Intermittent Tank Mixing Using Sensor Feedback for Fluid Homogeneity
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Solution Overview
Problem
Industrial facilities, such as refineries and oil and gas storage tanks, face challenges in efficiently collecting and analyzing data from multiple sensors, leading to delayed and inefficient decision-making and operational optimization due to the complexity of data handling and limited visibility of fluid characteristics, which affects production, safety, and cost.
Innovation Solution
A method utilizing upper and lower data acquisition devices to measure fluid characteristics within a tank, with a data analyzer generating a data packet to control an intermittent mixer, ensuring consistent fluid properties throughout the tank by adjusting operational speed and time, thereby automating the mixer's operation based on real-time data comparisons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the mixer operates continuously to maintain fluid homogeneity, then the fluid consistency is improved, but the energy consumption increases
Solution Approach 1:
The mixer operates intermittently rather than continuously. The system monitors fluid characteristics using sensors and activates the mixer only when heterogeneity is detected, switching between active mixing and idle states based on real-time conditions, thereby reducing energy consumption while maintaining fluid consistency.
Solution Approach 2:
The system uses sensors to continuously monitor fluid characteristics and feeds this information back to the control system. Based on the feedback regarding fluid homogeneity, the controller intelligently decides when to activate or deactivate the mixer, optimizing energy usage while ensuring fluid consistency is maintained when needed.
2Ease of operation
If manual data collection and analysis methods are used, then operational simplicity is maintained, but decision-making time increases
Solution Approach 1:
The system performs data collection, analysis, and mixing control automatically without requiring manual intervention. Sensors continuously monitor fluid characteristics, the controller autonomously analyzes the data, and the mixer is controlled automatically, freeing operators from manual tasks while enabling rapid decision-making.
Solution Approach 2:
The patent replaces manual mechanical data collection methods with automated electronic sensing and digital processing systems. This substitution of mechanical/manual operations with electronic automation systems enables both operational simplicity and rapid decision-making.
3Measurement precision
If multiple sensors are deployed to monitor fluid characteristics, then measurement accuracy is improved, but system complexity increases
Solution Approach 1:
The system employs multiple sensors that can detect various fluid characteristics (density, temperature, composition). These multi-functional sensors provide comprehensive monitoring capabilities, improving measurement accuracy across different parameters while managing system complexity through integrated sensing.
Solution Approach 2:
The patent combines multiple sensing functions and data processing capabilities into an integrated control system. By merging sensor data collection, analysis, and control functions into a unified system, the patent achieves high measurement accuracy while managing overall system complexity through integration.
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 reduces energy consumption by optimizing mixer operation, enhances data-driven decision-making, and ensures consistent fluid properties, facilitating quicker and more accurate custody transfers by maintaining consistent fluid characteristics, resulting in cost savings and improved operational efficiency.
Implementation Method 1
The intermittent mixer is capable of altering the fluid within the tank so that the at least one characteristic is consistent throughout the tank
Data Source
AI summary
A method is taught for maintaining a fluid within a tank. In this method an upper data acquisition device is operated which is capable of obtaining at least one characteristic of the fluid in a tank adjacent to the upper data acquisition device. A lower data acquisition device is also operated which is situated below the upper data acquisition device, capable of obtaining at least one characteristic of the fluid in the tank adjacent to the lower data acquisition device. A data analyzer is then utilized which is capable transmitting a data packet to the intermittent mixer. The method then automatically turns on the intermittent mixer from the data received from the data packet. Afterwards, the method automatically turns off the intermittent mixer from the data received from the data packet resulting in the at least one characteristic from the upper data acquisition device is within specifications of the at least one characteristic from the lower data acquisition device. In this method the intermittent mixer is capable of altering the fluid within the tank so that the at least one characteristic is consistent throughout the tank.