Engineering Report
In the energy-rich landscape of Saudi Arabia, where access to diverse fuels like natural gas, LPG, diesel, and heavy oil is abundant, industrial manufacturers face a unique challenge: leveraging local fuel advantages while ensuring efficient, safe, and compliant operations. For a leading Chinese state-owned enterprise (SOE) operating a gypsum powder drying furnace in the region, this challenge became urgent—their aging combustion system was limited to a single fuel type, suffered from poor process adaptability, and failed to meet modern safety and efficiency standards. That’s when Heatflam stepped in, delivering a tailor-made multi-fuel combustion solution that transformed their operations and set a new benchmark for industrial upgrades in the Middle East.
About Heatflam: Your Trusted Global Partner for Industrial Combustion
Founded in 2015, Shanghai Yan Controlled Industrial Technology Co., Ltd.—operating under the brand Heatflam—has established itself as a premier provider of safe, reliable, and clean industrial combustion solutions worldwide. Backed by four owned and strategic-partner factories, an R&D team with over 15 years of industry expertise, and certifications including CE, UL, ISO 9001, and ISO 14001, we specialize in customized burner systems, engineering consultancy, and end-to-end technical support. Our mission? To empower global manufacturers with cleaner energy use, higher efficiency (up to 30%+ fuel savings), and more stable production through cutting-edge thermal technology—and the Saudi gypsum drying project is a testament to this commitment.
The Challenge: Aging Equipment Meets Diverse Fuel Opportunities
The client’s existing gypsum drying furnace faced three critical pain points:
- Fuel Inflexibility: Limited to a single fuel source, the system was vulnerable to price volatility and supply disruptions, failing to capitalize on Saudi Arabia’s low-cost, diverse fuel reserves.
- Outdated Performance: After years of service, the system exhibited unstable combustion, uneven heating, and high energy consumption—resulting in inconsistent gypsum quality (moisture content fluctuations of ±5%) and rising operational costs.
- Safety Risks: Aging safety components and inadequate control systems posed risks of backfire, flameout, and even deflagration, failing to comply with local Saudi industrial safety regulations and international standards like ISO 834.
With a goal to enhance fuel adaptability, cut costs, and ensure long-term operational stability, the client turned to Heatflam for a comprehensive upgrade.
Heatflam’s Customized Solution: Multi-Fuel Technology + World-Class Safety Controls
Leveraging our core strengths in R&D innovation, global compliance expertise, and end-to-end service, we designed a fully integrated solution tailored to Saudi Arabia’s unique industrial environment:
1. High-Performance Multi-Fuel Burner (5 Fuel Compatibility)
Partnering with Honeywell—a Fortune 500 leader in industrial technology—we deployed a state-of-the-art burner integrated with technical insights from Honeywell’s legacy brands (Kromschröder, Hoerbiger, 天时 Tianshi, and Maxon). This burner was engineered to seamlessly switch between 5 fuel types:
- Gaseous fuels: Natural Gas (NG), Liquefied Petroleum Gas (LPG)
- Liquid fuels: Diesel, Kerosene, Heavy Oil
The design included a partitioned combustion chamber, independent fuel nozzles, and flame stabilizers to eliminate cross-fuel interference—ensuring stable combustion even during rapid fuel switches. For heavy oil (a cost-effective local fuel), we added a heat tracing and preprocessing system to prevent solidification in Saudi’s high-temperature (up to 45°C) yet arid climate.
2. Siemens Safety Control System: Triple-Layer Protection
To address safety concerns, we integrated a Siemens combustion control system—built on a century of German engineering excellence. This system created a “hardware protection + software interlock + full-process monitoring” safety framework:
- Pre-Ignition Checks: Automatic leak tests, flame detector calibration, and 3-minute furnace purging (per international safety standards) to eliminate explosive gas buildup.
- Real-Time Monitoring: UV flame detectors that cut fuel supply in 50ms if flame instability is detected, plus electronic proportional valves to maintain optimal air-fuel ratios for each fuel type (reducing CO emissions to ≤100ppm).
- Emergency Response: Automatic shutdown for over-temperature (≥600°C), over-pressure, or fuel supply interruptions, with a backup power system to prevent fuel leaks during blackouts.
3. End-to-End Project Execution
From design to commissioning, Heatflam provided turnkey support:
- Dual Technical Approval: Our schematics and prototypes passed rigorous reviews by the Chinese SOE and Saudi regulatory authorities, ensuring compliance with local IMO (for industrial marine) and NFPA 85 standards.
- Global Logistics: Streamlined shipping through major Middle Eastern ports (Jeddah, Dammam) to deliver equipment in 45 days—30% faster than industry averages.
- On-Site Deployment: A multilingual technical team (English, Arabic) traveled to Saudi Arabia for on-site installation and calibration, optimizing the system for local grid voltage (230V/50Hz) and fuel quality.
Transforming Results: Data-Driven Success
After 12 months of continuous operation, the upgraded system delivered measurable, game-changing outcomes—exceeding the client’s expectations:
| Metric | Before Upgrade | After Heatflam’s Solution | Improvement |
|---|---|---|---|
| Fuel Flexibility | 1 fuel type | 5 fuel types | 400% increase in fuel options |
| Energy Efficiency | 68% thermal efficiency | 92% thermal efficiency | 35% reduction in fuel consumption |
| Annual Fuel Cost Savings | N/A | $1.2M USD/year | Direct cost reduction via local fuel utilization |
| NOx Emissions | 85 mg/m³ | ≤30 mg/m³ | Compliant with EU 50mg/m³ & Saudi industrial norms |
| Equipment Uptime | 82% | 99.2% | 17.2% increase (8,000+ hours of trouble-free operation) |
| Gypsum Quality Consistency | ±5% moisture fluctuation | ±1% moisture fluctuation | 80% improvement in product uniformity |
| Maintenance Frequency | 12 times/year | 3 times/year | 75% reduction in downtime for repairs |
“The multi-fuel system has not only allowed us to switch between local low-cost fuels like heavy oil and natural gas seamlessly but also cut our energy bills by over $1 million annually,” said the client’s project manager. “The safety features and stable performance have given us complete peace of mind, even in Saudi’s harsh operating conditions.”
Why Heatflam Stands Out for Global Industrial Projects
This success in Saudi Arabia is rooted in Heatflam’s core strengths:
- Full-Spectrum Capability: From R&D to manufacturing and global delivery, we control every stage to ensure quality and efficiency.
- Global Compliance Expertise: Our products meet regional standards across the EU, US, Middle East, and Southeast Asia—eliminating compliance headaches for international clients.
- Innovation at Scale: Our R&D team’s focus on low-emission technology and multi-fuel adaptability has led to patents in combustion control systems, driving tangible savings for clients.
- 24/7 Global Support: Multilingual technical teams (English, Spanish, Arabic, German, French) are available around the clock to address maintenance or operational needs.
Ready to Transform Your Industrial Combustion Operations?
Whether you’re facing fuel flexibility challenges, aiming to reduce emissions, or upgrading aging equipment, Heatflam’s customized industrial combustion solutions are designed to deliver measurable results. With a track record of success in metallurgy, chemical processing, marine engineering, and waste treatment—across 20+ countries—we’re your trusted partner for global industrial excellence.
Contact Heatflam Today:
- WhatsApp: +86 18917086029
- Email: sun@heatflam.com
- Address: Room 301, No. 95 Jianhao Road, Shanghai, China
Let’s collaborate to turn your operational challenges into competitive advantages—just like we did for our Saudi Arabian gypsum drying project.