Composite Polymeric Sucker Rod Guides: State-of-Practice, Causes of Failure, and Circular Economy Opportunities

The oil and gas industry generates substantial amounts of polymeric waste each year, including sucker rod guides manufactured from premium thermoplastics such as Polyphenylene Sulphide (PPS), Polyacrylamide (PAA), Polyamide (PA), and Polyether ether ketone (PEEK). It is estimated that, annually, approximately 18,600 metric tonnes of polymeric sucker rod guides are discarded worldwide, contributing significantly to landfill accumulation. This paper critically reviews the behaviour of polymeric rod guides when exposed to downhole environments where high temperature, pressure, contamination, and severe mechanical stresses act simultaneously. These components are essential in maintaining system reliability, yet research and development on polymeric rod guides remain limited, and investigations into their degradation and failure mechanisms are non-existent. In addition, there are currently no established approaches for recycling or reusing worn polymeric guides, which restricts progress toward sustainability and contributes to the increased accumulation of polymer waste in landfills. This review highlights these gaps and discusses future research directions that could improve the performance and service life of glass-fibre-reinforced polymeric components, while also creating opportunities for recycling and circular economy.