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Losses
Introduction
• Energy Loss from the Insulation
• Method Used - Simplified Calculation of Heat Loss [ for surface Temp below 200 0C ] as per
BEE – Chapter 5 Insulation and Refractory, Para 5.5 - Page no - 126
S = [ 10 + ( Ts - Ta ) / 20 ] x [ Ts - Ta ]
» S = Surface heat loss in Kcal / Hr * M 2
» Ts = Hot surface temp in 0C
» Ta = Ambient temp in 0C
» Total Heat Loss = S X A [ Surface area in M 2 ]
» Thermal Conductivity of Insulation Material, Wind Speed has not been considered. However, Lower the
Thermal Conductivity of the material, Lower the heat losses, Higher the wind speed, higher the Heat
Losses.
Example
Steam Pipe 4” (114 mm OD), Steam Temp 180 0C, Ambient Temp - 35 0C,
Thermal Insulation – 75 mm LRB, Wind Speed – 0, Hours/Year – 7920 (330 days), Boiler Efficiency – 85%
GCV of Fuel – Lignite 3,100 Kcal/Kg, Imported Coal – 5,500 Kcal/Kg, Furnace Oil – 9,500 Kcal/Ltr
Design Actual
» Ts = Hot surface temp in 0C 45 50
» S = Surface heat loss (Kcal / Hr * M2 ) 105 161
» Heat Loss Per Year (Kcal/Meter of Pipe Length) 6,90,000 10,60,000
» Excess Heat Loss Per Year (Kcal/Meter of Pipe Length) 3,70,000
» Potential Fuel Losses per year in Kg/Meter of Pipeline Length Lignite 140 ~ 475 Kg
Imported Coal 80 Steam Loss/
Furnace Oil 50 Meter/Year
Higher the Surface Temperature, substantially higher heat losses.
THINK OF UNREALISED POTENTIAL TO SAVE ENERGY, ENVIRONMENT AND MONEY AS WELL
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Introduction
• Issues with Conventional Insulation Material
Glass Wool/Rock Wool (LRB) typically loses its thermal properties sooner than
later as it uses Organic Binders ( Decomposition due to heat up/moisture) and
hence results in substantially higher heat losses than designed heat losses.
Other issues with LRB are largely well known among the users.
Perlite/Calcium Silicate has substantially higher Thermal Conductivities
requiring much higher thicknesses apart from breakable nature of the material.
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Introduction
• HITLINTM – The Product
HITLINTM is an abbreviation for High Temperature Layered Insulation.
HITLINTM Industrial Insulation is high-density E-Glass product born of a revolutionary new manufacturing
process that combines a specially processed E-Glass needle mat and inorganic binder to produce a solid
high performance, low thermal conductivity, completely Non-Combustible and Unbreakable Thermal
insulation. HITLINTM is made by Rolling Process (No Molding).
HITLINTM is a Patented Product Manufactured by M/s Se Woon T&S Co., Ltd, South Korea. HITLINTM is
available in various forms like Pipe Cover, Elbow Cover, F-Board, R-Board and Felt. HITLINTM variants
includes HG (w/o AlGC film) and HGA (with ALGC film).
Patent already registered in South Korea, Japan, China, Taiwan & Thailand.
Patent Application is pending in USA, England, France, Germany, Belgium, Italy, The Netherlands, Norway, Russia, Spain,
Sweden, Swiss, Ukraine, Bahrain, Kuwait, Qatar, Saudi Arabia, The United Arab Emirates.
Certifications from Lloyds Register, DNV, BV, ABS, KTR, Komeri regarding Product Quality, Quality
Parameters, Quality System, Design Assessment, Occupational Health & Safety Management System
OHSAS etc
Se Woon then developed the E Glass Fiber based Thermal Insulation product in 1997 with first commercial
application in 2001 in Korean State Electricity Company.
Since then, Product has been widely used as a preferred Thermal Insulation in many Heavy Industries like
Refinery, Petrochemicals, Power Plants, Shipbuilding etc
High Speed
Air Jets Rotation Spinning
Spinner
Winding
Air Induction
X 750 X 750
(by Electron Microscope) (by ElectronFocus
Microscope)
on Invisible Losses
Manufacturing Process
Needle Punching
Manufacturing Process (Patent Pending)
Rolling
Packing Drying
Center Cutting
PIPE Cover 20 mm
20 – 1,100 mm 1 Meter 200±10%
(HG | HGA) Onwards
Elbow Cover 20 mm
20 – 1,100 mm - 200±10%
(HG | HGA) Onwards
750 0C
20 mm 1 Meter x 1
Board (HGA) - 180±10%
Onwards Meter
12 mm 1 Meter wide x
110~160
FELT 25 mm - 5 – 40 Meter
±10%
40 mm Length
pH Neutral: 7.6 pH
Chemistry
Low Chloride Content
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TM
HITLIN Product Features
Design Less Pipe-Rack Space Required
Savings Thinner Insulation plus, Higher Energy Efficiency
High Temp.
Suitable for -20 0C to 750 0C Temperature Range
Applications
Thermal Conductivity
Thermal Conductivity
Comparison
0.100
Unit : kcal/m.h℃(70℃)
0.07
0.090
0.78 11
10
0.76 11
9
0.77
9.1
0.74 8
0.75 7.6 Neutral
7
0.72
0.725
6
0.7 5
E-Glass Glass wool Mineral E-Glass Perlite Calcium
Fiber Wool Fiber Silicate
250 2
200
1.5 2 2 2
150 230
200 192
(±10%) 160
1
100
0.5 0.7
50
0 0
E-Glass Perlite Calcium Mineral E-Glass Perlite Calcium Mineral
Fiber Silicate Wool Fiber Silicate Wool
7 pH 7.6
UV/VIS(200~800nm) % - HG Type
10 0
UV/VIS(200~800nm) % - HGA Type
KOMIPO
13 Boryeong thermal #7,8 2007
(Korea Midland Power Co.,Ltd)
* Under Implementation
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HITLINTM Installation
Mineralwool | Glasswool
HITLINTM
Rockwool
Valves S K Energy
1000mm 300mm
600mm
1000mm
실리콘
Energy
Reduced
Practical Saving
Pipe
Space Rack
use
Hazards Identification
Continuous filament
III - - Inadequate Evidence
glass fiber
Inhalation
Determined by fineness.
SATANTON hypothesis :
- Fineness (Filament Dia.)
- continuous filament glass fiber > wools > asbestos
- continuous filament fiber glass : impossible inhalation
- wools : impossible inhalation
- asbestos : possible inhalation
Eye contact
Temporary stimulus
Skin contact
Temporary stimulus
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HITLINTM MSDS
Continuous filament NO NO NO NO
glass fiber
Bind NO NO NO NO
Bind NO NO NO
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HITLINTM MSDS
Disposal Considerations
Transportation Information
Combustibility 0 0
Reactivity 0 0
Thank You
Focus on Invisible Losses