Cargill Amsterdam · Heat Exchanger HX-01

Cargill GmbH
HX-01 Insulation Upgrade

Hairpin Heat Exchanger · 8 tubes · 46 m² surface · 225°C operating

April 2026 · Ref INZ-2026-CAR-AMS-001 · UK Patent GB2508992.1

Executive Summary

Project at a Glance

Modular insulation upgrade for heat exchanger HX-01 at Cargill Amsterdam — 46 m² surface, 225°C operating Power Plant. Based on 8,000 operating hours per year.

Annual Savings
1,132,285
EUR per year · 30,170 MWh saved
Payback Period
~12
months · break-even < 1 year
CO₂ Reduction
6,700
tonnes per year avoided
Project Investment
1,118,000
EUR · all-inclusive
Net Heat Rate
−6.5
· ~0.10% improvement
Gas Saved
~3M
m³ natural gas per year
Total Energy
102,935
MMBtu saved annually
15-Year Value
>15M
EUR cumulative savings

* Based on average 2025 actual heat rate: 6,164.94 (Net, LHV). Estimated annual net export: ~16.8 TWh/year (2.4 GW installed capacity, ~7,000 operating hours/year). Gas price: 11 EUR/MMBtu.

The Problem

Exposed Hot Surfaces · Continuous Heat Loss

Thermal Survey at HX-01 Units 11/12/21

Our on-site FLIR thermal survey at Cargill Amsterdam identified 8 uninsulated thermal components across three HX-01 units. Surface temperatures up to 300°C on non-metallic tube/flanges, valves, and flanged connectors create:

  • Continuous radiative and convective heat losses
  • Burn risk for operators and maintenance personnel
  • Elevated ambient temperature in trenches and pipe galleries
  • Wasted thermal energy: ~30,170 MWh/year
  • ~6,700 tonnes/year of avoidable CO₂ emissions
FLIR thermal image - tube/flange 194.4°C
FLIR thermal image - tube 165.7°C
Scope of Work

8 Components · 1 Heat Exchanger

Every component identified, measured, and engineered. Inzonex Modular Insulation panels designed to fit each surface precisely — clamshell construction with snap-fit assembly.

Tube trench overview Expansion joints row Bare heat exchanger — no insulation Hairpin HEX head Steam header piping Flanged connections
Interactive Model

Thermal Analysis · Before & After

Drag the slider to compare exposed tube with the Inzonex Modular Insulation upgrade. Click any of the 4 hotspots for per-tube heat loss data. Toggle Thermal Vision to see the 190°C surface heat. This view shows ONE typical trench — similar configurations in different combinations repeat across the project.

Equipment Breakdown

Thermal Savings Breakdown

Per ISO 12241 heat-loss calculation methodology. Single typical tube: 5.55 kW exposed → 0.18 kW with Inzonex (88.1% reduction).

Category Component Qty Surface Temp Annual Savings (EUR)
Expansion Joints Round non-metallic tube 312 190°C 750,000
Expansion Joints Oval non-metallic tube 36 190°C 110,000
Steam System Steam valves & flanges 252 180°C 272,285
Total (8 components) 8 — 1,132,285
The Solution

Inzonex Modular Insulation

Inzonex insulation layers

Materials & Compliance

  • Outer Shell: Silica-coated fabric, flame-retardant, abrasion-resistant, UV protected
  • Insulation Core: High-temperature mineral wool, up to +600°C continuous
  • Fasteners: AISI 316 stainless steel snap buttons
  • Stitching: Meta-aramid thread, +220°C continuous (ceramic up to +1000°C available)
  • Certifications: EN 13501-1 Class A1, REACH/RoHS, ASTM E84

Clamshell Construction · Tool-Free Access

Inzonex Modular Insulation for tube comes as two symmetric half-shells that close around the equipment like a clamshell. Snap-fit fasteners allow installation and removal in seconds — without tools, without disassembly, without process shutdown.

For HX-01 environments, panels use silica-coated fabric and AISI 316 stainless fasteners engineered to withstand temperatures up to 1000°C with full corrosion resistance.

Performance Benchmark
190°C
Bare tube surface
≤55°C
With Inzonex (safe touch)
5.55 kW
Heat loss per tube
0.18 kW
With Inzonex (−88.1%)
Investment

Investment

Ready to Recover 30,170 MWh per Year?

Start saving 1,132,285 EUR annually. Payback in ~12 months.

Approve Proposal →