Session: 09-10-02: Hydrogen Production, Storage, and Integrated Hydrogen Energy Systems II

Paper Number: 164866

Evaluating the Performance of Elastomeric Sealing Materials Under Medium-Pressure Hydrogen Aging: Implications for Reliability in Hydrogen Infrastructure 

Ensuring the compatibility of elastomeric sealing materials in hydrogen environments is essential for maintaining the safety and reliability of hydrogen storage and transportation systems. As hydrogen gains prominence in the transition toward sustainable energy, selecting resilient sealing materials is crucial to minimizing leakage, preserving system integrity, and improving the longevity of components. However, hydrogen exposure can accelerate material degradation, affecting performance and structural stability. This study explores the effects of medium-pressure hydrogen exposure (0–7500 psi) on five commonly used elastomers: nitrile butadiene rubber (NBR), ethylene propylene diene monomer (EPDM), silicone rubber, fluoroelastomer (FKM), and tetrafluoroethylene-propylene (FEPM). The objective is to assess the physical and mechanical changes induced by hydrogen exposure and determine their suitability for hydrogen infrastructure applications.

The research employs an experimental approach in which elastomeric specimens undergo hydrogen exposure at an ambient temperature for 192 hours. To evaluate degradation, multiple characterization techniques were utilized, including weight-based swelling analysis, tensile strength measurement, hardness testing (Shore A scale), electrical resistivity assessment, and morphological examination through scanning electron microscopy (SEM). These tests provide insights into hydrogen-induced effects such as embrittlement, permeability variations, and microstructural alterations.

The results indicate that all elastomers exhibited varying degrees of swelling, with silicone rubber showing the highest weight increase of approximately 1.7%, attributed to its higher permeability and hydrogen absorption tendency. In contrast, FEPM displayed the least swelling at around 0.8%, suggesting superior resistance to hydrogen ingress. Tensile strength reductions were observed in all materials, with silicone experiencing the most significant decline of 33% (from 75.97 lbf at 0 psi to 57.97 lbf at 7500 psi). However, FKM and FEPM exhibited greater stability, with only an 8% decrease, indicating enhanced resistance to hydrogen-induced degradation. Hardness measurements further corroborated these findings, with silicone showing a 10% reduction (from 56.6 Shore A to 50.8 Shore A), whereas FEPM demonstrated minimal change at 4.5%. Electrical resistivity increased in all materials under hydrogen exposure, with FEPM exhibiting the most pronounced change, suggesting potential applications in dielectric insulation. Additionally, morphological analysis revealed surface roughening and microvoid formations, highlighting degradation patterns unique to each elastomer.

This study provides a comprehensive evaluation of elastomeric materials subjected to hydrogen environments, offering critical insights into their long-term performance and reliability. The findings contribute to material selection strategies for hydrogen infrastructure, enhancing safety and efficiency in hydrogen applications. Furthermore, this research establishes a foundation for future investigations into advanced elastomer formulations and predictive modeling of material degradation under varying operational conditions.

Presenting Author: Md Monjur Hossain Bhuiyan University of Oklahoma

Presenting Author Biography: Md Monjur Hossain Bhuiyan is a PhD candidate in Mechanical Engineering at the University of Oklahoma, specializing in the performance evaluation of sealing materials for hydrogen storage and transportation infrastructure. His research focuses on the reliability and degradation mechanisms of elastomeric seals in hydrogen environments, integrating experimental testing, pilot plant design, and predictive modeling to enhance safety and efficiency in energy applications. With over eight years of industrial experience in the petrochemical and manufacturing sectors, he has expertise in machinery maintenance, condition monitoring, reliability management, and project execution.

Bhuiyan has led major overhaul projects for critical rotating equipment, such as gas turbines and compressors, managing budgets of up to $25 million. He has extensive hands-on experience with turbomachinery dynamics, in-situ rotor balancing, and maintenance strategies to optimize equipment performance. His technical skill set includes SAP Ariba, MAXIMO, AutoCAD, SolidWorks, ANSYS Workbench, MATLAB, R Programming, Python, and LabVIEW. He is also a Level II Certified Vibration Analyst by MOBIUS INSTITUTE, Australia.

His research and industry contributions aim to advance hydrogen infrastructure reliability, minimize fugitive emissions, and improve the performance of sealing materials in extreme operating conditions.

Authors:

Md Monjur Hossain Bhuiyan University of Oklahoma
Zahed Siddique University of Oklahoma