Case Study: Implementing VoltaSplit™ in the Chemical Industry

Introduction

As the chemical industry faces increasing demands for energy efficiency and sustainability, innovative technologies like Sulzer’s VoltaSplit™ are gaining attention. But how does VoltaSplit™ perform in real-world industrial settings? This case study explores the successful implementation of VoltaSplit™ in a chemical plant, highlighting the impressive results in energy savings, emissions reduction, and operational flexibility.

Industrial Background

A leading chemical manufacturer sought to modernize its distillation operations to meet stricter environmental regulations and reduce rising energy costs. The company’s existing distillation columns relied on traditional steam heating, resulting in high energy usage and significant CO₂ emissions.

Objectives:

• Cut energy consumption and operational costs

• Lower the plant’s carbon footprint

• Maintain or improve product quality and process reliability

  
  

Why VoltaSplit™?

After evaluating several solutions, the company selected Sulzer’s VoltaSplit™ for its:

• Electrified distillation technology.

• Renewable compatibility 

• Advanced process control

• Proven performance.

  
  

Implementation Process - VoltaSplit™ Case Study

1. Assessment & Planning: Sulzer’s engineering team conducted a detailed analysis of the existing distillation columns and energy usage patterns.

2. Retrofit Installation: The VoltaSplit™ system was installed as a retrofit, minimizing downtime and capital investment.

3. Integration with Controls: The plant’s automation system was upgraded to enable real-time monitoring and control of the electrified reboiler.

4. Commissioning & Training: Operators received training on the new system, and the plant was quickly brought back online.

   
   

Results Achieved

1. Energy Savings

• The plant achieved up to 45% reduction in energy consumption for the retrofitted distillation units.

• Direct electrical heating eliminated steam losses and improved overall efficiency.

  
  

2. Emissions Reduction

• By powering VoltaSplit™ with renewable electricity, the plant cut its CO₂ emissions from distillation by nearly 50%.

  
  

3. Operational Flexibility

• The new system allowed for rapid start-up and shutdown, reducing downtime.

• Advanced controls enabled precise adjustments, maintaining consistent product quality.

  
  

4. Cost Savings

• Lower energy use translated into significant cost savings on utility bills.

• Reduced maintenance requirements further decreased operational expenses.

  
  

User Feedback

“VoltaSplit™ has transformed our distillation process. We’re seeing real savings and making progress toward our sustainability goals—without compromising on performance.”— Plant Operations Manager

Conclusion

This case study demonstrates how Sulzer’s VoltaSplit™ can deliver measurable benefits in the chemical industry. By slashing energy use, reducing emissions, and enhancing flexibility, VoltaSplit™ is helping manufacturers stay competitive and sustainable in a rapidly changing market.

Want to see similar results in your facility? Contact Sulzer Chemtech to discuss how VoltaSplit™ can optimize your distillation operations.