A brief presentation on HOT and COLD THERMAL

INSULATION
If thermal Insulation if properly chosen and installed such that it is

non- complaining

maintenance free

patient work house

It looks after economy, safety and smoother process control. But insufficient or poor insulation can be
tremendous of loss of energy. So thermal Insulation is often defined as, A major tool in improving
energy availability.
Basic objective is to retard flow of heat:

From a hot surface to cold environment

From an warm environment to cold surface

Energy loss from hot surfaces:

Fig. 1: Example showing Heat Loss from Hot Surfaces

Economic reasons for Thermal Insulation in Industry Insulation:

Reduces fuel consumption, and hence overall operational cost so day to day economy
benefits.

Reduces capacity requirements for heating/cooling systems (boiler, refrigeration unit etc)

Savings in Capital costs

The basic criterion for thermal insulation is Economics. However, this is not the sole criterion.
Process Control reasons for thermal Insulation:

Reduces temp. drop of fluid in heated system

Reduces temperature gain of fluid in refrigerated system.

Reduces boil off rate in volatile liquid storage system

Assist in maintaining thermal balance in reaction system

In heated system, lowers temp. of exposed surfaces-protects workmen from burn hazard

Provides fire protection for plant, equipment & piping

Reduces capacity requirements for heating/cooling systems (boiler, refrigeration unit etc)

ECONOMIC THICKNESS (Fig. 2):

Fig. 2: Determination of Economic Thickness

Insulation, by virtue, shall resist transfer of heat by:

Radiation

Convection

Conduction

Types of Insulation:
1. Mass type insulation: Based on interposing a mass of material with a built in capacity to retard
heat flow
2. Reflective Insulation: Based on providing a series of reflective surface with the intervening
space s evacuated

3. Microporous Insulation:Based on a combination of Mass & Reflective technologies.

Physical properties OF THERMAL INSULATING MATERIALS:
Significant physical parameters of thermal insulating materials can be divided into,

Thermal Properties

Chemical Properties

Commercial Factors

Thermal Properties: Important thermal parameters of thermal insulation materials are

Temperature resistance

Thermal conductivity

Thermal diffusivity, and

Thermal shock resistance

Chemical Properties of Thermal Insulating Material: Important Chemical properties are:

Compatibility with the metal surface

Compatibility with environmental media

Deterioration arising out of the chemical action

Life of insulation material

Points to consider in selecting materials:

Alkalinity (pH) or acidity

Chemical Reactivity / passivity

Coefficient of Expansion / Contraction

Compressive Strength & Breaking Load

Abrasion Resistance

Combustibility

Most importantly, THERMAL CONDUCTIVITY

Thermal Conductivity Vs Density (Fig. 3):

Fig. 3: A curve showing relation between Thermal Conductivity and Density

Commonly used Hot Insulation Material:

Mineral Wool: e.g Rockloyd by Llyod Insulation

Ceramic Fibre: e,g Supercera range by Llyod Insulation

Calcium Silicate

Commonly used Cold Insulation Materials:

Expanded Polystyrene Foam (EPS)

Extruded Polystyrene Foam (XPS)

Polyurethane Foam (PUF)

Poly-isocyanurate Foam (PIR)

Foam glass

Phenolic Foam

Among the listed materials, Polyurethane and Polyisocyanurate have assumed the highest
importance because of the many superiorities they possess.
As is well known, these materials can be applied as Preformed shapes or installed in-situ-by Pouring
or by spray.
Insulation Finishes: The outer cover of insulation.

Weather barriers-claddings

Weather cum vapour retarder, Indoor coverings and finishes

These all have one basic function -to protect insulation from the external exposure media.
Insulation System Design:

Insulation system should perform to the expected level, undiminished over its life.

This needs full data on material behaviour under all conditions of exposure.

In particular, we need to know what would make a material lose its properties.

Thermal calculations need representative value of Thermal Conductivity for design

Standard materials like Rockwool and Calcium Silicate have well established Design k
values.

Limiting Service Temperature of use

In pipe applications, weight becomes critical. Abrasion is also a major problem with some
materials.

Related posts:
1. Supporting of Dual Insulated Piping System
2. Piping insulation: Important Considerations for Piping Engineer
3. Corrosion under insulation: A Presentation