Case study · Extreme Environment Simulation Systems
Custom High-Pressure Syringe Pump: Injecting Corrosive Fluids at 800 bar with Microliter Stability
For a fundamental chemistry research lab, IRIAN Mecatronics designed and built a high-pressure syringe pump to inject corrosive fluids at 800 bar. The equipment combines a five-order-of-magnitude flow range with microliter stability, where no standard equipment existed.
At a glance
- Client
- Public fundamental chemistry research laboratory
- Field
- Fundamental Chemistry, Geochemistry
- Technique
- Controlled injection of reactive fluids
01 — The research question
How to inject a corrosive fluid at a very low, stable flow rate under very high pressure?
Injecting a fluid with stability and precision is a common challenge, but the difficulty increases exponentially when very high pressure, extremely low flow rates, and high chemical corrosivity are involved. Most pumps excel in one or two of these areas: HPLC pumps offer precision but not chemical resistance, while industrial pumps handle pressure and corrosion but lack the finesse for microfluidics. In this project, a laboratory sought to continuously simulate the conditions of deep-sea hydrothermal vents for research on the origin of life. They needed to inject concentrated brines and dissolved corrosive gases into an experimental cell at 800 bar, with a flow range from rapid purging to quasi-static injection over several days.
The technical challenge was to reconcile the immense mechanical force needed to push a fluid at 800 bar with the fine control required to regulate a stable flow rate at the nanoliter-per-second scale.
02 — Our approach
Our design approach: four constraints, four solutions
Ensuring sample purity against corrosion
The fluids (brines, dissolved gases) were highly aggressive. To prevent any contamination of the experiments and ensure durability, we selected a unique alloy, Hastelloy C-276, for all wetted parts. This guarantees the user that their results are not skewed by metal leaching.
Mastering a five-order-of-magnitude flow range
To cover the range from 0.1 µL/min to 60 mL/min, we chose an oversized motor drive for power, controlled by high-resolution electronics for finesse. This precise feedback control allows the researcher to switch from a microfluidic experiment to a rapid purge with a single precision injection system.
Allowing for adaptation to future research protocols
Research equipment must be able to evolve. Instead of a monolithic design, we engineered a frame that accepts interchangeable syringe bodies. This allows the researcher to mount a small volume to reach maximum pressure with expensive products, or a large volume for long-duration tests at moderate pressure.
Ensuring operator safety at 800 bar
Such high pressure represents a major energy hazard. Safety is based on three independent levels: a physical shield against projectiles, a hardwired safety circuit that cuts power in case of a fault, and software limits. This redundancy is essential for any project involving the simulation of extreme environments.
03 — Technical specifications
| Maximum operating pressure | 800 bar (11,600 psi) |
|---|---|
| Flow rate range | 0.1 µL/min to 60 mL/min |
| Flow rate stability | 0.05 µL/min |
| Syringe volumes | 10 mL (at 800 bar / 11,600 psi) and 25 mL (at 340 bar / 4,930 psi) |
| Wetted parts material | Hastelloy C-276 |
04 — Other applications
Could this approach solve your problem?
Energy (CO2 capture, hydrogen)
The common constraint is the controlled injection of supercritical fluids or gases at very high pressure. The principle of a powerful mechanical drive with precision control would remain, as would the need for specific materials (H₂, H₂S compatibility), but certifications (ATEX) might change.
Pharmaceuticals (continuous flow synthesis)
The need for very precise dosing in pressurized microfluidic reactors is similar. The high flow stability and high-resolution motor control would be retained, but the materials (pharma-grade stainless steel, PEEK) and cleanability requirements (GMP, FDA) would be different.
Geosciences (Oil & Gas)
For enhanced oil recovery studies, the ability to maintain stable pressure and flow over long periods is key. Robustness and corrosion resistance remain relevant, as in our HPHT reactor bench in Hastelloy, but back-pressure regulation and temperature control would need to be added.
An engineer from our design office replies as soon as possible.