Thermal insulation

Today, energy is very expensive, and its prices continue to rise — every calorie saved brings measurable financial benefits.
That is why saving every possible calorie and caring for the environment is a smart strategy (after all, every calorie must first be generated). This applies to both hot and cold components.

Wherever we want to prevent an element from becoming excessively heated by its surroundings, we can protect it from ambient heat gain.

Many industries, in addition to using heat, also rely heavily on cold. A good example is the dairy industry, which traditionally uses chilled water systems to maintain proper conditions for dairy products.
One of the main problems in any cooling system is condensation forming on the surface of components transporting cold media. The resulting moisture leads to corrosion, surface degradation, and creates an ideal environment for bacterial growth.

Traditional insulation often fails to meet the requirements of such facilities, as over time it begins to absorb moisture. This leads to microbial growth inside the insulation, and eventually the insulation can detach under its own weight.

A practical application of this coating is in a dairy facility using a chilled water installation. A layer of just 2 mm is sufficient to reduce the temperature difference between the surface of the pipe and the surrounding air, effectively preventing condensation from forming.

Highly popular and quick to install, mobile containers (and metal garages) are commonly used as security booths, offices, or even living spaces. However, they are notoriously difficult to insulate.
Summer heat and winter cold easily penetrate the thin walls of these containers, leading to high heating and cooling costs. On sunny days, the internal temperature can reach as high as 40°C. However, thanks to the use of an insulating coating with thermal properties and the ability to reflect 90% of radiation, it was possible to reduce the internal temperature by more than 17°C.

Sometimes it is also necessary to protect objects located near heated furnaces from excessive thermal radiation and potential damage—especially items made of wood or plastics.

An additional benefit is protecting workers from excessive heat radiation and even burns.
Our company specializes in insulating heated furnaces or pipes to prevent heat loss. We apply a special product to hardening furnaces, central heating units, pipes, and other elements that generate excessive heat.

Our coating can be applied to various surfaces such as concrete, plaster, metal, wood, and plastics (with the exception of polyethylene).
Our thermal insulation emulsion can also be applied over existing paint, provided that it is water-based (not solvent-based) and strongly adheres to the surface.

We apply several thin layers of the emulsion—each just a few millimeters thick—at appropriate intervals to the element being insulated.

Attempting to insulate hot pipes using traditional methods such as pipe lagging is often difficult to implement. Common obstacles include confined spaces or densely packed pipe systems, which make it impossible to use traditional insulation with sufficient thickness. As a result, such insulation further reduces the volume of already tight spaces, making it much harder to move around and to inspect the condition of both the components and the insulation itself.

It’s also worth noting that a pipe protected with our method is easier to disassemble and replace, and is more resistant to damage. Potential leaks are also visible right away.

Rotary dryers are industrial machines designed for drying a wide range of raw materials, including limestone, coal, sand, coke, or slag. The drying process, which relies on the rotation of the drum combined with a flow of hot air and exhaust gases, is highly energy-intensive. Due to this high energy demand, proper insulation of the drum (especially in cement plants) is essential, as it otherwise releases a significant amount of heat into the environment.

The product we use is non-toxic and odorless — both during application and in use. It is a specialized emulsion, specifically a water-based paint, which makes it safe for both people and the environment!

Water-based paints use water as a primary solvent, meaning they contain no harmful solvents and only minimal levels of volatile organic compounds (VOCs).
These products are manufactured using the highest-quality raw materials, supplied exclusively by reputable producers.

The product is primarily applied by spraying, using specialized paint sprayers. We use several types of sprayers, selected based on the type of surface and the specific formulation of the emulsion.

Drying times and the intervals before reapplication depend on the thickness of the layer, ambient temperature, and relative humidity.

The standard color is white, but on request, we can also provide products in other colors. We can produce a tailored emulsion specifically suited to the equipment that needs to be protected and apply a layer of the appropriate thickness—also in the desired color. Colors are particularly important when different pipes or furnaces must be marked with specific colors, such as blue, red, or yellow. This is important for workplace safety, hygiene, and to avoid confusion or mistakes.

This emulsion is a thin ceramic coating that forms a ceramic filler integrated with an acrylic copolymer blend possessing insulating and reflective properties. The thermal insulating paint is a composite material based on acrylic resin reinforced with ceramic microspheres, which contain a near-vacuum internal pressure. The vacuum inside the microspheres increases thermal resistance, while the addition of microspheres of varying diameters improves the overall density and filling capacity of the coating. In a 1 mm layer, dozens of microspheres are present, significantly enhancing thermal resistance at the phase transition boundary.

To protect roofs and other surfaces exposed to solar radiation, titanium dioxide (TiO₂) can be added. TiO₂ is particularly suitable due to its high brightness and very high light reflectance coefficient. For this reason, it is often used in coatings for roofs and other structures that should remain cool. TiO₂ also offers excellent UV radiation absorption, ensuring durability, non-toxicity, and environmental friendliness.

The base of the emulsion consists of millions of hollow ceramic particles, each with an internal pressure close to vacuum, ranging in diameter from 20 to 120 microns. Once applied to the furnace surface and mineralized, they form a tight membrane that retains heat inside the combustion chamber, significantly reducing heat loss. As a result, fuel consumption is reduced due to less reheating required to maintain the desired operating temperature. The heat distribution in the furnace becomes more uniform. After applying the thermal insulation emulsion, the temperature drop is more significant in the hottest areas, resulting in a more even external surface temperature.

This emulsion ensures a safe working environment under continuous thermal loads up to 200°C and short-term peaks up to 240°C. On request, we can also produce and apply high-temperature-based coatings. The product exhibits excellent adhesion to metals (including stainless and acid-resistant steel) without surface corrosion, and it adheres well to most construction materials.

Based on conducted tests and measurements, the results show that a 1 mm layer of the emulsion corresponds to the equivalent of 3.0 to 10 cm of polystyrene insulation. The results vary depending on the chosen testing methodology and environmental conditions.
Due to the diversity of environments and parameters in which our coatings are used, it is recommended to adopt a conservative and safe conversion factor, assuming that 1 mm of the emulsion equals 3.0 cm of polystyrene for calculation purposes.

Sample Calculation of Heat and Energy Loss Reduction in a Furnace – Justification for Using Ceramic Emulsion as Insulation

Note:
1 kcal = 1.163 watts [W]

Calculation of Heat Loss Without Additional Insulation

Based on heat emission data for industrial furnaces, the amount of thermal energy released from the ceiling and side walls (per unit area) varies by surface and ranges from 220 to 1220 kcal/m²·h.

Total heat emission per hour:
33,000 kcal/h = 38,379 W
Total heat loss over 24 hours:
38,379 W × 24 h = 921,096 Wh = 0.921 MWh

This is the total daily heat loss through the furnace side walls and ceiling, which accounts for approximately 15.5% of the furnace’s daily thermal energy consumption.

Calculation of Heat Loss After Applying the Ceramic Insulation Emulsion

Note:
1 kcal = 1.163 watts [W]

After applying the recommended insulating ceramic emulsion, thermal emission values decrease significantly. Depending on the wall or ceiling, emission now ranges from 20 to 780 kcal/m²·h.

Total heat emission per hour:
18,300 kcal/h = 21,282 W
Total heat loss over 24 hours:
21,282 W × 24 h = 510,789 Wh = 0.510 MWh

Result:

Reduction in heat loss after applying ceramic emulsion:
From 0.921 MWh to 0.510 MWh
Net energy savings per day:
0.411 MWh/day, which corresponds to a reduction of approximately 44.6% in energy required to maintain furnace operating temperature.

Example Calculation of the Payback Time for Furnace Insulation (Surface Area: 6 m²)

(Based on energy cost: 1 MWh = 1100 PLN)

Note: A precise calculation is provided individually for each installation.
We also perform small-scale trial applications.

Technical Assumptions:

Heat loss at 100°C: 850 kcal/m²
Heat loss at 65°C: 450 kcal/m²
Temperature reduction: 35°C
Conversion factor: 1 kcal/m² = 1.163 W/m²

Energy Consumption Before Emulsion Application:

Heat dissipation per hour:
5,100 kcal/h = 5,931.3 W/h
Heat dissipation per 24 hours:
122,400 kcal = 142,361.2 W (0.142 MWh)

Energy Consumption After Emulsion Application:

Heat dissipation per hour:
2,700 kcal/h = 3,140 W/h
Heat dissipation per 24 hours:
64,800 kcal = 75,362 W (0.108 MWh)

Actual Energy Savings:

Difference:
0.142 MWh – 0.108 MWh = 0.0347 MWh/day
With temperature distribution coefficient of 0.7:
0.0347 MWh × 0.7 = 0.02429 MWh/day saved

Estimated Payback Period:

Daily savings:
0.02429 MWh × 1100 PLN = ~26.72 PLN/day
Estimated emulsion application cost for 6 m² surface:
Approx. 1500 PLN
Estimated payback time:
1500 PLN ÷ 26.72 PLN/day ≈ 56 days

Conclusion:

Applying a 3.6–4 mm thick ceramic emulsion over the entire furnace surface can reduce heat loss by 30–48%.
This results in energy/fuel cost savings of 22–27%.
The investment pays back in 9 to 11 months, depending on furnace operating intensity.
The emulsion maintains its insulating properties for at least 10 years, providing long-term economic and energy benefits.

Data source:
“Energy Performance Assessment of Furnaces” – Bureau of Energy Efficiency, INDIA