Energy & Resources: Cryogenic Applications

Innovative and Economical PUR and PIR Insulation Solutions

LNG & Petrochemical Sectors

Cryogenic Applications

Pacific Urethanes formulates UrePac® Cryo foam systems to be used in the manufacture of thermal insulation of industrial pipes, tanks, vessels and equipment used in cryogenic applications. Pacific Urethanes has a long history supplying UrePac® Cryo PIR & PUR foam systems in the LNG and Petrochemical industry sectors world-wide. These foam formulations have all been independently tested to comply with International Standards. Our technical experts are engaged in research and development providing innovative and sustainable technology to industry-wide thermal insulation solutions.

UrePac® Cryo closed-cell foam is used in applications that operate at temperatures that range from +70°C to -170°C. Formulations are available in a broad range of densities and compressive strengths amongst other properties, to ensure the performance characteristics of the product meet the unique requirements of the applications.

In particular, UrePac® Cryo provides exceptional thermal insulation, featuring one of the lowest k-factors among insulation materials used in cryogenic applications.

Cryogenic Applications - Pipe Supports

AT A GLANCE

Cryogenic Insulation Systems

Cryogenic Insulation limits the transmission of atmospheric heat in pipes or process equipment, maintaining the liquid or gas at its designated process temperature. The insulation must reliably prevent heat exchange between the pipes, tanks and plant structure. Cryogenic and below-ambient piping and tanks are insulated with closed-cell foam insulation, to ensure safe and efficient operations in these facilities.

Minimizing heat gain is particularly important in cryogenic applications like LNG. So, installing PUR/PIR closed cell foam, an insulation material that is both thermally efficient and moisture resistant, is critical.

AT A GLANCE

Cryogenic Insulation Systems

Cryogenic Insulation limits the transmission of atmospheric heat in pipes or process equipment, maintaining the liquid or gas at its designated process temperature. The insulation must reliably prevent heat exchange between the pipes, tanks and plant structure. Cryogenic and below-ambient piping and tanks are insulated with a closed-cell foam insulation, to ensure safe and efficient operations in these facilities.

Minimizing heat gain is particularly important in cryogenic applications like LNG. So, installing PUR/PIR closed-cell foam, an insulation material that is both thermally efficient and moisture resistant, is critical.

THE CHALLENGE

LNG Requirements

There has been an ongoing search for new energy supplies resulting in the global rise in demand for Liquefied Natural Gas (LNG). This is because LNG is cheaper, energy efficient and has lower carbon emissions than coal fuels.

However LNG, predominantly methane, is a natural gas that requires liquefaction and vaporization. Since the liquefied temperature of natural gas is -162 °C at atmospheric pressure, maintaining the conversion from gas to liquid phase requires a High Thermal Performance Insulator.

Transport and storage of LNG generate its own set of complex challenges, such as preventing:

  • energy losses through thermal inefficiencies
  • freezing of valves
  • surface icing
  • flammability after vaporisation

CRYOGENIC APPLICATIONS – LNG

LNG Schematic - Cryogenic Applications

(click to enlarge image)

LNG is piped from the drilling rigs to the processing plants, where it is liquified by cooling to Cryogenic temperatures. In order to sustain the liquid phase, it is critical to maintain the cryogenic temperature in the pipes, pipe supports, valves and flanges using high performance thermal insulation. UrePac® Cryo technology has been specifically developed to meet these challenges.

LNG takes <0.2% of the volume than its gaseous counterpart, meaning approximately 600 times the volume can be transported as a liquid compared to as a gas. It is therefore a highly efficient and cost effective system to transport LNG through pipes which are heavily insulated with our PUR and PIR foam systems. Heavily insulated pipes are capable of maintaining temperatures as low as -170oC, ensuring that the liquid gas doesn’t re-gasify as it travels through the pipes. The gas is then loaded into non-pressured containers and gets re-gasified at an onshore facility.

WORKING TOWARDS ZERO GDP

Pacific Urethanes Innovative Technology

In the past, foam blowing agents (CFCs & HCFCs) that played an important role in enhancing the thermal insulation performance of Polyurethane foam, contributed to the depletion of the Ozone Layer. HFCs (Hydrofluorocarbons) were introduced and widely adopted as Polyurethane foam blowing agents to provide zero ODP (Ozone Depletion Potential) while maintaining a high level of thermal insulation performance.

The emphasis now is on eliminating the GWP (Global Warming Potential) that is a feature of HFCs and the earlier generations of foam blowing agents. In this light, Pacific Urethanes is developing technology based on HFOs (Hydrofluoro-Olefins), which have minimal GWP.

An example of this technology is showcased in the cavity-filling product UrePac® Cryo LD PIR 50, specially developed for the North American market where HFCs are now banned in LNG applications.

WIND  | SOLAR | HYDROGEN

Future Sustainable Technologies

As the world transitions from fossil fuels to renewable energy resources in the coming decades, technology provided by Pacific Urethanes continues to play an important role in providing:

Composite Materials for the Manufacture of Wind Turbines | Insulation Components in Solar Panels | Insulation to Green Hydrogen Plants

UrePac® Cryo

Cryogenic Insulation Applications

HD PUF PIPE SUPPORTS

Insulated pipe supports provide insulation in the support area where regular pipe insulation cannot be installed. The formulation is optimised to ensure…

>> MORE INFORMATION

POUR IN PLACE CAVITY FILLING

Valves need to be insulated to prevent freezing and remain operational. In the past, such valves would be insulated in a time-consuming manual…

>> MORE INFORMATION

PIR BLOCK FOAM

UrePac® Cryo formulations can be used to make PIR foam blocks which are then cut to pipe section or sheet form for pipe, tank and other technical insulation applications.

>> MORE INFORMATION

PRE-INSULATED PIPES

Instead of taking pre-cut pipe insulation to the pipeline installation locations, pipes can be insulated in the factory using UrePac® Cryo PUR & PIR formulations…

>> MORE INFORMATION

CRYOGENIC INSULATION APPLICATIONS

UrePac® Cryo – HD PUF Pipe Supports

Insulated pipe supports provide insulation in the support area where regular pipe insulation cannot be installed. The formulation is optimised to ensure that the pipe support can both carry the load and allow the necessary movement at each support point. These pipe supports may be manufactured at densities from 160 kg/m3 to 500 kg/m3, moulded by standard foam dispensing equipment or hand-mixed and poured. They may also be cut from a poured foam block. These formulations are water-blown, meaning that they have zero Ozone Depletion Potential (ODP) and minimal Global Warming Potential (GWP).

SPECIFICATIONSUrePac® Cryo HDPUF 160UrePac® Cryo HDPUF 224UrePac® Cryo HDPUF 320
Nominal (Kg/m3)160224320
Compressive Strength (Mpa) @+23C2.003.006.00
Compressive Strength (Mpa) @ -170C4.007.009.00
180 days Aged K Value @ 20C W/m.K0.0280.0340.044
180 days Aged K Value @-170C W/m.K0.0190.0240.032
SPECIFICATIONSUrePac® Cryo HDPUF 160
Nominal (Kg/m3)160
Compressive Strength (Mpa) @+23C2.00
Compressive Strength (Mpa) @ -170C4.00
180 days Aged K Value @ 20C W/m.K0.028
180 days Aged K Value @-170C W/m.K0.019
SPECIFICATIONSUrePac® Cryo HDPUF 224
Nominal (Kg/m3)224
Compressive Strength (Mpa) @+23C3.00
Compressive Strength (Mpa) @ -170C7.00
180 days Aged K Value @ 20C W/m.K0.034
180 days Aged K Value @-170C W/m.K0.024
SPECIFICATIONSUrePac® Cryo HDPUF 320
Nominal (Kg/m3)320
Compressive Strength (Mpa) @+23C6.00
Compressive Strength (Mpa) @ -170C9.00
180 days Aged K Value @ 20C W/m.K0.044
180 days Aged K Value @-170C W/m.K0.032

CRYOGENIC APPLICATIONS: INSULATION

UrePac® Cryo – Pour-In-Place Cavity Filling Applications

Valves need to be insulated to prevent freezing and remain operational. In the past, such valves would be insulated in a time-consuming manual operation. UrePac® Cryo low-density PIR formulations allow the valve and other items such as flanges to be insulated quickly and simply in-situ. These lower density formulations (40 – 60 kg/m3), normally used to fill cavities such as valve boxes and flanges, are processed at the pipeline site. The pour-in-place formulations are HFC-blown, therefore having zero ODP.

SPECIFICATIONSUrePac® Cryo LDPIR 50UrePac® Cryo 65_55
Nominal (Kg/m3)5050
Compressive Strength (Mpa) @+23C200200
Compressive Strength (Mpa) @ -170C280280
180 days Aged K Value @ 20C W/m.K0.0270.027
180 days Aged K Value @-170C W/m.K0.0160.016
SPECIFICATIONSUrePac® Cryo LDPIR 50
Nominal (Kg/m3)50
Compressive Strength (Mpa) @+23C200
Compressive Strength (Mpa) @ -170C280
180 days Aged K Value @ 20C W/m.K0.027
180 days Aged K Value @-170C W/m.K0.016
SPECIFICATIONSUrePac® Cryo 65_55
Nominal (Kg/m3)50
Compressive Strength (Mpa) @+23C200
Compressive Strength (Mpa) @ -170C280
180 days Aged K Value @ 20C W/m.K0.027
180 days Aged K Value @-170C W/m.K0.016

CRYOGENIC INSULATION APPLICATIONS

UrePac® Cryo – PIR Block Foam

UrePac® Cryo formulations can be used to make PIR foam blocks which are then cut to pipe section or sheet form for pipe, tank and other technical insulation applications.

SPECIFICATIONSUrePac® Cryo LDPIR 45
Nominal (Kg/m3)45
Compressive Strength (Mpa) @+23C280/200
Compressive Strength (Mpa) @ -170C280/200
180 days Aged K Value @ 20C W/m.K0.027
180 days Aged K Value @-170C W/m.K0.016

CRYOGENIC INSULATION APPLICATIONS

UrePac® Cryo – Pre-Insulated Pipes

Instead of taking pre-cut pipe insulation to the pipeline installation locations, pipes can be insulated in the factory using UrePac® Cryo PUR & PIR formulations – either spray-applied or by rotationally cast methods, under controlled process conditions. In this way the pipe is delivered to the pipeline locations pre-insulated, with the subsequent labour cost savings and efficiencies.

SPECIFICATIONSUrePac® Cryo LDPUR 45
Nominal (Kg/m3)45
Compressive Strength (Mpa) @+23C200
Compressive Strength (Mpa) @ -170C280
180 days Aged K Value @ 20C W/m.K0.027
180 days Aged K Value @-170C W/m.K0.016

BENEFITS & DESIGN FEATURES

UrePac® Cryo – Thermal Insulation Foam Solutions

Benefits and design features to be taken into account when selecting UrePac® Cryo as your thermal insulation foam solution.

Available as PUR or PIR where specifications call for enhanced fire performance.

  • Moulded in simple, relatively low pressure, low-temperature moulds
  • Poured-in-place on-site using relatively simple, low-cost equipment in a fast operation eliminating conventional fabrication methods
  • Able to be formed around a pipe or other structure following the exact geometry of the substrate
  • Can be made in block form and cut to shape
  • Formulations can be moulded at a range of different densities to change the Compressive Strength and other physical properties to suit the application.
  • No chlorine content in our formulations, eliminating potential corrosion issues
  • The 2 Component PUR/PIR reaction takes place at room temperature in warm moulds
  • By granulating and using the powder as a filler in specifically designed parts