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KonRing – customised seals for H2 applications

The efficiency of systems that generate, transport, store and convert H2 back into electrical energy depends crucially on the material losses caused by leaks. According to previous surveys, around 20% of H2 is lost through leaks between its generation and utilisation, which highlights the immense economic importance of the sealing systems used.

The components in the hydrogen cycle, such as pumps, fittings, valves, pressure accumulators and couplings, require high-performance, safe sealing systems with a long service life that can prevent a potential explosion hazard under all operating conditions.

This is because hydrogen/air mixtures are flammable from approx. 4% upwards and explosive from 10% upwards. Throughout the entire process chain, units, pipes, connections, tanks and consumers such as fuel cells and their auxiliary units must be securely sealed.

The following section deals with the macroscopic view of the interaction between the surface topography of the installation space, the seal design and the material used.

In addition to the specific permeability of the elastomers used, the surface quality of the installation spaces is largely responsible for H2 gas losses. However, the commonly used roughness values, Ra, Rz, Rt, etc., alone are not sufficient to describe suitable installation spaces in a needs-oriented manner.

This can be clearly seen in the example of a surface with a given roughness depth Ra of 2.4 µm:

Fig. 1: Unsuitable design

Fig. 2: Desired design

The following constellation results at the contact point between the seal and the installation space:

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Fig. 3: Interface leakage

For effective sealing of the interface, it is important to press the seal as deeply as possible into the surface of the installation space in order to keep the leakage paths as small as possible. The necessary forces result from the given compression of the seal in the installation space. This is influenced by the material hardness of the seal, the necessary deformation of the seal and the permissible installation forces. Therefore, the sealing surface should be designed with a pronounced sealing edge if possible.

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Fig. 4: Comparison of sealing surface with KonRing and O-ring

Due to the extreme requirements already mentioned in the introduction, the selection of suitable materials is very limited and the core requirements are as follows:

High mechanical robustness (extrusion resistance, abrasion resistance)
Good cold flexibility
High elasticity
Low specific permeation rate
Long, maintenance-free service life

In addition, the design of the seal and support ring is crucial for the functioning of the present sealing requirements. This applies primarily to flange and coupling seals. However, the combination is also indispensable for all dynamic applications – whether as shaft seals or rod or piston seals.

Sealing System for H2 High Pressure Fluid Connector

KonRing – customised seals for H2 applications

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