Transcript The Declaration of Independence

Polymics
Leak-Proof Spill Containment System
for Oil & Gas Applications
By Tim Hsu, Ph.D.
Lin Zhang
www.polymics.com
Company Profile
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Founded 1994 in State College, PA.
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Production Facilities in US, China and Taiwan
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Headquartered in State College, PA
3 shifts provide 24 hour capability
Houston Sales & Support Office, TX
Manufacturing – Vertically Integrated
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Privately Owned Manufacturer
Technology Focused
 150 employees globally (50 US)
 Multiple patents on ultra-high performance
polymers being used by the Oil & Gas
Industry
Polymer Synthesis & Production
Specialty Formulation & Compounding
Compression & Injection Molding
Extrusion, Pultrusion & Filament Winding
Centrifugal Assisted Molding
Powder & Coating Technology
Testing & Pilot Development Laboratory
Clients include – Halliburton, Schlumberger
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Objectives in Drill Site Spill Containment
• Contain mud & frac fluid (water, sand, & chemicals) at drill sites
• Mat to be laid on graded patch of land with easy Installation & removal
• Mat to bear the load of any vehicle & containers On-Site
• Mat to provide leak-proof barrier without the need for an additional liner
Current Issues & Opportunities
• Limited supplier & availability of existing system components in use
• No primary sealing function provided by existing mat system
• Liner used as secondary seal but subject to tear, wear & potential for leakage
• Heavy components with complex Interlocking mechanism
• Difficult to dissemble during cold weather due to mud buildup
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Desirable Features by End Users
(Determined through Collaboration with Penn State)
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Leak Proof (proven through PSU Testing)
Installation without heavy equipment
Reusable (Durable)
Cost effective with minimal environmental impacts
Easy to transport from site to site
Manufacturability
Highly Functional (easy access, non-slip, built – in leak detection, etc.)
Quick assembly & disassembly
Target Technical Specifications
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Single piece dimensions not to exceed 10 ft. x 20 ft.
Material properties of the mat meets all loading requirements
Electrostatic dissipative desirable
Current Design – System Overview
Material Selection: Glass Fiber Reinforced Thermoplastic Composite
*Carbon fiber reinforced system could be used for specialty needs
Key Features:
•Each 5’ by 10’ mat weighs less than 150 Ibs!
(compared to over 500 lbs for the current Polyolefin mat system)
•Mats provide primary sealing eliminating the need for protective liner
•Significantly improved wear resistance
•Easy to assemble and disassemble
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Current Design - Mat
Internal Attachment
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Groves are cut on each side of the mat
Each mat is slid onto the interlocking support beam system
Gasket ensures leak proof connection between mats
No bolts are required for the attachment
“Brick Pattern” layout is adapted to ensure no leakage at the junction
Note: Mats currently utilized in Europe during mining operations to build temporary roads
(proven strength and durability)
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Current Curb Design
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Consistent design with thermoplastic GF
composite formed curb
Interlocking mechanism for sealing
Slides into the mat, no bolts required
Easy to manufacture and install
All pieces connect internally with secondary seal
Key Structural Components
a. Interconnecting Frame
b. Pultruded GRE channel
Allows Leak Detection Sensors and Hot Air Circulation during Winter
c. Interlocking internal connection with primary sealing function
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Cost & Supply Chain:
• Leasing Program will provide competitive cost versus existing system
• Elimination of protective liner reduces overall cost (and leak proof
mat system eliminates environmental impacts/ costs)
•Light Weight Components & Ease of Installation save on shipping and
handling (install/ disassembly) Costs
• All components currently available to offer system at this time
Path Forward
• Manufacture Prototype system for initial Pad test
• Goal: Mats and other components for demonstration
available in 60 to 90 days
• Produce 300 mats (15,000 sq. ft. pad)
• Team with drilling company to gather all performance data
• Ongoing research collaborative with PSU sponsoring graduate
research on specific topics
Summary
Acknowledgement
• Novel mat system will provide cost
effective alternative to existing system
• Minuteman Environmental Services
• In addition to providing leak and spill
containment, elimination of protective
liner also further reduces waste and
other environmental impacts
• Thermoplastic fiber reinforced mat
and curb design are ready for full scale
production & job site evaluation
• Assembly and manufacturing plant
can all occur in PA with minimal capital
investment
• Chesapeake Energy
• PSU Learning Factory