A highly abrasion-resistant pipe lining material and method of making the same

Abstract

This invention relates to a high wear-resistant pipe lining material and its preparation method. The high wear-resistant lining material comprises 5-20 parts by weight of rubber, 5-10 parts by weight of chlorinated polyethylene (CPE), 60-90 parts by weight of linear low-density polyethylene (LLDPE), 0-10 parts by weight of high-density polyethylene (HDPE), 0.1-5 parts by weight of antioxidant, 5-20 parts by weight of filler, 0.01-5 parts by weight of initiator, 0.02-7 parts by weight of co-initiator, and 1-6 parts by weight of magnesium oxide. The high wear-resistant pipe lining material obtained by this invention can be used to transport fluids containing solid particles, and has the characteristics of good wear resistance and long service life.

Description

Technical Field

[0001] This invention relates to the field of new materials for pipe linings, and in particular to a high wear-resistant pipe lining material with memory function and its preparation method. Background Technology

[0002] For pipelines used to transport fluids, especially those containing solid particles, wear resistance is a crucial performance indicator. Pipelines with good wear resistance not only avoid frequent replacement and maintenance, extending their service life, but also facilitate the repair of existing metal pipelines and aging lines, making construction easier.

[0003] Chinese patent CN 111171275A discloses a polyurethane material for pipe lining resistant to sand and water abrasion, its preparation method, and its application. This patent describes casting polyurethane onto the inner wall of a pipe using a rotary casting process to create a pipe lining material resistant to sand and water abrasion. The polyurethane can be uniformly and firmly coated onto the inner wall of the pipe, exhibiting good wear resistance and not affecting the connection between pipe ends. However, the preparation of the polyurethane lining requires vacuum dehydration at 120-130℃ and drying at 100-120℃ for 6-8 hours, making it unsuitable for in-situ pipe repair.

[0004] Chinese patent CN109280271A discloses a heat-insulating and wear-resistant polypropylene composite material pipe for oil pipeline lining. This pipe contains 100 parts polypropylene, 5-15 parts modified hollow glass microspheres, 0.1-0.5 parts tetrakis[β(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid, 0.11 parts pentaerythritol ester, 0.05-0.5 parts tris(2,4-di-tert-butylphenyl) phosphite, and 1-6 parts styrene-butadiene rubber. This polypropylene composite material pipe exhibits excellent thermal insulation performance, heat corrosion resistance, good mechanical strength, and a low coefficient of water friction. However, this material lacks memory function and cannot be used for trenchless in-situ repair of damaged pipelines.

[0005] Open-cut repair of damaged pipelines is time-consuming, costly, and difficult to perform. Trenchless polymer lining repair, on the other hand, is easier to implement, significantly extends pipeline lifespan, and offers substantial economic benefits compared to open-cut metal pipeline replacement. Therefore, developing feasible trenchless pipeline repair lining materials and their preparation methods is of great importance. Summary of the Invention

[0006] To address the shortcomings and deficiencies of existing technologies, the primary objective of this invention is to provide a highly wear-resistant pipe lining material.

[0007] The second objective of this invention is to provide a highly wear-resistant pipe lining material with shape memory function.

[0008] The third objective of this invention is to provide a method for preparing a highly wear-resistant pipe lining material with shape memory function.

[0009] A high wear-resistant pipe lining material, the technical solution adopted in this invention is as follows:

[0010] The high wear-resistant pipe lining material of the present invention is composed of 5-20 parts by weight of rubber, 5-10 parts by weight of chlorinated polyethylene (CPE), 60-90 parts by weight of linear low-density polyethylene (LLDPE), 0-10 parts by weight of high-density polyethylene (HDPE), 0.1-5 parts by weight of antioxidant, 5-20 parts by weight of filler, 0.01-5 parts by weight of initiator, 0.02-7 parts by weight of co-initiator, and 1-6 parts by weight of magnesium oxide.

[0011] The rubber is selected from one or more of nitrile rubber (NBR), chloroprene rubber (CR), cis-butadiene rubber (BR), ethylene propylene rubber (EPR), trans-butadiene rubber (TBIR), trans-polyisoprene (TPI), trans-polybutadiene (TPB), styrene-butadiene rubber (SBR), butyl rubber (IIR), and brominated butyl rubber (BIIR), and the weight average molecular weight of the rubber is 200,000 to 1,500,000.

[0012] The weight-average molecular weight of the LLDPE, HDPE, and CPE is 250,000 to 1,000,000, and the chlorine content of the CPE is 20 to 50 wt%.

[0013] The antioxidant is selected from one or more of antioxidants 1010, 264, 2264, 2264S, MB, D, H, RD, AW, DOD, NBC, 4010, and 4-1-NA.

[0014] The filler is selected from one or more of carbon black, silica, calcium carbonate, magnesium hydroxide, calcium hydroxide, magnesium carbonate, carbon nanotubes, graphene, kaolin, talc, and montmorillonite, wherein the carbon black is one or more of N220, N330, N550, N660, N990, N110, N115, N234, N326, N339, N375, N539, N550, N750, and N880.

[0015] The initiator is selected from one or more of the following: peroxide initiators: ketal peroxide, benzoyl peroxide (BPO), dicumyl peroxide (DCP), di-tert-butyl peroxide, 2,5-dimethyl-2,5-di-tert-butyl peroxide, di(2,4-dichlorobenzoyl) peroxide, azo initiators, diethylenetriamine (DTA), tert-butyl perbenzoate (TPB), methylenebis(o-chloroaniline) (MOCA), and silane initiators.

[0016] The co-initiator is selected from one or more of the following: triallyl isocyanurate (TIAC), triallyl cyanurate (TAC), ethylene glycol dimethacrylate (EDMA), divinylbenzene (DVB), trimethylolpropane trimethacrylate (TMPTMA), trimethylolpropane triacrylate (TMPTA), styrene, maleic anhydride, pentaerythritol tetraacrylate, benzoquinone, hydroquinone, 1,2-polybutadiene, and thiourea.

[0017] This invention also provides a method for preparing a highly wear-resistant pipe lining material with shape memory function, specifically including the following steps:

[0018] (1) Add 5-10 parts of CPE, 60-90 parts of LLDPE and 0-10 parts of HDPE to a mixer, set the mixing temperature of the mixer to 90-130℃, the mixing speed to 30-100rpm, and mix for 2-15min; then add 0.1-5 parts of antioxidant and 1-6 parts of magnesium oxide to the mixer, mix for 5-30min, and let the mixture stand at room temperature for 0.1-3h.

[0019] (2) Add the mixture obtained in step (1) to a mixer, set the mixing temperature of the mixer to 90-120℃, the mixing speed to 30-100rpm, add 5-20 parts of rubber and mix for 2-25min, add 5-20 parts of filler and mix for 2-25min, and let the mixture stand at room temperature for 0.1-3h.

[0020] (3) Add the two-stage mixture obtained in step (2) into a mixer, set the mixing temperature of the mixer to 90-120℃, the mixing speed to 20-50rpm, add 0.01-5 parts of initiator and 0.02-7 parts of co-initiator, the three-stage mixing time is 1-10min, and the mixture is left at room temperature for 10-144h.

[0021] (4) Add the mixture from step (3) into a screw extruder. The temperature of the screw zone 1 is 120-145℃, the temperature of the second zone is 130-185℃, the temperature of the third zone is 140-185℃, and the temperature of the fourth zone is 140-185℃. Prepare the inner liner tube by melt extrusion.

[0022] (5) Pull the inner lining tube out of the machine head in step (4) at a speed of 20-1000 mm / min and a distance of 2-20 m. After cooling at room temperature, a pipe lining material with high wear resistance and shape memory function is obtained.

[0023] The advantage of this invention lies in the fact that the pipe lining material of this invention, which possesses shape memory and high wear resistance, exhibits shape memory after melt extrusion molding. It changes shape under the influence of temperature and external force, and can recover its original shape under stimulated temperatures. This shape memory characteristic of the high wear-resistant pipe lining material of this invention allows it to be applied to trenchless lining repair of oilfield pipelines and domestic water pipes, thereby avoiding the disadvantages of traditional pipeline repair methods that require excavation and off-site repair. Detailed Implementation

[0024] Comparative Example 1

[0025] Weigh out 100 parts of high-density polyethylene (HDPE) and 1 part of antioxidant RD according to the specified weight.

[0026] (1) Add HDPE to the internal mixer at a speed of 70 rpm and a temperature of 110°C for 10 minutes. Then add antioxidant to the internal mixer and mix for 10 minutes. Let the mixture stand at room temperature for 0.5 hours.

[0027] (2) The mixture of adhesive from step (1) is added to a screw extruder. The temperature of the screw zone 1 is 120°C, the temperature of zone 2 is 130°C, the temperature of zone 3 is 140°C, and the temperature of zone 4 is 150°C. The inner liner is prepared by melt extrusion.

[0028] (3) Pull the inner liner tube out of the machine head in step (2) at a speed of 20 mm / min and a distance of 10 m. After cooling at room temperature, the HDPE pipe is obtained.

[0029] Example 1

[0030] Weigh out the following components by weight: 20 parts of nitrile rubber (NBR), 10 parts of chlorinated polyethylene (CPE), 60 parts of linear low-density polyethylene (LLDPE), 10 parts of high-density polyethylene (HDPE), 15 parts of carbon black N330, 4 parts of magnesium oxide, 1 part of antioxidant RD, 0.03 parts of dicumyl peroxide (DCP), and 0.06 parts of co-initiator TAIC.

[0031] (1) Add CPE, LLDPE and HDPE to the internal mixer. The internal mixer speed is 70 rpm, the internal mixer temperature is 110℃, and the internal mixing time is 10 minutes. Then add antioxidant and magnesium oxide to the internal mixer and mix for 10 minutes. Mix evenly and discharge the rubber to obtain a first-stage compound. Let the first-stage compound stand at room temperature for 0.5 hours.

[0032] (2) Add the first-stage compound obtained in step (1) to the internal mixer, set the internal mixer temperature to 100℃ and the internal mixer speed to 60rpm, add NBR, internal mixer time to 10min, add carbon black, internal mixer for 10min, and obtain the second-stage compound. Let the second-stage compound stand at room temperature for 0.5h.

[0033] (3) Add the two-stage compound obtained in step (2) into the internal mixer, set the internal mixer temperature to 90℃, the internal mixer speed to 50rpm, and the internal mixer time to 5min, add the initiator and co-initiator, and discharge the compound after 5min to obtain the three-stage compound. Let the three-stage compound stand at room temperature for 24h.

[0034] (4) Add the compounded rubber from step (3) into the screw extruder. The temperature of the screw zone 1 is 120°C, the temperature of zone 2 is 130°C, the temperature of zone 3 is 140°C, and the temperature of zone 4 is 150°C. Prepare the inner liner tube by melt extrusion.

[0035] (5) The inner lining tube exported from the machine head in step (4) is pulled at a speed of 20 mm / min and a distance of 10 m. After cooling at room temperature, a high wear-resistant pipe lining material with shape memory function is obtained.

[0036] Example 2

[0037] Weigh out the following components by weight: 10 parts of nitrile rubber (NBR), 5 parts of chlorinated polyethylene (CPE), 80 parts of linear low-density polyethylene (LLDPE), 5 parts of high-density polyethylene (HDPE), 10 parts of kaolin, 4 parts of magnesium oxide, 1 part of antioxidant 264, 0.3 parts of bis(2,4-dichlorobenzoyl peroxide), and 0.6 parts of co-initiator ethylene glycol dimethacrylate (EDMA).

[0038] (1) Add CPE, LLDPE and HDPE into a mixer. The mixer speed is 90 rpm, the mixer temperature is 100℃, and the mixing time is 7 min. Then add antioxidant and magnesium oxide into the mixer and mix for 3 min. Mix evenly and discharge the rubber to obtain a first-stage compound. Let the first-stage compound stand at room temperature for 0.2 h.

[0039] (2) Add the first-stage compound obtained in step (1) to the internal mixer, set the internal mixer temperature to 100℃ and the internal mixer speed to 70rpm, add NBR, internal mixer time to 6min, add kaolin, internal mixer for 6min, and obtain the second-stage compound. Let the second-stage compound stand at room temperature for 0.2h.

[0040] (3) Add the two-stage compound obtained in step (2) into the internal mixer, set the internal mixer temperature to 90℃, the internal mixer speed to 50rpm, and the internal mixer time to 5min, add the initiator and co-initiator, and discharge the compound after 5min to obtain the three-stage compound. Let the three-stage compound stand at room temperature for 72h.

[0041] (4) Add the compounded rubber from step (3) into the screw extruder. The temperature of the screw zone 1 is 140°C, the temperature of zone 2 is 150°C, the temperature of zone 3 is 160°C, and the temperature of zone 4 is 170°C. Prepare the inner liner tube by melt extrusion.

[0042] (5) The inner lining tube exported from the machine head in step (4) is pulled at a speed of 50 mm / min and a distance of 20 m. After cooling at room temperature, a high wear-resistant pipe lining material with shape memory function is obtained.

[0043] The materials produced in Examples 1 and 2 were tested and compared with existing commercially available pipe lining materials. The results are shown in Table 1.

[0044] As can be seen from Examples 1 and 2, the high wear-resistant pipe lining material prepared by this patent exhibits increased hardness, improved tensile strength, and enhanced oil resistance. Compared with existing commercially available pipe lining materials, it demonstrates improved wear resistance and shape memory recovery functionality.

[0045] Table 1 Data from Examples 1 and 2

[0046]

Claims

1. A high wear-resistant pipe lining material, characterized in that, The inner lining material is composed of 5-20 parts by weight of nitrile rubber, 5-10 parts by weight of chlorinated polyethylene (CPE), 60-90 parts by weight of linear low-density polyethylene (LLDPE), 5-10 parts by weight of high-density polyethylene (HDPE), 0.1-5 parts by weight of antioxidant, 5-20 parts by weight of filler, 0.01-5 parts by weight of initiator, 0.02-7 parts by weight of co-initiator, and 1-6 parts by weight of magnesium oxide.

2. The high wear-resistant pipe lining material according to claim 1, characterized in that, The weight-average molecular weight of the LLDPE, HDPE, and CPE is 250,000 to 1,000,000, and the chlorine content of the CPE is 20 to 50 wt%.

3. The high wear-resistant pipe lining material according to claim 1, characterized in that, The antioxidant is selected from one or more of antioxidants 1010, 264, 2264, 2264S, MB, D, H, RD, AW, DOD, NBC, 4010, and 4-1-NA.

4. The high wear-resistant pipe lining material according to claim 1, characterized in that, The filler is selected from one or more of carbon black, silica, calcium carbonate, magnesium hydroxide, calcium hydroxide, magnesium carbonate, carbon nanotubes, graphene, kaolin, talc, and montmorillonite, wherein the carbon black is one or more of N220, N330, N550, N660, N990, N110, N115, N234, N326, N339, N375, N539, N550, N750, and N880.

5. The high wear-resistant pipe lining material according to claim 1, characterized in that, The initiator is selected from one or more of the following peroxide initiators: ketal peroxide, benzoyl peroxide (BPO), dicumyl peroxide (DCP), di-tert-butyl peroxide, 2,5-dimethyl-2,5-di-tert-butyl peroxide, bis(2,4-dichlorobenzoyl) peroxide, and tert-butyl peroxide (TPB).

6. The pipe lining material according to claim 1, characterized in that, The co-initiator is selected from one or more of the following: triallyl isocyanurate (TIAC), triallyl cyanurate (TAC), ethylene glycol dimethacrylate (EDMA), divinylbenzene (DVB), trimethylolpropane trimethacrylate (TMPTMA), trimethylolpropane triacrylate (TMPTA), styrene, maleic anhydride, pentaerythritol tetraacrylate, and 1,2-polybutadiene.

7. The high wear-resistant pipe lining material according to claim 1, characterized in that, The pipe lining material, after being melt-extruded, has shape memory function. It changes shape under the action of temperature and external force, and can recover its original shape under a stimulating temperature.

8. The high wear-resistant pipe lining material according to claim 1, characterized in that, The inner lining material is composed of the following components: 20 parts by weight of nitrile rubber (NBR), 10 parts by weight of chlorinated polyethylene (CPE), 60 parts by weight of linear low-density polyethylene (LLDPE), 10 parts by weight of high-density polyethylene (HDPE), 15 parts by weight of carbon black (N330), 4 parts by weight of magnesium oxide, 1 part by weight of antioxidant (RD), 0.03 parts by weight of dicumyl peroxide (DCP), and 0.06 parts by weight of co-initiator (TAIC); or The inner lining material is composed of the following components: 10 parts by weight of nitrile rubber (NBR), 5 parts by weight of chlorinated polyethylene (CPE), 80 parts by weight of linear low-density polyethylene (LLDPE), 5 parts by weight of high-density polyethylene (HDPE), 10 parts by weight of kaolin, 4 parts by weight of magnesium oxide, 1 part by weight of antioxidant 264, 0.3 parts by weight of bis(2,4-dichlorobenzoyl) peroxide, and 0.6 parts by weight of ethylene glycol dimethacrylate (EDMA) co-initiator.

9. The high wear-resistant pipe lining material according to claim 1, characterized in that, The aforementioned pipeline lining material is used for trenchless lining repair of oilfield pipelines and trenchless lining repair of domestic water pipes.

10. A method for preparing a high wear-resistant pipe lining material as described in any one of claims 1 to 7, characterized in that, Includes the following steps: (1) Add 5-10 parts CPE, 60-90 parts LLDPE, and 5-10 parts HDPE to the internal mixer, and set the mixing temperature of the internal mixer to 90-130°C. o C. The mixing speed is 30-100 rpm, and the mixing time is 2-15 min. Then, 0.1-5 parts of antioxidant and 1-6 parts of magnesium oxide are added to the mixing machine, and the mixing time is 5-30 min. The mixture is left at room temperature for 0.1-3 h. (2) Add the mixture obtained in step (1) to a mixer, set the mixing temperature of the mixer to 90-120℃, the mixing speed to 30-100rpm, add 5-20 parts of nitrile rubber and mix for 2-25min, add 5-20 parts of filler and mix for 2-25min, and let the mixture stand at room temperature for 0.1-3h. (3) Add the two-stage mixture obtained in step (2) into the internal mixer, set the internal mixer temperature to 90-120℃, the internal mixer speed to 20-50rpm, add 0.01-5 parts of initiator and 0.02-7 parts of co-initiator, the three-stage internal mixing time is 1-10min, and the mixture is left at room temperature for 10-144h. (4) Add the mixture from step (3) into a screw extruder. The temperature of the screw zone 1 is 120-145℃, the temperature of the second zone is 130-185℃, the temperature of the third zone is 140-185℃, and the temperature of the fourth zone is 140-185℃. Prepare the inner liner tube by melt extrusion. (5) Pull the inner lining tube out of the machine head in step (4) at a speed of 20-1000 mm / min and a distance of 2-20 m. After cooling at room temperature, a pipe lining material with high wear resistance and shape memory function is obtained.

Images