Multi-Mode HPHT Reactor for Geochemical Simulation in Corrosive Media
Design and fabrication of a versatile reactor for a geoscience research laboratory, operating up to 550 bar (approx. 8000 psi) and 250°C (482°F). With a 0.7 L volume, the equipment is engineered for maximum experimental flexibility, enabling at least three test configurations (batch, floating piston, percolation) in the presence of highly corrosive fluids (brine, H2S, CO2).
Material selection, including Super Duplex with a PTFE coating and Inconel 625, was a key factor in ensuring long-term durability and data integrity.
The Technical Challenge: One Platform, Three Experimental Protocols
Studying fluid-rock interactions under deep geological conditions imposes severe constraints. Beyond high pressure and temperature, the fluid chemistry—often saturated brines containing dissolved gases like H2S or CO2—is extremely aggressive to most standard steels.
Our client’s requirement went beyond a simple corrosion-resistant autoclave. The laboratory needed to conduct a variety of experimental protocols using a single piece of equipment:
- Batch mode: To study the geochemical evolution of a crushed rock sample in static contact with a fluid.
- Controlled gas cap mode: To simulate a reservoir with a gas phase, controlling its volume and pressure via a movable piston.
- Percolation mode (future capability): To circulate a fluid through a rock core and measure changes in its permeability.
Standard off-the-shelf equipment is typically dedicated to a single one of these uses. The challenge was to design a unique, modular platform capable of withstanding these extreme conditions over the long term.
Our Custom Engineering Approach: Mechanical Modularity and Anti-Corrosion Barriers
Our engineering team based the design on two pillars: materials science and functional modularity.
1. A Multi-Layered Defense Against Corrosion: The main structure of the reactor (body and lid) is machined from Super Duplex, an alloy known for its high mechanical strength and excellent resistance to chloride-induced corrosion. To ensure near-total chemical inertness and protect the alloy from H2S attack, all wetted surfaces feature a PTFE coating. Sealing is achieved with FFKM, PEEK, and PTFE gaskets. The most exposed components, such as the sheath for the internal temperature thermocouple, are made of Inconel 625.
2. A Reconfigurable Architecture: The core of the system is a single reactor vessel that can accommodate different top-work assemblies.
- In batch configuration, the lid is equipped with dedicated ports for injection, sampling, and instrumentation (pH and ORP probes via 1/4″ NPT ports). A removable Teflon liner can be used to simplify cleaning and prevent cross-contamination.
- In “gas cap” configuration, a complete floating piston cell assembly is integrated. The piston’s position is continuously measured by an LVDT sensor, allowing for high-precision tracking of gas phase volume changes.
The entire reactor is mounted on an articulated stand that facilitates opening and access to the vessel interior. The external heating system and the control cabinet, which communicates via Ethernet/IP, manage all parameters and centralize data acquisition.
Transferability & Your Future Projects
The combination of high pressure, corrosion resistance, and modularity makes this type of design relevant for many other R&D fields:
- Carbon Capture, Utilization, and Storage (CCUS): To simulate CO2 injection into saline aquifers and study interactions with reservoir rock, wellbore corrosion, and long-term mineralization. This design is directly adaptable for our dedicated CO2 capture applications.
- Energy Production (Geothermal, Oil & Gas): To perform material aging tests or evaluate the effectiveness of corrosion inhibitors in real-world production fluids. Higher-temperature corrosion test rigs in Inconel 625 are also part of our expertise.
- Hydrogen Storage: To assess the compatibility of wellbore and reservoir materials with hydrogen under pressure and to study the induced biogeochemical reactions.
Technical specifications
- Operating Pressure: 550 bar (approx. 8000 psi)
- Operating Temperature: 250°C (482°F) maximum
- Volume: 0.7 L (0.18 US gal)
- Wetted Materials: Super Duplex, PTFE coating, FFKM, PEEK
- Main Ports: 2x 1/4″ NPT (probes), 4x 1/8″ Speedbite, 1x 1/16″ Valco
- Heating: External heating jacket, Inconel 625 sheathed Type T thermocouple
- Operating Modes: Batch (with/without liner), floating piston (LVDT tracking, 200°C max), adaptable for percolation
If your experiments are hitting the limits of standard equipment, tell us about your challenge. Our engineering team is structured to analyze the physical constraints of your experiment and design the instrument that will allow you to overcome them.
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