On March 4th 2024, a new satellite joined the likes of Starlink and GPS in orbiting the Earth. But, this satellite has a unique purpose—to detect and quantify methane emissions. It’s called MethaneSAT, and it was created by the Environmental Defense Fund (EDF) as a response to global goals to cut methane emissions and minimize global warming.
What does that have to do with control valves? Well, it’s a signal for engineers to get proactive about fugitive emissions, because control valves are a key contributor to the issue. With non-profits like the EDF and government bodies like the US Environmental Protection Agency applying more pressure on every industry, taking steps to reduce fugitive emissions from control valves is a critical priority.
The good news is that intelligent control valve design can go a long way to mitigating fugitive emissions. Let’s review the extent of the problem and how engineers can manage risks in the control valve selection process.
Fugitive emissions by the numbers
When we think of the climate crisis, we think of carbon dioxide (CO₂) and methane. The latter is 28 times more potent as a greenhouse gas (GHG) than CO₂. It also accounts for the majority of fugitive emissions from the oil, gas, and chemical industries.
To put this into context:
- 570 million tonnes of methane is released into the atmosphere every year, representing 20% of total GHG emissions
- 20% of those methane emissions are from the fossil fuel industry
- 60% of fugitive emissions come from valves, equating to 85.5 million tonnes of methane every year
Valve design for reduced emissions
According to the EPA, 80% of valve emissions escape through the packing material that seals the valve stem. Packing must be flexible enough to let the valve function properly without too much resistance, yet tough enough to ensure a robust seal and minimize leaks. The valve standard for measuring and rating fugitive emissions is ISO 15484.
Choose the right materials
Depending on their application, most industrial control valves are packed with materials such as:
- Teflon - resistant to most chemicals and temperatures, it offers a durable, low-friction option that is easy to maintain.
- Graphite – this low friction, durable, chemical is a pressure-tolerant substance that offers excellent sealing and thermal conduction properties.
- Exotic plastics - these are extremely tough and can maintain performance characteristics under the most extreme circumstances while remaining largely inert to chemical exposure.
The material choice reflects the media being transported, its volatility, and its corrosiveness. At Trimteck we offer a range of materials for any application, as well as packing design configurations that can reduce fugitive emissions.
Packing design
Most valve packings are configured as v-shaped o-rings, which offer a tight seal around the stem. Another effective configuration is live-loaded packing. This uses a spring, in addition to packing, to keep the stem under consistent pressure and maintain seal integrity.
Cross-sectional diagram of Trimteck’s standard packing box
Metal bellows seals
Metal bellows seals allow the least amount of leakage of any valve design. This precision is vital when the transported medium is dangerous or lethal, such as toxic chlorine or explosive hydrogen.
Apart from metal bellows seals, no other valve is completely fugitive emission-free. So, to ensure the safety of people and the environment, there are specific standards that all valves must meet.
Cross-sectional diagram showing Trimteck’s GuardMaster Metal Bellows Seal
Selecting the right valve and manufacturer
With environmental regulation becoming increasingly stringent across all industries, choosing the right valves for your application is crucial. At Trimteck, we refuse to compromise on valve design and the materials we use. Our control valves are engineered to the highest standards to last longer, perform better, and minimize emissions under all operating conditions. And, our GuardMaster Bellows Seal can help you eliminate emissions, whatever industry you’re in.
At Trimteck our innovations are mitigating the contribution that control valves—and the industries that use them—are making to the climate crisis. Whatever sector your business operates in, we can help you meet stricter regulations and reduce your environmental impact. Get in touch with our friendly Sales Engineers to find out more about our solutions.
