Aerogel Energy Saving Thermal Solution for CHP Industry

Global Background of Industry Thermal Insulation

Against the global push for carbon neutrality, strict climate regulations including the EU’s Fit for 55 Climate Package, the US Inflation Reduction Act, and ISO 50001 energy management standards are driving unprecedented demand for energy efficiency across industrial and utility sectors worldwide. Combined Heat and Power, district heating networks, and industrial process piping systems are core focus areas, as their thermal insulation performance directly determines operational costs, energy utilization efficiency, and carbon emission compliance.

Across North America, Europe, APAC, and emerging markets, traditional insulation materials including glass wool, aluminum silicate, and rock wool remain widely used, but they share universal industry pain points: rapid thermal performance degradation after moisture absorption, excessive heat loss, water hammer from condensed water, material settlement and loosening, and a short 2-3 year service life. 

These issues cause massive energy waste, frequent maintenance and replacement costs, and growing solid waste disposal burdens. Aerogel thermal insulation materials, with their disruptive performance, have become the mainstream upgrade solution for the global thermal insulation industry, fully compliant with core international standards including ISO 12241 (industrial thermal insulation engineering), EN 13501-1 , and ASTM C1728.

Avantages of High Performance AG-F Aerogel Blanket

Ultra-Low Thermal Conductivity for Maximum Space Efficiency

Aerogel insulation has the lowest thermal conductivity of any commercially available solid material, with a room-temperature thermal conductivity as low as 0.021W/(m·K) — only 1/2 to 1/5 that of traditional insulation materials. 

To achieve equivalent thermal performance, the required thickness of aerogel insulation blanket is just 1/3 to 1/2 that of traditional options. This drastically reduces excavation depth for directly buried pipelines, cuts material consumption for outer protective steel pipes, and frees up critical usable space for pipeline routing in urban utility tunnels. The material maintains stable thermal performance at continuous operating temperatures up to 650°C, making it suitable for even the most demanding high-temperature industrial applications.

Proven Full-Lifecycle Cost Savings & Fast ROI

Traditional insulation materials typically require full replacement every 2-3 years, while aerogel insulation blankets deliver a 10-15 year service life, eliminating the costs of repeated material purchases, labor, and facility downtime for re-insulation. In real-world applications, aerogel insulation solutions deliver energy savings of up to 50% or more, with the incremental upfront investment typically recouped within 2-3 years. Over the full service life of the material, the solution delivers hundreds of thousands of dollars in cumulative energy and maintenance savings for project operators, while also cutting carbon emissions to meet global climate targets.

Simplified Installation & Reliable Long-Term Operational Safety

Aerogel insulation blanket is a semi-rigid, flexible material that can be easily cut and fitted to complex geometries including pipelines, valves, flanges, and irregular equipment surfaces. Its reduced material volume for equivalent thermal performance cuts logistics costs and on-site installation time, with crews able to complete work efficiently after minimal training. The material has a >99% overall hydrophobic rate, which effectively mitigates Corrosion Under Insulation,a widespread, costly issue for industrial pipelines globally. Its fire performance meets the A2 non-combustible requirements of EN 13501-1, ensuring long-term safe and stable operation of facilities from the source.

Sustainable, Low-Carbon Environmental Performance

Aerogel insulation uses silica as its core raw material, which is non-toxic, non-hazardous, and fully recyclable or suitable for safe landfill disposal. Over a 15-year service cycle, the cumulative material consumption of traditional insulation can reach up to 8 times that of aerogel, meaning aerogel solutions drastically reduce solid waste generation and disposal burdens. Its industry-leading energy efficiency also cuts scope 1 and 2 carbon emissions for facilities, with the material holding CE, UL, and other key international certifications, making it a core material for meeting global net-zero targets.

Real-World Project Success & Performance Results

District Heating Pressure Isolation Station Retrofit

A leading regional district heating provider was facing critical challenges with uninsulated high-temperature hot water pipelines (up to 130°C) at a key pressure isolation station. The existing setup caused extreme heat loss, unsafe workplace temperatures, and significant energy waste during year-round operation, failing to meet required thermal efficiency targets in cold winter conditions.Our solution: We applied high-performance aerogel insulation blankets (30-40mm thickness) across all supply and return pipelines, valves, and flanges.

Results: The project achieved a 50.6% reduction in heat loss, cutting annual energy waste by 856.7GJ. Pipeline outer surface temperatures were strictly controlled to meet international industrial safety standards, drastically improving workplace safety while delivering consistent thermal performance even in extreme low-temperature environments.

Real-World Project Success & Performance Results

District Heating Pressure Isolation Station Retrofit

A leading regional district heating provider was facing critical challenges with uninsulated high-temperature hot water pipelines up to 130°C at a key pressure isolation station. The existing setup caused extreme heat loss, unsafe workplace temperatures, and significant energy waste during year-round operation, failing to meet required thermal efficiency targets in cold winter conditions.Our solution: We applied  30-40mm thickness AG-F high-performance aerogel insulation blankets across all supply and return pipelines, valves, and flanges.

Results: The project achieved a 50.6% reduction in heat loss, cutting annual energy waste by 856.7GJ. Pipeline outer surface temperatures were strictly controlled to meet international industrial safety standards, drastically improving workplace safety while delivering consistent thermal performance even in extreme low-temperature environments.

High-Temperature Power Plant Pipeline & Turbine Cylinder Insulation Upgrade

A top-tier thermal power generation facility was experiencing severe insulation degradation on its high-temperature steam pipelines 540°C internal temperature and low-pressure turbine cylinder. The failing traditional insulation caused excessive heat dissipation, inconsistent process temperatures, and a bulky insulation footprint that limited critical maintenance access.

Our solution: During a scheduled maintenance shutdown, we installed 80mm total thickness of A-grade aerogel insulation blankets across 400㎡ of steam pipelines, and applied a 15mm high-temperature aerogel coating system to the 120㎡ turbine cylinder.

Results: Post-upgrade, pipeline surface temperatures stabilized at approximately 50°C, while the turbine cylinder surface temperature was reduced to 33.7°C. Insulation thickness was reduced by over 50cm compared to the previous traditional solution, freeing up critical maintenance space, cutting heat loss dramatically, and improving overall plant thermal efficiency.

Critical Process Aerogel Pipeline Insulation for a World-Scale Chemical Processing Plant

A global leader in non-ferrous metal and chemical processing required reliable, long-lasting thermal insulation for the critical high-temperature digestion process in its new 2 million ton per year production facility.

 Traditional fiber insulation materials had a proven track record of sagging, water absorption, and rapid performance degradation in the plant’s hot, humid coastal environment, leading to unstable process temperatures and increased steam consumption.Our solution: We supplied 311.6m³ of 15-25mm thickness AG-F aerogel insulation blankets for the plant’s outdoor overhead process pipelines.

Results: Our AG-F aerogel solution delivered equivalent thermal performance with just 42% of the thickness required for traditional glass wool insulation. The material’s superior hydrophobicity eliminated moisture-related performance degradation, stabilized critical process temperatures, reduced steam consumption, and delivered more than 10 year service life with minimal maintenance, drastically reducing long-term operational costs.

For facilities looking to upgrade thermal performance, cut operational costs, and meet global carbon reduction targets, our aerogel insulation solutions are engineered to meet the strictest international standards and deliver unmatched long-term value.

 Visit to explore our full range of Indurtrial high performance thermal insulation case studies, or contact our  team to discuss your project’s specific requirements.

Case Studies-Aerogel Upgrade Industrial Energy Saving and Effciency