Industrial pipelines, during energy and media transportation and equipment operation, experience heat loss, condensation, surface dew, and increased equipment energy consumption due to temperature differences. Scientific insulation solutions can effectively reduce energy consumption, improve system stability, and extend pipeline lifespan. The following is a systematic pipeline insulation solution for industries such as petrochemicals, power, metallurgy, HVAC, food, and pharmaceuticals.

I. Solution Objectives

1. Reduce Heat Loss: Reduce energy consumption and maintain stable media temperature through appropriate insulation thickness.

2. Prevent Condensation: Avoid water vapor condensation caused by temperature differences on the external surface, which can lead to corrosion and performance degradation.

3. Improve System Operation Safety: Ensure reliable pipeline operation under high temperature, high humidity, and low temperature conditions.

4. Extend Pipeline Lifespan: Reduce the risk of temperature shock and wet corrosion.

5. Meet Industry Standards: Select materials and conduct construction according to relevant national and industry standards.

II. Applicable Operating Conditions Analysis

Different industrial scenarios have different performance requirements for insulation materials, mainly including:

1. High-temperature steam pipelines (150–650℃)

Key performance requirements include temperature resistance, shrinkage resistance, and vibration resistance.

2. Low-temperature/chilled water pipelines (-50–10℃)

Emphasis on moisture resistance, condensation prevention, and low thermal conductivity.

3. Outdoor open pipelines

Requires good weather resistance, water vapor penetration resistance, and UV protection.

4. Pipelines in corrosive environments

Requires corrosion resistance, water vapor resistance, and acid and alkali resistance.

5. Pipelines in high-humidity environments

Emphasis on hydrophobicity and the integrity of the moisture barrier.

III. Recommended Insulation Material Solutions

Based on pipe type, medium temperature, and environmental conditions, the following material combinations are preferred:

1. Glass Wool Pipe Shell (Ambient Temperature to 350℃)

Suitable for: Steam pipes, hot water pipes, general process pipes

Advantages: Lightweight, sound-absorbing, low thermal conductivity, easy to install

Can be fitted with: Aluminum foil facing, fiberglass cloth outer sheath

Glass Wool

2. Rock Wool Pipe Shell (Ambient Temperature to 650℃)

Suitable for: High-temperature steam, boiler pipes, flues, heating networks

Advantages: High temperature resistance, Class A non-combustible, good compressive strength

Can be fitted with: Galvanized iron sheet, stainless steel outer sheath

Rock Wool Pipe

3. Aerogel Felt (-200~650℃)

Suitable for: Space-constrained applications requiring high insulation efficiency

Advantages: Extremely low thermal conductivity, high temperature resistance, reduced structural thickness

Features: Suitable for high-standard projects such as LNG, chemical, and shipbuilding

Aerogel Felt

4. Rubber and Plastic Insulation Pipes/Boards (-50~105℃)

Applications: Chilled water pipes, air conditioning water pipes, ice storage systems

Advantages: High elasticity, closed-cell structure, water-repellent, anti-condensation

Suitable for: Indoor pipes requiring aesthetics and a clean appearance

Rubber and Plastic Insulation Materials

5. Fiberglass Duct Materials (Ventilation Duct Insulation)

Applications: Air conditioning ducts, supply air ducts, exhaust air systems

Functions: Integrated insulation and soundproofing, lightweight and easy to install

Fiberglass Ducts

IV. Insulation Structure Design Examples

The following are typical industrial pipe insulation structure combinations, which can be refined according to the project:

1. High-Temperature Steam Pipes (350–550℃)

Inner Layer: High-temperature rock wool pipe shell

Outer Sheath: Galvanized iron sheet or stainless steel plate

Joints: Fiberglass tape + rivet fixing

Waterproof Layer: Sealed rainproof measures for the outer sheath

2. Chilled Water Pipes (-20~10℃)

Inner layer: Rubber-plastic insulation pipe/rubber-plastic board secondary wrapping

Outer layer: Aluminum foil reinforced vapor barrier

Seams: Adhesive sealing to ensure no cold bridges

If necessary: Double-layer vapor barrier structure

3. Chemical corrosion-resistant pipelines

Inner layer: Aerogel insulation

Protective layer: Fiberglass reinforced plastic (FRP) outer shell

Features: Corrosion resistant, moisture resistant, high strength

V. Insulation thickness design

Insulation thickness can be calculated comprehensively based on medium temperature, ambient temperature, and energy-saving indicators. General reference factors are as follows:

Medium temperature (heating and cooling intensity)

Pipe diameter

Indoor/outdoor environmental differences

Design heat loss limits

Anti-condensation point calculation (key point for refrigerated pipes)

Common references:

Medium temperature Recommended thickness (glass wool/rock wool)

100℃ 40-60mm

200℃ 60-80mm

300℃ 80-100mm

450℃ 100-120mm

(Specific thickness depends on project thermal calculations)

VI. Construction Process and Quality Control

1. Base Treatment

Clean the pipe surface, free of oil and impurities.

Anti-corrosion paint should be applied and dried.

2. Material Installation

Pipe shells should be tightly fitted together without obvious gaps.

Multi-layer insulation should be installed with staggered joints.

Refrigerated pipes must ensure the vapor barrier is continuous and undamaged.

3. External Sheath Construction

Sheet metal wrapping or clip fixing.

Aluminum foil lining must be firmly pressed and wrinkle-free.

Outdoor pipes require rain and sun protection measures.

4. Key Node Treatment

Elbows, valves, flanges, etc., require additional wrapping.

Anti-cold bridging and water accumulation structures must be installed under the mounting brackets.

5. Final Acceptance

Neat appearance and secure fixing.

Temperature testing or condensation inspection should be conducted.

Complete record of material types and construction parameters.

VII. Application Industry Case Studies (Expandable)

Petrochemical Piping Systems

Heating Company Steam Piping Networks

LNG Cryogenic Transportation Systems

Power Plant Boilers and Main Steam Piping

Pharmaceutical Cleanroom Process Piping

Paper, Metallurgical, and Food Processing Piping

Building HVAC Systems

VIII. Solution Advantages

1. Complete Material Supply, Covering All Temperature Ranges: A full range of glass wool, rock wool, aerogel, rubber and plastic, and duct materials are available.

2. Own Factory, Custom Sizes: Processing can be done according to pipe diameter, density, thickness, and other requirements.

3. Engineering-level technical support: Provides thermal calculations and detailed node design.

4. Multi-industry experience: Adaptable to complex operating conditions and large-scale engineering needs.