High Performance Insulation based on Nanostructure encapsulation of air Theme: EeB.NMP.2010 ‐ 1 http://www.hipin.eu The HIPIN project received funding from the European Union's Seventh Framework Programme for research, technological development and demonstration under grant agreement no 260117.
HIPIN Partners Coordinator: TWI Ltd, UK EC Project Officer : Georgios Katalagarianakis
Project Overview • Huge potential market 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. • This opportunity can be met by new building materials containing aerogels that have very low thermal conductivity (< 0.01 W/(m . K) as a monolith and typically ~ 0.015 ‐ 0.018 W/(m . K) in granular form) Cost ‐ effective route to a robust aerogel for use as an insulation material in buildings
HIPIN Objectives Development of nano ‐ based high performance insulation system(s) for energy efficiency. THERMAL PAINT THERMAL PLASTER PANELS Develop new affordable building products based on aerogel, suitable for both retrofits and new buildings
HIPIN Aerogel Sol ‐ gel technology to produce aerogel precursor with high silica content (60%), followed by proprietary method for supercritical drying and surface treatment. • Very low density (100 ‐ 120 kg/m 3 ) • Low thermal conductivity (0.015 – 0.025 W/mK) • Robust synthesis route – multiple batches made to scale up to thousands of litres aerogel • Incorporated into a matrix system – paint, plaster, and polymer composite for panel Water Contact Angle: • Suitable for new & retrofitting buildings A ‐ hydrophilic, B ‐ hydrophobic A high silica content precursor for aerogels
HIPIN Aerogel Process Technology • Manufacturing route to a robust silica aerogel • High silica content (58% silica) precursor ( TWI and Thomas Swan ) - Robust and scaleable process development during project - Scaleable to larger quantities with minimal further development • Cost ‐ effective surface treatment for hydrophilic and hydrophobic silicas (Separex) • Optimisation of processes for incorporation into: - water ‐ borne systems (paint, plaster) - composite polymeric matrix (panels)
HIPIN aerogel based building products Incorporate aerogel granules into: Incorporate aerogel granules into: Plaster Plaster Paint Panels Paint Panels Methodo Vimark ICI (Akzo ‐ Nobel) Plaster formulated with HIPIN Paint formulated with HIPIN Panel composite containing aerogel aerogel HIPIN aerogel Aerogel formulated into 3 building materials
Demonstrators • Demonstrators for all 3 applications at Envipark, Turin – Demonstrators were set up in Sep ‐ Oct 2014 – Data collection over winter of 2014 ‐ 2015 – Measurement of thermal resistance of the wall with HIPIN building elements was carried out per ISO 9869:1994 standard – Protect sensors from direct sunlight for data accuracy – Data acquisition and analysis showed U value improvement compared to the bare wall Demonstrable impact on thermal performance
HIPIN Decorative Paint Paint with HIPIN aerogel over 9m 2 Demonstrator at Envipark provided • quantitative assessment of thermal performance benefits (W/mK) ‐ HIPIN paint 0.49 (Standard paint 0.64) • • U (W/m 2 K) ‐ 4.4% reduction with HIPIN paint in the demonstration • Addition of aerogel to paint did not affect other key paint properties compared to standard paint Imperial Chemical Industries Ltd. HIPIN Stakeholder Workshop 10 th March 2015
HIPIN Plaster Material Thickness (mm) L ambda U value ʎ [W/mK] (W/m2K) HIPIN Plaster 45 0.034 0.67 Conventional 45 0.47 3.76
HIPIN plaster based on HIPIN aerogels APPLICATION BENEFITS Suitable for old and External and Space optimization new buildings internal application (low thickness)
HIPIN aerogel ‐ based panels • Methodo produces state of the art ventilated façade systems formed by a structure supporting the tiles and an insulation layer. • HIPIN panels allow for reduced thickness of panels, with lowered costs of support structures • The developed product showed a thermal conductivity ( λ = 0.025 W/(m.K)); represents an improvement of ~25% compared to best in market EPS. • The development of the technology in the HIPIN project predicts a further reduction in the thermal conductivity could be achieved by refining the fabrication process.
Techno ‐ economic analysis Cost of aerogel drives techno ‐ economic analysis; depending on loading of aerogel in the system. Estimated cost of aerogel €2.2/liter (density 0.18g/cc) at 250tpa scale. Less than €1/liter possible with demand of > 5000 tpa. As cost of aerogel comes down with growing demand, economics will be even more favourable. Eg: For the plaster, energy savings via insulation benefits (U value achieved with less thickness) complemented by lower material use, which in turn has benefits in lowered cost of application of the plaster and transportation savings.
Mathematical Modeling • Mathematical models used to determine the reduction in heating energy achievable using the three products • Theory also used to predict the Heat transfer by Heat transfer by Heat transfer by conduction convection radiation thermal conductivity of the materials 0.700 based on knowledge of their arithmetic mean 0.600 geometric mean composition harmonic mean 0.500 11% Maxwell ‐ Euken 15% measurements • Theory confirms measured values 19% 0.400 e (W/m.K) and provides a basis for further 0.300 product optimisation 0.200 0.100 0.000 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Aerogel volume fraction (%) Thermal conductivity (measured vs. model prediction) at different aerogel loadings in plaster formulation 14
Life Cycle Analysis and Ecoprofiles • LCA model with Cradle to Grave analysis developed; end ‐ of ‐ life scenarios were considered (Envipark) • Product functionality and application dictate Functional Units definitions and comparative product For plaster and panels, the thickness in mm to obtain a thermal resistance over 1m 2 (R= 1 m2K/W) - - For paints, the thickness of paint in mm to obtain a thermal resistance of R= 0.00106 m 2 K/W For example, for HIPIN plaster ( =0,035 W/(m.K)), a comparison was made with a thermal - insulating plaster (Vimark’s Thermocalce, =0.088 W /mK) Global Warming Potential Impact Primary Energy Demand 15
Conclusions • Aerogels offer new option for Exploitable Results (ER) Key Partner insulation applications in building ER 1: High silica content TWI for know ‐ how, envelopes, via incorporation into precursor (TEOS58) Thomas Swan for scale ‐ up plaster, paint, and panel ER 2: Robust hydrophilic Separex applications and hydrophobic aerogel based on TEOS58 ER 3: HIPIN Thermal Vimark • Incorporation of aerogel into insulating plaster plaster and panel can provide a ER 4: HIPIN Thermal Methodo means to meeting new building insulating panels codes even for retrofits ER 5: Paint system with ICI enhanced insulating properties 16
Contact us…. For more information, see the HIPIN website at: www.hipin.eu or contact TWI at coatings@twi.co.uk
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