Sika Innsbruck · Tirol, Austria · Bitumen + Thermal Oil 220°C
Site survey on 5 May 2026 covered the bitumen line (140–180°C operating zones) and the thermal oil distribution room (220–240°C) — 167 elements across both zones. FLIR thermal imaging measured surface temperatures up to 161.5°C on bitumen process pipes and gear pumps. Inzonex modular insulation delivers 96.1% heat-loss reduction, saving 1,425 MWh of fuel input per year at the gas-fired thermal oil heater.
Adjust hours, gas price, thermal oil heater efficiency and CO₂ factor to see live savings.
All surface temperatures taken with calibrated FLIR thermal imaging. Heat-loss calculation uses Innsbruck climate (annual avg 9.5°C outdoor, 18°C indoor). Operating regime: gas-fired thermal oil heater feeds 220–240°C oil to bitumen tanks; bitumen line operates 140–180°C across multiple zones (storage, process, transfer).
Six general photographs of bare equipment and three FLIR thermal scans, taken across the bitumen line and thermal oil distribution room. The thermal imagery shows surface temperatures of 93–161.5°C on the elements scoped for Inzonex covers.
Every uninsulated hot surface combines two heat-transfer paths — natural convection and radiation. Outdoor elements (most of the bitumen line) face additional forced convection from wind. None of these elements are currently covered.
Bitumen pipes, gear pump bodies, heated ball valves — all running at 93–161.5°C exposed to ambient air. Personnel burn risk on every operating surface.
Bitumen storage and circulation runs year-round. Every degree of ΔT bleeds energy through 167 element groups across both indoor and outdoor zones.
1,425 MWh of natural gas burned at the thermal oil heater to compensate for the leak — directly quantifiable on Sika's Scope 1 emissions footprint.
Modular removable insulation system designed for industrial heated equipment. Engineered for full retrofit access — every module zips/buckles open for valve servicing, then re-closes in minutes. Manufactured to fit each element from on-site survey measurements.
Industrial-grade mineral wool sized for the operating temperature. Non-combustible (Class A1 per EN 13501-1), continuous service to 700°C, no chloride contamination of stainless steel substrate.
Chemical-resistant outer fabric — withstands bitumen contamination, fuel oil, hot water washdown. UV-stable for outdoor installation. Smooth surface for easy decontamination. Emissivity 0.85.
D-rings, buckles, lacing hooks — corrosion-resistant for outdoor and chemical environments. Designed for unlimited open/close cycles without fatigue.
Stitched seams use aramid thread rated above expected service temperatures. Lacing closures permit field adjustment without specialist tools.
Reflective inner layer reduces radiative heat transfer to the wool core and prevents moisture absorption. Critical for outdoor elements exposed to rain and condensation.
Modules account for bolts, valve stems, drain ports, gasket gaps. Each element gets a custom-fit pattern with extra wool depth where needed to maintain ≤45°C surface everywhere.
Standard convection + radiation energy balance per element, per VDI 2055-1 and ISO 12241. Surface temperatures from FLIR camera (non-contact). All inputs and outputs documented per element in the calculation annex.
Outdoor elements use whichever h is higher (forced wins above ~1.5 m/s wind). Innsbruck annual average wind 2.5 m/s.
Iterated outer surface temperature with λ(T_mean) per stone-wool datasheet. Target T_surface ≤ 45°C (ISO 13732-1, touch-safe). Achieved across all elements: 96.1% reduction.
Each element calculated individually. Detailed per-element worksheets — emissivity, h_conv, q_rad, before/after losses — documented in the calculation annex. Below: aggregated by section.
| # | Section | Elements | T (°C) | Before (kW) | After (kW) | Saved (kW) | Reduction | h/yr |
|---|---|---|---|---|---|---|---|---|
| 1 | Tank Farm — Bitumen pump area (gear pump + tank flanges) | 21 | 175 | 22.0 | 0.85 | 21.2 | 96.1% | 8,760 |
| 2 | Tank Farm — Heated ball valves (V209/V213/V217/V199/V201/V206/V215/V203 + flanges) | 52 | 175 | 40.5 | 1.58 | 38.9 | 96.1% | 8,760 |
| 3 | Tank Farm — Tank cross-connections (DN100 + DN25 flanges) | 14 | 175 | 11.8 | 0.46 | 11.4 | 96.1% | 8,760 |
| 4 | Tank Farm — Expansion joints (metal bellows + micro-bellows) | 9 | 175 | 7.9 | 0.31 | 7.6 | 96.1% | 8,760 |
| 5 | Tank Farm — HS10 buffer + indoor storage zone | 5 | 140 | 1.6 | 0.07 | 1.5 | 95.7% | 8,760 |
| 6 | Tank Farm — Outdoor Motor-Operated Valves (V74/V73/V72/V133/V76/V158) | 14 | 180 | 12.7 | 0.50 | 12.2 | 96.1% | 8,760 |
| 7 | Tank Farm — Outdoor heated valves (V208 + DN40, V103/V102 linear-actuated) | 22 | 180 | 14.6 | 0.59 | 14.0 | 96.0% | 8,760 |
| 8 | Tank Farm — Bare DN50/DN100 piping segments | 18 | 175 | 3.9 | 0.16 | 3.8 | 95.9% | 8,760 |
| 9 | Thermal Oil Distribution Room — manifold (220°C) + pumps (240°C) | 12 | 220–240 | 28.7 | 1.13 | 27.6 | 96.1% | 8,760 |
| TOTAL | 167 | 143.78 | 5.55 | 138.23 | 96.1% | — |
Bars show heat loss per section, before (red) vs after Inzonex (green) — same scale across all sections.
167 modular covers manufactured at our Ukrainian facility (~80 m² Paroc Lamella stone wool + ~230 m² PTFE-coated fiberglass outer fabric), delivered DAP Innsbruck. Installation scope to be agreed separately. Final price within ±10% — detailed sign-off after Step 2 (on-site detail surveys).
Outer surface drops from 93–161°C to ≤ 45°C. Eliminates burn risk on every valve, pump and pipe operators interact with daily. Compliant with ISO 13732-1 (touch surfaces).
Modular zip/buckle closures — every covered valve, pump or flange opens, services and re-closes in minutes. Versus glass-wool + cladding which is destroyed each time and re-applied.
PTFE-coated outer, stainless hardware, mineral-wool core. Re-usable across maintenance cycles — no recurring replacement cost. Bitumen contamination cleans off the PTFE surface.
Operating hours, gas price, heater efficiency. Sign-off on scope (167 elements) and acceptance criteria (≤ 45°C surface temperature).
2-day on-site detailed measurement of every element — exact dimensions, flange specs, mounting access, vessel orientations. Final pricing issued.
≈ 167 module groups built in 5–7 weeks at our Ukrainian facility. Road freight to Innsbruck.
Two-person team, 5–7 days on site, fitting against running plant. Handover with FLIR thermal verification (target ≤ 45°C across all elements).