Sulzer’s New Energy Optimisation Service – IAA

Sulzer’s new Energy Optimisation Service delivers major savings in energy-intensive industries.

In an industrial environment where energy costs are rising and sustainability is critical, inefficient pumps are a major problem. For one power generation company in Spain, its centrifugal pumps were operating at just 72% efficiency. This inefficiency was driving up energy costs and contributing to unnecessary carbon emissions, straining the company’s financial bottom line and environmental goals.

As energy expenses soared, the company knew something had to change, but the solution had to be cost-effective and impactful. Enter the Sulzer Energy Optimisation Service, which was launched recently. Ravin Pillay-Ramsamy, Services Division President at Sulzer, announced the solution: “Inefficient and unreliable pumps cost operators in the industrial sectors millions of dollars in unnecessary downtime, energy costs, and carbon emissions every year. Sulzer Energy Optimization Service offers a comprehensive solution that tackles this inefficiency—from identification through to improvement and monitoring.”

We provide all the details on this newly launched service, including how it works and its results, as well as what it means for industrial automation.

The Sulzer Solution: Boosting Efficiency With A Groundbreaking Energy Optimisation Service

Sulzer, a global leader in pump technology, came to the rescue with its Sulzer Energy Optimisation Service, a pioneering solution designed to maximise pump efficiency, reduce costs, and minimise carbon emissions.

By utilising a digital energy audit with its PumpWise calculator, Sulzer’s team identified the key inefficiencies in the company’s pumps. Armed with this data, Sulzer proposed a series of tailored retrofits, including hydraulic re-rates, specialized coatings, and adjustments to wear clearances. These upgrades aimed to optimise the pump’s performance, ensuring it operated at its best efficiency point.

The results were nothing short of remarkable: the Spanish company’s pump efficiency soared from 72% to 83%, substantially impacting the company’s energy consumption and carbon footprint.

Additionally, after implementing Sulzer’s advanced energy optimisation techniques, the company also achieved remarkable results:

• Annual energy savings: 5,000 MWh, enough to power thousands of homes
• Annual cost savings: €1 million
• Carbon emissions are reduced by 2,300 tonnes annually

How Sulzer’s Energy Optimisation Service Works

The service follows a four-step approach to maximise energy savings and efficiency:

1. Energy Audit & Analysis:

Sulzer’s proprietary PumpWise calculator identifies inefficiencies and estimates potential energy, carbon and cost savings.

 2. Tailored Retrofit Proposal:

Sulzer’s expert team develops a customised solution with options such as:

• Hydraulic re-rates
• Specialised coatings
• Wear clearance adjustments and more

Each option is evaluated based on operational costs, investment, downtime, payback period and efficiency guarantees.

3. Implementation & Optimisation:

Sulzer’s retrofit team has completed over 4,000 projects since 2010 and carries out the upgrades. The team is backed by a global network of 120+ service locations.

4. Continuous Monitoring & Performance Agreements:

Post-retrofit, Sulzer provides ongoing efficiency tracking and maintenance. The Blue Box™ machine learning system translates pump performance data into actionable insights.

“For operators who are constantly challenged to do more with less, making energy efficiency improvements is a win-win,” added Pillay-Ramsamy. “With pumps accounting for 20% of the world’s electricity demand, we want to offer a streamlined, futureproofed way for customers to improve their energy efficiency regardless of their pump OEM.”

Why It Matters? Setting A New Standard for Pump Efficiency

The Sulzer Energy Optimisation Service provides an end-to-end energy efficiency and carbon reduction solution that delivers real, measurable benefits by integrating digital analysis, machine learning, and Sulzer’s extensive engineering expertise.

Sulzer’s solution offers a future-ready, best-in-class approach to pump optimisation for industrial operators looking to cut costs, carbon, and energy waste.

About Sulzer Services

Through a network of over 100 service sites worldwide, Sulzer provides cutting-edge parts and maintenance and repair solutions for pumps, turbines, compressors, motors and generators. The company services its original equipment and all associated third-party rotating equipment run by our customers, maximising its sustainability and life cycle cost-effectiveness. Their technology-based solutions, fast execution and expertise in complex maintenance projects are available at our customers’ doorsteps.

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