CN110498140A - 一种复合材料和内浮顶储罐浮盘及其制备方法 - Google Patents
一种复合材料和内浮顶储罐浮盘及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种复合材料和内浮顶储罐浮盘及其制备方法,所述复合材料至少包括依次设置的导电层、底层玻璃钢、中间层、顶层玻璃钢和面漆层;各层结构之间通过粘结剂固化粘接;所述底层玻璃钢和所述顶层玻璃钢的树脂嵌有无碱短切玻璃纤维毡。玻璃钢采用喷涂工艺将无碱玻璃纤维毡嵌入树脂中,能够增加复合材料的强度,玻璃钢各向同性,各个方向上的机械性能差异小;玻璃钢能够提高内浮顶的机械强度,降低固化时收缩率,增加和调整内浮顶的厚度。而且可以现场加工制作,施工安全性高。
Description
技术领域
本发明储油罐密封领域,具体涉及一种复合材料和内浮顶储罐浮盘及其制备方法。
背景技术
常见的储油罐主要是立式圆柱形罐,按照罐顶的结构形式可以分为固定拱顶罐和浮顶储罐。内浮顶储油罐是在固定拱顶储罐内部增设浮顶而成,罐内增设随油面上下升降的浮顶可减少介质的挥发损耗,内浮顶将罐内液体和空气有效隔绝,一定程度上可以降低发生火灾爆炸的危险等级,外部的拱顶又可以防止雨水、积雪及灰尘等进入罐内,保证罐内介质清洁。浮顶储油罐密封技术的关键是浮盘密封。
现有的全液接浮盘中,全液接钢浮盘可用于内浮顶储罐或外浮顶储罐,但是因焊接钢板尺寸大于人孔,更换、维修困难,应用于内浮顶罐较少。全液接铝浮盘应用于内浮顶储罐,按照安装方式可以分为插接式浮盘和拼接式浮盘等。因为其为组装的浮盘,密封性尤其重要。铝性质活泼,易发生化学反应,铝浮盘的耐腐蚀性差。随着科技的发展,出现了非金属内浮顶,其中,玻璃钢内浮顶结构近年来备受关注。采用玻璃钢制作的内浮顶整体密度低于储液的密度,且整体铺设在液面的表面,浮顶及附加重量的浮力可达自身重力的3.5倍。而且,玻璃钢内浮顶导电性能良好、防化学腐蚀性能较好,弥补了铝合金浮顶不耐腐蚀的空缺。然而,玻璃钢内浮顶的不足之处是现场制作比较繁琐,需要将预制玻璃钢粘接成型模板。
发明内容
针对现有技术中的缺陷,本发明的一个目的是提供一种内浮顶储罐浮盘复合材料,利用该复合材料制备的内浮顶储罐复合材料不仅具密封性能好,还有优异的防腐蚀性能。
本发明的又一个目的是提供一种制备内浮顶储罐浮盘的方法。
一种内浮顶储罐浮盘复合材料,至少包括依次设置的导电层、底层玻璃钢、中间层、顶层玻璃钢和面漆层;各层结构之间通过粘结剂固化粘接;所述底层玻璃钢和所述顶层玻璃钢的树脂嵌有无碱短切玻璃纤维毡。
优选地,所述底层玻璃钢和所述顶层玻璃钢的制备步骤包括:将树脂溶液均匀喷涂在无碱玻璃纤维毡上,烘干,树脂固化,即得所述玻璃钢。
优选地,所述树脂为环氧乙烯基树脂。
优选地,所述导电层的材料为乙烯基树脂、石墨和固化剂形成的导电树脂;以所述所述乙烯基树脂计,石墨的用量为15-20重量%,固化剂为2-3重量%。
优选地,所述导电层和所述底层玻璃钢之间还设有防护层,所述防护层为在所述导电层的表面涂刷耐腐蚀材料得到;所述耐腐蚀材料为间苯二酸树脂、双酚树脂、乙烯基树脂中的一种或多种。
优选地,所述防护层的树脂基体中嵌有玻璃纤维。
优选地,所述中间层为带有独立封闭舱室的蜂窝结构;所述中间层的材料的为聚丙烯蜂窝、聚氨酯蜂窝、聚氯乙烯蜂窝中的一种或多种。
优选地,所述面漆层为石墨、阻燃树脂、固化剂的混合物;石墨、阻燃树脂、固化剂的重量百分比为10-15:82.5-88.5:1.5-2.5;所述粘结剂为环氧乙烯基树脂。
一种内浮顶储罐浮盘,包括能够悬浮于液面的浮盘主体,所述浮盘主体采用上述的内浮顶储罐浮盘复合材料。
本发明还提供了一种上述的内浮顶储罐浮盘的制备方法,在储罐内部制作,或预制拼接单元在储罐内拼接制作。
优选地,制备步骤包括:
(1)将模板清理干净,将模板上的连接缝隙或孔洞用高温胶带密封覆盖;
(2)配制导电树脂,以模板为基础均匀涂覆导电树脂;
(3)待步骤(2)中导电树脂干结后覆盖一层玻璃纤维,并喷涂一层防护层的树脂压平;
(4)步骤(3)中乙烯基树脂未干结前铺设底层玻璃毡,喷涂树脂使树脂充分浸润玻璃毡;
(5)均匀喷涂乙烯基树脂并立即安装蜂窝板至底层玻璃钢上;
(6)待蜂窝板与底层玻璃钢紧密贴合后,在蜂窝板上喷涂乙烯基树脂并立即铺设玻璃毡,使树脂充分浸润玻璃毡,得到顶层玻璃钢;
(7)在顶层玻璃钢上涂刷阻燃导电树脂得到面漆层。
本发明的有益效果体现在:
本发明的内浮顶储罐浮盘符合材料至少包括依次设置的导电层、底层玻璃钢、中间层、顶层玻璃钢和面漆层;玻璃钢采用喷涂工艺将无碱玻璃纤维毡嵌入树脂中,能够增加复合材料的强度,玻璃钢各向同性,各个方向上的机械性能差异小;玻璃钢能够提高内浮顶的机械强度,降低固化时收缩率,增加和调整内浮顶的厚度。而且可以现场加工制作,施工安全性高;
中间层为有独立封闭舱室的蜂窝结构,用来抵抗剪切变形,并增加内浮顶的厚度和惯性模量,具有重量轻、隔热、保温、强度高、刚度大的特点;导电层具有防静电的作用,导电效果优异。
附图说明
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案,下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍。在所有附图中,类似的元件或部分一般由类似的附图标记标识。附图中,各元件或部分并不一定按照实际的比例绘制。
图1为本发明一个实施例的内浮顶传感浮盘复合材料的结构示意图。
具体实施方式
下面将结合附图对本发明技术方案的实施例进行详细的描述。以下实施例仅用于更加清楚地说明本发明的技术方案,因此只作为示例,而不能以此来限制本发明的保护范围。
需要注意的是,除非另有说明,本申请使用的技术术语或者科学术语应当为本发明所属领域技术人员所理解的通常意义。
图1为本发明一个实施例的内浮顶储罐浮盘。包括依次设置的导电层101、防护层102、底层玻璃钢103、中间层104、顶层玻璃钢105和面漆层106。
本发明的各层结构之间通过粘结剂固化粘接。粘结剂具体可以为环氧乙烯基树脂。
玻璃钢采用喷涂法生产,工作原理为:经搅拌调和好的树脂溶液和固化剂经高速泵喷涂在无碱玻璃纤维毡上,固化后形成加强玻璃纤维板。
本发明的内浮顶浮盘可在储罐内制作,也可在工厂内预制2.2m*2.2m的拼接单元到储罐内部进行拼接制作。本发明的实施例以在储罐内制作为例。
本发明的内浮顶浮盘制作在焊接浮盘支腿、模板安装之后进行,安装模板时,模板表面应均匀平整,无明显气泡、裂纹,无纤维裸露和分层等缺陷。内浮顶下面模板用临时支柱支撑。内浮顶的施工制作全部在模板上进行。
实施例1
为本发明一个实施例的内浮顶储罐浮盘的制作方法,具体步骤如下:
1、喷涂前准备:
将模板清理干净,所有模板对接缝、模板与模板间所有的接口以及孔洞均用高温胶带覆盖,立沿上边缘以及附件模型上边缘模板裸露处亦用胶带全部覆盖,以防树脂渗漏而损坏模板。
喷涂:喷涂前物料准备,在喷涂前需要装备的物料包括树脂、无碱玻璃纤维毡、预促进剂、抑制剂、固化剂等。
本发明工艺使用的物料型号如下:
预混树脂包括如下的组分:酚醛环氧改性乙烯基树脂470,以酚醛环氧改性乙烯基树脂470的重量计,DMA促进剂的用量为0.5%、阻聚剂2,4-P的用量为0.02%;
玻璃毡:短切无碱玻璃纤维毡(以下简称玻璃毡);玻璃纤维:E玻璃纤维。
预混树脂与固化剂925H分别经喷枪的两个出口喷出,在喷枪出口混合得到树脂,树脂与固化剂比例为:预混树脂98.3%+固化剂1.7%。
2、制作导电层:
导电树脂配比:预混树脂+石墨粉(800目)+固化剂,以预促进树脂计,石墨粉的用量为16重量%,固化剂925H的用量为2.2重量%。
以模板为基础,将掺有石墨和固化剂的树脂均匀涂覆在模板上,在模板的边缘处涂刷,且导电层的厚度为0.02-0.06mm。
3、涂刷防护层:在导电层树脂表面覆盖玻璃纤维(60g/m2),然后均匀喷涂一层本实施例的树脂并压平。
4、铺设底层玻璃毡以及喷涂树脂:防护层树脂未干结前分层铺设两层玻璃毡(600g/m2),然后喷涂树脂,使树脂充分浸润玻璃毡。该过程充分控制玻璃毡之间的空气,防止出现气泡和分层的现象。底层玻璃刚层的厚度为2-2.5mm。具体地,该两层玻璃毡中与防护层连接的玻璃毡的厚度为2mm,靠近中间层的一层玻璃毡厚度为2.5mm。玻璃毡的用量为:27.5-32.5%。
5、安装聚丙烯蜂窝板:在底层玻璃钢上均匀喷涂一层树脂,立即将聚丙烯蜂窝板粘接至底层玻璃钢上,并向聚丙烯蜂窝板施加压力直至树脂凝固且蜂窝板与底层玻璃钢紧密贴合。
6、铺设顶层玻璃毡以及喷涂复合树脂:待蜂窝板与底层玻璃钢紧密贴合后在蜂窝板上均匀喷涂一层树脂,并立即铺设两层玻璃毡(450g/m2),立即将玻璃毡压平使树脂充分浸润玻璃毡。顶层玻璃钢的厚度为2-3.5mm。具体地,靠近中间层的玻璃毡的厚度为3.5mm,远离中间层的玻璃毡的厚度为2mm。
7、涂刷面漆层:
首先制备阻燃导电树脂:
①510阻燃树脂99.40%+DMA促进剂0.58%+抑制剂2,4-P 0.02%混合,得到面漆层预促进树脂;
②面漆层预促进树脂、石墨(800目)和固化剂混合,预促进树脂、石墨、固化剂的重量百分比为83.5:15:1.5,得到面漆层树脂;
环氧乙烯基树脂是溶于苯乙烯溶液的环氧双酚A乙烯基树脂,对酸、碱、盐有显著的耐化学腐蚀性,同时对应力破坏的敏感性也比较小,表现出很高的抗动态载荷性能。
实施例2
其与实施例1的区别在于用于防护层的树脂的配方如下:
预混树脂:树脂DM470+促进剂+阻聚剂;促进剂为环烷酸钴,辛酸钴,异辛酸钴中的一种或多种;阻聚剂为TBC。以树脂DM470的重量计,促进剂的用量为0.5%(金属含量为6%),阻聚剂的用量为1%。
预混树脂98%+固化剂CHP 1.7%+凝胶延长剂乙酰丙酮0.3%混合,得到防护层树脂。
作为一种具体的实施方式,涂刷防护层时,在导电层树脂表面覆盖玻璃纤维(60g/m2),然后均匀喷涂一层本实施例的防护层树脂并压平。导电层、底层玻璃钢、顶层玻璃钢、中间层以及面漆层的树脂与实施例1相同。
实施例3
其与实施例1的区别在于用于防护层的树脂的配方如下:
双酚A树脂包括A、B组分,其中A组分包括:树脂(等重量的E-44和E-51)+消泡剂0.5%+偶联剂2.5%+稀释剂20%;消泡剂为HT-010;偶联剂为KH-550;稀释剂为1,2-环己二醇二缩水甘油醚。B组分包括芳香胺固化剂和促进剂SnCl2。
等重量的E-44和E-51均匀混合,加入稀释剂和消泡剂,搅拌均匀,静置消泡,然后加入偶联剂,搅拌均匀得到A组分。将固化剂和促进剂搅拌均匀后静置,然后与A组分混合,即得防护层的树脂。以A组分的重量计,固化剂的用量为18%,促进剂的用量为1%。
作为一种具体的实施方式,涂刷防护层时,在导电层树脂表面覆盖玻璃纤维(60g/m2),然后均匀喷涂一层本实施例的防护层树脂并压平。导电层、底层玻璃钢、顶层玻璃钢、中间层以及面漆层的树脂与实施例1相同。
本发明采用聚丙烯蜂窝板和玻璃钢材料制作而成的蜂窝结构,大大降低了浮盘自身重量且提高了结构的弯曲模量,从而有效控制了夹层结构玻璃钢内浮盘在自重载荷作用下的挠度;导电层101和面漆层106均含有石墨粉,大幅提高了浮盘的防静电性能,面漆层利用阻燃树脂制备,还能有效避免火灾的安全隐患;防护层根据液体的种类利用不同的树脂,防腐性能优异,防护层树脂内嵌有玻璃毡,增加了防护层的防腐心梗,玻璃钢材料具有优异的耐化学腐蚀和耐老化性能,从而有效延长了内浮盘的使用寿命并有效减少后期的维护。
最后应说明的是:以上各实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述各实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分或者全部技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的范围,其均应涵盖在本发明的权利要求和说明书的范围当中。
Claims (10)
1.一种内浮顶储罐浮盘复合材料,其特征在于,至少包括依次设置的导电层、底层玻璃钢、中间层、顶层玻璃钢和面漆层;各层结构之间通过粘结剂固化粘接;所述底层玻璃钢和所述顶层玻璃钢的树脂嵌有无碱短切玻璃纤维毡。
2.如权利要求1所述的内浮顶储罐浮盘复合材料,其特征在于,所述底层玻璃钢和所述顶层玻璃钢的制备步骤包括:将树脂溶液均匀喷涂在无碱玻璃纤维毡上,烘干,树脂固化即得。
3.如权利要求1或2所述的内浮顶储罐浮盘复合材料,其特征在于,所述树脂为酚醛环氧改性乙烯基树脂。
4.如权利要求1所述的内浮顶储罐浮盘复合材料,其特征在于,所述导电层的材料为乙烯基树脂、石墨和固化剂形成的导电树脂;以所述所述乙烯基树脂计,石墨的用量为15-20重量%,固化剂为2-3重量%。
5.如权利要求1所述的内浮顶储罐浮盘复合材料,其特征在于,所述导电层和所述底层玻璃钢之间还设有防护层,所述防护层为在所述导电层的表面涂刷耐腐蚀材料得到;所述耐腐蚀材料为间苯二酸树脂、双酚树脂、乙烯基树脂中的一种或多种。
6.如权利要求5所述的内浮顶储罐浮盘复合材料,其特征在于,所述防护层的树脂基体中嵌有玻璃纤维。
7.如权利要求1所述的内浮顶储罐浮盘复合材料,其特征在于,所述中间层为带有独立封闭舱室的蜂窝结构;所述中间层的材料的为聚丙烯蜂窝、聚氨酯蜂窝、聚氯乙烯蜂窝中的一种或多种。
8.如权利要求1所述的内浮顶储罐浮盘复合材料,其特征在于,所述面漆层为石墨、阻燃树脂、固化剂的混合物;石墨、阻燃树脂、固化剂的重量百分比为10-15:82.5-88.5:1.5-2.5。
9.一种内浮顶储罐浮盘,包括能够悬浮于液面的浮盘主体,其特征在于,所述浮盘主体采用权利要求1-8任意一项所述的内浮顶储罐浮盘复合材料。
10.一种权利要求9所述的内浮顶储罐浮盘的制备方法,其特征在于,在储罐内部制作,或预制拼接单元在储罐内拼接制作;
储罐内制作时,包括步骤:
(1)将模板清理干净,将模板上的连接缝隙或孔洞用高温胶带密封覆盖;
(2)配制导电树脂,以模板为基础均匀涂覆导电树脂;
(3)待步骤(2)中导电树脂干结后覆盖一层玻璃纤维,并喷涂一层防护层的树脂压平;
(4)步骤(3)中乙烯基树脂未干结前铺设底层玻璃毡,喷涂树脂使树脂充分浸润玻璃毡;
(5)均匀喷涂乙烯基树脂并立即安装蜂窝板至底层玻璃钢上;
(6)待蜂窝板与底层玻璃钢紧密贴合后,在蜂窝板上喷涂乙烯基树脂并立即铺设玻璃毡,使树脂充分浸润玻璃毡,得到顶层玻璃钢;
(7)在顶层玻璃钢上涂刷阻燃导电树脂得到面漆层。
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CN211002809U (zh) * | 2019-09-19 | 2020-07-14 | 河北澳科中意环保科技有限公司 | 一种复合材料和内浮顶储罐浮盘 |
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CN114291436A (zh) * | 2022-01-18 | 2022-04-08 | 伟林环保科技(大连)有限公司 | 一种全接液复合材料内浮盘的制作方法 |
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