Chemical processing: Mechanical seals – where sustainability starts

Chemical operations involve the handling of fluids, gases and raw materials under extreme operating conditions, where equipment reliability is closely linked to operational continuity and cost control.

The first blog in this two-part series examined the demands these processes place on equipment. In this follow-up, we assess the support solutions John Crane provides to help operators improve mean time between repair (MTBR) and strengthen overall asset performance.

Seal support systems

Seal support systems, such as barrier fluid reservoirs, heat exchangers and gas control panels, enhance seal performance by creating optimal operating conditions for seals.

Meanwhile, monitoring equipment enables operators to respond quickly to issues and intervene before further mechanical seal damage, failure or contamination occurs.

This support helps to extend seal life, reduce maintenance, improve process efficiency and, crucially, help control emissions of the pumped product by directing leakage to safe containment infrastructure.

John Crane technologies, such as pressurised barrier systems, pump gas seals and Upstream Pumping (USP), are aligned with dedicated support systems. Both the direct connect (GS USP-D) and the reservoir version (GS USP-R), based on the API Plan 55 standard, can eliminate harmful emissions.

At John Crane, we design support systems that meet global standards, including ASME, API and ATEX, ensuring compliance and reliability for customers worldwide.

For example, the global standardised Plan 54 lubrication system provides a clean pressurised barrier fluid to a dual pressurised seal. Meanwhile, the GS 54 and GP-S/GP-D gas panels offer a non-API gas control panel to filter, regulate and monitor the supply to gas-lubricated pump seals.

Similarly, the 9280 Gas Box is optimised for use in the chemical industry. Aligned with the Type 2800E non-contacting, gas-lubricated dual cartridge seal, optimised for the chemical market, it can create an emissions-free environment in challenging conditions.

Power transmission couplings

Demanding environments require reliable power transmission between rotating equipment, while accommodating misalignment and minimising shock loads. Our mechanical shaft couplings comply with standards such as ATEX, ANSI, API 610 and API 671. They play a vital role in maintaining uptime and protecting equipment to ensure safety and optimal performance in harsh chemical plant operating conditions.

John Crane Diamond® seal face technology and Upstream Pumping (USP)

John Crane’s support for the chemical industry processes extends beyond standard seals and support systems. Innovations such as John Crane Diamond® seal face technology and USP make processes more reliable, efficient and sustainable, even in the harshest environments.

Applying a thin film of ultrananocrystalline diamond to the seal face simultaneously reduces friction and heat while lowering water and energy consumption, eliminating the need for auxiliary cooling equipment. Meanwhile, USP technology propels a small amount of barrier fluid across the seal face. This causes the faces to lift off and run without contact, reducing wear and contamination.

Particularly effective in caustic and abrasive chemical applications, it offers similar benefits to John Crane Diamond® seal face technology and support systems in extending equipment MTBR, reducing cooling and flush water requirements and saving energy – all with zero-emissions.

Sustainability in practice

The chemical industry is arguably one of the most demanding industries in terms of process equipment. The materials are more abrasive and managed at higher pressures and more extreme temperatures than most others. Chemical plants present demanding operating environments, and customers using Upstream Pumping report reduced emissions, lower maintenance and improved reliability.

Reliability and repairability

The chemical industry values the circular economy principles of ‘reuse, regenerate’, and demands maximum MTBF. We optimise our sealing solutions for maximum reliability and support all our customers with the necessary mechanisms to extract maximum value from their technology investments.

The modular service framework and digital monitoring tools underpinning John Crane Performance Plus™ service solutions enable predictive maintenance to power your people, plant and performance. It is a package of contracts and solutions that optimise performance, help extend equipment life and reduce total cost of ownership for customers running always-on operations in demanding environments.

Technology: Sealing a more sustainable chemical industry

As we have established during these two blogs, mechanical seals are more than just engineering components – they are enablers of sustainability, and a key infrastructure component for every chemical processing company.

The key is to recognise sustainability as a business goal, rather than an additional aspiration. It is a way of managing processes more efficiently. Less waste, more uptime. Fewer emissions, maximum MTBR. And, like most business goals, it’s attainable if you know how to do it – and who can help.

With the right technologies and support systems, chemical plants can reduce emissions, conserve water and improve operational reliability. John Crane continues to innovate, helping chemical industry customers meet their sustainability goals now and in the future.

We understand the unique challenges of the chemical industry and have a product portfolio and an appetite for innovation to help every customer overcome them on the path to operations that serve both our customers and the wider environment.

Discover how we can help you achieve your unique goals here.