Energy industry

Even minor defects or damage in the piping network of large industrial plants can have serious financial and ecological consequences. Especially in the oil, gas and petrochemical industries, the demands on insulation materials are particularly high. Often the pipelines are subject to high temperature fluctuations, strong weather influences or mechanical loads, which require special solutions with regard to insulation. Kaimann also offers suitable solutions for this. The insulation materials with a very high diffusion density ensure that the pipes remain dry over a long period of time and are thus optimally protected against corrosion. This reduces the likelihood of risky maintenance work as a result of leaks and thus not only ensures a high level of system safety, but also actively helps protect employees.

Thanks to the high temperature resistance, the sometimes critical media remain at a constant temperature level over long distances. Depending on the insulation material, this is even possible in the low temperature range of up to -196 °C, which is relevant for the transport of liquid gas, for example. Kaimann insulation materials are also resistant to chemicals and oils, making them ideal for use in this industrial sector. The multi-layer structure often used in this sector fulfills other important functions in addition to its function as an insulating material: The first three layers provide thermal insulation, which significantly increases energy efficiency and reduces the risk of corrosion under the insulation. The fourth layer provides acoustic insulation, while the fifth layer protects against heavy mechanical loads.

Energy efficiency

Optimal technical insulation can provide sustainable support in keeping energy losses in a building or operational system low in the long term. Cost-saving measures to increase energy efficiency and system performance can be easily realized by insulating the entire piping network with Kaiflex. Thanks to the low thermal conductivity of up to λ ≤ 0.033 W/(m·K) and the thus very good thermal performance, the energy budget can already be sustainably optimized with a minimum insulation layer thickness, as the following example shows: an uninsulated DN 50 pipe has an annual energy consumption of 172.2 kWh per pipe meter. At a heat price of 0.24 € / kWh, this results in additional costs of 41.33 Euros per meter and per year. If, on the other hand, the pipe is covered with 19 mm of Kaiflex insulation, heat losses are reduced to 39 kWh and operating costs shrunken to 9.36 Euros per meter per year (assuming ambient temperature of 23 °C, media temperature 6 °C, rel. humidity 75 %, system hours 6,000). This means that 77 % of costs can be saved and the use of Kaiflex has already paid for itself after a short time.

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Corrosion protection

Corrosion processes under insulation are among the hidden and particularly critical damage processes. Particularly at risk are refrigeration, cryogenic and alternating temperature installations, i.e. installations that tend to draw moisture from the air through the insulation. Kaimann corrosion protection systems play a significant role in protecting the material under the insulation, reducing the risk of a wide variety of corrosion types (e.g. oxygen or crevice corrosion) as well as costly system damage and downtime. The closed-cell structure provides a reliable vapour barrier, safely protects against moisture penetration, and has a chemically neutral pH of about 7, therefore not promoting acidic or alkaline corrosion. Kaifinish protective coatings provide corrosion protection through shielding, i.e. insulation of the pipe surface by excluding air and moisture.

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Condensation prevention

In order to ensure the thermal performance of an insulation material in the long term, high water vapours diffusion resistance is also important in addition to thermal conductivity. This additionally protects the refrigeration and air-conditioning systems from condensation and pipe corrosion. The closed-cell structure of Kaiflex is formed from individual, self-contained cells. As a result, the insulation material already has "by nature" a secure vapour barrier integrated across the entire insulation profile and offers a water vapour diffusion resistance of up to μ ≥ 10,000. Kaiflex cannot become soaked during its service life and therefore retains its excellent insulating performance. The result: Kaiflex insulation on cold-carrying pipes increases the service life of technical equipment and also prevents moisture damage to the building's inventory.

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Surface protection

Kaimann tube jackets combine high-performance insulation properties with resilient surface protection. Thanks to its very good properties, regarding e.g. elongation at break and tensile elongation or puncture resistance, the underlying insulation and pipelines are optimally protected against mechanical damage and the effects of UV radiation and weathering, when used out-of-doors. In buildings, the surface protection is convincing by its visual appearance, which blends harmoniously into the overall appearance when installed in an open installation. Kaiflex Protect systems are also a good alternative to conventional insulation sheathing, as there is no need to increase the thickness of the insulating layer and there is no need for the air gap caused by installation. Thanks to the durability of the insulation materials, no follow-up costs are incurred: As long as the Kaiflex tube jackets are not damaged, long service life without deterioration of its technical properties is guaranteed.

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Noise insulation

Effective noise control measures for building and operational systems upgrade the value of buildings, increase productivity and the well-being of users, and reduce stress-related health risks and the number of occupational accidents. Effective noise protection solutions, that comply with the strict legal requirements, should therefore be used particularly in the areas of rooms demanding such protection, as well as in working areas. Kaimann insulation materials make a valuable contribution to these requirements when used for these two types of noise reduction measures: Sound absorption and sound insulation. While sound absorption usually reduces sound energy by converting it into heat, sound insulation shields the propagation of airborne and structure-borne sound by creating a barrier. This means that architects and contractors are on the safe side, as the noise insulation solutions ensure compliance with legal requirements.

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Fire protection

Kaimann makes it easier to achieve fire protection pursuant to DIN EN 13501-1, and it also saves time and money. This is because no change of material or manufacturer is required to seal off piping systems in the area of wall or ceiling penetrations. Kaimann supplies coordinated system solutions for safe fire, personal and system protection, consisting of innovative insulation materials and matching accessories such as pipe supports, adhesives and tape. With smoke development classes s1 ("low smoke development") and s2 ("limited smoke development"), the insulation materials thus meet the highest European smoke specifications and provide at least 90 minutes or 120 minutes of fire resistance for a wide range of pipe penetration solutions - up to an outer pipe diameter of 133 mm for steel and 42 mm for copper even without an additional fire protection mat when penetrating pipes with Kaiflex KKplus s1 or Kaiflex KKplus s2. For larger pipe diameters and when passing through lightweight partition walls or for the partitioning of combustible piping systems, the "Kaiflex Pyrostar" bandage system is also used.

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Sustainability

From thermal performance to low pollutants to environmentally friendly manufacturing - there are many aspects that should be considered if a product or building is to be certified as sustainable, for example, according to DGNB, BREEAM or LEED. How is Kaimann making its contribution? Environmental Product Declarations (EPDs) make the life cycle assessment of Kaimann insulation materials even more transparent, helping the company to support the design and certification of sustainable buildings. Kaiflex insulation materials reduce up to 660 kg of CO2 emissions during their 20-30 years of service life and save up to 580 times the amount of CO2 which has been released by their manufacture. This is good news for the environment, as well as for the cost balance of companies and building operators. Kaiflex also offers health benefits due to its specific structure: with its closed-cell nature, it is free of dust and fibers for hygienic requirements during installation and during system operation. Without additives, the insulation materials have excellent protection against mould and bacteria growth, thus increasing the quality of indoor air.

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Thickness insulation calculator Kaicalc

Those who pay attention to careful planning, workmanship and quality in a project design, can avoid costly system malfunctions or even failures and can thus keep operating costs stable in the long term - or even reduce them sustainably. Decisive for this is both the choice of the right insulation material and the correct calculation of insulation thickness. Our insulation thickness calculator Kaicalc provides reliable support around the clock.

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