How Do Storage Tanks and Vacuum Receivers Improve Safety and Efficiency in Chemical Manufacturing?
Manufacturing environments, in which chemical usage is integral for production, have no way to store and handle chemicals safely as part of their operations. The storage tank/vacuum receiver system is an important tool for chemical manufacturers to manage the large volumes of chemicals they will handle in a cost-effective way while improving efficiency, thereby reducing the risk involved in manufacturing and optimizing workflow to improve overall efficiency and decrease costs associated with chemical manufacturing and handling. This article will examine how utilizing these types of storage tanks and vacuum receivers will enhance the throughput capability of the chemical handling process, while providing a safe and reliable method for manufacturers of chemicals to operate in an environmentally sustainable manner.
Understanding Storage Tanks and Vacuum Receivers
Storage Tanks contain large numbers of liquid products and gases, but can also hold other chemicals that need to be maintained or stored long-term. All types of chemicals, whether they are safe or harmful to the body, can be stored in these tanks before they go through the transfer process of manufacturing or processing. Depending on what type of chemicals are in them, you can build tanks using many different types of materials, such as fiberglass reinforced plastic (FRP), polypropylene (PP), polyvinyl chloride (PVC), stainless steel, etc.
Vacuum receivers contain special tank-like objects that work by pulling fluids and gases from something like a process line (pipeline) into a controlled vacuum-type tank. With regard to fluid usage, vacuum receivers allow for greater efficiency of fluids to flow through pipes during vacuum drying operations. When you are handling chemicals in this type of environment, you will often find that it is important to keep the chemical or fluids at a particular vacuum condition, as the temperature can vary greatly from the time you put them in the receiver to the time you get to the next step in chemical processing.
1. Ensuring Safe and Controlled Chemical Storage
Safety is one key advantage of utilizing the correct storage tanks. A number of the chemicals found in many industries are very corrosive, reactive, or toxic in nature. Storage tanks manufactured from FRP or PVDF materials are resistant to corrosion and therefore are able to provide an impermeable container in an aggressive environment for long periods of time.
If a storage tank fails due to chemical corrosion, it can create environmental problems, personnel exposure, closures of the plant, and chemicals leaking into groundwater or stormwater areas. In addition to not rusting or corroding compared to traditional metallic tanks, FRP and composite tanks provide significant safety enhancements and are much more reliable.
In addition to the physical features of the storage tank, many also have various types of sensors and monitoring systems, including level indicators and pressure gauges, that assist plant operators in optimizing the fill levels of their storage tanks, preventing overfilling, and pumping only the appropriate amounts of chemicals at any given time. With this added capability, there are fewer opportunities for human error, thus providing greater control over operations.
2. Reducing Risk and Hazard Exposure
The use of a centralized chemical storage tank system provides a safer and more efficient way to store chemicals compared to decentralized storage systems like multiple small drums and scattered storage containers. By using one large, centralized storage tank, it is possible to greatly reduce accidental spillage of non-reusable chemicals and hazardous materials on employees.
Another benefit of using a centralized tank is that they typically include many additional safety features, such as:
- Secondary containment systems for accidental spillage
- Emergency pressure relief valves to relieve excessive pressure in the storage tank during periods of high temperature
- Vent systemsare designed to avoid creating a vacuum when removing liquid from storage tanks.
3. Improving Material Handling and Workflow Efficiency
Storage tank solutions can help consolidate large volumes of chemical products into a single, centrally located tank. When chemicals are stored in a centralized location, fewer transfers are required from one vessel to another during processing. This results in faster processing times and reduced labor costs because fewer operators need to be involved, and the risk of making a handling mistake is reduced.
Vacuum receivers support faster fluid flow and improve the efficiency of transferring those fluids. In situations where viscosity limits the ability of gravity to move liquid materials from one location to another, the application of a vacuum receiver will allow the operator to use a vacuum to pull the material through the pipe into the vacuum receiver tank. This not only speeds up the transfer of the liquid, but it also minimizes the amount of residual material that remains in either the pipe or the vacuum receiver after the transfer is completed. For many food manufacturing, pharmaceutical production, or filtration applications, minimizing contamination and transfer accuracy is critical.
4. Enhanced Process Control and Consistency
In the chemical processing business, CONSISTENCY IS CRUCIAL. Storage tanks with correctly engineered Inlet/Outlet configurations and integrated sensing devices provide Batch Processing with Predictable Outcomes. Furthermore, Automation Systems can use real-time data produced from Storage Tanks to operate pumps, measure pressure, and maintain the required level of chemicals for production scheduling.
Like Vacuum Receivers, consistent pressure conditions across equipment help plants maintain more consistent pressure conditions throughout their operations as a whole. The vacuum drying and solvent recovery processes, for example, have almost no fluctuation in pressure during their operation; hence, all of these processes can operate without the possibility of delay or waste of product due to variations in pressure.
5. Reducing Downtime and Maintenance Costs
When compared to metal tanks, FRP tanks and high-quality plastic storage tanks require significantly less maintenance. Because they do not corrode or oxidize and can withstand most chemicals, they need to be repaired infrequently and have less overall maintenance expense than metal tanks.
Providing dedicated vessels to buffer pressure for vacuum receivers protects both the vacuum pumps and any ancillary equipment in the vacuum system from premature wear and tear. It allows a vacuum system to run longer without significant cycles of pumping, and without developing excessive wear/tear due to pressure variations; therefore, the overall cost of operating the vacuum system is reduced over its life cycle.
6. Space Optimization and Structural Benefits
Modern storage tanks are designed to maximize the storage of materials within a constrained area of floor space. An example of this is that vertical tank configurations use the height of a material rather than the footprint of the tank to optimize the layout of the plant where the material will be stored. This method is very useful in cases where space is limited in a facility.
In addition, in some situations, vacuum receivers may also be designed to incorporate other types of process equipment, which can provide additional opportunities for space savings as well as provide the needed balance between operation and design.
7. Enhancing Productivity and Throughput
The use of vacuum receivers provides an added benefit by buffering fluctuations and creating greater consistency in pressure during production operations. When rapid transportation of materials (or the rapid separation of materials) is required during the filtration or chemical production processes, vacuum receivers act as a buffer to reduce the rate of pressure change and create a more gradual transition from an empty to a full state. This results in shorter production cycles and reduced downtime associated with delays in transferring materials.
Storage tanks serve a similar purpose, allowing chemical inventories to remain at the optimal level. Thus, production operations do not have to stop because of material shortages.
8. Regulatory Compliance and Workplace Safety
Pipeline Collection and Ventilation (PCV) tanks and vacuum collection receivers are critical tools in helping industries maintain compliance with local, state, and federal environmental and safety regulations. Tanks designed with proper venting systems decrease the occurrence of fugitive emissions and other chemicals that are harmful to employees, the surrounding environment, and the atmosphere at large.
Engineered storage and vacuum systems ensure that companies adhere to regulatory requirements such as those established by the American Petroleum Institute (API) and provide solutions for meeting local fire code requirements.
By utilizing engineered tanks/vessels to support safe handling protocols, the probability of an accident occurring is significantly decreased. The workplace environment becomes safer for both workers and employers, as well as lowering the cost of coverage under a liability insurance plan and providing better compliance with regulations.
Conclusion
Industrial system operations are dependent upon three significant factors that contribute to cost-effectiveness and safety: cost, safety, and performance (CSP). Storage tanks and vacuum receivers provide more than just storage for chemicals; they are important in maintaining stable, predictable, and optimized operations of all aspects of chemical handling. The benefits of using storage tanks and vacuum receivers include reduced risk, maximized productivity and efficiency, improved productivity, and regulatory compliance, which all support a company’s financial success. By investing in the highest-quality available storage and vacuum equipment, industries will improve their operational performance while providing themselves with a competitive advantage in safety, productivity, and sustainable practices.
Although tanks and vacuum receivers have tremendous value and potential operating efficiencies, they are not always apparent to those who use the systems. Nevertheless, there is no doubt that storage tanks and vacuum receivers are essential for the increased efficiency of chemical handling in modern plants.