What to Expect in a Sulzer Lab or Pilot Validation Project

Introduction: A Transparent, Customer-Focused Validation Journey

Successful process innovation and scale-up hinge on rigorous, real-world testing. At Sulzer’s IntecH test centers, every lab and pilot validation project is conducted with a clear, customer-centric workflow that delivers actionable, investment-grade results. Knowing what to expect helps you plan, de-risk, and maximize every stage of your technology’s development.

Step 1: Initial Consultation and Scope Definition

Every project begins with a one-on-one consultation, where Sulzer’s experts:

• Define your process goals and performance targets

• Identify material requirements and feed sample needs

• Decide which unit operations (distillation, evaporation, extraction, absorption, etc.) best fit your challenge

This ensures both sides align expectations and determine the feasibility and potential value of the validation.

Step 2: Laboratory Feasibility and Data Collection

The first technical steps include:

• Physical property measurements (density, viscosity, VLE, LLE)

• Rapid screening of your actual feed using bench-top evaporation, extraction, or reaction tests

• Determining critical process data necessary for process selection and engineering

This early-stage work is rapid, cost-effective, and helps weed out non-viable pathways while highlighting optimization opportunities.

Step 3: Pilot Plant Trials with Real Feedstocks

Armed with lab data, Sulzer transitions the project to pilot scale, where:

• Scaled-down versions of the intended process run under authentic conditions (temperature, pressure, feed rate)

• Equipment is selected and tailored for simulation (e.g., column types, evaporator size, phase ratio)

• Both batch and continuous modes are possible to match your industrial target

Throughout, all key performance parameters are tracked in real time.

Step 4: Advanced Sampling, Analysis, and Reporting

Sulzer’s in-house laboratories analyze intermediate and final samples for:

• Product composition and purity

• Impurity removal efficiency

• Energy and mass balance closure

Clients receive technical reports combining raw data, expert interpretation, and practical recommendations for process optimization and scale-up.

Step 5: Path Forward From Data to Decision

Based on trial results, Sulzer provides:

• Go/no-go advice for full-scale investment

• Equipment sizing, process optimization suggestions, and risk assessment

• Guidance for next steps: further validation, skid-mounted pilot deployment, or direct transition to engineering design and commercial build

Close client communication continues throughout the process, ensuring clarity and actionable outcomes at every stage.

Why Choose Sulzer’s Approach?

• Transparency: Every project step and result is explained and justified.

• Customization: Trials and reporting can be adapted to unique feedstocks and business goals.

• Speed: Efficient lab and pilot workflows minimize project time and cost.

• Expert Partnership: Sulzer’s globally recognized specialists provide ongoing support and troubleshooting.

  
  

Conclusion: Empowering Smarter Process Decisions

Sulzer’s structured, transparent lab and pilot validation workflow is designed to turn your industrial separation ideas into viable, investment-ready projects. Expect a data-driven journey where your goals, samples, and questions drive the process, and Sulzer’s experience ensures robust, reliable progress from concept through commercialization.