Applications Analysis: Insulated 6” Horizontal Pipe at 500°F
Proposition:
An industrial boiler manufacturer is currently looking to insulate a 6” diameter, 72” long horizontal pipe in one of its boiler units. The pipe and boiler system to which the pipe is connected both operate 24 hours/day, 365 days per year continuously, and gives the pipe a hot face temperature of 500°F. Currently, the pipe is wrapped with a 1” thickness of standard fiberglass pipe wrap.
Goals:
Due to increases in energy cost associated with the operation of the boiler unit, in addition to an increasing demand for process efficiencies and conformity to new safety standards for the personnel who operate the machinery, the company is looking to achieve the following goals by re-insulating the pipe:
Proposition:
An industrial boiler manufacturer is currently looking to insulate a 6” diameter, 72” long horizontal pipe in one of its boiler units. The pipe and boiler system to which the pipe is connected both operate 24 hours/day, 365 days per year continuously, and gives the pipe a hot face temperature of 500°F. Currently, the pipe is wrapped with a 1” thickness of standard fiberglass pipe wrap.
Goals:
Due to increases in energy cost associated with the operation of the boiler unit, in addition to an increasing demand for process efficiencies and conformity to new safety standards for the personnel who operate the machinery, the company is looking to achieve the following goals by re-insulating the pipe:
- Minimize the amount of heat lost through the walls of the pipe, thus ensuring greater equipment process efficiency.
- Minimize energy cost associated with keeping the pipe at its desired temperature.
- Achieve a cold face temperature of 150F (touchable temp) for the proximity personnel who operate the equipment.
Proposals:
In addition to the fiberglass pipe wrap currently being used, the company decides to consider two other materials and compare them to the stated goals. The first of the additional two materials being considered is a rigid Calcium Silicate material. The second is ThermoDyne’s DynaGuardä Flexible 16# material.
In addition to the fiberglass pipe wrap currently being used, the company decides to consider two other materials and compare them to the stated goals. The first of the additional two materials being considered is a rigid Calcium Silicate material. The second is ThermoDyne’s DynaGuardä Flexible 16# material.
Thermal Analysis & Comparison:
Results:
- 1” of DynaGuardä Flexible 16# material yields a cold face temperature of 32°F lower than either of the other two materials, making it substantially safer for the employees who operate the machinery.
- 1” of DynaGuardä Flexible 16# material yields a heat loss of 72.17 Btu/Sf/Hr less than the Calcium Silicate material, and 70.32 Btu/Sf/Hr less than the Fiberglass Pipe Wrap.
- Over the course of a production year and given the size of the pipe, the DynaGuardä Flexible 16# material saves approximately 5.9 million Btu more than the Calcium Silicate material, and 5.8 million Btu more than the Fiberglass Pipe Wrap.
Financial Analysis & Comparison:
Given the differences in heat loss (Btu/Sf/Hr) for the three materials, the following can be estimated for the amount of heat lost through the system in $/year for each:
Results:
Given the differences in heat loss (Btu/Sf/Hr) for the three materials, the following can be estimated for the amount of heat lost through the system in $/year for each:
Results:
- The DynaGuardä Flexible 16# material saves $113.42/year over the Calcium Silicate material, and $110.50/year over the Fiberglass Pipe Wrap.
Conclusion:
The DynaGuard Flexible 16# material is the best material to accomplish all the objectives that the company set forth as their primary goals. It utilizes the least amount of material for the greatest thermal management and financial gains, and performs at the given temperature levels almost twice as efficiently as the other materials proposed.
For more information about how ThermoDyne’s DynaGuard Flexible, Ladle Liner, Board or Panel materials may be of use in your particular application, please contact us at [email protected]
The DynaGuard Flexible 16# material is the best material to accomplish all the objectives that the company set forth as their primary goals. It utilizes the least amount of material for the greatest thermal management and financial gains, and performs at the given temperature levels almost twice as efficiently as the other materials proposed.
For more information about how ThermoDyne’s DynaGuard Flexible, Ladle Liner, Board or Panel materials may be of use in your particular application, please contact us at [email protected]