Pump Insulation: Heat Loss & Savings
Hot-service pumps (boiler feed, hot-oil, condensate) lose heat from their casings and are a burn risk where operators work. Removable pump jackets insulate the casing while leaving the seal, bearings and coupling accessible.
Heat loss vs insulated — by surface temperature
| Surface temp | Bare loss | Insulated | Outer surface | Reduction |
|---|---|---|---|---|
| 100 °C | 800 W/m² | 74 W/m² | 27 °C | 90.7% |
| 120 °C | 1,000 W/m² | 97 W/m² | 30 °C | 90.3% |
| 160 °C | 1,400 W/m² | 147 W/m² | 35 °C | 89.5% |
| 200 °C | 1,800 W/m² | 204 W/m² | 40 °C | 88.7% |
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 |
|---|---|---|---|---|
| A feed-water pump casing (2.5 m², 160 °C) | 3.1 kW | 29 MWh | 6.0 t | €1,710 |
| A hot-oil pump body (1.2 m², 200 °C) | 1.9 kW | 18 MWh | 3.6 t | €1,046 |
FAQ
How much heat does a bare pump lose?
At 20 °C ambient (ASTM C680): a feed-water pump casing (~2.5 m², 160 °C) loses about 3.1 kW; a hot-oil pump body (~1.2 m², 200 °C) about 1.9 kW. Insulating a feed-water pump casing saves ≈29 MWh and ≈6.0 t CO₂ per year (8,000 h).
Can you insulate boiler-feed and similar?
Yes. Pump seals and bearings need frequent access. Removable jackets cover only the casing and lift off for maintenance. Inzonex covers boiler-feed, hot-oil, condensate and process pumps. The outer surface drops to a touch-safe ≤45 °C and the part stays serviceable.
How much does pump insulation save?
Each item saves up to 96% of its bare loss. A feed-water pump casing at 160 °C saves ≈1,710 €/yr of energy (≈29 MWh, ≈6.0 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.