Why Chemical Plants are Switching from Mineral Wool to Silica Aerogel Coatings for Tank Insulation

In recent years, we’ve observed a significant shift in chemical and processing plants: engineers are stripping away bulky mineral wool and metal cladding in favor of Hollow Silica Aerogel Coatings.

To the untrained eye, it’s just a "layer of paste." But to a plant manager looking at the bottom line, it’s a strategic upgrade. Here are the 5 reasons why this "coating revolution" is winning:

1. Eliminating "Convection Heat Loss" Traditional mineral wool is wrapped around the tank. No matter how skilled the installer is, gaps between the metal jacket, the wool, and the tank wall are inevitable. These gaps create a "chimney effect," leading to massive convection heat loss. Aerogel coating is applied directly, creating a 100% seamless bond with the tank surface. No gaps, no convection, no wasted energy.

2. Superior High-Temperature Performance The thermal conductivity of mineral wool spikes as temperatures rise. In contrast, the hollow silica structure of aerogel coatings 0.034W（m·K) remains incredibly stable at high temperatures. You get better insulation with a fraction of the thickness, making your tank farm safer and more energy-efficient.

3. Ending the Nightmare of CUI (Corrosion Under Insulation) Mineral wool acts like a "wet sponge" if the metal cladding leaks. It traps moisture against the tank wall, leading to severe corrosion that remains hidden until a catastrophic failure occurs. Aerogel coating is a hydrophobic barrier itself. The tank wall never touches the air, and if a leak occurs in the tank, it’s visible immediately—no more "searching for treasure" under wet wool.

4. Seamless Application on Complex Geometry Valves, elbows, and flanges are a nightmare for traditional cladding. Cutting metal jackets to fit these shapes always leaves thermal bridges. As a sprayable or brushable coating, aerogel follows the shape of any equipment perfectly. It’s 360-degree coverage with zero thermal dead zones.

5. The "Hidden" Cost of Waste Disposal This is the deal-breaker: Mineral wool eventually becomes "hazardous waste" or "solid waste," and disposal costs are skyrocketing globally. Aerogel coatings are designed to last the entire lifecycle of the tank. There is no recurring replacement, no cladding to repair, and zero solid waste generation.

The Bottom Line: When you factor in maintenance, energy savings, and disposal, switching to aerogel coating isn't just an environmental choice—it’s the most profitable financial decision for your facility.