Hydrogen-fired thermal oil boiler

Hydrogen is increasingly seen as a key building block of a climate-neutral industry. For companies that need high process temperatures, a hydrogen-fired thermal oil boiler can be an interesting route to reducing dependence on fossil fuels without the need to compromise on reliability or performance.

The Callens Group helps businesses with the technical evaluation of hydrogen applications and designs thermal oil systems that are ready for tomorrow’s energy challenges. To do so, our specialists take account of the available hydrogen infrastructure, heat demand, and the integration within the existing energy supply.

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When is a hydrogen-fired thermal oil boiler worthwhile?

A hydrogen-fired thermal oil boiler is especially worthwhile for companies that want to reach their high process temperatures in a sustainable way. Thermal oil allows you to reach temperatures of up to around 300 °C without high system pressure.

While hydrogen is not readily available everywhere yet, the technology is especially relevant where hydrogen is a by-product of or being used in the production procees, such as in energy-intensive sectors like the chemical and petrochemical industries, refining, and steel production. These sectors also have a high heat demand, and electrification is not always an obvious option there.

Reasons to consider a hydrogen-fired thermal oil boiler:

You need high process temperatures.
You want to reduce your use of fossil fuels.
You produce hydrogen as a by-product.
You have access to a hydrogen network, or you’re exploring a connection to one.
You’re looking for a solution for processes that are hard to electrify.

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 to30 barg
Efficiency	95%

Technical specifications of hydrogen-fired thermal oil boilers

Hydrogen differs in several ways from other fuels such as natural gas. Its combustion properties, energy density, storage methods, and safety requirements call for a specific approach when designing the installation.

That is why, at the Callens Group, we start every project with a thorough analysis of the fuel supply, consumption profile, heat demand, and the available infrastructure. The storage, distribution, and safety of hydrogen are an integral part of the design process too.

We take everything into account and fine-tune all the components so that they work seamlessly together and that you end up with a safe and reliable boiler installation.

BENEFITS

hydrogen-fired thermal oil boiler

Hydrogen offers businesses a way to make industrial process heat even more sustainable. Combined with thermal oil, it creates a solution that pairs high temperatures with less dependence on fossil fuels.

Lower CO₂ emissions

Burning hydrogen releases no CO2, so the climate impact of your heat production can drop significantly.

High process temperatures

Thermal oil makes temperatures up to around 300 °C possible without high system pressures.

Sustainable alternative to electrification

Hydrogen opens up possibilities for applications where full electrification is less feasible, technically or economically.

Fewer fossil fuels

Hydrogen can partly or fully replace natural gas or other fossil fuels to produce process heat.

combinable

Hydrogen combines perfectly with other technologies such as electric steam boilers, e-boilers, CHP units, and heat pumps.

Precise temperature control

Thermal oil ensures stable, controlled heat transfer, even for critical processes.

How do you prepare your heating plant for hydrogen?

For most companies, the switch to hydrogen happens step by step. And it’s not just the boiler that matters, but the entire fuel chain.

Depending on your situation, you can opt for hydrogen-ready burners, dual-fuel systems, or installations that run both on natural gas and hydrogen. This gives you maximum flexibility while your organization prepares for future developments in the energy market.

The Callens Group specialists map out the technical, operational, and safety aspects and advise you on the best approach to your situation.

Ashland Doel TO opwarmen drooglucht 2326 k W PRJ12553 14

Maintenance of your hydrogen-fired thermal oil boiler 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.

On top of that, you can count on fast support whenever an unexpected failure occurs. Thanks to our 24/7 on-call service, an extensive range of spare parts, and the expertise of our service technicians, interventions can be carried out quickly and precisely.

After all, even the best maintained installation can malfunction or unexpectedly come to a standstill. 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’re assured of the right support and maximum operational reliability.

More information about our service packages

PARTNERSHIP

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.

The working principle is similar: a burner heats thermal oil to produce process heat. The main difference lies in the fuel. On top of that, burning hydrogen releases no CO2. This means hydrogen can make a major contribution to more sustainable industrial heat production.

Our experts are happy to fill you in.

That will depend heavily on the availability and cost of hydrogen. For companies that have hydrogen on site as a by-product or that can access competitively priced hydrogen, the business case can already be attractive today. Future CO2 costs, sustainability targets, and regulations also play a role.

In many cases, an installation can be designed or adapted so that a future switch to hydrogen becomes possible. The technical feasibility will depend on the burner, the installation configuration, and the available infrastructure.

The Callens Group specialists will be happy to carry out an initial analysis.

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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