Case study · HPHT reactors & cells

Studying corrosive reactions at 100 bar & 350°C: a custom 2L Hastelloy C276 stirred reactor

For a chemical engineering research laboratory, IRIAN Mecatronics designed and built a pilot test rig to study chemical recycling processes. The equipment features a 2L stirred reactor made of Hastelloy C276, capable of operating up to 100 bar (1450 psi) and 350°C (662°F) while allowing for multiphase injections and sampling during the reaction.

Client: Chemical engineering research laboratory
Field: Process development
Technique: Reaction kinetics, Depolymerization, Chemical recycling

HPHT reactors & cells100 bar350 °C2 LConfidential project · photo withheld

01 — The research question

How to instrument and operate a high-pressure reactor to track reaction kinetics in a corrosive environment?

Studying the kinetics of a chemical reaction requires taking representative samples at different stages of the process without disturbing the conditions. This becomes complex when the reaction occurs at high pressure and high temperature, in a corrosive medium, and with potentially viscous fluids. The design must balance material resistance, absolute sealing, operator safety, and measurement reliability.

Our client, a university laboratory, needed a versatile tool to develop depolymerization processes. Standard lab reactors could not meet all their constraints: the combination of 100 bar pressure, 350°C temperature, Hastelloy C276 for all wetted parts, agitation for viscous fluids, specific sampling circuits, and safe ergonomics for frequent handling of the vessel. It required a fully custom design, conceived as an integrated system. IRIAN specializes in designing <a href="https://irian-mecatronics.com/custom-hpht-reactors-autoclaves-analysis-cells/">Custom HPHT reactors, autoclaves & analysis cells</a>.

Maintaining a perfect seal at 100 bar and 350°C in a stirred reactor, while ensuring simple and safe handling of the heavy vessel for loading, cleaning, and maintenance.

02 — Our approach

The design approach

The test rig's design was driven by four key challenges: safety and ergonomics, building installation constraints, the representativeness of samples, and control over thermal cycles to optimize experiment time.

Automating vessel handling for safety and efficiency

The 2L Hastelloy vessel is too heavy to be handled safely by hand. We designed a motorized system that lowers and pivots the vessel for emptying and cleaning. The lid, which holds all the instrumentation, remains fixed. This approach, chosen over a removable lid, preserves the integrity of the connections and drastically reduces the time between tests.
Designing a modular rig for a constrained installation

The complete test rig would not fit in the laboratory's service elevator. To avoid exceptional logistics, it was designed in two independent modules (process and control), each respecting the size limits. The two parts were transported separately and reconnected on-site, ensuring a quick and controlled installation.
Ensuring representative sampling without disturbing the process

To monitor kinetics without disrupting the reaction at 100 bar, we integrated dedicated, isolatable sampling circuits for the liquid and gas phases. A dip tube draws liquid from the heart of the mixture, while a port in the reactor's headspace captures gas. This allows the operator to obtain reliable data in complete safety.
Mastering the thermal cycle to accelerate test campaigns

The process required heating to 350°C in under an hour and rapid cooling. The solution combines powerful electric heating with high-performance insulation and an external active cooling system. Unlike an internal coil, this solution does not complicate cleaning and allows experiments to be run in quicker succession.

03 — Beyond this project

Does your project resemble this case study?

Fine chemicals and pharmaceuticals

The challenge is often synthesis under pressure in aggressive media, with precise kinetic monitoring. The principle of a special alloy reactor with a magnetic drive and dedicated sampling systems would be retained, adapting the volume and adding compliance with GMP standards or online sensors.

Energy and geosciences (CO2 storage)

For studying fluid-rock interactions under reservoir conditions, the need for corrosion resistance at high pressure and temperature is similar. The overall design would remain, but the reactor geometry could become a coring cell, and the instrumentation could include permeability or acoustic measurements.

Energy and hydrogen (materials, catalysis)

To test materials or catalysts for hydrogen, the rig's general architecture (gas management, P/T control, supervision) is transposable. The changes would concern the materials, to resist hydrogen embrittlement, and the addition of safety features specific to flammable gases (detectors, ventilation, ATEX certification). See our work on <a href="https://irian-mecatronics.com/hydrogen-atex-test-benches/">Hydrogen and ATEX test benches</a>.

04 — Specifications

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

Show specifications · 100 bar (1450 psi) · 120.6 bar · Ambient to 350 °C (662 °F)

Technical specifications — Studying corrosive reactions at 100 bar & 350°C: a custom 2L Hastelloy C276 stirred reactor
Maximum operating pressure	100 bar (1450 psi)
Design pressure	120.6 bar
Operating temperature	Ambient to 350 °C (662 °F)
Reactor volume	2 L
Wetted materials	Hastelloy C276
Agitation type	Magnetic drive
Agitation speed	5 to 1200 rpm
Maximum agitation torque	6 N.m
Minimum filling volume	1.3 L
Certification	Compliance with Pressure Equipment Directive (PED) 2014/68/EU

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

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05 — FAQ

Frequently asked questions

Can this type of reactor be used for processes involving high-pressure hydrogen (H2)?

Yes, the general principle is adaptable, but it requires critical changes. The choice of materials must account for the risks of hydrogen embrittlement at high temperatures. Furthermore, the entire test rig, including instrumentation and ventilation, must be designed with safety features specific to flammable gases, potentially requiring ATEX certification depending on the installation zone.

Can you design a similar stirred reactor for much higher pressures, like 500 bar?

Yes, our engineering team regularly designs equipment for higher pressures. While the principles of a fixed lid and a magnetic drive remain relevant, a pressure of 500 bar profoundly changes the design calculations: vessel wall thickness, main seal technology, and selection of valves and sensors. Each project undergoes a dedicated mechanical analysis. This is the case for this <a href="https://irian-mecatronics.com/project/high-pressure-reactor-550-bar-in-alloy-625-for-geoscience-research/">Multi-mode HPHT reactor for geochemical simulation in corrosive media</a>.

Is the vessel lift and tilt system adaptable to smaller reactors, for instance, 500 mL?

It is technically possible, but not always practical. Such a system is justified by the vessel's weight and the frequency of handling. For a 500 mL reactor, even in Hastelloy, the weight is lower, and an assisted manual handling solution (simple hoist, tilting stand) is often a better compromise between ergonomics, safety, and cost.

How are the reactor's controls managed, and can it be integrated with an existing supervisory system?

Each test rig is delivered with its own control system (PLC and HMI) that manages the control loops (pressure, temperature, agitation speed) and safety interlocks. As is our standard practice, our automation design office can integrate standard communication protocols (e.g., OPC-UA, Modbus TCP/IP) to allow the rig to communicate with a laboratory information management system (LIMS) or a central supervisor.

Does your process require pressure, temperature, and corrosion conditions that exceed the capabilities of standard reactors?

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

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