Strategies for improving energy efficiency in industrial heat transfer systems
FACILITIES MANAGEMENT TURNING UP EFFICIENCY
GLOBAL HEAT TRANSFER
Strategies for improving energy efficiency in industrial heat transfer systems
Sustainability is no longer just a buzzword but an essential strategy for facilities managers looking to reduce operational costs and improve their environmental impact. According to the International Energy Agency( IEA), industrial heat accounts for twothirds of industrial energy demand and nearly one-fifth of global energy consumption, making it a key area for efficiency improvement. By optimising heat transfer systems, facilities managers can reduce their energy usage while driving sustainability. Here Dave Dyer, technical sales engineer at thermal fluid specialist Global Heat Transfer, outlines practical steps to achieve this.
Thermal fluid systems face multiple operational challenges beyond just energy efficiency. One critical concern is the degradation of the fluid itself, which can occur when it’ s exposed to high temperatures or poorly maintained systems. Without proper preventative measures, this degradation can escalate into serious safety and environmental hazards. energy loss— such as piping and flanges. For example, flanges are joints connecting two pipes, which can allow heat to escape or even fluid to leak. Insulating these critical points prevents unnecessary heat loss, helping systems maintain consistent temperatures and reducing energy consumption.
Uninsulated equipment in heat transfer fluid systems can waste substantial amounts of energy, leading to higher costs. For example, if pipes carrying heated fluids aren’ t properly insulated, they can lose heat into the surrounding air. As a result, the system works harder to maintain the desired temperature, increasing both energy use and the likelihood of thermal fluid degradation.
Research from the U. S. Department of Energy estimates that adding insulation to pipes can cut heat loss by up to 90 per cent, yielding significant cost savings over time. For maximum efficiency, using sprayed glass insulation which is non-porous is recommended, particularly for areas within 600 millimetres of flanges. Beyond this, standard materials like a rock-based mineral fibre product can complete the insulation.
After addressing these critical areas, additional measures such as valve and strainer jackets should be considered. These removable covers are designed to fit over specific components that help further reduce heat loss and protect equipment in high-temperature environments. Once insulation is in place, how can you confirm it’ s performing as expected?
This is where thermal imaging comes in. By using infrared technology, thermal imaging cameras visualise heat retention and loss across a system, offering clear comparisons before and after insulation. This not only confirms insulation effectiveness but can also guide adjustments to boiler temperatures, improving overall energy efficiency.
Retain more, use less Uninsulated equipment in heat transfer fluid systems can waste substantial amounts of energy, leading to higher costs. For instance, if pipes carrying heated fluids aren’ t properly insulated, they lose heat to the surrounding air. As a result, the system must work harder to maintain the desired temperature, increasing both energy use and the likelihood of thermal fluid degradation.
In a heat transfer system, certain areas are particularly prone to
66 PECM Issue 80