Tag Archives: Kalrez

Kalrez PV8070 Parts in Reactors

High Performance Seals for Polycrystalline Silicon Process Equipment

The Challenge

To meet growing demand in solar cells, the Siemens* process is used to produce highly purified polycrystalline silicon by thermally decomposing tri-chloro-silane (TCS). The reactors employed require three kinds of high-performance seals in the following locations: A) bell jar seals; B) electrode seals between the electrode and ceramic inlet; and C) a gasket for the view port seal (see schematic).

pv8070 seals in Polycrystalline Silicon Process Equipment

Application Details

The process involves a very hot, dry environment with temperatures up to 1200°C (2100°F). Sealing components see up to 300°C (572°F). Process media include TCS and aggressive by-products of its decomposition, such as HCl gas. Superior compression set performance is needed for effective sealing and extended seal life. Very low outgassing is a key requirement for preventing contamination of the process environment.

The presence of harsh chemicals in high temperature conditions often require an upgrade from standard sealing materials to PTFE or fluoroelastomers (FKM) to improve thermal stability and chemical resistance. However, PTFE can deform and creep “hot flow” in the bell jar seal increasing the risk of product loss. FKM, with its high temperature rating of 200°C (392°F), also has deficiencies in this 300°C (572°F) environment.

The Solution and Key Advantages of Kalrez PV8070

Kalrez PV8070 perfluoroelastomer parts installed as washers and gaskets in reactors for the Siemens CVD process have demonstrated outstanding performance in this demanding application. Kalrez® PV8070 parts are effective seals that provide: Continue reading Kalrez PV8070 Parts in Reactors

Kalrez® Bonded Door Seals

picture of kalrez bonded door seals

Bonded door seals for gate valves and slit valve door seal applications provide improved sealing performance versus conventional O-rings by reducing particle generation, extending seal life, and minimizing replacement time during preventive maintenance.

DuPont Kalrez® bonded door seals are designed for easy installation and low particle generation. They combine a custom seal design and proprietary adhesion technology along with the excellent plasma resistance of Kalrez® perfluoroelastomer seal materials developed for semiconductor applications. The seal is held in a “fixed” position versus conventional O-rings, thereby eliminating “rolling/twisting” and abrasion during door actuation. In addition, the seal design has been optimized using finite element analysis (FEA) to minimize high concentrations of localized stresses. As a result, both particle generation and sealing performance are significantly improved versus conventional O-rings.

Typical Applications

Bonded door seals replace O-ring seals currently used in gate valve, and slit valve dovetail grooves in particle sensitive semiconductor etch, ash, strip and/or deposition processes.

Lower Particle Generation and Extended Seal Life versus Conventional O-rings

  • Sealing element held in a “fixed” position, i.e., eliminates “rolling/twisting” in service
  • Design eliminates O-ring abrasion against edge of dovetail groove during actuation/compression
  • Kalrez® semicon product grades used to minimize particle generation in reactive plasmas
  • Kalrez® Ultrapure post-cleaning and packaging reduces unwanted contamination
  • Improved sealing performance—optimal design minimizes high concentrations of localized stresses

Less Replacement Time Versus O-ring Seals During Preventive Maintenance

  • Quick and easy assembly/disassembly to mounting hardware
  • Reduces installation problems commonly experienced with O-ring seals
  • Eliminates need to clean the seal gland during preventive maintenance
  • Barcode on packaging plus bonded door seal part number and Kalrez® product number engraved on back of commercially available bonded door seals enables traceability and identification providing assurance that it is a Kalrez® perfluoroelastomer part (FFKM).

Availability

DuPont Kalrez® bonded door seals are available for a number of valve types used in semiconductor OEM equipment platforms.  In addition, a custom Kalrez® bonded door seal can be developed for most gate valve and slit valve door applications if not currently available.  Kalrez® UltraPure post cleaning and packaging is standard for all bonded door seals.


The original article was featured on Dupont Kalrez® website and can be found here.

Gallagher Fluid Seals is an authorized Kalrez® distributor. For more information about Kalrez products or to obtain a quote, please contact Gallagher Fluid Seals today.

Kalrez® 1050LF General Purpose FFKM

kalrez 1050LFDuPont™ Kalrez® 1050LF perfluoroelastomer parts are a carbon black-filled general-purpose product for o-rings, seals, and other parts used in chemical process industries. It is a classic-grade and longtime favorite for premium performance and provides a more economical option than similar compounds such as 7375.

Kalrez 1050LF o-rings can maintain their recovery with elasticity following high-pressure applications, maintaining a tighter seal for longer periods of time compared to other compounds. With a pressure rating of 1,500 PSI, it can help extend seal life and integrity, ultimately lowering costs.

With above-average hot water and steam resistance, the maximum application temperature for 1050LF is approximately 550°F (up to 288°C). This compound is also known for its excellent amine resistance and compression set properties. It has a Shore A durometer of 82.

In addition, Kalrez 1050LF has excellent chemical resistance, with the ability to withstand contact of over 1,800 different chemicals, plasmas, and solvents.

In particular, this compound stands out for wet applications in semiconductor manufacturing – stripping and copper plating, which include:

  • Door/lid seals
  • Drain seals
  • Seals for chemical containers
  • Fittings
  • Seals for filters/connectors
  • Flow meters

This reliable compound from DuPont is classified as a general usage product. It is not recommended for use in organic or inorganic acids as high temperatures and is not recommended for applications that require rapid temperature cycling properties.


For more information about Kalrez 1050LF, or to see if it is a good fit for your application, contact Gallagher Fluid Seals today.

Gallagher Fluid Seals is an authorized distributor for DuPont™ Kalrez®.

What Makes Kalrez® Different?

Oil and gas production and chemical manufacturing industries present sealing technologies with some of the harshest and most demanding operating environments.

Harsh and Demanding Operating Environments Require Chemically Resistant and Thermally Stable Seals

“We screen Kalrez against some of the most aggressive corrosive fluids,” says Dr Christopher Bish, Technical Fellow. “And in addition to the fluid testing, we did some compression set testing and stress relaxation testing at high temperatures. We now have one of the most chemically resistant and thermally stable compounds possible.”

We screen Kalrez against some of the most aggressive corrosive fluids

What really makes Kalrez sealing technology superior and more durable than competitors?

One of the things that sets Dupont Kalrez apart is their quality control system, which gives them the ability to track materials as they flow through the plant. Scanning the barcode on the part bag can pull up the entire production history of that part, including raw materials and process conditions.

Is Every Kalrez Seal Inspected?

Elastomer Seal: Perfluoroelastomer Parts

Dupont performs a 100% visual inspection. It’s one way to ensure the quality rate is high and the return rate is virtually non-existent.

Despite the foreseen images of clean rooms, manufacturing in the semiconductor industry can be a harsh environment and cost of o-ring and seal replacement is significant.

“Kalrez parts are used as sealing materials in semiconductor wafer processing equipment, where high temperatures, aggressive chemicals, and plasmas are used. The most important thing for Kalrez sealing prodcuts is that the materials are resisting those aggressive conditions and not degrading  or contaminating the chambers,” says  Dr. Shuhong Wang, Technical Fellow.

Chemical and Science That Makes Kalrez Better

The polymer chains are fully fluoronated, forming one of the most inert polymer structures possible. Other elastomers have weak points along the chain structure, which are vulnerable to chemical attack and thermal instability. This, in combination with the unique cross-link technologies, many of which are patented, provides optimum durability and protection.

Check out a tour of one of the Kalrez manufacturing plants and learn what makes it the best choice for your demanding applications.


The original video can be seen on the Dupont website.

For more information, or to find which compound is best for you, contact Gallagher Seals. We are an exclusive distributor of Kalrez® seals.

Kalrez® 7375 Offers Outstanding Properties & Performance

Kalrez 7375 offers broad chemical and water/steam resistance

The newer compound from DuPont™, Kalrez 7375, is an innovative FFKM oil-seal product exhibiting broad chemical and water/steam resistance properties required at high temperatures in chemical process industry applications. Kalrez 7375 parts present excellent compression set resistance, exceptional physical property retention, and improved mechanical strength properties. Other Kalrez compounds have done the job over the years when faced with many of these sealing challenges, but how does it compare to this new compound?

Three ways that Kalrez 7375 would be a suitable upgrade or compatible compound for your application:

1. Kalrez® 1050LF is a classic grade and longtime favorite for premium performance. 1050LF end-users will likely see a performance boost if they switched to 7375, especially if used in steam or hot water applications.

2. If using Kalrez® 4079 or Kalrez® 7075 and broad chemical resistance is essential (including water/steam), 7375 could be a superior compatibility match resulting in enhanced longevity. 7075 offers the highest thermal capability but cannot support 7375’s chemical compatibility with steam. See table below:

Volume Change between different FFKMs after 672 hours of chemical immersion.

3. If lifetime issues or seeking to extend time between repairs are concerns when using Kalrez® 6375, end-users would most likely see a significant impact with 7375. However, transitioning to 7375 is not necessary if 6375 is executing up to standards.

Kalrez 7375 Benefits

  • Superior thermal stability of 572 °F (300 °C)
  • Excellent broad chemical resistance
  • Outstanding steam and water resistance
  • Available in most O-ring sizes: AS568, Metric, JIS (custom shapes upon request)
  • Combination of Kalrez® quality and Gallagher Fluid Seals’ customer service
picture of kalrez compression graph
Kalrez 7375 demonstrates excellent long-term compression set in hot air at 500 degrees Fahrenheit.

Product Description

DuPont™ Kalrez 7375 perfluoroelastomer parts are an innovative FFKM product based on a patented crosslinking system for chemical process industry applications where broad chemical and water/steam resistance are needed at elevated temperatures. Kalrez 7375 parts exhibit excellent compression set resistance, outstanding physical property retention, and good mechanical strength properties. A maximum application temperature of 300 °C is suggested.


The original article was featured on Dichtomatik’s website and can be found here.

Gallagher Fluid Seals is an authorized distributor of Kalrez products. For information about selecting the correct compound for your specific application, contact our engineering department.

Switching from PTFE to Kalrez® O-Rings Increase Life by 6,000%

The Seal Challenge

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. 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.

The 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.

picture of kalrez as ptfe replacement

The Kalrez® Spectrum™ 6375 Solution

Dow Agro Sciences S.A. installed Kalrez 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!

Kalrez 6375 parts are designed specifically for the chemical process industry. They provide outstanding performance in an extremely wide range of chemicals including acids, bases, amines and steam. The innovative patented curing system allows for continuous upper service temperatures of up to 275 °C in applications such as mechanical seals, valves, flanges and pumps where elastomeric sealing is critical.

In addition, Kalrez is a thermoset perfluoroelastomer part and offers excellent elastic properties and resistance to mechanical damage, unlike PTFE which is a thermoplastic and appears to lack the necessary resilience to withstand mechanical shock in a process application such as this.

Key Advantages of Kalrez 6375

Since switching to custom Kalrez 6375 O-rings Dow AgroSciences S.A. reports an average seal lifetime of two months. That’s an increase of approximately 6,000% over the previously fitted PTFE seals.

The operating lifetime of the seals fitted to the piston rod of a Type SRC Alfa Laval valve increased from 8 hours to between 8–12 months.

Switching to Kalrez® Spectrum™ 6375 parts allowed Dow AgroSciences to increase the operating uptime of their filling machines and to improve overall reliability of their packing line. They have also significantly reduced the time spent in O-ring replacement. The Mechanical Maintenance Manager also reported cost savings as a result of major improvements in safety and reliability, and in reduced maintenance.


Gallagher Fluid Seals is a preferred distributor of Dupont Kalrez® products. For more information or to speak with an engineer, visit Gallagher Fluid Seals or call 1-800-822-4063.

Kalrez 7375® for High Temp Resistance

Kalrez® 7375DuPont™ Kalrez® 7375 FFKM sealing products provide high temperature as well as broad chemical and water/steam resistance properties. Sealing performance, reliability and safety are ensured for applications in the most demanding industrial, chemical and general industrial fields of operation.

These high performance perfluoroelastomer O-ring components are available from Gallagher Fluid Seals, the authorized distributor for a wide range of DuPont™ finished O-rings, as well as custom shapes, sheets and cord sealing components.

The Kalrez® 7375 parts are tailored for specialized chemical applications covering broad operating temperatures from -20°C to 300°C (-4ºF to 572ºF).

These products, which incorporate patented cross-linking technology, combine both superior chemical resistance with a thermal stability which exceeds many other competitive FFKM products. They are also available in most standard O-ring sizes including AS568, metric and JIS, with custom sizes and shapes also available on request.

Continue reading Kalrez 7375® for High Temp Resistance

Kalrez® Parts Extend Service Life for Process Instrument

The Challenge

By switching from gasket seals of PTFE to custom gaskets of DuPont™ Kalrez® perfluoroelastomer parts in the sensor head of a process instrument refractometer used by the food, pulp and paper and chemical industries, process instrument manufacturer K-Patents Oy, Vantaa, Finland, was able to dramatically extend instrument service life, increase reliability and safety, and reduce costs for the company and its customers.

Instrument - Refractometer
Delicate digital detector circuits and fibre optics in the sensor head of K-Patents’“PR-01-S” process refractometer are sealed from attack by aggressive process media, temperatures from –20 ° to +220 °C, and pressures from –0,7 to +25 bar, by two DuPont™ Kalrez® gaskets situated either side of the vital Spinel prism

The Solution

Aggressive environment
Through permanent in-line fluids immersion, K-Patents’ “PR-01-S” refractometer is exposed to temperatures      from –20 ° to +220 °C, pressures from –0,7 to +25 bar, and some 500 process fluids and chemicals, many of which are extremely aggressive. Delicate digital detector circuits and fiber optics in the sensor head are sealed by two gaskets from attack by aggressive fluids. Because of inherent inelasticity, the original PTFE gaskets could not withstand the dynamic temperature fluctuations of many food, pulp and paper and chemical manufacturing processes, creating a leak path allowing process media to enter and damage the device. As a result, costly replacement of the PTFE seal became necessary approximately every 6–12 months.

Continue reading Kalrez® Parts Extend Service Life for Process Instrument

[VIDEO] How to Choose a Fluoroelastomer

Fluoroelastomer Basics - Consideration When Choosing a FluoroelastomerGallagher Fluid Seals recently posted our new Fluoroelastomer Basics webinar on gallagherseals.com.  This is the third and final section of our webinar, focusing on Considerations When Choosing a Fluoroelastomer. The full video is now available on our Resources page.

This video discusses considerations when choosing a fluoroelastomer, including temperature performance range, performance in harsh chemical exposure, and the need to take caution when using fluoroelastomer blends.

[VIDEO] Fluoroelastomer Materials

Gallagher Fluid Seals recently posted our new Fluoroelastomer Basics webinar on gallagherseals.com.  This is the second section of our webinar, focusing on Fluoroelastomer Materials. The full video is now available on our Resources page.

This section of the video discusses different fluoroelastomer materials, along with their mechanical and physical properties, and in which applications they’re normally found.