Steam Header & Manifold Insulation: Heat Loss & Savings
Steam headers and manifolds carry the hottest steam in the plant and have large bare surfaces studded with branch flanges and valves. Insulating the header and its fittings with removable covers is one of the highest-value energy savings available.
Heat loss vs insulated — by surface temperature
| Surface temp | Bare loss | Insulated | Outer surface | Reduction |
|---|---|---|---|---|
| 200 °C | 4,012 W/m² | 210 W/m² | 34 °C | 94.8% |
| 300 °C | 8,075 W/m² | 204 W/m² | 34 °C | 97.5% |
| 400 °C | 14,273 W/m² | 321 W/m² | 41 °C | 97.8% |
| 430 °C | 16,665 W/m² | 360 W/m² | 44 °C | 97.8% |
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 steam header (3.0 m², 350 °C) | 31.8 kW | 299 MWh | 60.5 t | €17,360 |
| A distribution manifold (1.5 m², 300 °C) | 11.8 kW | 111 MWh | 22.4 t | €6,445 |
FAQ
How much heat does a bare steam header & manifold lose?
At 20 °C ambient (ASTM C680): a steam header (~3.0 m², 350 °C) loses about 31.8 kW; a distribution manifold (~1.5 m², 300 °C) about 11.8 kW. Insulating a steam header saves ≈299 MWh and ≈60.5 t CO₂ per year (8,000 h).
Can you insulate steam headers and similar?
Yes. Headers carry branch valves and instruments that need access. Removable covers insulate the body and each fitting while staying serviceable. Inzonex covers steam headers, distribution manifolds and branch connections. The outer surface drops to a touch-safe ≤45 °C and the part stays serviceable.
How much does steam header & manifold insulation save?
Each item saves 96–98% of its bare loss. A steam header at 350 °C saves ≈17,360 €/yr of energy (≈299 MWh, ≈60.5 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.