CN116533602A - 一种油气矿用高性能pe复合导电管道及其制备方法 - Google Patents
一种油气矿用高性能pe复合导电管道及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种油气矿用高性能PE复合导电管道及其制备方法,PE复合导电管道为三层结构,内外层为PE导电层,中间层为PE承压层,内外层所用原料组分包括高密度聚乙烯、导电碳纳米管、导电碳纤维、超导电炭黑、无卤阻燃剂、超高分子量聚乙烯、增容剂、硅烷偶联剂和抗氧剂,中间承压层所用原料组分为高密度聚乙烯。将内外层所用原料组分按比例在高速混合机上预混后,通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中的内外层流道;中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层流道,挤出、冷却成型后即得PE复合导电管道。本发明工艺流程简单,得到的管道具有优异的导电和力学性能,且易于连接,满足油气矿输送用要求。
Description
技术领域
本发明属于塑料管道技术领域,具体涉及一种油气矿用高性能PE复合导电管道及其制备方法。
背景技术
油气矿输送管道已经形成金属、塑料以及钢塑复合等多个管道种类,但目前仍以金属钢管为主。钢管用于油气矿存在较多缺陷:一是耐磨性较差;二是安装运输不便,钢管的重量和刚性给运输、安装、敷设带来不便;三是易腐蚀生锈,尽管钢管厂家一直在寻找可行的电化学修饰工艺,来解决钢管内外壁的腐蚀问题,但收效甚微。因此人们一直在寻求钢管的替代品。在一定时期内,玻璃钢管曾在煤矿抽排领域的一定范围内得到了应用,但由于接头多、易泄漏,产品综合性能差,现在在煤矿中已经很少使用。
聚乙烯(PE)管道具有耐酸、耐碱、耐油、耐腐蚀、重量轻、柔性好、安装方便、服务年限长(约为钢的2.5倍)等优点,这是钢管、玻璃钢管所不能比拟的,并且随着改性技术发展和新型设备的迭代升级,PE优异的力学性能和耐环境性能也得到了更好的应用,是用于油气矿输送的理想材料。即使如此,PE用于油气矿输送还存在一些安全问题,这主要是因为在油气矿输送过程中,塑料管材与其它介质的接触摩擦会导致材料表面产生静电荷,静电荷放电易产生火花,一旦出现放电以及火花的产生,就有可能导致火灾事故的发生。
一般情况下认为表面电阻达到108Ω,就有可能发生放电并且产生火花,而PE为非极性绝缘材料,表面电阻高达1015~1017Ω。因此为了杜绝事故的发生,一般要求材料表面电阻低于105Ω以下。市面上的PE管道虽然可实现表面电阻不高于105Ω,但导电剂添加量太高(15%~25%之间),管道综合力学性能下降明显,在实际应用中难以达到油气矿输送的要求,主要归结于改性材料的用量和设备的选用问题。为使油气矿输送用塑料管道安全地、可靠地替代钢管,有必要进行导电和力学性能方面的改性研究。有研究表明(高分子材料体积拉伸流变加工技术进展,全婷婷、黄照夏、肖和平、瞿金平,塑料,2020,49(02):85-89+94.),与传统螺杆塑化输运技术相比,体积拉伸流变塑化输运技术在多组分塑料共混增容改性、有机无机杂化功能改性和热塑性塑料纤维增强改性等方面,具有强制增容效果好、混合分散效果优、纤维折损断裂少等显著优势,因此非常适合PE管道改性。
发明内容
针对上述不足,本发明的目的提供一种油气矿用高性能PE复合导电管道及其制备方法。本发明所得到的管道具有高强度、高韧性、高导电等特性,特别适用于苛刻环境条件下的油气矿输送。实现上述发明目的的具体技术方案如下:
本发明提供一种油气矿用高性能PE复合导电管道及其制备方法,PE复合导电管道设计成三层结构,内外层(1,3)为PE导电层,中间层(2)为PE承压层。
所述内外层所用原料包括以下重量份数的组分:高密度聚乙烯100份,导电碳纳米管1-2份,导电碳纤维0.5-2份,超导电炭黑5-10份,超高分子量聚乙烯(UHMWPE)10-20份,无卤阻燃剂15-25份,增容剂2-5份,硅烷偶联剂0.3-0.5份,抗氧剂0.5-1份。
所述承压层所用原料为高密度聚乙烯(HDPE)。
所述超高分子量聚乙烯的分子量在250-500万之间。
所述无卤阻燃剂按重量份数计包括硅系阻燃剂聚硅氧烷2-5份、磷氮系阻燃剂10-15份、成炭剂3-5份,磷氮系阻燃剂为聚磷酸铵、三聚氰胺聚磷酸盐或聚磷腈中的一种或两种以上的组合,成炭剂为热塑性酚醛树脂或聚酰胺中的一种。
所述增容剂为乙烯-丙烯酸共聚物(EAA)、乙烯-丙烯酸甲酯共聚物(EMA)、乙烯-丙烯酸乙酯(EEA)、乙烯-丙烯酸丁酯(EBA)和乙烯-醋酸乙烯酯(EVA)中的一种或两种以上的组合,用以提高助剂与基体树脂,以及复合管各层之间的相容性。
所述抗氧剂为抗氧剂1010、330和168中的一种或两种以上的组合。
所述一种油气矿用高性能PE复合导电管的制备方法,包括如下步骤:
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合;
2)PE复合导电管管坯挤出:将1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中内外层,中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,挤出得PE复合导电管管坯;
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
所述步骤1)中的高速混合机的转速为700-1400r/min。
所述步骤2)中的拉伸流变挤出机的机筒温度为220-240℃,机头温度为220-240℃,熔体温度≤240℃。
所述步骤2)中的螺杆挤出机的机筒温度为180-220℃,优选200-220℃;机头温度为180-220℃,优选温度200-220℃,熔体温度≤220℃。
本发明的有益效果在于:①使用体积拉伸流变挤出机混炼挤出,可以在不破坏材料结构的情况下,使各组分原料有效地分散在基体树脂中;②利用碳纳米管、碳纤维、超导电炭黑微观结构上的特异性相互作用形成有效的导电通道,实现材料的高导电性能;③在此基础上使用超高分子量聚乙烯可以改善复合管道的耐磨性能;④三层复合结构可以保证管道既具有高的导电性能,又具有优异的力学性能;⑤易于连接可以采用传统PE管材连接方式进行连接。
具体实施方式
为了使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解,下面结合具体实施例和性能测试结果,进一步阐述本发明,但下述实施例仅为本发明的部分优选实施例,并非全部。基于实施方式中的实施例,本领域技术人员在没有做出创造性劳动的前提下所获得其他实施例,都属于本发明的保护范围。
实施例1
内外导电层原料:HDPE 100份,导电碳纳米管1份,导电碳纤维1份,超导电炭8份,聚硅氧烷3份,聚磷酸铵12份,聚酰胺4份,分子量为250万的UHMWPE 20份,EAA3份,硅烷偶联剂0.3份,抗氧剂1010 0.3份,抗氧剂1680.2份。中间承压层原料:HDPE。
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合,转速700r/min。
2)PE复合导电管管坯挤出:将1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中内外层,机筒温度为220℃,机头温度为220℃,熔体温度220℃;中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,机筒温度为200℃,机头温度为200℃,熔体温度200℃,挤出即得PE复合导电管管坯。
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
实施例2
内外导电层原料:HDPE 100份,导电碳纳米管2份,导电碳纤维1份,超导电炭6份,聚硅氧烷5份,三聚氰胺聚磷酸盐10份,热塑性酚醛树脂3份,分子量为250万的UHMWPE 20份,EBA5份,硅烷偶联剂0.5份,抗氧剂330 0.3份,抗氧剂168 0.3份。中间承压层原料:HDPE。
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合,转速1000r/min。
2)PE复合导电管管坯挤出:将1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中内外层,机筒温度为230℃,机头温度为230℃,熔体温度230℃;中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,机筒温度为210℃,机头温度为210℃,熔体温度210℃,挤出即得PE复合导电管管坯。
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
实施例3
内外导电层原料:HDPE 100份,导电碳纳米管2份,导电碳纤维0.5份,超导电炭10份,聚硅氧烷3份,聚磷酸铵15份,酚醛树脂3份,分子量为350万的UHMWPE 15份,EAA4份,硅烷偶联剂0.4份,抗氧剂1010 0.6份。中间承压层原料:HDPE。
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合,转速1000r/min。
2)PE复合导电管管坯挤出:将1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中内外层,机筒温度为230℃,机头温度为230℃,熔体温度230℃;中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,机筒温度为220℃,机头温度为220℃,熔体温度220℃,挤出即得PE复合导电管管坯。
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
实施例4
内外导电层原料:HDPE 100份,导电碳纳米管2份,导电碳纤维1份,超导电炭8份,聚硅氧烷4份,三聚氰胺聚磷酸盐12份,酚醛树脂4份,分子量为350万的UHMWPE 15份,EVA5份,硅烷偶联剂0.3份,抗氧剂1010 0.4份,抗氧剂168 0.3份。中间承压层原料:HDPE。
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合,转速1400r/min。
2)PE复合导电管管坯挤出:将1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中内外层,机筒温度为240℃,机头温度为240℃,熔体温度240℃;中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,机筒温度为220℃,机头温度为220℃,熔体温度220℃,挤出即得PE复合导电管管坯。
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
实施例5
内外导电层原料:HDPE 100份,导电碳纳米管1.5份,导电碳纤维1份,超导电炭9份,聚硅氧烷5份,聚磷腈15份,酚醛树脂4份,分子量为500万的UHMWPE 10份,EMA4份,硅烷偶联剂0.3份,抗氧剂1010 0.5份,抗氧剂168 0.2份。中间承压层原料:HDPE。
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合,转速1400r/min。
2)PE复合导电管管坯挤出:将1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中内外层,机筒温度为240℃,机头温度为240℃,熔体温度240℃;中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,机筒温度为220℃,机头温度为220℃,熔体温度220℃,挤出即得PE复合导电管管坯。
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
实施例6
内外导电层原料:HDPE 100份,导电碳纳米管2份,导电碳纤维1份,超导电炭8份,聚硅氧烷5份,聚磷腈12份,聚酰胺4份,分子量为500万的UHMWPE 10份,EEA5份,硅烷偶联剂0.3份,抗氧剂1010 0.5份,抗氧剂1680.2份。中间承压层原料:HDPE。
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合,转速1000r/min。
2)PE复合导电管管坯挤出:将1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中内外层,机筒温度为240℃,机头温度为240℃,熔体温度240℃;中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,机筒温度为220℃,机头温度为220℃,熔体温度220℃,挤出即得PE复合导电管管坯。
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
对比例1
管道的制备原料:HDPE。
1)将HDPE原料通过螺杆挤出机挤出得管坯,机筒温度为220℃,机头温度为220℃,熔体温度220℃。
2)冷却定型:将经过步骤1)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
3)切割:按照预设尺寸进行管道切割。
实施例1-6和对比例1所得管材的性能的检测结果如表1所示:
表1实施例1-6和对比例1的管材的性能检测结果汇总表
检测所用管材尺寸为dn110mm,SDR11(dn为管材外径,SDR为管材外径与壁厚之比)。拉伸屈服强度测试标准参考GB/T 8804.3-2003,爆破压力测试标准参考GB/T GB/T15560-1995,静液压强度测试标准参考GB/T 6111-2003,阻燃等级测试标准参考UL94,HDPE的性能数据以吉林石化的GC100S高密度聚乙烯测试结果为依据。从测试结果可以看出,本发明塑料管道表面电阻率低于105,阻燃等级均不低于V-1,力学性能高于常规HDPE管材,这些优异的性能使其可替代钢、玻璃钢等管道应用于油气矿输送。
Claims (10)
1.一种油气矿用高性能PE复合导电管道,其特征在于PE复合导电管道为三层结构,内外层为PE导电层,中间层为PE承压层,PE导电层所用原料包括以下重量份数的组分:高密度聚乙烯100份,导电碳纳米管1-2份,导电碳纤维0.5-2份,超导电炭黑5-10份,超高分子量聚乙烯10-20份,无卤阻燃剂15-25份,增容剂2-5份,硅烷偶联剂0.3-0.5份,抗氧剂0.5-1份。
2.如权利要求1所述的一种油气矿用高性能PE复合导电管道,其特征在于PE承压层所用原料为高密度聚乙烯。
3.如权利要求1所述的一种油气矿用高性能PE复合导电管道,其特征在于超高分子量聚乙烯的分子量在250-500万之间。
4.如权利要求1所述的一种油气矿用高性能PE复合导电管道,其特征在于无卤阻燃剂按重量份数计包括硅系阻燃剂聚硅氧烷2-5份、磷氮系阻燃剂10-15份、成炭剂3-5份,磷氮系阻燃剂为聚磷酸铵、三聚氰胺聚磷酸盐和聚磷腈中的一种或两种以上的组合,成炭剂为热塑性酚醛树脂或聚酰胺中的一种。
5.如权利要求1所述的一种油气矿用高性能PE复合导电管道,其特征在于增容剂为乙烯-丙烯酸共聚物、乙烯-丙烯酸甲酯共聚物、乙烯-丙烯酸乙酯、乙烯-丙烯酸丁酯和乙烯-醋酸乙烯酯中的一种或两种以上的组合。
6.如权利要求1所述的一种油气矿用高性能PE复合导电管道,其特征在于抗氧剂按为抗氧剂1010、330和168中的一种或两种以上的组合。
7.一种如权利要求1所述的油气矿用高性能PE复合导电管道的制备方法,其特征在于包括如下步骤:
1)内外层原料预共混:按照配比将内外层所用原料放入高速混合机中混合;
2)PE复合导电管管坯挤出:将步骤1)所得的预混料通过体积拉伸流变挤出机混炼塑化后输送至三层共挤模具中的内外层,中间层原料通过螺杆挤出机塑化后输送至三层共挤模具中的中间层,挤出得PE复合导电管管坯;
3)冷却定型:将经过步骤2)制成的管坯由履带式牵引机牵引导入真空冷却定型槽内,打开喷淋泵,进行冷却定型;
4)切割:按照预设尺寸进行管道切割。
8.如权利要求7所述的制备方法,其特征在于步骤1)中原料放入高速混合机中,混合机转速700-1400r/min。
9.如权利要求7所述的制备方法,其特征在于步骤2)中体积拉伸流变挤出机的机筒温度为220-240℃,机头温度为220-240℃,熔体温度≤240℃。
10.如权利要求7所述的制备方法,其特征在于步骤2)中螺杆挤出机的机筒温度为180-220℃,优选200-220℃;机头温度为180-220℃,优选温度200-220℃,熔体温度≤220℃。
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