The present invention relates to a production system for manufacturing of formulations, comprising a unit (1). The unit (1) includes a subunit (1.1) which includes a combination of a process mixer and a buffer tank, means of feeding defined amounts of feedstocks into the process mixer, a measurement unit for ascertaining properties of a part-batch of a formulation manufactured in the process mixer, an evaluation unit for determining a deviation of properties of the part-batches manufactured in the process mixer from the properties of a predefined target state, and a unit for adjusting the feed of feedstocks in view of the deviations. The present invention also relates to a process for manufacturing formulations.

Fluid mixing systems and methods to dynamically adjust a density of a fluid mixture are disclosed. A method to dynamically adjust a density of a fluid mixture includes obtaining data indicative of one or more characteristics of a mixture of a first fluid having a first density and a second fluid having a second density that is less than the first density. The method also includes determining, based on the one or more characteristics, an amount of additive to add to the mixture, and releasing a volume of the first fluid, which when mixed with the second fluid, forms a mixture having a ratio of the first fluid to the second fluid. The method further includes mixing the first fluid with the second fluid. The method further includes adding the determined amount of additive to the mixture having the ratio of the first fluid to the second fluid.

An apparatus for controlling blending of a gas mixture containing known components, including first, second, and third control valves for controlling the flow of first, second, and third components, respectively, a first gas density sensor to measure the density of a first mixture of the first and second components, a second gas density sensor to measure the density of a second mixture of the first mixture and the third component, and a controller to determine based on data from the first and second gas density sensors the relative compositions of the first, second, and third components in the second mixture, and to control the first, second, and third control valves to obtain a desired relative composition of the first, second, and third components in the second mixture.

Embodiments include systems and methods of in-line mixing of hydrocarbon liquids from a plurality of tanks into a single pipeline. According to an embodiment, a method of admixing hydrocarbon liquids from a plurality of tanks into a single pipeline to provide in-line mixing thereof includes determining a ratio of a second fluid flow to a first fluid flow based on signals received from a tank flow meter in fluid communication with the second fluid flow and a booster flow meter in fluid communication with a blended fluid flow. The blended fluid flow includes a blended flow of the first fluid flow and the second fluid flow. The method further includes comparing the determined ratio to a pre-selected set point ratio thereby to determine a modified flow of the second fluid flow to drive the ratio toward the pre-selected set point ratio. The method further includes controlling a variable speed drive connected to a pump thereby to control the second fluid flow through the pump based on the determined modified flow, the pump being in fluid communication with the second fluid flow.

An apparatus for measuring the composition of a gas mixture containing known components, including a first gas density sensor configured and arranged to measure the density of a first mixture made by combining a gaseous first component and a gaseous second component; a second gas density sensor configured and arranged to measure the density of a second mixture made by combining the first mixture with a gaseous third component; and a processor programmed to determined based on data from the first gas density sensor the relative compositions of the first component and the second component in the first mixture, and to determine based on the data from the second gas density sensor the relative compositions of the first mixture and the third component in the second mixture, and thus to determine the relative compositions of the first component, the second component, and the third component in the second mixture.

The systems and methods described herein assist a user in executing a recipe by recording and associating a blend sequence of blend steps with the recipe upon a first execution of the recipe. The systems and methods described herein further assist the user in modifying and executing the recorded blend sequence upon a second and subsequent execution of the recipe.

A slurry injection system includes low and high pressure clear fluid manifolds. Low pressure clear fluid is pressurized and communicated to high pressure manifold. A blender unit communicates slurry through a sensor system that generates a flow rate signal and a density signal of the low pressure slurry. The slurry pressurizer is in fluid communication with the high pressure clear fluid manifold through a bypass pump, a mixer, the blender unit and the low pressure clear fluid manifold. The slurry pressurizer forms high pressure slurry that is communicated to the mixer and communicates fluid to the low pressure clear fluid manifold. The mixer mixes the high pressure slurry and high pressure clear fluid from the high pressure clear fluid manifold to form a mixture that is communicated to a slurry injection site. A controller controls the bypass pump using the flow rate and density to control a density of slurry.

A slurry injection system includes low and high pressure clear fluid manifolds. Low pressure clear fluid is pressurized and communicated to high pressure manifold. A blender unit communicates slurry through a sensor system that generates a flow rate signal and a density signal of the low pressure slurry. The slurry pressurizer is in fluid communication with the high pressure clear fluid manifold through a bypass pump, a mixer, the blender unit and the low pressure clear fluid manifold. The slurry pressurizer forms high pressure slurry that is communicated to the mixer and communicates fluid to the low pressure clear fluid manifold. The mixer mixes the high pressure slurry and high pressure clear fluid from the high pressure clear fluid manifold to form a mixture that is communicated to a slurry injection site. A controller controls the bypass pump using the flow rate and density to control a density of slurry.

Aspects of the disclosure include a method for producing a batch according to a batch process that includes adding ingredients to water to form a batch, mixing the batch, measuring the drive gain of the batch in real time using an in-line density device, monitoring amplitude variation of the drive gain, comparing the amplitude variation of the drive gain to a predetermined threshold, and providing an indication based on the amplitude variation of the drive gain that the batch is homogeneously dispersed or fully dissolved. Other aspects of the disclosure relate to a method for detecting homogeneity of a mixture and a method of determining the degree of mixing of a batch.

Described herein is a production system including a unit, wherein the unit includes a subunit (1.1) for continuous manufacture of formulations. The subunit includes a combination of a small-volume process mixer and a buffer tank, means of feeding defined amounts of feedstocks into the process mixer, a measurement unit for ascertaining properties of a formulation manufactured in the process mixer, an evaluation unit for determining a deviation of properties of the formulation manufactured in the process mixer from the properties of a predefined target state, and a unit for adjusting the feed of feedstocks in view of the deviations. Also described herein is a process for manufacturing formulations.