Southwest Research Institute (SwRI) is poised to transform the landscape of hydrocarbon machinery testing and research with the construction of an expansive new facility dedicated to exploring the capabilities and challenges of flammable gas systems. This state-of-the-art 90,000-square-foot hydrocarbon research center, currently underway in San Antonio, Texas, represents a critical advancement for industries reliant on energy systems powered by hydrocarbons and other volatile gases. Designed to accommodate megawatt-scale testing, the facility will operate at the cutting edge of mechanical, aerodynamic, thermodynamic, and emissions evaluation, addressing efficiency, safety, reliability, and durability concerns across a broad array of applications.
Hydrocarbons, such as natural gas, form the backbone of modern energy infrastructure worldwide. These organic molecules composed primarily of hydrogen and carbon atoms not only serve as a cornerstone fuel source but also underpin a diverse range of petrochemical products. The facility at SwRI is uniquely engineered to safely handle an extensive spectrum of flammable fluids, including hydrogen, ammonia, hydrofluorocarbons, and advanced refrigerants, reflecting the growing importance of alternative and transitional energy carriers in power generation and industrial operations. This versatility will enable the research institute to push the boundaries of what machinery can achieve when powered or cooled by these complex chemical fluids.
At the heart of the facility’s design is a robust industrial infrastructure tailored to megawatt-scale testing demands. The complex includes an open-sided building optimized for the rigorous assessment of large-scale rotating equipment, such as high-performance gas turbines, turbo compressors, and reciprocating compressors frequently used in industrial processes. Equipped with a 30-ton overhead bridge crane, the facility allows for precise handling and installation of heavy machinery on foundations built to support loads of up to 150 tons. This engineering capability reflects the facility’s commitment to replicating real-world operational environments and ensuring that equipment testing scenarios are both comprehensive and representative.
Electrical and control systems within the facility are equally advanced, featuring a dedicated building capable of supplying up to five megawatts of electric power to support intensive testing regimens. A specialized control room, outfitted with fiber-optic connectivity, ensures low-latency, high-speed data transfers across the testing grounds, facilitating real-time monitoring and data acquisition essential to cutting-edge research. These digital capabilities provide researchers with the tools necessary to capture detailed insights into machinery performance and emissions characteristics, driving forward innovation in gas-powered technologies.
Complementing these testing environments is a third building dedicated to supporting sophisticated test protocols requiring auxiliary utilities such as steam and compressed air. These plants enable challenging experimental setups mimicking operational conditions found across various industrial sectors. In addition to these functional facilities, the site includes a carefully managed fuel yard designed to safely store and distribute a range of flammable gases. Overhead pipe racks provide safe and efficient routing for waste gas disposal, ensuring compliance with rigorous environmental and safety standards.
SwRI’s new hydrocarbon research facility addresses a vital industry need for independent testing and validation of machinery that relies on flammable gases. The facility’s capabilities extend beyond conventional natural gas applications, incorporating emerging technologies in hydrogen compression, industrial heat pumps, waste heat recovery, and turbomachinery-driven heating systems. This breadth reflects a forward-thinking approach that anticipates the evolution of energy systems as the global economy shifts towards lower-carbon solutions without compromising performance or affordability.
“Natural gas accounts for over a third of the electricity generation in the United States,” explains Dr. Tim Allison, director of SwRI’s Machinery Department. “Its relatively low cost and the ability to produce, store, and transport it affordably make it a key player in the nation’s energy portfolio. Importantly, natural gas combustion releases significantly fewer carbon emissions compared to other fossil fuels. Our new facility is designed to accelerate development workflows and bring advanced technologies to market that optimize these benefits while minimizing environmental impact.”
This research initiative is particularly timely as industries increasingly seek to integrate sustainable practices and cleaner energy modalities within existing systems. The facility’s testing platforms will support extensive characterization of machinery mechanics, aerodynamic flow dynamics, thermodynamic efficiency, and emissions profiles under varied operational stresses. These data-driven insights will empower manufacturers and energy providers to refine designs, improve safety protocols, and extend machinery lifespans, significantly enhancing overall system reliability and user safety.
Furthermore, addressing flammable gas handling and control is critical to facilitating emerging renewable and alternative energy applications. Whether compressing hydrogen for use as a clean fuel carrier or validating novel refrigerants for energy-efficient heat pumps, the facility’s versatile testing environment enables comprehensive evaluation under realistic, high-intensity conditions. This capability is crucial given the volatile nature and stringent safety requirements associated with handling such substances in industrial settings.
The facility’s construction reflects more than just infrastructural growth; it symbolizes an institutional commitment to serve as a neutral and unbiased resource for a diverse array of stakeholders, including government agencies, private sector innovators, and academic researchers. By providing access to advanced testing technologies and expertise, SwRI positions itself as a catalyst for accelerating technological breakthroughs that will shape the future of energy generation and industrial manufacturing.
As the global energy landscape rapidly evolves, technological validation and performance benchmarking remain indispensable steps in reducing greenhouse gas emissions and enhancing the sustainability of power production. The new hydrocarbon research facility will play a pivotal role in supporting this transition, enabling the scientific and engineering communities to devise solutions that balance economic feasibility with environmental stewardship.
Construction is projected to reach completion by November 2025, signaling the imminent availability of unparalleled testing resources. Once operational, SwRI’s hydrocarbon research hub will empower the next generation of engineers and scientists to explore innovative pathways toward cleaner and more efficient energy systems, fostering robust economic growth alongside environmental responsibility.
For more detailed information about the facility and its research initiatives, interested parties are encouraged to visit Southwest Research Institute’s dedicated energy and machinery web portal. The site offers comprehensive insights into how SwRI’s multidisciplinary efforts are advancing energy technologies through rigorous scientific inquiry and real-world application testing.
—
Subject of Research: Hydrocarbon machinery testing and research focused on flammable gas systems including natural gas, hydrogen, ammonia, and advanced refrigerants.
Article Title: Southwest Research Institute Advances Megawatt-Scale Hydrocarbon Machinery Testing with New State-of-the-Art Facility
News Publication Date: May 20, 2025
Web References: https://www.swri.org/markets/energy-environment/machinery?utm_campaign=hydrocarbon-facility-pr&utm_source=eurekalert!&utm_medium=referral
Image Credits: Southwest Research Institute
Keywords
Gas turbine engines, Energy, Renewable energy
