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:
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!