Biopolymer Industry

Challenge:

An API pharmaceutical manufacturer needed to treat wastewater containing organics and chlorinated compounds at variable capacities (1.5–3.5 t/h), while meeting strict discharge limits and reducing energy consumption. Long‑term reliability and operational flexibility were critical requirements.

Solution:

Sulzer delivered a skid‑mounted treatment unit integrating columns, heat exchangers, and pumps. The solution was validated through pilot testing to guarantee performance and compliance.

Challenge:

A global pharmaceutical manufacturer needed to recover ethyl acetate and cyclohexane from a multistep synthesis process with high purity and yield under strict GMP requirements. The existing setup suffered from high product losses, elevated operating temperatures, and a complex multi‑step system.

Solution:

Sulzer delivered an integrated solution comprising EXCELOT™ batch fractionation, DistilCare™ continuous pressure swing distillation, and EvapCare™, installed across four skid‑mounted units to enable efficient, GMP‑compliant solvent recovery.

Challenge:

Reduce high energy consumption, improve solvent recovery above 96–97%, increase API concentration by 30–40x, and overcome space constraints.

Solution:

Installed two EvapCare™-F units thermally coupled for efficient multi-effect evaporation, delivered as compact skid-mounted systems for easy transport and installation.

Challenge:

Stripping 1-propanol from wastewater to below 100 ppmv under varying feed temperature conditions and avoiding downstream disruptions. 

Solution:

Sulzer's PEMFlux stripping technology combined high-efficiency internals and heat recovery to reduce the alcohol to less than 100ppmv. The system was optimized for unsteady conditions and engineered to maintain performance across fluctuating feed temperatures.

Challenge:

An existing wastewater stripping system could not provide the operating flexibility and increase in capacity required by the client. Additionally, the stream contained organic and chlorinated compounds that needed to meet very low outlet concentrations. 

Solution:

Sulzer performed pilot testing with analysis to guarantee the organic content in the wastewater was <150 mg/l, and the chlorinated compounds were below 2mg/l. Using Sulzer's proprietary PEMFlux stripping technology, the system included high-performance internals, heat recovery and energy optimization.

Challenge:

The customer needed an ethanol recovery distillation system that could operate without steam (boiler at full capacity) and fit within a restricted space, while reducing energy use and emissions.

Solution:

Implemented an indirect VoltaSplit™ configuration with a high-temperature heat pump, delivered as a compact skid-built unit, eliminating steam consumption and avoiding costly boiler upgrades.

Challenge:

The pharmaceutical company needed to increase production capacity extremely quickly due to the COVID-19 emergency.

Solution:

OptimEXT™ system with Sulzer Kühni™ agitated column (ECR) for liquid-liquid extraction from available stock, shipped within one day, and provided installation and start-up support to ramp up production in less than two weeks.