Tank Power Washing, Sandblasting, & Painting at an Ethanol Plant

in Nebraska

Services Performed

Corrosion Control, Ethanol Plant Painting, Industrial Exterior Painting, Power Washing, Silo and Tank Painting

Location

Nebraska

Industrial storage tank exterior with visible staining as a worker uses a boom lift to perform power washing, sandblasting, and surface preparation before repainting

Client and Facility Overview

This ethanol production client, operating in Nebraska, is a key player in the renewable energy industry. The facility processes millions of gallons of ethanol per year, contributing to the United States' renewable energy goals. The plant includes several large storage tanks for various liquids used in ethanol production. These storage tanks are crucial to their operations, holding substances like denatured ethanol, diesel, and corrosion inhibitors.

Decision Driver and Timing

Mold and mildew growth was the primary driver for this maintenance project. Left unchecked, these issues could lead to faster deterioration of the tanks, threatening structural integrity and operational efficiency. Slowing deterioration of the real property investment made our expertise critical and the timing urgent.

Scope of Work

Power Washing: We started by power washing the tank surfaces using an industrial-grade power washer with 6,000 PSI strength. This process effectively removed the initial layers of mold and mildew.
Rust Removal: Applied power tools and manual scrubbing to clean off rust, ensuring the surface was optimally prepared for coating.
Masking and Protective Measures: All non-paintable equipment parts, such as signs and lights, were masked off meticulously to avoid any paint splatter.
Application of Coatings:

Detailed Breakdown of Painted Tanks

North Denatured Ethanol Tank: 250,000 gal
South Denatured Ethanol Tank: 250,000 gal
Denaturant Tank: 30,000 gal
Diesel Tank: 1,269 gal
Corrosion Inhibitor Tank: 5,287 gal
Waste Water Skirt
Additionally, sandblasted and painted the draft tube.

Notable Details

Our industrial-grade power washer operates at 6,000 PSI, almost triple the power of average home power washers. This demands expert handling to balance power and safety. Our team is thoroughly trained to use this equipment efficiently, ensuring effective cleaning without damaging the facilities.

We used Acrolon Ultra, a mildew-resistant coating, to prevent future mold and mildew growth. Combined with Macropoxy, this provides a durable, clean, and aesthetically pleasing finish.

To ensure that operations continued smoothly and without equipment damage, we meticulously masked non-paintable surfaces. This attention to detail maintained the integrity of non-target areas during the painting process.

Client Satisfaction

The project was completed without interrupting plant operations, reflecting our commitment to minimizing downtime for our clients. The ethanol plant was thrilled with the aesthetic and protective qualities of the new coatings and appreciated our professionalism, open lines of communication and timely completion of the project.