"Super tank Polymer Concrete Electrolytic Cells are designed, built and installed to satisfy the most stringent requirements requested by tank house operators worldwide. In most case their main request is to guarantee full operating availability throughout the plant' s lifespan, maximizing production of high-purity metal (copper, zinc, nickel, cobalt, lead or other) with absolute safety for people and the environment.
Additionally, Polymer Concrete Electrolytic Cells must accommodate changes for continuous improvement of electrolytic process, integrating efficiently with upgrades of complementary equipment such as anodes, cathodes, cap boards, overhead crane, electrolyte agitation systems, acid mist control devices, thermal insulation, among many others.
Super tank electrolytic cells are cast monolithically based on a patented, three stratum composite material system.
the internal stratum is a monolithic tank made with multiple layers of fiber-reinforced vinyl ester resin (FRP) complying with chemical barrier international norms that assure long term impermeability and corrosion resistance.
the intermediate stratum is the structural core made with Hyperbonded Polymer Concrete, with a patented formulation to achieve a low coefficient of thermal expansion, providing long term structural integrity with low thermally-induced stresses.
the external stratum is a standard seal layer of FRP that further protects the structural core from electrolyte splashes and spills. Optionally, this external seal may be specified with multi-layered oriented fiber reinforcements to guarantee trouble-free operation in unusually extreme operating environments.
Super tank electrolytic cells are characterized by their rounded shapes, optimized for aggressive thermal conditions through successive iterations using computer simulations and finite element analysis.
the Super tank design eliminates corners and sharp edges, replacing them with smooth curves in the interior and exterior junctions. Abrupt changes in wall thickness become gradual transitions throughout the structure, mitigating stress concentrations and reducing material usage and weight by 12-15% maintaining the cell's holding capacity.
Benefits of super tank electrolytic cellsAre as follows:
Guaranteed Long-Term Impermeability, Free of Corrosion
It is designed with a monolithic impermeable internal tank manufactured with multiple layers of fiber-reinforced premium vinyl ester resin. the specifications for this internal tank have been validated by proven impermeability and corrosion-free service for over 40 years in the chemical processing industries worldwide.
Manufacturer' s 20 Year Warranty
We guarantee Super tank cells for continuous service without leaks, free of corrosion and structural flaws, operating under normal conditions as specified for each Project.
Swift, Accurate and Less Costly Installation
Super tank cells include features that allow reduction of 25% or more 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 Water Consumption
the rounded internal shape, optional sloped cell floors, and smooth, flat finish of the internal tank, facilitate water sweeping and drainage of heavy sludge, with reduced water usage and accelerating return to service after each cleaning.
Minimum Maintenance Cost
the robust, virtually impervious internal tank that is chemically bound to the Hyperbonded polymer concrete structural core 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 sturdy external seismic reinforcement blocks confining its floor supports, and includes a robust, internal bidirectional, pultruded FRP bar mesh reinforcement which positively maintains integrity should the cell fail due to catastrophic events. Super tank cell installation protocols call for lateral wall collaboration between cells, thus reducing stress levels of cell around 40% under normal operating conditions.
Key Accessories Integrated with Super tank Cell Engineering
We design and manufacture cell thermal insulation, capping board and electrolyte agitation systems that can be incorporated in the cells, enhancing overall safety, cathode quality and tank house productivity.
Typical Cell Construction Features
Super tank electrolytic cells are manufactured with a proprietary "" tri-stratum polymer composite material"". this material consists of three monolithically bound layers.
(1) An electrolyte FRP seal or chemical barrier
(2) A structural core made with Hyperbonded polymer concrete (aggregate reinforcement grading according to US Patents No. 6143219)
(3) An external FRP seal."
