Automated Tank Mixing With Intermittent Mixer Control
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Solution Overview
Problem
Industrial facilities, such as refineries and oil and gas storage tanks, face challenges in efficiently collecting and analyzing data from multiple sensors, leading to delayed decision-making and operational inefficiencies due to the complexity of data handling and limited visibility of issues, which affects production, safety, and cost savings.
Innovation Solution
A system utilizing intermittent mixers in tanks equipped with data acquisition devices and analyzers that measure fluid characteristics, compare them to desired specifications, and generate data packets to adjust the mixer's operational speed and time, ensuring consistent fluid properties throughout the tank, thereby automating the mixing process and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual data collection and analysis methods are used, then data can be collected from tanks, but the process takes weeks or months and is limited to small data sets
Solution Approach 1:
The patent replaces manual mechanical data collection methods with automated electronic data acquisition devices and computer-based analysis systems. Sensors continuously collect tank data and transmit it to computers for automated analysis, eliminating the need for manual data collection and significantly reducing processing time from weeks/months to real-time or near-real-time operations.
Solution Approach 2:
The system implements continuous data collection through continuously operating sensors and data acquisition devices that monitor tank conditions without interruption. This continuous operation enables constant monitoring and analysis of fluid properties, allowing for immediate detection of mixing issues and real-time optimization of mixer operations.
2Reliability
If multiple sensors are deployed to monitor fluid characteristics, then monitoring coverage is improved, but data complexity increases and makes it difficult to produce smart solutions
Solution Approach 1:
The patent employs a multi-functional computer system that performs diverse functions including data acquisition from multiple sensors, data storage, signal processing, analysis, and control operations. This universal system consolidates multiple specialized functions into a single integrated platform, managing the complexity of multiple sensors while providing comprehensive monitoring and control capabilities.
Solution Approach 2:
The computer acts as an intermediary between the multiple sensors and the control system. It receives data from various sensors, processes and analyzes the information, and generates control signals for mixers. This intermediary role simplifies the overall system architecture by centralizing data handling and decision-making logic.
3Stability of the object's composition
If mixers are operated continuously to maintain homogeneous blends, then fluid homogeneity is improved, but energy consumption increases
Solution Approach 1:
The system implements closed-loop feedback control where sensors continuously monitor fluid density and other characteristics, the computer analyzes this data to determine mixing effectiveness, and control signals are automatically generated to adjust mixer operation. This feedback mechanism allows the system to maintain homogeneous blends while optimizing mixer runtime and speed to reduce unnecessary energy consumption.
Solution Approach 2:
The patent transitions from static continuous mixer operation to dynamic intermittent mixing. The system adjusts mixer operation based on real-time fluid conditions, varying mixer runtime and speed according to actual mixing needs. This dynamic approach maintains fluid homogeneity while significantly reducing energy consumption compared to continuous operation.
4Loss of time
If automated data analysis is implemented, then decision-making speed is improved, but system complexity increases
Solution Approach 1:
The computer system performs automated self-service functions including data acquisition, storage, processing, and analysis without requiring external human intervention. The system automatically generates control decisions and sends commands to mixers based on sensor data, enabling rapid autonomous decision-making while managing system complexity through integrated software routines.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables real-time monitoring and optimization of fluid properties within tanks, reducing energy usage, enhancing operational efficiency, and facilitating quicker custody transfers by ensuring consistent fluid properties, resulting in cost savings and improved safety.
Implementation Method 1
An intermittent mixer is used for agitating the first fluid within the tank
Implementation Method 2
An upper data acquisition device is capable of obtaining the density measurement of the hydrocarbon emulsion in the tank
Data Source
AI summary
In one embodiment, the present system describes a system wherein a first fluid is within a tank. An intermittent mixer is used for agitating the first fluid within the tank. At least one data acquisition device within the tank is capable of measuring at least one characteristic within the first fluid. In the embodiment, at least one data analyzer is capable of receiving the characteristics within the first fluid, comparing the characteristics within the first fluid to the characteristics of a second fluid, generating a data packet which contains a calculated operational speed and an operational time needed for the intermittent mixer to agitate the first fluid to obtain the characteristics of the second fluid and transmitting the data packet to the intermittent mixer. In this system the intermittent mixer is capable of altering the first fluid within the tank into the second fluid.