Project Summary
Aerogel Core has developed an advanced insulation material to support the thermal management of clean fuel systems such as ammonia, liquified natural gas and hydrogen in maritime applications. Work involves developing a so-called ultralight nanocellulose–graphene oxide composite aerogel, and validating the material’s ultra-low thermal conductivity, mechanical robustness and ability to be manufactured in a panel form. The project aims to take the technology from a TRL 2 to 3. Delivering a high-performance, bio-based and exceptionally lightweight insulation material that improves energy retention and safety for low-carbon fuel systems; this project directly advances TRIG’s mission to accelerate clean maritime technologies while contributing to emission reduction goals.
Project Achievements
Our TRL has progressed from level 2 to 3 by achieving successful manufacture and characterisation of proof-of concept material prototypes at laboratory scale. Thermal testing revealed conductivities competitive with rigid polyisocyanurate (PIR) foam at reduced density. Our aerogels offer increased flexibility allowing shaping to complex geometries in addition to enhanced multifunctionality through activation of high amplitude sound absorption effects at low frequencies. Our best compound simultaneously outperformed conventional open cell melamine acoustic foam in thermal performance, while being lighter by 11.3% compared to PIR. Our material’s superior sound attenuation between 0-3000Hz, makes it particularly well suited to maritime transportation applications where low frequency sound is commonplace (machinery spaces, engine rooms, HVAC and as a thermal and acoustic liners between cabins). Our engineered composite aerogel maintains stronger acoustic performance at lower thicknesses compared to the alternative acoustic foam, showing a 33.15% increase in mean absorption coefficient over the 1000-3000Hz frequency range.
Conclusions
Cryogenic clean-fuel systems (LNG, ammonia, liquid hydrogen) need highly effective insulation to reduce heat ingress and losses, yet incumbent solutions are often bulky/heavy, single-function, and difficult to manage at end-of-life. We developed and validated bio-based aerogel material which combines competitive thermal insulation with exceptional low-frequency acoustic absorption. Progressing our technology from TRL 2 to TRL 3 through prototype manufacture and laboratory proof-of-concept testing. Decarbonisation and environmental impacts arise from improved thermal management reducing fuel loss/boil-off while increasing the efficiency and safety case for clean fuels. Our material uses renewable and potentially biodegradable inputs, whereas many conventional insulation systems are petrochemical based being complex and costly to recycle. The medium/long-term impact for the transport sector is a pathway to thinner, lighter multifunctional insulation supporting cryogenic thermal performance and shipboard noise mitigation—improving crew wellbeing by meeting noise regulations without separate insulation layers.
Next Steps
Our next steps focus on moving our technology from TRL3 proof-of-concept to TRL4–6 validation in relevant maritime conditions. Over the next 12-24 months we aim to identify a vessel or shore-based clean-fuel installation partner (LNG/ammonia/hydrogen) defining the required product form (panel geometry, thickness, joining method, vapour barrier needs) while conducting live-environment trials in areas needing cryogenic thermal insulation and/or noise mitigation (e.g., fuel lines, valve skids, machinery spaces, accommodation interfaces). Additional work, will formally validate LCA, recyclability and circularity credentials. To reach TRL7–9 within 36-42 months we aim to: (1) lock a manufacturable panel architecture and repeatable process window; (2) complete standards-aligned thermal/acoustic, mechanical and durability testing (temperature cycling, moisture, vibration, compression/impact); (3) engage class/flag stakeholders early (e.g., DNV and SOLAS/IGF Code expectations for non-combustibility, smoke/toxicity and installation); (4) execute pilot installations and monitor performance; and (5) develop a supply chain and QA plan for scale-up.
