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.
At a glance
- Client
- A European university research center
- Field
- Process chemistry, energy (hydrogen, CCUS)
- Technique
- Chemical kinetics, process development, catalyst screening
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.
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
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 — Technical specifications
| Maximum operating pressure | 200 bar (2900 psi) |
|---|---|
| Maximum operating temperature | 300°C (572°F) |
| Reactor types provided | Continuous tubular (PFR) and stirred-tank (CSTR) |
04 — Other applications
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.
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