Modular & Skid-Mounted Solutions: Rapid Deployment for Plastic Recycling with Sulzer

Introduction

The drive for sustainable plastic recycling demands solutions that are fast to deploy, flexible to scale, and reliable to operate. Sulzer’s modular, skid-mounted purification units answer these demands delivering turnkey purification technology that transforms plastic-derived pyrolysis oil into valuable hydrocarbon streams, ready for use in refineries and chemical production.

Why Modular & Skid-Mounted Solutions?

• Plug-and-Play Integration:Units are pre-assembled and fully tested before delivery, allowing for rapid commissioning with minimal on-site work.

• Scalability:Easily expand capacity by adding more skids as production volumes increase; ideal for both pilot and large-scale commercial plants.

• Minimal Downtime:Retrofit existing facilities or install in new sites quickly, reducing operational disruption.

• Process Security:Supplied with full process simulation data, performance guarantees, and remote support capabilities.

  
  

Core Features Pre-Engineered, Modular Design

• Comprehensive process modules:

  • Quenching (rapid vapor condensation to stabilize products)

  • Hydrotreating (advanced impurity removal)

  • Fractionation & Distillation (separation of product streams)

  • BTX (Aromatics) Recovery (high-value product extraction)

• All major steps integrated into a single, compact footprint.

  
  

Flexible for Feedstock & Output

• Handles a wide range of plastic feedstocks (PE, PP, PS, PET, PVC), regardless of contamination or variability.

• Customizable product slate: naphtha, diesel, aromatics (BTX), waxes, and more.

  
  

Complete Lifecycle Support

• Field-Proven Reliability:

  Sulzer modular skids deliver proven performance in operational plants such as Quantafuel in Denmark.

• Remote Monitoring & Support:

  Optional digital support and diagnostics help maximize uptime and performance.

• Expandable:

  Start with a baseline configuration and add purification or product modules as business needs grow.

  
  

Application Examples

• Greenfield Plants:

  Quickly launch new plastic-to-oil recycling sites with little engineering or construction overhead.

• Brownfield Upgrades:

  Modernize existing facilities by adding advanced purification without redesigning your entire operation.

• Flexible Capacity Expansion:

  Ramp up production by adding more skids as local waste collection or market demand increases.

  
  

Table: Sulzer Modular Skid Solution Benefits

Feature	Benefit
Pre-assembled units	Fast, low-risk installation
Scalable architecture	Grows with your plant’s needs
Complete process scope	Quenching, hydrotreating, fractionation, BTX—all-in-one
Proven in operation	Commercial success at key European recycling sites
Remote support	Ongoing uptime, optimization, and troubleshooting

Real-World Success

At the Quantafuel facility, Sulzer’s modular purification skids were installed rapidly, allowing production of 48 tonnes per day of premium hydrocarbons from unrecyclable mixed plastics with minimal operational disruption and exceptional process control.

Conclusion

Sulzer’s modular and skid-mounted solutions enable faster, more flexible, and more reliable deployment of plastic recycling purification. Whether upgrading your current plant or launching a new operation, these units ensure minimal downtime, scalable capacity, and field-proven reliability with seamless support every step of the way.