News 27/05/2026Oxygen in industrial plants: understanding the risks and managing them safely.
Oxygen is essential for life and is indispensable in many industrial applications. At the same time, it is one of the most reactive industrial gases. It is therefore good to KNOW the risks associated with oxygen, why even the smallest impurities can be critical, and how ignition hazards can be reduced by choosing the right valves, materials and designs.
Why oxygen is so vital
Oxygen itself is not flammable. However, it acts as a powerful fire-promoting agent and can make materials flammable that are normally considered to be difficult to ignite. Even a slightly higher concentration of oxygen significantly increases the risk of fire.
Particularly problematic:
- Oil and grease residues
- Particles in pipes
- High flow velocities
- Rapid pressure rises
- Unsuitable materials
Under unfavourable conditions, even small sources of energy are sufficient to cause spontaneous ignition.
Where the greatest risks arise
One danger that is often underestimated is what is known as adiabatic compression. This causes extremely high temperatures to arise as a result of rapid changes in pressure. Friction, particle impact or sharp changes in direction within a valve can also cause localised temperature spikes.
It is therefore good to KNOW that it is not just the oxygen itself that is crucial, but above all the combination of pressure, flow, materials and cleanliness.
How to reduce risks
The safe sizing of oxygen systems starts with the right choice of materials. The following, amongst others, have proven their worth:
- high-alloy stainless steels
- copper alloys
- nickel-based materials such as Monel or Inconel
Titanium, on the other hand, is considered unsuitable for oxygen systems.
Equally important is the design of the components. Flow-optimised valves with as few dead spaces as possible and gentle bends help to avoid critical impact zones and unnecessary heating.
Cleanliness is not a minor detail, but a safety factor
Oxygen systems are subject to particularly stringent purity requirements. Components must be free from oil, grease and particles and must be cleaned in accordance with defined standards. Even the smallest residues can react dangerously when exposed to oxygen.
The correct sizing of pipes and valves also plays a vital role. Excessively high flow velocities increase friction and heat build-up, thereby raising the risk of ignition.
Further technical details in the white paper
Anyone wishing to explore the technical requirements of oxygen systems in greater depth will find further information in the white paper on:
- Ignition mechanisms
- Valve selection and sealing systems
- Flow velocities
- Piping sizing
- Installation and maintenance criteria
- Operational safety measures
👉 Download the white paper now to find out more about the safety considerations for the selection, calculation and installation of valves and components for oxygen applications.