Sulzer has unveiled the Sulzer Energy Optimisation Service, an innovative energy efficiency and carbon reduction initiative aimed at setting a new benchmark for centrifugal pump performance across their lifecycle. Targeting energy-intensive industries such as power generation, oil and gas, chemicals, and water desalination, the service promises significant operational, environmental, and financial improvements.
Launched in response to the increasing demand for industrial energy efficiency, the solution integrates digital analysis, machine learning, and continuous monitoring with Sulzer’s extensive engineering expertise. By optimising pump performance, the service aims to reduce carbon emissions, enhance reliability, and lower energy costs. A mere 1% increase in global pump efficiency could save approximately 59TWh of electricity—equivalent to New Zealand’s annual power consumption—while some pumps could see efficiency gains of up to 20-30%.
Driving Efficiency and Cost Savings
Announcing the new service, Ravin Pillay-Ramsamy, Services Division President at Sulzer, stated:
“Inefficient and unreliable pumps cost industrial operators millions in unnecessary downtime, energy expenses, and carbon emissions every year. The Sulzer Energy Optimisation Service provides a comprehensive solution to tackle this inefficiency—from identification to implementation and ongoing monitoring.”
A pilot project in Spain has already demonstrated the impact of the service, enabling a customer to save €1 million annually in energy costs while cutting over 2,300 tonnes of carbon dioxide emissions. By rerating five pumps, energy efficiency improved from 72% to 83%, delivering annual electricity savings of 5,000MWh.
A Four-Step Approach to Energy Optimisation
The Sulzer Energy Optimisation Service follows a structured four-step process:
- Pump Energy Audit – Using Sulzer’s proprietary PumpWise calculator, an initial audit identifies inefficiencies and outlines potential energy, carbon, and cost savings.
- Customised Retrofit Proposal – Sulzer’s expert team provides a tailored proposal detailing various retrofit options to restore the pump’s best efficiency point. These may include hydraulic re-rates, specialised coatings, and optimised wear clearances. Each option is assessed for operational cost, investment, downtime, payback period, and efficiency guarantees.
- Implementation and Upgrades – Sulzer’s dedicated retrofit team, which has delivered over 4,000 projects worldwide since 2010, executes the upgrades with support from Sulzer’s extensive global service network of over 120 locations.
- Performance Monitoring and Maintenance – Post-retrofit, Sulzer offers a performance agreement to sustain reliability and efficiency. This includes access to Blue Box™, Sulzer’s proprietary machine learning technology, which converts pump performance data into actionable insights.
Futureproofing Industrial Operations
Pillay-Ramsamy added:
“For operators facing constant pressure to do more with less, improving energy efficiency is a win-win. With pumps accounting for 20% of the world’s electricity demand, we are offering a streamlined, future-proofed solution that enhances efficiency across all pump brands.”
“By combining our engineering expertise with cutting-edge digital innovations in a collaborative and customer-focused approach, we are establishing a new industry benchmark for pump operation, helping businesses remain competitive and sustainable in the evolving energy landscape.”
