MODULAR BARRIER FOR LIQUID STORAGE TANKS

Abstract

A system for providing a modular barrier in a covered or enclosed storage tank is provided that reduces the amount of vapors released from liquid hydrocarbons and other liquids. The modular barrier is, in some embodiments, comprised a plurality of objects operable to form a barrier over a surface of stored liquid contained in the storage tank. The plurality of objects, when inserted into the storage tank, covers the surface of the stored liquid and conforms to a shape of the tank.

Claims

1. A system for covering liquids in a covered storage tank to reduce at least one of flashing and evaporation of vapors during storage, comprising: a storage tank having an outer wall and a roof that form an enclosed volume; a liquid at least partially filling the enclosed volume of the storage tank, the liquid having an upper surface; and a modular barrier comprising a plurality of objects, wherein the plurality of objects is operable to cover the upper surface of the liquid and conform to a shape of the storage tank when inserted into the enclosed volume.

2. The system of claim 1, wherein the plurality of objects are spheres.

3. The system of claim 1, wherein the plurality of objects are hexagonal prisms.

4. The system of claim 1, wherein the plurality of objects comprises individual objects.

5. The system of claim 1, wherein the plurality of objects comprise individual objects tethered to each other.

6. The system of claim 1, wherein the plurality of objects has a density less than a density of the liquid.

7. The system of claim 6, wherein the plurality of objects are resistant to deterioration cause by the liquid.

8. The system of claim 6, wherein the plurality of objects are at least one of plastic, carbon fiber, Styrofoam, polyethylene, and polypropylene.

9. The system of claim 1, wherein each object of the plurality of objects are the same size as each other.

10. The system of claim 1, wherein the storage tank comprises an access port and an outlet disposed on the roof, and wherein a size of each object of the plurality of objects is smaller than a perimeter of the access port and larger the perimeter of the outlet.

11. A method for covering liquids in a covered storage tank to reduce flashing of vapors during storage, comprising: storing liquid in a storage tank, the storage tank having an outer wall and a roof that form an enclosed volume, the liquid at least partially filling the enclosed volume of the storage tank, the liquid having an upper surface; and covering the upper surface of the liquid with a modular barrier, the modular barrier comprising a plurality of objects operable to cover the upper surface of the liquid and conform to a shape of the storage tank when inserted into the enclosed volume.

12. The method of claim 11, wherein the plurality of objects comprises at least one of a tetrahedron, a cube, an octahedron, a dodecahedron, and an icosahedron.

13. The method of claim 11, wherein the plurality of objects comprises individual objects.

14. The method of claim 11, wherein the plurality of objects comprise individual objects tethered to each other.

15. The method of claim 11, wherein the plurality of objects has a density less than a density of the liquid.

16. The method of claim 15, wherein the plurality of objects are at least one of plastic, carbon fiber, Styrofoam, polyethylene, and polypropylene.

17. The method of claim 11, wherein each object of the plurality of objects are different sizes from each other.

18. The method of claim 11, wherein the storage tank comprises an access port and an outlet disposed on the roof, and wherein a size of each object of the plurality of objects is smaller than a perimeter of the access port and larger the perimeter of the outlet.

19. The method of claim 18, further comprising inserting the plurality of objects through the access port disposed on the roof.

20. A system for covering liquids in a covered storage tank to reduce flashing of vapors during storage, comprising: a storage tank having an outer wall and a roof that form an enclosed volume, and an access port disposed on the roof; a liquid at least partially filling the enclosed volume of the storage tank, the liquid having an upper surface; and a modular barrier comprising a plurality of objects, wherein the plurality of objects is operable to cover the upper surface of the liquid and conform to a shape of the storage tank when inserted into the enclosed volume, and wherein a size of each object of the plurality of objects is smaller than a perimeter of the access port, and each object of the plurality of objects is configured to be inserted into or removed from the enclosed volume via the access port.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures.

[0019] FIG. 1 is a diagram of a typical oil production tank battery in accordance with at least one embodiment of the present invention;

[0020] FIG. 2A is a cross-sectional view of the oil storage tank of FIG. 1 with another embodiment of a modular barrier;

[0021] FIG. 2B is a cross-sectional view of the oil storage tank of FIG. 1 with another embodiment of a modular barrier;

[0022] FIG. 2C is a cross-sectional view of the oil storage tank of FIG. 1 with another embodiment of a modular barrier;

[0023] FIG. 3A is a top view of the oil storage tank with a roof of the tank removed for clarity and the modular barrier of FIG. 2A;

[0024] FIG. 3B is a top view of the oil storage tank with a roof of the tank removed for clarity and the modular barrier of FIG. 2B;

[0025] FIG. 3C is a top view of the oil storage tank with a roof of the tank removed for clarity and the modular barrier of FIG. 2C;

[0026] FIG. 4A is an example embodiment of an object of the modular barrier;

[0027] FIG. 4B is an example embodiment of an object of the modular barrier;

[0028] FIG. 4C is an example embodiment of an object of the modular barrier;

[0029] FIG. 4D is an example embodiment of an object of the modular barrier;

[0030] FIG. 4E is an example embodiment of an object of the modular barrier;

[0031] FIG. 4F is an example embodiment of an object of the modular barrier; and

[0032] FIG. 5 is an example flowchart illustrating a method for covering a liquid with a modular barrier.

[0033] To assist in the understanding of the embodiments of the invention the following list of components and associated numbering found in the drawings is provided herein:

Component No. Component [0034] 18 Inlet Fitting [0035] 22 Conduit [0036] 78 Storage Tank [0037] 82 Roof [0038] 86 Liquid [0039] 90 Vapor Space [0040] 94A Modular Barrier [0041] 94B Modular Barrier [0042] 94C Modular Barrier [0043] 98 Vent [0044] 102 Plurality of Objects [0045] 106 Access Port [0046] 110 Cover [0047] 112 Wall (of the storage tank)

[0048] It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

[0049] The disclosure has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts and may be modified in numerous ways within the scope and spirit of the invention.

[0050] Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.

[0051] Various embodiments of the invention are described herein and as depicted in the drawings. It is expressly understood that although the figures illustrate covers, floating covers, flaps, etc., the invention is not limited to these embodiments.

[0052] Now referring to FIG. 1, a typical oil production tank battery is provided. Oil, gas, and water flow from the well to a separator where the oil, gas, and water are separated from each other. Then, the water flows to a water storage tank, the separated gas flows to a pipeline (e.g., a sales pipeline) or to a flare, and the oil flows to a storage tank generally operated at an ambient pressure. In the storage tank, residual gas in the oil and oil vapors are emitted through the tank vent. The oil gathers in the storage tank until there is enough oil to fill a transport truck. In other embodiments, any mode of transport other than trucking may be employed.

[0053] Turning to FIGS. 2A-2C, a cross section of a closed or enclosed storage tank 78 is shown. The storage tank 78 includes a roof 82 and a vent 98 disposed on the roof 82 for venting gas from stored liquid 86. In the illustrated embodiment, a wall 112 of the storage tank 78 is a vertical wall. In other embodiments, the wall 112 may be curved, at an angle, or form any shape. It will be appreciated that in some embodiments, the enclosed storage tank 78 may be spherical and in other embodiments, the enclosed storage tank 78 may be any shape, size, or configuration.

[0054] In some embodiments, the stored liquid 86 comprises hydrocarbon liquid. The tank 78 also includes an access port 106 operable to provide an opening for inserting or removing a plurality of objects 102 (or any objects or liquids) into and out of the tank 78. The plurality of objects 102 may comprise a plurality of three-dimensional (3D) objects. The access port 106 may also have a lid 110 for enclosing the access port 106. The access port 106 may be, for example, an opening into the tank 78 and the cover 110 may be a hatch. A vapor space 90 of the tank 78 includes the stored liquid 86 and a modular barrier 94. As previously mentioned, residual gas in the oil and oil vapors may rise to the roof 82 and are emitted through the vent 98. However, such residual gas when emitted through the vent 98 is typically disposed of by flaring or venting directly to the atmosphere. In order to accommodate flaring, installation of additional equipment is required and thus, increases the cost of production. Loss of the residual gas and oil vapors may be mitigated by a modular barrier 94A, 94B, 94C as shown in FIGS. 2A, 2B, 2C, respectively.

[0055] The storage tank 78 may also include a conduit 22 (e.g., a downpipe) that channels liquid along a path into the liquid 86 stored in the tank 78. In some embodiments, the storage tank 78 comprises an inlet 18 for the incoming liquid (e.g., oil) on the roof 82 of the tank. The pipe from the well or the separator transports the liquid to the tank and this pipe is attached to a fitting on the top of the tank 78. The liquid enters the inside of the tank 78 through this fitting and the liquid splashes or otherwise falls into the tank 78. This can pose a problem if the modular barrier 94A, 94B, 94C is already deployed in the storage tank 78. The splashing of the liquid on top of the modular barrier exacerbates the generation of vapors. A solution for this is to introduce the liquid 86 below the stored liquid surface. In some embodiments of the present invention, a pipe, hose, or conduit 22 is installed in the interior of the tank 78. This conduit 22 can attach to the inlet 18 fitting on the top of the tank 78 and transport and channel the liquid to the bottom of the tank 78, or at least below a liquid level and below the modular barrier 94A, 94B, 94C in the storage tank so that oil or any other liquid does not splash on top of the modular barrier 94A, 94B, 94C.

[0056] In some embodiments, the modular barrier 94A, 94B, 94C may be a modular cover. The modular barrier 94A, 94B, 94C as shown, may cover a surface of the stored liquid 86. When the surface of the stored liquid 86 is covered by the modular barrier 94A, 94B, 94C, the modular barrier 94A, 94B, 94C may prevent the stored liquid 86 (which may be, for example, hydrocarbon liquids) from vaporizing. The barrier 94A, 94B, 94C advantageously prevents flashing of light end hydrocarbons to the atmosphere or vapors within the closed storage tank 78 and/or evaporation of the stored liquid 86 by forming a vapor barrier between the stored liquid 86 and the atmosphere of the tank 78.

[0057] The modular barrier 94A, 94B, 94C may comprise a plurality of objects 102. In some embodiments, each object of the plurality of objects 102 is smaller than the access port 106 of the tank such that the plurality of objects 102 may be inserted into the tank 78 and removed from the tank 78 via the access port 106. For example, a diameter of each object of the plurality of objects 102 may be between 5″ to 7 ¾″. In other embodiments, the diameter of each object may be less than 5″ or greater than 7 ¾″. When the plurality of objects 102 are inserted into the tank 78, the plurality of objects 102 align next to each other so as to form the barrier 94A, 94B, 94C. The barrier 94A, 94B, 94C is also self-adjusting in that the plurality of objects 102 may also conform to a shape and size of the tank 78. The plurality of objects 102 may form one layer to form a barrier 94C, as shown, for example, in FIG. 2C. The plurality of objects 102 may also form more than one layer to form a multi-layer barrier 94B, as shown, for example, in FIG. 7B. The plurality of objects 102 may also comprise objects of different sizes and shapes as shown, for example, in FIG. 7A. The plurality of objects 102 also have a density less than a density of the liquid (which may be, for example, a hydrocarbon liquid). For example, the plurality of objects 102 may be formed from any material such as, for example, fiberglass, plastic, carbon fiber, Styrofoam, Polyethylene, or Polypropylene.

[0058] Turning to FIGS. 3A, 3B, 3C, the storage tank 78 and the modular barrier 94A, 94B, 94C are shown from a top view with the roof 82 removed for clarity. As illustrated, the wall 112 is circular when viewed from the top. In other embodiments, the wall 112 may be other shapes such as, for example, a square, a rectangle, a triangle, an oval, etc. In still other embodiments, the wall 112 may form any shape, combination of shapes, or configurations.

[0059] In some embodiments, the plurality of objects 102 comprises individual, unconnected objects. In other embodiments, the plurality of objects may comprise objects 102 connected to each other (via a tether or magnets, for example). The plurality of objects 102 are inserted into the tank until enough objects to cover the stored liquid 86 are inserted. As the surface of the liquid 86 is covered with the objects, the objects will contact each other until movement of an adjacent object is limited or restricted. As such, the plurality of objects 102 may conform to the shape of the tank 78 and form the modular barrier 94A, 94B, 94C. In some embodiments, the objects may also form multiple layers as shown in FIGS. 7A and 7B.

[0060] As shown in FIG. 3A (and FIG. 2A), the plurality of objects 102 may comprise a plurality of spheres. In other embodiments, each object of the plurality of objects 102 may be any shape such as, for example, a rectangle, a square, an oval, etc. In some embodiments, the plurality of spheres comprises individual, unconnected spheres. In other embodiments, the plurality of spheres may comprise spheres connected to each other (via a tether or magnets, for example). The plurality of spheres is inserted into the tank until enough spheres to cover the stored liquid 86 are inserted. As the surface of the liquid 86 is filled, the spheres may contact each other until movement of an adjacent spheres is limited or restricted. As such, the plurality of spheres may conform to the shape of the tank 78 and form the modular barrier 94A. In some embodiments, the spheres may also form multiple layers.

[0061] Similarly, as shown in FIG. 3B (and FIG. 2B), the plurality of objects 102 may comprise a plurality of hexagonal prisms or other shapes. In some embodiments, the plurality of hexagonal prisms comprises individual, unconnected hexagonal prisms. In other embodiments, the plurality of hexagonal prisms may comprise hexagonal prisms connected to each other (via a tether or magnets, for example). The plurality of hexagonal prisms is inserted into the tank until enough hexagonal prisms to cover the stored liquid 86 are inserted. As the surface of the liquid 86 is filled, the hexagonal prisms may contact each other until movement of an adjacent hexagonal prisms is limited or restricted. As such, the plurality of hexagonal prisms may conform to the shape of the tank 78 and form the modular barrier 94B. In some embodiments, the hexagonal prisms may also form multiple layers.

[0062] Similarly, as shown in FIG. 3C (and FIG. 2C), the plurality of objects 102 may comprise a plurality of dodecahedrons (also shown in FIGS. 4E and 4F). In some embodiments, the plurality of dodecahedrons comprises individual, unconnected dodecahedrons. In other embodiments, the plurality of dodecahedrons may comprise dodecahedrons connected to each other (via a tether or magnets, for example). The plurality of dodecahedrons is inserted into the tank until enough dodecahedrons to cover the stored liquid 86 are inserted. As the surface of the liquid 86 is filled, the dodecahedrons may contact each other until movement of an adjacent dodecahedrons is limited or restricted. As such, the plurality of dodecahedrons may conform to the shape of the tank 78 and form the modular barrier 94C. In some embodiments, the hexagonal prisms may also form multiple layers.

[0063] Turning to FIGS. 4A-4F, a plurality of objects 102 of example shapes are shown. Each object of the plurality of objects 102 may be, for example, a hexagonal prism as shown in FIG. 4A. In some embodiments, the hexagonal prism may be sold under the trademark HEXPROTECT®. Each object of the plurality of objects 102 may be, for example, a sphere as shown in FIG. 4B. In other embodiments, each object of the plurality of objects 102 may be, for example, a cube as shown in FIG. 4C. In still other embodiments, each object of the plurality of objects 102 may be, for example, a 3D rectangle as shown in FIG. 4D. In other embodiments, each object of the plurality of objects 102 may have, for example, a body having twelve substantially identical quadrilateral faces (e.g., a dodecagon), as shown in FIGS. 4E and 4F.

[0064] It will be appreciated that though spheres, hexagonal prisms, dodecagons or other shapes are described above, that the modular barrier 94A, 94B, 94C may comprise a plurality of objects 102 of any shape or sizes. Further, in some embodiments, a modular barrier may comprise objects of different shapes. For example, the modular barrier 94A, 94B, 94C may comprise both hexagonal prisms, dodecahedrons, and/or spheres of different sizes (as illustrated in, for example, FIG. 2A and 2B).

[0065] In addition to covering the surface of the liquid, the modular barrier 94A, 94B, 94C can easily conform to different size tanks. To fill a larger tank, more objects (whether spheres, hexagonal prisms, dodecagons, or any object) are simply inserted into the tank until the surface of the liquid is substantially covered.

[0066] Turning to FIG. 5, a method 500 for storing and covering a liquid with a modular barrier is provided. The method may comprise storing a liquid (e.g., a hydrocarbon liquid) in a storage tank (step 504). The storage tank may be the same as or similar to the storage tank 78 and may have an outer wall such as the outer wall 112 and a roof such as the roof 82 to form an enclosed volume. The liquid may at least partially fill the enclosed volume of the storage tank and may have an upper surface.

[0067] The method also comprises covering the surface of the liquid with a modular barrier (step 508). The modular barrier may be the same as or similar to the modular barrier 94A, 94B, 94C. The modular barrier may comprise a plurality of objects such as the plurality of objects 102 operable to cover the upper surface of the liquid and conform to a shape of the storage tank when inserted into the enclosed volume.

[0068] While embodiments of the present invention are described with respect to oil storage tanks and hydrocarbon liquids, it will be appreciated that the present invention may be applied to a wider range of enclosed containers and contents of containers.

[0069] The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.

[0070] The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B, and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0071] Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification, drawings, and claims are to be understood as being modified in all instances by the term “about.”

[0072] The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

[0073] The use of “including,” “comprising,” or “having,” and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

[0074] It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts, and the equivalents thereof, shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

[0075] The foregoing description of the invention has been presented for illustration and description purposes. However, the description is not intended to limit the invention to only the forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.

[0076] Consequently, variations and modifications commensurate with the above teachings and skill and knowledge of the relevant art are within the scope of the invention. The embodiments described herein above are further intended to explain best modes of practicing the invention and to enable others skilled in the art to utilize the invention in such a manner, or include other embodiments with various modifications as required by the particular application(s) or use(s) of the invention. Thus, it is intended that the claims be construed to include alternative embodiments to the extent permitted by the prior art.