In ethanol production, where aggressive chemicals, high temperatures, and pressure fluctuations are routine, reliable sealing materials are essential. One chemical company specializing in ethanol-based solvents recently faced a critical issue when their existing gaskets began failing under the demands of a superheated and pressurized ethanol and water vapor mixture. The solution came in the form of Durlon® 9000 — a high-performance PTFE gasket material engineered to withstand severe industrial conditions.
The Sealing Challenge in Ethanol Applications
The company’s process involved high-temperature vapor mixtures under pressure. Initially, they used Virgin Teflon gaskets but quickly encountered a significant issue: cold flow. Cold flow occurs when a gasket material deforms permanently under load, compromising seal integrity and potentially leading to leaks or safety concerns. In this application, gasket relaxation and distortion during pressure cycles made the Virgin PTFE gaskets unreliable.
Additionally, the ethanol mixture and unique flange geometry created chemical and mechanical conditions that exceeded the capabilities of standard PTFE gaskets. The company required a sealing material that not only maintained dimensional stability but also resisted chemical attack and heat-induced relaxation.
Evaluating Options: Virgin PTFE vs. Durlon® 9000
After several discussions with technical experts and a detailed evaluation of gasket materials, the company focused on Durlon® 9000. While no specific ASTM standard exists for cold flow, comparative testing based on durometer hardness (ASTM D2240), compressibility (ASTM F36), and creep relaxation (ASTM F38) revealed critical differences between Virgin PTFE and Durlon® 9000.
Durlon® 9000 consistently outperformed Virgin PTFE in terms of creep resistance and structural stability. It demonstrated excellent recovery characteristics and retained its sealing properties even after repeated thermal cycles and prolonged mechanical stress. These advantages made it a clear candidate for the demanding ethanol process environment.
What Sets Durlon® 9000 Apart?
Durlon® 9000 is a filled PTFE gasket material that incorporates a blend of inert, inorganic fillers. These fillers are evenly dispersed throughout the PTFE matrix, enhancing the material’s resistance to cold flow while maintaining chemical compatibility.
Unlike standard Virgin PTFE, which is prone to wicking and mechanical relaxation, Durlon® 9000 remains stable over time and under pressure. Its homogenous structure prevents media penetration and minimizes the risk of flange corrosion. The material is also non-stick, allowing for clean removal during equipment shutdowns, which helps reduce maintenance time and cost.
Superior Performance in Field Applications
Once implemented, Durlon® 9000 demonstrated immediate improvements. Gaskets remained intact during shutdowns, and their condition confirmed the material’s resistance to cold flow and chemical degradation. The company reported zero sealing issues and no need for early replacement, which resulted in lower operational costs and reduced risk of unplanned downtime.
They have since standardized the use of Durlon® 9000 across similar applications, citing its performance consistency and reliability. In their own words, “The product is only matched by TFC’s excellent service.”
Key Benefits of Durlon® 9000 for Ethanol Processing
Cold Flow Resistance
Durlon® 9000 maintains thickness and integrity under compression, eliminating the risk of leaks due to material deformation. This makes it ideal for flanged joints exposed to continuous pressure and high temperatures.
Outstanding Chemical Compatibility
This gasket material is suitable for aggressive media commonly found in the chemical, ethanol, pulp and paper, and food and beverage industries.
Certifications and Compliance
Durlon® 9000 complies with numerous industry and regulatory standards, including FDA, USP Class VI, EU 1935/2004 & 10/2011, WRAS, BAM, TA-luft, ABS-PDA, Pamphlet 95, and the Chlorine Institute. It has passed the API 6FA fire test and is approved for oxygen service, making it a trusted solution in critical applications.
No Wicking or Flange Corrosion
The design and filler composition of Durlon® 9000 prevent fluid absorption and material degradation, which are common causes of flange surface damage.
User-Friendly Properties
The gasket is easy to cut, install, and remove. It separates cleanly from flanges, streamlining maintenance procedures.
A Proven Sealing Solution for Harsh Environments
For industrial processors working with harsh chemical mixtures and elevated operating conditions, Durlon® 9000 delivers dependable sealing performance. This case study highlights its effectiveness in the ethanol sector, where the ability to withstand vapor-phase conditions, aggressive solvents, and pressure cycling is non-negotiable.
Durlon® 9000 is engineered for safety, durability, and long-term performance. It is the preferred choice for companies seeking peace of mind in high-stakes industrial environments.
To learn more about how Durlon® 9000 can support your operations, contact the Durlon Sealing Solutions team today.