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.
At a glance
- Client
- Chemical engineering research laboratory
- Field
- Process development
- Technique
- Reaction kinetics, Depolymerization, Chemical recycling
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.
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
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 — Technical specifications
| 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 |
04 — Other applications
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).
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