Aerogel Insulation Case Studies for Industrial Procurement

Our Aerogel Insulation Case Studies help EPC contractors, engineering companies, plant owners, insulation distributors and international procurement teams evaluate aerogel materials through real operating conditions and measured project results.

The projects cover oilfield pipelines, district heating networks, high-temperature steam equipment, LNG cryogenic pipelines and thin building insulation. They demonstrate our capabilities as an industrial aerogel supplier, silica aerogel manufacturer, thermal insulation solution provider and factory-direct aerogel material exporter.

Featured Industrial Aerogel Projects

Oilfield Pipeline Insulation Retrofit

A DN114 oilfield pipeline previously used 80 mm alumina silicate wool. The project replaced it with 50 mm FMA650 aerogel blanket.

According to the customer’s test report, the energy-saving rate reached 38.5%, while linear heat loss was reduced by 70 W/m. The project demonstrates how a thinner insulation structure may improve thermal performance while reducing the space required around an existing pipeline.

District Heating Network

This project involved an 8 km pipeline with a diameter of 600 mm, a steam flow of 115 t/h and an operating temperature of 309°C. The customer required the temperature drop to remain below 5°C per kilometer.

The selected structure combined 20 mm FMA650 aerogel blanket with calcium silicate and polyurethane foam. The final temperature drop was 4.2°C per kilometer, meeting the customer’s target.

This project is particularly relevant to district-energy contractors that need to balance:

• Temperature-drop requirements

• Total insulation thickness

• Material and installation cost

• Pipeline length

• Composite insulation design

• Long-term energy loss

High-Temperature Oil Exploration Equipment

The project compared three insulation structures under a steam temperature of 350°C, an ambient temperature of 25°C and a wind speed of 1.0 m/s.

The 30 mm aerogel solution achieved:

• Surface temperature: 39.6°C

• Total insulation thickness: 35 mm

• Linear heat loss: 238.4 W/m

• Reported energy-saving rate: 46.2%

A composite system using 12 mm aerogel and 50 mm composite silicate achieved an energy-saving rate of 31.8%. The comparison gives buyers a practical basis for balancing insulation thickness, thermal performance and project budget.

LNG Cryogenic Pipeline

This LNG project involved an 89 mm pipeline operating at −162°C, with an ambient temperature of 28.5°C and relative humidity of 70%.

A 50 mm aerogel solution achieved a linear cold loss of 18.5 W/m and a reported energy-saving rate of 36.7%. A composite system using 20 mm aerogel and 60 mm rigid polyurethane foam was also evaluated.

For LNG and cryogenic projects, buyers should compare more than insulation thickness. Important procurement factors include:

• Cold-loss requirements

• Surface-temperature target

• Condensation and moisture conditions

• Joint and vapor-barrier design

• Standalone versus composite insulation

• Installation quality around supports and fittings

• Packaging protection during international transportation

Thin Building Insulation

A 6 mm aerogel insulation layer was used to reduce the required exterior-wall insulation thickness. The project also considered fire resistance, water resistance, sound insulation and occupant comfort.

This reference is suitable for architects, building-material distributors and renovation contractors working on projects where conventional thick insulation may reduce usable space or be difficult to install.

How Aerogel Insulation Case Studies Reduce Procurement Risk

A case from the same industry does not automatically guarantee the same result. Buyers should first compare the project conditions with their own technical requirements.

Before requesting a quotation, provide the following information.

Operating Conditions

Include:

• Continuous operating temperature

• Maximum or peak temperature

• Ambient temperature

• Relative humidity

• Wind speed

• Indoor or outdoor location

• Operating medium

• Frequency of heating and cooling cycles

Cryogenic pipelines, steam systems and building envelopes require different aerogel grades and insulation structures.

Required Thermal Performance

State the actual project target, such as:

• Maximum permitted surface temperature

• Maximum heat loss per meter

• Permissible temperature drop

• Required cold-loss value

• Condensation-control requirement

• Target energy-saving rate

• Required reduction in insulation thickness

Without a clear target, different suppliers may quote different thicknesses and material structures, making price comparison unreliable.

Equipment and Installation Information

Provide:

• Pipe diameter and total length

• Tank or equipment dimensions

• Number of valves, flanges and fittings

• Available installation space

• Outer cladding requirements

• Support and penetration details

• Drawings or site photographs

• Planned installation period

Standard aerogel blanket is suitable for many pipelines and large equipment surfaces. Valves, flanges and equipment requiring regular inspection may be better suited to removable insulation jackets.

Existing Insulation System

For a retrofit project, identify:

• Existing insulation material

• Current thickness

• Current surface temperature

• Reason for replacement

• Moisture or corrosion problems

• Available shutdown period

• Disposal requirements

• Installation restrictions

This information helps determine whether aerogel should completely replace the existing material or form part of a composite insulation system.

Review our Aerogel Insulation Case Studies and submit your project conditions. Our engineering and sales teams will help compare suitable insulation structures, prepare samples and provide a quotation based on the complete project rather than a generic unit price.