Pipe Insulation: Heat Loss & Savings
Hot pipework is the largest insulation opportunity on most plants: every metre of bare pipe loses heat around the clock, and the awkward parts — valves, flanges, bends — are usually left bare even where the straight runs are lagged. Removable pipe insulation closes exactly those gaps.
Heat loss vs insulated — by surface temperature
| Surface temp | Bare loss | Insulated | Outer surface | Reduction |
|---|---|---|---|---|
| 100 °C | 1,407 W/m² | 76 W/m² | 25 °C | 94.6% |
| 150 °C | 2,564 W/m² | 138 W/m² | 29 °C | 94.6% |
| 250 °C | 5,822 W/m² | 154 W/m² | 30 °C | 97.4% |
| 350 °C | 10,860 W/m² | 259 W/m² | 37 °C | 97.6% |
Per-m² flat-surface flux, ASTM C680 / ISO 12241, 50 mm Lamella (≤220 °C) or 100 mm Wired mat (>220 °C), 20 °C ambient. Multiply by the bare area.
Worked examples (per year, 8,000 h, natural gas)
| Item | Heat saved | Energy/yr | CO₂/yr | € saved/yr |
|---|---|---|---|---|
| 10 m of bare dn100 steam pipe (3.5 m², 180 °C) | 11.2 kW | 106 MWh | 21.4 t | €6,141 |
| A bare pipe section with fittings (1.5 m², 250 °C) | 8.5 kW | 80 MWh | 16.2 t | €4,641 |
FAQ
How much heat does a bare pipe lose?
At 20 °C ambient (ASTM C680): 10 m of bare DN100 steam pipe (~3.5 m², 180 °C) loses about 11.2 kW; a bare pipe section with fittings (~1.5 m², 250 °C) about 8.5 kW. Insulating 10 m of bare DN100 steam pipe saves ≈106 MWh and ≈21.4 t CO₂ per year (8,000 h).
Can you insulate steam and similar?
Yes. Pipe fittings, joints and instrument connections need regular access, so fixed lagging gets cut away and rarely refitted. Inzonex removable pipe insulation unzips at every fitting and refits in minutes. Inzonex covers steam, condensate, hot-water and thermal-oil pipework, pipe bends, valves and flanged joints. The outer surface drops to a touch-safe ≤45 °C and the part stays serviceable.
How much does pipe insulation save?
Each item saves 96–98% of its bare loss. 10 m of bare dn100 steam pipe at 180 °C saves ≈6,141 €/yr of energy (≈106 MWh, ≈21.4 t CO₂) at typical gas prices; payback is usually under two years.
What insulation thickness is used?
Up to 220 °C surface: 50 mm mineral-wool (Lamella); above 220 °C: 100 mm (Wired mat), because conductivity rises with temperature. Both keep the outer surface ≤45 °C.