Sulzer Chemtech Process Technology
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Process Technology at Sulzer Chemtech
Sulzer Chemtech, a member of the Sulzer Corporation, with headquarters in Winterthur, Switzerland, is active in the field of process engineering, employing 3'000 persons worldwide. Sulzer Chemtech is represented in all important industrial countries setting standards in the fields of mass transfer and static mixing with its advanced and economical solutions.
Sulzer Chemtech is organized into four business units, one of which is the Process Technology group. This business unit was formed in early 2009 following the acquisition of Kühni, a Swiss company with more than 75 years experience in innovative separation processes. Today, Sulzer Chemtech Process Technology is headquartered in Allschwil (Basel), Switzerland.
By combining Sulzer's and former Kühni's proven process technologies and exper-tise, Sulzer Chemtech Process Technol-ogy is now uniquely positioned to offer process solutions for demanding, indus-trial separations based on an excellent portfolio of the following unit operations:• Distillation, absorption and reactive distil-lation
• Film evaporation
• Liquid-liquid extraction
• Crystallization
• Membrane separation
In addition, Sulzer Chemtech has exten-sive experience and know-how in provid-ing process solutions for a wide range of process applications such as:
• Solvent recovery
• Product purification
• Wastewater and vent gas treatment • Food and beverage
• Biofuels and biochemicals
• Reaction technology
• Polymer production, including Polysty-rene (PS), Expandable Polystyrene (EPS) and Poly Lactic Acid (PLA) production This establishes our active position in the
following industry segments:
• Fine and specialty chemical industry
• Chemical and petrochemical industry
• Pharmaceutical industry
reactive to• Polymer production industry
• Food and beverage industry
• Biofuels and biorefinery industry
Our services and sales activities are orga-
nized globally, with the support of repre-
sentatives in all key countries of Europe,
Asia and the Americas. This way we are
close to our customers.
One of our core strengths is that the en-
tire project scope is provided from a single
point of responsibility. Our activities cover
the full project development cycle from the
initial conceptual design and testing up to
start-up of complete plant solutions. We
offer:
• Testing and sample production services,
provided by state-of-the-art laboratory
and pilot test centers
• Engineering services including feasibility
studies, plant optimization, revamp and
debottlenecking studies, and concep-
tual designs
• Basic and detail engineering packages
• Fabrication and supply of proprietary
and key process equipment
• Fabrication and supply of complete pro-
cess plants as modular units
• Project management, installation, com-
missioning, start-up and after sales ser-
vices
We have a proven track record in develop-
ing innovative solutions to complex sepa-
ration problems, where our unique and ex-
tensive experience in combining process
unit operations from our wide portfolio into
hybrid plant solutions is paramount. This,
together with our capabilities to supply
state-of-the-art process equipment and
complete plant solutions are key to our
success.
We are a reliable innovation partner and
preferred supplier for our customers glob-
ally. We deliver our solutions with guaran-
teed performance.
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Distillation, Absorption & Reactive Distillation
Distillation and Absorption
Distillation is the most commonly applied separation technology. Sulzer Chemtech has been supplying
process solutions in this fi  eld since 1940. To date more than 100'000 columns are operating with Sul-zer equipment, in over 500 different ap-plications.
Sulzer Chemtech is a leading expert and solutions provider for a range of distillation technologies:
• Continuous and batch distillation • Single- and multi-stage distillation • Extractive distillation • Azeotropic distillation • Pressure swing distillation • Reactive distillation • Divided wall columns
Our product portfolio includes a unique and complete range of the best perform-ing, state-of-the-art column internals:
Sulzer Chemtech has a long-standing experience in distillation and adsorption, with innovative solutions such as reactive distillation
• Structured packing (like MellapakPlus TM  and BXPlus TM  gauze packing)• Random packing
• Trays (conventional, high performance and cartridge trays)
• Column internals (like distributors and collectors)
• Vapor-liquid and liquid-liquid phase
separators (like KnitMesh TM
mist elimina-tors and Mellachevron TM  vane packs)The design of distillation units is geared to deliver an improved product quality, increased capacity and reduced energy consumption. Design activities are sup-ported by computer simulations and in-house pilot plant testing. Our vast experi-ence and know-how in the fi  eld of distil-lation combined with a profound under-standing of column hardware ensures we offer the optimum solution to our clients. We offer customers either a basic engi-neering package including key equipment (column shells, internals, heat exchangers and decanters), or a complete, often skid-mounted unit including process control and start-up support services.
Reactive Distillation
Reactive distillation is a state-of-the-art development combining distillation and chemical reaction in one single operat-ing unit. This technology is highly valuable for equilibrium-limited reactions, such as esterifi  cation. The level of conversion is increased by continuously removing the reaction products from the reaction zone via distillation. In general, reactive distilla-tion units feature:
• Fewer distillation columns • No or smaller recycle streams
• Utilization of heat of reaction for mass transfer
• Higher product yields • Lower capital investment
• Lower energy costs
L i q u i d
G a s
Installation of a slit tray
Distillation column sketch with different internals
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Vacuum conditions and a short contact time of the product with a heated surface are two essential parameters to prevent secondary reactions (like polymerization and condensation) and to preserve or-ganoleptic properties (color, smell, taste), as required in many industries - food, fine chemical, pharmaceutical. These param-eters are incorporated in our film evapora-tion technologies.
Falling Film Evaporator
The tubular falling film evaporator is spe-cifically suited for processing temperature sensitive products with a low viscosity and tendency for fouling. It consists of a tube bundle crowned by a proprietary liquid distribution device, which ensures an ef-ficient and uniform distribution of the liquid to all the tubes, as well as a continuous film along the tube length.
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Film Evaporation
Sulzer Chemtech's film evaporation technology produces high-purity substances from heat sensitive and complex products
Usually the liquid and resulting vapors flow co-currently from the top to the bottom and a gas-liquid separator is applied to separate the exhaust streams. This sepa-rator is not required in counter-current applications (stripping) or when the falling film evaporator is used as a reboiler of a distillation column.
Thin or Wiped Film Evaporator
The thin or wiped film evaporator is the ideal apparatus for continuous processing of heat sensitive, viscous and/or fouling products. It consists of a single evapora-tion tube fitted with a mechanical rotating device that ensures a uniform distribution of the liquid on the heated surface, a con-stant mixing of the film and minimal fouling of the evaporation surface.
The vapors produced rise upwards, counter-currently to the liquid and, when required, pass trough a mist eliminator mounted in the top section. Thanks to the large cross-sectional area, the pressure drop
across the evaporator is low (typi-cally less than 0.05 mbar) and operation in the vacuum range as low as 0.5 mbar is possible.
Short Path Evaporator
In the short path evaporator, a vertical condenser is placed inside the wiped evaporation chamber. This results in a very short distance between the heating and condensing surface. The pressure drop across the system is thus minimized and evaporation in the pressure range
below 1 mbar is feasible. Due to the short
residence time, highly temperature sensi-tive substances and compounds with high molecular weight can be purified at high purities and yields.
Typical Applications
Sulzer Chemtech’s falling and thin film evaporators are widely used in the organic chemical industry, as column reboilers in (high) vacuum distillation systems. Other typical applications are:• Product purification • Solvent recovery
• Concentration of solutions and slurries • Crystallization • Drying
• Treatment of industrial waste streams
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0611 4505Test rig for a wiped film evaporator
Rotor of a wiped film evaporator Falling film evaporator
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Liquid-Liquid Extraction
Sulzer Chemtech’s liquid-liquid extraction is a technically sophisticated separation technology, offering
a solution where other technologies are uneconomical or not suitable
Liquid-liquid extraction is a complex sepa-ration process in which the components are extracted from the feed stream with the help of an extractant, or solvent. The components to be extracted have a dif-ferent solubility in the two immiscible, or partially miscible, liquids. Both liquids have to be thoroughly contacted and subsequently separated. The liquids fl  ow counter-currently and the required purity and yield determines the number of sepa-ration stages.
In the fi  eld of liquid-liquid extraction, Sulzer Chemtech's range of equipment covers many industrial applications and is based on a number of modern, effi  cient types of extractors.
Column Type Extractors
• Kühni Agitated Column (ECR)
In applications with high mass transfer and/or changing physical properties, this is the column of choice. The com-partment geometry can be adapted to compensate for changing conditions re-sulting in a constant high column perfor-mance. The main features are the spe-cial mixing turbines and the perforated partition plates.
• Packed Column (ECP) The key benefi  t of a packed column is the high throughput which leads to small column diameters. Together with specially adapted liquid distributors, our structured packing provides the best ex-traction performance.
Mixer-Settler Type Extractors
Mixer-settlers, both as stand-alone and as in-column type, are offered for special ap-plications:
• Mixer-Settler (EMS)
Due to the pump-mix turbine no addi-tional feed pumps are required in most cases.
• Kühni Mixer-Settler-Column (ECMS)
This special type of equipment com-bines the stage-wise operation of mixer-settlers with the small footprint of a col-umn.
Typical applications are:
• Recovery of carboxylic acids, for exam-ple, acetic acid
• Extraction of aromatics, for example, from oil
• Washing of organic solvents
• Cleaning of aqueous effl  uents from high boiling impurities like phenol
• Wet purifi  cation of phosphoric acid (food grade)
• Recovery and purifi  cation of Active Phar-maceutical Ingredients (API's)• Solvent de-asphalting • Solvent recovery
Sulzer Chemtech is a market leader with
extensive experience in these applications. Our broad know-how covers selection of the most suitable solvent and optimum equipment selection and design. Equip-ment design is backed-up by elaborate research by universities. Furthermore, testing activities provide a solid basis for reliable designs and scale-up procedures, and a complete range of test equipment is available in our in-house test center. This way, even in diffi  cult cases, the optimum process solution is achieved.
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Kühni agitated column internals
Liquid-liquid extraction packing

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