LANXESS has now released a new version of its LewaPlus design software with a significantly expanded range of functions. The calculation tool, which enables sizing of ion exchange systems including individual process configurations, has been updated with improvements and additions to the modules for mixed bed calculation, condensate polishing and design of polishing stages in food and beverage production. The software also enables users to verify the effectiveness of existing systems and identify potential savings in operating costs.
dr. Nadja Hermsdorf, head of technical marketing in the Liquid Purification Technologies (LPT) business unit at LANXESS, explained: “We often find that the capacity of ion exchange resin units can be better utilized and that there is also potential for optimization in terms of water and chemical consumption. With LewaPlus we offer a powerful tool to determine such operating parameters in advance or retrospectively using simulation. After all, sustainability considerations and data are becoming increasingly important for our customers to reduce operational costs.”
Design and evaluation of mixed systems
New functionalities in the field of water treatment applications include a module for designing mixed systems with ready-to-use mixed layer (MB) resins. The starting point for this was standard mixed beds for which there are reliable data on working capacity. The module enables the design of filter hydraulics and enables a good estimation of the expected cycle time. As soon as the database is accurate enough to realistically calculate cycle times, the premium mixed beds will also be integrated in a further update.
In addition to designing new systems, LewaPlus now also enables the evaluation of existing mixed-bed systems, their optimization and performance monitoring of embedded resins. The MB-Check module was introduced as a logical next step. It is based on the proven Demi-Check module, a very effective tool for evaluating system performance by simulating the aging of embedded resins or changes in the composition of the feed water.
Determination of resin performance in condensate polishing applications
When it comes to condensate polishing, the further development of LewaPlus ensures a much more comprehensive calculation of resin efficiency. The revision of this module includes the following key improvements.
In a setup consisting of a strong acid cation exchange (SAC) resin and a downstream mixed bed stage, the cycle times can be calculated separately. Such a configuration is often used if the raw condensate has a high pH value. The SAC stage removes most of the conditioning agent so the mixed bed can run for much longer. The cycle time of the SAC stage can now be adjusted individually, independent of the mixed layer.
The volume ratio of SAC to strong base anion exchange (SBA) resin in the mixed bed can vary from 1:2 to 2:1. This means that hydraulic requirements, such as compliance with recommended minimum head or maximum specific volumetric load (BV/h), can be met without the need to adjust the safety factor. Actual working capacity and theoretical maximum working capacity are shown.
Furthermore, the silicon capacity calculation has been revised. In addition to laboratory data, data from real applications are also included in the calculation. This leads to a higher theoretical maximum working capacity.
Expansion of the food module
For the first time, LANXESS offers a feature within LewaPlus that can be used to evaluate the use of a mixed bed ion exchange system to produce the best possible sugar quality. Investment costs and potential savings in operating costs can also be identified. The first include installation of the system and procurement of ion exchange resins. Operating costs include the costs of regeneration and water supply and disposal. With the help of the cost forecast, the user can estimate the costs during the planned total operating life of the system (total cost of ownership, TCO).
As a design tool for the industrial production of aqueous sugar solutions, the LewaPlus FD module helps in the dimensioning of new systems and the verification of existing systems. To complete the portfolio of ion exchange processes for the food and beverage industry, LANXESS has expanded the existing module for appropriate applications. It is now also possible to design mixed systems that are used as the polishing phase of sugar solutions in the production of high purity sugar. Such sugar-containing solutions are either an integral part of end products produced from starch in a multiphase process, for example glucose, dextrose or concentrated fructose syrup, or liquid sugar obtained from sugar cane or sugar beet.
Detailed information on LewaPlus and LPT products and services can be found at https://lanxess.com/en/Products-and-Brands/Brands/Lewatit. The new version of the design software is now available for download here and can be used for free.