Enhanced chemical and thermal resistance of graphene-reinforced fluoroelastomer O-rings: Field testing in very sour service and laboratory characterization

O-rings made from graphene-enhanced fluoroelastomer (FE/GE) nanocomposites were tested in mechanical seals of centrifugal pumps in high-pressure sour condensates. After 18 months of service, the O-rings remained intact, with no cracks, swelling, or visible damage, demonstrating exceptional durability. Post-field-testing analyses, including Fourier Transform Infrared Spectroscopy (FT-IR) and Raman Spectroscopy, showed a decrease in fluorocarbon bands and an increase in C-S and C-H bonds, indicating chemical interactions with the condensate. Raman spectroscopy and Field Emission Scanning Electron Microscopy (FESEM) confirmed surface integrity, while Energy Dispersive Spectroscopy (EDS) detected reduced fluorine and increased sulfur content, highlighting the nanocomposite’s resilience. This study explores enhancements in FE thermal stability and durability through GE incorporation. Conventional FFKM (perfluoroelastomer) O-rings are costly and last only about 6 months. The FE/GE nanocomposite was characterized using various analytical techniques. Thermogravimetric Analysis (TGA) demonstrated superior thermal stability compared to pure FE. FT-IR and Atomic Force Microscopy (AFM) analyses before and after aging tests showed improved thermal resistance and minimal degradation due to presence of GE. Overall, GE-filled FE nanocomposites present a promising, cost-effective solution for durable O-rings in sour service applications. This work differs from previous GE-filled FE studies in that it combines laboratory characterization with 18-month field exposure in a very sour condensate environment to evaluate the real service performance of GE-reinforced FE O-rings.