Green Solutions Save Millions For Tank Repairs

‍

‍

Revitalize Your Infrastructure: Avoid Costly Wastewater Tank Replacement

Replacing wastewater tanks can be a costly and disruptive process, involving extensive demolition, new installations, and significant downtime. A recent report from the Whittier Daily News highlights Ridgeline Energy Services in Santa Fe Springs, CA, as they begin demolishing 19 aging tanks at their wastewater treatment plant. These tanks were located on the former Powerline Oil Co. refinery site and had been plagued by odor issues due to wastewater mixing with residual sludge. Several of the tanks had leaks, allowing contaminants to mix and release hydrogen sulfide gas through roof openings. While not toxic, these emissions impacted air quality. Each tank weighs 28 tons and holds 16,800 gallons of wastewater. The metal from the demolition will be recycled, but the real solution lies in removing and destroying the tanks rather than attempting repairs.

A Global Challenge

Ridgeline’s situation is not unique. Steel tanks are prone to corrosion and leaks over time, and temporary fixes like steel plates often fail in the long run. A more sustainable and cost-effective alternative is the use of Carbon Fiber Reinforced Polymer (CFRP) solutions, such as HJ3's CarbonSeal system. Replacing tanks can cost millions in materials and lead to massive production downtime. Additionally, the environmental impact is significant—producing one ton of steel requires about 60,000 gallons of water. Replacing Ridgeline’s 19 tanks would require around 32 million gallons of water, making it an unsustainable option for many facilities.

A Success Story: NRG Energy

HJ3’s CarbonSeal system has proven to be a game-changer, offering both financial and environmental benefits. One notable example is NRG Energy, a major power generation company. At one of its subsidiaries, a 2-million-gallon wastewater tank was leaking badly. Previous attempts using steel plates only worsened the problem, leading to thousands of additional holes forming in the walls and floor.

The project initially focused on repairing the tank’s walls, floors, and support columns. During the preparation phase, which included hydro-blasting and surface cleaning, 4,300 more holes were discovered. Steel plates were used to cover these areas, preventing further leakage. Then, HJ3’s CarbonSeal carbon fiber reinforcement system was applied to the tank’s structure. This involved sandblasting, thorough cleaning, hole inspection, testing, and priming to prevent flash rusting. After applying HJ3’s primer, high-modulus paste was added to the reinforcement zones, followed by the final application of the CarbonSeal system across the walls, floor, and support beams. A chemical-resistant topcoat was then applied to protect the structure.

A Sustainable Solution

By choosing to repair instead of replace, NRG extended the life of its wastewater tank by an estimated 30 years. This approach saved the facility millions in costs and significantly reduced its environmental footprint. Using HJ3’s CarbonSeal system led to a 90% reduction in energy consumption, 96% less CO2 emissions, and the conservation of 60 million gallons of water. Compared to replacement, NRG saved over $3 million or 75%. Whether you’re dealing with a failing wastewater tank or seeking sustainable repair options, HJ3 offers a reliable and eco-friendly solution. Contact our project managers today to learn more about how we can help you extend the life of your infrastructure while saving money and resources.

‍

‍

‍

Guide Disc

Guide disc, leveling roll, sizing roll, straightening roll, piercing plug for tube and pipe mill

Jiangsu Taigoo New Material Co. Ltd. , https://www.spun-castings.com