Spillback Loop Control for Precise In-Line Hydrocarbon Blending
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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 in the oil and gas industry.
Innovation Solution
The development of in-line fluid mixing systems that allow for the precise blending of two or more hydrocarbon liquids within a single pipeline by utilizing a network of tanks, headers, pumps, spillback pipes, and control valves, with a controller adjusting flow rates based on density and target ratios to achieve a consistent blend.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tank mixing is used to blend hydrocarbon liquids, then the mixing process is simple and inexpensive, but the mixing precision is poor with error rates of +/â about 10% and the mixed product stratifies without tank mixers
Solution Approach 1:
The patent replaces mechanical tank mixing systems with an in-line mixing system that uses controlled flow dynamics and density-based separation principles. The system uses pumps and control valves to regulate flow rates, allowing precise blending without mechanical mixers, while the density difference between hydrocarbon liquids enables natural separation that prevents stratification of the blended product.
Solution Approach 2:
The patent introduces an intermediary in-line mixing section between the storage tanks and the pipeline. This mixing section serves as a transition zone where liquids are precisely blended through controlled flow paths, and the density-based design ensures the blended mixture remains stable without requiring additional mixing equipment downstream.
2Quantity of substance
If dedicated blending tanks are used for mixing hydrocarbon liquids, then the blending capacity is sufficient, but the capital investment and equipment requirements are high
Solution Approach 1:
The patent merges the blending function with the existing pipeline transport system. Instead of separate blending tanks and pipelines, the in-line mixing system integrates blending directly into the flow path, using the pipeline itself as the mixing vessel. This eliminates dedicated blending tanks and reduces equipment complexity while maintaining blending capacity.
Solution Approach 2:
The patent makes the pipeline system multi-functional by enabling it to serve both as the transport conduit and as the mixing chamber. The in-line mixing section transforms the pipeline from a single-function transport device into a dual-function system that performs both blending and transportation, eliminating the need for separate blending equipment.
3Manufacturing precision
If parallel mixing with two pumps is used to achieve precise blending ratios, then the mixing precision improves, but the system complexity and control difficulty increase due to two independent control streams
Solution Approach 1:
The patent segments the control function by dedicating one pump exclusively to controlling the flow rate of the first hydrocarbon liquid, while the second pump controls the second liquid. This segmentation of control responsibilities, combined with independent control valves on each pump outlet, enables precise blend ratio control without the interference and steady-state difficulties associated with shared pump systems.
Solution Approach 2:
The patent implements feedback control through control valves on each pump outlet that respond to blend ratio measurements. The system monitors the actual blend ratio and adjusts the control valve positions to maintain the desired precision, creating a closed-loop control system that handles the complexity of dual-stream mixing automatically.
4Ease of manufacture
If tank mixing is used for crude oil blending, then the capital investment is low, but the mixing accuracy is limited to 50/50 blend ratios and requires entire tanks dedicated to blending
Solution Approach 1:
The patent introduces dynamic control capabilities through variable speed pumps and control valves that can adjust flow rates in real-time. This allows the system to achieve any desired blend ratio dynamically, unlike fixed tank mixing configurations. The dynamic adjustment of pump speeds and valve positions enables flexible blend ratios while maintaining low capital investment by using the existing pipeline infrastructure.
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 with reduced capital investment, eliminating stratification and the need for dedicated blending tanks, while maintaining precision within 1% of the desired set point, and allowing for on-demand blending.
Implementation Method 1
a first spillback pipe having a first connection to the first booster pipe between the first meter and the first pump and a second connection to the first header upstream of the first set of tanks
Implementation Method 2
METHODS AND SYSTEMS FOR INLINE MIXING OF HYDROCARBON LIQUIDS BASED ON DENSITY OR GRAVITY
Data Source
AI summary
Methods and systems of admixing hydrocarbon liquids from two or more sets of tanks into a single pipeline to provide in-line mixing thereof. In an embodiment of the in-line mixing system, hydrocarbon liquids stored in at least one tank of each of two or more sets of tanks positioned at a tank farm are blended into a blend flow pipe via in-line mixing and the blended mixture is pumped through a single pipeline. In one or more embodiments, the in-line mixing system employs a separate spillback or recirculation loop that is fluidly connected to each set of the two or more sets of tanks to control the flow of the hydrocarbon fluid/liquid from each set of tanks to the blend flow pipe. Associated methods of operating one or more embodiments of the system include regulation of spillback or recirculation loop flow rate and/or pressure to drive the actual blend ratio towards a desired blend ratio.