Mixing and Reaction Technology

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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 SMV and Turbulent Mixers ................................................. 7

Sulzer SMX Mixers ......................................................................... 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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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 SMV and Turbulent Mixers

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Sulzer SMV and Turbulent Mixers

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 SMX MixersSulzer SMX Mixers

Laminar mixing

Best handling of large viscosity difference

Homogenization and dispersing of viscous liquids

Blending melts and homogenizing bers

SMX

Gentle and efcientmixing of viscousproducts

SMXS

Extreme mechanical strength

SMX plus

Excellent mixing of viscous products withlowest pressure drop

SMX

Achieves shortest

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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-sensitive vis-cous 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 DeNOx over 2,500 references

SMV gas mixer for challenging

space limitations

- Excellent mixing performance forshortest space requirements

- Fits any duct dimension

- Well suited for dosing smallamounts of additive

- Low pressure drop

Main Applications

Admixing ammonia into uegas prior to SCR reactor

Gas conditioning in dryers

Gas conditioning in gas pipe-

lines

Contour mixer for gas

conditioning

The new Contour mixer provideseffective large scale eddy mixing

- For any required gas condition-ing task

- At lowest pressure drop in theindustry

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Energy DeNOx over 2,500 references

Sulzer mixers have enormous potential in energy technology, and theiruse is widespread. In gas treatment, small amounts of reactive agents areoften added to high volume ows and distributed very uniformly within ashort distance over the entire channel cross section. In other applications,it is necessary to uniformly distribute the concentration and temperatureof a process feed upstream of a catalyst or to dissolve gases into liquids

and to generate ne, uniform bubbles in insoluble liquids. Sulzer has theproven mixing technology and products for these growing processingtechnologies.

SMV mixer in an SCR-unit or optimized NOx removal

CFD simulation or a DeNOxapplication

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Sulzer ContourTM mixer in a coal red power station

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

Mixers for water/wastewater treatmentIn the eld of water and wastewater treatment, mixing and contacting arekey unit operations. There is a fundamental inuence on the performanceof individual process stages or even on the results of the entire processitself. The ever increasing demands on water quality drive continuous im-provement of the purication processes. This has led to an increasing

number of installations of in-line static mixers for mixing and contactingoperations in the water and wastewater sector.

The use of static mixers in the water/wastewater industry saves costs byreducing additive consumption.

Customer advantages

- High specic exchange arealeading to efcient mass transfer

- High utilization rate of the ozonegas

- Short installation length

- Low pressure drop

- Guaranteed absorption degree ofthe gas

- Steady absorption degree atturn-down and turn-up conditions

CompaX and SMV mixers in FRP or seawater desalination

Main Applications

Admixing of occulent into water or sludge

pH control or neutralization

Oxygen enrichment of drinking water

Ozonization of water

Admixing of disinfectants

Admixing of additives for the sea water treatment The SMF mixer in polypropylene or sludgetreatment

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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 o ruit 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 or 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 or LNG

desuperheating ina regasication 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.

SMV mixer PN 400 or temperature

homogenization

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Crude oil desalting unit equipped with Sulzer static mixers

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SMR reactor or polystyrene

Sulzer EPS units also allow production o

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

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 mixersare installed prior to line splitting,at the spin position and in the spinpacks 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 tubular reac-tor, a spinning polymer is producedwith a narrow molecular weight dis-tribution and low content of by-prod-ucts.

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 mixer handles great vis-cosity 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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OptioamTM or Extrusion

Plastics Processing over 30,000 references

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

- Consistent product quality

- Uniform wall thickness- Elimination of ow lines

- Closer tolerances

SMB-R or 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 OptifoamTM system 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 Computa-tional Fluid Dynamics (CFD)for both 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 rom a dispersion test and analysis o the acquired data

Residence time distribu-

tion or an SMX static mixer

determined by CFD

CFD (let) and LIF (right) prediction o concentration distri-

butions ater an SMX static mixer

LIF test rig or highly viscous fow

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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Pilot plants and test rigs forthe following applications canbe assembled for customertesting:

Reaction and devolatilisationof polymers

Admixing of additives into

highly viscous melts Extrusion foam with physical

blowing agents

Dispersion of immiscibleliquids and gas/liquid

Mixers are also available fortesting at customers sites

Unique in the eld of particle foamsis the Sulzer EPS pilot plant. It isan exact scale-down of the indus-

trial Sulzer EPS process and waserected to demonstrate to our cus-tomers the feasibility of the continu-ous EPS production with their spe-cic raw materials and formulations.The plant is fully automated andincludes the most recent underwa-ter pelletizer technology, speciallydeveloped for micro pellets produc-tion. Apart from customer testing,the rig serves for basic research onthe production of particle foams and

alternative, environmentally friendlytechnologies.

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.

Devolatilisation vessel and control system display o a pilot

plant or devolatilisation o polymers

EPS pilot plant

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Headquarters

Sulzer Chemtech AG

P.O. Box 65

CH-8404 Winterthur, Switzerland

Phone +41 52 262 67 20

Fax +41 52 262 00 69

[email protected]

www.sulzerchemtech.com

Distributed by:

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

quarters in Winterthur, Switzerland, is active in the eld of process engi-

neering and employs some 2500 persons worldwide.

Sulzer Chemtech is represented in all important industrial countries and

sets standards in the eld of mass transfer and static mixing with its

advanced and economical solutions.

North and South America

Sulzer Chemtech USA, Inc.

4019 South Jackson Avenue

USA-74107 Tulsa, OK

Phone +1 918 446 6672

Fax +1 918 446 5321

Asia Pacic

Sulzer Chemtech Pte. Ltd.

10 Benoi Sector

SGP-Singapore 629845

Phone +65 6515 5500

Fax +65 6862 7563

The activity program comprises:

Process components such as trays, structured and random pa-

ckings, internals for separation columns and reaction technology

Engineering services for separation and reaction technology such

as optimizing energy consumption, plant optimization studies, pre-

engineering for governmental approval, basic engineering

Separation and purication of organic chemicals by means of cry-

stallization and membranes

Mixing and reaction technology with static mixers

Mixing and Cartridges Technology

Tower eld services

Documents

Mixing and Reaction Technology