Thermal oil boiler in a combined configuration

Does your company have biogas, syngas, or liquid waste streams available, but not quite enough to cover your full heat demand? Or do you want to hold on to an existing gas-fired thermal oil boiler while you’re adding an electric or biogas-fired installation?

With a combined configuration, you bring together several heat sources within a single thermal oil system. This increases the flexibility of your energy supply, makes the most of the available energy streams, and keeps your heat production secure.

The specialists at the Callens Group design combined configurations that are perfectly tailored to your specific situation and future plans.

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When does a thermal oil boiler in a combined configuration make sense?

Companies with access to several energy sources — such as natural gas, electricity, biogas, syngas, liquid waste streams, or recovered heat — can make them work together intelligently in a combined configuration. This means that you will always be able to use the most suitable energy source, based on availability, cost, efficiency, or sustainability goals.

Reasons to choose a combined configuration:

You want to be less dependent on a single fuel.
You have easy access to several energy sources at your site.
You are looking for maximum operational reliability and redundancy.
You want to keep using existing installations.
You want to optimize energy costs.

Power	up to 60 MW
Capacity	100.000 kcal/h to 12.500.000 kcal/h
Process temperature	up to 300°C
Operating pressure	0,5 to 30 barg
Efficiency	95%

Technical specifications of thermal oil boilers in a combined configuration

The configuration of a combined set-up is entirely tailored to the available energy sources and the heat demand of your process.

It takes account of the required power, desired process temperatures, operating hours, and the interaction between the different heat sources.

To do so, our engineers develop an integrated solution with a customized control strategy and centralized management.

BENEFITS

Benefits of a thermal oil boiler in a combined configuration

By combining several technologies, businesses can respond more flexibly to changing market conditions, production needs, and sustainability goals.

Maximum flexibility

Each boiler is deployed whenever it makes the most technical and economic sense.

Higher operational reliability

Different installations can support or temporarily replace one another.

Less dependent on a single fuel

Companies are less at the mercy of price fluctuations or availability issues.

Step-by-step sustainability

New technologies can be added without fully replacing existing installations.

Lower energy costs

A combined configuration allows you to easily switch from one fuel to another, based on energy costs.

Optimal use of available energy

Available waste streams and alternative fuels are valorized to the fullest.

What is the difference between a combined configuration and a dual-fuel boiler?

These terms are often used interchangeably, but they refer to different concepts.

A thermal oil boiler in a combined configuration:

A combined configuration consists of two or more separate thermal oil boilers, which each use their own fuel and collectively cover the total energy demand. For example, a gas-fired thermal oil boiler can be combined with a biogas boiler, a hydrogen boiler, or an electric boiler. Each installation keeps its own function and characteristics.

A dual-fuel thermal oil boiler:

A dual-fuel boiler is a single thermal oil boiler with one burner that can automatically switch between two fuels, for example natural gas and biogas or natural gas and hydrogen.

Maintenance of your thermal oil boiler in a combined configuration and 24/7 service

The Callens Group’s maintenance and service team makes sure your installation keeps performing at its best long after commissioning. With an in-house team of more than 120 service and maintenance technicians, we schedule preventive maintenance in line with the legal and technical requirements of your installation.

You can also count on fast support whenever an unexpected breakdown occurs. Thanks to our 24/7 standby service, an extensive range of spare parts, and the expertise of our service technicians, interventions can be carried out quickly and effectively.

After all, even the best-maintained installation can malfunction or shut down unexpectedly. That is why the Callens Group offers a range of service packages, tailored to the response time and support you need. So even in unforeseen situations, you are assured of the right support and maximum operational reliability.

More information about our service packages

PARTNERSHIP

Why partner with the Callens Group?

60 years of experience in EPCS projects

Independent integrator focused on customer needs

Flexible customer and project approach

Short decision-making lines and a personal approach

Unique service and maintenance support

Always close to customers with 13 locations

“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your specific situation.”

FAQ

Questions? We have the answers.

Yes. In many cases, an existing thermal oil boiler is kept and complemented with an additional technology, such as an electric, biogas-fired, or hydrogen-fired installation. This allows you to make the most of your earlier investment and make your heating plant more sustainable. Want to know what expansion options there are for your current thermal oil boiler? The specialists at the Callens Group will happily look into that with you.

Absolutely. By combining several boilers of different capacities, heat production can be matched more precisely to actual demand. This prevents unnecessary energy consumption and increases the efficiency of your installation.

As an EPCS integrator, the Callens Group takes on the entire process: from on-site analysis and engineering to installation and service. That gives you a single point of contact throughout the full lifespan of your thermal oil boiler in a combined configuration. You can find out more about the different steps in our workflow here.

Because several boilers are available, heat production usually remains operational when one installation is temporarily out of service for maintenance or because of a breakdown. This significantly reduces the risk of production loss. Are you looking for more heat production redundancy? Our experts are happy to advise you on the possibilities.

Discuss your challenge or project with our experts

Would you like to explore which solution is suitable for your specific project?

Our engineers are happy to think along with you, from initial exploration to concrete engineering.

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