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Process diaphragm pump for supercritical CO2Supercritical fluids PGSS-CompositeProcess diaphragm pump for liquid carbon dioxideDruck/Temparatur-Diagramm von CO2

Process with supercritical fluid in the pharmaceutical, cosmetic and food sectors

In the life science area, processing is increasingly done with fluids in the supercritical aggregate condition.

The advantage of these processes is in the use of solvents that are environmentally friendly and non-damaging to the product, mainly carbon dioxide. The requirements of the pharma & biotech markets are met by working at low temperatures and moderate pressures (gentle handling of the product).

The requirements for the metering and process diaphragm pumps are very specific in these applications.

Solution

LEWA metering pumps and process diaphragm pumps are very well suited for supercritical processes, since they meet all the relevant requirements.

Advantages of LEWA pumps:

  • Hermetically tight
  • Layout of high pressure pumps and their
    peripheral equipment for liquid gases (refrigeration equipment)
  • Suitable for thin, non-lubricating fluids
  • High operational reliability
  • Low wear, almost no particle contamination
    due to minimal movement of pump head parts
  • Easy to clean, food design available
  • Hygienic design possible for pharmaceutical applications
    (Ra < 0.5 μm electro-polished, ASME BPPE, EHEDG)
  • Installation in GMP areas/clean rooms
  • Material conforms to FDA (GRAS: Generally Recognized As Safe)
  • Installation possible in potentially explosive areas
  • Optimum pump head material,
    for example Hastelloy, available for highly corrosive media
  • Diverse connection geometries
  • Custom valves possible
  • Documentation on qualification/validation
  • Tested for wafer cleaning (Fraunhofer IPA Tested Device®)

It must be noted that carbon dioxide must be in the liquid state to be pumped. This is not practical in the gaseous state due to its compressibility.

Areas of application

LEWA metering pumps and process diaphragm pumps have been successfully used in the following processes:

  • Extraction processes with supercritical CO2 (Supercritical Fluid Extraction SFE), such as decaffeination, degreasing, phytoextraction, as well as the extraction of oil seed, omega fish oil, flavors and spices
  • Supercritical preparative liquid chromatography (Supercritical Fluid Chromatography SFC), as well as separation of optically active substances
  • Supercritical Fluid Reactions SFR
  • Particle formation (e. g., Particles from Gas Saturated Solutions PGSS), such as high-pressure spraying process for pulverizing greases, baked goods, etc.
  • Cleaning processes, e.g., process integrated separation of substances, such as pesticide removal (wool grease, lanolin)
  • Cell breakdown, inactivation (gentle sterilization)



Principle of the PGSS process:

1) Conditioning and melting two reactants 1 and 2
2) Feed and compression with LEWA high pressure pumps P1, P2 and P3
3) Mixing both reactants with supercritical fluid
in a static mixer (SM)
4) Decompression in a spray tower (SP) via a nozzle
5) Droplet formation
6) Cooling of droplets and particle formation
7) Generation of powder in the spray tower with cyclone (ZK)

Illustration: scCO2 applications in the industry



Illustration: Principle of the PGSS process

Source: Department of Process Technology,
Transport processes, and particle design - technology,
University Bochum

Background

A supercritical fluid is a substance whose temperature and pressure are both over their critical point simultaneously (see diagram for CO2).

The critical temperature is the temperature over which the substance can no longer remain liquid, regardless of the pressure level.

Critical pressure is the pressure over which the substance can no longer form gas, regardless of the temperature.

Supercritical fluids have the density and good dissolving properties of fluids, as well as the viscosity, good compressibility, and diffusability of gases.

Due to their good mixing and mass transfer properties, they are classed as a fluid.


Important advantages of supercritical fluids:

  • Safe, cost-effective, environmentally friendly, non-toxic
  • They can replace organic solvents
  • Good influence over slight changes
    in operating conditions
  • Operating conditions under low temperature
    and pressure make them attractive for research
    and development in the pharmaceutical & biotechnology sector.

 

Selection criteria for the right supercritical fluid:

  • Physical-chemical properties of the
    desired mixture
  • Task of the solvent in the process in regards to
    solubility
  • Specific application
  • Safety, especially in regards to flammability,
    phase behavior under operating conditions
  • Cost of the fluid
  • Cost of the equipment


The most frequently used supercritical fluid is CO2.


Properties of carbon dioxide:

  • Low critical temperature (31.1°C)
  • Moderate critical pressure (73 bar)
  • Non-flammable
  • Non-toxic
  • Mixable with organic solvents
  • Recoverable after processing
  • Diffuses faster than conventional
    fluid solvents
  • GRAS status
  • Approved by the FDA for use in food and
    pharmaceuticals
  • Environmentally friendly
  • Cost-effective

Industries

Personal care

Processes with strict quality and hygiene requirements such as the GMP or the need to avoid preservatives, require the right equipment. We support you in your selection and the design of hygienic components and systems.

Pharma & Biotech

Special expertise is required in the production of pharmaceuticals in order to, for example, ensure meeting the legal requirements. Safety of production, documentation and validation are the top priorities.

Food & Beverages

Process integrity, recipe constancy, and product reliability are basic prerequisites in food technology. Hygienic aspects and cleanability play a central role: The process must remain closed and contamination of the process media must be impossible in every phase of production. LEWA pumps and systems make it possible!

Products

LEWA ecoflow diaphragm metering pump

The innovative and universal metering pumps with DPS Diaphragm Protection System in the proven modular system. Hydraulically coupled diaphragm metering pump.

LEWA ecoflow sanitary/hygienic

Absolutely safe, economical and multi-option metering pump with mechanically actuated diaphragm. The surfaces are adapted especially to hygienic production requirements. Mechanically actuated diaphragm metering pump in sanitary/hygienic capable design

LEWA ecodos diaphragm metering pump

Absolutely safe, economical and multi-option metering pump with mechanically actuated diaphragm. Their multiplex capability opens additional areas of application. Mechanically actuated diaphragm metering pump with monitored 4 layer sandwich diaphragm for low pressures.

LEWA micro-metering pump FC

The FC micro-metering plunger pumps for pressures up to 160 bar were developed especially for laboratories and test centers. The economical alternative for uncritical fluids. Packed plunger metering pump.

LEWA ecoflow process diaphragm pump

LEWA ecoflow process diaphragm pump. Durable and universal process pumps with DPS diaphragm protection system in a proven modular system.

LEWA triplex process pump

LEWA triplex is the most compact process diaphragm pump in the world for high-pressure processes in all branches of industry. Its space and weight saving monoblock design also makes it suitable for any application with extremely small installation space. Hydraulically actuated process diaphragm pump in monoblock design.

Customer-specific production units

LEWA customer-specific metering and mixing system Metering, mixing, filling, separating, controlling temperature – we work out the proper process-related flow with you and using this we produce the system that fits your production – right up to the end product.

LEWA customer-specific metering systems

LEWA customer-specific metering system Metering, cooling, heating, controlling, regulating – we ensure the interaction of pump, instrumentation and accessories. Your application and specification, your interface logic and your ideas are taken into consideration by LEWA and implemented right on target and comprehensively. You are our guideline for an economical solution.