Tank & Vessel Insulation: Heat Loss & Savings
Hot tanks and vessels have large surface areas, so even at modest temperatures they lose a lot of heat — a bare 30 m² tank at 85 °C wastes tens of kilowatts around the clock. Removable insulation cuts that and keeps the wall touch-safe.
Heat loss vs insulated — by surface temperature
| Surface temp | Bare loss | Insulated | Outer surface | Reduction |
|---|---|---|---|---|
| 60 °C | 646 W/m² | 35 W/m² | 22 °C | 94.6% |
| 85 °C | 1,106 W/m² | 60 W/m² | 24 °C | 94.6% |
| 120 °C | 1,839 W/m² | 99 W/m² | 27 °C | 94.6% |
| 150 °C | 2,564 W/m² | 138 W/m² | 29 °C | 94.6% |
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 |
|---|---|---|---|---|
| A process/storage tank (30 m², 85 °C) | 31.4 kW | 295 MWh | 59.7 t | €17,134 |
| A heated vessel head (8 m², 120 °C) | 13.9 kW | 131 MWh | 26.5 t | €7,598 |
FAQ
How much heat does a bare tank lose?
At 20 °C ambient (ASTM C680): a process/storage tank (~30 m², 85 °C) loses about 31.4 kW; a heated vessel head (~8 m², 120 °C) about 13.9 kW. Insulating a process/storage tank saves ≈295 MWh and ≈59.7 t CO₂ per year (8,000 h).
Can you insulate storage tanks and similar?
Yes. Tanks need access for level gauges, manways and inspection. Removable insulation panels lift off where needed and refit cleanly. Inzonex covers storage tanks, process vessels, reactors, autoclaves and feed-water tanks. The outer surface drops to a touch-safe ≤45 °C and the part stays serviceable.
How much does tank & vessel insulation save?
Each item saves 96–98% of its bare loss. A process/storage tank at 85 °C saves ≈17,134 €/yr of energy (≈295 MWh, ≈59.7 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.