Sulzer · Total Tower Care

Up to $1.9M* in avoidable costs. Every catalyst cycle.

A leading Ethylene Oxide/Ethylene Glycol (EO/EG) facility upgraded its CO₂ absorber with Sulzer's advanced column internals, extending catalyst life and reducing operating costs significantly.

 
CO₂ reduced by 0.2 to 0.3 mol% in reactor inlet
 
Estimated savings of $1.6 to $1.9M per catalyst cycle
 
Completed in 15 to 18 days, single contractor
*Actual savings vary depending on operating conditions.
Download the case study

Ethylene Oxide wash tower upgrade: process assessment, column internals modifications, and quantified results.

  Document language: English
 
  Your information is secure and will not be shared.
0.3 mol%
CO₂ reduction in reactor inlet gas*
~0.1 mol%
H₂O reduction in reactor inlet gas
$1.9M
Estimated savings per catalyst cycle*
18 days
Project turnaround, single contractor
The hidden cost of suboptimal CO₂ removal

Recognise these challenges in your Ethylene Oxide plant?

When CO₂ absorber internals underperform, the impact reaches far beyond the column. Elevated CO₂ and H₂O in the reactor inlet compound costs with every catalyst cycle.

 
Declining catalyst selectivity
Excess CO₂ and H₂O in the reactor feed reduce reaction selectivity, increasing side reactions and driving up ethylene consumption per ton of EO produced.
 
Accelerated catalyst deactivation
Lower catalyst activity forces higher reactor temperatures, which accelerates deactivation further, creating a compounding cycle of declining performance.
 
Shorter catalyst life, more turnarounds
Each cycle runs shorter than the last, increasing turnaround frequency and the cost of catalyst replacement. The economics deteriorate progressively.
 
Uncertain root cause
Without a structured process assessment, teams often focus on the catalyst itself rather than the upstream column performance that determines reactor inlet gas quality.
Case study
 Ethylene OxideEthylene Glycol (EOEG) Case study
Inside the case study: how one  Ethylene Oxide/Ethylene Glycol facility saved up to $1.9M per catalyst cycle
 
Process assessment identifying elevated CO₂ and H₂O as root causes of catalyst degradation
 
Column internals upgrade: structured packing, MellaTech™ liquid distributor, KnitMesh™ V Mister™ and Mellachevron™ mist eliminators
 
Quantified before and after performance data for CO₂, H₂O, and catalyst economics
 
Project execution: 15 to 18 day turnaround with Sulzer's one-stop service approach

*Actual savings vary depending on operating conditions.

Total Tower Care

Four specialized services.
One goal: maximum uptime.

This EO/EG upgrade is one example of what Sulzer's Total Tower Care delivers. From emergency response to planned revamps, a single partner covers the full lifecycle of your separation columns.

Turnaround Service
Turnaround service

Fast, systematic response when it matters most. Pre-shutdown engineering minimizes risk, and a complete portfolio of tower hardware is available from one source. Emergency replacements 24 hours, 7 days a week.

Revamp & Retrofit
Revamp and retrofit

Innovative solutions to restore original performance or increase capacity. Proven, cost-effective methods with local resources to improve energy efficiency and maximize operating revenue.

Automated Weld Overlay
Automated weld overlay

Fast, cost-effective repair of tower shells and critical components. A global network of certified experts ensures high quality and rapid execution, backed by industry-leading welding certifications.

Tower Field Service
Tower field service

Specialized mechanical services for tower maintenance and installation. Efficient, safe processes that minimize downtime and deliver on schedule, every time.

Questions? Contact us at totaltowercare@sulzer.com