Project Highlight: Economizer Insulation with Removable Reusable Blanket Insulation. Economizers recover energy from waste heat, but without proper insulation, part of that energy can still be lost.

By applying removable-reusable blanket insulation, these surface losses can be reduced, helping to retain the recovered energy and improve overall system performance.

Typical system includes:

• A vertical heat exchanger body
• Exposed tube bundles
• Connected piping, valves, and instrumentation
• Complex geometry and limited access areas

To address these challenges, we apply a removable reusable insulation system, designed specifically for this equipment.

Economizer + Insulation: Working Together

An economizer improves efficiency by recovering heat from flue gases. However, without proper insulation, part of this recovered energy can still be lost through exposed hot surfaces.

By applying blanket insulation (jacket insulation), these surface losses can be significantly reduced, helping to retain the recovered energy within the system and improve overall performance.

In simple terms:
The economizer recovers energy — insulation helps keep it.

Why Insulating Economizers Makes Sense

1. Reduction of Surface Heat Loss

Even well-functioning economizers have hot external surfaces, which can result in continuous heat loss if not properly insulated.

Without insulation:

• Heat is continuously dissipated into the surrounding environment
• Total energy efficiency is reduced

Applying removable blanket insulation helps to limit these losses and retain useful energy.

2. Large Surface Area = High Potential Losses

Economizers have:

• Large flat surfaces
• Extended vertical structures

Even moderate surface temperatures can result in significant total heat loss due to large surface area. This makes them strong candidates for blanket insulation solutions.

3. Improved System Efficiency

By reducing surface losses:

• More recovered heat remains in the system
• Fuel demand can be reduced
• Overall system performance improves

The exact savings depend on:

• Operating temperature
• Surface area
• Operating hours
• Energy cost
• Ambient temperature

4. Personnel Safety

Hot surfaces above approximately 60 °C present a burn risk. Uninsulated economizers and adjacent components can exceed this level.

Using removable reusable insulation:

• Reduces surface temperature
• Improves working conditions
• Supports internal safety requirements

5. Environmental and Compliance Benefits

Reducing heat loss contributes to:

• Lower energy consumption
• Reduced CO₂ emissions
• Support for energy efficiency targets

This aligns with:

• EU energy efficiency objectives
• CSRD reporting
• Energy saving schemes

Why Traditional Insulation Is Often Not Ideal

Economizers are not simple cylindrical equipment.

They include:

• Tube bundles and structural frames
• Connections and transitions
• Supports, instruments, and access points

Traditional insulation systems:

• Are difficult to apply accurately on complex geometry
• Can leave gaps or thermal bridges
• Are not designed for repeated removal
• Are often damaged during maintenance

As a result, long-term performance may be compromised.

Why Removable Reusable Blanket Insulation Is the Better Approach

1. Custom-Fit Blanket Insulation Design

Each blanket insulation / jacket insulation system is:

• Designed based on actual site geometry
• Manufactured to fit precisely

This ensures:

• Full coverage
• Minimal thermal bridging
• Consistent insulation performance

2. Removable Insulation for Maintenance

While the economizer body itself may not require frequent disassembly, surrounding areas often require access for:

• Inspection
• Cleaning
• Instrument servicing

With removable insulation blankets:

• Sections can be easily opened and reinstalled
• No damage to insulation during maintenance
• Faster and more efficient service work

3. Reusable Insulation = Long-Term Value

Unlike traditional systems, reusable blanket insulation:

• Can be removed and reused multiple times
• Maintains performance over time

This results in:

• Lower lifecycle costs
• More consistent energy performance

4. Ideal for Complex Equipment

Economizers are a typical example of equipment where:

• Geometry is irregular
• Access is required
• Thermal performance is important

In these cases, blanket insulation and jacket insulation systems are always more practical than fixed insulation.

Long-Term Benefits of Blanket Insulation

Over time, blanket insulation contributes to more stable system performance, reduced maintenance costs, and consistent energy savings. This makes it a reliable long-term solution for industrial heat recovery systems such as economizers.

Conclusion

Insulating economizers is a practical energy efficiency and safety measure. Using removable reusable blanket insulation (jacket insulation) provides additional advantages:

• Reduced heat loss
• Improved safety
• Maintained accessibility
• Long-term usability

Looking to Insulate Your Economizer?

At TAS Blanket Insulation, we design and manufacture:

• Removable reusable blanket insulation
• Custom jacket insulation systems
• Solutions tailored to complex equipment and fittings

Contact us to evaluate your system and identify potential energy savings.

With nearly four decades of experience, we manufacture precision-fit industrial insulation blankets for a wide range of industrial applications. You can read more about this on our website under the APPLICATIONS menu. View additional example projects on the ENERGY EFFICIENCY page, where fast return on investment is also quantified.

If we can assist you, please contact us or request a free TAS Energy Audit today.