Flexible Aerogel Insulation For Industrial Applications: April 2011

Confidential & Proprietary
Flexible Aerogel Insulation for Industrial Applications

April 2011
Presentation Outline
Product Overview Hot Work Cold Work Reference Projects Questions
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What Is An Aerogel?
Aerogels are nanoporous solids invented in the 1930s
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 reduces cycle times from months to hours Casting the wet gel into a fibrous batting provides mechanical integrity
The Aerogel Advantage: Superinsulation performance in a flexible blanket form
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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-solid solution Step 2: Extract solvents with supercritical carbon dioxide
Step 3: Resulting dry, fiber-reinforced aerogel blanket

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Aspens Aerogel Manufacturing Process

Casting Dopants Catalyst Silica Sol Gelation
Dry fiber blanket Rolls packed for shipment
Supercritical extraction
Drying
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Aerogel Factory In East Providence, RI
Casting
Extraction
Drying
Tank farm
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Heath and Safety Aspects of Aerogels

Aerogels are an amorphous (non-crystalline) silica with 97% of particles larger than 45mm
Only the pores are nano-scale (~0.01 mm) Aerogel particles are much larger Aerogel (amorphous silica)
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.
Crystalline silica
Typical dust loading in fab-shop is <5 mg/m3

OSHA limit for amorphous silica is 80 mg/m3 Recommended PPE is paper dust mask, work gloves, and safety glasses
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Aerogels Are Nanoporous, Not Nanoparticles

Particle Count Histogram 100% Air sampling in an aerogel fabrication shop reveals that 97% of dust particles are larger than 45 microns 53% 50% 33% 25% 3% 0% <45 mm 45 to 75 mm 75 to 150 mm >150 mm
75%
11%
Particle size (microns) 0.001
Nanoparticles 0.01 Aerogel nanopores (tiny air pockets) 0.1 1 Tobacco smoke 10 Red blood cell 100 1000
Cutting or installing Pyrogel or Cryogel does not generate nanoparticles

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Aspens Industrial Products Span the Temperature Range

Cryogel Z (5 and 10 mm)
-460F to 200F (-273C to 90C)
C 600 1000 500 400 300 200 100 800 600 400 F 1200
Pyrogel XT (5 and 10 mm)

-40F to 1200F (-40C to 650C)
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
200
0 -200 -400
0
-100 -200
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Aerogels Have the Lowest k-Value of Any Industrial Insulation

-400 Thermal Conductivity (Btu-in/hr-ft2-F) -200 0
Temperature (F) 200 400 600
800
1000
1200 250
1.6
1.4
Mineral Wool Pipe & Board Mineral Wool Blanket
Thermal Conductivity (mW/m-K)
200
1.2
1.0 0.8 0.6 0.4 Perlite Cellular glass Cryogel Z PUR/PIR
150 Calsil 100
Pyrogel XT
50
0.2
0.0
-200
-100
100
200
300
400
500
600
Temperature (C)
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Traditional Insulation Thickness Ratios vs. Pyrogel XT

5
Incumbent Thickness / XT Thickness 100 200 300 Process Temperature (F) 400 500 600 700 800 900 1000 1100 1200
Mineral Wool Blanket
Expanded Perlite Calcium Silicate
3
Cellular Glass Mineral Wool Pipe & Board
0 0 100 200 300 400 500 Process Temperature (C) 600 700
Ratios provide equal resistance in planar configurations. -11Does not account for geometric effects of pipe cover.
Weight Per Unit Area for Equivalent Thermal Performance

0.8
0.7 Areal Density (lbs/sqft) for R-1 0.6 0.5 0.4 0.3 0.2 0.1 0.0 Expanded Perlite Calcium Silicate Mineral Wool Blkt
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Pyrogel XT enables lighter designs at the same level of thermal protection, reducing loads on pipes, shoes and hangars
Mineral Wool Pipe
Cellular Glass
Pyrogel XT
Pyrogel Resists the Enemies of Insulation: Water, Heat, and Abuse

Damage Tolerant Cryogel 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. Water Repellant During Katrina, an aerogelinsulated 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.
Thermally Stable Aspen Aerogels products do not use organic binders, so will not crumble or sag in hot service.
Insulated space
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Pyrogel XT Shows No Thermal Degradation at 930F (500C)

600
1100 Hot face 1-2 interface 1000 900 800
500
Temperature (C) Temperature (C)
400
2-3 interface 3-4 interface
Temperature (F)
700 600 500
300
200
Long-term pipe test rig
400 300
100
Cold face
200 100
0 0 10 20 30 40 Elapsed Time (days) Elapsed Time (days)

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50
60
70
Aerogels Will Not Promote Corrosion Under Insulation (CUI)

Pyrogel and Cryogel are durably water repellent, even at high temperatures The open-cell nature of Aspens 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
Steam penetrates Pyrogel from kettle underneath
water vapor permeable
Water droplet with contact angle >150
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Hot Applications
Pyrogel XT Has Many Benefits On Hot Process Equipment

Industrys 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
All four designs provide the same level of thermal protection
Calcium Silicate 3
Greater in-service durability

Durably hydrophobic Will not crack, crumble, or sag
6 pipe at 600F (315C)
2 Mineral Wool or Fiberglass
Reduces jacketing, banding, and vapor barrier costs Packed volume reduced 5-10X
Less scrap, trucking, storage
Single part number simplifies logistics, planning Excellent fire protection
Pyrogel XT 20 mm (0.8)
3
Expanded Perlite
Ambient conditions = 65F, 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
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Pyrogel Enables Increased Pipe Density

Insulation Material
2 Pipe: 56% more on a rack
10.13 in.
Pyrogel
5.38 in.
Rigid Pipe Cover

8.38 in.
14.63 in.
2 in.
16.25 in.
20.75 in.
* Assumes 2 inch clearance space
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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

Distinct Part No.s
Insulation only
Pyrogel
1
790 rolls
28
36,000 pieces
Distinct Parts
45:1 ratio
Packed Volume
6:1 ratio
5700 m3
930 m3
53 m x 53 m Packed Footprint
2 m stack height
22 m x 22 m
Pyrogel can reduce the material handing and inventory management required on big jobs
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Pyrogel Reduces Local Portage of Insulation Materials

A 3 pipe at 300F can be insulated with 1 of fiberglass or 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 aerogel = 1 trip Staging depot
188 ft of 3 pipe with fiberglass = 7 trips

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Cryogel Z and Pyrogel XTF Provide Excellent Fire Protection

0 5 Better Cryogel Z 1
Thickness (in) 3 4
4
Time to 1000F (hours) Worse 3 Pyrogel XTF 2 Cellular glass
UL 1709 test results based on a 10W49 I-beam: Time-to-failure for different insulation types and thicknesses
1
Calcium Silicate 0 0 25 50 75 100 125 Thickness (mm)
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Expanded Perlite
150
175
200
A Pyrogel XT Over-Wrap Can Resuscitate Dying Insulation

Pyrogel XT 10mm overwraps keep in the heat and dry out wet insulation New cladding & banding re-weatherize the surface
Butt joint Damaged cladding Degraded insulation Field proven to be a fast, cheap, and effective repair
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Two-Step Recovery: Capture the Heat. Dry Out the Insulation.

The Pyrogel XT over-wrap instantly reduces heat loss and touch temperatures
Immediate Benefit 121 Btu hr-ft 135F Damaged Insulation 206 Btu hr-ft
The underlying insulation heats up

If that insulation is wet, much of the water is driven out, escaping through joints in the cladding
Pyrogel XTs combination of permeability and hydrophobicity mean that water vapor passes through, but doesnt stay
162F
Water vapor escapes
6 x 2 Fibrous Insulation on 125 psi Steam Pipe (344F)
123F
84
Btu hr-ft
Assumed Conditions: 90F, no wind, e = 0.13 Minwool TC tripled when wet
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Long Term Benefit
Pyrogel-Over-Mineral Wool for Temperatures Below 250C

Recent independent testing compared different insulation systems to conditions known to promote CUI:
Uncoated carbon steel pipe Cyclic operation between ambient and 80C every seven days Constant exposure to a slow water drip
CUI test rigs
Insulation materials included:

Cellular glass Calcium silicate Expanded perlite Elastomeric foam Mineral wool Pyrogel XT over mineral wool
10 mm Pyrogel XT over 30 mm mineral wool
Of the eight systems tested, only one was 100% corrosion-free after three months:
Pyrogel XT over mineral wool
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Mineral Wool-Over-Pyrogel for Temperatures Above 250C

Mineral wool over Pyrogel saves space by using the materials where theyre most effective
PGXT at high temperatures MW at low temperatures
500 400 300 200 100 500 400 300 200 100
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
6 pipe 550C Burnout zone
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Mineral Wool Over Pyrogel XT Can Be the Low-Cost Solution

$200 Material Cost (USD/m) $160 $120 $80 $40 Pyrogel XT Mineral Wool Alum. Jacket + Bands
PGXT (mm) MW (mm) Total (mm)
60 60
50 30 80
40 50 90
30 80 110
20 120 140
10 170 180
230 230
NPS = 6 Tin = 550C
All seven designs have -35- equivalent heat loss
Cold Applications
Cryogel Advantages In Cryogenics and Chilled Service

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 57 Btu/hr-ft 73F 70 Btu/hr-ft 73F
Packed volume reduced > 6X

Lower trucking & storage costs
Foam glass (4.5 in)
Contraction joints can be eliminated Cryogels low-temperature flexibility provides excellent inservice durability
No cracking or thermal shock Resists impact from footfall, tool strikes Stiffer support of jacketing means fewer dents and buckles
12 (300 mm) pipe at -274F (-170C)

PIR (4 in)
Cryogel is 20% lighter than PIR and 70% lighter than cellular glass More space efficiency in pipe racks
Cryogel (2 in)
73F 70 Btu/hr-ft
All three designs meet the same condensation control criteria

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Exceptional Installation Productivity On Cryogenic Piping
Cryogel Blankets
Joint tape
versus
Every joint buttered
Rigid Pipe Cover In addition to reducing labor, Cryogel blankets minimize sensitivity to workmanship
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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
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Installation: Vapor Stop with 90-66 Prior to 1st Piece
Photo courtesy Zampell Insulation

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

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Installation: Every Seam Butyl Taped

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Installation: 90-66 Application Prior to 3rd Piece

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Installation: Build Cryogel Up to Existing Diameter
Shoe diameter
10 inch Cryogel transition piece
Cryogel diameter

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Installation: Finishing Up with Alumaguard (Optional)

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Installation: Finished Aerogel Product Before Jacketing

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Cryogel Zs Foil Facing Makes It Impermeable to Water Vapor

120
100
80 Perm-inch
60
40
20
Cellular Cryogel Glass Z
PIR
Cryogel Expanded Calcium Perlite Silicate
Mineral Fiber
Fibrous Glass
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Cryogel Eliminates the Need for Insulation Contraction Joints

Conventional Contraction Joint for PIR or Cellular Glass System 6 Cryogel Ply Number
Cryogel compresses
5
4 3 2
Cryogel inner ply strain is -2.4 mm/m
No Contraction Joint for Cryogel System
Cryogel eliminates the expense, complexity, heat loss, and failure risk associated with insulation contraction joints
Steel Pipe Wall
SS pipe strain is -3.3 mm/m
-200
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-150
-100
-50
50
Temperature (C)
Traditional Expansion / Contraction Joints Are Cold Spots
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Reference Projects
Reference Projects Subsea Pipe-in-Pipe
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 subsea pipelines (6 11) to date Dates: Sept 2004 Present Process Temps: 140 180F Design Goal: Flow assurance, and reducing the size, weight, and cost of the carrier pipe Results:
By the end of 2007, Aspens 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
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Reference Projects Hot
Steam and Condensate Piping

Location: La Porte, TX Scope: 10,900 feet of pipe Date: Oct-Dec, 2006 Process Temp.: 180-500F Design Goal: Heat conservation Insulation: 1 Perlite 1 layer of 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
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Asphalt Tank at Refinery in Halifax, Nova Scotia

Scope: 45x60 tank (sides only) Date: April, 2008 Process Temp.: 300F Design Goal: Heat conservation Other Factors: VentureClad membrane was used as the final 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
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Tank Roof in Baton Rouge

Location: Baton Rouge, LA Scope: 150 tank roof Date: Feb, 2007 Process Temp.: 300F Design Goal: Heat conservation Other Factors: Installed during the rainy season Insulation: 2 layers of Pyrogel Results:
Capacitor discharge weld pins used for attachment
Protection from elements was not necessary

Finished insulation covered with CP-11 spray mastic
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160F Vessel In Carrolton, KY

Scope: 16 x 20 vessel, including elliptical heads Date: June 2006 Process Temp.: 160F Design Goal: Personnel protection Insulation: 1 rigid block w/ engineered head segments 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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Condensate Tank
Location: La Porte, TX Scope: 20 x 40 tank
Date: November, 2006

Process Temp.: 180F Design Goal: Heat conservation Insulation: 1 Perlite 1 layer of Pyrogel Other Factors: Heavy weather during 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
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Bullet Tank at Refinery in Le Havre, France

Scope: 3 m x 10 m desalter (110C); 20 m of 12 pipe (390C) Date: July-September 2008 Design Goal: Heat conservation Insulation: 4 layers (40 mm) of Pyrogel XT vs. 100 mm MW blanket and 110 mm MW pipe cover Other Factors: Contractors first time using the material Results:
Long-term product durability will be monitored w.r.t. CUI and energy efficiency
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Hot Air Ducts for Industrial Dryers

Location: Marshall, MN, USA Scope: 100s of meters of ductwork for an industrial dryer at a cornprocessing facility Date: May, 2009 Process Temp.: 175-650F
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
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SCR Duct, Billings, MT

Location: Millings, MT Scope: 10-14 SCR ducting Date: June, 2008 Process Temp.: 750F Design Goal: Heat conservation Other Factors: Insulated the duct-work on the ground Insulation: 50 mm of Pyrogel Results:
Fast, high-quality install
Has now become the standard worldwide specification for SCR ducting
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Large-Bore Water Lines Pre-Insulated with Pyrogel XT

Scope: 60 miles of 36-48 water pipelines near Ft. McMurray, AB Design Goal: Freeze protection during 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
Water at 40F (4C)
Insulated pipe laid directly on the ground

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80 Joints Delivered to Indoor Fabrication Facility in Edmonton
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High-Speed Pipe Spinners Ease Application of Insulation, Jacket
-83-
Single Layer of PGXT-10 Applied with Spray Adhesive
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Pipes Get Insulated In One Section of the Shop
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While the Jacket Gets Spray Applied in Another
-86-
Spraying Is Fast and Consistent with Minimal Overspray
-87-
Spray Application Yields Tough, Impermeable Membrane
-88-
System Easily Withstands Rigors of Transport, Installation
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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
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Three Layers Pyrogel XTF Installed on Bottom Head
-91-
SS Bands Used to Harness Material to the Head
-92-
Floating Ring Used Around the Bottom Nozzle
-93-
Bands and SS Jacket used for Final Securement
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Insulated from the Top Down, Removing Scaffold Along the Way
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The Finished Article
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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.:
750F (400C)
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
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Insulating Duct Supports
-98-
Insulating Duct Supports
-99-
Conical Reducer and Transition Section
-100-
Vessel Head with Manway
-101-
Completed Duct Section
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Drum Head
-103-
Completed Duct Section
-104-
Distillation Tower at Refinery in Chalmette, LA

Location: Chalmette, LA Scope: 166 x 13 diameter distillation tower Date: September, 2007 Process Temp.: 734F Design Goal: Process control Insulation: 7 perlite 4 perlite + 3/8 Pyrogel Other Factors: Nozzles and ladder clips designed for only 4 perlite Results:
Insulation cleared all the clips and nozzles Project finished 3.5 days ahead of schedule
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Wellhead Lines for Devon Energys 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.: 590F
Design Goal: Heat conservation

Original Spec: 3 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
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Ideal for Remote Locations, Large-Bore Piping
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Bridge Crossing Near Ft. McMurray, Alberta

Scope: 800 m of 24 pipe, pre-insulated in Edmonton and trucked 6 hours to remote site Date: Summer 2007 Process Temp.: 149C (300F) Design Goal: 7-day cool-down to 60C (140F) Insulation: 3 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
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Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
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Municipal Steam Tunnels In Baltimore, MD

Scope: Removable covers for manholes, steam tunnels Date: November, 2007 Process Temp.: 150-450F Design Goal: Personnel protection, heat conservation, reduced blanket weight Other Factors: Tunnel flooded shortly 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
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Piping in Kawasaki, Japan

Location: Kawasaki, Japan Scope: 8-12 piping Date: Nov, 2007 Process Temp.: 325C Design Goal: Heat conservation Other Factors: Productivity and performance 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
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Reference Projects Cryogenic & Cold
LNG Import Terminal In St. John, New Brunswick

Scope: >5000 m of cryogenic and utility piping Date: August 2008 Process Temps.: -260F (-162C) to ambient Design Goal: Condensation control; 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
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Traditional Cold Insulation System for LNG Service
-120-
Cryogel Requires No Contraction Joints
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Cryogel Z / PIR Composite System Specified
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Setup In the Fabrication Shop
Industrial hot knife

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Use a Hot Knife for Large-Volume Cutting of Cryogel
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Pieces Are Rolled, Tagged, and Sent to the Field
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Securing Layer #1 With Fiberglass Tape
-126-
Positioning Layer #2
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Cryogel over PIR
-128-
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 LNG off-load arms; 20 ft of 24 LNG line (installation trial only); Date: October 2007 Process Temp.: -260F (-162C) Design Goal: Minimizing ice formation during off-load; survive ice falling from uninsulated surfaces above Insulation: 8 layers (80 mm) of Cryogel Other Factors: Falling ice zone; Contractors 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 top and base of LNG tank Date: August 2008 Process Temps.: -260F (-162C) to ambient Design Goal: Slow the formation of 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
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Insulating Double-Gimbaled Cryogenic Flex Joints
Insulating Cryogenic Flex Joints

Scope:
36 LNG flex joints
Location:
Mexico
Temperature:
-260F (-162C)
Design Goals:
Condensation control on a doubly-gimbaled flex joint for 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
-136-
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 Process Temp.: -260F (-162C) 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 simplifies offshore 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.:
-260F (-162C)
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 glass Void 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 and small-bore piping Date: October 2008 Process Temps.: -155F (-104C) Design Goal: Condensation control; 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
-157-
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
-158-
10 x 60 Vessel As-Delivered from Fabrication Yard
-159-
On a 34-Layer System, Keeping an Accurate Count is Important
-160-
Patterns Created In-Place By Simply Removing Excess Material
-161-
Bands and Bridles Installed Every Fourth Layer for Support
-162-
Final Layer Installed, Banded and Sealed with Tape
-163-
Fiber Blankets Protect the Vapor Barrier from Screw Punctures
-164-
Finished Article Awaiting 250-Mile Transport by Truck
-165-
Rigging and Installation On Site
-166-
Liquid Ethylene Sphere in Brazil

Scope:
60 (18 m) ethylene sphere
Location:
Southern Brazil
Temperature:
-30F (-34C)
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
-167-
All Joints Taped to Provide Continuous Vapor Barrier
-168-
Standoffs Support Jacket While Bands Harness Bottom Head
-169-
Jacketing Near the Spheres Apex, Before Painting
-170-
The Finished Article
-171-
Bottom of Sphere in Dartmouth, NS

Location: Dartmouth, NS Scope: Bottom of 23 sphere Date: Nov, 2007 Process Temp.: 50F Design Goal: Freeze protection Other Factors: Used chicken wire for securement + peel-and-stick weather 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
-172-
Bottom of Sphere in Dartmouth, NS
-173-
Barge Terminal in Wilmington, NC

Location: Wilmington, NC Scope: 1200 ft of 8 line Date: July 2007 Process Temp.: 55F to ambient Design Goal: Paraxylene freeze protection Insulation: 1 perlite 1 layer of 3/8 Cryogel Other Factors: Heat traced, with 600 ft installed over water Results:
Fast installation over electric trace Minimized time and bulk handling over water
-174-
Insulating LNG Tank Risers

Scope: 150 of 24 and 12 pipe Process Temp.: -260F (-162C) 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
-175-
Steel Clamp Rings Used to Protect Insulation & Support Jacket

Ring 5
1 SS bands
Pipe wall
Ring 4
Ring 3
Pipe guide
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
Ring 2
Fabricated SS clamp ring

Ring 1
LNG
2.Periodically supporting the 150 of SS jacket 1 insulation support ring
Anchor
-176-
Material Was Pre-Cut on the Ground to the Right Circumference
-177-
During Installation, Cryogel Was Held In Place with Tape
-178-
Foster 90-66 Vapor Stops Being Painted
-179-
Minimal Clearance Between Insulation, Tank Stiffener Rings
-180-
Stainless Steel Clamp Ring Held on with Bands
-181-
Pipe Guides Constructed to Allow Minimal Rattle Space
-182-
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 access required 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
-183-
Single Man-Hole Access at Either End of the Tunnel
-184-
First, Strip 30-Year Old Insulation
-185-
Additional Task Lighting Had to Be Brought In
-186-
Periodic Flooding had Destroyed the Existing Insulation
-187-
Pyrogel XT and Cryogel Z with Aluminum Jacketing Installed
-188-
Thinner Insulation Easily Avoided Potential Clashes
-189-
On-Time Job Completion
-190-
Pre-Insulated Heat Exchangers

Location: Gonzales, LA Scope: 14 x 36 pre-insulated heat exchanger Date: July 2007 Process Temp.: 500F 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
-191-
Polycarbonate Plant
Location: Yeosu, South Korea Scope: Piping, towers and tanks for an entire polycarbonate plant Date: Mar-Aug, 2007 Process Temp.: 250-650F 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
-192-
Reactor Heads
Location: Freeport, TX Scope: 15 reactor vessel head Date: Feb, 2007 Process Temp.: 550F Design Goal: Process control Insulation: 12 of minwool 12 layer of 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
-193-
Heat Exchanger Modules

Location: Northern Alberta Scope: Three pre-insulated heat exchanger modules
Date: Mar, 2007

Process Temp.: 250-400F Design Goal: Heat conservation Insulation: 2 mineral wool 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
-194-
Heat Exchanger Insulation Survives Transport and Handling
-195-
Heat Exchanger Insulation Survives Transport and Handling
-196-
Distillation Tower
Location: Plaquemine, LA Scope: 14 x 119 tower with 2:1 elliptical head Date: Jan, 2007 Process Temp.: 200F Design Goal: Heat conservation Insulation: 1 Perlite block 1 layer of Pyrogel Other Factors: Original support rings protruded and had to be insulated around Results:
Fast, single layer application Thermal savings of $138K per year with only one layer of Pyrogel
-197-
Unique Application: Pre-Insulated Sweep Elbow
Aerogel Blankets Are Durable with Good Compression Resistance
-199-
-200-
-201-
-202-
-203-
-204-
-205-
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
-207-
Thank You

Flexible Aerogel Insulation For Industrial Applications: April 2011

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Flexible Aerogel Insulation For Industrial Applications: April 2011

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