BEADED THERMAL INSULATION MATERIAL
The present invention relates to beaded thermal insulation material .
In order to provide insulation for certain high temperature applications which restrict the use of sheets or blocks of insulating material (for example pipe in pipe insulation, such as for exhaust pipe systems, furnace cavities, double skin linings, areas over arched roofs, open joints and for levelling furnace bottoms and hearths) loose filled thermal insulation material can be used.
In order for loose filled thermal insulation material to be efficient it is necessary for the insulation material to be relatively free flowing such that the individual pieces of insulation material do not undergo cohesion to form larger pieces. Pieces of free flowing thermal insulation material need to be able to move past each other to enable the insulation material to settle into the most dense packing arrangement possible and thus avoid uninsulated areas being formed. The most efficient form for free flowing insulation material is to be granular (or beaded) .
Granular (or beaded) forms of thermal insulation material with good free flowing properties are known. However, free flowing thermal insulation products, for example aerogels such as NANOGEL (Registered Trade Mark of Cabot, Germany) , which have relatively low thermal conductivity, for example nominally 0.04 W/mK (mean temperature 200 degrees Celsius), comprise substantially 99 per cent by weight of silica which makes them relatively expensive. Aerogel-based free flowing thermal insulation materials tend to form soft granules and to diffuse into a solid form when heated to temperatures in excess of 700 degrees Celsius.
Other forms of granular free flowing thermal insulation material are based on granulated mixtures of clay and calcined diatomaceous earth, for example Moler 05 aggregate supplied by Skamol of Denmark. These insulation materials are relatively inexpensive but have relatively high thermal conductivity, for example 0.2 /mK (mean temperature 200 degrees Celsius) .
It is an object of the present invention to provide a beaded thermal insulation material which is free flowing and which has relatively low thermal conductivity and relatively high service temperature resistance but is comparatively inexpensive and possesses adequate mechanical properties .
According to the present invention there is provided a beaded thermal insulation material adapted to be free flowing comprising an intimate mixture of:
1-85% by dry weight volatilised silica;
5-50% by dry weight core material;
3-20% by dry weight inorganic binder;
0-20% by dry weight precipitated silica;
0-20% by dry weight fumed silica; and 0-30% by dry weight infrared opacifier.
The beaded thermal insulation material may have substantially the following composition:
10-85% by dry weight volatilised silica;
5-25% by dry weight core material;
5-20% by dry weight inorganic binder;
0-20% by dry weight precipitated silica;
0-10% by dry weight fumed silica; and 0-25% by dry weight infrared opacifier.
The beaded thermal insulation material may preferably have substantially the following composition:
30-85% by dry weight volatilised silica; 10-25% by dry weight core material; 5-15% by dry weight inorganic binder; 0-20% by dry weight precipitated silica; 0-10% by dry weight fumed silica; and 0-20% by dry weight infrared opacifier.
The diameter of the beads of thermal insulation material may be in a range from 0.2 mm to 5mm, preferably in a range from 0.2 mm to 2 mm.
The inorganic binder may be an alkali metal silicate solution, preferably sodium and/or potassium silicate solution. The solids content of the alkali silicate solution may be from 25 to 40 per cent by weight, preferably from 30 to 38 per cent by weight.
The inorganic binder may be a phosphate binder, for example aluminium orthophosphate solution.
The inorganic binder may be a hydraulic binder, for example an alumina cement.
The opacifier may be selected from opacifier materials comprising titanium oxide (rutile) , iron titanium oxide, zirconium silicate, zirconium oxide, iron oxide and silicon carbide.
The volatilised silica may have a specific surface area in a range from 12 m2/g to 30 m2/g, preferably in a range from
18 m/g to 22 m /g, more preferably nominally 20 m /g,
The core material may be selected from relatively coarse materials comprising exfoliated vermiculite, quartz sand, bauxite, glass microspheres and mica.
The exfoliated vermiculite may have a particle size in a range from 0.1 mm to 3 mm.
The fumed silica may have a specific surface area in a range from 50 m2/g to 400 m2/g, preferably in a range from 180 m2/g to 230 m2/g, more preferably nominally 200 m2/g.
The precipitated silica may comprise a specific surface area in a range from 100 m2/g to 800 m2/g, preferably in a range from 420 m2/g to 470 m2/g, more preferably nominally 450 m2/g.
The invention will be explained with reference to the following Examples.
EXAMPLE 1
Beaded thermal insulation material was made by mixing together in a paddle-type mixer a mixture of 17 per cent by wet weight of Micron grade exfoliated vermiculite available from Hoben International, and 17 per cent by wet weight of a potassium silicate binder available from Ineos Chemicals under the name Kββ.
The Micron grade exfoliated vermiculite has a particle size in a range from 0.1 mm to 3 mm. The Micron grade exfoliated vermiculite has a water content of about 5 per cent by weight. The potassium silicate binder has the nominal composition 35 per cent by weight solids content and 65 per cent by weight water.
The materials were mixed together for 10 minutes in order to obtain a homogeneous mixture. 66 per cent by dry weight of a volatilized silica, available from R Silicium GmbH under the name RW-Fuller, was added gradually to the homogenous mixture of potassium silicate binder and exfoliated vermiculite and mixed for 30 minutes to form beads of insulation material with a diameter in a range from 0.2 mm to 2 mm.
The volatilised silica has a nominal specific surface area of 20 m2/g.
The beaded thermal insulation material was heated at nominally 120 degrees Celsius for 30 minutes to substantially remove the water content present. The composition of the beaded thermal insulation material after heating was nominally 18.3 per cent by dry weight of Micron grade vermiculite, 74.9 per cent by dry weight of volatilised silica and 6.8 per cent by dry weight of potassium silicate binder.
The optimally settled density (tap density) of the beaded thermal insulation material was determined by repeat tapping of a sample using an automated tapping machine, known to a person skilled in the art, until the bulk density underwent no further change. This density was measured to be 520 kg/m3.
The beaded thermal insulation material was tested for thermal conductivity at a mean temperature of 200 degrees Celsius and at a loose filled tap density of 520 kg/m3 using cylindrical cell thermal conductivity methods as known by a person skilled in the art and as described in the European Fuel Cell News, volume 8, number 2, July 2001.
The beaded thermal insulation material was measured as having a thermal conductivity of 0.10 /mK.
The beaded thermal insulation material was also tested for its free flowing characteristics. The beaded thermal insulation material was used to fill an annulus of nominally 4 mm thickness and it was observed that the beaded thermal insulation material flowed freely into the annulus without the need of assistance, for example air pressure, and without undergoing cohesion which would form a bridge of material across the width of the annulus.
The beaded thermal insulation material was further tested to determine the effect of exposure of the material to an environment of 850 degrees Celsius for 24 hours. It was observed that the beaded material did not undergo densification or sintering following such a heating regime.
Compressibility of the beaded thermal insulation material was also determined by means of the beaded thermal insulation material being placed in an annulus of nominally 4 mm thickness and the filled annulus being subjected to a nominal pressure of 5 tonnes. No compaction of the beaded thermal insulation material was observed or measured.
EXAMPLE 2
The vermiculite and binder materials described in Example 1 were mixed together using the same procedure as described for Example 1. 66 per cent by dry weight of a volatilized silica, available from RW Silicium GmbH under the name RW- Fuller Ql, was added gradually to the homogenous mixture of potassium silicate binder and exfoliated vermiculite and mixed for 30 minutes to form beads of insulation material with a diameter in a range from 0.2 mm to 2 mm.
The volatilised silica has a nominal specific surface area of 20 m2/g.
As for Example 1, the beaded thermal insulation material was heated at nominally 120 degrees Celsius for 30 minutes to substantially remove the water content present. The composition of the beaded thermal insulation material after heating was nominally 18.3 per cent by dry weight of Micron grade vermiculite, 74.9 per cent by dry weight of volatilised silica and 6.8 per cent by dry weight of potassium silicate binder.
The beaded thermal insulation material was tested for thermal conductivity at a mean temperature of 200 degrees Celsius and at a loose filled tap density of 550 kg/m3 using cylindrical cell thermal conductivity methods known to a person skilled in the art.
The beaded thermal insulation material was measured as having a thermal conductivity of 0.11 W/mK.
The beaded thermal insulation material was also tested for its free flowing characteristics, resistance to sintering and compressibility using the same procedures as described for Example 1.
The beaded thermal insulation material was observed to flow freely into a 4 mm annulus without the need of assistance, for example air pressure, and without undergoing cohesion which would form a bridge of material across the width of the annulus.
The beaded thermal insulation material did not undergo densification or sintering following heating at 850 degrees Celsius for 24 hours.
No compaction of the beaded thermal insulation material was observed or measured following the application of a nominal pressure of 5 tonnes.
EXAMPLE 3
Beaded thermal insulation material was made by mixing together in a paddle-type mixer a mixture of 12 per cent by wet weight of Micron grade exfoliated vermiculite available from Hoben International, and 20 per cent by wet weight of a potassium silicate binder available from Ineos Chemicals under the name K66.
The vermiculite and binder materials were mixed together using the same procedure as described for Example 1. 69 per cent by dry weight of a volatilized silica, available from RW Silicium GmbH under the name RW-Fuller Ql, was added gradually to the homogenous mixture of potassium silicate binder and exfoliated vermiculite and mixed for 30 minutes to form beads of insulation material with a diameter in a range from 0.2 mm to 2 mm.
As for Example 1, the beaded thermal insulation material was heated at nominally 120 degrees Celsius for 30 minutes to substantially remove the water content present. The composition of the beaded thermal insulation material after heating was nominally 13 per cent by dry weight of Micron grade vermiculite, 79.0 per cent by dry weight of volatilised silica and 8.0 per cent by dry weight of potassium silicate binder.
The beaded thermal insulation material was tested for thermal conductivity at a mean temperature of 200 degrees Celsius and at a loose filled tap density of 695 kg/m3 using
cylindrical cell thermal conductivity methods known to a person skilled in the art.
The beaded thermal insulation material was measured as having a thermal conductivity of 0.13 W/mK.
The beaded thermal insulation material was also tested for its free flowing characteristics, resistance to sintering and compressibility using the same procedures as described for Example 1.
The beaded thermal insulation material was observed to flow freely into a 4 mm annulus without the need of assistance, for example air pressure, and without undergoing cohesion which would form a bridge of material across the width of the annulus.
The beaded thermal insulation material did not undergo densification or sintering following heating at 850 degrees Celsius for 24 hours.
No compaction of the beaded thermal insulation material was observed or measured following the application of a nominal pressure of 5 tonnes.
EXAMPLE 4
The vermiculite and binder materials described in Example 1 were mixed together using the same procedure as described for Example 1. 56 per cent by weight of a volatilized silica, available from RW Silicium GmbH under the name RW- Fuller Ql, was added gradually to the homogenous mixture of potassium silicate binder and exfoliated vermiculite. 10 per cent by weight of precipitated silica, available from Degussa AG under the Registered Trade Mark SIPERNAT 500LS,
was then added gradually to the binder, exfoliated vermiculite and volatilised silica mixture and mixed for 30 minutes to form beads of insulation material with a diameter in a range from 0.2 mm to 2 mm.
The precipitated silica has a nominal specific surface area of 450 m2/g.
As for Example 1, the beaded thermal insulation material was heated at nominally 120 degrees Celsius for 30 minutes to substantially remove the water content present. The composition of the beaded thermal insulation material after heating was nominally 18.3 per cent by dry weight of Micron grade vermiculite, 63.6 per cent by dry weight of volatilised silica, 11.3 per cent by dry weight of precipitated silica and 6.8 per cent by dry weight of potassium silicate binder.
The beaded thermal insulation material was tested for thermal conductivity at a mean temperature of 200 degrees Celsius and at a loose filled tap density of 510 kg/m3 using cylindrical cell thermal conductivity methods known to a person skilled in the art.
The beaded thermal insulation material was measured as having a thermal conductivity of 0.09 W/mK.
The beaded thermal insulation material was also tested for its free flowing characteristics, resistance to sintering and compressibility using the same procedures as described for Example 1.
The beaded thermal insulation material was observed to flow freely into a 4 mm annulus without the need of assistance, for example air pressure, and without undergoing cohesion
which would form a bridge of material across the width of the annulus.
The beaded thermal insulation material did not undergo densification or sintering following heating at 850 degrees Celsius for 24 hours.
No compaction of the beaded thermal insulation material was observed or measured following the application of a nominal pressure of 5 tonnes.
EXAMPLE 5
Beaded thermal insulation material was made by mixing together in a paddle-type mixer a mixture of 17 per cent by wet weight of Micron grade exfoliated vermiculite available from Hoben International, and 17 per cent by wet weight of a potassium silicate binder available from Ineos Chemicals under the name K66. 17 per cent by weight of infrared opacifier in the form of rutile (titanium oxide) , available from Eggerding Group, Amsterdam, was also added to the binder and exfoliated vermiculite mixture. The rutile has a mean particle size of 1.6 micron as measured using a Fischer sizer.
The vermiculite, binder and rutile were mixed together for 10 minutes in order to obtain a homogeneous mixture. 49 per cent by weight of a volatilized silica, available from RW Silicium GmbH under the name RW-Fuller, was added gradually to the homogenous mixture of potassium silicate binder, rutile and exfoliated vermiculite and mixed for 30 minutes to form beads of insulation material with a diameter in a range from 0.2 mm to 2 mm.
As for Example 1, the beaded thermal insulation material was heated at nominally 120 degrees Celsius for 30 minutes to substantially remove the water content present. The composition of the beaded thermal insulation material after heating was nominally 18.3 per cent by dry weight of Micron grade vermiculite, 55.6 per cent by dry weight of volatilised silica, 19.3 per cent by dry weight of rutile and 6.8 per cent by dry weight of potassium silicate binder.
The beaded thermal insulation material was tested for thermal conductivity at a mean temperature of 200 degrees Celsius and at a loose filled tap density of 660 kg/m3 using cylindrical cell thermal conductivity methods known to a person skilled in the art.
The beaded thermal insulation material was measured as having a thermal conductivity of 0.12 W/mK.
The beaded thermal insulation material was also tested for its free flowing characteristics, resistance to sintering and compressibility using the same procedures as described for Example 1.
The beaded thermal insulation material was observed to flow freely into a 4 mm annulus without the need of assistance, for example air pressure, and without undergoing cohesion which would form a bridge of material across the width of the annulus.
The beaded thermal insulation material did not undergo densification or sintering following heating at 850 degrees Celsius for 24 hours.
No compaction of the beaded thermal insulation material was observed or measured following the application of a nominal pressure of 5 tonnes.
EXAMPLE 6
Beaded thermal insulation material was made by mixing together in a paddle-type mixer a mixture of 20 per cent by wet weight of Micron grade exfoliated vermiculite available from Hoben International, and 20 per cent by wet weight of a potassium silicate binder available from Ineos Chemicals under the name K66.
The vermiculite and binder materials were mixed together using the same procedure as described for Example 1. 55 per cent by weight of a volatilized silica, available from RW
Silicium GmbH under the name RW-Fuller Ql, was added gradually to the homogenous mixture of potassium silicate binder and exfoliated vermiculite. 5 per cent dry weight, of fumed silica material available from Degussa AG under the Registered Trade Mark AEROSIL A200 was then added gradually to the binder, exfoliated vermiculite and volatilised silica mixture and mixed for 30 minutes to form beads of insulation material, for example with a diameter in a range from 0.2 mm to 2 mm.
The fumed silica has a nominal specific surface area of 200 m2/g.
As for Example 1, the beaded thermal insulation material was heated at nominally 120 degrees Celsius for 30 minutes to substantially remove the water content present. The composition of the beaded thermal insulation material after heating was nominally 22.1 per cent by dry weight of Micron grade vermiculite, 64.0 per cent by dry weight of
volatilised silica, 5.8 per cent by dry weight of fumed silica and 8.1 per cent by dry weight of potassium silicate binder.
The beaded thermal insulation material was tested for thermal conductivity at a mean temperature of 200 degrees Celsius and at a loose filled tap density of 580 kg/m3 using cylindrical cell thermal conductivity methods known to a person skilled in the art.
The beaded thermal insulation material was measured as having a thermal conductivity of 0.13 W/mK.
Beaded thermal insulation material according to the present invention has been described in which the inorganic binder is potassium silicate. It should be appreciated that the beaded thermal insulation material could also be manufactured from other suitable materials, for example sodium silicate binder, phosphate binders, for example aluminium orthophosphate solution, or hydraulic binders which set and harden on contact with water, for example alumina cements.
The solids content of the alkali silicate solutions can be in a range from 25 to 40 per cent by weight, preferably from 30 to 38 per cent.
Beaded thermal insulation material according to the present invention has been described in which the core material is exfoliated vermiculite. It should be appreciated that the beaded thermal insulation material could also be manufactured from other suitable relatively coarse materials, for example quartz sand, bauxite, glass microspheres and mica.
Although beaded thermal insulation material according to the present invention has been described in which the opacifier is rutile (titanium oxide) , it should be appreciated that the beaded thermal insulation material could also be manufactured from other suitable materials, for example iron titanium oxide, zirconium silicate, zirconium oxide, iron oxide and silicon carbide.
Beaded thermal insulation material in accordance with the present invention, although described in Example 6 as comprising 5.8 per cent dry weight of fumed silica material, could contain up to 20 per cent dry weight of fumed silica material. The proportion of fumed silica included in the beaded thermal insulation material is relatively low in order to minimise raw material costs. It should be appreciated that other fumed silica to that described in Example 6, for example with a specific surface area in a range from 50 m /g to 400 m /g, preferably in a range from 180 m2/g to 230 m2/g, could also be used.
Other forms of precipitated silica to that described in Example 4, for example with a specific surface area in a range from 100 m2/g to 800 m2/g, preferably in a range from 420 m2/g to 470 m2/g, could be used.
Other forms of volatilised silica to those described in Examples 1 to 6, for example with a specific surface area in a range from 12 m2/g to 30 m2/g, preferably in a range from 18 m2/g to 22 m2/g, could be used.
The diameter of the beads of thermal insulation material are described as being in a range from 0.2 mm to 2 mm. However, it should be appreciated that larger diameter beads, for example in a range from 0.2 mm to 5mm, could be formed.
Vermiculite and volatilized silica are relatively inexpensive, compared to the price of aerogel-based free flowing thermal insulation material, for example NANOGEL material which comprises substantially 99 per cent by weight of silica, and as such beaded thermal insulation material in accordance with the present invention is relatively inexpensive. Beaded thermal insulation material in accordance with the present invention also possesses relatively low thermal conductivity, high service temperature resistance and adequate mechanical properties.