Learn how this tower revamp reduced fouling and saved millions
Severe fouling tripled pressure drop. Sulzer fixed it in 14 days with enhanced internals and proven methodology delivering 74% pressure drop reduction and avoided 30 days of unplanned shutdown.
Learn how this tower revamp reduced fouling and saved millions
Severe fouling tripled pressure drop. Sulzer fixed it in 14 days with enhanced internals and proven methodology delivering 74% pressure drop reduction and avoided 30 days of unplanned shutdown.
Real-world RFCC revamp:
From critical fouling to designed performance.
Why this case study matters for your operations:
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Learn the troubleshooting methodology that identifies root causes fast
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Understand the execution strategy that delivered results in 14 days
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Identify which technologies work for severe fouling conditions
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Get quantifiable results that you can benchmark against your own operations
Why download this case study?
Proven methodology, quantifiable results, actionable strategies: Do not waste time on theoretical solutions. This case study delivers real data, proven technologies, and execution strategies that you can apply to your own operations, starting with your next turnaround.
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Prevent unplanned shutdowns before they cost millions
Learn the diagnostic approach that avoids 30 days of unplanned shutdown -
Identify which technologies solve severe fouling conditions
VES™ distributors + Mellagrid™ packing = 74% pressure drop reduction -
Execute tower revamps faster than your planned turnaround
Real project timeline: 14 days versus 17 days planned -
Get ROI data you can take to management
Zero downtime = measurable operational savings
Total Tower Care: Your all-in-one aftermarket solution
When tower performance is critical, you need more than parts. You need a complete partner. Sulzer Total Tower Care delivers everything from emergency repairs to planned revamps, ensuring minimal downtime and maximum reliability across your operations.
Turnaround Service
Fast and coordinated service when you need it most. Complete portfolio of tower hardware from one column internals provider. Pre-shutdown engineering service minimizes risk. Emergency replacements available 24 hours / 7 days.
Revamp & Retrofit
Innovative retrofit and revamp solutions that restore design performance or even increase capacity. Proven cost-effective solutions delivered with local resources. Focus on reliability and energy efficiency to maximize your operational ROI.
Automated Weld Overlay
Fast and cost-effective repair method for tower shells and critical components. Global network of certified weld-overlay experts ensures high quality and rapid turnaround. Guaranteed reliability with industry-leading welding certifications.
Tower Field Service
Leading provider of specialized mechanical services for tower maintenance and installation. Streamlined solutions ensure minimal downtime with efficient, safe execution always on time, every time.
Frequently asked questions
Severe fouling requires a systematic approach. First, diagnose the root cause through process simulation and operational data analysis. Then, revamp the identified fouling-prone conventional internals with fouling-resistant technology like enhanced liquid distributors and anti-fouling grid packing. In our RFCC case study, we reduced pressure drop from 27 mbar to 7 mbar using VES™ distributors and Mellagrid™ packing - delivering continuous operation.
A typical turnaround would take up to 30 days to complete. With proper planning and pre-shutdown engineering, tower revamps can be executed faster than expected. Our RFCC main fractionator revamp was completed in 14 days versus the planned 17 days. The key is the integrated and systematic approach with all-in-one solution provider leveraging expertise in hardware and services.
Extended run length starts addressing the root cause of performance degradation—usually fouling in critical sections. Deploy fouling-resistant internals, optimize liquid distribution, and use proven grid packing designed for fouling conditions. Our clients have avoided 30 days of unplanned shutdown after the revamp.
Start with rigorous process simulation to match actual operating conditions—temperature profiles, pressure drop across sections, and vapor-liquid loadings. Compare measured data against hydraulic calculations to identify where plugging or fouling is occurring. This diagnostic approach reveals whether the issue is in the main fractionator, internals, or specific pump-around sections - allowing targeted solutions instead of guesswork.
Conventional grid packing and gravity distributors can plug quickly in fouling services with catalyst fines or coke particles. Fouling-resistant technology - like VES™ enhanced distributors and Mellagrid AF™ packing - features larger flow passages, superior drainage, and mechanical designs that resist plugging. The result: 74% pressure drop reduction and multi-year operation without unplanned shutdowns, as demonstrated in our RFCC revamp.