INNOVATION SUBMERSIBLE PUMPS

FOR EXTRACTION OF OIL

WITH STAGES FROM AN ALUMINIUM ALLOY

WITH A PROTECTIVE CERAMIC COATING

We developed a conceptually new product – stages (main components) of submersible multi-stage oil extraction pumps from an aluminium alloy with a protective ceramic coating, which have no parallel in the world. The innovation stages are covered by three patents:

1. A new design of the stage with the open impeller, by Gubkin Russian State University of Oil and Gas;

2. A novel high-strength aluminium alloy with operating temperature up to 350 °C, by National University of Science and Technology MISIS;

3. A unique (Eurasian patent) nanostructured protective ceramic coating, which forms as the result of the action of low-temperature plasma on the surface of base material in an electrolyte medium, by LLC MEKHANIKA.

3.1. The protective ceramic coating on aluminium alloys possesses high wear resistance and corrosion resistance, does not change the geometric size of the item and enables substitution of traditional structural materials (iron, steel, bronze) in critical parts of various machines and mechanisms.

MARKET 1. Intensive extraction of oil leads to complicate the operating conditions of submersible pumps: temperature of borehole fluid, its chemical aggressiveness, amount of sand and gas increase. Under such conditions, pump stages undergo intensive abrasive wear and corrosion, which leads to reduce their life and to increase expenses for oil production.

2. In Russia, 77 % of oil is extracted by means of submersible pumps (80.5 thousand oil wells); their operation requires about 50 % of all electric energy consumed.

3. Annually, the industry requires about 25 million stages (one pump on average, 350 stages), the cost of which exceeds $ 1 billion; herewith, the real service life of the stages in oil wells with complicated extraction conditions is from 30 to 200 days.

4. Thus, essential tasks are to increase service life of submersible pumps and to decrease their electric energy consumption.

Competitive advantage

- An almost twofold reduction of stage height will enable a significant pump length decrease and operation in boreholes of greater curvature.

- Prime cost of novel stage production is 10 % lower than that of the standard stage from iron.

- Novel stages are primarily required for oil wells with complicated extraction conditions: 40 thousand wells now, 20 % more in four-year’s time.

- Reduced electric energy consumption by 15–20 % for the entire oil-producing industry of the Russian Federation will save $ 0.9–1.3 billion/year.

A pilot batch of novel stages successfully passed bench tests at the GRSU of Oil and Gas as compared with standard stages from iron with 18% Ni:

- Wear resistance of novel stages proved 5 times as high as the wear resistance of stages from iron.

- Weight of the stage decreased 4 times, which in practical terms ruled out vibrations ruining the pump.

THE TEAM

1. Vladimir N. Ivanovsky: Professor, DSc in Engineering; head, Department of

Machines and Equipment for Oil and Gas Industry, Gubkin Russian State University

of Oil and Gas; member, Expert Council on Mechanized Oil Recovery.

2. Nikolai A. Belov: Professor, DSc in Engineering; director, Engineering Centre

“Innovation casting technologies and materials” at the National University of

Science and Technology MISIS; author of over 30 patents on novel aluminium

alloys.

3. Aleksandr N. Alabin: PhD in Engineering; director general, LLC Mekhanika at

the National University of Science and Technology MISIS; co-author of the patent

for the novel aluminium alloy.

4. Vladimir N. Kokarev: Deputy director general, LLC Mekhanika; experience of

work in application-oriented projects at the Institute of Physics, Russian Academy

of Sciences; in microelectronics industry; work at executive positions in business.

5. Aleksandr S. Shatrov: Chief engineer of the project in LLC Mekhanika; one of

the founders of commercially successful company Keronite Ltd (UK), where he

worked for 5 years in the position of R&D director; author of 10 patents on PEO

technology.

1. Investments of $450 thousand for developing a new pilot installation to

form protective coatings, fabricate 1500 stages and conduct tests at an

operating oil well: 1.5 years.

2. Investments to the tune of $ 2.1 million for setting up a pilot section of

high-tech series production of innovative stages, 50 thousand/year: 1.5–2

years.

WHAT WE NEED

1. Establishing a joint venture with an interested investor. The market value

of only the MISIS patent is $ 1.9 million. The market value of all three

above-mentioned patents will be no less than $ 6.5 million, which amount

can be entered as registered capital.

2. Sales of stages for a sum of about $ 1.6 million per year will begin

immediately after the start of the pilot section to oil-related service

companies, which have already submitted applications for 200 thousand

stages.

3. Return of investments in 3 years.

4. We envisage expansion of production by scaling up in accordance with

demand, and production of other high-tech items.

5. In prospect, sales of licences are possible.

WHAT WE PROPOSE