Lab and Pilot validation trials for
confident process scale-up
With more than 1,000 pilot tests completed for customers, our dedicated test centers, IntecH, are at the core of our process development capabilities, offering customers a reliable and efficient pathway from concept to commercialization. Sulzer IntecH sites in Allschwil CH and Singapore provide deep expertise and advanced infrastructure to support customers’ innovations. The comprehensive lab and pilot facilities enable feasibility validation, process optimization, and development of cost-effective separation solutions.
Selection of lab and pilot testing services
Our portfolio of laboratory and pilot-scale validation services are designed to confirm process feasibility, optimized performance, and support scale-up across industries. From physical property measurements to real-feed pilot trials, Sulzer IntecH centers provide the technical foundation for reliable decision-making, reduced scale-up risk, and guaranteed results in full-scale implementation.
Realistic Process Validation
Test with actual customer feedstocks
Simulate industrial conditions with precision
Accelerated Time-to-Market
Reconfigurable modules for adaptive deployment and flexible testing
Reduce development cycles and uncertainties during scale-up
Reliable Data for Decision-Making
Advanced analytics and physical property measurements
Support for technology selection and process guarantees
We are here to help when...
You develop new separation or reaction processes
Confirm feasibility and optimize performance before scaling up.
You need to validate equipment selection
Test different configurations to ensure compatibility and efficiency.
You require performance guarantees
Generate reliable data to support investment and commissioning.
You operate in regulated or sensitive environments
Ensure product quality, purity, and compliance through validated trials.
Comprehensive pilot facilities across key separation technologies
Distillation and absorption
Even for proven technologies like distillation and absorption, pilot testing is strongly recommended to ensure process success in the following scenarios:
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Mixtures containing impurities or by-components (e.g., salts)
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Foaming systems or those with solid content
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Systems with unknown or unmeasurable vapor-liquid equilibrium (VLE)
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Processes requiring extremely high product purity
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Sensitive products where color, smell, or taste must be preserved
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Batch operation is targeted to deal with multiple feedstocks or products
Find more information about our test facilities for distillation and absorption
EvapCare™ evaporators
In many cases, it is not possible to accurately predict film evaporation performance from first principles, especially when the products are temperature-sensitive or viscous. Pilot testing are therefore mandatory in the following cases:
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Examination of flow and wetting behavior to ensure stable film formation
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Evaluation and optimization of evaporator type for process efficiency
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Determination of achievable concentrations, often down to ppm levels, to meet product specifications
Find more information about our test facilities for evaporation
OptimEXT™ liquid-liquid extractors
Sulzer offers various type of extractors ranging from agitated column extractor to mixer settler due to scale-up complexity and precise process validation, pilot testing are essential in the following scenarios:
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Systems where dispersion behavior, droplet size, and phase separation are unclear.
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Evaluation and optimization of extractor type and phase ratio for best performance
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Process validation and scale-up that require measurement of achievable concentrations.
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Selection of suitable equipment for reliable and efficient industrial implementation
Find more information about our test facilities for liquid-liquid extraction
MaxFlux™ advanced hydrotreating
Sulzer MaxFlux™ reactor technology is designed for high-efficiency hydrotreatment, but due to the complexity of scale-up and process validation, pilot testing remains essential in the following scenarios:
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Uncertain reaction kinetics or phase behavior under real feed conditions
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Optimization of reactor configuration and hydrogen integration for best performance
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Validation of temperature control and product yield during scale-up
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Selection of suitable MaxFlux™ setup for reliable industrial implementation
Find more information about our test facilities for advanced reactor technologies.
Comprehensive lab facilities for synthesis, characterization, and testing
Determination of physical properties and equilibrium data
Besides online literature research, we deploy our equipment and experience to measure the most realistic data necessary for scale up:
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Vapor-liquid equilibrium (VLE)
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Liquid-liquid equilibrium (LLE)
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Temperature-dependent density, viscosity, and interfacial tension data
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Impurities information in customer’s real feed
Find more information about our lab facilities
Bench scale tests
To quickly confirm the feasibility of a process solution with very small feed samples, bench scale tests are ideal:
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Evaporation tests with rotary evaporator or glass thin-film evaporator
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Extraction test based on single agitated cell or shaking test for dispersion and phase separation measurement
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Rectification test with a laboratory and spinning band column
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Liquid phase reaction in agitated glass reactor
Find more information about our lab facilities
Toll separation services
Almost all the equipment available in our state-of-the-art IntecH can be used, on demand, for toll separation and purification services. This can be especially interesting in the launch phase of new products, when no dedicated plant is available yet at your premises, or to provide test samples for application in your own in-house tests or for hand-over to your end customers.
Find more information about our lab facilities
Laboratory
Synthesis, separation, characterization and testing go hand-in-hand with each other.
In-house analytical equipment:
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GC (FID, TCD), Headspace GC, GC-MS
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HPLC with UV or RI detector
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UV-VIS spectroscopy
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Acidimetric and Karl-Fischer titration
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pH, conductivity
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Refractometry
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ICP-OES
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Solid resp. moisture content by Thermo balance
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Density, viscosity, and surface tension measurement.
In-house synthesis and separation equipment:
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Rotary evaporator (1 L)
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Agitated glass reactors (0.5, 3, 5 L)
Our laboratories are equipped with modern computer-controlled analytical equipment and cooperate with competent contract laboratories.
Liquid-liquid extraction
OptimEXT™ extractor types:
- Kühni agitated column ECR - Sulzer packed column ECP
- Mixer-settler-column ECMS - Mixer-settler EMS
ECR and ECP sizes:
- In glass: Ø 32, 50, 60, 150 mm
- In SS316L: Ø 50 mm
- Up to 20 theoretical stages and 10 m active height
Mixer-settler batteries sizes:
- In glass: 250x10-6 (250 ml), 0.005 m3 (5 L)
- In SS316L: 80 lt (0.080 m3)
Operating range:
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Temperature: 20-100 °C
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Pressure: ambient
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Throughput: 1-300 kg/h
The selection of the solvent is the first step to determine the feasibility of the extraction process. Typical test parameters are:
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Internals (geometry, number of stages),
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Energy input
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Loading, phase ratio
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Turn down
If necessary, mini-plant tests with recycle streams can be carried out to check the accumulation of impurities.
Operating range:
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Temperature: 20-320 °C
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Pressure: 0.01-1000 mbar (ambient)
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Throughput: 0.5-200 kg/h
Tests are set up based on the first results from a rotary evaporator or on customer’s data. By selecting the right type of evaporator, the test parameters are established:
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Operating pressure / feed flow
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Recirculation ratio
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Cocurrent/countercurrent
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tripping gas
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For wiped film evaporators: - Wiper geometry - Product take-off system
Evaporation
1. Falling film evaporators:
- In glass: 0.12 m2
- In SS316L: 0.4, 0.8, 1.2 m2
2. Wiped film evaporators:
- In glass: 0.025, 0.06 m2
- In SS316L: 0.14 m2
3. Short path evaporators:
- In glass: 0.05 m2
- In SS316L: 0.14 m2
Distillation and absorption
Distillation column sizes:
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Glass: Ø 30, 50 mm
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SS316L: Ø 100, 250 mm
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Spinning band column
Features:
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Up to approximately 100 theoretical stages
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Internals: structured packing (incl. Katapak), slit trays
Operating range:
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Temperature: up to 320 °C
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Pressure: 1 mbar to 16 bar
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Throughput: 1-200 kg/h
Tests are usually carried out using simulation or clients’ data as design basis.
Sensitive parameters are tunable during the test:
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Type of internals, tray height, number of stages
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Position of feed and side streams
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Feed flow
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Operating pressure
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Reflux ratio
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Batch or continuous mode
Distillation and absorption
Evaporation
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Laboratory
Liquid-liquid extraction
Measurable results and globally recognized expertise
less footprint than traditional construction
> 60%
faster delivery than stick-built alternatives
> 50%
Minimal site disruption with plug-and-play installation
+90
Comprehensive spare parts inventory and supply chain
+90
150+ Years Experience
Proven track record in chemical process engineering and equipment manufacturing.
Global Presence
Worldwide support network with local expertise and rapid response capabilities.
Quality Assurance
ISO certified processes and rigorous quality control for reliable, safe operations.