Case study · HPHT reactors & cells

Versatile R&D pilot plant: continuous flow (PFR) & stirred-tank (CSTR) reactors | 200 bar / 300°C

IRIAN Mecatronics designed and built a versatile experimental platform for a European university research center focused on bioprocess R&D. The equipment runs reactions in either a continuous flow (tubular) or a stirred-tank (CSTR) configuration at up to 200 bar (2900 psi) and 300°C (572°F), all managed by a single, unified control and safety system.

Client: A European university research center
Field: Process chemistry, energy (hydrogen, CCUS)
Technique: Chemical kinetics, process development, catalyst screening

HPHT reactors & cells200 bar300°CConfidential project · photo withheld

01 — The research question

How to study different reaction kinetics under reproducible and safe HPHT conditions?

In R&D, comparing data from reactors with different hydrodynamics—such as a plug flow reactor (PFR) and a continuously stirred-tank reactor (CSTR)—is crucial for understanding reaction mechanisms. The challenge is ensuring that operating conditions (pressure, temperature, flow rates) are identical and stable from one test to another. This is especially difficult at high pressure and high temperature, where even minor deviations can invalidate the results.

A university research center needed such a platform to accelerate its work on bioprocesses like CO2 capture and hydrogen production. Standard lab equipment fell short, as it is typically dedicated to a single reactor type. No off-the-shelf solution offered an integrated platform that could handle both methodologies with a unified control and safety system, especially at the required 200 bar and 300°C with high precision.

Ensuring reproducible measurements and operator safety on a multi-reactor R&D platform running both tubular and stirred-tank reactions at high pressure and temperature with flammable gases.

02 — Our approach

A design driven by flexibility, precision, and safety

To meet this need, our engineering team structured the design around three core principles: a modular architecture for versatility, high-precision instrumentation for reliable data, and a multi-layered safety system to protect operators.

Shared control and safety for two reactor types

The client needed to switch between a tubular reactor and a stirred tank without duplicating equipment. We designed a single ecosystem where the reactor modules are interchangeable but share the same PLC and safety interlocks. This gives researchers the flexibility to compare different kinetics using a common control framework.
Ensuring stable critical parameters at low flow rates

Maintaining a stable pressure at 200 bar with very low flow rates is critical for data validity. We implemented a closed-loop control for each parameter, including active back-pressure regulation. This allows researchers to run long-duration tests with confidence that the conditions are maintained with high fidelity.
Implementing defense-in-depth against multiple hazards

The combination of HPHT conditions (200 bar / 300°C) and flammable gases (H2) requires flawless safety. Our approach uses three independent and redundant layers of protection. Any failure—whether software, hardware, or human—is caught by a higher safety layer, ensuring the system fails safe autonomously.

03 — Beyond this project

Does your project have similar requirements?

Fine chemicals / pharmaceuticals

For catalyst screening or synthesis route optimization, the need for a flexible and precise platform is identical. We would keep the same control/safety architecture and fine-tuned regulation, but adapt the materials to pharmaceutical standards (cGMP) and add online purification modules.

Geosciences / reservoir studies

To simulate downhole conditions (HPHT), robust and stable controls are key. The principle would remain the same, but the reactor would be a core flooding cell to hold a rock sample, or a sapphire cell for visualization.

Materials Science

Synthesizing polymers under supercritical conditions requires precise control of pressure and temperature ramps. The automation and safety features are transferable, but the reactor and stirring system would be designed to handle very high-viscosity fluids or solid phases.

04 — Specifications

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

Show specifications · 200 bar (2900 psi) · 300°C (572°F) · Continuous tubular (PFR) and stirred-tank (CSTR)

Technical specifications — Versatile R&D pilot plant: continuous flow (PFR) & stirred-tank (CSTR) reactors | 200 bar / 300°C
Maximum operating pressure	200 bar (2900 psi)
Maximum operating temperature	300°C (572°F)
Reactor types provided	Continuous tubular (PFR) and stirred-tank (CSTR)

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 reaction pilot plant be used with highly corrosive fluids?

Yes, the design of such a pilot plant can be adapted for highly corrosive fluids. The modular architecture and precise control principles remain the same, but all wetted materials (tubing, reactor, valves, sensors) would be replaced with specific alloys like Hastelloy or Inconel, as we do for our corrosion test reactors. The material selection depends on the exact fluid chemistry and P/T conditions.

Is it possible to reach much higher pressures, such as 500 or 1,000 bar, with this multi-reactor system?

Yes, the unified platform concept can be applied to higher pressures. Reaching 500 or 1,000 bar would require a complete redesign of all pressure-containing components (reactors, tubing, valves) in accordance with the Pressure Equipment Directive (PED). The control and safety architecture would be preserved, but the instrumentation (pumps, sensors) would be replaced with models rated for the new pressure range.

Is this reaction pilot limited to the lab scale, or can it be designed for scale-up studies?

This platform is designed for R&D, but the approach is directly applicable to scale-up pilot plants. The reactor volumes, flow rates, and heating power would be increased. The control and safety philosophy remains the same, but the instrumentation would be selected for industrial ranges, and the entire system would be mounted on a larger skid.

How is such equipment certified for use with hydrogen in an ATEX zone?

For use in an ATEX zone, the entire design must incorporate this requirement from the outset. All electrical components would be ATEX-certified models. Ventilation would be enhanced, and gas detectors (H2) would be added and linked to the safety PLC to trigger an emergency shutdown and automatic inerting in case of a leak, similar to our test benches for flammable gases.

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