ENGINEERS AUSTRALIA

Perth, 5th March 2013

TANK COATING TECHNOLOGIES
FOR AGGRESSIVE
STORAGE

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STORAGE TANKS
Main Construction Materials
STEEL

CONCRETE

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 Number of Products Stored in Tanks

Gasoline White Oils

Water
2,500 Diesel

52 main products = about 80% of storage

Aviation fuel SOLVENTS
Acids
Crude Oil
Alkalis Vegetable oils

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Decisions for Coating Selection

Four Inter-related Considerations

Product Stored

Cost Tank Type &

Surface Condition

Lining Type
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 Selection of Internal Coating System

Three Considerations

The lining’s substrate

protection properties

The lining’s The lining’s resistance

contamination effect to stored cargoes and
on stored cargoes conditions

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Coating Selection Depends on Cargo Stored

VARIABLE CARGO DEDICATED

STORAGE CARGO STORAGE

Generically Changing
Products:
e.g. White Oils, e.g. Naptha,
Vegetable Oils, Crude Oil.
CARGO
Gasolines, Diesel Oil
STORED
Alkalis, Fire Water.
Acids Potable water, etc.
Aviation Fuels etc.

Changes in Storage Temperature

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 Coating Selection Depends on Steel Condition

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Main Generic Types of Lining Systems

Epoxy, SB

Inorganic Zinc Silicate 1 Phenolic/Novolac Epoxy, SB

8 2

Vinyl/Novolac Vinyl Ester, Epoxy, SF, w/wo

7 LINING TYPES 3
w/wo reinforcement reinforcement

Polyester w/wo 6 4 Phenolic/Novolac Epoxy,

reinforcement 5
SF, w/wo reinforcement

Polyurethane/Polyurea
Elastomers
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 Selection of Internal Coating System

Film Thickness Range

Thin Film Linings up to 500 microns.

Multi-coat systems.
Usually solvent-based Epoxy systems

Heavy Duty Linings: 500 – 1000 microns.

One or two coat systems.
Solvent-Free Epoxy
Vinyl Ester or Polyester.

Ultra HB or Reinforced Linings: >1000 microns

Epoxy, Polyester, Polyurea / Polyurethane or
Vinyl Ester resin based systems often
incorporating reinforcement.

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HIGH TECHNOLGY COATINGS

Typical Thickness Range
Total Coating Thickness:
Up to 5000µm (5.0mm)
1000 - 3000 µm (1.0 - 3.0mm)
500 -1000µm (0.5 -1.0 mm)

Blasted steel
Blasted Steel

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 Typical Aggressive Storage Conditions
• MINERAL ACIDS - various concentrations of sulphuric, nitric, hydrochloric,
phosphoric, etc.
• ORGANIC ACIDS - various concentrations of acetic, lactic, citric, fatty acids, etc.

• ALKALIS - various concentrations of sodium, potassium, calcium, ammonium

hydroxides etc.
• LOW M.Wt. ORGANIC SOLVENTS - alcohols, ketones, esters,
aromatics, ethers, etc.
• LOW M.Wt. AMINES - EDA, DETA, TETA, aniline, etc.

• VEGETABLE OILS - linseed, soya bean, olive, coconut, palm, fish, etc.
• PURIFIED WATER - distilled, deminerized, deionized, potable, etc.
• ELEVATED TEMPERATURES - generally above 70º C - localised heating
• HOT CRUDE OILS - incorporated water/vapour up to 120º C
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Epoxy Based Tank Linings

Typical Generic Description - Simplistic

• Epoxy – Normal Cross-Linked Network

• Epoxy Phenolic – High Cross-Linked Network

• Epoxy Novolac – Very High Cross-Linked Network

• Epoxy Novolac – Ultra High Cross-Linked Network

‘Polycyclamine’

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Traditional Epoxy Resins (chemistry)

Bisphenol ‘A’ type Epoxy

Bisphenol ‘F’ type Epoxy

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Traditional Epoxy Resins (diagrammatic)

Small molecule, low viscosity liquid

Larger molecule, high viscosity liquid

Even larger molecule, solid

Very large molecule, solid

Epoxy Groups
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 Complex Epoxy Resins (Chemistry)

Epoxy Phenol Novolac

Epoxy Cresol Novolac

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Complex Epoxy Resins (diagrammatic)

Epoxy Phenol or Cresol Novolac

Epoxy Groups
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 Epoxy Resins
functionality & relative viscosity

Epoxy type Typical Relative

functionality viscosity
Bisphenol A 1.9 Medium

Bisphenol F 2.1 Low

Epoxy phenol novolac 2.6 – 3.5 High

Epoxy cresol novolac 2.7 – 5.4 Very high

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Examples of Epoxy curing agents:

Aliphatic & Aromatic Amines (Chemistry)
Diethylene triamine

Triethylene tetramine

Tetraethylene pentamine

Meta xylylene diamine Methylene dianiline

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 Examples of Epoxy curing agents:
Cycloaliphatic Amines (Chemistry)

Isophoronediamine Diaminocyclohexane

4,4 bis (para aminocyclohexyl) N-aminoethylpiperazine

methane

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Examples of other types of epoxy

curing agents (Chemistry)

Mannich base Amidoamine

Ketimine

Polyamide

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 Examples of Epoxy curing agents:
polycycloaliphatic polyamines (Chemistry)

‘POLYCYCLAMINES’

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Curing Agents for Epoxy Resins

(Diagrammatic)

Linear amines

Complex multi - reaction amines

Amine groups

ComplexAll multi - reaction amines or polycycloaliphatic polyamines

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 Combination of Complex Epoxy Novolacs
and Complex Polyamines

Epoxy Phenol Novolac Epoxy Groups

Amine groups

Complex multi - reaction amines or polycycloaliphatic polyamines

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Combination of Epoxy Phenol Novolacs

and complex ‘Polycyclamines’

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 Cross Link Density (Simplified)

Normal cross-linked High cross-linked Very high cross-linked Ultra high cross-linked
network network network network

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Cross Link Density (Simplified)

• At ambient temperature the cross linking is sufficient to prevent permeation

of water through the film.

Water Water
Water Water
molecules molecules
molecules molecules

Normal cross-linked High cross-linked Very high cross-linked Ultra high cross-linked
network network network network

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 Effect of Temperature on Performance
• At ambient temperature the cross linking is sufficient to prevent permeation
of water through the film.
• Free volume increases in network with higher immersion temperatures due to
plasticization from the heated water.

• Water can permeate the film at a critical temperature.

Heat 60°C Water

Heat 80°C Water
Water molecules
molecules
molecules

Normal cross-linked
network
Increased free volume
due to immersion at higher
temperatures – still showing
reduced permeation
Water permeation – Coating Failure
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Effect of Temperature on Performance

• Even at 100 degC the tightly cross-linked structure is not permeated

Heat 80°C Heat100°C

Water Water Water
molecules molecules molecules

Ultra high cross-linked

epoxy / polycyclamine
lining network

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 Typical properties of various epoxy curing
agents

Category of Water Solvent Chemical Low temp Room Blush Viscosity

amine resistance resistance resistance cure Temp cure resistance
speed
Aliphatic amine Good Very Good Good Moderate Poor Low
good to fast

Aromatic amine Good Very Very Poor Slow Poor Medium

good good

Polyamide Very Good Moderate Poor Moderate Poor High

good

Polyamidoamine Very Good Moderate Poor Moderate Good Medium

good

Mannich base Very Good Moderate Very Fast Varies Medium

good good

Cycloaliphatic Good Very Good Good Moderate Varies Low

good to fast

Note: curing agent properties, especially blush resistance,

may be modified by adducting with epoxy resin

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‘Polycyclamine’ Performance vs other Curing

Agents
Category of amine Water Solvent Chemical Low temp Room Blush Viscosity
resistance resistance resistance cure Temp cure resistance
speed

Aliphatic amine Good Very Good Good Moderate Poor Low

good to fast

Aromatic amine Good Very Very good Poor Slow Poor Medium
good

Polyamide Very Good Moderate Poor Moderate Poor High

good

Polyamidoamine Very Good Moderate Poor Moderate Good Medium

good

Mannich base Very Good Moderate Very Fast Varies Medium

good good

Cycloaliphatic Good Very Good Good Moderate Varies Low

good to fast
Fast
Polycycloaliphatic Very Very Very good Very Fast
curing=fast Good Low
Polyamine good good good return to
(“polycyclamine”) service

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 Costs of Down-Time
Example 1:
Shell – Coating & corrosion problems in Crude Oil Tank:

• 48 m diameter

• Coating failure with severe pitting of floor plates

• Downtime Cost: US$ 67,000/day

Example 2:
BP – Crude Oil Tank:

• 78 m diameter

• Coating failure with pitting of the floor plates

• Downtime Cost: US$ 58,000/day

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Advantage of Fast Return to Service Linings

Time saving vs typical 1 coat system = 5 days

Time saving vs typical 2 coat system = 7 days

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 Epoxy Chemistry Summary
• Epoxy coating formulators can draw upon an incredible array
of raw materials

• Choice of epoxy resin type and curing agent (and ratio of

mixing them) can affect:
– Cross link density
– Tg (Glass Transition temperature)
– Chemical resistance
– Viscosity
– Cure response at different temperatures
– etc

• Pigments, additives and diluents further affect the coating

properties

• The complexity of epoxy chemistry is therefore too broad to

be covered by simple “generic descriptions”

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CONTROL RESPONSIBILITIES

Chemist Applicator Trained

and Approved
Applicator

Paint Manufacturer has direct control over the Advising on surface

product in the can: preparation and application
•Raw Materials Both equally
•Formulation Important to the
•Manufacturing quality of the
final film.
•Testing
Final coating performance realized as a dry film on the surface
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 Field Performance Data:
‘Polycyclamine’ cured Novolac Epoxy

18 months in hot
produced water at
88 -94 C .
Lining was placed in
service within 24
hours of coating
application

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Field Performance Data:

‘Polycyclamine’cured Novolac Epoxy

6 years in deionizer
vessel – operating
temperature 100 -107 C
and periodically dosed
with 7% hydrochloric acid
and 20% sodium
hydroxide

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 SUMMARY
TANK LININGS:
Lining selection is dictated by the following main criteria:
• Tank Type – Steel, Concrete.
• Condition of surface - smooth or pitted.
• Product or range of products to be stored.
• Duration of storage.
• Temperature of the storage.
• Expected lifetime to first or next maintenance.
• Compliant or approved for specific storage requirements (e.g. potable
water, aviation fuel).

• Effectively all Products/Cargoes and conditions can be catered for with

International’s Tank Lining Systems of

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ENGINEERS AUSTRALIA
Perth, 5th March 2013

All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings

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