Why are refineries replacing legacy calcium silicate and mineral wool with aerogel blankets?
The shift is driven by the need to solve spatial bottlenecks and maximize thermal efficiency. Petrochemical plants are notoriously congested. Traditional high-temperature insulation requires massive thickness (often exceeding 200mm) to manage 600°C+ process lines, leading to pipe clashing and difficult maintenance access. Aerogel blankets provide up to 5 times the thermal performance of legacy materials, allowing engineers to reduce insulation thickness by up to 75%. This ultra-thin profile eliminates spatial conflicts, minimizes the outer surface area (reducing overall heat loss), and streamlines the facility’s footprint.
How does aerogel perform in highly corrosive petrochemical environments?
Excellent. Refineries are highly susceptible to Corrosion Under Insulation (CUI) due to chemical vapors, coastal humidity, and routine washdowns. Traditional porous insulation absorbs moisture, accelerating pipe degradation. Our industrial-grade aerogel is engineered with permanent hydrophobicity—it actively repels liquid water while remaining vapor-permeable. This ensures the underlying steel pipes remain dry, effectively eliminating the root cause of CUI and saving millions in inspection and replacement costs.
Does aerogel meet the strict fire safety standards required for petrochemical facilities?
Yes, it exceeds them. Safety against hydrocarbon pool fires and jet fires is a critical mandate in refining (e.g., API 2218 guidelines). Aerogel is an inorganic, non-combustible material (Class A fire rating). It does not ignite, propagate flame, or release toxic smoke. When applied to critical pipework and vessels, it acts as a highly effective Passive Fire Protection (PFP) barrier, significantly delaying structural failure and buying crucial time for emergency response during a fire event.
Can aerogel be installed without shutting down active process lines?
Yes, and this is a major operational advantage. Plant turnarounds (shutdowns) are incredibly expensive. Aerogel blankets are flexible, lightweight, and can be easily cut and wrapped around complex geometries like valves, flanges, and elbows. Because it does not shed harmful fibers like traditional mineral wool, it can often be installed safely as “hot work” while the process lines remain fully operational, drastically reducing facility downtime.