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, 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 ****5% maintaining the cell’s holding capacity.  

 
     Benefits of super tank electrolytic cells are 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 *0 years in the chemical processing industries worldwide.
       Manufacturer’s *0 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 *5% 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 *0% 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. ******9)

(3)  An external FRP seal.

 

The polymer concrete structural core and both FRP seals are manufactured to ensure a high quality chemical bond between the three strata, forming a cohesive, monolithic composite material with very high chemical and mechanical strength. The formulation and properties of this composite material have been tailored for best performance electrolytic cells.

The electrolyte seal complies with the sections of norms DIN *8.****3 and ASTM C**2 regarding chemical barriers for FRP tanks. These forms have been validated by more than *0 years of successful industrial experience. This seal typically consists of three layers of fiberglass impregnated with vinyl ester resin.

The external seal is manufactured with same care and quality as the electrolyte seal, although with only one FRP layer it does not comply with the above standards.

 Both seals can be inspected according to norm ASTM D***7 Class IV. As an option the seals may be pigmented white, gray or other color favorable to refinery operation or purchase preference.

 The Hyperbonded polymer concrete material offers improved mechanical strength and excellent chemical and electric resistance, compared to conventional polymer concrete. It has also been formulated to reduce thermal dilatation that induces high mechanical stress in electro-refining cells.