Case Study: Aerogel Blankets in a Gujarat Refinery Retrofit – Cutting Heat Loss and Maintenance Costs

A couple of years back, we got a call from a procurement team at a mid-sized refinery in Gujarat—they were dealing with old pipelines losing heat like crazy, driving up energy bills and maintenance headaches in the hot climate. Traditional fixes meant thick wraps that complicated access, so they tried our aerogel blankets on a test section. What started as a small trial turned into a full retrofit across key lines.

The challenge: Pipes running at 150-200°C with limited clearance around supports. Rock wool would've added bulk, risking more corrosion under insulation in humid seasons. We supplied 10mm aerogel blankets (0.02 W/m·K conductivity), half the thickness of alternatives. Installation took the crew about 20% less time—no heavy cutting or multi-layers needed, just snug overlaps and stainless bands.

Results from their post-install audits: Heat loss dropped 35%, per IR scans and flow meters, trimming fuel use noticeably. In salty, dusty air, the hydrophobic surface held up without sagging or wick issues common in wool. Payback hit in 18 months via lower operating costs, and maintenance crews loved the easy access for inspections.

We've seen similar wins in other spots, like Middle East storage tanks where space savings allowed retrofits without shutdowns. It's not always a full swap—sometimes hybrid with rock wool for fire zones—but for efficiency in tight, hot runs, aerogel paid off here.

If your facility's facing similar pipeline woes, what's the biggest bottleneck? We'd love to hear and see if we can tailor something.

Sources: Client feedback from Gujarat Refinery Project; Internal energy audit data; ASTM C177 conductivity benchmarks.