Safe and Durable Sealing for H2-Systems

Reliable hydrogen (H2) infrastructure requires sealing materials that can withstand extreme pressures, temperature variations, and cyclic loads. Seals are vital components throughout the H2 value chain, including in storage tanks, pipelines, fuel cells, and re-fueling systems. Current elastomeric seals are prone to gas permeation, rapid gas de-compression (RGD), and limited durability, posing safety and sustainability challenges. H2SAFE develops next-generation elastomer compounds that offer enhanced gas barrier performance, RGD resistance, and recyclability. Advanced mechanical and AI-assisted modeling will predict long-term durability of demonstrator sealing, supported by in-situ H2 testing up to 1000 bar. The project will enhance the safety, efficiency, reliability, and sustainability of H2 technologies, extend the lifetime of sealing components by ≥20%, reduce H2 leakage by ≥15%, integrate recycled materials, and strengthen Europe’s technological leadership in clean energy materials.