Sulzer Liquid Liquid Extraction Technology
High-performance solutions for complex separations
Sulzer is a global leader in liquid-liquid extraction (LLE) technology, providing high-efficiency separation processes for industries where conventional distillation is not feasible due to thermal sensitivity, close boiling points, or energy constraints. Our expertise combines advanced column internals, proprietary solvents, and full-scale process plant delivery to solve your most challenging separation requirements.
How liquid-liquid extraction works
The liquid-liquid extraction process at Sulzer involves a systematic approach to separating components based on their solubility in two immiscible liquids
A suitable extractant (solvent) is chosen based on its favorable partition coefficient, high selectivity, and ease of separation from the extracted product.
Extractant Selection
One liquid is dispersed into the second liquid in the form of droplets to maximize contact area.
Creating Dispersion
The equipment creates optimal conditions for mass transfer between the two phases by controlling droplet formation, transport, and settling.
Mass Transfer
The two liquids flow countercurrently through the extractor to achieve high purities and yields.
Countercurrent Operation
After contacting the phases, the two liquids are subsequently separated from each other.
Phase Separation
Throughout the column, the process maintains an adapted droplet size and a uniform hold-up profile to ensure high performance.
System Optimization
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Kühni agitated columns (ECR)
Sulzer liquid-liquid extraction Portfolio
When dealing with processes involving high mass transfer or fluctuating physical properties, the ECR is the industry standard. Its agitated compartment geometry is fully adaptable, ensuring stable performance even when hydrodynamic conditions shift.
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Key Features: Specially designed mixing turbines and perforated partition plates for superior mass transfer.
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Main Benefits: Universal utility, high flexibility for varying parameters, reliable scale-up, and the capability of achieving over 30 theoretical stages in a single column.
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Design Specs: Diameter 30 mm – 3.5 m | Turndown 1:3 | Viscosity up to 500 mPas.
What is liquid liquid extraction
OptimEXT™ solutions leverage Sulzer’s expertise in liquid-liquid extraction and distillation to optimize process efficiency. By integrating our proprietary Kühni™ agitated columns with advanced distillation units, we provide a robust, reliable path to cost-effective solvent recovery.
Main Benefits
Reliable Performance
Sulzer combines proven extraction technologies with systematic pilot-scale testing to provide full process guarantees for industrial production.
Economic & Operational Advantages of Skid-Mounted Units:
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Cost and Schedule Efficiency: Turnkey skid design lowers investment costs and enables faster delivery via fast-track execution.
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Simplified Installation: Modular construction minimizes on-site erection time and reduces site disruption.
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Guaranteed Quality: Workshop-based manufacturing allows for comprehensive Factory Acceptance Testing (FAT) before delivery.
Process Target
Energy & utility savings
By-product recovery
Product Recovery & Purification
Solvent extraction & separation
of complex mixtures
Sustainability & environmental
compliance
Process simplification & inventory
reduction
Typical Applications
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Organic acids like acetic acid and formic acid
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Various mineral acids including nitric, sulfuric, and hydrochloric acids
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Extraction and purification of flavors, fragrances, essential oils, vitamins, and nutraceuticals
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Purification of antibiotics and active pharmaceutical ingredients (APIs)
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Brochure
Advanced solutions for extraction and solvent recovery
12 pages
Brochure
12 pages
Sulzer OptimEXT™: Advanced solutions for extraction and solvent recovery
Overview
Sulzer cutting-edge extraction technology including Kühni Columns (ECR), Packed Column (ECP), Mixer-Settlers (EMS), and Mixer-Settler Columns (ECMS), with state-of-the-art distillation technology, OptimEXT delivers a reliable, high-performance, and cost-effective solution to diverse industrial needs.
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Contact an expert
Our technical specialists are ready to help you find the optimal evaporation solution for your specific application
Felix Feng
Global product line manager
Sulzer Advantage
Proven Process Solution Provider for complex and challenging separations
Full Service Provider for proprietary process equipment and plant solutions, backed by guaranteed performance
Provide solutions from design to operation
Unique technology portfolio and extensive application know-how
Unique experience in combining unit operations
Extraction is chosen when distillation is either uneconomical or technically impossible. This includes separating components with similar boiling points, breaking azeotropes, purifying thermally sensitive components, or recovering high-boiling pollutants present in low concentrations.
The ECR column features agitated compartments with turbine mixers that create small droplets of the discontinuous phase, facilitating radially mixed liquid phases for reliable scale-up. Perforated plates between stages reduce back-mixing to enhance overall separation performance.
Successful separation requires an extractant with a favorable partition coefficient and high selectivity. Additionally, the liquid pair must have a low mutual solubility and a sufficient difference in density to drive droplet motion.
Skid-mounted units provide short delivery times, lower overall investment costs, and reduced on-site erection time. They are manufactured under workshop conditions to ensure high quality and undergo full Factory Acceptance Testing (FAT) before delivery.
Pilot trials are essential because extraction equipment cannot be designed from first principles alone. These trials establish optimal operating conditions, determine geometric parameters, and allow for safe, guaranteed scale-up to industrial-sized units.
OptimEXT™ is applied across various sectors, including the bulk chemical, petroleum, fine chemical, pharmaceutical, biotech, food, and hydrometallurgy industries.
150+ Years Experience
Proven track record in chemical process engineering and equipment manufacturing.
Global Presence
Worldwide support network with local expertise and rapid response capabilities.
Quality Assurance
ISO certified processes and rigorous quality control for reliable, safe operations.