Sealing Solutions for Hydrogen Service Valves: An Essential Guide

As the world transitions to cleaner energy sources like hydrogen, the demand for advanced technology to handle and store this volatile gas has increased. Hydrogen is colourless, odourless, highly flammable, and has unique properties that make it difficult to store and transport. One critical component in hydrogen systems is the valve, and by extension, the sealing solutions that ensure the valves operate efficiently and safely.

This blog explores the operational conditions of hydrogen valves and the various sealing solutions designed to meet these demands.

Understanding Hydrogen Valve Operating Conditions

Before delving into sealing solutions, it’s important to understand the challenges hydrogen presents in valve operations:

1. Molecular Size
Hydrogen has the smallest molecular size of any element, allowing it to penetrate lower-grade stainless steel and leak through poorly designed packings and joints. Such leakage poses significant safety risks and leads to unnecessary material loss.

2. High-Pressure Storage
Hydrogen’s low volumetric energy density necessitates storage in high-pressure tanks, typically ranging from 350-700 bar (5,000-10,000 Psi). These extreme pressures demand robust sealing solutions that can withstand such conditions without failure.

3. Speed and Vibration
The high-speed flow of hydrogen can create turbulence and sudden pressure surges. This dynamic environment impacts the structural integrity of the system and the performance of sealing components.

4. Hydrogen Embrittlement (HE)
Hydrogen embrittlement is the degradation of a metal’s mechanical properties due to hydrogen absorption. Materials not specifically chosen to resist this phenomenon can erode and lead to seal failure and leaks.

5. Wide Temperature Range
Hydrogen systems operate across a vast temperature spectrum—from cryogenic conditions (-253°C for liquid hydrogen) to high temperatures exceeding 300°C in industrial settings. Seals must perform reliably across these extremes.

Types of Sealing Solutions for Hydrogen Valves

Hydrogen systems utilize various sealing materials and profiles, tailored to specific operating conditions. Here’s a detailed overview of the sealing solutions available:

1. Elastomer Sealing Profiles

O-Rings
X-Rings
Square Rings

These elastomer seals are flexible, making them suitable for dynamic and static applications. They are often used in conjunction with other materials to enhance performance.

2. Engineering Plastic Sealing Profiles

PTFE (Polytetrafluoroethylene)
PCTFE (Polychlorotrifluoroethylene)
PEEK (Polyether ether ketone)

Plastic sealing profiles are highly resistant to chemical attacks and extreme temperatures. They are commonly used for valve seats and dynamic seals.

3. Soft Materials for Seals and Gaskets
Soft materials are essential for creating seals in critical environments. Below is a breakdown of high-performance materials used for hydrogen valve sealing:

Name	Material	Temperature Range	Properties
Vertex H 17	HNBR 90 LT AED	-46°C to +160°C	– Excellent resistance to Hydrogen permeation – Good mechanical strength and abrasion resistance
Vertex FC 10	FKM 90 GLT AED	-30°C to +204°C	– High chemical resistance and low permeability to hydrogen. – Not ideal for low-temperature applications
Vertex FC 15	FKM 90 LT AED	-46°C to +204°C	– High chemical resistance and low permeability to hydrogen. – Not ideal for low-temperature applications
Vertex F 01 ED	FFKM 90	-10°C to +250°C	– Exceptional chemical resistance, even at high temperatures – Low permeability to hydrogen – High cost, used in critical or extreme environments
Vertex F 04 HT	FFKM 90 HT	-10°C to +315°C	– Exceptional chemical resistance, even at high temperatures – Low permeability to hydrogen – High cost, used in critical or extreme environments
Vertex F 07 LT	FFKM LT AED 90	-10°C to +315°C	– Exceptional chemical resistance, even at high temperatures – Low permeability to hydrogen – High cost, used in critical or extreme environments
Novum P 01	Virgin PTFE	-200°C to +260°C	– Used for static and dynamic seals, often paired with backup rings to prevent extrusion – Very low hydrogen permeability
Novum PK 01	PEEK	Continuous +250°C	– High mechanical strength and wear resistance – Suitable for dynamic applications
Novum PCT 01	PCTFE	-200°C to +150°C	– Outstanding performance at cryogenic temperatures – Low permeability and high chemical resistance – Ideal for liquid hydrogen applications
Novum PA 01	Polyamide	-60°C to +120°C	– Good mechanical properties and moderate resistance to hydrogen permeation

Choosing the Right Sealing Solution

Selecting the ideal sealing solution for hydrogen valves involves considering:

• Operating pressure and temperature
• Environmental exposure (cryogenic, high temperature, etc.)
• Dynamic or static application
• Material compatibility with hydrogen

Final Thoughts

As hydrogen continues to play a pivotal role in the global energy transition, ensuring the safety and efficiency of hydrogen systems is paramount. Advanced sealing solutions designed for hydrogen service valves are not just a necessity but a critical component in achieving sustainable and reliable energy storage and transportation.
Investing in high-quality, application-specific sealing solutions will help industries navigate the challenges of hydrogen systems while ensuring safety and operational efficiency.

Do you need expert advice on choosing the right sealing solution for your hydrogen systems? Contact us today for tailored recommendations and high-performance sealing products that ensure safety and efficiency in your applications!

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Food & Beverage Industry Sealing Solutions

Elastomers are resistant to chemicals and temperature fluctuations, which helps protect equipment from corrosion and degradation, especially in the food & beverage industry.

These sealing solutions are generally used in pumps, valves, mixers and grinders. These components are designed to maintain high hygiene and safety standards that comply with relevant best practices for various industrial applications, including the food and beverage industry.

Choosing the right elastomer materials is pivotal in ensuring safety and non-toxicity and delivering quality food products to consumers.

The Critical Role of Sealing in Food & Beverage Production

These materials are highly suitable for the food industry, being easy to clean and sanitize, which minimizes the risk of bacteria, mold, or other microorganisms.

They also resist high-temperature cooking, pasteurization, freezing or sterilization processes. ISMAT chooses premium elastomer materials, ensuring the food quality remains unaltered while preventing reactions with ingredients such as oils, fats, or sugar.

Food Safety demands strict adherence to global industrial standards, serving as a benchmark for material compliance.

•     FDA 21 CFR 177 (U.S. Food Contact Substance Regulations)
•     European Commission Regulation (EC) No 1935/2004
•     NSF (National Sanitation Foundation) standards

The Science of Elastomer Selection

Food-grade certifications are essential; they ensure that food processing and packaging are sterilized and protected. These safety measures prominently reduce the risk of food contamination caused by leaching.

Apart from safety measures, the food industry should deliver high-quality products, i.e., hygienic products, to consumers. ISMAT meticulously works on both industrial standards such as safety and hygiene and chooses quality elastomer materials that possess chemical-resistance to detergents, cleaning agents, acids and solvents

Physical Properties for Effective Sealing:

High-temperature resistance sealing properties of rubber seals and gaskets, are essential for ensuring leakage-proof, a crucial factor in safeguarding food and beverage products. The elasticity element in elastomer material retains the ability to stretch and maintain its original shape, which helps the rubber seal and gasket function in dynamic conditions.

Environmental Factors:

The food processing environment is highly susceptible to absorb water, steam, or moisture which causes swelling, and degradation.  Elastomer materials should be resistant to UV and Ozone radiation, which prevents the materials from degradation, cracks and seal failures.

Types of Elastomers Used in the Food & Beverage Industry

Here are the various Elastomers that are widely used in food and beverage equipment based on needed specifications. Let us see how it is practically applied in the food and beverage industry.

1. EPDM (Ethylene Propylene Diene Monomer): Though this type of elastomer material has high resistance to temperature and chemicals, it is highly suitable to withstand steam and water but not oils and fats.
2. Silicone: This type is highly resistant to temperature and chemicals; silicone is commonly used in rubber seals and gaskets, in equipment like ovens, mixers, and dispensers.
3. FKM (Fluoroelastomers): This type of material is highly resistant to chemical and temperature, frequently used in food and beverage equipment, where it is highly exposed to harsh chemicals and high-temperature.
4. Nitrile Rubber (NBR): Nitrile rubber is highly suitable for oils, fats, and fuels, offering excellent protection against greasy or fatty foods.
5. Polyurethane: This material highly withstands chemical abrasion and is a durable choice for distinct industrial applications.

The Cost-Benefit Analysis

Cost reduction with increased productivity are key factors in industrial operations. The choice of the right materials will meet the industrial standards with their specific requirement. The high-quality, temperature and chemical resistance elastomers will ensure the equipment’s longevity and smooth functioning, thereby cutting down on costs that can be incurred due to failure rates, replacements, production delays and downtime.

We analyze, craft and install the best elastomer materials suitable for your industrial needs.

Conclusion

At ISMAT, we help you in choosing the right elastomer materials. Furthermore, we provide you with maintenance tips to extend the shelf life of food equipment, and its effective functioning.

These elastomer materials with unique properties such as high-temperature and chemical resistance and their elasticity (for Rubber seals and Gaskets) fit dynamic applications and ensure safety and hygiene along with Food Safety Regulations, contributing to the best service across the globe with overall efficiency and reliability.

Reach out to our technical team to choose an ideal sealing solution, ensuring optimal performance with enhanced durability for your food and beverage applications.

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