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).
At a glance
- Client
- Leading European university research center
- Field
- Process development (CO2 capture, hydrogen)
- Technique
- Catalyst screening, reaction kinetics studies
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.
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
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 — Technical specifications
| 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 |
04 — Other applications
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.
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