Materials of Construction - Storage Tanks

November 11, 2002

Introduction Shell Linings Phenolic Coatings Glass-lined Recommended Materials

Associated Links Storage Tanks Anodic Protection

Introduction The material selected for sulphuric acid storage tanks will depend on a number of factors such as: Tank size Desired acid quality Costs Acid concentration Storage temperature

Back to Top Shell The materials of construction will depend on the acid concentration, temperature and composition. The table under the heading Recommended Materials lists the options for materials of construction. By far the most common material of construction is carbon steel. Where iron pickup needs to be minimized stainless steel can be used for the shell although at considerably higher costs. An alternative to stainless steel is anodically protecting the tank. Back to Top Linings Linings can serve to minimize or eliminate corrosion of the tank and reduce contamination of the acid. Back to Top Phenolic Coatings Baked phenolic coatings are use to minimize iron pickup and corrosion in tanks storing 93% H 2SO4. The life of this type of coating is severely limited in 98% to 99% service. Phenolic coatings should never be exposed to alkaline neutralizations because alkali attacks phenolic coatings even in dilute concentrations. The integrity of the lining is dependent on the quality of the surface preparation and the actual application of the lining. All internal surfaces must be inspected, degreased and sandblasted. A thermally cured phenolic coating #P403 of 0.178 mm to 0.254 mm (0.007 to 0.010 in.) thick is applied using a multi-coat procedure immediately following sandblasting. Back to Top

Glass-lined Glass-lined storage tanks are used where the acid is extremely pure and no contamination of the acid is permitted. The storage requirements for high quality acid are generally small so storage tanks are generally small. Back to Top Recommended Materials The following materials are recommended for sulphuric acid service. Acid Concentration Temperature Material Carbon Steel ASTM A131 Gr. B ASTM A516 Gr. 70 ASTM A573 ASTM A662 Carbon Steel with phenolic lining Carbon Steel ASTM A131 Gr. B ASTM A516 Gr. 70 ASTM A573 ASTM A662 Carbon Steel with phenolic lining Carbon Steel ASTM A131 Gr. B ASTM A516 Gr. 70 ASTM A573 ASTM A662

70 to 80% H2SO4

< 40C

88 to 100% H2SO4

< 40C

0 to 65% Oleum

< 40C

When specified, plate material shall be: Impact tested required where ambient temperatures are low such as in northern climates. Fully killed as per API 650. Fine grain practice as per API 650.

Some investigators claim that copper bearing steels such as ASTM A285 Gr. C, S57 provide lower corrosion rates and resistance to hydrogen grooving but others feel that there is no advantage and the added cost of the steel is not warranted. The following steels are not recommended for use in sulphuric acid storage tanks: Carbon steel to ASTM A36, A283, A285, A515 High strength steels and low alloy steels

When carbon steel to ASTM A36 or A285 is specified, it shall be made using other than rimmed or capped steel practices.

Eng-Tips Forums is Member Supported. Click Here to donate. metallurgist5 (Materials) hello guys, i am going to coat Carbon steel storage tanks containing sulfuric acid 60%, at 130 degrees centigrade, with a pressure of 4 bars.what do you suggest as the best coating considering corrosion resistance, ease of application and price? many thanks to everyone, 4 Mar 11 8:40

TVP (Materials)

4 Mar 11 11:18

Why would you want to use a coated, carbon steel tank? enmax (Materials) 4 Mar 11 12:55

There are no coatings that would be suitable - even if there were would you risk a break in the coating? You might consider building a plastic tank in a fluorinated polymer (but consult potential vendors first!). I'd be concerned about using carbon steel to contain 60% sulphuric at this temperature. As TVP says - why are you doing this? A high silicon cast iron would do this job with little risk. If you were to store the acid at higher concentrations (subject to certain precautions) you could leave the steel uncoated. http://uk.linkedin.com/pub/terry-roberts/28/a9a/a10 metallurgist5 (Materials) 4 Mar 11 16:19

to TVP: thank you for your consideration. the reason is because the corrosion rate at the moment is higher than expected. the mentioned service conditions are highly corrosive and we have no other choice except coating the inside of the tanks. the wide range of coatings had made us confused a little, i really appreciate your comments. metallurgist5 (Materials) 4 Mar 11 16:32

to enmax: thank you very much for your time and consideration. the fact is that unfortunately, the company has bought these tanks and at the moment, we want to try our best to coat the tanks rather than rebuilding them. till now, we are considering all the available coatings than can be chosen like : glass, TEFLON, Tantalum, PEEK, VITON, etc. i really appreciate your precise comments on both solutions: coating and rebuilding the tanks. TVP (Materials) 7 Mar 11 11:10

PTFE (Teflon) coatings are resistant to sulfuric acid. Here are some links: http://www2.dupont.com/Clean_Technologies/es_MX/assets/downloads/Equipment_FAQs.pdf

http://www.polyprocessing.com/pdf/technical/ChemicalResistanceChart.pdf http://www.xpress-link.net/ChemResult.asp metallurgist5 (Materials) 7 Mar 11 14:14

to TVP: thank you once again for your reply. i checked all the links you provided. it seems the last link does not work properly, so its a great help if you just reupload it. at the moment, we have put TEFLON on the first rank list till now. we are also considering the following at the same time : 1- Phenolics (Concentration= 50%- T=121C) 2- Perfluoroalkoxy/ PFA (Concentration= 10%-100%- T=232C) 3- Fluorinated Ethylene Propylene/ FEP (Concentration= 10%-100%- T=204C) 4- TEFLON/ PTFE (Concentration= 10%-100%- T=232C) 5- Tefzel/ ETFE (Concentration= 10%-100%- T=149C) 6- Halar /ECTFE (Concentration= 10%-70%- T=121C) 7- Fluoroelastomers (Concentration= 10%-98%- T=149C) many thanks to your help.

dmp3418 (Industrial)

12 Mar 11 19:53

Here is a product that is designed for acid storage in carbon steel tanks. http://www.tnemec.com/product/view/Series-365-TankArmor 100% solids novolac epoxy. Our company has used this with success in the past. Corrosion in these tanks can be very accelerated, so a very dense, thick film lining would be required. Try giving the local Tnemec rep a call. corrosionman (Mechanical) 14 Mar 11 18:04

Metallurgist5.Your job is completely impossible.Phone Cleveland Corrosion Co in UK and I'll repeat what othereshave said already. CM unclesyd (Materials) 17 Mar 11 11:47

There are two possibilities not eluded to in the above posts and they are Rubber and Lead Lined tanks. These tanks can be economical in many cases. I don't have anyone now that specifically does Lead Lining. For Rubber Lined Tanks I would contact someone like Bittner to discuss your application. http://bittnerindustries.com/capabilities.htm

Jmoore1 (Mechanical)

31 Mar 11 13:41

How big are these tanks... you could weld overlay or clad them as well. pennastik (Mechanical) 21 Apr 11 12:15

I hope you have already solved your problem. We solved some similar problems in UAE for an off-shore installation utilizing cold applied, polymeric repair compound. The name of product is Belzona. In any case, forget a long life for your tanks. Bye rustbuster (Petroleum) 6 May 11 14:04

There are some fairly good thermal spray alloys you might consider.

http://cr4.globalspec.com/thread/16138

Introduction Existing codes are inadequate for the design of sulphuric acid storage tanks. The corrosion allowances and the design for corrosion control are left to the individual designer/owner/operator of the tank. Large storage tanks are usually built to the following codes: API Standard 650 API Standard 620 Welded Steel Tanks for Oil Storage Recommended Rules for Construction of Large, Welded, Low Pressure Storage Tanks

ASME Boiler and Pressure Vessel Code, Section VIII, Division I These codes are sufficient for the mechanical design of the storage tank but are not adequate to address the peculiarities of the corrosion by sulphuric acid. Corrosion The corrosion resistance of carbon steel in the presence of sulphuric acid is due to iron sulphate which is formed in the initial contact period. Any condition causing sufficient turbulence to remove the sulphate film is likely to lead to corrosion.

Corrosion rates are usually stated in 'mpy' mils per year. One mil per year (1 mpy) is equivalent to 0.001 inches/year or 0.025 mm/year. Metal loss increases as the acid strength decreases below 98% H 2SO4. 77% H2SO4 is usually regarded as the practical lower limit at which sulphuric acid can be stored at ambient temperatures in unprotected carbon steel tanks. Uniform Corrosion The figure below illustrates the corrosion rate of steel by sulphuric acid as a function of concentration and temperature. To compensate for uniform corrosion an adequate corrosion allowance has to be included in the design of the tank. It should be based on design life, with consideration given to factors such as temperature, tank utilization and acid purity.

Temperature The steel isocorrosion curves clearly illustrates that the corrosion rates increase with increasing acid temperature. Product acid from a plant should be cooled to a maximum of 40C (104F). Within the storage tank the bulk acid temperature should be kept as low as possible without freezing the acid. Climatic conditions contribute to the temperature variation within a storage tank. Season temperature changes are generally not a problem because rarely will the ambient temperature be higher than 40C (104F). Of greater importance is the effect of the sun heating the tank contents. Higher corrosion rates have been reported on the side of tanks heated by the sun. To minimize this problems the tank should be painted with a heat reflecting colour. Tank Utilization The rate of corrosion generally decreases progressively up the shell of the tank because the upper sections are not exposed to acid as often as the lower parts.

Acid Purity The purity of acid can be relatively high leaving the acid plant with iron contents can be as low as 30 ppm. Acid will become more corrosive as the iron content is decreased. Corrosion rates will be higher than normal unless precaution are taken such as lining the tank or the use of anodic protection.

Non-Uniform Corrosion Non-uniform corrosion can severely reduce the life of a storage tank. Most occurrences can be minimized in the design of the tank and by performing regular inspections of the tank internals. Hydrogen Grooving Hydrogen is generated when sulphuric acid corrodes carbon steel. The hydrogen gas formed rises towards the surface and the passage of these bubbles over the steel surface can result in the formation of grooves. The grooves can be of varying width and depth. The loss of metal in this area occurs at a far greater rate than uniform corrosion at the same acid concentration and temperature. The effects of hydrogen grooving can be minimized by a properly located acid inlet. Hydrogen grooving can also occur at the top of the nozzle of a side manway.

Horizontal Grooving Horizontal grooving occurs when a layer of dilute acid sits on top of a layer of stronger acid. Dilute acid is formed when water infiltrates the tank and contacts the acid surface resulting in an acid of lower strength. The lower specific gravity of the weaker acid means it will remain on the surface. The

lower the acid concentration the more rapid the corrosion rate. Several horizontal grooves can be formed as the level in the tank fluctuates. In one incident, water was accidentally pumped into the storage tank with the result that the shell was cut in half. Localized temperature increases can also result in horizontal grooving. Hot acid pumped into a tank will not easily mix with the cooler contents of a storage tank. The result will be a layer of hotter acid which will corrode the shell of the tank faster than the colder acid. External Corrosion External corrosion of a storage can be as much a problem as internal corrosion. External corrosion can occur in three areas: Improper foundation which allows water and debris to come in contact with the bottom of the tank Crevices between the tank and supports or attachments that allow water or spilled acid to collect Wet insulation

When a storage tank is insulated to prevent freezing of its contents, corrosion under the insulation can occur if the insulation gets wet. This type of corrosion is very common and will occur where water can accumulate such as near nozzle necks, roof or shell attachments (i.e. handrails, stairs, etc.), insulation support rings, etc. Any cladding or insulation that has become damaged or is missing should be repaired immediately. Foundations that allow water to accumulate will result in corrosion of the tank bottom. This type of corrosion is difficult to detect since the bottom of the tank is generally not accessible for external examination. Corrosion can be a general loss of metal or a localized attack in the form of pitting.

An example of external corrosion is shown in the photo to the right. Here the tank bottom was attacked from below due to what is believed to be moisture under the steel. This type of corrosion is very difficult to detect during a tank inspection because it is so localized. The entire tank bottom would need to be scanned in order to determine the extent of the corrosion.

Hydrogen Blistering When carbon steel corrodes in the presence of sulphuric acid, atomic hydrogen is formed. Some of this atomic hydrogen diffuses into the metal and migrates to the exterior. If there is avoid or lamination in the plate, the hydrogen will accumulate there as molecular hydrogen. Molecular hydrogen does not diffuse as easily as atomic hydrogen so it becomes trapped in the void. As more hydrogen accumulates the pressure in the void increases significantly to the point where the plate will begin to bulge. As the

pressure in the void increases the size of the blister may increase as the plate delaminates or the blister will rupture. Special precautions must be taken if work is done near a hydrogen blisters. The heat generated from drilling or welding may be sufficient to ignite the hydrogen gas. Defects such as voids or laminations are common in milled plate but are very difficult to detect. Experience has shown that blistering occurs in a large percentage of storage tanks. Tank Farms Tank farms are common where a facility produces or handles acid of varying concentration and quality or when the quantity of acid to be stored exceeds the capacity of a single tank. Multiple tanks adds the flexibility of the facility to handle the unexpected. Containment Due to environmental pollution control a containment area will be required around all new tank installations. The dike or bund should be designed to contain 110% of the largest tank within the diked area. Safe access into and out of the diked area must be provided as well as a sufficient number of escape routes. The diked area should also provide for the draining and collection of water. The area should be sloped to a centrally located sump where any water or spills can be treated and disposed. Pumps Pumps should be located inside the diked area as close to the tank as possible to avoid long suction lines. Pumps located outside a dike area means there may be pipes penetrating the dike. Differential settlement of the tank and the pump may lead to unacceptable strains on the piping, tank and pump nozzles. Design Details Corrosion Allowance The corrosion allowance should be based on the required service life, acid concentration, temperature, geographic location and upon whether or not anodic protection or an internal protective coating is installed. In general, the roof of a storage tank should be designed with a minimum 3 mm corrosion allowance. The shell and tank bottom should have a minimum of 6 mm corrosion allowance. Acid Inlet Nozzles For vertical storage tanks the inlet nozzles should be positioned as close to the centre of the roof to minimize the potential for hydrogen grooving of the shell. One source recommends locating the inlet nozzle a minimum of 2.44 m (8 ft) away from the shell. Another source requires a minimum of 3.66 m (12

ft). A third reference requires a minimum of 3.05 m (10 ft). In all cases the inlet nozzle should project into the tank at least 150 mm (6 in.). When the required distance from the wall can not be accommodated (i.e.. in small tanks) all acid inlets should be equipped with dip pipes which will bring the acid to within 0.914 m (3 ft) of the tank bottom. The dip tube should be located a minimum of 1.83 m (6 ft) from the side wall. The bottom of the tank should be equipped with a protective impingement plate. The dip tube should include a siphon break in its design. Tank Sizing Some of the factors that will determine the number and size of tanks are: Plant production rate Number of different grades of acid Acid usage Acid sales

Once the number and size of each tank has been determined the individual tanks can be sized. A good guide to determine the capacity of a tank is 1.5 times the size of the normal delivery or the normal delivery plus two weeks consumption which ever is greater. For tank truck delivery, the capacity should be at least 40 tons. For tank car delivery (100 tons), the storage tank capacity should be at least 200 tons. Storage tank capacities are usually given based on the weight of acid in the tank rather than the volume (i.e.. 5000, 10000 tonne). The shell of the tank will be fabricated from flat plate rolled to the required curvature. To minimize fabrication costs full plates should be used for each course. Vents The vent should be at least the same diameter as the fill line, the discharge line or drain connection, which ever is greater. Preferably, the vent should be one pipe size larger. The presence of other vent lines into the tank from an oleum tank should be considered when sizing the vent. The cross-sectional area of all incoming vents should be added to the vent line size. Oleum Vents For oleum tanks the vent should be sized using the above criteria but should be at least 75 mm (3 in) diameter. The vent should be at heat traced and insulated to prevent freezing of SO3 fumes. To contain the SO3 fumes the vent may be directed to the vapour space of a storage tank containing 93% or 98% sulphuric acid. Otherwise, the vent should be directed to a scrubber.