Vapor Recovery Unit Control for Terminal Loading Optimization
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Solution Overview
Problem
Terminal loading capacity is limited by the vapor recovery unit (VRU) capacity, leading to undesirable shutdowns due to inefficient regeneration and saturation, straining the VRU's ability to handle increased loads.
Innovation Solution
Real-time monitoring and coordination of load rack and VRU operations using data processors and controllers to adjust fuel flow rates based on ambient temperature, product type, and VRU performance, ensuring the VRU remains within its capacity and preventing shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the terminal operates at full capacity, then the loading productivity increases, but the VRU becomes saturated and shuts down causing operational interruptions
Solution Approach 1:
The system continuously monitors VRU performance parameters (adsorber saturation levels, cycle timing, vacuum pump operation) and uses this feedback to dynamically adjust fuel dispensing rates. When the VRU shows signs of approaching saturation or regeneration delays, the system automatically reduces the loading rate to prevent shutdown, ensuring continuous reliable operation while maximizing productivity within VRU capabilities
Solution Approach 2:
The fuel dispensing rate is made dynamic rather than fixed. The system adjusts the loading rate in real-time based on VRU operational state, allowing higher rates when the VRU is operating efficiently and reducing rates when regeneration is delayed or adsorbers are near saturation. This dynamic adjustment optimizes productivity while preventing the binary shutdown state
2Speed
If the VRU processes vapors at high rates, then the loading speed increases, but the adsorbers cannot regenerate quickly enough causing saturation
Solution Approach 1:
The system monitors VRU cycle timing and adsorber saturation levels in advance to predict when regeneration will be insufficient. By detecting early signs of imbalance between vapor processing rate and regeneration rate, the system proactively reduces the loading rate before saturation occurs, preventing shutdown rather than reacting after the problem manifests
Solution Approach 2:
The system applies a counteracting reduction in fuel loading rate when VRU performance indicators suggest that vapor processing is outpacing regeneration capability. This preliminary anti-action prevents the harmful effect of saturation by reducing the vapor generation rate at the source (fuel dispensing) before the VRU becomes overwhelmed
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
Maximizes terminal loading capacity by optimizing fuel flow rates, preventing VRU shutdowns and allowing continuous fuel dispensing by maintaining the VRU within its operational limits.
Implementation Method 1
A typical VRU unit has at least two adsorber vessels filled with adsorbent, such as activated carbon
Implementation Method 2
The fuel vapor is commonly removed by vacuum and purge air stripping. A vacuum pump extracts the fuel vapor from the saturated adsorbent
Implementation Method 3
The absorption column vessel contains a packing material to increase the efficiency of the absorption process. The fuel vapors from the adsorber flow up through the absorption column while liquid fuel flows down through the packing. The liquid fuel absorbs the vapors retained in the packing.
Data Source
AI summary
This vapor control logic system is for optimizing terminal loading capacity by controlling load rack fuel dispensing with a vapor recovery unit (VRU) to prevent undesirable shutdown of fuel dispensing at terminal facilities.