Not all boilers produce steam. Some produce hot water (for space heating, domestic hot water, or low-temperature processes). Others produce high-temperature thermal fluids (for processes that require high temperature at low pressure). The thermal boiler market covers these applications.

Hot Water Boilers

The [LSI keyword: thermal boiler market] includes hot water boilers (also called hot water generators or hydronic boilers). They heat water to below its boiling point (typically 80-90°C, but can be up to 200°C if pressurized). The hot water is circulated through a distribution system (pipes, pumps) to heat exchangers (radiators, fan coils, or process heat exchangers). Hot water systems are simpler and cheaper than steam systems (no steam traps, no flash steam, less water treatment). They are used for space heating in commercial and industrial buildings, for district heating (central plant supplying heat to multiple buildings), and for some process heating (e.g., preheating, washing). The thermal boiler market for hot water includes condensing boilers (high efficiency, as described in the commercial boiler article) and non-condensing boilers.

The thermal boiler market also includes "electric hot water boilers" using resistance heating elements (like a large kettle). Electric boilers are 99% efficient and have zero on-site emissions. They are used where natural gas is unavailable or where the customer wants to use renewable electricity. However, electricity is often more expensive than gas, so the operating cost is higher.

Thermal Fluid (Oil) Heaters

For processes requiring temperatures above 200°C but at low pressure (to avoid the expense and safety risk of high-pressure steam), the thermal boiler market offers thermal fluid (also called thermal oil) heaters. A thermal fluid (a synthetic oil or organic fluid) is heated in a closed loop and circulated through heat exchangers. The fluid can be heated to 300-400°C at near-atmospheric pressure. Thermal fluid systems are common in chemical plants (reactor heating), in plastics and rubber processing (calendering, extrusion), in asphalt and bitumen heating, and in some food processing (frying, drying). The thermal boiler market for thermal fluid heaters has grown as industries seek to avoid the regulatory burden (boiler inspections, certified operators) associated with high-pressure steam boilers. The disadvantage is that thermal fluid degrades over time (requiring replacement) and is flammable.

District Heating and Cogeneration

District heating is a system where a central thermal boiler plant supplies hot water (or steam) through a network of pipes to multiple buildings (residential, commercial, public). District heating is common in cold climates (Europe, Russia, North America, China). The thermal boiler market for district heating uses large, high-efficiency boilers (often condensing, often using biomass or waste heat). District heating can achieve economies of scale (larger boilers are more efficient) and can use waste heat from industry, power plants, or incinerators. In a cogeneration (combined heat and power - CHP) plant, a gas turbine or engine generates electricity, and the waste heat is recovered in a heat recovery boiler to produce hot water or steam for district heating. The thermal boiler market for CHP is growing, as it offers high overall efficiency (70-90%). The thermal boiler market also includes "heat pumps" (which are not boilers but can provide low-temperature heat for district heating or space heating). As the thermal boiler market evolves, the integration of renewable energy (solar thermal, biomass) and thermal storage will increase. A solar thermal array (solar collectors) can pre-heat water for a boiler, or a heat pump can upgrade waste heat to a usable temperature. The thermal boiler of the future is part of a low-carbon, flexible, and efficient thermal energy system.

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