Private Sector Approaches to Extreme Weather and Climate Change. Jeff Silva. Senior Project Manager Aspen Aerogels

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1 Private Sector Approaches to Extreme Weather and Climate Change Jeff Silva Senior Project Manager Aspen Aerogels

2 Climate Change Solutions: Better Insulation Manufacturing in New England Jeff Silva Aspen Aerogels

3 What Is An Aerogel? Aerogels are nanoporous solids invented in the 1930 s Aerogels are created when amorphous silica is gelled in a solvent When the solvent is removed, what remains is puffed-up sand, with up to 99% porosity Nanoporosity slows heat and mass transport, providing record-low thermal conductivity Hydrophobic Vapor Permeable The Aspen Advantage: Superinsulation performance in a flexible blanket form Flexible & Robust 3

4 Fiber Reinforced Blankets: Toughened Aerogel Fiber reinforcement Flexible Aerogel 4 Microstructure Improved mechanical properties

5 5 Product Range

6 Thermal Conductivity (Btu-in/hr-ft 2 - F) Thermal Conductivity Comparison Aerogels Have the Lowest k-value of Any Industrial Insulation Temperature ( F) Cryogel Z Cellular glass PUR/PIR Mineral Wool Blanket Mineral Wool Pipe & Board Perlite Calsil Pyrogel XT Thermal Conductivity (mw/m-k) 0.0 Spaceloft Temperature ( C) 0 6

7 Aspen s Products Span the Temperature Range Cryogel Z (5 and 10 mm) -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 C F Pyrogel XT (5 and 10 mm) F to 1200 F (-40 C to 650 C) 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

8 Pyrogel XT Has Many Benefits On Hot Process Equipment 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 protection 8 All four designs provide the same level of thermal protection Pyrogel XT 6 pipe at 600 F (315 C) 20 mm (0.8 ) 3 3½ Calcium Silicate 2½ Mineral Wool or Fiberglass Expanded Perlite Ambient conditions = 65 F, 2 mph wind, 0.1 emissivity

9 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. s Insulation only Distinct Parts 45:1 ratio ,000 pieces 790 rolls Packed Volume 6:1 ratio Packed Footprint 2 m stack height 5700 m m 3 53 m x 53 m 22 m x 22 m Pyrogel can reduce the material handing and inventory management required on big jobs 9

10 Cryogel Insulation for Cryogenic Applications 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 57 Btu/hr-ft 73 F Cryogel (2 in) 12 (300 mm) pipe at -274 F (-170 C) Foam glass (4.5 in) PIR (4 in) 70 Btu/hr-ft 73 F 73 F 70 Btu/hr-ft 10 All three designs meet the same condensation control criteria

11 B&C Example: Internal Wall Insulation Spaceloft is the thinnest insulation material available for internal insulation Thinner insulation = more space for occupants & preserves property value for investors Spaceloft can be prepared offsite or applied onsite as required Naturally vapour open or integrate an air & vapour control layer No foils required to maintain insulation performance = mechanical fixing compatible Indoor air quality is maintained Data package available for hygrothermal software simulations 11

12 B&C Example: External Wall Insulation Project Renovation Location Venice, Italy Bldg. Type Private Dwelling Application External Wall 10mm Benefit Heritage protected, breathable thermal bridge treatments approx 50% heat loss reduction SL 10 5mm 10mm SL 10 12

13 Aspen Aerogels East Providence, RI Facility Flexible Aerogel Insulation Manufacturing: 150,000 SF single story, manufacturing facility Full operation began in 2008 Doubled capacity in 2011 Facility operates 24 hours/day; ~350 days/year (lights are always on) 13

14 Energy Reduction Opportunities Long Term Operational Efficiency Electrical equipment Pumps, compressors, blowers Gas burning equipment Boilers, process hot air heaters, coating drying oven Air Pollution control equipment (air permit) Thermal oxidizers 14

15 Lighting Projects (must do) Facility is always occupied (24 hr/day; 7 days/week) Building constructed in 1991; existing metal halide lights Relamped facility (185 fixtures) Better lighting (30 + ceiling heights; lower light heights as needed) Timers for areas not occupied 24 hours/day (warehouse, utility rooms) Reduced estimate light usage by >320,000 kwh/year (~225,000 lbs CO2); Cost savings: ~$50,000/year Payback with National Grid incentives ~1 year Few challenges for project Contractors handled all paperwork and installation/disposal 15

16 Process Equipment Operational Control Plant automation Numerous pumps and motors, as needed operation Variable frequency drives (VFDs) match speed to load Control by pressure, temperature, flow meters, etc. Boiler pumps, process pumps, chiller, air compressors Reduce wear and tear on motors Reduces load peaks at start ( soft start ) 16

17 New Process Chiller (999 ton) Variable frequency chiller installed Improved performance at partial loads Annual Saving Electricity 800,000 kw Carbon Dioxide 600,000 pounds Water 250,000 Cost Savings $70,000 17

18 Process Gas Compressor (200 hp) Problem: peak load at start up (amperage draw) Solution: Retrofit VFD: Reduced peak load at start Reduced maintenance expected Added benefit of energy savings (i.e. not project driver) 18

19 Air Pollution Control Equipment Problem: Process equipment emissions must be controlled by Air Pollution Control Equipment Solutions: Regenerative Thermal Oxidizer (replaced recuperative) Ceramic media to retain heat (vs. shell and tube of recuperative) Controls organic emissions >99% Estimate gas savings of >400,000 therms/year Automated ventilation controls Blower VFDs and actuated dampers, pressure monitors 19

20 What s Next Rail transportation for bulk materials Compressed air improvements Ventilation optimization Combined heat & power (CHP) evaluation 20