Polyurea-Coated EPS Tank Base for Spill Containment
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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 system using encapsulated expanded polystyrene (EPS) coated with polyurea, which is biodegradable and provides a strong, impervious barrier against spills and leaks, allowing for easy cleaning and environmentally friendly disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If porous materials like pea gravel are used for tank base protection, then contaminants can be absorbed, but the materials lead to permanent contamination and require labor-intensive construction
Solution Approach 1:
The patent uses a composite structure combining expanded polystyrene foam blocks with polyurea coating. The foam provides structural support and void space for contaminant containment, while the polyurea coating creates an impermeable barrier that prevents contamination of the underlying soil. This composite approach eliminates the need for labor-intensive pea gravel construction while maintaining contaminant containment capability.
Solution Approach 2:
The polyurea coating acts as a flexible impermeable shell or film that encapsulates the expanded polystyrene foam blocks. This thin film barrier prevents contaminants from penetrating through to the soil, eliminating the permanent contamination problem associated with porous materials while requiring minimal construction labor.
2Object-affected harmful factors
If porous materials like pea gravel are used for tank base protection, then contaminants can be absorbed, but permanent contamination occurs
Solution Approach 1:
The polyurea coating serves as an impermeable shell or film that completely encapsulates the expanded polystyrene foam blocks. This barrier prevents any contaminant penetration to the underlying soil, eliminating permanent contamination while maintaining effective contaminant containment through the foam structure.
Solution Approach 2:
The composite structure combines the contaminant-containing foam blocks with the impermeable polyurea coating, creating a system that contains contaminants within the foam voids while the coating prevents any migration to the environment, thus eliminating permanent contamination.
3Strength
If traditional tank base systems are used, then structural support is provided, but maintenance costs are high and cleaning is difficult
Solution Approach 1:
The polyurea coating provides a smooth, non-porous surface that is easy to clean and maintain. This impermeable film prevents contaminant adhesion and allows for simple cleaning operations, significantly reducing maintenance costs compared to traditional porous materials that require expensive treatment and cleaning operations.
Solution Approach 2:
The patent changes the surface parameters of the tank base by applying a polyurea coating that transforms the surface from porous and contaminant-adhesive to non-porous and non-adhesive. This parameter change makes the surface easy to clean and maintain while preserving the structural support function of the foam blocks.
4Reliability
If encapsulated EPS coated with polyurea is used, then an impervious barrier against spills is created, but the material must be biodegradable for environmental safety
Solution Approach 1:
The patent uses a composite material system where expanded polystyrene foam blocks (which are biodegradable) are coated with polyurea. The foam provides the structural basis for spill containment while being environmentally safe and biodegradable, and the polyurea coating enhances the impervious barrier property without compromising the overall environmental safety of the system.
Solution Approach 2:
The polyurea coating creates an impervious barrier that provides reliable spill containment, while the underlying expanded polystyrene foam blocks remain biodegradable. This allows the system to provide effective spill containment while maintaining environmental safety and biodegradability of the primary structural material.
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 easy cleaning and disposal, while maintaining structural integrity and environmental safety.
Implementation Method 1
an encapsulated polystyrene structure serves as a load bearing material for use in protecting against accidental spills and leaks
Implementation Method 2
an encapsulated polystyrene structure serves as a load bearing material
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.