require.
Thermal oil systems are designed and operated according to DIN 4754 or NFPA 87. Overheating splits the oil into light fractions, which lower the flash point, and heavy, tar-like fractions, which cause coking, so the working temperature must stay below the limit given by the oil manufacturer. Oil that leaks into fibrous insulation can self-ignite, which is why insulation and leak detection deserve attention. Pressure equipment is subject to PED 2014/68/EU; see certifications.
Fuel, energy and sustainability
One heat source can supply many consumers: a central boiler heats the fluid, which is distributed to several presses or lines, and each platen is regulated through its own three-way valve or secondary loop. Heating can be by gas or liquid fuel or by electricity; electric heating warms up faster and needs less maintenance, while oil gives a more even field on large platens. TIPO Kotlogradnja builds thermal oil boilers for liquid and gaseous fuels, for solid fuels and biomass, or for electric power.
Decarbonisation of industrial heat is usually considered through electrification and biomass. Electrification is often described as the simplest route, with limits in cost and infrastructure. Biomass is used mostly at lower temperature levels and calls for secure supply, storage space and control of fuel quality. The decision depends on local energy prices and availability rather than on any single technology; see biomass boilers. Long-term fuel supply arrangements are repeatedly cited as important for investment certainty.
What to define when selecting a boiler
Choosing the heat source for a rubber or plastics plant starts from the consumers, not from the boiler. Before an offer is prepared, the points below should be settled, because they determine the boiler type, its design and the scope of auxiliary equipment, including water treatment where steam is used. The approach is described in our guide on how to choose an industrial boiler. These answers are best recorded in a technical specification, since every later decision on design, standards and scope of supply rests on them.
- Number and type of consumers (presses, moulds, extruders, autoclaves) and their layout in the plant
- Required temperature level and permitted deviation across the surface, which points to steam, hot water or thermal oil
- Operating mode: continuous, or with frequent heating and cooling cycles
- Fuel or energy source, and the option of switching to another in future
- Standby capacity, applicable standards, area classification and space in the boiler house
Boiler types for this industry
Thermal oil boilers
Thermal oil boilers serve process heating in industrial plants that need high and stable operating temperatures.
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Steam generators, rapid steam boilers
FAST-P is a steam generator for rapid production of dry saturated steam, with forced water circulation and a three-pass design, built for liquid and gaseous fuels.
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Thermal oil boilers
- Plastics and rubber
- heating of moulds, presses and production lines
Steam generators, rapid steam boilers
- Plastics and rubber
- process heating
Frequently asked questions
When should I choose a thermal oil boiler instead of steam?
When the process needs high, precisely controlled temperatures without high-pressure operation: thermal oil carries heat at high temperature and low pressure, with no evaporation or water treatment.
Which heat transfer fluid to choose: water or thermal oil?
The choice depends on the required operating temperature and the process requirements. Water is the right choice for heating systems and processes at lower temperatures. Thermal oil is chosen when the process needs higher, stable temperatures, precise control and heat transfer without the high pressures typical of water systems at a comparable temperature level. The final solution is defined by the required capacity, operating temperature, pressure and plant operating conditions.
Which fuels does a thermal oil boiler use?
Liquid and gaseous fuels (model TKT-TU), solid fuels and biomass, or electricity (model VAT-V-TU) where no flue gases or burners are wanted.
How is a thermal oil boiler maintained?
By regular checks of thermal oil quality, cleaning of heating surfaces and inspection of fittings; TIPO Kotlogradnja offers preventive maintenance and overhaul of thermal oil systems.
For several presses, is a central thermal oil system better than electric heating of each platen?
It depends on the plant. A central oil system gives more even heating of large platens and allows a separate loop for each press, but costs more to install. Electric heating warms up faster and needs less maintenance. The decision depends on the number of presses, platen size, energy prices and whether a boiler house already exists.
What happens to thermal oil if it overheats?
Overheating splits the oil into light fractions, which lower the flash point, and heavy, tar-like fractions, which form coke deposits and impair heat transfer. Controls and protections must therefore keep the oil temperature below the limit given by the manufacturer, and the oil should be sent regularly for laboratory analysis.
Why do thermal oil systems call for particular attention to insulation and fire protection?
Oil that leaks into fibrous insulation can self-ignite as it oxidises, so closed-cell insulation is recommended for critical parts and soaked insulation is replaced. Water is not a suitable extinguishing agent; foam or inert gas is used. The specific solutions follow from the risk assessment and the regulations at the place of installation.
Standards we design and build to
TIPO Kotlogradnja designs and manufactures boilers and complete boiler plants according to the investor's requirements, fuel type, capacity and operating regime. The process covers requirement analysis, solution proposal, offer, design, material procurement, manufacturing, erection, testing and commissioning. Whatever the complexity of the project or the market, the equipment is designed and built to European and international standards, including EN 12952, EN 12953, EN 13445, EN 13480, ASME BPVC and AD 2000, in line with the project documentation and the investor's requirements.
Other industries
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