Foamed Polyamide Floating Cover for Hydrocarbon Tanks
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Solution Overview
Problem
Existing oil field collection tank designs face challenges in maintaining the required temperature for efficient separation of heavy crude oil from water and sediment, leading to trapped impurities, increased operational costs due to heat loss, and health risks from chemical surfactant additives used to prevent frothing, while prior art floating covers are unsuitable for hydrocarbon liquids due to density issues and material incompatibility.
Innovation Solution
A system and method involving the formation of elements with a specific gravity less than that of hydrocarbon liquids, using a polyamide resin and foaming agent to create a floating cover that impedes thermal energy transfer and vapor emission, achieved through a unique injection molding process with multiple velocity and pressure stages to achieve the desired density and structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal insulation is added to the outside of the tank to reduce heat loss, then energy efficiency is improved, but device complexity and cost increase
Solution Approach 1:
The floating cover elements perform multiple functions including thermal insulation, vapor containment, and surface coverage without requiring external support structures or additional heating systems. The system uses the natural buoyancy and physical properties of the cover materials to achieve heat retention.
Solution Approach 2:
The floating cover elements are constructed from composite materials such as foamed plastics or rigid foam boards that provide inherent thermal insulation properties. These materials combine structural integrity with heat retention capabilities in a single component.
2Productivity
If the mixture is removed from the container before reaching 80°C due to rapid production rate, then productivity is maintained, but separation efficiency deteriorates and impurities remain trapped
Solution Approach 1:
The floating cover elements are installed in the container before the hydrocarbon mixture is introduced. This preliminary action establishes the thermal insulation and vapor containment system in advance, allowing the mixture to rapidly reach and maintain conditioning temperature even at high production rates.
Solution Approach 2:
The floating cover elements continuously maintain the thermal environment and prevent heat loss throughout the entire conditioning process, ensuring that the mixture reaches and sustains the required 80°C temperature regardless of production rate variations.
3Ease of operation
If chemical surfactant additives are used to prevent frothing, then froth control is improved, but health risks and environmental harm increase
Solution Approach 1:
The patent eliminates chemical surfactant additives from the system by using physical containment methods. The floating cover elements prevent froth formation through mechanical means, extracting the need for harmful chemical substances entirely.
Solution Approach 2:
The floating cover elements act as an intermediary physical barrier between the hydrocarbon mixture and the atmosphere, preventing froth escape and vapor emission without requiring chemical additives. This physical mediator replaces the chemical surfactants.
4Area of stationary object
If prior art floating covers made from polypropylene or polyethylene are used, then coverage is achieved, but the covers sink quickly due to high density and absorb/adsorb hydrocarbons
Solution Approach 1:
The patent changes the density parameter of the cover materials by using foamed plastics or rigid foam boards with densities significantly lower than hydrocarbons. This parameter change ensures the covers float stably and do not sink, unlike the denser polypropylene or polyethylene materials.
Solution Approach 2:
The use of foamed plastic composites provides both the required low density for floatation and the necessary structural integrity for vapor containment. The foam structure creates a material that is both buoyant and mechanically sound.
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
The solution effectively maintains the temperature for efficient crude oil separation, reduces energy inputs, minimizes health risks, and provides a durable, long-lasting cover that prevents vapor emission and thermal energy loss, thereby improving processing efficiency and safety.
Implementation Method 1
impedes thermal energy transfer
Implementation Method 2
impedes emission of vapours
Implementation Method 3
elements that are engaged or engageable with one another to form a system for floating at least partially on a surface of an at least partially liquid hydrocarbon mixture
Data Source
AI summary
A method of forming an element to float at least partially on a surface of an at least partially liquid hydrocarbon mixture. The method includes mixing a polymer resin and a foaming agent together in preselected proportions to provide a material mixture, and heating the material mixture, to at least partially liquefy it. The material mixture is injected into a mold cavity configured to define the element's exterior surface in a series of at least three steps, commencing with an initial step. In each step, the material mixture is injected over a predetermined time period at a predetermined velocity and under a predetermined pressure. Each predetermined velocity in the steps following the initial step is less than the predetermined velocity in an immediately preceding step thereof. Each predetermined pressure in the steps following the initial step is less than the predetermined pressure in the immediately preceding step thereof.