ELYSeal – Service life and safety of seals in PEM electrolysers

ZBT and Fraunhofer IMWS are developing improved testing and evaluation methods for seal materials in safe and durable PEM electrolysers.

Seals perform a vital safety function in PEM electrolysers, but are subjected to high thermal, mechanical and chemical stresses. In the ELYSeal project, ZBT is working with Fraunhofer IMWS to develop practical methods for systematically assessing degradation, service life and operational safety.

Investigating ageing, assessing service life

Typical sealing materials such as EPDM, FKM and silicone are tested under conditions specific to electrolysis. In these tests, temperature, pressure, contact with media and duration of exposure are varied, and the changes in the materials are analysed mechanically, chemically and microstructurally.

The aim is to produce reliable test reports, benchmarks and safety parameters that enable the application-oriented assessment and qualification of sealing materials.

Projektinfos

Project acronym: ELYSeal
Project title: Degradation mechanisms, service life and safety assessment of seals in electrolysis
Duration: 1.10.2026 – 31.03.2029
Funding programme and project number: Joint Industrial Research; IGF_2025_02239
Project partners:
- Fraunhofer Institute for Microstructure of Materials and Systems IMWS
- ZBT – The Hydrogsn and Fuel Cell Center

Contact person

Verena Lukassek

v.lukassek@zbt.de

Areas of expertise

The project builds on ZBT’s extensive expertise in the fields of electrolysis, measurement and testing technology, ageing studies, as well as modelling and data-driven analysis. The existing test infrastructure and expertise enable the experimental investigation and evaluation of electrolysers under dynamic operating conditions and are also available to industrial partners as part of development services and contract research.

Measurement and testing services – Experimental investigation and characterisation of electrolysers and hydrogen systems under realistic operating conditions.
Modelling and Simulation – Modelling, data-driven analysis and simulation for the evaluation and optimisation of hydrogen and electrolysis systems.
Development Services – Development, testing and optimisation of components and systems for hydrogen and electrolysis technology.

Further current projects

20. October, 2026

ELYSeal – Service life and safety of seals in PEM electrolysers

17. August, 2026

pAST-EL – Predictive AST Protocols for Alkaline Electrolysis

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3. August, 2026

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