March 03, 2008

New Idea for better & low cost Insulation

Common problem of carrying out calculation of optimum insulation thickness, Yet loosing lot of energy in the form of heat loss or cold loss, need re-work on insulation due to damage over a certain period of 2-3 years during annual turnaround etc. etc..............

Poor process engineers. Need survey of thickness, need good maintenance & monitoring program....lots of cost items..& still not satisifed.

After so many years of struggle, I thought about this Idea which is very cost effective & higher savings for lifetime. No need of re-work etc. No maintenance cost.

Interesting.........Ya....Very good business idea too....here is my input.


The idea came to my mind when I was looking for a cold insulation in ASU unit for liquid oxygen lines & found that best insulation also need of lot of investment still we would be incurring >2% losses in our system.

Therefore I thought if I can utilize some kind of vacuum on the surface of process pipes, the losses can be reduced to minimum due to poor conductivity of heat in vacuum.

Now the next question was how to design such a system which can be easily implemented from mechanical erection point of view and can be maintained without much problems.

So I prepared a sketch & its implementation strategy. The sketch is attached below for giving you exact idea how it will be done.




There is inner pipe which is carrying process fluid say it is 4" in size. Then next higher size pipe of 6" can be considered for insulation & it can be any cheapest material available e.g. CS etc. irrespective of the type of fluid handled. So the difference in ID is 2" therefore put some bars welded on the inner pipe of slightly smaller size of the difference in the radius of these two pipes. May be 0.8 Or 0.9" in this case. The allowance depends on the linearity of your pipe layout & size but should be sufficient to push bigger size pipe over the main process pipe.

Therefore, it also requires that this insulation is done in many smaller parts instead of doing it in lengths. Weld it at the ends to the process pipes with some reducers of B to S ratio (B is bigger pipe ID & S is smaller pipe ID.

Keep a tapping from the bigger pipe to vacuum system with PI for indication & combine all such smaller segments to one single vacuum system which will not be very large & high capacity due to practically nil losses in welded construction.

That's It.......................


  1. So Simple,

  2. One time construction,

  3. No change, No maintenance,

  4. Limited running cost due to only intermittent running of Vacuum system, leakage thru PI tappings only,

  5. Very low energy losses,

  6. Very low payback period

  7. No fire hazards due to enclosed vacuum,

  8. Immediate knowledge of system leak - saving costly products / raw materials loss,

  9. Less effluent cost,

  10. Need less safety instruments,

  11. Easy construction in grass root projects,

  12. No special material of separate services,

  13. No expert needed, In-house team can do it,

  14. ....................You can fill more benefits here if you can identify them.............

Hope You Enjoyed it........


If somebody need any guidance to use it for business purpose I can support the design with very nominal charges for my time only.

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