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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.




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




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.




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.




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.




Miscellaneous Miscellaneous

Processing aids.

Protectors to improve the storage life.

Hardening or softening resins.

Pigments, blowing agents, flame retardant, insulating

components…




NewNew advances advances in PCPin PCP

elastomers elastomers technology technology




Content Content

Introduction

1- Compound formulation

2- Elastomers for oil industry

3- Elastomer development procedure

Conclusions

Questions




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.




11-- Compound formulationCompound formulation

Elastomer 60 %

Fillers 20 %

Plasticizers 5 %

Curing agents 10 %

Miscellaneous 5 %




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.




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.





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.





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.





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.





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




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.





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.





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





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





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.




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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