1. Phenolic Resins and Phenolic Molding Compounds
Greg Spaeth
Project Engineer,
Materials Engineering Laboratory
Plastics Engineering Company
Presented at 2013 SPE Thermoset Division TOPCON

2. Phenolic Resins

3. Phenolic resins are synthesized in a pressure vessel by repeatedly linking phenolic monomers with aldehyde chemicals
Typically phenol and formaldehyde
Other phenols include
Cresol
Cashew nutshell oil
Another aldehyde used
Furfural
Process variations can result in a assortment of resin structures each demonstrating a wide range of properties

4. There are Two Types of Phenolic Resins
Novolac
Molar excess of phenol
Require an external curing agent
Two Stage
Usually hexamethylenetetramine or “Hexa”
Two year shelf life
Resol
Typically there is a molar excess of formaldehyde
Do not require an external curing agent
Single Stage
Six month shelf life

5. Phenolic Molding Compounds

6. Phenolic Molding Compounds
Phenolic Molding Compounds are produced by compounding
various fillers with Phenolic Resin
Typical Formula
50 % Phenolic Resin, resol or novolac
45 % filler
Woodflour
Minerals, talc, clay, ATH, etc.
Cotton
Glass Fibers
Carbon Fibers or graphite powder
5 % colorants and lubricants
Carbon Black
Zinc Stearate

7. The Oil and Natural Gas
Mining Process
as a Case Study for
Phenolic Materials

8. A well begins by drilling a large diameter hole extending below the fresh water

9. A surface casing is inserted to isolate fresh water and support the blow out preventer

10. Cement is pumped into the casing

11. The cement is forced out of the casing and up the well hole sealing of the aquifer

12. Wiper Plugs and Darts
Phenolic Core
Over molded rubber shell

13. Why Phenolic Molding Compounds?
The molded phenolic core provides superior strength and rigidity to enable the wiper plug to withstand the high pressures involved in forcing hundreds of cubic feet of concrete through the well casing
High Modulus provides stiffness and stability for the darts mandrel core and tighter griping for the elastomer wiper segments
Heat resistance allowing plugs rated for use at 400ºF
Easy drill out with small debris

14. The wiper plug is then drill out and the production well is drilled.

15. Production casing is lowered
It takes more than 350 casings weighing more then 85 tons to case a 10,500 foot well

16. Cement is once again pumped into the well

17. Again using a wiper plug the cement is force back up the well securing the casing

18. Fracturing the well then begins by lowering a perforation gun down the well casing

19. Small shaped explosives blast holes through the casing, cement, and into the formation

20. Fracturing fluid is pumped into the well

21. The fluid under extreme pressure causes the formation to fracture

22. Resin Coated Proppant Sand
Fracturing fluids varies among regions and well types, but typically consists of water (90+%) proppant (9%) and chemicals (<2%)

23. Resin Coated Proppant Sand
Once the fracturing fluid is removed, the phenolic resin coated sand remains behind and works as a prop to keep the fissures from sealing on release of pressure

24. Why Phenolic Resin?
Phenolic’s high modulus and excellent heat and creep resistance resists fracture under pressure as proven in industry “Conductivity test”

25. Why Phenolic Resin? Chemical Resistance
harsh chemicals found down hole can attack various proppant
including ceramic proppant
Curable Proppant
Enables the proppant to remain in place in wells with high pressure flow

26. The now fractured portion of the well is sealed off using fracturing ball

27. Fracturing Balls

28. Fracturing Balls

29. Why Phenolic Molding Compound?
Phenolic Balls offer an excellent combination of chemical and heat resistance with superior tensile and compressive strength compared with other plastic balls.
Customizable formulations allowing a specific gravity range of 0.8 to 3.5+

30. The perf gun is again lowered and detonated

31. The perf gun is again lowered and detonated
Again fracturing fluid is pumped into the well to fracture the new section of the well while the already fractured section is isolated by the frac ball

32. Fracturing Balls

33. Perforation and well fracturing is repeated as often as needed

34. Once fracturing is complete the balls are usually drilled or floated out

35. Surface equipment is put in place

36. Well begins production

37. Valve Components

38. Valve Components

39. Why Phenolic Molding Compounds?
Strength, rigidity, dimensional stability, creep resistance
A phenolic back-up ring allows internal pressure to anchor the seat within the valve body and prevents seat walking
Non-collapsible, stretch resistant, blow out proof, field replaceable
Chemical resistance and high hardness
Provide valve components that resists corrosive environments and do not deform under pressure allowing for repeated ball sealing

40. Other Applications Corrosive coatings for
Storage tanks, semi tank trailers, railroad tank cars, fans blowers, and fin tube coils
Binder for
Friction pads, brake pads, grinding wheels, plywood and particle board
Wear Resistance
Gas meter valves, pump seals, caster wheels
Dimensional Stability &Thermal Performance
Brake pistons, transmission parts, electrical motor brush cards
Electrical insulation
terminal strips, commutators, capacitor cans and caps

41. Offshore Applications

42. Why Phenolic Resin? Superior Creep Resistance
Strength and stability under load
Low weight high strength and modulus
Strength and rigidity
Chemically Resistant
Harsh marine environment
Excellent flammability resistance and low smoke and toxicity
Increased level of safety
High carbon and char yield
Retains level of strength and integrity should fire break out

43. Phenolic Properties Chemical Resistance Transmission oil,150ºC (302ºF)
Salt water, 65ºC (150ºF)
Beach, 65ºC (150ºF)
Unleaded gasoline, 22ºC (72ºF)
E85 Unleaded gasoline, 22ºC (72ºF)
SAE 30 Motor oil, 150ºC (302ºF)
Propylene glycol, 100ºC (212ºF)
Crude oil, 22ºC (72ºF)

44. Phenolic Properties
Chemical Resistance

45. Phenolic Properties
Chemical Resistance

46. Phenolic Properties
Chemical Resistance

47. Phenolic Properties
Chemical Resistance

48. Phenolic Properties
Chemical Resistance

49. Phenolic Properties
Comparison of Phenolic molding compound to engineering grade thermoplastics
Thermoplastics
20% fiber glass filled ABS
20% fiber glass filled Acetal
20% fiber glass filled PPA
20% fiber glass filled PPS
20% fiber glass filled Nylon66
Phenolic Molding Compound
Glass and mineral filled
PLENCO glass and mineral filled
PLENCO general purpose woodflour filled
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values

50. Data for phenolic and PLENCO materials are approximated from E scale
Phenolic Properties
Hardness
Data for phenolic and PLENCO materials are approximated from E scale
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values

51. Phenolic Properties Strength and modulus
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values

52. Phenolic Properties Strength and modulus
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values

53. Phenolic Properties Compressive Strength
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values

54. Phenolic Properties
Heat Resistance

55. Phenolic Properties Flammability resistance UL V-0 at 0.5mm
IEC Glow Wire GWFI and GWFI Rating 960ºC+ at 0.75mm
ASTM E162 Flame Spread 0.85*
*Source: Composites World
Author: Michael LeGault
Posted on: 2/14/2013

56. Phenolic Properties Post bake What is it? Why do it? How is it done?
Postbaking is a manufacturing step where molded parts are heated in an oven after being removed from the die.
Why do it?
Dimensional stabilize a part, especially for high temperature applications
Out-gas residual ammonia which is a by product of two stage cure
Improve strength
Sometimes only because the print tells you to
How is it done?
Ramp oven from room temperature to 15ºC below parts initial tg at 5º/min
Ramp oven to desired temperature at ºC/min to keep the oven temperature under the parts instantaneous tg
Do I need to do it?
Many Applications do not require a postbake, only a thorough understanding of the reasons to postbake will help you answer this question

57. Thank You Questions? Greg Spaeth Project Engineer,
Materials Engineering Laboratory
Plastics Engineering Company
Presented at 2013 SPE Thermoset Division TOPCON