Polyurea-Coated EPS Tank Base for Leak and Corrosion Control
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Solution Overview
Problem
Current methods for protecting above-ground storage tanks (ASTs) from accidental spills and leaks are inefficient, costly, and environmentally harmful, as they rely on porous materials like pea gravel that absorb contaminants and require labor-intensive construction, leading to permanent contamination and corrosion.
Innovation Solution
A tank base constructed with encapsulated polystyrene (EPS) coated with polyurea, which is biodegradable and provides a strong, impervious barrier against spills and leaks, allowing for easy steam cleaning and environmentally friendly disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If porous materials like pea gravel are used to protect tanks from spills and leaks, then the tank base allows for fluid accumulation and contamination absorption, but it leads to permanent contamination, requires labor-intensive construction, and causes corrosion to tank walls
Solution Approach 1:
The patent uses expanded polystyrene (EPS) foam, a porous material, as the core structure of the tank base. The porosity of the EPS provides void spaces for fluid accumulation and contamination containment, while the material itself remains chemically inert and does not contribute to permanent contamination or corrosion of the tank walls
Solution Approach 2:
The patent creates a composite structure by coating expanded polystyrene foam with polyurea elastomer. The EPS provides structural volume and contamination containment capacity, while the polyurea coating provides a protective, non-corrosive barrier that prevents contamination of the underlying materials and eliminates the need for labor-intensive construction
2Strength
If a metal grade band base is used to support the tank, then structural support is provided, but it requires bolted assembly, is labor-intensive to construct, and allows standing fluid to cause deterioration
Solution Approach 1:
The patent employs expanded polystyrene foam, a relatively inexpensive material that can be easily manufactured and installed, as the core base structure. This replaces the need for costly and labor-intensive metal grade band assembly, while the material's properties allow it to withstand the required structural loads
Solution Approach 2:
The patent applies a polyurea elastomer coating, which forms a flexible protective shell around the EPS foam core. This coating provides a continuous protective barrier that prevents standing fluid contact with the base materials, eliminating deterioration while maintaining structural integrity without requiring complex assembly
3Quantity of substance
If pea gravel is used in the tank base, then fluid accumulation is allowed, but contaminants are permanently contaminated and require costly and difficult treatment
Solution Approach 1:
The patent converts the potential harm of contamination into a beneficial containment system. The EPS foam structure provides dedicated void spaces for fluid accumulation, while the polyurea coating creates a barrier that prevents contaminants from permeating into the base material. This allows for easy removal and treatment of accumulated fluids without contaminating the base structure itself
Solution Approach 2:
The patent enables easy discarding and recovering of contaminated fluids from the tank base. The EPS foam structure with its integrated void spaces allows for simple drainage and removal of accumulated fluids, which can then be treated or disposed of without requiring costly and difficult treatment processes, while the base material remains clean and reusable
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The EPS-polyurea tank base effectively prevents contamination, reduces maintenance costs, and ensures safe disposal, while maintaining structural integrity and ease of installation.
Implementation Method 1
encapsulated polystyrene (EPS) coated with polyurea, which is biodegradable and provides a strong, impervious barrier against spills and leaks
Implementation Method 2
allowing for easy steam cleaning and environmentally friendly disposal
Data Source
AI summary
A method for the construction of an improved tank base. A tank base is constructed for protection against accidental spills and/or leaks associated with a tank battery. The improved tank base comprises at least one part of a suitable substrate, which allows for the adhesion of an elastomer such as polyurea. Polyurea is preferably applied using a spray device which yields an average coverage of about 50-80 mils, and most preferably 60 mils. If more than one substrate is used, one or more substrates can be bound together with a fastening system. Once pressure is applied in the form of weight, the fastening system can be removed, resulting in an improved tank base having at least one seam and impervious to the fluid of the tank battery.