OTC-25340-MS Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals Christopher Dyke, Scott Horton, David Peake, Jim Poole, NanoRidge Materials, Inc. Enrique Barrera, Liehui Ge, Santoshkumar Biradar, Travis Boyer, Luke Boyer, Robert Vajtai, Pulickel Ajayan, Rice University Slide 2 OUTLINE • Contributors • RPSEA Project Overview • Brief Carbon Nanotube Tutorial • Project Application – Umbilicals • Project Timing • Production • Results • Conclusions/Acknowledgements OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 3 CONTRIBUTORS • NanoRidge; Christopher Dyke (PI), Jim Poole, Scott Horton, Mayra Vasquez, Douglas Crouch,David Peake • Rice University • Graduate Students: Travis Boyer, Luke Boyer • Postdocs: Liehui Ge, Santoshkumar Biradar, Matias Soto Castillo • Senior Research Scientist/Faculty Fellow: Robert Vajtai • PIs: Pulickel Ajayan, Enrique V. Barrera • DUCO, Dave Madden • CurTran, Gary Rome • RPSEA, James Pappas (PM) OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 4 RPSEA PROJECT OVERVIEW • Three year, phase-gated development effort • Funding provided by RPSEA and cost share partners; Total, Shell, DUCO, and Baker Hughes • Subcontractors include Rice University, DUCO, and Cambridge University • Objective: To produce a wire comprised of carbon nanotubes with resistivity of 10-6Ω•cm and operational at 38 MPa (5500 psig) pressure • Demonstration program planned for Q4, Year 3 • Phase I deliverable, wire with resistivity of 10-5Ω•cm was achieved in July 2013 • Phase II began August 5, 2013; the deliverable is wire with resistivity of 10-5Ω•cm at 38 MPa pressure OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 5 RPSEA PROJECT OVERVIEW – TASKS • Task 5.0 is divided into phases, deliverables • Task 6.0 focuses on industrialization, demonstration program OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 6 CARBON NANOTUBES • • • PNU® cable comprised of a carbon nanotube conductor jacketed with a polymer CNT conceptualized as graphene rolled into seamless cylinder Consists exclusively of sp2-hybridized carbon OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 7 CARBON NANOTUBES ‒ ELECTRICAL • • • • • Electrical properties depend on chirality and variety Metallic SWNT(arm chairs) have current-carrying capacity of 109 A/cm2 (1) DWNT has the highest current-carrying capacity due to shell coupling (2) Ballistic conduction within CNT; resonant quantum tunneling between tubes Reduction in voids and minimization of the d-spacing in pure wire 1. Yao, Z., Kane, C.L., Dekker, C. 2000 Phys. Rev. Lett. 84 (13): 2941. 2. Moon, S., Song, W., Kim, N., Lee, J., Na, P., Lee, S., Park, J., Jung, M., Lee, H., Kang, K., Lee, C., Kim, J. 2007 Nanotechnology 18: 235201. OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 8 CARBON NANOTUBES ‒ MECHANICAL • Tensile strength of individual CNT is 22 GPa; Young’s modulus approaching 950 GPa in the axial direction • Translation of nanoscale properties to macroscale is a challenge • Carbon nanotube fiber (d = 7 µm) with tensile strength of 6 GPa reported (3); copper is 0.25 GPa • Same techniques employed in this project 3. Koziol, K., Vilatela, J., Moisala, A., Motta, M., Cunniff, P., Sennett, M., Windle, A. 2007. High-Performance Carbon Nanotube Fiber. Science 318:1892-1895. OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 9 POWER CABLE UMBILICALS • Umbilical – number of functional components contained within a flexible package • Single power cable umbilical – standard sheathing, steel wire armoring, 120 mm2 Cu conductor with copper screen • • • • 106 mm diameter 21.9 kg/m linear density 18 tonne top tension at 3,000’ 30 miles is 1057 tonnes Provided by DUCO OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 10 UMBILICAL – CNT REPLACES CU • • • • Weight savings – 1/6th of copper, less self weight • Less steel armor required • Reduction in linear density • More installation vessels Corrosion resistance • Stable in salt • Stable in conc. acids Mechanicals • 6 MPa vs. 0.25 GPa for Cu • Top tension capability • Less need for armor Skin depth Provided by DUCO OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke PROJECT TIMING Slide 11 • Initial focus is continuous production of the bare conductor • Polymer jacketing to form PNU® • Extensive characterization and testing of bare and jacketed wire OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 12 PROCESS FLOW DIAGRAM CNT Production Spinning Purification Post Processing Densification Polymer Conditioning Co-Extrusion Wire Stranding PNU® • • Purification and wire stranding as needed Co-extrusion process anticipated for sheathing OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 13 PRODUCTION FURNACE • • • Liquid feedstock injected CNT growth occurs in the heated zone of furnace Aerogel consolidated into fiber and collected on spool OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 14 PRODUCTION FURNACE – DESIGN • Inlet Flange: • Serves to consistently give a specified catalyst diameter prior to tube furnace • Heaters positioned to define temperature gradient • Flow profile modified by multiple production gas inlet ports and geometry • Exit Flange • Serves to convert to inert gas and allow smooth passage of CNT aerogel • Pressure control system and inert gas ring remove hydrogen • Inert gas creates vortex to add downward twist OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 15 TAKE-UP SYSTEM • • • • Aerogel converted to wire form V-notch guide roller keeps sock true to furnace center Traversing guide migrates back and forth Spool material selected for convenience OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 16 PHASE II RESULTS – TGA 100 • Weight (%) 80 Purified As-Produced 60 • 40 20 Amorphous carbon and residual catalyst Cleaner systems through production and purification 0 0 200 400 Temperature (°C) 600 800 OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 17 PHASE II RESULTS – RAMAN 45000 CNT Wire G 40000 • 35000 • Intensity 30000 25000 • 20000 15000 10000 D RBM Analysis of as-produced wire Minimal contamination RBM, D, and G indicate CNTvariety and defects 5000 0 100 300 500 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 2900 Shift (1/cm) OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 18 PHASE II RESULTS – SEM • • • Amorphous carbon contamination Clean as-produced nanotube sample Alignment and densification required in wire form OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 19 POST PROCESSING AND PNU® FORMATION • • • • Production conditions being optimized for purity, nanotube alignment and spinning Purification • Serves to clean the as produced wire • Techniques developed to remove amorphous carbon and residual catalyst • Processes are amenable to in-line, continuous operation Several routes to densification Polymer jacketing • Jacketing material specified • Equipment operational • Co-Extrusion process OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 20 PHASE II RESULTS – RESISTIVITY • • Comparable American Wire Gauge (AWG) Resistivity STP (Ω•cm) Wire Name Resistance (Ω) Crosssectional area (μm2) Resistivity -5500 PSIG (Ω•cm) R001 0.4342 35343 No. 32 1.19e-4 7.45e-5 R002 0.878 9424 No. 37 7.65e-5 6.39e-5 R003 1.047 9896 No. 36 6.19e-5 5.62e-5 Clean wire gives 10-4 to 10-5 Ω•cm resistivity Pressure serves to densify and lower resistivity OTC-25340 • Ultra-High Conductivity Umbilicals: Polymer Nanotube Umbilicals • Christopher Dyke Slide 21 Conclusions • Three year development effort currently in Q3 Year 2 • Project concludes with a prototype umbilical demonstration program planned for July 2015 • Carbon has advantages over copper • Optimization of growth is underway • Clean, densified wire gives Phase II targeted conductivity • Anticipate improvements to growth, alignment, and densification to achieve 10-6 resistivity Slide 22 Acknowledgements The presenter would like to thank Rice University for contributing to the paper and presentation. We gratefully acknowledge RPSEA and cost share partners, Shell, Total, DUCO, and Baker Hughes for their generous support. More information: [email protected] 713-928-6166 x 25 Questions
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