Energy Savings in the Asphalt Manufacturing Industry
Saving Enery Whjilst making the Molten Asphalt
Typical Hot Mix Asphalt (HMA) plants are equipped with hundreds of feet of uninsulated flexible metal “jumper” hoses. The primary function of the “jumper” hose is to transfer hot process oil in a primary jacketed pipe across a connection flange. Traditional insulating technologies that utilize mineral wool and hard aluminum cladding are not capable of servicing these hoses as they have a small diameter and a very tight bend radius. The result is that the “jumper” hoses, left uninsulated, are a significant source of heat loss costing HMA plants thousands of dollars each year in energy inefficiencies.
Recent improvements in thermal insulation technology, however, are finally enabling HMA plants to insulate the neglected “jumper” hoses and recover significant capital in energy savings.
The Technology
Insulation producers are now utilizing closed cell silicone sponge rubber as a primary source of high temperature insulation protection. The advantage of this material is that it has a very low thermal conductivity making it an excellent insulator. In addition silicone sponge rubber is non fiberous, unlike traditional mineral wool, and it does not require a hard aluminum cladding to contain the insulation materials. The inherent flexibility of silicone sponge rubber in combination with its insulating properties, makes it an excellent solution for protecting the tight bend radius “jumper” hoses.
Economic Benefits
Insulating 1 ½” OD flexible metal hoses with silicone sponge rubber sleeves (under typical operating conditions) enables HMA plants to recover up to $30 in heat losses for every foot of “jumper” hose in one seven-month operating season (assuming a winter shut down). This translates into fuel heating cost savings of approximately $6,000 per operating season (assuming 200 feet of “jumper” hose, based on 2005 North America fuel costs).
In most applications the flexible insulation sleeve will pay for itself within the first four months of installation.
Installation Benefits
In addition to the economic benefits, the new insulation sleeve technology is easily cut to length with an ordinary pair of scissors and is quickly installed in the field. In many cases the insulation sleeve may be equipped with a hook and loop closure to further simplify the installation on existing lines without line disconnection or interruption. The hook and loop closure also allows for easy access to process lines while performing maintenance procedures or trouble-shooting system components.
Introducing the HMA industry to silicone rubber sponge insulation technologies will help businesses to capture unrealized energy savings while creating a safer workplace environment.
About the Author
For more information by Ryan Worral regarding this article and how high temperature insulation can protect parts, materials and equipment from damage due to excessive heat, visit www.worbo.com.
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