Lead Performer: Liatris Inc. – Bethesda, MD; Partners: Sto Corp. – Atlanta, GA, Dvele – La Jolla, CA, Auburn University – Auburn, AL
February 15, 2022
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Lead Performer: Liatris Inc. – Bethesda, MD
Partners:
-- Sto Corp. – Atlanta, GA
-- Dvele – La Jolla, CA
-- Auburn University – Auburn, AL
Total Funding: $2,214,850
DOE Funding: $1,659,850
Cost Share: $555,000
Project Term: October 1, 2021 – September 30, 2024
Funding Type: BENEFIT 2020 Funding Opportunity Announcement
Project Objective
The strategic focus of this project is to leverage a primarily inorganic nanocomposite formulation of cellulose/clay/silica, and substantially increase the thermal performance without sacrificing cost-effectiveness. Our key high-level technical objective is to develop a new nanopore processing scheme that leverages ambient pressure drying. This process must ultimately be compatible with industry-standard extrusion and molding processes used to manufacture existing insulation products, to reduce the capital and processing costs of making aerogel-based super-insulation.
Aerogel-based composites have the potential for extremely high insulation values due to high porosity and nanometer-size pores. These special structural attributes are also reasons for processing difficulties resulting from the loss of nanopores in a weak material under high drying stresses, which today can be avoided only by supercritical drying with no interfacial stresses. However, the high-cost pressurized and batch drying of a high-amount of solvent from weak gel limits use in conventional building applications. Our approach leverages the mechanical properties of cellulose and proprietary strengthening techniques to mitigate this issue.
Liatris plans to integrate three key elements in its product development to make this composite super-insulation for buildings that is competitive on an installed cost / R-value basis:
- Developing a new aerogel composite formulation from three known nanogel precursors of cellulose, clay, and silica to reduce shrinkage during ambient pressure drying
- Raising the performance value of super-insulation while maintaining a Class A1 fire rating by reducing the use of organic materials that are highly flammable
- Integrating the pressurized drying of smaller nanopores with high-volume foaming so that the product can be mass produced on industry-standard manufacturing equipment
Liatris will also work with customers in retrofit and new construction to perform field validation of prototypes in a pilot environment. Sto is a leading player in exterior wall systems, including energy-efficient exterior retrofits through its Restore program. Dvele is a leading player in high-performance residential construction that produces new residential construction off-site in a controlled factory environment.
Project Impact
This technology has the potential for industry-leading performance breakthroughs and field demonstration. It is readily suitable for both retrofits, where thinner insulation significantly reduces complexity of trimming around windows and doors, and new builds, and meets key industry requirements as it is easy to install (drop-in replacement for foam; fastenable), nonflammable (Class A or above), and moisture-resistant. This technology combines substantial energy savings and carbon reduction with a fast payback profile. Based on a comparison of projected technology performance versus existing manufacturers' specifications for polyiso and use of the DOE Scout tool to calculate emissions and energy impact, the potential energy savings total is 1.65 Quads per year, which would reduce up to 8.7 billion metric tons of CO2 emissions per year. The simple payback is two years or less for both commercial and residential utility rates based on average electricity and gas rates nationwide.
Targeting R-10/in on a novel yet scalable inorganic nanocomposite is consistent with DOE’s goal to pursue high levels of insulation in thin products that can cost-effectively meet fire, safety, and other building code requirements that the private sector is not pursuing on its own. Cost-effective R-value advancements would expand the construction industry’s ability to offer deep energy retrofits using thinner insulation, where reaching R-15 with <1.5 inches of insulation is critical for minimizing installed cost. The thickness reduction will also benefit applications with building density and wall thickness constraints (e.g., multifamily, urban infill) without increasing installation cost.
Contacts
DOE Technology Manager: Sven Mumme
Lead Performer: Arthur J. Yang, Liatris Inc.