Less heat into the hall
44.4 kW less heat released from the covered surface, based on your inputs.
Inzonex Modular Insulation · Brewhouse
Brewing kettle
BeforeBare metal
AfterInzonex insulation
Removable dome insulation
Energy cost saving / year£15,598£50.00/MWh fuel
Heat retained / year293.2 MWhAt your selected operating hours
Emissions avoided / year57.7 t CO₂e185.0 kg CO₂e/MWh fuel
Modelled outer surface25.0 °CBelow the 45 °C design target
Estimate: 1 kettle · 39 m² · 99 °C bare surface · 6,600 operating hours/year.
Inzonex benefits
Less heat loss.
Easy access for inspection.
Inzonex removable insulation covers exposed brewing-kettle surfaces while leaving the manway, instruments and stack connections accessible.
A cooler outer cover
25.0 °C calculated outer temperature with 50 mm insulation.
Open, inspect, refit
Remove the insulation section, inspect the equipment and refit it.
Access points stay usable
Separate sections around the manway, instruments and stack. Keep vents, safety devices and required clearances unobstructed.
Inzonex · Brewing kettle
Insulation savings estimate
For your operating conditions
Your savings
Enter the area to insulate, surface temperature and operating hours.
Surface heat loss: convection and radiation, with conduction through insulation. Annual totals use the inputs above; fuel equivalent assumes the heat supply reduces its input accordingly. Calculation method and assumptions.
Reference & method
What the numbers mean
Calculation inputs, formulas and limits.
Worked example
1 kettle · 39 m² · 99 °C · 6,600 h/yr- Bare heat loss
- 46.9 kW
- Insulated heat loss
- 2.5 kW
- Annual heat retained
- 293.2 MWh
- Outer surface
- 25.0 °C
50 mm mineral wool · air 20 °C at 0.5 m/s · emissivity 0.90 bare / 0.85 cover. Starting area: 39 m²; bare surface: 99 °C. Area and temperature are editable. The dome is a shared brewhouse design illustration; confirm your vessel dimensions before ordering.
Annual example: 6,600 operating hours; natural gas at £50/MWh, 94% heat-supply efficiency and 185 kg CO₂e/MWh fuel. Price and hours are editable starting values. The efficiency and fuel factor follow our Cochran calculator. Price and factor apply to the same fuel-energy basis; no second efficiency adjustment is applied to the money or CO₂ totals.
Does kettle insulation reduce evaporation losses?
This calculator covers heat lost through the vessel surface, not heat carried away with vapour. The 99 °C starting temperature is a surface-temperature assumption. Enter your measured metal temperature and leave the vapour outlet unobstructed.
How is heat loss calculated?
For each square metre, bare heat loss combines convection and radiation: q = h(Ts − Ta) + εσ[(Ts + 273.15)⁴ − (Ta + 273.15)⁴]. The convection coefficient is estimated as h = 5.7 + 3.8v W/m²K, where v is air speed in m/s.
The insulation calculation balances conduction through the layer against heat released from its outer surface. Conductivity is approximated as λ = 0.031 + 0.000188 × mean layer temperature, in W/mK. This conductivity curve is an assumption; check it against the selected insulation’s certified data.
Heat retained per year = (bare kW − insulated kW) × operating hours ÷ 1,000. The calculation uses a flat-area approximation and does not separately resolve thermal bridges, fixings, dome curvature, gaps or temperature changes during a batch. Validate coverage, temperatures and material properties for a project estimate.
Is retained heat the same as a gas saving?
No. Retained heat is energy no longer lost through the modelled surface. For a fuel-fired heat supply, the fuel equivalent divides that heat by the heat-supply efficiency. This assumes the heat supply controls reduce input accordingly.
A boiler nameplate efficiency alone may not include steam distribution losses. Use a consistent net or gross calorific basis for efficiency, tariff and emissions factor. The estimate does not include evaporation, flue-gas losses, batch throughput gains or measured changes in burner consumption.
Are these thermal images measured?
No. The thermal view uses coloured 3D images, not camera measurements. Changing the inputs updates the numbers, not the images. Use a site thermal survey to measure surface temperatures.
What should I check before ordering?
Confirm the area, surface finish, measured temperatures, operating hours and access requirements. Use your energy tariff and an installed quotation for payback. The calculation covers surface heat loss only; it excludes maintenance savings and changes in equipment life or room temperature.
The 45 °C outer-surface value is a design target, not a universal safe-touch guarantee. Actual contact conditions, joints and exposed parts need a site-specific check.
Compare insulation thicknesses
Engineering basis: Calculation methodology · Inzonex Modular Insulation