Super Tank Cells: Innovations for Tank House Productivity
Super tank 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
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
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
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
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 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
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
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.
(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
18.820-3 and ASTM C582 regarding chemical barriers for FRP tanks.
These forms have been validated by more than 40 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 D4097 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.
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
Typical properties are as follows.
Physical Properties Table
Density (standard hammered)
Thermal expansion coefficient