BLENDING FACILITY SET-UP AND OPERATION

Abstract

A continuous blending system can be used to prepare burner fuel or blasting agent, and includes a mixer, a first hydrocarbon system, a second hydrocarbon mixer, and a computing system. The mixer is configured for continuously mixing a continuous supply of a first hydrocarbon and a continuous supply of second hydrocarbon to provide a mixed hydrocarbon at a flow rate and a predefined ratio of first and second hydrocarbon. The first hydrocarbon system provides a continuous flow of first hydrocarbon into the mixer. The second hydrocarbon system provides a continuous flow of second hydrocarbon system into the mixer. The computing system is in communication with and configured for simultaneously controlling the first and second hydrocarbon systems in order to obtain the mixed hydrocarbon at the predefined flow rate and at the predefined ratio of first and second hydrocarbon.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates an embodiment of a continuous mixing system of the present invention.

FIG. 2 illustrates an embodiment of a continuous mixing system of the present invention.

Claims

1. A continuous blending system for use in preparing burner fuel on location, the system comprising: a mixer configured for continuously mixing a continuous supply of a first hydrocarbon and a continuous supply of second hydrocarbon in order to provide a mixed hydrocarbon at a flow rate and having a predefined ratio of first and second hydrocarbon;a first hydrocarbon system in fluid communication with the mixer, the first hydrocarbon system being configured for supplying a continuous flow of first hydrocarbon to the mixer at a flow rate to achieve the predefined ratio, the first hydrocarbon system comprising: a first pump;a first flow meter in fluid communication with and downstream from the first pump; anda first valve in fluid communication with and downstream from the first flow meter, the first valve being configured to open for supplying a continuous flow of first hydrocarbon to the mixer;a second hydrocarbon system in fluid communication with the mixer, the second hydrocarbon system being configured for supplying a continuous flow of second hydrocarbon to the mixer at a flow rate to achieve the predefined ratio, the second hydrocarbon system comprising: a second pump;a second flow meter in fluid communication with and downstream from the second pump; anda second valve in fluid communication with and downstream from the second flow meter, the second valve being configured to open for supplying a continuous flow of second hydrocarbon to the mixer; anda computing system in communication with and configured for simultaneously controlling the first and second hydrocarbon systems in order to obtain the mixed hydrocarbon at the predefined flow rate and at the predefined ratio of first and second hydrocarbon.

2. A system as in claim 1, further comprising: a first hydrocarbon inlet upstream of the first pump;a first feed back loop comprising: a first feedback inlet between the first flow meter and first valve; anda first feedback outlet between the first hydrocarbon inlet and the first pump;a second hydrocarbon inlet upstream of the second pump; anda second feed back loop comprising: a second feedback inlet between the second flow meter and second valve; anda second feedback outlet between the second hydrocarbon inlet and the second pump.

3. A system as in claim 2, further comprising: the first pump being in electronic communication with the computing system so that the computing system can control the output of the first pump;the first flow meter being in electronic communication with the computing system and being configured for providing first hydrocarbon flow data to the computing system so that the computing system can control the output of the first pump;a first valve being in electronic communication with the computing system and configured to receive first valve control data to open or close the first valve, the first valve being opened for supplying a continuous flow of first hydrocarbon to the mixer;the second pump being in electronic communication with the computing system so that the computing system can control the output of the second pump;the second flow meter being in electronic communication with the computing system and being configured for providing second hydrocarbon flow data to the computing system so that the computing system can control the output of the second pump;a second valve being in electronic communication with the computing system and configured to receive second valve control data to open or close the second valve, the second valve being opened for supplying a continuous flow of second hydrocarbon to the mixer.

4. A system as in claim 3, further comprising at least one of the following: a first safety solenoid valve disposed downstream from the first pump and upstream from the mixer, the first safety solenoid valve being closed unless opened by the computing system; ora second safety solenoid valve disposed downstream from the second pump and upstream from the mixer, the second safety solenoid valve being closed unless opened by the computing system.

5. A system as in claim 4, further comprising at least one of the following: a first strainer disposed upstream from the first pump, the first strainer being configured to strain the first hydrocarbon; ora second strainer disposed upstream from the second pump, the second strainer being configured to strain the second hydrocarbon.

6. A system as in claim 5, further comprising: used oil as the first hydrocarbon and being disposed within the first hydrocarbon system; anddiesel fuel as the second hydrocarbon and being disposed within the second hydrocarbon system.

7. A system as in claim 3, wherein the computing system is configured to control operation of the continuous blending system by a user inputting data into the computing system, wherein operation of the continuous blending system comprises: a startup mode for calibrating the flow rate of the first hydrocarbon and the second hydrocarbon, the startup mode comprising: operating the first pump with the first valve closed so that the first hydrocarbon flows through the first feedback loop;measuring the first hydrocarbon flow rate with the first flow meter;regulating the first pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the first hydrocarbon;operating the second pump with the second valve closed so that the second hydrocarbon flows through the second feedback loop;measuring the second hydrocarbon flow rate with the second flow meter; andregulating the second pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the second hydrocarbon.

8. A system as in claim 7, wherein the startup mode further comprises: the first flow meter is configured to read the flow rate of the first hydrocarbon to obtain a first plurality of flow rate data per gallon;the computing system is configured to control the flow rate of the first hydrocarbon in response to the first plurality of flow rate data by modulating a variable frequency drive in the first pump;the second flow meter is configured to read the flow rate of the second hydrocarbon to obtain a second plurality of flow rate data per gallon; andthe computing system is configured to control the flow rate of the second hydrocarbon in response to the second plurality of flow rate data by modulating a variable frequency drive in the second pump.

9. A system as in claim 3, wherein the computing system is configured to control operation of the continuous blending system by a user inputting data into the computing system, wherein operation of the continuous blending system comprises: a steady-state mode for dispensing the mixed hydrocarbon at a flow rate and having the predefined ratio of first and second hydrocarbon, the steady-state mode comprising: regulating the first pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the first hydrocarbon;opening the first valve so as to supply a continuous flow of first hydrocarbon to the mixer at the flow rate to achieve the predefined ratio with respect to the first hydrocarbon;regulating the second pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the second hydrocarbon; andopening the second valve so as to supply a continuous flow of second hydrocarbon to the mixer at the flow rate to achieve the predefined ratio with respect to the second hydrocarbon.

10. A system as in claim 3, wherein the computing system is configured to automatically stop the continuous blending system from dispensing the mixed hydrocarbon by at least one of the following: a stop command being input into the computing system;a predefined time limit expiring for dispensing the mixed hydrocarbon;a predefined amount of mixed hydrocarbon being dispensed from the mixer;at least one of the first or second hydrocarbon having a flow rate that does not achieve the predefined ratio of the first and second hydrocarbon; andthe ratio of the first and second hydrocarbon being a ratio other then the predefined ratio.

11. A continuous blending system for use in preparing burner fuel on location, the system comprising: a computing system configured for controlling components of the continuous blending system, the computing system having a user input interface and a user output interface to provide system operation information to the user;a mixer configured for continuously mixing a continuous supply of spent hydrocarbon and a continuous supply of fresh hydrocarbon in order to provide a mixed hydrocarbon having a predefined ratio of spent hydrocarbon and fresh hydrocarbon, the predefined ratio being input into the computing system by the user;a spent hydrocarbon system in electronic communication with the computing system and being configured for supplying a continuous flow of spent hydrocarbon to the mixer in an amount to achieve the predefined ratio, the spent hydrocarbon system comprising: a spent hydrocarbon pump in electronic communication with the computing system so that the computing system can control the output of the spent hydrocarbon pump;a spent hydrocarbon flow meter in fluid communication with and downstream from the spent hydrocarbon pump, the spent hydrocarbon flow meter being in electronic communication with the computing system and being configured for providing spent hydrocarbon flow data to the computing system so that the computing system can control the output of the spent hydrocarbon pump; anda spent hydrocarbon valve in fluid communication with and downstream from the spent hydrocarbon flow meter, the spent hydrocarbon valve being in electronic communication with the computing system and configured to receive spent hydrocarbon valve control data to open or close the spent hydrocarbon valve, the spent hydrocarbon valve being opened for supplying a continuous flow of spent hydrocarbon to the mixer; anda fresh hydrocarbon system in electronic communication with the computing system and being configured for supplying a continuous flow of fresh hydrocarbon to the mixer in an amount to achieve the predefined ratio, the fresh hydrocarbon system comprising: a fresh hydrocarbon pump in electronic communication with the computing system so that the computing system can control the output of the fresh hydrocarbon pump;a fresh hydrocarbon flow meter in fluid communication with and downstream from the fresh hydrocarbon pump, the fresh hydrocarbon flow meter being in electronic communication with the computing system and being configured for providing fresh hydrocarbon flow data to the computing system so that the computing system can control the output of the fresh hydrocarbon pump; anda fresh hydrocarbon valve in fluid communication with and downstream from the fresh hydrocarbon flow meter, the fresh hydrocarbon valve being in electronic communication with the computing system and configured to receive fresh hydrocarbon valve control data to open or close the fresh hydrocarbon valve, the fresh hydrocarbon valve being opened for supplying a continuous flow of fresh hydrocarbon to the mixer.

12. A system as in claim 11, further comprising: a spent hydrocarbon inlet upstream of the spent hydrocarbon pump;a spent hydrocarbon first feed back loop comprising: a spent hydrocarbon feedback inlet between the spent hydrocarbon flow meter and spent hydrocarbon valve; anda spent hydrocarbon feedback outlet between the spent hydrocarbon inlet and the spent hydrocarbon pump;a fresh hydrocarbon inlet upstream of the fresh hydrocarbon pump; anda fresh hydrocarbon feed back loop comprising: a fresh hydrocarbon feedback inlet between the fresh hydrocarbon flow meter and fresh hydrocarbon valve; anda fresh hydrocarbon feedback outlet between the fresh hydrocarbon inlet and the fresh hydrocarbon pump.

13. A system as in claim 12, further comprising at least one of the following: a spent hydrocarbon safety solenoid valve disposed downstream from the spent hydrocarbon pump and upstream from the mixer, the spent hydrocarbon safety solenoid valve being closed unless opened by the computing system; ora fresh hydrocarbon safety solenoid valve disposed downstream from the fresh hydrocarbon pump and upstream from the mixer, the fresh hydrocarbon safety solenoid valve being closed unless opened by the computing system.

14. A system as in claim 13, further comprising at least one of the following: a spent hydrocarbon strainer disposed upstream from the spent hydrocarbon pump, the spent hydrocarbon strainer being configured to strain the spent hydrocarbon; ora fresh hydrocarbon strainer disposed upstream from the fresh hydrocarbon pump, the fresh hydrocarbon strainer being configured to strain the fresh hydrocarbon.

15. A system as in claim 14, further comprising: used oil as the spent hydrocarbon and being disposed within the spent hydrocarbon system; anddiesel fuel as the fresh hydrocarbon and being disposed within the fresh hydrocarbon system.

16. A system as in claim 12, wherein the computing system is configured to control operation of the continuous blending system by a user inputting data into the computing system, wherein operation of the continuous blending system comprises: a startup mode for calibrating the flow rate of the spent hydrocarbon and the fresh hydrocarbon, the startup mode comprising: operating the spent hydrocarbon pump with the spent hydrocarbon valve closed so that the spent hydrocarbon flows through the spent hydrocarbon feedback loop;measuring the spent hydrocarbon flow rate with the spent hydrocarbon flow meter;regulating the spent hydrocarbon pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the spent hydrocarbon;operating the fresh hydrocarbon pump with the fresh hydrocarbon valve closed so that the fresh hydrocarbon flows through the fresh hydrocarbon feedback loop;measuring the fresh hydrocarbon flow rate with the fresh hydrocarbon flow meter; andregulating the fresh hydrocarbon pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the fresh hydrocarbon.

17. A system as in claim 16, wherein the startup mode further comprises: the spent hydrocarbon flow meter is configured to read the flow rate of the spent hydrocarbon to obtain a first plurality of flow rate data per gallon;the computing system is configured to control the flow rate of the spent hydrocarbon in response to the first plurality of flow rate data by modulating a variable frequency drive in the spent hydrocarbon pump;the fresh hydrocarbon flow meter is configured to read the flow rate of the fresh hydrocarbon to obtain a second plurality of flow rate data per gallon; andthe computing system is configured to control the flow rate of the fresh hydrocarbon in response to the second plurality of flow rate data by modulating a variable frequency drive in the fresh hydrocarbon pump.

18. A system as in claim 12, wherein the computing system is configured to control operation of the continuous blending system by a user inputting data into the computing system, wherein operation of the continuous blending system comprises: a steady-state mode for dispensing the mixed hydrocarbon at a flow rate and having the predefined ratio of spent and fresh hydrocarbon, the steady-state mode comprising: regulating the spent hydrocarbon pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the spent hydrocarbon;opening the spent hydrocarbon valve so as to supply a continuous flow of first hydrocarbon to the mixer at the flow rate to achieve the predefined ratio with respect to the spent hydrocarbon;regulating the fresh hydrocarbon pump output so as to be a continuous flow having a flow rate to achieve the predefined ratio with respect to the fresh hydrocarbon; andopening the fresh hydrocarbon valve so as to supply a continuous flow of fresh hydrocarbon to the mixer at the flow rate to achieve the predefined ratio with respect to the fresh hydrocarbon.

19. A system as in claim 12, wherein the computing system is configured to automatically stop the continuous blending system from dispensing the mixed hydrocarbon by at least one of the following: a stop command being input into the computing system;a predefined time limit expiring for dispensing the mixed hydrocarbon;a predefined amount of mixed hydrocarbon being dispensed from the mixer;at least one of the spent or fresh hydrocarbon having a flow rate that does not achieve the predefined ratio of the spent and fresh hydrocarbon; andthe ratio of the spent and fresh hydrocarbon being a ratio other then the predefined ratio.

20. A continuous blending system for use in preparing burner fuel on location, the system comprising: a computing system configured for controlling components of the continuous blending system, the computing system having a user input interface and a user output interface to provide system operation information to the user;a mixer configured for continuously mixing a continuous supply of spent hydrocarbon and a continuous supply of fresh hydrocarbon in order to provide a mixed hydrocarbon having a predefined ratio of spent hydrocarbon and fresh hydrocarbon, the predefined ratio being input into the computing system by the user;a spent hydrocarbon system in electronic communication with the computing system and being configured for supplying a continuous flow of spent hydrocarbon to the mixer in an amount to achieve the predefined ratio, the spent hydrocarbon system comprising: a spent hydrocarbon pump in electronic communication with the computing system so that the computing system can control the output of the spent hydrocarbon pump;a spent hydrocarbon flow meter in fluid communication with and downstream from the spent hydrocarbon pump, the spent hydrocarbon flow meter being in electronic communication with the computing system and being configured for providing spent hydrocarbon flow data to the computing system so that the computing system can control the output of the spent hydrocarbon pump; anda spent hydrocarbon valve in fluid communication with and downstream from the spent hydrocarbon flow meter, the spent hydrocarbon valve being in electronic communication with the computing system and configured to receive spent hydrocarbon valve control data to open or close the spent hydrocarbon valve, the spent hydrocarbon valve being opened for supplying a continuous flow of spent hydrocarbon to the mixer;a spent hydrocarbon inlet upstream of the spent hydrocarbon pump;a spent hydrocarbon first feed back loop comprising: a spent hydrocarbon feedback inlet between the spent hydrocarbon flow meter and spent hydrocarbon valve; anda spent hydrocarbon feedback outlet between the spent hydrocarbon inlet and the spent hydrocarbon pump;a fresh hydrocarbon system in electronic communication with the computing system and being configured for supplying a continuous flow of fresh hydrocarbon to the mixer in an amount to achieve the predefined ratio, the fresh hydrocarbon system comprising: a fresh hydrocarbon pump in electronic communication with the computing system so that the computing system can control the output of the fresh hydrocarbon pump;a fresh hydrocarbon flow meter in fluid communication with and downstream from the fresh hydrocarbon pump, the fresh hydrocarbon flow meter being in electronic communication with the computing system and being configured for providing fresh hydrocarbon flow data to the computing system so that the computing system can control the output of the fresh hydrocarbon pump;a fresh hydrocarbon valve in fluid communication with and downstream from the fresh hydrocarbon flow meter, the fresh hydrocarbon valve being in electronic communication with the computing system and configured to receive fresh hydrocarbon valve control data to open or close the fresh hydrocarbon valve, the fresh hydrocarbon valve being opened for supplying a continuous flow of fresh hydrocarbon to the mixer;a fresh hydrocarbon inlet upstream of the fresh hydrocarbon pump; anda fresh hydrocarbon feed back loop comprising: a fresh hydrocarbon feedback inlet between the fresh hydrocarbon flow meter and fresh hydrocarbon valve; anda fresh hydrocarbon feedback outlet between the fresh hydrocarbon inlet and the fresh hydrocarbon pump.