Production
Processing
Distribution &
Storage
Usage
The production of relevant volumes of clean hydrogen is the fundamental first step to establish a hydrogen economy. The process of generating hydrogen without carbon emissions demands advanced technologies and significant energy inputs, often derived from renewable sources like wind and solar. Key challenges include scaling up production to meet global demand, optimizing efficiency to reduce costs, and ensuring minimal environmental impact throughout the lifecycle. Overcoming these hurdles requires innovative approaches in electrolysis and renewable energy integration, fostering a transition towards a hydrogen economy that promises to revolutionize clean energy sectors worldwide. Our advanced sealing solutions will leverage cost-efficient clean hydrogen production.
Production
Electrolyzers turn excess renewable electricity into hydrogen for energy storage and clean fuel. They balance the grid, support renewables, and offer a green option for industries, making the energy future more sustainable and low carbon. Sealing electrolyzer stacks come with several challenges: The seals must prevent gas and electrolyte leaks, as well as withstand mechanical stresses, thermal cycling, and gas pressure changes. They must also resist contamination, corrosion, and degradation to for a long lifetimein the harsh electrolyzer chemical environment. Designing cost-effective and scalable sealing solutions is an often-overlooked challenge that requires balancing material costs, manufacturing complexity, and overall system integration. Scaling up sealing technologies for large industrial electrolysis is critical. New engineering approaches are needed to solve these problems and improve electrolyzers for the energy transition.
Harsh electrolyzer environment brings unique material durability challenges in PEM-, AEM-, and alkaline electrolysis technologies.
High level of material know-how and experience to provide materials for optimal system performance. In-house material testing under application-relevant conditions supporting lifetime prediction.
Leachable ions and material impurities can impair long-term performance of electrolyzers.
Materials and production processes optimized to ensure high cleanliness standards for durable electrolyzer systems.
High volume production of electrolyzer stacks requires automated processes.
Smart sealing designs to reduce the number of components and ensure automated handling without compromising on functionality.
Homogeneous pressure distribution across the active cell area and across all cells within one stack.
Precision molded rubber gaskets capable of compensating for manufacturing tolerances. Design supported by simulation and testing on product level.
Harsh electrolyzer environment brings unique material durability challenges in PEM-, AEM-, and alkaline electrolysis technologies.
High level of material know-how and experience to provide materials for optimal system performance. In-house material testing under application-relevant conditions supporting lifetime prediction.
Leachable ions and material impurities can impair long-term performance of electrolyzers.
Materials and production processes optimized to ensure high cleanliness standards for durable electrolyzer systems.
High volume production of electrolyzer stacks requires automated processes.
Smart sealing designs to reduce the number of components and ensure automated handling without compromising on functionality.
Homogeneous pressure distribution across the active cell area and across all cells within one stack.
Precision molded rubber gaskets capable of compensating for manufacturing tolerances. Design supported by simulation and testing on product level.
Product Range
Media resistance is essential for durable stack sealing solutions, whether in acidic or alkaline environments. Our elastomers are specifically formulated to maintain their integrity and sealing capabilities in the harsh chemical conditions of electrolyzers. Additionally, the low hydrogen permeability of our elastomers promotes process safety and high electrolyzer efficiency.
Elevated internal pressures in modern electrolyzers require specialized seal geometries to maintain stack tightness and compensate for manufacturing tolerances in high volume production. We offer a broad range of precision elastomer seal designs, covering both O-rings and gaskets, depending on the individual requirements of the application.
With our advanced prototyping capabilities, we can support our customers in each development stage from an early concept phase all the way to mass manufacturing.
Our extruded elastomer seals engineered with materials optimized for low hydrogen permeability, ensuring durability in harsh electrolyzer environments for PEM- as well as AEM- or alkaline electrolyzers. Leveraging high-level design expertise, these seals deliver optimal sealing performance and maintain homogeneous pressure distribution, compensating for manufacturing tolerances. Our advanced production technologies achieve tolerances close to molded parts, guaranteeing precision and reliability. Trust our solutions for superior performance, longevity, and efficiency in your water electrolyzer systems.
With our advanced prototyping capabilities, we can support our customers in each development stage from early concept phases all the way to mass manufacturing.
Thermoplastic frames in water electrolysis ensure electrical insulation between neighboring cells and serve as a spacer and containment for the electrochemical cell components. The incorporation of elastomeric seals onto the frame revolutionizes the assembly process. It markedly increases the ease of handling and accelerates the assembly speed, which are critical factors in high-volume production environments.
For optimal sealing function, material-specific bonding agents are meticulously applied between the gasket and the frame. This precise application guarantees that the seal performs at its best, underpinning the reliability of the entire assembly.
Freudenberg brings vast experience in elastomer bonding to thermoplastics and our global footprint allows production of integrated parts across many regions in the world.
Metal frames in electrolyzer stack assemblies serve as spacers, contain the electrochemical cell components, and ensure mechanical integrity under high pressure electrolysis operation. Metal frames can be designed to accommodate edge bonded or overmolded elastomer seals that provide additional electrical insulation functionality. The integration of elastomer seals onto the frames significantly improves the handling and speed of assembly.
With this design, the durability of the stack assembly is greatly increased, ensuring a longer lifespan and consistent performance under various operational conditions.
Bipolar plates ensure the electrical connection and gas separation between neighboring anode and cathode compartments in the electrolyzer. Imprinted flow field geometries are one option to guide the water/electrolyte flow across the electrolyzer´s active cell area and open the possibility for additional cooling channels inside the bipolar plate. Integration of sealing on bipolar plates significantly simplifies the stack assembly process and even allows for frame-less stack designs with very thin cell pitches. Our advanced bonding capabilities allow durable sealing designs for high longevity.
Our customers benefit from our vast experience in highly automated series production due to our strong background in the automotive industry.
Plug & Seals are innovative rubber-coated pipe sections that provide a safe and leak-free connection between housings. These sections are designed to be secure and easy to assemble, making them an ideal solution for the transport of air, water, and oils. With the ability to combine several functions into a single component, Plug & Seals can compensate for conduit misalignment and tolerance variations, ensuring a reliable and efficient connection. Available in a wide variety of elastomer coatings, Plug & Seals can be customized to meet the specific needs of any system. Additionally, the integration of a temperature sensor is possible, allowing for system surveillance and fast reaction times. With their versatility, ease of use, and reliability, Plug & Seals are a perfect sealing solution.
Reliable and easy-to-assemble solution that combines multiple functions in one component, compensates for misalignment, and reduces assembly forces. It also offers high vibration resistance, acoustic and mechanical decoupling, and a patented sealing bead geometry.
Production
Photochemical and photoelectrochemical water splitting are methods for producing clean hydrogen fuel from water apart from water electrolysis. Solar water splitting uses sunlight to separate water into hydrogen and oxygen, providing a sustainable way to harness solar energy for clean hydrogen fuel production. In photoelectrochemical water splitting, semiconductors are employed to convert sunlight into chemical energy, which is then used to split water into hydrogen and oxygen for clean fuel. These processes contribute to sustainable hydrogen production for various applications, including fuel cells, energy storage, and industrial processes.
Material compatibility and chemical resistance in reactive environments featuring strong acids or bases and reactive oxygen species generated in the reaction.
Freudenberg’s material competence and in-house testing capabilities allow focused development or selection of resistant materials.
Reliable sealing and mechanical integrity under significant temperature and pressure variations.
Combining Freudenberg´s material and sealing design know-how allows reliable sealing.
Permeability of H2 and O2.
Materials optimized to minimal gas permeation.
Material compatibility and chemical resistance in reactive environments featuring strong acids or bases and reactive oxygen species generated in the reaction.
Freudenberg’s material competence and in-house testing capabilities allow focused development or selection of resistant materials.
Reliable sealing and mechanical integrity under significant temperature and pressure variations.
Combining Freudenberg´s material and sealing design know-how allows reliable sealing.
Permeability of H2 and O2
Materials optimized to minimal gas permeation
Our learnings from sealing solutions for electrolyzers enable material selection and optimal design for water splitting devices.
Product Range
Regardless of the water splitting technology, media resistance is a pivotal aspect for durable reactor sealing solutions. Our elastomers are specifically designed to maintain their integrity and sealing capabilities under the relevant conditions water splitting devices operate in. Furthermore, low hydrogen permeability ensures process safety and high system efficiency even at elevated operating pressures. We offer a broad range of precision elastomer seals covering both molded gaskets and O-ring solutions depending on the individual requirements of our customers.
With our advanced prototyping capabilities, we can support our customers in each development stage from early concept phases all the way to mass manufacturing.
Our extruded elastomer seals engineered with materials optimized for low hydrogen permeability, ensuring durability in harsh water splitting environments in both acidic and alkaline conditions. Leveraging high-level design expertise, these seals deliver optimal sealing performance and maintain homogeneous pressure distribution, compensating for manufacturing tolerances. Our advanced production technologies achieve tolerances close to molded parts, guaranteeing precision and reliability. Trust our solutions for superior performance, longevity, and efficiency in your water splitting devices.
With our advanced prototyping capabilities, we can support our customers in each development stage from early concept phases all the way to mass manufacturing.
The processing of hydrogen, encompassing compression, chemical conversion, and purification is a complex endeavor critical for its widespread utilization. Compression is essential to increase efficiency in storage and transportation of gaseous hydrogen, requiring robust infrastructure for safe handling. Alternatively, chemical conversion of hydrogen into energy carriers such as ammonia or carbon-based power-to-x fuels facilitates the infrastructure requirements for efficient energy transport across the globe. Purification processes ensure hydrogen meets stringent quality standards, removing impurities like water, carbon monoxide, and sulfur compounds to prevent contamination particularly in end-use applications like fuel cells or the semiconductor industry. Our sealing solutions are designed to ensure the highest level of cleanliness, safety and durability in the processing of hydrogen.
Processing
Hydrogen compressors play a vital role in various hydrogen applications, particularly in hydrogen storage, fueling stations and industrial processes. These compressors are specifically designed to handle the unique properties of hydrogen gas, such as its low viscosity and high diffusivity. Typically, hydrogen compressors utilize specialized materials and sealing systems to prevent leaks and ensure safe operation. They operate by drawing in hydrogen gas and then compressing it to higher pressures for storage or transportation. These compressors may employ different mechanisms such as piston, diaphragm, or screw configurations, each with its advantages in terms of efficiency, reliability, and maintenance requirements. Additionally, hydrogen compressors often incorporate advanced safety features to mitigate the risks associated with handling hydrogen, including leak detection systems and explosion-proof designs. As the demand for hydrogen grows for applications like fuel cell vehicles and renewable energy storage, the development of efficient and reliable hydrogen compressors becomes increasingly critical for the widespread adoption of hydrogen technology.
Several challenges within hydrogen compressors include ensuring sealing lifetime, high output-pressures, and high hydrogen purity requirements. Our sealing solutions help to address these challenges in several ways:
Lubrication-free operation.
Unique materials exhibiting low wear rates, low friction coefficients, low permeability for hydrogen and resistance to explosive gas decompression.
High outlet pressures (> 500 bar).
Engineering design know-how to achieve low frictions and tight sealing solutions for efficient operation.
Material compatibility with hydrogen atmosphere.
Analytical know-how including tribological testing under relevant conditions to provide best engineering support.
Reduced leakage.
Broad sealing portfolio & sealing know-how. From O-rings to reciprocating seals, radial shaft seals and diaphragms or any other multi-component special sealing solutions.
Lubrication-free operation.
Unique materials exhibiting low wear rates, low friction coefficients, low permeability for hydrogen and resistance to explosive gas decompression.
High outlet pressures (> 500 bar).
Engineering design know-how to achieve low frictions and tight sealing solutions for efficient operation.
Material compatibility with hydrogen atmosphere.
Analytical know-how including tribological testing under relevant conditions to provide best engineering support.
Reduced leakage.
Broad sealing portfolio & sealing know-how. From O-rings to reciprocating seals, radial shaft seals and diaphragms or any other multi-component special sealing solutions.
Product Range
Piston rings and rod seals are essential components in the operation of piston compressors. Our compounding expertise and sealing mechanism expertise allow us to create tailored products that provide optimal performance in piston compressors. Using tribological testing capabilities, we ensure that our products can bear the demanding loads on the seals. Products are designed with finite element analysis (FEA) to achieve the highest quality level. We offer solutions for a wide range of compressors, from high-pressure compression to high-volume compressors with moderate pressures and scroll compressors.
In-house development and production of high-performance plastics compounds and in-depth know-how in sealing mechanisms.
Tip seals in hydrogen scroll compressors play a crucial role in ensuring efficient and reliable operation by preventing gas leakage between the spiral tips of the moving and fixed scrolls. Our advanced tip seals, made from cutting-edge wear-resistant PTFE-based materials, are designed to significantly enhance the lifetime and reliability of your compressor.
In-house development of future-proof PFAS-free high-performance plastics with high wear-resistance.
Freudenberg Sealing Technologies’ O-rings meet rigorous standards and ensure reliable performance under high hydrogen pressures up to 700 bar (nominal working pressure) and down to temperatures of -60 °C. Our materials feature very low hydrogen permeability and resist rapid gas decompression. For our customers we offer advanced simulation methods based on empirical parameters to ensure optimal performance of our O-ring products.
Our broad portfolio of in-house developed elastomer compounds allows tailor-made O-ring solutions suitable for a wide range of applications.
Elastomeric valve sealing components are used in a wide range of applications along the hydrogen value chain. Our in-depth understanding of the interplay between materials and design allows us to tailor reliable components with a high level of functional integration. Freudenberg in-house experts support customers with FEA-based design know-how, material expertise and advanced bonding methods to create valve plungers for temperatures between -50 to +200 °C with variable hard components such as thermoplastics or metals.
Custom made valve components based on advanced materials and bonding methods designed to meet all application specific requirements for durable operation.
Processing
Pumps play a crucial role in the hydrogen economy, serving as essential components in various stages of hydrogen production, distribution, and utilization. In the hydrogen production process, particularly in electrolysis, pumps are responsible for circulating water and maintaining the flow of electrolyte solutions. Besides that, pumps also play an important role in methane pyrolysis, refining processes, and handling of hydrogen for e.g., transportation.
Media compatibility.
In-depth application know-how allows fine-tuning of material properties and product design for durable pumps in various environments along the H2 value chain.
Hydrogen permeability and leakages.
Our advanced composite materials with very low hydrogen permeability enable the design of gas-tight diaphragm pumps.
Media compatibility.
In-depth application know-how allows fine-tuning of material properties and product design for durable pumps in various environments along the H2 value chain.
Hydrogen permeability and leakages.
Our advanced composite materials with very low hydrogen permeability enable the design of gas-tight diaphragm pumps.
Strict requirements for cleanliness and long-term durability of sealing materials in harsh electrolyzer environment
Product Range
Pump diaphragms are essential components that convert force into volume flow. Their design and material components must meet high requirements to ensure the best functionality of the pump, as they must fit perfectly within the pump and operate under various conditions such as pressure, stroke, temperature, and media. The design of the diaphragm is tailored to the customer’s specific application and can be composed of multiple components, including an elastomer, metal insert, and sometimes a PTFE layer or fabric inlays. The elastomer provides dynamic behavior and sealing function, and its selection depends on the operating conditions, particularly temperature and media. The metal insert is necessary for installation, while additional components such as a PTFE layer can protect the elastomer material and improve chemical resistance. Fabric inlays can increase pressure stability and are used in applications with higher pressure. Overall, the careful selection and design of pump diaphragms are crucial for optimal pump performance.
Extensive know-how in the design and material selection of diaphragms with a wide material portfolio and in-house material development. Whereas calculation tools are used to simulate the diaphragm in operation conditions and create customer-specific products to ensure a perfect fit for the application.
Processing
Hydrogen purification is a critical process in the hydrogen value chain, ensuring the delivery of high-purity hydrogen for various applications, including fuel cells, industrial processes, and chemical production. Purification methods employed are very diverse ranging from physical particle filtration, pressure swing adsorption all the way to catalytic purification or electrochemical hydrogen separation.
Sealing solutions play an essential role in hydrogen purification systems. Effective sealing prevents leaks and contamination, ensuring that the purity of hydrogen is maintained throughout the process. Advanced sealing materials with low H2 permeability, which maintain integrity over extended periods are required to ensure reliability and efficiency even at high gas pressures.
Durability of sealing materials in contact with harsh chemical conditions.
By understanding the chemical environment and selecting appropriate materials and designs, the longevity and reliability of elastomeric seals in hydrogen purification processes is significantly enhanced.
System contamination through inadequate material selection or process-related impurities limits hydrogen purity.
Materials and production processes optimized for highest cleanliness standards.
Stack-based hydrogen purification systems face challenges in homogeneous distribution of contact pressure.
Vast experience in designing sealing solutions for fuel cells and electrolyzers capable of compensating for stack manufacturing tolerances for optimal system performance.
Durability of sealing materials in contact with harsh chemical conditions.
By understanding the chemical environment and selecting appropriate materials and designs, the longevity and reliability of elastomeric seals in hydrogen purification processes is significantly enhanced.
System contamination through inadequate material selection or process-related impurities limits hydrogen purity.
Materials and production processes optimized for highest cleanliness standards.
Stack-based hydrogen purification systems face challenges in homogeneous distribution of contact pressure.
Vast experience in designing sealing solutions for fuel cells and electrolyzers capable of compensating for stack manufacturing tolerances for optimal system performance.
Product Range
Low permeation elastomers are essential in meeting the specific performance requirements in high efficiency electrochemical hydrogen separation (EHS) systems. Our elastomers are designed to maintain their integrity and sealing capabilities throughout the service life of EHS devices for various operating temperature ranges. To ensure long-term stability, our elastomers are free of electrochemical poisons. For EHS, we can leverage our fuel cell know-how to design and manufacture cost-efficient sealing solutions.
With our advanced prototyping capabilities, we can support our customers in each development stage from early concept phases all the way to mass manufacturing.
The distribution and storage of hydrogen are crucial aspects of the hydrogen value chain due to their significant impact on the efficiency, safety, and economic viability of hydrogen as an energy carrier. Efficient distribution networks ensure that hydrogen can be transported from production sites to end-use locations, whether for industrial applications, transportation, or residential use. This involves the development of pipelines, refueling stations, and shipping methods capable of handling hydrogen's unique properties. For long-distance transport, the chemical conversion of H2 into energy carriers such as ammonia, methanol or e-methane plays an important role to maintain overall efficiency. Storage solutions are equally important, as they enable the balancing of supply and demand, ensuring a reliable and steady supply of hydrogen even during production fluctuations or peak usage periods. Our sealing solutions are well suited to meet the diverse challenges along the logistics chain of hydrogen.
Distribution & Storage
Hydrogen pressure tanks, pivotal for hydrogen-powered innovation, are engineered to store hydrogen gas under high pressure for fuel cells and engines in vehicles and energy applications. Crafted from robust composite materials like carbon or glass fiber with a protective liner, they ensure durability and prevent leakage. With pressures of 350 bar for trucks and 700 bar for cars, these tanks adhere to stringent safety standards like UNECE’s ECE R 1341, undergoing rigorous tests for endurance and environmental resilience. As a significant cost factor in hydrogen technology due to their sophisticated materials and manufacturing, ongoing research aims to enhance their storage capacity and efficiency while reducing weight and cost, propelling the hydrogen economy forward into a sustainable future.
High safety requirements due to the use of compressed hydrogen gas.
Composites pressure vessels offer superior strength, durability, and feature a thoroughly safe design offering predictable leak-before-burst characteristics and minimal hydrogen permeation.
Long service life during operation.
Durable, high-quality materials ensure pressure are designed to last a long service life and are designed to accommodate frequent fill and empty cycles.
High safety requirements due to the use of compressed hydrogen gas.
Composites pressure vessels offer superior strength, durability, and feature a thoroughly safe design offering predictable leak-before-burst characteristics and minimal hydrogen permeation.
Long service life during operation.
Durable, high-quality materials ensure pressure are designed to last a long service life and are designed to accommodate frequent fill and empty cycles.
Strict requirements for cleanliness and long-term durability of sealing materials in harsh electrolyzer environment
Product Range
Freudenberg Sealing Technologies O-rings meet rigorous standards and ensure reliable performance under high hydrogen pressures up to 700 bar (nominal working pressure) and down to temperatures of -60 °C. Our materials feature very low hydrogen permeability and resist rapid gas decompression. For our customers we offer advanced simulation methods based on empirical parameters to ensure optimal performance of our O-ring products.
Our broad portfolio of in-house developed elastomer compounds allows tailor-made O-ring solutions suitable for a wide range of applications.
Back-up rings are used in high-pressure valves and prevent gap extrusion of elastomeric seals. Freudenberg´s back-up rings are made of high-performance plastics and enable high-pressure applications up to 800 bar.
We combine state-of-the art high-performance plastics material with our know-how on elastomers to design reliable solutions for our customers.
Elastomeric valve sealing components are used in a wide range of applications along the hydrogen value chain. Our in-depth understanding of the interplay between materials and design allows us to tailor reliable components with a high level of functional integration. Freudenberg in-house experts support customers with FEA-based design know-how, material expertise and advanced bonding methods to create valve plungers for temperatures between -50 to +200 °C with variable hard components such as thermoplastics or metals.
Custom made valve components based on advanced materials and bonding methods designed to meet all application specific requirements for durable operation.
Distribution & Storage
Hydrogen Refueling Stations (HRS) are essential for the adoption of hydrogen-powered vehicles, including Fuel Cell Electric Vehicles (FCEV) and Internal Combustion Engines (ICE) powered by hydrogen. The refueling process involves four main steps: compression, storage, cooling, and dispensing. Hydrogen fueling storage buffers, located above or below ground, use a cascade pressure balancing process to meet the required fueling profile. The cooling unit regulates the hydrogen temperature to ensure an optimal filling rate and compliance with fueling protocol standards. The dispenser delivers fuel to the vehicle tank, refueling it with up to 700 bar. Sensors and safety valves are included throughout the process to ensure system safety.
Proper sealing solutions are critical for the use and safety of refueling stations and the increased distribution of hydrogen-powered vehicles:
Strict safety standards of refueling station infrastructure.
Reliable sealing solutions for hydrogen applications specifically designed to meet the ambitious needs.
Limited lifetime of seals in reciprocating piston compressors.
Unique materials exhibiting low wear rates, low friction coefficients, low permeability for hydrogen to support lubrication-free compressor operation with extended lifetimes.
Strict safety standards of refueling station infrastructure.
Reliable sealing solutions for hydrogen applications specifically designed to meet the ambitious needs.
Limited lifetime of seals in reciprocating piston compressors.
Unique materials exhibiting low wear rates, low friction coefficients, low permeability for hydrogen to support lubrication-free compressor operation with extended lifetimes.
High hydrogen pressures need to be achieved for optimal storage density of the gas in on-board applications.
Strict requirements for cleanliness and long-term durability of sealing materials in harsh electrolyzer environment
Product Range
Piston rings and rod seals are essential components in the operation of piston compressors. Our compounding expertise and sealing mechanism expertise allow us to create tailored products that provide optimal performance in piston compressors. Using tribological testing capabilities, we ensure that our products can bear the demanding loads on the seals. Products are designed with finite element analysis (FEA) to achieve the highest quality level. We offer solutions for a wide range of compressors, from high-pressure compression to high-volume compressors with moderate pressures.
In-house development and production of high-performance plastics compounds and in-depth know-how in sealing mechanisms.
Freudenberg Sealing Technologies O-rings meet rigorous standards and ensure reliable performance under high hydrogen pressures up to 700 bar (nominal working pressure) and down to temperatures of -60 °C. Our materials feature very low hydrogen permeability and resist rapid gas decompression. For our customers we offer advanced simulation methods based on empirical parameters to ensure optimal performance of our O-ring products.
Our broad portfolio of in-house developed elastomer compounds allows tailor-made O-ring solutions suitable for a wide range of applications.
Elastomeric valve sealing components are used in a wide range of applications along the hydrogen value chain. Our in-depth understanding of the interplay between materials and design allows us to tailor reliable components with a high level of functional integration. Freudenberg in-house experts support customers with FEA-based design know-how, material expertise and advanced bonding methods to create valve plungers for temperatures between -50 to +200 °C with variable hard components such as thermoplastics or metals.
Custom made valve components based on advanced materials and bonding methods designed to meet all application specific requirements for durable operation.
Distribution & Storage
Hydrogen is a highly versatile energy carrier, but it can be challenging to store in large quantities due to its low energy density by volume. However, hydrogen energy carriers such as ammonia, methanol, or liquid organic hydrogen carriers (LOHCs) provide solutions for storing hydrogen in a more compact and manageable form, enabling storage and transportation of large energy amounts over long distances. For example, hydrogen can be produced where renewable energy is inexpensive and abundant, converted to a hydrogen energy carrier, and then transported over long distances, such as from Australia to the EU. These carriers can be used directly as a feedstock for the chemical industry or as a fuel, such as in ammonia engines in ships or co-firing in power plants. They can also be re-converted to hydrogen for downstream use in hydrogen applications. Overall, hydrogen energy carriers are essential enablers of the hydrogen economy, providing solutions for overcoming challenges related to hydrogen storage, transportation, and integration with renewable energy sources, thereby helping to realize the potential of hydrogen as a clean and sustainable energy carrier.
While energy carriers are on the rise, there are still challenges to overcome. Our sealing solutions can help address these challenges and improve the efficiency and effectiveness of energy carriers:
Toxicity of energy carriers like ammonia or methanol.
Reliable sealing solutions for a broad range of operating conditions.
Material compatibility.
Advanced material development to meet application-specific requirements.
Broad range of operating temperatures and pressures.
In-house testing capabilities to predict lifetime in application relevant operating conditions.
Toxicity of energy carriers like ammonia or methanol.
Reliable sealing solutions for a broad range of operating conditions.
Material compatibility.
Advanced material development to meet application-specific requirements.
Broad range of operating temperatures and pressures.
In-house testing capabilities to predict lifetime in application relevant operating conditions.
Freudenberg Sealing Technologies’ O-rings meet rigorous standards and ensure reliable performance. Our proprietary materials cover a wide range of operating conditions (e.g., temperatures between -60 to +260 °C and elevated pressures) and compatibility with typical H2 energy carriers such as ammonia, methanol, or associated process gases. With our in-depth application know-how, we offer advanced simulation methods based on empirical parameters to ensure optimal performance of our O-ring products.
Our broad portfolio of in-house developed elastomer compounds allows tailor-made O-ring solutions suitable for a wide range of applications including our high performance FFKM SIMRIZ® materials for best chemical resistance and high temperature performance.
Elastomeric valve sealing components are used in a wide range of applications along the hydrogen value chain. Our in-depth understanding of the interplay between materials and design allows us to tailor reliable components with a high level of functional integration. Freudenberg in-house experts support customers with FEA-based design know-how, material expertise and advanced bonding methods to create valve plungers for temperatures between -50 to +200 °C with variable hard components such as thermoplastics or metals.
Custom made valve components based on advanced materials and bonding methods designed to meet all application specific requirements for durable operation.
Clean hydrogen can be used to decarbonize several processes in the chemical industry and steel production. Moreover, it can power fuel cells, producing electricity with water as the only byproduct, making it an eco-friendly option for transportation, portable power, and stationary power generation. Additionally, hydrogen can be used in internal combustion engines and turbines, either directly or through H2 energy carriers like ammonia, methanol, or e-methane. These carriers enable easier storage and transport and can be utilized in existing infrastructure with minimal modifications. The adoption of hydrogen and its carriers supports a diverse and resilient energy system, promoting energy security and advancing the transition to a sustainable, low-carbon future. With our wide range of sealing solutions, we support optimal performance and safety in hydrogen end-use applications.
Usage
Internal combustion engines (ICE) fired with hydrogen or derived sustainable fuels facilitate the short-term transition from fossil to renewable fuels. Besides the direct combustion of gaseous hydrogen, the use of power-to-x fuels such as ammonia, methanol or e-methane is possible. Today, use cases for such engines involve:
Varying material requirements for different fuel types.
Freudenberg has developed a range of materials suitable for hydrogen, ammonia and low-carbon fuels. Through our global R&D centers we can support the design of specific sealing components for optimal combustion.
Release of toxic power-to-x fuels such as ammonia must be prevented.
In-house testing capabilities to predict seal-lifetime under application relevant conditions.
Varying material requirements for different fuel types.
Freudenberg has developed a range of materials suitable for hydrogen, ammonia and low-carbon fuels. Through our global R&D centers we can support the design of specific sealing components for optimal combustion.
Release of toxic power-to-x fuels such as ammonia must be prevented.
In-house testing capabilities to predict seal-lifetime under application relevant conditions.
Freudenberg Sealing Technologies operates the largest testing facility for engine components. For sustainable fuel engines we leverage our material expertise with know-how in sealing solutions for classical ICEs to offer flexible sealing solutions for many fuel types.
Strict requirements for cleanliness and long-term durability of sealing materials in harsh electrolyzer environment
Product Range
Plug & Seals are innovative rubber-coated pipe sections that provide a safe and leak-free connection between housings. These sections are designed to be secure and easy to assemble, making them an ideal solution for the transport of air, water, and oils. With the ability to combine several functions into a single component, Plug & Seals can compensate for conduit misalignment and tolerance variations, ensuring a reliable and efficient connection. Available in a wide variety of elastomer coatings, Plug & Seals can be customized to meet the specific needs of any system. Additionally, the integration of a temperature sensor is possible, allowing for system surveillance and fast reaction times. With their versatility, ease of use, and reliability, Plug & Seals are a perfect sealing solution.
Reliable and easy-to-assemble solution that combines multiple functions in one component, compensates for misalignment, and reduces assembly forces. It also offers high vibration resistance, acoustic and mechanical decoupling, and a patented sealing bead geometry.
Freudenberg Sealing Technologies’ O-rings meet rigorous standards and ensure reliable performance in a wide range of different conditions for all sealing points within a combustion engine powered by different sustainable fuels such as hydrogen, ammonia, methanol. Our materials feature exceptionally low hydrogen permeability and resist rapid gas decompression and compatibility with used fuels. For our customers we offer advanced simulation methods based on empirical parameters to ensure optimal performance of our O-ring products.
Our broad portfolio of in-house developed elastomer compounds allows tailormade O-ring solutions suitable for a wide range of applications.
Elastomeric valve sealing components are used in a wide range of applications along the hydrogen value chain. Our in-depth understanding of the interplay between materials and design allows us to tailor reliable components with a high level of functional integration. Freudenberg in-house experts support customers with FEA-based design know-how, material expertise and advanced bonding methods to create valve plungers for temperatures between -50 to +200 °C with variable hard components such as thermoplastics or metals.
Custom made valve components based on advanced materials and bonding methods designed to meet all application specific requirements for durable operation.
When hydrogen powers a combustion engine, it burns faster and hotter than standard fuels, exposing valve stem seals to higher temperatures and demanding greater chemical resistance. Our valve stem seals, made from peroxide-cured FKM ter-polymer, are designed to meet these challenges. Compared to bisphenol-cured systems, our peroxide-cured FKM ter-polymer offers superior oil and fuel compatibility, exceptional high-temperature performance, and enhanced chemical resistance against engine oils. These advanced seals ensure reliable, long-lasting protection for hydrogen combustion engines, optimizing performance and durability under extreme conditions.
CASCO® seals offer a tailor-grooved, axially-loaded, rubber sealing lip, with combined pump and centrifugal effect for enhanced sealing performance on crankshaft applications, and a “hovercraft effect” between the sealing lip and working counter-surface results in very low wear. CASCO® seal power loss level is unchanged when increasing shaft diameters.
CASCO® generates 70% less friction compared to elastomeric engine seals due to the use of a unique sealing mechanism that utilizes centrifugal force as an advantage, with the result of an overall reduction in fuel consumption
Usage
Fuel cells produce electricity from an electrochemical reaction, typically involving hydrogen as a fuel and oxygen from the air. The primary byproducts of this process are water and heat, contributing to a significant reduction in greenhouse gas emissions when using clean hydrogen. Fuel cells are highly efficient in converting fuel into electricity, making them a more sustainable option compared to traditional combustion-based power generation. They are versatile and can be used in a variety of applications, from small-scale portable devices to larger stationary power plants, providing power for electric vehicles, backup power for homes and businesses, and even supporting off-grid applications. Fuel cells enable decentralized power generation, allowing for the creation of smaller, distributed energy systems.
High-quality integrated sealing solutions in fuel cells can address several critical challenges, contributing to the overall efficiency, durability, and reliability of fuel cell systems. Some of the key challenges that our sealing solutions support to overcome.
Leakage of hydrogen fuel.
Gas-tight sealing is vital for high fuel efficiency and safety.
Contamination with cooling media.
For failure-free operation, effective sealing maintains separation of cooling media from the fuel cell´s reactant compartments.
Inhomogeneities in contact pressure distribution can cause local hot-spots and accelerate degradation.
Precision seals maintain uniform pressure and dedicated seal geometries ensure compensation of manufacturing tolerances.
Process automation for high volume production.
Integrated sealing solutions reduce the number of parts during assembly and facilitate automated stacking processes with fast cycle times.
Material selection and chemical compatibility.
Carefully chosen seals are resistant to degradation, compatible with fuel cell environment and free of harmful catalyst- and membrane poisons.
Leakage of hydrogen fuel.
Gas-tight sealing is vital for high fuel efficiency and safety.
Contamination with cooling media.
For failure-free operation, effective sealing maintains separation of cooling media from the fuel cell´s reactant compartments.
Inhomogeneities in contact pressure distribution can cause local hot-spots and accelerate degradation.
Precision seals maintain uniform pressure and dedicated seal geometries ensure compensation of manufacturing tolerances.
Process automation for high volume production.
Integrated sealing solutions reduce the number of parts during assembly and facilitate automated stacking processes with fast cycle times.
Material selection and chemical compatibility.
Carefully chosen seals are resistant to degradation, compatible with fuel cell environment and free of harmful catalyst- and membrane poisons.
Strict requirements for cleanliness and long-term durability of sealing materials in harsh electrolyzer environment
Product Range
Our precision-molded elastomer seals are assembled between adjacent stack components or as endplate sealing to prevent leakage of coolant and reactant gases while effectively compensating for stack tolerances. Our low permeation elastomers are compatible with most materials used in fuel cell systems. This compatibility is essential for maintaining the integrity of the seal and the overall functionality of the system. With our worldwide network of experienced manufacturing locations, we can support the design and development of stack sealing solutions for your fuel cell program and our advanced prototyping capabilities allow us to support our customers in each development stage from early concept phases all the way to mass manufacturing.
Gas diffusion layers are an integral component in fuel cells guaranteeing optimal distribution of reactant gases and humidification of membrane and catalyst layers. With our proprietary technology, seals can be integrated onto a wide range of nonwoven gas diffusion layers. A three-dimensional seal pattern uniformly distributes the linear load across the seal, effectively preventing leakage and lifetime-limiting inhomogeneities in contact pressure across the active area.
Our polyolefin elastomers are designed to meet the stringent cleanliness requirements of the stack system. Its low permeation properties ensure minimal loss of reactant gases, while the high adhesion quality guarantees a secure bond with various components. The enhanced compression set of the material contributes to the longevity and reliability of the system, even under fluctuating temperatures and pressures.
Unique sealing system that opens the possibility to design subgasket-free fuel cells without compromising on performance.
Bipolar plates ensure the electrical connection and gas separation between neighboring cells and the distribution of reactant gases through flow fields. In addition, bipartite bipolar plates feature internal cooling channels to distribute reaction heat. The integration of elastomeric seals onto the bipolar plates significantly reduces the number of parts during stack assembly, improving the handling and speed of assembly for mass production. Our elastomers are designed for low permeability for reactant gases and chemical compatibility with common cooling media for efficient and durable fuel cell performance. Moreover, our precision molded low-durometer compound seals allow for greater compensation of manufacturing tolerances fostering accurate pressure distribution across the active area, which enhances the fuel cell´s longevity significantly.
Our sealing solutions integrated onto fuel cell bipolar plates facilitate automated high-volume production of reliable fuel cells.
Precision molded elastomeric seals on subgasket-like polymer films (e.g., Polyethylene naphthalate, PEN) combine multiple functionalities in one component: electrical insulation at the bipolar plate´s fringe area, separation of reactant gases between anode and cathode, and sealing towards the outside of the stack. When it comes to flexible selection of bipolar plates and membrane electrode assembly (MEA) components, this sealing concept offers the highest level of flexibility to our customers. To reduce the number of parts during stack assembly, a subsequent integration of further components such as the MEA is possible.
With our dedicated fuel cell polyolefin elastomer, very high cleanliness standards can be achieved, which is vital to prevent fuel cell poisoning. The combination of our specific seal designs and the compound´s low shore hardness can compensate for manufacturing tolerances and ensure homogeneous contact pressures across the cells.
Elastomeric gaskets are meticulously designed to integrate seamlessly with fuel cell systems, ensuring a robust seal that prevents leakage and enhances system performance. These gaskets are designed to fit perfectly within a machined or as-cast groove, which is crucial for precise gasket placement and optimal sealing efficacy. The cross section of the gasket is a defining factor in its sealing characteristics, allowing for a tailored approach to meet the specific needs of each fuel cell system.
We prioritize the selection of low permeation elastomers that are compatible with most materials used in fuel cell systems. This compatibility is essential for maintaining the integrity of the seal and the overall functionality of the system. Our commitment to quality and performance is evident in our careful choice of materials and our attention to detail in the design process. Our elastomeric gaskets represent a harmonious blend of precision engineering and material science, designed to provide a reliable and effective sealing solution for fuel cell systems. They are a testament to our dedication to advancing fuel cell technology and our commitment to delivering products that meet the highest standards of quality and performance.
Balance-of-Plant Gaskets: Ensuring System Integrity.
Housing gaskets prevent intrusion of dust, dirt, salt, and water. Selection of elastomers suitable for all housing materials, such as aluminum, steel, and composite. We offer several different gasket technologies to meet the sealing requirements and dimensions for a wide range of housing applications.
Our all-elastomer gaskets are specifically designed to fit within a groove in the housing, ensuring they are correctly positioned for optimal sealing. The cross section of the gasket is crucial as it establishes the sealing characteristics, providing a reliable and durable seal for various applications. These gaskets are an essential component in maintaining the integrity and performance of the housing, offering a tailored solution to meet the unique sealing needs of each system.
Gaskets are designed with precision to ensure optimal compression, controlled by limiters at bolt locations. The wide double bead design not only improves sealing performance but also offers enhanced corrosion protection, making it an ideal choice for various applications.
The rigid carrier of the gasket is perfectly suited for quick assembly, whether automated or by hand. Alignment pins are incorporated to facilitate straightforward assembly and secure retention of the gasket, enhancing the efficiency of the process. This thoughtful design is indicative of our dedication to providing sealing solutions that are not only effective but also user-friendly and conducive to streamlined operations.
Plug & Seals are innovative rubber-coated pipe sections that provide a safe and leak-free connection between housings. These sections are designed to be secure and easy to assemble, making them an ideal solution for the transport of air, water, and oils. With the ability to combine several functions into a single component, Plug & Seals can compensate for conduit misalignment and tolerance variations, ensuring a reliable and efficient connection. Available in a wide variety of elastomer coatings, Plug & Seals can be customized to meet the specific needs of any system. Additionally, the integration of a temperature sensor is possible, allowing for system surveillance and fast reaction times. With their versatility, ease of use, and reliability, Plug & Seals are a perfect sealing solution.
Reliable and easy-to-assemble solution that combines multiple functions in one component, compensates for misalignment, and reduces assembly forces. It also offers high vibration resistance, acoustic and mechanical decoupling, and a patented sealing bead geometry.
Freudenberg offset seals are static seals capable of sealing radial and axial offsets. They are suitable for sealing feedthroughs of all kinds and port connections in housings. Available in a wide variety of elastomer coatings, offset seals can be customized to meet the specific needs of any system.
Offset seals are a reliable and easy-to-assemble solution that compensates for misalignment and reduces assembly forces. They also offer high vibration resistance, acoustic and mechanical decoupling, and a patented sealing bead geometry.
DIAvent Light is a purpose-built ePTFE laminate that reliably handles bidirectional pressure equalization, even in the harshest of operating conditions. This technology has a wide range of applications, including battery systems in electric and hybrid vehicles, dry E-axles, dry E-motors, inverters, chargers, and many other systems and applications. With its ability to withstand challenging environments, DIAvent Light is a reliable solution for managing pressure equalization in various systems.
DIAvent Light offers bidirectional pressure regulation with high gas permeation while remaining watertight, and features tamper-resistant retention clips, quick assembly, and a radial seal independent from axial compression, suitable for different wall thicknesses, with a wide temperature operation range of -40 to +150° C and is available in standard sizes.
Elastomeric valve sealing components are used in a wide range of applications along the hydrogen value chain. Our in-depth understanding of the interplay between materials and design allows us to tailor reliable components with a high level of functional integration. Freudenberg in-house experts support customers with FEA-based design know-how, material expertise and advanced bonding methods to create valve plungers for temperatures between -50 to +200 °C with variable hard components such as thermoplastics or metals.
Custom made valve components based on advanced materials and bonding methods designed to meet all application specific requirements for durable operation.
