Oil pipes account for more than 10% of the total steel used in the petroleum industry, and are major consumables and cost items in oilfield production. Remanufacturing technology can turn waste and unused tubing into new tubing with better performance. For oilfield companies that scrap a large number of tubings every year, it contains considerable economic benefits.
However, the tubing remanufacturing industry is still in the pilot stage in China, and there are not many people who know the remanufacturing technology, and fewer companies are applying it.
How to promote the concept of remanufacturing of used oil pipes and accelerate the development of the remanufacturing industry? Not long ago, the Chinese Academy of Engineering convened a conference on China's petroleum and natural gas pipe remanufacturing development strategy research project. More than 40 experts, including 5 academicians, discussed the development model and technical methods of China's petroleum pipe remanufacturing.
Remanufacturing 1 ton saves 50,000 yuan
Because of corrosion and partial wear all the year round, the inner wall of the tubing pipe and the joint threads are easily scrapped. Based on an average life of 10 years, the amount of waste oil pipes produced in China's oil fields each year is about 700,000 tons, and there are tens of millions of meters of scrapped sucker rods.
滨 Mr. Xu Binshi, academician of the Chinese Academy of Engineering and founder of China Remanufacturing Project, said that through the recycling and optimization of waste resources, petroleum pipe remanufacturing can save enterprises costs, guarantee production, and reduce energy consumption and pollution.
From the perspective of investment costs, remanufacturing of petroleum pipes can improve the performance of anticorrosion and wear resistance of oil pipes, prolong the service life of used oil pipes, and reduce the consumption of new oil pipes. Taking the N80 tubing of the injection well as an example, the rebuilt ceramic tubing is 89 yuan per meter without additional anticorrosion investment, and the investment per meter is reduced by 40 yuan. In addition, the service life of the rebuilt tubing is more than five times that of ordinary tubing, which means that one investment can save 5 investments. Based on the N80 tubing price of 0.76 million yuan / ton, rebuilding 1 ton of used tubing can save tubing costs by more than 50,000 yuan.
益 Li Yiliang, deputy director of the Equipment Research Institute of the China Petroleum Exploration and Development Research Institute, pointed out that from 2013 to 2014, China's petroleum oilfields consumed 25,440 tons of tubing and pipes, and the application of remanufacturing in petroleum pipes has good economic benefits.
再 In the production of oil wells, remanufactured tubing has greatly improved wear resistance, anti-wax, and anti-scaling performance than ordinary tubing, which can effectively save the high workover operation costs caused by tubing damage. Taking Changqing Oilfield as an example, the oilfield will use remanufactured waste tubing in 13 oil and water wells with the most severe corrosion and scaling. Among them, the operating times of 9 oil and water wells decreased from 66 to 10 times, saving operating costs of 730,000 yuan, increasing oil efficiency of 790,000 yuan, and greatly reducing tubing corrosion and wear.
In terms of resources and environment, waste oil pipes containing hazardous materials are easy to accumulate to form solid waste. Remanufacturing technology has activated these scrap assets. More importantly, the average life of remanufactured tubing is more than three times that of ordinary new tubing. The remanufacturing of 1 ton of used tubing means that 5 tons of steel can be reduced, 4.3 tons of standard coal can be saved, and 27.5 tons of water can be saved. Tons, reducing carbon dioxide by 10 tons.
Xu Binshi believes that the remanufacturing of petroleum tubing can not only recover the direct loss of the tubing, but also a large amount of the indirect loss of the oil field, which has "huge potential and imperative" in China.
Oil pipe rebuilding starts late, industry scale to grow
Petroleum equipment remanufacturing technology has been developed on the basis of prototype product manufacturing since it was developed in Europe, America, Japan and other places in the 1970s. It is mainly based on dimensional repair method and replacement repair method. , Manufacturing equipment and technical standards.
The remanufacturing of waste pipe in China started in the exploration of "waste pipe recycling technology" carried out in Jilin Oilfield in 2005. It has undergone the concept proposal, technology research and development, and pilot advancement, and its development has been only 10 years.
Technically, China's tubing remanufacturing technology started late, but later came on top, and individual technologies have made breakthroughs. The catalog of remanufactured products released by the Ministry of Industry and Information Technology shows that currently there are two types of self-developed tubing remanufacturing technologies in China: self-propagating repair technology and lining anticorrosive and wear-resistant tubing technology. Among them, self-propagating repair technology is in a leading position in China's petroleum equipment industry and even worldwide.
Yang Yongli, chairman of most companies that developed the technology, told reporters that currently there are bottlenecks in foreign self-propagating technology, and the length of repairable tubing is limited to 2 to 3 meters, while the technology independently developed in China has been able to successfully repair more than 10 meters. Tubing, and the cost per meter is 10 to 40 yuan lower than the new tubing.
In terms of application, about 10 oilfields in China have used remanufactured oil pipes on a trial basis, and basically received good results. As of the end of 2014, the lining anticorrosive tubing used in Shengli, Dagang, Jidong, Zhongyuan, Yanchang and other oilfields has reached more than 5 million meters, and it has treated more than 3,000 wells for anticorrosion, scale prevention and deviation prevention. Changqing, Xinjiang, Jilin and other oilfields have applied self-propagating repair technology to achieve a repair rate of 80% for oilfield waste oil pipes. Many oilfields have proposed to expand the use of recycled tubing.
On the scale of production capacity, the domestic remanufacturing capacity of tubing still needs to be further improved. China's annual scrap of oil pipes is about 700,000 tons, and it is also increasing year by year. However, the current domestic oil pipe remanufacturing capacity is less than 100,000 tons per year.
Li Yiliang said at the meeting that although there are a large number of state-owned private repair shops engaged in oil pipeline repairs in domestic oilfields, most of the utilization technology is only the primary classification and processing of waste oil pipes, which does not reach the level of remanufacture of "old, medium, new," used oil pipes. Recycling benefits are limited. This fundamentally limits the capacity scale of tubing remanufacturing.
The concept of “reengineering” for rebuilding of oil pipes
At present, the promotion of tubing remanufacturing faces rare policy opportunities. The state grants 10% of "replacement of old" subsidies for remanufactured products. If 500,000 tons of waste oil pipes are remanufactured, the state subsidy fund is 540 million yuan. For remanufacturing enterprises, remanufacturing 10,000 tons of used oil pipes can bring 80 million yuan in output value and considerable profits.
However, the remanufacturing project investigation team pointed out at the meeting that most employees in many oilfields in China, including material supply personnel, know very little about the waste pipe recycling policy and benefits. Zhang Feng, director of the Oil Well Tube Research Office of Baoji Steel Pipe Research Institute, said that the business direction of the oil pipe manufacturing companies of China Petroleum is mainly new oil pipes.
专家 The experts at the project meeting agreed that the current scale of the tubing remanufacturing industry is not large, and there are not many remanufacturing entities. The main reason is that the tubing remanufacturing concept is not popular enough. Therefore, the first thing is to increase the propaganda of the tubing remanufacturing industry.
In addition to the problem of conception and understanding, in the process of industrialization of the remanufacturing of the petroleum industry, it also faces technical and management problems.
Li Helin, an academician of Yanzhong Petroleum Pipe Research Institute, said at the meeting that in terms of technology, China's oil pipe remanufacturing technology has made some breakthroughs at present, but the future has a long way to go.
On the one hand, the liquid composition in oil and water wells is becoming more and more complicated as the development proceeds. At the same time, the development of deep wells and high pressure wells requires oil well pipes to have better corrosion resistance and higher strength. China's independent reconstruction technology of oil pipes has achieved initial success in some aspects, but the scope and depth of application needs to be expanded.
On the other hand, the types of tubing used in China's oil fields are diverse, with different calibers and complicated situations. To promote remanufacturing, we also need to adapt to local conditions and further develop its technology and equipment. Qi Dongtao, director of the Research Center for Composite Materials of the China Petroleum Pipe Research Institute, also said that non-metallic and composite tubing will be competitors to remanufactured tubing in the future.
In terms of management, tubing remanufacturing is an emerging industry, and relevant departments need to formulate industry standards as soon as possible. Li Yiliang said that at present, a systematic and perfect technical standard and quality of petroleum rod and tube remanufacturing should be established as soon as possible. In addition, it is necessary to improve the remanufacturing theory system, study the life assessment theory of waste tubing and remanufactured products, and establish a residual life assessment method for oil well tubing.