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Revitalize Your Infrastructure: Avoid Costly Wastewater Tank Replacement
Wastewater tank replacement can be an incredibly expensive endeavor, involving demolition, new tank installation, and significant production losses. An article from the Whittier Daily News highlights Ridgeline Energy Services in Santa Fe Springs, California, as they begin the demolition of 19 tanks at their wastewater treatment plant. Situated on the grounds of the former Powerline Oil Co. refinery, the plant has faced numerous odor violations due to wastewater mixing with residual Powerline sludge. Several tanks leaked, allowing the mixing of substances and the release of hydrogen sulfide gas through roof holes, which reduced air quality but posed no toxic threat. Each of these massive tanks weighs 28 tons and can hold up to 16,800 gallons of wastewater. The metal from the demolition will be recycled. The solution for addressing odor issues involves removing and destroying these wastewater tanks rather than attempting repairs.
A Global Challenge
Ridgeline’s situation is just one example among many worldwide. Steel tanks can corrode and develop leaks over time. While steel welded plates can temporarily stop leaks, these plates also corrode over time. An effective and sustainable alternative to replacement is Carbon Fiber Reinforced Polymer (CFRP) solutions, including HJ3’s CarbonSeal reinforcement systems. Complete tank replacement incurs millions in material and downtime expenses and has a significant environmental impact. For instance, producing one ton of steel requires 60,000 gallons of water. Replacing Ridgeline’s 19 tanks would consume an estimated 32 million gallons of water.
A Success Story: NRG Energy
HJ3’s CarbonSeal system offers a compelling solution, saving both money and the environment. A notable case is the work with NRG Energy, one of the nation’s largest power generation and retail electricity businesses. At one of NRG’s subsidiaries, a 2-million-gallon wastewater tank was experiencing leaks. Earlier attempts at repair using steel plates had failed, leading to even more issues, with thousands of through holes developing in the walls and floors.
The initial repair scope involved tank walls, floors, and roof support columns. As surfaces were being prepared and hydro-blasted, 4,300 additional through holes were discovered, requiring further reinforcement. Steel plates were used to cover these holes, preventing further leakage. Then, HJ3’s CarbonSeal carbon fiber reinforcement system was applied to the tank walls, floors, and support beams, with special preparation to address extensive corrosion. The surfaces underwent sandblasting, cleaning, hole inspection, testing, and priming to prevent flash rusting. After these steps, they were primed with HJ3’s primer, and high modulus paste was applied to the reinforcement area. Finally, HJ3’s CarbonSeal carbon fiber reinforcement system was installed on the walls, floor, and support columns, safeguarded with a chemical-resistant topcoat.
A Sustainable Solution
By repairing, rather than replacing NRG’s wastewater tank, HJ3’s CarbonSeal system is expected to extend the tank’s life by another 30 years. Replacement would have incurred substantial costs for the plant and the environment. Utilizing HJ3’s CarbonSeal repair system resulted in remarkable savings, including a 90% reduction in kWh consumption, 96% less CO2 emissions, and a conservation of 60 million gallons of water. Compared to replacement, NRG saved over $3 million or 75%. Whether you have a wastewater tank or seek sustainable repair solutions, reach out to our project managers today at [contact information].
For those looking for innovative solutions to tank repair, consider HJ3’s CarbonSeal technology. This approach not only addresses current structural issues but also provides long-term durability and sustainability. The images below showcase the effectiveness of this method in action.
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In conclusion, adopting advanced technologies like HJ3’s CarbonSeal can transform infrastructure management by offering cost-effective, eco-friendly alternatives to traditional replacement methods. This approach not only saves money but also contributes significantly to global sustainability efforts.