Anti-corrosion and heat-preservation composite structure of cargo oil tank deck and construction method

Abstract

The invention discloses a cargo oil tank deck anti-corrosion heat-preservation composite structure and a construction method, the composite structure comprises a composite layer and edge sealing strips arranged on the periphery of the composite layer, and the composite layer comprises an anti-corrosion primer layer, a water-based heat-preservation layer, a grating plate, an oily heat-preservation layer and a finish paint layer which are sequentially arranged from inside to outside; the anti-corrosion primer layer is coated on the deck base material; the water-based heat preservation layer is coated on the anti-corrosion primer layer and is filled among the pores of the grating plate; the bottom surface of the grating plate clings to the top surface of the anti-corrosion primer layer; the construction method comprises the steps of deck base material surface pretreatment; spraying anti-corrosion primer; battens are arranged in a surrounding mode, and water-based heat preservation coating is poured; laying a grating plate; pouring an oily thermal insulation coating; supplementing an oily thermal insulation coating; spraying finish paint; the battens are dismantled; carrying out edge sealing treatment and the like. According to the composite structure, heat loss is remarkably reduced, the deck operation environment is improved, the durability is improved, the requirements of high temperature, high stress and marine environment are met, and an efficient and reliable anti-corrosion heat preservation solution is provided for the cargo oil tank deck.

Description

Technical Field

[0001] The present invention belongs to the technical field of anti-corrosion and thermal insulation construction of marine oil and gas production facilities, and in particular relates to an anti-corrosion and thermal insulation composite structure for a cargo oil tank deck and a construction method thereof. Background Art

[0002] Cargo tanks are widely used on floating production storage and offloading (FPSO) vessels and oil tankers to store and transport crude oil. To maintain the fluidity of the crude oil, the tanks must be heated to approximately 70°C, causing surface temperatures on the main deck to reach 50°C or higher. As an operational area, the deck is subject to frequent foot traffic, equipment impact, and mechanical stress. Therefore, the insulation layer must possess excellent thermal insulation, corrosion resistance, and mechanical stress resistance to minimize heat loss, improve the operational environment, and ensure durability.

[0003] In existing technology, the main deck of the cargo oil tank is mostly protected against corrosion using epoxy resin or polyurea coatings, but these coatings lack insulation, resulting in a heat loss of approximately 20% to 30%, increasing energy consumption. Conventional insulation materials are not resistant to being trampled, crushed, or mechanically impacted, are prone to deformation or peeling, and require additional anti-corrosion coatings, increasing construction complexity and cost. While adding a metal protective layer can increase strength, it can easily cause delamination or electrochemical corrosion, resulting in poor durability. Water-based insulation coatings have low thermal conductivity but insufficient weather resistance and toughness; oil-based insulation coatings have better toughness but limited insulation efficiency. A single material cannot meet the combined needs of high-temperature, high-stress working conditions. A high-temperature deck surface worsens the working environment, increases the risk of burns and the effects of heat radiation, and reduces efficiency. Temporary insulation pads or cooling equipment are costly and have limited effectiveness, making it difficult to address energy waste and environmental issues.

[0004] The above problems lead to defects in the existing technology, including: (1) conventional insulation materials are not resistant to mechanical stress and are easily damaged; (2) the insulation layer lacks anti-corrosion function and the construction is complicated; (3) the protective layer and the insulation layer are not firmly bonded and are prone to delamination or corrosion; (4) it is difficult for a single material to take into account both insulation and mechanical properties; (5) there is serious energy waste and a harsh working environment.

[0005] In view of the above problems, there is an urgent need for a deck insulation layer composite structure and a construction method thereof that has the advantages of thermal insulation, corrosion resistance and mechanical stress resistance. Summary of the Invention

[0006] The present invention is proposed to solve the problems in the prior art of severe heat loss of the insulation layer, lack of mechanical stress resistance, lack of anti-corrosion function and complex construction. Its purpose is to provide an anti-corrosion and thermal insulation composite structure for the cargo oil tank deck and a construction method.

[0007] The present invention is achieved through the following technical solutions:

[0008] A cargo oil tank deck anti-corrosion and thermal insulation composite structure, comprising a composite layer and edge banding strips arranged around the composite layer, wherein the composite layer comprises an anti-corrosion primer layer, a water-based thermal insulation layer, a grating plate, an oil-based thermal insulation layer and a topcoat layer arranged in sequence from the inside to the outside; the anti-corrosion primer layer is applied on a deck substrate; the water-based thermal insulation layer is applied on the anti-corrosion primer layer and fills the pores of the grating plate; the bottom surface of the grating plate is in close contact with the top surface of the anti-corrosion primer layer.

[0009] In the above technical solution, the thickness of the anticorrosive primer layer is 100 μm to 150 μm; the anticorrosive primer layer is obtained by applying an anticorrosive primer on a deck substrate; the anticorrosive primer is prepared from modified epoxy resin or phenolic epoxy resin.

[0010] In the above technical solution, the thickness of the water-based thermal insulation layer is 2mm to 3mm; the water-based thermal insulation layer adopts nano-aerogel water-based thermal insulation coating, which is based on water-based acrylic resin and is mixed with nano-aerogel or microporous ceramic filler.

[0011] In the above technical solution, the grid plate is a high-strength fiberglass grid plate made of vinyl ester resin-based glass fiber reinforced material; the thickness of the grid plate is 3.5mm to 4.5mm, and the pore size of the grid plate is preferably 38×38mm.

[0012] In the above technical solution, the oily insulation layer is coated on the grating plate and embedded in the pores of the grating plate, and the topcoat side of the oily insulation layer is flat; the oily insulation layer adopts high-temperature resistant fiber oily insulation coating, and the high-temperature resistant fiber oily insulation coating is based on oily polyurethane resin and mixed with ceramic fiber; the thickness of the oily insulation layer is 2mm~3mm.

[0013] In the above technical solution, the topcoat layer is coated on the surface of the oily insulation layer; the thickness of the topcoat layer is 50μm to 80μm; the topcoat layer adopts self-repairing wear-resistant topcoat, and the self-repairing wear-resistant topcoat is based on polyurethane resin and added with self-repairing microcapsules.

[0014] In the above technical solution, the edge banding strip is bonded to the composite layer around by epoxy modified adhesive; the edge banding strip is a glass fiber reinforced edge banding strip, and the glass fiber reinforced edge banding strip is made of vinyl ester resin-based glass fiber reinforced material, and the width of the edge banding strip is consistent with the thickness of the composite layer.

[0015] In the above technical solution, the composite structure also includes a continuous protective layer, which covers the top surface of the edge banding strip, the side surface of the edge banding strip and the extended area of ​​the deck substrate; the extended area of ​​the deck substrate is an area at a vertical distance of 5mm to 10mm from the edge of the composite structure; the continuous protective layer is formed by spraying topcoat.

[0016] In the above technical solution, the composite structure is a flat layered structure; the thickness of the composite structure is 3.0mm to 3.5mm; the composite structure has a temperature resistance of 120°C and a mechanical impact strength of ≥50J / cm 2 , heat loss rate <10%.

[0017] A construction method for a cargo oil tank deck anticorrosion and thermal insulation composite structure comprises the following steps:

[0018] (I) Pre-treat the deck substrate surface in the cargo oil tank main deck construction area;

[0019] (II) Spraying anti-corrosion primer;

[0020] spraying an anti-corrosion primer on the surface of the deck substrate pretreated in step (I), and forming an anti-corrosion primer layer after the anti-corrosion primer is cured;

[0021] (III) Enclose with slats and pour water-based thermal insulation coating

[0022] Set up slats around the construction area to form a closed enclosure, pour water-based thermal insulation paint into the closed enclosure, and spread it flat to form a water-based thermal insulation layer;

[0023] (IV) Laying the grating

[0024] When the water-based thermal insulation paint is self-leveling and still fluid, lay the grating plate, ensuring that the bottom surface of the grating plate is in contact with the anti-corrosion primer layer, and there is no water-based thermal insulation paint between the bottom surface of the grating plate and the anti-corrosion primer layer;

[0025] (V) Pouring oil-based thermal insulation coating

[0026] After the water-based thermal insulation coating is completely cured, pour the oil-based thermal insulation coating into the pores of the grid plate to fill the pores of the grid plate;

[0027] (VI) Supplement oil-based thermal insulation coating

[0028] After the oily thermal insulation coating poured in step (V) is solidified and within the maximum recoating interval, additional oily thermal insulation coating is poured to form a final oily thermal insulation layer after solidification;

[0029] (VII) Spraying topcoat

[0030] Spray topcoat on the surface of the oily insulation layer, and form a topcoat layer after the topcoat is cured;

[0031] (VIII) Removal of lath;

[0032] (Ⅸ) Edge banding

[0033] Clean the edges of the composite structure, insert the edge banding and spray the topcoat to extend the coverage to form a continuous protective layer.

[0034] The beneficial effects of the present invention are:

[0035] The present invention provides a cargo tank deck anti-corrosion and thermal insulation composite structure and construction method suitable for the main deck of a large oil tanker cargo tank. By innovating the material system and construction process, the present invention solves the problems of energy waste, harsh operating environment and insufficient durability, and provides an efficient and reliable solution for the FPSO cargo tank deck. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is a structural schematic diagram of the present invention.

[0037] in:

[0038] 1. Deck base material; 2. Anti-corrosion primer layer; 3. Water-based insulation layer; 4. Grille plate; 5. Oil-based insulation layer; 6. Topcoat layer;

[0039] For ordinary technicians in this field, other relevant drawings can be obtained based on the above drawings without any creative work. DETAILED DESCRIPTION

[0040] In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be further described below with reference to the accompanying drawings and through specific implementation methods.

[0041] like Figure 1 As shown, a cargo oil tank deck anti-corrosion and thermal insulation composite structure includes a composite layer and edge banding strips arranged around the composite layer; the composite layer includes an anti-corrosion primer layer 2, a water-based thermal insulation layer 3, a grille plate 4, an oil-based thermal insulation layer 5 and a topcoat layer 6 arranged in sequence from the inside to the outside.

[0042] The anticorrosive primer layer 2 is obtained by applying an anticorrosive primer to the deck substrate 1; the thickness of the anticorrosive primer layer 2 is 100 μm to 150 μm; the anticorrosive primer is a high-temperature-resistant anticorrosive primer; the anticorrosive primer comprises a resin, pigments, fillers, additives, and a diluent, and the resin is a modified epoxy resin or a phenolic epoxy resin; the anticorrosive primer layer 2 has a temperature resistance of up to 120°C, an adhesion of ≥5 MPa, and excellent oil resistance and seawater corrosion resistance; the anticorrosive primer layer 2 is applied to the deck substrate to form a basic anticorrosive barrier, resisting high temperatures and chemical erosion, and providing a stable adhesion foundation for subsequent layers;

[0043] The anticorrosive primers used in this application are commercially available products, specifically: MC-STE-2 modified epoxy paint or MC-NE-1 phenolic epoxy paint produced by CNOOC Changzhou Coatings Chemical Research Institute Co., Ltd.;

[0044] The water-based thermal insulation layer 3 is applied on the anti-corrosion primer layer 2 and fills the pores between the grid plates 4. The water-based thermal insulation layer 3 uses a nano-aerogel water-based thermal insulation coating, which is based on a water-based acrylic resin and is mixed with nano-aerogel or microporous ceramic fillers. The thickness of the water-based thermal insulation layer 3 is 2 mm to 3 mm, and the thermal conductivity of the water-based thermal insulation layer 3 is ≤0.03 W / m·K. The water-based thermal insulation layer 3 provides efficient thermal insulation, and the optimized formula improves leveling and rapid curing, thereby reducing construction defects.

[0045] The nano-aerogel water-based thermal insulation coating selected in this application is a commercially available product, specifically: MC-HSC-1 water-based thermal insulation coating produced by CNOOC Changzhou Coatings Chemical Research Institute Co., Ltd.;

[0046] The bottom surface of the grid plate 4 is in close contact with the top surface of the anti-corrosion primer layer 2; the grid plate 4 is a high-strength fiberglass grid plate made of vinyl ester resin-based glass fiber reinforced material; the thickness of the grid plate 4 is 3.5mm to 4.5mm, and the pore size of the grid plate 4 is 28mm×28mm to 48mm×48mm, preferably 38mm×38mm; the tensile strength of the grid plate 4 is ≥300MPa, and the impact strength is ≥50J / cm 2 ; The grid plate 4 serves as a structural skeleton, providing the main mechanical support, withstanding frequent trampling and crushing by heavy equipment, while resisting corrosion in the marine environment; the grid plate 4 selected in this application is a commercially available product;

[0047] The oily thermal insulation layer 5 is coated on the grid plate 4 and embedded in the pores of the grid plate 4. The topcoat side of the oily thermal insulation layer 5 is flat. The thickness of the oily thermal insulation layer 5 is 0.5 mm to 1 mm.

[0048] The oily insulation layer 5 is made of a high-temperature resistant fiber oily insulation coating, which is based on an oily polyurethane resin and mixed with ceramic fibers. The thermal conductivity of the oily insulation layer 5 is ≤0.05W / m·K, the thickness of the oily insulation layer 5 is 2mm-3mm, and the elongation at break is ≥5%. The oily insulation layer 5 provides additional insulation and has excellent toughness and weather resistance, protecting the fiberglass grating from mechanical stress and damage in high temperature and salt spray environments.

[0049] The high-temperature resistant fiber oil-based thermal insulation coating selected in this application is a commercially available product, specifically: MC-HSC-2 oil-based thermal insulation coating produced by CNOOC Changzhou Coatings Chemical Research Institute Co., Ltd.;

[0050] The topcoat layer 6 is applied to the surface of the oily thermal insulation layer 5; the thickness of the topcoat layer 6 is 50 μm to 80 μm; the topcoat layer 6 is a self-repairing wear-resistant topcoat, which is based on polyurethane resin and contains self-repairing microcapsules; the topcoat layer 6 is resistant to trampling friction and mechanical impact, supports local repair, provides surface protection and color recognition functions, has strong weather resistance, and is suitable for exposure to ultraviolet rays and salt spray in marine environments;

[0051] The self-repairing wear-resistant topcoat selected in this application is a commercially available product, specifically: AMP-WASH 100 two-component chromium-free self-repairing coating produced by Autonomic Materials Inc;

[0052] The edge banding is bonded to the composite layer around the edge by an epoxy modified adhesive; the edge banding is a glass fiber reinforced edge banding, which is made of a vinyl ester resin-based glass fiber reinforced material, and the thickness of the edge banding is consistent with the thickness of the composite layer; the width of the edge banding (material thickness) is 15 to 50 mm;

[0053] The composite structure further includes a continuous protective layer, which covers the top surface of the edge banding, the side surface of the edge banding, and the extended area of ​​the deck substrate;

[0054] The deck substrate extension area is an area 5mm to 10mm vertically away from the edge of the composite structure;

[0055] The continuous protective layer is formed by spraying a topcoat;

[0056] The composite structure is formed into an integrated structure through edge sealing treatment, and the edge sealing treatment includes embedding prefabricated glass fiber reinforced edge banding strips and extending them to cover with wear-resistant topcoat to prevent corrosion under the insulation layer.

[0057] The composite structure is a flat layered structure; the thickness of the composite structure is 4.0mm to 5.0mm; the composite structure has a temperature resistance of 120°C and a mechanical impact strength of ≥50J / cm 2 The heat loss rate is less than 10%, meeting the high temperature and high stress working conditions of FPSO and oil tanker cargo tank decks.

[0058] The various layers of the composite structure work together to achieve efficient thermal insulation, excellent corrosion resistance, and resistance to trampling, crushing, and mechanical stress. Through material optimization, interlayer bonding reinforcement, and improved construction techniques, the composite structure significantly reduces energy consumption, improves the working environment, and enhances durability, providing an efficient, reliable, and economical anti-corrosion and thermal insulation solution for cargo tank decks.

[0059] A construction method for a cargo oil tank deck anticorrosion and thermal insulation composite structure comprises the following steps:

[0060] (I) Pretreatment of deck substrate surface

[0061] First, determine the area on the cargo oil tank main deck to be constructed;

[0062] Then, start pre-treating the deck substrate surface in the construction area;

[0063] The pretreatment specifically includes: first removing oil, rust and impurities from the deck substrate surface, then using sandblasting or power tools to treat the deck substrate surface to meet the requirements of anti-corrosion primer application and ensure that the substrate is clean and flat; the anti-corrosion primer application requirements are rust removal grade Sa2.5 and a roughness of 40μm to 70μm;

[0064] The inspection points for pretreatment are: check the cleanliness and roughness of the deck substrate surface, measure it with a roughness meter, and ensure that it meets the requirements for anti-corrosion primer application;

[0065] The stopping point of pretreatment is: if the surface treatment is unqualified, construction will be suspended and re-processed until it meets the standards;

[0066] (II) Spraying anti-corrosion primer;

[0067] Using high-pressure airless spraying equipment, the anti-corrosion primer is evenly sprayed on the surface of the deck substrate pretreated in step (I), and the anti-corrosion primer is cured to form an anti-corrosion primer layer;

[0068] The curing condition of the anticorrosive primer is curing at room temperature for 24h to 48h;

[0069] The thickness of the anticorrosive primer layer is 100 μm to 150 μm, and the adhesion is ≥ 5 MPa;

[0070] The anticorrosive primer is a modified epoxy resin or a silane modified resin;

[0071] Inspection points for spraying anti-corrosion primer are: using a dry film thickness gauge to check the primer thickness to ensure it is uniform and within the range of 100μm to 150μm; using the cross-hatch method to test adhesion to confirm that it is ≥5MPa;

[0072] The stopping point for spraying anticorrosive primer is: after spraying, the primer is cured at room temperature for 24 to 48 hours, and the construction is suspended until it is completely cured;

[0073] (III) Enclose with slats and pour water-based thermal insulation coating

[0074] Laths are set up around the construction area to form a closed enclosure, and a water-based thermal insulation coating is poured into the closed enclosure and flattened to form a water-based thermal insulation layer; the water-based thermal insulation coating is a water-based acrylic resin doped with nano-aerogel or microporous ceramic filler, and the solid content of the water-based thermal insulation coating is 50% to 55%;

[0075] The height of the slats is determined according to the designed thickness of the water-based insulation layer. The slats are fastened with sealant or fixing clamps to prevent the coating from leaking. The amount of water-based insulation coating is calculated according to the construction area, grid plate size, water-based insulation layer thickness and solid content of the water-based insulation coating. Pour the water-based insulation coating and use a spatula to initially flatten it to ensure uniform dispersion to form a water-based insulation layer.

[0076] The inspection points for installing slats / pouring water-based thermal insulation coatings are: checking the fixation and sealing of the slats to ensure there is no risk of leakage; measuring the amount of coating used to confirm that it is consistent with the calculated value.

[0077] The stopping point for laying slats / pouring water-based thermal insulation coating is: if the slats are not sealed tightly or the coating dosage deviation is >5%, suspend construction, adjust the slats or recalculate the dosage.

[0078] (IV) Laying the grating

[0079] When the water-based thermal insulation coating is self-leveling and still fluid (30 to 60 minutes after pouring), lay the high-strength fiberglass grating; use a wooden hammer to tap the grating to make it embedded in the water-based thermal insulation coating layer and in direct contact with the anti-corrosion primer layer, ensuring that there is no water-based thermal insulation coating residue between the bottom surface of the grating and the anti-corrosion primer layer to prevent collapse;

[0080] Inspection points for laying grating plates are: check the contact surface between the grating plate and the anti-corrosion primer layer to confirm that there is no residual water-based thermal insulation paint; measure the levelness and embedding depth of the grating plate to ensure that it is consistent with the designed thickness;

[0081] The stopping point for laying the grating plate is: if the grating plate does not fully contact the anti-corrosion primer layer or is embedded unevenly, suspend construction and readjust or tap until it is qualified;

[0082] (V) Pouring oil-based thermal insulation coating

[0083] Calculate the amount of oil-based thermal insulation coating based on the size of the FRP grating, the designed thickness of the oil-based thermal insulation layer, and the solid content of the oil-based thermal insulation coating. After the water-based thermal insulation coating is completely cured, pour the oil-based thermal insulation coating into the pores of the grating and use a spatula to spread it flat to fill the pores of the grating.

[0084] The oily thermal insulation coating is an oily polyurethane resin mixed with ceramic fibers, and the solid content of the oily thermal insulation coating is 60% to 65%;

[0085] Inspection points for pouring oil-based thermal insulation coatings are: check the amount of coating used and the uniformity of paving to ensure that the pores are completely filled; measure the flatness of the coating surface, with a deviation of <0.5mm;

[0086] The stopping point for pouring oil-based thermal insulation coating is: if the pores are not filled or the surface is uneven, suspend construction and add coating or re-spread;

[0087] (VI) Supplement oil-based thermal insulation coating

[0088] After the oily thermal insulation coating poured in step (V) is cured and within the maximum recoating interval, additional oily thermal insulation coating is poured to fill the depressions in the grid plate pores caused by curing shrinkage, ensuring that the overall insulation structure is flat and the thickness of the oily thermal insulation layer meets the design requirements, and forming the final oily thermal insulation layer after curing;

[0089] The curing time of the oil-based thermal insulation coating is related to the thickness and the construction environment, and is generally 24 hours. The curing of the oil-based thermal insulation coating is verified by a test method to determine whether it is completely cured. The test method is as follows: a cotton cloth soaked in acetone is gently wiped on the coating surface. A completely cured coating will not be dissolved or softened, while an uncured coating will transfer to the cotton cloth.

[0090] The maximum recoating interval is 3 days;

[0091] The thickness of the additional pouring oil-based thermal insulation coating is 0.5mm to 1mm;

[0092] The solid content of the oily thermal insulation coating is 60% to 65%;

[0093] The inspection points for supplementary oil-based thermal insulation coating are: after the supplementary oil-based thermal insulation coating is completely cured, use a laser level to check the surface flatness to ensure that the deviation is <0.3mm; measure the thickness of the total insulation layer to confirm that it meets the design requirements.

[0094] The stopping point for replenishing oil-based thermal insulation paint is: if the surface depression is not filled or the thickness is insufficient, suspend construction and replenish the coating until it meets the standard.

[0095] (VII) Spraying topcoat

[0096] After the oil-based thermal insulation coating is completely cured, use high-pressure airless spray equipment to evenly spray the wear-resistant topcoat on the surface of the oil-based thermal insulation layer. After the topcoat is cured, a topcoat layer is formed.

[0097] The thickness of the topcoat layer is 50 μm to 80 μm;

[0098] The topcoat is a polyurethane-based wear-resistant topcoat doped with self-repairing microcapsules;

[0099] Inspection points for spraying topcoat are: using a dry film thickness gauge to check the topcoat thickness to ensure it is uniform and within the range of 50μm to 80μm; conducting abrasion resistance tests to confirm that the performance meets the standards;

[0100] The stopping point for spraying topcoat is: after spraying, the topcoat is cured at room temperature for 12 to 24 hours, and the construction is suspended until the topcoat is completely cured (no stickiness on the surface);

[0101] (VIII) Removal of laths

[0102] After the topcoat is completely cured, remove the slats and check the surface flatness, thickness and appearance of the composite structure to ensure that it meets the design requirements;

[0103] Inspection points for removed slats are: checking overall structural integrity and color uniformity, measuring total thickness to ensure there are no cracks, bubbles or peeling;

[0104] The stopping point for strip removal is: if coating defects are found (such as cracks or thickness deviation >5%), the acceptance inspection shall be suspended and repairs or rework shall be carried out until the coating is qualified;

[0105] (Ⅸ) Edge banding

[0106] Clean the edges of the composite structure, insert the edge banding strips and spray wear-resistant topcoat to extend the coverage to form an integrated structure.

[0107] To prevent corrosion under the insulation layer, the edge sealing process adopts a comprehensive edge sealing process that combines prefabricated fiberglass edge banding strips with wear-resistant topcoat extension coverage. The edge sealing process specifically includes the following steps:

[0108] (Ⅸ-ⅰ) Edge cleaning

[0109] After removing the lath, use compressed air and a brush to clean the edges of the composite structure and the surrounding deck substrate extension area to remove dust and impurities;

[0110] The peripheral deck substrate extension area is a range of 5mm to 10mm vertical distance from the edge of the composite structure;

[0111] Inspection points for edge banding are: confirming that the edges and extended areas of the composite structure are clean and free of residue;

[0112] The stopping point of edge sealing treatment is: if there are impurities, clean it again until it is qualified;

[0113] (Ⅸ-ⅱ) Install prefabricated fiberglass edge banding

[0114] The edge banding is embedded into the edge of the composite structure through epoxy modified adhesive to form a structural connection;

[0115] Use prefabricated fiberglass reinforced edge banding, apply epoxy modified adhesive, and embed it into the edge of the composite structure. The edge banding should cover the anti-corrosion primer layer to the anti-corrosion primer layer, and the edge banding should be seamlessly connected to the side wall of the grating plate. Use a clamping tool to compact the edge banding, squeeze out the excess adhesive and scrape it off, and completely cure it at room temperature to form a structural connection.

[0116] The edge sealing adopts prefabricated glass fiber reinforced edge sealing strips;

[0117] The solid content of the epoxy modified adhesive is 65% to 75%;

[0118] The inspection points for installing prefabricated fiberglass edge banding are: check the flatness of the edge banding, the bonding strength, and whether there is any looseness or gap;

[0119] The stopping points for installing prefabricated fiberglass edge banding are: if the edge banding is uneven or not firmly bonded, reinstall it or add adhesive;

[0120] (Ⅸ-ⅲ) Spraying topcoat to extend coverage

[0121] Clean the edge banding surface and the extended area of ​​the deck substrate, spray the topcoat to cover the top of the edge banding and the extended area of ​​the deck substrate, and form a continuous protective layer after complete curing at room temperature. The thickness of the continuous protective layer is 50μm to 80μm;

[0122] Inspection points for extended coverage of spray topcoat are: confirming topcoat thickness, checking coating continuity and smooth transition;

[0123] The stopping points for extended coverage of spray topcoat are: if the coating is discontinuous or the thickness is unacceptable, re-spray;

[0124] (Ⅸ-ⅳ) Final Inspection

[0125] Check the total thickness and sealing of the edge sealing area to confirm that the edge sealing strip is integrated with the composite structure and there are no cracks, bubbles or leakage risks;

[0126] The final inspection points are: check the appearance and sealing of the edge sealing area, and check whether there is any color difference or delamination;

[0127] The stopping point of the final inspection is: if defects are found, they will be repaired until they are qualified.

[0128] The construction method is applicable to the main deck of a cargo oil tanker of a large oil tanker. The composite structure forms an insulation layer under high temperature, high stress and marine environment, and the surface temperature of the insulation layer is lower than the temperature of the deck substrate, thereby reducing heat loss and improving the working environment.

[0129] The cargo oil tank deck anticorrosive and heat-insulating composite structure of the present invention is suitable for a floating production storage and offloading (FPSO) device and a cargo oil tank main deck of an oil tanker.

[0130] Example 1

[0131] The cargo tank temperature of a tanker is 71℃~73℃, the deck surface temperature is 48℃~53℃, the ambient temperature is 25℃~28℃, and the deck insulation construction area is 1200m 2 ;

[0132] The cargo oil tank deck anticorrosive thermal insulation composite structure comprises, from the inside (deck substrate side) to the outside, an anticorrosive primer layer 2, a water-based thermal insulation layer 3, a grating plate 4, an oil-based thermal insulation layer 5 and a topcoat layer 6.

[0133] The specific preparation process of the cargo oil tank deck anti-corrosion and thermal insulation composite structure is as follows:

[0134] (I) Pretreatment of deck substrate surface

[0135] Remove oil stains, rust and impurities from the construction area of ​​the main deck of the cargo oil tank of a large oil tanker, and use sandblasting to Sa2.5 level with a roughness of 40μm to 70μm to ensure the base material is clean;

[0136] (II) Spraying anti-corrosion primer;

[0137] Use high-pressure airless spray equipment to spray phenolic epoxy resin primer with a dry film thickness of 120μm and cure at room temperature for 24h;

[0138] (III) Enclose with slats and pour water-based thermal insulation coating

[0139] Set the slats to 3mm in height and secure with sealant to prevent leakage. 2 Based on the construction area, grid porosity of 80%, water-based insulation thickness of 2.5mm, and volume solid content of 52%, the amount of water-based insulation coating required is calculated to be 4615.4L, which is spread evenly with a spatula.

[0140] (IV) Laying the grating

[0141] 40 minutes after pouring the water-based thermal insulation coating, after the water-based thermal insulation coating has completed self-leveling, lay the vinyl ester resin-based glass fiber reinforced grating plate. The thickness of the grating plate is 4mm. Use a wooden hammer to tap it to ensure that it is in contact with the primer and there is no insulation coating on the grating plate.

[0142] (V) Pouring oil-based thermal insulation coating

[0143] After the water-based thermal insulation coating is cured for 48 hours, press 1200m 2 Based on the construction area, grid porosity of 80%, thickness of 1.5mm, and solid content of 64%, the amount of oil-based thermal insulation paint used is 2250L, which is smoothed and filled with pores;

[0144] (VI) Supplement oil-based thermal insulation coating

[0145] After the oil-based thermal insulation coating poured in step (V) is cured for 24 hours, an additional coat of oil-based thermal insulation coating is applied with a thickness of 0.8 mm to fill the shrinkage depressions, and the total thermal insulation thickness is 3.3 mm;

[0146] (VII) Spraying topcoat

[0147] After the oil-based thermal insulation coating is cured for 48 hours, spray the wear-resistant topcoat with a thickness of 60μm and cure for 12 hours;

[0148] (VIII) Removal of laths

[0149] Remove the slats and check the uniformity of the total thickness of the composite structure to ensure there are no cracks, bubbles or other coating defects;

[0150] (Ⅸ) Edge banding

[0151] (Ⅸ-ⅰ) Edge cleaning

[0152] Use compressed air and a brush to clean the edges of the composite structure and the area extending 10mm from the surrounding deck substrate to remove dust and impurities;

[0153] (Ⅸ-ⅱ) Install prefabricated fiberglass edge banding

[0154] Select prefabricated fiberglass-reinforced edge banding (10mm wide, 3.3mm thick, cut to length based on the edge), apply epoxy-modified adhesive, and fit it to the edge of the composite structure. Apply primer to the oil-based thermal insulation coating layer to ensure a seamless connection with the grating. Use a clamping tool to compact the adhesive, squeeze out and scrape off any excess adhesive, and cure at room temperature for 24 hours.

[0155] (Ⅸ-ⅲ) Spraying topcoat to extend coverage

[0156] Clean the edge banding surface and the 10mm extension area of ​​the deck substrate, spray the base wear-resistant topcoat with a thickness of 60μm, covering the top of the edge banding and the extension area, and cure at room temperature for 12 hours;

[0157] (Ⅸ-ⅳ) Final Inspection

[0158] Check the total thickness and sealing of the edge banding area to confirm that the edge banding is integrated with the composite structure and there are no cracks, bubbles or leakage hazards.

[0159] In this embodiment, by optimizing the construction process, 2 A composite insulation structure with a total thickness of approximately 3.3mm is formed on the main deck of the cargo oil tanker of a large oil tanker. The surface temperature of the insulation layer is <35°C, which greatly improves the working environment of the main deck of the oil tanker, saves 21% of heating energy, and meets the energy-saving and consumption-reduction needs of the oil tanker.

[0160] The applicant declares that the above is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention fall within the scope of protection and disclosure of the present invention.

Claims

1. A cargo oil tank deck anticorrosion and thermal insulation composite structure, characterized by: The composite structure comprises a composite layer and edge banding strips arranged around the composite layer, wherein the composite layer comprises an anti-corrosion primer layer (2), a water-based thermal insulation layer (3), a grille plate (4), an oil-based thermal insulation layer (5) and a topcoat layer (6) arranged in sequence from the inside to the outside; the anti-corrosion primer layer (2) is coated on the deck substrate (1); the water-based thermal insulation layer (3) is coated on the anti-corrosion primer layer (2) and fills the pores of the grille plate (4); the bottom surface of the grille plate (4) is in close contact with the top surface of the anti-corrosion primer layer (2).

2. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The thickness of the anticorrosive primer layer (2) is 100 μm to 150 μm; the anticorrosive primer layer (2) is obtained by coating an anticorrosive primer on a deck substrate (1); the anticorrosive primer is prepared from a modified epoxy resin or a phenolic epoxy resin.

3. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The thickness of the water-based thermal insulation layer (3) is 2 mm to 3 mm; the water-based thermal insulation layer (3) adopts a nano-aerogel water-based thermal insulation coating, which uses a water-based acrylic resin as a base material and is mixed with nano-aerogel or microporous ceramic filler.

4. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The grid plate (4) is a glass fiber reinforced plastic grid plate.

5. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The oily thermal insulation layer (5) is coated on the grid plate (4) and embedded in the pores of the grid plate (4), and the topcoat side of the oily thermal insulation layer (5) is flat; the oily thermal insulation layer (5) adopts a high-temperature resistant fiber oily thermal insulation coating, and the high-temperature resistant fiber oily thermal insulation coating uses an oily polyurethane resin as a base material and is mixed with ceramic fiber; the thickness of the oily thermal insulation layer (5) is 2mm to 3mm.

6. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The topcoat layer (6) is coated on the surface of the oily thermal insulation layer (5); the thickness of the topcoat layer (6) is 50 μm to 80 μm; the topcoat layer (6) adopts a self-repairing wear-resistant topcoat, and the self-repairing wear-resistant topcoat uses polyurethane resin as a base material and is mixed with self-repairing microcapsules.

7. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The edge banding is bonded to the composite layer around by epoxy modified adhesive; the edge banding is a glass fiber reinforced edge banding, which is made of vinyl ester resin-based glass fiber reinforced material, and the width of the edge banding is consistent with the thickness of the composite layer.

8. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The composite structure also includes a continuous protective layer, which covers the top surface of the edge banding strip, the side surface of the edge banding strip and the extended area of ​​the deck substrate; the extended area of ​​the deck substrate is an area 5mm to 10mm vertically away from the edge of the composite structure; the continuous protective layer is formed by spraying topcoat.

9. The cargo oil tank deck anticorrosion and thermal insulation composite structure according to claim 1, characterized in that: The composite structure is a flat layered structure; the thickness of the composite structure is 4.0mm to 5.0mm; the composite structure has a temperature resistance of 120°C and a mechanical impact strength of ≥50J / cm 2 , heat loss rate <10%.

10. A construction method for the cargo oil tank deck anticorrosion and thermal insulation composite structure according to any one of claims 1 to 9, characterized in that: The following steps are involved: (I) Pre-treat the deck substrate surface in the cargo oil tank main deck construction area; (II) Spraying anti-corrosion primer; spraying an anti-corrosion primer on the surface of the deck substrate pretreated in step (I), and forming an anti-corrosion primer layer after the anti-corrosion primer is cured; (III) Enclose with slats and pour water-based thermal insulation coating Set up slats around the construction area to form a closed enclosure, pour water-based thermal insulation paint into the closed enclosure, and spread it flat to form a water-based thermal insulation layer; (IV) Laying the grating When the water-based thermal insulation paint is self-leveling and still fluid, lay the grating plate, ensuring that the bottom surface of the grating plate is in contact with the anti-corrosion primer layer, and there is no water-based thermal insulation paint between the bottom surface of the grating plate and the anti-corrosion primer layer; (V) Pouring oil-based thermal insulation coating After the water-based thermal insulation coating is completely cured, pour the oil-based thermal insulation coating into the pores of the grid plate to fill the pores of the grid plate; (VI) Supplement oil-based thermal insulation coating After the oily thermal insulation coating poured in step (V) is solidified and within the maximum recoating interval, additional oily thermal insulation coating is poured to form a final oily thermal insulation layer after solidification; (VII) Spraying topcoat Spray topcoat on the surface of the oily insulation layer, and form a topcoat layer after the topcoat is cured; (VIII) Removal of lath; (Ⅸ) Edge banding Clean the edges of the composite structure, insert the edge banding and spray the topcoat to extend the coverage to form a continuous protective layer.

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