Polymer-Blend Sealing Element for Subzero CCUS Pressure Sealing
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Solution Overview
Problem
Existing elastomers used in hydrocarbon recovery, such as NBR, HNBR, FKM, and FEFM, have limited low temperature service and glass transition temperatures above −60°C, making them unsuitable for extreme low temperature applications like CCUS sealing where adiabatic cooling can reach −80°C.
Innovation Solution
A polymer blend of non-polar elastomers like EPDM with low temperature elastomers like silicone is used, balancing strength and flexibility to achieve a glass transition temperature below −60°C, suitable for CCUS applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional elastomers (NBR, HNBR, FKM, FEPM) are used for sealing, then mechanical strength and hydrocarbon resistance are maintained, but low temperature service capability deteriorates with glass transition temperatures above −60°C
Solution Approach 1:
The patent applies composite materials by blending EPDM elastomer (providing mechanical strength and hydrocarbon resistance) with silicone elastomer (providing low temperature flexibility with Tg below −60°C). This composite approach allows the sealing element to simultaneously achieve adequate mechanical properties and extreme low temperature service capability, resolving the contradiction between strength and temperature performance.
Solution Approach 2:
The patent changes the chemical composition parameters of the elastomer by incorporating silicone content ranging from 5-95 weight percent into the EPDM matrix. This parameter modification adjusts the glass transition temperature of the blending polymer to below −60°C while maintaining sufficient mechanical strength through the EPDM continuous phase, directly addressing the temperature-strength contradiction.
2Adaptability or versatility
If non-polar elastomers are used for CCUS applications, then hydrocarbon exposure compatibility is improved, but low temperature service capability remains limited with Tg values of −60°C or higher
Solution Approach 1:
The patent creates a composite elastomer system combining non-polar EPDM (compatible with hydrocarbon environments) and polar silicone (providing low temperature flexibility). This composite structure enables the sealing element to adapt to CCUS conditions with hydrocarbon compatibility while achieving glass transition temperatures below −60°C through the silicone component, resolving the adaptability-temperature contradiction.
Solution Approach 2:
The patent modifies the elastomer composition by incorporating silicone content from 5-95 wt% into the non-polar EPDM matrix, changing the thermal parameters (Tg below −60°C) while maintaining hydrocarbon exposure compatibility through the EPDM continuous phase. This parameter change enables simultaneous achievement of adaptability and low temperature performance.
3Strength
If elastomers with high glass transition temperature are used, then mechanical integrity is maintained, but sealing performance at extreme low temperatures (approaching −80°C) deteriorates
Solution Approach 1:
The patent employs composite materials where EPDM elastomer provides the mechanical integrity framework and silicone elastomer provides low temperature sealing capability. The blending polymer structure ensures that at extreme low temperatures approaching −80°C, the silicone component remains flexible enough to maintain sealing reliability while the EPDM matrix preserves mechanical strength, resolving the strength-sealing performance contradiction.
Solution Approach 2:
The patent changes the glass transition temperature parameter of the elastomer composition by incorporating silicone content ranging from 5-95 wt%, achieving Tg below −60°C. This parameter modification enables the sealing element to maintain both mechanical integrity through the EPDM phase and reliable sealing performance at extreme low temperatures through the flexible silicone phase.
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 polymer blend provides enhanced low temperature sealing performance and mechanical integrity, enabling effective sealing in extreme low temperature environments with high pressure differentials.
Implementation Method 1
most of the common materials used in sealing applications have glass transition temperature (Tg) values of −60° C. or higher limiting their service at the extreme low temperature potentials in CCUS sealing applications
Implementation Method 2
adiabatic cooling may result in extreme low localized temperatures approaching −80° Celsius (C.)
Data Source
AI summary
An apparatus comprises a sealing element for a carbon sequestration in a location that is within a subsurface formation, wherein the sealing element is composed of a non-polar elastomer blended and co-cured with a low temperature elastomer having a glass transition temperature that is lower than a glass transition temperature of the non-polar elastomer.