Investigation of Applications of 3D Printing to Oilfield Equipment: A Case Study of Hydrocyclones

Abstract Three-dimensional (3D) printing offers several advantages, including flexible design, faster production, cost-effectiveness, suitability for small-batch production and reduction of carbon emissions. In particular, by optimizing the structure of oilfield equipment and adjusting the microstructure of metal 3D printed parts, high-performance components can be manufactured for complex working conditions in the oilfield. Taking the hydrocyclone as an example, the preparation process is as follows. Firstly, the optimization of the hydrocyclone's structure. The response surface design was combined with computational fluid dynamics to optimize the type and parameters of the hydrocyclone. Secondly, the selection of 3D printing material. Maraging stainless steel was chosen as the 3D printing material based on the performance requirements of the hydrocyclone. Thirdly, determining the 3D printing process parameters. Parameters were selected based on the microstructures, mechanical properties, wear resistance, and corrosion performance of the 3D printed parts. Ultimately, a novel hydrocyclone was 3D printed, and its separation performance was evaluated using a laboratory testing system. Results show a variable pitch hydrocyclone structure with high separation efficiency was designed and a high-density hydrocyclone part was successfully printed. Heterogeneous microstructures present in 3D printing stainless steel lead to excellent strength (tensile strength, σb = 1184 MPa), toughness (impact energy, Wt = 149 J) and wear and corrosion resistance. The 3D-printed complex hydrocyclone features greatly improved separation efficiency (99.38%, which is 0.58% higher than that of the conventional structure). Based on the above results, an innovative mindset based on 3D printing for cost reduction and efficiency enhancement was formed, and a comprehensive technical system, from structural design to manufacturing, microstructure characterization and performance evaluation, was developed. The challenges and prospects of applying 3D printing in the oilfield were analyzed, with a focus on the research and development of key oilfield equipment. This research promotes applications of 3D printing in the petroleum industry and advocates for the intelligent manufacturing of high-end petroleum equipment.