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ERK Eckrohrkessel GmbH (2017) 1

PowerfulFirst-Class Boiler and Combustion Systems &Complete Engineering Services


Background Eckrohrkessel� Eckrohr (corner tube) boiler technology was developed in the mid 1940’s� First licensees started to build Eckrohr-boilers worldwide� Outsourcing of the ERK technology from La Mont Boiler Ltd. in 1977� ERK is headquartered in Berlin, Germany, with a global licensee network� ERK provides engineering services while licensees manufacture, supply, and install boiler/heater systems� Today 35 licensees in 26 countries worldwide ranging from small boiler manufacturers to turn-key suppliers, e.g. John Thompson, JFE, and Thyssen Krupp

History


Background Eckrohrkessel� The pressurized body is made of a stable frame-work out of downcomers, headers and tube walls, which are welded together with the tube walls to a gas-tight tube cage.� The unique arrangement of mixture pipes (4), steam back-flow pipes (5), overflow pipes (6) and unheated downcomers and return pipes (2, 7, 8) allows a pre-separation of steam before the steam drum. This results to a excellent load change behavior as well as a high steam purity. � This tube cage with all welded or separately supported heating surfaces is self-supported by downcomers in the corners of the boiler (2, 7).

Technical concept of the ERK boiler


� Licenses for ERK boiler and combustion system designs with ongoing engineering and development support� Boiler/ combustion system engineering services, including detail engineering, expert reports, boiler optimisation etc.� Rankine and Brayton cycle optimisation with unique boiler and heater equipment expertise� ERK tube technology to improve component performance, size, and weight� Research and development

Background EckrohrkesselBusiness areasBackground EckrohrkesselCFD simulationsip tube technology

Boiler/heater engineering


Background Eckrohrkessel� More than 6,000 boiler and heater references with capacities from 0.3-250MW� Broad fuel spectrum with >80,000MW installed capacity worldwide� Expertise with steam, thermal oil, hot water, and chemical heating systemsReferences01.0002.0003.0004.0005.0006.0001944 1949 1954 1959 1964 1969 1974 1979 1984 1989 1994 1999 2004 2009 2014Number of units Year

coal oilgas waste heatwaste multi fuelbiomass


35 licensees in 26 countriesBackground EckrohrkesselBackground Eckrohrkessel� Large number of licensees not only enables large number of references but also rapid implementation of innovations through local contacts� ERK is a European SME with global reach


Heat recovery systemsReferences overview� >200 references for clean and contaminated exhaust (1.5-250 MWth)� Heat recovery only but also supplementary and fresh air firing� Clean exhaust references include gas turbine and engine exhaust� Contaminated exhaust references include cement kilns, metallurgical processes, industrial furnaces, and marine oil exhaust� Steam (single, dual and triple pressure), hot water and thermal oilMWth 6 25025 13045


HRSG parameter:� References 6-250 MW� Working fluids hot water, steam, thermal oils� Design options - single, dual and triple pressure- heat recovery only, supplementary firing and fresh air firing- horizontal and vertical designs- multiple heat sources in a single HRSG- optimisation for load flexibility� Market Energy efficiency is a growth market worldwide with significant opportunities in the industrial sector

Heat recovery systemsHRSG downstream gas turbines


HRSG parameter:� References 1-15 MW� Working fluids steam and hot water� Design options - single and dual pressure- heat recovery only, supplementary firing and fresh air firing- horizontal and vertical designs- multiple heat sources in a single HRSG- optimisation for load flexibility� Market Increasing deployment of engine plants to mitigate intermittent PV and wind generation as well as marine applications

Heat recovery systemsHRSG downstream engines


HRSG parameter:� References 4-50 MW� Working fluids steam and hot water� Industries cement, metallurgical, glass, industrial furnaces etc.� Design options - single and dual pressure- horizontal and vertical designs- natural and forced circulation- optimisation to minimise fouling- multiple heat sources in a single HRSG� Market Energy efficiency is a growth market worldwide with significant opportunities in the industrial sector

Heat recovery systemsOther heat sources


Energy from biomass and wasteConversion system overviewBiomass and waste materials gasificationcombustion (grate and fluidised bed)� ERK has references for all grates, fluidised bed ad gasification systems� Choice of firing system depends on fuel quality, process and efficiency requirements as well as commercial constraints


Energy from biomass & wasteCombustion reference overview� >450 references for biomass plants (1-160 MWth)� >580 references for waste plants (2-75 MWth)� Different grate and fluidised bed systems� Biomass fuels: wood, bagasse, rice husk, straw, olive pits, fruit bunches etc.� Waste fuels: RDF, MSW, industrial & hazardous waste, sewage sludgeMWth 5 16020 50 70


Energy from biomass & wasteWaste combustion exampleBoiler parameter:� Steam capacity 2x 98 t/h� Steam pressure 50 bar� Steam temperature 350°C� Fuels Municipal solid waste� Outputs Electricity and processheat


Energy from biomass & wasteWaste combustion exampleBoiler parameter:� Steam capacity 3x 20 t/h� Steam pressure 40 bar� Steam temperature 400°C� Fuels Municipal solid waste� Outputs Electricity and process heat� Design features Patented parallel flow design; First in the world optimised for minimal fouling


Energy from biomass & wasteMulti-fuel combustion exampleBoiler parameter:� Steam capacity 50 t/h� Steam pressure 42 bar� Steam temperature 310°C� Fuels Coal, waste, paper sludge, plastic, and wood waste� Outputs Electricity and process heat


Fluidised bed technologyPatented ERK design for multi-fuel systems� ERK has developed and is patenting a bubbling fluidised bed technology with multiple compartments� The design has the following benefits:

� Simultaneous use of fuels with different properties,� Individual air supply for each compartment,� Very low part-loads possible through shutdown of one or more compartments,� Large units possible without instabilities in the compartments.


Energy from biomass & wasteGasification reference overviewMWth 5 20 50 70� >100 references for gasification plants (1-70 MWth)� References up to 20 MWe� Fuels: Waste, wood, wood waste, bagasse, sawdust, sander dust and bark� Expertise with various licensee technologies


Energy from biomass & wasteWorlds largest waste gasification plantBoiler parameter:� Steam cpacity 90 t/h� Steam pressure 60 bar� Steam temperature 450°C� Electric capacity 20 MW� In operation since 2004� Fuel type RDF and coal


Energy from biomass & wasteBiomass waste materials with 4 gasifiers attached to a single boilerBoiler parameter:� Steam capacity 90 t/h� Steam pressure 82 bar� Steam temperature 480°C


CoalCombustion reference overview� >550 references for biomass plants (3-120MWth)� >4,450MW installed capacity� Up to 500MW units possible� Different grate, fluidised bed and burner systems� Coal type: black coal, lignite, coal washings, coal mixtures� Co-firing: Coal with biomass, waste, gas and oilMWth 4 12035 50


CoalCoal and biomass fired boilerBoiler parameter:� Steam capacity 120 t/h� Steam pressure 115 bar� Steam temperature 540°C� Fuel flexibility to react to fuel and carbonprice changes without changing the plant


CoalCoal and biomass fired boilerBoiler parameter:� Steam capacity 40 t/h� Steam pressure 66 bar� Steam temperature 465°C� Fuel flexibility to react to fuel and carbonprice changes without changing the plant


Concentrating solar powerSteam generator designs� Natural circulation to minimise parasitic consumption� Forced and once through designs possible� Steam generator for molten salts and thermal oils� Compact design optimised for rapid installation� Designs maximised for modularisation to minimise installation cost and time


� Natural gas/oil fired boiler (start up to full load in <5 minutes)� Single unit oil heaters up to 150MW to minimise cost and plant complexityReference example: � Steam capacity 130 t/h� Operation pressure 36 bar� Steam temperature 540 °C� Location Germany

Quick start-up back-up boiler/heaterConcentrating solar power


� Current thermal oil heater in parabolic trough plants are gas fired but a mult-fuel system could lower gas consumption and increase renewable energy generation� ERK has design capabilities for thermal oil and molten salt heaters up to 150MW� Large thermal oil heater can lower total heater quantity, plant cost and complexityMulti-fuel fired thermal oil heater

Biomass and gas fired thermal oil heater in GermanyConcentrating solar power


ERK tube technologyConcept and benefits� ERK tube = industrial power tube� Patented technology with IP protection for variousapplications, designs, and manufacturing processes� ERK tubes can double heat transfer rates without tube side pressure drop increase; Heat transfer rate increase of up to 4.5 possible� Heat transfer is enhanced through turbulent flow on the tube inside and outside� Specially shaped dimples individually engineered forvarious purposes, such as heat transfer, pressure drop, fouling, and acoustics� Beneficial fouling behavior through induced turbulences proven in various applications� More than 150 ERK tube references available worldwide and active marketing through ERK’s licensee network


HRSG comparisonERK tube technology� 2,3MWth HRSG with 10bar, saturated steam, inlet temp. 500°C, outlettemp. 220°C, identical flue gas pressure drop, and steam space� HRSG comparison based on 3,5 t/h, 11bar, sat. steamCriteria Plain tube ERK tube*1 ERK tube*2 Delta� Shell diameter 1,300 mm 1,400 mm 1,580 mm -8% / 22%� Shell length 5,750 mm 4,000 mm 2,400 mm -30% / -58%� Heating surface 237 m2 147 m2 134 m2 -38% / -43%� Tube weight 4.5 t 2.9 t 2.5 t -36% / -44%� HRSG weight 6.1 t 4.1 t 3.7 t -32% / -39%*1 *2


ERK tube technologyMarkets� Heat recovery smoke tube boiler� Directly fired smoke tube boiler� Shell & tube heat exchanger� Marine boiler systems� Flue gas condenser� Thermal oxidiser� Air preheater� Heating surfaces for refuse and biomass fired boilers, WHB in cement industry and other high dust applications


ContactsProf. Dr. Udo HellwigManaging Director� p: +49 30 8977 46-21� e: [email protected]. Julio Cèsar RincònSenior Boiler EngineerManager Business Development Ibero-America� p: +49 30 8977 46-24� e: [email protected]:� Am Treptower Park 28-30� Schuckert-Höfe, Haus A� 12435 Berlin� Germany

powerful - ahk mexiko (camexa) · powerful first-class boiler and combustion systems & ......

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