Case study · HPHT reactors & cells

Unbiased catalyst comparison: a dual-reactor HPHT R&D platform

For a leading European university research center, IRIAN Mecatronics designed and built a custom R&D platform for gas-liquid process studies. The equipment integrates two reactors, tubular and stirred, to compare catalysts and study reaction kinetics at up to 200 bar (2900 psi) and 300°C (572°F).

Client: Leading European university research center
Field: Process development (CO2 capture, hydrogen)
Technique: Catalyst screening, reaction kinetics studies

HPHT reactors & cells200 bar300°CConfidential project · photo withheld

01 — The research question

How to compare catalytic processes without the equipment biasing the results?

In R&D, reliably comparing the performance of different catalysts or building valid kinetic models is a major challenge. The test equipment must not become the limiting factor: if its hydrodynamics are poorly controlled or if operating conditions fluctuate, the collected data is useless. Months of research can depend on the test rig's ability to provide stable, repeatable conditions tailored to the measurement.

Our client needed to explore gas-liquid processes for CO2 capture and hydrogen production. This involved two distinct tasks: rapid screening of multiple solid catalysts and detailed kinetics studies. Standard solutions offer reactors optimized for one (plug flow) or the other (perfect mixing), but rarely an integrated platform that allows comparing both approaches with a single control system and under strictly identical conditions.

Obtaining comparable data from two reactors with very different geometries and hydrodynamics (plug flow vs. perfect mixing), while operating at low flow rates under high pressure, where the slightest instability skews the results.

02 — Our approach

A design driven by measurement reliability

To ensure the validity of comparisons, every design choice was made to optimize a specific function and master the operating conditions without compromise. The system's architecture was conceived so that the researcher always has the most relevant tool for the question at hand.

Specializing each reactor to ensure data relevance

A single, multi-purpose reactor would have yielded mediocre data for both screening (which requires plug flow) and kinetic studies (which demand perfect mixing). We therefore designed two distinct but integrated units, sharing the same peripherals to ensure test consistency. This gives the researcher the optimal tool for each measurement.
Maximizing mass transfer to isolate chemical kinetics

For a kinetic study, the chemical reaction must be the sole rate-limiting step. By injecting gas directly into the agitator's zone of maximum shear, bubbles are broken up instantly. This forced mechanical dispersion maximizes the exchange surface area and ensures the measurement truly reflects the reaction speed, not the mixing performance.
Accelerating screening with a removable reactor core

Changing a catalyst in a high-pressure reactor is a time-consuming operation. To minimize downtime, the tubular reactor's core was designed as a removable module. This allows the operator to pack the catalyst offline, without dismantling the HP circuit, and run consecutive tests much faster.
Ensuring process stability with indirect pressure control

At low flow rates, the slightest disturbance can destabilize the pressure. We used a back-pressure regulator balanced by an external pressure reference, not by the process fluid itself. This self-contained system absorbs fluctuations and maintains an extremely stable working pressure, which is essential for the reproducibility of long-duration tests.

03 — Beyond this project

Does your process involve similar conditions?

Pharmaceutical synthesis

To master a hydrogenation reaction (gas-liquid-solid) where mass transfer is critical, the principle of the high-pressure stirred reactor, precise fluid control, and easy catalyst replacement would remain relevant choices.

Food processing

Controlling the hydrogenation of vegetable oils relies on the same need for optimal contact between gas, liquid, and catalyst. High-shear dispersion and fine control of pressure and temperature are directly transferable, with materials adapted to meet sanitary standards.

Wastewater treatment

Wet air oxidation requires excellent gas-liquid mass transfer to break down pollutants at high pressure and temperature. The dispersion principle and the control of severe conditions are the same, although materials must be adapted to resist high corrosion.

04 — Specifications

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

Show specifications · 200 bar · 300°C · One tubular reactor (PFR) and one stirred reactor (CSTR) on the same platform

Technical specifications — Unbiased catalyst comparison: a dual-reactor HPHT R&D platform
Maximum operating pressure	200 bar
Maximum operating temperature	300°C
Reactor types	One tubular reactor (PFR) and one stirred reactor (CSTR) on the same platform
Automation	Fully automated units
Fluid control	Ultra-precise control of low gas and liquid flow rates

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 dual-reactor system be used with highly corrosive fluids?

Yes, the design can be adapted for corrosive environments. The operating principle of the reactors and control system remains the same, but the wetted materials would be changed. Depending on the type of corrosion, we would use materials like Hastelloy, Inconel, or titanium, as on this 6-reactor bench in Hastelloy.

How can this reactor platform be adapted for scale-up studies towards a pilot plant?

To move to a pilot scale, the reactor volumes and flow rates would be increased. The instrumentation would be adapted to be representative of industrial technologies. However, the dual architecture (screening/kinetics) and the principles of mastering hydrodynamics and pressure stability would remain the cornerstones of the design to ensure the relevance of the scale-up data.

Can such a test rig be installed in an ATEX environment to work with flammable gases?

Absolutely. ATEX compliance is part of our standard practice. This involves selecting certified electrical and mechanical components, integrating specific safety features (detectors, ventilation), and performing a complete risk analysis. The rig's general architecture is compatible with operation in an explosive atmosphere, as it is for our hydrogen test benches.

Can the system run continuously over long periods without constant supervision?

Yes, the system is fully automated for autonomous and safe operation. The control software manages test sequences, data logging, and safety procedures in case of any anomaly. This allows for running kinetic studies or catalyst aging tests over several days, ensuring stable conditions and data traceability.