Heat-Loss Calculator › 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 |
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.