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
The University of Tennessee, Knoxville is a comprehensive public land‑grant research university—the flagship of the UT System—classified as R1 and serving more than 40,000 students. Industry engagement is anchored by the UT Research Park at Cherokee Farm, where corporate R&D and joint university–national lab facilities sit just across the river from campus, including assets such as the Volkswagen Innovation Hub and an AT&T 5G testbed. UT’s long‑standing partnership with Oak Ridge National Laboratory—via UT‑Battelle and the UT–Oak Ridge Innovation Institute—gives companies streamlined access to national lab capabilities, talent, and joint programs. A statewide Extension network and established co‑op programs connect companies to faculty expertise and student talent across Tennessee and into federal labs. Research is supported by competitive federal sponsors such as the National Science Foundation and the U.S. Department of Energy. Commercialization is managed by the University of Tennessee Research Foundation, which handles IP, licensing, and startup formation.
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