Aerogel Insulation in India for Industrial & EV Applications

Aerogel insulation is an advanced thermal insulation solution used where space constraints, high temperatures, fire safety, and energy efficiency are critical. In India, aerogel insulation is increasingly adopted across industrial process equipment, refineries, power plants, EV battery systems, and high-performance thermal applications where conventional insulation materials are technically inadequate.

DARQ supplies aerogel insulation solutions in India for industrial and EV applications, offering multiple product formats, application engineering support, and project-specific customization.

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What Is Aerogel Insulation?

Aerogel insulation is based on silica aerogel, a nanostructured material composed of more than 90% air by volume. Its internal structure consists of interconnected nanopores that drastically reduce heat transfer through conduction, convection, and radiation.

Unlike traditional insulation materials that rely on bulk thickness, aerogel insulation achieves exceptionally low thermal conductivity at minimal thickness, making it suitable for applications where space, weight, or surface temperature control is critical.

Aerogel insulation is typically supplied in flexible blanket, roll, composite, or powder form and is used as a high-performance thermal barrier in both low- and high-temperature environments.

 

Key Technical Properties of Aerogel Insulation

Aerogel insulation is selected based on measurable engineering performance rather than general insulation category comparison.

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• Thermal Conductivity

Aerogel insulation exhibits extremely low thermal conductivity values, significantly lower than conventional insulation materials such as mineral wool, ceramic fiber, or polyurethane foam. This allows equivalent thermal resistance at a fraction of the thickness.

• High Temperature Resistance

Depending on formulation and reinforcement, aerogel insulation can operate across a wide temperature range, including high-temperature industrial environments where polymer-based insulation materials fail.

• Thin Profile and Space Efficiency

One of the most important advantages of aerogel insulation is its thin profile. Where traditional insulation requires large thicknesses that interfere with equipment layout or clearance, aerogel delivers thermal performance in compact assemblies.

• Fire Performance

Silica aerogel insulation is inherently non-combustible and does not melt or drip under high temperatures. This makes it suitable for fire-sensitive applications and passive fire protection systems when properly engineered.

• Lightweight Construction

Aerogel insulation is extremely lightweight compared to dense refractory or mineral insulation systems, reducing structural load and simplifying installation in retrofit applications.

Why Aerogel Insulation Is Used in Industrial & EV Systems

Aerogel insulation is not a general-purpose replacement for all insulation materials. It is used where technical constraints demand superior performance.

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Industrial Thermal Insulation Applications

In industrial environments, aerogel insulation is widely used for:

• High-temperature piping and vessels

• Process equipment with limited insulation clearance

• Energy efficiency upgrades in existing plants

• Surface temperature control for personnel safety

• Corrosion under insulation (CUI) mitigation systems
   

Because aerogel insulation maintains thermal performance at reduced thickness, it is particularly valuable in retrofit projects, where increasing insulation thickness is not feasible.

 

EV & Battery Thermal Management Applications

In electric vehicle and battery systems, aerogel insulation is used to manage heat propagation and thermal isolation within compact battery modules and enclosures.

 

Typical EV-related uses include:

• Thermal barriers between battery cells or modules

• Insulation layers near high-temperature components

• Space-constrained thermal protection zones

• Lightweight thermal solutions where mass reduction is critical
   

Aerogel insulation supports modern battery system designs where thermal performance, weight, and space efficiency must coexist without compromise.

Aerogel Insulation Product Forms Available

Aerogel insulation is supplied in different physical formats to suit specific engineering and installation requirements.

 

Aerogel Blanket / Roll Insulation

Aerogel blanket insulation consists of silica aerogel integrated into a flexible fiber reinforcement. It is widely used for industrial piping, equipment insulation, and thermal barriers.

 

Typical characteristics:

• Flexible and conformable

• Suitable for curved and irregular surfaces

• Available in multiple thickness options

• Used in both hot and cold insulation systems

This form is commonly selected for industrial insulation projects requiring thin, high-performance thermal layers.

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Aluminium Foil Aerogel Blanket

Aluminium foil aerogel blankets incorporate a metallic facing to improve radiant heat reflection and provide additional surface protection.

 

Typical applications include:

• High-temperature equipment insulation

• Areas exposed to radiant heat

• Systems requiring vapor or moisture barrier properties

• Industrial and power sector applications

The aluminium foil layer enhances durability and thermal control in demanding operating environments.

 

EV Battery Aerogel Thermal Insulation Pads

Aerogel thermal pads are engineered specifically for EV and battery applications, where controlled thermal isolation and compact design are essential.

 

Key features:

• Thin thermal insulation layers

• Application-specific shapes and formats

• Designed for battery pack integration

• Suitable for high-energy density systems

These pads are supplied based on application requirements rather than standard catalog dimensions.

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Aerogel Insulation Powder

Aerogel insulation powder is used in specialized insulation systems, gap filling applications, or composite formulations where flexible insulation forms are not suitable.

 

Typical use cases include:

• Insulation of complex cavities

• Integration into custom thermal assemblies

• Specialized industrial applications

Selection depends on system design and thermal performance requirements.

 

Aerogel Insulation Price in India (Indicative)

Aerogel insulation pricing in India depends on multiple technical and commercial factors. Unlike commodity insulation materials, aerogel insulation is application-specific and project-driven.

 

Key factors influencing price include:

• Product form (blanket, foil composite, pad, powder)

• Thickness and density

• Operating temperature requirements

• Quantity and project scale

• Customization or cutting requirements
   

Indicative pricing ranges (for reference only):

• Aerogel blanket insulation: typically priced INR 1800/- to INR 3800/- per square meter based on thickness and quantity

• EV battery aerogel insulation pads: application-specific pricing INR 150/- per pc

• Industrial bulk supply: volume-based project pricing INR 2800/- per square meter for 10mm thickness

Final pricing is determined after reviewing technical requirements and application conditions.

 

Why DARQ for Aerogel Insulation in India

DARQ focuses on application-driven aerogel insulation solutions, not generic product supply.

 

Key strengths include:

• Engineering-led application assessment

• Support for industrial and EV-specific requirements

• Custom thicknesses and product formats

• India-based coordination and technical support

• Supply for prototype, pilot, and commercial projects
   

DARQ works closely with engineers, consultants, and procurement teams to ensure the correct aerogel insulation solution is selected for each application.

 

Technical Datasheets & Application Consultation

Selecting aerogel insulation requires understanding thermal performance, temperature limits, installation constraints, and compliance considerations.

To support engineering and procurement teams, DARQ provides:

• Detailed technical datasheets

• Application discussion and feasibility review

• Support during insulation system design

• Assistance with product selection and specification
   

For technical documentation or to discuss your application requirements, you may request a datasheet or connect directly with an engineer.

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• Request Technical Datasheet

• Discuss Your Application with an Engineer
   

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