Transmix Fraction Blending Control Under Sulfur Limits
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Solution Overview
Problem
Transmix, a mixture of off-specification hydrocarbons created when different fuel products mix in pipelines, cannot be directly reused in commerce due to violating pre-set physical property limits, particularly sulfur content, requiring costly reprocessing and recertification.
Innovation Solution
A system and method for blending transmix fractions into defined hydrocarbon streams without exceeding pre-determined physical property limits, using an Information Processing Unit (IPU) to calculate and regulate the blending ratio based on real-time measurements of physical properties, ensuring continuous recertification and compliance with ASTM standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If transmix is directly reused in commerce, then productivity increases and processing costs decrease, but the physical property limits (particularly sulfur content) are violated
Solution Approach 1:
The system dynamically adjusts the blending ratio of transmix to the certified fuel stream based on real-time measurements of physical properties (sulfur content, specific gravity, flash point). By continuously monitoring and adjusting these parameters, the system enables maximum transmix recycling while maintaining compliance with specification limits.
Solution Approach 2:
The system employs continuous feedback loops where physical property measurements of the blended stream are taken in real-time, compared against specification limits, and used to adjust the transmix injection rate. This closed-loop control ensures compliance while maximizing transmix utilization.
2Loss of energy
If transmix is blended into certified fuel streams, then commercial value increases and processing costs decrease, but sulfur content may exceed pre-specified limits
Solution Approach 1:
The system continuously monitors sulfur content in the blended stream and adjusts the transmix blending rate in real-time. When sulfur content approaches the specification limit, the system automatically reduces the transmix injection rate, preventing specification violations while maximizing the use of transmix fuel.
Solution Approach 2:
The system dynamically changes the blending parameter (transmix to certified fuel ratio) based on the measured sulfur content of both the transmix stream and the certified fuel stream, allowing optimal utilization of transmix while maintaining sulfur content within specification limits.
3Manufacturing precision
If real-time monitoring and control systems are implemented, then compliance with specifications is maintained, but device complexity increases
Solution Approach 1:
The system uses a multi-functional integrated controller that performs multiple functions: measuring physical properties, calculating blending ratios, controlling flow rates, and monitoring compliance. This consolidation reduces overall system complexity compared to having separate dedicated systems for each function.
Solution Approach 2:
The system is designed to be self-regulating, automatically adjusting blending rates based on real-time measurements without requiring constant operator intervention. The automated control logic and feedback mechanisms enable the system to maintain compliance autonomously.
4Adaptability or versatility
If transmix is separated into distillate and gasoline fractions, then the fractions can be blended into appropriate streams, but processing time and complexity increase
Solution Approach 1:
The system separates transmix into distillate and gasoline fractions based on their different properties, allowing each fraction to be blended into the appropriate certified fuel stream (distillate into diesel, gasoline into gasoline). This segmentation enables versatile blending options while managing processing through dedicated pathways for each fraction type.
Data Source
AI summary
Automated methods and systems for blending high sulfur hydrocarbons, particularly those derived from transmix, into low sulfur hydrocarbon streams are provided. Also provided are methods for splitting transmix into usable hydrocarbon fractions and blending the fractions back into defined hydrocarbon streams.