Sulzer Technical Review 3/2019

Anniversary edition

100 years of engineering insights

Serving our customers: Innovative pumps Customer-oriented Chemical process 100 years of knowledge for 185 years — and reliable — technology for the transfer Sulzer pumps Sulzer services industry since 1946 2 Imprint Sulzer Technical Review 3/2019

About Sulzer Sulzer is a global leader in fluid engineering. We specialize in pumping, agitation, mixing, separation and application technologies for fluids of all types. Our customers benefit from our commit- ment to innovation, performance and quality and from our responsive network of 50 world-class manufacturing facilities and 100 service centers across the globe. Sulzer has been headquartered in Winterthur, Switzerland, since 1834. In 2018, our 15’500 employees delivered revenues of CHF 3.4 billion. Our shares are traded on the SIX Swiss Exchange (SIX: SUN).

Pumps Equipment The Pumps Equipment division specializes in pumping solutions specifically engineered for the processes of our customers. We provide pumps, agitators, compressors, grinders and screens developed through intensive research and development in fluid dynamics and advanced materials. We are a market leader in pumping solutions for water, oil and gas, power, chemicals and most industrial segments.

Rotating Equipment Services Through a network of over 100 service sites around the world, Sulzer provides cutting-edge parts as well as maintenance and repair solutions for pumps, turbines, compressors, motors and generators. We service our own original equipment, but also all associated third-party rotating equipment run by our customers, maximizing its sustainability and life cycle cost-effectiveness. Our technology-based solutions, fast execution and expertise in complex maintenance projects are available at our customers’ doorstep.

Chemtech The Chemtech division is the global market leader in innovative mass transfer, static mixing and polymer solutions for petrochemicals, refining, LNG, biopolymers and biofuels. Our product offering ranges from process components to complete separation process plants, including licensing. Customer support covers engineering services and field services to tray and packing installation, tower maintenance, welding and plant turnaround projects.

Applicator Systems Through its Mixpac, Transcodent, Geka and Cox brands, Sulzer develops and delivers innovative fluid applicators for the dental, adhesives, healthcare and beauty markets. Our IP-protected applicator solutions leverage our expertise in plastic-injection molding, micro-brushes and two-component mixing to make our customers’ products precise, safe, unique and more sustainable.

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Publisher Imprint Sulzer Management Ltd © Sulzer Ltd 2019 – All rights reserved, reprints of articles and illustrations are permitted subject to the prior approval of the editor. P.O. Box The Sulzer Technical Review has been compiled according to the best knowledge and belief of Sulzer Management Ltd and the authors. 8401 Winterthur, Switzerland Sources: Anna Bálint, Sulzer im Wandel, ISBN: 978-3-03919-319-6. Sulzer Technical Review editions from 1919–2019. Archive documents of Sulzer. [email protected] Editor-in-Chief: Nadia Qaud; Editorial Assistant: Tanja Bosshart www.sulzer.com/stories Design: Pavla Balcarová, pb studio, CZ-Jaromer Translations: think global Milengo GmbH, Berlin, Germany; Thore Speck, Flensburg, Germany Publication 3/2019 Editing: Olivia Raths, Wetzikon, Switzerland; Bouqui Stautmeister, Winterthur, Switzerland 101st year of the STR ISSN 1660-9042 Photos Cover: Sulzer Photos: Pages 7, 12, 33, 34, 35: Fotolia. Page 36: Luftbilderschweiz.ch. All other pictures: Sulzer. 3 Contents Sulzer Technical Review 3/2019

100 years of engineering insights

In 1919, Sulzer published its first customer magazine. Since that first edition, the Sulzer Technical Review (STR) has been published without interruption several times a year. For a century, the STR has reported on our products, developments and technical insights, providing an important source of information for our customers and business partners. Sulzer has always been an incredible incubator, developing and then spinning off businesses built on its unrivalled engineering prowess. This 100-year anniversary edition contains compelling overviews of the company's history from all four of our current businesses, including our very first — the pumps business which we founded in 1834. After a century of publication in magazine form, the STR will do what Sulzer has always done: reinvent itself without nostalgia to continue to lead the way. The stories and the insights will remain, but the format will change. In a world where our customers and partners are in constant contact with us, we will use the many digital channels of Sulzer to bring the gospel to them faster and better. As we move from the heavy production cycle of a magazine to agile digital formats, we will continue to inform whenever new articles are published. We look forward to the next century of increasingly interactive STR articles with you, our loyal readers. Gregoire Poux-Guillaume, CEO, Sulzer Management AG, Winterthur, Switzerland

4 Serving our customers: 100 years of knowledge transfer

Knowledge transfer today and in the future

10 Innovative pumps 16 Customer-oriented and for 185 years reliable — Sulzer services

History of the development From the first retrofit set of centrifugal pumps to worldwide service

21 Chemical process tech- 27 Precise application since nology for the industry 1956 since 1946 How application systems Milestones in separation became a part of Sulzer and mixing 4 Serving our customers: 100 years of knowledge transfer Sulzer Technical Review 3/2019

Serving our customers: 100 years of knowledge transfer

How does a company like Sulzer succeed in asserting itself on the market for over 185 years, continuously creating innovative products? What influence does the transfer of knowledge have? What will the knowledge transfer of the future look like?

In 1919 — 85 years after the company was founded — Sulzer’s first customer magazine was published in French. Since then, the Sulzer Technical Review has provided technical information on Sulzer’s current product range without interruption. The magazine’s 100th anniversary gives us a glimpse into the history of Sulzer as well as the future of knowledge transfer.

Networks for knowledge transfer in pre-industrial times Professional networks are not an invention of our contemporary age. In earlier centuries in Johann Jakob Sulzer (1806–1883) Europe, craftsmen acquired knowledge within the family business, then moved on foot from shop to shop to learn additional skills. Before the Sulzer brothers (Fig. 1) established their new foundry (Fig. 2) in Winterthur in 1834, they collected technical and craft expertise in Switzer- land, France and the Kingdom of Bavaria through apprenticeships. Johann Jakob Sulzer’s journey led him from Bern and Lyon to Paris between 1827 and 1830. Salomon Sulzer apprenticed in Munich, Ulm and Guebwiller in Alsace.

Salomon Sulzer (1809–1869)

Fig. 1 The two founders of the Sulzer company.

Fig. 2 The building where the Sulzer company Fig. 3 The Sulzer site in Winterthur in 1931. was born in 1834. 5 Serving our customers: 100 years of knowledge transfer Sulzer Technical Review 3/2019

Pioneering achievements thanks to a fascination with technology As early as 1839, the Sulzer brothers used a steam engine instead of horsepower to drive the foundry’s bellows. The Sulzer company was intensively involved with steam because of its founders’ enthusiasm for new technology. This was not only used as a working medium for power transmission in the foundry; energy transmission by steam also led to the development of new, innovative products. Sulzer was a Swiss pioneer in boiler construction and heating technology. The company built the first large, steam-powered central heating system in 1841 (Figs. 4 and 5).

Fig. 4 Sulzer built Switzerland’s first heating boiler in 1841. Fig. 5 Heating pipes in Winterthur boys’ school.

Success thanks to recruiting the best talent The Sulzer brothers recognized early on how important the skills and knowledge of their employees were for new developments and improvements within the company. In the early nineteenth century, England was a pioneer in the fields of steam engines, tool construction and mechanical engineering. During a trip to England, Johann Jakob Sulzer met the young engineer Charles Brown (Fig. 6) and recruited him, along with his knowledge, for steam engine construction in Switzerland.

At Sulzer, Brown enjoyed a great deal of freedom and was able to creatively translate his in-depth knowledge and wealth of ideas into numerous new designs, improvements in operations and new products. Sulzer built its first steam engine with 2.2 kW (3 hp) in 1854. Brown’s persistence and perfectionism led to the centrifugal valve control and thus to an increase in performance and safe operation of the steam engine. The Sulzer valve steam engine (Fig. 7) already had 121 kW (165 hp) in 1865 and was awarded first prize at the 1867 World Exhibition in Paris. Sulzer thus gained worldwide renown and even granted manufacturing licenses to partner companies to manufacture the steam engines around the globe. 6 Serving our customers: 100 years of knowledge transfer Sulzer Technical Review 3/2019

Fig. 6 Charles Brown (1827–1905) worked for Fig. 7 The award-winning Sulzer valve steam engine from 1867, developed Sulzer from 1851 to 1871. by Charles Brown.

In 1878, a young, talented student completed an internship at Sulzer and got a taste of industrial work. His name is world-famous today: Rudolf Diesel (Fig. 8). After applying for his patent for the diesel combustion engine in 1893, he offered it to Sulzer for use. Sulzer thus established an extremely successful mainstay and produced diesel engines from 1898 until 1997. Fig. 9 shows the assembly hall for diesel engines in 1909.

Discovering new talent and using the energy as a driving force is a skill that is still held in high regard in the Sulzer Corporation today. Close connections and cooperation with leading universities worldwide not only open up access for Sulzer to the latest knowledge, but also to the talent pool of bright minds in the fields of science and technology.

Fig. 8 Rudolf Diesel (1858–1913) completed an Fig. 9 Diesel engines in the assembly hall at Sulzer in 1909. internship at Sulzer in 1879. 7 Serving our customers: 100 years of knowledge transfer Sulzer Technical Review 3/2019

Energy supply as a driver of innovation Sulzer established itself in the energy supply sector long ago with its valve steam engine and steam heaters. A look at the technological history of the last 200 years shows how rapidly energy technologies have changed. Numerous groundbreaking product developments and patents in this field originate from Sulzer. From the very beginning, Sulzer has distinguished itself by rapidly implementing the latest scientific findings and offering reliable, tested and safe processes.

From the water mill to solar energy At the beginning of the industrial revolution, grain mills, sawmills and forges were mainly driven directly by water wheels, partly also by windmills, and later by steam engines (optimized by J. Watt in 1765). Generators (1866) powered by steam engines or hydroelectric power supplied electricity for the first electric motors in the factories. This was followed by thermal power stations, in which fossil fuels such as coal, oil or gas generated steam, which in turn was used to drive steam turbines and generators. After the expansion of the power grids and electrifica- tion (around 1880), the electric motor finally established itself as a universal driver for stationary applications. With the invention of the combustion engine (1807 – F. I. de Rivaz) and the diesel engine (1893 – R. Diesel), power generation became economical even in smaller units, and automobiles conquered the roads of the world. The civil use of nuclear energy through nuclear fission (1938 – O. Hahn/F. Strassmann) led to the construction of nuclear power plants. Today, renewable energies have come to the forefront — energy from biomass, geothermal energy, ocean energy from the tides, wind energy and solar energy.

Sulzer was involved in all of these advances: steam engines, turbines, generators and pumps for storage power plants, as well as heavy water distillation technology for nuclear power plants. Sulzer is considered a pioneer due to the speed with which the company has translated technical innovations into technically mature, reliable product developments. Electric motors were used in Sulzer pumps as early as 1894, four years after the introduction of high-voltage electrical networks. Only five years passed between the licensing and market launch of the first 14 kW (20 hp) diesel engine in 1898. Diesel ship engines were introduced in 1904, and the first diesel locomotive in 1912 already had 882 kW (1’200 hp). Sulzer’s high-performance pumps were essential for equipping the first hydroelectric reservoir power plants. As early as 1904, a 590 kW pump was used for this purpose.

Fig. 10 Change in energy supply — from thermal power and nuclear power to renewable wind and solar power. 8 Serving our customers: 100 years of knowledge transfer Sulzer Technical Review 3/2019

Today, Sulzer is involved in the development of technology for renewable energies, be it separation technology for renewable energies with microbes or molten salt pumps used in concentrated solar power plants.

The following listing shows how the focus of Sulzer’s main activities changed during the course of the company’s history: foundry 1834–1993, pumps 1834–today, services 1834–today, heating and air-conditioning 1841–2001, thermal power systems 1841–1997, steam engines 1854–1952, vessel manufacturing 1867–1934, rock drilling and tunneling 1876–1905, refrigeration systems 1877–2001, piston compressors 1878–2002, diesel engines 1898–1989, water turbines 1911–1999, locomotives 1912–1998, production of thermal turbomachinery from 1939–2001, waste combustion plants 1941–1994, jet engines 1945–1999, textile machinery 1952–2002, chemical process engineering 1956–today, applicator systems 1958–today, medical technology 1962–2001, electronics 1963–1999, paper machinery 1966–2006, surface technology 1985–2013, fuel cells 1997–2005.

Sulzer Technical Review – 100 years of knowledge transfer The first customer magazine was published in 1919 to make it easier for Sulzer’s customers to understand complex technical interrelationships. The magazine promoted Sulzer’s technical achievements, patents and development progress, as well as making it known to the public. Since then, Sulzer’s Technical Review has been a source of knowledge for people with a wide range of technical interests (Fig. 11).

New times – new paths The transfer of knowledge has changed with the advent of the Internet. Transfer takes place on numerous channels with varying depths of information and uses media such as videos, anima- tions and webinars to attract readers’ attention. Who still takes the time to read extensive issues of a customer magazine? With this in mind, and now that 100 years have passed, Sulzer is breaking new ground in knowledge transfer.

Fig. 11 The Sulzer Technical Review over the years. 9 Serving our customers: 100 years of knowledge transfer Sulzer Technical Review 3/2019

Fig. 12 The future — “Sulzer Stories”.

Knowledge transfer with “Sulzer Stories” Sulzer remains loyal to the technical transfer of knowledge and the broadening of horizons, but in the future distribution will take place in smaller, more frequent portions. Individual articles will be published on the website in the www.sulzer.com/stories section and through our various social media platforms. Those who subscribe to our STR newsletter will automatically receive these technical tidbits. Those who love to do things themselves can use the search functions on the site to find what they need. And if you want to immerse yourself in figures and technical details, you can continue to enjoy the Sulzer White Paper.

The “Sulzer Stories” are committed to the tradition of knowledge transfer. In the future, we will offer our readers stories and knowledge about new materials, production processes, data Nadia Qaud, technology, product innovations, and process innovations that benefit our customers. Register Winterthur, Switzerland now to start benefiting: www.sulzer.com/str-newsletter. 10 Innovative pumps for 185 years Sulzer Technical Review 3/2019

Innovative pumps for 185 years

Did you know that Sulzer manufactured its first water pump in 1834? Instead of supplying a simple fire hose as ordered by the customer, the newly founded Sulzer Brothers company developed a complete fire extinguisher including hose and pump. Thinking ahead and setting innovative standards – this has been Sulzer’s motto for 185 years.

The first fire extinguishers delivered by Sulzer in 1834 were hand-operated (Fig. 1). In 1923, Sulzer supplied fire pumps for motorized fire engines (Fig. 2). Since the company was founded, the range of applications for its centrifugal pumps has been extended from irrigation and drainage to drinking water. Subsequently, pumps were developed to support energy generation in power plants. Storage and hydroelectric power stations were the initial customers for these large pumps. Due to their reliability and high efficiency, centrifugal pumps are used in fossil and nuclear power plants as well as in gas and steam power plants.

Fig. 1 Hand-operated fire piston (reconstruction). Fig. 2 Sulzer fire extinguisher pump in a fire brigade automobile from Saurer. 11 Innovative pumps for 185 years Sulzer Technical Review 3/2019

Applications of Sulzer pumps Sulzer pumps — whether they are pipeline, injection, multiphase or subsea pumps — are the technology drivers in oil and gas production and the petrochemical industries. With the rise of sustainable power generation processes, Sulzer pumps are also used in solar power plants and for energy recovery. Pumps for large-scale installations are designed, calculated, manufactured and tested specifically for each customer. Sulzer offers pump solutions for drinking water, water and wastewater management, as well as accessories for water treatment. In general industry applications (paper, beverages, food, fertilizer, desalination, etc.), Sulzer’s rugged and Fig. 3 energy-saving pumps meet the highest demands. Centrifugal pump built in 1862. History of pump manufacturing at Sulzer Sulzer has been mass-producing centrifugal pumps since the 1860s (Fig. 3). At first, Sulzer pumps were mostly used as wastewater pumps, in ore processing, and as brine-circulating pumps in refrigeration plants.

Pumps for irrigation and drainage From 1890 onwards, Sulzer manufactured drainage pumps for Egypt (Nile Delta) and for other countries. At the Codigoro pumping station in Northern Italy, for example, the company supplied five axial pumps with vertical shafts that each achieved a flow rate of 28’8003 m per hour and a delivery head of 4–5 meters.

Sulzer’s centrifugal pumps for large-scale irrigation were first used in 1892. At that time, the first major plant, which had a total pumping capacity of 6’500 m3 per hour, was installed in Egypt for the Say refinery (Fig. 4). Spiral housings with cast guiding ribs were already used to handle these quantities of water back in the 19th century. The first pumps had a belt drive, and the subsequently designed large installations featured direct coupling of the pumps to steam engines, diesel engines or electric motors.

The design of sewage pumps with a vertical shaft eliminated suction issues. Sulzer has been optimizing its hydraulics continuously since the last century. Double-curved impeller blades with optimized suction efficiency made it possible to increase the speed of the pumps.

Fig. 4 Centrifugal pumps for irrigation projects in Egypt (1892 to 1906). 12 Innovative pumps for 185 years Sulzer Technical Review 3/2019

High pressure – also thanks to electric drive system The installation of electric motors for power transmission resulted in increased delivery heads. Sulzer first tested this technology when the company installed electric motors in a multistage pump in 1894. There were three impellers connected in series on a vertical shaft; the impellers were separated from one another by spacers. This pump was designed for the world’s first hydraulic power storage system.

The first high-pressure centrifugal pump was introduced in 1896. The municipal waterworks in Geneva (Fig. 5) ordered a large multistage pump directly coupled to a 1’000 hp (735 kW) electric motor that lifted 1’350 m3 of water per hour to a height of 140 meters. The first Jet See video about d’Eau (water fountain) in Lake Geneva was used at that time to release excess pressure from the Jet d'Eau. this system. Later, Sulzer pumps were used to permanently operate this fountain (Fig. 6).

Fig. 5 Centrifugal pump for the drinking water supply of the city Fig. 6 Jet d’Eau – the water fountain in Lake Geneva. of Geneva, Switzerland.

Borehole pumps for wells and mines To do away with the need for well shafts, Sulzer developed borehole pumps in 1910. They became popular very quickly and were also used in mines. The first pump had a 24 m drive shaft. Versions with a 170 m drive shaft and a drive power of 800 hp (590 kW) were in operation as early as 1930. At that time, Sulzer was already building underwater electric pumps that did not have a vertical shaft, but instead featured a design where the motor was integrated directly on the pump.

The high-pressure centrifugal pump tapped into a huge market potential that had previously been completely dominated by piston pumps. The first high-pressure centrifugal pump was ordered in 1898 to dewater the Horcajo lead and silver mine in Spain down to a depth of 390 meters. This system worked with several pumps arranged on top of each other on different levels, while a pumping water column established a force-lock connection among these pumps. These mine pumps were already directly coupled to electric motors (Fig. 7).

Ingenious design provided relief Another major step forward in the design of the multistage pump was the introduction of the balance disk in 1905. Initially, the axial forces were largely balanced using impellers arranged in Fig. 7 pairs. Balance pistons and ball or journal bearings absorbed the residual forces. The advent of Mine dewatering pump with electric motor and operator the balance disk made it possible to arrange only in-line impellers across the entire shaft and (1902). fully neutralize the axial thrust. 13 Innovative pumps for 185 years Sulzer Technical Review 3/2019

Storage pumps for hydropower With the expansion of hydroelectric power plants along rivers, the storage of power gained in importance. High-level tanks were built to increase the efficiency of power plants. For the Hüssy weaving mill in Italy, Sulzer built the world’s first storage pump in 1894. In 1904, Sulzer built the first large storage pump system with an 800 hp (590 kW) high-pressure pump for the Olten-Aarburg power station. Another noteworthy milestone is the installation of giant pumps for the Niederwartha storage facility near Dresden with a unit output of 27’000 hp (19.9 MW) in 1929. The world’s largest — at the time — pumped storage plant was installed in Wales in 1957. It employed four vertical, two-stage double-flow pumps with 69.7 MW of drive power each. Figs. 8 and 9 show how large these high-pressure pumps were.

Full steam ahead As steam power plants got increasingly larger, centrifugal pumps were used to feed boilers from 1912 onwards. These pumps were built to withstand temperatures of up to 200°C (392°F) and operating pressures of over 100 bar. Sulzer designed thermal power plants for the generation of electricity and steam. Fig. 10 shows a model for a power and steam generation plant from 1946 and Fig. 11 shows a realized plant from 1950. In 1975, Sulzer installed the largest boiler feed pump in Europe at that time in the Dutch town of Maasbracht. The largest turbine-driven boiler feed pump (47.5 MW) was delivered to Neurath, Germany, in 2006 (Fig. 12).

Fig. 8 Installation of a hydropower storage Fig. 9 Difficult heavy transport of a storage pump in pump (1951). the Swiss Alps.

Fig. 10 Model of a thermal power Fig. 11 High-pressure steam power station (1950). Fig. 12 World’s largest boiler feed pump station for steam and with turbine drive: installed in electricity (1946). Neurath, Germany, in 2006. 14 Innovative pumps for 185 years Sulzer Technical Review 3/2019

Important pump innovations of Sulzer

World’s first pump World’s largest World’s largest for desalination offshore pump for World’s multiphase pump desalination first storage World’s largest High-pressure Subsea 4.5 MW 5.5 MW Single-stage pump High-pressure injection pump injection multiphase pump centrifugal storage pump 18.8 MW pump 517 bar/1’800 m pump 67.9 MW 605 bar deep

1860 1894 1894 1896 1906 1957 1965 1977 1980 1981 1995 1999 2000 2001 2002 2004 2006 2018 2019

World’s first World’s first First medium- First pump World’s largest High-pressure pump with boiler feed consistency with injection pump injection electric motor pump pump integrated Offshore 27 MW pump degassing multiphase 800 bar World’s first World’s largest pump World’s largest multistage high- injection pump 6.0 MW boiler feed pump pressure pump 15.7 MW 471 bar/200°C

Fig. 13 The pump design history was influenced by Sulzer — the graph shows only a handful of the innovations.

Milestones in the evolution of pumps Injection pumps are used in the oil and gas sector. In 1975, Sulzer installed 13 duplex injection pumps in Algeria for the first time in the company’s history. The two largest injection pumps, each with 15.7 MW, were delivered to Saudi Arabia in 1977, but this record was already broken in 1981, when Sulzer shipped and installed two 18.8 MW pumps to Alaska, US. In 2002, the drive power of the largest injection pumps had already reached 27 MW.

In the Gulf of Mexico, high-pressure injection pumps with a pressure of 605 bar were used for the first time in 2001 secondary oil recovery from the reservoir. In 2011, Sulzer began developing a concept pump with 800 bar for seawater injection. This pump was been tested successfully in 2019 at full size. The two largest offshore multiphase pumps for oil-gas-water mixtures with a drive power of 4.5 MW each were installed in the North Sea in 1999. In 2000, the two largest multiphase pumps with a drive power of 6 MW each were delivered to Russia. A Sulzer multiphase pump (Fig. 14) was installed 1’800 m below sea level in 2018.

Pipelines for oil or water Sulzer is also the leading provider in the pipeline pump market. The first pipeline was put into operation in 1934, and led from Kirkuk in Iraq to the Mediterranean Sea (Fig. 15). In 1985, Sulzer installed 100 pumps for the longest pipeline across Canada and the US. The world’s largest pipeline pumps with a drive power of 14.5 MW were installed in Russia in 2008. In the same year, the longest Canadian crude oil pipeline was fitted with Sulzer pumps.

Fig. 14 Subsea pump in the test bed at Sulzer Fig. 15 Pipeline installation from Kirkuk to Haifa in Leeds, UK, in 2012. and Tripoli (1934). 15 Innovative pumps for 185 years Sulzer Technical Review 3/2019

Main history milestones for Pumps Equipment

Companie de Joint venture with Integration of Ahlström Pumps, FI, Cardo Flow Solutions, Sulzer Saudi Pump Ensival Moret, FR, Construction Weise & Monski, Weise & Monski pulp & paper and SE, water and Company, SA, pumps for industry Mécanique, FR, DE, water and GmbH, industry pumps wastewater solutions pumps production applications pump production industry pumps Bruchsal, DE (founded 1891) (founded 1918) (founded 1868) (founded 1872)

1834 1918 1959 1965 1966 1972 1988 2000 2004 2011 2012 2014 2014 2017 2018

Sulzer Bros. Cooperation with Escher Wyss, CH, Bingham Willamette, Precision Castparts Hidrotecar S. A., Tartek Oy, FI, JWC Environ- foundry, CH, English Electric Co. storage pumps and US, pumps Corporation, US/CN, ES, water and high-quality seals mental LLC, US, fire pumps Ltd., UK, pump pump turbines (founded 1906) pump production desalination (founded 1978) wastewater turbines (founded 1805) (founded 1953) pumps equipment (founded 1918) (founded 1966) (founded 1973)

Fig. 16 The most important historical milestones in expanding the business area of pumps.

The leading pumps for the pulp and paper industry Ahlström in Finland was a leading supplier of pumps for the pulp and paper industry. Through the acquisition of Ahlström Pumps in 2000, Sulzer has become a global leader in innovative and reliable pump, agitator and mixing solutions for the pulp and paper industry. The acquisition of Cardo Flow Solutions in 2011 expanded Sulzer’s complete product portfolio for the pulp and paper industry with ABS submersible pumps and HST turbo compressors, which can also be used in other process industries.

Optimization of development and capture of pump data Less spectacular, but just as important, are projects such as the development of new impellers, the optimization of pump hydraulics, and process optimization options. The use of the most suitable pump material, adapted to the medium to be pumped, has always been an essential aspect of pump design at Sulzer. As early as in the 1920s Sulzer produced acid pumps for the production of nitric acid, for which V2A material (nickel-chromium steel) was used.

Sulzer patented the first clog-free impeller for wastewater pumps in 1996. CFD calculations were used at Sulzer in the late 1980s. A CFD-optimized impeller was patented in 2009, and in 2013 Sulzer launched the first CFD-optimized multichannel impeller.

With the introduction of the first pumps for medium consistency materials in 1980, Sulzer helps to save energy in paper and board production as well as in other industrial processes. Nadia Qaud, Integrated degassing, first introduced to the market in 1995, is a key decision criterion for Winterthur, Switzerland Sulzer pumps in many industrial processes.

Sulzer launched its Industry 4.0 initiative in 2017. BLUE BOX™ is an innovative, cloud-based data analytics platform developed by Sulzer. BLUE BOX is able to analyze data from pump and pipeline equipment of any manufacturer, helping operators optimize their plants, operate them more efficiently, and streamline maintenance.

In order to offer such a broad range of pumps and pump accessories, Sulzer acquired Dr. Philippe Dupont, companies around the world and integrated them into the Sulzer family. The most important Winterthur, Switzerland milestones in the expansion of the business are shown in Fig. 16. 16 Customer-oriented and reliable — Sulzer services Sulzer Technical Review 3/2019

Customer-oriented and reliable — Sulzer services

From the start, Sulzer realized that customer loyalty isn’t just based on customer-oriented thinking and technology-based solutions but also on good service. In 1834, Sulzer delivered a fire extinguisher including a pump to the city of Winterthur. This sale included regular service after each fire. When Sulzer delivered the second extinguisher in 1839, we added an improved piston to be used on the pump delivered in 1834. This was the first retrofit set invented by Sulzer.

When you enter the historic Feldschlösschen brewery, Rheinfelden, CH (title picture), you immediately smell grease in the air. The brewery houses early Sulzer products that are still in operation today, and the smell is a clear sign that the plant is well-maintained and lubricated. Today, service activities are much more complex than lubricating all rotating parts with an oil can, and Sulzer customers rely on our outstanding electromechanical and mechanical support and rapid spare parts deliveries. We publish our most interesting service stories regularly in the Sulzer Technical Review. Today, the Rotating Equipment Services division provides cutting-edge maintenance and repair solutions for turbines, compressors, pumps, motors and generators, also for third-party equipment. The division is dedicated to optimizing life cycle costs of the products. Sulzer is renowned as a service specialist for technology-based solutions, fast execution and expertise in complex maintenance projects. Repair is often a more sustainable choice than replacing a whole turbine or compressor. Innovative repair solutions, thorough material expertise and ultramodern coating processes for parts are the main reasons that customers choose Sulzer’s services. With a network of over 100 service sites around the world, we are present at our customers’ doorsteps. 17 Customer-oriented and reliable — Sulzer services Sulzer Technical Review 3/2019

More than just repair – developments incorporated Sulzer offers not only repair services but also smart retrofit sets to save time, money and energy at customers’ installations — this is called life cycle engineering. Whenever a new product idea has been realized for the current product range, a team of engineers checks how to implement these ideas into retrofit solutions. Sometimes a pump gets a second life through retrofitting.

Incorporating material improvement into repair solutions is one of our strengths. Did you know that Sulzer offers customized weld repair solutions for critical rotating equipment? In 2013, our engineers developed a specialized weld procedure — gas-tungsten arc welding. This technique can be used for repair when conventional welding is not sufficient (Fig. 1).

In 2001, Sulzer developed a zirconium-based thermal barrier coating, which reduced the fatigue breaks of gas turbine components. Sulzer customers benefit from the prolonged lifetime of their components because specific metallic-ceramic coatings, corrosion-resistant coatings (Fig. 2) or special material hardening is used during repair.

Sulzer is proud to transfer advanced material solutions into new repair solutions. We developed an innovative welding method using a 12% chromium steel specifically for the repair of turbines in corrosive environments such as geothermal turbines.

New technologies for improved repair results We use the latest technologies and diagnostic instruments in our labs to investigate the root causes of cracks. Our engineers design replacement parts with the help of finite element analysis (FEA) to ensure that the materials and design are reliable. Numerous tests after the repair and the subsequent high-speed balancing guarantees our customers that their repaired equipment is working correctly.

History of Sulzer’s service offerings Ever since Sulzer was founded, service and retrofits have been part of our standard offering, though they were not housed in an independent division. In 1974, Sulzer founded the Thermal Turbomachinery division to develop turbocompressors and gas turbines. That division’s Technical Services department built up a service network around the globe and already had 17 service sites by 1980. In 1983, Sulzer decided to enlarge its customer base by using our expertise to repair not only our own turbomachinery but third-party turbines as well.

Fig. 1 Sulzer developed a proprietary welding procedure — gas- Fig. 2 Increasing the lifetime of rotor blades — metallic-ceramic tungsten arc welding—for gas turbine repair. coating in blue. 18 Customer-oriented and reliable — Sulzer services Sulzer Technical Review 3/2019

A new division is born in 2000 — Turbomachinery Services In 2000, Sulzer created a new division, called Turbomachinery Services, where all services and repair activities for turbines and compressors were consolidated. Being faster, better and more flexible when realizing a service order was the credo. From third place for turbomachinery service in 2001, the newly founded division rose to become market leader in only five years. In 2004, the division was renamed Sulzer Turbo Services. The service network was enlarged in South America in 2008. It expanded geographically to Russia in 2010.

Growing steadily since 2014 — Rotating Equipment Services division Combining all service activities for gas turbines and compressors with the pumps services was a strategic step. Since 2014, Sulzer has offered all services for rotating equipment through the consolidated division Rotating Equipment Services (RES). This step allowed us to achieve many synergies (Fig. 3).

Milestones in Sulzer’s service history

Dowding & Mills Brithinee Electric (founded 1913) (founded 1963) Thermal Hickham Turbomachinery Turbomachinery & Industries Services Precision Services division (founded 1972) division Gas Turbine Repco Turbo Hua Rui (founded 1997) Rotec (founded 1988) Services (service joint venture) GT division in China

1974 1983 1985 1986 1996 1999 2000 2003 2004 2010 2014 2014 2014 2015 2015 2017 2018 2019

Service of Enpro Elbar Hickham Rotating Grayson EIPS Alba Power third-party (founded 1982) (founded 1973) Indonesia Equipment (founded 2011) (founded 2003) turbines (founded 1973) Services division

Fig. 3 The most important milestones in the development of Sulzer’s rotating equipment services.

Main acquisitions – enlarging Sulzer’s service footprint In 1985, Sulzer acquired Hickham Industries, situated in La Porte, close to Houston, TX, US. In 1983, Sulzer started servicing and retrofitting third-party turbines, and Hickham Industries had specialized in the fabrication of customer-specific components for third-party turbocompressors and gas turbines since 1974. Thus, the Houston Service Center in La Porte (Fig. 4) was born. Besides steam turbine, pump, gearbox and compressor repairs, this service center does gas turbine repairs and specialized airfoil manufacture. Houston Service Center continues to develop innovative repair technologies necessary to maintain leadership in the industry. Fig. 4 Sulzer Houston Service Enpro Services Co. in New Orleans, known primarily for its work on offshore platforms in the Center in Houston, TX, US. US, was acquired by Sulzer in 1986. The New Orleans service center now includes services for reciprocating and rotating equipment and is a distributor for ancillary equipment. 19 Customer-oriented and reliable — Sulzer services Sulzer Technical Review 3/2019

The company Repco Rozenburg was founded in 1988 in Rotterdam. At the doorstep of the port of Rotterdam, it is in a prime location to offer fast repair services to many refineries, petrochemical plants and other industries situated there. Sulzer Repco has offered field and in-house services for steam turbines, turbocompressors, reciprocating compressors, hot gas expanders and blowers since 1996. It now offers these services as Sulzer’s Rotterdam Service Center.

In 1999, another acquisition enlarged the Sulzer service network. Sulzer took over Elbar B.V., which was founded in 1973 in Venlo, the Netherlands, as a repair center for gas turbines. Elbar’s in-depth technical and material expertise in producing extremely reliable and durable components for aviation purposes was integrated successfully into the Sulzer organization. It was transformed into Sulzer’s competence center for gas turbine parts in Venlo.

In 2003, Sulzer integrated PT. Hickham Indonesia in Purwakarta, Indonesia. This service center has specialized in the service and overhaul of rotating equipment ever since, and still exists today as the Purwakarta Service Center (Fig. 5).

Fig. 5 Repair of turbines in the Purwakarta Service Center, Indonesia.

To become a major player for rotating equipment services in China, Sulzer signed a joint venture agreement in 2014 with China Huadian Corporation for the service of gas turbines. The agreement covers field service, component repair, and the delivery of new capital parts. The joint venture operates under the name of Hua Rui (Jiangsu) Gas Turbine Services Co., Ltd.

With the acquisition of Expert International Pompe Service (EIPS) in Casablanca, Morocco, Sulzer’s service offerings in North Africa further expanded in 2015.

Precision Gas Turbine Inc., located in Florida, US, was acquired in 2015. The company was founded in 1997 and offers various field services, maintenance for gas turbines, inspections, failure investigations and repairs, as well as retrofits.

In 2017, Sulzer acquired control of Rotec’s gas turbine maintenance business, which is headquartered in Moscow and mainly active in the Russian market.

In 2019, Sulzer acquired the Scottish aero-derivative gas turbine service provider Alba Power. Through this acquisition, Sulzer diversified its gas turbine service business into distributed power and offshore as well as marine applications. 20 Customer-oriented and reliable — Sulzer services Sulzer Technical Review 3/2019

Fig. 6 Sulzer offers service and repair for motors and generators.

Electromechanical repair solutions It was a strategic step to offer service from a single source by integrating service and repair solutions for generators and motors (Fig. 6) into the Sulzer service network. With the acquisition of the company Dowding & Mills, UK, in 2010, Sulzer took over 1’350 employees in the UK, US, Australia and United Arab Emirates. Since then, we have offered electromechanical repair solutions in addition to all other service offerings. The origins of Dowding & Mills date back to 1913, when William Dowding and Harry Mills first set up an electrical wiring company in Bordesley, Birmingham, UK. As electric motors became more commonplace, the focus of the business soon switched to rewinding and repair. The company quickly established a reputation for high quality, and through its philosophy of working “around-the-clock,” it became known for fast, reliable service.

Ever since the acquisition of Grayson Armature businesses in 2014, Sulzer has been one of the largest partners for electromechanical services in the Gulf Coast area in the US. We can offer more extensive service capacities in the US since the acquisition of Brithinee Electric in 2018.

On duty for all customers since 1834 Sulzer will enlarge its service network in the future to be even closer to the customers’ installations. A focus on digitalization will ensure that we can create customer-specific spare parts quickly for the fastest possible repairs. We want to achieve the lowest downtimes with lowest costs for the benefit of our customers. All Sulzer service employees are highly dedicated and Claudia Pröger, service-oriented. It is in our DNA to do all we can to keep our customers’ rotating equipment Winterthur, Switzerland running. All around the globe. Since 1834. 21 Chemical process technology for the industry since 1946 Sulzer Technical Review 3/2019

Chemical process technology for the industry since 1946

Nuclear fission, discovered in 1938, opened up access to an energy source of previously unknown dimensions. As early as 1946, Sulzer focused its development activities on the production and upgrading of

heavy water (D2O), which was needed for the first natural uranium reactors. Sulzer thus laid the foundation for today’s Chemtech division.

The conventional process for D2O production at that time was the rectification of water. In 1951, Sulzer decided to license the rectification apparatus of one Professor Kuhn from Basel. The Kuhn column proved unsuitable for industrial-scale separation, but over the course of numerous experiments, Sulzer gained sound knowledge in the field of distillation processes. 22 Chemical process technology for the industry since 1946 Sulzer Technical Review 3/2019

New ideas from the process technology laboratory New people, new insights – the hiring of Max Huber in 1957 brought a new approach to the company. As head of the laboratory for process technology, he uncovered the weaknesses of the Kuhn column (Fig. 1). His ideas led to the invention of the first Sulzer structured packing, with a regular structure made of folded metal wire gauze for installation into the column.

In contrast to mechanical engineering, process engineering focuses on tailor-made customer solutions. The design of the plants is always customer-specific. Column size, internal types, separating trays, material specification — all this is adapted to the chemical components to be processed and the throughput quantities specified. Sulzer set up a special laboratory (Fig. 2) for distillation in 1958. In addition to the separation of isotopes, the lab used the new columns to research and test the separation of substances from the chemical industry and refinery, and then extrapolated the findings to industrial standards.

Fig. 1 Rectification apparatus (Kuhn column) from Sulzer. Fig. 2 Vacuum pilot column in the laboratory.

The founding of the Chemtech division in 1989 In 1989, Sulzer brought together all process technology activities into one unit. The Chemtech division was born, encompassing distillation, mixing, reaction and separation technology, as well as crystallization. The separation and mixing processes proved to be particularly successful and continue to shape the face of Chemtech to this day.

From the very beginning, Chemtech has pursued three objectives in the development of customer-specific processes: low pressure drop in the process, high efficiency and scalability. These requirements have led to the invention and continuous improvement of Sulzer’s structured packings. The segmented design (Fig. 3) of these packings was an intelligent solution that allowed the packings to be used in columns of any diameter. Fig. 3 Installation of segmented structured packings in a column. 23 Chemical process technology for the industry since 1946 Sulzer Technical Review 3/2019

The market launch of gauze packing in 1964 Building on their experience with the Kuhn column, Sulzer engineers first developed a packing with a regular structure from self-wetting wire gauze. A number of tests were carried out to assess and optimize various geometric arrangements. In 1964, the product was presented to the experts for the first time at Achema, the world’s largest trade fair for chemical engineering, process engineering, and biotechnology. The first delivery was provided for a batch column with a diameter of 300 mm and a height of 9 m for the separation of fragrances, and the next column was for the separation of xylenols. The column already had a diameter of 900 mm. These packings were also used for heavy water columns. Sulzer gauze packings (Fig. 4) are still used for the distillation of temperature-sensitive materials such as perfume bases.

MellapakTM for greater separating efficiency since 1976 The manufacturing of wire gauze is complex. In their search for an efficient and cost-effective solution, the use of thin metal sheets has been tested. Thanks to their special patented surface, good wetting of the sheets was achieved (Fig. 5). Sulzer introduced this new packing under the name MellapakTM 250.Y at Achema in 1976. The first large orders were placed for a tall oil column in 1977 and a year later for a styrene column.

The Mellapak structured packing can be used as a revamp solution for existing columns. When customers replace separating trays or random packings with this packing in existing columns, they can either increase throughput or drastically reduce energy consumption. This explains their continued success on the market. Sulzer has continuously expanded the application area, on the one hand by varying the packing geometry, and on the other by using new materials such as plastics, ceramics and carbon fibers.

Another important application is air separation. The individual air components are separated

from each other by low-temperature rectification to obtain nitrogen (N2), oxygen (O2) and noble gases. Packing types with a high separating efficiency are used here. The structured packings make air separation more economical because the considerable reduction in column volume allows the size of the cooled shell around the columns (cold box) to be reduced, and less cooling capacity is required.

Fig. 4 The first generation of Sulzer Fig. 5 Made of sheet metal with a special surface Fig. 6 Process installation for heavy gauze packing BX. structure — Mellapak packing. water production in 1960. 24 Chemical process technology for the industry since 1946 Sulzer Technical Review 3/2019

A new generation of packing — MellapakPlus™ Detailed measurement of liquid holdup over the full height of a packed bed using gamma scanning showed an increased holdup at the interface of the packing layers. This phenomenon limiting the capacity could be confirmed with CFD calculations. By modifying this interface, the structure of the packing could be optimized in such a way that capacity could be increased by 20–30% with the same efficiency. This packing type was called MellapakPlus (Fig. 7) which quickly conquered the market in 1999.

The MellapakPlus high-performance packing was specifically tested and optimized for new applications. The development of the absorption packing MellapakCCTM, a packing type

adapted for use in CO2 separation (gas scrubbing), is worth mentioning.

Separating trays for further growth Fig. 7 The structured packings are particularly suitable for vacuum rectification due to their low MellapakPlus™ — the pressure drop. For applications with normal or high pressure, separating trays are usually high-performance packing of Sulzer. preferred. In 1987, Sulzer bought Metawa Tray in Tiel, the Netherlands, to better position itself in the market for separating trays. This company manufactured conventional separating trays and proprietary high-performance trays for Shell. This was followed in 1999 by the acquisition of Nutter in Tulsa, US, which had two tray types in its product range: one with fixed valves and the other with movable valves (Fig. 8). Based on this technology, Sulzer developed its own high-performance tray in the following years. The result is the VGPlusTM tray, which has proven itself on the market since 2004 and was further improved in 2012 with the special movable valve UFMTM.

Random packings in perfection More than 100 years ago, distillation columns were mainly equipped with separating trays or random packings. With the acquisition of Nutter, Sulzer expanded its product range to include its own random packing, the Nutter RingTM. Sulzer’s process engineering know-how and Fig. 8 Separating tray with knowledge of materials was also incorporated into the further development of these products. movable valves. The new Sulzer random packing NeXRing™ is a mechanically extremely stable, high-capacity ring of the fourth generation and was launched in 2015.

Mixing instead of separating At the beginning of the 1970s, experiments on the propagation of gases in structured packings revealed remarkably good cross-mixing. This led to the idea of using the structure as the basis for a static mixer (Fig. 9). As early as 1973, the SME mixer (now the SMVTM static mixer) was presented to customers at Achema. The field of application is very large, from mixing liquids with large differences in viscosity (Fig. 10) to mixing gases (Fig. 11).

Fig. 9 Patent application for Fig. 10 Test of the SMV mixer in the lab. Fig. 11 Installation of the SMV mixer for flue gas. static mixing in 1972. 25 Chemical process technology for the industry since 1946 Sulzer Technical Review 3/2019

In 1975, Sulzer acquired a license from Bayer for the BKM, a static mixer for viscous liquids. This mixer is successfully marketed by Sulzer under the name SMXTM. Another proven product is the Sulzer SMRTM mixing reactor. It was licensed from Höchst in 1985. This is a tubular bundle system built in the form of an SMX structure. An important application for the SMR mixing reactor is the polymerization reaction for the production of plastics such as polystyrene or polylactide (PLA). Sulzer subsequently developed other, similar products: the SMITM static mixer for turbulent flows (1996), the very compact CompaXTM mixer for admixture of additives (2004), and the ContourTM gas mixer for flue gas cleaning systems (2007).

Further milestones in separation and mixing are: In 1982, Sulzer began using crystallization as a separation equipment after acquiring MWB Buchs in Switzerland. In 1996, the first two-component Quadro mixer was launched by Sulzer and laid the foundation for the later establishment of a new Sulzer division (Applicator Systems) in 2017. Since 2000, thanks to a license agreement, Sulzer has been able to manufacture and distribute products developed by the Shell Corporation. In 2007, Sulzer acquired part of the business of the UK company Knitmesh and has since offered separators and mist eliminators. The integration of Kühni in Allschwil, Switzerland, in 2009 brought additional products and equipment for thermal process engineering into the product portfolio. Since 2010, most process technology tests have been carried out at the customer test center in Allschwil. Sulzer’s distillation technology supports sustainable energy production where microbes are used to produce biofuels. After intensive process tests in Allschwil the steel producer ArcelorMittal ordered in 2018 Sulzer equipment for the production of biofuels out of carbon-monoxide-rich gas.

Plastics technology and bioplastics Sulzer acquired the German company Aixfotec in 2014. Its plants for the production of foamable polymer granules and for the foaming of polymers are well-established in the market. The product portfolio for foamed products (Fig. 12) is expanding steadily and now comprises expandable polyethylene terephthalate (XPET).

Sulzer had the foresight to develop a production process for bioplastic polylactide (PLA, Fig. 13) and installed a process plant in the market already in 2010. The world’s largest PLA plant was installed in 2018 and uses Sulzer’s technology. Sulzer sells complete polymer systems for the production of PLA (Fig. 14), or only the key equipment as required. Sulzer continues to focus on the development of further bio-based polymer technologies, which represents an important contribution to the protection of our environment.

Fig. 12 Rolls for fascia training – produced Fig. 13 Biodegradable bioplastic polylactic acid Fig. 14 Installed in 2010 — production with Sulzer’s patented process for (PLA). plant for bioplastics. foamed polymers. 26 Chemical process technology for the industry since 1946 Sulzer Technical Review 3/2019

Main milestones in Chemtech’s history

New division: First PLA Distillation Sulzer Chemtech bioplastic process process of Distillation installation biofuels and laboratory in microbes Tests Winterthur First static Crystallization VGPlus™ high- NeXRing™ to produce mixer SMVTM QuadroTM performance high-performance D2O mixer tray random packing

1946 1951 1958 1964 1973 1976 1982 1988 1989 1996 1999 2004 2009 2010 2014 2015 2016 2018

Process VIEC™ Licensing of Expandable technology oil/water rectification First structured Mellapak™ Sulpak design MellapakPlus™ polymer center in separation apparatus gauze packing packing program for packing process distillation Allschwil technology

Fig. 15 Important milestones of the history of Chemtech.

A Danish company developed a novel conversion process for recycling mixed plastic waste and uses Sulzer’s distillation technology as an important part of the depolymerization process.

Closer to the source Since the integration of the Dutch companies Ascom and ProLabNL in 2014, a large test center for separation technologies revolving around crude oil, water, sand and associated natural gas has been available to Sulzer customers. This allows customers to benefit from extensive technology expertise in the processing of petroleum flows near the production site. This technology is particularly important in offshore and subsea applications for the elimination of water, sludge and sand. VIECTM technology, acquired in 2016, is used to separate difficult- to-separate oil/water mixtures using electric fields, expanding Sulzer’s offering in this area.

Calculation basis for developments At Sulzer, product development is based on two main pillars: computational fluid dynamics Dr. Marc Wehrli, (CFD) calculations and tests in the company’s own laboratories, including the validation of Winterthur, Switzerland CFD calculations. For customer-specific projects, CFD simulations are used to calculate the flow dynamics of gases or liquids in order to optimize the design of the systems and save energy.

Digitalization to serve customers Sulzer made its first digital design program, Sulpak, available to customers as early as 1988. Today, this knowledge is contained in the SULCOLTM calculation program. The program is available to Sulzer customers for the design of separation columns and is based on years of Dr. Lothar Spiegel, experience from the process engineering laboratory, combined with theoretical knowledge Winterthur, Switzerland gained from cooperation with leading universities and scientists. 27 Precise application since 1956 Sulzer Technical Review 3/2019

Precise application since 1956

New materials and new areas for use call for the development of new application processes and dispensing systems to optimize handling. As early as 1956, the Danish company Kroeger (now Sulzer) launched the first caulking guns for Bostik (a single-component adhesive) on the market. The first dispensing system developed by Sulzer was launched in 1986 and consisted of a dispenser, a cartridge and a static mixer. The establishment of the Applicator Systems division in 2016 shows how important this innovative business has become for Sulzer.

The catalyst for developing application systems was the invention of reactive adhesives based on chemical cross-linking mechanisms, such as two-component adhesives and silicone-based adhesives. The English chemist Frederic Stanley Kipping discovered silicone-based adhesives in 1901, but industrial production was not developed until 1940. It became more widely established in the market at the beginning of the 1950s. Silicone elastomers are often used in the construction industry for sealing and insulation purposes.

Trailblazing silicone During these years, several companies developed application systems to achieve a uniform adhesive discharge with little effort. The Danish company Kroeger (now Sulzer) launched the H2 dispenser in 1956, a dispenser for 600 ml tubular bags (Fig. 1). In 1958, a manual dispenser was developed for smaller packaging sizes to provide smaller quantities for DIY enthusiasts. 28 Precise application since 1956 Sulzer Technical Review 3/2019

In the same year, PC Cox (part of Sulzer since 2016) in Great Britain manufactured the often-copied Wexford skeleton metal frame caulking gun (Fig. 2). It is still on the market today under the name EasiFlow HD.

Two-component materials for one job More materials and adhesives were developed for the construction industry and for various industrial applications. These could not be applied or dispensed uniformly with high precision without dispensers and suitable cartridge systems. Mixing and application by hand were no longer economical with these systems and, above all, not reliable. To mix materials or adhesives from two different components evenly, industrial users needed two-component (2K) dispensers and mixing systems.

Versatile dispensers from Denmark After 1956, Kroeger developed manual, pneumatic and battery-powered dispensers with different cartridge sizes for single-component and two-component materials. The first two- component dispenser was launched in 1965. Pneumatically operated dispensers for industrial applications were introduced in 1986 for single-component applications and in 1991 for two-component applications. Battery-powered dispensers have delivered uniform, high dispensing performance without compressed air supply since 2006 for single-component materials and since 2014 for two-component materials (Fig. 3).

Ergonomic industrial standard from Great Britain PC Cox initially developed manual dispensers for mastic; these dispensers were made from die-cast components and had an automatic relief function. Pneumatic dispensers were launched in the 1960s. Thanks to the relief valve, which was integrated into the pneumatic dispensers in the following years, application quality improved significantly. The dispensers were so successful in Great Britain that PC Cox also boosted exports and, as early as the 1980s, had an export share of 80%. In the 1980s, pneumatic dispensing systems were developed for two-component materials (Fig. 4).

Fig. 1 The manual H2 dispenser — a traditional product from MK™ Fig. 2 EasiFlow™ HD — a manual metal (formerly Kroeger). dispenser by COX™.

Fig. 3 Battery-powered dispenser for two-component cartridges from MK. Fig. 4 Two-component material application using compressed air and the pneumatic COX dispenser. 29 Precise application since 1956 Sulzer Technical Review 3/2019

Process optimization with simultaneous mixing In 1986, W.A. Keller Prozesstechnik in Risch, Switzerland, combined two process steps into one with its static metal mixers. These allowed mixing and application to take place simultane- ously. These mixers were used for various stationary mixing tasks in chemical and industrial applications. The first portable dispensing system for dental and industrial applications was also launched in 1986, followed in 1988 by the C-system for large cartridges.

The company Mixpac took over all of W.A. Keller’s equipment and activities in 1990 and became the market leader for two-component dispensing and mixing systems. Mixpac, in close cooperation with the specialists at Werfo in Haag, Switzerland, took the risk of transferring the mixing technology and manufacturing it with plastic injection molding. This proved to be a breakthrough for portable discharge systems. High mixing quality was maintained, while weight and manufacturing costs were significantly reduced. The complex geometry of the mixing elements was a major challenge in the manufacture of the first injection molds for the mixing elements. Sulzer Mixpac’s strengths include a high level of innovation in toolmaking and optimizing process technology.

Mixpac then went on to develop numerous new dispensing systems and product lines: the S-system for dental applications in 1997, still the most widely used and highly successful two-component dispensing system for dentists; a motor-driven dynamic table mixer (BD system) for dental applications in 2000; the L-double syringe system for dental applications in 2001 (Fig. 5), the F-system with separate outlets for even more reliable application in 2002; and many other product lines for single-component and two-component applications.

Fig. 5 Sulzer’s L-double syringe system for two-component dental applications.

Sulzer gets involved with mixing Sulzer’s Chemtech division launched static mixers for chemical applications in 1972. In 1996, Chemtech used the knowledge it had acquired to develop the Quadro™ mixer (Fig. 6) and associated cartridges for mixing two-component materials for industrial applications and the construction industry. The Quadro mixer was — and still is — the ideal solution for difficult mixing tasks and, due to its short design, the measure of all things in static mixing.

Fig. 6 The Quadro mixer was developed by Sulzer in 1986. 30 Precise application since 1956 Sulzer Technical Review 3/2019

Following the acquisition of Mixpac and Werfo in 2006, all product development activities were merged, and Sulzer’s mixer and dispenser systems were offered from a single source. Sulzer’s innovative strength led to numerous innovations, such as the spray system for protective coatings in 2012 and the T-mixer with a 30% shorter mixer length in 2013 (Fig. 7), which reduced material loss accordingly. In 2015, small single-use spray dispensers were developed for local anesthesia in the throat area. These led Mixpac to win an internationally renowned prize for innovative pharmaceutical packaging.

Fig. 7 The T-mixers launched in 2013 — reduced material loss with equivalent or greater mixing capacity.

Sulzer integrated the know-how of other established companies from the world of adhesive application into its business activities. It acquired the Danish firm Kroeger in 2013 and the British firm PC Cox in 2016. Today, Sulzer is a leading global supplier of industrial application solutions for the construction, electronics, marine, automotive and aircraft industries. Sulzer also offers custom-tailored solutions for customers in these fields. Many of Sulzer’s products are also available in hardware stores and are valued by end users.

To reduce plastic waste, Sulzer recently developed the new ecopaCC™ cartridge (Fig. 8). It can be folded and consists of a multilayer high-tech film that is suitable for storing various chemicals. This provides customers with advantages in transport, storage and disposal, and also improves the shelf life of the two-component material.

Fig. 8 The ecopaCC cartridge with collapsible packaging to reduce plastic waste. 31 Precise application since 1956 Sulzer Technical Review 3/2019

Clean room production for health and dental solutions Certified manufacturing plants with controlled environmental conditions ensure the production of clean (and, if necessary, sterile and aseptic) mixing and application systems for health and dental solutions. Sulzer is a leader in this field.

One of the first manufacturers of disposable syringes was the German company Transcoject. After its market launch in 1972, this line of business became so successful that, just three years later, there were 34 factories in ten countries producing disposable syringes. In 2008, Transco- ject’s dental division was spun off and Transcodent was founded. Transcodent has been part of Fig. 9 Sulzer’s dental business since 2017. The product range includes application systems for Disposable syringe and multiple and single applications, as well as high-quality dental needles (Fig. 9). matching cannula attach- ment (Painless Steel®) from Transcodent. Medmix Systems AG was founded in 2007 and has been part of the Sulzer corporation since 2018. The product range includes applicators for tissue adhesives and bone cements as well as for oral surgery and drug delivery systems in the health care market.

Decades of innovation for beauty Innovative manufacturing processes for applicators and sophisticated application techniques distinguish the beauty products made by Geka in Bechhofen, Germany. Geka was founded in 1925 as a brush factory.

In the 19th century, mascara in the form of a black block was invented by the Frenchman Eugène Rimmel (1820–1887). A small brush was moistened in order to remove the color from the block and to apply it to the eyelashes. In 1957, Helena Rubinstein (1872–1965) developed the first viscous mascara, which was packed in a small tube along with a brush. Today all mascaras are sold in this form. Geka quickly recognized the new trend, and in the 1960s the company began to focus on cosmetic brushes and mascara brushes.

Fig. 10 Applicators for beauty applications by Geka. 32 Precise application since 1956 Sulzer Technical Review 3/2019

Milestones in Applicator Systems history

First First First single-use First plastic mixer Integration of Mixpac Integration New division: Integration Kroeger COX syringes and dispenser (founded 1990) of PC Cox Sulzer Applicator of Medmix dispenser dispenser (Transcoject) (Mixpac) (founded 1958) Systems (founded 2007)

1956 1958 1960 1972 1986 1990 1996 2006 2013 2016 2016 2017 2017 2018

First Geka First steel mixer Patent for Sulzer Integration of Integration Integration plastic injection and dispenser Quadro mixer Kroeger of Geka of Transcodent molded brushes (Keller Prozesstechnik) (founded 1922) (founded 1925) (founded 2008)

Fig. 11 History of the Sulzer Applicator Systems division and its integrated companies.

As a pioneer in plastics processing for cosmetic applicators, Geka positioned itself as the market leader for mascara brushes. In the 1980s, Geka expanded its range and has since offered complete packaging solutions for liquid cosmetics such as mascara, lip gloss, eyeliner and nail polish (Fig. 10). Sulzer acquired Geka in 2016.

Geka used new manufacturing processes to produce plastic mascara applicators that set new standards. The soft brushes, which are manufactured using a two-component or Moltrusion® process, were launched in 2005 and have been contributing significantly to the sales success Nadia Qaud, of numerous cosmetic brands since that time. Geka is also a leader in twisted wire brushes Winterthur, Switzerland and is constantly developing new geometries and fiber materials. Sulzer’s sophisticated applicators make it easier to apply cosmetics.

Innovative application technology Innovative application technology is closely linked to development in numerous other areas: discharge material, plastic material, injection molding technology, alternative 3D manufacturing processes, fluid dynamics and mixing technology, to name but a few. The combination of this knowledge from all of the Sulzer companies listed here (Fig. 11) leads to remarkable Paul Jutzi, synergies in product development in Sulzer’s Applicator Systems division. Future-oriented Haag, Switzerland and innovative — that’s Sulzer. 33 A billion heartbeats Sulzer Technical Review 3/2019

A billion heartbeats

The Sulzer Technical Review is very proud to be able to look back on 100 years. In honor of this occasion, we examined the maximum life spans of various plants and animals — and discovered some incredible facts along the way.

Fruit flies have a life span of just one month, but earthworms live for ten years — and parrots can reach the ripe old age of 100 (Fig. 1). Generally speaking, the longest-living members of the animal kingdom tend to be the less highly evolved ones. For example, a koi carp in Japan has been proven to be 226 years old, while an Aldabra giant tortoise (Fig. 1) in an Indian zoo was discovered to be 256, and a mussel, the Icelandic cyprine “Ming” is — believe it or not — 507 years old.

The longest-living species within the various animal families are often found in the coldest climates. For example, whales and sharks usually live to be around 100 years old. However, the bowhead whale (title picture), which makes its home in Arctic waters, has a maximum life span of over 200 years, and the ground shark (Fig. 1) can live to be over 400 years old. Cold climates go hand in hand with greatly reduced bodily activity and a slower metabolism, both of which could play key roles in ensuring a longer life. 34 A billion heartbeats Sulzer Technical Review 3/2019

A question of bodily size When it comes to mammals, the bodily warmth required to sustain life plays a decisive role in determining maximum life span. Heat loss depends on the size of the physical surface relative to the body’s volume. The larger the animal, the more favorable this ratio and the lower the metabolic rate, meaning the total energy turnover throughout the bodily mass. That’s why larger mammals live longer than smaller ones do. Interestingly, if you multiply an animal species’ metabolic rate by its maximum life span, you get the same figure across the board, whether you’re looking at a mouse or an elephant: specifically, around 220 kilocalories per gram. It’s as though each animal species has the same amount of “life force.” If the animal has a more vigorously physical lifestyle, it burns through this capital more quickly.

The vigorous lifestyle is reflected in factors such as differing pulse rates. A mouse’s heart beats 500 times per minute (if there are no cats around), whereas an elephant’s heart beats around 26 times a minute (Fig. 1). Extrapolating this figure to the maximum life span of a mouse (four years) and for an elephant (70 years) yields the same result, astoundingly: A mammal’s heart beats 1’000’000’000 times before falling silent.

Humans form the exception to the rule Those of us who might be tempted to calculate our own number of heartbeats will be horrified to find that we should actually be dead a long time ago. Since our hearts beat 75 times a minute, we would reach our billion heartbeats at the age of 20. Luckily, though, we generally live four times longer than that (if we act responsibly, of course). At 122 years of age, the French woman Jeanne Calment (1875–1997), the oldest known person, has surpassed biological expectations six times over. How has Homo sapiens managed to evolve to enjoy such a long life span? Researchers are still pursuing answers to this question. One probable cause is the strongly delayed bodily development seen in humans at birth and during their first few years of life. This also causes humans to stay youthful — and, therefore, capable of learning and adaptation — for longer than other mammals do.

Mouse Worm Elephant Parrot Humans Aldabra turtle

4 10 70 100 122 256 400 5’070

Ground shark Bristlecone pine

Fig. 1 Timeline with the maximum life span of different species. 35 A billion heartbeats Sulzer Technical Review 3/2019

Fig. 2 Bristlecone pines growing in the White Mountains of California.

Ancient trees Plants barely move, have no pulse, and continually regenerate the majority of their body parts. So they can live far longer than people or animals do. Trees, in particular, can enjoy astonishingly long lives. Cherry trees can live to 400, spruces can live to 1’100, and fig trees can even live up to the age of 2’000. In 2012, an ancient intermountain bristlecone pine (Fig. 2) was discovered in the White Mountains of California. As dated by its rings, this tree is now 5’070 years old. The cold climate in these mountains supports its longevity. It also helps Dr. Herbert Cerutti, that it has a summery growing season of a mere three months and the minimal amount of Maseltrangen, Switzerland local pests. 1862 1925

1945 1970

2018