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High Performance Insulation based on Nanostructure encapsulation of air

Theme: EeB.NMP.2010‐1

The HIPIN project received funding from the European Union's Seventh Framework Programme for research, technological development and demonstration under grant agreement no 260117.

http://www.hipin.eu

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. Develop new affordable building products based on aerogel, suitable for both retrofits and new buildings

THERMAL PAINT THERMAL PLASTER PANELS

HIPIN Aerogel

Sol‐gel technology to produce aerogel precursor with high silica content (60%), followed by proprietary method for supercritical drying and surface treatment.

Water Contact Angle: A‐hydrophilic, B‐hydrophobic

A high silica content precursor for aerogels

• Very low density (100‐120 kg/m3)
• 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

• Suitable for new & retrofitting buildings

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:

Plaster Paint Panels

Incorporate aerogel granules into:

Plaster Paint Panels

Aerogel formulated into 3 building materials

Plaster formulated with HIPIN aerogel Vimark Paint formulated with HIPIN aerogel ICI (Akzo‐Nobel) Panel composite containing HIPIN aerogel Methodo

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

Imperial Chemical Industries Ltd. HIPIN Stakeholder Workshop 10th March 2015

• Paint with HIPIN aerogel over 9m2 Demonstrator at Envipark provided

quantitative assessment of thermal performance benefits

•  (W/mK) ‐ HIPIN paint 0.49 (Standard paint 0.64)
• U (W/m2K) ‐ 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

HIPIN Plaster

Material Thickness (mm) Lambda ʎ [W/mK] U value (W/m2K) HIPIN Plaster 45 0.034 0.67 Conventional 45 0.47 3.76

APPLICATION BENEFITS

Suitable for old and new buildings External and internal application Space optimization (low thickness)

HIPIN plaster based on HIPIN aerogels

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

• f 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.

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Mathematical Modeling

• Mathematical models used to

determine the reduction in heating energy achievable using the three products

• Theory also used to predict the

thermal conductivity of the materials based on knowledge of their composition

• Theory confirms measured values

and provides a basis for further product optimisation

Heat transfer by convection Heat transfer by conduction Heat transfer by radiation

11% 15% 19% 0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% e (W/m.K) Aerogel volume fraction (%) arithmetic mean geometric mean harmonic mean Maxwell‐Euken measurements

Thermal conductivity (measured vs. model prediction) at different aerogel loadings in plaster formulation

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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 1m2 (R= 1 m2K/W)
• For paints, the thickness of paint in mm to obtain a thermal resistance of R= 0.00106 m2K/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) Primary Energy Demand Global Warming Potential Impact

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Conclusions

Exploitable Results (ER) Key Partner ER 1: High silica content precursor (TEOS58) TWI for know‐how, Thomas Swan for scale‐up ER 2: Robust hydrophilic and hydrophobic aerogel based on TEOS58 Separex ER 3: HIPIN Thermal insulating plaster Vimark ER 4: HIPIN Thermal insulating panels Methodo ER 5: Paint system with enhanced insulating properties ICI

• Aerogels offer new option for

insulation applications in building envelopes, via incorporation into plaster, paint, and panel applications

• Incorporation of aerogel into

plaster and panel can provide a means to meeting new building codes even for retrofits

For more information, see the HIPIN website at: www.hipin.eu or contact TWI at coatings@twi.co.uk

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