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Chapter 2.5 - Insulation and Refractories

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5. Insulation and Refractories 5. INSULATION AND REFRACTORIES Syllabus Insulation and Refractories: Insulation-types and application, Economic thickness of insulation, Heat savings and application criteria, Refractory-types, selection and application of refractories, Heat loss. 5.1 Purpose of Insulation A thermal insulator is a poor conductor of heat and has a low thermal conductivity. Insulation is used in buildings and in manufacturing processes to prevent heat loss or heat gain. Although its primary purpose is an economic one, it also provides more accurate control of process temperatures and protection of personnel. It prevents condensation on cold surfaces and the resulting corrosion. Such materials are porous, containing large number of dormant air cells. Thermal insulation delivers the following benefits: Reduces over-all energy consumption Offers better process control by maintaining process temperature. Prevents corrosion by keeping the exposed surface of a refrigerated system above dew point Provides fire protection to equipment Absorbs vibration 5.2 Types and Application The Insulation can be classified into three groups according to the temperature ranges for which they are used. Low Temperature Insulations (up to 90oC) This range covers insulating materials for refrigerators, cold and hot water systems, storage tanks, etc. The commonly used materials are Cork, Wood, 85% magnesia, Mineral Fibers, Polyurethane and expanded Polystyrene, etc Medium Temperature Insulations (90 325oC) Insulators in this range are used in low temperature, heating and steam raising equipment, steam lines, flue ducts etc. The types of materials used in this temperatures range include 85% Magnesia, Asbestos, Calcium Silicate and Mineral Fibers etc. High Temperature Insulations (325o C above ) Typical uses of such materials are super heated steam system, oven dryer and furnaces etc. The most extensively used materials in this range are Asbestos, Calcium Silicate, Mineral Fibre, Mica and Vermiculite based insulation, Fireclay or Silica based insulation and Ceramic Fibre. Bureau of Energy Efficiency 119

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