Industrial storage tanks are the backbone of chemical handling facilities. Yet, even proven practices can sometimes fall short when unexpected impurities or operational conditions come into play. At Crescent PPG, with over 30 years of expertise in industrial lining and tank failure prevention, we’ve seen how subtle factors can lead to major losses—and how customized solutions make all the difference.

The Case Study: Hydrochloric Acid Storage Tanks

A leading chemical facility had everything in place—8 bulk storage tanks, all built with mild steel and rubber lining, following the gold standard for storing Hydrochloric Acid (HCl). For years, operations ran smoothly. The tanks stood tall, the acid stayed contained, and the team trusted the system.
Until one day, a small hole appeared. Then another.
1–2 cm punctures at the bottom of the tanks.
Silent. Periodic. Costly.
The leaks triggered alarms—not just environmental, but financial and operational. Downtime mounted. Safety protocols scrambled. And the question loomed:
Why was a proven lining system failing?

• Customer Profile: 8–10 bulk acid storage tanks used for Hydrochloric Acid (HCl).
• Tank Construction: Mild Steel (MS) tanks with internal rubber lining, a standard and widely accepted practice for HCl storage.
• Problem: Periodic punctures (1–2 cm diameter holes) at the bottom of tanks, leading to:
• Acid leakage
• Environmental hazards
• Operational downtime
• Financial losses

Investigating the Failure

At first glance, rubber lining should withstand HCl without issue. However, deeper investigation revealed:

• Impurity Detected: Ethylene Dichloride (EDC) present at ~5000 PPM.
• Key Insight:
• Density of EDC = 1.35 (vs. HCl = 1.1–1.2).
• When tanks remained idle for months, EDC settled at the bottom, especially in sloped areas.
• This localized deposit compromised the lining, causing punctures.

This highlights a critical truth: standard solutions don’t always account for hidden impurities or operational patterns.

The Crescent PPG Solution

Leveraging our decades of expertise, we designed a customized lining plan:

• Applied acid-resistant brick lining with suitable material specifically engineered to withstand EDC.
• Protected the bottom of tanks up to a height of 0.7 meters.
• Result: No further punctures, no leakage, and complete operational safety.

Why Crescent PPG Tanks Stand Apart

• 30+ Years of Experience: Deep knowledge of industrial lining failures and preventive strategies.
• Customized Solutions: We don’t just follow standards—we adapt to your unique chemical environment.
• Dual Expertise: Both tank construction and lining technology are our strengths.
• Proven Results: From rubber linings to brick linings, we engineer solutions that last.

Always consider impurities beyond the primary chemical when selecting linings.

• Idle storage conditions can create hidden risks.
• Customized lining plans prevent costly failures.
• Partnering with experts like Crescent PPG ensures long-term reliability and environmental safety.

At Crescent PPG, we believe knowledge sharing builds stronger industries. This case study is not just about solving one customer’s problem—it’s about showing how experience, customization, and expertise protect your assets and reputation.
Engage with us today to explore tailored solutions for your storage challenges.