Starline - Hydrogen seals for the energy transition

Although demand for energy is increasing, CO₂ emissions have to be curbed. Climate-neutral hydrogen could help replace fossil fuels – and industry is investing heavily in the technology. Repurposing existing pipeline infrastructures for hydrogen requires seals that can retain the smallest of molecules. MCM S.p.A is working on providing factual data on such seals.

Environment and climate protection policies are pushing for everore decarbonisation. Hydrogen is a highly promising source of energy for the future. Its calorific value is greater than oil or natural gas and it combusts with neutral impact on the climate – that is, without releasing CO₂. Hydrogen is known as “green” hydrogen when it is produced from renewable sources. Costs are going down but are still relatively high – for the time being ... Nowadays, hydrogen is generally blended with methane or natural gas to reduce the CO₂ footprint.

Reliable permeability data 

Although hydrogen itself does not damage elastomers chemically, environmental conditions can be an issue. In general, this means: the higher the pressure or temperature the more permeable the seals become. Depending on the intended application, chemical resistance can also be a requirement. All these factors limit the choice of elastomer – and usually a compromise is sought. MCM aims to present its customers with reliable data on applications involving hydrogen.

The current project for Starline required exceptionally hard seals that can withstand pressure to 35 bar – but also modest temperatures from minus 10 to 65 degrees Celsius. “Starline could use one of the compounds in our portfolio to develop valves for its Iberdrola project, but we are now checking what our portfolio can further deliver. The portfolio is already enormous but we would nonetheless be prepared to develop new elastomer compounds for hydrogen seals,” explains Raffaella Villa. At the end of the day, they would also be of interest to other industries such as the automotive industry.


Experience and expertise for new applications

Reliable data and choice of material are one thing – MCM is also contributing its expertise in compression and injection molding of the parts. “The moulds for such materials are not a trivial matter,” adds Oliviero Mismetti, who is Project Manager at MCM. MCM’s experience is crucial for the required tolerances in manufacture. MCM’s knowledge is also in demand for AED (Anti-Explosive Decompression) approvals – that is, for decompression resistant seals. “It is exciting that, thanks to our capabilities, we are asked to produce pioneering work on new technologies that will force decarbonisation in Europe,” Raffaella Villa is delighted to report to other industries such as the automotive industry.

In a hurry, team members in Lausanne made new parts and brought them to the next event at the Autodrom Most in the Czech Republic. There, the team was able to compete in dynamic competitions for the first time and achieved the fastest acceleration in their team history. That was enough for 8th place out of 36. In addition, there was a fifth place in the "Cost and Manufacturing" category. "That's where we wanted to go," says Etienne Hofstetter happily. Finally, the most important event took place in Hockenheim, Germany. The EPFL team impressed with a 13th place (out of 71 teams) in Engineering Design. "My personal highlight was the flawless battery inspection with praise from the inspectors. Few pass it at the first attempt." So thanks should also go to Angst+Pfister. "They enabled us to present a very professional battery."

Given the many innovations in the car, the team is very satisfied with individual performances. At the same time, a good foundation was laid for the coming seasons to score even more broadly. Angst+Pfister is keeping their fingers crossed.