Composite Insulated Steam Pipes Without Vacuum Failure
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Solution Overview
Problem
Current steam pipe technology using archaic vacuum insulation is prone to hydrogen penetration, leading to vacuum loss and reduced thermal insulation effectiveness, resulting in operational issues and costly replacements in steam injection processes for enhanced oil recovery (EOR) methods.
Innovation Solution
Development of thermally insulating pipes with multiple fiber-reinforced composite layers and epoxy resin insulation, allowing for efficient heat retention and resistance to moisture and caustic environments, enabling the transportation of high-temperature fluids and steam over extended distances with improved durability and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If vacuum insulation technology is used in steam pipes, then thermal insulation performance is improved, but hydrogen penetration causes vacuum loss and insulation failure
Solution Approach 1:
The patent removes the vacuum environment from the insulation system and replaces it with a solid foam insulation material filled in the annular space between inner and outer pipes. This eliminates the vulnerability to hydrogen penetration while maintaining thermal insulation performance.
Solution Approach 2:
The patent changes the physical state of the insulation medium from a vacuum (absence of matter) to a solid foam material. This parameter change transforms the insulation mechanism from relying on vacuum integrity to relying on the thermal properties of the foam material, which is impervious to hydrogen penetration.
2Loss of energy
If thick insulation layers are used to maintain thermal performance, then heat retention is improved, but pipe weight and complexity increase
Solution Approach 1:
The patent uses foam insulation material that provides high thermal resistance with relatively low density. The composite structure of inner pipe, foam insulation, and outer pipe achieves effective thermal insulation without the excessive weight that would result from thick metal or traditional insulation layers.
Solution Approach 2:
The foam insulation material has a porous structure that provides high thermal resistance due to the trapped gas pockets within the foam matrix. This allows effective insulation with a compact thickness, reducing both weight and structural complexity compared to solid insulation materials of equivalent performance.
3Loss of energy
If traditional vacuum pipe systems are used, then initial insulation effectiveness is achieved, but operational lifespan is limited due to getter degradation
Solution Approach 1:
The patent replaces the limited-life vacuum system with a foam insulation material that has no consumable components. The foam is impervious to hydrogen and requires no maintenance or replacement, providing indefinite service life without the degradation issues inherent in vacuum-based systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new pipe design maintains thermal insulation integrity, reduces operational risks, and minimizes heat loss, ensuring consistent heat delivery to oil reservoirs while being lightweight, durable, and economically viable for EOR applications.
Implementation Method 1
a first insulation layer surrounding the first pipe layer configured to thermally insulate the inner pipe chamber
Implementation Method 2
multiple fiber-reinforced composite layers and epoxy resin insulation, allowing for efficient heat retention and resistance to moisture and caustic environments
Data Source
AI summary
Thermally insulating pipes are provided for use in the transportation of a heated substance, such as steam or a fluid. The thermally insulating pipes allow the substance traveling through the pipes to retain their heat during transport. The thermally insulating pipes may include one or more layers each of pipe and insulating material, which are overlapping and alternating in the thermally insulating pipe. An outer pipe layer is also provided on the thermally insulating pipe, which may have an increased thickness for threading, splicing or swedging the thermally insulating pipe.