1. Introduction
With the continuous development of oil and gas exploration and production technology, PDC oil and gas composite sheets are a key drilling tool material. Its performance and quality are crucial to improving drilling efficiency, reducing costs and ensuring the smooth progress of mining operations. significance. This research report aims to deeply explore the material composition, preparation process, performance characteristics, application status and future development trends of PDC composite sheets, and provide a reference for research and production in related fields.
2. Structure and composition of PDC composite sheet
PDC composite sheets usually consist of a polycrystalline diamond layer (PCD) and a carbide substrate.
(1) Polycrystalline diamond layer (PCD)
PCD is made of diamond powder sintered under high temperature and high pressure conditions. It has extremely high hardness, wear resistance and cutting ability, and can effectively cut hard formations such as rocks. Factors such as the particle size distribution, mass purity, and sintering process parameters of diamond powder have a significant impact on the performance of the PCD layer.
(2) Carbide substrate
As a support for the PCD layer, the cemented carbide substrate has good toughness and strength and can withstand the impact force and torque during drilling. The selection and preparation process of the substrate material also play an important role in the overall performance of the composite sheet. Common cemented carbide components include WC (tungsten carbide), Co (cobalt) and other elements, which can be adjusted by adjusting their composition ratio and microstructure. Optimize substrate performance.
3. Preparation process of PDC composite sheets
(1) High temperature and high pressure synthesis method
This is currently one of the most commonly used methods for preparing PDC composite tablets. After uniformly mixing the diamond powder with an appropriate amount of metal catalyst, place it on the cemented carbide substrate, and then sinter it in a high-temperature and high-pressure equipment, so that the diamond powder undergoes phase change and sintering under high-temperature and high-pressure conditions to form a polycrystalline diamond layer and Composite sheets with substrates tightly bound together. This method can prepare PDC composite sheets with high quality and performance stability, but the equipment cost is high and the process control requirements are strict.
(2) Other preparation methods
In recent years, some new preparation methods such as plasma enhanced chemical vapor deposition (PECVD) and explosion sintering have also received certain attention in the preparation research of PDC composite sheets. These methods have certain advantages in specific aspects. For example, the PECVD method can prepare the PCD layer at a lower temperature, which is beneficial to improving the toughness of the composite sheet; the explosion sintering method has the characteristics of fast and efficient, but currently these methods are not used in industrial production. There are relatively few applications and are still in the research and optimization stage.
4. Performance characteristics of PDC composite sheets
(1) Hardness and wear resistance
PDC composite sheet has extremely high hardness, its hardness value can reach HV3000-8000, which is much higher than ordinary carbide and steel. This makes it have excellent wear resistance when cutting rocks and can significantly improve the use of drill bits. life, reducing the number of tripping trips, thereby improving drilling efficiency.
(2) Cutting performance
Due to the high hardness of the PCD layer and the sharp cutting edge, the PDC composite sheet can generate less cutting force and heat when cutting rock, which is beneficial to protecting the integrity of the rock and reducing problems such as well wall collapse and formation damage during drilling. , and also reduces the energy consumption of drilling equipment.
(3) Impact toughness
Although the hardness of the PCD layer is very high, through reasonable design and preparation process, the PDC composite sheet can have a certain impact resistance and toughness, and can withstand various impact loads encountered during drilling, such as formation changes, drill bit runout, etc., and is less likely to occur. rupture and damage, ensuring the continuity and stability of drilling operations.
(4) Thermal stability
PDC composite sheets have good thermal stability within a certain temperature range and can maintain stable performance in high-temperature environments. They will not cause graphitization or other performance degradation of diamond due to high temperatures, which is important for high-temperature applications such as deep wells and ultra-deep wells. Drilling operations in environmental conditions are particularly important.
5. Current application status of PDC composite sheets in the oil and gas industry
(1) Drilling field
As one of the main tools for oil and gas drilling, PDC drill bits are widely used in drilling operations in various formations, especially in soft to medium-hard formations. PDC drill bits have the characteristics of fast drilling speed, long drill bit life and low drilling cost. Low-grade drill bits have obvious advantages and have become the mainstream drill bit type in modern drilling technology. With the continuous improvement of the performance of PDC composite sheets and the innovation of drill bit design and manufacturing technology, its application scope is gradually expanding to hard formations and complex formations.
(2) Well completion field
In oil and gas well completion operations, PDC composite sheets are also used in the manufacture of some special tools, such as slotted liners, sand control screens, etc. By inlaying PDC composite sheets on the surfaces of these tools, their wear resistance and resistance can be improved. Corrosive, extend the service life of tools and ensure the quality and effect of completion operations.
6. Market status and competition landscape of PDC composite tablets
(1) Market size
As global oil and gas exploration and development activities continue to be active, the demand for PDC composite sheets is also growing. In recent years, the size of the PDC composite sheet market has shown a steady upward trend, and is expected to maintain a certain growth trend in the next few years, mainly driven by factors such as oil and gas development in emerging markets and the production increase and transformation of old oil fields.
(2) Competitive landscape
At present, the global PDC composite sheet market is highly competitive, with major manufacturers concentrated in the United States, China, South Korea and other countries. Internationally renowned companies such as Schlumberger and Halliburton in the United States occupy a large share of the high-end PDC composite chip market with their advanced technology, brand advantages and global sales network; domestic companies such as Sifangda and Huanghe Tornado continue to increase research and development Investment and technological innovation have gradually improved product quality and market competitiveness. It has also gained a certain market share in the mid-to-low-end market and some high-end market areas, and has shown a trend of marching into the high-end market.
7. Development trends and challenges of PDC composite tablets
(1) Development trends
High performance
In the future, PDC composite sheets will develop towards higher hardness, wear resistance, impact toughness and thermal stability to meet the needs of oil and gas exploration and development to expand into deep wells, ultra-deep wells, ocean deep water and complex formations. By improving the material formula, optimizing the preparation process, and using new diamond powder and substrate materials, the comprehensive performance of the composite sheet is continuously improved.
Personalized customization
With the continuous development of drilling technology and the increasing diversity of drilling conditions, the performance requirements for PDC composite sheets are becoming more and more personalized. In the future, production companies will pay more attention to developing customized PDC composite sheet products based on different formation conditions, drilling processes and customer needs to achieve the best drilling results and economic benefits.
Intelligent manufacturing
Utilize advanced digital technology, intelligent manufacturing technology and big data analysis technology to realize intelligent control and quality monitoring of the PDC composite sheet production process, improve production efficiency and product quality stability, reduce production costs, and provide support for product development and optimization Provide data support.
(2) Challenges faced
Technical bottleneck
Although significant progress has been made in the development and production of PDC composite sheets, there are still some technical problems that need to be overcome, such as how to further improve the cutting performance and service life of composite sheets in super-hard formations and high-temperature and high-pressure environments, and how to solve The problem of the interface bonding strength between the PCD layer and the substrate, and how to achieve large-scale, low-cost preparation of high-performance PDC composite sheets, etc.
Raw material supply and costs
The supply stability and price fluctuations of diamond powder and some special cemented carbide raw materials have a certain impact on the production and cost control of PDC composite sheets. As market demand increases, the supply of raw materials may face certain pressure. At the same time, rising raw material prices will also compress the profit margins of enterprises. Therefore, how to ensure a stable supply of raw materials and reduce raw material costs is one of the important challenges faced by enterprises. .
market competition pressure
Competition in the global PDC composite sheet market is fierce. Companies not only have to face competition from internationally renowned brands, but also price competition and technology competition among domestic peers. As market competition becomes increasingly intense, companies need to continuously improve their core competitiveness, strengthen brand building and market expansion capabilities, so as to remain invincible in the fierce market competition.
8. Conclusion
As a key material in the oil and gas industry, PDC oil and gas composite sheets play an important role in drilling and completion. By continuously improving the preparation process and optimizing material composition and performance, the market size and application scope of PDC composite sheets continue to expand. However, its development also faces many challenges such as technical bottlenecks, raw material supply and cost, and market competition. In the future, with the continuous advancement and innovation of technology, PDC composite sheets are expected to make breakthroughs in high performance, personalized customization and intelligent manufacturing, providing more powerful support for efficient and safe mining of the oil and gas industry.
