Oxygen contamination in storage tanks is a serious concern for industries storing chemicals, fuels, food products, and pharmaceuticals. Oxygen exposure can lead to degradation, oxidation, and even safety hazards, especially in volatile or sensitive substances. To address this issue, many facilities rely on blanketing systems, which provide a protective layer of inert gas to shield the stored material from atmospheric oxygen.

In this blog, we’ll discuss why oxygen contamination is problematic, how blanketing systems work, and the steps you can take to implement an effective blanketing system in your storage tanks.

The Risk of Oxygen Contamination in Storage Tanks

Oxygen can have a damaging effect on various products stored in tanks. In industries like chemicals and pharmaceuticals, where product integrity is paramount, oxygen can cause several issues:

1. Oxidation: Exposure to oxygen can trigger oxidation reactions, leading to the deterioration of sensitive materials. For instance, oils, fuels, and food products can spoil, reducing their shelf life and quality.
2. Corrosion: In metal storage tanks, oxygen can react with the metal, causing rust and corrosion. This not only weakens the tank’s structure but also introduces contaminants into the stored substance.
3. Flammability and Explosions: Oxygen can be dangerous when stored near flammable liquids or gases. It increases the risk of fire or explosion, especially in industries dealing with volatile substances like chemicals and fuels.
4. Product Contamination: For industries such as pharmaceuticals or food and beverage, even the smallest level of contamination can alter the product’s effectiveness, flavor, or safety, leading to compromised product quality.

Given these risks, it’s essential to mitigate oxygen exposure as much as possible.

The Solution: Blanketing Systems

Blanketing systems are designed to prevent oxygen contamination by maintaining an inert atmosphere above the stored substance. This is achieved by introducing a non-reactive gas, such as nitrogen, into the tank. The inert gas displaces oxygen, creating a protective layer that prevents contact between the product and atmospheric oxygen.

These systems are widely used across multiple industries, including:

• Chemical and Petrochemical Storage: Blanketing systems protect chemicals and fuels from oxidation and contamination.
• Food and Beverage: Inert gases protect oils, wine, and other products from spoilage and preserve freshness.
• Pharmaceuticals: Blanketing ensures the stability and integrity of sensitive compounds.
• Agriculture: Protects stored grains and seeds from mold growth and degradation.

How Blanketing Systems Work

At the heart of a blanketing system is the principle of introducing an inert gas to create a blanket that covers the top of the liquid inside a storage tank. Here’s a breakdown of how it works:

1. Inert Gas Supply: The system is connected to a supply of an inert gas, such as nitrogen or carbon dioxide, which has no reactive properties and doesn’t interact with the stored material.
2. Pressure Regulation: A pressure-regulated valve is used to ensure the tank maintains a constant positive pressure, preventing the ingress of atmospheric oxygen. It ensures that the inert gas remains at the correct pressure level to form a protective barrier.
3. Gas Distribution: The inert gas is distributed throughout the tank, either by introducing it through a vent or nozzle positioned at the top or by using a more advanced method like an agitator that ensures proper mixing and even distribution.
4. Continuous Monitoring: Modern blanketing systems are equipped with sensors to monitor the pressure and the concentration of the inert gas, ensuring the system operates effectively. If the pressure drops or oxygen levels rise, the system automatically adjusts to maintain the correct balance.
5. Ventilation and Release: If the tank is venting, the system ensures the vented gas is replaced with fresh inert gas, preventing oxygen from entering and displacing the protective layer.

Benefits of Using a Blanketing System

Blanketing systems provide numerous advantages for industries that require safe, long-term storage of sensitive products:

1. Prevents Oxidation and Spoilage: The primary benefit of blanketing is the prevention of oxidation, which preserves the quality and shelf life of products, especially in the food, pharmaceutical, and chemical industries.
2. Enhances Safety: By preventing oxygen from coming into contact with flammable materials, blanketing systems reduce the risk of explosions or fires in storage tanks, particularly in industries such as petrochemicals and oil storage.
3. Minimizes Corrosion: The use of inert gas helps prevent corrosion inside storage tanks, increasing their lifespan and reducing maintenance costs. This is especially important for tanks storing aggressive chemicals or fuel.
4. Improved Product Integrity: For pharmaceutical and food products, even small amounts of oxygen can compromise the efficacy and quality of the product. Blanketing helps maintain the integrity of these sensitive materials.
5. Cost-Effective: Although there is an upfront cost for the installation of blanketing systems, the long-term benefits of preserving product quality and reducing the need for frequent maintenance make them a cost-effective solution.

Implementing an Effective Blanketing System

To implement a successful blanketing system in your storage tanks, follow these key steps:

1. Assess the Storage Tank Requirements

The first step in designing a blanketing system is to assess the storage tank’s specific needs. Consider the following:

• The type of material being stored
• The tank’s size and capacity
• The temperature and pressure conditions inside the tank
• The volatility and flammability of the stored substance
• Regulatory requirements for storage

2. Select the Appropriate Inert Gas

Most blanketing systems use nitrogen because it is readily available and cost-effective. However, in certain situations, carbon dioxide or other gases may be a better choice, depending on the specific needs of the stored material.

3. Choose the Right Blanketing Equipment

There are several types of blanketing systems, including:

• Pressure-vacuum valves: These regulate the pressure inside the tank by controlling the flow of inert gas.
• Nitrogen generators: These produce nitrogen on-site, reducing the need for external gas supply.
• Automatic controllers and sensors: These ensure the gas levels and pressure are maintained, optimizing efficiency.

4. Design the Distribution System

Ensure that the inert gas is evenly distributed throughout the tank. Proper placement of distribution points and vents is essential for maintaining the integrity of the protective blanket.

5. Regular Monitoring and Maintenance

A blanketing system requires regular maintenance to ensure it continues to function properly. This includes checking the gas supply, inspecting valves and sensors, and verifying that there are no leaks or faults in the system.

Conclusion

Oxygen contamination in storage tanks is a risk that cannot be ignored, especially for industries that rely on the long-term storage of sensitive materials. Blanketing systems provide an effective and efficient solution to this problem, offering protection against oxidation, corrosion, spoilage, and safety hazards.

By understanding how blanketing systems work and following the steps to implement one, you can ensure the longevity of your stored products, enhance safety, and improve operational efficiency. Whether you’re storing chemicals, pharmaceuticals, food, or any other sensitive material, investing in a high-quality blanketing system is a step toward protecting your products and optimizing your storage process.

If you need expert advice or assistance in designing and implementing a blanketing system, reach out to our team at Regport Technology. Our engineers specialize in providing customized solutions tailored to your specific needs. Let us help you protect your products and enhance your operations today!