From Lab to Plant: Reliable Scale-Up and Performance Guarantees with OptimEXT™
- jesusrangel3
- Jun 20
- 2 min read
Introduction
Scaling up a liquid-liquid extraction process from laboratory trials to full industrial operation is a critical—and often risky—step for process industries. Inconsistent performance, unexpected bottlenecks, or equipment mismatches can lead to costly delays and lost production. With Sulzer’s OptimEXT solution platform, you gain access to proven scale-up methodologies, advanced pilot testing, and performance guarantees that ensure your extraction process delivers as promised, from lab to plant.
The Risks of Scaling Up Extraction Processes
Many promising extraction processes can falter during scale-up due to:
Differences in hydrodynamics between lab and industrial scale
Inaccurate prediction of mass transfer and phase separation
Equipment selection mismatches
Lack of validated process data
These issues can result in poor product quality, lower yields, and increased costs.
Sulzer’s Approach to Reliable Scale-Up
In-House Pilot Facilities and Miniplant Technology
Sulzer’s dedicated test center is equipped with state-of-the-art pilot columns, miniplants, and laboratory-scale extractors. This allows for:
Real feedstock testing: Validate process performance on your actual materials, not just simulations.
Flexible pilot trials: Test different extractor types—Kühni columns, packed columns, mixer-settlers—to identify the optimal solution.
Reliable data collection: Gather precise information on mass transfer, droplet size, phase separation, and operating windows.
Advanced Mathematical Modeling
Sulzer combines pilot trials with advanced mathematical modeling, including population balance and Monte-Carlo methods. These models predict the performance of extraction columns at pilot and full scale, reducing the need for extensive pilot trials and accelerating time-to-market.
Predictive performance: Models help optimize column design and scale-up parameters.
Reduced risk: Confidently move from lab to plant with data-driven decisions.
Performance Guarantees for Industrial Success
With OptimEXT, Sulzer offers performance guarantees based on pilot plant results and validated models. This means:
Guaranteed throughput, purity, and recovery rates
Reliable scale-up from lab to industrial scale
Minimized risk of costly downtime or non-performance
Sulzer’s decades of experience and hundreds of reference installations worldwide back these guarantees, giving you peace of mind for your investment.
Customer Success Stories
Example 1: Chemical Manufacturer
A specialty chemical producer needed to scale up a new extraction process for a heat-sensitive product. Sulzer’s pilot trials and modeling identified the optimal Kühni column configuration, ensuring seamless transition to full-scale operation—with guaranteed product purity and yield.
Example 2: Hydrometallurgy Operation
A mining company faced challenges in scaling up metal extraction from electrolytic solutions. Sulzer’s miniplant trials and performance modeling enabled a tailored mixer-settler solution, delivering reliable scale-up and consistent metal recovery.
The Value of Partnering with Sulzer
Sulzer’s OptimEXT platform offers more than just equipment it delivers a complete process solution, from feasibility studies and pilot testing to guaranteed industrial performance. With Sulzer, you benefit from:
Decades of extraction expertise
Advanced pilot and modeling capabilities
Proven, reliable scale-up procedures
Global support and reference applications
Conclusion
Scaling up liquid-liquid extraction doesn’t have to be a leap of faith. With Sulzer’s OptimEXT, you gain a partner committed to your success—offering pilot-tested, model-validated, and performance-guaranteed solutions for smooth, reliable industrial implementation.
Contact Us
Ready to scale up your extraction process with confidence? Contact Sulzer for pilot trials, modeling support, and guaranteed results with OptimEXT.
