Getting Ideas for Energy Management Opportunities
Proper insulation helps to reduce greenhouse gas emissions. How? Except for nuclear power and hydro-electricity, energy is produced by burning fossil fuels. Insulating against heat loss (e.g., melting furnace) reduces the amount of fuel needed to produce the heat – and thus the emissions. The reduction may take place locally or, in the case of electricity, upstream at the generating station.
We insulate process equipment, ducts, piping and buildings to:
- Prevent heat gains and losses;
- Maintain consistent process temperatures;
- Prevent burns (and frostbite) to employees;
- Prevent condensation from forming on cold equipment surfaces; and
- Maintain comfortable working environments around hot or cold process equipment.
• Halocarbon-free
• Flammability/resilience
• Performance/price
Thermal insulation deteriorates over time. A re-evaluation of long-established systems may show that the insulation is inadequate or damaged. For larger foundries, an investment
in an infrared thermograph (video camera) may pay for itself in a short time. Alternatively, a thermography consultant may help in discovering areas in need of repair, or additional insulation, or air leakage control. The benefits of upgrading or increasing insulation on process equipment and piping are clear: since the installation and initial insulation of equipment in most Canadian foundries, fuel prices have skyrocketed.
Insulation that depends on air-filled voids to function effectively must be kept dry. Exposure to moisture, particularly in the case of loose-fibre or open-cell foam insulation types, causes the displacement of insulating air by moisture/ water ingress (e.g., leaking steam or condensate pipes). Effective cladding of the insulation is just as important as selecting the most effective type of insulation and installing an economic thickness. Waterproofing is therefore an integral part of any insulating job. For high-temperature applications, chose a vapour-permeable covering that will allow moisture to pass outward.
Choose appropriate types of jacketing/cladding with sealed joints and, where the potential for mechanical damage is a factor, consider using insulation that is more resilient and has mechanical protection (barriers, bulwarks, shields, bridges, etc.), to minimize chances of damage.
Other EMOs
Housekeeping
- Review economic thickness requirements; consider long-range energy costs.
- Check condition of insulation and covers/cladding periodically.
- Repair damaged insulation, coverings and finishes as soon as possible.
- Replace wet insulation; it has very little insulating value.
- Locate source of moisture; in particular, establish whether a pipe or piece of equipment is leaking.
- Maintain safety requirements for hot surfaces.
- Repair seals around furnace openings, lids, etc.
- Minimize access to the furnace through doors, ports or covers to an absolute minimum to lessen radiation heat loss.
- Cover the exposed metal surface furnace spouts during non-production periods with graphite or a ceramic fibre lid.
Low cost
- Fit long exposed lauders with removable ceramic fibre lids.
- Insulate non-insulated pipe and ductwork.
- Insulate not-yet-insulated equipment.
- Upgrade existing insulation levels; add insulation to reach recommended thickness.
- Insulate major non-insulated equipment/process areas.
- Hire a thermography consultant to discover areas in need of (additional) insulation or air leakage control.
- Improve insulation of zinc baths in galvanizing foundries.
- Cover the zinc baths during the night.
Retrofit; high cost
- Replace refractory firebrick with ceramic pyrobloc insulation on ladles, lauders and furnaces.
- Add insulation/exterior cladding to foundry buildings, roofs, crawl spaces, etc.