10154201AEROTWIN: Enhancing Thermulon’s novel aerogel process with a digital twin to enable their rapid deployment in the insulation retrofit of UK solid-wall propertiesClosedCollaborative R&DInnovate UKThe urgency of achieving net-zero is heightened by soaring energy costs and the inefficiency of the UK's housing stock. Retrofitting homes with energy-efficient solutions is critical, and sustainable insulation materials are essential for reducing embodied carbon. Thermulon addresses this challenge by creating high-performance insulating aerogels from silica. Silica aerogels are exceptional insulation materials, combining superior thermal performance with fire safety. However, their high cost, driven by complex manufacturing processes, has traditionally limited their adoption. Thermulon's innovative chemical process breaks through this cost barrier by leveraging economies of scale and incorporating recycled glass, significantly lowering production costs and enabling the widespread use of aerogels in retrofitting products like plasters, blankets, and cladding. A key aspect of this innovation is the development of a simulation-driven process model in collaboration with Siemens UK, which will cut laboratory costs and materials waste by replacing extensive physical trials with virtual optimization. This approach not only accelerates scaling but also saves resources, further enhancing affordability and sustainability. Thermulon's process minimizes reliance on synthetic chemicals, reduces industrial waste, and strengthens the insulation supply chain's sustainability and resilience. By optimizing the integration of recycled glass and silicate minerals, this project advances Thermulon's commitment to environmentally responsible manufacturing while supporting the UK's net-zero goals. Siemens will be able to support innovation in sol-gel industries (eg pharma, textiles, ceramics) with the newly developed chemical libraries.