New Componit

From Efficiency to Safety: Strategies, Benefits, and Real-World Applications of Industrial Thermal Insulation

In the last few months how many times have you heard about energy saving?

How many and which solutions have been proposed to you to optimize the consumptions of your plant?

I can imagine this is a recurrent topic for you too.

Among the various technological solutions there are different insulation systems which, as you already know, contribute to energy efficiency, offer economic savings and improve the sustainability of your company.

Because of the widespread use of these solutions, many companies often contact us to ask if it is possible to insulate the fabric expansion joints.

The answer depends on the characteristics of the fabric expansion joints. Let’s see in detail.

Standard fabric expansion joints

The fabric expansion joints made in standard execution are designed to dissipate the heat of the internal fluid towards the outside; in this way they can carry out their function as compensators even at very high operating temperatures.

Therefore any element( that prevents or limits heat dissipation ) is added to the standard expansion joint, will shorten the expansion joint life.

In fact, since it was not designed to be externally insulated, it will not be able to dissipate the heat and the fabrics will end up deteriorating quickly; in this condition the fabric expansion joint tends to open and break.

The answer to the initial question seems to be “no”… but there are other solutions to make the insulation compatible with fabric expansion joints.

Compatible expansion joints

If we talk about expansion joints compatible with insulation system, first of all we have to do an important premise: there are several types of fabric expansion joints which among other things can be customized on the specific needs of customers .

In this case , if during the design step of the expansion joint, the customer specify the presence of insulation, its characteristics etc, the product can be realized with particular materials that do not provide for thermal reduction. Heat dissipation will instead be guaranteed by the external insulation which will subsequently cover the expansion joint.

These two possibilities do nothing but confirm a concept that we at NEW COMPONIT often repeat to our customers : to be sure that the final product perform at its best, all the relevant specifications must be indicated during the request phase.

I return to the initial premise: fabric expansion joints, insulation and many other technologies dedicated to energy efficiency are really effective only if they are conceived and designed on the basis of an initial study of the energy situation and the specific characteristics of the plant;  only in this way it is possible to propose an adequate solution able to guarantee effective results.

We at New Componit specialize in textile solutions capable of solving problems related to heat, temperature changes, noise and fire. For over 35 years we have been bringing our engineering experience all over the world, dealing with all types of critical issues in systems that develop extreme temperatures and finding increasingly innovative solutions.

We offer our customers a tailor-made service, called  Efficiency Box® which allows us to respond to every type of customer need, in order to make production systems more efficient and safer.

Efficiency Box® includes:

  • monitoring of plants, carried out directly by a skilled New Componit technician
  • design and supply of the required interventions with simple but technologically advanced solutions
  • installation with New Componit personnel or assembly supervision
  • direct assistance and prompt intervention by a dedicated toll-free number.

Want to improve comfort and performance in your plant with a tailored solution?

Today I would like to talk you about an issue that I have been hearing about for several months: the development of hexavalent chromium and derivatives on equipment thermally insulated.

I have thoroughly documented myself and I think it is worthwhile to make some consideration.

We at New Componit want to highlight the danger of working in contact with waste insulation materials in general and in particular, with those containing calcium which worked under defined operating conditions.

The good news? There are fabric solutions especially designed to prevent the formation of hexavalent chromium.

Want to improve comfort and performance in your plant with a tailored solution?

When we talk about textile solutions for high temperatures inside industrial plants, we know that many related issues arise, such as the expansion of joints, energy efficiency, and personnel safety.

Over the years, by regularly visiting our clients’ facilities, we have learned to recognize these different issues and consequently to develop new products that can solve them.

In fact, all our products are developed based on the most common issues indicated by our clients. The opportunity to engage in dialogue with you and your team is crucial, as it provides us with the insights necessary to develop tailored solutions for any heat-related issues.

Want to improve comfort and performance in your plant with a tailored solution?

Good morning, today I would like to talk to you about an important department of our company: the technical office.

Nowadays the technical office must be more and more flexible, working in close contact with sales office.

The work of our technical department is supported by a solid modeling software called “Solidwork”.

Working with a mathematical 3D model allows us to be able to analyze the object at 360° and therefore assess its exact dimensions; in this way we do not risk losing some details that with the 2D drawing might not be clearly visible.

Thanks to a 3D model that faithfully reflects the object, as it is made and installed, surveys are no longer necessary; the product is modeled directly on the object to which it will be applied, making the engineering process more streamlined and safer in terms of dimensional errors.

Want to improve comfort and performance in your plant with a tailored solution?

 

Davide Oldani – Technical Manager

For months now, there has been talk about the growing problem of hexavalent chromium formation on insulated structures in industrial plants.

Why has there been a debate on this issue?

Because this compound, resulting from thermochemical reactions among metal alloys containing chromium and oxides in conventional insulation materials, is a safety threat.

The danger of hexavalent chromium

Hexavalent chromium is classified as a very hazardous substance, with toxic effects on the environment and serious risks to human health. It is, therefore, essential to understand which situations are at risk and how to deal with them.

Since we have clearly in our minds what happened in the past with asbestos, we cannot ignore the situation and take decades before we recognise the hazardous nature.

It is therefore vital to understand the conditions that facilitate its formation. This compound is the result of a thermochemical reaction that causes the oxidation of chromium (contained in many metal alloys), under certain environmental conditions with the calcium oxide contained in many conventional insulation materials.

The result is a compound called hexavalent chromium, which no longer volatilises below 800°C.

But what are the environmental conditions to pay particular attention to?

  • The presence of ‘old style’ insulating materials containing calcium, sodium or potassium.
  • The reaching of operating temperatures between 300°C and 600°C.
  • The presence of metal alloys containing chromium.
  • A specific percentage of oxygen in the working environment

Should all these conditions occur, an imaginary alarm bell must be set off.

How to deal with the problem

Recognising the presence of hexavalent chromium is crucial. During dismantling operations the presence of a yellowish powder is an important indicator.

In such cases, it is essential to act promptly:

  • disassembly of insulators must be carried out by properly trained personnel;
  • the result of rapid chromium tests can confirm its presence;
  • in the event of a positive result, it is important to proceed with immediate remediation;
  • handling of materials contaminated with this compound must be entrusted to experienced personnel capable of working safely;
  • contaminated materials must be disposed of properly

But what preventive measures can be implemented?

The aspect of prevention is very close to our hearts: in addition to correct information on these risks, what preventive measures can be implemented in industrial plants?

New Componit’s response, which is the result of intensive product research and development, is the design of calcium-free high-temperature insulation systems to ensure the safety of people and environment, in full compliance with international occupational and environmental safety regulations.

Want to improve comfort and performance in your plant with a tailored solution?

Today I would like to talk you about the constant investment our company makes in employees training and professional development programs.

I would like to explore the many benefits this has brought to our organization and employees.

When a company invests in employee training, not only the employees but also the customers benefit from it.

In fact, relying on a constantly updated supplier means collaborating with someone who: wants to stay in step with changing times and evolve technologically to improve its products and services.

Want to improve comfort and performance in your plant with a tailored solution?