Even through it is already the end of January we want to wish you a Happy New Year and trust it has started well for you! Throughout the year we will keep you informed about our activities on a three monthly basis and are looking forward to working with you in 2018.
Management transition at ERK
2017 in review
Boiler conservation in changing energy markets
Featured project – Sludge fired boiler in Turkey
Combining waste management and power generation is a global trend and ERK has decades of experience and >650 references for waste to energy boilers. More recently new waste materials, such as sewage sludge, are used in boiler systems to provide process heat and/or electricity.
In 2017 our Turkish licensee Eralp Kazan has installed and commissioned two sewage sludge fired boilers with steam parameters of 5.6 tph, 460°C and 40 bar. We want to congratulate the Eralp team for realising this interesting project with us.
In the future sewage sludge fired boilers will be deployed more frequently all over the world and we already got the next orders with our licensee Mackenzie from Malaysia.
Starting the last quarter of this year we would like to provide an update on our recent activities and developments.
One important milestone this year was our technical training in Berlin. Know-how exchange and discussions with our licensees are very important to ensure that each project is designed according to the clients’ needs, commercial constraints and licensee manufacturing capability. We want to thank all participants and are looking forward to meeting you again in the near future.
PARAT from Norway joins ERK licensee network
New ERK brochure
ERK introduces new container power plant concept
Featured project - Fiji biomass project
Most remote islands use reciprocating engines with heavy fuel oil or diesel for power generation. However, many island states have renewable energy policies in place and are working on its implementation.
Earlier this year our licensee LAWI Engineering GmbH from Germany commissioned a multi-fuel boiler island for a 12 MWe biomass plant in Fiji. This power plant generates base load power for the Fijian public grid and is expected to annually reduce CO2 emissions by more than 50,000 tonnes. For many islands in the tropics biomass is a very interesting fuel to:
a) generate renewable electricity or heat/cooling,
b) use locally available feedstocks, and
c) create direct and indirect long-term employment.
We congratulate LAWI to this interesting project and are looking forward to join LAWI in further projects delivering renewable energy to the remoter parts of our world.
We are already in the 2nd quarter of 2017 and hope the 1st quarter has been good for you. ERK has started the year with some new waste to energy, biomass and heat recovery boiler projects.
In addition to our day to day activities we have started to update our marketing materials and will inform you in the next newsletter about new brochures, presentations etc.
ERK won 2016 German resource efficiency award
New ERK representative for Southeast Asia
Boosting efficiency with zeolites
2016 has been a good year for ERK with multiple new boiler registrations from various industries, such as waste to energy, biomass power generation, offshore, oil & gas, and energy efficiency. In addition to boilers systems we received multiple orders to design bubbling fluidised bed combustions systems too. Our engineering activities have increased significantly, adding references to various expert reports for steam and hot water boilers as well as CFD and FEM analyses and optimisation.
Looking ahead more strategically we have continued our expansion into further renewable energy markets, such as concentrating solar power and geothermal, through conference talks, R&D projects and business development activities.
One highlight was our bi-annual licensee conference in September, which many licensee attended. We had very fruitful discussions about current projects, market challenges/opportunities and new products.
We are quite optimistic about next year and wish all of you a relaxing festive season and a great start into 2017.
New boiler and heater enquiry form online
Flue gas condensation
Rapid response boilers to compensate intermittent generation
With the rising deployment of intermittent renewable energies and in the absence of large scale energy storage, new power and cogeneration plants need to be highly flexible to handle the load demands.
Load flexibility and fast ramp rates are key characteristics of ERK boilers and we have rapid response units in operation for more than 15 years, e.g. 130 tph and 540°C oil and gas fired unit in Cottbus, Germany. These boilers can start from 0-100% load in <4.5 minutes and have been tested to do this in only 3 minutes.
ERK is now transferring this know-how to load flexible HRSG’s for gas turbine combines cycle plants as these are likely to provide balancing power in the future. To maximise load change capabilities we have applied for patents, which reduce the wall thickness of the high pressure drum and headers.
We have already quoted this new design with one of our licensees and are looking forward to future project opportunities.
New machine for ERK Tube production
Over the last years the sales of our ip tube technology and corresponding engineering activities have grown continuously. To cope up with the demand, ERK decided to provide its licensee La Mont with a new ERK Tube production machine. After months of engineering and assembly, the new machine is now in commercial operation and can manufacture ERK Tube technology from carbon and stainless tubes with the following parameters:
- Tube diameter 6-120 mm
- Wall thickness up to 8 mm
With the improved manufacturing capabilities, it is now possible to strengthen ERK’s position in fire tube boilers and the first successes are 6x ip tube boiler with our licensee Gonella and 2x with Schneider Kessel.
We are looking forward to grow this business and in time lease ERK Tube production machines to our licensees worldwide.
Our colleague Michael Göbel retires after 46 years at ERK
After 46 years our dear colleague Michael Goebel retired earlier this month. He started with us in 1970 and has designed hundreds of boilers, including the 6,000th ERK boiler in 2016. His career spanned more than 4,000 ERK boiler references and we believe it’s very hard to find someone who can match his expertise. Luckily, we will not lose his expertise at once as he agreed to train our young engineers and provide his know-how on a part-time basis. We wish Michael all the best for his retirement and are looking forward to see him around the office occasionally.
We are already in the third quarter of 2016 and we would like to update you on our activities over the last four months. We continued to receive multiple boiler registrations from our licensees worldwide and are now looking forward to meeting most of them at our upcoming ERK licensee conference in September.
ERK ranked among top boiler technology providers worldwide
According to recent analysis by McCoy Power Reports ERK ranks among the top boiler technology providers worldwide with a 4.7% global market share from 2006 to 2015. ERK achieved 8th place for fossil fuel, 5th place for waste to energy, and 3rd place for biomass and bubbling fluidised bed boilers. Off all companies in the top 10 ERK is the only one working exclusively with license agreements. Ranking high in low carbon and renewable energy boiler systems is very important to ERK and a goal we are actively pursuing with our energy transition strategy. We are therefore excited to see that we rank very well in these two categories. Based on these results we will continue to improve the efficiency of biomass, waste and fossil fuel fired boilers to strengthen our market position and reduce the impact on the environment.
12MWe biomass gasification cogenaration plant won U.S. Award for Corporate Excelence in Environmental Sustainability
In 2011 our licensee Berkes from Uruguay commissioned the 12 MWe Weyerhauser biomass gasification cogeneration plant in Uruguay. 5 years later the plant is not only performing as designed but received the Award for Corporate Excellence in Environmental Sustainability by the U.S. Deputy Secretary.
Our client Weyerhaeuser Productos S.A. in Uruguay received the award for building the 80 MWth renewable energy facility. Additionally, the plant has been recognized as a “Project of National Interest” by the government of Uruguay. Berkes has a biomass gasification track-record of more than 800 MWth, which helped them win this project. We like to congratulate all involved in this project for this achievement and are looking forward to expanding our biomass and RDF gasification reference list with Berkes in the future.
Combination of ERK boilers with algae for carbon capture
Lowering the carbon intensity of boiler systems is a key part of ERK’s energy transition strategy and we believe that the incorporation of algae is one promising option to achieve this. In addition to a lower carbon intensity algae is an interesting product for multiple industries, such as food and pharmaceuticals, which opens up new business opportunities for owners of boiler plants worldwide.
After having completed an algae R&D project with the University of Applied Sciences Wildau, where we successfully operated a small cogeneration plant, ERK now aims to build a first commercial plant
ERK to exhibit at leading marine conference SMM in Hamburg
ERK has decades of experience with marine boiler and heater systems and >600 references on bulkers, passenger vessels, oil tankers, drilling platforms and FPSO’s. Almost all references are directly fired or heat recovery water tube boilers. However, since the late 1990’s ERK designs fire tube boilers and is now capable to lower weight and volume of these by up to 50% by using our proprietary ERK Tube technology. Another new product in our marine portfolio are shell & tube heat exchangers.
To strengthen our position in the marine market ERK is going to attend the upcoming SMM Exhibition and Conference in Hamburg, 6-9th of September, and we are looking forward to meeting existing and new customers.
ERK won Berlin company rowing competition
On the 11th of June this year our ERK rowing team participated for the first time in a competitive Berlin company rowing regatta and won in the men’s division. Our Prof. Dr. Hellwig is a long-term rowing enthusiast and has established the team last year. Big congratulations to the team and we are looking forward to the 2017 regatta.
We are already in the second quarter of 2016 and we would like to update you on our activities over the last three months. We already have various new boiler registrations since the beginning of this year and we are looking forward to further projects in 2016. An interesting observation is the growing number of bubbling fluidised bed boilers, three already in 2016, which demonstrates ERK experience in this field.
Thermal energy storage: A new business area for ERK
Thermal energy storage (TES) is a growing trend and we see synergies, as ERK is well established in the industrial boiler and heater market. TES is particularly interesting for process and district heating applications, which are key markets for ERK and where we have a strong track record. We have the expertise to design thermal energy storage systems using hot water (atmospheric and pressurised), steam (various pressure levels) and thermal oil. In addition to these well-established working fluids we can also opt for advanced materials, such as zeolites.
In addition to the working fluid we can support licensees and other clients with the optimisation of the TES capacity, dispatch strategy and system configuration. To improve design times and option comparison we are currently integrating the TES design into our new in-house boiler design software.
ERK announces its 28th licensee Conference
From 14th till 16th September 2016, ERK is going to host its 28th biannual licensee conference and workshop. We have chosen Berlin for this event, as we believe the current changes in the German energy system are of interest to many participants and are likely to occur similarly in other countries through the rising deployment of renewable energy systems.
The program will be comprehensive, ranging from technology solutions for the energy transition via improved design options for ERK boilers to expert reports and system optimisation. Key topics will include:
- Breaking new ground in cooperation between ERK licensees, presentations on best practices.
- New demands - new solutions, e.g. rapid response, power-to-heat, thermal energy storage and marine boilers.
- Improving boiler design and performance, e.g. flue gas condensation, multi-fuel units, ERK Tube design and new cleaning devices.
- Advances in modern combustion technologies, e.g. low NOx burners and flame detectors.
- Expert reports on problems and damages, e.g. furnace design and flame impingement.
We are looking forward to meeting our licensees again to discuss business opportunities but also to build and maintain personal relationships with each other.
CSP hybrid project
ERK is already active in the concentrating solar power (CSP) business and we are glad to inform you about our cooperation with Industrial Solar on solar process heating and cooling. Industrial Solar is the world leader in Fresnel type solar fields for process heat with a track record of more than 13 reference plants worldwide.
Our technologies align very nicely from a technical perspective, such as working fluids, temperature and pressure, and a market perspective as both of us focus on industrial applications, such as food processing, manufacturing and energy efficiency. With ERK and Industrial Solar competencies a solar field can be integrated without process heat supply interruption to the client as the ERK boiler can compensate solar field load changes very rapidly. ERK has detailed expertise with CSP hybrids through our project team and a PhD candidature in this area.
ERK and Industrial Solar are already developing a few projects worldwide but we are interested in further greenfield and retrofit opportunities. Please do not hesitate to contact us if you have any questions.
ERK introduces compact fire tube heat recovery boiler range for marine and industrial applications
ERK has a long track record of marine boilers with more than 600 references for hot water, thermal oil and steam boiler. These references include directly fired and heat recovery boilers on tankers, platforms, FPSO’s etc.
Until now, all our marine projects involved natural or forced circulation water tube boilers but with ERK’s proprietary ERK Tube technology, we are now also offering licenses for fire tube boilers. The ERK Tube technology enables weight and volume reductions of up to 40%. The case study on the right shows three different marine boilers with thermodynamically identical parameters , with a plain tube example at the top and two ERK Tube versions below. The smaller ERK Tube units lower the direct boiler cost and associated costs, such as transport, number and size of deck openings, and installation cost.
ERK Tubes are already being used in stationary fire tube boilers and marine heat exchangers. Total ERK Tube marine references to date exceed 20 units with forward contracts until 2018. The stronger focus on energy efficiency in the marine industry is likely to lead to a growing marine boiler market. ERK is now uniquely positioned to provide designs for standard and tailor-made projects with natural and forced circulation water tube boilers as well as compact fire tube boilers.
With the end of 2015 coming close we would like to update you on the latest activities within ERK. We would like to wish all of you an enjoyable and relaxing festive season and are looking forward to new and exciting projects in 2016.
2015: A review
6,000th ERK boiler reference
70 years after the installation of the 1st ERK boiler we are proud to announce the 6,000th ERK reference! The boiler is a heat recovery system behind an electric arc furnace and is going to be installed in a steel plant in Japan. The unit was registered by our licensee Tenova and ties together nicely ERK’s expertise with natural and forced circulation steam systems. The project consists of a water-cooled duct with forced circulation and a natural circulation heat recovery steam boiler with a total capacity of 58MW. Energy efficiency is a key market for ERK and with more than 200 references in this field we are looking forward to future projects.
ERK strengthens its position in the fluidised bed market
Load flexible heat recovery boiler for engine plants
Increasing deployment of intermittent wind and photovoltaic generation requires flexible back-up systems and reciprocating engines seem to be one technology of choice. The global deployment of engine plants is rising with plant capacities increasing to well above 200MWe. ERK is actively involved in this trend with high efficiency and load flexible HRSG’s. In the last 18 months our licensees supplied more than 15 such units and we are designing HRSG’s using the exhaust gas from a single and multiple engines.
Rapid load change capabilities are a key benefit of engine plants and ERK’s HRSG range is designed to follow engine loads changes very quickly. ERK has some boilers with more than 20% load change per minute in operation. Depending on the site footprint we can design horizontal and vertical HRSG for superheated steam, saturated steam, hot water, thermal oil or other working fluids.
In addition to the common one-on-one design (one HRSG for each engine) ERK has designs for two-on-one and three-on-one configurations. The benefit of coupling multiple engines to one HRSG are lower capital cost, a decrease in plant complexity and reduced maintenance cost. The experience to manage the flow distribution, back pressure and part-load operation of such HRSG’s is available at ERK.
Over the last months our licensee Selnikel was very successful supplying more than 10 HRSG's to engine projects. We would like to congratulate them for their success and are looking forward to further projects with Selnikel and other licensees worldwide.
98% thermal efficiency? No Problem!
Recently, our licensee Remming successfully commissioned a natural gas fired 58 MW corner tube type hot water heater for the Novi Sad district heating plant in Serbia. The boiler achieves a thermal efficiency >98% and is listed in our reference list as E5960.
A novel ERK Tube air preheater downstream the finned tube economizer enables flue gas condensation and this outstanding efficiency. Our licensee La Mont provided the ERK Tube technology for the air preheater. ERK supported Remming right from the start which demonstrates that our close cooperation is of benefit to our licensees and the plant owner/operator.
Remming delivered the project on time and budget and the plant operator is very satisfied with his new boiler. We are now looking forward to a similar unit commencing operation later this year in Germany.
For more detailed information about this project please contact our Mr. Sagasser.
References first quarter 2015
In the first months of 2015 ERK recorded 10 new boilers from various licensees within the group. We want to congratulate
- JFE Engineering on 2x waste fired boilers,
- Schneider Kessel on one gas and one oil fired boiler,
- Descon on a waste fired boiler,
- Selnikel on 2x HRSG’s, and,
- Getabec on a biogas fired boiler.
These new units increase ERK’s total number of references to 5,986 units with an installed capacity of more than 80,000MW. For more detailed reference information please contact our Mr. Sharma.
ERK expands engineering portfolio
For more detailed information about our engineering capabilites please contact our Mr. Beyer.
New staff and expertise at ERK Berlin
ERK is glad to announce that in late March Dr. Juergen Peterseim joined us again in our Berlin office after representing ERK in Australia for almost 8 years. He has started his new role as Director Strategy & New Products due to his international expertise and in depth knowledge with boilers, power plants, and energy transition trends.
During his time in Australia he strengthened ERK's business in Oceania and successfully supported our license Gasco to enter the boiler business. Dr. Peterseim will complement ERK's core boiler expertise with his power plant modelling capabilities. His focus in this area is on biomass, energy from waste, combined cycle, coal, concentrating solar power, and hybrid plants. This topics and the role of the different energy sources in Australia's transition to a low carbon future was the topic of his PhD candidature at the University of Technology, Sydney, where he is an honorary associate. He will also complement our R&D team and please feel free to contact our Dr. Peterseim if you have any questions.