Bare surfaces at 190 °C →
touch-safe 30 °C. Measured.

The bare spots cladding can't follow

Across the boiler room, 35 of 38 infrared frames showed exposed hot metal above 60 °C — the components rigid cladding and metal boxes leave open: valve bodies, flanges, the boiler door and burner connection.

Same surfaces, measured twice

Three locations from the same survey. Spot values are the camera's on-image markers (full radiometric correction); full-field values via raw2temp agree to ~1 °C.

Steam valves

−93% surface heat loss

Boiler door

−93% surface heat loss

Burner flange

−96% surface heat loss

Installed — and removable

Boiler door & burner flange

Angled view — shaped Inzonex panels, removable in seconds for inspection.

Boiler door & burner flange

Front view — the same door and flange, fully panelled.

Steam valves & piping

Valve bodies and pipe runs panelled; hand-wheels left clear.

Verifiable, not decorative

The numbers

Camera spot markers, FLIR S62 Pro (full radiometric correction), 13 Oct 2025. *Surface heat-loss reduction = 1 − (T_panel − T_amb)/(T_bare − T_amb), T_amb 25 °C. All panel surfaces touch-safe (≤45 °C).

Model validation — C680 vs measured

C680 gives the ideal continuous-panel surface; real panels read a few °C warmer at seams and at deliberately-exposed service points — all well within touch-safe. Per-component surface-temperature dataset & data descriptor (CC BY 4.0): doi.org/10.5281/zenodo.20832589.

Cooler plant room

Cutting 93–96% of surface loss removes most of the equipment heat load on the room air. For fixed ventilation, the room's excess temperature falls roughly in proportion — an estimate, pending paired room-air measurement.

Illustrative model (room load ∝ surface loss, ventilation constant). [Replace with measured room-air temperature, before vs after].

Larger boilers — same principle

The same modular-removable-panel approach applies unchanged to bigger boilers: the boiler doors, the valves on top of the shell and the hot saddle supports are each panelled and stay fully removable for service.

Boiler door

Boiler doors insulated with Inzonex modules — less than one minute to remove for inspection.

Valves

The valves on top of the boiler — panelled individually, removable; hand-wheels left clear.

Boiler supports

The hot boiler supports — the thermal-bridge points rigid cladding usually misses.

From CAD area to saved kilowatts

Each component is rebuilt in CAD from the field-surveyed boiler, and its true outer surface area is measured straight off the model. A +12% allowance is then added for bolts, nuts, weld seams and surface irregularities — these enlarge the real radiating and convecting area, so they enter the heat-loss calculation only (it is a thermal correction, nothing to do with the insulation itself).

2.08 m²→ 2.33 m² surface

Front door

Bare 96 °C → panel 30 °C. The largest single removable face; opens for inspection.

0.76 m²→ 0.85 m² surface

Boiler burner flange

Bare 146 °C → panel 30 °C. The hot flange around the burner connection.

0.40 m²→ 0.45 m² surface

Steam valves

Bare 190 °C → panel 36 °C. Valve bodies and short pipe runs panelled; hand-wheels left clear.

Individual calculation, ISO 12241 detailed tier: forced convection at air velocity v = 0.5 m/s (h_c ≈ 7.6 W/m²·K) plus explicit radiation (ε 0.90), ambient 25 °C — the site-realistic engine documented at /calc/methodology (distinct from the still-air h₀ = 10 quick tier). Energy on a fuel basis (boiler efficiency 0.85) at 7,700 h/yr, € at €0.06/kWh, CO₂ at 0.20 kg/kWh — the same basis as the ROI model. These three are the removable access components only and together save 49.5 MWh/yr (€2,970); the whole 6-ton boiler (12 element types, 28 pieces) totals 23.4 → 1.2 kW — 201 MWh/yr, €12,083/yr in the ROI calculator. Payback < 2 years typical (this boiler ≈ 4 months).

Interactive boiler visualizers

Two different Bosch steam boilers, each rebuilt in 3D from a field survey. Drag the before/after handle and set your own hours, fuel price and CO₂ factor — heat loss, savings and payback recompute live.

Single flame tube

Bosch UL-S — 6-ton steam boiler

Before/after on every element + live ROI. Bare 23.4 kW → 1.2 kW, payback ≈ 4 months on one boiler.

Open the UL-S visualizer →

Double flame tube

Bosch ZFR — double flame-tube boiler

Before/after + live ROI on the larger twin-furnace boiler (ZFR / ZFR-X, three-pass double-flame-tube class).

Open the ZFR visualizer →

Who did the work

Field survey, CAD reconstruction and modelling by the Inzonex engineering team. The 3D models behind the calculators are built by hand in CAD from real, field-surveyed equipment.