Modular Engineering Excellence: Inside Sulzer’s Complete Skid-Mounted Plant Design & Delivery

Introduction: Delivering Excellence in Modular Chemical Plants

In today’s competitive process industries, speed, quality, and reliability define successful plant projects. Sulzer’s proven track record in delivering skid-mounted modular plants combines decades of process engineering expertise with high-quality fabrication and advanced automation to meet these exacting demands.

From the initial concept to the final handover, Sulzer’s modular plant solutions reduce project risk, shorten schedules, and guarantee operational excellence—no matter the application or geography.

End-to-End Modular Plant Execution: What Makes Sulzer Unique?

1. Conceptual & Basic Engineering

Once the process concept is agreed upon, Sulzer develops a detailed engineering package, including:

• Comprehensive Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs)

• Heat and mass balance calculations

• Equipment and instrumentation specifications

• Process control and safety system design

• Preliminary equipment layout focusing on modular skid integration

• Capital expenditure estimates tailored to skid-mounted plant modules

  
  

2. Detail Engineering & 3D Modeling

• Detailed mechanical design for all key equipment and structural steel

• Creation of a full 3D plant model for skid layout, piping isometrics, cable routing, and instrumentation

• Implementation of plant automation concepts ensuring safety and seamless operation

• Hazard and operability (HAZOP) studies to optimize safety and functionality

  
  

3. Fabrication and Skid Assembly

• Construction in Sulzer’s modern, certified workshops or approved subcontractor facilities

• Assembly of steel structures, process equipment, valves, piping, cabling, and instrumentation into fully integrated skid-mounted units

• Insulation and surface treatment as required for customer and process specifications

  
  

4. Factory Acceptance Testing (FAT)

• Complete pressure, leak, and functionality testing under rated conditions

• Verification of automation, safety interlocks, and control sequences to validate process integrity

• FAT conducted with customer participation remotely or onsite to ensure transparency and confidence

  
  

5. Transport, Installation, and Commissioning

• Skids are shipped as complete units, minimizing onsite welding and rebuild

• Experienced Sulzer installation supervisors support offloading, site hookup, startup, and operator training

• Structured commissioning program culminating in Site Acceptance Testing (SAT) for performance verification

  
  

6. Lifecycle Support

• Long-term technical support including spare parts management, troubleshooting, and upgrades

• Regular maintenance and revamp services to extend plant life and adapt to evolving production needs

  
  

Proven Across Multiple Industries

Sulzer’s skid-mounted modular plants serve a wide array of applications including:

• Specialty chemicals such as ethanolamines and glycol ethers

• Petrochemical and refining operations including amine gas treating and solvent recovery

• Bio-based and sustainable fuel production

• Carbon capture, recycling, and waste valorization plants

• Pharmaceutical and fine chemical manufacturing

  
  

Why Clients Trust Sulzer for Skid-Mounted Plants

Feature	Benefit
Comprehensive engineering support	Fully integrated design from concept to delivery
Advanced 3D modeling	Reduced design conflicts and accelerated project approval
Factory-assembled skid units	Reduced onsite construction risk and time
Rigorous FAT & testing	Guaranteed plant startup and operational performance
Global footprint & support	Local expertise with global standards

Conclusion: Modular Excellence Delivered with Sulzer

Sulzer’s full-service skid-mounted plant approach transforms how chemical and process plants are realized delivering faster, safer, and more cost-effective solutions. With commitment from concept through life cycle, Sulzer guarantees your modular plant will meet specifications, start smoothly, and perform reliably for years to come.

Contact Sulzer today to discuss your modular plant project and experience how engineering excellence and modular innovation come together for your success.