Journal Article

Research on High-Performance Underwater-Curing Polymer Composites for Offshore Oil Riser Pipes

Wan, Jun, Zhao, Xuan, Zhao, Huiyan, Qv, Xuefeng, Yu, Yajun

2025

Overview

In offshore oil and gas extraction, riser pipes serve as the first isolation barrier for wellbore integrity, playing a crucial role in ensuring operational safety. Protective coatings represent an effective measure for corrosion prevention in riser pipes. To address issues such as electrochemical corrosion and poor adhesion of existing coatings, this study developed an underwater-curing composite material based on a polyisobutylene (PIB) and butyl rubber (IIR) blend system. The material simultaneously exhibits high peel strength, low water absorption, and stability across a wide temperature range. First, the contradiction between material elasticity and strength was overcome through the synergistic effect of medium molecular weight PIB internal plasticization and IIR crosslinking networks. Second, stable peel strength across a wide temperature range (−45 °C to 80 °C) was achieved by utilizing the interfacial effects of nano-fillers. Subsequently, an innovative solvent-free two-component epoxy system was developed, combining medium molecular weight PIB internal plasticization, nano-silica hydrogen bond reinforcement, and latent curing agent regulation. This system achieves rapid surface drying within 30 min underwater and pull-off strength exceeding 3.5 MPa. Through systematic laboratory testing and field application experiments on offshore oil and gas well risers, the material’s fundamental properties and operational performance were determined. Results indicate that the material exhibits a peel strength of 5 N/cm on offshore oil risers, significantly extending the service life of the riser pipes. This research provides theoretical foundation and technical support for improving the efficiency and reliability of repair processes for offshore oil riser pipes.

• Publisher: MDPI AG,MDPI
• Subject: Bond strength / Butyl rubber / Carbon steel / Coatings / Composite materials / Corrosion / Corrosion and anti-corrosives / Corrosion prevention / Crosslinked polymers / Crosslinking / Curing / Curing agents / Elastomers / Electrochemical corrosion / Epoxy resins / Gas wells / Mechanical properties / Medical research / Medicine, Experimental / Molecular weight / Natural gas reserves / Offshore oil exploration & development / Oil field services / Oil reserves / Peel strength / Petroleum in submerged lands / Petroleum mining / Pipes / Polyisobutylene / Polymer blends / Polymer industry / Polymer matrix composites / Protective coatings / R&D / Research & development / Riser pipes / Risers / Rubber / Seawater / Service life / Synergistic effect / Tensile strength / Underwater / Water absorption