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Contenido archivado el 2024-06-18

High Performance Insulation based on Nanostructure encapsulation of air

Final Report Summary - HIPIN (High Performance Insulation based on Nanostructure encapsulation of air)

Executive Summary:
In this project, the key enabling technology is the development of a precursor with a higher silica content than the conventional 28% silica content precursor, TEOS. It was anticipated that higher silica content precursor would lead to more robust gels that can be incorporated and formulated into paint, plaster, and panel products that can provide high thermal insulation benefits for new constructions as well as retrofits. For retrofit applications especially, the application of thick insulation to the inside of walls is often unwelcome because it impacts on the internal floor area. Thus, new insulation products that can provide equivalent performance with less thickness would be desirable. The very low thermal conductivity of aerogel (less than 0.02 W/(m.K) typically) makes this possible. However, the challenge is in maintaining the porous structure of the aerogels after mixing into building products like paint and plaster.

The insulation concepts developed by the HIPIN project involve the development of a high silica content aerogel precursor, which can provide a cost-effective route to a robust aerogel. The precursor developed during the project contained 58% silica and was made into both hydrophilic and hydrophobic aerogel by a cost-effective method. This aerogel was then incorporated into 3 main types of building products, viz. paint, plaster, and panels. The thermal performance of these three products was validated not only via a lab evaluation of the thermal conductivity of these products but also via demonstrators set up under commercially relevant conditions. Thus, the aerogel containing paint, plaster, and panels were set up on a wall (9 square meters for each application) at Envipark in Turin. Data was collected continually on each of these demonstrators over a 3-month period to validate the insulation benefits of the products.

A detailed techno-economic analysis was completed and showcases the cost-vs-performance balance that can be achieved for each product at commercial scales. It is clear that the cost of the aerogel, its loading in the final products, and the durability of the final product (especially for the plaster) are the key factors that drive the techno-economics of this technology. A detailed life-cycle analysis (LCA) model, including envisaged end-of-life scenarios, was developed within the project for the paint, plaster, and panel products using the HIPIN aerogel.

Project Context and Objectives:
Aerogels are low density solid materials (density less than 100-200 kg/m3, typically) containing air-filled pores within a solid framework. The encapsulated air not only provides the low density but also imparts very low thermal conductivity, with the very small pore sizes making it possible to achieve thermal conductivities less than the thermal conductivity of still air. Thus, silica-based aerogels have very low thermal conductivity (0.01-0.02 W/(m.k) typically) and can thus potentially be used for high performance insulation materials. However, their fragility has limited application in building products, making widespread use in the construction section not feasible in the past.

The overall goal of the project was to develop new affordable building products based on aerogel, suitable for both retrofits and new buildings. Specifically, the three products investigated during the project are paints, plaster, and panels, which incorporated a low thermal conductivity aerogel in the form of granules. A huge potential market exists for a highly insulating material for new buildings and retrofits that can satisfy the needs of high density housing and new insulation regulations in Europe. All three products can be applied using methods used in the building and construction industry today on the exterior of the building. It can be envisaged that the paint and plaster products can also be used for indoor applications.

The main objectives of HIPIN were:
• Develop aerogel building blocks (precursors) which enable stronger aerogels to be manufactured and incorporated into typical building products like paint, plaster, and panels.
• Develop an aerogel production route of lower cost, with a realistic cost target of €5 per litre of aerogel possible for manufacturing in large volume quantities.
• Develop the appropriate surface functionality needed to provide properties like hydrophobicity that can promote incorporation of aerogel without the absorption of water and retain the aerogel porous network to contribute to enhanced thermal performance.
• Develop cost-effective and commercially viable methodologies to mix the aerogels into the paint, plaster or panel systems, and apply the system to buildings. This objective includes developing suitable technology to ensure that the systems can be manufactured and applied with reliability and ease using procedures currently used in the industry.
• Develop and test three new products that incorporate aerogel: paint, plaster and paint.
• Generate material properties to demonstrate the thermal conductivity enhancement of the products after incorporation of the aerogel.
• Validate overall system performance data via suitable demonstrators that can be used for dissemination to allow the market to see the quantified benefits of the HIPIN approach.
• Validate the techno-economics of the aerogel-containing products, with the intention of getting the right balance of cost to performance.

Project Results:
The following are the key results from the project:

* Multi-liter scale production of high silica content precursor, scaling up the lab method developed at TWI to an industrially feasible process
• Synthesis protocols for making a high silica content precursor (58% silica, as compared to TEOS, which is a 28% silica precursor used in the literature previously) were developed by TWI.
• Three batches of 450 litres each were produced by Thomas Swan, demonstrating good scale-up robustness as indicated by the uniformity of the 3 batches.

* Investigation of functionalized Stöber silica nanoparticles for the precursor technology
• The incorporation of functionalized Stöber silica nanoparticles into the precursor synthesis route was investigated by TWI as a route to increase the silica content of the aerogel (to render it more robust) as well as introduce suitable functionality via these particles (to render it hydrophobic).
• Separex’s proprietary method to render the aerogel hydrophobic was used during the scale-up for the demonstrators and the technology for incorporation of the functionalized silica nanoparticles into the aerogel precursor synthesis protocols was not scaled-up.
• Aerogel thermal conductivity of < 0.01 W/(m.K) as a monolith and ~ 0.015-0.03 W/(m.K) in granular form) was obtained.

* Production of robust aerogel using HIPIN precursor
• Separex produced over 500 liters of aerogel for the demonstrators.
• Cost-effective methods for hydrophobization of aerogel were used in cases where such a surface treatment was found to be necessary to preserve insulation performance after incorporation into the paint and plaster matrix.
• Over 450 liters of hydrophobic aerogel was sent to Vimark for incorporation into a plaster formulation.
• 100 grams of <1mm powder of the same hydrophobic aerogel was sent to ICI for incorporation into a paint formulation, which was used for the paint demonstrator.
• Over 500 liters of hydrophilic aerogel was sent to Methodo for incorporation into a polyurethane (PU) matrix and making over 36 panels using this PU-aerogel composite.

* Paint containing aerogel - ICI
• Optimised formulation of paint with aerogel developed to provide thermal performance via a thin layer of paint (about 250 microns)
• ICI has delivered a formulation that shows an improvement in thermal performance compared to standard paint, without affecting any other properties. The thermal conductivity of the HIPIN paint is 0.49 W/(m.K) compared to 0.64 W/(m.K) for a standard paint.

* Plaster containing aerogel – Vimark
• Optimised formulation of a plaster containing the HIPIN aerogel was developed to provide high thermal performance. The plaster containing the aerogel was then used for setting up the demonstrator using traditional machine application of the plaster onto a wall.
• Vimark delivered a plaster-aerogel formulation with good thermal insulation possible both at lab and demo scale compared to standard plaster. The HIPIN plaster has a thermal conductivity (lambda) value of 0.034 W/(m.K) compared to 0.47-0.5 W/(m.K) for a standard plaster.
• Durability and strength of the plaster product with high aerogel loadings (> 30%) needs to be further optimized before commercialisation is possible.

* Panels containing aerogel – Methodo
• Optimised formulation to produce a panel with aerogel developed by Methodo after trials with a number of polymer systems
• Methodo has developed a methodology to combine the aerogel with polyurethane in a panel.
• The panel developed by them gave a lambda value of 0.025 W/(m.K) a 25% improvement over a standard insulation board made of EPS (lambda value of 0.036 W/(m.K).

* Demonstrators
• Demonstrators of the paint, plaster, and panel products were set up at Envipark by ICI, Vimark, and Methodo, respectively, in September-October 2014.
• Measurement of thermal performance of the 3 products was undertaken over the winter months (Nov 2014 to February 2015) and the calculated U-value for these walls, with and without HIPIN products, was measured, validating the performance benefits for all 3 products.
• The thermal resistance of the wall for these building elements was measured per the ISO 9869:1994 standard.
• Data from the labs and demonstrators was used to quantify the improvements in thermal performance possible from the HIPIN paint, plaster, and panel products

* Techno-economic analysis
• A detailed techno-economic analysis was carried out by Orient Research to understand the applicability of the HIPIN products in the market, with respect to performance and economics. This was based on an estimate of the price of the aerogel, assuming an initial introduction of the HIPIN aerogel into the market at the 250 tons per annum scale.

* Modelling
• Mathematical models were development to predict the reduction in heating energy achievable using the three products. Theoretical models were developed that will enable the partners to predict the thermal conductivity of the materials for varying loadings of aerogel.
• The theoretical models confirmed the measured values and provide a basis for further product optimisation after the project.

* Lifecycle analysis (LCA)
• Eco-profiles, including envisaged end-of-life scenarios, have been created for the aerogel and the HIPIN paint, plaster, and panel products via a detailed LCA model developed by Envipark
• For example, HIPIN plaster when compared to thermal insulating plaster (Vimark’s thermal insulating plaster Thermocalce, lambda =0.088 W /mK) gave a Global warming potential (100 years) reduction of 87% and Primary Energy Demand (PED) reduction of 47%.

* Exploitation
• A detailed report (PUDF) was completed to outline the exploitable results, including market analysis to understand risks and intervention needed to help commercially exploit the technologies.
• The cost of the aerogel and its loading are the key drivers that will drive commercial exploitation.

Potential Impact:
The construction sector is the highest energy consumer (about 40 %) in Europe and also the main contributor to GHG emissions (about 36 % of the EU’s total CO2 emissions. The energy policy scenarios by 2050 show that a 40 % to 50 % reduction of the building ‘sector’energy consumption is mandatory by 2050, where fossil fuel heating represents a major share (60 %). Thus, a large reduction in the CO2 emissions from buildings is critical in the coming decades. This can be achieved via improved energy efficiency through the use of high-performance insulation and energy-efficient systems. The walls, roof and windows of a building account for the majority of its heat loss in winter and heat gain in summer and hence research into novel improved cost-effective insulation technology is a positive investment for Europe and the world’s future. Although novel building materials are often used in new constructions, availability of cost-effective insulation for existing buildings is critical since the percentage of existing buildings is very high in Europe. Reduction of thickness can be a key need for retrofits due to lack of design options in existing buildings. Thus, aerogels, with their very low thermal conductivity (0.01-0.02 W/(m.k) typically) provide an innovative option for improved thermal performance for the existing building infrastructure in Europe.

Thus, the 3 products developed within the HIPIN project all allow for this improved thermal performance for retrofits as well as new construction due to their superior thermal properties as compared to existing insulation options. Although cost of the aerogel and its loading are the key drivers that will drive commercial exploitation, we anticipate that the cost of aerogel can drop significantly further if the demand is higher and economies of scale can be generated. Within the HIPIN project, the price of the aerogel was estimated to be €2.20/liter (much less than the cost target of €5 per litre of aerogel mentioned in the original HIPIN proposal). This was based on a possible initial market of 250 tons of aerogel. However, if the demand increases significantly to thousands of tons and the capital investment needed for aerogel plants to meet this demand can be made, a target price of aerogel of less than of €1 per litre of aerogel can also be envisaged at these high demands.

The technology developed within HIPIN project was widely disseminated across Europe during the project. Specific activities for dissemination included:
• Creating and maintaining a public web site - http://www.hipin.eu.
• Publications in technical trade journals about the project aim (first phase) and the project results (second phase) focusing on how it will benefit the sector in the long term.
• Attending and presenting HIPIN technology via technical seminars and presentations at relevant leading conferences in the nanomaterials and building materials industry sector.
• Production of flyers which were distributed at several exhibitions and conferences and updated at the end of the project for future dissemination.
• A HIPIN Workshop at which relevant stakeholders from the building industry were invited; this was held at Envipark, the site of the demonstrators, allowing attendees to visually see the building products on a wall.

Overall, dissemination was carried out via presentations at 14 conferences, attendance at 11 exhibitions, participation in EEB and other related workshops and seminars (9), and 8 articles published in relevant journals, including one peer-reviewed journal article.

Five main exploitable results came out of the project, namely:
1) A high silica content precursor for aerogel synthesis - A pre-polymerised TEOS precursor with a silica content of 58% (TES58)
2) Hydrophobic and hydrophilic aerogel based on the high silica content precursor (TES58), providing a low thermal conductivity (< 0.02 W/(m.K)).
3) Thermal insulating plaster containing a suitably surface treated aerogel and providing high insulation benefits (thermal conductivity < 0.034 W/(m.K)).
4) Thermal insulating panels based on a polyurethane (PU) – HIPIN aerogel composite, for easy installation on buildings and thermal conductivity 25% lower than the traditional insulation material used in buildings (EPS).
5) Thermal insulating paint formulation containing HIPIN aerogel that can provide enhanced insulating properties compared to standard paint (thermal conductivity 24% lower than standard paint), without affecting any of the other paint properties (e.g.: gloss, sheen, abrasion resistance, etc.)

List of Websites:
Project website address http://www.hipin.eu

Project Coordinator - TWI Ltd, UK
Contact Person - Dr. Sanjeev Naik
Tel - +44 (0) 1223 899 000
E-mail - coatings@twi.co.uk