Sulzer is committed to accelerating circular economies while supporting energy security and the energy transition. We enable new ecological markets such as biofuels and renewable energy, bio-based chemicals and polymers, as well as recycling and carbon capture.
Transitioning from fossil fuels to renewable and low-carbon energy sources is a complex and costly process that demands extensive research and coordination. There are many challenges to overcome, including social and environmental impacts, and they will take time to resolve. In the meantime, the traditional industries that contribute to growth, employment and society require support in reducing their environmental impact and improving their energy efficiency.
Repairs and retrofits
Retrofits are beneficial to circularity almost by definition. Designed to extend the life of infrastructure and equipment, they directly serve to minimize waste, typically improve operational performance and can result in a lower emissions footprint than building new.1 In Africa, for example, we are working with water utility companies to ensure a continuous water supply as we deliver and oversea the complex refurbishment of eleven pump sets within their network.
Repairs and retrofits have a key role to play in bridging the gap to net-zero targets and circularity. Heavy industry is vital to social progress, yet reportedly consumes some 40% of the total global energy demand,2 mostly from fossil fuels. Moreover, these processes contribute more than 20% of global greenhouse gas emissions.3 As industrial plants and assets tend to have long lifespans, Sulzer’s expertise can help accelerate the transition.
As an expert in power generation applications, Sulzer is well-positioned to support industry with retrofits that reduce emissions and long-term costs. In 2023, for example, Sulzer developed and implemented a modular retrofit solution for a gas turbine powerplant in Jiangsu Province, China, that reduced nitrogen oxide (NOx) emissions by 120 tonnes per year and operating expenses by CHF 400’000 per year.
The retrofit implemented a combustion automatic tuning adjustment system (CATS) that optimized combustion stability in the gas turbine. The advanced circular solution also improved power generation while further saving the plant a large capital expenditure and long upgrade lead times.
Reducing waste and improving efficiencies
With a focus on enabling more clean and renewable energy, retrofit solutions can offer significant ongoing value in terms of efficiency gains, longevity and reduced emissions. Repairs and maintenance also add value by keeping critical services up and running for society. For example, Sulzer recently delivered a turbine repair to a hydropower plant in West Java that restored renewable energy to the community seven months earlier than expected.
Given the urgent need to reinstate the power service, Sulzer’s local experts in Java drew on the company’s global network of expertise to develop and implement the innovative repair solution that restored the power service quickly and cost-effectively. They saved time and money by sourcing the parts locally and customizing them to measure using laser scans and reverse engineering techniques. The repair resulted in total cost savings of CHF 2.15 million for the customer and invaluable benefits for the community.
State-of-the-art digital solutions enable recovery and reverse engineering of components to significantly reduce lead times, ultimately reducing customer downtime and costs. Sulzer’s additive manufacturing capabilities enable reproduction of parts and components that otherwise may be unavailable ¾ faster and more sustainably.
Sulzer is committed to serving the needs of the industry and continues to invest in its global presence and infrastructure to be close to its customers. In 2023, Sulzer expanded operations in Germany, the USA and Singapore.
Getting ready for the future
Closer to Switzerland, Sulzer has partnered with Crosstown H2R Ltd, another Swiss-based technology firm, to develop the next generation of hydrogen combustion systems for global energy challenges. By integrating an advanced micromixer into the existing combustion system, this technology represents a quantum leap from conventional burner types. The scheduled upgrade involves replacing the existing burner and preparing the entire combustion system to accommodate the new component, thus making it capable of using 100% hydrogen. The technology will play a key role in eliminating CO2 emissions from existing gas turbines across Europe to ensure they can continue operating reliably for decades to come.
Repurposing salt sugar wood and wasteFebruary 21, 2024Sulzer is collaborating with industry, governments and educational institutes around the world to leverage its technologies and help repurpose resources for a more sustainable future. Our solutions are ensuring material inputs are being maximized to their fullest extent, contributing to the preservation of scarce resources, energy efficiency, diversion of waste from landfills and heaps of other benefits.
Recycling waste and recapturing valueFebruary 21, 2024As the basis of life on earth, carbon is present in most materials. Thus, when industrial and consumer goods are no longer of use and mechanical recycling options have been exhausted, chemistry becomes the hidden force that serves to reduce ecological impacts.
