Our case study focuses on the successful implementation of Microtherm panels for heat loss reduction in with the use of Furnace Insulation. The project involved utilizing these panels to address the challenge of heat dissipation in a furnace wall and door. Let’s delve into the details of this remarkable undertaking.

Industrial furnaces play a vital role in various manufacturing processes, requiring high temperatures to achieve desired outcomes. However, these furnaces often suffer from substantial heat loss, leading to energy inefficiencies and increased operating costs. To address this challenge, the introduction of Microtherm panels proves to be a promising solution.

Microtherm Panel as Heat Loss Solution

Microtherm panels are innovative furnace insulation materials specifically designed to provide exceptional thermal resistance. Their unique composition, comprising of high-performance microporous insulation, enables them to offer superior heat retention properties. When applied to industrial furnaces, these panels significantly reduce heat loss, optimizing energy consumption and overall operational efficiency.

In this case study, an industrial furnace used in a manufacturing plant was selected as the testing ground for the panel application. The furnace had a long history of excessive heat loss, resulting in increased fuel consumption and elevated operational costs. The objective was to evaluate the efficacy of Microtherm panels in reducing heat loss and improving energy efficiency.

Implementation in Industrial Furnace

To initiate the project, our Prolific Engineering & Services Co., Ltd (PES) Team visited and surveyed the customer’s facility and furnace to understand the initial heat loss problem and to take measurements as well as suggesting the customer what type of Microtherm insulation fits with their furnace. After that, we will send the proposal, which includes the report on the heat loss calculation calculated by Microtherm (PROMAT) team. After the customer’s approval, our PES team is supporting the installation of panels on the furnace wall by overhauling the furnace.

The panels were custom-fitted to ensure complete coverage and minimize potential heat leakage points. The team also conducted a thorough thermal analysis before and after the panel installation to measure the impact on heat loss reduction. In its principle, a low thermal conductivity insulator, Microtherm lowers heat loss inside the furnace that escapes the furnace when Microtherm insulation is installed and is substantially diminished due to the material properties. Having little porosity is a wise option to stop heat loss.

Result of Case Study Sample on Heat Loss Reduction

With the thickness of furnace insulation only 10 mm thick; and with a maximum heating temperature of 500oC. We can see that the surface temperature calculations in Figures 1 & 2 show which temperature will differ significantly from the left side without the installation of the Microtherm panel; and on the right side after the Microther Panel is installed. When Microtherm was installed, the average heat loss at the surface was 162.30C (Figure 2). After it was installed, it became only 95.4ºC. Comparing Microtherm to traditional furnace insulation, a 66.9°C reduction in heat loss is possible.

Fig.1 162.3ºC is the average surface temperature Fig.2 Average is surface temperature =95.4ºC with Microtherm.

Insulation for Special Application: Microtherm Waterproof

Fig.3 Waterproof Panel

Industry Application

Insulation for industrial furnaces in:

  • Aluminum melting and foundry industry
  • Food and Beverage Industry
  • Glass and Ceramics Industry
  • Steel and Aluminum Galvanizing and Annealing Processes

Thermal conductivity

Fig.4 Thermal conductivity

Other Industry Application: Oil and Gas

the petrochemical sector (i.e. hydrogen reformer)

Sample of Implementation

Heat loss is prevented via microtherm. It helps prevent heat loss inside the furnace and offers insulating qualities. (Conventional insulation for a 600 cubic meter furnace will require an additional investment of around 14 million baht.)

Fig.5 Before installation Fig.6 After installing Microtherm

Figures 5 and 6, depict the heat loss calculation graph inside the furnace wall at a temperature of 930°C. Figure 5 contains four layers of fiber blanket insulation, and it is evident from the image that the heat loss is 72 °C. Insulation, three layers of fiber blankets, and two layers of Microtherm Panel-1000R made up the sixth layer. So, the result of heat loss equals 56°C

The observed temperature ranged from 930°C in layers 2 and 3. The Microtherm Panel-1000R can prevent heat loss by up to 16°C when placed, reducing the temperature to 538°C.

Fig.7 Microtherm is installed at Continuous Bright annealing.

Benefits of Implementation of Microtherm Panel

The implementation of Microtherm panels yielded several economic and environmental benefits. The reduced heat loss resulted in substantial cost savings by lowering fuel consumption, which directly impacted the organization’s bottom line. Furthermore, the decreased emission of greenhouse gases contributed to a greener manufacturing process, positively impacting the environment and fulfilling regulatory requirements.

The case study showcased the effectiveness of Microtherm panels in industrial furnace applications. By minimizing heat loss, these panels offer a cost-effective solution to enhance energy efficiency, optimize operational processes, and reduce environmental impact. With their successful implementation in this case, the potential for Microtherm panels to revolutionize insulation practices in various industrial sectors is evident, setting a new benchmark for sustainable and efficient manufacturing processes.

For more information on the Microtherm Panel and if you would like to have our Engineers to do a site survey on your facility for the possibility of Microtherm implementation for heat loss reduction, please don’t hesitate to contact us!