Case study · Extreme environment simulation systems

High-Pressure Bioreactor Retrofit: Reliable Operation at 10 000 Psi in Corrosive Media

For a marine environmental science research lab, IRIAN Mecatronics recommissioned and improved the reliability of an existing test rig. The work involved integrating an injection and pressure control system capable of operating at 10 000 Psi and 150°C with highly corrosive saline fluids.

Client: University research laboratory in marine environmental sciences
Field: Hydrothermal environment simulation
Technique: Pressure control and fluid injection

01 — The research question

How to ensure stable and accurate pressure control in a corrosive environment?

Maintaining stable pressure in a reactor is key to the reproducibility of many experiments in chemistry, geoscience, or environmental science. The challenge grows when the fluid is corrosive, the pressure is high, and the temperature varies: standard control components reach their limits, lacking precision, responsiveness, or chemical resistance.

In this project, a lab had a test rig to simulate deep hydrothermal conditions, but it was out of service. An off-the-shelf solution was not an option, as new, reliable components had to be integrated into an existing architecture while staying within a tight budget, far below the cost of a new bench.

How to guarantee stable and accurate pressure control at 10 000 Psi in a hot saline fluid, by adapting high-performance components to a failing existing rig, without exceeding the budget for a recommissioning project?

02 — Our approach

A pragmatic approach: diagnose, improve, and secure

Analyzing the existing test rig led to three targeted interventions to restore its functionality and ensure the precision required for future test campaigns.

Delivering continuous and stable injection at 10 000 Psi

To feed the reactor, the system needed a stable and precise flow rate, even a very low one, without being affected by the 10 000 Psi back-pressure. We selected a positive displacement syringe pump. Its mechanism guarantees a pulse-free flow and direct control of the injected volume, unlike HPLC pumps. This allows the user to program precise injections or constant flow rates over long periods.
Maintaining stable back-pressure in a corrosive environment

The reactor pressure had to remain stable within 0.5 bar despite temperature fluctuations. We integrated a dome-loaded back-pressure regulator driven by an electronic pressure controller. This design separates the control circuit (air) from the process circuit (corrosive HPHT fluid), providing much more precise, responsive, and automatable control than a manual spring-loaded system. It is a core component of our test rigs for <a href="https://irian-mecatronics.com/fluid-dynamics-phase-behavior/">fluid dynamics</a>.
Restoring the safety and functionality of the existing rig

The budget required replacing only what was strictly necessary. After a complete diagnosis, our technicians brought the electrical cabinet into compliance, replaced defective sensors, and added a certified safety relief valve. This pragmatic approach, typical of our <a href="https://irian-mecatronics.com/maintenance-retrofit-requalification-services/">maintenance, retrofit, and requalification</a> services, made the rig functional and safe again at a controlled cost.

03 — Beyond this project

Could this approach solve your own technical challenge?

Geosciences / Oil & Gas (EOR)

The challenge is similar when injecting brines or polymers into rock core plugs. Using a syringe pump for a stable flow rate and a dome-loaded regulator for back-pressure remains the most robust solution to ensure reliable permeability measurements.

Chemistry / Catalysis

For the continuous feed of a high-pressure reactor, stable pressure and precise flow are critical. The syringe pump and dome-loaded regulator combination is still relevant. Only the wetted materials would need to be adapted for specific solvents or reactants, as we do for our <a href="https://irian-mecatronics.com/process-development-chemical-pilot-plants-instrumented-experimental-systems/">process pilot plants</a>.

Energy / Geothermal

Studying geothermal fluids in supercritical conditions involves managing high pressure, high temperature, and corrosion simultaneously. The control principle can be transposed, although the pressure and temperature levels may require higher-grade alloys and sealing technologies.

04 — Specifications

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

Show specifications · 690 bar (10,000 psi) · 0.0001 to 79 mL/min · ± 1% of full scale (FS)

Technical specifications — High-Pressure Bioreactor Retrofit: Reliable Operation at 10 000 Psi in Corrosive Media
Maximum operating pressure	690 bar (10,000 psi)
Pump flow rate range	0.0001 to 79 mL/min
Pressure control accuracy (back-pressure)	± 1% of full scale (FS)
Pressure control accuracy (pump)	± 0.7 bar
Flow control accuracy (pump)	± 0.3% of setpoint
Maximum fluid temperature	150 °C (302 °F)
Syringe volume	170 mL

IRIAN Mecatronics designs and builds custom high-pressure, high-temperature equipment for research laboratories, technical centres and industry.

About the company

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05 — FAQ

Frequently asked questions

Can this type of control system be used with gases or supercritical fluids?

Yes, this principle is compatible with both gases and liquids. The syringe pump can precisely control the flow or pressure of a gas like nitrogen or CO2. For supercritical fluids, special attention is paid to materials and seals, and cooling the pump head may be necessary, as on our <a href="https://irian-mecatronics.com/supercritical-co2-equipment/">supercritical CO₂ equipment</a>.

Can this control principle be adapted for pressures above 1,000 bar?

Yes, the dome-loaded regulator and syringe pump technology is scalable to higher pressures. The choice of components, materials (specialty steels, nickel alloys), and sealing technologies is then adapted to ensure safety and performance. Our engineering team regularly designs <a href="https://irian-mecatronics.com/project/1380-bar-hpht-aging-bench-simulating-extreme-conditions-for-cement-and-fluids/">equipment up to 1380 bar</a> and beyond.

Do you design complete test rigs that include these solutions?

Absolutely. Although this project was a retrofit, our core business is designing and manufacturing custom test rigs. Starting from a blank slate allows us to optimize component integration, operator ergonomics, and design a unified control system. Our <a href="https://irian-mecatronics.com/about-us/">engineering team and workshop</a> have all the in-house skills for this.

What level of automation is possible for such a pressure control system?

This system is fully automatable. The syringe pump and the electronic controller that pilots the back-pressure regulator can be interfaced with a supervisor (PC or PLC). This makes it possible to program complex scenarios: pressure ramps and cycles, maintaining a constant flow rate regardless of pressure variations, or slaving the system to another measurement.

Is your high-pressure test rig lacking in reliability or precision?

Describe your challenge, your fluid, and the operating conditions. Our engineering team will analyze the feasibility of your project and get back to you with a proposal for a custom-built system.

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