Protecting MW-Scale Battery Energy Storage Systems

Battery Energy Storage Systems (BESS) are the backbone of modern renewable energy grids. At MW scale, hundreds of lithium-ion cells are packed in close proximity — creating a critical vulnerability: thermal runaway propagation. When one cell overheats, cascading heat transfer can ignite adjacent cells within minutes.

Aerogel pads and blankets interrupt this propagation pathway, acting as thermal firewalls and giving BMS systems the time needed to respond before catastrophic failure occurs.

• Inter-cell thermal barriers: 1–3 mm pads delay thermal runaway propagation by 35+ seconds, enabling BMS intervention before cascading failure.
• Module & rack-level insulation: Blankets maintain optimal temperature in containerized BESS across −40°C to +60°C.
• HVAC load reduction: Superior insulation reduces thermal management overhead, improving round-trip efficiency and lowering LCOE.
• Cabinet & enclosure lining: Thin panel lining prevents external temperature extremes from affecting internal cell performance.

Stop Thermal Runaway Before It Stops You

EV battery packs demand insulation that is simultaneously fire-resistant, ultra-thin, and resilient under mechanical load. Aerogel composite is the only material delivering all three.

A single cell undergoing thermal runaway generates temperatures exceeding 700°C and releases up to 10 liters of flammable gas per Ah. Conventional insulation fails catastrophically — aerogel does not melt, does not ignite, and does not deform.

Tests show aerogel barriers successfully prevent propagation in series-connected systems and delay propagation in parallel configurations by 35+ seconds.

• Cell-to-cell thermal barriers: 1.5–3 mm pads block lateral heat transfer during thermal events without increasing pack volume.
• Module-level encapsulation: Blankets protect against external heat ingress and limit egress during internal thermal events.
• Swelling compensation: Compressible composites tolerate 3–8% volume change per cycle without degradation.
• Cold-climate performance: Retards heat loss in sub-zero environments, reducing cold-start capacity fade.

Wrap. Protect. Perform. In the Harshest Environments.

Petrochemical and LNG facilities operate from cryogenic pipelines at −196°C to steam and process lines exceeding 650°C. Every degree of heat loss translates directly into operational inefficiency.

Aerogel blankets deliver unmatched thermal performance in a flexible form factor that conforms to valves, elbows, and complex geometries. Non-combustible aerogel enhances facility-wide fire safety while minimizing insulation thickness — recovering pipe rack space and reducing structural dead load.

• LNG cryogenic insulation: Performs from −200°C to +650°C without phase changes — one material across the entire operating range.
• Flexible pipe & valve insulation: Conforms to bends, valves, and flanges, eliminating cold-bridging gaps of rigid systems.
• Moisture & CUI resistance: Hydrophobic aerogel resists water ingress and chloride-induced corrosion — the leading cause of offshore pipe failure.
• Space-saving & lightweight: Replacing 80 mm mineral wool with 25 mm aerogel recovers significant pipe rack space.
• Energy efficiency & ESG: Minimizing heat loss reduces fuel consumption and CO₂ emissions, supporting GHG reduction targets.