advantages of aerogel insulation for pip subsea tiebacks
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ADVANTAGES OF AEROGELINSULATION FOR PIPE-IN-PIPE
SUBSEA TIEBACKS
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Agenda
Aerogel technical overview and history
Nanogel particulate aerogel
Product forms for pipe-in-pipe systems
Benefits of particulate aerogel systems
Economic benefits for operators and EPIC contractors
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Many Shortcomings in Traditional
Pipe-in-Pipe Insulation Materials
Traditional insulation materials such as PU foam, rock wool,
and others have signif icant shortcomings such as:
Mediocre K-values resulting in sub-optimal U-values
Performance degradation over time - worse performancelater in field life when it is needed most
Poor compatibil ity with high-temperature systems -volatile components degrade rapidly with heat
Air gaps around rigid pre-formed units - convection
micro-currents degrade system performance Incompatibili ty with moisture and UV exposure -
increases overhead in the yard and on barge
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Aerogels - The Worlds Best InsulatorsMany Advantages vs. Traditional Insulation Materials
Source: LBNL Image Library
Source: NASA
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Aerogel Thermal Efficiency Supports
Improvement in Project Economics
Equivalent U-value
Lower steel costs
Lower vessel costs
Better U-value
Eliminates need foradditional platform
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Aerogel Superior Thermal Performance
Driven by Nano-sized Pores
20 Nano
Heat Source
Gas Molecules in Open Gas Molecules in Nano-Pores
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Aerogel at Ambient:
Ultra-Low Thermal Conductivity
Notes: Assumes atmospheric pressure and room temperature
Source: Various sources; Cabot analysis
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(1) Equivalent to 20 and -196 degrees C and 70 and -321 degrees FSource: Aerogel Insulation Systems for Space Launch, Dr. J .E. Fesmire,NASA Kennedy Space Center
NASA Experiments Highlight Outstanding
Performance of Aerogels at Cryogenic
Nanogel conductivity of
10.7 mW/mK at
atmospheric pressure
Test conducted under
steady-state conditions
at boundary
temperatures of
approximately 293 and77 kelvin (K)1
Results at atmospheric
pressure demonstrated
that Nanogel
performssignificantly better than
any other material
tested
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Aerogel was Discovered in Early 1930sDevelopment Limited by High Costs and Low Scalabil ity
Aerogel was invented in 1931 by
Steven Kistler at the College of the
Pacific using supercritical drying
Removal of liquid from a gelunder both high temperature
and pressure
No collapse of aerogels fine,porous structural skeleton
1950-1970 Monsanto attempted to
commercialize - exited business
due to high costs and low
scalabili ty associated with batch
production
1980-1990 BASF and others tr ied to
develop but fail for similar reasons
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Atmospheric Aerogel Production
Pioneered in Early 1990s
1992
1993
1996-1998
1998-1999
2000
2003
University of New Mexico researchers discover control of
gel shrinkage via silation of organogels
Cabot, Dow Corning, Hoechst, Nanopore all undertakeresearch programs aimed at control ling shrinkage through
surface modification
Cabot, Dow Corning, Hoechst file series of patents on
direct silation routes to control shrinkage
Cabot purchases/licenses Hoechst, Nanopore and Dow
Corning patent estates (46 issued patents)
Cabot begins construction of state-of-the-art plant inFrankfurt, Germany
Start-up of Nanogel aerogel production plant
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NanogelAerogel - A Unique Material
from Cabot Corporation
Worlds best insulating solid
Lightweight
Water repellant
Highly porous
Unique microstructure
High surface area
Can be IR-opacified
Available in a variety of grades
(scale in mm)
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Nanogel Manufacturing Process
Unique, Safe and Reasonable Cost
organogel
silation
organic water
aerogel
drying
nitrogen organic
hydrogel
silica sol
water
Patented
sub-critical
manufacturing
process
OHOH
OHOH
OHOHsilating agent
OSiRR
RSiO2 SiO2 O SiR
RR
O
Si
RRR
OSi R
RR
OSi
RR
R
OSi
R
RR
the Rs are
methyl groups
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Aerogel is an Excellent Thermal Insulator
For Oil and Gas Applications
Extremely low thermal
conductivity
Performs from cryogenic toHPHT
Inert material - performance
stable over time
Water resistant and UV
stable - no fuss in the yard
Extremely l ight weight
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Expansion Pack
Particle Pack Aerogel Blanket
Compression Pack
Multiple Methods of Applying Aerogel
in Pipe-in-Pipe Systems
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Nanogel Expansion Pack
for Pipe-in-Pipe Applications
Inner PipeOuter Pipe
Over-compaction Improves Thermal Performance and Enhances
Structural Capabilities of Entire System
Over-compaction Improves Thermal Performance and Enhances
Structural Capabilities of Entire System
Mold
Target Outer
Pipe Size
Target Inner
Pipe Size
Compressed
Nanogel
Target Pipe-in-Pipe System
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NanogelAlso Provides Significant
Mechanical Benefits to Pipe Systems
System of
cohesively packed
particles that hasrobust mechanical
properties
Strong andcompressible
particles
+Interlocking of
particles in a
packed bed
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NanogelAlso Provides Significant
Mechanical Benefits to Pipe Systems
Before
Packed Nanogel aerogel at compression level similar to
in-service levels for pipe-in-pipe applications
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NanogelAlso Provides Significant
Mechanical Benefits to Pipe Systems
Under Compression
Packed Nanogel aerogel easily supports weight of
3,200 lb ( 1,450 kg) car with negligible strain
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NanogelAlso Provides Significant
Mechanical Benefits to Pipe Systems
Mechanical properties of Nanogel enable supporting loads in
pipe-in-pipe systems during installation and in operation
Mechanical properties of Nanogel enable supporting loads in
pipe-in-pipe systems during installation and in operation
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NanogelAlso Provides Significant
Mechanical Benefits to Pipe Systems
After
Nanogel blocks remain unscathed
RearTire
FrontTire
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Stress-Strain Analysis Shows Good
Stiffness and Stability Under Cycling
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
0 5 10 15 20 25 30 35 40 45 50
Strain (%)
Stres
s(Pa)
0
2
4
6
8
10
12
14
16
18
20
Stress(PSI)
100 Cycles at +/- 1%strain of expansion pack
10000
15000
20000
25000
30000
35000
28 29 30 31 32Strain (%)
Stress(Pa)
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
Stress(psi)
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Impressive Performance at High Pressure
Stress / strain analysis of a packed bed of Nanogel
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
0 10 20 30 40 50 60 70 80 90
Strain (%)
Stress
(Pa)
0
1,000
2,000
3,000
4,000
5,000
Stress
(psi)
Ambient Temp
High Temp (200 C)
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No Significant Degradation of
Performance with Accelerated Aging
Thermal Testing of Aged Samples
(1) Tested at mean temperature of 12.5 C
-20%-15%
-10%
-5%
0%
5%
10%
15%
20%
0 2 4 6 8 10Aging Time (weeks)
%C
hangein
Conductivity
160 C
200 C
240 C
Upper Limit
Lower Limit
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Nanogel Thermal Efficiency Supports
Improvement in Project Economics
Equivalent U-value
Lower steel costs
Lower vessel costs
Better U-value
Eliminates need foradditional platform
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Illustration of Smaller Jacket Pipe CaseExpansion Pack Nanogel Creates Superior System
Notes:Pipe thickness=0.5(12.7mm)Assume K values of 15.0 and 27.0 for Expansion Pack and PU foam, respectively (before spacer impact)
Spacers assumed to be 50mm wide with conductivities of 200 mW/mK; 6-meter spacing for Expansion Pack case; no spacers for PU foam case 12.06/ 0.82
PU
Foam
Expansion Pack
Nanogel
Inner pipe OD (inches)
Target U-value(W/m2K)
Required OD for outerpipe (inches)
Achieved U-value(W/m2K)
8.625
0.70
14.0
0.68
8.625
0.70
12.75
0.55
Nanogel system requires less steel
and delivers superior barge efficiency
Nanogel system requires less steel
and delivers superior barge efficiency
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Illustration of Longer Tieback CaseExpansion Pack Nanogel Allows >70% Longer Tieback
Notes:Pipe thickness=0.5(12.7mm)Assume K values of 15.0 and 27.0 for Expansion Pack and PU foam, respectively (before spacer impact)
Spacers assumed to be 50mm wide with conductivities of 200 mW/mK; 6-meter spacing for Expansion Pack case; no spacers for PU foam case 12.06/ 0.82
PU
Foam
Expansion Pack
Nanogel
Pipe System Size (inches)
U-value(W/m2K)
Max tieback distance (km)Wellhead temp @ 70 C
Arrival temp @ 50 C
8x12
0.90
23
8x12
0.55
40
Nanogel system increases options for field developmentNanogel system increases options for field development
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Conclusion: Many Advantages of
Aerogel vs. Traditional Insulation
Ultra-low K-values enable best-in-class U-valueswithout vacuum - significant cost savings for operators
No performance degradation over time - strongperformance later in field life when it is needed most
Performance across a wide temperature range from
Cryogenic to HPHT
Available in product forms that eliminate air gaps - noconvection micro-currents to degrade performance
Hydrophobic and UV stable - no fussin the yardand on barge
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