Ultracargo won the InovaInfra 2025 Prize after implementing a novel tank cleaning and inspection method, raising operational standards to a new level at its Itaqui terminal located in the state of Maranhão (MA). This award-winning solution stands out for its pioneering spirit, being the first time the process was carried out without the need to empty the company´s storage tanks.
“The process has further boosted our efficiency and sustainability standards, supporting the consolidation of the company as a benchmark for innovation in the sector, and demonstrates Ultracargo´s commitment with the integrity of its assets and safety of its people, the environment, and logistic operations. For this reason, we celebrate this award with immense pride,” highlights Leopoldo Gimenes, Vice-President of Engineering and Operations.
According to the executive, the idea is to apply the same method in future cleaning and inspection operations, extending the new process to other terminals.
The method
The robot-assisted method uses specialized equipment, which is hoisted to the top of the tank and then lowered through an inspection window, allowing complete access to the inner structure, without needing to interrupt the tank operation. During the process, the cleaning robot navigates along the tank bottom, detecting and removing sediments accumulated over the years.
Bathymetry is one of the solutions used to map the distribution of sediments, for the subsequent removal operation, enabling visual and ultrasonic inspection of the bottom plates in accordance with API653, a standard that establishes the minimum requirements for inspection, repair, modification, and reconstruction of storage tanks. A heat map is generated with the collected information, revealing the thickness of the buildup.
During the operation, the robot scours the reservoir bottom repeatedly, precisely removing only the residue it finds. With the data obtained by measuring the thickness of the tank bottom plates, carried out by a remotely controlled submersible ultrasound vehicle, it is possible to calculate the corrosion rate and the remaining useful life of these plates, ensuring the operation of the asset until the next inspection.
“The joint action of the diverse operational areas was essential to safely enable the inspection to be carried out. We sought a solution that respected technical standards while preserving the integrity of the assets,” remarked Leonardo Barbosa, coordinator of Integrity and Reliability at Ultracargo.
“It was an important technical challenge, especially in developing the mechanical strategy to enable the equipment to enter and move inside the tank. Recognition through the award reinforces the value of collaborative work and purposeful applied engineering,” highlights Eduardo Suenaga, Mechanical expert at Ultracargo.
“Sediment accumulation in the tank can be attributed mainly to impurities in the water which, over the years, decant and settle at the bottom of the reservoir. If not removed, the waste can compromise the operation of the system’s pumps and pipes. “It is a really necessary, innovative, and safe method, which is why we are happy to have been recognized with this award,” concludes Everaldo Silva Sena, Maintenance Planning and Control Manager at Ultracargo, who is one of the individuals responsible for the award-winning project.