C2 - ENGINEERING THE ENERGY TRANSITION

ERK® Energy Systems | © 2018
E N G I N E E R I N G T H E
ENERGY TRANSITION
IGC 2018 Presentation, Dr. Jürgen Peterseim, 26/04/2018

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▪ Brief introduction of ERK
▪ Historical electricity production
▪ Lessons to be learned
▪ Design aspects
▪ Technical concepts
▪ Summary
AGENDA

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▪ ERK was founded in 1977 as an offshoot from La Mont Herpen GmbH & Co. KG
▪ ERK has always been a licensor for boiler & combustion systems
▪ It is headquartered in Berlin, Germany & has a global licensee network
HISTORICAL DEVELOPMENT

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REFERENCES
▪ More than 6,000 boiler & heater references with capacities from 0.3-250 MW
▪ Broad fuel spectrum with >80,000 MW installed capacity worldwide
▪ Expertise with steam, thermal oil, hot water, and chemical heating systems
▪ References for biomass, waste, multi-fuels, oil, gas, coal and heat recovery systems

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ERK LICENSEES WORLDWIDE
▪ ERK licensee network comprises 10.000 employees and > €1.6 billion revenue worldwide

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INSTALLED REFERENCES WORLDWIDE
▪ Installations in almost every part of the world and for a multitude of applications

REFERENCES
MORE THAN 6,000 INDUSTRIAL AND UTILITY ERK INSTALLATIONS WORLDWIDE

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▪ Bulk of the product cost and environmental impact is determined in design stage
▪ With time and project stage costs of changes increases significantly
▪ Know what technologies are out there and its field experiences
COST DRIVERS
Adapted from: Libra, J.A. (2007) Environmental Process Engineering: Building Capacity for Sustainability, Journal of
Professional Issues in Engineering Education and Practice. Vol. 133, Issue 4, pp: 308-319.

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▪ Fouling is a problem many industrial applications have to deal with, e.g. waste to energy, steel
and cement plants
▪ Expertise partially transferable to geothermal applications
▪ Fluid temperatures, tube pitch, velocities, cooling rate, and tube type are all relevant aspects
DESIGN TO MINIMISE FOULING

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▪ Heating surface design affects fouling
▪ Media velocity and flow direction has a significant impact
▪ Tube type can reduce fouling behavior
Conventional heating surface design Optimised heating surface design

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▪ Use of different tube types to enhance heat transfer, optimise pressure drop or reduce fouling
▪ Less fouling, longer operational cycles, less cleaning & less downtime
▪ Higher efficiency, fluid turbulences create increased heat transfer
High Flexibility Less Fouling Higher Efficiency

1313
Germany
70 kW
8 bar
Flue gas (610-90°C)
to water (80-90°C)
Heat recovery
0
20
40
60
80
100
120
140
160
0 600 1.200 1.800 2.400 3.000
Exhaustgasexittemperature,°C
Operating hours
Thermal capacity
Operating pressure
Working media
Application
SPECIAL FEATURE
Significant increase in mean time between
maintenance from 500 h to 3,000 h

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▪ Modularisation is widely used in the oil & gas and other industries
▪ Project location determines size of modules
▪ Lower equipment and installation cost
▪ Reduces installation time / cost
▪ Increases product quality
MODULARISATION

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▪ Multifunctional components can lower plant cost and reduce complexity
▪ Widely used in automotive and aviation industries but examples in other areas available
▪ Examples below show the use of boiler downcomer tubes to serve three purposes: a) water
circulation, b) boiler support structure, and c) platform support
MULTIFUNCTIONAL COMPONENTS

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▪ Geothermal plant suffer from comparatively low cycle efficiency
▪ Higher steam parameters desirable to raise efficiency and lower specific CapEx
EXTERNAL STEAM SUPERHEATING
Adapted from: Zarrouk and Moon, Efficiency of geothermal power plants:
A worldwide review, Geothermics, vol. 51, pages 142-153, 2014
Up to
48%
Up to
62% Up to
58%

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▪ The external superheating concept has been applied to waste to energy plants
▪ External superheating with natural gas, such as Holstebro, or gas turbine exhaust, such as Bilbao
▪ Applicable to geothermal using fossil and renewable sources
Holstebro waste to energy plant, DK Bilbao waste to energy plant, ES

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▪ Steam superheating from a waste to energy plant in the HRSG of a gas turbine combined cycle
installation in Bilbao, Spain
Source: Gohlke, O., Spliethoff, H. (2007). Innovative approaches to increase
efficiency in EfW plants - potential and limitations. In ISWA conference. Amsterdam.

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▪ Basic scenario: flash steam geothermal only
▪ 7 MWe net capacity with 11.4% net cycle efficiency

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▪ Geothermal with external natural gas superheating post-flashing
▪ 8.6 MWe net capacity with 12.9% net cycle efficiency or 10 MWe with 14.3% efficiency when heating to 525°C

Natural gas reserves (2004)
Land available for biomass growth
▪ Multiple renewable energy sources are principally available for external superheating, including
biomass and concentrating solar

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▪ A lot of boiler and heat exchanger design
expertise available in conventional energy industry
▪ Most cost reductions possible in design stage
▪ Various design, manufacturing and installation
concepts can be transferred to geothermal
▪ Adaptations to geothermal applications necessary
▪ To capture expertise and transfer it close
communication with geothermal players necessary
SUMMARY

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ERK ECKROHRKESSEL GMBH
CONTACT
Dr. Jürgen Peterseim
Director Strategy & New Products
+49 30 8977 46-41
jpeterseim@eckrohrkessel.com
Address
Am Treptower Park 28-30
Schuckert-Höfe, Haus A
12435 Berlin, Germany
www.erk-systems.com
THANK YOU

C2 - ENGINEERING THE ENERGY TRANSITION

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