Case study · HPHT reactors & cells

Custom 500°C reactor for high-temperature corrosion testing

For a public energy research center, which needed to test materials in an oxidizing gas environment at 500°C, IRIAN Mecatronics designed and built two custom reactors. The design ensures a perfect seal and reliable stirring in conditions that destroy standard steels and gaskets.

Client: Public energy research center
Field: Materials Research
Technique: High-temperature corrosion testing

01 — The research question

How to maintain the integrity and sealing of a reaction vessel in a chemically aggressive, very high-temperature environment?

Studying materials under extreme conditions requires building a vessel that can withstand those same conditions without interfering with the test. As temperature and chemical aggressiveness increase, standard construction materials reach their limits: they corrode, contaminate the experiment, lose their mechanical strength, or can no longer guarantee a proper seal.

This project involved running corrosion tests at 500°C (932°F) under 130 bar (1885 psi) of oxidizing gas. At this temperature, conventional stainless steels are subject to rapid corrosion, and the polymer seals (elastomers, thermoplastics) used in most standard reactors and autoclaves are immediately destroyed.

Ensuring a perfect seal and reliable mechanical stirring at 500°C—a temperature where standard steels corrode and polymer seals are destroyed.

02 — Our approach

Our design approach

To meet the required performance, our in-house engineering team analyzed each technical challenge. We selected solutions that manage the physical constraints without adding unnecessary complexity, focusing on the user's specific needs.

Choosing an intrinsically stable material

At 500°C in an oxidizing environment, a conventional steel would be quickly attacked, contaminating the tests and compromising safety. We selected a material whose chemical composition gives it intrinsic stability under these conditions. This choice guarantees the long-term integrity of the reactor and the purity of the experimental results.
Ensuring a leak-tight seal without polymer gaskets

Since the 500°C temperature prohibits any soft seals, the main seal is achieved by the controlled plastic deformation of a metal gasket. This principle, common in ultra-high vacuum applications, is adapted here for high pressure. It provides a perfect and reliable seal using a material compatible with the thermal and chemical stresses of the test.
Stirring without contact or active cooling

To stir the reaction medium, we used a magnetic drive for motion transfer. A careful thermal design isolated the sensitive components (magnets, bearings) from the hot zone. This solution eliminates the need for a complex and failure-prone external cooling circuit, ensuring reliable stirring.

03 — Beyond this project

Does your project have similar challenges?

Energy production (incineration, biomass)

The challenge is to sample or install sensors in very hot and corrosive flue gas streams. The principle of a superalloy probe with metal-to-metal sealed passages would be the same to ensure durability and reliability.

Aerospace

The goal is to test the resistance of materials (for engines, heat shields) in a simulated reactive atmosphere. This would require a vessel made of an inert, oxidation-resistant material and a reliable high-temperature seal to maintain the controlled atmosphere.

Materials chemistry

When synthesizing powders (ceramics, catalysts) under a controlled atmosphere, preventing contamination is critical. The principle of a non-reactive reactor with a metal-to-metal seal would be used to guarantee product purity and atmosphere control.

04 — Specifications

The values for this project. Every system is custom-built, so they adapt to your requirements.

Show specifications · 500°C (932°F) · 130 bar (1885 psi) · 2 identical reactors

Technical specifications — Custom 500°C reactor for high-temperature corrosion testing
Maximum operating temperature	500°C (932°F)
Maximum operating pressure	130 bar (1885 psi)
Number of units	2 identical reactors

IRIAN Mecatronics designs and builds custom high-pressure, high-temperature equipment for research laboratories, technical centres and industry.

About the company

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05 — FAQ

Frequently asked questions

What is the maximum volume for this type of high-temperature reactor?

Volume is a key design parameter; there is no standard limit. Increasing the volume at constant pressure and temperature requires thicker walls (according to design codes like CODAP), a more powerful heating system, and higher stirring torque. Our engineering team sizes each custom test bench to meet the exact experimental need.

Is this reactor design compatible with highly corrosive gases like H2S or halogens?

Yes, the design principle can be adapted. The key is the choice of construction material, which must be suited to the specific chemical corrosion. For sulfur or chlorine-containing environments, we turn to nickel-based superalloys like certain grades of Hastelloy or Inconel, as we did for Hastelloy reactors for geoscience applications.

How is compliance with the Pressure Equipment Directive (PED 2014/68/EU) ensured for a custom reactor?

Every piece of pressure equipment we design undergoes a risk analysis and is designed in compliance with the PED. Depending on the risk category (defined by pressure, volume, fluid type, and temperature), we compile the technical file, perform the strength calculations, and follow qualified welding procedures. The factory acceptance tests (FAT) include a hydrotest to validate the mechanical integrity.

Can in-situ measurements (probes, sampling) be integrated into a 500°C reactor?

Yes, this is a common need in R&D. Integrating ports for probes (thermocouples, pressure sensors), sampling valves, or even viewports is entirely possible. Each port is designed using the same principles as the main seal: materials compatible with the conditions and metal or graphite-based sealing solutions to ensure reliability.

Is your equipment limited by temperature or corrosion?

Describe your challenge, even at a preliminary stage. Our engineering team will analyze your project's feasibility and get back to you with a detailed technical proposal.

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