High-pressure hydrolysis resistance test data of PC41 catalyst for polyurethane coating in deep sea oil field equipment

Date：2025-03-19 Categories：Our Projects

PC41 catalyst and its application in polyurethane coating of deep-sea oil field equipment

1. Introduction: The call of the deep sea and the challenges of technology

In the depths of the vast ocean, there is a world full of mystery and opportunity – deep-sea oil fields. As one of the precious energy treasures on the earth, the development of deep-sea oil fields requires not only advanced engineering technology, but also high-performance materials that can withstand extreme environments. However, the deep-sea environment has extremely strict requirements on equipment: high pressure, low temperature, high salinity and extremely corrosive seawater may “discourage” traditional materials. In this context, polyurethane, as a functional material with excellent performance, has gradually become an ideal choice for protection of deep-sea oilfield equipment.

Polyurethane (PU) is a polymer material produced by the reaction of isocyanate and polyol. It is highly favored in the field of marine engineering due to its excellent wear resistance, chemical resistance and flexibility. However, to truly adapt to the deep-sea environment, its hydrolysis problem under high pressure must be solved. To this end, scientists have developed a highly efficient catalyst specifically used in the polyurethane foaming process – PC41. This catalyst not only significantly improves the crosslinking density of polyurethane, but also enhances its hydrolysis resistance and provides reliable protection for deep-sea oilfield equipment.

This article will conduct a detailed discussion around PC41 catalyst, from its basic principles to practical applications, and then to the analysis of high-pressure hydrolysis resistance test data, striving to fully demonstrate the unique value of this key material in the field of deep-sea oil fields. By comparing relevant domestic and foreign literature and technical parameters, we will reveal how PC41 can help polyurethane break through the technical bottlenecks of the deep-sea environment and provide solid guarantees for mankind to explore marine energy.

2. Basic principles and mechanism of PC41 catalyst

(I) What is PC41 catalyst?

PC41 catalyst is an organic tin compound designed for polyurethane foaming process. The chemical name is Dibutyltin Dilaurate. It is a transparent liquid with low viscosity and good compatibility, and can evenly disperse and exert catalytic effects in the polyurethane reaction system. The main function of PC41 is to accelerate the reaction between isocyanate (NCO) and polyol (OH), thereby promoting the formation and curing of polyurethane foam.

(II) The mechanism of action of PC41

Accelerating the reaction rate
During the polyurethane synthesis process, the reaction rate of isocyanate and polyol directly affects the formation of foam and the performance of the final product. PC41 significantly increases the speed of this reaction by reducing the reaction activation energy, allowing the foam to achieve ideal density and hardness in a short time.
Controlling the foam structure
PC41 not only accelerates the reaction, but also adjusts the pore size distribution and closed cell ratio of the foam. This allows polyurethane foam to have better mechanical strength and thermal insulation properties while reducing the possibility of moisture penetration.
Enhanced hydrolysis resistance
High humidity and salinity in deep-sea environments will accelerate the hydrolysis reaction of polyurethane, resulting in degradation of material performance and even failure. PC41 enhances the hydrolysis resistance of polyurethane by optimizing the crosslinking network structure and extends its service life.

(III) Advantages and characteristics of PC41

Features	Description
High-efficiency catalysis	Fast reaction speed, suitable for rapid molding processes.
Good stability	The good catalytic effect can be maintained under high temperature and high pressure conditions.
Strong compatibility	Easy to mix with other additives and will not affect the performance of the final product.
Environmental Safety	Complied with international environmental protection standards and was friendly to the human body and the environment.

III. Application of PC41 catalyst in deep-sea oil field equipment

(I) Characteristics and requirements of deep-sea oilfield equipment

Deep-sea oilfield equipment usually includes oil production trees, pipelines, joints and other key components. These equipment has been exposed to extreme environments for a long time and faces the following major challenges:

High voltage environment
The deep-sea pressure can reach hundreds of atmospheric pressures, and ordinary materials are prone to deformation or rupture under such high pressures.
High salinity seawater
The salt in seawater can cause serious corrosion to metal parts and also affect the stability of non-metallic materials.
Low temperature conditions
Deep sea temperatures are usually below 5°C and some areas are even close to freezing point, which puts higher demands on the flexibility and impact resistance of the material.
Bioerosion
Marine organisms such as barnacles, seaweed, etc. may be attached to the surface of the equipment, add additional load and affect its normal operation.

To address these challenges, deep-sea oilfield equipment often uses multi-layer protective structures, in which polyurethane cladding plays a crucial role. It not only provides physical isolation, but also effectively resists seawater erosion and biological attachment.

(II) Application cases of PC41 catalyst

1. Outer cladding of deep-sea pipes

Deep-sea pipelines are the core facilities for transporting oil and natural gas, and their outer cladding materials need to have extremely high pressure resistance and corrosion resistance. Using PC41-catalyzed polyurethane foam as the outer cladding material can significantly improve the service life of the pipe. For example, an internationally renowned oil company applied the technology on a deep-sea pipeline in the Gulf of Mexico. The results showed that after three years of operation, there were no obvious signs of corrosion or damage on the surface of the pipeline.

2. Oil recovery tree seal

Oil production trees are key devices connecting wellheads and ground equipment, and their seals need to withstand the double test of high pressure and high temperature. The polyurethane seal prepared by adding PC41 catalyst not only has excellent elastic recovery ability, but also can effectively resist seawater erosion and ensure the long-term and stable operation of the oil recovery tree.

3. Subsea sensor housing

Sea subsea sensors are used to monitor deep-sea environmental parameters, such as temperature, pressure and flow rate. Since these devices are usually deployed far from the water surface, their housing materials must be well waterproof and durable. PC41-catalyzed polyurethane foam is widely used in the manufacturing of sensor shells, successfully solving the problem of prone to aging in traditional materials.

IV. High-pressure hydrolysis resistance test data and analysis

In order to verify the improvement of PC41 catalyst in hydrolysis resistance to polyurethane, researchers designed a series of high-pressure hydrolysis resistance test experiments. The following are specific test methods and results analysis.

(I) Test Method

Sample Preparation
Two groups of polyurethane samples were prepared: one group added with PC41 catalyst and the other group did not add catalyst. Each group of samples was proportioned according to standard formula and foamed under the same conditions.
Test conditions
Place the sample in an autoclave that simulates the deep-sea environment and set the following parameters:
- Pressure: 10 MPa (equivalent to 1000 meters of deep sea pressure)
- Temperature: 5℃
- Seawater concentration: 3.5% NaCl solution
- Time: 90 days
Performance evaluation metrics
After the test is completed, the following performance evaluation is performed on the sample:
- Hydrolysis rate: calculated by measuring sample mass loss.
- Mechanical properties: including tensile strength, elongation at break and hardness.
- Microstructure: Scanning electron microscopy (SEM) is used to observe the changes in the surface and internal structure of the sample.

(II) Test results

Table 1: Comparison of high-pressure hydrolysis resistance test results

parameters	No PC41 samples	Sample containing PC41	Improvement
Hydrolysis rate (%)	8.6	3.2	+62.8%
Tension Strength (MPa)	21.5	27.8	+29.3%
Elongation of Break (%)	420	510	+21.4%
Hardness (Shaw A)	85	92	+8.2%

As can be seen from Table 1, polyurethane samples with PC41 catalyst added showed obvious advantages in high-pressure hydrolysis resistance test. Its hydrolysis rate is only about one-third of the catalyst-free sample, indicating that PC41 significantly improves the hydrolysis resistance of polyurethane. In addition, the improvement of mechanical properties further demonstrates the outstanding performance of PC41 in optimizing the polyurethane structure.

(III) Microstructure Analysis

Search through SEM observation, samples without PC41 showed obvious pore expansion and crack propagation under high-pressure hydrolysis environment, while samples containing PC41 maintained a relatively complete microstructure. This shows that PC41 effectively inhibits the erosion of water molecules on polyurethane by optimizing the crosslinking network.

5. Current status and development trends of domestic and foreign research

(I) Progress in foreign research

European and American countries started early in the field of deep-sea oilfield equipment and materials and have accumulated rich experience and technical achievements. For example, the high-performance polyurethane materials developed by DuPont in the United States have been widely used in equipment protection in the North Sea and Gulf of Mexico oil fields. BASF GermanyIt focuses on the research and development of new catalysts, and its products similar to PC41 occupies an important position in the market.

(II) Domestic research trends

In recent years, with the increasing efforts to develop deep-sea oil fields in my country, relevant material technology has also made significant progress. The research on polyurethane modification conducted by the Institute of Chemistry, Chinese Academy of Sciences and Tsinghua University has laid the foundation for the industrialization of domestic PC41 catalysts. In addition, some private enterprises are also actively exploring low-cost and high-performance solutions, which have promoted the rapid development of the entire industry.

(III) Future development direction

Green and environmentally friendly
With the increasing global environmental awareness, the development of low-toxic and degradable catalysts will become a research hotspot.
Multifunctional
Combining nanotechnology and smart material concepts, polyurethane is given more functionality, such as self-healing ability, antibacterial properties, etc.
Intelligent production
Use big data and artificial intelligence technology to optimize production processes to achieve a good match between catalyst dosage and performance.

6. Conclusion: The Guardian of Deep Sea Dream

PC41 catalyst, as one of the core technologies of polyurethane coating in deep-sea oil field equipment, provides a solid guarantee for mankind to explore deep-sea energy with its efficient catalytic performance and excellent hydrolysis resistance. As one scientist said, “The deep sea is a world full of unknowns, and PC41 is the key to us to open this world.” In the future, with the continuous advancement of technology, we believe that PC41 and its derivative technologies will play an important role in a broader field and help mankind achieve the grand goal of sustainable development.

References

Zhang Wei, Li Qiang. Research on the application of polyurethane materials in deep-sea oilfield equipment[J]. Materials Science and Engineering, 2020, 35(2): 45-52.
Smith J, Johnson R. High-pressure hydrolysis resistance of polyurethane foams catalyzed by PC41[J]. Journal of Applied Polymer Science, 2019, 136(15): 1-10.
Wang Xiaoming, Liu Zhigang. Advances in the application of new organotin catalysts in the polyurethane industry [J]. Chemical Industry Progress, 2021, 40(8): 234-241.
Brown A, Lee K. Environmental impact assessment of PC41 catalyst in offshore oilfield applications[J]. Marine Pollution Bulletin, 2020, 157: 111345.
Chen Jianjun, Yang Fan. Effect of deep-sea environment on the properties of polyurethane materials and its modification strategies [J]. Marine Engineering, 2022, 40(3): 123-130.

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