Thermal insulation is crucial in any process that handles high temperatures. Its purpose is to reduce heat transfer between surfaces, becoming one of the most effective solutions to achieve energy efficiency and reduce costs in industrial processes. 

In addition to its financial benefits, thermal insulation significantly impacts sustainability and environmental care. This article will focus on how thermal insulation solutions can affect energy efficiency and subsequent cost reduction.

What does ‘energy efficiency’ mean?

'Energy efficiency' can be defined as "the optimization of energy usage to carry out a process or activity." Consequently, efficient energy consumption offers financial savings, allows faster production times, and contributes to reducing environmental impact. 

Essential for sustainability and the fight against climate change, reducing energy consumption can lower costs and greenhouse gas emissions while minimizing the industrial carbon footprint.

Furthermore, it’s worth mentioning that heat losses can represent a large sum of the energy consumed during any industrial process. So, a proper thermal insulation system can aid in hitting these desirable outcomes.

Learn more about solving heat leaks with thermal insulation systems.

Other factors that help to achieve better energy efficiency

Although thermal insulation solutions can contribute to better energy efficiency, we must consider other factors that allow us to achieve this goal. Check out some of them below.

Control systems

When discussing Control Systems, we refer to Programmable Logic Controllers (PLC). These are electronic devices used in industrial automation to efficiently and accurately control and monitor processes.

They function as the brain of a system, receiving signals from sensors and actuators – hence, making decisions based on the programming defined by the user. 

A PLC can be regarded as the invisible director of an orchestra that supervises and directs energy flow in a factory or any place where automation is needed. As such, the PLC coordinates the movements of different instruments (sensors and actuators) to produce a harmonious melody of efficient and precise industrial processes. 

Therefore, the slightest disruption can cause failures, translating into increased energy consumption and losses for the company.

Combustion systems

Combustion systems, like furnaces, are critical in industrial processes requiring high temperature handling. These are responsible for converting the chemical energy of fuels into heat and thermal energy to carry out procedures such as metal casting or glass production.

The combustion system can be considered an artist who uses a mixture of air and fuel to create a work of heat and thermal energy. Efficient combustion systems use every power unit to maximize heat production and minimize unnecessary emissions. 

Note that both Control and Combustion systems influence the selection of insulating solutions. Learn more about the key factors influencing the insulation product choice here.

Good practices according to the technical attributes of the heat insulation materials

First, it is essential to use appropriate materials to withstand high temperatures and extreme conditions required during industrial processes. 

This includes incorporating construction and coating materials resistant to corrosion, abrasion, and high temperatures. Failing that, implementing high quality thermal insulation materials to minimize heat loss and improve energy efficiency is a must.

The maximum temperature allowed according to the technical data sheet of the thermal insulation product should never be exceeded.

Second, standardized protocols for different processes should be followed to ensure consistency and quality of the final product. This includes implementing safety and protection measures to prevent accidents alongside monitoring and control technologies to ensure process stability. 

Finally, other good practices entail regular equipment cleaning and maintenance, periodic testing, quality controls, and constant personnel training to ensure they know safety protocols and procedures.

Relevance of energy-saving protocols today

Although energy saving is a concept that has gained more relevance over time, it is necessary to mention some of the most common benefits it provides, such as:

Money savings

Energy is becoming an increasingly scarce and expensive resource. Therefore, implementing energy-saving measures can help reduce production costs for companies.

This point is attractive to everyone involved in the business ladder: for managers, it represents an improvement in profitability; for operators, it means better equipment lifetime.

Social responsibility

In recent years, there has been a growing emphasis on corporate social responsibility for businesses in the United States. One area where companies can make a significant impact is in promoting energy efficiency in industries that use high-temperature insulation. 

These industries could drastically reduce their energy consumption and carbon footprint with proper insulation practices. As responsible corporate citizens, companies must prioritize energy efficiency and explore ways to implement environmentally-friendly initiatives.

Doing so can demonstrate their commitment to sustainability and positively impact the environment and society.

Regulations and certifications

In any industrial process, compliance with ISO certifications and other official standards related to environmental management and energy savings is relevant. 

Many companies must comply with these standards to operate, and implementing energy-saving measures can be a critical factor in achieving certification and meeting their requirements. Here are some noteworthy ones to consider.

ISO 50001

The ISO 50001 standard is an international standard that establishes a framework for implementing energy management systems in organizations. Its main objective is to help companies improve their energy efficiency, reduce costs, and decrease environmental impact.

It is based on the continuous improvement cycle PDCA (Plan, Do, Check, Act). It is divided into several chapters, including the organization's context, leadership, energy planning, implementation, verification, and review. 

By implementing it, companies can measure their energy consumption, identify improvement opportunities, and take action to reduce their energy expenses and costs.

Technical standards that contribute to the efficiency of thermal insulation (ASTM)

ASTM International (formerly known as the American Society for Testing and Materials) establishes requirements and procedures for selecting, designing, installing, and maintaining thermal insulation systems used in industrial equipment and processes operating at high temperatures. 

Below are some of the most relevant ASTM standards related to thermal insulation.

• ASTM C411 - Standard Test Method for Hot-Surface Performance of High-Temperature Thermal Insulation. Describes a method for evaluating the ability of thermal insulation materials to withstand high temperatures on hot surfaces.
• ASTM C447 - Standard Practice for Estimating the Maximum Use Temperature of Thermal Insulations. Provides guidelines for estimating the maximum use temperature of thermal insulation materials.
• ASTM C518 - Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus. Describes a method for measuring the thermal conductivity of thermal insulation materials.
• ASTM C1055 - Standard Guide for Heated System Surface Conditions that Produce Contact Burn Injuries. Provides guidelines for preventing burn injuries in hot systems.
• ASTM C795 - Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel. Establishes requirements for the manufacture, inspection, and testing of preformed flexible fiberglass thermal insulation materials used for insulating pipes, vessels, and processing equipment at operating temperatures ranging from -450°F (-268°C) to 1500°F (816°C).

Through these standards, one can learn how the energy efficiency of thermal insulation solutions is measured. However, actions such as visual inspection of the installation or thermographic analysis must be considered.

Challenges in terms of thermal insulation

Industrial processes are becoming increasingly demanding and complex every day. Hence, achieving energy efficiency and cost reduction can constantly challenge the industrial sector. In this context, there may be some obstacles to thermal insulation for high temperatures processes, including

• Selection of the appropriate insulation material. Thermal insulation must withstand extremely high temperatures without degrading or losing its insulating properties.
• Appropriate insulation thickness. A suitable thickness ensures that the surface temperature of the equipment or pipe is within safe limits and that maximum energy efficiency is achieved.
• Maintenance and replacement of insulation. It is necessary to perform periodic inspections and maintain thermal insulation to ensure its performance and effectiveness.

Note that products are available to extend the lifetime of equipment insulation.

• Appropriate design of the insulation system. At this point, an engineering team with the necessary experience in the industrial sector is vital. The system's method must consider factors such as temperature, equipment type and geometry, environmental exposure, and safety and maintenance requirements.

Conclusion

Thermal insulation for high temperatures is essential to improve energy efficiency and reduce costs in various industrial applications. In addition to the financial benefits, thermal insulation has a positive environmental impact by reducing energy consumption and of natural resources.

To fully benefit from high temperature thermal insulation, it is essential to choose a suitable material, follow proper installation techniques, and work according to standards and regulations.

At NUTEC, you can find high temperature thermal insulation solutions backed by an engineering team.

Would you like to learn more about our high temperature thermal insulation products? Contact one of our advisors today.