Improving Thermal Efficiency on a 250°C+ Industrial Storage Tank
Industrial storage tanks at the chemical plant in Shanxi Province, China.
250°C+ OPERATING TEMP | >35% HEAT LOSS REDUCTION | Dual-Layer COATING SYSTEM | Shanxi CHEMICAL PLANT |
A chemical plant in Shanxi Province, China, operating a high-temperature storage tank faced ongoing challenges related to heat loss, insulation durability, and maintenance costs. The storage tank operated continuously at temperatures exceeding 250°C, creating significant thermal management requirements.
The existing insulation system required substantial thickness, involved complex installation procedures, and presented long-term maintenance concerns. To improve thermal efficiency while reducing lifecycle costs, a coating-based insulation solution incorporating aerogel insulation coating technology was adopted for the insulation upgrade.
LOCATION Shanxi Province, China | APPLICATION | INDUSTRY Chemical Processing |
OPERATING TEMPERATURE Above 250°C | INSULATION SOLUTION | HEAT LOSS REDUCTION More than 35% |
| Application | Industrial Storage Tank |
| Industry | Chemical Processing |
| Operating Temperature | Above 250°C |
| Insulation Solution | High-Temperature Insulation Coating + Aerogel Insulation Coating |
| Installation Method | Coating-Based Insulation System |
| Tank Surface | Curved Steel Surface |
| Project Objective | Heat Loss Reduction and Thermal Protection |
Continuous operation at temperatures above 250°C
Significant thermal losses through the tank shell
Excessive insulation thickness requirements
Difficult installation on curved and irregular surfaces
Aging conventional insulation materials
Increasing maintenance and repair requirements
Rising operating and lifecycle costs
Following evaluation of the operating conditions and thermal requirements, a dual-layer insulation system was adopted.
STEP 1 High-Temperature Coating Application of a high-temperature insulation coating to provide primary thermal protection. | STEP 2 Aerogel Coating Application of an aerogel insulation coating to further reduce heat transfer and improve thermal performance. | STEP 3 Seamless Insulation Layer Formation of a seamless insulation layer conforming to curved surfaces, weld seams, supports, and complex tank details. |
BEFORE UPGRADE • Thick conventional insulation system • Higher maintenance requirements • Increased installation complexity • Larger space requirements • Ongoing heat-loss concerns | AFTER UPGRADE • Thin coating-based insulation system • Improved thermal performance • Simplified installation process • Better adaptability to curved surfaces • Reduced maintenance requirements |
| Operating Temperature | Above 250°C |
| Insulation System | High-Temperature Coating + Aerogel Coating |
| Heat Loss Reduction | >35% under project conditions |
| Installation Complexity | Reduced ↓ |
| Surface Adaptability | Improved ↑ |
| Maintenance Requirements | Reduced ↓ |
* Performance results are based on the operating conditions of this project and may vary depending on equipment design, operating temperature, environmental exposure, installation quality, and insulation system configuration.
BENEFIT 01 Reduced Heat Loss Helps reduce thermal losses from the tank surface and improve overall thermal performance. | BENEFIT 02 Reduced Surface Temperature Limits heat transfer through the tank shell, contributing to safer operation. | BENEFIT 03 Lower Energy Consumption Reduced heat loss contributes to improved thermal energy utilization. |
BENEFIT 04 Reduced Insulation Thickness Requires significantly less thickness than conventional insulation assemblies. | BENEFIT 05 Simplified Maintenance The seamless coating system reduces maintenance burden. | BENEFIT 06 Improved Surface Coverage Effectively covers curved surfaces, weld seams, supports, and difficult areas. |
Aerogel insulation coatings combine low thermal conductivity with a thin, lightweight, and continuous insulation layer.
This project highlights the potential of aerogel insulation coatings in high-temperature storage tank applications where conventional insulation systems face challenges related to insulation thickness, installation complexity, and long-term maintenance.
By combining a high-temperature insulation coating with an aerogel insulation layer, the facility achieved improved thermal efficiency, reduced heat loss, and implemented a more compact insulation system suitable for demanding industrial operating conditions.
APPLICATIONS | PRODUCTS |
High-temperature industrial storage tank insulated with a coating-based aerogel insulation system designed to reduce heat loss, improve thermal efficiency, and simplify long-term maintenance.
