WO2019169451A1

WO2019169451A1 - Containment system for storing and transporting bulk liquid

Info

Publication number: WO2019169451A1
Application number: PCT/AU2019/050207
Authority: WO
Inventors: Holger KELLE; Bastian SCHEEPERS
Original assignee: Incitias Pty Ltd
Priority date: 2018-03-09
Filing date: 2019-03-08
Publication date: 2019-09-12
Also published as: AU2019231331A1

Abstract

A vessel for storing and transporting bulk liquid has an inner liner, an intermediate core, and an outer skin. The inner liner defines an internal cavity of the vessel in which to contain bulk liquid, and provides an inner fluid impervious barrier of the vessel. The intermediate core surrounds the inner liner, and includes one or more structural layers. At least one insulating foam layer that has greater thermal insulation properties relative to the structural layers. The outer skin surrounds the intermediate core, and provides an outer fluid impervious barrier of the vessel. The intermediate core provides structural rigidity to at least one of the inner liner or outer skin, and provides a thermal barrier between the internal cavity and the environment surrounding the vessel.

Description

Containment System for Storing and Transporting Bulk Liquid

Field of the invention

The present invention relates to a containment system for storing and transporting bulk liquid.

Background

Transporting normally gaseous fluids as cryogenic liquids is efficient due to the significantly smaller volume required, when compared with the same mass at standard temperature and pressure. For example, LNG (Liquid Natural Gas) in liquid form occupies l/600th of the volume of the same mass in gas form at standard temperature and pressure. Similarly, hydrogen in liquid form occupies l/788th of the volume of the same mass in gas form at standard temperature and pressure. Further, LNG will remain in liquid form when at atmospheric pressure, and at temperatures at or below -163°C. Hydrogen will remain in liquid form when at atmospheric pressure, and at temperatures at or below -253°C.

Transportation of cryogenic and refrigerated liquid - such as hydrogen, ethylene, ethane, propane, and NG (Natural Gas) at temperatures and pressures to be in liquid state - is now commonplace in large volumes (>25,000 m³ per tank) by ship, in mid-size volumes (600-18,000 m³ per tank) by ship, and in small volumes (20-60 m³ per tank) by truck, rail and road across the world. For the purposes of this specification, the term "bulk liquid" is to be understood to mean volumes of at least 20 m³.

Containment systems for storing and transporting bulk fluids at cryogenic temperatures have some unique challenges. Materials for use in such systems are required to have high toughness and strength qualities at both ambient and cryogenic temperatures, and a low coefficients of thermal expansion (CTE). Typical materials used include: stainless steel, aluminium and nickel alloys such as Invar (FeNi36, also known as 64FeNi). In addition, national and international regulators impose various requirements on the design and construction of components of containment systems. Regulations extend to the design of tanks and conduits (pipes) to manage the egress of the cryogenic fluid in the event of damage to the containment system. For instance, as a protection measure, industry regulators require that cryogenic tanks used for transportation must have two barriers between the internal cavity and the atmosphere. For instance, a full or partial secondary (outer) barrier is required to retain the liquid within the tank in case of breach of the primary (inner) barrier.

The requirements imposed by regulators are not consistent, so that in some cases a tank that is suitable for one transport type (such as by ship), may be unsuitable for other transport types (such as by road or rail). Consequently, it be necessary to transfer bulk liquid between different containment systems at road, rail, and/or shipping terminals, which creates inefficiencies in transport.

There is a need to address the above, and/or at least provide a useful alternative.

Summary

There is provided a vessel for storing and transporting bulk liquid, the vessel including:

an inner liner that defines an internal cavity of the vessel in which to contain bulk liquid, and provides an inner fluid impervious barrier of the vessel;

an intermediate core that surrounds the inner liner, the intermediate core including one or more structural layers, and at least one insulating foam layer that has greater thermal insulation properties relative to the structural layers; and

an outer skin that surrounds the intermediate core, and provides an outer fluid impervious barrier of the vessel,

wherein the intermediate core provides structural rigidity to at least one of the inner liner or outer skin, and provides a thermal barrier between the internal cavity and the environment surrounding the vessel. Preferably, the inner cavity of the vessel has a general prismatic shape, and the outer surface of the vessel has a plurality of faces that meet at vertices.

In some embodiments, the vessel is formed such that at least one of the inner liner or outer skin has reinforcing corrugation formations. Preferably, both the inner liner and outer skin are formed with reinforcing corrugation formations, and the reinforcing corrugation formations are arranged such that the intermediate core has a substantially uniform thickness between the inner liner and outer skin.

The vessel further includes a supporting frame that extends around the outer skin. The supporting frame includes a plurality of beam members that are arranged in rectilinear grids adjacent to the faces of the outer surface of the outer skin. Preferably, the beam members include face beam members that are disposed in depressions on the outer surface of the outer skin that are formed by the reinforcing corrugation formations.

In at least some embodiments, at least the outer skin includes channel formations along the vertices of the outer surface, and the beam members include edge beam members that are disposed in the channel formations.

The supporting frame can further include connectors that are connected to the beam members, wherein the connectors are used to secure the supporting frame to complementary connectors on other equipment.

There is also provided a conduit for moving bulk liquid, the conduit including: an inner liner that defines a throughway through which to pass bulk liquid, and provides an inner fluid impervious barrier of the conduit;

an intermediate core that surrounds the inner barrier, the intermediate core including one or more structural layers, and at least one insulating foam layer that has greater thermal insulation properties relative to the structural layers; and an outer skin that surrounds the intermediate core, and provides an outer fluid impervious barrier of the conduit,

wherein the intermediate core provides structural rigidity to at least one of the inner liner or outer skin, and provides a thermal barrier between the throughway and the environment surrounding the conduit.

In at least some embodiments, the intermediate core has:

a first structural layer that surrounds, and is in contact with, the inner liner;

an insulating foam layer that surrounds, and is in contact with, the first structural layer; and

a second structural layer that surrounds the insulating foam layer.

Preferably, the second structural layer is in contact with both the insulating foam layer of the intermediate core, and the outer skin.

Preferably, the first structural layer is bonded to the inner liner such that the inner liner is supported by the intermediate core.

Alternatively or additionally, the second structural layer is bonded to the outer skin such that such that the outer skin is supported by the intermediate core.

In certain embodiments, the insulating foam layer is bonded to each of the first and second structural layers.

In some embodiments, the bond between adjacent layers of the intermediate core is a mechanical bond. The mechanical bond can be created with a bonding material interposed between the adjacent bonded layers. In one example, the bonding material can be a thermoset plastic. In some examples, the inner liner and/or outer skin can be made from a fibre- reinforced resin. The fibres can be carbon and/or glass and/or basalt within a thermoset plastic matrix. The fibres can be woven, unidirectional and/or chopped fibre strands.

Preferably, the inner liner and outer skin have a thickness of at least 3 millimetres. More preferably, the inner liner and outer skin have a thickness in the range of 4 to 12 millimetres. Preferably, the inner liner and outer skin have a Young's Modulus of at least 100 GPa. More preferably, the inner liner and outer skin have a Young's Modulus in the range of 200 to 500 GPa.

Preferably, the thickness of the insulating foam layer is greater than, or equal to, the thickness of the or each structural layer. In some embodiments in which the intermediate core has first and second structural layers that are separated by the insulating foam layer, the first and second structural layers are of equal thickness.

The ratio of the thickness of the insulating foam layer to the thickness of the or each structural layer is in the range of 1: 1 to 40: 1. In some examples, the ratio of the thickness of the insulating foam layer to the thickness of the or each structural layer is approximately 5: 1.

The material of the or each structural layer can have a closed cell structure. In at least some embodiments, the or each structural layer of the intermediate core is made of a foam material. In such embodiments, the material of the or each structural layer differs from the material of the insulating foam layer. Alternatively or additionally, the density of the or each structural layer is greater than the density of the insulating foam layer.

The ratio of the density of the insulating foam layer to the density of the or each structural layer is in the range of 4:5 to 4:20.

In one example, the or each structural layer is made of polymethacrylimide (PMI) foam, and the insulating foam layer is made of polyurethane (PU) foam. There is provided a containment system for storing and transporting bulk liquid, the containment system comprising one or more vessels as previously described, and one or more conduits as previously described.

Brief of the drawinqs

In order that the invention may be more easily understood, embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1: is a cut-away perspective view of a vessel according to a first embodiment of the present invention;

Figure 2: is an enlarged view of Region A in Figure 1;

Figure 3: is a vertical section through the vessel in Region B of Figure 1;

Figure 4: is a schematic vertical section through a pipe according to a second embodiment of the present invention; and

Figure 5: is a table of material geometries and properties for embodiments of a vessel substantially in accordance with Figure 1.

Detailed description

Figures 1 to 3 show a vessel 10 according to a first embodiment of the present invention. The vessel 10 has an internal cavity 12, which in this embodiment has a generally rectangular prismatic shape, and an outer surface that forms six major faces meeting at vertices. Accordingly, the vessel has a roof R, four side walls 5, and a floor F. Figure 1 is a cut-away view taken vertically through the vessel 10, and parallel to one of the side walls 5. Accordingly, one wall of the vessel 10 is omitted from this view, and only one side wall S is shown in its entirety.

The vessel 10 is for use in storing and transporting bulk liquid, and finds particular application in instances in which the bulk liquid is at non-ambient temperatures. Further, the vessel 10 has features that make it suitable for storing and transporting bulk fluid at cryogenic temperatures, or refrigerated bulk fluid that is in liquid form.

Figures 2 and 3 illustrate the containment structure of the vessel 10 in further detail. As shown in Figures 1 and 2, the vessel 10 has an inner liner 14 that defines the internal cavity 12 of the vessel in which to contain bulk liquid, an intermediate core 16 that surrounds the inner liner 14, and an outer skin 18 that surrounds the intermediate core 16. In this particular embodiment, the intermediate core 16 provides structural rigidity to both the inner liner 14 and outer skin 18, and provides a thermal barrier between the internal cavity 12 and the environment surrounding the vessel 10. Each of the inner liner 14 and outer skin 18 provides a fluid impervious barrier.

In this embodiment, the vessel 10 includes a supporting frame 20 that extends around the outer skin 18. The supporting frame includes beam members 20 that are arranged in rectilinear grids adjacent the faces of the outer surface of the outer skin. In other words, the beam members 20 of the supporting frame form a space-frame structure surrounding the outer skin 18.

When the vessel 10 is filled with a bulk liquid, substantially all of the hydrostatic forces imparted by the liquid within internal cavity are supported by the intermediate core 16 and support frame. Further, when the internal pressure of the vessel 10 exceeds the surrounding atmospheric pressure, substantially all of the internal stress is supported by the intermediate core 16 and the support frame.

As shown in Figure 3, the intermediate core 16 has a first structural layer 22, an insulating foam layer 24, and a second structural layer 26. The first structural layer 22 surrounds the inner liner 14 and, in this embodiment, is bonded to the inner liner 14. The outer skin 18 surrounds the second structural layer 26 and, in this embodiment, is bonded to the second structural layer 26. The insulating foam layer 24 that surrounds the first structural layer 22, and the second structural layer 26 that surrounds the insulating foam layer 24. In other words, the insulating foam layer 24 is sandwiched between the first and second structural layers 22, 26. Further, in this particular embodiment, the insulating foam layer 24 is bonded to each of the first and second structural layers 22, 26.

At least some embodiments of the vessel 10 have the benefits of being lightweight, satisfying International Maritime Organisation (IMO) Tank Type A, IGC (2016 Edition) design requirements for prismatic tanks, and can be transported in any of an empty, filled, and incompletely (partially) filled state.

The bonds between adjacent layers of the intermediate core is a mechanical bond. Similarly, the bonds between the inner liner 14 and the intermediate core 16, and between the intermediate core 16 and outer skin 18 are also mechanical bonds. These mechanical bonds are formed with a bonding material interposed between the adjacent bonded elements. In one example, the bonding material can be a thermoset plastic. However, it will be appreciated that in some alternative embodiments, the bonds between adjacent bonded elements can be chemical. In some further alternative embodiments, the bonds can be mechanical between some adjacent elements, and chemical between other adjacent elements.

In this example, both the inner liner 14 and outer skin 18 are made from a fibre- reinforced resin. By way of example only, embodiments of the vessel 10 may have a fibre- reinforced resin in which the fibres are carbon and/or glass and/or basalt, and the resin is a thermoset plastic. The fibres can be woven, unidirectional and/or chopped fibre strands. With appropriate selection of fibre shape, length and orientation, and material properties, each of the inner liner 14 and outer skin 18 can be designed for impact resistance and inhibition of crack propagation.

The outer skin 18 can retain integrity in the event of a breach of the inner liner 14, so as to provide containment for greater than 15 days from the time the inner liner 14 is breached. Similarly, the inner liner 14 can retain integrity in the event of a breach of the outer skin 18, so as to provide containment for greater than 15 days from the time the outer skin 18 is breached.

To accommodate stresses resulting pressure differential between the atmosphere and the internal cavity 12, and from thermal contraction or expansion of the inner liner 14, the intermediate core 16 and/or outer skin 18, the vessel 10 is formed with reinforcing corrugation formations 28, 30 in the inner liner 14 and outer skin 18. Preferably, both the inner liner and outer skin are formed with reinforcing corrugation formations, and the reinforcing corrugation formations are arranged such that the intermediate core 16 has a substantially uniform thickness between the inner liner 14 and outer skin 18.

As shown in Figure 3, the beam members 20 include face beam members that are disposed in depressions formed by the reinforcing corrugation formations 30 of the outer skin 18. In this embodiment, the beam members 20 are tubular. Further, the face beam members 20 have a thickness that corresponds with the depth of the corrugation formations 30. In this way, the protrusion of the face beam members 20 outwardly of the outer skin 18 in the region of each outer face is minimal.

As shown in Figure 2, the outer skin 18 includes channel formations 32 along the vertices of the outer surface. The beam members include edge beam members (not shown) that are disposed in channels formations 32.

In this particular example, the first and second structural layers 22, 26 are made of polymethacrylimide (PMI) foam, and the insulating foam layer 24 is made of polyurethane (PU) foam.

Figure 5 is a table that lists, by way of example only, ranges of material geometries and properties that may be used in the vessel 10, and/or alternative embodiments of the vessel. The supporting frame can also include connectors (not shown) that are integrally connected to the edge beam members. In use of the vessel 10, the connectors facilitate securing the supporting frame (and thus the vessel 10 itself) to complementary connectors on other equipment. Such equipment may include decks / chassis of ships, trucks and rail cars; shipping containers; other vessels 10 of like construction; and/or cranes. This provides the advantages of a tank system that can be used in multi-modal transportation, and thus avoids the inefficiencies in transport created by transfer bulk liquid between different containment systems at road, rail, and/or shipping terminals. In one example, the connectors of the vessel 10 may be corner castings that mate with ISO twistlocks.

To provide additional structural stiffening and/or to dampen the free liquid motions (sloshing) resulting from partial tank filling levels and motion excitation due to transportation, the vessel 10 additionally has internal bulkheads 34. As shown in Figure 1, the bulkheads 34 are attached to the inner liner 14, and extend between adjacent and/or opposing internal wall faces within the internal cavity. The bulkheads 34 can be made from composite fibre in resin matrix. The bulkheads 34 in this example include an internal core material. Preferably, the internal core material is a closed cell structure, such as structural foam or honeycomb paper are placed in the tank.

The vessel 10 has a construction that enables it to maintain structural integrity for a range of accelerations in 6 degrees of freedom, and for a range of inclination angles during transportation.

A pump tower 36 is provided to support pumps, tank instrumentation and access to the internal cavity 12. The tower 36 is made from composite fibre resin matrix or metal such as aluminium.

As will be appreciated, embodiments of the vessel may be provided with design pipe work (such as 20", 40" or 48" piping), valves and excess hatches directly through the walls. To compensate overpressure within the internal cavity 12, embodiments of the vessel can be provided with a pressure release valve system. Figure 4 shows a conduit according to a second embodiment of the present invention. The conduit can be a pipe 100 for moving bulk liquid. The pipe 100 has an inner liner 114 that defines a throughway 112 through which to pass bulk liquid, an intermediate core 116 that surrounds the inner liner 114, and an outer skin 118 that surrounds the intermediate core 116.

It will be evident on comparison of Figures 3 and 4 that the vessel 10 and pipe 110 have similarities. Component elements of the pipe 100 with similar mechanical and material properties to the component elements of the vessel 10 have the same reference numerals with the prefix "1". Flowever, it will be understood that there are inherent differences between pipe and pressure vessel design considerations.

The pipe 110 has an inner liner 114, the intermediate core 116, and the outer skin 118 of the pipe 110 are substantially similar to the inner liner 14, the intermediate core 16, and the outer skin 18 respectively of the vessel 10. Further, the intermediate core 116 provides structural rigidity to both the inner liner 114 and outer skin 118, and provides a thermal barrier between the throughway 112 and the environment surrounding the pipe 110. Each of the inner liner 114 and outer skin 118 provides a fluid impervious barrier.

It will be understood that values of material properties stated throughout this specification correspond with the values at ambient conditions, unless explicitly stated otherwise.

Where used in this specification, the term "fluid impervious barrier" is to be understood to include providing a gas tight barrier.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims

CLAIMS:

1. A vessel for storing and transporting bulk liquid, the vessel comprising:

wherein the intermediate core provides structural rigidity to at least one of the inner liner or outer skin, and provides a thermal barrier between the internal cavity and the environment surrounding the vessel.

2. A vessel according to claim 1, wherein the vessel is formed such that at least one of the inner liner or outer skin has reinforcing corrugation formations.

3. A vessel according to either claim 1 or 2, wherein both the inner liner and outer skin are formed with reinforcing corrugation formations, and the reinforcing corrugation formations are arranged such that the intermediate core has a substantially uniform thickness between the inner liner and outer skin.

4. A vessel according to any one of claims 1 to 3, further comprising a supporting frame that extends around the outer skin.

5. A vessel according to claim 4, wherein the supporting frame includes a plurality of beam members that are arranged in rectilinear grids adjacent to the faces of the outer surface of the outer skin.

6. A vessel according to claim 5, wherein the beam members include face beam members that are disposed in depressions on the outer surface of the outer skin that are formed by the reinforcing corrugation formations.

7. A vessel according to any one of claims 4 to 6, wherein at least the outer skin includes channel formations along the vertices of the outer surface, and the beam members include edge beam members that are disposed in the channel formations.

8. A vessel according to any one of claims 5 to 7, further comprising connectors that are connected to the beam members, wherein the connectors are used to secure the supporting frame to complementary connectors on other equipment.

9. A conduit for moving bulk liquid, the conduit including:

an inner liner that defines a throughway through which to pass bulk liquid, and provides an inner fluid impervious barrier of the conduit;

an intermediate core that surrounds the inner barrier, the intermediate core including one or more structural layers, and at least one insulating foam layer that has greater thermal insulation properties relative to the structural layers; and

an outer skin that surrounds the intermediate core, and provides an outer fluid impervious barrier of the conduit,

10. A vessel according to claim 1, or a conduit according to claim 9, wherein the intermediate core has:

a second structural layer that surrounds the insulating foam layer.

11. A vessel or a conduit according to claim 10, wherein the second structural layer is in contact with both the insulating foam layer of the intermediate core, and the outer skin.

12. A vessel or a conduit according to either claim 10 or 11, wherein the first structural layer is bonded to the inner liner such that the inner liner is supported by the intermediate core.

13. A vessel or a conduit according to any one of claims 10 to 12, wherein the second structural layer is bonded to the outer skin such that such that the outer skin is supported by the intermediate core.

14. A vessel or a conduit according to any one of claims 10 to 13, wherein the insulating foam layer is bonded to each of the first and second structural layers.

15. A vessel or a conduit according to any one of claims 10 to 14, wherein the thickness of the insulating foam layer is greater than, or equal to, the thickness of the or each structural layer.

16. A vessel or a conduit according to any one of claims 10 to 15, wherein the first and second structural layers are of equal thickness.

17. A vessel or a conduit according to any one of claims 10 to 16, wherein the or each structural layer of the intermediate core is made of a foam material.

18. A vessel or a conduit according to claim 17, wherein the material of the or each structural layer differs from the material of the insulating foam layer.

19. A vessel or a conduit according to any one of claims 10 to 18, wherein the density of the or each structural layer is greater than the density of the insulating foam layer.

20. A containment system for storing and transporting bulk liquid, the containment system comprising:

one or more vessels according to any one of claims 1 to 8, or claims 10 to 19 when dependent on claim 1; and

one or more conduits according to claim 9, or claims 10 to 19 when dependent on claim 9.