Industrial Applications of VoltaSplit™: Decarbonizing Distillation Across Industries

Sulzer VoltaSplit™: Electrifying the Future of Distillation

Introduction

Distillation is one of the most widely used separation technologies across multiple industries, from chemicals and petrochemicals to pharmaceuticals and biofuels. However, it is also one of the most energy-intensive operations, traditionally relying on steam generated from fossil fuels. This drives high operating costs and creates a significant carbon footprint.

Sulzer’s VoltaSplit™ technology offers a smarter way forward: electrified distillation that reuses its own energy to minimize external utility demand. By compressing overhead vapors and recovering their latent heat, VoltaSplit™ makes distillation more efficient, cost-effective, and sustainable. But where exactly can this innovation deliver the greatest value?

Applications of VoltaSplit™ Across Industries

Chemicals

Chemical manufacturing, energy accounts for a large share of production costs. VoltaSplit™ enables the efficient separation of complex mixtures while reducing energy input by up to 50–95%, depending on the process setup. This allows plants to improve competitiveness while meeting tightening emission targets.

Petrochemicals

Large-scale distillation operations in the petrochemical sector are major contributors to global CO₂ emissions. By replacing steam-driven reboilers with electrically powered vapor compression, VoltaSplit™ provides a direct pathway to decarbonization.

Plants can lower both OPEX and emissions without compromising throughput or reliability.

Pharmaceuticals

Pharmaceutical distillation demands high product purity and process stability. VoltaSplit™ combines advanced process control with efficient energy recovery, helping manufacturers maintain product quality while reducing environmental impact. This aligns with the industry’s growing focus on sustainability and green production standards.

Biofuels and Biochemicals

For producers of biofuels and biobased chemicals, sustainability is a key market driver. VoltaSplit™ supports green production pathways by cutting fossil-fuel dependency and enabling near-zero direct CO₂ emissions when powered by renewable electricity. This helps operators improve both environmental performance and market positioning.

Flexible Integration: Retrofit or New Build

One of VoltaSplit™’s strengths is its flexibility. The system can be retrofitted into existing distillation columns to upgrade efficiency without major redesigns, or integrated into new facilities as part of a sustainable design strategy. In both cases, the technology is tailored to meet specific process requirements, ensuring reliable and efficient operation at industrial scale.

Conclusion

Distillation is essential across industries but it doesn’t have to come at the expense of high energy costs or CO₂ emissions. Sulzer’s VoltaSplit™ technology offers a future-proof solution that combines efficiency, sustainability, and reliability. From chemicals and petrochemicals to pharmaceuticals and biofuels, VoltaSplit™ is shaping the future of sustainable production.

Ready to explore where VoltaSplit™ can make the difference in your process? Contact Sulzer Chemtech to evaluate your potential savings and emission reductions.