Turning Innovation into Reality: The Critical Role of Lab and Pilot Validation Trials

Introduction: Bridging the Gap from Concept to Commercial Plant

In the chemical and process industries, turning a promising laboratory idea into a reliable, cost-effective commercial process is one of the greatest challenges and most critical steps in technology development. This is where Sulzer’s IntecH lab and pilot validation trials come into play, providing the rigorous technical foundation needed to de-risk investment and accelerate successful market entry.

Why Lab and Pilot Validation Trials Matter

Sulzer’s IntecH test centers, with over 1,000 completed pilot tests, are purpose-built to validate feasibility and optimize processes with real feed materials.

The result is a trusted bridge from concept to commercialization, enabling:

• Proof of process feasibility across a wide range of separation technologies

• Optimization of yields, purity, and energy use

• Robust data for scale-up and reliable commercial plant design

• Faster and more confident investment decisions

  
  

Sulzer’s Expertise and Facility Capabilities

Comprehensive Testing for Every Challenge

At its Allschwil (Switzerland) and Singapore sites, Sulzer’s IntecH facilities offer:

• Pilot plants for unit operations such as distillation, evaporation, absorption, extraction, rectification, and crystallization

• Bench-scale and pilot-scale equipment for both standard and custom tests

• Advanced analytics for real-time and post-process monitoring (GC, HPLC, ICP-OES, etc.)

• Expert staff to design trials for unique customer feedstocks or process goals

  
  

Flexible, Realistic Testing

Every validation project can be tailored to:

• Customer-supplied samples, including challenging or impure feedstocks

• Operation under a wide range of temperatures, pressures, phase ratios, or modes (batch and continuous)

• Simulation of commercial plant operating conditions for accurate performance prediction

  
  

The Sulzer Pilot Validation Workflow: What to Expect

1. Initial Consultation:

   Clear scope definition, feed sample requirements, and success criteria.

2. Lab-Scale Feasibility Studies:

   Measurement of physical properties, phase equilibria, and rapid screening.

3. Pilot Plant Trials:

   Scaled simulations with actual process conditions, solvent selections, or equipment screening.

4. Analysis and Data Review:

   Quantitative and qualitative product testing; insightful technical reporting with actionable recommendations.

5. Scale-Up and Implementation Support:

   Data-driven process design, investment-grade risk assessment, and when needed engineering support for modular, skid-mounted plant fabrication and on-site startup.

   
   

The Benefits: Why Sulzer’s Approach Excels

• Confident Proof-of-Concept:

  Reduce technical and financial risk through validated, realistic process data.

• Process Optimization:

  Maximize product quality, efficiency, and robustness before major capex decisions.

• Faster Commercialization:

  Streamline project approval cycles and accelerate time-to-market with reliable performance guarantees.

• Integrated Technology Development:

  Sulzer’s engineers translate pilot-proven results into full-scale plant solutions with minimal loss of fidelity between trial and deployment a hallmark of effective scale-up.

  
  

Example:

A specialty chemical producer used Sulzer’s pilot plant to optimize a complex amine-ether process. The trial validated EO dosing, safety protocols, and purity, so Sulzer engineered and delivered a full-scale, skid-mounted plant within 12 months. The result: >99.5% product purity, high yield, and low operating costs—proven first at pilot, then perfectly replicated at commercial scale.

Conclusion: From Idea to Industry, Sulzer’s Validation Trials Lead the Way

Sulzer’s lab and pilot validation trials are the gateway to reliable process transfer, de-risked capital investment, and successful, efficient industrial plant operation. With world-class facilities, expert staff, and unmatched customer focus, Sulzer provides the shortest, safest path from concept to commercial reality.

Ready to discuss your project? Contact Sulzer’s validation team to learn how a custom trial can unlock the next step in your innovation journey.