Stackable Cast Stone Composite Fermentation Tank
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Solution Overview
Problem
Current wine storage solutions, such as Portland cement concrete tanks, react with acidic wines, leading to oxygen production and pH imbalances, which can result in spoilage, and have limited longevity due to decomposition, while geopolymer concrete tanks with high fly ash content are toxic and not suitable for long-term storage.
Innovation Solution
A two-layered composite wall structure comprising a geopolymer concrete interior layer with a unique blend of natural clay, carbonates, and industrial waste materials, and a fiber-reinforced concrete exterior layer, providing a non-reactive, high thermal mass surface that maintains consistent temperatures and controls oxygen and pH levels, while being stackable and cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Portland cement concrete is used for wine storage tanks, then structural strength and thermal mass are improved, but chemical reactivity with acidic wine causes oxygen production and pH imbalances leading to spoilage
Solution Approach 1:
The tank wall is divided into multiple functional layers: an interior geopolymer concrete layer that provides chemical inertness and prevents spoilage, and an exterior Portland cement concrete layer that provides structural strength and thermal mass. This segmentation allows each layer to perform its specialized function without the harmful interactions that occur when a single material must fulfill all requirements.
Solution Approach 2:
The invention uses composite material construction combining geopolymer concrete and Portland cement concrete in a multi-layer wall structure. The geopolymer concrete (made from fly ash, slag, and natural aggregates) provides chemical stability and non-reactivity with wine, while the Portland cement concrete provides mechanical strength and thermal properties, creating a composite system that overcomes the limitations of either material alone.
2Reliability
If geopolymer concrete with high fly ash content is used for storage tanks, then chemical inertness and durability are improved, but toxic heavy metal content makes it unsuitable for long-term food and beverage storage
Solution Approach 1:
The invention modifies the chemical composition parameters of geopolymer concrete by using fly ash with controlled heavy metal content, adjusting the fly ash-to-cement ratio, and incorporating supplementary materials like slag and natural aggregates. These parameter changes maintain the chemical inertness and durability benefits of geopolymer concrete while reducing toxic heavy metal content to safe levels for food and beverage storage.
Solution Approach 2:
The interior surface layer of the tank is specifically formulated with controlled geopolymer composition to ensure chemical inertness and low heavy metal content, while the exterior layers can use different compositions optimized for structural performance. This local quality differentiation ensures that the material in direct contact with stored products meets safety requirements while maintaining overall structural integrity.
3Reliability
If kiln fired clay ceramics are used for wine storage, then chemical inertness is improved, but extremely high manufacturing costs and complexity make them impractical for large units
Solution Approach 1:
The invention replaces expensive, labor-intensive kiln-fired clay ceramic tanks with geopolymer concrete tanks that can be manufactured more economically using cast-in-place or precast concrete techniques. While geopolymer concrete has shorter service life than fired ceramics, the reduced manufacturing cost, ease of construction, and adequate durability make it a practical alternative for large-scale wine storage applications.
Solution Approach 2:
The invention replaces the traditional ceramic firing process (thermal mechanical system requiring extreme temperatures) with geopolymer chemistry (chemical system using alkaline activation at ambient or low temperatures). This substitution eliminates the need for expensive kilns and complex firing schedules while achieving comparable or superior chemical inertness through the geopolymerization reaction that forms a stable, non-reactive matrix.
4Duration of action of stationary object
If stainless steel tanks are used for wine storage, then durability and low maintenance are improved, but lack of thermal mass results in inconsistent storage temperatures
Solution Approach 1:
The invention merges the advantages of stainless steel (durability, low maintenance) with the advantages of concrete (thermal mass for temperature stability) by using geopolymer concrete construction. The resulting tank combines the chemical inertness and ease of cleaning associated with stainless steel, the structural durability of concrete, and the thermal mass properties that maintain consistent storage temperatures, creating a hybrid solution that captures benefits from both material types.
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 solution provides a long-lasting, low-maintenance storage vessel that minimizes oxygen exposure, maintains optimal temperature and pH levels, and reduces heavy metal content, offering a cost-effective alternative to oak barrels and fired clay ceramic vessels, suitable for both wine and beer storage.
Implementation Method 1
Concrete quickly became and remained the first choice for large volume wine fermentation and storage because of the ready availability of its raw materials and because of its property of having a large thermal mass. That large thermal mass maintains a consistent storage temperature for wine.
Implementation Method 2
an exterior layer fabricated with a fiber reinforced cementitious material designed for structural stability and for effectively containing internal atmospheres
Implementation Method 3
geopolymer concrete interior layer with a unique blend of natural clay, carbonates, and industrial waste materials, providing a non-reactive, high thermal mass surface
Data Source
AI summary
A liquid storage vessel having a base with a bottom and an interior floor; a continuous side extending vertically from the base and having an interior surface, the bottom and continuous side each including an internal layer and an external layer separated by a material barrier and configured such that the interior layers form an inner containment liner, and the external layers form a continuous exterior structural shell enclosing the inner containment liner. A top is affixed to the continuous side and has an interior ceiling. Access to the tank interior is provided by one or more manways. Mounting and connecting structures enable the tanks to be stacked directly atop one another and then structurally connected. The exterior structural shell is fabricated from high performance fiber reinforced concrete, and the inner containment liner is fabricated from a geopolymer concrete blend.