aerogel industrial presentation april 2011

Confidential & Proprietary

Flexible Aerogel Insulation for Industrial Applications

April 2011


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Presentation Outline

• Product Overview

• Hot Work

• Cold Work

• Reference Projects

• Questions


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The Aerogel Advantage:Superinsulation performance

in a flexible blanket form

What Is An Aerogel?

• Aerogels are nanoporous solids invented in the 1930’s– Aerogels are created when silica is gelled in a solvent

• When the solvent is removed, what remains is “puffed-up sand”, with up to 99% porosity

– Nanopores cage the air molecules, retarding heat flow

– Long molecular chains increase the solid path-length through the silica, reducing thermal conductivity

• Twin innovations helped move aerogels from lab curiosity to industrial product

– Supercritical CO2 extraction reducescycle times from months to hours

– Casting the wet gel into a fibrousbatting provides mechanical integrity


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Aerogel Thermal Performance – With the Flexibility of a Blanket

• Start with a non-woven blanket– Typically polyester, glass,

carbon, or ceramic fiber

• Fill that blanket with a wet gel

• Remove the solvents via supercritical CO2 extraction

• Roll the blanket onto a spool

Step 1:Fill fibrous batting with a liquid-solidsolution

Step 2:Extract solventswith supercriticalcarbon dioxide

Step 3:Resulting dry,fiber-reinforcedaerogel blanket


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Aspen’s Aerogel Manufacturing ProcessS

ilica

Sol

Cat

alys

t

Dop

ants

Rolls packedfor shipment

Dry fiberblanket

Casting

Gelation

Supercriticalextraction

Drying


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Aerogel Factory In East Providence, RI

CastingCasting ExtractionExtraction

DryingDrying Tank farmTank farm


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Heath and Safety Aspects of Aerogels

• Aerogels are an amorphous (non-crystalline) silica with 97% of particles larger than 45m

– Only the pores are nano-scale (~0.01 m)

– Aerogel particles are much larger

• Amorphous silicas have been studied by OSHA, EPA, and the OECD, concluding:

– “Demonstrated lack of toxicity, mutagenicity.”

– “Is not expected to pose a carcinogenic risk.”

– “Silicas are inert when ingested, and unlikely to be absorbed through the skin.”

– “No concerns for human health.”

• Typical dust loading in fab-shop is <5 mg/m3

– OSHA limit for amorphous silica is 80 mg/m3

Aerogel (amorphous silica)

Crystalline silica

Recommended PPE is paper dust mask, work gloves, and safety glasses


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Aerogels Are Nanoporous, Not Nanoparticles

0%

25%

50%

75%

100%

<45 m 45 to 75 m 75 to 150 m >150 m

Par

ticl

e C

ou

nt

His

tog

ram

0.001 0.01 0.1 1 10 100 1000

Red blood cellTobaccosmoke

Nanoparticles

3%11%

33%

53%

Aerogel nanopores(tiny air pockets)

Particle size(microns)

Air sampling in an aerogel fabrication shop reveals that 97% of dust particles are larger than 45 microns

Cutting or installing Pyrogel or Cryogel does not generate “nanoparticles”

Cumulative


-9-

Aspen’s Industrial Products Span the Temperature Range

1200

1000

800

600

400

200

0

-200

-400-200

-100

0

100

200

300

400

500

600

°F°C Pyrogel XT (5 and 10 mm)Pyrogel XT (5 and 10 mm)-40°F to 1200°F (-40°C to 650°C)-40°F to 1200°F (-40°C to 650°C)

Cryogel Z (5 and 10 mm)Cryogel Z (5 and 10 mm)-460°F to 200°F (-273°C to 90°C)-460°F to 200°F (-273°C to 90°C)

• 2 to 3 times lower k-value than cellular glass or PUR/PIR foams

• Fast, simple installation is insensitive to workmanship or site conditions

• Excellent durability and fire resistance• Available with integral vapor barrier:

– Single-step installation– Multiple plies provide system

redundancy

• 3 to 5 times lower k-value than perlite, calcium silicate, cellular glass, or mineral/glass fiber

• Excellent productivity, especially on towers, vessels, and large pipe

• Water repellant

• Resists mechanical abuse and thermal degradation


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Aerogels Have the Lowest k-Value of Any Industrial Insulation

0

50

100

150

200

250

-200 -100 0 100 200 300 400 500 600

Temperature (°C)

Th

ermal C

on

du

ctivity (mW

/m-K

)Pyrogel XT

Perlite

Mineral WoolPipe & Board

Calsil

Cryogel Z PUR/PIR

Mineral WoolBlanket

-400 -200 0 200 400 600 800 1000 1200Temperature (°F)

Th

erm

al C

on

du

ctiv

ity

(Btu

-in

/hr-

ft2 -

°F)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Cellularglass


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Traditional Insulation Thickness Ratios vs. Pyrogel XT

0

1

2

3

4

5

0 100 200 300 400 500 600 700Process Temperature (°C)

Incu

mb

ent

Th

ickn

ess

/ XT

Th

ickn

ess

100 200 300 400 500 600 700 800 900 1000 1100 1200Process Temperature (°F)

Mineral Wool Mineral Wool Pipe & BoardPipe & Board

Mineral WoolBlanket

Calcium Silicate

Expanded Perlite

Cellular Glass

Ratios provide equal resistance in planar configurations.Does not account for geometric effects of pipe cover.


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Weight Per Unit Area for Equivalent Thermal Performance

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

ExpandedPerlite

CalciumSilicate

MineralWool Blkt

MineralWool Pipe

CellularGlass

PyrogelXT

Are

al D

ensi

ty (

lbs/

sqft

) fo

r R

-1

Pyrogel XT enables lighter designs at the same level of

thermal protection, reducing loads on pipes, shoes and hangars


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Pyrogel Resists the Enemies of Insulation: Water, Heat, and Abuse

Water RepellantDuring Katrina, an aerogel-

insulated pipe was flooded with sea water. Afterward, the pipeline

was drained, dried, and retested with no degradation. That pipe was then sealed, and is now in service off the coast of Africa.

Insulated Insulated spacespace

Damage TolerantCryogel and Pyrogel easily withstand most impact or

compressive loading events (e.g., footfalls, tool strike), and will spring back to the original

performance even at loads > 100 psi. Further, because

there is no brittle failure mechanism (its a flexible

blanket), damage remains local and will not propagate.

Thermally StableAspen Aerogel’s products do not use organic binders, so will not crumble or sag in hot service.


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Pyrogel XT Shows No Thermal Degradation at 930°F (500°C)

0

100

200

300

400

500

600

0 10 20 30 40 50 60 70

100

200

300

400

500

600

700

800

900

1000

1100

Elapsed Time (days)

Tem

peratu

re (°F)T

emp

erat

ure

(°C

)

Hot face

1-2 interface

2-3 interface

3-4 interface

Cold face

Long-termpipe test rig


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Aerogels Will Not Promote Corrosion Under Insulation (CUI)

• Pyrogel and Cryogel are durably water repellent, even at high temperatures

• The open-cell nature of Aspen’s Aerogel blankets allows any water that gets around or beneath the insulation to evaporate out

• Aerogel pH is engineered to be > 7

Pyrogel is super-hydrophobic, yet also… …water vapor permeable

Water droplet withcontact angle >150°

Steam penetrates Pyrogel from kettle

underneath


Hot Applications


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Pyrogel XT Has Many Benefits On Hot Process Equipment

MineralWool or

Fiberglass

ExpandedPerlite

CalciumSilicate

3½”

2½”

3”

Pyrogel XT

6” pipe at 600°F(315°C)

• Industry’s best k-value saves energy with 2-5X less material

– Greater space efficiency

• Installation productivity– Shop- or field fabrication– Very fast in 1 & 2 ply designs– Single-man installs– Good in difficult-access areas

• Greater in-service durability– Durably hydrophobic– Will not crack, crumble, or sag

• Reduces jacketing, banding, and vapor barrier costs

• Packed volume reduced 5-10X– Less scrap, trucking, storage

• Single part number simplifies logistics, planning

• Excellent fire protection20 mm(0.8”)

All four designs provide the same level of thermal protection

Ambient conditions = 65°F, 2 mph wind, 0.1 emissivity


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Installation of Flexible Aerogel Blankets Is Fast and Intuitive

Pyrogel blanket wraps over the pipe

Cladding & banding provide mechanical and

weather protection

Butt joints (staggered if using

multi-ply construction)


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Flat-Pack Elbows Ship Easy and Install fast

Pre-kitted “lobster tail” elbows ship flat for better packing efficiency

Multi-layer lobster tails are quickly layed up on the elbow and taped in place

Subsequent layers are installed with a

staggered joint pattern

The finished elbow is covered with a vapor barrier and jacketed with metal


-24-

Pyrogel Enables Increased Pipe Density

Insulation Material Pyrogel Rigid Pipe Cover

20.75 in.16.25 in.2 in.

14.63 in.10.13 in.

8.38 in.5.38 in.

* Assumes 2 inch clearance space

2” Pipe: 56% more on a rack




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Aerogel Offers Simplified Inventory Management and Logistics

• Results of a trade study of a typical new-build plant insulation project…

Rigid Pipe Cover Pyrogel

Distinct Part No.’sInsulation only

28 1

Distinct Parts45:1 ratio

36,000 pieces 790 rolls

Packed Volume 6:1 ratio

5700 m3 930 m3

Packed Footprint2 m stack height

53 m x 53 m 22 m x 22 m

Pyrogel can reduce the material handing and inventory management required on big jobs


-26-

Pyrogel Reduces Local Portage of Insulation Materials

• A 3” pipe at 300°F can be insulated with 1” of fiberglass or ¼” of aerogel

• Under many workplace rules, one person can lift no more than 40 lbs

• A 40 lb box of 3x1 fiberglass weighs 40 lbs, and insulates 27 lineal feet

• A 40 lb roll of aerogel would insulate 188 lineal feet

• Using aerogel instead of fiberglass reduces manual portage by 7X

188 ft of 3” pipe with fiberglass = 7 trips

188 ft of 3” pipe with aerogel = 1 trip

Stagingdepot


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Cryogel Z and Pyrogel XTF Provide Excellent Fire Protection

0

1

2

3

4

5

0 25 50 75 100 125 150 175 200Thickness (mm)

Tim

e to

100

0°F

(h

ou

rs)

Cryogel Z

Pyrogel XTF Cellularglass

ExpandedPerlite

0 1 2 3 4 5 6 7 8Thickness (in)

UL 1709 test results based on a 10W49 I-beam:

Time-to-failure for different insulation types and

thicknesses

Calcium Silicate

Better

Worse


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A Pyrogel XT Over-Wrap Can Resuscitate Dying Insulation

Degraded insulation

Damaged cladding

Pyrogel XT 10mm over-wraps keep in the heat

and dry out wet insulation

Butt joint

New cladding & banding re-weatherize the surface

Lap joint

Field proven tobe a fast, cheap, and effective repair


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Damaged Insulation

206 Btuhr-ft

162°F

Assumed Conditions:90°F, no wind, = 0.13

Minwool TC tripled when wet

6” x 2”Fibrous Insulation

on 125 psi Steam Pipe(344°F)

Immediate Benefit

121 Btuhr-ft

135°F

Watervaporescapes

Long Term Benefit

84Btuhr-ft

123°F

Two-Step Recovery: Capture the Heat. Dry Out the Insulation.

• The Pyrogel XT over-wrap instantly reduces heat loss and touch temperatures

• The underlying insulation heats up

• If that insulation is wet, much of the water is driven out, escaping through joints in the cladding

– Pyrogel XT’s combination of permeability and hydrophobicity mean that water vapor passes through, but doesn’t stay


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Pyrogel-Over-Mineral Wool for Temperatures Below 250°C

• Recent independent testing compared different insulation systems to conditions known to promote CUI:

– Uncoated carbon steel pipe– Cyclic operation between ambient and

80°C every seven days– Constant exposure to a slow water drip

• Insulation materials included:– Cellular glass– Calcium silicate– Expanded perlite– Elastomeric foam– Mineral wool– Pyrogel XT over mineral wool

• Of the eight systems tested, only one was 100% corrosion-free after three months:

– Pyrogel XT over mineral wool

10 mm Pyrogel XT over 30 mm mineral wool

CUI test rigs


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Mineral Wool-Over-Pyrogel for Temperatures Above 250°C

• Mineral wool over Pyrogel saves space by using the materials where they’re most effective

– PGXT at high temperatures– MW at low temperatures

• The cost of the Pyrogel is minimized by using it at the smallest diameters

• The burnout of the mineral wool binders is minimized by limiting its exposure to the highest process temperatures

– This should increase the mechanical durability and overall longevity of the system

100

200

300

400

500

100

200

300

400

500

6” pipe550°C

Burnoutzone


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-230

10170

20120

3080

4050

5030

60-

$200

$160

$120

$80

$40

PGXT (mm)MW (mm)

Mat

eria

l Co

st (

US

D/m

)

Pyrogel XTMineral WoolAlum. Jacket + Bands

Mineral Wool Over Pyrogel XT Can Be the Low-Cost Solution

NPS = 6”Tin = 550°C

Total (mm) 230180140110908060

All seven designs have equivalent heat loss


Cold Applications


-37-All three designs meet the same condensation control criteria

70 Btu/hr-ft73°F

73°F70 Btu/hr-ft

57 Btu/hr-ft73°F

• At the same touch temperature, Cryogel has much less surface area:

– Up to 50% less heat gain and BOG– Requires 35% less jacketing,

banding, and vapor barrier materials

• Packed volume reduced > 6X– Lower trucking & storage costs

• Contraction joints can be eliminated

• Cryogel’s low-temperature flexibility provides excellent in-service durability

– No cracking or thermal shock– Resists impact from footfall, tool

strikes– Stiffer support of jacketing means

fewer dents and buckles

• Cryogel is 20% lighter than PIR and 70% lighter than cellular glass

• More space efficiency in pipe racks

12” (300 mm)pipe at -274°F

(-170°C)

Cryogel Advantages In Cryogenics and Chilled Service

Cryogel(2 in)

Foam glass(4.5 in)

PIR(4 in)


-38-

Exceptional Installation Productivity On Cryogenic Piping

In addition to reducing labor, Cryogel blankets minimize sensitivity to workmanship

Cryogel Blankets

Rigid Pipe Cover

versus

Every joint buttered

Joint tape


-39-

Handling Cryogel-Z On the Job Site Is Simple and Efficient

Cryogel-Z, as delivered to site Material dispensed and cut to length

Cut-to-length pieces ready for installation, two plies at a time


-40-

Installation: Vapor Stop with 90-66 Prior to 1st Piece

Photo courtesy Zampell Insulation


-41-

Installation: 7 Layers (70 mm) Applied In 4 Pieces



-42-

Installation: Every Seam Butyl Taped



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Installation: 90-66 Application Prior to 3rd Piece



-44-

Installation: Build Cryogel Up to Existing Diameter

Cryogel diameter

Shoe diameter

10 inch Cryogel transition piece



-45-

Installation: Finishing Up with Alumaguard (Optional)



-46-

Installation: Finished Aerogel Product Before Jacketing



-48-

Cryogel Z’s Foil Facing Makes It Impermeable to Water Vapor

0

20

40

60

80

100

120

CellularGlass

CryogelZ

PIR Cryogel ExpandedPerlite

CalciumSilicate

MineralFiber

FibrousGlass

Per

m-i

nch


-49-

Cryogel Eliminates the Need for Insulation Contraction Joints

-200 -150 -100 -50 0 50

Temperature (°C)

SS pipestrain is -3.3 mm/m

Cryogelinner plystrain is-2.4 mm/m

Cryogel compresses

SteelPipeWall

1C

ryog

el P

ly N

umbe

r

2

3

4

5

6

Cryogel eliminates the expense, complexity, heat loss, and failure risk associated with insulation contraction joints

Conventional Contraction Jointfor PIR or Cellular Glass System

No Contraction Jointfor Cryogel System


-50-

Traditional Expansion / Contraction Joints Are Cold Spots


Reference Projects


Reference Projects

Subsea Pipe-in-Pipe


-56-

Cumulative Experience In Subsea Pipe-In-Pipe Flowlines

• Clients: ExxonMobil, Total, Maersk, Kerr-McGee, Eni

• EPCs: Technip, Saipem

• Projects: Marimba, K2, Rosa, Dalia, Ticonderoga, Affleck

• Scope: 70 miles of subseapipelines (6” – 11”) to date

• Dates: Sept 2004 – Present

• Process Temps: 140 – 180°F

• Design Goal: Flow assurance, and reducing the size, weight, and cost of the carrier pipe

• Results:– By the end of 2007, Aspen’s aerogel blankets will be

qualified for use by every major pipelay contractor

– By 2008, Aspen expects to have 40% of the PiP market

Aerogel

PUF


Reference Projects

Hot


-58-

Steam and Condensate Piping

• Location: La Porte, TX

• Scope: 10,900 feet of pipe

• Date: Oct-Dec, 2006

• Process Temp.: 180-500°F

• Design Goal: Heat conservation

• Insulation: 1½” Perlite 1 layer of ¼” Pyrogel

• Other Factors: T&M contract

• Results:

– Insulation “drag race” on adjacent 8” lines showed 5:1 productivity advantage

– Remainder of job was converted to Pyrogel 6350

– Job finished ahead of schedule and 26% under the original perlite bid


-59-

Asphalt Tank at Refinery in Halifax, Nova Scotia

• Scope: 45’x60’ tank (sides only)

• Date: April, 2008

• Process Temp.: 300°F


• Other Factors: VentureCladmembrane was used as thefinal weather barrier

• Insulation: 1 layer of 10 mm Pyrogel XT

• Results:

– Eliminated scaffolding entirely – two man-lifts used instead

– Insulation + jacketing completed in three days


-60-

Tank Roof in Baton Rouge

• Location: Baton Rouge, LA

• Scope: 150’ tank roof

• Date: Feb, 2007



• Other Factors: Installed during the rainy season

• Insulation: 2 layers of ¼” Pyrogel

• Results:

– Capacitor discharge weld pins used for attachment

– Protection from elements was not necessary

– Finished insulation covered with CP-11 spray mastic


-61-

160°F Vessel In Carrolton, KY

• Scope: 16’ x 20’ vessel,including elliptical heads

• Date: June 2006


• Design Goal: Personnel protection

• Insulation: 1½” rigid block w/ engineered head segments ¼” Pyrogel w/ field-fabricated heads

• Other Factors: Skeptical contractor had never worked with aerogel before

• Results:

– Tank insulated in 1 day with 3 people vs. 3-5 days estimated for cellular glass

– Heads fabricated on the spot vs. 4 week lead time for engineered segments


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Excellent Labor Productivity On Tanks, Towers and Vessels


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-70-

Condensate Tank

• Location: La Porte, TX

• Scope: 20’ x 40’ tank

• Date: November, 2006



• Insulation: 1½” Perlite 1 layer of ¼” Pyrogel

• Other Factors: Heavy weatherduring installation

• Results:

– Entire tank was insulated in one day

– Despite heavy rain fall, the aluminum jacketing was left off for a week; the insulation experience no damage or water absorption


-71-

Bullet Tank at Refinery in Le Havre, France

• Scope: 3 m x 10 m desalter (110°C);20 m of 12” pipe (390°C)

• Date: July-September 2008

• Design Goal: Heatconservation

• Insulation: 4 layers (40 mm) ofPyrogel XT vs. 100 mmMW blanket and 110 mm MW pipe cover

• Other Factors: Contractor’s first time using the material

• Results:– Long-term product durability will be

monitored w.r.t. CUI and energy efficiency


-72-

Hot Air Ducts for Industrial Dryers

• Location: Marshall, MN, USA

• Scope: 100’s of meters of ductworkfor an industrial dryer at a corn-processing facility

• Date: May, 2009



• Insulation: 20-70 mm of Pyrogel XT

• Results:

– Original mineral wool had become water-logged, heavy, thermally inefficient, and corrosive

– Pyrogel XT installed on the ground in a fraction of the time required for mineral wool


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-80-

SCR Duct, Billings, MT

• Location: Millings, MT

• Scope: 10-14’ SCR ducting

• Date: June, 2008



• Other Factors: Insulated theduct-work on the ground

• Insulation: 50 mm of Pyrogel

• Results:

– Fast, high-quality install

– Has now become the standardworldwide specification for SCR ducting


-81-

Large-Bore Water Lines Pre-Insulated with Pyrogel XT

• Scope: 60 miles of 36-48” water pipelines near Ft. McMurray, AB

• Design Goal: Freeze protectionduring a 12-hr flow stoppage

• Insulation Design: 0.4” (10 mm) of Pyrogel XT, jacketed with 0.125” (3 mm) of spray-applied polyurea coating, similar to truck-bed liner

• Results:– 80’ joints get insulated and jacketed

in Edmonton, then trucked 5-hours north for installation

– Pipes are laid directly on the ground, without use of sleepers or supports

– Field-joints are welded, insulated, and spray-coated on-site for a 100% sealed system Insulated pipe laid

directly on the ground

Water at 40°F (4°C)


-82-

80’ Joints Delivered to Indoor Fabrication Facility in Edmonton


-83-

High-Speed Pipe Spinners Ease Application of Insulation, Jacket


-84-

Single Layer of PGXT-10 Applied with Spray Adhesive


-85-

Pipes Get Insulated In One Section of the Shop…


-86-

…While the Jacket Gets Spray Applied in Another


-87-

Spraying Is Fast and Consistent with Minimal Overspray


-88-

Spray Application Yields Tough, Impermeable Membrane


-89-

System Easily Withstands Rigors of Transport, Installation


-90-

Insulation and Passive Fire-Protection of a Distillation Tower

• Scope: – 17’ OD x 230’ (5 x 70 m)

distillation tower

• Location: – Northern Italy

• Design Goals:– Heat conservation

– 90-minute passive fire protection per the UL1709 standard

• Results: – As the result of a fire, refinery capacity

was reduced by 70%

– Tower needed to be re-insulated and put back in service as quickly as possible

– All Pyrogel XTF was manufactured and air-freighted within 7 days ARO


-91-

Three Layers Pyrogel XTF Installed on Bottom Head


-92-

SS Bands Used to Harness Material to the Head


-93-

Floating Ring Used Around the Bottom Nozzle


-94-

Bands and SS Jacket used for Final Securement


-95-

Insulated from the Top Down, Removing Scaffold Along the Way


-96-

The Finished Article


-97-

Hot Air Ducts In an SCR Unit

• Scope: – 800’ of 10-12’ ductwork as part of a

flue-gas treatment project

• Location: – Northern California

• Process Temp.: – 750°F (400°C)

• Design Goals:– Heat conservation

– Process control (could not tolerate wet insulation)

• Results: – All duct-work was pre-insulated in

the contractors laid-down yard, then trucked or craned into place


-98-

Insulating Duct Supports


-99-

Insulating Duct Supports


-100-

Conical Reducer and Transition Section


-101-

Vessel Head with Manway


-102-

Completed Duct Section


-103-

Drum Head


-104-

Completed Duct Section


-105-

Distillation Tower at Refinery in Chalmette, LA

• Location: Chalmette, LA

• Scope: 166’ x 13’ diameterdistillation tower

• Date: September, 2007


• Design Goal: Process control

• Insulation: 7” perlite 4½” perlite + 3/8” Pyrogel

• Other Factors: Nozzles and ladder clips designed for only 4½” perlite

• Results:– Insulation cleared all the clips and nozzles

– Project finished 3.5 days ahead of schedule


-106-

Wellhead Lines for Devon Energy’s Jackfish SAGD Facility

• Client: Devon Energy, Northern Alberta

• EPC: Colt Engineering

• Scope: 9800 ft of 12”, 18”and 20” pipe

• Date: May, 2006



• Original Spec: 3½” calsil

• Other Factors: Skeptical contractors; calsil not available; remote job site

• Results:

– Faster installation than calsil; Aerogel accelerated jacketing process

– Much easier transport, with less waste, spoilage, and packaging debris


-107-

Ideal for Remote Locations, Large-Bore Piping


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-111-

Bridge Crossing Near Ft. McMurray, Alberta

• Scope: 800 m of 24” pipe,pre-insulated in Edmonton andtrucked 6 hours to remote site

• Date: Summer 2007

• Process Temp.: 149°C (300°F)

• Design Goal: 7-day cool-downto 60°C (140°F)

• Insulation: 3½” minwool w/ electric heat trace 3.3” Pyrogel, no heat trace

• Other Factors: Eliminate electric heat tracing, transformers, and utilities

• Results:

– Saved $330K in heat tracing and $100K per year in O&M costs


-112-

Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment


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-116-

Municipal Steam Tunnels In Baltimore, MD

• Scope: Removable covers formanholes, steam tunnels

• Date: November, 2007


• Design Goal: Personnelprotection, heat conservation,reduced blanket weight

• Other Factors: Tunnel floodedshortly after installation

• Results:– After the tunnel was flooded

for 10 days during a winter storm, the blankets were inspected and found to be “good as new”


-117-

Piping in Kawasaki, Japan

• Location: Kawasaki, Japan

• Scope: 8-12” piping

• Date: Nov, 2007

• Process Temp.: 325°C


• Other Factors: Productivity andperformance trial vs. 65 mm calsil

• Insulation: 18 mm of Pyrogel

• Results:

– Were able to insulate even in the rain

– Field-fabricated all fittings

– Pyrogel now accepted within all ExxonMobil refineries in Japan


Reference Projects

Cryogenic & Cold


-119-

LNG Import Terminal In St. John, New Brunswick

• Scope: >5000 m of cryogenic and utility piping

• Date: August 2008

• Process Temps.: -260°F (-162°C)to ambient

• Design Goal: Condensationcontrol; flash-freeze protection of fire-water lines in LNG spills

• Insulation: 2 layers (20 mm) Cryogel-Z over PIR

• Results:– Material was specified because of the reduced labor force, faster installation

schedule, and fire protection

– Contractor stated that wished he could have done 100% Cryogel, as it “would have gone on five times faster”


-120-

Traditional Cold Insulation System for LNG Service


-121-

Cryogel Requires No Contraction Joints


-122-

Cryogel Z / PIR Composite System Specified


-123-

Setup In the Fabrication Shop

Industrial hot knife


-124-

Use a Hot Knife for Large-Volume Cutting of Cryogel


-125-

Pieces Are Rolled, Tagged, and Sent to the Field


-126-

Securing Layer #1 With Fiberglass Tape


-127-

Positioning Layer #2


-128-

Cryogel over PIR


-129-

Cryogel On An Elliptical Head


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Elbow Design


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This Is What 200 Cryogel Z Elbows Looks Like In Storage


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LNG Import Terminal In Cameron, LA

• Scope: Two 20” elbows on LNGoff-load arms; 20 ft of 24” LNGline (installation trial only);

• Date: October 2007

• Process Temp.: -260°F (-162°C)

• Design Goal: Minimizing iceformation during off-load; surviveice falling from uninsulatedsurfaces above

• Insulation: 8 layers (80 mm) ofCryogel

• Other Factors: Falling ice zone;Contractor’s first time using the material

• Results:– Installation on large-bore piping was 5 times faster than rigid materials


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LNG Peak Shaver in Haverhill, MA

• Scope: Flexible bellows at topand base of LNG tank

• Date: August 2008

• Process Temps.: -260°F (-162°C)to ambient

• Design Goal: Slow the formationof dense ice within the corrugations of the bellows

• Insulation: 2-5 layers (20-50 mm) Cryogel-Z inside removable pad

• Results:– Cryogel flexes with the bellows

without constraining movement

– Prevents ice balls from forming, falling


Insulating Double-Gimbaled Cryogenic Flex Joints


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Insulating Cryogenic Flex Joints

• Scope: – 36” LNG flex joints

• Location: – Mexico

• Temperature: – -260°F (-162°C)

• Design Goals:– Condensation control on a

doubly-gimbaled flex jointfor large bore pipe

• Insulation: – 4-5” (11-13 layers) Cryogel Z

to match 8-9” of PIR

• Results: – Insulated in Houston and trucked to Mexico

– Worked with EPC, joint manufacturer and contractor on the overall design


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As-Delivered Flex Joints Prior to Insulation


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Void-Filling with Fibrous Blanket Material


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Installing Cryogel Layers


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Insulation Complete w/ External Expansion-Contraction Joint


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Finished Article Ready for Transport


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Delivered to Site


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Vertical Lift


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Installation Onto Tank Wall (36” Liquid + 24” Vapor Return)


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Valves and Flanges on Offshore LNG Import Terminal

• Location: Southeast of Venice, Italy

• Scope: 1000+ valves & flanges >2”

• Date: Ongoing


• Design Goal: Condensation control

• Other Factors: Mechanical clashes and supply issues with baseline foam glass

• Insulation: Cryogel Z

• Results:

– All clashes resolved

– Very fast, high-quality install

– Single part number greatly simplifiesoffshore supply-chain and planning


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Valves and Flanges on Offshore LNG Import Terminal

• Scope: – 1500+ valves & flanges >2”

• Location: – Southeast of Venice, Italy

• Process Temp.: – -260°F (-162°C)

• Other Factors: – Clashes and supply / logistical issues

with baseline material

• Insulation: – 7-11 layers Cryogel Z

• Results:– All material air-freighted to job site

within 4-weeks ARO

– 700 insulators trained on Cryogel

– All clashes resolved ahead of schedule


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Shrink an LNG Import Terminal to 300’ x 600’…


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…and Mechanical Clashes Spring Up…


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…Everywhere


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A Spec Was Created For Tying Cryogel Into Adjacent Insulation

Cellular glassVoid fill

Cryogel


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Particular Attention Was Paid to the Tie-Ins


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Void Spaces Were Stuffed With Fiber


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Cryogel Layers Were Then Applied And Held With Tape

Cryogel Z

Void Fill


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Each Layer Was Marked for Inspection


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SS Bands Used to Secure the Cryogel Over the Foamglas


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Cryogel Joints Were Sealed with Foil-Faced Butyl Tape


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Valves Were Finished With a Butyl Membrane & UV-Cure GRP


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Valves and Piping In An Ethylene Unit, Antwerp

• Scope: Ball valves andsmall-bore piping

• Date: October 2008

• Process Temps.:-155°F (-104°C)

• Design Goal: Condensationcontrol; in-service inspection

• Insulation: 5 layers (50 mm) of Cryogel-Z

• Results:– Installed cost was par with PU foam on 3” piping

– Installation was much faster and less expensive on valves and large-bore piping

– Ideal for maintenance because one roll of material can be used to cover all manner of equipment and piping


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Super-Insulated Liquid Ethylene Vessel

• Scope: 10’ x 60’ ethylene bullet

• Location: Southampton, UK

• Design Goals: – Maintain liquid during 6-week T/A without refill or refrigeration (BOG <5 kg/day)

– Passive fire protection

• Insulation Design:– 13.4” (340 mm) of Cryogel,

jacketed with SS

• Results:– Vessel was pre-insulated in

Manchester, then trucked 250 miles to Southampton

– Unit successfully installed and operated during T/A

– Now in-service as just a very well-insulated ethylene storage vessel


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10’ x 60’ Vessel As-Delivered from Fabrication Yard


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On a 34-Layer System, Keeping an Accurate Count is Important


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Patterns Created In-Place By Simply Removing Excess Material


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Bands and Bridles Installed Every Fourth Layer for Support


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Final Layer Installed, Banded and Sealed with Tape


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Fiber Blankets Protect the Vapor Barrier from Screw Punctures


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Finished Article Awaiting 250-Mile Transport by Truck


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Rigging and Installation On Site


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Liquid Ethylene Sphere in Brazil

• Scope: – 60’ (18 m) ethylene sphere

• Location: – Southern Brazil

• Temperature: – -30°F (-34°C)

• Design Goals: – Condensation control– 90-min fire protection

• Insulation: – 50 mm Cryogel Z +

10 mm Pyrogel XT + galvanized steel jacket

• Results: – Reduced thickness by 67%– 20% faster installation than with spray foam– Sproule Mfg. designed cut patterns, resulting in a 98.5% material yield


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All Joints Taped to Provide Continuous Vapor Barrier


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Standoffs Support Jacket While Bands Harness Bottom Head


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Jacketing Near the Sphere’s Apex, Before Painting


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The Finished Article


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Bottom of Sphere in Dartmouth, NS

• Location: Dartmouth, NS

• Scope: Bottom of 23’ sphere

• Date: Nov, 2007


• Design Goal: Freeze protection

• Other Factors: Used chicken wire for securement + peel-and-stickweather barrier; steam tracing

• Insulation: 20 mm of Cryogel

• Results:– Original bid was for stainless steel cladding over mineral wool board

– Contractor submitted 200 man-hours vs. a 420 man-hour bid

– Estimated that the Cryogel alone reduced labor by 40%

– Cryogel and Pyrogel are now written into the specification


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Bottom of Sphere in Dartmouth, NS


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Barge Terminal in Wilmington, NC

• Location: Wilmington, NC

• Scope: 1200 ft of 8” line

• Date: July 2007

• Process Temp.: 55°F toambient

• Design Goal: Paraxylenefreeze protection

• Insulation: 1½” perlite 1 layer of 3/8” Cryogel

• Other Factors: Heat traced, with600 ft installed over water

• Results:– Fast installation over electric trace

– Minimized time and bulk handling over water


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Insulating LNG Tank Risers

• Scope: 150’ of 24” and 12” pipe


• Insulation: – 2.8” (70 mm) Cryogel Z

• Other Factors: – Frequent thermal cycling

– Only 3” of clearance between pipe surface and tank stiffening rings

– All work done between LNG deliveries

– Insulated pipes pass through hoop guides designed to limit sideways deflection due to wind loads. Insulation had to withstand compressive-, shear-, and impact-loading

• Results: – Lines are in-service; Tank 2 this year


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Steel Clamp Rings Used to Protect Insulation & Support Jacket

Anchor

Ring 1

Ring 3

Ring 4

Ring 5

Ring 2

LNG

Pipe w

all

Pipe guide

1¼” SS bands

FabricatedSS clamp ring

1” insulationsupport ring

Heavy-gage stainless steel clamp rings at each tank ring pulled double duty:

1.They acted as a bumper between the insulation and the pipe guide, and

2.Periodically supporting the 150’ of SS jacket


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Material Was Pre-Cut on the Ground to the Right Circumference


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During Installation, Cryogel Was Held In Place with Tape


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Foster 90-66 Vapor Stops Being Painted


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Minimal Clearance Between Insulation, Tank Stiffener Rings


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Stainless Steel Clamp Ring Held on with Bands


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Pipe Guides Constructed to Allow Minimal Rattle Space


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Re-Insulating Steam and Chilled-Water Lines in a Tunnel

• Scope: – 200+ ft of steam and chilled

water piping running through a tunnel beneath a street

• Location: – Providence, RI

• Other Factors: – Periodic flooding

– Extremely limited accessrequired a “hole watch”

– Confined working space

– Work carried out beneath heavy car and pedestrian traffic

• Results: – Contractor received an ABC “Excellence in Construction” award for the project


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Single Man-Hole Access at Either End of the Tunnel


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First, Strip 30-Year Old Insulation


-186-

Additional Task Lighting Had to Be Brought In


-187-

Periodic Flooding had Destroyed the Existing Insulation


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Pyrogel XT and Cryogel Z with Aluminum Jacketing Installed


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Thinner Insulation Easily Avoided Potential Clashes


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On-Time Job Completion


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Pre-Insulated Heat Exchangers

• Location: Gonzales, LA

• Scope: 14’ x 36” pre-insulated heatexchanger

• Date: July 2007



• Insulation: 3” perlite 2 layers of 3/8” Pyrogel

• Results:– Two layers of Pyrogel 10350 outperformed 3” perlite

– Heat exchanger with two rings and four nozzles was insulated in 2 hours


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Polycarbonate Plant

• Location: Yeosu, South Korea

• Scope: Piping, towers and tanksfor an entire polycarbonate plant

• Date: Mar-Aug, 2007



• Other Factors: Product availability, labor productivity

• Results:– Material availability and labor productivity enabled on-time installation within

a compressed construction schedule

– Demonstrated excellent productivity, particularly on towers and vessels


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Reactor Heads

• Location: Freeport, TX

• Scope: 15’ reactor vessel head

• Date: Feb, 2007


• Design Goal: Process control

• Insulation: 12” of minwool 12 layer of ¼” Pyrogel (3” total)

• Other Factors: Original insulation caused mechanical interference

• Results:

– Unit put into service April 2007

– BASF published results company-wide on global intranet site


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Heat Exchanger Modules

• Location: Northern Alberta

• Scope: Three pre-insulatedheat exchanger modules

• Date: Mar, 2007



• Insulation: 2” mineral wool ¾” Pyrogel

• Other Factors: Modules insulated in Kansas City; transported to Alberta

• Results:

– Insulation survives the abuse of long-distance road transport

– Thinner profile reduced interference near inlets, outlets, and structural supports


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Heat Exchanger Insulation Survives Transport and Handling


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Heat Exchanger Insulation Survives Transport and Handling


-197-

Distillation Tower

• Location: Plaquemine, LA

• Scope: 14’ x 119’ tower with 2:1 elliptical head

• Date: Jan, 2007



• Insulation: 1½” Perlite block 1 layer of ¼” Pyrogel

• Other Factors: Original support ringsprotruded and had to be insulated around

• Results:

– Fast, single layer application

– Thermal savings of $138K per year with only one layer of ¼” Pyrogel


Unique Application:Pre-Insulated Sweep Elbow


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Aerogel Blankets Are Durable with Good Compression Resistance


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Summary and Conclusions

• Efficiency– Most efficient insulation materials in the world

– Saves energy

– Reduces touch temperatures

• Productivity– Flexible blanket form for increased productivity

– Streamlined planning, supply chain, and logistics

– Better space efficiency

– Enables pre-insulation of piping and equipment

• Durability– Resistance to damage by water, heat, and mechanical abuse

– Will not promote corrosion under insulation

– Exceptional fire protection

Thank You

aerogel industrial presentation april 2011

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