Sulzer’s technology for reactive distillation
Sulzer’s reactive distillation combines reaction and separation into a single, efficient unit operation. This method is ideal for equilibrium-limited reactions involving volatile components, where continuous byproduct removal is crucial for conversion and product quality. With expertise in reactor design and separation, Sulzer delivers complete solutions for esterification, hydrolysis, and acetalization. Our proprietary Katapak™ catalytic packing enables simultaneous reaction, enhancing productivity, purity, and energy efficiency while reducing CAPEX and OPEX.
Maximized product purity
Achieve unparalleled purity and color with zero odor
Lower CAPEX and OPEX
Combine multiple reactors and columns into one
Reduced by-products and wastes
Avoid side reactions and minimize purge
Main benefits
Consistently high product quality Setting a new standard for the industry in terms of purity, color and odor level
Lower CAPEX and OPEX Combining unit operations and minimizing maintenance cost to achieve higher energy efficiency and performance; examples are Katapak™ and the dividing wall column
Extended catalyst lifespan and boosted selectivity Catalyst lifespan >7 years and selectivity up to 99.5%, thanks to careful catalyst selection and reactor design
Reduction and elimination of waste streams Integrating novel recycling, but also minimizing side reactions and downstream processing
Key characteristics
Fatty acid esters: Isopropyl palmitate (IPP), myristate (IPM) and laurate (IPL); 2-ethylhexyl palmitate (2-EHP) and stearate (2-EHS); n-butyl oleate (NBO) and stearate (NBS)
Acetates synthesis and their hydrolysis: Methyl-, ethyl-, propyl- and butyl-acetates
Acetals and methylal
Diglycol-dibenzoate
Wastewater treatment: Carboxylic acid removal
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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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