ERK Eckrohrkessel GmbH (2017) 1. First-Class Boiler and Combustion Systems & Complete Engineering Services

Transcription

1 ERK Eckrohrkessel GmbH (2017) 1 Powerful First-Class Boiler and Combustion Systems & Complete Engineering Services

2 Background Eckrohrkessel History 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 ERK Eckrohrkessel GmbH (2017) 2

3 Background Eckrohrkessel Technical concept of the ERK boiler 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). ERK Eckrohrkessel GmbH (2017) 3

4 Background Eckrohrkessel Business areas 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 Boiler/heater engineering ip tube technology ERK Eckrohrkessel GmbH (2017) 4 CFD simulations

5 Background Eckrohrkessel References More than 6,000 boiler and heater references with capacities from MW Broad fuel spectrum with >80,000MW installed capacity worldwide Expertise with steam, thermal oil, hot water, and chemical heating systems Number of units coal gas waste biomass oil waste heat multi fuel Year ERK Eckrohrkessel GmbH (2017) 5

6 Background Eckrohrkessel 35 licensees in 26 countries 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 ERK Eckrohrkessel GmbH (2017) 6

7 Heat recovery systems References overview >200 references for clean and contaminated exhaust ( 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 oil MWth ERK Eckrohrkessel GmbH (2017) 7

8 Heat recovery systems HRSG downstream gas turbines HRSG parameter: References Working fluids Design options Market MW hot water, steam, thermal oils - 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 Energy efficiency is a growth market worldwide with significant opportunities in the industrial sector ERK Eckrohrkessel GmbH (2017) 8

9 Heat recovery systems HRSG downstream engines HRSG parameter: References Working fluids Design options Market 1-15 MW steam and hot water - 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 Increasing deployment of engine plants to mitigate intermittent PV and wind generation as well as marine applications ERK Eckrohrkessel GmbH (2017) 9

10 Heat recovery systems Other heat sources HRSG parameter: References Working fluids Industries Design options Market 4-50 MW steam and hot water cement, metallurgical, glass, industrial furnaces etc. - single and dual pressure - horizontal and vertical designs - natural and forced circulation - optimisation to minimise fouling - multiple heat sources in a single HRSG Energy efficiency is a growth market worldwide with significant opportunities in the industrial sector ERK Eckrohrkessel GmbH (2017) 10

11 Energy from biomass and waste Conversion system overview 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 Biomass and waste materials combustion (grate and fluidised bed) gasification ERK Eckrohrkessel GmbH (2017) 11

12 Energy from biomass & waste Combustion 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 sludge MWth ERK Eckrohrkessel GmbH (2017) 12

13 Energy from biomass & waste Waste combustion example Boiler parameter: Steam capacity 2x 98 t/h Steam pressure 50 bar Steam temperature 350 C Fuels Outputs Municipal solid waste Electricity and process heat ERK Eckrohrkessel GmbH (2017) 13

14 Energy from biomass & waste Waste combustion example Boiler parameter: Steam capacity 3x 20 t/h Steam pressure 40 bar Steam temperature 400 C Fuels Outputs Design features Municipal solid waste Electricity and process heat Patented parallel flow design; First in the world optimised for minimal fouling ERK Eckrohrkessel GmbH (2017) 14

15 Energy from biomass & waste Multi-fuel combustion example Boiler parameter: Steam capacity 50 t/h Steam pressure 42 bar Steam temperature 310 C Fuels Outputs Coal, waste, paper sludge, plastic, and wood waste Electricity and process heat ERK Eckrohrkessel GmbH (2017) 15

16 Fluidised bed technology Patented 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. ERK Eckrohrkessel GmbH (2017) 16

17 Energy from biomass & waste Gasification reference overview >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 MWth ERK Eckrohrkessel GmbH (2017) 17

18 Energy from biomass & waste Worlds largest waste gasification plant Boiler 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 ERK Eckrohrkessel GmbH (2017) 18

19 Energy from biomass & waste Biomass waste materials with 4 gasifiers attached to a single boiler Boiler parameter: Steam capacity 90 t/h Steam pressure 82 bar Steam temperature 480 C ERK Eckrohrkessel GmbH (2017) 19

20 Coal Combustion 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 oil MWth ERK Eckrohrkessel GmbH (2017) 20

21 Coal Coal and biomass fired boiler Boiler parameter: Steam capacity 120 t/h Steam pressure 115 bar Steam temperature 540 C Fuel flexibility to react to fuel and carbon price changes without changing the plant ERK Eckrohrkessel GmbH (2017) 21

22 Coal Coal and biomass fired boiler Boiler parameter: Steam capacity 40 t/h Steam pressure 66 bar Steam temperature 465 C Fuel flexibility to react to fuel and carbon price changes without changing the plant ERK Eckrohrkessel GmbH (2017) 22

23 Concentrating solar power Steam 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 ERK Eckrohrkessel GmbH (2017) 23

24 Concentrating solar power Quick start-up back-up boiler/heater 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 complexity Reference example: Steam capacity 130 t/h Operation pressure 36 bar Steam temperature 540 C Location Germany ERK Eckrohrkessel GmbH (2017) 24

25 Concentrating solar power Multi-fuel fired thermal oil heater 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 complexity Biomass and gas fired thermal oil heater in Germany ERK Eckrohrkessel GmbH (2017) 25

26 ERK tube technology Concept and benefits ERK tube = industrial power tube Patented technology with IP protection for various applications, 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 for various 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 ERK Eckrohrkessel GmbH (2017) 26

27 ERK tube technology HRSG comparison 2,3MWth HRSG with 10bar, saturated steam, inlet temp. 500 C, outlet temp. 220 C, identical flue gas pressure drop, and steam space HRSG comparison based on 3,5 t/h, 11bar, sat. steam Criteria 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 m m m 2-38% / -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 Eckrohrkessel GmbH (2017) 27

28 ERK tube technology Markets 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 ERK Eckrohrkessel GmbH (2017) 28

29 Contacts Prof. Dr. Udo Hellwig Managing Director p: e: Dipl.-Ing. Julio Cèsar Rincòn Senior Boiler Engineer Manager Business Development Ibero-America p: e: Address: Am Treptower Park Schuckert-Höfe, Haus A Berlin Germany ERK Eckrohrkessel GmbH (2017) 29