Insulation for 100–250 °C — saturated steam (4–40 bar), thermal oil, most process heat

The industrial heartland: most steam systems live here. Stone wool (lamella up to ~220 °C per Inzonex tiering, wired mat beyond) is the value play; aerogel where space is tight; needle-mat cores in every removable cover.

Valid materials

What survives 100–250 °C

Material (serves this class)	Max service	λ at 180 °C duty
Stone wool (mineral wool)	640 °C	0.046
Glass wool	450 °C	0.044
Ceramic fibre (RCF / AES blanket)	1200 °C	0.060
Aerogel blanket	650 °C	0.025
Calcium silicate	650 °C	0.062
Expanded perlite	650 °C	0.065
Cellular glass	430 °C	0.052
Microporous (fumed-silica) panels	1000 °C	0.022
E-glass needle mat	550 °C	0.045
Silica needle mat / fabric	1000 °C	0.055

Computed · DN100 at 180 °C, 50 mm

The numbers at this temperature

Material	λ W/m·K	Loss W/m	Surface	Saving €/m·yr	t CO2/m·yr
Stone wool (mineral wool)	0.046	69	30 °C	€247	0.9
Glass wool	0.044	66	30 °C	€248	0.9
Ceramic fibre (RCF / AES blanket)	0.060	88	33 °C	€237	0.9
Aerogel blanket	0.025	39	26 °C	€261	1.0
Calcium silicate	0.062	91	33 °C	€236	0.9
Expanded perlite	0.065	95	34 °C	€234	0.9
Cellular glass	0.052	77	31 °C	€243	0.9
Microporous (fumed-silica) panels	0.022	34	25 °C	€264	1.0
E-glass needle mat	0.045	67	30 °C	€247	0.9
Silica needle mat / fabric	0.055	81	32 °C	€241	0.9

DN100 pipe at 180 °C, 50 mm insulation, per metre of pipe; bare loss 575 W/m. λ at mean temperature; € and CO2 per metre·year at €0.05/kWh, 8000 h, 82% efficiency. Method: ASTM C680 simplified (h=10).

FAQ

Questions on this topic

What insulation is best for 100–250 °c?

Shortlist for saturated steam (4–40 bar), thermal oil, most process heat: Stone wool (mineral wool), Glass wool, E-glass needle mat, Aerogel blanket. The industrial heartland: most steam systems live here.

How much heat does a pipe at 180 °C lose?

A bare DN100 pipe at 180 °C loses ≈575 W per metre in still air (ASTM C680 simplified). 50 mm of stone wool (mineral wool) cuts that to ≈69 W/m — ≈€247 and 0.90 t CO2 saved per metre·year at €0.05/kWh.