Chemical Engineering December 2011 - 47

Engineering Practice
Why a tank's coatingapplication
process
makes all the difference
Preventing
Tank Corrosion
David Wheat
CST Storage
Tony Thill
CST Industries, Inc.
he interior surfaces of your storage
tanks are constantly at risk.
You undoubtedly walk past a tank
and do not give thought to what is
happening on the inside, but that is because
you trust the interior coating to
protect not only the storage vessel, but
also the product being stored from corrosion
that might occur on the tank.
Without a doubt, corrosion is the
principal enemy of a storage vessel. It
shortens a tank's lifespan incrementally
and increases the possibility of
contamination. Dry bulk chemicals
are often abrasive to the tank walls,
requiring a strong coating to resist
scratches and gouges, which expose
the steel to corrosion. All liquid products
- even water - are corrosive.
Unprotected steel can begin to corrode
in a matter of hours.
T
So coating the interior of a tank is
essential when it comes to protecting
a tank. Dry bulk materials require
hard, abrasion-resistant coatings that
are slick, ensuring that all material
passes out of the tank leaving minimal
residue. Liquids require strong, consistent
coatings that provide complete
coverage without thin or missed spots.
Choosing a tank with a high-quality
coating that has been tested and
proven to withstand these materials
means less maintenance over time and
less concern for you.
Variety in coatings
The quality of a coating and its resistance
to corrosion determines the
lifespan and quality of the tank. Many
FIGURE 1. Shown here is a glassfused-to-steel
storage tank including a
containment tank
different coatings are found on the
market today, including the common
epoxy, glass-fused-to-steel, high heat
coatings, cold weather coatings and
coatings designed to withstand high
levels of acidity or alkalinity.
The choice of one coating over another
should be made depending on
the product to be stored. Each product
has its own requirements and specifications.
Epoxy coatings are commonly
found in the tank industry. They are
generally tough and chemical resistant,
with excellent corrosion resistance.
Epoxy coatings can be applied
electrostatically, either as a powder or
a liquid. On the exterior, epoxy coatings
are typically combined with polyurethane
topcoats to provide protection
against environmental elements.
Glass-fused-to-steel coatings (Figure
1), which are commonly referred
to as porcelain enamel, are applied in
liquid slurry form to specialty steel
and fired in a furnace (Figure 2) at
1,500°F to create an inert coatings
that are very resistant to dry and liquid
chemicals and materials. They are
an excellent choice for certain applications
where an organic coating may
not be compatible with the material
being stored, and where a long service
life is desired.
Paint-based coatings are very common
in the industry. They are factory
applied for
factory-welded storage
FIGURE 2. In the typical
porcelain-enamel coating process,
a liquid slurry of glass
frit and proprietary chemicals
are applied in multiple coats to
cover the sheets and exposed
edges. A chemical bond is created
in the furnace where the
steel and glass coating meet
tanks and field applied in the case
of site-welded tanks. Though generally
inexpensive, they do not have the
service life that factory applied coatings
provide, and extreme care must
be taken to ensure the right environmental
conditions when site-applying
these materials to ensure uniformity
and integrity of the final coating.
Regardless of the type of coating used,
it is critical that the coating be suited
for its intended storage application.
The coating process is critical
While the market offers a variety of
coatings, the one true difference in
coatings lies in the application process.
Coatings themselves may have great
selling points and use advanced technology,
but if the coating is not applied
correctly, the tank wall will be left exposed
and vulnerable to corrosion.
The most consistent coating applications
are achieved at the factory
under electronically regulated and
environmentally controlled circumstances.
Taken one step further, the
most durable tank coatings also are
thermally cured at the factory. Some
tank manufacturers apply coatings
in the factory by hand and then allow
them to air-dry and cure with ambient
heat, which exposes the cure to environmental
factors such as dust and
humidity. Other manufacturers outsource
the coating process altogether.
An optimal coating solution is one that
is both applied and thermally cured in
controlled factory conditions, such as
glass-fused-to-steel processes, before
the tank is shipped and erected in the
field. Factory welded and bolted tanks
often offer this feature.
Field-welded and concrete tanks
receive their coatings onsite after the
CHEMICAL ENGINEERING WWW.CHE.COM DECEMBER 2011 47
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Chemical Engineering December 2011

Table of Contents for the Digital Edition of Chemical Engineering December 2011

Contents
Chemical Engineering December 2011 - Cover1
Chemical Engineering December 2011 - Cover2
Chemical Engineering December 2011 - Contents
Chemical Engineering December 2011 - 2
Chemical Engineering December 2011 - 3
Chemical Engineering December 2011 - 4
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