Managing heat transfer fluid and system performance in industrial applications

Christopher Wright

doi:10.24294/tse11788

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Managing heat transfer fluid and system performance in industrial applications

Christopher Wright

Thermal Science and Engineering 2025, 8(4), 11788; https://doi.org/10.24294/tse11788

Submitted：06 Jun 2025

Accepted：29 Dec 2025

Published：04 Jan 2026

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Abstract

Heat transfer fluids (HTFs) are critical in numerous industrial processes (e.g., the chemical industry, oil and gas, and renewable energy), enabling efficient heat exchange and precise temperature control. HTF degradation, primarily due to thermal cracking and oxidation, negatively impacts system performance, reduces fluid lifespan, and increases operational costs associated with correcting resulting issues. Regular monitoring and testing of fluid properties can help mitigate these effects and provide insights into the health of both the fluid and the system. To date, there is no extensive literature published on this topic, and the current narrative review was designed to address this gap. This review outlines the typical operating temperature ranges for industrial heat transfer fluids (i.e., steam, organic, synthetic, and molten salts) and then focuses specifically on organic and synthetic fluids used in industrial applications. It also outlines the mechanisms of fluid degradation and the impact of fluid type and condition. Other topics covered include the importance of fluid sampling and analysis, the parameters used to assess the extent of thermal degradation, and the management strategies that can be considered to help sustain fluid and system health. Operating temperature, system design, and fluid health play a significant role in the extent of thermal degradation, and regular monitoring of fluid properties, such as viscosity, acidity, and flash point, is crucial in detecting changes in condition (both early and ongoing) and providing a basis for decisions and interventions needed to mitigate or even reverse these effects. This includes, for example, selecting the right HTF for the specific application and operating temperature. This article concludes that by understanding the mechanisms of thermal degradation and implementing appropriate management strategies, it is possible to sustain the lifespan of thermal fluids and systems, ensure safe operation, and help minimise operational expenditure.

Keywords

array and electrolytic

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