Mixing and Reaction Technology e 23270640

7/22/2019 Mixing and Reaction Technology e 23270640

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Sulzer Chemtech

Mixing and Reaction Technology

Pace-setting technology, worldwide

Sulzer Chemtech


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Contents

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Contents

Page

Sulzer mixers: Broadly imitated never duplicated ................... 4

Static mixing to your advantage ....................................................... 5

Leading technology for your process intensication..................... 6

Sulzer Mixers for turbulent ow ....................................................... 7

Sulzer Mixers for laminar ow .......................................................... 8

Sulzer Heat Exchangers and Reactors ............................................ 9

Chemical Process Industry .............................................................. 10

Energy ................................................................................................ 11

Water & Wastewater .......................................................................... 12

Food Processing Industry ................................................................ 13

Oil, Gas & Renery ............................................................................ 14

Polymer Production ........................................................................... 15

Fiber Production ................................................................................ 16

Plastics Processing ........................................................................... 17

Research & Development ................................................................. 18

Customer Testing .............................................................................. 19


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Always a step ahead

Since the early 1970s Sulzer Chemtech has pioneered static mixing to en-able homogenization and dispersion of gases and liquids without resortingto moving parts. The ongoing development and innovation brought diversi-cation in the area of heat and mass transfer, reaction technology, polymerproduction and plastics processing over a wide range of uid properties

and process conditions.

Today, we are the undisputed market and technology leader serving theglobal needs of our customers with the widest range of products and appli-cations. Our solutions are backed by the experience of more than 100,000references and the latest methods in development, client testing, engi-neering and fabrication to meet the processing challenges of our custo-mers and create long term benets.

Sulzer mixers: Broadly imitated never duplicated

What can our customersrely on?

- Customized solutions

- Joint development work

- Proven design proven compo-

nents

- Execution of smallest and largestprojects on time

- Troubleshooting and global ser-vice

- Improvement of process reli-ability, energy consumption andproduct quality

- Highest rates of return due tobest mixing effect

- Competitive pricing

What is the secret of theSulzer mixers?

- Decades of experience in design,manufacturing and applications

- Backed by unparalleled know-how in uid dynamics

- Best R&D facilities in the industry

- Standardized and accuratedesign standards

- Customized customer testingunits

- Widest range of mixer types,sizes and materials of construc-tion

- Fit for any mixing requirement

Innovative engineering

and production

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Static mixing to your advantage 100,000 references

Static mixers are tubular internals of appropriate shape and strength

to cause desired mixing and dispersion effects as the uid owsaround suitably arranged motionless mixer parts. The uid ow isprovided by pumping.

In practice, small volumes, low maintenance,

simple installation and cleaning and excellentreliability characterize the static mixer.

Laminar mixing

Laminar mixing is achieved by re-peated division, transposition andrecombination of liquid owingaround a static mixer. The compo-nents to be mixed are spread into a

large number of ne layers. A staticmixer consists of several identicalmixing elements. The more mixingelements, the ner the layers. Thener the layers, the better the ho-mogeneity of the mixture.

Laminar mixing in the Sulzer SMX mixer

shown wi th Laser Induced Fluorescence

Turbulent mixing

Some turbulent mixing is observedeven in an empty pipe. By installa-tion of a static mixer, however, thedistance required to achieve a goodhomogeneity is reduced by a factor10 and more. A static mixer has oneor several mixing elements gene-rating eddies in the ow. Any kindof inhomogeneity will be dissipated

by strong cross currents within themixing elements and downstream.

Turbulent mixing with eddies in the

CompaX mixer shown in a CFDsimulation

Pump

Static Mixer

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Leading technologyfor your process intensication

Mixing

Blending of miscible components regardless of thevolume, density, viscosity and properties of themedia.

Dispersing and Contacting

Dispersing two or more products for scrubbingprocesses, reactions, mass transfer.

Contacting of liquids with gases to create highmass transfer surface area and high rates of ab-sorption, reaction, vaporization and condensation.

Conditioning

Conditioning of process ows up-stream of reactors and heat ex-changers for increased efciency.

Heat Exchange and Reaction

Heat exchangers for controlled re-actions, high conversion or gentletempering of viscous media.

Reactions within a narrow resi-dence time distribution and maxi-

mum possible driving force.

Leading technologyfor your process intensication

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Sulzer Mixers for turbulent ow

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Sulzer Mixers for turbulent ow

Turbulent mixing, dispersing and contacting for masstransfer and reactions

Mixing and homogenizing of liquids and gases of lowviscosity

Admixing low viscous additives

SMV

Turbulent mixing with highest masstransfer rate

SMV Gas Mixer

Shortest mixing length

Contour Gas Mixer

Optimized turbulent ow

SMI

Prevents clogging

CompaX

Shortest space requirement

KVM

Smallest pressure drop

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Sulzer Mixers for laminar flowSulzer Mixers for laminar ow

Laminar mixing

Best handling of large viscosity difference

Homogenization and dispersing of viscous liquids

Blending melts and homogenizing bers

SMX plus

Excellent mixing of viscous

products with lowest pressuredrop

SMX / SMX plus

Design for high mechanical strength

SMX / SMX plus

Special design for the food processingindustry

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Sulzer Heat Exchangers and ReactorsSulzer Heat Exchangers and Reactors

Selective control of exothermic or endothermic reactions

Narrow residence time distribution

Gentle cooling and heating of temperature-sensitiveviscous media

Enhancement of heat transfer rates in heat exchanger

tubes for viscous and temperature-sensitive products

SMR

Plug ow behavior with large heatexchange area for applications withdemanding rheology

Heat Exchange

Enhanced heat transferfor highly viscous pro-ducts

SMXL Mono Tube SMXL Multi Tube

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Chemical Process Industry over 16,000 references

Customer benets

Uniform and consistent processconditions in respect to

- Concentration

- Temperature

- Residence time distribution

- Consistent product quality

- High yield- High selectivity for continuous

reactions

SMV EDC reactor

Main Applications

Dilution of liquids In-line mixing of various addi-

tives

Liquid and gas ow conditio-ning

Dispersing of liquids

Evaporation of liquids into gasstreams

Gas/liquid contacting

Absorption of gases in liquids

SMV Spray evaporator

- Low energy consumption

- Low volume of the mixer/reactor

- Low volume/hold up of the pro-cessed products

- Low maintenance cost (no mo-ving parts)

- Easy start up and operation

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Chemical Process Industry over 16,000 references

Thousands of references document the versatility of Sulzer mixers in thechemical process industry. The applications range from mixing of liquidsat various viscosities, mixing including reaction, gas liquid contacting,mass transfer and absorption, gas mixing and liquid evaporation. In orderto cope with corrosive chemicals the mixers are available in a wide rangeof materials.

Sulzer CompaXTM

: The space saving mixerwith additive dosing

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Energy ue gas ducts - SCR DeNOx systemsmore than 2500 references

Main Applications

Highly homogeneous admixing of ammonia

to the main ue gas stream for maximumperformance of SCR DeNOx reactor at verylow pressure drop

General homogenization of the gas stream with

respect to species concentration, temperature,dust and velocity at very low pressure drop

Homogenization of erosive y ash in front of

catalyst to enhance catalyst life time

Optimization of ue gas duct geometry andduct internals with respect to overall pressure

for reduction of power consumption

Heating of ue gas with hot gas after the

desulfurization unit

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Energy ue gas ducts - SCR DeNOx systemsmore than 2500 references

Sulzer offers a number of advanced solutions for highest ue gas cleaning performance, signi-cantly reduced power consumption and minimum operational expenses for thermal power plants,cement factories, steel works, gas furnaces, diesel engines and more.

Our expertise is based on more then 30 years experience and numerous references. AdvancedCFD simulations partly combined with physical model tests are a signicant element in ndingsolutions with maximum performance, lowest pressure drop and shortest payback time.

Depending on the situation, various specically developed mixer and internal designs for both,large scale ducts with rectangular cross sections, and smaller ducts with circular cross sections,are available.

SMV mixer in an SCR-unit for optimized NOx removal

CFD simulation for a

DeNOxapplication

Sulzer CompaXTM

for DeNOxsystems

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Sulzer ContourTMmixer in a coal fired power station

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Water & Wastewater over 5,000 referencesWater & Wastewater over 5,000 references

Advanced solutions for seawater desalinationSulzer Chemtech offers a wide range of mixers for water and waste watertreatment. Advanced solutions can be supplied for the seawater desali-nation process (Reverse Osmosis). In this process, the mixing and con-tacting are important unit operations having a fundamental inuence onthe performance of the whole plant. Therefore Sulzer has developed the

Sulzer CompaX mixer made of FRP (ber-reinforced plastic) which iswidely used these days in desalination processes. The Sulzer CompaXmixer is the most economic and energy efcient solution for additive mix-ing in the turbulent ow regime. The optimized and patented wing geome-try offers highly effective mixing of additives even at very small dosingrates of 1% and less.

Customer advantages

- Excellent mixing performance atlowest pressure drop and shor-test installation length

- No risk of clogging thanks tothe unique feed system withoutinjection lances

- Possibility of multiple dosing inthe same mixer unit

- Easy installation and handling

- Unique turndown capability

- Excellent price /performanceratio

Sulzer CompaX mixer

during installation

Main Applications Seawater Desalination Additive Mixing

Sulzer CompaX in FRP

for seawater desalination

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Food Processing Industry over 4,500 references

Static mixers and heat exchangers have been used in the food industryfor over 30 years.

Sulzer mixers offer an outstanding mixing performance combined withexcellent cleaning and sterilization abilities, an essential requirement forcontinuous food processes. They are used in various branches in the foodindustry (e.g. dairy, sweets, beverage, ingredients, etc.).

Applications range from blending, dispersing, foaming, aerating, condi-tioning, heat exchange to various other operations in the liquid, gas andsometimes solid eld.

Static mixers for

- Easy cleaning and sterilization inplace (CIP)

- Uniform and gentle product treat-ment

- Reproducible product quality- Shorter process time

Gentle mixing of fruit into yoghurt

Static mixer heat exchangers

The Sulzer mixer heat exchangersSMXL or SMR are well suitedfor cooling, heating or sterilizationof food products.

- No dead zones

- Excellent in-line cleaning abilityand sterilization

- Capability to process viscousuids

- No sealing and wearingproblems

- Low shear stress, gentlehandling

Main Applications

Cooling of chocolate, creamsor sweet masses

Heating of dough or coffeeextract

Crystallization of caramel

Sterilization of vegetable or

fruit concentrates

Main Applications

Mixing avors and colors intocreams, yoghurt, chocolate,etc.

Desliming vegetable oils with

phosphoric acid

Homogenization of sweetmasses

Carbonization of beer withCO2

SMR for chocolate cooling

Food Processing Industry over 4,500 references

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Oil, Gas & Rening over 3,500 references

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SMV mixers for LNG

desuperheating ina regas ification plant

Main Applications

Desalting of crude oil

Gas scrubbing for removal ofsulphur compounds

LNG desuperheating

Blending of gasoline, diesel,lubricants, natural gases, etc.

Crude oil sampling

Oil, Gas & Rening over 3,500 references

There are numerous applications for static mixing units in the petroleumindustry.

By using Sulzer mixers some widely recognized corrosion problems in oilreneries and gas plants can be signicantly reduced. Sulzer Chemtechhas the right solution for offshore platforms, for transporting oil, for themeasurement of the water content of crude oil, for desuperheating pur-

poses, for the desalination plant, for distillation units or for alkylation orcatalytic processes. Our static mixers not only reduce operating costs,but also increase plant on-stream time. As a result, they are a sure de-monstration that Sulzer Chemtech mixing and reaction technology paysoff, whatever the application.

SMVmixer PN 400 for temperature

homogenization

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Crude oil desalting unit equipped with Sulzer static mixers

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SMR reactor for polystyrene

Sulzer EPS units also allow production of

EPS with pigment colors

SMR bundle

Polymer Production over 400 referencesPolymer Production over 400 references

Handling of highly viscous melt is often one of the key tasks in the poly-mer production industry. Sulzer has the right equipment and the neces-sary fundamental understanding of mixing phenomena to handle your ap-plication.

Value creation for the polymerindustry

- Customized solutions

- Customer testing and pilot work- e.g. in the Sulzer lab

- Scale-up know-how

- Broad expertise in process andequipment engineering

Main Applications

Loop and plug ow reactors

Removal of volatile compo-nents

Heating and cooling of poly-mer melts

Admixing of liquid additives ormasterbatch

Production systems for variouspolymers, i.e. PS, EPS and

PLA

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Customer advantages

Increased product quality through

- Shortest possible residence time

- Reduced degradation

- Lowest residual volatile contents

- Precise heat transfer control

- Plug ow behavior

Reduced costs through

- Virtually no maintenance

- Very high polymer conversion

- Lowest energy consumption

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SMX plus

melt homogenizer

SMR

heat exchanger

Fiber Production over 2,500 references

Static mixers and coolers are used in fiber production to ensure optimalmixing, homogenization and cooling of the polymer melt (PET). This pro-vides a basis for an economic production of man made fibers of consis-tently high quality.

Melt homogenization

In spinning plants SMX plus mix-ers are installed prior to line split-ting, at the spin position and in thespin packs to avoid fiber breakage.

Main Applications

Homogenization of melts

Mixing of additives

Cooling of polyester melt indirect spinning plants

Gentle heat-up of spinningsolutions

Polymerization in a plug ow

reactor

Polymerization

Due to the narrow residence timedistribution in a SMX plus tubular

reactor, a spinning polymer is pro-duced with a narrow molecularweight distribution and low contentof by-products.

Cooling / heating

In cooling applications the SMRstructure achieves mixing, booststhe heat transfer and provides plugflow. Very low temperature drivingforce and low pressure drop opera-tion without maldistribution or plug-ging are possible. In addition, thecapital and operating cost of ancil-lary equipment like pumps is up to25% lower than in the case of mul-titube heat exchangers filled withmixing elements.

Admixing of additives

The SMX plus mixer handles greatviscosity differences as well as dis-persive mixing. The highly effectivemixing characteristics prevent un-necessary over dosing of additivesand result in substantial cost sa-vings.

Fiber Production over 2,500 references

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CO2 / N

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OptifoamTMfor Extrusion

Plastics Processing over 30,000 references

SMK-R mixing head for injection moldingThe benefits for the extrusionprocess

- Consistent product quality

- Uniform wall thickness- Elimination of ow lines

- Closer tolerances

SMB-R for extrusion

The benefits for injection mold-ing technology

- Reduced color costs

- Lower reject rates

- Faster cycle times

- Improved mixing of regrind

- Fast payback

Plastics Processing over 30,000 references

A perfectly homogenized melt is one of the most important requirementsin achieving high quality polymer products.

Irregularities, such as color streaks, flow lines, uneven wall thickness, flowvariations etc. lead to increased reject rates and increased productioncosts and are often the result of poor quality melt homogenization.

The Sulzer mixing head SMK-R is an efficient tool developed to provideconsistent melt homogeneity in injection molding machines. For extrusionand blow molding applications, the Sulzer Melt Blender SMB-R is used toachieve the same results. These Sulzer mixers provide a larger proces-sing window, allow higher throughputs and give improved product qualitywhile ensuring that products are produced more economically.

Physical Foaming in extrusion

The Sulzer OptifoamTMsystem is a

very efcient, cost competitive re-trot system for physical foaming inextrusion lines. Sulzer Optifoam isa modular system designed to suitany existing extrusion line indepen-dent of make or model. The Opti-foam system comprises an injectionnozzle, a well-proven Sulzer mixerand a dosing device for the uidblowing agent. The system is sup-plied by Sulzer as a package andcan be easily and rapidly installed

without any modications or changeof components.

The benets of physical foamingwith OptifoamTM

- Retrotting independent of system- Utilization of existing extrusion

line without need for modica-tions

- Easy and rapid installation

- Quicker start-up than with other

physical foaming process

- Reduced raw material costs

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Research & Development

In the R&D lab of Sulzer Chemtech, engineers are developing new andimproved products as well as analyzing and optimizing processes to sup-port our customers and improve our design tools. Close relationships toUniversities and independent research organisations are maintained.

Our Capabilities:

Measurement and predictionof dispersion behaviour ofimmiscible uids or gases inuids

Measurement of gas mixing

Prediction of polymerisationas well as devolatilisation per-formance using computerizedprocess simulation

Prediction of ow and mixingbehaviour using Computation-al Fluid Dynamics (CFD) forboth highly viscous and lowviscosity applications

Measurement of residencetime distributions in plug owreactors, heat exchangers andall mixers

Measurement and optimiza-tion of heat exchanger per-formance for highly viscousmedia

Viscosity measurementsunder realistic conditions oftemperatures and pressures

Laser Induced Fluorescence(LIF) for characterization andquantication of mixing per-formance and residence timedistributions

Laboratory measurementsusing small test reactors

Picture from a dispersion test and analysis

of the acquired data

Residence time distribu-

tion for an SMX static mixer

determined by CFD

CFD (left) and LIF (right) prediction of concentration

distributions after an SMX static mixer

LIF test rig for highly viscous flow

1.00 10.00 100.00 1000.00 10000.00

Energy dissipation [W/kg]

10000.0

1000.0

100.0

D32[m]

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Customer Testing

Sulzer Chemtech offers a variety of pilot testing services at companyheadquarters in Winterthur, Switzerland. Whenever physical properties,phase behaviour or product purities are not known to the extent requiredfor reliable design, Sulzer Chemtech has the ability to perform test worktailored to the specic project requirement and customer objectives. Thepilot installations are large enough to enable our experts to reliably scale

up the process to commercial size.

Optifoam pilot plant

An Optifoam pilot plant for cus-tomer trials is now available atthe Sulzer lab in Winterthur. Theinstallation permits the produc-tion of foamed sheets of differentmaterials with a variable thicknessand raw density using eco-friendlyblowing agents such as CO2or Ni-trogen. The Optifoam technologyallows processors to convert theproduction of solid thermoplastic

products to foamed products with-out having to invest into a new ex-trusion line. If you use a chemicalfoaming process already, you canreduce costs by switching your ex-trusion process from chemical tophysical blowing agents using theOptifoam technology. The systemusually allows density reductions inthe range of 20 60 %, dependingon the process conditions.

The pilot plant offers potential cus-tomers process validation capabili-ties in order to conrm the perfor-mance of the technology prior topurchasing the system. Apart fromcustomer testing, the plant servesfor research & development projectswith static mixers in extrusion.

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Distributed by:

23.27.06.40 - III.13 - 10 - Printed in SwitzerlandLegal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any

warranty or guarantee of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.

The activity program comprises:

Process components such as fractionation trays, structured and ran-

dom packings, liquid and gas distributors, gas-liquid separators, and

internals for separation columns

Engineering services for separation and reaction technology such asconceptual process design, feasibilities studies, plant optimizations in-

cluding process validation in the test center

Recovery of virtually any solvents used by the pharmaceutical and

chemical industry, or difficult separations requiring the combination of

special technologies, such as thin film/short-path evaporation, distilla-

tion under high vacuum, liquid-liquid extraction, membrane technology

or crystallization.

Complete separation process plants, in particular modular plants

(skids)

Advanced polymerization technology for the production of PLA and

EPS

Tower field services performing tray and packing installation, tower

maintenance, welding, and plant turnaround projects

Mixing and reaction technology with static mixers

Cartridge-based metering, mixing and dispensing systems, and dis-

posable mixers for reactive multi-component material

www.sulzer.com

Please check for your local contact

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquar-

ters in Winterthur, Switzerland, is active in the field of process engineering

and employs some 4000 persons worldwide.

Sulzer Chemtech is represented in all important industrial countries and

sets standards in the field of mass transfer and static mixing with its ad-vanced and economical solutions.

Documents

Mixing and Reaction Technology e 23270640