Mixing and Reaction TechnologyThe pace making technology, worldwide

Sulzer Chemtech

4588 8004-58

Always a step ahead

Since the early 1970s, Sulzer Chemtech has been involved in co- current flowprocessing for the homogenization and dispersion of gases and liquids, andthe optimization of heat and mass transfer in single-, or multiphase, laminar orturbulent flows.

Today, we combine years of mixing and reaction technology experience withthe latest methods in development, engineering and fabrication to help youmeet your processing challenges of tomorrow.

We endorse

– individual problem solving basedon innovative engineeringachievements

– prompt deliveries that, withstandard solutions, fully meet allyour requirements

– competitive prices in line withmarket expectations

We guarantee

– a presence, orientation andattitude that is truly global

– a readiness to direct our effortstoward filling your needs, quicklyand thoroughly

– interdisciplinary teamwork withwell-trained employees and anentrepreneurial spirit at all level

Innovative solutions foryour special problems

Production in our ownfacilities, worldwide

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

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Static mixing to your advantage

In principle, static mixing denotes mixing without mechanical stirringelements. All movement takes place solely in the components being mixed.

The products are mixed by flow energy alone, with fixed-position mixingelements 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 removaland excellent reliability characterize the static mixer.

Continuous mixing of liquids and gaseswith Sulzer Chemtech static mixers

Mixing of two epoxy resinsin the Sulzer SMX mixer

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Reacting

Reacting within a narrow residencetime distribution for continuousprocesses

Heat exchangers

Heat exchanging for controlled reac-tions or gentle tempering of viscousmedia

Mixing and reaction technology for your plants

Mixing and reaction technology is used in continuous processes throughoutthe processing industries. Sulzer Chemtech is a technology leader with inno-vative ideas and products that continually set new standards. We offer you awhole series of technical and commercial advantages.

What, in real terms, can that mean for your plants?

Mixing

Blending of miscible components re-gardless of the volume, density,viscosity and properties of the media

Contacting

The contacting of liquids with gasesto create high mass transfer surfacearea and high rates of absorption,reaction, vaporization and conden-sation

Empty tube

Sulzer mixer

Dispersing

Dispersing, emulsifying or coalescingtwo or more products for scrubbingprocesses, reactions, mass transfer

Sulzer mixer

Plug flow

Emptytube

Conditioning

Conditioning of process flows up-stream of reactors and heat ex-changers for increased efficiency

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Product line

Static mixers play an important role in the processing industries. Over theyears, Sulzer Chemtech has incrementally optimized the different mixingtechnologies and has taken a careful look at the specific requirements ofeach. Today, we can offer solutions customized for your specific mixing andreaction task.

The Sulzer Chemtech mixer product line is extensive:

Sulzer SMI mixer

For blending low-viscosity fluids witha low energy input

Sulzer SMF mixer

For gentle mixing and dispersingliquids with solid particles insuspension

Sulzer SMX mixer

For mixing and dispersing of viscousliquids, for conditioning temperature-sensitive fluids, and as a tubularreactor with short residence timedistribution

Sulzer SMXL mixer

For increasing heat transfer rates inheat-exchanger tubes for heatingtemperature-sensitive, viscous media

Sulzer SMV mixer

For dispersing low-viscosity, immis-cible liquids and contacting gaseswith liquids in reaction and contactequipment at short residence timedistribution and high selectivity

Sulzer SMR mixer

For controlling exothermic or endo-thermic reactions with liquid mediaover a narrow residence time distri-bution with high selectivity and turn-over, or for cooling and heatingtemperature-sensitive viscous media

Sulzer Quadro® mixer

For mixing and dispersing adhesive and sealant compounds as adisposable mixer with small volumes and a low pressure drop

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Chemicals industry

Sulzer Chemtech mixers are used for continuous mixing of both high and lowviscosity liquid chemicals having a wide range of concentrations. Corrosive-resistant mixers are available when required for corrosive applications.

By using Sulzer Chemtech mixers, you have their operational reliability andour wide experience in configuration and design working for you. Consistentproduct quality and low energy costs are exceptional benefits.

Applications

• Diluting of strong acids andbases

• Adding additives and inhibitorsto process streams

• Mixing of different liquidstreams to attain uniformity ofconcentration and temperaturefor process measurements

• Dispersing alkali in hydrocarbons

Evaporation of liquids

The spray-mix evaporator is used to completely evaporate liquids in super-heated gas streams and to normalize the concentration and temperature of theresulting gas stream. By using a spray-mixing vaporizer, you achieve greaterreaction yields and higher selectivity.

Application

• Manufacture of nitric acid andsulfuric acid

Mixer from special materialsfor corrosive service

Spray-mix evaporator for completeevaporation of liquid additives insuperheated gases

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Chemicals industry

To attain high selectivity and a high yield in catalytic gas phase reactions,uniform concentration and temperature distributions plus a flat velocity profileat the reactor inlet are essential. Sulzer Chemtech mixers are used upstream ofreactors to attain continuous mixing of additives and conditioning of the inletgases. 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 mixingand conditioning of process gases

Two-phase reactors

As a continuous tubular reactor for two-phase reactions, the Sulzer SMV mixerproduces a high yield and high selectivity at low energy input and minimumvolumes. These typical characteristics are essential for economical and eco-logical processes.

Sulzer SMV mixer in a liquid phase, bubble bedreactor achieves high mass transfer rates withinnarrow residence times distribution

Applications

• Oxidation of organic productsas a cascade bubble column,under high temperature andpressure

• Chlorination of organics in aloop reactor

• Hydration of aromatics, forexample as a loop reactor

• Absorption of gases, and rapidreactions in straight-throughreactors

• Phosgenation of aromatics

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Hydrocarbon Processing Industries

By using Sulzer mixers, recognized corrosion problems in oil refineries andgas plants can be significantly reduced. Whether on offshore platforms, fortransporting oil, the measurement of the water content of crude oil, for thedesalination plant, in a distillation unit or for alkylation or catalytic processes- Sulzer Chemtech has the solution. Our static mixers not only reduceoperating costs, but also increase plant on-stream time. As a result, they are asure demonstration that Sulzer Chemtech mixing and reaction technologiespayoff, whatever the application.

The DN 350 PN 400 Sulzer mixerfor temperature homogenizationupstream of a hydration reactor

Applications

• Desalting of crude oil

• Gas scrubbers for neutralizationor desalination

• Sulfur removal scrubbingprocesses

• Blending of gasoline, diesel,lubricants, and other refineryproduct

The Sulzer SMV mixerfor the neutralizationof alkylate products

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Fiber production

Mixing

For the manufacture of high-qualityfilaments, a homogenous melt ordope is essential. Using static mixersin your plants prevents the degra-dation of your melts and greatlyreduces the separation of suspensi-ons. Your filaments will be constantquality and have a minimum numberof broken fibers.

Heating/cooling

The tempering of spinning massesplaces high demands on heatexchangers. Despite its low volume,a SMR heat exchanger can gentlyheat and cool temperature sensitivespinning masses.

Polymerization

Due to the narrow residence timedistribution in a SMX tubular reactor,a spinning polymer is produced witha narrow molecular weight distribu-tion and low volume of by-products.

The Sulzer SMR heat exchanger forgentle tempering of spinning masseswithin a narrow residence timedistribution

Direct spinning plant withSulzer SMR heat exchangerand Sulzer SMX mixers for

excellent filament quality

Application

• In-line homogenization formelts, polymer solutions andsuspension

• Mixing of various additivesupstream of the spinning heads,and thus minimum changeovertimes

• Cooling of polyester melts indirect spinning plants foroptimum processingtemperatures

• Gentle heat-up of spinning solu-tions prior to flash degassing

• Continuous polymerization inthe tubular reactor within anarrow residence timedistribution

Reactor

SMR heat exchanger

Additive

SMX mixer

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Extruding and injection molding

Perfect homogenization of the melt is one of the most important prerequisitefor achieving high and uniform quality in the manufacture of plastic products.Defects in cast components such as color streaks, stains, irregular wallthickness or distortion are usually the result of insufficiently plasticized melts.

By installing a Sulzer injection blender in your injection-molding machine or aSulzer melt blender in your extruder, you obtain constant - and thus perfect -melt homogeneity.

The benefits for injectionmolding technology

– Improved product quality whenprocessing regenerates

– Less wastage:Much greater balancethroughout the process

– Extended applications:In the case of difficult polymers,perfect products can also bemanufactured using universalscrews

– Reduction in color costs:A comparable degree ofcoverage can be attained witha clear reduction of master-batches (30% and more)

Sulzer SIB injection blender for aconstantly high product quality ininjection molding technology

The benefits for theextrusion process

– Optimal inlet flow to the moldingtool through the compensationof velocity differences causedby temperature and flow condi-tions in the flow-channel crosssection

– Uniform wall thickness in thecase of hollow bodies, anduniform cell structure in the caseof foamed products

– Improved color density evenwith lower color concentrationin the melt

Sulzer SMB-R melt blender for anoptimized extrusion process

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Adhesives, resins, sealants

Sulzer Chemtech has a range of practical products designed for mixingadhesives, resins and sealants:

Sulzer polyol mixer

Sulzer Chemtech polyol mixersguarantee excellent foam structureswith hard- and soft-polyurethanefoams. They have been speciallydesigned for loading PUR formula-tions with physical raising agentssuch as pentanes or CO2, but canalso be used to mix in additives andcatalysts.

Sulzer SMX mixer

The SMX mixer is particularlysuitable for the perfect mixing ofresins, additives, colors and catalysts.It is used in production and dosingplants for resins and sealants, anddue to its perfect mixing performanceis effective also in applications in-volving masses with very difficultmixing characteristics.

Sulzer Quadro®

The Sulzer Quadro disposable mixersets new standards for mixing reac-tive resins. It is made of plastic and ismainly used in dosing plants or fortwo-component resin applications.The unique mixing geometry of theSulzer Quadro makes it the dis-posable mixer with the lowest wastevolumes, the shortest overall lengthand the lowest pressure drop.

Applications

• Mixing of two-componentcartridge resins

• Mixing of reactive resins whenprocessing or dosing

• Mixing of additives and colorsinto resins

• Direct coloring of silicones

Sulzer SMX mixer for reactive resins

• Mixing of reactive resins in theglass sealing industry

• Mixing of LSR silicones

• Mixing in physical blowingagents for the manufacture ofpolyurethane foam

• Cooling of resins prior to filling

A selection from theSulzer Quadroproduct range

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Food processing industry

The Sulzer mixer fulfils important tasks in the food processing industry. It isparticularly suited to mixing additives, such as flavorings, minerals, traceelements, vitamins, emulsifiers and preservatives. Other applications arefound in pasteurization, sterilization and the tempering of sensitive products.

Sulzer Chemtech has the rightsolution for your mixing and heatexchanging process. Our mixer lineis extensive and covers the entireapplication spectrum. They can allbe customized to your specific needs

Applications

• Mixing of flavoring into fruitjuices

• Desliming of vegetable oilswith phosphoric acid

• Carbonation of water

• Mixing of fruit pieces withyogurt

• Homogenization of sweetmasses

• Mixing of flavoring intochocolate

• Mixing of citric and malicacids into sugar solutions

• Cooling and heating ofchocolates, crèmes,confectionary and otherpaste-like masses

The Sulzer SMR heat exchanger forgentle heating and cooling of sensitiveproducts

The Sulzer SMX mixer for high-viscositymedia

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Energy, water and wastewater industry

Sulzer mixers have enormous potential in energy, water and wastewatertechnology, and their use widespread. Because the processes of thesetechnologies are continuous, often small amounts of reactive agents must beadded to high volume flows and distributed uniformly within a short distanceover the entire channel cross section.

In other cases, it is necessary to uniformly distribute the concentration andtemperature of a process feed upstream of a catalyst or to dissolve gases intoliquids and to generate fine, uniform bubbles in insoluble liquids. Sulzer hasjust the right mixing technology and products for these growing processingtechnologies.

Applications

• Injecting ammonia into flue gasat the inlet of the SCR unit forNOx removal

• Mixing of flocculants into slurry

• Mixing of acids into liquids forneutralization

• Ozonization, de-acidificationand oxygen enrichment ofwater

• Mineralization of drinkingwater

• Dispersing of water into fuels,upstream of the burner

Sulzer SMI mixer for water/wastewatertechnology and optimum dosing ofadditives

Sulzer SMV mixer for conditioning offlue gas at minimum space and energyrequirement

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Polymerization plants

Sulzer Chemtech’s broad spectrum of engineering expertise in widely diffe-rent processing fields puts it in a position to plan and build plants that willmeet your requirements precisely. The polymerization industry is only oneexample. From the development of state-of-the-art equipment for the productionof plastics through the design of advanced process systems for theoptimization of product quality to a fully documented plant, Sulzer Chemtechis your competent partner.

Polymerization section from SulzerChemtech on a polystyrene plant

Applications

• Loop reactor for exothermicreactions

• Plug-flow reactors

• Removal of volatile componentsfrom polymer melts

• Mixing of additives

Plants for mixing additivesinto a SAN melt

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Development and application technology

Sulzer Chemtech has its own laboratories institute where the use of staticmixers and mixer reactors in various processes are studied and tested. SulzerChemtech has a high level of know-how and years of experience in thecomputational fluid dynamics (CFD) modeling of mixing processes.

We apply our expertise, know-how, and analytical skills to creating individualsolutions, specially customized for your particular processing situation:

Development of componentsand processes

– Application trials, conducted inour own laboratory facilities orwith the customer, for upgradingand ascertaining guarantees

– CFD-supported process andproduct optimization

– Feasibility studies and basicengineering

CFD simulation of a Sulzer mixer

Applications

• Pilot plants for poly-merization processes

• Pilot plants for the degassing ofpolymers

• Investigation of the flowbehavior of plastics in injectionmolding equipment

• Inspection of mixerconfiguration in the case ofdifficult-to-mix components

• Flow optimization of DeNOxplants, including model testingand CFD

• Optimization of mixing ofeducts upstream of reactors,with CFD

Optimization of flow in a DeNOx plant on the model(scale 1:25)

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Sulzer Chemtech LtdP.O. Box 65CH-8404 Winterthur, SwitzerlandPhone +41 (52) 262 67 20Fax +41 (52) 262 00 69E-mail chemtech@sulzer.comInternet www.sulzerchemtech.com

Sulzer Chemtech USA, Inc.4106 New West DriveUSA-Pasadena, TX 77507Phone +1 (281) 604 4100Fax +1 (281) 291 0207

Sulzer Chemtech Pte. Ltd.11 Tuas Avenue 18SGP-63 88 95 SingaporePhone +65 6863 75 60Fax +65 6861 15 16

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, withheadquarters in Winterthur, Switzerland, is active in the field of processengineering and employs some 1200 persons worldwide.

Sulzer Chemtech is represented in all important industrial countries andsets standards in the field of mass transfer with its advanced andeconomical 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 asoptimizing energy consumption, plant optimization studies, pre-engineering for governmental approval, basic engineering

• Processes and plants for the separation and purification ofchemicals by means of fractional crystallization and pervaporation

• Mixing and reaction technology with static mixer