Inline Hydrocarbon Blending With Variable-Speed Pump 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 inaccuracies in blending ratios and high capital investment requirements, particularly in achieving precise and cost-effective blending of hydrocarbon liquids for pipeline transportation.
Innovation Solution
An in-line fluid mixing system that positions pumps and flow control valves at a tank farm to blend hydrocarbon liquids directly into a pipeline, using gravity-fed streams and controlled pump pressures to achieve precise blending ratios with reduced infrastructure and energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tank mixing is used to blend crude oils, then capital investment is relatively low, but mixing precision is poor with error rate of +/- 10% and the mixed product stratifies without continuous mixing
Solution Approach 1:
The patent replaces the mechanical tank mixer system with a flow-based mixing system that uses the kinetic energy of flowing crude streams and static mixing elements to achieve homogeneous mixing. This eliminates the need for mechanical mixers while improving mixing precision to within +/- 1% of target composition.
Solution Approach 2:
The patent introduces static mixing elements as intermediaries between the crude oil streams and the blended product. These elements facilitate thorough mixing without requiring mechanical motion, thereby improving mixing precision while avoiding the complexity and cost of mechanical tank mixers.
2Manufacturing precision
If parallel mixing with two pumps is used to achieve precise blending ratios, then mixing precision improves, but control difficulty increases due to interference between independent control systems
Solution Approach 1:
The patent merges the control of multiple crude streams into a single coordinated system rather than using independent control for each stream. By controlling the streams sequentially through a common flow path and using a single pump system, the patent achieves precise blending ratios while eliminating control interference between multiple independent systems.
Solution Approach 2:
The patent implements preliminary flow control and metering before the streams are combined, ensuring that each crude component is precisely measured and prepared for mixing. This preliminary action allows for accurate blending ratios to be achieved without the need for complex real-time control of multiple independent streams.
3Productivity
If high-pressure pumps are used to transport blended crude through pipelines, then transportation capability is sufficient, but capital investment and energy consumption increase
Solution Approach 1:
The patent uses a dynamic pump control system that adjusts pump operation based on real-time flow requirements and pipeline conditions. By optimizing pump operation dynamically rather than using continuously high-pressure pumps, the system achieves sufficient pipeline transportation capability while significantly reducing power consumption and capital investment in pump equipment.
Solution Approach 2:
The patent changes the operating parameters of the pump system by using variable speed drives and adjusting flow rates to match actual transportation needs. This allows the system to achieve required pipeline transportation capability only when necessary, reducing overall power consumption and enabling the use of smaller, less expensive pump equipment.
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 blending within 1% of the set point, reduces capital investment by eliminating high-pressure pumps and static mixers, and allows for on-demand blending without stratification, enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
a pump having an inlet connected to the second output pipe and an outlet to increase pressure of the flow of second fluid from the second pressure to a pump pressure at the outlet
Implementation Method 2
a blended fluid pipe connected to and in fluid communication with the first output pipe and the mixing booster pipe to admix the flow of first fluid at the first pressure and the flow of second fluid at the pump pressure 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.