Sulzer has launched the Sulzer Energy Optimization Service, a cutting-edge solution designed to improve energy efficiency and reduce carbon emissions in energy-intensive industries such as power generation, oil and gas, chemicals, and water desalination. The company aims to establish a new industry standard for centrifugal pump performance.
A Data-Driven Approach to Efficiency
The Sulzer Energy Optimization Service integrates digital analysis, machine learning, and continuous monitoring to enhance pump efficiency, lower energy costs, and drive sustainability. According to Sulzer, even a 1% increase in global pump efficiency could save approximately 59TWh of electricity—equivalent to New Zealand’s annual power consumption. Some pumps may achieve efficiency gains of 20–30%.
“Inefficient and unreliable pumps cost industrial operators millions in unnecessary downtime, energy expenses, and carbon emissions annually,” said Ravin Pillay-Ramsamy, President of Sulzer’s Services Division. “Our Energy Optimization Service provides a comprehensive solution—from identifying inefficiencies to implementing improvements and ongoing monitoring.”
Proven Results: Significant Cost and Carbon Savings
A pilot project in Spain demonstrated the impact of Sulzer’s optimization service. By rerating five pumps, efficiency increased from 72% to 83%, leading to:
✔ €1 million in annual energy cost savings
✔ Over 2,300 tonnes of CO₂ emissions eliminated per year
✔ 5,000MWh of electricity saved annually
How the Optimization Process Works
The service follows a four-step approach:
- Pump Energy Audit – Using Sulzer’s proprietary PumpWise calculator, experts assess pump inefficiencies and quantify potential energy, carbon, and cost savings.
- Customized Improvement Plan – Sulzer engineers develop tailored retrofit options, incorporating techniques such as hydraulic re-rates, specialized coatings, and wear clearance adjustments. Proposals weigh investment, operational costs, payback periods, and efficiency guarantees.
- Implementation & Retrofit – Sulzer’s global retrofit team, which has completed over 4,000 projects since 2010, executes the upgrades. Supported by 120+ service locations worldwide, they ensure seamless integration.
- Performance Monitoring & Optimization – A post-retrofit performance agreement ensures sustained efficiency using Sulzer’s Blue Box machine learning technology, which translates pump performance data into actionable insights.
Future-Proofing Industrial Pump Operations
“For industrial operators facing growing energy challenges, improving pump efficiency is a win-win,” added Pillay-Ramsamy. “With pumps consuming 20% of the world’s electricity, we offer a streamlined, future-proofed approach to maximizing efficiency—regardless of the pump OEM. By combining our engineering expertise, digital tools, and customer-focused approach, we are setting a new benchmark for pump optimization.”
