Inside Sulzer’s Test Centers: World-Class Facilities for Pilot Plant Testing and Process Development

Introduction: Sulzer’s Test Centers as Innovation Hubs for Process Development

At the forefront of process technology development, Sulzer’s lab and pilot test centers, located in Allschwil, Switzerland, and Singapore, provide state-of-the-art facilities dedicated to the testing and optimization of mass transfer separation processes. These globally recognized test centers serve as vital platforms to bridge laboratory research and commercial plant design, offering the data, insights, and validation necessary to confidently scale up and guarantee industrial operations.

Comprehensive Coverage of Unit Operations at Sulzer’s Test Centers

Sulzer’s lab and pilot test centers cover the full spectrum of unit operations required for separation and purification, ensuring that every process variable can be explored and optimized:

Distillation and Absorption

• Pilot columns from 30 mm to 250 mm in glass and stainless steel (SS316L), including specialty spinning band columns

• Up to approximately 100 theoretical stages

• Multiple internals, including structured packing (Katapak) and slit trays

• Operating ranges: Temperature up to 320 °C, pressure from 1 mbar to 16 bar, throughput between 1 and 200 kg/h

• Fully tunable parameters: internals configuration, feed and side stream location, reflux ratio, batch or continuous mode

  
  

Evaporation

• Falling film evaporators (glass and stainless steel) with surface areas from 0.12 to 1.2 m²

• Wiped film evaporators (glass and stainless steel) with surface areas ranging from 0.025 to 0.14 m²

• Short path evaporators designed for thermally sensitive materials

• Operating conditions: Temperature range 20–320 °C, pressures from 0.01 to 1000 mbar, throughput 0.5 to 200 kg/h

  
  

Liquid-Liquid Extraction

• OptimEXT™ extractors including Kühni agitated columns, Sulzer packed columns, and mixer-settler units

• Column diameters ranging from 32 to 150 mm, stages up to 20 and heights up to 10 meters active length

• Mixer-settler batteries in volumes from 250 ml glass units to 80 liters stainless steel vessels

• Operating temperature range between 20–100 °C and ambient pressure

• Throughput capabilities from 1 to 300 kg/h

  
  

Advanced Analytical Laboratories Integrated into Sulzer’s Test Centers

Supporting all pilot testing activities are Sulzer’s fully equipped analytical laboratories, crucial for verifying process performance and meeting rigorous product specifications. Key analytical techniques include:

• Gas chromatography (GC, FID, TCD, GC-MS) and headspace analysis

• High-performance liquid chromatography (HPLC) with UV or refractive index detectors

• Spectroscopic methods such as UV-VIS and ICP-OES

• Acidimetric and Karl-Fischer titration for water content

• Measurements of pH, conductivity, refractometry, density, viscosity, and surface tension

• Moisture and solid content determination via thermobalance

This comprehensive analytical capacity ensures data accuracy and supports the iterative development of process conditions during pilot trials.

Why Choose Sulzer’s Lab and Pilot Test Centers?

• Global Reach, Local Expertise: Strategically located centers with consistent operation standards across continents

• Full-Scale Simulations: Pilot plants replicate real industrial conditions with tunable parameters and a variety of operating modes

• Extensive Experience: Over 1,000 successful pilot trials yielding reliable data for process guarantees and engineering design

• Integrated Approach: Seamless collaboration among synthesis, separation, testing, and analytical teams to accelerate project timelines

• Flexible Operation: Capable of handling a wide range of feedstocks, including complex or sensitive materials

  
  

Conclusion: Sulzer’s Test Centers Your Partner for Confident Process Scale-Up

Whether optimizing distillation, validating evaporation strategies, or fine-tuning liquid-liquid extraction, Sulzer’s lab and pilot test centers in Allschwil and Singapore provide a comprehensive, flexible, and expertly supported environment that transforms your process development from concept to commercial reality.

With advanced equipment, integrated analytical services, and unmatched expertise, Sulzer’s test centers deliver the pilot testing foundation you need to ensure success and secure performance guarantees in your industrial separation plants.

Contact Sulzer today to learn how our lab and pilot test centers can accelerate your development and scale-up journey.