Case study · Precision pumps & injection systems

Safely maintaining 6000 bar static pressure: designing a non-reversible drive pump

For a public process engineering laboratory, IRIAN Mecatronics designed and built a static pressurization pump capable of generating and holding 6000 bar in a closed volume. The equipment automates test cycles (ramps, holds) and provides intrinsic safety, maintaining pressure even during a power failure.

Client: Public research laboratory in food process engineering
Field: Process Engineering
Technique: Static and cyclic liquid pressurization

01 — The research question

How to generate 6000 bar static pressure with fine control and absolute safety?

Generating very high static pressure in a closed volume is a different challenge from producing continuous flow. The goal is to control extremely small volume changes with high precision to finely manage pressure ramps and holds, and above all, to ensure the system's long-term stability.

The need here was to replace a manual pump to automate pressurization cycles, improving test repeatability and operator safety. Standard UHP pumps designed for chromatography or waterjet cutting are optimized for flow. They cannot maintain a static pressure in an intrinsically safe way during a power outage, which would ruin a long-duration test.

How can we combine precise motorized control to generate pressure ramps up to 6000 bar with absolute safety that guarantees this pressure is held without any power, even if the control system fails?

02 — Our approach

Designing an intrinsically safe pump

Our integrated engineering team (mechanical, instrumentation, automation) analyzed the requirements to design a custom solution. Three key decisions enabled us to achieve the performance and safety levels specified.

Ensuring safety with a non-reversible mechanical drive

At 6000 bar, the energy stored in the fluid is considerable. To prevent any sudden depressurization during a power failure, we ruled out direct drives. The chosen mechanical transmission system is intrinsically non-reversible: the fluid pressure can never push the piston back, guaranteeing that pressure is maintained without any electrical power.
Selecting very high-strength steels

Standard stainless steels would deform plastically under 6000 bar. To ensure reliability and safety over repeated cycles in these extreme conditions, all wetted parts were machined from special steel grades with a yield strength compatible with these stresses.
Developing an intuitive, traceable control interface

To replace the manual operation, we created a dedicated software interface. The operator programs test cycles in physical units (bar/s, holds) from a PC. The system translates these setpoints into precise motor commands, manages the process, and records all data for perfect traceability and repeatability of experiments.

03 — Beyond this project

Could this technology solve your problem?

Geosciences / Petrophysics

The principle of generating high static pressure with fine control and non-reversible safety is directly transferable to simulating deep geological reservoir conditions. It allows for stable, long-term tests on confined rocks or fluids.

Materials Science

The ability to reach and regulate 6000 bar is applicable to the synthesis of materials under pressure (specialty ceramics) or to isostatic strength testing of components. The fine control of pressurization cycles allows for precise management of test conditions.

Pharma / Health

For cold sterilization (pascalization) or studying protein denaturation, precise pressure control is essential. The pump's principle ensures process safety and could be adapted with biocompatible materials and a cleanable design.

04 — Specifications

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

Show specifications · 6000 bar [87,000 psi] · 6 mL · 22 mL

Technical specifications — Safely maintaining 6000 bar static pressure: designing a non-reversible drive pump
Operating pressure	6000 bar [87,000 psi]
Pump volume	6 mL
Target cell volume	22 mL
Ramp-up control	up to 35 bar/s
Ramp-down control	up to 100 bar/s
Flow rate control precision	up to 0.0002 mL/min
Control	External PC via Ethernet

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

About the company

They trust us

05 — FAQ

Frequently asked questions

Can this 6000 bar static pump work with fluids other than water?

Yes, the principle is adaptable to other liquids like oils or heat transfer fluids. The materials for seals and wetted parts would then be selected for chemical compatibility. For gases, their high compressibility would require a complete redesign of the safety and control system; a pressure intensifier would often be a more suitable solution.

Can you design this type of pump for lower pressures (e.g., 1000 bar) but larger volumes?

Absolutely. The non-reversible drive principle remains relevant for safety and stability, even at lower pressures. A lower operating pressure would allow for larger piston diameters and thus larger pump volumes, enabling the pressurization of multi-liter vessels while maintaining very fine control.

How do I integrate this static pressure generator into my existing lab setup?

The equipment is designed as a self-contained module controlled by a PC via an Ethernet connection. It can be integrated into a custom test rig or connected to an existing cell or reactor. Our engineering team validates mechanical and control system compatibility, and we provide on-site commissioning and training.

Can this pump also be used to inject fluid at a very low, constant flow rate?

Yes, the system is fundamentally a very high-precision syringe pump. The control system can switch from a pressure control mode to a constant flow rate injection mode. Its mechanical design allows for extremely low and stable flow rates, such as 0.0002 mL/min, which is ideal for microfluidics or fine chemistry applications.

Need to maintain high static pressure with stability, repeatability, and safety?

Tell us about your pressure, volume, and cycle requirements. Our engineering team will analyze your project's feasibility and get back to you with a technical proposal.

Discuss your project Download the case sheet (PDF)