Modern terminals are changing faster than ever

Tank terminals have always played a vital role in global supply chains. For decades, their primary purpose was relatively straightforward: storing crude oil, refined petroleum products and commodity chemicals before transportation by ship, rail, truck or pipeline.

Today, however, the industry is changing rapidly.

Operators such as Royal Vopak, Oiltanking, TEPSA, Evos, Koole Terminals, LBC Tank Terminals, Advario and other independent storage companies are investing billions of euros in infrastructure that supports not only conventional fuels but also the energy transition.

Across Europe and beyond, terminals are expanding their capabilities to handle:

• Sustainable Aviation Fuel (SAF)
• Hydrotreated Vegetable Oil (HVO)
• Renewable feedstocks
• Biofuels
• Methanol
• Process chemicals
• Fertilisers
• Acids and alkalis
• Water treatment chemicals
• Carbon capture supply chains
• Future hydrogen and ammonia logistics

This diversification creates entirely new engineering challenges.
Products are becoming chemically more aggressive, environmental regulations continue to tighten, and terminal operators are under increasing pressure to maximise uptime while reducing maintenance costs.
As a result, material selection has become a strategic engineering decision rather than simply a procurement choice.

Why corrosion remains one of the industry's biggest challenges

Storage tanks are long-term assets.

Many remain operational for 30, 40 or even 50 years.

During that lifetime they are continuously exposed to:

• aggressive chemicals
• moisture
• marine environments
• UV radiation
• temperature fluctuations
• mechanical loading
• filling and emptying cycles

Carbon steel has traditionally been the standard construction material.
While extremely suitable for many petroleum products, carbon steel often requires protective coatings, cathodic protection and periodic maintenance when exposed to corrosive chemicals.
Even stainless steel is not immune to corrosion. Depending on chloride concentration, temperature and chemical composition, localized corrosion mechanisms such as pitting or stress corrosion cracking can occur.

The result?

• Maintenance shutdowns.

• Inspection programmes.

• Repair costs.

• Operational risk.

As terminals diversify into increasingly aggressive products, corrosion management becomes a growing part of total ownership cost.

Why FRP has become an established engineering material

Fibre Reinforced Plastic (FRP), also known as Glass Reinforced Plastic (GRP), has been used in industrial process industries for decades.
Unlike steel, whose corrosion resistance depends on protective coatings or alloy composition, FRP derives its performance from the combination of glass fibres and corrosion-resistant thermosetting resins. The structural fibres provide mechanical strength while the resin system provides chemical resistance.

By selecting the correct resin system for the stored medium, engineers can design tanks suitable for a broad range of corrosive chemicals.

Common resin systems include:

• Vinyl ester
• Epoxy vinyl ester
• Isophthalic polyester
• Bisphenol polyester
• Specialised chemical-resistant formulations

The correct material selection always depends on:

• chemical composition
• concentration
• operating temperature
• pressure
• design life
• cleaning procedures
• applicable standards

This engineering approach ensures the material matches the application rather than forcing every application into a single material solution.

Where FRP tanks outperform traditional materials

FRP should not be viewed as a universal replacement for steel.
Instead, it excels where corrosion resistance is the primary design requirement.

Typical advantages include:

Outstanding corrosion resistance

Properly engineered FRP tanks resist a wide range of corrosive chemicals without requiring protective coatings.

Reduced maintenance

Because corrosion protection is inherent to the laminate itself, routine coating repairs are generally unnecessary.

Long service life

Many FRP installations have operated successfully for decades when properly designed, manufactured and maintained.

Lightweight construction

Composite tanks are significantly lighter than comparable steel structures, reducing foundation loads and simplifying installation.

Design flexibility

FRP can be manufactured in virtually any diameter or height, allowing storage capacity to be tailored to the available footprint.

Typical applications inside tank terminals

Modern tank terminals consist of much more than large fuel tanks.
Throughout the facility are dozens of smaller process installations handling aggressive chemicals.

Examples include:

Water treatment

Storage of:

• sodium hypochlorite
• ferric chloride
• hydrochloric acid
• sulphuric acid
• sodium hydroxide

Chemical dosing systems

Corrosion-resistant storage for treatment chemicals used in wastewater and firewater systems.

Process chemicals

Dedicated storage for specialty chemicals used throughout terminal operations.

Odour control systems

FRP scrubbers and ducting systems provide excellent corrosion resistance in chemically aggressive exhaust streams.

Utility systems

FRP piping and vessels are frequently applied where long-term corrosion resistance reduces maintenance requirements.

Why the energy transition increases the need for corrosion-resistant materials

One of the biggest changes in the industry is not simply storing different products—it is storing products with different chemical behaviour.
Renewable feedstocks, recycled chemicals and new industrial processes often require storage infrastructure beyond what traditional petroleum terminals were originally designed for.
Terminal operators increasingly evaluate infrastructure based on:

• lifecycle cost
• inspection intervals
• environmental performance
• future adaptability

Rather than replacing infrastructure every time product portfolios evolve, operators increasingly seek materials capable of handling multiple future applications.
This is one reason composites continue to gain attention within the liquid bulk storage sector.

Large-diameter tanks: overcoming transportation limitations

One of the most overlooked constraints in tank construction is transportation.
As tank diameters increase, logistics become exponentially more complex.
Prefabricated tanks must comply with transport regulations governing width, height and weight. 
Oversized transport often requires specialised trailers, escorts, route modifications and heavy lifting equipment.
For very large tanks, transportation may become impractical—or impossible. This is where Plasticon Projects offers a distinct advantage.

Manufacturing tanks where they will operate

Rather than transporting complete tanks to site, Plasticon Projects manufactures large-diameter FRP storage tanks directly at the customer's location using mobile filament winding technology.
This field fabrication process removes transport limitations almost entirely.
Instead of designing a tank around what can be transported, engineers can design it around the operational requirements of the terminal.
Benefits include:

• virtually no transport restrictions on diameter
• efficient use of available site space
• reduced logistical complexity
• fewer heavy lifts
• shorter installation sequences for very large tanks
• custom dimensions tailored to each project

For expanding terminals—where space is often limited and operations must continue during construction—this flexibility can be a significant project advantage.

Beyond tanks: complete corrosion-resistant systems

Modern terminals increasingly prefer integrated systems rather than individual components.
Plasticon Projects therefore engineers complete composite solutions including:

• large storage tanks
• process vessels
• dual laminate tanks
• scrubbers
• piping systems
• ventilation ducting
• stack systems
• process equipment
• custom composite structures

Integrating these systems simplifies maintenance while ensuring material compatibility throughout the installation.

Engineering first, materials second

Selecting a storage tank should never begin with choosing a material.
It should begin with understanding the process.
Every application requires consideration of:

• stored medium
• operating temperature
• chemical compatibility
• pressure
• applicable design standards
• inspection philosophy
• expected service life

Only then can engineers determine whether carbon steel, stainless steel, coated steel, dual laminate or FRP represents the optimal solution.
At Plasticon Projects, this engineering-first philosophy underpins every project. The goal is not to promote a single material, but to deliver the most appropriate corrosion-resistant solution for each application.

Building infrastructure for the next generation of tank terminals

The tank storage industry is entering a new era.
As operators expand into sustainable fuels, specialty chemicals and emerging energy carriers, storage infrastructure must evolve alongside the products it contains.
For many corrosive applications, FRP has proven itself as a durable, low-maintenance and highly adaptable construction material.

When combined with Plasticon Projects' expertise in engineering and on-site manufacture of large-diameter storage tanks, composite technology offers terminal operators new possibilities that extend beyond the limitations of conventional prefabricated construction.

The future of tank storage will not be defined by one material alone.
It will be defined by selecting the right material, the right engineering approach and the right manufacturing method for every application.
For many of tomorrow's storage challenges, FRP will play an increasingly important role.

Frequently Asked Questions

Can FRP replace steel for every storage tank?

No. Steel remains the preferred material for many hydrocarbons, cryogenic products, high-temperature services and applications with demanding structural or fire-resistance requirements. FRP is particularly advantageous for many corrosive chemical applications where its inherent corrosion resistance can reduce maintenance and extend service life.

How large can FRP storage tanks be?

When manufactured on site using field fabrication techniques, FRP tanks can exceed the transport limitations that apply to prefabricated vessels. This enables the construction of large-diameter tanks tailored to the site's operational requirements.

Which industries use large FRP storage tanks?

FRP tanks are widely used in chemical processing, water and wastewater treatment, mining, fertiliser production, pulp and paper, food processing and liquid bulk storage terminals.

What standards are used to design FRP tanks?

Depending on the application and region, FRP tanks may be designed in accordance with standards such as EN 13121, BS 4994, ASME RTP-1 or other recognised design codes.

Why choose on-site tank construction?

On-site manufacturing eliminates transport constraints, reduces logistical complexity, allows greater flexibility in tank dimensions and is particularly beneficial for very large storage tanks that cannot be transported economically as complete units.