An Indonesian Oil and Fat Chemical Group | 4.2 Million kcal Biomass Thermal Oil Boiler Project

Project Overview

Indonesia is a major global producer and processor of palm oil, home to numerous local oil processing and value-added manufacturing enterprises. In the processes of palm oil refining, deodorization, fractionation, drying, and related oleochemical production, a large number of process units require a long-term, continuous, and stable medium-to-high-temperature heat source. The client for this project is a major Indonesian manufacturer of oil, fat, and chemical products that has long been engaged in the deep processing of palm oil and the production of related industrial goods. As the company’s production capacity continued to expand, its existing heating system gradually revealed issues such as insufficient heating capacity, high fuel costs, and a lack of flexibility in system adjustment. At the same time, the local palm oil industry chain provides a relatively abundant supply of palm kernel shells, wood-based fuels, and other agricultural biomass resources. The client sought to utilize local biomass fuel resources to construct a high-temperature thermal oil system capable of meeting continuous production demands, ensuring stable operation, and suitable for long-term industrial applications. After a comprehensive evaluation of boiler design, fuel adaptability, automation levels, and overseas project service capabilities, the client ultimately selected Huano Boiler to provide the biomass thermal oil boiler system solution.

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Solution

To address the characteristics of the client’s production line—including continuous operation, high thermal load requirements, and the need for stable process temperatures—Huanuo Boiler configured the following system for the project: a YGL-4200MA biomass thermal oil boiler system. The complete system primarily consists of:

Biomass thermal oil boiler unit·
Biomass combustion and fuel feeding system·
High-temperature thermal oil circulation system·
Expansion and oil storage units·
Flue gas and dust removal system·
Automated control system·
Safety monitoring and interlock protection devicesIn

Accordance with production process requirements, the thermal oil circulates in a closed-loop system within the system, with high-temperature thermal oil being delivered to various heat-consuming equipment via circulation pumps. After releasing heat, the thermal oil returns to the boiler for reheating, ensuring a continuous and stable supply of thermal energy.

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Core Project Advantages

High-temperature heat supply to meet continuous production needsUnlike traditional steam systems, thermal oil boilers utilize a circulating organic heat carrier to provide stable medium- to high-temperature thermal energy for industrial production. For production processes that require high temperature stability—such as oil refining, deodorization, heating, drying, and chemical reactions—the thermal oil system can adjust temperatures according to actual process requirements. This project is designed for a maximum oil supply temperature of 320°C, capable of meeting the client’s needs for simultaneous operation of multiple heat-consuming equipment.

Coil-Type Heat Exchanger Structure for Enhanced Heat Exchange Efficiency

The YGL series biomass thermal oil boilers feature a coil-type heat exchanger structure, with radiant and convective heat transfer surfaces optimally arranged to meet combustion and heat exchange requirements. High-temperature flue gas transfers heat within the furnace chamber and the tail flue, while the thermal oil circulates through the coils to ensure stable heat exchange. This optimized arrangement of heat transfer surfaces not only improves heat utilization but also meets the operational requirements of industrial users for long-term, continuous heat supply.

Forced Circulation for More Stable Heat Supply

This project employs a forced circulation system for the thermal oil. A high-temperature circulation pump continuously pumps the thermal oil, establishing a stable circulation loop between the boiler and the production equipment. Compared to intermittent heating methods, the continuous circulation system better accommodates the prolonged, continuous heat load demands of the oil and fat chemical production process. Even when there are multiple heat-consuming points on the production line, relatively stable heat distribution can be achieved through system design and temperature control.

Multi-Level Safety Monitoring and Automated Control

The thermal oil furnace system is equipped with monitoring devices for key parameters such as temperature, pressure, flow rate, and liquid level. The control system is configured with multi-level alarms and safety interlock protections based on actual project requirements, enabling real-time monitoring of the boiler’s operating status. Key functions include: thermal oil temperature monitoring, system pressure monitoring, circulation flow rate monitoring, liquid level monitoring, over-temperature alarm protection, combustion system interlock control, fan and fuel system interlocks, fault alarms, and automatic protection. The automated control system reduces the need for frequent manual intervention and enhances the operational convenience of the entire heating system.

Configuration of Flue Gas Treatment Systems Based on Fuel Characteristics

Since biomass fuels vary in ash content, moisture content, and combustion characteristics, Huanuo Boilers configures flue gas systems based on the actual fuel conditions of each project. This project is equipped with appropriate dust removal and flue gas treatment devices to meet industrial site operational requirements. For different countries and regions, Huanuo Boilers can also provide customized designs for dust removal, flue gas treatment, and emission systems in accordance with local environmental regulations and project emission requirements.

Customer Benefits

Meets the continuous heating demands of multiple production lines.The 4.2 MW biomass thermal oil system provides a stable, high-temperature heat source for the customer’s edible oil deep-processing production lines, meeting the demand for simultaneous operation of multiple process heat points.

Improves the utilization rate of local biomass resources

By using palm kernel shells and other suitable biomass fuels, the customer can establish a more flexible energy supply plan tailored to local fuel availability. The system can be adapted to actual fuel conditions to accommodate palm kernel shells, wood chips, wood shavings, biomass pellets, and other solid biomass fuels that meet combustion requirements. By optimally configuring the fuel feeding and combustion systems, the system helps the client maximize the value of local biomass resources and reduce reliance on a single fossil fuel source.

Reduced Manual Labor

Automated control and safety interlock systems minimize the need for frequent manual adjustments to boiler operating parameters. Operators can centrally monitor the boiler and major auxiliary equipment through the control system, improving the efficiency of daily operations and management.

Client Testimonial

“During the project’s construction, we focused on the equipment’s fuel adaptability, high-temperature heating stability, and ease of operation and maintenance. The biomass thermal oil system provided by Huanuo Boiler is highly compatible with our production process and can meet the thermal energy demands of continuous production. The project team also provided active cooperation in equipment installation, commissioning, and technical support.”

Amanda

Project Manager at an Indonesian Oil and Fat Chemical Company

“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

An Indonesian Oil and Fat Chemical Group | 4.2 Million kcal Biomass Thermal Oil Boiler Project

Project Overview

Solution

Core Project Advantages

Customer Benefits

Improves the utilization rate of local biomass resources

Reduced Manual Labor

Client Testimonial

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