Thermal insulation of industrial tanks is not only a matter of comfort, but above all, reliability and safety of the installation. In various industries – from chemical, through petrochemical, to food – proper insulation allows maintaining optimal conditions for storing materials. Without it, serious problems easily arise: from energy loss, through corrosion under insulation (CUI), to higher operating costs related to energy inefficiency.
The insulation of water, fuel, technological or gas tanks is intended not only to protect against extreme temperatures, but also to maintain stable internal conditions. This is especially important in the case of tanks that store substances that require precise temperature management – both high and low. Proper insulation helps reduce heat loss, prevents damage to materials and ensures the safety of stored substances.
In this article, we will look at what problems can occur when there is a lack of thermal insulation, and why it is worth investing in appropriate thermal insulation materials, such as mineral wool, PUR foam or Styrodur.
Types of tanks and their insulation needs
Industrial tanks have different functions depending on the industry, and each of them has specific requirements for thermal insulation. Choosing the right thermal insulation material depends on the material being stored and the conditions in which the tank is used.
Water tanks
In the case of water tanks, insulation is crucial for protection against heat loss, especially in processes where water acts as a heating medium. Insulation helps reduce energy costs and also prevents freezing at low temperatures. Mineral wool and PUR foam are the most frequently chosen materials that effectively prevent heat loss in such tanks.
Fuel tanks
Fuel tanks storing crude oil, liquefied gas and other flammable substances require specialist insulation that not only reduces heat loss but also ensures safety. Proper insulation protects against overheating of the substance and also protects against the risk of explosion. Stone wool and insulating foams are materials with high resistance to high temperatures that work well in such applications.
High-temperature tanks
High-temperature tanks used in the chemical, petrochemical or energy industries must be properly insulated to maintain the internal temperature at the required level. Insulation of these tanks is essential to ensure the stability of technological processes and minimize energy losses. PUR foam, stone wool and ceramic insulation are materials with high resistance to extreme temperatures that work best in such cases.
Gas tanks
Thermal insulation of gas tanks – both low-temperature (e.g. nitrogen, oxygen) and high-temperature (e.g. propane-butane) – is essential to maintain appropriate gas storage conditions. Insulation allows you to control the gas temperature, preventing uncontrolled reactions. For low-temperature tanks, mineral wool or PUR foam are most often used, while for high-temperature gases, more advanced materials resistant to high temperatures are used.
Cylindrical tanks
The insulation of cylindrical tanks is intended to provide uniform protection of the entire surface, which allows for maintaining a stable temperature inside. PUR foam or Styrodur are ideal materials for insulating large surfaces of cylindrical tanks, which effectively prevent heat loss and also improve energy efficiency.
Tips on specific insulation requirements
Thermal insulation of tanks should always be adapted to the characteristics of the stored materials and operating conditions. In the case of high-temperature tanks, it is necessary to use materials resistant to extreme temperatures that will not lose their insulating properties in difficult conditions. In turn, for low-temperature tanks, it is important that the materials protect against heat loss and the risk of freezing.
Insulation of fuel tanks, on the other hand, must provide resistance to chemicals and fire, and in the case of water and technological tanks, the purpose of insulation is primarily to maintain optimal thermal conditions, which affects the efficiency of industrial processes and reduces energy costs.
Problems related to lack of insulation
Lack of proper insulation can lead to many problems in terms of operational efficiency, safety and operating costs. Here are the most important ones:
Heat losses
Without thermal insulation, industrial tanks – especially those storing liquids that require constant temperature – generate large heat losses. These losses increase energy consumption and lead to inefficient process management. In the case of fuel or process tanks, lack of insulation also results in increased operating costs, because the heating systems have to work harder.
Corrosion under insulation (CUI)
Corrosion under insulation (CUI) is one of the most serious problems faced by industrial tanks without proper insulation. Moisture that accumulates under the insulating material leads to the development of corrosion on the metal surfaces of the tanks. CUI is a particular threat in fuel and process tanks, where the metal walls of the tanks are exposed to water and moisture.
Energy inefficiency
Lack of proper insulation means that heat (or cold) is not retained inside the tank, forcing heating and cooling systems to work at full capacity. This results in increased energy consumption and higher operating costs. Well-designed insulation can significantly improve energy efficiency, which translates into lower bills and reduced energy consumption.
Risk of failure
Lack of insulation can lead to serious failures, especially in tanks storing flammable substances. Too high a temperature can increase the risk of explosion or fire. Additionally, lack of insulation in tanks that require a constant temperature (e.g. in the food or chemical industry) can cause system failures and production disruptions, which is associated with high repair and downtime costs.
Benefits of using thermal insulation
Proper thermal insulation has many benefits, including:
Improved energy efficiency – proper insulation reduces heat loss (in high-temperature tanks) or prevents their cooling (in low-temperature tanks), which leads to lower energy consumption and lower operating costs.
Protection against corrosion and damage – insulation protects against damage resulting from extreme weather conditions and minimizes the risk of corrosion, which significantly extends the life of the tanks.
Increased durability – well-designed insulation reduces the risk of failure and reduces maintenance costs, which has a positive impact on the long-term maintenance of the installation.
Types of insulation materials
Choosing the right thermal insulation materials is crucial for energy efficiency and durability of the installation. The most commonly used materials include: mineral wool, stone wool, PUR foam and Styrodur. Each of these materials has its own specific properties that make them an ideal solution for different types of tanks and operating conditions.
Thermal insulation of industrial tanks from Deffor
Thermal insulation of industrial tanks is a key element that affects the operational efficiency, safety and longevity of the installation. Proper insulation allows for:
Improving energy efficiency by reducing heat loss and preventing excessive energy consumption in industrial processes.
Protection against corrosion and damage, protecting tanks from adverse weather conditions and reducing the risk of corrosion under insulation.
Increasing the durability of tanks, which translates into lower maintenance and repair costs, and also reduces the risk of technological failures.
Properly selected insulation can significantly reduce operating costs, improve the safety of industrial processes and increase the profitability of the company. For this reason, it is worth investing in professional insulation, adapted to the specifics of tanks and working conditions.
We encourage you to use the services of Deffor, which offers comprehensive solutions in the field of industrial insulation. Our experience, high quality materials and individual approach to each project guarantee that the insulation will be made in accordance with the highest standards, providing long-term benefits and safety. Contact us to find out how we can help improve the energy efficiency of your company and protect your industrial infrastructure.
