aerogel industrial presentation april 2011
TRANSCRIPT
Confidential & Proprietary
Flexible Aerogel Insulation for Industrial Applications
April 2011
Confidential & Proprietary
-2-
Presentation Outline
• Product Overview
• Hot Work
• Cold Work
• Reference Projects
• Questions
Confidential & Proprietary
-3-
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
Confidential & Proprietary
-4-
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
Confidential & Proprietary
-5-
Aspen’s Aerogel Manufacturing ProcessS
ilica
Sol
Cat
alys
t
Dop
ants
Rolls packedfor shipment
Dry fiberblanket
Casting
Gelation
Supercriticalextraction
Drying
Confidential & Proprietary
-6-
Aerogel Factory In East Providence, RI
CastingCasting ExtractionExtraction
DryingDrying Tank farmTank farm
Confidential & Proprietary
-7-
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
Confidential & Proprietary
-8-
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
Confidential & Proprietary
-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
Confidential & Proprietary
-10-
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
Confidential & Proprietary
-11-
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.
Confidential & Proprietary
-12-
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
Confidential & Proprietary
-13-
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.
Confidential & Proprietary
-14-
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
Confidential & Proprietary
-15-
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
Confidential & Proprietary
Hot Applications
Confidential & Proprietary
-17-
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
Confidential & Proprietary
-19-
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)
Confidential & Proprietary
-20-
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
Confidential & Proprietary
-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
6” Pipe: 44% more on a rack
12” Pipe: 28% more on a rack
Confidential & Proprietary
-25-
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
Confidential & Proprietary
-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
Confidential & Proprietary
-27-
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
Confidential & Proprietary
-28-
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
Confidential & Proprietary
-29-
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
Confidential & Proprietary
-33-
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
Confidential & Proprietary
-34-
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
Confidential & Proprietary
-35-
-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
Confidential & Proprietary
Cold Applications
Confidential & Proprietary
-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)
Confidential & Proprietary
-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
Confidential & Proprietary
-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
Confidential & Proprietary
-40-
Installation: Vapor Stop with 90-66 Prior to 1st Piece
Photo courtesy Zampell Insulation
Confidential & Proprietary
-41-
Installation: 7 Layers (70 mm) Applied In 4 Pieces
Photo courtesy Zampell Insulation
Confidential & Proprietary
-42-
Installation: Every Seam Butyl Taped
Photo courtesy Zampell Insulation
Confidential & Proprietary
-43-
Installation: 90-66 Application Prior to 3rd Piece
Photo courtesy Zampell Insulation
Confidential & Proprietary
-44-
Installation: Build Cryogel Up to Existing Diameter
Cryogel diameter
Shoe diameter
10 inch Cryogel transition piece
Photo courtesy Zampell Insulation
Confidential & Proprietary
-45-
Installation: Finishing Up with Alumaguard (Optional)
Photo courtesy Zampell Insulation
Confidential & Proprietary
-46-
Installation: Finished Aerogel Product Before Jacketing
Photo courtesy Zampell Insulation
Confidential & Proprietary
-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
Confidential & Proprietary
-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
Confidential & Proprietary
-50-
Traditional Expansion / Contraction Joints Are Cold Spots
Confidential & Proprietary
Reference Projects
Confidential & Proprietary
Reference Projects
Subsea Pipe-in-Pipe
Confidential & Proprietary
-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
Confidential & Proprietary
Reference Projects
Hot
Confidential & Proprietary
-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
Confidential & Proprietary
-59-
Asphalt Tank at Refinery in Halifax, Nova Scotia
• Scope: 45’x60’ tank (sides only)
• Date: April, 2008
• Process Temp.: 300°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-60-
Tank Roof in Baton Rouge
• Location: Baton Rouge, LA
• Scope: 150’ tank roof
• Date: Feb, 2007
• Process Temp.: 300°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-61-
160°F Vessel In Carrolton, KY
• Scope: 16’ x 20’ vessel,including elliptical heads
• Date: June 2006
• Process Temp.: 160°F
• 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
Confidential & Proprietary
-62-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-63-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-64-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-65-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-66-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-67-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-68-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-69-
Excellent Labor Productivity On Tanks, Towers and Vessels
Confidential & Proprietary
-70-
Condensate Tank
• Location: La Porte, TX
• Scope: 20’ x 40’ tank
• Date: November, 2006
• Process Temp.: 180°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-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
Confidential & Proprietary
-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
• Process Temp.: 175-650°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-73-
Hot Air Ducts for Industrial Dryers
Confidential & Proprietary
-74-
Hot Air Ducts for Industrial Dryers
Confidential & Proprietary
-75-
Hot Air Ducts for Industrial Dryers
Confidential & Proprietary
-76-
Hot Air Ducts for Industrial Dryers
Confidential & Proprietary
-77-
Hot Air Ducts for Industrial Dryers
Confidential & Proprietary
-78-
Hot Air Ducts for Industrial Dryers
Confidential & Proprietary
-79-
Hot Air Ducts for Industrial Dryers
Confidential & Proprietary
-80-
SCR Duct, Billings, MT
• Location: Millings, MT
• Scope: 10-14’ SCR ducting
• Date: June, 2008
• Process Temp.: 750°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-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)
Confidential & Proprietary
-82-
80’ Joints Delivered to Indoor Fabrication Facility in Edmonton
Confidential & Proprietary
-83-
High-Speed Pipe Spinners Ease Application of Insulation, Jacket
Confidential & Proprietary
-84-
Single Layer of PGXT-10 Applied with Spray Adhesive
Confidential & Proprietary
-85-
Pipes Get Insulated In One Section of the Shop…
Confidential & Proprietary
-86-
…While the Jacket Gets Spray Applied in Another
Confidential & Proprietary
-87-
Spraying Is Fast and Consistent with Minimal Overspray
Confidential & Proprietary
-88-
Spray Application Yields Tough, Impermeable Membrane
Confidential & Proprietary
-89-
System Easily Withstands Rigors of Transport, Installation
Confidential & Proprietary
-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
Confidential & Proprietary
-91-
Three Layers Pyrogel XTF Installed on Bottom Head
Confidential & Proprietary
-92-
SS Bands Used to Harness Material to the Head
Confidential & Proprietary
-93-
Floating Ring Used Around the Bottom Nozzle
Confidential & Proprietary
-94-
Bands and SS Jacket used for Final Securement
Confidential & Proprietary
-95-
Insulated from the Top Down, Removing Scaffold Along the Way
Confidential & Proprietary
-96-
The Finished Article
Confidential & Proprietary
-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
Confidential & Proprietary
-98-
Insulating Duct Supports
Confidential & Proprietary
-99-
Insulating Duct Supports
Confidential & Proprietary
-100-
Conical Reducer and Transition Section
Confidential & Proprietary
-101-
Vessel Head with Manway
Confidential & Proprietary
-102-
Completed Duct Section
Confidential & Proprietary
-103-
Drum Head
Confidential & Proprietary
-104-
Completed Duct Section
Confidential & Proprietary
-105-
Distillation Tower at Refinery in Chalmette, LA
• Location: Chalmette, LA
• Scope: 166’ x 13’ diameterdistillation tower
• Date: September, 2007
• Process Temp.: 734°F
• 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
Confidential & Proprietary
-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
• Process Temp.: 590°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-107-
Ideal for Remote Locations, Large-Bore Piping
Confidential & Proprietary
-108-
Ideal for Remote Locations, Large-Bore Piping
Confidential & Proprietary
-109-
Ideal for Remote Locations, Large-Bore Piping
Confidential & Proprietary
-110-
Ideal for Remote Locations, Large-Bore Piping
Confidential & Proprietary
-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
Confidential & Proprietary
-112-
Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
Confidential & Proprietary
-113-
Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
Confidential & Proprietary
-114-
Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
Confidential & Proprietary
-115-
Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
Confidential & Proprietary
-116-
Municipal Steam Tunnels In Baltimore, MD
• Scope: Removable covers formanholes, steam tunnels
• Date: November, 2007
• Process Temp.: 150-450°F
• 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”
Confidential & Proprietary
-117-
Piping in Kawasaki, Japan
• Location: Kawasaki, Japan
• Scope: 8-12” piping
• Date: Nov, 2007
• Process Temp.: 325°C
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
Reference Projects
Cryogenic & Cold
Confidential & Proprietary
-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”
Confidential & Proprietary
-120-
Traditional Cold Insulation System for LNG Service
Confidential & Proprietary
-121-
Cryogel Requires No Contraction Joints
Confidential & Proprietary
-122-
Cryogel Z / PIR Composite System Specified
Confidential & Proprietary
-123-
Setup In the Fabrication Shop
Industrial hot knife
Confidential & Proprietary
-124-
Use a Hot Knife for Large-Volume Cutting of Cryogel
Confidential & Proprietary
-125-
Pieces Are Rolled, Tagged, and Sent to the Field
Confidential & Proprietary
-126-
Securing Layer #1 With Fiberglass Tape
Confidential & Proprietary
-127-
Positioning Layer #2
Confidential & Proprietary
-128-
Cryogel over PIR
Confidential & Proprietary
-129-
Cryogel On An Elliptical Head
Confidential & Proprietary
-130-
Elbow Design
Confidential & Proprietary
-131-
This Is What 200 Cryogel Z Elbows Looks Like In Storage
Confidential & Proprietary
-132-
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
Confidential & Proprietary
-133-
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
Confidential & Proprietary
Insulating Double-Gimbaled Cryogenic Flex Joints
Confidential & Proprietary
-135-
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
Confidential & Proprietary
-136-
As-Delivered Flex Joints Prior to Insulation
Confidential & Proprietary
-137-
Void-Filling with Fibrous Blanket Material
Confidential & Proprietary
-138-
Installing Cryogel Layers
Confidential & Proprietary
-139-
Insulation Complete w/ External Expansion-Contraction Joint
Confidential & Proprietary
-140-
Finished Article Ready for Transport
Confidential & Proprietary
-141-
Delivered to Site
Confidential & Proprietary
-142-
Vertical Lift
Confidential & Proprietary
-143-
Installation Onto Tank Wall (36” Liquid + 24” Vapor Return)
Confidential & Proprietary
-144-
Valves and Flanges on Offshore LNG Import Terminal
• Location: Southeast of Venice, Italy
• Scope: 1000+ valves & flanges >2”
• Date: Ongoing
• Process Temp.: -260°F (-162°C)
• 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
Confidential & Proprietary
-145-
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
Confidential & Proprietary
-146-
Shrink an LNG Import Terminal to 300’ x 600’…
Confidential & Proprietary
-147-
…and Mechanical Clashes Spring Up…
Confidential & Proprietary
-148-
…Everywhere
Confidential & Proprietary
-149-
A Spec Was Created For Tying Cryogel Into Adjacent Insulation
Cellular glassVoid fill
Cryogel
Confidential & Proprietary
-150-
Particular Attention Was Paid to the Tie-Ins
Confidential & Proprietary
-151-
Void Spaces Were Stuffed With Fiber
Confidential & Proprietary
-152-
Cryogel Layers Were Then Applied And Held With Tape
Cryogel Z
Void Fill
Confidential & Proprietary
-153-
Each Layer Was Marked for Inspection
Confidential & Proprietary
-154-
SS Bands Used to Secure the Cryogel Over the Foamglas
Confidential & Proprietary
-155-
Cryogel Joints Were Sealed with Foil-Faced Butyl Tape
Confidential & Proprietary
-156-
Valves Were Finished With a Butyl Membrane & UV-Cure GRP
Confidential & Proprietary
-157-
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
Confidential & Proprietary
-158-
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
Confidential & Proprietary
-159-
10’ x 60’ Vessel As-Delivered from Fabrication Yard
Confidential & Proprietary
-160-
On a 34-Layer System, Keeping an Accurate Count is Important
Confidential & Proprietary
-161-
Patterns Created In-Place By Simply Removing Excess Material
Confidential & Proprietary
-162-
Bands and Bridles Installed Every Fourth Layer for Support
Confidential & Proprietary
-163-
Final Layer Installed, Banded and Sealed with Tape
Confidential & Proprietary
-164-
Fiber Blankets Protect the Vapor Barrier from Screw Punctures
Confidential & Proprietary
-165-
Finished Article Awaiting 250-Mile Transport by Truck
Confidential & Proprietary
-166-
Rigging and Installation On Site
Confidential & Proprietary
-167-
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
Confidential & Proprietary
-168-
All Joints Taped to Provide Continuous Vapor Barrier
Confidential & Proprietary
-169-
Standoffs Support Jacket While Bands Harness Bottom Head
Confidential & Proprietary
-170-
Jacketing Near the Sphere’s Apex, Before Painting
Confidential & Proprietary
-171-
The Finished Article
Confidential & Proprietary
-172-
Bottom of Sphere in Dartmouth, NS
• Location: Dartmouth, NS
• Scope: Bottom of 23’ sphere
• Date: Nov, 2007
• Process Temp.: 50°F
• 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
Confidential & Proprietary
-173-
Bottom of Sphere in Dartmouth, NS
Confidential & Proprietary
-174-
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
Confidential & Proprietary
-175-
Insulating LNG Tank Risers
• Scope: 150’ of 24” and 12” pipe
• Process Temp.: -260°F (-162°C)
• 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
Confidential & Proprietary
-176-
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
Confidential & Proprietary
-177-
Material Was Pre-Cut on the Ground to the Right Circumference
Confidential & Proprietary
-178-
During Installation, Cryogel Was Held In Place with Tape
Confidential & Proprietary
-179-
Foster 90-66 Vapor Stops Being Painted
Confidential & Proprietary
-180-
Minimal Clearance Between Insulation, Tank Stiffener Rings
Confidential & Proprietary
-181-
Stainless Steel Clamp Ring Held on with Bands
Confidential & Proprietary
-182-
Pipe Guides Constructed to Allow Minimal Rattle Space
Confidential & Proprietary
-183-
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
Confidential & Proprietary
-184-
Single Man-Hole Access at Either End of the Tunnel
Confidential & Proprietary
-185-
First, Strip 30-Year Old Insulation
Confidential & Proprietary
-186-
Additional Task Lighting Had to Be Brought In
Confidential & Proprietary
-187-
Periodic Flooding had Destroyed the Existing Insulation
Confidential & Proprietary
-188-
Pyrogel XT and Cryogel Z with Aluminum Jacketing Installed
Confidential & Proprietary
-189-
Thinner Insulation Easily Avoided Potential Clashes
Confidential & Proprietary
-190-
On-Time Job Completion
Confidential & Proprietary
-191-
Pre-Insulated Heat Exchangers
• Location: Gonzales, LA
• Scope: 14’ x 36” pre-insulated heatexchanger
• Date: July 2007
• Process Temp.: 500°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-192-
Polycarbonate Plant
• Location: Yeosu, South Korea
• Scope: Piping, towers and tanksfor an entire polycarbonate plant
• Date: Mar-Aug, 2007
• Process Temp.: 250-650°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-193-
Reactor Heads
• Location: Freeport, TX
• Scope: 15’ reactor vessel head
• Date: Feb, 2007
• Process Temp.: 550°F
• 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
Confidential & Proprietary
-194-
Heat Exchanger Modules
• Location: Northern Alberta
• Scope: Three pre-insulatedheat exchanger modules
• Date: Mar, 2007
• Process Temp.: 250-400°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
-195-
Heat Exchanger Insulation Survives Transport and Handling
Confidential & Proprietary
-196-
Heat Exchanger Insulation Survives Transport and Handling
Confidential & Proprietary
-197-
Distillation Tower
• Location: Plaquemine, LA
• Scope: 14’ x 119’ tower with 2:1 elliptical head
• Date: Jan, 2007
• Process Temp.: 200°F
• Design Goal: Heat conservation
• 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
Confidential & Proprietary
Unique Application:Pre-Insulated Sweep Elbow
Confidential & Proprietary
-199-
Aerogel Blankets Are Durable with Good Compression Resistance
Confidential & Proprietary
-200-
Aerogel Blankets Are Durable with Good Compression Resistance
Confidential & Proprietary
-201-
Aerogel Blankets Are Durable with Good Compression Resistance
Confidential & Proprietary
-202-
Aerogel Blankets Are Durable with Good Compression Resistance
Confidential & Proprietary
-203-
Aerogel Blankets Are Durable with Good Compression Resistance
Confidential & Proprietary
-204-
Aerogel Blankets Are Durable with Good Compression Resistance
Confidential & Proprietary
-205-
Aerogel Blankets Are Durable with Good Compression Resistance
Confidential & Proprietary
-207-
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