The ZipaTankTM is an innovative modular tank developed by Xstrata Technology that can be easily assembled to meet the tough requirements of above ground slurry storage and leaching tanks in the mining industry. The ZipaTankTM incorporates an elegant modular design with a novel join locking mechanism to provide all the benefits of a traditional welded tank, with lower costs, reduced installation times and far greater flexibility.
The ZipaTankTM consists of individual vertical panels that are sized for transport in conventional shipping containers. These panels are connected to each other using an interlocking join that can be rapidly installed and provides a join that is stronger than a conventional weld.
All components of the ZipaTankTM are fabricated off site and shipped to site in sections for assembly. No site welding is required. Off site fabrication significantly reduces the cost of the ZipaTankTM, relative to a site welded tank.
ZipaTankTM Features
Interlocking Vertical Panels
The ZipaTankTM consists of a series of panels that are locked together to form the tank shell and the tank base. Each panel is manufactured from a cold rolled section of mild or alloy steel to the total height of the tank, and at a width designed to fit in a standard shipping container.
The panels making up the tank shell are curved to match the required diameter for the assembled tank. Each panel is joined to two adjacent panels during assembly, and comes pre welded to an annular ring at the base of the panel and a stabilising ring at the top to provide the tank with rigidity and stability.
The panels making up the tank floor are laser cut to match the diameter of the assembled tank. The floor panels have bolt holes cut into the outer edge of the panel, to connect to the annular ring on the vertical panels during assembly.
During assembly, the base panels are first joined, and located on the tank foundation using holding down bolts. The vertical panels are then moved into place with a crane and bolted to the base panels. All bolts sit outside the tank and are not subject to attack by slurry.
All panels are then locked together using a proprietary compression joining system to provide a leak free joint that is as strong as a welded joint. The compression join is not subject to weld line corrosion that often affects the heat affected zone adjacent to a weld line, and does not require non destructive testing after installation.
Nozzles and other penetrations are fabricated into the tank panel as required. The ZipaTankTM also has a range of modular accessories, from access manholes, baffles, slurry risers and launders, access ways and ladder ways, agitators and agitator support and maintenance platforms.
The ZipaTankTM Compression Joint
The panel joining system used in the contruction of the ZipaTankTM is an innovative method of joining flat plates that was developed in partnership with JoinloxTM.
The joint consists of two interlocking sinusoidal sections fabricated on each edge of the panel, which are brought together and then locked with a compression key, resulting in a spring-loaded join. One edge of the panel is lined with a rubber gasket, and the gasket is compressed during joining, providing a leak free seal between the panels.
The compression key is located on the outside of the panel, away from the contents of the tank. Lugs are also located on the outside of the panels, and the compression key is pushed into place between these lugs, squeezing the two panels together and compressing the rubber gasket, locking the joint.
The join is entirely mechanical, and no site welding is required to assemble the ZipaTankTM. All quality control is carried out during fabrication of the panels in a controlled factory environment, and non destructive testing of the assembled tank is not required.
All penetrations, edges and bolt holes are laser cut during fabrication, ensuring rapid assembly.
ZipaTank™ Applications
The ZipaTank™ can be used in a wide range of applications in the mining industry, including the following:
Single tank slurry storage applications:
- Concentrate storage and conditioning tanks
- Thickener underflow storage tanks
- Limestone and lime slurry storage
- Reagent storage
- Filter cake repulp
- Tailings processing
- Flotation tanks and equipment
- Thickening and clarification tanks and equipment
Multiple tank leaching applications:
- Acid leaching of copper oxide ores and tailings
- Acid leaching of uranium ores
- Acid leaching of zinc calcines
- Sulphide oxidation plants (Albion, BIOX)
- CIP/CIL processing of gold ores
ZipaTank™ Design
All ZipaTank™ components are designed to a minimum standard exceeding API 650, AS1210, or BS 2654 (1989) for above ground steel storage tanks. All designs incorporate relevant site factors, such as wind, snow, rain and seismic loads. ZipaTank™ dimensions are customised to suit the clients’ needs.
The ZipaTank™ can be designed to withstand the buckling loads associated with overhung agitators and other structural steel components, to allow mounting of these components directly onto the tank shell.
ZipaTank™ Fabrication
Each shell and floor panel is manufactured according to the client’s requirements, from a single cold rolled section of mild or alloy steel to the total height of the tank. Each panel is supplied in a single section from the mill, and so the panel is not weakened by welding.
All panels are laser cut to the required dimensions, and all penetrations and edge details are laser cut during fabrication to ensure rapid, trouble free assembly on site. Shell panels are formed to shape in the factory and welded to precisely cut annular rings that ensure the shell curvature is maintained during transport and assembly.
ZipaTank™ panels can incorporate low cost lining systems, which are applied under controlled factory conditions. Materials such as rubber, GRP, FRP or more specialised materials can be used as the lining system. All linings are applied in controlled temperature and humidity rooms to ensure a consistent bond to the parent plate.
ZipaTank™ Foundation
The ZipaTank™ can be assembled on a conventional tank foundation, such as an infilled concrete ring beam or slab. A flexible gasket is placed between the tank floor and the tank foundation and sealed at the floor edge to prevent slurry or water contacting the underside of the tank floor area.
Xstrata Technology will assist in the design of the tank foundation, by providing general arrangements for the tank foundation, and design loadings.
ZipaTank™ Transport and Assembly
All ZipaTank™ modular components are fabricated in modular sections designed for transport in standard 40 ft shipping containers. Assembly does not require specialised labour and an installation supervisor will be provided by Xstrata Technology. No special tools are required for the assembly of the ZipaTank™ , as the tank can be assembled with a mobile crane.