Hydrogen has emerged as a promising alternative energy source, playing a crucial role in clean energy initiatives and reducing reliance on fossil fuels. One of the fundamental technologies in hydrogen production is electrolysis, which utilizes electrical current to separate water into its elemental components, hydrogen and oxygen. Specialized sealing solutions are essential to ensure the efficient and reliable operation of electrolyzers and those auxiliary systems.
The Importance of Sealing Solutions
Sealing solutions are essential in maintaining the integrity and efficiency of hydrogen production systems. In electrolyzers, where water is converted into hydrogen and oxygen, the seals must withstand challenging operating conditions while preventing leakage and ensuring the separation of hydrogen and oxygen. By meeting the following key requirements for both the anode and cathode path, sealing solutions contribute to the overall efficiency, safety, and sustainability of hydrogen production processes.
- Withstand pressures up to 65 bars
- Deal with temperatures up to 80°C
- High purity and cleanliness
- Chemical resistance against hydrogen, oxygen, sulfuric acid, potassium hydroxide and water
- Low hydrogen permeability rate
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Securing Electrolyzer Efficiency with Bipolar Plate Seals |
| Elastomeric seals have to withstand a variety of media. This would include not only pressurized hydrogen at elevated temperatures but also pressurized pure oxygen, water, and sulfuric acid or potassium hydroxide solutions. At the same time the cleanliness of the material is of high importance. (Ionic) organic and metallic substances may leach out into the media present in the electrolyzer and may harm the catalytic system and/or the membrane. The high pressures further demand a durable compound and to provide good sealing over the entire product life-time, a good compression set is vital. |  |
Ensuring Performance in Balance of Plant Components
Balance of Plant (BoP) components play a crucial role in the overall functionality of electrolyzer systems, supporting the efficient and reliable production of hydrogen. Within the BoP, various sealing solutions, including static seals, O-rings, and overmolded seals are essential to maintain system integrity and prevent leaks.
Critical Testing Methods for Hydrogen Sealing Solutions
Testing is a crucial part in the development of materials compatible with hydrogen applications. Testing methods include permeability evaluations using hydrogen or helium gas at various pressures and temperatures, volume and weight changes in contact with hydrogen, and tests simulating rapid gas decompression (RGD) events that may cause severe material damages. Aging tests in pure, pressurized oxygen at elevated temperatures and chemical aging tests in aqueous sulfuric acid or potassium hydroxide solutions are vital for lifetime prediction as well. Oxygen attacks and degrades the polymer backbone over time and the contact with aqueous media may cause swelling and additional degradation.
For above mentioned reasons, deep knowledge of the application, testing methodology and materials is absolutely essential in order to develop cutting-edge sealing solutions for hydrogen applications.
Datwyler’s Answer to Hydrogen Challenges
Leveraging decades of expertise in material science, solution design and operational excellence, Datwyler provides a range of high-performance sealing solutions tailored to meet the specific and demanding requirements of hydrogen systems.
With a commitment to innovation and quality, Datwyler is a trusted partner for customers seeking reliable sealing solutions, including electrolysers, for their hydrogen applications along the entire value chain.
Dr. Sarah-Elisabeth Dechent
Material Development Manager
Products & Services 
