Comparing Aerogel Blankets to Traditional Insulation: What We've Learned from Real-World Pipeline Projects

Running a wholesale insulation operation out of Hebei for a while now, I've talked to countless buyers wrestling with the same choice: stick with familiar rock wool or glass wool, or try aerogel blankets for their pipelines and facilities? It's not always an easy call—traditional materials have been reliable for decades—but in harsher setups, like high-temp refineries or space-tight retrofits, aerogel often pulls ahead. Here's a straightforward comparison based on what we've seen in actual projects, from Gujarat's hot petrochemical lines to cooler European builds.

Thickness and space: That's where aerogel shines right away. A 10mm aerogel blanket can match the thermal performance of 50-60mm rock wool, thanks to its super-low conductivity (around 0.013-0.020 W/m·K versus 0.035-0.040 for rock wool, per ASTM C177 tests). In one refinery job we supplied, switching saved major room around pipes, making maintenance easier without ripping out supports. Glass wool needs even more bulk for similar R-values, which can complicate wraps on bends.

Heat resistance and durability: Rock wool handles up to 650°C well and won't burn (A1 fire rating), great for fireproofing. Aerogel goes to 650°C too in silica forms, but stays hydrophobic—repels water better than fiberglass, which can sag when wet. We've had feedback from damp offshore-like conditions where aerogel held up longer, cutting corrosion under insulation (CUI) risks, a big headache noted in NACE standards.

Cost and payback: Upfront, aerogel runs higher—maybe 2-3x traditional per square meter—but energy savings add up. In a solar facility we heard about, thinner aerogel cut heat loss 40-50%, paying back in 18-24 months via lower fuel or cooling needs (backed by U.S. DOE efficiency reports). Rock wool or glass wool cheaper initially, ideal for budget jobs, but need replacing sooner in extremes.

At the end of the day, it depends on your setup. For standard building walls, traditional might suffice. But for industrial pipes facing heat, moisture, or space limits, aerogel's paid off for many of our partners. What's your go-to material been, and why? If you've got a project spec, happy to chat options.

Sources: ASTM C177 (Thermal Conductivity Testing); NACE SP0198 (CUI Control); U.S. Department of Energy Industrial Case Studies.