Energy Conservation and Management

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Energy Efficiency in Thermal Utilities

Insulation & Refractories
 Purpose of insulation or why thermal insulation?
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A thermal insulator is poor conductor of heat as it has low thermal conductivity

Used in Buildings and various industrial production process
It prevents heat loss or heat Gain
Its economic
It is more accurate to control the process temperatures and protection of personnel
It prevents condensation on clod surfaces and the resulting corrosion

These materials are porous in nature and contains large No., of dormant cells
 The right benefits of insulation
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 Reduces over all energy consumption

 Helps better control on the process by maintaining the temperature

 Prevents corrosion by keeping the exposed surface above dew point

 (the temperature to which air must be cooled to become saturated with water vapor, assuming constant air pressure and water
content )

 Provides fire protection to equipment

 Absorbs vibration
NITT Classification of Insulation

Based on the
Temperature temperature range
Range used
Material made of Usage

Up to 90 º C LTI (Low Cork, Wood,85% Magnesia Refrigerators , Cold and Hot

temperature insulation) Mineral fibers , Polyurethane water system storage tanks

90º to 325 º (MTI) Asbestos , Calcium silicates Steam rising equipment,

steam lines , flue ducts

Above 325 º (HTI) Asbestos , Calcium silicates, Mica, Super heated steam
fire Clay etc system ,Oven Dryers
 What is Thermal conductivity ?
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Heat loss per unit area per unit insulation thickness per unit temperature difference

Unit : W/m2/mºC It is always specified at the mean temperature

Thermal conductivity increases with temperature

 Calculation of insulation thickness
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 The factors determine the economic thickness
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Cost
Annual operation hours
Heat content of the fuels
Boiler efficiency
Operating surface temperature
Pipe diameter and surface thickness
Estimated cost of insulation
Ambient air temperature

Determination of economic thickness of insulation

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 Measure the bare pipe temperature, dia, length , surface area

 Assume average temperature

 Here we use trial and error calculation by assuming surface

temperature between 55 &65 deg C

 Select an insulation material whose thermal conductivity is

known
 Simplified formula for heat loss calculation
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NITT Refractories
A material which can withstand the action of abrasives or corrosive solids , liquids and gases at high temperature
Example : Fire clay , Alumina, magnesite etc.
 Refractory materials are made in various combination for various shapes and for different requirements
General requirements for refractory materials
 Ability to with stand high temperature
 Ability to with stand sudden changes of temperature
 Ability to with stand action of molten metal, slags, glass , hot gases
 Ability to with stand load at service condition
 Ability to with stand load and abrasives forces
 Low coefficient of thermal expansion
 Should be able to conserve heat
 Should not contaminate the material with which it contacts
 Some of the refractories properties
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Properties
1 Size
2 Bulk Density
3 Porosity
4 Pyrometric cone equivalent
(PCE)
5 Refractoriness under load
(RUL)
6 Creep at High Temperature
7 Volume stability , expansion &
shrinkage at high temperature
8 Reversible thermal expansion
9 Thermal conductivity
Significant effects
It affects the structure , Accuracy is important for fitting in construction
It defines the material presence in the given volume .Increase in bulk density increases the volume stability ,
heat capacity etc.,
It is a measure of volume of open pores in to which liquid can penetrate . Low porosity is preferable
Temperature at which the refractories will deform under its own weight is known as its softening which
is measured by PCE
This indicates the temperature at which the brick will collapse in service condition with similar load
This determines the deformation at the given time and it given temperature
Permanent changes due to Contraction or expansion may be due to operational factors
This is reflection on the phase transformation that occurs during heating or cooling
High and low conductivity requires based on the usage
Example
High conductivity when using with bricks and low conductivity for conservation of heat
 Classification of refractories
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 Typical refractories industrial use
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NITT How to select refractories
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Heat loss from furnace walls

 Heat loss from furnace walls depends on

 Emissivity of walls
 Conductivity of refractories
 Wall thickness
 Whether furnace is operated continuously or intermittently
 Heat losses can be reduced by increasing the wall thickness
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