Glass Fused to Steel Tanks is the most common tank specification for CSTR biogas digester reactor tanks. In this article, we discuss their pros and cons.
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Enamel tanks, GFS tanks (GFtS), and Glass Fused Bolted Steel (Porcelain Enameled) tanks are all terms used to describe this type of tank.
It is essential that all anaerobic digestion tanks must be extremely durable, which means they must be resistant to corrosion as well as impact and abrasion. These tanks have that characteristic but as in most things, their advantages come with a few disadvantages. Read on and find out what those pros and cons really are.
Advantages of Glass Coating in Steel Technology
Undoubtedly, the apex of coating technology in the storage tank industry lies in glass-fused-to-steel technology. These tanks find extensive application in various sectors including bio-energy (especially CSTR biogas plants), municipal sewage, landfill leachate, and industrial wastewater treatment.
How Challenging is it to Select the Right Tank Material?
Selecting a liquid storage tank might seem straightforward. After all, it's a vessel for holding liquids. Is there truly a substantial difference?
The reality is that each type of tank boasts its own set of advantages and disadvantages. The key to choosing the optimal product lies in evaluating these pros and cons against your specific requirements.
Tanks Made of Glass Fused to Steel
Glass-fused steel, also known as enameled steel, represents an advanced technology offering long-term performance with minimal maintenance requirements.
These tanks stand out as the preferred material for biogas digesters due to their fusion of steel toughness with the corrosion resistance of glass. Moreover, they serve as excellent choices for storing potable water, wastewater, industrial chemicals, bio-digesters, sludge, and various dry bulk materials.
In a cutting-edge furnace, enamel frit (glass compounds) undergoes chemical fusion with steel sheets at exceptionally high temperatures (ranging between 800 and 1,000 degrees Celsius). This process generates an integrated, porcelain-like coating that is firmly bonded, chemically inert, and impermeable to liquids.
Suppliers tout these tanks as capable of withstanding a range of conditions, such as temperatures up to 140°F and pH levels between 3 and 11, without succumbing to corrosion.
Advantages of Glass-Fused-to-Steel Tanks
Glass fused to steel liquid tanks combines the strength of steel with the exceptional corrosion resistance of glass, offering numerous advantages over traditional epoxy-coated or welded painted storage tanks, including:
1. Outstanding anti-corrosion properties.
2. Swift installation in the factory, coupled with high-quality design, production, and stringent quality control.
3. Safety and simplicity: Operators require minimal long-term training, and plant owners benefit from reduced maintenance, leading to less time spent by workers in elevated positions.
4. Minimal impact from local weather conditions on these tanks.
5. Low initial investment, especially pertinent for biogas digesters and industrial wastewater treatment projects.
6. Cost-effective maintenance and ease of repair.
7. Reduced life-cycle costs due to the enduring coating.
8. Flexibility for relocation, expansion, and repurposing.
9. Aesthetic appeal with various color options.
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10. Simplified cleaning compared to unlined equipment.
11. Customization for specific applications with tailored tank designs.
Even stainless steel tanks, while normally an ideal material for these tanks, cannot withstand the high sulphur which may accumulate at the top rim of commercial digester tanks.
Disadvantages of Glass-Fused-to-Steel Tanks
While Glass Fused To Steel Tanks offer numerous benefits, it's important to acknowledge some drawbacks that, although not extensive, are noteworthy:
1. Joint sealing is crucial at the points where the tank is bolted to the concrete base slab to prevent potential leaks.
2. Physical damage, like impacts from moving equipment or machinery, can lead to chipping of the glass coating at the impact site.
3. Concrete-based biogas tanks in Anaerobic Digestion Plants provide superior insulation compared to steel tanks, thereby avoiding the need for additional thermal insulation and associated costs.
4. When considering burial or partial burial, steel tanks might be less suited to withstand soil loads compared to reinforced concrete tanks.
5. Ensure that the purchased Glass Fused To Steel tank includes edge corrosion protection, as untreated panel edges may pose long-term issues in bolted steel tanks.
Nevertheless, implementing excellent design, installation, and operational practices can prevent or mitigate these aforementioned issues effectively.
In moderate climates, digester tanks are typically insulated and enveloped with plastic-coated aluminum profile sheeting along their outer edges.
This practice serves the purpose of safeguarding the installed insulation and provides additional protection to the tanks, shielding them from accidental impact damage to the fused-to-glass enamel during their operational use.
The Primary Drawback of GFS Tanks: Initial Cost
While the benefits of GFS tanks are substantial, their most notable disadvantage is often the initial expense. Glass-lined tanks tend to be considerably pricier compared to epoxy tanks.
Consequently, some businesses might initially perceive these upfront costs as prohibitive. However, it's crucial to examine the total cost of ownership throughout the tank's lifespan, considering reduced maintenance expenses and longer-lasting durability offered by GFS tanks, which can result in less frequent replacements.
Quality Assurance and Standards for Glass-Fused-To-Steel Bolted Tanks
Engineers and industry experts worldwide are increasingly selecting glass-fused-to-steel tanks for their resilience in challenging conditions, ensuring decades of trouble-free operation. However, tanks employing this unique technology require strict adherence to quality standards, notably ISO certification, to ensure superior manufacturing and defect-free performance.
Well-manufactured porcelain-enameled tanks boast a lasting coating that eliminates the need for recoating.
Among various substrates for glass coating like steel, aluminum, cast iron, copper, and brass, steel is commonly used in porcelain-enameled tanks, chosen based on size requirements&#;larger tanks often necessitate a more durable steel grade.
Delivering Quality Glass-Fused-to-Steel Tanks
It's imperative to procure tanks only from manufacturers holding ISO certification, indicating adherence to over 16 standard inspections before sale approval. Glass Fused to Steel tanks prove highly advantageous for containing potable, municipal, agricultural, and industrial fluids due to their minimal maintenance needs and inherent resistance to contamination.
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