Aerogel Insulation for High-Temperature Industrial Applications

Extreme heat places continuous strain on piping systems in refineries, power plants, and heavy industrial environments. Maintaining control in these conditions requires high-temperature insulation that performs consistently without adding unnecessary bulk.

Traditional materials such as calcium silicate and mineral wool insulation remain widely used. These options increase system thickness and can retain moisture that can raise corrosion under insulation (CUI) risk and complicate installation. Aerogel insulation offers a more efficient solution.

An industrial aerogel blanket delivers thermal resistance that maintains stable operation in harsh environments and varying temperatures.

What Is Aerogel Insulation?

Aerogel insulation is most commonly a silica-based material used in industrial systems. It's often engineered into a flexible blanket for tight or irregular layouts.

The manufacturing process removes liquid from a silica gel, leaving a highly porous structure that restricts heat transfer. This structure delivers strong thermal performance without the thickness associated with rigid insulation.

Aerogel performs well at high temperatures due to the following characteristics:

• Limits heat flow through an ultra-low-thermal-conductivity structure
• Conforms closely around pipes, fittings, and equipment with irregular shapes
• Reduces overall insulation thickness compared to rigid board or pipe coverings
• Maintains stable performance under sustained thermal exposure within its rated temperature range

Benefits of Aerogel Insulation in High-Temperature Environments

Aerogel insulation maintains consistent insulation performance even under elevated temperatures, where other insulation materials can fail. It also performs effectively in confined areas where clearance limits, vibration, and ongoing operation complicate thermal protection.

Using aerogel offers:

• Improved high-temperature thermal performance: Aerogel insulation helps retain process heat by maintaining low thermal conductivity.
• Reduced insulation thickness in limited spaces: Higher R-value per inch allows thinner insulation profiles than many traditional materials.
• Lower heat loss from insulated systems: Limiting heat transfer from pipes and equipment lowers overall thermal losses in insulated systems.
• Safer surface temperatures for personnel: Lower external surface temperatures reduce burn risk for staff working near equipment. Aerogel can help systems meet ASTM C1055 standards.
• Improved moisture resistance and CUI risk management: Aerogel limits moisture ingress, reducing the chance of corrosion under insulation.
• Enhanced durability in high-activity environments: Flexible aerogel blankets usually tolerate vibration and handling better than rigid materials.

Best-Fit Applications of Aerogel Insulation

Blanket aerogel is most effective for equipment that operates in heightened thermal conditions and presents installation challenges for rigid materials.

Consider using aerogel on:

• Pipes: Thermal insulation for industrial pipes must maintain performance under sustained heat without increasing pipe rack congestion.
• Valves: Effective coverage of complex geometries and protrusions prevents gaps and heat leaks where rigid materials can't conform.
• Turbines: Resistance to vibration and mechanical stress allows insulation to remain stable on rotating equipment.
• Furnaces and ovens: Consistent thermal containment supports process equipment designed for raised internal operating temperatures.
• Exhaust systems: Repeated thermal cycling and extreme heat in ducts and stacks need insulation that accommodates expansion and contraction.

Material Options and Temperature Limits

Pyrogel® is a high-temperature insulation material, and Cryogel® aerogels are engineered for industrial cold service. They're both designed for piping, vessels, and equipment where clearance limits, thermal efficiency, durability, and long-term performance matter.

Both have aerogel's baseline properties, but Pyrogel and Cryogel exhibit different characteristics depending on the specific material.

Pyrogel® XTE for Medium- to High-Temperature Service

Pyrogel® XTE is designed for protection in medium- and high-temperature industrial processes, with a maximum continuous use temperature of 1,200° Fahrenheit.

Statistics show that in comparable thermal applications, Pyrogel XTE can deliver insulation systems up to 75% thinner than traditional insulation blankets. Pyrogel XTE is used in:

• Corrosion under insulation mitigation.
• Medium- and high-temperature piping systems.
• Vessels and industrial equipment.
• District energy steam networks.
• Petrochemical and liquefied natural gas facilities.

Pyrogel® XTF for Hot Service With Passive Fire Protection

Pyrogel® XTF combines thermal insulation and passive fire protection in a single material for hot service applications up to 1,200° Fahrenheit. It's intended for facilities that require both thermal efficiency and fire exposure mitigation.

The material is used in scenarios aligned with American Petroleum Institute (API) 521 guidance for pressure relief and vapor depressuring during fire exposure.

Typical use cases include:

• Passive pool fire and jet fire protection.
• Hot service insulation in industrial and commercial facilities.
• Fire exposure mitigation for pressure-relieving and depressuring systems.

Pyrogel® HPS for High-Temperature Industrial Processes

Pyrogel® HPS is an aerogel for extreme temperatures of up to 1,200° Fahrenheit. It delivers high thermal resistance in a thin profile and is commonly used where thermal efficiency and long-term performance are priorities.

It's found in:

• High-temperature hydrocarbon and chemical processing.
• Steam piping systems.
• Industrial vessels and equipment.
• Gas and steam turbines.

Cryogel® Z for Sub-Ambient and Cryogenic Service

Cryogel® Z is engineered for cold applications, operating in conditions from minus 460° to 195° Fahrenheit. It uses silica aerogel insulation reinforced with nonwoven glass fiber batting to maintain flexibility at extremely low temperatures.

The hydrophobic structure helps reduce the risk of condensation. It's used in:

• Sub-ambient pipelines and cryogenic applications.
• Cold service equipment and vessels.
• Gas liquefaction and regasification equipment and facilities.

Installation and Handling Basics

Installation quality directly affects how aerogel insulation performs in high-temperature industrial environments. Handling discipline and installation sequence matter because gaps, compression loss, or poor sealing reduce thermal effectiveness.

Cutting and Wrapping Techniques

Aerogel blankets are designed for precise field cutting and flexible wrapping around industrial components. Clean edges and tight fits help maintain optimal thermal coverage.

Consider these cutting and wrapping practices:

• Cut with utility knives, scissors, tin snips, or hot knives to control dust and produce clean edges.
• Measure lengths that allow a full wrap with edges tightly abutted.
• Pre-cut sections for valves, flanges, and irregular geometries to avoid gaps during placement.
• Install multiple layers with staggered joints to limit thermal bridging.

Installation Practices

One reason aerogel is considered the best insulation for high-temperature applications is that it installs at a fraction of the thickness of other materials, simplifying work in congested areas. Proper fastening and surface preparation protect long-term performance.

Recommended installation practices are as follows:

• Clean and dry pipe or equipment surfaces before applying insulation.
• Wrap blankets tightly and evenly to maintain consistent compression.
• Secure insulation with banding, wire, tape, or adhesive spray to prevent movement.
• Use vapor barriers or sealed metal jacketing in cold or cycling service where moisture is a concern.

Handling and Safety Practices

The aerogel materials can release fine dust if mishandled, so controlled movement and protective measures are required. Storage conditions also affect installation quality.

Follow these safety practices:

• Wear gloves, safety glasses, and a dust mask or respirator during cutting and handling.
• Avoid dragging, dropping, or throwing material to reduce dust release and structural damage.
• Store blankets flat or on pallets in a dry, covered area to prevent bending before installation.

Selection Factors

Choosing aerogel insulation requires evaluating operating temperature limits and available installation space. These factors may determine suitability, durability, and long-term thermal performance in the intended application.

• Maximum service temperature: Select an aerogel grade rated for the highest temperature the system will experience. Consider both continuous operating conditions and short-duration heat excursions.
• Thickness: Determine required thickness based on process control or surface temperature limits. Aerogel often meets these targets with fewer layers than conventional insulation.
• Hydrophobicity: Verify water repellency at the material level for the selected aerogel product. Moisture resistance supports corrosion under insulation mitigation strategies.
• Jacketing and cladding: Specify appropriate metal jacketing to protect the insulation from impact, weather, and washdowns. Proper outer protection helps maintain insulation integrity and alignment over time.

Find the Right Aerogel Solution With Specialty Products and Insulation (SPI)

Choosing aerogel insulation involves more than thermal calculations. Operating envelopes, mechanical exposure, installation tolerances, and long-term maintenance conditions all shape whether an installation system performs as designed.

SPI fabricates and supplies aerogel insulation solutions designed around your system, including custom-fit components for pipes, vessels, and equipment.

Contact us to discuss your insulation requirements and get a solution that fits your application.