A Ceramic and Building Materials Group in India | WRF-120 Biomass Hot Air Furnace Project

Project Overview

India possesses a relatively well-developed industrial base in the ceramics, building materials, and manufacturing sectors. In the production of ceramic tiles, sanitaryware, and other building materials, the drying of raw materials and green bodies, as well as related heat treatment processes, require a long-term, stable supply of industrial hot air. As the client’s production scale expanded, the existing hot air system gradually faced issues such as insufficient heating capacity, limited fuel adaptability, and high labor intensity. The customer sought to establish a thermal energy system capable of supporting continuous production, meeting industrial hot air demands above 200°C, and allowing for flexible fuel selection based on local fuel supply conditions. After a comprehensive evaluation of equipment performance, hot air temperature, fuel adaptability, automation configuration, and long-term operational reliability, the customer ultimately selected the WRF series industrial hot air furnace solution provided by Huanuo Boiler.

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Solution

To address the continuous hot air requirements of the client’s ceramic production line, Huanuo Boiler configured the project with one WRF-120 industrial hot air furnace. The unit has a rated heating capacity of 1.4 MW, and the hot air outlet temperature can be designed and adjusted within the range of 200–300°C according to process requirements. Taking into account the client’s local fuel supply and operating cost requirements, this project employs a hot air system configuration primarily fueled by biomass. The complete system primarily includes:

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Biomass fuel storage and conveying equipment

Combustion system

Clean, low-NOx emissions

Hot air generation unit

Blower and induced draft systems

Hot air distribution ductwork

Flue gas exhaust and dust removal system

Automatic control and safety protection system

Once the fuel enters the combustion system, it generates high-temperature flue gas, which transfers heat to the process air through a highly efficient heat exchange structure. The heated hot air is then delivered to the customer’s drying production line via the air supply system.

Core Project Advantages

Stable hot air at 200–300°C to meet industrial drying requirements

The WRF-120 hot air furnace provides customers with stable medium- to high-temperature industrial hot air. For applications such as ceramic body drying, building materials drying, chemical raw material processing, and other continuous production processes, a stable hot air temperature is essential for ensuring production continuity. Based on the customer’s production process, this project designs the system’s hot air temperature within the 200–300°C range. Through coordinated control of the combustion and air supply systems, it continuously supplies thermal energy to the production line.

Multi-Fuel Design for Enhanced Energy Adaptability

The WRF series hot air furnaces offer excellent fuel adaptability. Depending on the energy supply conditions of different projects, customers can choose from:Natural gas | Diesel | Coal | Biomass fuels. In India and other regions rich in biomass resources, customers can select wood chips, biomass pellets, or other solid fuels that meet the equipment’s requirements based on local conditions. This flexible fuel configuration allows industrial users to select solutions based on local energy prices and supply conditions.

Indirect Heat Exchange Structure, Suitable for Various Industrial Processes

For industrial production processes requiring relatively clean hot air, the hot air furnace can utilize an indirect heat exchange method. Flue gas generated by fuel combustion flows through the heat exchange system, transferring heat to the process air. The hot air is then separated from the combustion flue gas before being delivered to the production equipment. This structure is suitable for applications such as: 1.Ceramic body drying2.Building material drying3.Drying of chemical raw materials4.Drying of food raw materials 5.Drying of wood and engineered wood panels 6.Drying of agricultural products 7.Drying of rubber and related industrial materials

Automated Operation Reduces Manual Labor

The system can be equipped with a PLC-based automated control system to centrally manage fuel supply, combustion equipment, fans, and hot air temperature. Depending on the actual equipment configuration, the system can achieve:1.Automatic fuel feeding2. Hot air temperature monitoring3.Interlock control of fans4.Control of the combustion system5.Over-temperature alarms6.Abnormal air pressure alarms7.Equipment failure alarms 8.Multi-level safety interlock protection.The automated control system reduces the need for frequent manual adjustment of equipment parameters and improves the efficiency of daily operation and management.

Modular Design Reduces On-Site Infrastructure Requirements

The WRF series hot air furnaces feature a highly integrated equipment design. The combustion system, heat exchange system, and hot air system can be optimally configured to fit the customer’s on-site space, reducing the need for some of the supporting infrastructure typically required for traditional large boiler rooms. For new production lines or retrofit projects involving outdated hot air systems, customized designs can be developed based on the on-site layout.

Design life of ≥20 years, suitable for long-term industrial operation

Industrial hot air systems typically need to operate in tandem with production lines over extended periods, so the structural reliability of the equipment and ease of long-term maintenance are particularly important. The WRF series hot air furnaces are designed to meet the long-term operational requirements of industrial equipment, with a design life of over 20 years. The actual service life of the equipment depends on factors such as fuel quality, operating load, maintenance, operational management, and on-site environmental conditions.

Client Testimonial

“Our production process requires a long-term, stable supply of hot air, and we also need equipment that can adapt to varying local fuel conditions. Huanuo Boiler provided a comprehensive hot air system solution tailored to our production needs. The equipment aligns well with our production line requirements in terms of hot air temperature control, fuel configuration, and automated operation.”

Mike

Corporate Project Manager

“Huanuo’s SZS series steam boiler has performed very stably on our continuous paper production line. The steam pressure fluctuation is minimal, fully meeting the high-quality steam requirements of the drying cylinders. After more than a year of operation, it has maintained high thermal efficiency and a low failure rate—one of the most reliable pieces of equipment on our line.”

Budi Santoso.

Equipment Manager, a major paper group in Indonesia

“Pharmaceutical processes have extremely high requirements for steam cleanliness and temperature control. Huanuo’s electric steam boiler produces clean steam with no on-site emissions and provides precise temperature control. It helped us smoothly pass several international quality system audits. It is a boiler that truly understands the needs of the pharmaceutical industry.”

María González.

Production Director, a pharmaceutical company in Mexico

“Our hotels have very high requirements for the quietness and safety of hot water supply. Huanuo’s vacuum hot water boiler operates very quietly and maintains a stable water temperature—guests hardly notice the equipment is there. Since the upgrade, hot water complaints have dropped significantly, and management has become much easier.”

Ahmed Hassan.

Head of Engineering, a hotel group in Egypt

“The stenter machines in our dyeing and finishing process are very sensitive to thermal oil temperature stability. Huanuo’s thermal oil heater heats up quickly with minimal temperature fluctuation, and the finishing effect has improved noticeably. Fuel consumption is also considerably lower than that of the original equipment. Their after-sales service responds promptly, making the cooperation very smooth.”

Mehmet Yılmaz

Production Manager, a textile dyeing and finishing company in Türkiye

“Our washing workshop requires frequent steam on/off cycles and has limited space. Huanuo’s once-through steam boiler occupies a small footprint and produces steam within 2 to 4 minutes, fully keeping up with our pace. The steam is stable and operation is simple—very suitable for our high-intensity washing conditions.”

Rafiq Islam.

Operations Supervisor, a garment washing company in Bangladesh

“Food processing has strict requirements for both steam quality and emissions. Huanuo’s condensing steam boiler has high thermal efficiency and a low exhaust gas temperature, with NOx emissions far below local standards. It helped us easily pass environmental reviews, while natural gas costs have also dropped noticeably.”

Khalid Al-Farsi

Plant Manager, a food processing plant in Saudi Arabia

“We use local agricultural and forestry residues as boiler fuel. Huanuo’s biomass steam boiler has strong fuel adaptability and runs stably, which not only reduces fuel costs but also eases solid waste disposal pressure. Emission indicators meet local environmental requirements, and the overall benefits have exceeded expectations.”

Johan van der Merwe

Energy Manager, a beverage producer in South Africa

“Chemical plants have extremely high requirements for heat source continuity. The waste heat boiler customized by Huanuo fully recovers waste heat from process tail gas and produces steam stably, significantly reducing the cost of purchased steam. Since commissioning, the equipment has operated reliably and provided real help for our energy-saving and consumption-reduction efforts.”

Rajesh Kumar

Technical Director, a chemical company in India

“Our region has long winters and extremely low temperatures, so heating equipment must withstand severe conditions. Huanuo’s hot water boiler starts quickly and supplies heat stably even in low-temperature environments. Throughout the entire heating season, there were no unplanned shutdowns, and our residential heating guarantee capability has improved markedly.”

Dmitry Ivanov

Operations Manager, a district heating company in Russia

“Our exported fruits and vegetables have very high requirements for drying color and moisture content. Huanuo’s hot air furnace provides precise temperature control and clean hot air. After drying, the fruits and vegetables retain a natural color and stable quality, fully meeting export standards. Energy consumption is also lower than that of the original equipment, giving us more reliable capacity during peak season.”

Camila Rojas

Production Head, a fruit and vegetable processor in Chile