Wear-Resistant Pump Steel Composition for Corrosive Fracking Fluids
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Solution Overview
Problem
Hydraulic fracturing pump components are prone to fluid leakage, failure, and mechanical malformation due to wear, corrosion, and degradation from exposure to abrasive and corrosive fracking fluids, leading to high replacement frequencies and costs, with stainless steel being cost-prohibitive and carbon steel having a short lifespan.
Innovation Solution
A resistant steel composition with specific alloying elements (3-4% nickel, 0.5-1.5% manganese, 12-13.4% chromium, 0.3-0.7% molybdenum, and <0.40% copper) is developed, which is processed through melting, refining, and purifying to enhance mechanical resilience, wear resistance, and corrosion resistance, while reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stainless steel is used for pump components, then wear resistance and corrosion resistance are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent modifies the chemical composition parameters of steel by precisely controlling the content of alloying elements (nickel: 2.5-3.5%, chromium: 12-13.4%, manganese: 0.5-1.5%, molybdenum: 0.3-0.7%, copper: <0.40%, carbon: <0.05%) to achieve optimal mechanical properties and corrosion resistance while reducing manufacturing cost compared to traditional stainless steel
Solution Approach 2:
The patent creates a composite steel alloy by combining multiple elements in specific proportions, where nickel provides mechanical resilience, chromium provides corrosion resistance, manganese enhances strength, molybdenum improves hardenability, and low copper content prevents brittleness, achieving a balance between performance and cost
2Ease of manufacture
If carbon steel alloy is used for pump components, then manufacturing cost is reduced, but lifespan decreases significantly
Solution Approach 1:
The patent significantly improves the lifespan of carbon steel by optimizing alloying element parameters, particularly increasing chromium content to 12-13.4% for enhanced corrosion resistance, nickel to 2.5-3.5% for mechanical resilience, and molybdenum to 0.3-0.7% for improved hardenability and strength, achieving up to 500% longer lifespan compared to conventional carbon steel
Solution Approach 2:
The patent applies different functional properties to different aspects of the steel material: nickel concentrates on mechanical resilience and toughness, chromium focuses on corrosion and oxidation resistance, manganese targets strength and hardness, and molybdenum enhances hardenability, creating localized quality improvements throughout the material structure
3Strength
If higher alloying element content is added to steel, then mechanical resilience and wear resistance are improved, but manufacturing cost increases
Solution Approach 1:
The patent optimizes the balance between strength and cost by precisely controlling alloying element parameters: nickel at 2.5-3.5% for mechanical resilience, chromium at 12-13.4% for corrosion resistance, manganese at 0.5-1.5% for strength enhancement, and molybdenum at 0.3-0.7% for hardenability, avoiding excessive additions that would increase cost without proportional benefit
Solution Approach 2:
The patent uses a cost-effective steel composition that, while not as expensive as high-grade stainless steel, provides sufficient durability for hydraulic pump applications, replacing the need for expensive stainless steel components while maintaining acceptable service life through optimized rather than maximal alloying
Data Source
AI summary
The present disclosure relates to a resistant steel composition comprising a nickel content from about 3% MB to about 4% MB; a manganese content from about 0.5% MB to about 1.5% MB; a chromium content from about 12% MB to about 13.4% MB; a molybdenum content from about 0.3% MB to about 0.7% MB; and a copper content of less than about 0.40% MB. In some embodiments, the present disclosure relates to a process for generating a resistant steel composition, the process comprising melting one or more resistant steel components together to form a melted steel; refining the melted steel to form a refined steel; and purifying the refined steel to form the resistant steel composition.