Custom Semi-Industrial Pilot Plant for Complex Fluid Process Optimization
For a major industrial leader, IRIAN MECATRONICS designed and manufactured a semi-industrial “pilot plant” test bench. The objective was to enable the detailed study of a multi-phase fluid mixing and separation process under controlled pressure and temperature conditions. We delivered a custom, automated pilot unit engineered to provide high measurement accuracy while ensuring maximum operator safety and ergonomics.
The Challenge: Mastering a Multi-Fluid Process in Real-World Conditions
Our client’s request required a system capable of reproducing an industrial process at a reduced scale, involving the mixing and separation of non-miscible fluids under specific pressure and temperature conditions.
Key requirements included:
Storage and Mixing: The system needed to include several storage tanks and one main mixing tank, all operating under pressure.
Process Control: High-precision pumps were required to ensure fine control of flow rates to simulate various operating scenarios.
Critical Measurement: The major constraint was the need to reliably measure the phase separation (the interface) in the main tank and to analyze the mixture’s composition in real-time.
Safety and Ergonomics: Handling fluids under pressure and at high temperatures demands rigorous safety measures and an ergonomic design to simplify operations.
The Added Value: A Design Focused on Measurement Accuracy and Process Safety
Our design office engineered an integrated system where every technical choice delivers a direct client benefit, ensuring the reliability of test data and the safety of the operating teams.
Precise Interface and Composition Measurement To allow for a detailed analysis of fluid separation, the pilot is not limited to standard visual indicators. The mixing tank is equipped with a guided-wave radar sensor. This advanced technology measures the exact height of the interface between the two fluid phases with millimetric accuracy (±2 mm). This crucial data is supplemented by an in-line capacitive sensor to determine the mixture’s composition continuously.
Multi-Level Safety and Automation Operator safety is our top priority. The equipment integrates redundant safety loops (software, passive, and mechanical) for pressure and temperature management. We selected critical sensors compliant with SIL 2 requirements for safety functions. The entire process is automated via a Programmable Logic Controller (PLC) and a Human-Machine Interface (HMI), ensuring test repeatability and reliable data export.
Ergonomics and Simplified Maintenance (Design for Maintenance) A semi-industrial pilot must be easy to operate and maintain. The static mixer is flange-mounted for quick disassembly and cleaning. Aware of the weight of the tank lids (approx. 100 kg), we integrated a manual hoist on a jib. This simple solution drastically reduces the risk of musculoskeletal injuries and minimizes downtime during cleaning or test campaign changeovers.
Examples of our Custom Designs
