Aliphatic Polyketone Pipe Liners for High-Aromatic Flowlines

Solution Overview

Problem

Spoolable composite pipes and polymer-lined carbon steel pipes face limitations in temperature ratings and mechanical properties when exposed to high aromatic components, leading to reduced performance and the need for costly upgrades in oil and gas applications.

Innovation Solution

The use of aliphatic polyketones as a lining material in spoolable composite pipes and internally lined carbon steel pipes, which are configured to operate at temperatures up to 110°C and handle hydrocarbons with up to 35% aromatic content, providing enhanced mechanical properties and resistance to permeation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polyethylene polymers are used in liner layers and reinforcement, then ease of manufacture and cost are improved, but temperature rating and mechanical properties deteriorate when exposed to high aromatic components

Engineering Contradiction:

Improveease of manufactureVSAvoidtemperature rating

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent changes the chemical composition parameter of the liner material from polyethylene to aliphatic polyketone, which fundamentally alters the material's resistance to aromatic hydrocarbons and high-temperature stability, thereby resolving the contradiction between ease of manufacture and temperature rating

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material structure with aliphatic polyketone as the liner material that combines the benefits of processability with enhanced thermal and chemical resistance properties, achieving both ease of manufacture and high temperature rating

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If polyethylene polymers are used in liner layers, then ease of manufacture is improved, but mechanical properties and chemical resistance deteriorate when exposed to high aromatic components

Engineering Contradiction:

Improveease of manufactureVSAvoidmechanical properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent changes the chemical composition parameter of the liner material from polyethylene to aliphatic polyketone, which fundamentally alters the material's resistance to aromatic hydrocarbons and high-temperature stability, thereby resolving the contradiction between ease of manufacture and temperature rating

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material structure with aliphatic polyketone as the liner material that combines the benefits of processability with enhanced thermal and chemical resistance properties, achieving both ease of manufacture and high temperature rating

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If polyethylene polymers are used in liner layers, then ease of manufacture is improved, but permeation resistance deteriorates in sour environments

Engineering Contradiction:

Improveease of manufactureVSAvoidpermeation resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the chemical composition parameter of the liner material from polyethylene to aliphatic polyketone, which fundamentally alters the material's resistance to aromatic hydrocarbons and high-temperature stability, thereby resolving the contradiction between ease of manufacture and temperature rating

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material structure with aliphatic polyketone as the liner material that combines the benefits of processability with enhanced thermal and chemical resistance properties, achieving both ease of manufacture and high temperature rating

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If polymer-lined carbon steel pipes are used, then ease of manufacture is improved, but operating temperature is limited due to swelling and plasticization effects

Engineering Contradiction:

Improveease of manufactureVSAvoidmaximum allowable operating temperature

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent changes the chemical composition parameter of the liner material from polyethylene to aliphatic polyketone, which fundamentally alters the material's resistance to aromatic hydrocarbons and high-temperature stability, thereby resolving the contradiction between ease of manufacture and temperature rating

Inventive Principle:

Principle #35Parameter changes

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

Aliphatic polyketones maintain desirable mechanical properties and prevent permeation in high-temperature, high-aromatic environments, extending the maximum allowable operating temperature and reducing material costs by offering improved chemical resistance and barrier performance.

Implementation Method 1

the permeation and resulting corrosion effects of such polymer-lined carbon steel pipes limit their maximum allowable operating temperatures

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

The swelling and plasticization effects of polyethylene polymers used in liners in polymer-lined carbon steel pipes used in the presence of aromatic crude

Methodology Applied

Scientific EffectSwelling:

Implementation Method 3

The swelling and plasticization effects of polyethylene polymers used in liners in polymer-lined carbon steel pipes used in the presence of aromatic crude

Methodology Applied

Scientific EffectPlasticization:

Data Source

PatentUS12169043B2Extruded aliphatic polyketone permeation barrier for spoolable composite pipes

Publication Date: 2024.12.17 SAUDI ARABIAN OIL CO

AI summary

Spoolable composite pipes for oil and gas flowlines may include an inner extruded tubular liner, a reinforcement layer surrounding the inner extruded tubular liner, and an outer extruded tubular cover surrounding the reinforcement layer. In these spoolable composite pipes, the inner extruded tubular liner may include an aliphatic polyketone. Internally lined pipes for oil and gas flowlines for oil and gas flowlines may include inner extruded tubular liner containing an aliphatic polyketone, and a carbon steel pipe surrounding the inner extruded tubular liner. The spoolable composite pipes and the internally lined pipes may be configured to operate at temperatures of up to about 110° C., and to carry hydrocarbons having an aromatic content of up to about 35% by volume of the total hydrocarbons content.