The Problem
A major chemical plant faced recurring leaks in its Bromine Tower, leading to:
- Reduced productivity: Frequent leaks forced the plant to use alternative resources, slowing down production.
- Increased explosion risks: Chlorine leaks created a hazardous environment, endangering employees and the surrounding community.
- High maintenance and operational costs: Frequent repairs and downtime increased expenses.
The Root Cause
After seeking help from Teadit, its sealing experts conducted an analysis and found that:
- The rigid PTFE gaskets (skived or molded) used on the Bromine Tower flanges required high seating stress to deform and create a proper seal.
- However, the available bolt stress was insufficient to fully conform the gasket to the flange surfaces, leading to persistent leaks.
The Solution
To resolve the issue, Teadit recommended:
Tealon™ TF 1570, a high-performance PTFE-based gasket material with superior chemical resistance. Its high compressibility allowed it to form a reliable seal even under low loads, eliminating leak paths. Precise torque calculations ensured optimal sealing without compromising Bromine Tower operations.
The Results
- 100% leak elimination – The new gaskets completely stopped the recurring leaks.
- Increased productivity – The plant no longer needed alternative resources, restoring efficient production.
- Lower maintenance costs – Fewer leaks meant fewer repairs and less downtime.
- Eliminated explosion risks – Improved sealing significantly reduced the dangers associated with chlorine leaks.
A simple gasket upgrade made a huge impact on safety, efficiency, and cost savings!
To learn more about how Tealon™ gaskets can provide the ideal solution for applications with corrosive media, [read the full case study!]
