High-Temperature Insulation: A Guide for Industrial Applications

Some insulation types aren’t suitable in industrial settings where extreme temperatures are common. That is because high-temperature insulation is a specialized product manufactured to withstand temperatures exceeding 200°C. Lower performing insulation insulation with a lower maximum service temperature would degrade under these circumstances, rendering it defective. However, mineral wool, in particular stone wool is naturally suited to producing high-temperature insulation.

High-temperature insulation is commonly used in manufacturing, petrochemical and processing industries, as well as energy generation plants. When the operating temperature is over 200°C, the risk is as high as the temperature. High-temperature insulation is essential for safe and efficient performance. Without specialized insulation, energy loss and long-term running costs increase, and operators jeopardize regulatory compliance and worker safety.

What is High-Temperature Insulation?

High-temperature insulation is a specialized thermal barrier, manufactured for extreme heat conditions, typically from 200°C to 700°C. High-temperature insulation must maintain its structural integrity and performance, so has a different composition from other forms of insulation, and even compared to lower density mineral wool insulation.

High-temperature insulation is commonly used for maintaining energy efficiency and limiting thermal stress in energy-intensive industries.

• Power Generation: Boilers, steam pipes, furnaces, reactors, turbines and flue ducts.
• Petrochemical Industry: Processing equipment, vats, reactors and pipeline systems operating at high temperatures need reliable thermal protection.
• Manufacturing: Furnaces, kilns and heat treatment equipment.
• Process Industry: Heat processing, incinerators, furnaces and refineries.
  

Selecting High-Temperature Insulation

It’s important to specify the most suitable high-temperature insulation for each application. There are plenty of technical insulation products to choose from.

Mineral wool and, in particular, stone wool insulation is an exceptionally good choice for high-temperature applications because of its unique properties. Made from volcanic rock (96-98% by weight), stone wool has excellent thermal properties and is structurally stable even at temperatures up to 700°C.

PAROC^® Stonewool high-temperature insulation helps you comply with safety and energy regulations. It is reusable and can be recycled into new stone wool products, which reduces the need for virgin material. To help you select the best high-temperature insulation, our Technical Insulation Industry Guide provides detailed specifications and application recommendations for all our industrial insulation products and accessories.

We’ve divided the guide into different categories:

• PAROC^® Pro Section: Precision engineered pipe sections with coordinating joints and seals for easier installation.
• PAROC^® Pro Slab: Sheet and slab insulation for tanks, walls and roofs.
• PAROC^® Pro Wired Mats: Stone wool mat with stitched wired mesh. Ideal for irregular surfaces or complex shapes.

Benefits of High-Temperature Insulation

High-temperature insulation has to perform long-term in a tough environment. Good high-temperature insulation can provide cost savings, boost performance and limit downtime, while meeting regulatory requirements. The best high-temperature insulation will do all this and minimize installation and maintenance while keeping your people and plant safe for years to come.

More Energy Efficient

High-temperature insulation can immediately lower energy loss, consumption and operational costs.

Studies by the European Industrial Insulation Foundation showed that 10% of industrial equipment is un-insulated or covered with damaged or poor insulation. This leads to substantial energy waste and CO₂ emissions worldwide. However, there is a real opportunity to immediately reduce energy consumption, unlock long-term financial savings and meet carbon emission regulations with high-temperature insulation.

Safer Emissions During Initial Heat-Up

Insulation for high temperature indoor industrial applications usually generates emissions during the first heat-up. But there is a possibility to reduce those emissions. The right insulation can make a big difference.

PAROC ® PRO WIRED MAT LE is a thermal insulation specifically designed for indoor industrial high temperature applications. During first heat-up of insulated equipment, it emits up to 50% less formaldehyde and up to 90% less monoisocyanates than traditional wired mat insulation*.

We have created a new generation of binders based on renewable, biobased ingredients and it is the lowest emission high-temperature stone wool insulation on the market. It emits up to 59% fewer monoisocyanates and 57% less formaldehyde emissions than competing stone wool products in comparative third-party laboratory tests^**.

The team at Jämtkraft’s new combined heat and power (CHP) plant in Lugnvik, Sweden used PAROC^® Pro Wired Mat LE high-temperature insulation with great effect. Installation was quicker and thanks to the lower risk to workers during the heat-up phase, there was less downtime, making the whole process a lot more efficient.