EPC Turnkey Scrubber Systems: One Supplier, One Responsibility

01 One supplier, one responsibility

Industrial emission control demands precision, reliability and clear lines of accountability. In practice, projects involving several separate parties, each responsible for their own scope, frequently run into interface problems, delayed decisions and disputes over responsibility. The result is longer lead times, higher costs and uncertainty for the client.

Lechler addresses this by bringing the entire project under one roof. As an EPC turnkey contractor and Original Equipment Manufacturer in one, Lechler takes end-to-end responsibility: from the first process calculation through to formal handover. There is no gap between engineering and manufacturing, and no mismatch between design intent and commissioning.

02 From process data to engineering package

Analysing and evaluating process data

Where the gas composition entering the scrubber is unknown or insufficiently characterised, Lechler can carry out inline measurements with process analysers directly at the client's installation. These measurements give a real-world dataset of gas composition, pollutant concentrations and flow characteristics under actual operating conditions.

The data is then evaluated by our engineers and becomes the technical basis for absorber sizing, reagent selection and process design, so that the system is engineered to match reality, not assumptions. How such a measurement campaign works is described in Measuring an Unknown Emission.

Process engineering and engineering packages

All technical development is carried out in-house. Lechler performs mass transfer calculations, absorber sizing, liquid-to-gas ratio analysis, stress calculations and material selection based on corrosion resistance, operating temperature and chemical compatibility. Every engineering decision is made by the same team that will subsequently build and install the system.

Resource efficiency is part of the engineering from the outset. By optimising reagent consumption, liquid-to-gas ratio and energy input at the design stage, Lechler designs every system for the lowest resource consumption that still meets the required performance.

The engineering process produces a complete documentation package. All deliverables conform to the applicable international standards, including ASME, ASTM, API and ISO.

03 Procurement, fabrication and installation

Procurement and fabrication

Lechler manages the entire supply chain, from construction material to auxiliary equipment.

Because core equipment and electrical cabinets are made in-house, Lechler keeps full quality control and traceability throughout fabrication. Welding procedures, non-destructive testing, surface treatment and factory acceptance testing (FAT) are all carried out within one quality management framework, without relying on third-party subcontractors for critical scope.

Site construction and installation

Lechler manages the complete site installation: mechanical erection, pipework, electrical and instrumentation works, and integration with upstream and downstream process units. Construction supervision, safety compliance and interface coordination are handled by the same team throughout this phase, which keeps the project aligned with the plant layout and the client's operational requirements.

04 Commissioning and performance testing

Project completion follows a structured commissioning programme. At each stage, the scrubber system is verified against its guaranteed parameters.

Process analysers for resource-efficient operation

A key element of modern scrubber commissioning is the integration of high-end process analysers. Lechler specifies and integrates analysers for continuous monitoring of gas composition, pollutant concentrations and absorption efficiency. They provide real-time data for precise, dynamic control of reagent dosing, liquid flow rates and other system parameters, which translates into savings in chemicals, water and energy during operation. See also Do You Really Know What Your Process Consumes?

05 After handover: lifetime support

At handover, the client receives a complete documentation package. Long-term technical support remains available throughout the system's design life, for reliable and compliant operation of the scrubber well beyond commissioning. Our engineers can also support the installation remotely through the PLC; see PLC control and remote support.

06 Why integrated execution makes the difference

In traditional project structures, engineering, fabrication and installation are divided between separate parties. Each transition between disciplines is a risk: information is lost, assumptions diverge and the client is left to manage the interfaces.

Lechler removes these risk points. Because design, production and execution are in the hands of one organisation, technical decisions made during engineering carry straight through to fabrication and installation. There is no reinterpretation, no finger-pointing and no ambiguity over who is accountable when something needs to be resolved.

Because every Lechler scrubber system is individually engineered and built to the requirements of each project, there are no constraints imposed by standardised, off-the-shelf configurations. Designing from first principles means Lechler can build current technology into every system, from process analysers and smart instrumentation to modern control architectures, regardless of scale or application. Clients get a solution tailored to their process rather than one limited by a fixed product range. Read more about our open spray scrubbers or, for an existing installation, Upgrade or Replace?