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Proven in Cryogenic Service
Project Profiles
www.aerogel.com
Cryogel Z®
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LNG Gimbal Joints
Project Manzanillo LNGLocation Manzanillo, Colima, MexicoOwner KOGAS, Mitsui, SamsungEngineer SamsungContractor Insulations, Inc.In Service September 2011
To accommodate the accumulation of pipe strains at the base of each LNG storage tank, flexible gimbal joints were installed. By using flexible bellows and a U-joint mechanism, these piping elements could allow two simultaneous degrees of freedom in the liquid and vapor return lines. The challenge was to insulate them to the same level of thermal performance as the adjacent line pipe. To do this, 10 to 12 layers of Cryogel® Z were used in a slip-joint configuration. Because the Cryogel® Z remains flexible at cryogenic temperatures, it is able to follow the movements of the joint without cracking, sagging, or opening up any thru-joints.
TOP: Cryogel® Z being installed over the flexure
ABOVE: Uninsulated gimbal joint
FAR LEFT: Gimbal joint lifted into place
LEFT: Gimbal joint welded to the liquid line
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Location Everett, Massachusetts, USAOwner Suez EnergyContractor ZampellIn Service October 2010LNG Tank Risers
TOP: Vapor stop applied above the clamp band
CLOCKWISE FROM LEFT: Clamp band applied over the Cryogel®; Failed urethane insulation; Insulators working on different levels; Cryogel® insulation being applied
The LNG tank risers at Distrigas in Boston are located so close to the tank stiffener rings that there is only 3 inches (75 mm) of room for the insulation. This severe space constraint, combined with wind- and temperature-induced movements of the lines, created the need for a thin and mechanically durable insulation design. Seven 10 mm layers of Cryogel® were applied to the risers and held in place with stainless steel bands. At the pipes’ closest approach to the stiffener rings, pre-fabricated stainless steel clamp bands were applied. These bands now provide mechanical protection where the pipe rubs against the guides and stiffener rings, and serves to support the jacketing above.
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Pre-Insulated Cryogenic Vessel
Project Fawley RefineryLocation Southampton, UKOwner EssoContractor CapeIn Service December 2009
In preparation for a turnaround in their ethylene unit, Esso Fawley designed a super-insulated bullet tank that could maintain a charge of liquid ethylene for six weeks with a BOR of <5 kg/day. To achieve this, they installed 34 layers (340 mm) of Cryogel® Z at a remote fabrication facility. Because of Cryogel’s mechanical resilience, the completely insulated, vapor-sealed, and jacketed unit was able to withstand the subsequent 400 km of over-road transport prior to final installation.
TOP: Layer 28 installed and banded in place
CLOCKWISE FROM LEFT: Installation of the unit onto the insulated plinths; Completed vessel awaiting transport to site; Layer 2 installed on 2:1 elliptical head
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Location Rio Grande do Sul, BrazilOwner BraskemEngineer OdebrechtContractor IsolengeIn Service June 2010Sphere: Insulation and Passive-Fire Protection
TOP: Completed sphere
CLOCKWISE FROM ABOVE: Top hemisphere vapor sealed prior to jacketing; galvanized steel jacket being installed; stainless steel bridle system on bottom hemisphere
Braskem required additional storage capacity at its Eteno Verde plant. The insulation system needed to provide both condensation control and 90 minute passive-fire protection while operating at -29°F (-34°C). A total aerogel insulation thickness of 60 mm replaced the originally specified 150mm of polyurethane foam. Braskem embraced the Cryogel® Z system as a faster, cleaner technology that allowed for a more rapid commissioning of the project. Cryogel® Z’s fire performance was a key factor in Braskem’s decision not to use traditional polyurethane foam systems.
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LNG Gasification Piping and Equipment
A composite insulation system of polyisocyanurate covered with 50 mm of cellular glass was originally specified for the gasification section of this facility. Due to time constraints in the construction schedule, 20 mm of Cryogel® Z was used in place of the cellular glass. The Cryogel® Z / PIR composite offered equivalent protection against heat gain, moisture, and fire, and greater durability against mechanical damage. Most importantly, the Cryogel® Z flexible blankets installed 80% faster than the cellular glass and eliminated expansion/contraction joints.
Contractor installing two layers of Cryogel® Z over PIR pipe cover.
Project Canaport LNGLocation St. John, New Brunswick, CanadaOwner Repsol, IrvingEngineer Saipem and SNC LavalinContractor BIS OKIIn Service June 2009
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Project Mejillones LNGLocation Mejillones, Northern ChileOwner Tractebel SuezEngineer Technicas ReunidasManufacturer FMC TechniologiesContractor PreziosoLNG Loading Arms
Loading arms are usually uninsulated due to the severestresses of cycling between ambient and LNG (-160°C)temperatures. This can result in heavy ice formations during operation, and dangerous ice falls during the subsequent warm up. The Mejillones LNG loading arms were insulated with Cryogel® Z because it is impervious to cryogenic cycling, light enough to not affect the structural dynamics, and thin enough to avoid interference with the swing mechanism.
LNG loading arms in operation.
Cryogel® Z installed on an elbow at the base of a loading arm.
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Location Everett, Massachusetts, USAOwner Suez EnergyContractor ZampellIn Service October 2007LNG Unloading and Vapor Return Lines
LNG loading/unloading lines in this facility commonly used rigid polyisocyanurate insulation or cellular glass. Since this facility does not continuously maintain the piping at cryogenic temperatures, the constant thermal cycling poses severe stresses on the insulation. To combat the wear-and-tear on the pipe insulation, a trial with Cryogel® Z was performed in October 2007. In addition to the decreased thickness, the contractor found substantial improvements in application time. The system has been through more than 200 deep thermal cycles to date, with outstanding results.
Cryogel® Z tie-in to adjacent insulation material.
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LNG Cryogenic Valves
Adriatic LNG is an offshore LNG receiving terminal located just south of Venice, Italy. Rigid insulation material was specified for the piping, but due to construction timing issues, Cryogel® Z was used to insulate the cryogenic valves and flanges. Cryogel® Z was chosen due to its extremely thin profile, ease of construction and logistics, and fast application time.
Cryogenic valves before and after being insulated with Cryogel® Z.
Project Adriatic LNGLocation Adriatic SeaOwner ExxonMobilEngineer Aker KvaernerContractor KaeferIn Service August 2009
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LNG Cryogenic Bellows
This uninsulated bellows coupling at the base of an LNG tank was accumulating ice balls and impairing the movement of the stainless steel corrugations. The relative motion inherent to bellows necessitated the use of Cryogel® Z because it always remains flexible, even at cryogenic temperatures.
Project Haverhill Peakshaving PlantLocation Haverhill, Massachusetts, USAOwner National GridContractor Anchor InsulationIn Service November 2007
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LNG Field Joints
The Freeport LNG terminal uses vacuum piping for the LNG transfer lines, and the field joints required an insulation that could be easily applied and have a very thin profile. Cyrogel® flexible insulation blankets offered the best solution for this application.
Project Freeport LNGLocation Freeport, Texas, USAOwner DowEngineer TechnipIn Service April 2008
Flexible Industrial Insulation With Integral Vapor Barrier for Sub-Ambient and Cryogenic Applications
Cryogel® Z has the lowest k-value of any cryogenic insulation material in the world, reducing thicknesses by 50%-75%. Cryogel® Z’s flexible blanket form, with a factory-applied vapor barrier, is both faster to install and more durable once in service, resulting in lower-cost, higher-performing designs.
Applications for Cryogel® Z include sub-ambient piping and equipment, cryogenic storage and transport, industrial gases, and LNG import/export pipelines and process areas.
Cryogel® Z Insulation System Advantages
Thinness creates more space in and around pipe racks and equipment. Thinness can decrease the overall size of a production facility, resulting in major material reductions and cost savings. Thinness results in volume and freight savings, decreased accessory materials, minimal site storage, and simplified logistics. Unique flexible form and wrap application makes installation faster, easier, and less costly. Rigid insulation systems require numerous segments that must be effectively sealed. Will not break during shipment or once in service.Competitive with other insulation systems on an installed basis due to decreased material requirements, logistics improvements, reduced installation time, and shorter construction schedules.
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Service Temperature Range -460°F (-270°C) to 195°F (90°C)
Thermal Performance Cryogel® Z has the lowest thermal conductivity of any material used for cryogenic service. It is therefore much thinner compared to other cold insulation materials. In most cases, condensation control thickness is sufficient to meet the desired heat gain limitations. Cryogel® Z’s minimal thickness results in a smaller surface area and reduced heat gain compared
to other insulation materials. This heat gain “safety factor” maximizes system performance by improving process control, reducing boiloff and saving energy. Also, Cryogel® Z does not have blowing agents that diffuse out over time, so its thermal performance remains constant.
Moisture and Vapor Resistance Permeability to water and water vapor are critical to any insulation system operating at cryogenic temperatures. Cryogel® Z uses a factory-applied mylar vapor barrier to achieve a zero-perm system.
Structural Integrity Cryogel® Z is well-suited for sub-ambient and cryogenic applications. Under these severe conditions, its structure experiences no thermal shock and remains totally flexible. This is unlike rigid, cellular insulation materials, which experience contraction, thermal shock, extreme stresses, damaged structure, freeze-thaw crack propagation, and degraded insulation performance under the same conditions.
Dimensional Stability Cryogel® Z insulation has a coefficient of thermal expansion similar to that of stainless steel, so there is minimal movement of the insulation system. Its low contraction rate and flexible wrap application eliminate the need for costly and labor-intensive expansion and contraction joints required by traditional rigid insulation systems.
Cryogel Z
Cryogel® Z(50 mm)
NPS 12”(300 mm)at -170°C
23°C66 W/m
67 W/m23°C
55 W/m23°C
PIR(100 mm)
Cellular Glass(110 mm)
All three designs meet the same condensation control criteria.
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In addition to reducing labor, Cryogel® Z blankets minimize sensitivity to workmanship.
Joint sealing tape
Cryogel® Z Blankets
Cellular Glass or PIR Segments
All joints sealed
Aspen Aerogels, Inc.30 Forbes Road, Building BNorthborough, MA 01532USA
Aspen Aerogels and Cryogel are registered trademarks of Aspen Aerogels, Inc.© 2011 Aspen Aerogels, Inc.
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