EXCELOT™ platform for batch processes
Multipurpose distillation | extraction batch systems
Waste management, fine and specialty chemicals, as well as flavors and fragrances require flexible purification processes while maintaining high product quality. EXCELOT offers modular batch solutions customizable to ensure optimal space utilization and maximized purity.
>99% purity for multiple products
Achieve exceptional product purity in a single solution
Flexibility & cost savings
Substitute complex processes by one unit
Enhanced productivity
Reduce transition time to <15% of total batch
Main benefits
Improve product quality Achieving >99% purity for multiple products in one batch cycle
Unlock process agility Offering a highly flexible unit with CAPEX minimized by up to 80%
Shorten batch time for higher productivity Designing concepts and workflows to reduce start-up and shutdown time to <15% of total
Key characteristics
Integration of Sulzer’s latest unit operations such as EvapCare™ evaporators and Mellapak™ packings
Optimized control system that fine-tunes reflux ratio and process scheme to minimize product losses
Flexible and compact modular solution
Guaranteed performance
Proven and reliable technologies with more than 30 references worldwide
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Charlie Chou
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GT‑DWC is a unique distillation technique called dividing wall column, that produces three or more purified products in a single tower that otherwise in conventional way is done by 2-3 columns in series.
A vertical wall splits typically the mid‑section into two functional zones so the column can pre‑fractionate the feed on one side while the other side refines the middle cut (heart‑cut) from the top and the bottom cuts. Compared with a conventional in-series distillation columns, this integrated column reduces investment by half of the equipment count, and its internal arrangement reduces remixing that lower the utility consumption as well.
When comparing with the normal column with a side draw, GT-DWC produces the heart‑cut where it is most concentrated with contamination from top & bottom products, and achieves the same (or better) product specs as by the multi-column system.
A two‑column sequence inevitably wastes duty by splitting and then remixing components between shells, causing thermal inefficiency that drives up utility consumptions for reboiling and condensing. GT‑DWC® consolidates that work inside one shell, so the separation is done once without such thermal inefficiency, with one reboiler and one condenser. That means fewer separation efficiency losses, lower internal flows, and smaller overall duty. Where applicable, GT-DWC typically provide 20-30% energy saving comparing with two-column system with the same or better product separation quality.
Yes. GT‑DWC is often a revamp enabler because it replaces two columns with one shell, freeing plot space and reducing energy consumption. It can also be applied for revamping an existing column with sidedraw to greatly improve the middle heartcut purity/quality that benefit its value and downstream units. Sulzer high-efficiency tower internals and proprietary DWC design are key to guarantee the success of the revamp. Dynamic simulation is used to validate start‑up/shutdown procedures as well as the feed variation to prove controllability within your existing utility envelope.
Sulzer supplies the full set of trays or structured packings, along with distributors, collectors, and when needed, custom wall hardware. The internals are engineered to maintain pressure balance and uniform liquid/vapor distribution on both sides of the wall—this is critical to prevent maldistribution, channeling, or cross‑leakage that can degrade efficiency. Selection (trays vs. packing) depends on capacity, turndown, fouling tendency, and pressure drop targets; our design team sizes distributors/redistributors and sealing elements to keep performance stable across the operating range.
Yes. A single shell creates a clean condenser ↔ reboiler pairing that a heat pump can bridge: the overhead releases heat while condensing; VoltaSplit™ lifts that heat to the reboiler temperature replacing a large share of steam with electricity and reusing condenser heat that would otherwise be rejected.
GT‑DWC excels when there is a meaningful middle cut (heart‑cut) to recover, and when the alternative would be a two‑column arrangement. Typical examples include aromatics heart‑cuts, naphtha splitter, reformate splitter, iso/normal-separation column, and light/medium hydrocarbon fractionations where three product slates are needed. As a rule of thumb, if your feed has a clear light, middle, and heavy region—and the middle product purity/yield matters—GT‑DWC is a strong candidate.
We pair a standard temperature/reflux control structure with additional loops to maintain vapor/liquid splits around the dividing wall. It ensures high controllability, and robust operation even facing the feed variation. Dynamic simulation is used to test disturbances (feed swings, utility changes) and to finalize startup/shutdown sequences before commissioning.
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