Optimum insulation thickness in process pipelines

Abstract

Thermal insulation of pipelines and components is an important step in aerospace, automotive and process industries where the operating fluid is at high temperatures. Thermal insulation is provided to reduce system heat loss, protect humans from burns and injuries, and protect nearby components from damage. Different insulation materials are available in the market with different properties, resulting in different optimum thicknesses of the insulation materials for the least heat loss from the system, and different costs. Insulation material cannot be chosen in an industry based on its cost or thickness alone. A balance of both cost and safety has to be upheld, which are considered top priorities in industries, along with time. In this paper, a significantly easier method of comparing the effects of different insulation materials for a given system is discussed, along with concluding the best material and its thickness for the same. Heat loss at various process temperatures and various insulation materials for different pipe diameters is obtained through simulations in ANSYS. Theoretical calculations are further used to find the optimum thickness of insulation concerning cost and system heat loss, and if required, the outer surface temperature of the system. This is important since too much of insulation can lead to increased costs and too little leads to reduced safety. Stainless steel pipe diameters of 1, 2 and 4 in., and insulation materials EPS, XPS and fiber glass are considered for this study.