Structural Integrity Assessment of Corroded Chemical Storage Tank Walls Using Finite Element Analysis

Abstract

The structural integrity of chemical storage tanks is significantly affected by corrosion-induced wall thinning, which can compromise operational safety, reliability, and service life. This study presents a comprehensive assessment of corroded chemical storage tank walls using Finite Element Analysis (FEA) to evaluate stress distribution, deformation behavior, and failure susceptibility under varying corrosion conditions. A three-dimensional numerical model of the storage tank wall was developed and analyzed under realistic loading scenarios, including internal hydrostatic pressure and material degradation caused by localized and uniform corrosion. The investigation focused on identifying critical stress concentration zones and quantifying the influence of corrosion depth and distribution on structural performance. Simulation results indicated that increasing corrosion severity substantially elevates von Mises stress and deformation, particularly near weakened regions, leading to a reduction in load-carrying capacity and overall structural stability. Comparative analysis between intact and corroded tank sections demonstrated that localized corrosion produces more severe stress intensification than uniform material loss. The study further highlights the effectiveness of finite element modeling as a predictive tool for evaluating residual strength and supporting maintenance planning in industrial storage systems. The findings contribute to improved structural health monitoring and risk-based inspection strategies for chemical storage infrastructure, thereby enhancing operational safety and minimizing the probability of catastrophic failure in corrosive industrial environments.