Heat-Loss Calculator › Brewery › Reference › DN100 (4″) @ 200°C
Heat loss from a DN100 (4″) pipe at 200 °C
A bare DN100 (4″) pipe running at 200 °C in 20 °C still air loses about 646 W per metre. Wrap it in 50 mm of removable lamella mat and loss drops to about 102 W/m — a 84% cut — while the outer surface falls to about 35 °C (touch-safe). Figures use the ASTM C680 steady-state method.
These conditions are typical of medium-pressure saturated-steam distribution and thermal-fluid (hot-oil) headers. Heat loss climbs steeply with temperature in this band, so removable insulation pays back fastest on exactly these lines.
Per-metre heat loss
| Quantity | Bare | Insulated (50 mm) |
|---|---|---|
| Heat loss | 646 W/m | 102 W/m |
| Heat loss (imperial) | 672.4 BTU/hr·ft | 106.3 BTU/hr·ft |
| Reduction | — | 84% |
| Outer surface temp | ~200°C | 35°C |
| Conductivity k (at 110°C mean) | — | 0.062 W/m·K |
This chart shows the dramatic reduction in heat loss when insulation is applied. The orange bar represents the insulated condition with 50 mm of mineral wool.
How much insulation thickness?
The same DN100 (4″) line at 200 °C, with different removable-insulation thicknesses (lamella mat, k≈0.062 W/m·K). Heat loss and surface temperature both fall as thickness increases — with diminishing returns past 50–75 mm.
| Thickness | Heat loss | Reduction | Surface temp |
|---|---|---|---|
| 25 mm | 160 W/m | 75% | 51°C |
| 40 mm | 118 W/m | 82% | 39°C |
| 50 mm | 102 W/m | 84% | 35°C |
| 75 mm | 79 W/m | 88% | 30°C |
| 100 mm | 67 W/m | 90% | 27°C |
This is the band where insulation economics are strongest — the heat saved per metre is high and the payback shortest.
Example: a 50 m line with 4 valves
| Result | Value |
|---|---|
| Heat loss, bare | 33.9 kW |
| Heat saved by insulation | 28.5 kW |
| Fuel energy saved | 268.4 MWh/yr |
| Money saved | €18,787/yr |
| CO₂ avoided | 53.7 t/yr (≈ 11.7 cars off the road, 2,556 trees, 11.2 homes’ power, 124 barrels of oil, 219,807 km of driving or 54 transatlantic flights) |
| Payback (removable insulation) | 5.6 months |
Assumptions. 50 m pipe + 4 valves (each ≈0.6 m bare pipe), 8000 h/yr, 85% boiler efficiency, €0.07/kWh fuel, 0.20 kg CO₂/kWh, 50 mm insulation at €250/m². CO₂ equivalences use US EPA / DEFRA conversion factors. Change any of these in the live calculator. Estimates for guidance — confirm with a site survey.
Run your own numbers
Adjust size, temperature, thickness, hours and energy price live — or get an exact heat-loss study and fixed insulation price for your equipment list.
Open the calculator →Get an exact quoteWhy does insulating a DN100 (4″) line at 200 °C pay back so fast?
Because heat loss rises steeply with temperature: a bare DN100 (4″) line at 200 °C loses about 646 W/m, so the money saved per metre is high. Removable insulation on these lines typically pays back in well under two years.
Related heat-loss tables
DN100 @ 120°CDN100 @ 150°CDN100 @ 180°CDN100 @ 250°CDN100 @ 300°CDN100 @ 350°CDN25 @ 200°CDN40 @ 200°CDN50 @ 200°CDN65 @ 200°CDN80 @ 200°CDN125 @ 200°CDN150 @ 200°CDN200 @ 200°CAll tables →Cutting these losses in practice: removable Inzonex Modular Insulation for valves, flanges and steam lines.