Flexible hose made of heat-resistant and fire-resistant synthetic rubber used for drilling wells wit

1、 Technological breakthrough: Collaborative innovation of high temperature resistance, fire resistance, and high pressure bearing capacity

In oil drilling operations, the square drill pipe kill hose needs to withstand extreme high temperature, high pressure, and open flame environments, while also possessing chemical corrosion resistance, high flexibility, and long service life characteristics. In response to this demand, the new high-temperature and fire-resistant synthetic rubber hose has achieved a comprehensive breakthrough in performance through material formula optimization, structural design innovation, and manufacturing process upgrading.

 

（1） High temperature resistant synthetic rubber material system

Main rubber substrate

Fluorine silicone rubber (FVMQ) blended with hydrogenated nitrile rubber (HNBR): Fluorine silicone rubber has excellent high temperature resistance (long-term use temperature ≥ 250 ℃) and oil resistance, while hydrogenated nitrile rubber provides high strength (tensile strength ≥ 25MPa) and tear resistance. The two are blended in a 7:3 ratio to form a matrix material that combines flexibility and heat resistance. For example, after working continuously for 500 hours at a high temperature of 300 ℃, the tensile strength retention rate of a certain formula is ≥ 80%, far exceeding the 30% of traditional nitrile rubber (NBR).

Nano reinforced filler: Adding 5-10wt% carbon nanotubes (CNTs) and graphene oxide (GO) composite filler to enhance the thermal conductivity (≥ 0.5W/(m · K)) and mechanical strength of the material. For example, after adding CNTs/GO to a certain rubber formula, the thermal conductivity efficiency increased by 40%, effectively reducing the risk of heat accumulation in high-temperature operations.

Fire resistant and thermal insulation functional layer

Ceramic silicon rubber (CSR) coating: Apply ceramic silicon rubber with a thickness of 0.5-1mm on the outer layer of the hose. When the temperature exceeds 500 ℃, the coating rapidly ceramics to form a dense insulation layer, and the thermal conductivity decreases to below 0.1W/(m · K). For example, in a flame spraying test (temperature ≥ 1000 ℃), the inner rubber temperature of a certain hose is ≤ 150 ℃ to protect the internal structure from damage.

Aerogel insulation interlayer: silica aerogel felt (density ≤ 150kg/m ³) is embedded between the rubber layer and the reinforcement layer to further reduce the heat conduction. For example, when transporting fluids at a high temperature of 200 ℃, the outer layer temperature of a certain hose should be ≤ 60 ℃ to avoid burns to the operator.

（2） Design of High Voltage Bearing and Anti Fatigue Structures

Enhancement layer technology

High strength fiber weaving layer: using a mixed weaving structure of aramid fiber (Kevlar) and stainless steel wire, with a weaving angle of ± 54.7 °, it can still maintain structural stability under a working pressure of 50MPa. For example, a certain hose can withstand a pressure of up to 120MPa during a burst test, far exceeding the API 7K standard (usually 35-50MPa).

Multi layer winding and gradient density design: Through three-layer fiber winding (inner layer density of 80%, middle layer density of 90%, outer layer density of 95%), the pressure load is dispersed to avoid local stress concentration. In the test of simulating drilling fluid pulses (pressure fluctuation ± 10MPa), the hose cycled 1 million times without leakage, and its lifespan was extended by 8 times compared to traditional rubber hoses.

Joint sealing and impact resistance design

Metal sleeve+O-ring dual seal: The joint adopts 316L stainless steel sleeve, matched with fluororubber O-ring, with a leakage rate of ≤ 0.005mL/min under 50MPa pressure, and certified by API 6A standard. For example, a certain hose worked continuously for 2000 hours without leakage during high-pressure sealing testing.

Anti stripping and impact resistant structure: The joint thread adopts a trapezoidal thread design, matched with a locking nut, to prevent the joint from loosening under high pressure. In the 1m height drop test, the hose joint showed no deformation and the sealing performance was not affected.

（3） Chemical corrosion resistance and wear resistance

Inner lining protection

Polytetrafluoroethylene (PTFE) lining: PTFE lining with a thickness of 0.3-0.5mm has excellent chemical corrosion resistance (acid, alkali, salt, and organic solvents), with a friction coefficient as low as 0.04, reducing drilling fluid flow resistance. For example, when transporting acidic drilling fluid containing 15% H ₂ S, a certain hose has no corrosion on the inner lining and a lifespan of over 2 years.

Ceramic particle reinforced inner wall: Aluminum oxide (Al ₂ O ∝) ceramic particles (particle size 30-50 μ m) are sprayed on the inner lining surface, with a hardness of HV1200 and a wear resistance 5 times higher than that of pure PTFE lining. For example, a certain hose worked continuously for 500 hours in a sand containing drilling fluid (with a sand particle concentration of 5%), and the inner wall wear depth was ≤ 0.02mm.

Outer wear-resistant protection

Polyurethane (PU) elastomer coating: Polyurethane coatings with a thickness of 1-1.5mm have high elasticity (Shore hardness 70 ± 2 degrees) and wear resistance (DIN abrasion ≤ 50mm ³). In rock friction tests, the coating wear rate is ≤ 0.1mm/1000 hours.

Anti slip texture design: The outer surface is set with diamond shaped anti slip texture to enhance the stability of the operator's grip and prevent the hose from slipping.

2、 Application scenarios and typical cases

The new type of high-temperature and fire-resistant synthetic rubber hose is widely used in the fields of petroleum drilling, well killing operations, and high-temperature fluid transportation, meeting the safety and efficiency requirements under extreme working conditions.

 

（1） Oil drilling and well killing operations

Application scenarios

During the drilling process of deep and ultra deep wells, the square drill pipe needs to withstand high temperature drilling fluid (temperature ≥ 180 ℃) and high pressure pulses (pressure fluctuation ± 15MPa), while also dealing with sudden fire risks such as blowouts.

The hose is required to have high temperature resistance, fire resistance, high pressure bearing capacity, and chemical corrosion resistance.

classic case

A deep-sea drilling platform uses aramid fiber-reinforced hoses with a diameter of 76mm and an inner lining of PTFE+ceramic particle composite structure. When transporting drilling fluid containing 5% H ₂ S at 200 ℃, the service life can reach 18 months, which is three times longer than traditional hoses.

Drilling operation in a shale gas well: The outer layer of the hose was coated with ceramicized silicone rubber, and it worked continuously for 30 minutes without failure during the well blowout disaster, in order to gain critical time for emergency rescue.

（2） High temperature fluid transportation system

Application scenarios

In scenarios such as geothermal energy development and high-temperature medium transportation in refineries, the fluid temperature can reach 250-300 ℃ and the pressure is 10-30MPa.

The hose is required to have high temperature resistance, heat insulation and aging resistance.

classic case

A geothermal power station: 50 mm diameter aerogel insulation hose is used to transport 280 ℃ high-temperature steam, the outer layer temperature is ≤ 70 ℃, reducing heat loss by 15% and improving power generation efficiency.

Catalytic cracking unit of a certain refinery: The inner lining of the hose is made of fluororubber, which is resistant to high-temperature oil corrosion and has been working continuously for 3 years without leakage, reducing maintenance costs by 40%.

（3） Emergency rescue and firefighting field

Application scenarios

In petrochemical fire fighting, high-pressure water or foam extinguishing agent (pressure ≥ 20MPa) shall be delivered, and the hose shall withstand high temperature flame (temperature ≥ 800 ℃).

The hose is required to have fire-resistant, wear-resistant, and lightweight characteristics.

classic case

Rescue of a certain oil field fire: A 100mm diameter ceramic coated silicone rubber hose was used to work continuously in the flame for 20 minutes without burning through, successfully extinguishing the blowout fire.

Fire drill in a chemical industrial park: The weight of the hose is reduced by 60% compared to traditional steel braided hoses, making it easier to deploy quickly and improving emergency response efficiency.

3、 Industry Trends and Product Upgrade Directions

（1） Technological development trends

Ultra high temperature and ultra-high pressure technology

Deep well drilling is developing towards depths below 3000 meters, requiring hoses to withstand high temperatures of 300 ℃ and pressures of 80MPa. For example, a carbon fiber reinforced hose developed by a certain laboratory has a working pressure of 100MPa and a long-term use temperature of ≥ 300 ℃.

3D printing technology is used to manufacture irregular joints, reduce stress concentration, and improve the overall lifespan of hoses.

Intelligent and predictive maintenance

Integrated fiber optic sensors for real-time monitoring of temperature, pressure, leakage, and fiber breakage. For example, a certain smart hose predicts its remaining lifespan through AI algorithms and provides a 90 day early warning of replacement needs.

RFID chips achieve full lifecycle traceability and can be monitored throughout the entire process from production to disposal.

Environmental Protection and Sustainability

Biobased rubber (such as Eucommia ulmoides gum) and recyclable fiber materials can be used to recover 80% of the raw materials through pyrolysis after disposal.

Low VOC outer layer material, compliant with EU REACH regulations, reduces environmental pollution.

（2） Changes in market demand

Driven by new energy and deep-sea development

Emerging fields such as combustible ice mining and deep-sea hydrothermal deposit development require hoses to have higher temperature resistance (≥ 350 ℃), pressure resistance (≥ 100MPa), and corrosion resistance requirements.

High end equipment manufacturing (such as deep-sea drilling rigs and high-temperature reactors) requires customized hoses to meet high cleanliness and low friction requirements.

Globalization and Localization Services

Multinational corporations require suppliers to have global supply capabilities and localized services. For example, an international brand requires suppliers to respond to overseas after-sales needs within 72 hours and provide on-site installation guidance.

（3） Product upgrade strategy

Differentiated product positioning

Small and medium-sized manufacturers focus on segmented markets, such as a company specializing in acidic drilling fluid hoses, which occupies 30% of the mid to low end market share through the combination of "PTFE lining+fluororubber reinforcement".

Large manufacturers monopolize the high-end market through technology, such as an international brand of carbon fiber hoses that are priced 50% higher than similar products, but have extremely strong customer stickiness.

Service oriented transformation

Provide a one-stop solution of "hose assembly+installation tools+training". For example, a manufacturer customized hose installation fixtures for a drilling company, which increased assembly efficiency by 50%.

Carry out the "trade in" business, recycle old hoses and remanufacture them to achieve 80% performance of new products, reducing costs by 30%.

Globalization Layout and Compliance

Establish production bases in oil and gas rich regions such as the Middle East and North America to avoid trade barriers. For example, a domestic manufacturer has established a factory in Saudi Arabia, with products radiating to ten Middle Eastern countries, resulting in a 20% reduction in tariff costs.

Through international certifications such as API 16C (fire-resistant hoses) and ISO 14693 (high-temperature resistant hoses), it meets the regulatory requirements of different industries.

（4） Future innovation direction

Self repair and long-term protection

Develop a rubber matrix for microencapsulated repair agents. When microcracks appear on the inner wall of the hose, the repair agent will automatically release and solidify, extending its service life. For example, the self-healing fluororubber material developed by a certain laboratory has a crack repair rate of 85%.

Modular rapid replacement system

Design detachable joints and modular pipe sections, which can be quickly replaced when a single pipe section is damaged, without the need to shut down and replace the entire section. For example, the replacement time for a modular hose system has been reduced from 8 hours for traditional welded joints to 30 minutes.

Energy recovery and energy-saving design

Integrating piezoelectric materials on the outer wall of the hose to convert fluid flow energy into electrical energy and supply power to the sensor. For example, a certain piezoelectric hose can achieve an output power of up to 10W under a pressure of 20MPa, meeting the electrical needs of some monitoring equipment.

In the future, high-temperature and fire-resistant synthetic rubber hoses will require continuous technological iteration to adapt to deep-sea drilling, new energy development, and extreme environmental rescue needs. Manufacturers need to strengthen cooperation with oilfield enterprises, deeply participate in drilling system design, and build technical barriers and cost advantages through material innovation and process optimization, in order to take the initiative in global competition. For example, developing ultra wear-resistant lining (such as diamond-like carbon coating), lightweight reinforcement structure (such as hollow fiber weaving), etc., further enhancing product competitiveness.