🧭 Project Overview
A leading textile manufacturer in Ho Chi Minh City (9 production lines, annual output 12,000 tons) needed to modernize its dyeing & finishing thermal system. The factory replaced an aging steam system with a custom electric thermal oil boiler from Ruiyuan to improve energy efficiency, achieve tighter temperature control, and reduce downtime on continuous dyeing lines.
Primary goals: reduce energy cost, achieve ±1°C temperature stability, eliminate steam-related maintenance, and lower CO₂ emissions.
🏭 Client Profile
- Industry: Textile dyeing & finishing
- Location: Ho Chi Minh City, Vietnam
- Annual Production: ~12,000 tons textile fabric
- Existing System: Old steam boiler + heat exchangers (high maintenance, unstable temperature)
- Installed Solution: Ruiyuan electric thermal oil boiler (600 kW system with dual-loop control, flange heaters)
⚠️ Challenge (Why Change Was Needed)
- Frequent temperature swings (±4–6°C) caused dye inconsistencies and product rejects.
- High operating cost from steam generation (fuel + condensate treatment).
- Long maintenance downtime: about 8–12 hours/month for boiler and steam traps.
- Safety and regulatory pressure to reduce onsite combustion and emissions.
✅ Solution: Ruiyuan Electric Thermal Oil Boiler Retrofit
We designed and installed a custom 600 kW electric thermal oil boiler with the following key features:
- Electric heating elements (flange-mounted) for clean combustion-free operation.
- PLC/PID dual-loop control achieving ±1°C process stability at operating temperatures up to 320°C.
- High-efficiency ceramic insulation for ≥98% thermal efficiency.
- Forced circulation pump & automated valve manifold to integrate with existing heat distribution loops.
- Safety package: over-temperature cutoffs, automatic air purge, and pressure interlocks.
- Optional: remote monitoring & DCS integration.
Installation timeline: 6 weeks (site survey → custom fabrication → on-site install → commissioning & operator training).
📈 Results — Measurable Impact (Post-Installation, 12-Month Average)
Note: figures are conservative, validated by metered data from the client.
- Energy cost reduced → 28% average savings.
Replacing steam with electric hot-oil eliminated fuel losses, condensate handling, and improved heat transfer efficiency. - Temperature control improved → ±1°C (from ±4–6°C).
Reduced rework and improved shade consistency across dye lots. - Production uptime increased → +9–12% annual throughput.
Faster ramp-up and fewer stoppages for steam system maintenance. - Maintenance time reduced → 60% fewer boiler-related service hours.
Flange-mounted heaters and modular design simplified repairs. - Payback period → 18–30 months (project-specific, dependent on local energy prices & duty cycle).
🔧 Technical Summary (Installed System)
- Product: Electric Thermal Oil Boiler (custom Ruiyuan model)
- Power: 600 kW (modular elements)
- Operating Temp: up to 320 °C
- Thermal Efficiency: ≥98%
- Control: PLC/PID, ±1°C accuracy
- Heaters: Flange-mounted electric elements (easy-replace)
- Material: All-welded carbon steel body with ceramic fiber insulation
- Integration: Pump skid, valve manifold, remote monitoring support
💡 Why This Solution Delivered Results
- Electric heating + thermal oil gives high temperatures at low pressure — safer and more stable than steam.
- Direct control (PLC/PID) enables precise process temperature, critical for dye consistency.
- Energy efficiency (≥98%) means most input energy goes into product heating, not losses.
- Modular maintenance design reduces downtime and replacement cost.
🗣 Client Feedback (paraphrased)
“After installing Ruiyuan’s electric thermal oil boiler, our dye line quality improved immediately. Temperature stability has solved our shade variation problems — and monthly energy bills dropped significantly. Commissioning and operator training were fast and professional.” — Plant Manager, Textile Manufacturer (Vietnam)
📌 Key Takeaways for Purchasing Engineers
- If you need high-temperature stability, choose electric thermal oil boilers for safer, cleaner, and more energy-efficient performance vs steam.
- Prioritise PLC/PID control and ±1°C accuracy for processes like dyeing, extrusion, and drying.
- Ask suppliers about modular heater design (flange-mounted) for fast repairs and minimal downtime.
- Use measured payback calculations (energy price, duty cycles) to compare alternatives — electric systems often show 1.5–3 year ROI for 24/7 operations.
📞 Want a similar retrofit or custom design?
We’ll run a free site-assessment and ROI estimate for your plant: provide your heat duty (kW), operating temperature, and current system type.
Contact Technical Sales
📱 WhatsApp: +86-19106101572
📧 Email: sabbir@cnryan.com