Topic : Insulation Material

Name : Sathis Kumar .S

Email : [email protected]

Selection of insulation material

Name : Sathis Kumar .S

Designation : Energy Engineer

Company Name : Dr.Ambedkar Institute of Productivity

National Productivity Council, Chennai.

Postal Address : P-248, MMDA Colony,

Arumbakkam, Chennai-600 106.

Fax No : 044-26254904

Email Id : [email protected]

User Id : sathis_svg
INTRODUCTION

Materials or combination of materials, which have air or gas-filled pockets or void spaces
that retard the transfer of heat with reasonable effectiveness, are thermal insulators.
Generally insulation plays a very important role in a chemical industry. While placing
insulation onto a pipe is fairly easy, resolving issues such as what type of insulation to
use and how much, is not so easy. Insulation is available in nearly any material
imaginable. The most important characteristics of any insulation material include a low
thermal conductivity, low tendency toward absorbing water, and of course the material
should be inexpensive.

Heat is transferred by radiation, conduction and convection. Radiation is the primary

mode and can occur even in a vacuum. The amount of heat transferred for a given area is
relative to the temperature differential and emissivity from the radiating to the absorbing
surface.

EMISSIVITY (k)

Emissivity is a measure of the ability of a material to radiate energy. It is expressed as a

ratio (decimal) of the radiating ability of a given material to that of a black body. A black
body emits radiation at the maximum possible rate at any given temperature, and has an
emissivity of 1.0. The emissivity values(k) for various materials can be obtained from
Heat Transfer Data Books.

TYPES OF INSULATION

The Insulation can be classified in to three groups according to the temperature ranges for
which they are used.

Low Temperature Insulations (up to 90oC)

This range covers insulating materials for refrigerators, cold and hot water systems,
storage tanks, etc. The commonly used materials are Cork, Wood, 85% magnesia,
Mineral Fibers, Polyurethane and expanded Polystyrene, etc

Medium Temperature Insulations (90 – 325oC)

Insulators in this range are used in low temperature, heating and steam raising equipment,
steam lines, flue ducts etc. The types of materials used in this temperatures range include
85% Magnesia, Asbestos, Calcium Silicate and Mineral Fibers etc.

High Temperature Insulations (325o C – above )

Typical uses of such materials are super heated steam system, oven dryer and furnaces
etc. The most extensively used materials in this range are Asbestos, Calcium Silicate,
Mineral Fibre, Mica and Vermiculite based insulation. Fireclay or Silica based insulation
and Ceramic Fibre etc.

The following table describes the characteristics of various insulating materials and how
they should be used.

TYPE OF INSULATION APPLICATION RECOMMENDATIONS

Polystyrene Suitable for low temperatures Advantages – Rigid and

An organic form made by (-167oC to 82 oC). Mainly used in lightweight
polymerizing styrene cool rooms, refrigeration piping Disadvantages – Combustible,
and concrete retaining structures has a low melting point, is UV
degradable, and susceptible to
attacks by solvents
Polyurethane Suitable for low temperatures (- Advantages – Closed cell
Made by reacting isocyanates and 178oC to 4oC). Mainly used in structure, low density and high
alcohols. Made in continuous cool rooms, refrigerated mechanical strength
slab or foamed in situ. transports, deep freezing cabinets, Disadvantages – Combustible,
refrigeration piping and floor and produces toxic vapours and has a
foundation insulation tendency to smoulder
Rockwool (mineral fibre) Suitable for temperatures up to Has a wide density range and is
Manufactured by melting basalt 820oC. Mainly used to insulate available in matts, blankets, loose
and coke in a cupola at about industrial ovens, heat exchangers, form or preformed for pipe
1500oC. Phenolic binders used. driers, boilers and high insulation. It is chemically inert,
temperature pipes non-corrosive and maintains
mechanical strength during
handling
Fibreglass Suitable for temperatures up to Will not settle or disintegrate
Formed by bonding long glass 540oC. Mainly used to insulate with ageing.
fibres with a thermo setting resin industrial ovens, heat exchangers, Fibreglass products are slightly
to form blankets and batts, semi- driers, boilers and pipework alkaline –PH9 (neutral is PH7).
rigid boards, high density rigid It should not promote or
boards and preformed pipe accelerate the corrosion of steel,
sections provide it is protected from
external contamination
Calcium Silicate Suitable for temperatures up to Has a minute air cell structure,
Made from anhydrous calcium 1050oC. Mainly used to insulate has a low thermal conductivity
silicate material reinforced with a furnace walls, fire boxes, back-up and will retain its size and shape
non-asbestos binder. Available in refractory, flue lining and boilers in its useable temperature range.
slab form of various sizes. It is lightweight, but has good
structural strength so it can
withstand mechanical abrasion.
It will not burn or rot, is moisture
resistant and non-corrosive
Ceramic fibre Suitable for temperatures up to Suitable for many applications
Made from high purity alumina 1430oC. Mainly used to insulate because of the variety of forms.
and silica grains, melted in an furnace and kiln back-up These include cloth, felt, tape,
electric furnace and blasted by refractory, fire boxes, glass feeder coating cements and variform
high velocity gases into light bowls, furnace repair, induction castable (fire brick)
fluffy fibres. Made in a variety of coil insulation, high temperature
forms gaskets and wrapping material
SELECTION OF INSULATING MATERIALS

A few important factors, which should be considered while choosing proper insulating
materials are:
a. The operating temperature of the system
b. Type of fuel being fired
c. Resistance of the materials to heat, weather and adverse conditions
d. Thermal conductivity of the material
e. Thermal diffusivity of the material
f. Ability of the material to withstand the various conditions viz. thermal shock,
Vibration, Chemical attack etc.
g. Resistance of the material to retard the spread of flame
h. Permeability of the material
i. Total cost, including the cost of material, installing and thereafter its maintenance.

HEAT LOSS CALCULATION

Consider a pipe having R1, R2 as inside and outside radius over which an insulation is
provided, whose radius is R3. We need to find out the linear heat loss or heat loss per unit
length. For that we need to calculate the over all heat transfer coefficient (U) of the pipe
including the insulation.

Where,
U-the overall heat transfer coefficient
hi & ho are the convective heat transfer coefficient.

Generally, the heat transfer coefficient of ambient air is 40 W/m2 K. This coefficient can
of course increase with wind velocity if the pipe is outside. A good estimate for an
outdoor air coefficient in warm climates with wind speeds under 15 mph is around 50
W/m2 K.

The total heat loss per unit length(Q/L) can then be calculated by:

……(2)
Since heat loss through insulation is a conductive heat transfer, there are instances when
adding insulation actually increases heat loss. The thickness at which insulation begins to
decrease heat loss is described as the critical thickness. Since the critical thickness is
almost always a few millimeters, it is seldom (if ever) an issue for piping. Critical
thickness is a concern however in insulating wires. Figure shows the heat loss vs.
insulation thickness for a typical insulation. It's easy to see why wire insulation is kept to
a minimum as adding insulation would increase the heat transfer.

INSULATION THICKNESS

Your economics depends on the cost of insulation, which in turn depends upon the
thickness of insulation, that you are going to provide. So it is very important that you
determine the exact insulation thickness that is required.

Method-1

This formula can be used for flat surfaces:

Operating Temperature (deg C ) − Surface Temperature (deg C )

Thickness = * k
Heat Loss (kCal / h)
Note:

The important factor, which affects the thickness is the emissivity(k). So higher the ‘k’,
higher the insulation thickness required and hence higher the cost. By using the mean
value of the insulating material, we get lower ‘k’ value, and therefore a lower insulation
thickness.

To find the ‘k’ value, find the mean temperature:

Operating Temperature + Surface Temperature

2
Based on this mean temperature, ‘k’ values can be obtained from Heat Transfer
Handbooks.

Method-2

Readymade tables are available to calculate the Economic Thickness of Insulation.

Example of Economic Thickness Determination:

Using the table (Adapted from Perry’s Chemical Engineer’s Handbook) below, assuming
a 8.0 inch pipe at 3450C in an indoor setting with an energy cost of $3.792/million kJ,
what is the economic thickness?

Answer: Find the corresponding block to 203.2 mm (8.0 inch) pipe and $3.792/million
kJ energy costs, we see temperatures of 343.3 0C, 371.1 0C and 565.6 0C. Since our
temperature does not meet 565 0C or 371 0C, we use the thickness before it. In this case,
for 343.3 0C, 50.8 mm (2 inch) thickness of insulation is sufficient. At 371 0C, it can be
increased to 63.5 mm (2.5 inch) thickness of insulation.

Economic thickness charts from other sources will work in much the same way as this
example.
Conclusion

Insulation definitely saves money, but above that it very vital in safety point of view.
Pipes that are readily accessible by workers are subject to safety constraints. The
recommended safe "touch" temperature range is from 54 0C to 65 0C. Insulation
calculations should aim to keep the outside temperature of the insulation around 60 0C.