Microporous Insulation Granules for Bulk Handling Without Heat Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercially available microporous granules have high thermal conductivity and mechanical instability, making them unsuitable for bulk transportation and storage, and they disintegrate easily, leading to loss of insulating performance.
Innovation Solution
Developing granules with a nominal tap density of at most 250 g/l, a granule size range of 0.25 to 3 mm, and incorporating silica or alumina for increased mechanical strength, along with post-treatments like waterglass or silicic acid to reduce dust and thermal conductivity, allowing for bulk transportation and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the density of granules is increased to improve mechanical stability, then mechanical strength is improved, but thermal conductivity increases and insulation performance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the tap density of granules to at most 250 g/l, which is a specific parameter threshold that balances mechanical stability and thermal insulation performance. This density parameter optimization prevents excessive compaction that would increase thermal conductivity while ensuring sufficient mechanical strength for bulk handling.
Solution Approach 2:
The patent uses composite materials by combining microporous powder composition with specific granulation treatments and surface coatings. The composite structure includes the core microporous material (alumina/silica) combined with binding agents and surface treatments that enhance mechanical strength without significantly increasing density, thus maintaining low thermal conductivity while improving durability for transportation.
2Reliability
If granules are made with low density to maintain low thermal conductivity, then insulation performance is improved, but mechanical stability decreases and granules disintegrate during transport
Solution Approach 1:
The patent optimizes the tap density parameter to a specific range (at most 250 g/l) that maintains low thermal conductivity while preventing excessive fragility. This parameter control ensures granules remain sufficiently intact during bulk transportation and storage without requiring higher density that would compromise insulation performance.
Solution Approach 2:
The patent introduces binding agents and surface treatments as intermediary substances that coat or bind the microporous particles together. These intermediaries provide mechanical strength and reduce dust generation during handling, while being applied in controlled amounts to minimize impact on thermal conductivity. Examples include waterglass or silicic acid post-treatments mentioned in the summary.
3Ease of operation
If granules are produced with fine particle size to improve filling characteristics, then flowability is improved, but dust content increases indicating disintegration
Solution Approach 1:
The patent controls the granule size distribution parameter, specifying a nominal tap density and size range (0.25 to 3 mm) with limited fine particles (at most 7 wt% below 0.25 mm). This size parameter optimization ensures good flowability for filling complex spaces while minimizing dust generation and disintegration during handling and storage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The granules achieve low thermal conductivity up to 400°C, sufficient mechanical strength, and reduced dust content, enabling effective insulation and bulk handling without loss of performance.
Implementation Method 1
Granules comprising microporous powder composition typically have a higher thermal conductivity than other insulation product with a microporous powder composition, which is due to the granulation process. The thermal conductivity of commercially available granulates sold by Promat under the tradename Freeflow TM
Implementation Method 2
When the granules disintegrate during transport or during the filling of any desired space, the material may no longer meet customer requirements and a loss of insulating performance may occur.
Data Source
AI summary
The granulate comprises a microporous powder composition comprising an insulation powder chosen from alumina and silica, an opacifier and optionally a filler, having a nominal tap density of at most 250 g/l, a granule size in the range of 0.25 to 3 mm as defined by sieving, with material having a size of at most 0.25 mm being present in an amount of at most 7 wt% based on dry weight of the granules. These granules can be used for filling a space in an apparatus and creating an insulating layer, and for bulk transport and bulk storage. Preferably, the granules are stored in the storage container to a maximum height of 3 meter, preferably maximum 2.5 meters.