Pressure vessels are sealed containers that hold gases or liquids at pressures significantly different from atmospheric pressure. Industries such as chemicals, power generation, and oil extensively use pressure vessels. The evolving demand and technological advances are shaping the future of pressure vessels. This blog explores the latest trends in pressure vessel design, materials, manufacturing, and regulatory standards. Valued at USD 47.9 billion, the pressure vessel market is expected to grow at a CAGR of 5.22% during the forecast period (2024–2022). Indian pressure vessel manufacturers are embracing these trends to compete globally.
Learn about different types of pressure vessels.
Advanced design concepts
Modern pressure vessel designs adapt powerful tools and methodologies to improve cost-effectiveness and performance.
- Finite element analysis (FEA) software allows designers to stimulate stress and detect potential failure points. EEngineers rely on FEA software to ensure safety compliance, design pressure vessels, minimise weight, and maximise the strength of these vessels. allows designers to explore complex geometries and material distributions, leading to lighter, stronger, and more efficient pressure vessels.
- Computational Fluid Dynamics (CFD) software is essential for optimising internal geometries, reducing pressure drops, and enhancing flow efficiency, particularly in sectors like oil and gas.
Advanced manufacturing techniques
- Automated welding: Robotic welding and laser beam welding techniques are replacing manual welding, improving weld consistency, and reducing the margin of human error. This is crucial in applications requiring high-quality welding, such as the nuclear power and aerospace sectors. Want to keep up with the latest fabrication trends?
- Additive manufacturing: Additive manufacturing, or 3D printing, has revolutionised manufacturing. The technology uses techniques such as powder bed fusion (PBF) and direct energy deposition (DED) to manufacture complex geometric shapes that would otherwise be impossible in traditional manufacturing.
Integration of Smart Technologies for Predictive Maintenance
We are now integrating smart technologies into pressure vessels enabling real-time monitoring and predictive maintenance.
- Internet of Things (IoT) Sensors: By installing IoT sensors inside pressure vessels, we can monitor vital indicators such as temperature, level, and pressure continuously. Real-time data collection can help you make proactive maintenance plans, identify irregularities and potential equipment problems early on and prevent catastrophic failure.
- Machine Learning and Predictive Analytics: Machine learning techniques applied to previous sensor data can construct predictive models that foresee potential problems and plan maintenance before failures occur. This strategy improves overall plant safety and reduces downtime and maintenance costs.
- Functional coating: Manufacturers are coating pressure vessel surfaces with functional coatings, such as self-healing, corrosion-resistant, and anti-fouling coatings, to improve durability, lower maintenance costs, and reduce material degradation. These coatings can improve the performance of pressure vessels in challenging environments.
Material innovations
One of the biggest developments in pressure vessel technology is the use of composite and advanced materials. High-performance alloys and composite materials will replace or supplement conventional materials like Carbon Steel (CS) and Stainless Steel (SS). Proper material selection is critical in safe pressure vessel operations.
- Composite materials: Composite materials such as Carbon Fibre-Reinforced Polymers (CFRP), Fibre-Reinforced Ceramics and Metal Matrix Composites offer superior mechanical, thermal, and physical properties with a significant weight reduction. Manufacturers use composite materials in the automotive, marine, and aerospace industries.
- Nanostructured alloys: Scientists are developing nanostructured alloys with properties such as superior mechanical strength, flexibility, and corrosion resistance for pressure vessel applications. The material is showing promising results, particularly in extreme conditions such as high-pressure hydrogen storage for fuel cell vehicles.
- High-entropy alloys: High-entropy alloys (HEA) are made up of multiple elements in almost equal proportion and display remarkable mechanical properties and corrosion resistance. These properties make them ideal for pressure vessels operating under extreme conditions such as high temperatures or a corrosive environment.
- Advanced polymers: New polymers and polymer composites are being developed for overwrapped pressure vessels (COPVs) with high strength-to-weight ratios. These vessels store high-pressure liquids and gases, consisting of a thin liner wrapped in a structural fibre composite.
Regulatory Compliance and standards
Pressure vessels need to comply with strict regulatory requirements. In India, manufacturers use pressure codes IS 2825:1969 for unfired pressure vessels and IBR for fired pressure vessels. Pressure vessel manufacturers must follow the codes during design, fabrication, inspection, testing, and certification. Current developments include:
Updated codes and standards: Regulatory bodies update codes and recommendations to keep up with the latest industrial trends. E.g.ASME Boiler and Pressure Vessel Code (BPVC) regularly incorporates new materials, design techniques, and safety features. The government regularly updates the IS 2825 code to keep up with the changing technologies.
| COUNTRY | ORGANISATION | ABBREVIATION | CODES |
| USA | American Society of Mechanical Engineers | ASME | ASME VIII |
| INDIA | Bureau of Indian Standards | BIS or IS | IS 2825 |
| CANADA | Canadian Standard Association | CSA | CSA B51 |
| EUROPE | Committee of European Normalisation | EN or CEN | EN 13445 |
| BRITAIN | British Standard Institute | BS or BSI | BS 5500 |
| GERMANY | Deutsche Institute of Normalising | DIN | AD 2000 |
| JAPAN | Japanese Industrial Standardisation Committee | JISC or JIS | JIS B 8243 |
| WORLD | Organisation for Industrial Standards | ISO | ISO 16528 |
Environmental Sustainability:
Green manufacturing process: Implementing sustainable manufacturing methods can help you reduce the environmental impact of pressure vessel manufacturing with methods such as energy-efficient procedures, material recycling, and minimal waste.
Alternative Energy: Pressure vessels are used in energy storage systems such as thermal energy storage (TES), hydrogen storage, and compressed air energy storage (CAES).
Conclusion
The pressure vessel landscape is evolving rapidly. Advanced materials, design optimisation, and smart manufacturing promise enhanced safety, efficiency, and sustainability. By embracing these trends and investing in R&D, Indian manufacturers can become key players in the global pressure vessel market.
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