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reportFocus Report 2010: Aerogels
3.9 Focus Report 2010: Aerogels; Executive Summary
Aerogels can be characterised as materials with the lowest density of any known matter. Aerogels are a heterogeneous class of porous, solid materials which exhibit a number of extreme properties. They are predominantly known for their extremely low densities ranging from 0.0011 to ~0.5 g/cm3. Silica aerogel in particular is only three times heavier than air. Typically aerogels consist of 95-99 % air or vacuum in volume. Essentially an aerogel is a dry, low-density, open-porous, solid framework of a gel with pore diameters in the range of 1 to 100 nm in diameter. Aerogels represent a nanomaterial with promising application possibilities although, technological developments and market maturity remain challenging issues.
From an ecological point of view aerogels offer excellent thermal insulation properties, for example in the oil and gas industry or in architectural engineering. In the latter, they are meeting a long term trend towards more energy-efficient construction. The energy consumption of buildings in central Europe is around 20 litres of heating oil per square metre per year, whilst the current standard for energy efficient buildings is about 7 litres and pilot projects are already being implemented for "3-litre houses". Consistent thermal insulation is a crucial issue in that respect. Due to the optical transmission of aerogels there are also new opportunities for architectural design of translucent, heat-insulating building facades. Not only in architectural engineering but also in a variety of industrial processes (e. g. high temperature and cryogenic processes) and in household appliances aerogel based insulation materials offer considerable application potential. That holds true also with respect to noise protection requirements.
From a technological perspective aerogels have potential in various areas; for example, in microelectronics, where an accelerated miniaturization of integrated circuits requires materials with lower dielectric permittivity than SiO2. Here, aerogel films are a likely candidate. In power engineering, catalysis, and sensors materials with large specific surfaces, which can easily be doped with functional substances, are required. Aerogel materials offer these properties. This also applies to controlled release applications in agriculture and pharmaceutics. Due to the low density of aerogels further application possibilities as a basic lightweight material e. g. in automotive technology are opening up. This is especially true if aerogels with high mechanical stability may be produced at low cost in the future.
With respect to market attractiveness, positive developments in the long term may be expected. Aerogels offer potential in a variety of market segments, ranging from volume markets at the raw material level (including fillers, adsorbents, granules for cosmetics, pharmaceuticals, and construction machinery) up to the component level (including windows for buildings, electrode materials for batteries, and capacitors). The major issue is an economically competitive production. However, in the medium term aerogel materials could achieve a significant share of the global market for thermal insulation products. Low cost aerogel materials could also be utilised as fillers for various products in specialty chemistry and pharmaceutical industry (rubber, toner, detergent, cosmetics, pharmaceuticals) to compete with conventional products, such as Aerosil. In addition, special applications for high-tech products (including sensors, catalysts, micro electronics, and electronic engineering) are being investigated. Aerogel composites utilised as highly efficient catalysts give rise for obtaining high economic savings in the manufacture of chemical products.
The global market for aerogels accounted for $82.9 million in 2008 and it is expected to reach $646.3 million in 2013 with a compound annual growth rate (CAGR) of 50.8%. The market will be driven by thermal and acoustic insulation applications. Currently this segment accounts for 70% of the total aerogel revenues. However, up to now only a few consumer products have been commercialised with a focus on high-tech products. This is due to high manufacturing costs and high dust production during aerogel material installations. Based on a new, patented manufacturing process developed by Aspen Aerogels, Inc. the problem of costly fabrication should be overcome.
The market for aerogels is quite small and only a limited number of manufacturers play a key role in this market segment. Therefore, changes in companies activities will have an impact on both manufacturing and sales distribution.
The degree of novelty of the technology itself is considered to be low; the production technology is based on the classical sol-gel-process. However, there is still potential for optimization with regard to production processes and new combinations of materials.
The patent situation has been considered unfavourable. A variety of patents are held by US-based companies. That holds especially for Cabot, which acquired the former aerogel activities of Hoechst/Aventis underlining the current weakness of the European market position.
The product potential may be classified as high. Key factor for commercial success is an economic production of aerogel materials. On the basis of additional material modifications and material doping a host of new products in specialty chemicals could be further developed without high investment costs in the medium term. However, for chemical companies even destructive competition effects with respect to other product lines, such as aerosol, could partly occur.
Currently a relatively low number of companies is engaged in aerogels. Apart from some niche players, the most important player, is Cabot, which has achieved a broad commercialization of aerogels and manufacturing processes on the industrial scale.
Some application areas of aerogels are characterised by a strong dependence of customers and system developers. In these areas, market collaborations will be crucial.
The market framework for aerogel products may to be positively assessed. In particular, in an ecological perspective aerogel products may improve energy and resource efficiency. On a long run, improvements with respect to noise insulation, optimised pharmaceuticals, or a sustainable water infrastructure can be expected. Regarding the supply of raw materials, there are no limiting factors, from either an economic or an ecological point of view.
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Tags: Aerogel, Nanofoam, \"frozen smoke\", \"solid smoke\"