Individual solutions for your special application
LEWA process experts can help solve your application requirements. Our first key is to listen intently to your objectives and goals, which may include converting a batch process to continuous, optimizing an existing system, or designing a new concept.
Our process, mechanical, automation and design professionals simplify and optimize all aspects of the project, while creating a quality solution.
Service contracts individually tailored to the customer’s requirements and original spare parts increase the operational safety, reduce the operating costs and extend the service life of the plant.
Individual pump configuration und state-of-the-art design
One of LEWA’s strengths is the design of customer specific solutions. In cooperation with the customer skids, packages or complete process systems are developed. This not only includes the mechanical design, but also the control protocols.
In addition to individual process parameters, the design is in line with the corresponding requirements of the guidelines in force, e.g. ATEX, DGRL (PED); VbF, WHG. All LEWA products go through strict quality checks.
Fluid evaluations
Moreover the fluid evaluation offered by LEWA provides detailed information about whether and how the fluid can be metered. Thus recommendations can be given on the selection of the wetted materials, the pump design and also on the complete installation, which can save costs. All safety regulations e.g. for hazardous fluids are considered in these recommendations.
M900 diaphragm pump heads
LEWA provides the most advanced diaphragm metering pumps in the world with maximum security for both production and the environment, primarily through the unique DPS (Diaphragm Protection System)* used for the ecoflow and ecosmart series.
The DPS system assures safety, even under extreme operating conditions, like high suction pressure or closed suction line. The internal overpressure protection is assured by a integrated pressure limit valve..
LEWA diaphragm pump heads are the safe and hermetically tight alternative for medium to high pressures. They present the economical solution for a variety of metering applications.
Ecologically damaging, dangerous, sensitive or abrasive fluids today are metered with zero leakage diaphragm pumps only. Any diaphragm damage is displayed reliably. In spite of this the pump remains tight and operation can continue for a limited time.
Piping calculations
To assure proper function of the pump in the plant, the interaction of the reciprocating positive displacement pump and the pipelines connected to it, must be considered in the early stages of development.
With our software “Pump Design” specially developed for LEWA pumps, we can check the installation for cavitation / overload and excessive metering, as well as resonance, taking the properties of the fluid into consideration. If required, optimizing measures for pipeline dimensioning, pulsation damping etc. are proposed. If requested, a full pulsation study can be provided.
Long service life and high reliability with low maintenance costs
LEWA develops pumps and systems for high availability (annual continuous operation 8,000 h) and for a service life of over 25 years. Assuming continuous operation over several years, we calculate - even for process pumps under extreme operating conditions - total downtime of at most 3 days.
In other words: LEWA assumes an availability of up to 99 %. Given normal operation, the operator can expect these service lives for the most important components:
- Diaphragms, e.g. PTFE: up to 20,000 hours
- Pump valves: up to 20,000 hours (depending on design and application)
Our definition of customer benefit includes more than just technical features and high standards for quality. A critical core expertise of LEWA is the worldwide service and spare parts support. Through ongoing training of the entire personnel in the global after sales organization the customer can count on speedy and expert support in the event of a problem.
Apart from the global assistance for packages and systems during assembly and commissioning, economical modernization or optimization concepts are also developed together with the customer (e.g. Register your pump, Health check).
International engineering and project competencies
Customers worldwide benefit from LEWA’s experience and expertise which stretches back for over 50 years: If the customer manufactures in China for instance, the LEWA consultant is familiar with the relevant certificates and documentation in the Native language. If the EPC is based in the USA, the local branch can coordinate with engineers and operators onsite about process details. If the company is trading in Singapore, LEWA also has a branch there. The same applies to the Middle East, Africa, South America, Australia or every other distant part of the world.
LEWA project management covers the world of planning, construction, building and installation; the capable commissioning as well as the briefing for customers’ staff members and later the regular maintenance and supply of spare parts even in remote areas of the world.
Low lifecycle costs
To this day, many system operators base their decision for purchasing a new pump solely on the purchase price, even though the majority of costs arise later on. Aside from the initial investment costs, operators should therefore particularly take energy consumption, operating expenses as well as maintenance, downtimes and resulting production losses into consideration when determining the overall life cycle costs of a metering pump. When it comes to small and medium-sized metering pumps, differences with regard to energy costs between different models or manufacturers are negligible. The primary focus for purchasing should, therefore, be maintenance costs and possible production losses.
More efficient, environmentally friendly processes
LEWA products are often used for applications that allow more environmentally friendly processes and a more energy-efficient production. This is due to the fact that LEWA pumps amongst others have the best possible pump efficiency rate. For example, in CO2 re-injection in fossil waste disposal sites up to 35% of the energy costs can be saved, if LEWA pumps are used instead of compressors. This saving is possible because LEWA pumps have an efficiency of > 90 %.
References
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CO2 Metering of liquid CO2 (blowing agent)
CO2 Metering of liquid CO2 (blowing agent)
The customer’s challenge: For the manufacturing of insulation materials the metering of liquid CO2 (blowing agent) is required
LEWA’s scope of delivery: System
Delivery in detail: Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDB1 / M200, cooling unit, mass flow meter, DCS with control according to set point setting
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoamFluid Pressure in bar Flowrate in l/h Carbon dioxide 300 4.2 Market Process Synthetic Fibers -
Synthetic Materials / PlasticsBlowing agents,
Expanded foam, Extrusion -
Metering of liquid CO2 (blowing agent)
Metering of liquid CO2 (blowing agent)
The customer’s challenge: For the manufacturing of insulation materials the metering of liquid CO2 (blowing agent) is required
LEWA’s scope of delivery: Skid
Delivery in detail: 1 Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDE3 / M200, cooling unit, mass flow meter, DCS with control according to set point setting
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pumpFluid Pressure in bar Flowrate in l/h Carbon dioxide 414 100 Market Process Synthetic Fibers -
Synthetic Materials / PlasticsBlowing agents;
Expanded foam, Extrusion -
Metering of liquid butane (blowing agent)
Metering of liquid butane (blowing agent)
The customer’s challenge: For the manufacturing of insulation materials and packaging materials the metering of liquid butane (blowing agent) is required
LEWA’s scope of delivery: System
Delivery in detail: 1 Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDC3 / M910S, mass flow meter, piping, filter, pressure regulator and control cabinet with LEWA smart control controller
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA smart controlFluid Pressure in bar Flowrate in l/h Butane 340 30 Market Process Synthetic Fibers -
Synthetic Materials / PlasticsBlowing agents,
Expanded foam, Extrusion -
Metering of antistatic agent
Metering of antistatic agent
The customer’s challenge: In a refinery process additives have to be reliably metered
LEWA’s scope of delivery: System
Delivery in detail: Custom-designed metering system completely installed in container with 2 LEWA ecoflow diaphragm metering pumps, type LDB / M900, for hazardous area zone 1, including pulsation damper, strainer, valves, pressure transmitter and mass flow meter
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pumpFluid Pressure in bar Flowrate in l/h Antistatic agent 14 50 Market Process Petroleum Refining / Refineries Additive (final products i.e.fuel,wax) -
Metering of butane (blowing agent)
Metering of butane (blowing agent)
The customer’s challenge: For the manufacturing of insulating material a metering system for butane (blowing agent) is needed
LEWA’s scope of delivery: System
Delivery in detail: Custom-designed metering system with 1 LEWA ecoflow diaphragm pump, type LDD3 / M910, cooling unit, mass flow meter, DCS with control according to set point setting
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoamFluid Pressure in bar Flowrate in l/h Butane 350 88 Market Process Synthetic Fibers -
Synthetic Materials / PlasticsBlowing agents,
Expanded foam, Extrusion -
Metering of liquid butane (blowing agent)
Metering of liquid butane (blowing agent)
The customer’s challenge: For the manufacturing of insulation materials a metering system for liquid butane (blowing agent) is required
LEWA’s scope of delivery: SystemDelivery in detail: 1 Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDE3 / M900, mass flow meter, DCS with control according to set point setting
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoamFluid Pressure in bar Flowrate in l/h Butane 350 100 Market Process Synthetic Fibers -
Synthetic Materials / PlasticsBlowing agents,
Expanded foam, Extrusion -
Metering of dispersion of polymers
Metering of dispersion of polymers
The customer’s challenge: For the manufacturing of roofing tiles a metering system for dispersion of polymers is needed
LEWA’s scope of delivery: Skid
Delivery in detail: 1 Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDE1 / M900, reduced pulsation at 2 different pressures, 2 pressure retaining valves, control unit
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pumpFluid Pressure in bar Flowrate in l/h Polymer 80 300 Market Process Synthetic Fibers - Synthetic Materials / Plastics Dispersions -
Metering of flame retardant
Metering of flame retardant
The customer’s challenge: In the production of plastics flame retardant has to be metered
LEWA’s scope of delivery: System
Delivery in detail: Custom-designed metering system completely electrical heat traced and insulated, with 1 gear wheel pump, storage tank, strainer, valves, mass flow meter and control cabinet, for operating temperature of 80 °C
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoamFluid Pressure in bar Flowrate in l/h Flame retardant 137 14 Market Process Synthetic Fibers - Synthetic Materials / Plastics Polyester -
Metering of flame retardant (Irganox 1081)
Metering of flame retardant (Irganox 1081)
The customer’s challenge: In the production of plastics the metering of flame retardant is required
LEWA’s scope of delivery: System
Delivery in detail: Custom-designed metering system completely installed in heated cabinet, with 1 LEWA ecoflow diaphragm metering pump, type LDB1 / M900, strainer, valves, mass flow meter and control cabinet, with melting tank 50 l, for operating temperature of 100 °C.
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pumpFluid Pressure in bar Flowrate in l/h Flame retardant 20 14 Market Process Synthetic Fibers - Synthetic Materials / Plastics PVC - E-PVC -
Metering of chlorofluorocarbon (CFC) (blowing agent)
Metering of chlorofluorocarbon (CFC) (blowing agent)
The customer’s challenge: For the manufacturing of insulating packing material the metering of chlorofluorocarbon (CFC), freon 152 a as blowing agent is required
LEWA’s scope of delivery: System
Delivery in detail: Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDC3 / M910, cooling unit, mass flow meter, DCS with control according to set point setting
LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoamFluid Pressure in bar Flowrate in l/h Foaming agent 300 30 Market Process Synthetic Fibers -
Synthetic Materials / PlasticsBlowing agents,
Expanded foam, Extrusion -
Metering of phosphate precipitation
Metering of phosphate precipitation
The customer’s challenge: Modernization of a phosphate precipitation metering station in compliance with statutory regulations and savings in power consumption
LEWA's scope of delivery: Pump
Delivery in detail: 4 LEWA ecosmart diaphragm metering pumps, type LCA1
LEWA main product/s: LEWA ecosmart
Fluid Pressure in bar Flowrate in l/h Phosphate precipitation max.12 26 Market Process Customer Water treatment / Chemicals Metering of phosphate precipitation Conaqua Wassertechnik GmbH -
Metering of citric acid
Metering of citric acid
The customer’s challenge: In an extraction process citric acid shall be reliably metered
LEWA’s scope of delivery: Skid
Delivery in detail: 1 Custom-designed metering system with 1 LEWA ecodos sanitary pump, type 550
LEWA main product/s:
Custom-designed metering system
LEWA ecodos sanitary / hygienicFluid Pressure in bar Flowrate in l/h Citric acid 5 550 Market Process Chemical / Pharmaceuticals / Cosmetics Basic operations (separating, extract.) -
Injection of scale inhibitor
Injection of scale inhibitor
The customer’s challenge: For the injection of scale inhibitor a compact injection package for offshore service is required
LEWA’s scope of delivery: Package
Delivery in detail: Compact LEWA Chemical Injection pump skid with LEWA ecoflow diaphragm metering pump, type LDB and interconnecting tubing
LEWA main product/s:
LEWA Chemical Injection Package (CIP)
LEWA ecoflow diaphragm metering pumpFluid Pressure in bar Flowrate in l/h Scale inhibitor 60 6 Market Process Offshore / Oil & Gas Oil production, Offshore -
Methanol injection
Methanol injection
The customer’s challenge: For FPSO operation in arctic conditions a package for the injection of methanol shall be installed in a minimum available space
LEWA’s scope of delivery: Package
Delivery in detail: LEWA triplex process diaphragm pump, type G3G, G3S and GS
LEWA main product/s: LEWA triplex process diaphragm pump
Fluid Pressure in bar Flow rate in l/h Methanol 250 52,400 Methanol 305 8,000 Methanol 364 1,500 Market Process Offshore floater / Oil & Gas Oil production, Offshore floater -
Disposal of hydrocarbon condensate
Disposal of hydrocarbon condensate
The customer’s challenge: Hydrocarbon condensate is a waste product during the production of natural gas. For the disposal hermetically tight process diaphragm pumps are required
LEWA’s scope of delivery: Pump
Delivery in detail: 2 LEWA triplex process diaphragm pumps, type LDE3 mounted on a base frame with roof
LEWA main product/s: Custom-designed skid & package
Fluid Pressure in bar Flowrate in l/h Hydrocarbon condensate 99 2,000 Market Process Onshore / Oil & Gas Gas production, Onshore -
Disposal of Condensate
Disposal of Condensate
The customer’s challenge: Condensate is a waste product during the production of natural gas. For the disposal hermetically tight process diaphragm pumps are required
LEWA’s scope of delivery: Skid
Delivery in detail: Sealless LEWA triplex process diaphragm pump, type G3F with magnetic driven booster pump in Alloy 625
LEWA main product/s: LEWA triplex process diaphragm pump
Fluid Pressure in bar Flowrate in l/h Condensate 301 2,500 Market Process Offshore / Oil & Gas Gas production, Offshore -
Chocolate production
Chocolate production
The customer’s challenge: Production of complex fat mass (low/to high viscous) with refined sugar
LEWA’s scope of delivery: Pump
Delivery in detail: PLP3-3 and PLP2-2 pumps mounted with drive, base frame, coupling and coupling protection
LEWA main product/s: Pomac lobe pump
Fluid Pressure in bar Flowrate in l/h Fat Not Specified 250 - 10,000 Market Process Cutomer Food & Beverage Confectionery - Chocolate Bühler AG -
Odorization of biogas
Odorization of biogas
The customer’s challenge: A biogas plant had to be equipped with an odorization system to add the typical warning odor to the gas. Therefore metering precision was of particular importance.
LEWA’s scope of delivery: System
Delivery in detail: 1 LEWA odorization system type OD60 on 230 Volt (AC version) with stationary reservoir, solenoid operated diaphragm pump type MAH, flowmeter (KMM 1-BIO), capacitative sensor (FMI 51), controls
LEWA main product/s:
LEWA microflow-metering pump MFluid Pressure in bar Flow rate in l/h Tetrahydrothiophene 5 - 17 0,001 - 0,005 Market Process Odorization Storage applications, Odorizing -
WIN COSMETIC
WIN COSMETIC
LEWA delivers to WIN COSMETIC customized production units for the cleaning & detergents and personal care industries.
One application example is the production of fabric softener.
