基于白云石改性的深海石油开采用高强度刚玉陶瓷研究
Study on High-Strength Corundum Ceramics Based on Dolomite Modification for Deep-Sea Oil Exploitation
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摘要: 深海油田开采所处的高温、高压、强腐蚀与高磨损极端环境,对传统油气压裂支撑剂陶瓷材料提出极高的性能适配要求,受材料本身性能局限,其在实际服役过程中易出现腐蚀、破碎问题,直接影响开采作业的稳定性与效率。本研究以二级铝矾土为基体原料,白云石为核心改性剂,软锰矿为烧结助剂,采用固相烧结法制备高强度刚玉陶瓷材料,系统研究白云石添加量对其物相组成、微观结构、力学性能及耐腐蚀性的影响机制。结果表明:适量添加白云石(质量分数为5%)时,白云石热分解生成的CaO与基体反应形成钙长石液相,促进烧结致密化与晶界强化,同时生成的MgO原位形成弥散分布的尖晶石相,协同提升材料力学性能与耐蚀性;而过量添加白云石(质量分数超过5%)则导致尖晶石相过量生成与团聚,破坏基体连续性,并因钙长石液相过多形成连续层状结构,引发孔隙率上升与结构劣化,最终导致性能衰退;当白云石的质量分数为5%,锰矿粉的质量分数为6%,1 400 ℃下烧结2 h所制备的刚玉陶瓷的综合性能最优,该材料通过“钙长石液相烧结-刚玉晶粒细化-尖晶石弥散强化”的协同作用实现了致密化与强韧性的同步提升,为深海极端环境下石油开采用陶瓷材料升级提供技术方案。Abstract: The extreme environmental conditions with high temperature, high pressure, severe corrosion and severe wear in deep-sea oilfield exploitation impose stringent requirements for traditional oil/gas fracturing proppant ceramic materials. Due to performance limitations of the ceramic materials, failure problems from corrosion and breakage may frequently occur in the proppants which seriously affects the stability and efficiency of mining operations. In this study, high-strength corundum ceramics were prepared by solid phase sintering methods with secondary bauxite as matrix raw material, dolomite as core modifier, and pyrolusite as sintering aid. Effects of dolomite addition on the phase composition, microstructure, mechanical properties and corrosion resistance of the ceramic materials were systematically studied. The results showed that, when adding an appropriate amount of dolomite(the mass fraction is 5%), CaO generated by dolomite thermal decomposition might react with the matrix material to form anorthite liquid phase, thus promoting sintering densification and grain boundary strengthening. At the same time, the generated MgO could transform into a dispersed spinel phase in situ, which synergistically improved the mechanical properties and corrosion resistance of the ceramic materials. However, the excessive addition of dolomite(the mass fraction exceeds 5%) caused an excessive formation and agglomeration of spinel phase, thus destroying the matrix continuity and formed a continuous lamellar structure due to the excessive liquid phase of anorthite, thus increaseing the porosity ratio and structural deterioration, which ultimately leaded to a property deterioration of the ceramics. The ceramic material with an optimal comprehensive performance could be prepared with dolomite mass fraction of 5%, pyrolusite mass fraction of 6%, and being sintered at 1 400 ℃ for 2 h. The simultaneous improvement of densification and toughening through the synergistic effect of “anorthite liquid phase sintering-corundum grain refinement-spinel dispersion strengthening”, can provide technical solutions for upgrading the ceramic materials for deep-sea oil exploitation.
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