FRACTURING LIQUID DELIVERY HOSE FOR RECOVERY OF SHALE OIL AND GAS, AND MANUFACTURING METHOD AND CO-EXTRUSION MOLD THEREOF

Abstract

A fracturing liquid delivery hose for recovery of shale oil and gas, and manufacturing method and co-extrusion mold thereof are provided. The method includes extrusion of a cover layer with a first adhesive layer and an inner lining layer with a second adhesive layer, formation of an enhancement layer, heating and pressurizing for bonding between the cover layer and the enhancement layer and between the inner lining layer and the enhancement layer, so that the formed fracturing liquid delivery hose has resistance at least to high pressure and chemical corrosion. The cover layer and the inner lining layer can use different types of materials.

Claims

1.-10. (canceled)

11. A method for manufacturing a liquid delivery hose, the method comprising: forming a first tube including a cover layer and a first adhesive layer, the first adhesive layer being attached outside the cover layer; forming a second tube including a lining layer and a second adhesive layer, the second adhesive layer being attached outside the lining layer; obtaining a third tube having an inner surface and an outer surface; forming a fourth tube by bonding the first adhesive layer of the first tube with the inner surface of the third tube; turning the fourth tube inside out such that the cover layer becomes an outer layer of the turned fourth tube and the outer surface of the third tube becomes an inner layer of the turned fourth tube; and forming the liquid deliver hose by bonding the second adhesive layer of the second tube with the inner layer of the turned fourth tube.

12. The method of claim 11, wherein forming a first tube including a cover layer and a first adhesive layer comprising: extruding, by a first part of a co-extrusion mold, a plurality of first particles to form the cover layer; extruding, by a second part of the co-extrusion mold, a plurality of second particles to form the first adhesive layer; and forming the first tube by bonding the cover layer with the first adhesive layer.

13. The method of claim 12, wherein the plurality of first particles include a color concentrate.

14. The method of claim 12, wherein forming the first tube by bonding the cover layer with the first adhesive layer comprising: attaching the first adhesive layer on the cover layer to form a first laminate layer; cooling the first laminate layer; and pulling and squashing the cooled first laminate layer to form the first tube.

15. The method of claim 12, wherein forming the first tube by bonding the cover layer with the first adhesive layer comprising: immersing the cover layer and the first adhesive layer in a solution for physical permeation.

16. The method of claim 11, wherein the cover layer of the first tube and the lining layer of the second tube are made of different materials.

17. The method of claim 11, wherein: the cover layer of the first tube includes Thermoplastic Polyurethane (TPU) or a mixture of TPU and Polyvinyl Chloride (PVC), and the lining layer of the second tube includes TPU, a mixture of TPU and PVC, or a mixture of the PVC and butyronitrile.

18. The method of claim 11, wherein the third tube having an inner surface and an outer surface is manufactured by weaving a tubular enhancement layer including at least one of Terylene filaments, Nylon filaments, and aramid fibers.

19. The method of claim 18, wherein the third tube includes a copper wire woven along an axial direction of the tubular enhancement layer.

20. The method of claim 11, wherein forming a fourth tube by bonding the first adhesive layer of the first tube with the inner surface of the third tube comprising: placing the first tube into the third tube; fixing both ends of the first tube and the third tube; and forming the fourth tube by treating the first tube and the third tube under a steam for a first time interval and under air for a second time interval.

21. The method of claim 20, wherein the steam is maintained at a pressure being within a range of 0.10 MPa to 0.35 MPa.

22. The method of claim 11, wherein forming the liquid deliver hose by bonding the second adhesive layer of the second tube with the inner layer of the turned fourth comprising: placing the second tube into the turned fourth tube; fixing both ends of the second tube and the turned fourth tube; and forming the liquid deliver hose tube by treating the second tube and the turned fourth tube under a steam for a third time interval and under air for a fourth time interval.

23. The method of claim 11, further comprising: passing the turned fourth tube through rollers to perform surface processing on the outer layer of the turned fourth tube.

24. A liquid delivery hose, comprising: a first tube including a cover layer and a first adhesive layer, the first adhesive layer being attached inside the cover layer; a second tube including a lining layer and a second adhesive layer, the second adhesive layer being attached outside the lining layer; and a third tube having an inner surface and an outer surface, wherein the first adhesive layer of the first tube is bonded with the outer surface of the third tube, and the second adhesive layer of the second tube is boned with the inner surface of the third tube.

25. The liquid delivery hose of claim 24, wherein the first adhesive layer is bonded with the cover layer, and wherein: the cover layer is formed by a plurality of first particles, the plurality of first particles being extruded by a first part of a co-extrusion mold; and the first adhesive layer is formed by a plurality of second particles, the plurality of second particles being extruded by a second part of the co-extrusion mold.

26. The liquid delivery hose of claim 25, wherein the plurality of first particles include a color concentrate.

27. The liquid delivery hose of claim 24, wherein the cover layer of the first tube and the lining layer of the second tube are made of different materials.

28. The liquid delivery hose of claim 24, wherein: the cover layer of the first tube includes Thermoplastic Polyurethane (TPU) or a mixture of TPU and Polyvinyl Chloride (PVC), and the lining layer of the second tube includes TPU, a mixture of TPU and PVC, or a mixture of the PVC and butyronitrile.

29. The liquid delivery hose of claim 24, wherein the third tube having an inner surface and an outer surface is manufactured by weaving a tubular enhancement layer including at least one of Terylene filaments, Nylon filaments, and aramid fibers.

30. The liquid delivery hose of claim 29, wherein the third tube includes a copper wire woven along an axial direction of the tubular enhancement layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 is a schematic illustration of the structure of the co-extrusion mold of the present invention.

DETAILED DESCRIPTION

Embodiment 1

[0029] The fracturing liquid delivery hose for recovery of shale oil and gas includes from outer to inner, a cover layer, an enhancement layer and an inner lining layer, where bonding between the cover layer and the enhancement layer and between the enhancement layer and the inner lining layer are achieved by first and second adhesive layers, respectively.

[0030] The cover layer has a thickness of 0.5 mm, the enhancement layer has a thickness of 5.0 mm, the inner lining layer has a thickness of 4.0 mm, and each of the first and second adhesive layers has a thickness of 0.35 mm.

[0031] The enhancement layer is woven by warp and weft filaments or fibers to be of tubular shape.

Embodiment 2

[0032] This embodiment is different from Embodiment 1 in that, the cover layer has a thickness of 4.0 mm, the enhancement layer has a thickness of 1.0 mm, the inner lining layer has a thickness of 4.0 mm, and each of the first and second adhesive layers has a thickness of 0.10 mm. The material of the warp and weft filaments or fibers is Nylon.

Embodiment 3

[0033] This embodiment is different from Embodiment 1 in that, the cover layer has a thickness of 2.5 mm, the enhancement layer has a thickness of 3.5 mm, the inner lining layer has a thickness of 2.5 mm, and each of the first and second adhesive layers has a thickness of 0.25 mm. Moreover, two copper wires are uniformly distributed along an axial direction in the enhancement layer. Addition of copper wires achieves antistatic effect.

Embodiment 4

[0034] This embodiment is different from the preceding embodiments in that, eight copper wires are uniformly distributed along an axial direction in the enhancement layer. In other embodiments, a number of the copper wires can be 3, 4, 5, 6 or 7.

Embodiment 5

[0035] A method for manufacturing the fracturing liquid delivery hose for recovery of shale oil and gas includes the following steps:

[0036] (1) Forming a cover layer with an adhesive layer by extrusion, which includes extruding particles, used to form the cover layer and a first adhesive layer by two extruders into a co-extrusion mold to form a co-extruded first laminate layers, subjecting the co-extruded first laminate layer to cooling, pulling and squashing the co-extruded first laminate layer to form a first flat tube, i.e., the cover layer with the first adhesive layer where the first adhesive layer has a thickness of 0.10-0.35 mm and the cover layer has a thickness of 0.5-4.0 mm.

[0037] (2) Forming an inner lining layer with an adhesive layer by extrusion, which includes extruding particles used to form the inner lining layer and a second adhesive layer by two extruders into a co-extrusion mold to form a co-extruded second laminate layer, and subjecting the co-extruded second laminate layer to cooling, pulling and squashing the co-extruded second laminate layer to form a second flat tube, i.e., the inner lining layer with the second adhesive layer, where the second adhesive layer has a thickness of 0.10-0.35 mm and the inner lining layer has a thickness of 0.5-4.0 mm.

[0038] (3) Separately treating the surfaces of the co-extruded first and second laminate layers in Step (1) and Step (2), which includes immersing the first and second laminate layers in a solution for physical permeation prior to use, where the solution is formulated from a curing agent and ethyl acetate, and a ratio of the curing agent to the ethyl acetate ranges between 10:90 and 30:70. In this embodiment, the adhesive particles are TPU hot melt adhesive. Specifically, UB410B from Lubrizol Corp. is used in this embodiment. The curing agent in this embodiment is a material named diphenylmethane diisocyanate (MDI), and BASF M20S is adopted. The curing agent (having an active NCO) can be bonded firmly, through physical permeation and chemical reaction at a certain temperature and pressure, to the Terylene filaments which has a hydroxyl group. The amino-isocyanate of Nylon can serve as active site readily reacting with hydroxyl and amino groups to form carbamate and urea structure, which also firmly bond together by physical permeation and chemical reaction at certain temperature and pressure. The treated aramid fiber can contain amino and isocyanate groups, which can also firmly bond through physical permeation and chemical reaction with the curing agent at a certain temperature and pressure.

[0039] (4) Forming an enhancement layer, which includes weaving a tubular enhancement layer according to product design specification.

[0040] (5) Bonding the cover layer with the enhancement layer to form a tubular third laminate layer, which includes pulling the surface-treated cover layer with the first adhesive layer in Step (that is, the first laminate layer, into the tubular enhancement layer, fixing both ends of the tubular enhancement layer and the pulled-in first laminate layer, introducing a steam of 0.10-0.35 Mpa into the tubular enhancement layer with the pulled-in first laminate layer for 4-10 minutes, and discharging the steam while introducing air into the tubular enhancement layer with the pulled-in first laminate layer to replace the steam, maintain the air pressure therein and cool the tubular enhancement layer with the pulled-in first laminate layer to a desired temperature such that the tubular third laminate layer is formed by the tubular enhancement layer and the first laminate layer.

[0041] (6) Turning the tubular third laminate layer of Step (5) inside out so that an inner surface of the tubular third laminate layer of Step (5) becomes an outer surface of the turned tubular third laminate layer.

[0042] (7) Passing the turned tubular third laminate layer from Step (6) through rollers to perform surface processing on the turned tubular third laminate layer.

[0043] (8) Bonding the inner lining layer with the enhancement layer of the turned third tubular laminate layer, which includes pulling the surface-treated inner lining layer with the second adhesive layer in Step (3), that is, the second laminate layer, into the turned tubular third laminate layer of Step (7), fixing both ends of the turned tubular third laminate layer and pulled-in second laminate layer, introducing a steam of 0.10-0.35 Mpa into the turned tubular third laminate layer with pulled-in second laminate layer for 4-10 minutes, and discharging the steam while introducing air into the turned tubular third laminate layer with pulled-in second laminate layer to replace the steam, maintain the air pressure therein and cool the turned tubular third laminate layer with pulled-in second laminate layer to a desired temperature.

[0044] In this embodiment, the cover layer and the inner lining layer are made of TPU, specifically, a polyether type TPU, named R185A, of Lubrizol Corp.

Embodiment 6

[0045] This embodiment is different from Embodiment 5 in that, the cover layer uses polyether type TPU (R185A of Lubrizol Corp.) the inner lining layer uses liner PVC (medical grade PVC of Shanghai Chloro-Alkali Chemical Co., Ltd.) or a mixture of PVC and butyronitrile (medical grade PVC of Shanghai Chloro-Alkali Chemical Co., Ltd., the Powder Nitrile Butadiene Rubber (PNBR) is LG830 of LG Chemical, a mass ratio of PVC to powdered butyronitrile ranges between 100:0 and 100:70).

Embodiment 7

[0046] This embodiment is different from Embodiment 6 in that, the enhancement layer described in Step (4) is woven from Terylene filaments, Nylon or aramid fibers.

Embodiment 8

[0047] A co-extrusion mold, as shown in FIG. 1, includes a housing 1 equipped with a shaft 2 therein. A distributor block 4 is provided below the shaft and has a lower part in the shape of a frustum. A gap exists between the shaft 2 and the distributor block 4. The distributor block 4 is fixedly connected to the housing 1. The housing 1 has a first feed inlet 6 connected to a TPU particle extruder for extruding the particles used to form the cover layer or inner lining layer. The first feed inlet 6 penetrates through the housing 1 and is connected to the gap between the shaft 2 and the distributor block 4. A mold case 5 is arranged on the distributor block 4 where a gap exists between the mold case 5 and the distributor block 4. The mold case 5 is fixedly connected to the housing 1, and the mold case 5 has a second feed inlet 7 connected to an adhesive particle extruder for extruding particle used to form adhesive layer(s). The second feed inlet 7 penetrates through the mold case 5 and is connected to the gap between the mold case 5 and the distributor block 4. In operation, the shaft 2 rotates, and because the first feed inlet 6 is connected to the gap between the shaft 2 and the distributor block 4, TPU flows out along the gap between the shaft 2 and the distributor block 4. The adhesive is fed through the second feed inlet 7 and flows out along the gap between the distributor block 4 and the mold case 5. The lower part of the distributor block is in the shape of a frustum such that a gap between a TPU extruding port and an adhesive extruding port is very small, thereby allowing the adhesive to be attached on the outer layer of the produced TPU tube to form a final product obtained at high temperature.

Embodiment 9

[0048] In the co-extrusion mold described in Embodiment 8, a clamping ring 3 is provided between the distributor block 4 and the housing.