Zhejiang Runhui New Materials Co., Ltd.
Zhejiang Runhui New Materials Co., Ltd., headquartered in Shengzhou, Zhejiang Province, is a pioneer in aerogel technology, particularly in addressing the critical challenge of material recycling. As a pioneer in its high-performance flagship product, aerogel blanket, the company has shifted its focus from production innovation to closed-loop sustainable development, integrating circular economy principles into every stage of its operations. This commitment is reflected in its mission: to transform aerogel from a linear "single-use" material into a reusable resource, in response to global efforts to reduce industrial waste and carbon footprint.
Runhui's aerogel felt is a composite material composed of silica aerogel and reinforcing fibers (glass fiber, ceramic fiber), known for its ultra-low thermal conductivity and chemical resistance. Many advanced materials widespread application faces a challenge: scrap recycling. Traditional aerogel products are often discarded. Runhui's breakthrough in recycling technology has now enabled it to recover more than 90% of raw materials from scrapped felt, making the company a leader in circular economy solutions in the field of industrial insulation.
The recycling challenge
Aerogel's nanoporous structure and composite design made recycling inherently complex, with three key barriers:
Bonding complexity: The hydrophobic coating and tight integration of aerogel with fibers created a matrix resistant to mechanical separation. Shredding or grinding, damaged components-fibers frayed, and aerogel pores collapsed-rendering them unfit for reuse in high-performance applications.
Contamination risks: Industrial use exposed aerogel blankets to diverse contaminants: LNG carriers left saltwater residues; petrochemical plants introduced hydrocarbons; and construction sites added dust and concrete particles. These contaminants clogged aerogel pores, reacted with the silica matrix, or coated fibers, complicating reprocessing.
Economic viability: Early recycling attempts relied on energy-intensive processes: high-temperature incineration (releasing CO₂ and toxic ash) or harsh chemical baths (generating hazardous wastewater). These methods cost 2–3 times more than using virgin materials, making recycling economically unfeasible for most industries.
Runhui tackled these challenges through a three-pronged approach: chemical deconstruction, fiber-aerogel separation, and coating recovery, supported by its in-house R&D lab-equipped with advanced microscopy and thermal analysis tools-and specialized wet/dry production lines optimized for recycling.
Key breakthroughs in Aerogel Blanket recycling
Chemical deconstruction
Runhui developed a low-temperature hydrolysis process that breaks down the silica aerogel network without damaging reinforcing fibers. By introducing a proprietary catalyst solution-pH-balanced to avoid fiber degradation and energy-efficient to operate-the company dissolves the aerogel into silica nanoparticles while preserving 95% of the fibrous matrix.
This process stands out for its:
Adaptive contaminant handling: The catalyst neutralizes specific industrial contaminants: it breaks down hydrocarbons from petrochemical use, precipitates salt residues from maritime applications, and dissolves concrete dust from construction sites. This adaptability ensures even heavily used blankets can be recycled without pre-cleaning.
Energy efficiency: Operating at 60–80°C (far below the 500°C+ of incineration), the process cuts energy use by 70% compared to traditional methods. Waste heat from the hydrolysis reactors is recycled to warm pre-treatment tanks, further reducing energy consumption.
Silica purity: Recovered silica nanoparticles, with a purity of 99.5%, are reused in new aerogel and repurposed for high-value applications: as fillers in advanced ceramics, additives in anti-corrosion paints, or thickeners in cosmetic formulations-diversifying revenue streams beyond insulation.
Reusing reinforcing materials
The fibrous matrix (glass or ceramic fibers) in Runhui's Aerogel Blanket provides mechanical strength, making it a valuable resource. Traditional recycling crushed or melted fibers, reducing tensile strength by 50%+ and limiting reuse to low-grade applications (insulation for non-critical pipes). Runhui's mechanical fibrillation technique addresses this:
Gentle separation: Rotating brushes with precisely calibrated bristle stiffness-paired with low-pressure air jets (1–2 bar)-dislodge residual aerogel from fibers without causing structural damage. This preserves 85% of the original tensile strength, allowing recycled fibers to meet the rigorous standards of aerospace and LNG applications.
Automated grading: Post-separation, fibers pass through optical scanners that measure length, diameter, and tensile strength, sorting them into grades: high-grade (90% of output) for reintegration into new Aerogel Blankets; medium-grade for automotive composites; and low-grade for soundproofing in buildings. This ensures maximum value extraction from every fiber.
Reduced virgin fiber demand: By reusing 40% recycled fibers in new blankets, Runhui cuts reliance on virgin glass/ceramic production-a process that consumes significant silica sand and energy, generating 2 tons of CO₂ per ton of virgin fiber.
Sustainable hydrophobicity
The hydrophobic coating on Runhui's Aerogel Blanket-a fluorosilane compound-is critical for water resistance but historically difficult to recycle. Runhui's solvent-based extraction method overcomes this:
Selective dissolution: A mild, aliphatic solvent-chosen for its low toxicity and high affinity for fluorosilanes-dissolves the coating without affecting silica or fibers. This allows 80% of the coating to be recovered, even from blankets exposed to decades of maritime humidity.
Closed-loop solvent use: The solvent is distilled and reused in 95% of extraction cycles, with only trace amounts lost to evaporation. This eliminates hazardous wastewater and reduces reliance on virgin solvent production, which involves energy-intensive distillation of crude oil derivatives.
Coating reformulation: Recovered fluorosilanes are blended with 10% virgin additives to restore performance, then reapplied to new blankets. Testing confirms recycled coatings maintain 95% of the water repellency of virgin ones, meeting Class A hydrophobicity standards (water contact angle >130°).
Closed-loop system
Runhui's recycling process integrates seamlessly with its production lines, creating a circular ecosystem that minimizes waste and maximizes resource efficiency:
Collection network: Runhui partners with logistics firms (global shipping companies) and industrial clients to establish 50+ collection points across Asia, Europe, and North America. GPS-tracked containers and blockchain-based documentation ensure traceability-a requirement for industries, where material provenance is critical for regulatory compliance.
Pre-treatment: Blankets undergo automated sorting via robotics, which identify material type (glass vs. ceramic fibers) and contamination level using near-infrared (NIR) spectroscopy. This is followed by ultrasonic cleaning-high-frequency sound waves (20–40 kHz) dislodge loose debris without damaging fibers or aerogel, ensuring consistent input to deconstruction.
Continuous deconstruction: Hydrolysis, fiber separation, and coating extraction occur in a synchronized, continuous process, with each stage feeding directly into the next. This minimizes energy loss from heating/cooling and reduces labor costs compared to batch processing.
Quality assurance: Recycled blankets undergo the same rigorous testing as virgin ones: thermal conductivity measurements, fire resistance trials (per ISO 1182), and chemical resistance tests (exposure to salt spray, acids, and alkalis). This ensures they meet the performance standards of industries from LNG to aerospace.
This system has been validated in partnership with a major Asian LNG terminal operator, which recycled 1,000+ tons of retired blankets over three years. The project diverted 85% of waste from landfills, cut insulation costs by 30%, and reduced the terminal's carbon footprint by 1,500 tons-equivalent to taking 300 cars off the road for a year.
Industry impact
Aerospace demands lightweight, high-performance insulation for engines, cabins, and satellites-areas where aerogel excels. Runhui's recycling enables reuse of aerogel from retired aircraft: a European aerospace firm recycled insulation from 50 decommissioned jet engines, reusing the material in new aircraft cabins. This reduced waste by 90% and cut lifecycle emissions by 25% per aircraft, aligning with the EU's "Flightpath 2050" goal of carbon-neutral aviation.
Refrigerated shipping containers and cold storage facilities rely on aerogel to maintain temperatures (-20°C to 10°C) for pharmaceuticals, fresh produce, and frozen goods. Runhui's recycled blankets-with identical thermal performance to virgin ones-are now used by a global logistics firm in 10,000 containers. This reduced spoilage of perishables by 15% (thanks to consistent insulation) and cut CO₂ emissions by 12,000 tons annually by avoiding virgin aerogel production.
Runhui's recycling aligns with global circular economy regulations:
China's 14th Five-Year Plan for Circular Economy: Mandates 50% recycling rates for industrial composites by 2025-Runhui's 90%+ recovery exceeds this target.
EU's Circular Economy Action Plan: Classifies recycled aerogel as a "secondary raw material," qualifying users for tax breaks under the EU Ecolabel scheme.
ISO 14001 certification: Runhui's recycling facilities meet international standards for environmental management, with third-party audits verifying 99% waste diversion from landfills.
LNG Carrier Fleet
A fleet of 15 LNG carriers in the South China Sea faced rising costs: decommissioned insulation required specialized hazardous waste disposal (€500/ton), and virgin aerogel cost €2,000/ton. Partnering with Runhui, the operator recycled 2,000 tons of blankets over five years. Recycled insulation cost €1,400/ton, saving €1.2 million, while reducing landfill waste by 1,700 tons. Post-installation testing showed no difference in thermal efficiency (-162°C retention) or durability compared to virgin blankets.
Cold Storage Facility
A German cold storage provider with 20 facilities struggled with inconsistent insulation performance in aging facilities, leading to 10% food spoilage. Retrofitting with Runhui's recycled Aerogel Blankets stabilized temperatures (-25°C ±0.5°C) and reduced energy use by 15% (saving 500,000 kWh/year). The project diverted 300 tons of waste from landfills, earning the facility EU Ecolabel certification and boosting customer trust in its sustainability claims.
Automotive Supplier
A major EV battery supplier needed lightweight thermal insulation to prevent thermal runaway in battery packs. Traditional materials (mineral wool) added weight and absorbed moisture. Integrating recycled aerogel fibers-recovered from industrial insulation-reduced battery pack weight by 8% and improved heat dissipation by 10%, lowering fire risk. Production costs dropped 18% by using recycled fibers, supporting the supplier's goal of affordable, sustainable EVs.
Future innovations
Runhui is expanding its recycling capabilities through three key initiatives:
AI-driven sorting: Cameras and machine learning algorithms-trained on 10,000+ images of decommissioned blankets-classify materials by type, contamination, and usage history. This reduces sorting time by 60% and ensures each blanket is processed via the most efficient route (heavy contamination → focus on fiber recovery; light contamination → full silica/coating reuse).
Bio-based coatings: Research into plant-derived hydrophobic coatings (from soybean oil or castor beans) aims to replace fluorosilanes. Early prototypes maintain 90% water resistance of traditional coatings while dissolving completely in hydrolysis, eliminating the need for solvent extraction. This would make aerogel fully biodegradable at end-of-life.
Modular recycling units: Shipping container-sized mobile facilities-equipped with miniaturized hydrolysis reactors and fiber separators-can be deployed to remote sites (Arctic LNG projects, offshore platforms). These units process 100 kg/day, reducing transportation emissions (no need to ship blankets to central facilities) and enabling on-site recycling in hard-to-reach locations.
Redefining aerogel's lifecycle
Zhejiang Runhui New Materials Co., Ltd.'s recycling breakthroughs have transformed Aerogel Blanket from a linear "use-and-dispose" product into a circular asset. By solving the technical and economic barriers of aerogel recycling, Runhui reduces environmental impact and unlocks new value streams for industries reliant on advanced insulation.
As global demand for aerogel grows-driven by energy efficiency and decarbonization-Runhui's closed-loop system sets a precedent for sustainable materials innovation. For industries seeking to balance performance with responsibility, Runhui's recycled Aerogel Blanket offers a blueprint for a circular future, proving that advanced materials can be high-performing and eco-friendly.
