In industrial sealing applications, selecting the appropriate gasket material is critical, particularly in environments where exposure to aggressive chemicals is a concern. Corrosion and chemical degradation can compromise gasket integrity, leading to system failures, safety hazards, and operational inefficiencies. At Dobson Gaskets, we specialise in engineering sealing solutions that withstand corrosive conditions, ensuring reliable performance and longevity in demanding applications.

Historically, gasket materials such as asbestos were widely used due to their durability and resistance to high temperatures. However, health and safety concerns led to the development of modern alternatives like compressed non-asbestos fibre (CNAF), PTFE-based materials, and advanced elastomers.

PTFE gaskets, first introduced in the mid-20th century, revolutionised sealing technology with their near-universal chemical resistance. Similarly, the advancement of high-performance elastomers like Viton® provided enhanced resistance to fuels and aggressive solvents. Today, engineered composites and metallic gaskets continue to push the boundaries of chemical resistance and mechanical performance, offering solutions for extreme industrial conditions.

The Effects of Corrosion on Gasket Materials

Corrosion in gasket materials results from chemical interactions between the gasket and the process media. These interactions can lead to:

• Material Breakdown Chemical exposure can cause swelling, embrittlement, softening, or dissolution of the gasket material, reducing its mechanical integrity.
• Loss of Sealing Performance Degraded gaskets lose their ability to maintain a tight seal, leading to leaks and pressure loss in pipelines and equipment.
• Equipment Damage Corrosive fluids escaping through a failed seal can lead to pitting, oxidation, or other forms of damage to flanges, pipes, and machinery.
• Operational Safety Risks  In chemical processing, oil and gas, or pharmaceutical applications, gasket failure can result in hazardous leaks, posing risks to personnel and the environment.
• Regulatory Non-Compliance Many industries must adhere to strict environmental and safety standards; a gasket that cannot withstand its operating environment may lead to non-compliance and regulatory penalties.

To ensure gasket longevity and reliability, material selection must be based on a thorough assessment of chemical compatibility.

Manufacturing corrosion-resistant gaskets at Dobson: graphite material (left) and spiral wound gaskets (right)

Corrosive Environments and Their Gasket Requirements

Different industries require gaskets that can withstand specific corrosive substances. Below are key sectors and the chemicals they commonly encounter:

• Chemical Processing Plants Sulfuric acid, hydrochloric acid, nitric acid, chlorine, sodium hydroxide, and solvents necessitate chemically resistant gaskets to prevent degradation.
• Petrochemical and Refining Hydrocarbons, hydrogen sulfide (H₂S), aromatic solvents, and high-temperature steam require gaskets with resistance to both chemical attack and thermal degradation.
• Pharmaceutical and Food Processing Strong cleaning agents, peroxides, acids, and caustic sanitisers demand regulatory-compliant gaskets that resist chemical degradation while maintaining purity.
• Pulp and Paper Industry High concentrations of sulfur compounds, chlorine dioxide, and sodium hydroxide used in bleaching and processing require gaskets that resist extreme pH conditions.
• Power Generation Exposure to steam, ammonia, and cooling tower chemicals necessitates high-temperature and corrosion-resistant materials.

Gasket Material Selection for Corrosive Environments

Selecting a gasket material requires evaluating its resistance to the chemicals present in the application. Each gasket material must be assessed not only for its chemical resistance but also for mechanical properties such as temperature tolerance, compressibility, and resistance to creep and stress relaxation.

Selecting the correct gasket material for a corrosive environment requires in-depth knowledge of both the process media and gasket performance characteristics. At Dobson Gaskets, we leverage decades of experience to provide precision-engineered sealing solutions tailored to your application’s demands. Whether you require PTFE, graphite, high-performance elastomers, or metallic gaskets, our team can recommend the optimal material to ensure long-term reliability and regulatory compliance.