Efficient Pipe insulation - Germany

The Phoenix Compounding Technology GmbH facility in Germany undertook a significant project to modernize its hot water pipe insulation systems. Since 1993, the facility's production has relied entirely on steam generated by a natural gas boiler with a 44 MW capacity, installed on-site.

At the heart of the production facilities is the boiler house, which supplies two large operational buildings with heat via a 1.8 km-long steam pipeline (273 mm in diameter). Patrick Kaufmann, engineer for building and energy technology and Head of Facility Management at Phoenix, explained:
 

Through the pipeline network, steam at 200 °C with 12 bar pressure is delivered to the production areas. However, the pipeline network originally had only a 30-year-old insulation with a thickness of 40 mm, which is clearly undersized by today’s standards. Energy efficiency calculations showed that with modern insulation, almost 90,000 kWh per year could be saved over a distance of just 320 meters. This was a potential we definitely wanted to utilize.

The main objectives of the project were to reduce energy losses, optimize thermal performance, and achieve sustainability goals by lowering CO₂ emissions. Additionally, the project aimed to improve the facility’s operational efficiency and align with industry standards for technical thermal insulation.

Advanced Pipe Insulation Solution Using Mineral Wool

To meet the facility’s requirements, a customized solution using ISOVER U TECH Wired Mat MT 4.0 was implemented. This insulation system utilized two layers of 100 mm mineral wool insulation, reinforced with galvanized mesh, providing exceptional thermal and fire-resistant properties.

Key features of the solution include:

• Thermal Efficiency for Technical Pipework Insulation: The material's low thermal conductivity (0.035 W/(m·K)) ensures outstanding performance, making it ideal for hot water pipe insulation.

• Fire Protection Insulation: Classified as Euroclass A1 (incombustible) with a melting point above 1,000 °C, ensuring safety in high-temperature environments.

• Durability for HVAC Pipe Insulation Applications: Designed for long-term use in technical environments, with a maximum application temperature of 560 °C.

This advanced pipe insulation material is suitable for both indoor and outdoor applications, addressing complex technical challenges with reliable performance.

Image

Key Benefits of our Technical Insulation Solutions

Energy Savings with Pipework Thermal Insulation
The installation of the mineral wool pipe insulation significantly reduced heat loss along the pipeline. Calculations showed annual energy savings of 90,000 kWh over a pipeline distance of 320 meters, leading to substantial reductions in energy costs.

Fire Safety with Fire Protection Insulation
The dual-layer pipework insulation system provided robust protection against heat loss while meeting rigorous fire safety requirements. Its fire barrier insulation properties ensure compliance with industry standards and provide peace of mind in technical operations.

Sustainability with Energy Saving Insulation
By optimizing thermal performance, the facility achieved measurable reductions in CO₂ emissions, supporting its commitment to sustainable practices. The energy savings allowed the investment to pay off in under a year, contributing to compliance with the European quota exchange system.

Specifications for Pipe Insulation Materials

• Insulation Type: ISOVER U TECH Wired Mat MT 4.0 (2 x 100 mm layers)

• Material: Mineral wool insulation with galvanized mesh reinforcement

• Applications: Hot water pipe insulation, HVAC pipe insulation, and technical thermal insulation

• Properties: Fire-resistant, energy-efficient, and durable under high temperatures

• Thermal Conductivity: 0.035 W/(m·K)

• Operating Temperature Limit: Up to 560 °C

Innovative Approaches to Energy Efficiency and Sustainability

This project underscores the importance of advanced technical insulation solutions in technical applications. By utilizing ISOVER U TECH Wired Mat MT 4.0, Phoenix Compounding Technology GmbH achieved significant energy savings, improved fire safety, and reduced environmental impact. This solution highlights how pipe insulation materials can drive energy efficiency and sustainability, reinforcing their critical role in the future of technical processes.