Enhancing Lubricant Production Efficiency with Customized Thermal Oil System Solution
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Enhancing Lubricant Production Efficiency with Customized Thermal Oil System Solution

By 20/04/2023August 24th, 2023No Comments

Thermal Engineering Specialist Malaysia

The lubricant industry is a dynamic and highly competitive field where companies are always striving to enhance their operations and achieve a competitive edge. Efficient and reliable thermal oil systems are crucial in ensuring the optimal production of high-quality lubricants. Our client specializes in the production of high-quality lubricants for various applications. With a strong emphasis on innovation and customer satisfaction, they are continuously seeking ways to improve their processes. To address some challenges in their thermal oil system, they turned to Dpstar for a solution. With over 30 years of experience in the field, Dpstar has the expertise and knowledge to design, build, and maintain customized thermal systems that meet the specific needs of clients in various industries.

In this blog post, we will highlight how Dpstar helped our client overcome their thermal oil system challenges and achieve greater efficiency, reliability, and cost savings. We will also provide insights into the key features and benefits of the solutions we provided, as well as how they align with our product and service offerings.

Challenges in Lubricant Production

The thermal oil system is a critical component of lubricant production processes. It is responsible for heating the various components of the lubricant to specific temperatures to ensure proper mixing and chemical reactions. This is important because the quality of the lubricant is directly related to the precise control of the temperatures during the production process. Without an efficient and reliable thermal oil system, the lubricant production process may suffer from inconsistencies in quality, production delays, and other issues. Here are some of the common issues that can arise:

Inaccurate Temperature
Any deviation from the required temperature can lead to inconsistent quality of lubricants.

Energy Inefficiencies
Inefficient use of energy can lead to higher operating costs and decreased profitability.

System Leaks
Leaks in the system can lead to fluid loss and equipment damage, resulting in costly repairs and production delays.

Inadequate Capacity
Inadequate system capacity can limit production output and efficiency.

Safety hazards
Improper handling of the thermal oil system can create safety hazards for workers and cause equipment damage.

Inaccurate Temperature
Any deviation from the required temperature can lead to inconsistent quality of lubricants.

Energy Inefficiencies
Inefficient use of energy can lead to higher operating costs and decreased profitability.

System Leaks
Leaks in the system can lead to fluid loss and equipment damage, resulting in costly repairs and production delays.

Inadequate Capacity
Inadequate system capacity can limit production output and efficiency.

Safety hazards
Improper handling of the thermal oil system can create safety hazards for workers and cause equipment damage.

How does a thermal oil system work?

The thermal oil system is a closed-loop system that uses a heat transfer fluid (also known as thermal oil) to transfer heat energy from a heat source to the point of use. The heat transfer fluid circulates through a network of pipes, transferring heat to equipment such as heat exchangers, reactors, and distillation columns. The system typically consists of a heater or boiler, which heats the thermal oil to a specific temperature, a circulation pump, which circulates the thermal oil through the pipes, and a heat exchanger, which transfers the heat energy from the thermal oil to the process fluid. The process fluid can be a variety of materials, such as lubricants, chemicals, or gases, depending on the specific application.

The thermal oil system works by maintaining a precise temperature range. The temperature is controlled by a temperature controller, which monitors the temperature of the thermal oil and adjusts the heating and cooling systems as necessary to maintain the desired temperature range. The system operates under a vacuum or low-pressure condition to prevent the thermal oil from degrading or oxidizing at high temperatures. The thermal oil is also periodically tested for degradation and contamination and can be replaced or treated to maintain system performance. Overall, the thermal oil system plays a critical role in maintaining optimal operating conditions and ensuring consistent quality in producing high-quality lubricants.

Success Stories

Customized Thermal Oil Heating System for Oil Treatment Companies, LubeWorld (LW)

Dpstar is a leading manufacturer and supplier of high-quality industrial heating solutions. With over 30 years of experience in the industry, we have built a reputation for delivering reliable, efficient, and cost-effective heating systems for a wide range of applications. Our valued client, LubeWorld (LW) is a company that specializes in producing high-quality lubricants for various applications. They are committed to providing top-quality lubricants and related products to their customers, ensuring optimal performance and longevity for their equipment. LW approached Dpstar for a solution to address the issues they were facing with their existing heating system, which was affecting their operations.

Customer Pain Point

  • The existing heater has a shorter lifespan.
  • Replacing the heater requires draining the entire system.
  • The heating time is longer.
  • The operation area is warm and uncomfortable for the operator.

At Dpstar, we understand that every project is unique and requires a customized solution. Our experience and expertise enable us to provide tailored solutions that meet the specific needs of our clients, no matter how complex the project may be. The purpose of this project is to design and allocate two sets of 1000-liter tanks with platforms that can fit within a 3×6.6m area. The objective is to improve the efficiency of the heating process, reducing heating time and increasing the overall production efficiency. This project also aims to address the pain points identified by the customer, including the need for heater replacement without draining the entire system, and creating a more comfortable working environment for operators in the operation area.

Dpstar successfully executed a thermal oil system project, which involved the design, installation, and testing of a new system to improve heating efficiency and productivity. The project was executed in several phases, starting with the demolition of the existing tank, heater, piping, and accessories. We then modified the platform gantry and ladder to accommodate the 2000-liter tank and built a barn to house the tank. We installed a pump system with a control valve, completed piping and insulation work for the tank, and conducted comprehensive tests to ensure the proper functioning of the new system.

The thermal oil system works by circulating hot oil through a piping system that is connected to the tank and heater. The oil is heated by the Dpstar bobbin heater, which is a hybrid design composed of MGO powder. The heater is CE-certified and has a high heat transfer efficiency, making it an excellent choice for this project. The control valve regulates the flow of hot oil, ensuring that the temperature is consistent and within the desired range. To improve efficiency and productivity, we added 30% more heater power, which significantly reduced heating time and improved electricity efficiency. Additionally, we top-mounted the heater vertically, eliminating the need for oil drainage during heater replacement. The barn and skid platform provided a comfortable and safe working environment for operators, and the insulation work prevented heat loss and improved system performance.

Thanks to the new system design and innovative products from Dpstar, our client experienced significant improvements in efficiency, productivity, and customer satisfaction. With our tailored solutions and expertise, we helped our client achieve their goals and improve their thermal oil system. At dpstar, we’re committed to providing our clients with innovative solutions that improve their operations and drive lasting partnerships. We’re proud to have been a part of this successful project, and we look forward to continuing to help our clients achieve their goals with our cutting-edge products and expertise.

Items supplied

  • Heater
  • Tank
  • Piping
  • Pump and accessories
  • Insulation work
  • Wiring work

Customer Benefits

Improved efficiency and productivity due to the reduced heating time and improved electricity efficiency of the new system design.

Improved control over their thermal oil system, allowing the customer to have more oversight and management of their operations.

Higher heat transfer efficiency with the hybrid design and MGO composition of the bobbin heater, resulting in cost savings for the customer.

Improved efficiency and productivity due to the reduced heating time and improved electricity efficiency of the new system design.

Improved control over their thermal oil system, allowing the customer to have more oversight and management of their operations.

Higher heat transfer efficiency with the hybrid design and MGO composition of the bobbin heater, resulting in cost savings for the customer.

Enhanced safety features and protocols in the new system design, minimizing the risk of accidents and ensuring a safe working environment.

Eliminated the need for oil drainage during heater replacement, saving time and resources.

Assurance of quality and safety of the system with the CE certification.

Enhanced safety features and protocols in the new system design, minimizing the risk of accidents and ensuring a safe working environment.

Eliminated the need for oil drainage during heater replacement, saving time and resources.

Assurance of quality and safety of the system with the CE certification.

Industries We Serve

Oil & Gas

Petrochemical

Semiconductor

Automotive

Pharmaceutical

Pulp & Paper

HVAC

Wastewater Treatment

Food & Beverage

Agriculture

Thermal System Design & Installation Experts

At Dpstar Group, we strive to be the leading provider of thermal engineering solutions in the region, and we are dedicated to staying at the forefront of technology and innovation in our field and continuously improving our services to better serve our clients. Whether you need a new system installed or an existing system upgraded, we have the expertise to get the job done right.  With our team of skilled engineers and technicians, we strive to deliver top-quality products and services that meet the unique needs of our customers. We are committed to excellence in all aspects of our work, from design and engineering to installation and maintenance. With a focus on innovation, safety, and efficiency, we aim to exceed our clients’ expectations and provide them with reliable and sustainable solutions for their thermal management needs. Contact us today to learn more about how we can help you improve your thermal oil system and optimize your operations.

Get In Touch With Our Experts Today!

Dpstar Group
No 35, Jalan OP ½, Pusat Perdagangan One Puchong,
Off Jalan Puchong, 47160 Puchong,
Selangor Darul Ehsan, Malaysia.
Email: [email protected]

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