32
Against such tank corrosion challenges,
traditional polymer paints and epoxy-based coatings have long been used as physical barriers to keep corrosion promoters such as water and oxygen away from steel substrates. This works until the paint is scratched, chipped, or breached and corrosion promoters enter the gap between the substrate and coating. Tank trucks and rail tank cars carrying
waste from fracking operations are particularly at risk of such damage, as the produced water regularly contains sand and other sediments. Such damage can trap water, oxygen and other corrosion promoters, allowing corrosion to spread. Stainless steel is one solution but is costly – six times the price of carbon steel or even more.
A NEW SOLUTION A new generation of anti-corrosion coatings - chemically bonded phosphate ceramics (CBPCs) – promise an alternative way of minimising tank damage, improving safety and extending tank life in the transport sector and beyond, while minimising maintenance and downtime. In contrast to traditional polymer coatings
GET YOUR COAT
CORROSION • A NEW APPROACH TO TANK COATINGS GIVES A CERAMIC FINISH TO PREVENT DAMAGE AND THE POTENTIAL FOR CORROSION TO SPREAD
THOUSANDS OF PRODUCTS carried every day in bulk in tank trucks, rail tank cars or tank containers can cause corrosion. Many chemicals are aggressive to carbon steel and some are similarly corrosive to stainless steel. Some refined products and even crude oil can cause corrosion in transport tanks as well as in storage tanks, holding tanks and process vessels.
With the growth of onshore oil production
in the US, through the exploitation of tight oil reserves, has come another problem for tank operators – highly corrosive brine. Unchecked corrosion of carbon steel tanks can lead to early replacement and maintenance and also poses a safety risk in terms of potential leaks, spills, and even fire and explosion.
that sit on top of the substrate, the new coating bonds through a chemical reaction with the substrate and slight surface oxidation actually improves the reaction, forming an alloy layer. This makes it impossible for corrosion promoters like oxygen and humidity to get behind the coating as they can with ordinary paints. The corrosion barrier is covered by a ceramic shell that resists corrosion, fire, water, abrasion, chemicals, and temperatures up to 400˚F (205˚C). Although traditional polymer coatings mechanically bond to substrates that have been extensively prepared, if gouged, moisture and oxygen will migrate under the coating’s film from all sides of the gouge. By contrast, the same damage to the ceramic-coated substrate will not spread corrosion because
CORRODED TANK INTERIORS (ABOVE) CAN QUICKLY AND SAFELY BE COATED WITH A CBPC TO REDUCE THE POTENTIAL FOR FURTHER DAMAGE THAT COULD PROVE COSTLY OR DANGEROUS
HCB MONTHLY | SEPTEMBER 2016
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84 |
Page 85 |
Page 86 |
Page 87 |
Page 88 |
Page 89 |
Page 90 |
Page 91 |
Page 92 |
Page 93 |
Page 94 |
Page 95 |
Page 96 |
Page 97 |
Page 98 |
Page 99 |
Page 100 |
Page 101 |
Page 102 |
Page 103 |
Page 104 |
Page 105 |
Page 106 |
Page 107 |
Page 108
