1. Project Context
An important European multinational company with a depot in Portugal requested a TEAL unloading system in an area classified as ATEX Zone 2 IIB T3, with ambient temperatures ranging between 0–31°C.
TEAL is an extremely reactive and pyrophoric compound, which requires:
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absolute hermetic sealing on all connections,
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compatible materials (standard elastomers are rapidly degraded),
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elimination of any moisture ingress,
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smooth, shock-free movements, to avoid ignition and localized stress.
All these factors made a dedicated design by Zipfluid’s engineering team necessary.
2. Customer Requirements
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Maximum safety in handling a pyrophoric fluid;
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Complete elimination of leakage risk;
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Structural and operational reliability for long-term cycles.
3. Specific Technical Challenges for TEAL
Following an in-depth analysis of TEAL’s chemical compatibility, it was found that TEAL rapidly degrades FKM, EPDM, and most polymers.
To prevent degradation, spills, and unwanted reactions, it was therefore necessary to use FFKM (Kalrez or equivalent), the only elastomer family capable of ensuring chemical stability.
3.1 Material Compatibility
3.2 Ignition Risk Management
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Complete elimination of moisture through nitrogen injection;
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Design aimed at avoiding any impact or friction points;
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Certified electrical continuity to neutralize any potential electrostatic charges.
3.3 Envelope Design
The length of sections A-B-C was defined to:
- avoid interference with the platform;
- reduce stress on joints and seals;
- ensure controlled and safe movements;
- keep the line fully operational in compliance with ATEX standards.
4. Custom Solution Designed by Zipfluid
The Zipfluid team provided 1 TEAL unloading station, complete with:
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SJ900 Joints with dedicated nitrogen injection
- Split-type joints allowing quick maintenance without disassembling the arm
- Spare safety seals and leak detection inspection port to verify seal integrity.
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Appropriate materials for TEAL
- FFKM elastomers,
- AISI 304/304L structure with pickling and ASTM A380 passivation.
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Dedicated balancing
Counterweights or spring cylinders selected to minimize operational effort and reduce the risk of impacts.
5. Achieved Results
Technical
- Sealing guaranteed even with an extremely reactive fluid;
- Eliminated the risk of material degradation;
- Effective reduction of leaks compared to traditional elastomeric systems.
Operational - Stable and safe handling;
- Faster connection and operation times thanks to optimized balancing;
- Simplified maintenance thanks to SJ900 split-type joints.
Regulatory - Full compliance with ATEX and PED Directives;
- Complete documentation provided: FAT, ITP, MDB, material certifications, leak tests.
6. Conclusion
The solution designed, engineered, and manufactured by the Zipfluid team enabled completely safe and ergonomic handling, while fully complying with applicable Directives and standards, eliminating the risks associated with managing this highly complex fluid and ensuring reliable operation throughout the plant’s entire lifecycle.
