Glass Fused to Steel Tanks is the most common tank specification for CSTR biogas digester reactor tanks. In this article, we discuss their pros and cons.
Enamel tanks, GFS tanks (GFtS), and Glass Fused Bolted Steel (Porcelain Enameled) tanks are all terms used to describe this type of tank.
It is essential that all anaerobic digestion tanks must be extremely durable, which means they must be resistant to corrosion as well as impact and abrasion. These tanks have that characteristic but as in most things, their advantages come with a few disadvantages. Read on and find out what those pros and cons really are.
Undoubtedly, the apex of coating technology in the storage tank industry lies in glass-fused-to-steel technology. These tanks find extensive application in various sectors including bio-energy (especially CSTR biogas plants), municipal sewage, landfill leachate, and industrial wastewater treatment.
Selecting a liquid storage tank might seem straightforward. After all, it's a vessel for holding liquids. Is there truly a substantial difference?
The reality is that each type of tank boasts its own set of advantages and disadvantages. The key to choosing the optimal product lies in evaluating these pros and cons against your specific requirements.
Glass-fused steel, also known as enameled steel, represents an advanced technology offering long-term performance with minimal maintenance requirements.
These tanks stand out as the preferred material for biogas digesters due to their fusion of steel toughness with the corrosion resistance of glass. Moreover, they serve as excellent choices for storing potable water, wastewater, industrial chemicals, bio-digesters, sludge, and various dry bulk materials.
In a cutting-edge furnace, enamel frit (glass compounds) undergoes chemical fusion with steel sheets at exceptionally high temperatures (ranging between 800 and 1,000 degrees Celsius). This process generates an integrated, porcelain-like coating that is firmly bonded, chemically inert, and impermeable to liquids.
Suppliers tout these tanks as capable of withstanding a range of conditions, such as temperatures up to 140°F and pH levels between 3 and 11, without succumbing to corrosion.
Glass fused to steel liquid tanks combines the strength of steel with the exceptional corrosion resistance of glass, offering numerous advantages over traditional epoxy-coated or welded painted storage tanks, including:
1. Outstanding anti-corrosion properties.
2. Swift installation in the factory, coupled with high-quality design, production, and stringent quality control.
3. Safety and simplicity: Operators require minimal long-term training, and plant owners benefit from reduced maintenance, leading to less time spent by workers in elevated positions.
4. Minimal impact from local weather conditions on these tanks.
5. Low initial investment, especially pertinent for biogas digesters and industrial wastewater treatment projects.
6. Cost-effective maintenance and ease of repair.
7. Reduced life-cycle costs due to the enduring coating.
8. Flexibility for relocation, expansion, and repurposing.
9. Aesthetic appeal with various color options.
10. Simplified cleaning compared to unlined equipment.
11. Customization for specific applications with tailored tank designs.
Even stainless steel tanks, while normally an ideal material for these tanks, cannot withstand the high sulphur which may accumulate at the top rim of commercial digester tanks.
While Glass Fused To Steel Tanks offer numerous benefits, it's important to acknowledge some drawbacks that, although not extensive, are noteworthy:
1. Joint sealing is crucial at the points where the tank is bolted to the concrete base slab to prevent potential leaks.
2. Physical damage, like impacts from moving equipment or machinery, can lead to chipping of the glass coating at the impact site.
3. Concrete-based biogas tanks in Anaerobic Digestion Plants provide superior insulation compared to steel tanks, thereby avoiding the need for additional thermal insulation and associated costs.
4. When considering burial or partial burial, steel tanks might be less suited to withstand soil loads compared to reinforced concrete tanks.
5. Ensure that the purchased Glass Fused To Steel tank includes edge corrosion protection, as untreated panel edges may pose long-term issues in bolted steel tanks.
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Nevertheless, implementing excellent design, installation, and operational practices can prevent or mitigate these aforementioned issues effectively.
In moderate climates, digester tanks are typically insulated and enveloped with plastic-coated aluminum profile sheeting along their outer edges.
This practice serves the purpose of safeguarding the installed insulation and provides additional protection to the tanks, shielding them from accidental impact damage to the fused-to-glass enamel during their operational use.
While the benefits of GFS tanks are substantial, their most notable disadvantage is often the initial expense. Glass-lined tanks tend to be considerably pricier compared to epoxy tanks.
Consequently, some businesses might initially perceive these upfront costs as prohibitive. However, it's crucial to examine the total cost of ownership throughout the tank's lifespan, considering reduced maintenance expenses and longer-lasting durability offered by GFS tanks, which can result in less frequent replacements.
Engineers and industry experts worldwide are increasingly selecting glass-fused-to-steel tanks for their resilience in challenging conditions, ensuring decades of trouble-free operation. However, tanks employing this unique technology require strict adherence to quality standards, notably ISO certification, to ensure superior manufacturing and defect-free performance.
Well-manufactured porcelain-enameled tanks boast a lasting coating that eliminates the need for recoating.
Among various substrates for glass coating like steel, aluminum, cast iron, copper, and brass, steel is commonly used in porcelain-enameled tanks, chosen based on size requirements&#;larger tanks often necessitate a more durable steel grade.
It's imperative to procure tanks only from manufacturers holding ISO certification, indicating adherence to over 16 standard inspections before sale approval. Glass Fused to Steel tanks prove highly advantageous for containing potable, municipal, agricultural, and industrial fluids due to their minimal maintenance needs and inherent resistance to contamination.
Safety first. A quick and simple two-word phrase we&#;ve all heard countless times before. Whether we&#;re strapping on a helmet for a bike ride, buckling our seatbelts, or looking both ways before crossing the street, we&#;ve been taking preventative measures to ensure our safety, and the safety of others, since day one. Unfortunately, however, this isn&#;t always the case in above-ground storage tank repair.
According to the Chemical Safety Board (CSB), since , there have been over 60 fatalities due to explosions and fires caused by hot work repairs/maintenance on ASTs. In addition, the National Institute for Occupational Safety and Health (NIOSH) reports an additional 160 fatalities associated with confined space entry since .
Before starting any storage tank repair, it&#;s important to ask the right questions in order to be fully prepared for the task at hand. Below, we&#;ve outlined the nine most important safety-related questions to ask before starting the next repair on your AST.
This is the first question that should be answered on every storage tank repair. With 80% of all confined space fatalities attributed to a hazardous atmosphere, employees need to be aware of the hazards and risks associated with the particular chemical(s) the tank contained.
Although you may have come to fix only the tank, make sure first that there aren&#;t any additional hazards in your work area.
Lock out/tag out procedures are always a main concern of storage tank repair. However, is simply locking and tagging out a valve enough? Make sure the tank doesn&#;t need to be physically isolated before moving forward. If the tank does need physical isolation, do not proceed with repairs until it has been properly isolated.
When working in a confined space like a storage tank, proper air ventilation is crucial to ensuring a safe repair. As a rule of thumb, the American Petroleum Institute recommends a minimum of five air changes per hour to ensure suitable ventilation.
How stable is the roof? Are there any holes in the tank? The inspection report will answer questions like these, and provide valuable knowledge to your repairmen.
Make sure all parts of the tank (pontoons, floors, sumps, pipes, roof drains, etc.) are free of gas before starting any hot work. Remember, more than 60 deaths have been directly caused by hot work on storage tanks since .
Overexposure to lead is common in the industry and is a leading cause of workplace illness. Make sure you conduct a lab analysis to determine if lead is present, as lead &#;swab sticks&#; only have a threshold of detection near 500 ppm. Any detectable amount of lead triggers the OSHA Requirements.
To ensure roof safety, make sure a form of anti-rotation is in place and in working order. Be sure to verify that all legs have landed and remain vertical as well. For additional safety measures, you can also install roof supports on the shell.
No one plans for accidents to happen. That being said, when accidents do happen, you need to be prepared. Have a safety plan in place and make sure emergency services are available to help in the event something goes wrong.
With the health and safety of your employees on the line, it&#;s extremely important that you answer these questions before starting your next storage tank repair. For additional information regarding storage tank safety, please check out OSHA&#;s guide on Major Work Activities for Tank Cleaning Operations.
Stop the problem before it starts! Download our free tip sheet, &#;6 Signs Your Tank Needs Some TLC&#; and learn to identify the warning signs associated with a damaged storage tank.
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