Regan Brown
Low permeation fuel tanks are designed to reduce the amount of fuel and fuel vapour that escapes from a tank, preventing pollution and reducing the risk of fire. Fuel vapours can escape from tanks due to daily temperature changes, and also as a result of fuel heating up and expanding during the day. Fuel tanks with low permeability are often made from rigid polymers, such as high-density polyethylene, polybutylene terephthalate (PBT), polycarbonate, and nylon 6. Low permeation fuel tanks are commonly used in marine vessels, aircraft, and military vehicles.
Characteristics and Values of a Low Permeation Fuel Tank
| Characteristics | Values |
|---|---|
| Purpose | To meet new low hydrocarbon emission standards |
| Emission standards | 0.4 g/gallon/day for diumal venting from a fuel tank at 35.6 degrees C |
| 1.5 g/gallon/day permeation from a fuel tank at 40 degrees C | |
| 151 g/sq. meter/day for hose and primer bulb permeation at 23 degrees C | |
| Preferred materials | Any rigid polymer that meets the new low permeation standards of 15 g/sq. m/day |
| Examples of materials | High-density polyethylene, polybutylene terephthalate (PBT), polycarbonate, polycarbonate PBT (PC/PBT), Nylon 6, acetal(acetyl) |
| Other characteristics | Stackable due to matching protrusions and recesses on the top and bottom |
| Has side recesses that match straps and a handle that is designed to lift and pour | |
| An epoxy layer painted over the interior plastic surfaces to reduce permeability levels | |
| Valves to prevent fuel spilling out of the tank vent |
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What You'll Learn
Marine fuel tanks with low hydrocarbon emission standards
The U.S. government has set specific rules for marine fuel system hydrocarbon emissions, including diurnal venting and fuel tank permeation standards. These standards vary depending on the temperature and type of fuel used. For example, the permeation standard for a fuel tank at 35.6 degrees Celsius is 0.4 g/gallon/day, while at 40 degrees Celsius, it increases to 1.5 g/gallon/day. These rules also apply to hose and primer bulb permeation, with a standard of 151 g/sq. meter/day at 23 degrees Celsius.
To meet these low hydrocarbon emission standards, marine fuel tanks are often made from rigid polymers such as high-density polyethylene, polybutylene terephthalate (PBT), polycarbonate, or nylon. These materials can be enhanced with the addition of nanomaterials such as carbon nano-fibers or treated clay particles, which further reduce hydrocarbon permeation. One example is the incorporation of 5% nanomer into a poly vinyl ester resin matrix, which effectively retards hydrocarbon migration through the fuel tank walls.
In addition to material selection, the design of marine fuel tanks also plays a role in achieving low hydrocarbon emission standards. For instance, the EPA has specified that marine SI vessels with a filler neck extending to the side of the boat should be designed for automatic fuel shutoff. This prevents the overflow of fuel and reduces emissions. The EPA has also established regulations for diesel fuel production and distribution, requiring refiners and importers to designate the type of diesel and sulfur level for each batch, ensuring the use of low-sulfur diesel fuel in marine applications.
Overall, the implementation of low hydrocarbon emission standards for marine fuel tanks involves a combination of innovative materials, careful design considerations, and stringent regulations. These measures aim to reduce the environmental impact of marine vessels and contribute to cleaner air and improved public health.
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Polymer materials used to reduce hydrocarbon permeation
Low permeation fuel tanks are designed to reduce the amount of fuel emitted into the atmosphere. Marine fuel tanks, for instance, are now subject to stricter federal government regulations on hydrocarbon emissions. To meet these new standards, fuel tanks can be made from polymer materials that reduce hydrocarbon permeation.
Polymer materials have been used to separate and remove hydrocarbons from natural gas. Membrane-based separation technologies have emerged as an economically favourable alternative due to reduced capital and operating costs. Polymeric membranes have been used to fractionate or split complex mixtures of organic molecules such as crude oil.
Polymeric membranes have also been used to enhance the energy efficiency of separation and purification systems. Physics-informed machine learning algorithms (ML) and mass transport simulations are combined to create an integrated predictive model for the separation of complex mixtures containing up to 400 components via any arbitrary linear polymer membrane.
For low permeation fuel tanks, any rigid or semi-rigid polymer that can meet the new low permeation standards of 15 g/sq. m/day can be used. Some of the materials that can be used include high-density polyethylene, polybutylene terephthalate (PBT), polycarbonate, polycarbonate PBT (PC/PBT), Nylon 6, and acetal(acetyl). Introducing around 5% nanomer into a polyvinyl ester resin matrix, for instance, retards hydrocarbon migration through the fuel tank walls.
Polymer liners and composite structures are also used in hydrogen storage systems to prevent leaks and ensure safety. EVOH liners, for example, have been found to significantly reduce hydrogen permeation rates.
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Fuel evaporative emissions from venting fuel-tank vapours
Diurnal venting refers to the evaporation of fuel due to the sun's heat, causing the vapours to escape through emission control hoses. While it has been argued that losses from diurnal evaporation are relatively small, other forms of evaporative emissions, such as running losses and heat soak, can be more challenging to estimate and may have a more significant impact.
To address these emissions, the government has set standards for low permeation fuel tanks, which are designed to reduce the permeation of hydrocarbons through the tank walls. These tanks are typically made from polymers, such as high-density polyethylene or polybutylene terephthalate, with a hydrocarbon permeation rate of less than 15 g/sq. m/day.
Additionally, modifications to the EVAP system, which is responsible for venting during refueling, have been suggested to reduce fuel evaporative emissions. However, some have noted that the small lines of the EVAP system may not be effective in reducing emissions, and alternative solutions, such as adding a separate second filler vent line or implementing the "`Hi-Tee dual fuel tank vent upgrade", have been proposed.
Overall, the focus on reducing fuel evaporative emissions from venting fuel-tank vapours has led to the development of low permeation fuel tanks and the exploration of various venting systems to minimise the impact on the environment.
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Self-sealing fuel tanks to prevent fuel leaks
Self-sealing fuel tanks are designed to prevent fuel leaks and increase safety. They are typically used in aircraft and vehicles that are at risk of being perforated, such as military and armoured vehicles, and aircraft exposed to gunfire. When the tank is perforated, the fuel infiltrates the different layers of the tank, causing one of the layers to swell and seal the puncture. This prevents fuel leaks and the risk of fire.
Self-sealing fuel tanks consist of multiple layers of technical fabrics coated with rubber and polymer foam. The layers include one of vulcanized rubber and one of untreated natural rubber. When the tank is perforated, the fuel is absorbed into these layers, causing the untreated layer to swell and seal the puncture.
The concept was first patented in 1917 by George J. Murdock, who applied for the patent "War Aeroplane Fuel Tanks". However, an order from the Federal Trade Commission blocked any discussion or publication of the invention until September 26, 1918, when the order was rescinded and Murdock was granted the patent. Early attempts at protecting fuel tanks included using metal tanks covered inside or outside by a material that expanded after being pierced.
Self-sealing fuel tanks were extensively used during World War II, particularly in American aircraft. Combat experience showed that American aircraft with self-sealing fuel tanks had better chances of surviving damage than Japanese aircraft without this technology, such as the Mitsubishi A6M Zero. However, the use of self-sealing fuel tanks made the aircraft heavier and therefore slower and less manoeuvrable.
Today, self-sealing fuel tanks are still used in various applications, including military aircraft, F1 cars, and fuel storage tanks on refuelling trucks and trailers.
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Fuel system safety tips for boating
Fuel system safety is an important aspect of boating, and there are several precautions to take when fuelling your boat to ensure your safety and protect the marine environment. Here are some detailed tips for safe boating:
Before fuelling:
- Check your fuel lines, hoses, clamps, vents, and tank for any damage, including loose connections, rub spots, cracks, rust, and corrosion. Ensure your vents are not blocked.
- If using portable containers, check them for wear and fill them on the ground, not on your boat, to avoid static electricity.
- Secure your boat to the dock with multiple lines to minimise movement and add stability.
- Ask all passengers to disembark for safety and to help keep the boat stable.
- Ensure no one is smoking, and extinguish any flames or electronics, including phones and flashlights (unless it is an emergency and you are fuelling at night).
- Turn off your engine and any electrical equipment that could cause a spark.
During fuelling:
- Hold the nozzle firmly against the tank opening to ground any static electricity and fill the tank slowly to avoid splashes and spills.
- Keep your hands steady and watch your progress to prevent overflow.
- Never fill your tank beyond 90% full, leaving room for gas to expand.
After fuelling:
- Tightly replace the gas cap to prevent the escape of fuel vapours.
- Wipe up any spills immediately and dispose of absorbent pads properly.
- Open all doors, windows, and hatches to allow fresh air to circulate and remove any gasoline fumes.
- Run your ventilation system for around 5 minutes if you still smell gasoline and wait until fumes dissipate before starting the engine.
- Store portable containers in a cool, dry, well-ventilated place away from the engine.
Other considerations:
- Regularly inspect your fuel system and perform maintenance to address any issues.
- Keep your engine well-maintained with proper oil mixes, fuel filters, and propeller care for optimal performance and fuel efficiency.
- Understand how different types of fuel affect your engine and consider using low permeation fuel tanks to reduce hydrocarbon emissions.
By following these safety tips, you can help ensure a safe and enjoyable boating experience while minimising environmental impact.
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Frequently asked questions
A low permeation fuel tank is designed to reduce the amount of fuel that evaporates and escapes into the atmosphere. These tanks are typically made from rigid polymers, such as high-density polyethylene, polybutylene terephthalate (PBT), or polycarbonate, and have a hydrocarbon permeation rate of less than 15 g/sq. m/day.
Low permeation fuel tanks help to prevent pollution and reduce evaporative emissions. They also improve fuel efficiency and safety by minimizing the risk of fuel leaks and fires.
Low permeation fuel tanks use materials with low permeability, such as polymers with embedded carbon fibers or nano-materials, to retard the migration of hydrocarbons through the tank walls. Some tanks may also have coatings or epoxy layers to further reduce permeability.
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