| Summary: | The growing demands for oleochemical products are expected to reach approximately RM 157.59 billion by 2026 due to an increased drive from the food and beverages, chemicals, and pharmaceutical industries. However, this will lead to an increase in energy consumption and subsequent flue gas emission. Proper utilization of waste gas recovery systems is thus a major research area, focusing on reducing fuel consumption and emissions of greenhouse gases without affecting process performance. In this paper, a palm oil-based oleochemical plant is studied. The fuel consumption and emission of flue gas from a thermal oil boiler were measured and the feasibility of implementation of a waste heat recovery system and its environmental impact study. The results show that the implementation of such a system can reduce natural fuel gas consumption by 17.29% and approximately 149.29 t per annum of carbon dioxide gas (CO<sub>2</sub>). Moreover, the concentration of CO<sub>2</sub> released into highly-populated communities is estimated through a Gaussian Plume Model at different wind speed conditions. The preliminary results show that the CO<sub>2</sub> concentration at two locations—an apartment and a local school located within 1.5 km of the plant—is well below the concentration limit of 1.938 g/m<sup>3</sup> recommended by the Wisconsin Department of Health and Services.
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