N A N O T E C H N O L O G Y A T W O R K TM. Pyrogel Insulation TECHNICAL GUIDE

Transcription

1 N A N O T E C H N O L O G Y A T W O R K TM Pyrogel

2 Contents Introduction 3 Thermal Conductivity ASTM C Thermal Conductivity 5 ASTM C Thermal Conductivity 5 Dimensional Stability ASTM C Linear Shrinkage Under Soaking Heat 6 ASTM C 411/C Hot Surface Performance 6 ASTM E Linear Coefficient of Thermal Expansion 6 Effects of Long Term Thermal Exposure 6 Mechanical Resilience ASTM C Compressive Strength (Room Temp) 7 ASTM C 592, Section Procedure for Heat and Vibration 7 ASTM C 1101, Section 7.1 and Flexibility and Resilient Flexibility 7 Compression Recovery at High Stress Load 7 Water Resistance ASTM C Wicking 8 ASTM C Water Vapor Adsorption 8 ASTM C Water Repellency 8 Chemical Resistance ASTM C 665, Section Corrosion Test 9 ASTM C Standard Specification for Thermal for Use in Contact With Austenitic Steel 9 Extractable ph Measurements of Pyrogel ASTM C Fungal Resistance 9 Fire Testing ASTM E 84 - Flame and Smoke Spread 10 UL Structural Steel Fire Protection 10 European Testing 10 Acoustical Properties ASTM E Insertion Loss of Pipe Lagging Systems 11 Appendix A - C 177 THERMAL CONDUCTIVITY 12 Appendix B - ASTM C 335 CONDUCTIVITY 21 Appendix C - ASTM C LINEAR SHRINKAGE UNDER SOAKING HEAT 26 Appendix D - ASTM C 411/C HOT SURFACE PERFORMANCE 28 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 32 Appendix F - EFFECTS OF LONG TERM THERMAL EXPOSURE 39 Appendix G - MECHANICAL RESILIENCE 44 Appendix H - PYROGEL 6350 COMPRESSION RECOVERY AFTER HIGH STRESS LOAD 51 Appendix I - ASTM C 795 STANDARD SPEC FOR THERMAL INSULATION FOR USE IN CONTACT WITH AUSTENITIC STEEL 57 Appendix J - EXTRACTABLE ph MEASUREMENTS OF PYROGEL Appendix K - ASTM C FUNGAL RESISTANCE 64 Appendix L - ASTM E 84 - FLAME AND SMOKE SPREAD 69 Appendix M - UL STRUCTURAL STEEL FIRE PROTECTION 71 Appendix N - EUROPEAN TESTING 88 Appendix O - ASTM E INSERTION LOSS OF PIPE LAGGING SYSTEMS 93

3 Introduction Pyrogel is a high-temperature insulation blanket formed of silica aerogel and reinforced with a non-woven, carbon- and glass-fiber batting. Silica aerogels possess the lowest thermal conductivity of any known solid. Pyrogel achieves this industry-leading thermal performance in a flexible, environmentally safe, and easy-to-use product. Ideal for insulating the curved surfaces and complex shapes typical of today s refining and petrochemical infrastructure, Pyrogel is an essential material for those seeking the ultimate in thermal protection. Pyrogel Advantages: Superior Thermal Performance 2 to 8 times better than competing insulation products Reduced Thickness and Profile Equal thermal resistance at a fraction of the thickness Less Time and Labor to Install Easily cut and comformed to complex shapes, tight curvatures, and spaces with restricted access Physically Robust Soft and flexible but with excellent springback, Pyrogel recovers its thermal performance even after compression events as high as 50 psi Shipping and Warehousing Savings Reduced material volume, high packing density, and low scrap rates can reduce logistics costs by a factor of five or more compared to rigid, pre-formed insulations Simplified Inventory Unlike rigid pre-forms such as pipe cover or board, the same Pyrogel blanket can be kitted to fit any shape or design Excellent Fire Protection Equal to or better than other insulation materials, including mineral wool and calcium silicate Hydrophobic Yet Breathable Pyrogel repels liquid water but allows vapor to pass through Environmentally Safe Landfill disposable, shot-free, with no respirable fiber content 3

4 Introduction Pyrogel s main properties are categorized and described on the following pages. Below is a a summary of key test results. Specification Compliance and Performance Test Procedure Property Results ASTM C165 Compressive Strength Stress at 10% strain = 11.6 psi (80 kpa) Stress at 25% strain = 24.7 psi (170 kpa) ASTM C356 Linear Shrinkage Under Soaking Heat < 2.5% ASTM C411 Hot Surface Performance Passed ASTM C592 Modified Mineral Fiber - Weight Loss From Vibration Passed ASTM C871 Leachable Chloride, Flouride, Silicate and Sodium Ions Passed chemical requirements of C795 ASTM C1101 Classifying the Flexibility of Mineral Fiber Blankets Class: Resilient Flexible ASTM C1104 Water Vapor Sorption 4% (by weight) ASTM C1338 Fungal Resistance of Materials Passed ASTM C1511 Liquid Water Retention After Submersion 4% (by weight) ASTM C1559 Modified Wicking of Water Into Glass Fiber Passed (no wicking) ASTM E84 Surface Burning Characteristics Flame Spread Index = 0 Smoke Developed Index = 5 UL 1709 Hydrocarbon Pool Fire - 4 (100 mm) steel pipe (0.4 mm) stainless steel cladding 6 mm = 15 min 12 mm = 25 min 18 mm = 34 min 24 mm = 42 min 30 mm = 51 min 4

5 Thermal Conductivity ASTM C THERMAL CONDUCTIVITY Aspen has completed third-party validation of its thermal conductivity results. Thermal conductivity of the Pyrogel 6350 material is as follows: Pyrogel 6350 = C Pyrogel 6350 = C The final report in Appendix A shows the full thermal conductivity curve from 50 C to 300 C. Thermal Conductivity ASTM C 177 Results Thermal Conductivity, k (BTU-in/hr-ft 2 - F) Temperature ( F) Temperature ( C) Thermal Conductivity, k (mw/m-k) Mean Temp. C F k mw/m-k BTU-in/hr-ft 2 - F ASTM C THERMAL CONDUCTIVITY Aspen completed a third-party validation of its thermal conductivity using the guarded end pipe configuration. Results are in agreement with C-177 within the standard deviation of the two test results and are as follows: Pyrogel 6350 = C The final report is in Appendix B. 5

6 Dimensional Stability ASTM C LINEAR SHRINKAGE UNDER SOAKING HEAT ASTM C 356 measures linear shrinkage when subjected to soaking heat for 24 hours. The third party result for Pyrogel 6350 at 309 C was <2.5%. The third party test result can be found in Appendix C. ASTM C 411/C HOT SURFACE PERFORMANCE Dimensional stability is also part of the criteria for determining maximum use temperature, ASTM C411/C447. This is a pipe test configuration. At a hot surface temperature of 385 C, shrinkage across the length of the pipe was <0.33%, and circumferential shrinkage measured at 10 cm intervals was <2.3%. Third party test results can be found in Appendix D. ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION ASTM E 228 can be found in Appendix E. A number of materials were tested in this report. However, only the table and plot for Pyrogel 6350 have been included in Appendix E. Testing was done from -170 C C. EFFECTS OF LONG TERM THERMAL EXPOSURE An internal analysis of simulated long term exposure (up to 20 years) was done to understand thermal and mechanical stability. The report is attached in Appendix F. The simulated 20-year exposure indicates that Pyrogel will exhibit minimal shrinkage and thermal performance degradation over the course of its lifetime at its recommended operating temperature. The shrinkage was less than 2% with no change in thermal performance. 6

7 Mechanical Resilience ASTM C COMPRESSIVE STRENGTH ( ROOM TEMP) Compressive resistance measured at both 10% and 25% compression for standard conditions is shown in Appendix G, section 3.0, tables 2 and 3. It is part of a large report from Bodycote outlining a number of tests. The average compressive resistance was 80 kpa (@10%) and 170 kpa (@25%). ASTM C 592, SECTION PROCEDURE FOR HEAT AND VIBRATION In this test method, the sample is heated for C and then vibrated for 6 12 Hz and 3 mm displacement. The results are attached in Appendix G, Table 1. Pyrogel 6350 shows a 6.4% weight loss upon heat treatment, which is mostly absorbed water. After vibration, the material recovers some of its weight due to re-absorption of water. The net result of heating and vibration is that there is essentially no loss due to vibration. Appendix G, Fig 1 shows the material after heating and vibration. As may be observed, the material is essentially pristine. ASTM C 1101, SECTION 7.1 AND FLEXIBILITY AND RESILIENT FLEXIBILITY The sample was tested for flexibility and resilient flexibility. The sample is classified as resilient flexible. The results of third party testing are in Appendix G, Page 6. COMPRESSION RECOVERY AT HIGH STRESS LOAD An internal analysis of compression recovery showed Pyrogel 6350 to recover 80% of its thickness after loads as high as 875 psi. The report is given in Appendix H. The stress strain curve is shown in Chart 1 at right. Compressive Stress, MPa Chart 1 Compressive Stress vs. Percent Strain Crosshead Speed = 5 ipm Maximum Stress = Mpa = 875 psi % Strain PG6350 7

8 Water Resistance ASTM C WICKING In this test, insulation is suspended in water, and the distance that water wicks is measured over 168 hours. Pyrogel 6350 is hydrophobic (repels water) and shows no water wicking. Results of third party testing are located in Appendix G, Tables 7 and 8. ASTM C WATER VAPOR ADSORPTION This test measures the water absorbed by insulation exposed to a high humidity environment. Results are shown in Appendix G, Table 5. The average weight gain is 4%, and the average volume gain is 1%. Pyrogel 6350 meets the requirements for ASTM C 547 Standard Specifications for Mineral Fiber Pipe. ASTM C WATER REPELLENCY Water repellency test results are given in Appendix G, Table 6. Average weight gain was 2.3 grams, which is kg. ASTM C 800 Specification for Fibrous Glass Blanket requires Repellency in kg max. Pyrogel 6350 passes the requirement of ASTM C800. 8

9 Chemical Resistance ASTM C 665, SECTION CORROSION TEST Pyrogel 6350 was tested using the Standard Specification for Mineral-Fiber Blanket Thermal for Light Frame Construction and Manufactured Housing Section 13.8 only, aluminum and copper. The performance criteria for this test are outlined in ASTM C 547 Standard Specification for Mineral Fiber Pipe Section 7.4. The specification is corrosion no greater than comparative plates in contact with sterile cotton and is greater than or equal to 21 for aluminum and copper. Our test results in Appendix G, Table 4 give values of 39.5 and 40 for aluminum and copper respectively, a clear pass for these criteria. ASTM C STANDARD SPECIFICATION FOR THERMAL INSULATION FOR USE IN CONTACT WITH AUSTENITIC STEEL Difficulties were encountered with testing in accordance with ASTM C 795 Standard Specification for Thermal for Use in Contact with Austenitic Steel. This specification requires testing in accordance with C 871 and C 692. The chemical requirements of this specification, C 871, were easily met with our results being well within specification. The results were: ph 8.6, chloride 24 ppm, and fluoride 1 ppm. However, testing in accordance with C 692 proved to be an obstacle. Aspen s insulation blanket is hydrophobic; the C 692 method requires contact between the insulation and the water. To circumvent the non-wicking behavior of our materials, tunnels were cut into the insulation coupons, and the water dripped directly into these cracks. The test result was a pass with 4 coupons showing no cracking. Appendix I has the results for C 795. Extractable ph Measurements of Pyrogel 6350 Pyrogel 6350 is hydrophobic, therefore there was some question as to the validity of the ph measurement for C871. This test is also designed for materials that readily wick water. In order to replicate real-world conditions involving the use of Pyrogel 6350, a modified ASTM C871 test was done to determine surface extractable ph. The method was meant to replicate small amounts of water that may inadvertently compromise the insulation system. Details of the test are found in Appendix J. The results indicated that extractable ph values for Pyrogel 6350 using a modified ASTM C871 did not differ significantly from the values obtained by ASTM C871 ph was 7.1 for the modified test and 7.3 for the official test. ASTM C FUNGAL RESISTANCE Pyrogel 6350 was tested using the Standard Test Method for Determining Fungi Resistance of Materials and Facings. The criteria for a pass are that test specimens have growth no greater than on the comparative item. Pyrogel 6350 showed zero or no growth and is considered a pass. Appendix K has the third party test data. 9

10 Fire Testing ASTM E 84 - FLAME AND SMOKE SPREAD Testing in accordance with ASTM E 84 Standard Test Method for Surface Burning Characteristics of Building Materials was performed on Pyrogel 6350 and is given in Appendix L. Pyrogel 6350 satisfies the criteria for a Class A rating with flame spread index: 0, smoke developed index: 5, and fuel contribution: 0. UL STRUCTURAL STEEL FIRE PROTECTION Pyrogel 6350 was tested for Rapid Rise Fire Tests of Protection Materials for Structural Steel. The sample is subjected to furnace heat of 2000 F and the approximate heat flux of 204 kw/m2. Thermocouples recorded the temperature of the steel pipe under the insulation and the time to reach 1000 F under the insulation is reported. Four layers of Pyrogel 6350 take 47:20 (MM:SS) to reach 1000 F. The third party test results can be found in Appendix M. Pipe Temperature ( F) Hydrocarbon Pool Fire UL 1709 Results mm (in) 6 (0.24) 12 (0.48) 18 (0.72) 24 (0.96) Pipe Temperature ( C) (1.20) Time (min) EUROPEAN TESTING Pyrogel 6350 was tested according to EN ISO and EN ISO The results for the third party testing are located in Appendix N. 10

11 Acoustical Properties ASTM E INSERTION LOSS OF PIPE LAGGING SYSTEMS ASTM E1222 Standard Test Method for Laboratory Measurement of the Insertion Loss of Pipe Lagging Systems. The third party test results are presented in graph form and the complete test report is located in Appendix O. Pipe Lagging Insertion Loss ASTM E Results Insertion Loss (db) f (khz) IL (db) f (khz) IL (db) Frequency (Hz) 11

12 Appendix A - C 177 THERMAL CONDUCTIVITY 12

13 Appendix A - C 177 THERMAL CONDUCTIVITY 13

14 Appendix A - C 177 THERMAL CONDUCTIVITY 14

15 Appendix A - C 177 THERMAL CONDUCTIVITY 15

16 Appendix A - C 177 THERMAL CONDUCTIVITY 16

17 Appendix A - C 177 THERMAL CONDUCTIVITY 17

18 Appendix A - C 177 THERMAL CONDUCTIVITY 18

19 Appendix A - C 177 THERMAL CONDUCTIVITY 19

20 Appendix A - C 177 THERMAL CONDUCTIVITY 20

21 Appendix B - ASTM C THERMAL CONDUCTIVITY 21

22 Appendix B - ASTM C THERMAL CONDUCTIVITY 22

23 Appendix B - ASTM C THERMAL CONDUCTIVITY 23

24 Appendix B - ASTM C THERMAL CONDUCTIVITY 24

25 Appendix B - ASTM C THERMAL CONDUCTIVITY 25

26 Appendix C - ASTM C LINEAR SHRINKAGE UNDER SOAKING HEAT 26

27 Appendix C - ASTM C LINEAR SHRINKAGE UNDER SOAKING HEAT 27

28 Appendix D - ASTM C 411/C HOT SURFACE PERFORMANCE 28

29 Appendix D - ASTM C 411/C HOT SURFACE PERFORMANCE 29

30 Appendix D - ASTM C 411/C HOT SURFACE PERFORMANCE 30

31 Appendix D - ASTM C 411/C HOT SURFACE PERFORMANCE 31

32 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 32

33 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 33

34 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 34

35 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 35

36 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 36

37 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 37

38 Appendix E - ASTM E LINEAR COEFFICIENT OF THERMAL EXPANSION 38

39 Appendix F - EFFECTS OF LONG TERM THERMAL EXPOSURE 39

40 Appendix F - EFFECTS OF LONG TERM THERMAL EXPOSURE 40