A modular storage / process structure and method of assembly thereof

Abstract

The present disclosure relates to structural systems in general, and more particularly to modular storage / process structure comprising of a plurality of pipe segments (1) and other structural elements that can be harmoniously joined together, and method of assembly thereof. The modular storage / process structure can be assembled for above-ground, underground, or semi-buried applications and utilized for fluid storage / process / transport in various commercial, industries and infrastructure applications.

Description

A MODULAR STORAGE / PROCESS STRUCTURE AND METHOD OFASSEMBLY THEREOFTECHNICAL FIELD

[0001] The present disclosure relates to structural systems in general, and more particularly to modular storage / process structure comprising of a plurality of pipe segments or a plurality of curve / segmented curve molded segments and other structural elements that can be harmoniously joined together, and a method of assembly thereof.BACKGROUND INFORMATION

[0002] Over the past few years, the demand for modular storage / process structures has significantly increased. This is because the implementation of a modular configuration provides greater versatility to customize various tank sizes and shapes, easier handling, lower transportation costs, higher storage capability, and solves current practical storage limitations where constraints exist. Therefore, modular storage / process structures are mainly utilized for fluid storage / fluid process in various industries and applications which include but are not limited to mining, chemical, commercial, residential, industrial, water treatment, and urgent supply or storage of water in case of emergency and humanitarian situations.

[0003] Nowadays, there is a growing interest in utilizing the versatility of pipe segments to construct different industrial structures. For instance, the Chinese patent CN106116089 discloses a method for fabrication of a segmented electric heating connection type plastic septic tank which is composed of a semi-spherical head pipe and one or more than two round pipe segments. The septic tank can be produced only by two molds, namely a mold for processing the semi -spherical head pipe and a mold for processing the round pipe segments. As a result, septic tanks of various specifications and sizes can be produced.

[0004] The Chinese patent CN111486276 discloses a method for the assembly and orientation of a plurality of unit pipe segments (corrugated and linear) to result in a double wall steel corrugated steel pipe.SUMMARY

[0005] Therefore, it is an object of the present disclosure to provide a modular storage / process structure comprising: a plurality of wall modules, each of the wall modules comprises a plurality of pipe or curved / segmented curve molded segments arranged in a harmonious arrangement to form a skeleton of the storage / process structure; a plurality of structural support elements as a means for interconnecting the plurality of wall modules and pipe or curved / segmented curve molded segments; a base module connected to the plurality of wall modules in order to provide a three- dimensional space; and a plurality of fixing means configured to connect the plurality of wall modules to the base module from an inner and / or outer surface of the plurality of wall modules.

[0006] In aspects of the present disclosure, the modular storage / process structure comprises one or more layers of the wall modules.

[0007] In some aspects of the present disclosure, a plurality of modular storage / process structures, each of a different capacity are assembled in a coaxial manner.

[0008] In other aspects of the present disclosure, a plurality of modular storage / process structures are assembled in an array matrix.

[0009] In some aspects of the present disclosure, the modular storage / process structure further comprises a top module.

[0010] In some aspects, the top module comprises a plurality of pipe or curved / segmented curve molded segments connected to each other.[OH] In other aspects, the top module comprises a planar layer.

[0012] In other aspects, the top module may be a light-weight structure.

[0013] In some aspects, the top module may require internal support structures.

[0014] In some aspects, one or more of the plurality of wall modules comprises a preexisting natural or man-made foundation.

[0015] In some aspects, the base module may be placed over a pre-existing foundation.

[0016] In some aspects, the base module is treated to be leak-proof.

[0017] In other aspects, the structure further comprises a rigid module with a first end and a second end, wherein each of the first and second ends are connected to a wall module of the plurality of wall modules.

[0018] In other aspects, the structure further comprises one or more internal collars / knuckles configured to connect the plurality of wall modules to the base module from an inner surface of the plurality of wall modules.

[0019] The modular storage / process structure may have a capacity ranging from about 2 m3to capacity that could exceed 20,000 m3.

[0020] In aspects of the present disclosure, the modular storage / process structure is configured to contain / store a liquid, viscous, slurry, or bulk material.

[0021] In aspects of the present disclosure, the modular storage / process structure is fully assembled above ground, partially buried, or fully buried under the ground.

[0022] In some aspects, the structure further comprises one or more anchoring means configured to prevent buckling and any potential movement, i.e., horizontal, or vertical displacement, of the modular storage / process structure with reference to the preexisting foundation.

[0023] In some aspects, the structure further comprises at least one structural or functional accessory.

[0024] In some aspects of the present disclosure, the plurality of pipe or curved / segmented curve molded segments is manufactured through cutting of a pipe or using predefined molds.

[0025] In other aspects of the present disclosure, the plurality of pipe or curved / segmented curve molded segments is manufactured through a sloped axial cutting of a pipe.

[0026] In yet other aspects of the present disclosure, the plurality of pipe or curved / segmented curve molded segments is manufactured through a circumferential cutting of a pipe.

[0027] In yet other aspects of the present disclosure, the plurality of pipe or curved / segmented curve molded segments is manufactured through a miter cutting of a pipe. Such a way of cutting may result in assembling a tapered storage / process structure.

[0028] In some aspects, the plurality of pipe or curved / segmented curve molded segments has a corrugated, smooth, or rough interior and / or exterior surface.

[0029] In some aspects, each of the plurality of pipe or curved / segmented curve molded segments has a similar or different shape and / or diameter compared to the shape and / or diameter of other pipe or curved / segmented curve molded segments in the plurality of pipe or curved / segmented curve molded segments.

[0030] In some aspects, each of the plurality of pipe or curved / segmented curve molded segments has similar or different mechanical and / or chemical properties compared to the mechanical and / or chemical properties of other pipe or curved / segmented curve molded segments in the plurality of pipe or curved / segmented curve molded segments.

[0031] In some aspects, the plurality of pipe or curved / segmented curve molded segments is constructed from the same material or a combination of different materials.

[0032] In some aspects, the plurality of pipe or curved / segmented curve molded segments is constructed from a metallic material, a polymeric material, fiberglass, or a composite material or a combination thereof, or any other suitable material.

[0033] In some aspects, the plurality of pipe or curved / segmented curve molded segments is made in a sandwiched configuration consisting of 2 or more materials (e.g., inner, outer layer and different core layer).

[0034] In some aspects, the metallic material comprises iron, steel, copper, brass, titanium, or a combination thereof, or any other suitable metal.

[0035] In some aspects, the polymeric material comprise polypropylene, polyethylene, high density polyethylene, or a combination thereof, or any other suitable polymer.

[0036] In some aspects, the composite material comprises at least one resin type and / or fiber type or a combination of.

[0037] In some aspects, the at least one resin type comprises polymer resin, polyester resin, vinyl ester, epoxy resin, phenol-formaldehyde resin, or a combination thereof, or any other suitable resin.

[0038] In some aspects, the fiber comprises glass fiber, synthetic fiber, polymer fiber, polyester fiber, or carbon fiber or a combination thereof, or any other suitable fiber.

[0039] In some aspects, the composite material may further comprise a filling material.

[0040] In some aspects, the filling material, comprises silica sand, calcium carbonate or any other suitable filling material.

[0041] In aspects of the present disclosure, the plurality of structural support elements comprises structural joints (e.g., lamination structural joint, composite material, or mechanical joint), internal or external vertical or horizontal stiffeners, bracers (e.g., stiffening rib, plate, puddle), roof support (e.g., vertical pipe column) elements, soil support, knuckle, and anchoring elements (e.g., hold-down lugs), or a combination thereof, or any other suitable structural support element when needed.

[0042] Aspects of the present disclosure further provide a method for assembly of the modular storage / process structure of claim any of the preceding claims, comprising the steps of:Cutting a pipe into a plurality of pipe segments, or providing a plurality of curved / segmented curve molded segments;- Positioning and assembling each of the plurality of the pipe or curved / segmented curve molded segments to other pipe segments of the plurality of the pipe or curved / segmented curve molded segments at a predetermined contact point to form a corrugated structural j oint;- Fixing the corrugated structural joint between the plurality of pipe segments with a plurality of structural support elements to form a plurality of wall modules; and Assembling the plurality of wall modules into any geometrical or harmonious pattern to form a skeleton of the modular storage tank structure.

[0043] In some aspects, the positioning and assembling the plurality of the pipe or curved / segmented curve molded segments to other pipe segments of the plurality of the pipe or curved / segmented curve molded segments at a predetermined contact point to form a corrugated structural joint may be achieved by interlocking a pipe or curved / segmented curve molded segments with one or two adjacent pipe or curved / segmented curve molded segments.

[0044] In some aspects, the method further comprises connecting the assembled plurality of wall modules to a base module using a plurality of fixing means leak tight structural joints.

[0045] In some aspects, the connection between the assembled plurality of wall modules to a base module using a one or more internal / external collars / knuckles leak tight structural joints.

[0046] In some aspects, the method may further comprise curing the contact point of the plurality of pipe or curved / segmented curve molded segments with fast curing resin mix and glass reinforced batch lamination.

[0047] In some aspects, the method further comprises assembling and connecting / joining of a top module to at least one of the wall modules.

[0048] In some aspects, the method further comprises incorporating at least one structural accessory to be part of the complete assembly of the modular storage / process structure.BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The present disclosure will now be described with reference to the accompanying drawings, which illustrate embodiments of the present disclosure, without however limiting the scope of protection thereto, and in which:

[0050] FIG. 1 illustrates a perspective view of an exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure.

[0051] FIG. 2A illustrates a perspective view of three coaxial exemplary assemblies of a modular storage / process structure constructed in accordance with the present disclosure.

[0052] FIG. 2B illustrates a top view of the three coaxial exemplary assemblies of a modular storage / process structure of FIG. 2A.

[0053] FIG. 2C illustrates a perspective view of three adjacent exemplary assemblies of a modular storage / process structure constructed in accordance with the present disclosure.

[0054] FIG. 3 A illustrates a perspective view an exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure, wherein a pre-existing foundation forms a part of the modular storage / process structure.

[0055] FIG. 3B illustrates a perspective view an exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure, wherein a lined pre-existing side structure forms a part of the modular storage / process structure.

[0056] FIG. 3C illustrates a perspective view of another exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure, wherein a rigid module and a pre-existing side structure forms a part of the modular storage / process structure.

[0057] FIG. 3D illustrates a perspective view of a matrix of modular storage / process structures constructed in accordance with the present disclosure.

[0058] FIG. 4 illustrates a perspective view of an exemplary assembly of a modular storage / process structure with a top module made of a light-weight structure, wherein the structure is constructed in accordance with the present disclosure.

[0059] FIG. 5 illustrates a perspective view of a multi-layered modular storage / process structure constructed in accordance with the present disclosure.

[0060] FIG. 6 illustrates a schematic partial top view of an exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure.

[0061] FIG. 7 illustrates a perspective view of an exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure, wherein such structure is used as a clarifier.

[0062] FIG. 8 illustrates a perspective view of an exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure, wherein such structure is tapered along its axial direction.

[0063] FIG. 9 illustrates a perspective bottom view of an exemplary assembly of a modular storage / process structure constructed in accordance with the present disclosure, wherein such structure is used as a silo.

[0064] FIG. 10 illustrates a typical flowchart of a method of for assembly of the modular storage / process structure, the method being configured in accordance with some embodiments of the present disclosure.

[0065] FIG. 11A illustrates a schematic front view of two pipe segments formed by cutting a pipe through an axial cut.

[0066] FIG. 1 IB illustrates a schematic front view of two pipe segments formed by cutting a pipe through a circumferential cut.

[0067] FIG. 11C illustrates a schematic front view of two pipe segments formed by cutting a pipe through a miter cut.

[0068] FIG. 1 ID illustrates a schematic front view of two pipe segments formed by cutting a pipe through a sloped axial cut.

[0069] FIG. 12A illustrates a schematic perspective view of a wall skeleton of a modular storage / process structure constructed in accordance with embodiments of the present disclosure, wherein such wall skeleton is made of segmented curve molded segments.

[0070] FIG. 12B illustrates a top view of a wall skeleton of a modular storage / process structure constructed in accordance with embodiments of the present disclosure, wherein such wall skeleton is made of segmented curve molded segments.DETAILED DESCRIPTION

[0071] Embodiments of the present disclosure provide a modular storage / process structure comprising: a plurality of wall modules 1, each of the wall modules comprises a plurality of pipe or curved / segmented curve molded segments 10 arranged in any geometrical or harmonious pattern to form a skeleton of the storage / process structure; and a plurality of structural support elements 2 as a means for interconnecting the plurality of wall modules 1 and pipe or curved / segmented curve molded segments 10.

[0072] In embodiments of the present disclosure, the modular storage / process structure forms a storage space against one or more pre-existing foundations 5. In some embodiments, such one or more pre-existing foundations 5 may be tangential to a base module 3 (FIGS. 3A-C, 5, 6), while in other embodiments may form a wall module 1 (FIGS.3A-3C).

[0073] In embodiments of the present disclosure, the one or more pre-existing foundation 5 may be treated to be leak-proof. This pre-existing foundation 5 may be natural such as a mountain or a cliff, or can be man-made such as a slab, or a wall.

[0074] In some embodiments of the present disclosure, the base module 3 may be formed of a plurality of pipe or curved / segmented curve molded segments harmoniously connected to each other or may be made of a planar layer. The base module 3 may be treated to be leak-proof.

[0075] In embodiments of the present disclosure, the base module 3 may be lined with one or more materials.

[0076] In some embodiments of the present disclosure, each wall module 1 may be made up of a single layer of pipe or curved / segmented curve molded segments 10 (FIGS. 1, 2A-C, 3 A-C, 4), while in other embodiments, each wall module may be made of a plurality of layers of or curved / segmented curve molded segments (FIG. 5).

[0077] In some embodiments, the plurality of pipe or curved / molded segments 10 may be manufactured by an axial cut of one or more pipe (FIG. 11 A), or by using predefined molds.

[0078] In some embodiments, the plurality of pipe or curved / segmented curve molded segments 10 may be manufactured by a circumferential cut of one or more pipe (FIG. 1 IB), or by using predefined molds.

[0079] In some embodiments, the plurality of pipe or curved / segmented curve molded segments 10 may be manufactured by a sloped axial cut of one or more pipe (FIG. 1 ID), or by using predefined molds.

[0080] In some embodiments, the plurality of pipe or curved / segmented curve molded segments 10 may be manufactured by a miter cut of one or more pipe (FIG. 11C), or by using predefined molds. The use of miter cut may result in having a tapered modular storage / process structure (FIG. 8).

[0081] In some embodiments of the present disclosure, the modular storage / process structure is either open-top or closed-top, e.g., covered with a roof structure, e.g., lightweight roof structure.

[0082] In some embodiments of the present disclosure, the modular storage / process structure comprises a top module 4 acting as a roof structure connected to at least one of the wall modules 1, wherein such top module 4 may be formed of a plurality of pipe or curved / segmented curve molded segments 40 harmoniously connected to each other (FIG. 5) by interlocking or any other suitable means, or may be made of a planar layer (not shown), or a conical or curved layer (FIG. 9). In some embodiments, the top module may require internal support structures and / or an external support frame (not shown).

[0083] The modular storage structure of the present disclosure may be installed above the ground, completely buried under the ground, or partially buried under the ground, depending on the application.

[0084] In some embodiments, the plurality of wall modules 1 together with top module 4 and the base module 3 may form a confined space, wherein the base module 3 may be tangential to the ground, elevated from the ground (FIG. 9), partially or completely buried under the ground. In case where the base module 3 is elevated from the ground, support structures may be used (not shown) to hold and maintain the position of the formed confined space relative to the ground.

[0085] In embodiments of the present disclosure, a plurality of modular storage / process structures may be installed in a coaxial manner, such that each storage / process structure is configured to enclose a different material (FIG. 3 A). In such embodiments, the capacity of each modular storage / process structure might be different than the capacity of the other modular storage / process structures.

[0086] In some embodiments of the present disclosure, a plurality of modular storage / process structures may be arranged in proximity or adjacent to each other to form an array matrix of adjacent storage structures (FIG. 3D).

[0087] In embodiments of the present disclosure, the modular storage / process structure confines a liquid, slurry, or bulk material.

[0088] In some embodiments, the modular storage / process structure can be used to modify or rehabilitate an existing storage structure and / or increase safety levels under worst accident conditions.

[0089] In embodiments of the present disclosure, the modular storage / process structure as standalone structure has a capacity ranging from about 2 m3to capacity that could exceed 20,000 m3.

[0090] In some embodiments of the present disclosure, the modular storage / process structure may further comprise a rigid module 6 having a first end 60 and a second end 61, wherein each of the first and second ends 60, 61 are connected to an adjacent wall module 1. Similar to the connection between the pipe or curved / segmented curvemolded segments 10, the connection between the first and second ends 60, 61 and the wall modules 1 is achieved by the structural support elements 2 (FIG. 6), or by interlocking.

[0091] In some embodiments, the rigid module 6 may act as a liner to a preexisting foundation 5 when such foundation 5 cannot be treated to be leak-proof (FIG. 3B).

[0092] In embodiments of the present disclosure, the connection between the wall modules 1, and the base module 3 is achieved by means of structural joint, fixing means 7 and an internal / extemal collar / knuckle 8. Such fixing means 7 may be configured to fix the one or more wall modules 1 from an inner and / or outer surface to the base module 3, and the internal collar / knuckle 8 may be configured to fix the one or more wall modules and optionally the rigid module 6 from an inner surface to the base module 3. In some embodiments, the fixing means 7 may be lugs.

[0093] In some embodiments of the present disclosure and depending on the capacity and application of the modular storage / process structure, the modular storage / process structure may further comprise anchoring / fixing means 9, such anchoring / fixing means 9 may be tangential or in contact with the one or more wall modules 1, the anchoring / fixing means 9 prevent buckling of the modular storage / process structure of the present disclosure. Such anchoring / fixing means 9 may also prevent any potential movement, i.e., horizontal, or vertical displacement with reference to the wall module 10.

[0094] In some embodiments, the anchoring / fixing means 9 are tangential or in contact with an inner surface of the one or more wall modules 1, while in other embodiments, the anchoring / fixing means 9 are tangential or in contact with an outer surface of the one or more wall modules 1.

[0095] In embodiments of the present disclosure, the plurality of pipe or curved / segmented curve molded segments 10 is manufactured through axial cutting of a pipe or curved / segmented curve molded segments built using predefined molds.

[0096] In some embodiments of the present disclosure, the plurality of pipe or curved / segmented curve molded segments 10 has a corrugated, smooth, or rough inner and / or outer surface.

[0097] In some embodiments of the present disclosure, the plurality of pipes or curved / segmented curve molded segments 10 has a similar or different shape and / or diameter.

[0098] In some embodiments of the present disclosure, the plurality of pipes or curved / segmented curve molded segments 40 has a similar or different shape and / or diameter.

[0099] In some embodiments of the present disclosure, the plurality of pipes or curved / segmented curve molded segments 10 has similar or different mechanical and / or chemical properties.

[0100] In some embodiments of the present disclosure, the plurality of pipes or curved / segmented curve molded segments 40 has similar or different mechanical and / or chemical properties.

[0101] In some embodiments of the present disclosure, the plurality of pipes or curved / segmented curve molded segments 10 is constructed from the same material or a combination of different materials.

[0102] In some embodiments of the present disclosure, the plurality of pipes or curved / segmented curve molded segments 40 is constructed from the same material or a combination of different materials.

[0103] In some embodiments of the present disclosure, the plurality of pipe segments 10, 40 is constructed from a metallic material, a polymeric material, fiberglass, or a composite material or a combination thereof, or any other suitable material.

[0104] In some embodiments, the plurality of pipe or curved / segmented curve molded segments is made in a sandwiched configuration consisting of 2 or more materials (e.g., inner, outer layer and different core layer).

[0105] In embodiments of the present disclosure, the metallic material comprises iron, steel, copper, brass, titanium, or a combination thereof, or any other suitable metal.

[0106] In embodiments of the present disclosure, the polymeric material comprises polypropylene (“PP”), polyethylene (“PE”), high density polyethylene (“HDPE”), or a combination thereof, or any other suitable polymer.

[0107] In embodiments of the present disclosure, the composite material comprises at least one resin type and / or fiber type or a combination of.

[0108] In other embodiments of the present disclosure, the composite material further comprises a filling material.

[0109] In embodiments of the present disclosure, the at least one resin comprises polymer resin, polyester resin, vinyl ester, or epoxy resins, or any other suitable resin.

[0110] In embodiments of the present disclosure, the fiber comprises glass fiber, synthetic fiber, polymer fiber, polyester fiber, or carbon fiber or a combination thereof, or any other suitable fiber.[OHl] The filling material, if used, may comprise silica sand, calcium carbonate or any other suitable filling material.

[0112] In embodiments of the present disclosure, the plurality of structural support elements 2 comprises suitable structural joints (e.g., lamination structural joint, composite material, or mechanical joint), bracers, internal or external vertical or horizontal stiffeners (e.g., stiffening rib, plate, angle, puddle), roof support (e.g., vertical pipe column) elements if needed (not shown), soil support, knuckle, and anchoring elements (e.g., hold-down lugs) or a combination thereof, or any other suitable structural support element.

[0113] The modular storage / process structure in embodiments of the present disclosure may further comprise at least one structural or functional accessory that could be selected from a group including one or more access manholes 41, one or more vent nozzles 42, one or more overflow nozzles 11, one or more nozzle connections 12, a stair assembly (not shown), a safety gauge (not shown), or a rail (not shown), or a combination thereof, or any other suitable structural or functional accessory.

[0114] In embodiments of the present disclosure, the plurality of pipes or curved / segmented curve molded segments 10 are connected to each other and / or interlocked in a wall module 1 at a predetermined contact line / point to form a corrugated structural joint using the plurality of structural support elements 2, wherein such contact line / point may be cured by a leak-tight structural joint in order to provide the structuralintegrity / capacity of the structural joint and prevent leakage of enclosed material through such corrugated structural joint.

[0115] In some embodiments, the rigid module 6 may be connected to a wall module at a predetermined contact line / point to form a structural joint using the plurality of structural support elements 2 and / or by interlocking, wherein such contact line / point may be cured by a leak-tight structural joint in order to provide the structural integrity / capacity of the structural joint and prevent leakage of enclosed material through such structural joint.

[0116] Reference is now being made to FIG. 10, which illustrates a typical flowchart of a method for assembly of the modular storage / process structure in accordance with embodiments of the present disclosure, the method includes the steps of:Cutting a plurality of pipes into a plurality of pipe segments, or providing a plurality of curved / segmented curve molded segments (process block 10- i);- Positioning and assembling each of the plurality of pipes or curved / segmented curve molded segments to other segments at a predetermined contact line / point to form a corrugated structural joint (process block 10-2);- Fixing the corrugated structural joint between the plurality of pipe or curved / segmented curve molded segments with a plurality of structural support elements to form a plurality of wall modules (process block 10-3); andAssembling the plurality of wall modules into any geometrical or harmonious pattern to form a skeleton of the modular storage tank structure using the plurality of structural support elements (process block 10-4).

[0117] In some embodiments of the present disclosure, cutting the plurality of pipes may be in axial, sloped axial, miter, or circumferential manner.

[0118] In embodiments of the present disclosure, the positioning and assembling of the plurality of pipes or curved / molded segments to other segments at a predetermined contact line / point may be achieved by interlocking each of the plurality of pipes or curved / molded segments by one or two adjacent pipes or curved / molded segments.

[0119] In some embodiments, the method may further comprise connecting a rigid module to two wall modules at a predetermined line / point of contact, and curing, if required, the contact line / point with a leak-tight structural joint (process block 10-5).

[0120] In other embodiments of the present disclosure, the method for assembly of the modular storage / process structure further comprises connecting the plurality of assembled wall modules to a base module with a leak-tight structural joint (process block 10-6). The connection may be achieved using the plurality of fixing means 7 and optionally with the one or more internal collars / knuckles 8. The base module may also be formed by a plurality of harmoniously connected pipes / flat or corrugated plates and may also be lined with one or more composite materials.

[0121] In other embodiments of the present disclosure, the method for assembly of the modular storage / process structure further comprises assembling and connecting / joining a top module to at least one of the wall modules (process block 10-7). The top module may be made of a light-weight material.

[0122] In other embodiments of the present disclosure, the method for assembly of the modular storage / process structure further comprises incorporating at least one structural accessory before or after complete assembly of the modular storage / process structure (process block 10-8). The at least one structural accessory is selected from a group including one or more access manholes, one or more vent nozzles, one or more overflow nozzles, one or more nozzle connections, a stair assembly, a safety gauge, or a rail, or a combination thereof, or any other suitable structural or functional accessory.

[0123] In some embodiments, the method for assembly of the modular storage / process structure may optionally comprises curing, if required, the contact line / point of the plurality of pipe or curved / segmented curve molded segments with a leak tight structural j oint like fast curing resin mix and glass reinforced batch lamination (process block 10-9).

[0124] It should be understood by a person skilled in the art that although the accompanying drawings illustrate a vertically oriented modular storage / process structure, the modular storage / process structure may be also oriented horizontally without departing from the scope of the present disclosure.

[0125] While embodiments of the present disclosure have been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various additions, omissions, and modifications can be made without departing from the spirit and scope thereof.

[0126] In describing and claiming the present invention, the following terminology was used.

[0127] The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0128] As used herein, the term “modular storage / process structure” refers to a prefabricated storage / process structural parts that consist of various wall modules, that can be either used as one or more materials storage space or as a container for enclosing one or more materials in a process(s) (e.g. an industrial process), or to transport fluids for long distances between a starting point and an end point regardless the distance therebetween.

[0129] As used herein, the term “wall module” refers to a free-standing wall system that is made up of different parts or modules, particularly pipe segments, that are joined together to form one solid structure.

[0130] As used herein, the term “axial cut” refers to a cut formed in a pipe in which the cutting line is parallel to the axial direction of the pipe, as illustrated in FIG. 11 A.

[0131] As used herein, the term “circumferential cut” refers to a cut formed in a pipe in which the cutting line is perpendicular to the axial direction of the pipe, as illustrated in FIG. 11B.

[0132] As used herein, the term “miter cut” refers to a cut formed in a pipe in which the cutting line intersects with the axial direction of the pipe and the circumference of the cut is totally tangential to the circumference of the pipe being cut, as illustrated in FIG. 11C.

[0133] As used herein, the term “sloped axial cut” refers to a cut formed in a pipe in which the circumference of the surface being cut is partially tangential to the circumference of the pipe being cut, as illustrated in FIG. 1 ID.

[0134] As used herein, the term “molded segments” refers to segments that were produced using a mold or using an extrusion process.

Claims

CLAIMSWhat is claimed is:

1. A modular storage / process structure comprising: a plurality of wall modules, each of the wall modules comprises a plurality of pipe or curved / segmented curve molded segments arranged in a harmonious arrangement to form a skeleton of the storage / process structure; a plurality of structural support elements as a means for interconnecting the plurality of wall modules and pipe or curved / segmented curve molded segments; a base module connected to the plurality of wall modules in order to provide a three- dimensional space; and a plurality of fixing means configured to connect the plurality of wall modules to the base module from an inner and / or outer surface of the plurality of wall modules.

2. The modular storage / process structure of claim 1 , wherein the modular storage / process structure comprises one or more layers of the wall modules.

3. The modular storage / process structure of claim 1, wherein a plurality of modular storage / process structures, each of a different capacity are assembled in a coaxial manner.

4. The modular storage / process structure of claim 1, wherein a plurality of modular storage / process structures are assembled in an array matrix.

5. The modular storage / process structure of claim 1 , wherein the modular storage / process structure further comprises a top module.

6. The modular storage / process structure of claim 5, wherein the top module comprises a plurality of pipe or curved / segmented curve molded segments connected to each other.

7. The modular storage / process structure of claim 5, wherein the top module comprises a planar or conical / corrugated conical / curved layer.

8. The modular storage / process structure of claim 5, wherein the top module is made of a light-weight material.

9. The modular storage / process structure of claim 1, wherein one or more of the plurality of wall modules comprises a pre-existing foundation.

10. The modular storage / process structure of claim 1, wherein the base module comprises a conical shape.

11. The modular storage / process structure of claim 1, wherein the base module is elevated from a ground level.

12. The modular storage / process structure of claim 1, wherein the base module is tangential to a ground level.

13. The modular storage / process structure of claim 9 wherein the pre-existing foundation is treated to be leak-proof.

14. The modular storage / process structure of claim 1, further comprises a rigid module with a first end and a second end, wherein each of the first and second ends are connected to a wall module of the plurality of wall modules.

15. The modular storage / process structure of claim 1, further comprising one or more intemal / extemal collars / knuckles configured to connect the plurality of wall modules to the base module from an inner surface of the plurality of wall modules.

16. The modular storage / process structure of claim 1, wherein the modular storage / process structure has a capacity ranging from about 2 m3to capacity that could exceed 20,0003 m .

17. The modular storage / process structure of claim 1, wherein the modular storage / process structure confines a liquid, viscous, slurry, or bulk material.

18. The modular storage / process structure of claim 1, wherein the modular storage / process structure is fully assembled above ground, partially buried, or fully buried under the ground.

19. The modular storage / process structure of claim 1, further comprises one or more anchoring means configured to prevent buckling of the modular storage / process structure, and to prevent any potential movement of the modular storage / process structure.

20. The modular storage / process structure of claim 1, further comprises at least one structural or functional accessory.

21. The modular storage / process structure of claim 1, wherein the plurality of pipe or curved / segmented curve molded segments is manufactured through an axial cut of a pipe or using predefined molds.

22. The modular storage / process structure of claim 1, wherein the plurality of pipe or curved / segmented curve molded segments is manufactured through a sloped axial cut of a pipe or using predefined molds.

23. The modular storage / process structure of claim 1, wherein the plurality of pipe or curved / segmented curve molded segments is manufactured through a miter cut of a pipe or using predefined molds.

24. The modular storage / process structure of claim 1, wherein the plurality of pipe or curved / segmented curve molded segments is manufactured through a circumferential cut of a pipe or using predefined molds.

25. The modular storage / process structure of claim 1, wherein the plurality of pipe or curved / segmented curve molded segments has a corrugated, smooth, or rough interior and / or exterior surface.

26. The modular storage / process structure of claim 1, wherein each of the plurality of pipe or curved / segmented curve molded segments has a similar or different shape and / or diameter compared to the shape and / or diameter of other pipe or curved / molded segments in the plurality of pipe or curved / segmented curve molded segments.

27. The modular storage / process structure of claim 1, wherein each of the plurality of pipe or curved / segmented curve molded segments has similar or different mechanical and / or chemical properties compared to the mechanical and / or chemical properties of other pipe or curved / segmented curve molded segments in the plurality of pipe or curved / segmented curve molded segments.

28. The modular storage / process structure of claim 1, wherein the plurality of pipe or curved / segmented curve molded segments is constructed from one material or a combination of different materials.

29. The modular storage / process structure of claim 1, wherein the plurality of pipe or curved / segmented curve molded segments is constructed from a metallic material, a polymeric material, fiberglass, a composite material, or a combination thereof, or any other suitable material.

30. The modular storage / process structure of claim 29, wherein the plurality of pipe or curved / segmented curve molded segments is made in a sandwiched configuration.

31. The modular storage / process structure of claim 29, wherein the metallic material comprises iron, steel, copper, brass, titanium, or a combination thereof, or any other suitable metal.

32. The modular storage / process structure of claim 29, wherein the polymeric material comprise polypropylene, polyethylene, high density polyethylene, or a combination thereof, or any other suitable polymer.

33. The modular storage / process structure of claim 29, wherein the composite material comprises at least one resin type and fiber.

34. The modular storage / process structure of claim 33, wherein the at least one resin type comprises polymer resin, polyester resin, vinyl ester, epoxy resin, phenolformaldehyde resin, or a combination thereof, or any other suitable resin.

35. The modular storage / process structure of claim 33, wherein the fiber comprises glass fiber, synthetic fiber, polymer fiber, polyester fiber, or carbon fiber or a combination thereof, or any other suitable fiber.

36. The modular storage / process structure of claim 33, wherein the composite material further comprises a filling material.

37. The modular storage / process structure of claim 36, wherein the filling material comprises silica sand, calcium carbonate or any other suitable filling material.

38. The modular storage / process structure of claim 1, wherein the plurality of structural support elements comprises structural joints (e.g., lamination structural joint, composite material, or mechanical joint), bracers, internal or external vertical or horizontal stiffeners, (e.g., stiffening rib, plate, angle, puddle), roof support (e.g., vertical pipe column) elements, soil support, knuckle, and anchoring elements (e.g., hold-down lugs), or a combination thereof, or any other suitable structural support element.

39. A method for assembly of the modular storage / process structure of claim 1, comprising the steps of:Cutting a pipe into a plurality of pipe segments, or providing a plurality of curved / segmented curve molded segments;Positioning and assembling each of the plurality of the pipe or curved / segmented curve molded segments to other pipe segments of the plurality of the pipe or curved / segmented curve molded segments at a predetermined contact point to form a corrugated structural joint;Fixing the corrugated structural joint between the plurality of pipe segments with a plurality of structural support elements to form a plurality of wall modules; andAssembling the plurality of wall modules into any geometrical or harmonious pattern to form a skeleton of the modular storage tank structure.

40. The method of claim 39, wherein the positioning and assembling the plurality of the pipe or curved / segmented curve molded segments to other pipe segments of theplurality of the pipe or curved / segmented curve molded segments at a predetermined contact point to form a corrugated structural joint is achieved by interlocking a pipe or curved / segmented curve molded segments with one or two adjacent pipe or curved / segmented curve molded segments.

41. The method for assembly of the modular storage / process structure of claim 39, further comprising connecting the assembled plurality of wall modules to a base module using a plurality of fixing means and leak tight structural joints.

42. The method for assembly of claim 39, wherein the connection between the connecting the assembled plurality of wall modules to a base module using a one or more intemal / extemal collars / knuckles and leak tight structural joints.

43. The method for assembly of the modular storage / process structure of claim 39, further comprising assembling and coupling of a top module to at least one of the wall modules.

44. The method for assembly of the modular storage / process structure of claim 39, further comprising incorporating at least one structural accessory to be part of the complete assembly of the modular storage / process structure.

45. The method for assembly of the modular storage / process structure of claim 39, further comprising curing the contact point of the plurality of pipe or curved / segmented curve molded segments with fast curing resin mix and glass reinforced batch lamination.

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