Super Tank Cells: Innovations for Tank HouseProductivity

Super tank Electrolytic cells are designed, built and installedto satisfy the most stringent requirements requested by tank houseoperators worldwide. In most case their main request is toguarantee full operating availability throughout the plant''slifespan, maximizing production of high-purity metal (copper, zinc,nickel, cobalt, lead or other) with absolute safety for people andthe environment.

Additionally, electrolytic cells must accommodate changes forcontinuous improvement of electrolytic process, integratingefficiently with upgrades of complementary equipment such asanodes, cathodes, cap boards, overhead crane, electrolyte agitationsystems, acid mist control devices, thermal insulation, among manyothers.

Super tank electrolytic cells are cast monolithically based on apatented, three stratum composite material system:

The internal stratum is a monolithic tank made with multiplelayers of fiber-reinforced vinyl ester resin (FRP) complying withchemical barrier international norms that assure long termimpermeability and corrosion resistance.

The intermediate stratum is the structural core made withHyperbonded Polymer Concrete, with a patented formulation toachieve a low coefficient of thermal expansion, providing long termstructural integrity with low thermally-induced stresses.

The external stratum is a standard seal layer of FRP thatfurther protects the structural core from electrolyte splashes andspills. Optionally, this external seal may be specified withmulti-layered oriented fiber reinforcements to guaranteetrouble-free operation in unusually extreme operatingenvironments.

Super tank electrolytic cells are characterized by their roundedshapes, optimized for aggressive thermal conditions throughsuccessive iterations using computer simulations and finite elementanalysis.

The Super tank design eliminates corners and sharp edges,replacing them with smooth curves in the interior and exteriorjunctions. Abrupt changes in wall thickness become gradualtransitions throughout the structure, mitigating stressconcentrations and reducing material usage and weight by 12-15%maintaining the cell’s holding capacity.  

Benefits of super tank electrolytic cells areas follows:

Guaranteed Long-Term Impermeability, Free ofCorrosion

It is designed with a monolithic impermeable internal tankmanufactured with multiple layers of fiber-reinforced premium vinylester resin. The specifications for this internal tank have beenvalidated by proven impermeability and corrosion-free service forover 40 years in the chemical processing industries worldwide.
Manufacturer’s 20 Year Warranty

We guarantee Super tank cells for continuous service withoutleaks, free of corrosion and structural flaws, operating undernormal conditions as specified for each Project.
Swift, Accurate and Less Costly Installation

Super tank cells include features that allow reduction of 25% ormore in time needed for cell erection, alignment and leveling,compared to time required with conventional polymer concrete cells.Dimension tolerances for Super tank cells are consistently tight,simplifying installation in the most demanding applications,including plants with automated crane systems.
 Minimum Cleaning Time and WaterConsumption

The rounded internal shape, optional sloped cell floors, andsmooth, flat finish of the internal tank, facilitate water sweepingand drainage of heavy sludge, with reduced water usage andaccelerating return to service after each cleaning.
 Minimum Maintenance Cost

The robust, virtually impervious internal tank that ischemically bound to the Hyperbonded polymer concrete structuralcore during molding is tolerant to operating abuse. Its smooth,non-stick surfaces minimize adhesion of contaminants.
 Maximum Operational Safety

The structural core of Super tank cells is bolstered with sturdyexternal seismic reinforcement blocks confining its floor supports,and includes a robust, internal bidirectional, pultruded FRP barmesh reinforcement which positively maintains integrity should thecell fail due to catastrophic events. Super tank cell installationprotocols call for lateral wall collaboration between cells, thusreducing stress levels of cell around 40% under normal operatingconditions.
Key Accessories Integrated with Super tank CellEngineering 

We design and manufacture cell thermal insulation, capping boardand electrolyte agitation systems that can be incorporated in thecells, enhancing overall safety, cathode quality and tank houseproductivity.

Typical Cell Construction Features

Super tank electrolytic cells are manufactured with aproprietary “tri-stratum polymer composite material”. This materialconsists of three monolithically bound layers.

(1)  An electrolyte FRP seal or chemical barrier

(2)  A structural core made with Hyperbonded polymerconcrete (aggregate reinforcement grading according to US PatentsNo. 6143219)

(3)  An external FRP seal.

The polymer concrete structural core and both FRP seals aremanufactured to ensure a high quality chemical bond between thethree strata, forming a cohesive, monolithic composite materialwith very high chemical and mechanical strength. The formulationand properties of this composite material have been tailored forbest performance electrolytic cells.

The electrolyte seal complies with the sections of norms DIN18.820-3 and ASTM C582 regarding chemical barriers for FRP tanks.These forms have been validated by more than 40 years of successfulindustrial experience. This seal typically consists of three layersof fiberglass impregnated with vinyl ester resin.

The external seal is manufactured with same care and quality asthe electrolyte seal, although with only one FRP layer it does notcomply with the above standards.

Both seals can be inspected according to norm ASTM D4097 ClassIV. As an option the seals may be pigmented white, gray or othercolor favorable to refinery operation or purchase preference.

 The Hyperbonded polymer concrete material offers improvedmechanical strength and excellent chemical and electric resistance,compared to conventional polymer

concrete. It has also been formulated to reduce thermaldilatation that induces high mechanical stress in electro-refiningcells.

The Hyperbonded polymer concrete material offers improvedmechanical strength and excellent chemical and electric resistance,compared to conventional polymer concrete. It has also beenformulated to reduce thermal dilatation that induces highmechanical stress in electro-refining cells.