High-temperature pipelines are widely used in power plants, petrochemical facilities, oil refineries, steel mills and other industrial systems. Without effective insulation, these pipes can lose significant heat, increase energy consumption and create unsafe surface temperatures.

Traditional materials such as mineral wool, glass wool, ceramic fiber and calcium silicate are commonly used for pipe insulation. However, they may require a relatively thick insulation layer to achieve the target thermal performance.

Aerogel felt provides an alternative solution for projects that require efficient insulation within limited installation space. Its low thermal conductivity, flexible structure and hydrophobic properties make it particularly suitable for high-temperature industrial pipelines.

What Is Aerogel Felt?

Aerogel felt, also known as an aerogel blanket, is a flexible insulation material made by combining silica aerogel with a reinforcing fiber matrix.

Silica aerogel contains a nanoscale porous structure that restricts heat transfer through solid conduction, gas movement and convection. The fiber reinforcement improves flexibility and handling strength, allowing the material to be rolled, cut and installed around curved surfaces.

Silica aerogel felt is commonly supplied in rolls with different thicknesses, widths, densities and temperature grades.

Typical industrial applications include:

High-temperature steam pipelines

Petrochemical process pipes

Oil and gas transmission systems

Exhaust and flue-gas pipelines

Power-generation equipment

Refinery piping systems

Tanks, vessels and boilers

Valves, flanges and pipe fittings

Removable insulation jackets

Why High-Temperature Pipes Need Insulation

High-temperature pipe insulation performs several important functions.

Reducing Heat Loss

An uninsulated hot pipe continuously releases heat into the surrounding environment. This increases energy demand and reduces overall system efficiency.

A correctly designed insulation layer helps retain process heat and maintain a stable fluid temperature throughout the pipeline.

Controlling Surface Temperature

Exposed hot pipelines can create burn risks for workers. Insulation lowers the external surface temperature and supports safer operation in maintenance areas, workshops and processing facilities.

Maintaining Process Conditions

Some industrial processes require the transported fluid to remain within a specific temperature range. Excessive heat loss may affect viscosity, flow rate, pressure or process stability.

Protecting Nearby Equipment

Heat radiating from uninsulated pipes may damage cables, instruments, coatings and other nearby components.

Reducing Energy Costs

Lower heat loss can reduce boiler load, fuel consumption and operating costs. Over the service life of a pipeline, these savings may offset part of the insulation investment.

Benefits of Aerogel Felt for Pipe Insulation

1. Low Thermal Conductivity

Thermal conductivity indicates how easily heat passes through a material. A lower value generally means better insulation performance at the same thickness.

Many aerogel felt products provide room-temperature thermal conductivity of approximately 0.015–0.020 W/(m·K), depending on product grade and test conditions.

For example, Nano Aerogel Felt has a listed thermal conductivity of approximately 0.018–0.020 W/(m·K) at 25°C.

Thermal conductivity normally increases as the mean operating temperature rises. Buyers should therefore request conductivity values covering the actual pipeline temperature rather than relying only on the value measured at 25°C.

2. Reduced Insulation Thickness

Aerogel felt can achieve the required thermal resistance with a thinner layer than many conventional insulation materials.

Reduced thickness is especially useful for:

Closely spaced pipelines

Restricted pipe racks

Congested processing areas

Valves and flanges with limited clearance

Marine and offshore equipment

Existing insulation systems being upgraded

Pipes installed near walls or structural supports

A thinner insulation system also reduces the finished pipe diameter and may lower the quantity of external cladding required.

3. Flexible Installation

Aerogel felt can be cut and wrapped around straight pipes, bends and irregular components.

It is suitable for insulating:

Straight pipe sections

Elbows

Tees

Reducers

Valves

Flanges

Expansion joints

Pipe supports

Its flexibility makes it easier to fit around complex surfaces than rigid insulation sections.

4. Resistance to Moisture

Moisture is a common problem in industrial insulation systems. If water enters conventional fibrous insulation, thermal conductivity may increase and corrosion under insulation may develop.

Hydrophobic aerogel felt resists liquid-water penetration. This makes it suitable for outdoor pipelines, humid environments and facilities exposed to changing weather conditions.

Some aerogel thermal insulation felt products have a listed hydrophobic rate above 99%.

However, hydrophobic insulation does not make the complete pipe system waterproof. Joints, penetrations and external cladding must still be correctly sealed.

5. Performance Under Thermal Cycling

Industrial pipelines may repeatedly heat up and cool down during startup, shutdown and process changes.

Aerogel felt has a flexible reinforced structure that can accommodate normal pipe movement and thermal cycling. Unlike some rigid insulation materials, it is less likely to crack because of minor vibration or dimensional changes.

The fastening and cladding systems must also be designed to accommodate pipeline expansion.

6. Lower Insulation Volume

Because less thickness may be required, aerogel insulation can reduce the total material volume used around a pipeline.

This can provide practical benefits during:

Transportation

On-site storage

Material handling

Installation in elevated pipe racks

Installation in restricted plant areas

Maintenance and removal

Aerogel Felt vs Traditional Pipe Insulation

Aerogel felt is not automatically the best option for every pipeline. Mineral wool may remain more economical for large, uncomplicated installations with sufficient space. Ceramic fiber may be preferable for extremely high-temperature furnace areas, while calcium silicate is useful where greater compressive strength is required.

Aerogel felt is most valuable when insulation thickness, moisture resistance and installation flexibility are major project considerations.

Selecting the Correct Aerogel Felt

Operating Temperature

Confirm both the normal and maximum pipeline temperatures.

The product's stated maximum temperature should not be the only basis for selection. Buyers should also review:

Continuous operating temperature

Short-term peak temperature

Mean insulation temperature

Frequency of thermal cycling

Direct or indirect heat exposure

Required service life

Different aerogel formulations and reinforcing fibers are designed for different temperature ranges.

Thermal Conductivity at Service Temperature

Do not compare products using only room-temperature conductivity.

Request a thermal conductivity curve or values at several mean temperatures. This provides a more realistic basis for calculating heat loss and insulation thickness.

Required Insulation Thickness

Common aerogel felt thicknesses include:

3mm

5mm

6mm

8mm

10mm

Multiple layers can be installed to achieve the required thermal resistance. The final thickness should be determined according to:

Pipeline temperature

Pipe diameter

Ambient temperature

Required outer-surface temperature

Allowable heat loss

Wind speed

Installation location

External cladding

Personnel-protection requirements

An aerogel insulation blanket may be supplied in different thicknesses and temperature grades according to project requirements.

Pipe Size and Geometry

Provide the pipe outside diameter as well as information about elbows, valves, flanges and supports.

Complex fittings may require templates, smaller cut sections or removable insulation covers.

Indoor or Outdoor Installation

Outdoor installations require protection against:

Rain

Wind

UV exposure

Mechanical impact

Chemical contamination

Damage during maintenance

Metal jacketing or another suitable weather barrier should be installed over the aerogel felt.

Fire and Safety Requirements

Confirm whether the project requires a specific fire classification, smoke rating or test standard.

The complete insulation system should be evaluated, including the aerogel felt, adhesives, fasteners, vapor barriers and outer cladding.

Recommended Installation Procedure

Installation procedures may vary according to pipe size and project specifications, but the following steps provide a general reference.

Step 1: Inspect the Pipe Surface

Before installation, confirm that the pipe surface is:

Clean

Dry

Free from loose rust

Free from oil and contaminants

Properly coated where corrosion protection is required

Any damaged protective coating should be repaired before the insulation is installed.

Step 2: Measure and Cut the Material

Measure the pipe circumference and required overlap. Cut the aerogel felt using a sharp insulation knife or suitable cutting tool.

Installers should wear appropriate gloves, protective eyewear and dust protection.

Step 3: Wrap the Aerogel Felt

Wrap the blanket evenly around the pipeline without excessive compression.

The insulation should fit closely against the pipe while maintaining its specified thickness.

Step 4: Stagger the Joints

When multiple layers are installed, stagger the longitudinal and circumferential joints.

This reduces direct heat-transfer paths and improves insulation continuity.

Step 5: Secure the Insulation

Use stainless-steel wire, bands or another approved fastening system.

Fasteners should hold the material securely without crushing or significantly reducing its thickness.

Step 6: Treat Fittings and Supports

Carefully fit the material around elbows, valves, flanges, hangers and pipe supports.

These areas are common sources of thermal bridging and require particular attention.

Step 7: Install External Cladding

Apply aluminum, stainless-steel or another specified outer covering to protect the insulation from weather and mechanical damage.

All joints, overlaps and penetrations should be sealed according to the project requirements.

Common Installation Mistakes

Excessive Compression

Compressing the blanket reduces its installed thickness and therefore lowers its thermal resistance.

Gaps Between Sections

Open joints allow heat to bypass the insulation. Sections should be fitted closely together without large gaps.

Aligned Joints in Multiple Layers

If all layer joints are aligned, they create a more direct heat-transfer path. Joints should be staggered wherever practical.

Incorrect Conductivity Data

Using a room-temperature thermal conductivity value for a high-temperature pipeline can result in insufficient insulation thickness.

Poor Cladding and Sealing

Even hydrophobic aerogel felt requires correctly installed external protection. Poorly sealed cladding may allow water to enter the system.

Ignoring Pipe Supports

Pipe shoes, hangers and supports can create thermal bridges. These areas should be addressed in the insulation design.

Information Required for a Pipe Insulation Quotation

Buyers should provide the following information:

Pipeline application

Transported medium

Normal operating temperature

Maximum short-term temperature

Pipe outside diameter

Total pipeline length

Number of elbows, tees, valves and flanges

Required outer-surface temperature

Maximum allowable heat loss

Indoor or outdoor installation

Ambient temperature and wind conditions

Available insulation space

Required fire classification

Preferred thickness and roll width

External cladding requirements

Project quantity and delivery location

Complete project information allows the manufacturer to recommend a more appropriate product and thickness.

Frequently Asked Questions

Is aerogel felt suitable for steam pipes?

Yes. The correct aerogel grade can be used for high-temperature steam pipelines. Selection should be based on continuous operating temperature, maximum temperature and the required heat-loss or surface-temperature target.

How thick should aerogel pipe insulation be?

The correct thickness depends on pipe diameter, process temperature, ambient conditions and allowable heat loss. A thermal calculation should be completed before final selection.

Can aerogel felt be installed in multiple layers?

Yes. Multiple layers are commonly used. The joints should be staggered to reduce thermal bridging.

Does aerogel felt require metal cladding?

Metal cladding is generally recommended for outdoor industrial pipelines and areas exposed to mechanical damage. The cladding protects the insulation and improves system durability.

Can aerogel felt prevent corrosion under insulation?

Hydrophobic aerogel felt can reduce moisture retention, which may help lower the risk of corrosion under insulation. However, proper pipe coating, sealing, inspection and cladding are still required.

Is aerogel felt more expensive than mineral wool?

Its initial material price is normally higher. However, the complete comparison should include insulation thickness, installation space, labour, heat loss, cladding dimensions and long-term maintenance.

Conclusion

Aerogel felt is a practical insulation material for high-temperature industrial pipes where thermal efficiency, reduced thickness and moisture resistance are important.

Its low thermal conductivity allows designers to create thinner insulation systems, while its flexible structure makes installation easier around pipes, elbows, valves and other complex components. Hydrophobic grades also provide additional protection in outdoor and humid environments.

However, successful performance depends on correct material selection and installation. Buyers should confirm conductivity at the actual service temperature, calculate the required thickness and use suitable fastening and cladding systems.

By providing complete pipeline and operating information, project engineers can select an aerogel felt solution that balances heat-loss control, surface safety, installation space and lifecycle cost.