Brochure ERK
Brochure ERK
Renewable energies
gasification
solar thermal applications
ip tube
What is ip tube?
ip tube and applications
ip tube offshore
Fuel References Fuel spectrum
3,725
_.. Coal/coke/peat 651
_.. Waste arisings 603 Domestic waste, hazardous
waste, sewage sluge, landfill
gas, sulphite
1
_.. Waste heat 31
1
341 Timber, used wood, ground-
nut shells, bark, bagasse, rice
husk, straw, olive stones, bio-
gas, palm residue, palm oil,
grinding dust
,l
266 Various Fuels
5.825
c o r esse ~
ERK Eckrohrkessel GmbH and LaMont GmbH offer a broad spectrum of calculations for boiler construction.
These calculations are carried out using both in-house software (for thermal calculation, water circulation)
and commercial products.
~ Thermal calculation of new boiler projects ~ Flow calculations for Eckrohr boilers, two-drum boi-
lers, and also forced circulation systems (e.g. hot wa-
~ Thermal review of boiler modifications, up-scaling
ter units, La Mont boilers)
fuel switch or adjustment and boiler damage
~ calculation of new boiler projects
Strength analysis
~ Recalculation of existing systems to increase output
~ Strengthcalculations for pressure vessels based on and identification of failures induced by water flow
conventional standards (AD/TRD, ASME, Germanischer
Lloyd, Det Norske Veritas)
~ Interna! pressure calculations Flow simulation
~ Structural
strength parameters, including wind and
~ cFD (Computational Fluid Dynamics) calculations for
earthquake resistance
boiler systems
~ FEM calculations for specialized situations
~ Flow and combustion simulation, including analysis of
slagging and fouling
FEM strength simulation CFD simulation of a boiler Detailing for tube bend-out
for excentric joint fired by wood waste at secondary air nozzles
Water circulation
Thermal calculations Flow simulation Strength analysis
calculation
Our activity as a company essentially breaks down Our Engineering department provides services to
into two lines of service. On the licensing side, we manufacturers and operators alike. We offer plant
issue global licences for the use of our know-how design and implementation, detail engineering,
to reputed boiler manufacturers. re-engineering, technical calculations, structural
design, measurements and expertise.
Operation example: Heat exchanger for an improved engine cooling circuit, cooled by sea water.
II> Power: 300 kW
II> Operating conditions: low-temperature field (up to 95 °()
II> Pressure: 50 bar
The aim was to replace plain tubes with ip tube The La Mont solution included the following steps:
whilst retaining the same dimension. Normally ip
tube possess a larger outer diameter compared to
II> Replacing the plain tubes with ip tube of the
the original plain tubes, which therefore caused a
same dimensions
problem in manufacturing. Our new ip tube struc-
tures solved this problem as weil as achieving the 11> Developing of a new ip tube structure without
required pressure drop. widening the outer diameter, for the common
After the tube bundle was delievered, the client manufacturing and baffle plate openings
performed measurements of heat capacity and 11> Manufacturing and delivering of the tube
pressure drop for ip tube solution as weil as for the bundle
plain tube solution. The 20 % enhancement in the
heat transfer coefficient is accompanied by-17 %
increase in the tube side pressure drop and no
measureable increase in shell side pressure drop.
La Mont has been through numerous different stages of developement and testing with the ip tube tech-
nology. A unique testing facillty solely for ip tube has been set up. Simulatons on single tubes and com-
plete units have taken place and prototypes have been developed in conjunction with different clients.
All this data then provides an accurate basis for the selection of the ideal tube st ructure for the various
applications - for example, gas/gas, fluid/gas and fluid/fluid heat exchangers.
lndustrial
applications
The use of ip tube technology as a replacement for conventional tubes in power plants and boilers leads to
significantly more efficient components, as well as considerable savings in space and material.
Recuperators
Recuperators are used for the creation of steam
or hot water and are essential for power plants as
well as plants in the chemical and petrochemical
industry.
„__
~·~ ...
.,. Example:
~! ~ ip tube recuperator at the back of a gas turbine
' rry~
from a power plant. This example is based on
!:J'„
the following data:
A comparison of two recuperators with .,,. thermal power 5.1 MW
ip tubes (left) and plain tu bes (right) .,,. pressure 10.5 bar
S<m>ut>C>„
1~ tti „..:;•c c.- oo·
' tU' 1
".i~
-
Modern manufacturing technology, innovative
products, and skilled staff are essential in remai-
ning competitive in a globalised economy.
!il.!. !~·
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ready after 5.5 minutes. 1 1
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1 20 +----....:..:..:~~=----___jb~:.:=~
~ 100 ~----~'----------
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~ 60+ - - -*--- - ·ec - ·ec - - - - - ct - i i
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The steam flow/time chart of the boiler in Cottbus The back up boiler in Cottbus (Germany)
Reference
Location : Montevideo (Uruguay)
Year of manufacture :2007
Steam capacity : 70 t/h (70 bar)
Boiler type : Steam boiler (525 °C)
ERK boiler (background) with gasifyer (Uruguay)
The vibrat ing grate is designed for t he
Combusoon Deck In cooled
combustion of a w ide range of fuels. Membrane sty1e constructlOll Bouom Ash FIOw
Waste
fired boiler
Reference
Location : Bamberg (Germa ny)
Year of manufacture : 2006
Steam capacity : 20 t /h
Boiler type : Steam boiler (400 °C)
The generation of power from biomass is a relati-
vely recent discovery. Nowadays more and more
companies gain electrical power by using biomass
power plants. Biomass is however, a generic term
for various kinds of fuels like timber, used wood,
groundnut shells, bark, bagasse, rice husks, straw,
olive stones, palm residue, palm oil and grinding
dust.
The utilization of these fuels depends for the most
part on the fuel quality, but the right boiler design
is just as important.
With 341 references and 65 years practical expe-
rience in biomass boiler design, ERK provides a
solution for every requirement. We consider every
particular problem whilst designing our custo-
mers boilers from high moisture content to high
combustion temperatures. ERK designs and calcu-
lates every single boiler component starting with
the adequate firing system, up to the efficient flue
gas treatment. Today a biomass fired ERK boiler re-
aches steam capacities of up to 180 t/h and steam Biomass fired boiler with ERK thermal oil heater
temperatures up to 540 °C. (Menznau, Switzerland)
Reference -~1.~
t
Power :25MW
Boiler type : Waste heat (285 °C)
EckRohrKessel ....,
Coal
fired boiler
Today, in numerous countries all over the world,
coal is still the number one basis for power gen-
eration. New plant technologies allow higher de-
grees of efficiency (over 50 o/o are possible) and
contemporaneously the impact on the enviro-
ment decreases substantially. Through special
techniques, the percentage of sulphur dioxide,
nitrous oxides, dust and fine dust in the flue gases
can all be considerably reduced.
Reference
Location : Chandrapur (lndia)
Year of manufacture : 2009
Steam capacity : 90 t/ h (75 bar)
Boiler type : Steam boiler (490 °C)
One of the most efficient ways to gain electrical
power is by the use of gas or oil. Boilers that use
these kinds of fuel are much smaller and therefore
cheaper than biomass and waste boilers.
Reference
Location : Teheran (Iran)
Year of manufacture : 2006
Steam capacity : 85 t/h (15 bar)
Boiler type : Steam boiler (295 °C)
EckRohrKessel ""i
ERK Eckrohrkessel
The foundations for today's success were laie over All rights relating to the basic technology rest
half a century ago. In the mi<li-1940s a Berlin en- with ERK Eckrohrkessel GmbH. The company does
gineer called Dr. Heinrich Vorkauf devlsed a sim- not actually build systems, but focuses its efforts
ple yet ingenious principle which resulted In his exclusively on:
efficient natural ciFeulation boiler. His patent was • basic and detailed englneering
originally conceived to power motor vehicles by
steam (see figure below). The idea was to separa- • continuous system development
te the steam from a steam and water mixture, via the qualitative and quantitative
unheated downcoming tubes. These tubes slmul- modlficatlons requlred by each
taneously formed the boundary ofthe system and speclfic appllcation
its supporting structure. The prototypefortoday's
technology~riented
Eckrohr boiler was thus born.
consultancy for cllents
Over the next decade, this same principle of a The boiler systems themselves are built and as-
self-supporting, high-ca libre boiler was also ap- sembled by leading international boiler manu-
plied to industrial conditions using very different facturers under license from ERK. In this way,
fuels for very different purposes. ERK technology practical experience gleaned from a wide variety
rapidly acquired an international reputation and of situations from across the globe is constantly
presence. being fed back to Berlin. This continuous flow and
exchange of information explains the company's
unique strategic edge and ensures that they cont-
inue to remain at the forefront of the industry.
EckRohrKessel • '
4 La