Process Heating and Heat Containment

Process heating is essential in the manufacture of most consumer and industrial products, including those made out of metal, plastic, rubber, carbon fiber, concrete, glass, and ceramics. Process heating systems can be broken into three basic categories: fuel-based, electric-based, and steam-based heating. Proper heat containment methods in all of these categories ensures that the least amount of heat is wasted throughout the system. Applying best energy management practices and purchasing energy-efficient equipment can lead to significant savings in process heating and heat containment systems.


Basic Learning Materials

If you are new to process heating or are unsure of how efficient your system is, a great place to start is familiarizing yourself with the basics and checking if you have already implemented the most basic energy saving measures.

The Process Heating Info Card contains a brief summary of the top energy saving measures you can implement in your plant.

The Improving Process Heating System Performance Sourcebook contains a more detailed explanation of process heating methods.


Courses and Videos

For a more detailed learning experience, check out the eLearning and video courses available online.

Combustion Basics

Author: Armstrong University

A course on combustion and boiler basics

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Combustion Processes

Author: Schneider Electric

A course covering combustion basics

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IAC 101 Basics of Process Heating

Author: Industrial Assessment Centers

20 minute video describing process heating basics

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IAC 101 Heat Containment and Reusing Waste Heat

Author: Industrial Assessment Centers

15 minute video on heat containment and heat recycling methods

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Industrial Insulation I

Author: Schneider Electric

An introduction to insulation basics

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Industrial Insulation II

Author: Schneider Electric

A course covering the design of insulation data calculations

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Industrial Insulation III

Author: Schneider Electric

A course covering insulation inspection and maintenance

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Tools and Calculators

There are many resources available to help you calculate specific costs and savings for your plant. Some of these tools, calculators, and software are listed below.

3E Plus Insulation Calculators

Author: 3E Plus

Calculators used to estimate how much insulation you need

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Combustion Excel Spreadsheet

Author: GCCoE

A spreadsheet tool used with MEASUR to optimize combustion

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MEASUR Air Heating Using Flue Gas Tool

Author: U.S. Department of Energy

Savings calculator for flue gas heating

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MEASUR Flue Gas Loss Tool

Author: U.S. Department of Energy

Calculator for savings with improving flue gas loss

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MEASUR Pipe Insulation Calculator

Author: U.S. Department of Energy

A calculator used to estimate amounts and effects of pipe insulation

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MEASUR Pre-Assessment Screening Tool

Author: U.S. Department of Energy

A tool used to record utility and other data before an assessment

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MEASUR Process Heating Assessment Tool

Author: U.S. Department of Energy

A tool used to do a comprehensive analysis of a heating system

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These and other resources can be found on the Resource Library page.