Blending System

Backed by more than 60 years’ experience in the design, manufacture, and supply of customized turnkey measurement systems.

In-line blending involves the continuous and controlled mixing of various components to create a finished product with closely defined quality. This method allows for real-time quality control during production, enabling blending, analysis, and loading in a single process. This is particularly valuable for continuous process industries.

On the other hand, in-tank blending entails sequentially introducing measured volumes of each component into a tank, followed by mixing, sampling, quality analysis, and potential adjustments to the blend. While this method is time-consuming and requires storage of pre-blended and finished products, it can still be a cost-effective option, especially for small volumes and specific applications.

Density Trim Blenders

Ratio Control Blenders

Viscosity Trim Blenders

Density Trim Blenders

Density or API gravity trim blenders are used for blending liquid hydrocarbons when the feedstock quality is inconsistent due to varying supply or product layering in tanks. These blenders are particularly suitable when the main parameter of importance in the final blended product is density.

In the case of an in-line density trim blender, the final product is produced based on a component ratio in the recipe. However, to continuously optimize the quality of the final product during the batch, a densitometer analyzer mounted at the exit to the blend header is used. This ensures that the density of the final product is maintained within the desired range throughout the blending process.

This method of in-line density monitoring and adjustment allows for greater precision and control over the blending process, resulting in a final product with consistent and accurate density characteristics

Product quality is maintained during the batch by the closed loop control between the flow signals from the field equipment (flow meters, pressure, temperature sensors and densitometer) and the control signals from the controller back to the field equipment. The accuracy of the blender is determined by the accuracy of the density measurement and control system. All blenders are designed to minimize heating, noise and other process variations, which can affect density measurements.

The field equipment:

The field equipment (valves, meters and densitometer etc) enable the components to be simultaneously metered into the lend header to produce the final blended product. Products normally exit the blend header through a mixer to ensure that a homogenous product is delivered at all times. This also provides an ideal location for an automatic sampler. The field equipment for every blender is selected to ensure minimal pressure drop and maximum reliability.

The control system:

The real-time control system monitors the outputs from the field equipment (flow rates, etc), performs calculations for meter linearization, temperature compensation, etc. and feeds back appropriate control signals to the field equipment to maintain the blending process within the required parameters (i.e. closed-loop control).

The controller has unique self-learning control algorithms that instantly respond to changes in process conditions or feedstock quality and the components are continuously measured and adjusted during the batch to ensure optimum quality and minimum give-away. Blended products are volume corrected to standard conditions using API 2540 / IP 200. Loading and blend documentation can be automatically produced in volume or mass units by the controller.

Sensia's density trim blenders are designed to ensure consistent quality throughout the batch even during tank changes, feedstock starvation, loss of power or the unlikely failure of a system component. All of our density trim blenders are supplied fully skid mounted, piped, wired and tested ready for installation at your site and guaranteed to perform to your specifications.

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Ratio Control Blenders

Ratio control blenders are well-suited for liquid hydrocarbon blending applications where the feedstock quality is consistent and known. These blenders are designed to produce a final blended product with an extremely accurate component ratio, determined by the flow meters and the efficiency of the control system. They can achieve impressive accuracy, often better than +/- 0.25% over the full metering range.

In a ratio control blender, the component ratio is maintained throughout the batch by employing closed-loop control between the flow signals from the field equipment (such as flow meters, pressure, and temperature sensors) and the control signals from the controller back to the field equipment. This ensures that the desired component ratio is consistently and precisely maintained at all times during the blending process.

By leveraging closed-loop control and accurate flow measurement, ratio control blenders enable the production of final blended products with highly precise and consistent component ratios.

The field equipment

The field equipment (valves and meters etc) enable the components to be simultaneously metered into the lend header to produce the final blended product. Products normally exit the blend header through a mixer to ensure that a homogenous product is delivered at all times. This also provides an ideal location for an automatic sampler. The field equipment for every blender is selected to ensure minimal pressure drop and maximum reliability.

The control system

The real-time control system continuously monitors the outputs from field equipment, such as flow rates, and performs various calculations for meter linearization, temperature compensation, and more. The system then provides feedback in the form of control signals to the field equipment to maintain the blending process within the required parameters, effectively operating in a closed-loop control fashion.

The controller's self-learning control algorithms are particularly noteworthy as they instantly respond to changes in process conditions, ensuring that the components are continuously measured and adjusted during the batch to optimize quality and minimize product giveaway.

Additionally, the blending process seems to include volume correction to standard conditions using API 2540 / IP 200, and the system can automatically produce loading and blend documentation in either volume or mass units as required.

Furthermore, the robust design of the system ensures consistent quality throughout the batch, even in scenarios such as tank changes, feedstock starvation, loss of power, or potential system component failures.

It's also great to know that the viscosity trim blenders are supplied fully skid-mounted, piped, wired, and tested, ready for installation at the site, and guaranteed to perform to specifications

All Sensia's ratio control blenders are supplied fully skid mounted, piped, wired and tested ready for installation at site and guaranteed to perform project specifications.

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Viscosity Trim Blenders

Viscosity trim blenders, which are indeed suitable for blending liquid hydrocarbons when the feedstock quality varies due to inconsistent supply or tank layering. These blenders are particularly useful when viscosity is the main parameter of importance in the blended product.

In-line blender produces the final product based on a component ratio in the recipe, with a viscosity analyzer continuously optimizing the product quality.

This is achieved through closed-loop control between the flow signals from field equipment (flow meters, pressure, temperature sensors, and viscometer) and the control signals from the controller back to the field equipment. The accuracy of the blender relies on the accuracy of the viscosity measurement and control system. Additionally, all blenders are designed to minimize heating, noise, and other process fluctuations that could affect viscometer measurements.

The field equipment

The field equipment (valves, meters and viscometer etc) enable the components to be simultaneously metered into the lend header to produce the final blended product. Products normally exit the blend header through a mixer to ensure that a homogenous product is delivered at all times. This also provides an ideal location for an automatic sampler. The field equipment for every blender is selected to ensure minimal pressure drop and maximum reliability.

The control system

Real-time control system is effectively monitors and processes outputs from field equipment, such as flow rates, and applies various calculations like meter linearization and temperature compensation. This system then provides control signals back to the field equipment to maintain the blending process within the required parameters, effectively operating in a closed-loop control manner.

Moreover, the controller features unique self-learning control algorithms that can promptly adapt to changes in process conditions or feedstock quality. The components are continuously measured and adjusted during the batch to ensure optimal quality and minimal giveaway. Additionally, the blended products are volume corrected to standard conditions using API 2540 / IP 200, and the controller can automatically produce loading and blend documentation in volume or mass units.

Sensia's viscosity trim blending systems are designed to ensure consistent quality throughout the batch even during tank changes, feedstock starvation, loss of power or the unlikely failure of a system component. All of our viscosity trim blenders are supplied fully skid mounted, piped, wired and tested ready for installation at your site and guaranteed to perform to your specifications.

Viscosity trim blenders can be skid mounted (for installation on a barge, jetty or shore), mounted in a container offering a portable, safe working environment or self-contained on a trailer allowing one blender to be used at multiple locations.

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Blending System

Density Trim Blenders

Ratio Control Blenders

Viscosity Trim Blenders

Density Trim Blenders

Ratio Control Blenders

Viscosity Trim Blenders