Non-flammable silica alumina aerogel from coal combustion waste
A cost-effective aerogel insulation derived from coal fly ash, offering superior thermal properties and fire resistance with reduced production costs. Ideal for space-constrained retrofits, this solution repurposes waste and eliminates the need for supercritical drying.
Overview
This innovative solution leverages coal fly ash, a common waste product, to produce a non-flammable silica alumina aerogel insulation. By extracting valuable ions and using the remaining silica-alumina-rich solution, this method produces a cost-efficient aerogel with exceptional thermal insulation and fire resistance. The process eliminates the need for expensive supercritical drying by using ambient pressure drying and TMCS surface modification, making it an economically viable alternative to traditional aerogels.
Technical specifications
- Materials: Utilizes silica-alumina-rich waste from coal fly ash
- Production Process:
- Sintering of fly ash with sodium carbonate to enhance solubility
- Acid leaching to extract metal ions, including rare earth elements
- Sol-gel process to form aerogel structure
- Fiber impregnation to produce reinforced composite
- Ambient pressure drying with TMCS surface treatment
- Performance:
- Thermal conductivity measured by TPS and heat flow meter
- Fire resistance tested per ASTM E136, E84, and UL790
- Off-gas analysis for safety compliance
Technology readiness level
Currently at a Technology Readiness Level of 3, this solution is in the validation phase. Future work includes optimization of processing parameters, fiber-reinforced composite fabrication, and performance testing to demonstrate scalability and application readiness.
About University of Tennessee, Knoxville
UT offers a partnership model that reduces risk, accelerates time-to-value, and supports long-term growth strategies for industry—providing an attractive platform for companies seeking to formalize collaboration and establish a long-term presence in the East Tennessee region. By aligning institutional investment with regional and national priorities, UT provides a stable and effective platform for industry collaboration, technology deployment, and sustained economic impact.
delivered to your inbox.