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The energy-saving benefits of insulating air conditioning and refrigeration systems are sometimes overlooked, however such measures have great environmental and cost-saving potential, says Armacell.

The insulation of cold pipes is usually aimed at preventing condensation, with insulation thicknesses of 6-13mm being common practice to control condensation.

However, as the results of a recent study carried out by Armacell show, such thicknesses are not optimally designed to reduce associated energy losses, with substantial energy and CO2 savings possible when thicker insulation materials are used.

The objective of the study was to find an optimal, cost-effective insulation thickness for various types of plant.

For this purpose, Armacell determined the savings that are achieved through the use of thicker levels of insulation.

These savings were then compared with the cost of investment.

A wide range of applications were tested, incorporating building air-conditioning systems with different cooling demands, together with typical refrigeration systems used in supermarkets for food and drink storage.

Irrespective of the complexity of the system and the cooling demand, an optimal insulation thickness of 15.5 to 25mm Armaflex insulation was determined for chilled-water pipes.

The higher investment for this thicker insulation pays for itself in the course of the service life, accruing considerable financial savings after only a few years.

For refrigeration system pipework an even thicker level of insulation pays off and for these applications Armacell recommends 32 to 50mm as the optimal insulation thickness.

The results are also favourable from an environmental point of view.

CO2 emissions from the systems investigated were reduced by several tonnes annually, just by insulating the pipes to the optimal thickness.

These findings allow the following generalisations about the environmental performance of the insulation material.

Per installed cubic metre of Armaflex, the use of optimal insulation thicknesses allows annual CO2 savings of approximately: 1,150kg in the operation of air-conditioning systems; 1,900kg in the operation of refrigeration systems with a line temperature of -5C; and 2,550kg in the operation of refrigeration systems with a line temperature of -36C.

The study shows that considerable potential for savings exist through the use of optimal insulation levels in refrigeration and air-conditioning applications.

Moreover, the investigation findings were not achieved on specialised equipment, but with standard commercial systems.

In future, the objective when insulating pipes in cold applications should therefore not only be condensation control, but also energy saving for sound economic and ecological reasons.

Armacell is a manufacturer of engineered foams.

Apart from Armaflex, the company also produces thermoplastic insulation materials covering systems, fire-protection and noise-control products, as well as special foams for a multitude of industrial applications.

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