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 operations, which require significant infrastructure and result in increased costs.
Innovation Solution
An in-line fluid mixing system that positions density or gravity-measuring devices and flow control systems at a tank farm to precisely blend hydrocarbon liquids based on their densities, allowing for continuous adjustment of flow rates to achieve a target blend density, thereby eliminating the need for dedicated high-pressure pumps and reducing 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 accuracy is poor with an error rate of +/−about 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 fluid dynamics and controlled flow injection. The lighter crude is injected into the heavier crude stream through a mixing section, eliminating the need for large mixing tanks and mechanical mixers while achieving superior blend accuracy within +/−about 1% of target ratio.
Solution Approach 2:
The patent changes the operating parameters by controlling flow rates, pressures, and injection points of the different crude streams. By adjusting these parameters through controllers and flow control valves, the system achieves precise blend ratios without the stratification problems inherent in static tank mixing.
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% to 200% and the system becomes more difficult to control
Solution Approach 1:
The patent merges the mixing function into the existing single pipeline infrastructure rather than requiring separate parallel pumping systems. The in-line mixer integrates both crude streams into a single mixing section followed by a single booster pump, eliminating the need for duplicate pumping infrastructure and reducing overall system complexity.
Solution Approach 2:
The patent introduces an in-line mixing section as an intermediary component between the crude sources and the booster pump. This mixing section provides the blending function without requiring complex parallel pumping systems, serving as a mediator that simplifies the overall infrastructure while maintaining precise control through flow control valves.
3Reliability
If dedicated high-pressure pumps are used to boost both streams to 50-200 psi, then adequate suction pressure is provided to the mainline booster pump, but the capital investment and horsepower requirements increase significantly
Solution Approach 1:
The patent extracts the pressure boosting function from the mixing process itself, allowing the mainline booster pump to handle the pressurization after mixing occurs. This eliminates the need for dedicated high-pressure boosting pumps for each crude stream, reducing capital investment and horsepower requirements while maintaining adequate suction pressure through the mixed stream.
Solution Approach 2:
The patent makes the mainline booster pump serve multiple functions by having it handle both the mixing output and the final pressurization for pipeline delivery. This multi-functional approach eliminates the need for separate dedicated boosting pumps, reducing infrastructure complexity while maintaining system reliability.
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 reduced capital investment, maintaining blend ratios within 1% of the target, and prevents stratification by continuously monitoring and adjusting the blend density during the mixing process.
Implementation Method 1
Methods and systems for inline mixing of hydrocarbon liquids based on density or gravity
Implementation Method 2
Methods and systems for inline mixing of hydrocarbon liquids based on density or gravity
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.