Disruptive innovation for high-spec heat exchangers

UAE

Rukaiya A. G., chief strategy officer of Dolphin Group, talks to The Energy Year about building the largest manufacturing facility in the UAE dedicated to heat exchangers and the transformational role of AI in industrial thermal engineering. Dolphin Group is an oilfield services provider and manufacturer of industrial heat transfer equipment.

How has Dolphin Group’s business been evolving in the past few years?
At Dolphin Group, true industry leadership comes from moving ahead of market needs. In 2024, we decided to expand our manufacturing capabilities, the natural progression of a legacy built over more than three decades of specialised industrial services. Having grown up around the industry, I have seen how attention to the smallest operational details can set great companies apart from good ones.
Dolphin was founded as a maintenance and refurbishment provider, servicing some of the region’s most critical heat transfer units. Over the decades, we acquired a deep understanding of the engineering improvements that could enhance thermal performance and maintenance efficiency. We saw how small design adjustments could vastly improve operational reliability. This insight now drives our manufacturing philosophy.
Today, we are constructing a landmark, large-scale manufacturing facility within KEZAD [Khalifa Economic Zones Abu Dhabi], spanning approximately 45,000 square metres. Scheduled for completion by end-2025, it will be the largest facility dedicated to manufacturing heat exchangers in the UAE, and potentially the Middle East.
Importantly, our growth is entirely self-financed – we have no external debt or shareholder pressure – and we have the freedom to prioritise quality, client success and long-term sustainability over short-term returns. It’s a deliberate path that reinforces Dolphin Group’s position as a trusted, resilient market leader.

How has the market for heat exchangers changed since you began manufacturing?
One significant shift is the consolidation of manufacturing assets. Many of the major heat exchanger production facilities globally are no longer independent; they are now owned or controlled by EPC companies seeking secure supply chains. While this model suits large projects, it often prioritises volume over quality and innovation, affecting product reliability and lifecycle support.
We are taking a different path. As an independent manufacturer with in-house process design technology, we can offer bespoke, full-scope solutions, not just production. We engineer units with operational longevity, maintenance and maximum thermal efficiency as standard features, not afterthoughts.
Looking ahead, localisation is a key priority. Today, many of the inputs we use – tubes, plates, forgings – are imported. This creates vulnerabilities, so we are planning to localise our critical supply chains. In particular, we are setting a bold target: establishing the first dedicated tube mill in the UAE – and likely the entire GCC – within the next three years.
This will allow us to serve our own manufacturing needs and supply critical components to the energy, petrochemical and industrial sectors. It is a strategic leap that reinforces our commitment to national industrialisation and to providing faster, more resilient solutions.

In what geographical areas do you see the most opportunities for growth?
We are intensifying our focus on Oman, Qatar, Bahrain and Kuwait, markets where demand for high-efficiency thermal equipment is growing. They value not just products, but end-to-end solutions – and that is where Dolphin stands out.
Saudi Arabia presents enormous potential, but our strategy there is measured. Replicating the quality, expertise and service standards that Dolphin is known for would require establishing a full-scale localised setup and significant human capital development. Until we can guarantee our standards, we prefer to enter as a supplier and not dilute our brand.
This disciplined approach ensures that wherever Dolphin operates, clients experience the same level of engineering excellence, responsiveness and collaboration that has made us the go-to provider in the UAE.

What are your plans for Dolphin Group in the next five years?
I can’t reveal too much at this stage, but one of our most exciting initiatives is an AI-powered pricing and design solution. Pricing in industrial manufacturing is complex and highly nuanced, and we are developing proprietary software to automate the process. With inputs about design and scope of work, our system will propose intelligent cost structures, ensuring accuracy, transparency and speed.
We are also exploring AI-enhanced design optimisation. Traditional thermal design, while effective, leaves significant energy-saving potential untapped. By integrating CFD [computational fluid dynamics] and FEA [finite element analysis] simulations into our design workflows, we can push the boundaries of efficiency and structural integrity. These simulations feed into AI algorithms that help us engineer next-generation heat exchangers with proprietary complex geoid geometries that are impossible to manufacture with conventional methods.
To realise these innovations, we are embracing additive manufacturing techniques to fabricate heat exchangers with intricate internal structures that optimise thermal transfer, reduce pressure drop and minimise material waste. This convergence of AI, CFD and FEA simulation, and additive manufacturing represents a true paradigm shift in the way thermal equipment is designed and built.
We are also utilising digital twins, IoT-based real-time monitoring and predictive maintenance analytics to ensure our units deliver maximum uptime, operational intelligence and lifecycle performance.
With the launch of our manufacturing facility and the establishment of a localised supply chain, Dolphin Group will emerge as the definitive regional hub for advanced heat transfer solutions, additive manufacturing technologies and proprietary equipment design.

Read our latest insights on:

• Bahrain
• Kuwait
• Oman
• Qatar
• Saudi Arabia
• UAE