Solar radiation on above-ground LPG lines often leads to pump failures due to vapor bubble formation. A flow simulation proves: ISORYX drastically reduces heat absorption and protects against CUI.
At filling stations, above-ground pipelines, especially those for liquefied petroleum gas (LPG), are exposed to massive solar radiation. The consequence: the medium inside heats up, pressure rises, and pumps can fail due to the formation of vapour bubbles (cavitation). Conventional insulation is often bulky, high-maintenance, and prone to corrosion under insulation (CUI).
The Physical Challenge: Solar Heat Input and Plant Safety
When LPG lines lie in the blazing sun, their dark or metallic surfaces absorb enormous amounts of heat energy. For filling station operators, this represents a massive safety and operational cost risk. As soon as the temperature of the medium reaches the boiling point at a given pressure, gas bubbles form. These implode inside the pump – a phenomenon known as cavitation – leading to mechanical destruction and costly downtime.
An effective solution must therefore not only stabilize the internal temperature but also persist long-term under the harsh conditions of a filling station (fuels, weather, UV light).
How ISORYX Reflection-Barrier Works
In contrast to classic insulating materials that only delay heat flow over time, ISORYX addresses the root cause: radiation absorption. The coating reflects over 90% of incident infrared radiation (thermal radiation). The ultra-thin layer acts as a heat shield directly on the substrate.
Due to its extremely low emissivity, radiation absorption is drastically reduced before the heat can even penetrate the pipe material. This makes ISORYX the ideal solution for all types of above-ground media transport.
Simulation Results: Uncoated vs. ISORYX
In a professional flow simulation (CFD - Computational Fluid Dynamics), a 50 mm aluminum pipe was examined under solar radiation of 1000 W/m². The simulation compared an untreated pipe with an ISORYX-coated surface.
| Parameter | Without Coating | With ISORYX |
|---|---|---|
| Absorbed heat flow | High (> 400 W/m) | ~47.5 W/m |
| Medium temperature rise | Critical | ~0.08 °C |
| Layer thickness | 0 mm | < 1 mm |
| Corrosion risk (CUI) | High (with insulation) | Non-existent |
| UV resistance | Material dependent | Excellent |
Minimal Heating, Maximum Process Stability
The simulation results are clear: while unprotected lines quickly reach critical temperatures, the temperature rise of the medium with ISORYX remains at only 0.08 °C under test conditions. The LPG remains stable in the liquid phase, and the risk of gas bubbles is eliminated. This ensures maintenance-free operation of LPG pumps, even during extreme heat periods.
Versatile Industrial Applications
The benefits of ISORYX pipe protection are not limited to LPG filling stations. Wherever media must be protected from ambient heat or condensation must be avoided, the system offers advantages:
- LPG & LNG: Above-ground storage tanks and supply lines for liquefied petroleum gas and liquefied natural gas.
- Fuel Infrastructure: Pipelines at tank farms and loading stations to reduce evaporation losses.
- Chemical Industry: Protection of temperature-sensitive process media in outdoor facilities.
- Water Pipes: Protection against unauthorized heating (e.g., drinking water hygiene) or as condensation protection for cold pipes in warm halls.
- LPG Tanks: Coating of above-ground gas tanks in private and commercial sectors for pressure stability.
Advantages for Operators and Maintenance Staff
- Cavitation Prevention: Reliable protection of LPG pumps against mechanical damage caused by vapor bubbles.
- Permanent CUI Protection: Since ISORYX adheres fully to the pipe, no moisture can reach the metal. Corrosion under insulation is excluded.
- Easy Inspection: Pipelines and weld seams remain accessible for visual inspections and non-destructive testing (NDT) at all times without having to remove insulation.
- Space-saving Application: With a layer thickness of less than 1 mm, it is ideal for the narrowest shafts, wall penetrations, or complex groups of fittings.
- Weather Resistance: 10-year system warranty on the protective effect when applied correctly.
ISORYX offers heat protection that isn't bulky but works where it counts: directly on the surface of the pipe. It solves the dilemma between effective insulation and necessary corrosion protection.
Frequently asked questions
Why is cavitation a problem for LPG pumps?
If the LPG in the line heats up too much, vapor bubbles form. These implode in the pump and lead to massive mechanical damage (material erosion) and system failure. ISORYX prevents this overheating by reflecting solar radiation.
What is 'Corrosion under Insulation' (CUI) and how does ISORYX prevent it?
With conventional insulation, moisture often collects between the pipe and the insulating material, leading to undetected corrosion. ISORYX is a directly adhering coating without cavities, which physically eliminates CUI because no moisture can reach the metal.
Can ISORYX be applied to existing pipelines?
Yes, ISORYX can be easily retrofitted to cleaned and, if necessary, primed metal pipes. The operation of the filling station usually does not have to be interrupted, which is a major advantage over complex insulation work.
Is ISORYX resistant to fuels and chemicals?
Yes, the ISORYX coating has high resistance to common fuels, oils, and atmospheric chemicals, making it ideal for use in filling stations and industrial plants.
What is the service life of the coating outdoors?
ISORYX is extremely UV-stable and weather-resistant. When applied professionally, we offer a 10-year system warranty on the protective effect, although the actual service life is often significantly longer.
Does ISORYX also prevent water pipes from freezing?
ISORYX massively reduces heat exchange via radiation. It alone does not provide full protection against the freezing of stagnant water during prolonged frost like thick insulation, but it delays the process significantly and, above all, prevents heating in summer.
Can ISORYX be colored to identify lines?
ISORYX is supplied in white as standard, as this offers the highest reflection. However, it can be tinted in light pastel shades, although a slight reduction in reflection performance must be noted. Safety marking rings can be applied over the coating for identification.
How is ISORYX applied to pipelines?
Application is usually carried out using airless spray methods or, for smaller areas, with a brush/roller. A clean, grease-free surface is important. The low layer thickness allows for fast drying and easy processing even on complex geometries.
