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Sulzer Chemtech is the process engi-neering division of the internationalSulzer Corporation with headquar-ters in Winterthur, Switzerland. Acti-vities include equipment and (appli-cation) know-how in separation andmixing technology. Products includestructured packing and trays forseparation columns, fractional crys-tallisation systems, equipment formixing and reaction processes andcatalyst supports.

Excellence in Refining Technology

Leading in research anddevelopment

With proven design procedures andinnovative engineering solutions,Sulzer Chemtech can meet the re-finery’s objectives. Sulzer Chemtechhas the personnel, experience andengineering capability to model andanalyse mass and heat transferproblems in distillation, absorption,extraction, mixing and reaction andfractional crystallisation. Apart frompilot tests, computational fluid dy-namics (CFD) for optimising and finetuning of the geometry are used forthe development of new products.

Pilot plant

Customer-specific applications canbe tested in our pilot plant. Resultingdata can be used for a reliable de-sign of the production plant.To achieve the design criteria for distillation applications on movingbarges and platforms, pilot testswith a swinging laboratory columnwere done to simulate offshore con-ditions.

Components, engineeringand systems

For more than 30 years SulzerChemtech has provided innovativemass transfer technology to the oil,gas and petrochemical industry. Awide variety of separation and mixingmethods and process equipmentallows us to design optimal systems.

Crude oil distillationFCC vacuum towers and gas plantsLube oil distillationLiquid-liquid extractionCoking and visbreaking1-Butene separation plantsFractional crystallisationetc.

Process simulationFeasibility studiesBasic designDetailed engineering HardwareInstallationCommissioningStart up assistance

for

Numeric simulation of the cross-sectionalconcentration distribution in the SMImixer.

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Sulzer Chemtech has experience indesigning column internals for mov-ing platforms. The design is basedupon the successful combinationof laboratory tests with a movingcolumn and industrial applications.

Industrial applications includes:

• Separators (oil, gas, water)

• Gas drying

• Gas sweetening

• Multi cyclone separators

• Crude oil stabiliser

• Sea water deaeration

Sulzer Chemtech can provide following services:

• Feasibility studies

• Process design and basicengineering packages

• Hardware supply, i.e. Mellapakand internals

Crude Oil Production

Sulzer Chemtech stabiliser system basic process steps.

Special liquid distributor for moving columns

Moving pilot column

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Stabilised Condensate

Feed L/VSeparation

WaterRemoval

PartialEvaporation

Distillation

Lights + LPGSea orCooling Water

Tempered Wateror Hot Oil

Produced Water

Spindle oil

SAE 10

SAE 30

Aromatic Extraction

Raffinate

Solvent +aromatics

Distillates

Solvent

Gas oil

Lube Tower

Tankfarm

Desalter

Salt water

Atmospheric tower

Vacuum tower

LPG

Steam

Preflash Tower

Kersosene

Lightgas oil

Heavygas oil

Long residue

LVGO

HVGO

Slop wax

Airblowe

Naphta

Sweet gas

H2S

Off gas

Reformate

Amine Contactor

Stripper

Gasoline Stabiliser

Separater

GasolineReformer

Desul-phuriser

Short residue

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Atmospheric Tower

Pollution RegulationsBetter fractionation between LGOand HGO will increase the LGO (citydiesel) yield and improve the quality.

Increased HGO yieldBetter fractionation and less entrain-ment, with Mellapak in the washsection, will increase the HGO yield.This will also relieve the vacuumtower.

Increased CapacityDebottlenecking a pump aroundsection often results in 20% or morecapacity. Structured packing nor-mally does not require more spaceto achieve the required heat transfer.

ExampleA revamped wash section with aninvestment of about US$ 0.5 Mio.for hardware and installation workwill result in a pay back time of ap-prox. 4 months.

Static Mixer

TankfarmCrude sampling homogeniserCrude blender

DesalterProduce the water dispersion forcrude desalting. • No moving parts.• Danger of leakage and mainte-

nance are eliminated.

Overhead LinesRemove salts from gases in over-head lines.• Preventing salt deposits in piping,

cooler or column top section.

Crude Distillation Unit

LGO

HGO

Crude

Steam

Long residue

Gas

Naphtha

Kerosene

Diesel

Gas oil

Fuel oil

VisbreakerFractionator

Cokedrum

wer

Wash water

Fractionatorbottoms

Heavy cycle oil

Light cycle oil

Rich oil

Lightnaphtha

Heavynaphtha

NaphthaSplitter

DebutaniserLean oil

Stripper

PrimaryAbsorber

SecondaryAbsorber

Propane

Propylene

C3-Splitter

Fuel gas

Deethaniser

Deprop-aniser

C4

Acid gasremoval

Mainfractionator

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Vacuum Tower for CrackerFeed Preparation

Additional Diesel Side CutAn additional fractionation sectionbetween LVGO and HVGO will re-cover diesel from the LVGO.

Wash SectionIn deepcut operation flash zone tem-peratures greater than 400° C arerequired. The preferred solution forthis mode operation is a combinedbed with Mellapak in the upper andMellagrid in the lower part.This together with the Sulzerpatented VEP gravity distributor hasbeen used in more than 30 washsections.

Flash ZoneA special vane feed inlet deviceimproves the phase separation ofthe liquid from the gas. This meansless entrainment into the washsection.

Vane feed inlet device

Crude Distillation Unit

Diesel

LVGO

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Today the lube oil market is chal-lenged by new product require-ments. The refinery must cope withthe new situation. This has a directinfluence on the lube oil tower andthe aromatic extraction of lube cuts.Sulzer Chemtech has a large experi-ence with more than 50 referencecolumns world-wide.

Aromatic Extraction

Sulzer Chemtech can offer a reliabletechnology for the extraction of aro-matics from lube oils.

We have experience with Furfurol,Phenol and NMP as solvents.

Extraction columns equipped with the Sulzer extraction packing SMVPoffers:

• Increased capacity for debottlenecking of existingcolumns.

• Moderate contacting of the phases for reduced entrainment.

• High flexibility.

• No moving parts and thereforelow maintenance costs.

Lube Oil Plant

Lube Oil Tower

Advantages of Mellapak Benefits for the customer

• Low pressure drop • Increased capacity

• Good separation efficiency • High distillate yields

• High flexibility • Improved distillate quality

• Selected packing types • Additional new lube cuts

• Compact internals

Aromatic extraction

Lubetower

SolventSpindle oil

SAE 10

SAE 30

Solvent +aromatics

Raffinate

Gas oil

Distillates

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The “bottom of the barrel” has become more important to refineriesbecause heavier crudes are beingprocessed and the market forvacuum residues is decreasing.

Sulzer Chemtech can offer solutionsthat increase plant capacity, reducethe risk of fouling and extend therun time.

Our products are successfullyinstalled in:

• Delayed Coker Fractionators

• Flexicoker Fractionators

• Visbreaker Fractionators

• Vapour quench cooler with static mixers.

Comparison of tray and Mellapak column for H2S removal (to scale).

Coking and Thermal Cracking Processes

Mellagrid

Sulzer Mellagrid was specificallydeveloped to combine the efficiencyof Mellapak with the mechanicalresistance of grid. Advantages are:

• Not sensitive to coking or foulingdue to its geometrical structureand smooth surface.

• Much better demisting and sepa-ration efficiency than traditionalgrid.

• The structure and element heightallow for easy cleaning. It can beremoved, unscrewed and cleanedwith water jet.

• Mechanically robust structure.

Special Liquid Distributor

Plugging resistant and with a highturn down ratio.

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uum tower

LVGO

HVGO

Slop wax

Airblower

Wash water

Fractionatorbottoms

Heavy cycle oil

Light cycle oil

Rich oil

DLean oil

Stripper

PrimaryAbsorber

SecondaryAbsorber

Deani

Acid gasremoval

H2S

Off gas

Reformate

Amine Contactor

Stripper

Gasoline Stabiliser

Mainfractionator

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FCC Main Fractionator

The advantages using structuredpacking in the FCC Main Fractiona-tor are:

• Reduced pressure drop (typicallyfrom approx. 350 mbar to about60 mbar).

• Increased capacity.

• Improved separation betweenside products.

Slurry Section

The use of Sulzer Mellagrid togetherwith a slurry distributor increases column throughput and heat transferperformance while reducing risk offouling.

Due to the geometrical structure ofMellagrid entrainment of catalystparticles is reduced.

FCCU Compressor

Sulzer Turbo supplied the Pernisrefinery, NL with a compressorpackage (here on the test stand)which has a rating of 5.3 MW andcompresses 58200 Nm3/h FCCUgas.

FCC Unit

Lightnaphtha

Heavynaphtha

NaphthaSplitter

DebutaniserPropane

Propylene

C3-Splitter

Fuel gas

Deethaniser

eprop-niser

C4

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Complete Systems

Propylene Plant

Sulzer Chemtech can offer theprocess and basic engineering,tower internals, reboilers and theturbocompressor for a grass rootpropylene plant with vapour recom-pression.

Example

• Production of 125,000 tons peryear polymer grade propylene.

• Use Sulzer Chemtech vapour recompression technology.

• Use high efficiency structuredpacking Mellapak to reduce towerdimensions and compressor power.

1-Butene Technology

Sulzer Chemtech is able to supply a process for the separation of 1-butene. A number of variations arepossible depending on the customerrequirements. Years of experienceand continuous development haveresulted in the capability of supply-ing tailor made designs, assuring themost economic 1-butene produc-tion. Sulzer Chemtech’s structuredpacking, heat coupling or heat pump systems have been proved in com-mercial service.

FCC Unit

Fractionation Trays

Sulzer Chemtech’s tray experience isbased on the tray technologies ofNUTTER and METAWA. Over the last40 years the product knowledge hasdeveloped to a leading mass transfertechnology with a wide applicationarea.The High Performance Trays with theunique V-Grid technology of Nutterand the innovative downcomer designof the VortexTray.

Example• Deethanisers• Depropanisers• C2- and C3-Splitters• Debutanisers• Deisobutanisers• Dehexanisers• Xylene Splitters 0697 2511

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LPG Sweetening with Amines

Sulzer Chemtech has experiencewith amine sweetening in bothliquid-liquid and gas-liquid systems.

Liquid-liquid Extraction

Extraction packing SMVP in aminetreating of LPG offers:

• Capacity increase of existing columns.

• High flexibility.• Low amine entrainment.• Low maintenance costs.• Small investment for the revamp

of existing columns.

Amine Contactors

Sulzer Chemtech has extensiveexperience with the absorption ofH2S and CO2 with various amines.More than 100 columns are inoperation world-wide.

Furthermore selective absorptioncan be used in sour gas systemscontaminated with CO2.

The advantages using Sulzer Chem-tech column internals are:

• High selectivity through short residence time.

• Small solvent quantities.• Low regeneration costs.• Low pressure drop.• Low investment costs.

Off (Tail) Gas Treating

The use of Mellapak in the Quenchand H2S absortion column results ina small pressure drop and thereforein important energy saving.

Desulphurization

Hydrodesulphurization

Static mixers from Sulzer Chemtechare used to remove salts from thereactor effluent and fractionatorover-head to avoid fouling of thecoolers. Reactor effluent scrubberalso clean the recycled hydrogen.

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SweetLPG

Amine

SulzerSMVPExtractionPacking

LPG + H2S

H2S-rich Amine

H2

Feed

Reactor

H2O

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Acid Wash Mixer

Removes the alkyl-sulphates fromthe effluent stream for returningthem to the reactor.

Caustic Wash Mixer

Removes the acid traces from thereactor effluents to protect theseparation columns and other downstream equipment from corrosion.

Alkylation

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Acid Spent Causticacid

Spentcaustic

Deisobutaniser

Caustic

Spent caustic

Depropaniser

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Only advanced process solutionstogether with high quality com-ponents can secure the competitiveadvantage of refineries in today’s highly competitive environment.

Innovative Components

Mellapak Columns with structured packing Mellapak,pioneered by Sulzer, have following advantages:

• High performance

• High capacity

• Low pressure drop

• High flexibility

MellapakPlus The invention of Sulzer gauze packing resulted ina decisive breakthrough in mass transfer equip-ment. A further milestone was the development ofthe Sulzer Mellapak. Mellapak opened up newand unforeseen perspectives in all areas ofthermal mass transfer.The new MellapakPlus is the latest developmentand offers the lowest pressure drop of all struc-tured packings available on the market.

Mellagrid Mellagrid can be used in every area, where themechanical strength of Mellapak could causesome concern or where plugging or coking are likely to occur.

Column internals The great success of our products has only beenpossible in conjunction with the continuingdevelopment of distributors and other internals.

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Innovative Components

Fractionation Trays A full range of fractionation trays especially suited for refinery applica-tions.

Optimised for fast installation andeasy maintenance.

Static mixers Advanced static mixing and reactiontechnology is suitable to many refin-ing process units.

• Blending liquids or gases.

• Dispersing liquids or contacting gases to equilibrium conditions.

• Washing or scrubbing hydrocar-bons.

• Vaporise liquids or condense gases.

Shell Mass Transfer The complete Shell Mass TransferTechnology Technology Package, previously

used only by Shell companies, isnow available from Sulzer Chemtechunder the terms of the alliance be-tween Shell Global Solutions BV andSulzer Chemtech Ltd.The technology covers high perfor-mance trays, associated internalsand phase separation equipment.The technology has been the Shellstandard for years and it is backedby an abundance of operational anddesign experience. Sulzer Chentechnow offers these dependable highperformance trays and separators totheir customers.

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Industrial Applications from A to Z

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Mixers, Packings, Process design,Trays and Installation Service formany applications.

Alkylation – static mixer for product neutralisationAmine ContactorAromatic extraction from LubeOilAtmospheric Crude Oil Tower – more than 80 columnsworld-wide with Mellapak

Benzene TowerBitumen tower1-Butene –Distillation and heat pump technology

Coker FractionatorCrude sampling mixerC3-SplitterC4-SplitterC5-Splitter

DebutaniserDeethaniserDehexaniserDemethaniserDepropaniser

Deepcut Vacuum Tower –Mellagrid, Mellapak and VEPdistributorDesalting Water-oil Mixer

Ethylene Water Quench

FCC Main Fractionator – Mellagrid in slurry section

Gasoline blending mixer

H2S extraction from LPG

Kerosene Stripper

LNG-StabiliserLube Oil Tower – Low pressure drop, high separa-tion efficiency with Mellapak

Naphtha Splitter

Off-gas treatingOlefin separation

Para Xylene –Heat pump crystallisationPreflash TowerPrimary Absorber

Quench Tower

Reformer Feed Gas Mixer

Secondary AbsorberSolvent StripperSour Water StripperStabiliser

Toluene Tower

Vacuum Tower for Cracker Feed – over 150 columns with Mellapak world-wideVisbreaker Fractionator –Application for Mellagrid and Mellapak

Xylene Splitter

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Services to Customers

Worldwide Sales and Manufacturing

Sulzer Chemtech has together withthe Sulzer Corporation world-widepresence with offices in most coun-tries.Furthermore Sulzer Chemtech hasits own production facilities inSwitzerland, the Netherlands,Poland, India, Singapore, China,Brazil and Mexico.

Field Service

Sulzer Chemtech has the projectmanagement and technical skills toassure successful installations for newcolumns and revamps in refineries,gas processing and petrochemicalplants.Abilities range from site supervisionto complete installation.

ExampleIn Europe Sulzer Palladin, UK offersextensive field services.

Emergency Services

In the event of a break down or otherplant upsets, Sulzer Chemtech cansupply packing, column internalsand trays at short notice.

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