I-Cover™ Case Study - Solving Critial Insulation Failures I-Cover™

Solving Critical Insulation Failures: How KLAY EnerSol’s I-Cover™ System Transformed a Fertiliser Plant’s Efficiency

When a major chemical fertiliser plant in Malaysia began struggling with energy inefficiencies and heat loss, the issue pointed to a common culprit — aging insulation that could no longer keep up with the plant’s high-temperature operations. The result? Significant heat loss, higher fuel consumption, and nearly US $250,000 in annual energy costs.

KLAY EnerSol stepped in with a smarter approach: the I-Cover™ Insulation Jacket paired with the Flexible Tube Sleeve. A modern insulation system designed to solve the plant’s most persistent performance problems.

The Challenge: Heat Loss, Sagging, and Inefficiency

The plant’s insulation relied on conventional seal sleeves and ceramic blankets that were rigid and prone to sagging. Over time, these systems became ineffective, especially around the tight bends and complex hairpin tube arrangements found throughout the facility.

Thermal imaging revealed critical “hot spots” where heat escaped due to gaps and deformed insulation. Poor adaptability, sagging during thermal cycles, and the need for frequent maintenance further added to downtime and operational costs.

Solving Critical Insulation Failures with I-Cover™ System

KLAY EnerSol stepped in with a smarter solution: the I-Cover™ Insulation Jacket paired with the Flexible Tube Sleeve — a precision-engineered system designed to deliver consistent thermal protection, eliminate sagging, and simplify maintenance even on complex tube geometries.

The results spoke for themselves — significant heat-loss reduction, improved operational stability, and measurable fuel savings.

This project showcases how modern insulation design can go beyond protection to drive real energy efficiency and reliability.