Comparison of materials for reactor insulation sleeves: which one is the most durable and energy-efficient?

Having worked in the chemical industry for so many years,withReactor insulationThe number of times this matter has been contestedI go shopping with my wife much more often than I do. My colleagues often ask me: Which material can last for a few more years without using electricity or steam when the insulation sleeves of the kettles in your workshop are changed again and again? Today, taking advantage of the maintenance gap, let's have a heart to heart talkReactor insulation sleeveThe real comparison of materials is all valuable!!

Below, we will break down one by one the most common insulation core materials on the marketdurableandenergy savingCompare it to these two most critical indicators.

1. Fiberglass needle punched blanket‐ — Cheap bowl, but; Collapsed house; too fast

This is the most common insulation core material, and many factory standard insulation sleeves come with it. Soft to touch, easy to construct, wrapped in a few centimeters thick layer, the initial insulation effect is indeed effective.

In terms of energy conservation:The thermal conductivity is usually between 0.035-0.045 W\/(m· K), which is decent at room temperature, but as the temperature increases, the performance deteriorates.
In terms of durability: Sincerely not reassuring.This thing is particularly afraid of water and moisture. When the reaction kettle is cooled or heated, or splashed with water during cleaning, the fiber gaps quietly absorb moisture. When wet, the thermal conductivity skyrockets in a straight line, causing insulation to change; Cold conduction;. What's even more deadly is that when it gets wet and dries, it willSettlement and thinningJust like a cotton quilt that has been washed several times and compacted, originally 5 centimeters thick, after two years, the top 3 centimeters are empty shells, and the bottom shrinks to 2 centimeters, with the top of the pot appearing directly; Hot Bridge” The heat whizzed out.

Sincere statement:If you don't miss those three melons and two jujubes, try not to let them be the main force. I have seen a kettle that has been in use for less than two years. When I opened the insulation cover, the glass wool inside collapsed into a pile of fluff. The upper part of the kettle was so hot that it could be fried, and the lower part was so cold; — It's no wonder the energy consumption is not high. The lifespan generally ends in 2-3 years.

2. Rock wool‐ — The physique of a tough guy, the life that absorbs water

Rock wool is harder than fiberglass and typically has a temperature resistance rating of 600 ° C; Above C, when first installed, it is square and looks very secure.

Energy saving and durability:The thermal conductivity is similar to that of glass wool, around 0.04, but its fatal flaw is alsoabsorb waterAnd it sucks more water. Rock wool often contains trace amounts of chloride ions, which will undergo electrochemical corrosion with the metal shell after absorbing water. This is why some insulation layers may peel off, causing rust stains on the outer wall of the reaction vessel. In addition, rock wool fibers are brittle, and after a few dismantling, the edges and corners will break into slag. The sharp fiber stubble will not only prick the hand, but the scattered cotton blocks will cause voids in the insulation layer.

Sincere statement:This material is more suitable; A package of Yongyi; For equipment such as reaction vessels that require frequent opening, sampling, and maintenance, the durability of rock wool will be compromised if the pipeline is never disassembled and tossed back and forth a few times. Energy saving relies on a complete piece, which absorbs moisture when broken, and energy saving is beyond discussion.

3. Aluminum silicate ceramic fiber‐ — High temperature resistant; Crispy Assassin;

This thing can carry 1200° High temperatures above C are commonly used in many high-temperature reactors. There are a bunch of white flowers, which look very professional.

In terms of energy conservation:The thermal conductivity at high temperatures is superior to that of rock wool and glass wool, controlled at around 0.03-0.04. For high-temperature reactors, energy-saving foundations are good.
In terms of durability: it ' s a long story.The biggest problem with ceramic fibers ispowderingUnder continuous vibration and alternating cold and heat, fibers will break off one by one and turn into fine powder. If you remove the insulation cover once, it will be covered in white powder, and there is a risk of biological persistence if inhaled into the lungs. The powder settles to the lower part of the insulation sleeve, and the upper part becomes an empty shell, resulting in a sharp increase in heat loss. What's even more concerning is that this material is not hydrophobic and can easily absorb oil stains. Once contaminated, its insulation properties will be completely destroyed. Its durability lies in; Absolute stillness, non removable, dry and waterless; It was said in an ideal state. In the real workshop, the lifespan is not very good and the inner core often needs to be replaced.

Sincere statement:Unless the temperature really reaches 800 degrees Celsius; Other materials above C cannot withstand it, otherwise I do not recommend using it. Cover a reaction kettle with ceramic fibers at over 200 degrees, completely; Kill a chicken with a cow knife; And this ox knife also rolls its blade quickly.

4. Aerogel felt— — Expensive is expensive, using it is truly fragrant

Finally, I came to the popular aerogel in recent years. To be honest, the first time I received the quotation, I also thought it was expensive, but after using one, I couldn't go back.

In terms of energy conservation: Reduce dimensional impact.The thermal conductivity of aerogel can be as low as 0.018-0.022 W\/(m· K), nearly half lower than other materials. This means that with the same insulation effect, the thickness is only half, the heat dissipation surface area of the kettle body is reduced, and the heat loss is naturally lower. Even more amazing, it as a wholeHydrophobic rate greater than 99%When water is splashed on it, it feels like it's dripping onto a lotus leaf, without seeping in at all. So the insulation performance will never drop due to moisture.
In terms of durability: Almost no weaknesses can be found.The aerogel felt is flexible and elastic, and does not pulverize or settle when folded. No matter how vigorously the reactor is stirred or vibrated, it still sticks firmly there without settling or breaking. Dismantled dozens of times, the shape remains unchanged, and it still fits snugly when plugged back in. The lifespan can cover more than half of the maintenance cycle of the reactor, and it is common to have a lifespan of more than 5 years.

Sincere statement:The initial investment cost is several times that of traditional materials. But the accounts have to be balanced: the saved steam money, combined with years of labor and materials that don't need to be replaced, can often be recovered from the saved energy consumption in one to one and a half years. And it is thin, saving a lot of operating space around the reactor. Besides being expensive, I really can't find any other problems.

A table, clean your underwear thoroughly

Don't just focus on the core, you also need to pay attention to the jacket

Finally, touch up the insulation sleeve; Skin” It also determines durability. Equally important as the core material:

• Silicone coatingCheap, temperature resistant 250 ° C; Up and down, the weather resistance is average, and it will crack and become sticky after several years of outdoor use.

• PTFE coatingHigh price, but temperature resistance of 300 ° C; C, anti-aging, anti-corrosion invincible. There is solvent evaporation and acid and alkali splashing in the workshop. If you grit your teeth and use a PTFE jacket, it can protect the inner core from damage and prolong the overall life.

• High silica fabricHigh temperature resistance, but not waterproof, suitable for use in specific dry and high-temperature environments.

How to choose? My heartfelt suggestion

• Budget tight, low temperature (<200 ° C), pure indoor, infrequent dismantlingYou can use a fiberglass needle punched blanket with hydrophobic treatment, but you need to have a balance in mind and check and replace it after about three years.

• High temperature (>300 ° C), not frequently disassembled, dry environmentUse aluminum silicate, but accept its powdering and loss, and take good precautions.

• Want to achieve a permanent solution, frequent disassembly and assembly, with water or solvents, high energy-saving requirements：Direct upper aerogel felt+PTFE outer sheathThis is currently the most durable and energy-efficient combination, without a doubt. Although the first ticket was heartbroken, it was really stable to use. You don't have to worry about the kettle temperature dropping in the middle of the night, nor do you have to scold your mother every year for removing the insulation cover.

After years of hard work in the workshop, the biggest realization is:When it comes to insulation, one is not afraid of buying expensive, but afraid of changing frequently.Energy is saved bit by bit, and durability is the key to long-lasting energy savings. I hope this time; Big competition” Can save a few packs of cigarette money and sweat for colleagues.