A Chemical Group in Indonesia | 15-Metric-Ton Low-Nitrogen Condensing Gas Boiler Energy-Saving Retrofit Project

Project Overview

As a leading manufacturer of industrial chemicals in Indonesia, the company’s products are widely used in the textile, dyeing, and water treatment industries across Southeast Asia. As the Indonesian government continues to tighten emission standards for industrial air pollutants and implement incentives for green industries, the company’s aging boilers could no longer meet both energy efficiency and environmental protection requirements, creating an urgent need to upgrade to a high-efficiency, clean, and extremely stable steam supply system.

After a comprehensive comparison of technical proposals, measured energy efficiency, and proven track records in the chemical industry from multiple international boiler brands, the company ultimately selected the SZS series integrated condensing gas-fired steam boiler solution provided by Huanuo Boilers.

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Solution

Given the characteristics of chemical production—which involves continuous operations, stable steam loads, and extremely high standards for quality and safety—Huanuo Boilers equipped the client with an SZS15-1.6-Q integrated condensing gas-fired steam boiler:

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High-Efficiency, Energy-Saving Boiler Structure

The boiler features a dual-drum, longitudinally arranged large-firebox design that optimizes the layout of radiation and convection heat transfer surfaces. Combined with a high-efficiency condensation recovery unit at the rear, it fully recovers waste heat from flue gases, achieving a comprehensive thermal efficiency exceeding 98%. Compared to traditional gas boilers, fuel consumption is reduced by more than 15%, resulting in significant energy savings.

Clean, Low-NOx Combustion

Equipped with a fully automatic low-NOx burner and flue gas recirculation technology, NOx emissions are well below the limits set by Indonesia’s current environmental regulations. This easily meets increasingly stringent emission inspections and helps enterprises achieve low-carbon manufacturing.

Stable and Reliable Steam Quality

Leveraging Huano Boilers’ extensive engineering experience in the chemical industry, the equipment consistently delivers high-quality steam with sufficient dryness and stable pressure, fully meeting the heat source requirements for core processes such as chemical reactions and distillation, thereby ensuring the intrinsic safety of continuous production from the source.

Intelligent Operation, Maintenance, and Safety Assurance

The boiler control system supports fully automated operation, adaptive load regulation, and multi-level safety interlock protection. Local Indonesian operators can master the system after a short training period, significantly reducing labor costs and operational workload.

Core Project Advantages

Steam energy consumption per unit of product has dropped significantly, resulting in an average annual natural gas cost savings of approximately 15% and a shorter-than-expected return on investment.

The boiler’s emission indicators passed local environmental inspections on the first attempt, earning the company a reputation for green production and enabling it to successfully enter the green supply chains of multiple international clients.

Steady steam pressure and consistent quality effectively prevent batch non-conformities caused by fluctuations in the heat source, thereby improving overall product yield.

Since the equipment was commissioned, there have been zero unplanned shutdowns, providing a solid guarantee for the long-term safe operation of chemical plants.

Client Testimonial

“Huanuo Boilers operate stably and reliably, fully meeting the specific requirements of our chemical production. Their after-sales service is prompt and attentive, making them a trusted partner. Since commissioning, energy consumption has been significantly reduced, emissions have easily met standards, and our competitiveness within the industry has been greatly enhanced.”

Hendra Setiawan.

Director of Engineering and Technology

“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