Lewa has delivered a total of six Ecoflow type LDH5 process diaphragm pumps to the Arabian Gulf in order to expand the pumping capacity of two offshore gas fields. The pumps are used to inject mono ethylene glycol (MEG) to prevent bore hole icing at critical points along the pipeline. This job follows two earlier major projects. As part of the largest job in Lewa’s history, a total of 40 process diaphragm pumps for MEG injection were built for the end customer, an international company, in 2013. A follow-up order in the summer of 2017 included the delivery of 12 Ecoflow series type LDH5 pumps, among other products. The experience, gained on the two previous projects has helped to handle the current, third project with even more speed and efficiency.
The major order arrived at the end of March 2018. Its goal was to increase the pumping capacity of two offshore gas fields in Saudi Arabia. For this purpose, an international oil and gas company ordered a total of six Ecoflow type LDH5 process diaphragm pumps from Lewa. They are installed on wellhead platforms (WHPs) together with the corresponding M8 pump heads. From there, the pumps will inject mono ethylene glycol into the pumping process. This will prevent methane hydrates from accumulating at critical process locations, thereby effectively countering bore hole icing. “The six LDH5 pumps work with an operating pressure of approximately 520 bar and are designed for a flow rate of 5000 l/h,” said Klaus Figgle, Senior Project Manager of Engineering at Lewa. “As such, they are ideally suited for the application and contribute to complication-free gas pumping.”
As part of the cooperative effort with the end customer, this current major project represents what is now the company from Leonberg, Germany’s third MEG-injection project for the Arabian Gulf gas field. The shipment of 40 process diaphragm pumps back in 2013 (as part of what was previously the largest order in Lewa’s company history) was supplemented in 2017 by the follow-up order of 12 process pumps and 8 boxer pumps. The company received the letter of intent for the current project Lewa in May 2018, and the contract followed in July 2018. “Since the previous order involved the delivery of identical systems, we completed the project promptly and efficiently by November of the same year,” Figgle reported. “We were even able to shorten the delivery process of the first two systems by three weeks. The customer has expressed a high level of satisfaction with both the quality of the pumps and the course of the project.” The systems are currently being installed on the platform.
Fresh fragrance on feminine hygiene products
Smallest quantities sprayed continuously but flexibly
A new project of Visctotec Asia at the end of 2019 was the application of a fragrance on top of feminine hygiene products. Before implementation, dosing tests were carried out for the customer. A preeflow Eco-Spray dispenser was employed for this. The aim of the tests was to check the dosing accuracy and repeatability of the Eco-Spray for the small quantities. A particular challenge was to achieve precise results for various different products. Various quantities were to be tested for several products in the customer portfolio: 1.5, 1.8 and 2.5 mg per part – to allow flexible automated production. The in-depth dosing tests consistently demonstrated the accuracy and consistency of the small volumes required for the process. With the preeflow spray dispenser, Visctotec Asia is able to spray with less than 1 % deviation from the nominal value.
An example from the customer’s portfolio: The parts to be dispensed run in a roll form under the Eco-Spray. The speed of the roll is over 1,500 parts per minute. At the final stage, the customer wants to apply a small amount of <1.6 mg of fragrance to each product. The material is gravity fed from a container suspended about 2.5 meters above the floor. The method used up to now could not precisely dose such a small volume in each part and had poor repeatability. In conclusion, the customer decided to purchase the Eco-Spray from preeflow to integrate the spray dispenser into the existing line.
The key to success: The dosing tests proved that the customer required volume accuracy and consistency for product model could be achieved. In addition, the change from a pressure tank or gear pump tank, which was previously used, to product being fed by a gravity tank was convincing. An analog signal with PLC now also makes it possible to link the speed of the production line with the flow rate of the dispenser. This means that the amount of liquid to be sprayed can be dynamically adjusted according to the speed of the roll.
For consumers and the government, a maximum of safety and quality in the production of food is essential. In order to ensure the highest standards of hygiene, food producers and processors are obliged to clean their machinery regularly via washdowns. To guarantee that vacuum pumps are effectively protected from the used aggressive cleaning media, Leybold has developed a series of Hygienic Enclosures. The vacuum specialist offers users these stainless steel housings in seven different sizes, tailor made for each vacuum pump.
Risk of contamination eliminated
In the food industry, vacuum pumps are often placed directly next to the processing and packaging lines and thus not implemented in the equipment. On the one hand, this leads to a higher vacuum performance because, losses in pumping speed over longer pipelines are avoided. A direct positive consequence of this, are shorter process cycles and a better product quality. On the other hand, unprotected pumps are directly exposed to aggressive cleaning media during the rinsing processes. Over time, this leads to corroded vacuum pumps, shorter life cycles, higher costs and ultimately even to food contamination.
Effectively protected in stainless steel enclosures
In order to counteract these risks, Leybold has developed a new protection concept with the Hygienic Enclosures. Encased by these stainless steel enclosures, the vacuum pumps can be positioned near machines and systems without any problems. „On the basis of the protected Leybold vacuum pumps we can create better and more robust solutions for the demanding food applications“, emphasizes the responsible product manager Niels Gorrebeeck. „Of course, this applies all the more to applications such as stuffers, tumblers and of course packaging machines, where the machines and systems are cleaned and disinfected particularly frequently and intensively,“ the product manager explains.
Tailor made & easy to install
Gorrebeeck explains that these stainless steel enclosures are tailor made for each vacuum pump. As a result each enclosed pump can run constantly on every working pressure. The only limitation is the maximal ambient temperature for the enclosure. Nevertheless, the normal working temperature in F&P environments are around 10 °C, we qualified most enclosures up to 25 °C. Further all the enclosures are offered as a Do It Yourself kit and can be as well installed as commissioned by the user themselves without great effort. „These properties make of the Hygienic Enclosures a cost-effective, sustainable solution. In the end, Hygienic Enclosures makes investments in expensive piping obsolete and at the same moment they offer a better pumping speed performance“, argues Niels Gorrebeeck.
Incidentally, this also applies not least with regard to future packaging concepts. Gorrebeeck believes that the industry is also well equipped for this with the new enclosures: „Regardless of which solutions will prevail, food applications can be operated from today more hygienically, ergonomically as well as flexibly. Leybold can successfully accompany these processes into the future with our holistic solution approaches.“
Compressed air for jet milling applications
When it comes to generating compressed air, operators of jet milling equipment for the production of very fine powders can achieve significant energy cost savings through the skilful use of heat recovery. It is for this very reason that Kaeser has recently expanded the options palette for its range of oil-free compression rotary screw compressors from the CSG, DSG and FSG series.
Aside from steam, jet mills are most commonly operated using nitrogen or compressed air. In the case of the latter, heat energy can be recovered from the compressed air inside the jet nozzles and subsequently reused for the milling process. Exhaust heat arises as a by-product of compressed air generation, which essentially makes it a cost-free source of energy.
With the specific needs of jet milling applications in mind, Kaeser has now extended the options palette available for its two-stage, oil-free compression rotary screw compressors to include such features as compressed air discharge temperature control. Operating via flexible, controlled adjustments to the intercooler, this option can lead to a clear reduction in specific energy consumption per tonne of the final product, depending on the type of material being processed.
Kaeser offers the option of compressed air discharge temperature control on compressors from the CSG, DSG and FSG model range, featuring a power output from 37 – 355 kW and pressure from 4 – 11 bar. Both air-cooled and water-cooled versions are available.
Furthermore, Kaeser also offers compressors specially adapted for operation with nitrogen, in which the compressor can be individually configured to the specific nitrogen circuit.