Emulsion tank

Types of emulsion tanks

An emulsion tank is industrial storage equipment for holding emulsion-stabilized liquids, which are mixtures of water, oil, and other additives. Emulsion tanks are commonly used in the asphalt industry, the cosmetics sector, the food industry, chemical production, and other commercial applications. There are multiple ways to classify the emulsion tanks. They can be classified according to the mixing power, heating source, the material of the tank, or the shape of the tank.

• According to the mixing power: There are two main types of emulsion tanks with and without agitators. The emulsion tank with an agitator has a mixing device (mixer) to keep the emulsion uniform and prevent separation. On the other hand, emulsion tanks without agitators do not have this maintaining feature, which can lead to the settlement of substances within the emulsion.
• According to the heating source: An emulsion mixing tank with a heater can heat the liquid, which is especially useful when dealing with high-viscosity materials or specific chemical processes that require a certain temperature. On the contrary, emulsion tanks without heaters cannot heat the contents, thus limiting the applicable liquids and processes.
• According to the material of the tank: The stainless steel emulsion tank is anti-corrosive, clean, sturdy, and long-lasting, making it a remarkable option for the chemical industry and food production. Steel emulsion tanks are also durable but may need to be more resistant to particular chemicals or hygiene standards.
• According to the shape of the tank: The vertical emulsion tank usually occupies a small area, improving space utilization, and can store large capacities. Emulsion tanks are typically cylindrical in shape. The horizontal emulsion tank generally can store a larger number of liquids and is suitable for permanent installation.

Specification & Maintenance

Emulsion tanks maintain the asphalt mixture's consistency by controlling temperature and circulation. Here's a quick look at some specifications along with their maintenance tips.

• Capacity: The size of an emulsion tank can vary, ranging from 500 gallons to 5000 gallons or even more. To maintain its ideal performance, users must calculate the right capacity based on the project demand. A suitable size will ensure material quality and user efficiency.
• Temperature Control: Asphalt emulsion tanks often come with temperature control systems that can heat or cool materials. Regularly check whether the heating or cooling system works well and repair or replace it immediately if not. Also, calibrate the temperature controller from time to time so it can control the tank's temperature accurately.
• Agitation System: The asphalt emulsions must constantly circulate to keep them uniform. Users need to ensure the agitation system works well and adjust its speed based on project requirements. Also, make sure the stirring system is suitable for the viscosity of the materials to be used.
• Insulation: The emulsion tank must be insulated to maintain the temperature of the materials. Users can regularly check the insulation for damage or gaps and then repair them in a timely manner.
• Fuel Consumption: The energy required to heat or cool the material may be high, so users need to keep track of the fuel consumption during use and analyze the data to improve efficiency.
• Safety Features: Regularly check the safety devices of the asphalt emulsion tank, such as pressure relief valves, safety covers, etc., and make sure they are working properly and reliably.
• Wheels and Axles: Asphalt emulsion tanks with wheels and axles need to be maintained to ensure ease of movement and stability during use. Regularly check the tires for pressure and wear. For axles, users should clean them and add lubricating oil periodically to extend their service life.

Scenarios

The main use of emulsion tanks is to store and mix materials that can create compounds such as polymers. This is often done at variable temperatures in order for these materials to become smoother and easier to work with, thereby creating a stable product. Such mixing processes are done by using mixers with different blade designs to suit the material being mixed.

There are a lot of industry applications where emulsion tanks are used and here are some of them:

• Oil and Gas: In this industry, emulsion tanks are used to store petroleum products as well as treat emulsions that can be derived from crude oil to separate water and other substances.
• Food and Beverage: Emulsion tanks are used to produce food emulsions such as sauces, dressings, margarine, dairy products, etc. They can also be used to process emulsions like fat replacement in low-fat products.
• Chemical Industry: Emulsion tanks are widely used in chemical industries to produce and store chemical emulsions like adhesives, coatings, agrochemicals, and textile chemicals.
• Pharmaceuticals: Emulsion tanks are used to produce pharmaceutical emulsions, including antibiotic emulsions, vitamin emulsions, and drug delivery systems.
• Cosmetics : Cosmetic emulsion tanks are used to produce creams, lotions, moisturizers, and other emulsion-based cosmetic products.
• Construction: In the construction industry, emulsion tanks are used to store bitumen emulsions, seal coats, and other emulsions used in road construction and waterproofing.

In all the given scenarios industrial emulsifier tanks work as the main mixing vessels to combine various materials into stable mixtures. Without these tanks, it would be very hard to produce refined liquids and pastes that can then be use in agricultural, construction or culinary industries.

How to choose emulsion tanks

When it comes to selecting the right emulsion tank, there are a couple of things buyers need to consider.

• Capacity and size

  The capacity of the emulsion tank refers to the volume or amount of material it can hold. It is typically measured in gallons or liters. The size of the tank is also important as it needs to fit into the existing infrastructure or production space. Businesses should carefully assess their requirements, considering factors, such as production volume and frequency of use before deciding on the size and capacity of the tank.

• Material and construction

  The choice of material used for constructing emulsion tanks directly affects the quality and integrity of stored emulsions. Stainless steel stands out as a top choice due to its remarkable resistance to corrosion and ability to maintain product purity. Its durable and hygienic attributes make it ideal for industries that demand strict cleanliness standards. Moreover, the construction of an emulsion tank involves not only selecting suitable materials but also employing intelligent design techniques that guarantee structural stability and prevent leaks or spills during storage or transportation.

• Agitation and mixing

  Proper agitation and mixing capabilities of the emulsion tank are crucial for maintaining homogeneity throughout stored products. Tanks equipped with efficient stirrers, paddles, or propellers ensure consistent dispersion of solid particles within the liquid medium while preventing sedimentation from occurring. The choice of the mixing device depends on factors such as viscosity levels, volume capacity of the tank, and specific requirements related to the end product quality. By providing effective agitation and mixing solutions during storage periods, these equipment items help preserve desired characteristics in final products.

Emulsion tank FAQ

Q1: Which types of emulsions does the emulsion tank make?

A1: Emulsion tanks can produce different types of emulsions, including oil-in-water emulsions, water-in-oil emulsions, multiple emulsions, volatile oil-in-water emulsions, and solid-in-oil emulsions, as per the industrial requirements.

Q2: What is the difference between an emulsion and suspension?

A2: An emulsion is a mixture of two immiscible liquids, such as oil and water, stabilized by emulsifying agents, while a suspension is a heterogeneous mixture in which solid particles are dispersed in a liquid medium.

Q3: How long does the emulsion tank last?

A3: The emulsion tank may last for 5 to 10 years or even up to 20 years if adequately maintained and cared for. However, the vital components of the tank, such as the agitator, motor, heating system, and sealing system, may require replacement or repair within this period.