How to Reduce Energy Consumption in Edible Oil Refining Plants

A topic that quickly becomes important after the plant starts running

When investors first plan an edible oil refinery, most of the attention naturally goes to equipment selection and project cost.

But once the plant starts operating, another question appears very quickly:

“Why is our energy consumption higher than expected?”

In edible oil refining, energy is one of the largest operating costs. Steam, electricity, and cooling utilities are used throughout the process — from degumming all the way to deodorization.

From my experience working with refinery projects, reducing energy consumption usually doesn’t come from one single change. Instead, it comes from a series of improvements in process design, heat recovery, and operational control.

Let’s go through the areas that typically make the biggest difference.

1. Heat recovery is one of the most effective ways to save energy

If there is one area that has the biggest impact on refinery energy efficiency, it is heat recovery.

In many refining processes, large amounts of heat are generated and then simply released or wasted. Modern refinery design focuses on recovering this heat and reusing it elsewhere in the process.

For example, heat from the deodorization stage can often be used to preheat incoming oil streams. When this is done properly, the plant can significantly reduce steam consumption.

In well-designed systems, heat integration alone can improve overall energy efficiency in a very noticeable way.

2. Deodorization is usually the largest energy consumer

Among all refining stages, deodorization typically consumes the most energy. This stage requires:

🔸high temperatures

🔸deep vacuum conditions

🔸continuous steam usage

If the deodorization system is not properly optimized, steam consumption can quickly increase.

Careful design of heat exchangers, vacuum systems, and temperature control can greatly improve efficiency while maintaining oil quality.

In many refinery upgrades, deodorization is the first area engineers evaluate when looking for energy-saving opportunities.

3. Stable process control reduces unnecessary energy usage

Another factor that often surprises refinery operators is the impact of process stability.

When the refining process fluctuates — for example when temperatures or flows change frequently — the system often consumes more energy than necessary.

Automation and process monitoring can help maintain consistent operating conditions.

With stable control, the plant avoids repeated heating and cooling cycles, which can quietly increase energy usage over time.

4. Steam management plays a critical role

Steam is used throughout the refining process, particularly in:

🔸heating stages

🔸deodorization

🔸stripping operations

If steam pressure and distribution are not properly managed, significant energy losses can occur.

Common issues include:

🔸steam leakage

🔸inefficient condensate recovery

🔸poor insulation

Even small improvements in steam management can noticeably reduce total energy consumption.

5. Equipment design affects long-term energy performance

Energy efficiency is also strongly influenced by the original equipment design.
For example:

🔸efficient heat exchangers improve heat transfer

🔸optimized process layout reduces heat loss

🔸properly designed vacuum systems minimize energy demand

In many cases, energy performance is largely determined during the engineering stage, before the plant is even built.

This is one reason experienced engineering companies focus heavily on energy integration when designing refinery systems.

Companies with long experience in edible oil processing — such as Myande Group — often prioritize energy-efficient process design because it directly affects the long-term operating cost of the plant.

6. Operator awareness is more important than many people think

Even with well-designed equipment, daily operation still plays a major role.

Simple practices can make a difference, such as:

🔸monitoring steam consumption regularly

🔸maintaining stable operating temperatures

🔸checking insulation and heat losses

🔸ensuring proper condensate recovery

When operators understand how the refining system uses energy, they are better able to keep the plant running efficiently.

A practical perspective on refinery energy efficiency

When discussing energy efficiency with refinery operators, I often explain it this way:

Energy efficiency is not one improvement, it is the result of many small optimizations across the entire process.

When heat recovery, automation, process stability, and good operation all work together, the impact can be significant.

Reducing energy consumption is one of the most effective ways to improve the long-term profitability of an edible oil refinery.

Unlike many other improvements, energy efficiency delivers benefits every single day the plant operates.

From my experience, refineries that pay attention to energy optimization from the design stage — and continue improving during operation — often achieve the most stable and cost-effective performance over time.

Frequently Asked Questions (FAQs)

1. Which refining stage consumes the most energy?

Deodorization is usually the most energy-intensive stage because it requires high temperature and deep vacuum conditions.

2. Can heat recovery significantly reduce refinery energy consumption?

Yes. Proper heat integration can reduce steam demand and improve overall thermal efficiency in the refining process.

3. Does automation help improve energy efficiency?

Automation stabilizes the process and prevents unnecessary heating or cooling cycles, which can reduce energy usage.