Inline Hydrocarbon Blending Using Density Feedback Control
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Solution Overview
Problem
Current methods for mixing hydrocarbon liquids, such as crude oil and renewable products, in the oil and gas industry face challenges including imprecision, high capital investment, and stratification issues, particularly in tank mixing and parallel mixing techniques, which require significant infrastructure and result in increased costs.
Innovation Solution
An in-line fluid mixing system that uses density or gravity measurements to control the blending of hydrocarbon liquids from multiple tanks into a single pipeline, employing flow control devices and controllers to adjust the flow rates of the liquids based on real-time density measurements, ensuring accurate and precise blending without the need for extensive tank mixing or high-pressure pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tank mixing is used to blend crude oils, then the mixing process is relatively inexpensive, but the mixing accuracy is poor with an error rate of ±10% and the mixed product tends to stratify
Solution Approach 1:
The patent replaces the mechanical tank mixing system with an in-line mixing system that uses controlled flow rates and density-based separation principles. Instead of relying on mechanical agitation in tanks, the system uses flow control devices and density differences to achieve precise blending ratios, eliminating stratification while maintaining cost-effectiveness.
Solution Approach 2:
The patent changes the operating parameters from batch tank mixing to continuous in-line mixing with controlled flow rates. By adjusting flow rates and utilizing density differences, the system achieves precise blend ratios (within ±1%) while preventing stratification that occurs in static tank mixing conditions.
2Manufacturing precision
If parallel mixing with two pumps is used to achieve precise blending, then the blend ratio accuracy improves, but the infrastructure cost increases by 180-200% and the control complexity increases
Solution Approach 1:
The patent merges the functions of multiple pumps and control systems into a single in-line mixing apparatus. Instead of using two separate pumps with independent controls, the system combines flow control devices in a unified in-line configuration, reducing infrastructure complexity while maintaining precise blend ratio control through density-based measurement and adjustment.
Solution Approach 2:
The patent introduces density measurement as an intermediary parameter to control blend ratios. Instead of directly controlling flow rates with multiple pumps, the system uses density measurements to indirectly control and verify the blend ratio, simplifying the control mechanism while achieving high precision blending.
3Reliability
If dedicated high horsepower boost pumps are used for each stream in parallel mixing, then adequate suction pressure is provided to mainline pumps, but the capital investment and operational costs increase significantly
Solution Approach 1:
The patent extracts the need for multiple high horsepower boost pumps by implementing in-line mixing before the mainline booster pump. The system provides adequate suction pressure through a single mainline booster pump rather than requiring dedicated pumps for each stream, significantly reducing capital investment while maintaining reliable operation.
Solution Approach 2:
The patent makes the mainline booster pump serve multiple functions: it provides suction pressure for the mixing operation and simultaneously handles the blended output. Instead of having dedicated pumps for each crude stream, the single mainline booster pump handles the combined flow, reducing infrastructure costs while maintaining adequate pressure for pipeline transport.
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 system achieves precise blending with reduced capital investment, eliminating stratification and achieving blend ratios within 1% accuracy, while minimizing infrastructure requirements and operational costs compared to traditional methods.
Implementation Method 1
uses density or gravity measurements to control the blending of hydrocarbon liquids
Implementation Method 2
employing flow control devices and controllers to adjust the flow rates of the liquids based on real-time density measurements
Data Source
AI summary
Embodiments include systems and methods of in-line mixing of hydrocarbon liquids and/or renewable liquids from a plurality of tanks into a single pipeline based on density or gravity. According to an embodiment, a method of admixing hydrocarbon liquids from a plurality of tanks into a single pipeline to provide in-line mixing thereof includes initiating a blending process. The blending process including continuously blending two or more liquids over a period of time, each of the two or more liquids stored in corresponding tanks, each of the corresponding tanks connected, via pipeline, to a blend pipe thereby blending the two or more liquids into a blended liquid. The method further includes determining a density of each of the two or more liquids to be blended during the blending process. The method includes, in response to a determination that the blend process has not finished and after the passage of a specified time interval, determining an actual blend density of the blended liquid, via a blend sensor connected to the blend pipe, the blended liquid flowing through the blend pipe and in contact with the blend sensor, and the specified time interval less than a total duration of the blending process. The method includes determining an actual blend density of the blended liquid, via a blend sensor connected to the blend pipe, the blended liquid flowing through the blend pipe and in contact with the blend sensor, and the specified time interval less than a total duration of the blending process; comparing the actual blend density with a target blend density; and in response to a difference, based on the comparison, of the actual blend density and target blend density determining a corrected ratio based on each density of the two or more liquids, the actual blend density, and the target blend density and adjusting, via one or more flow control devices, flow of one or more of the two or more liquids, based on the corrected ratio.