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ChemCo Systems InsulPOX™ Cryogenic Insulating Polymer Concrete (IPC) Overlay for LNG terminals

InsulPOX is a cryogenic liquid-applied secondary containment epoxy insulating polymer concrete (IPC) overlay with low thermal conductivity for LNG and other cryogenic liquids storage and shipping terminals.

Stemming from research conducted with Brookhaven National Laboratory, ChemCo Systems is proud to announce a recent installation of CCS InsulPOX at an LNG facility on Long Island in New York. InsulPOX has also been installed as an insulating liner in the concrete trenches and sumps of a newly constructed Texas LNG liquification terminal now in operation.

This lightweight 3/4-1" thick insulating polymer concrete (IPC) overlay system reduces heat transfer from sump, dike and trench walls and floors. This low modulus epoxy polymer lining reduces the evaporation rate of spilled LNG and the vapor plume spread and lowers the concentration of flammable methane gas in the surrounding atmosphere. As the surface secondary containment layer, it also provides protection to the concrete and structural steel from potential cryogenic brittle fracture by insulating it from the -260 °F liquid should a spill occur.

The flexibility and toughness of the low modulus insulating layer provides excellent mechanical and thermal shock resistance. A long mixed useful life of the polymer during application makes installation hassle-free. InsulPOX can be installed as a seamless overlay directly on floors or cast in place on walls. Optionally, InsulPOX can be supplied in finished precast panels of 3/4-1" thickness and 4' x 8' width and length and installed quickly on both walls and floors. InsulPOX is formulated with a non-flammable, chemical resistant, thermoset binder. We are excited to contribute to the safe growth of LNG and LPG storage and terminal operations.

Why InsulPOX?
• Slows evaporation of spilled LNG by reducing the heat transfer of underlying concrete. Lowers the airborne concentration of evaporated vapors to avert explosive levels.
• Protects concrete from cracking and flexing due to severe thermal cycling due to exposure to -260°F (-160°C) LNG liquid or other cryogenic liquids such as liquid oxygen or liquid nitrogen.
• Protects reinforcing steel from cryogenic embrittlement.
• Resistant to mechanical and thermal shocks.
• Provides seamless installation.
• Field repair uses non-sag version.
• High compressive and tensile strength tolerates foot and light vehicle traffic.
• Can be installed very quickly in larger areas if precast panels are selected.


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ChemCo Systems InsulPOX™ Cryogenic Insulating Polymer Concrete (IPC) Overlay for LNG terminals

  1. 1. CCS InsulPOXCCSConstructionPolymers CCS InsulPOX™ High-performance epoxy insulating polymer concrete (IPC) overlay for cryogenic secondary containment in LNG terminal dike walls, sumps and floors
  2. 2. CCS InsulPOXCCSConstructionPolymers Why? Slows evaporation of spilled LNG by reducing the heat transfer of underlying concrete. Lowers the airborne concentration of evaporated vapors to avert explosive levels. Protects concrete from cracking and flexing due to exposure to -260oF (-160oC) LNG liquid. Protects reinforcing steel from cold embrittlement. Resistant to and mechanical and thermal shocks. Provides seamless installation. Field repair uses non-sag version. High compressive and tensile strength tolerates foot traffic. 2
  3. 3. CCS InsulPOXCCSConstructionPolymers How does it work? Durable, flexible, UV-stable, nonflammable epoxy insulating polymer concrete (IPC) system is filled with lightweight nano spheres and applied in thickness of ¾-2” on concrete. Low modulus polymer provides toughness—it won’t shatter when subjected to mechanical or thermal shocks. Can be installed quickly in precast panels for horizontal or vertical applications. 3
  4. 4. CCS InsulPOXCCSConstructionPolymers What is it? Lightweight mixed density ~48 lbs/ft3 (0.768 kg/m3) (concrete ~ 150 lbs/ft3) Tensile strength = 1,750 psi Elongation = 60 % Bond strength = 500 psi (to concrete or steel) Thermal conductivity = 0.043 btu/hr/ft/oF, or 0.074 W/m/K at -160oC Nonflammable UV stable Available in self- leveling or non-slump versions Can be fabricated in ¾- 1” precast panels for rapid installation 4
  5. 5. CCS InsulPOXCCSConstructionPolymers Product Testing Evaporation rate Heat Conductance 1% grade slump Vertical Anchor Dart Drop 5 0.000 0.020 0.040 0.060 0.080 0.100 0.120 0.140 0.160 -260 -220 -175 -135 -100 -70 -25 15 40 70 115 ThermalConductivity,BTU/hr-ft-oF Temperature oF InsulPOX Thermal Conductivity (ASTM F433)
  6. 6. CCS InsulPOXCCSConstructionPolymers Testing Vertical Anchor testing for pre-cast panels 6
  7. 7. CCS InsulPOXCCSConstructionPolymers Testing Dart Drop testing for shatter resistance 7
  8. 8. CCS InsulPOXCCSConstructionPolymers Surface Texture 8
  9. 9. CCS InsulPOXCCSConstructionPolymers FIELD APPLICATION: LNG Terminal Truck Filling Station 9
  10. 10. CCS InsulPOXCCSConstructionPolymers Spill Containment Trench 10 Truck Filling Station
  11. 11. CCS InsulPOXCCSConstructionPolymers Containment Pit: 3 of 4 sections installed. 2 of 3 sections broadcasted with sand. 11 Truck Filling Station
  12. 12. CCS InsulPOXCCSConstructionPolymers Mixing 12 1. Pour liquid into separate pail and scrape gel from bottom of pail with shovel or trowel.
  13. 13. CCS InsulPOXCCSConstructionPolymers Mixing 13 2. Mix gel into liquid resin with jiffy mixer blade
  14. 14. CCS InsulPOXCCSConstructionPolymers Mixing 14 3. Pour mixed components into mixing container and mix for 1 minute.
  15. 15. CCS InsulPOXCCSConstructionPolymers Mixing 15 4. Mix in pre-weighed ceramic microbeads, adding slowly until uniformly mixed.
  16. 16. CCS InsulPOXCCSConstructionPolymers Installing 16
  17. 17. CCS InsulPOXCCSConstructionPolymers Installing 3/26/2018 17
  18. 18. CCS InsulPOXCCSConstructionPolymers Installing 18 Expansion Joints.
  19. 19. CCS InsulPOXCCSConstructionPolymers Installing 19
  20. 20. CCS InsulPOXCCSConstructionPolymers Installing 20

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