Fluoropolymer Insulation Layer for High-Temperature Offshore Conduits
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Solution Overview
Problem
Conventional thermal insulation layers for transport conduits in offshore, deep water environments fail to maintain temperature above 200°C, requiring crosslinked thermoset materials that increase complexity and cost, and are not effective in preventing hydrate and wax formation in transported liquids.
Innovation Solution
A thermoplastic fluoropolymer composition with a fluoroplastic polymer content of at least 50 parts by weight and a fluoroelastomer content of 20 to 50 parts by weight, applied as a melt processable layer via extrusion, providing thermal insulation with a conductivity of less than 0.20 W/mK at 205°C without the need for crosslinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional thermal insulation layers are used, then they provide thermal insulation, but they fail to maintain temperature above 200°C and require crosslinking processes that increase complexity and cost
Solution Approach 1:
The patent changes the material parameters by developing a thermoplastic fluoropolymer composition with specific compositional ratios (fluoroplastic polymer 40-80 wt%, fluoroelastomer 20-60 wt%, fluorinated elastomer 10-40 wt%) that enables the insulation layer to maintain temperatures above 200°C without crosslinking. This parameter change in material composition resolves the contradiction by achieving high-temperature performance through compositional optimization rather than complex crosslinking processes.
Solution Approach 2:
The patent applies composite materials by creating a multi-component fluoropolymer system combining fluoroplastic polymer, fluoroelastomer, and fluorinated elastomer. This composite approach achieves superior thermal insulation performance at high temperatures while maintaining thermoplastic processability, eliminating the need for crosslinking and reducing application complexity.
2Reliability
If crosslinked thermoset materials are used for thermal insulation, then temperature maintenance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the crosslinking requirement from the thermal insulation system by developing a thermoplastic fluoropolymer composition that achieves equivalent or superior thermal insulation effectiveness without crosslinking. This extraction simplifies manufacturing by eliminating complex crosslinking processes while maintaining reliability for high-temperature applications.
Solution Approach 2:
The patent changes the chemical state parameter from crosslinked thermoset to thermoplastic, while compensating for potential performance losses through optimized compositional parameters. The specific ratio of fluoroplastic polymer (40-80 wt%), fluoroelastomer (20-60 wt%), and fluorinated elastomer (10-40 wt%) ensures thermal insulation effectiveness matches or exceeds crosslinked materials, while enabling simpler extrusion-based manufacturing.
3Object-affected harmful factors
If conventional thermal insulation layers are used, then they provide basic insulation, but they are not effective in preventing hydrate and wax formation in transported liquids
Solution Approach 1:
The patent uses composite materials combining fluoroplastic polymer, fluoroelastomer, and fluorinated elastomer to achieve superior thermal insulation performance that effectively prevents hydrate and wax formation. The synergistic combination of these components provides enhanced thermal properties that outperform conventional single-material insulation layers, directly addressing the harmful effect of hydrate and wax formation while maintaining high reliability.
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 solution effectively maintains temperature above 200°C, prevents hydrate and wax formation, and offers excellent mechanical properties, thermal insulation, and stability, suitable for depths exceeding 1,000 meters, while reducing complexity and cost by avoiding crosslinking processes.
Implementation Method 1
The fluoropolymer composition has a thermal conductivity less than about 0.20 W/mK at 205° C.
Implementation Method 2
The method also includes extruding the melt processable fluoropolymer composition to form the thermal insulation layer about the outer surface of the pipe of the conduit.
Data Source
AI summary
An insulated conduit for use in offshore, deep water environments includes a pipe and a fluoropolymer composition. The pipe has an outer surface with the fluoropolymer composition disposed about the outer surface of the pipe for providing a thermal insulation layer. The fluoropolymer composition includes a fluoroplastic polymer present in an amount of at least 50 parts by weight based on 100 parts by weight of the fluoropolymer composition. The fluoropolymer composition also includes a fluoroelastomer present in an amount of a fluoroelastomer present in an amount of from about 20 to about 50 parts by weight based on 100 parts by weight of the fluoropolymer composition. The fluoropolymer composition has a thermal conductivity less than about 0.20 W/mK at 205° C.