Kalrez®

Agro-Chemicals

Conditions

The filling line at Dow AgroSciences plant in Drusenheim, France - a global leader in pest management and biotechnology products - processes aggressive solvents, surfactants and concentrated herbicides at temperatures ranging from 10 to 45 °C, and pressures from 1.5 to 3.5 bars Eff.

Previous Seal Material

Filling machine valves on the line were fitted with dynamic PTFE O-rings, while the machine hoses were equipped with static O-rings, also of PTFE.
Each time the mechanical maintenance team performed a clean-in-place procedure at 80 °C, or made a product change on the filler, the PTFE seals became mechanically damaged. This meant they had to change the PTFE O-rings on a daily basis, since seal lifetime never extended beyond 24 hours before replacement.
In a different application at the same plant, seals of FEP/FKM, fitted to the piston rod of a Type SRC Alfa Laval valve, failed regularly after only 8 hours operation.
Dow AgroScienceThe cost to Dow AgroSciences in extra performance time and maintenance had become unacceptable, and the company sought a much more resilient sealing material that would better withstand frequent cleaning and product changes.

Results

Dow Agro Sciences S.A. installed Kalrez® Spectrum™ 6375 perfluoroelastomer O-rings to replace the PTFE seals, with dramatic and immediate improvement.
They managed to extend the lifetime of dynamic and static seals fitted to their product filling line from one day to an average of two months, an improvement of some 6000%.  
Also the seals of FEP/FKM, fitted to the piston rod of a Type SRC Alfa Laval valve, were replaced by Kalrez® perfluoroelastomer parts.   Operating lifetime has increased from 8 hours to between 8–12 months

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Chemical Process Industry

Conditions

Kalrez® seals were used to process hydrochloric acid, nitric acid, sodium hydroxide and sodium hypochlorite at 98°C.

Previous Seal Material

Most elastomers lasted only three days. Although more labour-intensive, a PTFE wedge and packing were considered.

Results

Kalrez® seals lasted for 12 months and could be replaced during the annual shutdown, saving an estimated $30,000 per year.

Oil and Gas

Conditions

Halliburton Energy Services utilised Kalrez® seals in the production of oil and gas under sour conditions at 121°C and 6,000 psi.

Previous Seal Material

The company had not previously used seals in its production process.

Results

Kalrez® seals have provided reliable service for over 21 years.

Pharmaceutical/Cosmetics/Food

Conditions

Kalrez® seals were used to handle diphyl, methanol and anil at 250°C in a pharmaceutical environment.

Previous Seal Material

The high temperature of the agitator used in a particular application led to the degradation of FKM O-rings.

Results

Kalrez® parts lasted six months, reducing the emissions of flammable solvents into the atmosphere. By switching to Kalrez®, the company also enjoyed increased production and reduced costs.

Semiconductor

Conditions

Kalrez® O-rings were employed to handle aggressive solvents at 40°C in a semiconductor environment.

Previous Seal Material

Fluoroelastomer (FKM) O-rings lasted one day.

Results

Kalrez® O-rings lasted for six months, enabling the company to save an estimated $109,000 annually.