Inline Hydrocarbon Blending With Flow-Ratio Pump Control
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Solution Overview
Problem
Current methods for mixing hydrocarbon liquids, such as tank mixing and parallel mixing, are inefficient and costly, with limitations in precision and require significant infrastructure, leading to errors and high capital investment.
Innovation Solution
An in-line fluid mixing system positioned at a tank farm that combines hydrocarbon liquids from multiple tanks into a single pipeline, using gravity-fed and controlled streams with pumps and flow control valves to achieve precise blending with minimal equipment and infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tank mixing is used to blend hydrocarbon liquids, then capital investment is reduced, but mixing precision deteriorates with error rates of ±10% and stratification occurs
Solution Approach 1:
The patent replaces the mechanical tank mixing system with an in-line mixing system that uses fluid dynamics and controlled injection. The mixing process occurs in a pipeline through the interaction of fluid streams rather than mechanical agitation, eliminating the need for large mixing tanks and mechanical mixers while achieving superior mixing precision within ±1% of target composition.
Solution Approach 2:
The patent introduces an intermediary mixing section in the pipeline where controlled injection of one hydrocarbon stream into another creates intense mixing through fluid interaction. This intermediary zone allows precise composition control without requiring large storage tanks or mechanical mixing equipment.
2Manufacturing precision
If parallel mixing with two pumps is used to control feed streams, then mixing precision improves, but device complexity and capital investment increase by 180-200%
Solution Approach 1:
The patent merges the feeding and mixing functions into a single in-line process. Instead of using separate pumps and control systems for each feed stream as in parallel mixing, the invention combines multiple hydrocarbon streams in a pipeline where they mix through controlled injection and fluid dynamics, reducing the number of active components and control systems.
Solution Approach 2:
The patent employs self-regulating flow control where the system automatically maintains the desired mix ratio through inherent fluid dynamics and simple control mechanisms. The in-line mixing process naturally balances the streams through pressure and flow rate relationships, eliminating the need for complex pump control systems and variable speed drives required in parallel mixing.
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 capital investment and operating cost increase significantly
Solution Approach 1:
The patent uses a single mainline booster pump that handles the combined mixed stream, eliminating the need for multiple dedicated boost pumps for each feed stream. The in-line mixing system consolidates the pumping function, requiring only one high-capacity booster pump to handle the total flow, thereby reducing capital investment and operating costs while maintaining adequate suction pressure.
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 provides accurate and cost-effective blending with precision within 1.0% of the desired set point, reducing capital investment and eliminating stratification, while allowing for on-demand blending and efficient pipeline transportation.
Implementation Method 1
permitting a first hydrocarbon fluid to flow from a first crude tank at a tank farm to a first output pipe
Data Source
AI summary
Embodiments include systems and methods of in-line mixing of hydrocarbon liquids from a plurality of tanks into a single pipeline. 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 determining a ratio of a second fluid flow to a first fluid flow based on signals received from a tank flow meter in fluid communication with the second fluid flow and a booster flow meter in fluid communication with a blended fluid flow. The blended fluid flow includes a blended flow of the first fluid flow and the second fluid flow. The method further includes comparing the determined ratio to a pre-selected set point ratio thereby to determine a modified flow of the second fluid flow to drive the ratio toward the pre-selected set point ratio. The method further includes controlling a variable speed drive connected to a pump thereby to control the second fluid flow through the pump based on the determined modified flow, the pump being in fluid communication with the second fluid flow.