Inline Hydrocarbon Blending for Precise Pipeline Mix Ratios
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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 inefficiency, particularly in achieving accurate and cost-effective blending of crude and renewable liquids.
Innovation Solution
The implementation of an in-line fluid mixing system that positions pumps and flow control valves to blend hydrocarbon liquids directly within a pipeline, utilizing gravity-fed streams and controlled pressure to achieve precise ratios with reduced infrastructure costs.
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 precision is poor with error rates of +/â about 10% and the mixed product stratifies in the tank
Solution Approach 1:
The patent replaces the mechanical tank mixing system with an in-line mixing system that uses fluid dynamics and controlled flow through a static mixer. This substitution eliminates the need for large mixing tanks and mechanical mixers, achieving precise blending (within +/â about 1%) through the controlled flow paths and mixing elements in the pipeline, while avoiding stratification issues.
2Manufacturing precision
If parallel mixing is used to achieve precise blending, then the blend ratio precision improves, but the device complexity and capital investment increase significantly with 180% to 200% cost increase
Solution Approach 1:
The patent merges the functions of multiple separate mixing streams into a single in-line mixing operation. Instead of requiring separate tanks and distribution piping for each crude stream as in parallel mixing, the system combines multiple crude flows through a unified in-line mixing apparatus, achieving precise blending while dramatically reducing infrastructure complexity and capital investment.
Solution Approach 2:
The patent transitions from the spatial dimension of tank-based mixing to the temporal dimension of continuous in-line mixing. By moving the mixing process from a batch operation in a tank to a continuous operation in the pipeline flow, the system achieves precise control over blend ratios without requiring complex infrastructure, as the mixing occurs dynamically along the flow path.
3Ease of manufacture
If tank mixing is used, then capital investment is reduced, but the mixed crude product stratifies without tank mixers requiring additional capital investment
Solution Approach 1:
The patent extracts the mixing function from the storage tank environment and relocates it to the pipeline flow. By taking out the mixing operation from the tank, the system eliminates the stratification problem that occurs when crude products sit in tanks without continuous agitation. The mixing occurs in the dynamic flow environment of the pipeline where homogeneity is maintained by the continuous motion and controlled mixing elements.
4Manufacturing precision
If parallel mixing with multiple controlled feed streams is used, then blending precision improves, but the control difficulty increases as both streams are pumped by booster pumps into a common stream with independent controls that may interfere
Solution Approach 1:
The patent creates a universal mixing point where multiple crude streams converge and are mixed by a single in-line mixing apparatus. Instead of requiring separate control systems for each stream that may interfere with each other, the system uses one mixing zone that handles all streams simultaneously, simplifying control while maintaining precision through the design of the mixing elements and flow distribution.
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, maintaining blend ratios within a narrow error range, reducing capital investment, and eliminating stratification issues, while allowing for on-demand blending and efficient pipeline transportation.
Implementation Method 1
a pump having an inlet and an outlet, and the inlet of the pump may be connected to the second output pipe to increase pressure of the flow of the second fluid from the second pressure to a pump pressure at the outlet of the pump
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.