Typical heat losses identified across reactor vessels, distillation columns, and heat exchangers in chemical plants.
Detection rate for corrosion under insulation using infrared thermographic survey methodology.
Average payback period for insulation upgrades on high-temperature chemical process equipment.
Chemical Processing
Heat Loss Audit
Chemical processing plants operate reactor vessels, distillation columns, and heat exchangers at extreme temperatures — all critical sources of thermal loss. Our specialised heat loss audits for the chemical sector use advanced infrared and drone-based thermography to identify insulation failures and thermal inefficiencies, delivering a clear roadmap to cut costs, improve process efficiency, and reduce emissions.
The Heat Loss Challenges
Facing Chemical Processors
From reactor vessels to distillation columns and heat exchangers, every thermal process holds untapped savings potential.
Reactor Vessel Insulation
Reactor vessels operating at high temperatures lose significant energy through degraded insulation, damaged cladding, and corrosion under insulation (CUI) — a hidden but costly problem.
Distillation Column Losses
Tall distillation columns with extensive surface areas and multiple temperature zones are particularly susceptible to insulation degradation and significant heat losses.
Heat Exchanger Efficiency
Poorly insulated heat exchangers, connecting pipework, and valve assemblies waste energy that should be transferred within the process, reducing overall plant efficiency.
CUI & Safety Risks
Corrosion under insulation (CUI) is a major safety and integrity concern. Thermal imaging can detect moisture ingress and insulation failures before they lead to equipment failure.
Our 4-Stage
Methodology
A structured approach tailored to chemical processing environments, combining drone thermography with on-site assessment.
Comprehensive Heat Loss Audit
Thorough evaluation of your facility combining advanced infrared thermography, environmental data logging, and hands-on on-site inspections to pinpoint every source of thermal loss.
Our engineers deploy drone-based infrared thermography for elevated or hard-to-reach assets such as rooftops, flue stacks, and overhead pipework, while ground-level inspections use calibrated IR cameras to capture surface emissivity variations. The resulting thermal profile is cross-referenced with ambient temperature, wind speed, and process data to quantify real-world heat dissipation rates.
Detailed Reporting & Analysis
Comprehensive deliverables including annotated thermal images, calibrated heat maps, and quantitative data that clearly highlight priority areas of concern.
Each report includes high-resolution thermograms with temperature gradients, a ranked deficiency register prioritised by energy impact, and projected annual savings in both kWh and cost. Where applicable, we benchmark your facility against industry norms so you can measure performance relative to best practice.
Insulation & Mitigation Solutions
Tailored engineering recommendations covering insulation thickness calculations, material selection, and installation techniques suited to your operating environment.
We specify insulation systems based on operating temperature, pipe diameter, and ambient conditions, selecting from mineral wool, calcium silicate, cellular glass, and flexible elastomeric foams. Every recommendation addresses condensation prevention, safe-to-touch surface temperatures, and corrosion under insulation (CUI) risk, supported by a full cost-benefit analysis that includes projected CO₂ reduction and payback period.
Partnership with AAI Drones
Strategic partnership with AAI Drones delivering drone-based infrared thermography that safely surveys hard-to-reach, elevated, or hazardous areas without scaffolding or shutdowns.
Drone surveys eliminate the need for costly access equipment and reduce on-site safety risk, while covering large roof areas, storage tanks, and elevated pipework in a fraction of the time of conventional methods. High-resolution radiometric sensors capture pixel-level temperature data, enabling our engineers to detect insulation voids, moisture ingress, and thermal bridging with pinpoint accuracy.
What You
Receive
Actionable intelligence, not just a report — everything you need to make investment decisions.
Thermal Survey Report
Comprehensive infrared thermographic survey of all reactors, columns, exchangers, and pipe networks with annotated thermal images.
Heat Loss Quantification
Precise calculation of heat loss rates (W/m²) across all surveyed assets with comparison to design specifications and economic insulation thickness.
CUI Risk Assessment
Identification of areas at high risk of corrosion under insulation using thermal anomaly detection, prioritised for remediation.
Insulation Improvement Plan
Specific recommendations for insulation upgrades including materials compatible with chemical process environments and operating conditions.
Carbon Reduction Roadmap
Phased plan showing CO₂ reduction trajectory from insulation improvements aligned with Net Zero and emissions reduction targets.
ROI & Investment Case
Board-ready financial analysis with NPV, IRR, and payback calculations for each recommended insulation improvement.
Proven Results
in Chemical Processing
Based on completed heat loss audits across chemical plants, petrochemical facilities, and specialty chemical manufacturers.
Chemical Processing
Audit Questions
Common questions from chemical plant operators about our heat loss audit service.
Ready to Reduce
Heat Loss?
Our chemical processing specialists are ready to identify thermal savings across your facility.
- Advanced infrared & drone-based thermography
- Chemical Processing-specific thermal benchmarking
- Detailed insulation & CO₂ impact report