Reducing Energy Loss in Industrial Operations
- Reducing Heat Loss: Uninsulated or under-insulated industrial equipment is a recognised source of ongoing energy inefficiency. Aerogel-based insulation materials offer high thermal resistance in a thinner profile, supporting more efficient temperature control where space or weight is constrained.
- Managing Corrosion Under Insulation (CUI) Risk: Moisture ingress beneath insulation is a well-known contributor to corrosion and premature asset degradation. Aerogel materials are designed with water-repellent characteristics that may help reduce moisture exposure and associated corrosion risk when properly specified and installed.
- Payback Considerations: In suitable industrial applications, the combined effect of reduced energy loss and lower maintenance requirements may support an attractive payback timeframe. Actual results will vary depending on operating conditions, system design, and installation quality.
The Cost of Thermal Inefficiency
In process industries such as oil and gas, chemical processing, and manufacturing, thermal management is closely linked to operational efficiency. Heat loss from pipes, valves, and vessels increases fuel consumption and operating costs over time.
Conventional insulation materials, including mineral wool and perlite, can experience performance degradation due to compression, settlement, or moisture absorption. This reduction in effectiveness can lead to incremental increases in energy usage that are often difficult to detect in day-to-day operations.
Corrosion Under Insulation (CUI)
In addition to energy loss, Corrosion Under Insulation (CUI) presents a significant asset integrity risk across many industrial facilities. When insulation systems retain moisture against metal surfaces, corrosion can progress unnoticed until inspection or failure.
CUI is widely recognised as a contributor to piping damage and unplanned maintenance across the industry, resulting in increased inspection costs, repairs, and downtime.
Aerogel Insulation: Design Characteristics
Advanced Aerogel insulation blankets are developed to address both thermal performance and moisture management:
Evaluating the Economic Case
For asset owners and operators, insulation upgrades are typically assessed on a total cost of ownership (TCO) basis. While aerogel materials generally carry a higher upfront cost than conventional insulation, potential value drivers may include:
- Reduced energy consumption through improved thermal retention
- Lower maintenance exposure related to corrosion and insulation replacement
- Installation efficiencies in space-constrained or complex areas
Advanced Aerogels works with industrial customers to support material selection, system design, and specification development, helping ensure insulation solutions are aligned with operational goals and budget requirements.
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