Choosing proper insulation is an important step in the design of a thermal fluid system. The wrong choice here can have serious safety implications, so it’s important to understand your options.

Selecting the right insulation is a critical step when designing a thermal fluid system. Choosing the wrong type can create serious safety risks, so it’s important to understand the available options.

The two primary types of insulation used in heat transfer systems are open cell and closed cell.

Closed cell insulation is the preferred choice. Commonly made from materials like calcium silicate or glass-foam, it resists absorbing fluid in the event of a leak. An industrial insulation contractor can guide you toward a closed cell material that matches your system’s temperature requirements.

Open cell insulation, such as fiberglass, is not recommended. Because it is porous, it can absorb and trap leaked fluid. This presents a significant hazard: once fluid is absorbed, it begins to oxidize inside the insulation.

As oxidation occurs, heat builds up in the space between the process piping or reactor jacket and the insulation. This lowers the fluid’s fire safety thresholds, and combined with the heat from ongoing degradation, can lead to smoldering. If oxygen enters the mix, it could escalate into an auto-ignition fire. (Always use proper fire suppression equipment and extreme caution when dealing with smoldering insulation.)

Regardless of the insulation type, make sure it does not allow fluid to become trapped in vulnerable areas—such as around flanges, valves, or other points where leaks are possible.

If you’d like to discuss the safest insulation options for your system, our team is always here to help.