If advanced insulation systems offer so many benefits, why would the value of energy not be realized? Here’s why:.
Dyplast’s primary focus has been on Industrial/Commercial Mechanical Insulation Systems which encompass lower-temperature pipe, equipment, and tanks. [Lower Temperature Insulation Systems range from low-temperature steam (<350°F) through hot water, chilled water, refrigeration, and down to cryogenic.] Almost every power plant, petrochemical, pharmaceutical, liquid natural gas, ethylene plant, etc. has a considerable amount of pipe and equipment operating at temperatures close to low-pressure steam down to cryogenic. Such systems include steam system condensation, lube oil cooling, chilled water, gas compression/expansion, and cold liquid distribution, among many others. Indeed, virtually all commercial buildings have significant HVAC systems operating at below-ambient temperatures, as do industrial food processing and storage facilities.
“Industry” consumes roughly 24% of U.S. electrical generation. A conservative assumption is that 30% of this energy goes toward mechanical system “building” and “room” heating/cooling, and 70% toward “process”. Again, conservatively, empirical audits point toward at least 25% of energy consumption going toward lower-temperature processes (<350°F) with mechanical equipment that requires insulation. The average net R-value per inch in insulation around pipes and equipment is at best 3.5 per inch. Polyiso, at an aged R-value of 5.6, could thus increase thermal efficiencies by 60%. Again, we do not expect all industrial facilities to retrofit to new insulation next year, so let’s assume a reasonable 10% do (motivated by increasing realization of a positive < 3-year ROI). This results in a reduction of electricity consumption by 4.2%. Considering transmission line loss, this could be 5% “at the fence” of the power generation plant. This once again results in a positive ROI for the end-user.
This reduction in electricity consumption is equivalent to 20% of the coal generation.
As previously stated, increased utilization of Advanced Insulation Systems has the highest likelihood of having a material impact on regional, national, and indeed global energy consumption with integral impact on climate change and sustainability. Dyplast is working to reverse negative trends by offering aggressive, full-disclosure of information, while working hand-in-hand with the industry and standards organizations use to enhance the abilities of end-users to readily select their optimal insulation systems.
There are many alternative insulants utilized in mechanical pipe and building envelop applications. The selection of the optimal insulant can appear daunting, but it doesn’t need to be! Dyplast offers that we can demonstrate that Polyisocyanurate is ideal in the vast number of applications from cryogenic to 350°F due to its:
This and subsequent Blogs will address each of these issues, and more. Stay tuned!
But for the first blog in this series, let’s start by asking the question: “If advanced insulation systems are such an obvious solution to major global energy and environmental challenges, why haven’t they already been implemented?” Let’s find out!
Energy has a long and complex value chain from origination through end-user consumption. In addition to minimizing the loss of energy along the chain, issues related to pollutants, emissions, and of course costs are inextricably linked. Each of the multiple chains includes a role for insulation in both hot and cold applications to varying degrees.
This includes the extraction/origination of oil, coal, natural gas, plus energy originating from nuclear power, wind, hydropower, geothermal power, and wave sources. During the origination of energy, it is also important to look at:
We have multiple corporate and employee initiatives that focus on regional high schools and universities as we’ve built ongoing relationships with students in such areas as:
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The event was hosted by Dyplast at its Miami facility as part of a Manufacturers Industry Roundtable Event sponsored by the South Florida Manufacturing Association. Opening remarks were presented by Ted Berglund, President & CEO of Dyplast followed by Matt Rocco, President of the SFMA who shared insights on how collectively the association and its members are handling the talent shortage and skill training revamp that’s needed.
The interactive discussion led by Department of Commerce Secretary Ross invited manufacturers to share ways in which manufacturers could use existing resources, that with some fine-tuning, could be expanded to impart the greatest impact in workforce development. Secretary Ross also asked about activities that the industry could partake in to attract younger talent in manufacturing. Among the ideas offered, the dialogue centered around creating a manufacturing-focused certification program, establishing an open house forum for counselors and parents to attend manufacturing facilities, streamlining the time in takes to have an apprentice program approved from eight-months to two-months, and even considered the possibility of expanding the already federally funded Job Corps program to establish a machinist apprenticeship program within their purview.
We are grateful to have had the opportunity to represent our perspectives on the workforce development within our industry, not only within the Southeast but Nationally.
About Dyplast Products:
Headquartered in Miami, FL, Dyplast has been a leading manufacturer of polyisocyanurate (a modified polyurethane) and expanded polystyrene products - - including innovative and cost-saving pipe and equipment insulation, sheet/block insulation, and leading-edge products for the composites industry. Insulation solutions include an array of low temperature applications such as cryogenic, chilled water, refrigeration, low temperature steam, and hot process lines. Additionally, our insulation sheets are ideal for insulated metal panels, architectural panels, and specialty applications.
We are so proud of the achievements of all the nine teams from Rockway, but in particular Rock-G-Bots (an all-girls team) and RockBots 2929-A (6th graders). Team 2929A qualified for World Competition & won 2 awards (Sportsmanship & 2nd Place in Teamwork) at the South FL VEX State Championship! VEX Rock-G-B got to finals at US Open CREATE Robotics Championship in Iowa. They teamed up with Team 8193C from Shanghai China (yes each team must team with another), to compete against the 80 best teams from China &USA.
As Vincent Fuster, CFO of Dyplast and active supporter of the Robot Teams, summarized in his Tweet “When these young engineers work all season long and experience accomplishments like these, that’s when they realize that perseverance, dedication and discipline really pays off. Top two in the nation in skills and top 12 teams in teamwork...WOW...!!!!”
This will be the 7th consecutive year that Dyplast has been honored with the Safety Award, the last 6 of which have been NIA's highest level---Platinum.
Previously, Dyplast received its first Silver Award in 2012. Congratulations to the entire Dyplast Team on this outstanding achievement!
Holey-Board is Dyplast Products expanded polystyrene (EPS) foam insulation specifically designed for user in lightweight concrete (LWC) roof applications. It is a rigid cellular, lightweight, resilient, foam board with excellent physical properties. When structural concrete roofing applications demand high value insulation, Dyplast Holey-Board leads the way.
It cost-effectively provides superior energy efficiency, temperature range, damage and moisture control, low flammability rating, and low moisture vapor permeability. Dyplast's new facility utilizes the latest EPS technology and equipment, producing quality that leads the industry. Holey-Board is lightweight, sturdy, and workable, making it easy for one person to handle and install.