Multi-Layer Elastomer Liners for Buoyancy and Delamination Control
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Solution Overview
Problem
Conventional secondary containment systems for oil and gas storage face issues with high costs, blistering, and delamination due to inadequate surface preparation, and the weight of thick polyurea coatings affects the buoyancy of liners.
Innovation Solution
A multi-layered elastomer-based liner system with a first elastomer coating applied at controlled temperatures, followed by a second elastomer coating free of sulfur, and optionally embedded with abrasive material to create a non-slip surface, reducing the need for extensive surface preparation and minimizing delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick polyurea coating is applied to the liner, then the liner provides adequate containment and protection, but the weight of the coating impacts the engineered buoyancy of the liner
Solution Approach 1:
The coating is divided into multiple thin layers (primer coat, intermediate coats, topcoat) rather than applying one thick coating. This segmentation allows the total protective coating weight to be distributed across multiple applications, each at optimal thickness, thereby maintaining buoyancy while achieving adequate containment protection through cumulative coverage.
2Strength
If a single layer thick polyurea coating is applied directly to the substrate, then the coating provides protection, but surface preparation must be performed over the entire substrate surface to prevent inter-coat delamination
Solution Approach 1:
The coating system is segmented into multiple layers applied in sequence, with each layer providing specific functions. The primer coat adheres to the substrate, intermediate coats build protection, and the topcoat provides final protection. This segmentation reduces the requirement for extensive surface preparation compared to a single thick coating, as each thin layer has better adhesion characteristics and can be applied with less stringent surface preparation.
Solution Approach 2:
The primer coat is applied first to prepare the substrate surface, creating a suitable base for subsequent coating layers. This preliminary action of priming the surface reduces the need for extensive mechanical surface preparation (such as grinding) that would otherwise be required to ensure proper adhesion of the full coating system.
3Strength
If an overspray or topcoat is applied in the field, then the liner provides enhanced protection, but proper surface preparation must be performed over the entire substrate surface to prevent delamination
Solution Approach 1:
The initial coating layers are applied and cured in the controlled factory environment before field installation. This preliminary coating action completes the majority of the protective coating system prior to installation, so that when the liner is installed in the field, minimal additional coating and surface preparation is needed, significantly reducing on-site time and labor requirements.
Solution Approach 2:
The coating application process is segmented into factory-based applications (primer and intermediate coats) and field-based applications (topcoat or overspray). This segmentation allows the time-consuming surface preparation and coating steps to be performed in the controlled factory environment using automated equipment, rather than requiring extensive field preparation and manual application.
4Strength
If conventional thick polyurea coating is applied, then the liner provides containment protection, but the high cost of different polyurea coatings for specific applications such as potable water can be cost prohibitive
Solution Approach 1:
Different coating formulations are applied to different layers or zones of the liner system. The primer coat may use a formulation optimized for adhesion, intermediate coats may use cost-effective protective formulations, and the topcoat may use specialized formulations (such as NSF 61 certified coatings) only where required for potable water contact. This local quality approach ensures that expensive specialized coatings are used only where necessary, reducing overall material costs while maintaining protection and meeting regulatory requirements.
Data Source
AI summary
The present disclosure relates to multi-layered elastomer-based liners. In at least one embodiment, a coated substrate includes a substrate and a first elastomer coating disposed on the substrate. The first elastomer coating is substantially free of sulfur and includes a first elastomer selected from the group consisting of a polyurea, a polyurethane, a polyurea-polyurethane copolymer, and combinations thereof. The coated substrate includes a second elastomer coating disposed on the first coating. Tire second elastomer coating includes a second elastomer selected from the group consisting of a polyurea, a polyurethane, a polyurea-polyurethane copolymer, and combinations thereof. The first elastomer is the same as or different than the second elastomer and at least one of the first elastomer or the second elastomer is a polyurea-polyurethane copolymer.