Sulzer Chemtech
Mixing and Reaction Technology The pace making technology, worldwide
Always a step ahead
Since the early 1970s, Sulzer Chemtech has been involved in co- current flow processing for the homogenization and dispersion of gases and liquids, and the optimization of heat and mass transfer in single-, or multiphase, laminar or turbulent flows. Today, we combine years of mixing and reaction technology experience with the latest methods in development, engineering and fabrication to help you meet your processing challenges of tomorrow.
We endorse – individual problem solving based on innovative engineering achievements
Innovative solutions for your special problems
– prompt deliveries that, with standard solutions, fully meet all your requirements – competitive prices in line with market expectations
We guarantee – a presence, orientation and attitude that is truly global – a readiness to direct our efforts toward filling your needs, quickly and thoroughly – interdisciplinary teamwork with well-trained employees and an entrepreneurial spirit at all level Production in our own facilities, worldwide
4588 8004-58
Sulzer Chemtech – a guarantee of added value • Your world-class partner for static mixing • Your most favored supplier of selected polymer process systems • Your No. 1 address for exceptional mixing and reaction technology, products and services 2
Static mixing to your advantage
In principle, static mixing denotes mixing without mechanical stirring elements. All movement takes place solely in the components being mixed. The products are mixed by flow energy alone, with fixed-position mixing elements causing continuous split-off, expansion and redistribution of the flow. Pumps create the flow energy for mixing. In practice, small volumes, low maintenance, simple installation and removal and excellent reliability characterize the static mixer.
Continuous mixing of liquids and gases with Sulzer Chemtech static mixers 4588 4056/45884057
Mixing of two epoxy resins in the Sulzer SMX mixer
3
Mixing and reaction technology for your plants
Mixing and reaction technology is used in continuous processes throughout the processing industries. Sulzer Chemtech is a technology leader with innovative ideas and products that continually set new standards. We offer you a whole series of technical and commercial advantages. What, in real terms, can that mean for your plants?
Mixing
Reacting Plug flow 0691 2726-4
Blending of miscible components regardless of the volume, density, viscosity and properties of the media
Empty tube
Sulzer mixer
Reacting within a narrow residence time distribution for continuous processes
0691 2722-5
Contacting
0685 2019-1
The contacting of liquids with gases to create high mass transfer surface area and high rates of absorption, reaction, vaporization and condensation
Dispersing Dispersing, emulsifying or coalescing two or more products for scrubbing processes, reactions, mass transfer
Conditioning Heat exchangers Empty tube Sulzer mixer
Heat exchanging for controlled reactions or gentle tempering of viscous media 4
Conditioning of process flows upstream of reactors and heat exchangers for increased efficiency
Product line
Static mixers play an important role in the processing industries. Over the years, Sulzer Chemtech has incrementally optimized the different mixing technologies and has taken a careful look at the specific requirements of each. Today, we can offer solutions customized for your specific mixing and reaction task. The Sulzer Chemtech mixer product line is extensive:
Sulzer SMV mixer
Sulzer SMI mixer
0697 2708-1 0691 2724-3
For dispersing low-viscosity, immiscible liquids and contacting gases with liquids in reaction and contact equipment at short residence time distribution and high selectivity
For blending low-viscosity fluids with a low energy input
Sulzer SMX mixer
0691 2724-5
For mixing and dispersing of viscous liquids, for conditioning temperaturesensitive fluids, and as a tubular reactor with short residence time distribution
Sulzer SMF mixer
Sulzer SMR mixer
0691 2724-4 0691 2724-2
For gentle mixing and dispersing liquids with solid particles in suspension
Sulzer SMXL mixer 0691 2724-1
For controlling exothermic or endothermic reactions with liquid media over a narrow residence time distribution with high selectivity and turnover, or for cooling and heating temperature-sensitive viscous media
For increasing heat transfer rates in heat-exchanger tubes for heating temperature-sensitive, viscous media
Sulzer Quadro速 mixer 0698 2727
For mixing and dispersing adhesive and sealant compounds as a disposable mixer with small volumes and a low pressure drop 5
Chemicals industry
Sulzer Chemtech mixers are used for continuous mixing of both high and low viscosity liquid chemicals having a wide range of concentrations. Corrosiveresistant mixers are available when required for corrosive applications. By using Sulzer Chemtech mixers, you have their operational reliability and our wide experience in configuration and design working for you. Consistent product quality and low energy costs are exceptional benefits.
Applications • Diluting of strong acids and bases • Adding additives and inhibitors to process streams • Mixing of different liquid streams to attain uniformity of concentration and temperature for process measurements
0680 2046-1
• Dispersing alkali in hydrocarbons Mixer from special materials for corrosive service
Evaporation of liquids The spray-mix evaporator is used to completely evaporate liquids in superheated gas streams and to normalize the concentration and temperature of the resulting gas stream. By using a spray-mixing vaporizer, you achieve greater reaction yields and higher selectivity.
Application • Manufacture of nitric acid and sulfuric acid
0694 2701-1
Spray-mix evaporator for complete evaporation of liquid additives in superheated gases
6
Chemicals industry
To attain high selectivity and a high yield in catalytic gas phase reactions, uniform concentration and temperature distributions plus a flat velocity profile at the reactor inlet are essential. Sulzer Chemtech mixers are used upstream of reactors to attain continuous mixing of additives and conditioning of the inlet gases. As a result, catalyst life is extended considerably in your plants.
Applications • Manufacture of monomers • Manufacture of organic acids • Manufacture of anhydrides
Sulzer SMV gas mixer for mixing and conditioning of process gases
0681 2075-6
Two-phase reactors As a continuous tubular reactor for two-phase reactions, the Sulzer SMV mixer produces a high yield and high selectivity at low energy input and minimum volumes. These typical characteristics are essential for economical and ecological processes.
Applications • Oxidation of organic products as a cascade bubble column, under high temperature and pressure • Chlorination of organics in a loop reactor • Hydration of aromatics, for example as a loop reactor
0699 2531-5
0679 2009
Sulzer SMV mixer in a liquid phase, bubble bed reactor achieves high mass transfer rates within narrow residence times distribution
• Absorption of gases, and rapid reactions in straight-through reactors • Phosgenation of aromatics 7
Hydrocarbon Processing Industries
By using Sulzer mixers, recognized corrosion problems in oil refineries and gas plants can be significantly reduced. Whether on offshore platforms, for transporting oil, the measurement of the water content of crude oil, for the desalination plant, in a distillation unit or for alkylation or catalytic processes - Sulzer Chemtech has the solution. Our static mixers not only reduce operating costs, but also increase plant on-stream time. As a result, they are a sure demonstration that Sulzer Chemtech mixing and reaction technologies payoff, whatever the application.
0698 2712
The DN 350 PN 400 Sulzer mixer for temperature homogenization upstream of a hydration reactor
Applications • Desalting of crude oil • Gas scrubbers for neutralization or desalination • Sulfur removal scrubbing processes
The Sulzer SMV mixer for the neutralization of alkylate products
8
0696 2702
0696 2520
• Blending of gasoline, diesel, lubricants, and other refinery product
Fiber production
Mixing
Reactor
For the manufacture of high-quality filaments, a homogenous melt or dope is essential. Using static mixers in your plants prevents the degradation of your melts and greatly reduces the separation of suspensions. Your filaments will be constant quality and have a minimum number of broken fibers.
SMR heat exchanger
Heating/cooling The tempering of spinning masses places high demands on heat exchangers. Despite its low volume, a SMR heat exchanger can gently heat and cool temperature sensitive spinning masses.
Additive SMX mixer
Polymerization Due to the narrow residence time distribution in a SMX tubular reactor, a spinning polymer is produced with a narrow molecular weight distribution and low volume of by-products.
Direct spinning plant with Sulzer SMR heat exchanger and Sulzer SMX mixers for excellent filament quality
Application • In-line homogenization for melts, polymer solutions and suspension • Mixing of various additives upstream of the spinning heads, and thus minimum changeover times • Cooling of polyester melts in direct spinning plants for optimum processing temperatures 0690 2750
The Sulzer SMR heat exchanger for gentle tempering of spinning masses within a narrow residence time distribution
• Gentle heat-up of spinning solutions prior to flash degassing • Continuous polymerization in the tubular reactor within a narrow residence time distribution 9
Extruding and injection molding
Perfect homogenization of the melt is one of the most important prerequisite for achieving high and uniform quality in the manufacture of plastic products. Defects in cast components such as color streaks, stains, irregular wall thickness or distortion are usually the result of insufficiently plasticized melts. By installing a Sulzer injection blender in your injection-molding machine or a Sulzer melt blender in your extruder, you obtain constant - and thus perfect melt homogeneity.
The benefits for injection molding technology – Improved product quality when processing regenerates – Less wastage: Much greater balance throughout the process – Extended applications: In the case of difficult polymers, perfect products can also be manufactured using universal screws
Sulzer SIB injection blender for a constantly high product quality in injection molding technology
0698 2740
– Reduction in color costs: A comparable degree of coverage can be attained with a clear reduction of masterbatches (30% and more)
The benefits for the extrusion process – Optimal inlet flow to the molding tool through the compensation of velocity differences caused by temperature and flow conditions in the flow-channel cross section – Uniform wall thickness in the case of hollow bodies, and uniform cell structure in the case of foamed products
0698 2741-2
0698 2732-1
Sulzer SMB-R melt blender for an optimized extrusion process
10
– Improved color density even with lower color concentration in the melt
Adhesives, resins, sealants
Sulzer Chemtech has a range of practical products designed for mixing adhesives, resins and sealants:
Sulzer polyol mixer Sulzer Chemtech polyol mixers guarantee excellent foam structures with hard- and soft-polyurethane foams. They have been specially designed for loading PUR formulations with physical raising agents such as pentanes or CO2, but can also be used to mix in additives and catalysts.
Sulzer SMX mixer The SMX mixer is particularly suitable for the perfect mixing of resins, additives, colors and catalysts. It is used in production and dosing plants for resins and sealants, and due to its perfect mixing performance is effective also in applications involving masses with very difficult mixing characteristics.
0690 2727
Sulzer SMX mixer for reactive resins
Applications • Mixing of two-component cartridge resins
• Mixing of reactive resins in the glass sealing industry
• Mixing of reactive resins when processing or dosing
• Mixing of LSR silicones
• Mixing of additives and colors into resins
• Mixing in physical blowing agents for the manufacture of polyurethane foam
• Direct coloring of silicones
• Cooling of resins prior to filling
Sulzer Quadro®
0698 2736-4
The Sulzer Quadro disposable mixer sets new standards for mixing reactive resins. It is made of plastic and is mainly used in dosing plants or for two-component resin applications. The unique mixing geometry of the Sulzer Quadro makes it the disposable mixer with the lowest waste volumes, the shortest overall length and the lowest pressure drop.
A selection from the Sulzer Quadro product range
0698 2739-1
11
Food processing industry
The Sulzer mixer fulfils important tasks in the food processing industry. It is particularly suited to mixing additives, such as flavorings, minerals, trace elements, vitamins, emulsifiers and preservatives. Other applications are found in pasteurization, sterilization and the tempering of sensitive products. Sulzer Chemtech has the right solution for your mixing and heat exchanging process. Our mixer line is extensive and covers the entire application spectrum. They can all be customized to your specific needs
Applications
0681 2040
• Mixing of flavoring into fruit juices
The Sulzer SMX mixer for high-viscosity media
• Desliming of vegetable oils with phosphoric acid • Carbonation of water • Mixing of fruit pieces with yogurt • Homogenization of sweet masses • Mixing of flavoring into chocolate • Mixing of citric and malic acids into sugar solutions • Cooling and heating of chocolates, crèmes, confectionary and other paste-like masses
0699 2706-3
The Sulzer SMR heat exchanger for gentle heating and cooling of sensitive products
12
Energy, water and wastewater industry
Sulzer mixers have enormous potential in energy, water and wastewater technology, and their use widespread. Because the processes of these technologies are continuous, often small amounts of reactive agents must be added to high volume flows and distributed uniformly within a short distance over the entire channel cross section. In other cases, it is necessary to uniformly distribute the concentration and temperature of a process feed upstream of a catalyst or to dissolve gases into liquids and to generate fine, uniform bubbles in insoluble liquids. Sulzer has just the right mixing technology and products for these growing processing technologies.
Applications • Injecting ammonia into flue gas at the inlet of the SCR unit for NOx removal • Mixing of flocculants into slurry • Mixing of acids into liquids for neutralization • Ozonization, de-acidification and oxygen enrichment of water
Sulzer SMI mixer for water/wastewater technology and optimum dosing of additives 0696 2704-1
• Mineralization of drinking water • Dispersing of water into fuels, upstream of the burner
0692 4575
Sulzer SMV mixer for conditioning of flue gas at minimum space and energy requirement
0687 4031-1
13
Polymerization plants
Sulzer Chemtech’s broad spectrum of engineering expertise in widely different processing fields puts it in a position to plan and build plants that will meet your requirements precisely. The polymerization industry is only one example. From the development of state-of-the-art equipment for the production of plastics through the design of advanced process systems for the optimization of product quality to a fully documented plant, Sulzer Chemtech is your competent partner.
Polymerization section from Sulzer Chemtech on a polystyrene plant
Applications • Loop reactor for exothermic reactions • Plug-flow reactors • Removal of volatile components from polymer melts • Mixing of additives
0696 2701-1
Plants for mixing additives into a SAN melt
14
9901 2844-1
0697 2710-2
Development and application technology
Sulzer Chemtech has its own laboratories institute where the use of static mixers and mixer reactors in various processes are studied and tested. Sulzer Chemtech has a high level of know-how and years of experience in the computational fluid dynamics (CFD) modeling of mixing processes. We apply our expertise, know-how, and analytical skills to creating individual solutions, specially customized for your particular processing situation: Development of components and processes – Application trials, conducted in our own laboratory facilities or with the customer, for upgrading and ascertaining guarantees
0696 2707
– CFD-supported process and product optimization – Feasibility studies and basic engineering CFD simulation of a Sulzer mixer
Applications • Pilot plants for polymerization processes • Pilot plants for the degassing of polymers • Investigation of the flow behavior of plastics in injection molding equipment • Inspection of mixer configuration in the case of difficult-to-mix components • Flow optimization of DeNOx plants, including model testing and CFD
0695 2716
• Optimization of mixing of educts upstream of reactors, with CFD
0699 2707-2
Optimization of flow in a DeNOx plant on the model (scale 1:25)
15
Sulzer Chemtech Ltd P.O. Box 65 CH-8404 Winterthur, Switzerland Phone +41 (52) 262 67 20 Fax +41 (52) 262 00 69 E-mail chemtech@sulzer.com Internet www.sulzerchemtech.com
Sulzer Chemtech USA, Inc. 4106 New West Drive USA-Pasadena, TX 77507 Phone +1 (281) 604 4100 Fax +1 (281) 291 0207
Sulzer Chemtech Pte. Ltd. 11 Tuas Avenue 18 SGP-63 88 95 Singapore Phone +65 6863 75 60 Fax +65 6861 15 16
Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquarters in Winterthur, Switzerland, is active in the field of process engineering and employs some 1200 persons worldwide. Sulzer Chemtech is represented in all important industrial countries and sets standards in the field of mass transfer with its advanced and economical solutions. The activity program comprises: • Process components such as packings, trays and internals for separation and reaction technology •
Engineering services for separation and reaction technology such as optimizing energy consumption, plant optimization studies, preengineering for governmental approval, basic engineering
•
Processes and plants for the separation and purification of chemicals by means of fractional crystallization and pervaporation
•
Mixing and reaction technology with static mixer
Distributed by:
23.27.06.40 – III. 03 – 50
Printed in Switzerland