Polymeric Slurry Storage Vessel with Vapor Recirculation
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Solution Overview
Problem
Existing devices for storing, mixing, and pumping polymeric slurries are limited by inferior construction, poor design, unreliable components, lack of chemistry knowledge, piping and electrical code violations, and inadequate handling strategies, leading to inconsistent suction streams, plugging issues, and inaccurate metering, especially when dealing with two-phase flow chemicals.
Innovation Solution
A vertical storage vessel with a sloped bottom, closed-loop vapor recirculation, liquid recirculation, and temperature control systems, combined with flow monitoring and remote level measurement, and an onboard microprocessor for automated control, to maintain a homogeneous mixture and prevent plugging, while ensuring accurate metering and pumping of polymeric slurry chemicals into pipelines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If horizontal containers or square containers with limited recirculation methods are used to store polymeric slurry, then storage capacity is improved, but the solids component settles in dead zones and becomes unpumpable
Solution Approach 1:
The patent employs a vertical cylindrical storage tank with a conical bottom instead of horizontal or square containers. The curved conical surface eliminates dead zones where solids could settle, ensuring all areas are subject to recirculation flow and maintaining pumpability of the polymeric slurry while providing adequate storage capacity.
Solution Approach 2:
The patent implements a recirculation system with a pump and agitator that continuously circulates the polymeric slurry throughout the storage tank. This continuous motion prevents solids settlement and maintains homogeneous mixture, ensuring the slurry remains pumpable even during extended storage periods.
2Stability of the object's composition
If mixing is employed to maintain slurry homogeneity, then settling is prevented, but ambient air introduces weathering that creates concentrated polymer slurries unable to be pumped
Solution Approach 1:
The patent fills the storage tank with inert nitrogen gas to displace ambient air. This inert atmosphere prevents oxidation and weathering of the polymeric slurry during storage and recirculation, maintaining the slurry's original composition and pumpability while still allowing mechanical mixing to prevent settling.
Solution Approach 2:
The patent replaces ambient air mixing with a controlled inert gas atmosphere and mechanical recirculation system. The nitrogen atmosphere eliminates harmful chemical weathering, while the mechanical pump and agitator provide controlled mixing that prevents settling without introducing oxidizing agents.
3Productivity
If oversized meters designed for high flow rates are used, then handling capability is improved, but measurement accuracy deteriorates for low injection rates
Solution Approach 1:
The patent employs a variable stroke pump with adjustable injection rates and a flow meter that can accurately measure across a wide range of flow rates. This dynamic system allows the apparatus to handle high volumes when needed while maintaining precise measurement and control at low injection rates, eliminating the need for oversized fixed-capacity meters.
4Device complexity
If simple control loops with low precision meters are used, then device complexity is reduced, but control accuracy and reliability deteriorate
Solution Approach 1:
The patent implements a microprocessor-based control system with feedback from flow meters, level sensors, and temperature sensors. The system continuously monitors injection rates, storage tank level, and slurry temperature, automatically adjusting pump operation to maintain precise control and alert operators to potential problems, significantly improving reliability over simple control loops.
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 solution provides a stable, accurate, and automated method for storing and delivering polymeric slurry chemicals, preventing settling and plugging, ensuring consistent injection rates, and enhancing user safety with integrated monitoring and control systems, making the system more versatile and reliable than prior art devices.
Implementation Method 1
a vapor recirculation system that circulates vapor back into the storage vessel
Implementation Method 2
preventing any weathering off effects on the chemical
Implementation Method 3
a liquid recirculation system that circulates liquid from the storage vessel back into the storage vessel
Implementation Method 4
maintain a homogeneous mixture of the chemical in the storage vessel
Implementation Method 5
a means for heating the chemical
Implementation Method 6
a means for cooling the chemical
Implementation Method 7
a means for measuring storage vessel level
Implementation Method 8
flow monitoring
Data Source
AI summary
The present invention generally comprises a storage vessel for the polymeric slurry chemical, a vapor recirculation system, a chemical recirculation system, a device for chemical temperature control, a device for measuring storage vessel level, a device for metering and pumping chemical, and a device for controlling apparatus. The vapor recirculation system, chemical recirculation system, mechanism for chemical temperature control, mechanism for measuring storage vessel level, mechanism for metering and pumping and mechanism for controlling apparatus are housed in the pumping equipment container and are connected to the storage vessel by control conduits, and piping for vapors and liquid chemicals to make the complete apparatus. The apparatus is used to maintain slurry materials in a usable state and to inject the slurry materials as required for specific applications, such as injecting drag reducing agent into operating pipelines.