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7/23/2019 File 2 PCM New Advances in PCP Elastomer
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PCP Workshop – Houston 04/19/2004
Elastomers Elastomers
Natural rubber is the sap from hevea brasilensis. It has been used for
many years by the Amazonian Indians but didn’t find industrial
applications before the beginning of the nineteenth century.
After the second world war, American chemists synthesized polyisoprene
and successively all elastomers known at the present time.
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Elastomers Elastomers
Elastomers belong to the huge
polymers family.
A polymer is a chemical
combination of small molecules,
called monomers. They form longmacromolecular chains tangled
together.
Isoprene
monomer
Polymer
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FillersFillers
Elastomer compounds need to be reinforced to increase their mechanical
properties such as hardness, tensile strength or compression moduli.
The main filler is carbon black.
Graphite
Elementary particle
Agglomerate
Aggregate
Elastomers are made of linear chains of carbon
atoms so they can link very easily with the carbon
black particles. When several macromolecules are
linked to the same aggregate they are jammedtogether, increasing the cohesion of the material.
Size and structure of the carbon black particles give
different behaviours of the compounds. Smaller is
the particle, higher is the structural cohesion.
Other fillers can be used such as silica, talc, kaolin,
chalk or calcium carbonate but their reinforcement
is lower.
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Plasticizers Plasticizers
Plasticizers lead to a decrease of hardness and modulus butan increase of elongation at break .
They are necessary to make mixing and moulding operationseasier by allowing the macromolecules of polymer to slide
on each other.
They are made of different mineral or vegetal oil to fit with
each type of elastomer.
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Curing Curing agentsagents
To keep their shape from moulding, elastomers must be cured or
vulcanised.
Vulcanisation is the creation of cross links between the polymer chains
to reduce their movements.
Cross linking is obtained by the action of sulphur or peroxide under
appropriate temperature and pressure.
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Miscellaneous Miscellaneous
Processing aids.
Protectors to improve the storage life.
Hardening or softening resins.
Pigments, blowing agents, flame retardant, insulating
components…
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NewNew advances advances in PCPin PCP
elastomers elastomers technology technology
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Content Content
Introduction
1- Compound formulation
2- Elastomers for oil industry
3- Elastomer development procedure
Conclusions
Questions
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Introduction Introduction
1930 : The University of Paris awards René Moineau,
a doctorate of science for its work on “new capsulism”
groundwork of the progressive cavity technology.
1932 : Foundation of PCM by René Moineau and Robert
Bienaimé inside the GEVELOT group.
René Moineau was convinced that the elastomer part was the heart of the
progressing cavity pump and decided that PCM has to master this
technology from conception to manufacturing.
Since that day, PCM is following his strategy by developing new elastomer
formulations to fit the various evolutions of pumping conditions.
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11-- Compound formulationCompound formulation
Elastomer 60 %
Fillers 20 %
Plasticizers 5 %
Curing agents 10 %
Miscellaneous 5 %
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11-- Compound formulationCompound formulation
- 10 to 20 components in a formulation.
- Thousands of possible combinations -type, quantity.
- Chemical modifications during vulcanisation.
- No possible predictions on the behaviour of a compound.
Empirical science where experience and knowledge of the
applications are the key factors.
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22-- Elastomers Elastomers for for oil oil industryindustry
3 types of elastomers can be used for oil applications :
NBR Suitable for medium and heavy oil, sand, gas.
HNBR Suitable for high temperatures -SAGD-, sand.
FKM Suitable for light oil -high aromatic content.
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22-- Elastomers Elastomers for for oil oil industryindustry
butadiene
H
NC
))( (C CC CC C
H
HH
H
HH
H
H
Acrylonitrile
(18 to 50%)
NBR
Tmax = 260 F
Mechanical properties : excellent
Abrasion resistance : good
Chemical resistance to light aromatic solvents : limited
Gas resistance : limited for CO2
and poor for H2S
Explosive decompression resistance : good
Manufacturing : easy
PCM’s references : 159, 194, 199, 205.
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22-- Elastomers Elastomers for for oil oil industryindustry
saturated
butadiene
Acrylonitrile
(18 to 45%)
N
C
H
H
C
H
H H
C
))( ( CC C
H
HH
H
C
H
H
HNBR
Tmax = 300 F
Mechanical properties : good
Abrasion resistance : excellent
Chemical resistance to light aromatic solvents : limited
Gas resistance : good for CO2
and excellent for H2S
Explosive decompression resistance : limited
Manufacturing : easy
PCM’s reference : 198.
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22-- Elastomers Elastomers for for oil oil industryindustry
FKM
Chemical resistance to light aromatic solvents : excellent
Mechanical properties : limited
Tmax = 175 F (static use 400 F)
Abrasion resistance : poor tetrafluoroethylene
)( C
H
H
C
C
C C C C )(
F
F
F
F F
FF
) (F
FF
F
F
Vinilydenefluoride
hexafluoropropylene
Gas resistance : poor for CO2 but excellent for H
2S
Explosive decompression resistance : limited
Manufacturing : difficult
PCM’s reference : 204.
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22-- Elastomers Elastomers for for oil oil industryindustry
We need to enhance the behaviour of elastomers under severe physical -
pressure, temperature, speed, abrasion… - and chemical - monoaromaticsolvents, H2S… - conditions.
FKM
NBR
HNBR
Mechanical properties
Chemical resistance
T e m p e r a t u
r e r e s i s t a n c e
Abrasion resistance
H 2 S
r e s i s t a n c e
Limits of use
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33-- Elastomer Elastomer development development procedure procedure
1- Discovery of a specific need.
Widen the PCPs field applications.
2- Turn the application strains into specifications.
Rheological properties :
Injection and curing parameters : ML, T S2 , T 90…
Mechanical properties :
Tensile properties : tensile strength, elongation at break, moduli, tear strength…
Hardness
Compression modulus
Compression set
Abrasion loss
Sliding friction
Adhesion (peeling test)
Chemical compatibility :
Volumic swelling and hardness change after 14 days in fluid immersion.
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33-- Elastomer Elastomer development development procedure procedure
3- Create a formula and mix the different components.
Improve the compromise between mechanical and chemical resistance.
Choose the elastomer type :
NBR Easily attack by H2S and limited in temperature resistance.
Too limited in mechanical properties.FKM
HNBR Best candidate but we need to improve its chemical resistance.
Find new formulation components to solve the chemical compatibility problem.
5- Repeat points 3 and 4 until the properties fit the specifications.
Mix all the components together in a special order.
4- Test the compound properties in the laboratory.
Modifying only one component in each trial if you want to see its influence on thecompound behaviour.
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33-- Elastomer Elastomer development development procedure procedure
6- Choose and codify the final formula.
Property unit NBR 1 NBR 2 FKM 1 FKM 2 HNBR1 Trial 1 Trial 2 Trial 3 206
Tensile strength MPa 23 20 9 8 25 19 17 18 18
Tear strength N/mm 48 44 19 19 46 58 35 37 40
Abrasion loss mg 850 760 2660 2130 460 720 650 680 640
Swelling in toluene % 110 83 12 15 134 57 47 40 37
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33-- Elastomer Elastomer development development procedure procedure
New compound 206
FKM
NBR
HNBR
FKM
NBR
HNBR
New compound 206
Mechanical properties
Chemical resistance
T e m p e r a t ur e r e s i s t a n c e
Abrasion resistance
H 2
S r e s i s t a n c e
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33-- Elastomer Elastomer development development procedure procedure
7- Industrialize the mixing operation.
8- Injection moulding of the various stators.
Injection parameters, injection and curing time, bonding, shrinkage…
9- Characterize the pumps on the bench test.Optimize the interference fit between rotor and stator to obtain the best compromise in
terms of flow rate and running life.
10-Test the running life of the new stators in real pumping conditions.
11- Sales introduction.
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ConclusionsConclusions
Development of a new elastomer is iterative and
needs a lot of lab studies and knowledge.
Industrialization is under way for first field trials.
This new elastomer will widen even more the use of
PCPs in oil fields.
Combined with the large volume PCPs recently
developed, PCP will become a major actor in
artificial lift.
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