Spillback-Controlled In-Line Mixing for Hydrocarbon Blend Precision
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Solution Overview
Problem
Current methods for mixing hydrocarbon liquids, such as tank mixing and parallel mixing, face challenges including imprecision, high capital investment, and increased costs due to the need for high-pressure pumps and extensive infrastructure, particularly in achieving accurate and cost-effective blending of crude and renewable hydrocarbon products.
Innovation Solution
The implementation of an in-line fluid mixing system that positions pumps and headers to blend hydrocarbon liquids directly within a pipeline, utilizing spillback loops and control valves to adjust flow rates based on density and pressure differences, allowing for precise blending of multiple hydrocarbon liquids into a single pipeline without the need for dedicated high-pressure pumps or static mixers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tank mixing is used to blend hydrocarbon liquids, then mixing can be performed with simple infrastructure, but the mixing precision is poor (error rate of +/−about 10%) and the mixed product stratifies without tank mixers
Solution Approach 1:
The patent replaces mechanical tank mixing systems with an in-line mixing system that uses fluid dynamics and pressure differentials to achieve mixing. The system employs a mixing section with turbulent flow generation through specific geometric configurations (such as alternating wall arrangements) to mix hydrocarbon liquids without mechanical agitators, thereby eliminating stratification while maintaining infrastructure simplicity.
Solution Approach 2:
The patent utilizes hydraulic principles by employing pressure-driven flow through the mixing section. The system uses pressure differentials created by pumps to drive the hydrocarbon liquids through the mixing section, where turbulent flow conditions are generated hydraulically to achieve thorough mixing without mechanical components.
2Manufacturing precision
If parallel mixing with two pumps is used to achieve precise blending, then mixing precision improves, but the system complexity and capital investment increase due to requiring two separate pump systems and control mechanisms
Solution Approach 1:
The patent merges the functions of multiple pumps into a single pump system. Instead of requiring two separate pumps for parallel mixing, the invention uses one pump to supply both hydrocarbon liquids to a common mixing section, thereby reducing system complexity while maintaining precise blending capability through the in-line mixing mechanism.
Solution Approach 2:
The single pump in the system performs multiple functions: it supplies both hydrocarbon liquids to the mixing section and provides the pressure differential needed for turbulent flow generation. The mixing section itself serves multiple purposes by combining fluids and generating mixing action through its geometric configuration, eliminating the need for separate mixing devices.
3Length of moving object
If extensive piping and high-pressure pumps are used for pipeline transportation, then long-distance transport is enabled, but capital investment and operational costs increase
Solution Approach 1:
The patent performs mixing action upstream in the pipeline before the fluids enter the main transportation line. By pre-mixing the hydrocarbon liquids in-line before they enter the extensive piping system, the need for additional mixing infrastructure downstream is eliminated, and the blended product can be transported efficiently through long pipelines without further intervention.
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 approach enables accurate and cost-effective blending of hydrocarbon liquids, reducing capital investment and operational costs while improving precision, allowing for on-demand blending and eliminating stratification issues, with the ability to maintain blend ratios within 1% of the target set point.
Implementation Method 1
utilizing spillback loops and control valves to adjust flow rates based on density and pressure differences
Implementation Method 2
utilizing spillback loops and control valves to adjust flow rates based on density and pressure differences
Implementation Method 3
blend hydrocarbon liquids directly within a pipeline
Implementation Method 4
blend hydrocarbon liquids directly within a pipeline
Data Source
AI summary
Methods and systems of admixing hydrocarbon liquids from two or more sets of tanks into a single pipeline to provide in-line mixing thereof. In an embodiment of the in-line mixing system, hydrocarbon liquids stored in at least one tank of each of two or more sets of tanks positioned at a tank farm are blended into a blend flow pipe via in-line mixing and the blended mixture is pumped through a single pipeline. In one or more embodiments, the in-line mixing system employs a separate spillback or recirculation loop that is fluidly connected to each set of the two or more sets of tanks to control the flow of the hydrocarbon fluid/liquid from each set of tanks to the blend flow pipe. Associated methods of operating one or more embodiments of the system include regulation of spillback or recirculation loop flow rate and/or pressure to drive the actual blend ratio towards a desired blend ratio.