Aliphatic Polyketone, An Alternative Material For The Oil & Gas Industry

Aliphatic polyketone, an
alternative material for

the Oil & Gas industry.
Nick Barron
Global Industry Manager Oil & Gas
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. Must not be reproduced,
forwarded or distributed except in accordance with NATIONAL COMPOSITES CENTRE's agreement with Applied Market Information Ltd.
13/12/2016 This document is digitally watermarked.AMI Non-metallics for Oil & Gas 2016 (Röchling) 1
Presentation Agenda
• Röchling who we are?
• What is polyketone?
• Material features:
- Chemical resistance
- Tribology properties
• Application information.
• Conclusion
Rӧchling: Materials processor & Machinists
Thermoplastic range Thermoplastic processing
Extrusion
Compression
Moulding
Casting
Röchling: Corporate overview
Presentation Agenda
• Conclusion
What is Polyketone?
• Polyketone (SustaKON) is a new polymer to the global thermoplastic market.
1930s Nylon (PA)

1938 PTFE
1939 LD-PE
1940s PET
1953 HD-PE
1959 POM-H
1962 POM-C
1969 PVDF
1977 PAEK
1983 PEEK
1980s PPS
Present Polyketone (PK)
What is Polyketone?
• Polyketone (SustaKON) is a terpolymer aliphatic polyketone.
• What are the differences between a terpolymer, copolymer & homopolymer:
Homopolymer
Copolymer
Terpolymer
• Polyketone (SustaKON) is a terpolymer aliphatic polyketone with the polymer

structure being
- Ethylene
- Propylene
- Carbon Monoxide
What is Polyketone?
O O
C O O C O
O O C O O
O
Aliphatic Polyketone (SustaKON) Aromatic Polyketone (e.g. PEEK)
• Semi-crystalline
O O O • Semi-crystalline
O
• ExcellentC chemical resistance
C C • ExcellentCchemical resistance
O
• C Low moisture absorption

O
• Low moisture absorption
O C C
• O Short term max. usage temp. 150 °C • Short term max. usage
O temp. 310 °CO
• Elongation at break >70% • Elongation at break >20%
• Hardness 78 (Shore D) • Hardness 88 (Shore D)
• E-Modulus 1700 Mpa (ISO 527) • E-Modulus 4000 Mpa (ISO 527)
• ££ • £££££
Polyketone: material properties
Dimensional stability: moisture and thermal expansion.
3
Water absorption (%) 50% RH @ 24 h
Nylon 66
2.5
1.5
1 Nylon 12
0.5
PEEK (450G) Polyketone
POM-C (Acetal) UHMW-PE
0 PVDF
0 50 100 150 200 250
Coefficient of linear thermal expansion (10-6 K-1)
Mechanical properties: impact strength and elongation at break.
UHMW-PE
25
Charpy notched impact strength
20 Nylon 12 (dry)
(kJ/m2)
15
PVDF Polyketone
10
POM-C (Acetal) Nylon 66 (cond.)
5
Nylon 66 (dry)
0 PEEK (450G)
0 50 100 150 200
Elongation at break (%)
Mechanical properties: yield stress and E-Modulus
120
PEEK (450G)
100
Yield Stress (MPa)
Nylon 66 (dry)
80
Polyketone
POM-C (Acetal)
60 PVDF
Nylon 12 (dry)
40 Nylon 66 (cond.)
20
UHMW-PE
0
0 500 1000 1500 2000 2500 3000 3500 4000
E-Modulus (MPa)
Presentation Agenda
• Conclusion
Chemical resistance: 38% H2SO4 (Battery acid).
After 30 h After 48 h After 35 days
Nylon 66 GF30 Polyketone GF30

Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. Must not be reproduced, [Source: AKRO-Plastic GmbH]
Chemical resistance: comparison between polyketone & nylon 66
ZnCl2 as per SAE J 2044

Retention of tensile strength after
continuous exposure at 80 °C for 25 days
Chemical Polyketone Nylon 66

H2O 102% 61%
1% HCl(aq) 102% Failure PA 66 GF30 after 2 h
1% NaOH(aq) 101% 59%

5% CaCl2 (aq) 102% 63%
50% ZnCl2 (aq) 81% Failure
Ethylene Glycol 104% 65%
PK GF30 after 200 h
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. Must not be reproduced, [Source: AKRO-Plastic GmbH]
Polyketone: friction and wear
Wear rate vs. Steel.
100
UHMW-PE
PU (Shore D 62)
Dynamic wear rate (μm/h)
80
PTFE + 20% Carbon
60
PTFE + bronze PTFE + 23% carbon

+ 2% graphite
40
Polyketone Rotating shaft test conditions:
Pressure; 7 Mpa, Rotational speed 0.1 m/s,
20 Counter surface 16MnCr5,
PTFE + 10% Carbon 50 °C, 48 h.
Esso Nuto H68 Oil.
0
0 50 100 150 200 250 300
Initial wear rate (μm)
[Source:
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. UnibeStuttgart,
Must not Institut für Maschinenelemente]
reproduced,
Polyketone: friction and wear
Coefficient of friction vs. Steel.
Coeficient of friction vs. Steel
0.2 Rotating shaft test conditions:
Pressure; 7 Mpa, Rotational speed 0.1 m/s,
Counter surface 16MnCr5,
50 °C, 48 h.
0.15 Esso Nuto H68 Oil.
0.1
0.05
0
PTFE + 10% PTFE + 20% PTFE + 23% PTFE + PU (Shore D UHMW-PE Polyketone
Carbon Carbon carbon + 2% bronze 62)
graphite [Source:
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. UnibeStuttgart,
Must not Institut für Maschinenelemente]
reproduced,
Polyketone: Tribology
Polymer thrust washers on steel (stainless).
Static coefficient Dynamic coefficient Limiting PV

Polymer Average wear
(10-15 m3/N-m)
of friction of friction @ 0.5 m/s
(0.17 Mpa) (0.17 Mpa, 0.5 m/s) (Mpa – m/min)
Polyketone 4.33 0.07 0.49 67.67

Nylon 66 16.01 0.09 0.64 56.75
POM-C 13.09 0.04 0.30 48.35
POM-H 4.23 0.04 0.45 31.7
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. Must not be reproduced, [Source: Carilon]
Polyketone: wear resistance
Tribology: polymer on polymer gear wear
Spur-Gear Wear Polymer/ Average wear
(12 Diametral pitch 20° pressure angle, 4.4 m/s)
Polymer (10-15 m3/N-m)
PK/PK 18.9
POM-C/
PA/PA 24.7
POM-C
POM-C/
231.7
POM-C
PA/ PA PV = 2.1 (P = 0.35 Mpa, V = 6 m/s)
PK/ PK
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. Must not be reproduced, [Source: Shell]
Presentation Agenda
• Conclusion
Polyketone: Application information
Barrier properties: Fuel line permeability to unleaded gasoline at 93 °C
Testing occurred following a similar process to: GM 9061P (Permeability Test for
Fuel Hose and Tubing)
Thermoplastic tube filled with media

and sealed then held at constant
temperature with the mass loss
measured as function of exposure time.
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. Must not be reproduced, [Source: Carilon]
Creep resistance.
Licensed for the exclusive use of NATIONAL COMPOSITES CENTRE downloaded on 22/12/2016 at 15:32:29. Must not be reproduced, [Source: Shell]
Polyketone: application
Further applications.
Function.
• Roller
Properties.
• Good sliding properties.
• Excellent wear resistance.
• Good dimensional stability.
• Thermal resistance
Function.
• Gear
Properties.
• Good sliding properties.
• Excellent wear resistance.
• Good dimensional stability.
Polyketone: Potential advantages
• Enhanced safety factor, regarding wear resistance and chemical resistance for
nylon (6, 6.6, 12…) for seal/ lining or gasket applications.
• Possible to replace PE, PP, POM, PVDF and PEEK depending on the application
environmental conditions.
• Potential applications include:
- valve seats and seals.
- gear wheels and rollers.
- guide pulleys for steel/PE polymer ropes.
- further sliding and wear applications (slide pads).
- impact and creep resistant applications.
Polyketone: Summary of features
• Polyketone (SustaKON) is a new terpolymer aliphatic polyketone.
• This special polymer chain combines the best of common thermoplastic
materials such as nylon (PA), polyethylene (PE), polyvinylidene fluoride (PVDF)
and polypropylene (PP) and polytetrafluoroethylene (PTFE).
• These optimal properties include:
- naturally excellent chemical resistance
- very high wear resistance
- good dimensional stability (thermal & moisture)
Rods Tubes Sheets

Up to 180 mm Up to 350 mm Up to 50 mm
diameter diameter thickness
Polyketone with 30% Glass fibre also possible.
Polyketone: Summary of features
• The unique property profile of Polyketone (SustaKON) makes it a universally suitable
material (<150 °C) for applications that require a range of properties at the same time.
Water
absorption
Yield Stress
Polyketone
Chemical Elongation at
UHMW-PE
resistance Break Nylon 66
Nylon 12
PVDF
PEEK (450G)
Price E-Modulus
Service
Wear resistance
temperature
We don`t sell products
we sell added value
Competence Quality Innovation
PE, PP, POM, PA (nylon), PET, PK, PVDF, PTFE, PEEK, PEI, PPS, PPSU, PES, PSU, Epoxy, Polyester.
This document is digitally watermarked.
Contact us
Dr. Nick Barron
Global Industry Manager Oil & Gas
Tel. +44 7807 842 644
nbarron@sustapast.de
Competence Quality Innovation

www.roechling.com
PE, PP, POM, PA (nylon), PET, PK, PVDF, PTFE, PEEK, PEI, PPS, PPSU, PES, PSU, Epoxy, Polyester.
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Aliphatic polyketone, an

alternative material for

1930s Nylon (PA)

• Polyketone (SustaKON) is a terpolymer aliphatic polyketone with the polymer

• C Low moisture absorption

After 30 h After 48 h After 35 days

Nylon 66 GF30 Polyketone GF30

ZnCl2 as per SAE J 2044

Chemical Polyketone Nylon 66

1% NaOH(aq) 101% 59%

PTFE + bronze PTFE + 23% carbon

Static coefficient Dynamic coefficient Limiting PV

Polyketone 4.33 0.07 0.49 67.67

Thermoplastic tube filled with media

Rods Tubes Sheets

Competence Quality Innovation

Competence Quality Innovation

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