Inline Hydrocarbon Blending With Feedback Flow Ratio 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, accuracy, and infrastructure requirements.
Innovation Solution
The development of in-line mixing systems that allow for the precise blending of two or more hydrocarbon liquids within a single pipeline, using a combination of gravity-fed and pumped streams, with control systems to maintain desired flow ratios and pressures.
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 precision and accuracy of the mixing ratio are poor with error rates of +/−about 10% based on target set point
Solution Approach 1:
The patent replaces the mechanical tank mixing system with an in-line mixing system that uses controlled flow meters and pumping systems to achieve precise mixing ratios. Flow meters measure actual flow rates of each crude oil stream, and control valves adjust the mixing ratios dynamically, eliminating the imprecision of tank mixing while maintaining cost-effectiveness.
Solution Approach 2:
The patent implements feedback control by continuously measuring the flow rates of individual crude oil streams using flow meters and comparing them to target mixing ratios. The system automatically adjusts control valves to maintain the desired mixing ratios, achieving precision of within 1.0% of set point while keeping the system relatively simple and cost-effective.
2Device complexity
If tank mixing is used to blend crude oils, then the infrastructure requirements are simpler, but an entire tank must be dedicated to blending with separate distribution piping
Solution Approach 1:
The patent merges the mixing function into the existing pipeline infrastructure by installing in-line mixers at strategic locations within the tank farm. This eliminates the need for separate dedicated blending tanks and distribution piping, as mixing occurs directly in the pipeline before products are distributed to storage tanks or loading racks.
Solution Approach 2:
The patent extracts the mixing function from the traditional tank-based system and relocates it to an in-line positioning within the pipeline. This removes the requirement for entire dedicated tanks and separate distribution piping, reducing infrastructure complexity while maintaining mixing capability.
3Manufacturing precision
If parallel mixing is used to pump controlled feed streams, then the mixing precision is improved, but the system becomes more difficult to control with two sets of independent controls that may interfere with each other
Solution Approach 1:
The patent implements a unified control system that manages both feed streams through a single control interface. The system uses flow meters on each stream and a centralized control algorithm that coordinates both control valves to achieve the desired mixing ratio, eliminating the interference problems of independent dual-control systems while maintaining high precision.
4Manufacturing precision
If in-line mixing is used to blend hydrocarbon liquids, then the precision is improved to within 1.0% of set point, but the system requires control systems to maintain desired flow ratios and pressures
Solution Approach 1:
The patent uses feedback control where flow meters continuously measure the actual flow rates of each crude oil stream and feed this data to a control system. The control system compares measured flows to target mixing ratios and automatically adjusts control valves to maintain precision within 1.0% of set point, managing complexity through automated feedback rather than manual intervention.
Solution Approach 2:
The patent replaces complex manual control mechanisms with automated electronic control systems that use flow meter data to dynamically adjust valve positions. This substitution of mechanical control with electronic feedback control achieves high precision while keeping the system manageable through software-based coordination rather than complex mechanical linkages.
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 infrastructure costs and improving precision, with the ability to maintain mix ratios within 1.0% of the set point.
Implementation Method 1
a first hydrocarbon liquid to flow from a first tank to a first output pipe
Implementation Method 2
a second pump to increase pressure of the second hydrocarbon liquid from the second pressure to the pump pressure
Implementation Method 3
the first hydrocarbon liquid from the first output pipe and the second hydrocarbon liquid from the second pump into a blended fluid flow
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.