Inline Hydrocarbon Blending With Single-Pipeline 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 crude and renewable liquids.
Innovation Solution
The implementation of an in-line fluid mixing system that positions pumps and valves to blend hydrocarbon liquids directly within a pipeline, using gravity-fed streams and controlled pressure to achieve precise blending ratios with reduced infrastructure costs, allowing for on-demand blending and accurate control of mix ratios within a single pipeline.
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 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 mechanical mixers and tank agitation, achieving both cost-effectiveness and high mixing accuracy (within +/â 1% of set point) by using the flow itself to create thorough mixing through the static mixer elements.
Solution Approach 2:
The patent extracts the mixing function from the tank environment and places it directly in the pipeline flow. By taking out the mixing operation from the stationary tank and implementing it in-line, the system eliminates stratification issues and achieves consistent mixing accuracy while reducing infrastructure requirements.
2Manufacturing precision
If parallel mixing with two pumps is used to achieve precise blending ratios, then the mixing accuracy improves, but the infrastructure cost increases by 180% to 200% and the control becomes more difficult
Solution Approach 1:
The patent merges the function of multiple pumps and control systems into a single pump that feeds both streams to the static mixer. This consolidation reduces infrastructure complexity and cost while maintaining precise blending ratios through the inherent flow control characteristics of the static mixer design, eliminating the need for two separate pump systems.
Solution Approach 2:
The single pump in the in-line mixing system serves multiple functions: it provides suction pressure for both feed streams, delivers the combined flow to the static mixer, and enables on-demand blending. This multi-functional approach reduces infrastructure cost while achieving the precision previously requiring multiple dedicated pumps.
3Manufacturing precision
If parallel mixing with variable speed pumps is used to control flow rates, then the blending precision improves, but the control stability deteriorates as the two sets of independent controls interfere with each other
Solution Approach 1:
The patent extracts the control complexity from the pump systems and places it in the static mixer design. By using a single pump feed and a static mixer with designed flow distribution, the system eliminates the interference between multiple independent control systems while maintaining precise blending ratios through the mixer's inherent flow control characteristics.
Solution Approach 2:
The static mixer design provides self-regulating flow distribution that automatically balances the two feed streams without requiring complex external control systems. The mixer geometry itself creates the necessary flow patterns and pressure distributions to achieve stable, precise blending ratios, making the system self-regulating and highly reliable.
4Ease of operation
If high pressure pumps are used in parallel mixing to provide adequate suction pressure, then the flow control improves, but the capital investment increases significantly
Solution Approach 1:
The patent replaces the need for high-pressure pumps with a single pump operating at lower pressure, using the static mixer to generate the necessary flow dynamics and mixing action. The static mixer elements create turbulence and flow redistribution that would otherwise require high-pressure pumping, thereby reducing capital investment while maintaining operational control.
Solution Approach 2:
The system changes the pressure parameter from high-pressure operation (required in parallel mixing) to lower-pressure operation with a single pump. The static mixer compensates for the lower pressure by creating the necessary flow patterns and mixing action through its geometry, achieving the same flow control capability with reduced capital investment.
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 precise and cost-effective blending of hydrocarbon liquids, reducing errors to within 1% of the set point and eliminating the need for high-pressure pumps and static mixers, thereby lowering infrastructure costs and improving operational efficiency.
Implementation Method 1
using gravity-fed streams and controlled pressure to achieve precise blending ratios
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.