Case study · Extreme environment simulation systems
Safe HPHT materials testing in flammable gas: a custom ATEX multi-autoclave rig
IRIAN Mecatronics designed and built a custom test rig for an R&D center studying materials aging under extreme conditions. The equipment safely exposes samples to reactive gases like hydrogen at high pressure and high temperature within an ATEX-certified environment.
At a glance
- Client
- R&D Center
- Field
- Materials science, energy
- Technique
- Aging tests, Materials compatibility, ATEX environment testing
01 — The research question
How can we safely test materials in a flammable HPHT environment?
Testing materials in a controlled environment that combines high pressure, high temperature, and a flammable gas is a major challenge. Ensuring absolute safety for operators and the facility imposes design constraints that go far beyond standard laboratory equipment. For this project, an R&D center needed to expose materials to hydrogen at high pressure and temperature. Off-the-shelf autoclaves are not designed to handle these three constraints (HP, HT, flammable gas) simultaneously. This required a custom design and certification compliant with the ATEX directive, integrating risk management that only custom equipment can provide from the ground up.
The key challenge was to achieve high experimental performance—including rapid pressure and temperature ramps—while completely mitigating the explosion risk associated with handling flammable gases that have low ignition thresholds.
02 — Our approach
Our approach: A design centered on risk management
Managing explosion risk with multi-layered safety
Since the pressurized gas is flammable, any leak could create an explosive atmosphere. We combined prevention (ATEX-certified components), containment (zone separation), and an active response (leak detection and automatic safety shutdown). This allows the operator to launch tests with confidence, as the system autonomously manages any anomalies.
Selecting a material resistant to embrittlement
At high pressure and temperature, hydrogen can embrittle standard steels like 316L stainless steel, leading to failure. Our approach was to select a material grade inherently resistant to this phenomenon, ruling out standard solutions. This ensures the long-term longevity and integrity of the high-pressure autoclave over its entire service life.
Simplifying handling for rapid test cycles
HPHT autoclave lids are heavy, and opening and closing them frequently is a source of risk and wasted time. We designed an assistance system that eliminates operator strain and avoids disconnecting rigid piping. Sample changes are faster, simpler, and safer.
03 — Technical specifications
| Test environment | Reactive or flammable gas (e.g., hydrogen) under high pressure and high temperature |
|---|---|
| Safety | Designed for use in potentially explosive atmospheres (ATEX) |
| Process control | Independent pressure and temperature control of multiple autoclaves on a single test bench |
| Dynamics | Rapid temperature and pressure ramps |
| Safety function | Automatic vacuum and purge sequences |
04 — Other applications
Does your project look like this case?
Energy production (e-fuels, hydrogen, ammonia)
For testing the durability of catalysts or reactor materials in the presence of reactive HPHT fluids, the multi-level safety approach (ATEX, detection), compatible material selection, and independent control of multiple custom reactors would remain identical.
Pharmaceutical industry
For synthesis reactions like hydrogenation under pressure with flammable reagents, the ATEX risk management, precise temperature control, and loading ergonomics are directly transferable. Materials (e.g., Hastelloy) and cleanability requirements would be adapted.
Aerospace
For qualifying the compatibility of components with propellants like hydrogen, the integrated safety approach and critical material selection are essential. The main adaptations would involve managing cryogenics or faster thermal cycles.
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