Cutting costs, curbing climate change: industrial businesses have put the subject of energy efficiency at the very top of their agenda. And they have already used a whole number of ways and means to achieve this. So have all possible options been exhausted? Not yet. Industrial insulation can play an important role here.
Modernised buildings, energy-saving production processes, low-energy machinery: industrial companies have done a lot to reduce their energy consumption. And yet there are still areas of their business where huge savings could still be made – particularly when it comes to the thermal insulation used in their plants as, in many cases, this hasn’t been replaced for decades.
Being an industrial insulation specialist, XERVON is able to deliver highly effective solutions to minimise heat loss – both for normal and high temperature environments. Indeed, XERVON is able to cut the costs caused by heat loss by more than 90% when it is called in to renovate insulation systems that had originally been installed without energy efficiency in mind.
Experience has shown that there are energy savings potentials in all industrial sectors, no matter what type of plant or what process temperatures they use. It is becoming increasingly important for these companies to exploit this potential and minimise their industrial heat loss – not only because of the rising energy prices but also because of their duty to make their business more sustainable. This aside, effective insulation systems offer many other advantages as well, such as higher levels of efficiency, more stable processes and safer operations. Companies that choose to optimise their insulation systems, therefore, benefit in a variety of ways: cutting costs, improving their operational activities and promoting sustainable and responsible business practices.
The huge cost savings achieved by installing new insulation mean the investment costs are recouped within a very short time, often within just a few months.
A chemicals firm uses pipes (nominal pipe sizes: DN50 and DN150) to convey a medium kept at a constant temperature of 100°C. The weather data for the site shows the average surrounding temperature over the year to be 11.2°C and the average wind speed to be 1 metre per second. Based on these figures, the costs caused by heat loss could be reduced by more than 90% if an efficient insulation system were to be installed. The costs for the DN150 pipes would fall from 265 euros per metre per year to 20 or 12 euros respectively depending on the thickness of the insulation material. With the savings being so great, the money invested in installing a more effective insulation system would be recouped very quickly – within just three months if a 40mm thick insulation material were to be used. It is hard to find a more profitable way to invest in operating equipment:
Savings potential of insulated pipes in euros per metre (€/a)
Improving heat insulation in plants – what exactly does this achieve? An energy audit carried out in line with the TIPCHECK standard can provide concrete answers to this question. Specially trained XERVON engineers carry out such audits to detect exactly where heat is being lost and then draw up a suggested plan of action that can be implemented immediately. This plan also includes precise details about the energy, cost and CO2 savings that can be achieved. The exact investment costs are calculated as is the individual return on investment. These facts and figures provide a reliable basis for industrial businesses to make a decision: around 75% of all companies that have had such an audit carried out at their business have already implemented the recommended changes or plan to do so in the near future.
TIPCHECK was developed by the European Industrial Insulation Foundation (EiiF) and corresponds with the energy audit standards EN 16247 and ISO 50002
The company is also able to carry out highly unusual insulation projects. For example, removing old insulation material containing asbestos from pipes that make up part of a pipe bridge and reach temperatures of 350°C and then re-insulating them immediately.
A XERVON and BUCHEN project.
49 megatonnes CO2
49 megatonnes CO2 can be avoided by improving industrial insulation – the same volume of emissions generated by eight million cars
172,200,000 MWh of energy can be saved each year by optimising the insulation systems used at industrial plants