The wastewater industry is full of general rules of thumb and best practices, often ignored within these is selecting the right storage tank with the right coating for the application. As the term 'wastewater' represents a broad cross-section of constituents, waste stream makeup, compounds, origin and strength it is no wonder that the general rule of thumb is just that, too general. Wastewater streams vary widely, especially in the industrial sector, as do the options effective in their treatment. Just as careful selection of the right process and technology is a necessity to achieve successful (i.e., permit-driven) treatment results, so too is the tank in which the initial storage and eventual treatment process takes place.
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The success or failure of any tank is largely dependent on its coating. While there are generally two main albeit different types of steel storage tanks on the market today, welded steel and bolted steel, they are relational in they both rely on a steel substrate for structural integrity (steel sheets welded together, steel sheets bolted together) and a coating system (field-applied paint, factory applied glass or epoxy) in order to effectively store liquid.
The storage and treatment of wastewater, in all of its variations and sources is some of the hardest liquid to store. The components that make up strong waste streams often produce heavy corrosion-causing conditions that challenge storage tanks of all types. The 'right tank' in the wrong application carries monetary and operational consequences, commonly referred to as time & money.
Welded steel tanks are the oldest of all storage tank designs, which includes ground storage tanks commonly used for wastewater treatment. The design of a welded steel tank includes the application of a field-applied coating, the success or failure of the coating is largely reliant on two things; the applicability of the coating ('paint') being used and most importantly the proper application of the coating. Even the best coating system will fail if not properly applied, field conditions often change quickly allowing environmental conditions to affect the application process. The true weakness in field-applied coating lies in the fact that they are carbon-based systems, meaning they can and will chalk, fade and eventually fail due to corrosion. Additionally, while there are various types of custom or heavy-duty coating systems available the costs associated with coatings themselves and the stringent nature of their application often make them too costly to consider.
Bolted, powder-coated-epoxy-steel tanks are some of the most widely used in wastewater storage and treatment operations. Their low initial cost compared to field welded and bolted, glass-fused-to-steel tanks often give them an advantage. Additionally, bolted, powder-coated-epoxy-steel tanks are quick to erect and can be built on small sites with limited space around the tank in which to work. This is due to modular building techniques unique to bolted tank construction. As with all coated steel tanks, the bolted-powder-coated-epoxy-steel tank relies on its coating system to provide the protection against the harsh environment found in wastewater. While the powder-coat epoxy is a carbon-based, the advantage bolted-powder-coated-epoxy steel tanks have is in the actual application of the coating; bolted-powder-coated-epoxy-steel tanks are factory-coated, this allows ever-changing environmental factors that adversely affect field-applied coatings to be eliminated. The coating process is fully automated, using state-of-the-art robotic applicators and the latest in steel sheet preparation ensure the epoxy coating is evenly applied, in precise thicknesses and properly cured in order to achieve a robust coating system. This results in a ready-to-build product that is fully coated and ready for service once it is delivered to the site.
Bolted, glass-fused-to-steel tanks have become a viable and sought after technology for wastewater storage and treatment. Although higher in initial cost compared to bolted, powder-coated-epoxy-steel tanks, it is a truly unique product that uses a factory applied glass coating (porcelain enamel) to protect the steel against corrosion. The glass is 'fused' to the steel, this 'fusion' process is only achieved at > 1,500° F and produces an inert coating that is mechanically and chemically bonded to the steel. The result of this 'fusion' is a coating system that is impermeable to most liquids, eliminates undercutting caused by corrosion, will not chalk, fade or rust and will never need recoating. Glass-fused-to-steel is more than twice as hard as any field-applied paint/coating system and has a bond rating 12.5 times stronger than factory-applied, powder-coat. Similar to the powder-coating process used on bolted epoxy tanks, the application of the glass coating is fully automated, using robotic spray guns and applicators that ensure consistent, uniform liquid glass coating is applied to every sheet. Glass-fused-to-steel tanks are erected using modular construction methods that allow the tank to be constructed on small sites with limited work space. This form of specialized construction utilizes lifting jacks, designed specifically for Aquastore® glass-fused-to-steel tanks provides safe, OSHA-friendly construction with quick and efficient erection time.
The investment in waste treatment and storage is a necessity, driven by EPA-mandated regulations and enforced by local municipal and utility agencies that serve the public trust. This investment in is seldom a small one, requiring capital expenditure and operational impact that constantly move the bottom-line, profitability needle. The economic comparison for selecting the right tank, the right coating, the right technology for waste treatment and storage can be summed up like this;
The reality in any and all of these tanks is they will require significant investment; time, money, resources, operational impact and will become another piece of the plant's infrastructure. They also become another line item on the maintenance list that will affect the company's bottom line in some capacity. The money will get spent on capital investment in the tank itself and over the life of the tank in scheduled/routine maintenance costs. The decision on where and how to spend that money will be affected by the technology chosen ' a company will spend less in capital costs on a bolted, powder-coated-epoxy-steel tank but will eclipse that initial cost with maintenance (repair/recoating and eventual replacement) costs. Conversely, a company will spend more in capital costs on a bolted, glass-fused-to-steel tank but will achieve overall cost reduction in maintenance (minimal repair, no recoating or replacement) savings over the life of the tank.
The improvement in the plant's waste treatment process will provide peace of mind for regulatory compliance and a good name in the community, the storage tank used in that process is an integral part ' both economically and operationally. Let Southeastern Tank, Inc. help you select the right tank with the right coating with the right technology for your waste treatment application.
Picking a fluid tank must be easy. It's a tank that holds liquid. There are pros and cons to all kinds of tanks. And the only method to select the very best item is to consider those pros and cons against your requirements. Allow us check out two of the most preferred tanks, the epoxy-coated tank and the glass-fused-to-steel tank.
Epoxy-coated tank is specifically fit to the restrictions of liquid storage.
On receipt of the raw steel, it is cut out, formed as well as pierced in accordance with the layout specified by our layout workplace.
The sheet once eliminated and all the accessories to be coated are then cleaned up in acid and also based on fired blowing up in order to get rid of all traces of rust and also any type of contaminations.
Following this preparation, the components are after that coated with their epoxy defense. The covering is attained by electrostatic application of the customized epoxy powder complied with by polymerisation at 200 °C.
A topcoat of urethane, related to the exterior face of the sheet, ensures additional UV protection and offers a wide variety of colors.
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The greatest benefit to picking an epoxy tank is budget plan. If you are restricted in what you can spend or want to spend, these tanks are commonly the best selection as well as have a variety of applications. They are usually optimal for small capability tanks, also, due to the fact that they give a considerable cost advantage over various other products.
The greatest negative aspect to picking epoxy-coated tank is longevity. In lots of applications, the tank will certainly more than likely requirement to be changed in twenty years. For leachate tanks and wastewater tanks, the life expectancy can be much shorter.
Some utilities as well as companies have actually had bad experiences with epoxy-coated tank in the past. Nevertheless, in a lot more recent years, the innovation has actually evolved to consist of thicker steel, less infiltration points as well as a maximized screw pattern created to attend to some previous weak points as well as client problems. When it comes to their much shorter lifespan, this choice isn't constantly the most cost-efficient over the life of a tank
Integrating glass to steel is quickly coming to be the premier innovation in the tank industry today. This process, which entails home heating the steel to over degrees and afterwards using a covering of silica glass, develops an enamel surface that never ever requires to be repainted and also is suitable for the storage of alcohol consumption water, mass products, wastewater or perhaps bio-solids storage. This sort of tank is also described as Enamel Tanks, gfs tanks, or glass fused Bolted Steel Tanks.
Glass-fused-to-steel produces a nonporous obstacle perfect for the storage space of lots of different products since it is not impacted by liquids or vapors, controls undercutting that can be caused by rust as well as due to its sturdiness-- immune to effect and also abrasion. It is likewise a special deterrent to most usual graffiti since it can be conveniently eliminated and it never ever requires paint.
Glass-fused-to-steel (GFS) tanks have actually come to be exceptionally popular for their sturdiness as well as lengthy life. The fused layer is ideal for any kind of application but they are especially efficient at holding hostile fluids like wastewater and also landfill leachate, due to the fact that the finish holds up against the chemical attacks that can harm and deteriorate various other kinds of tanks. GFS tanks never require to be painted, as well as regardless of what is kept inside, they can be cleansed with a power washing machine and also call for extremely little upkeep. Like epoxy-coated tank, GFS tank tanks can likewise be increased to meet transforming demands in time.
The very first downside of GFS tanks may be cost. They can be a little bit much more pricey than epoxy tanks. Nonetheless, it deserves discovering the total expense of ownership over the life of the tank, as upkeep expenses are much lower with a GFS and also they do not need to be changed as usually.
GFS has the toughness and also flexibility of steel integrated with the deterioration resistance of glass, however with little of the usual brittleness of glass. This is due to the fact that as the steel cools complying with combination the glass is positioned under compression and continues to be under compression even when the steel flexes. Glass goes to its toughest under compression.
The ended up plate shows the attributes of a true composite product in which the fine glass matrix eliminates tensions as well as protects against split propagation.
We have a sample of glass magnified by 100 times under the light microscope.
If we take an also closer check out the glass/steel boundary we can see that the glass and also the steel have actually truly integrated together developing a highly keyed interface which makes for a very strong physical bond in between the two components.
Contrast this with a manufacturing facility applied epoxy layer at the same zoom and you can see exactly how striking the difference is. If you look very closely at the typical epoxy/steel border you will even see a gap in between the finishing and also the steel plainly revealing a point where there is no bonding at the epoxy/steel user interface which can be a potential resource of blistering.
In practice this indicates that Glass-Fused-to-Steel is much better able to withstand the rigours of the construction site and also supply a lengthy life even in rough and also chemical environments.
By comparison epoxy paint is a soft product which continues to heal for a long time after application, also when manufacturing facility applied. Running the edge of coin throughout the surface area will generally reveal its integral weak point. Terrific care has to be taken when taking care of epoxy coated sheets at the slightest scrape can supply a path for liquid to track along the steel/epoxy user interface enabling corrosion to progress unhindered.
Before exploring different tank choices, analyze your company' needs, budget plan and conformity demands. Tanks are constantly advancing, so it's important to get the most up-to-date information. The more details you can collect, the better. Once these specifications are detailed, we can aid you select the best materials and find an option that works for your demands.
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