Report
Teaser, summary, work performed and final results
Periodic Reporting for period 1 - CORRO STOP (EDS 2500 - Cold degassing of boiler water for a corrosion-free water pipeline network to minimize repair costs)
Teaser
When heat is needed for industrial processes and buildings, it is usually generated from a central source via steam. This steam comes from high-speed steam generators and boiler systems and is a key component of industrial infrastructure. It is used for a variety of technical...
Summary
When heat is needed for industrial processes and buildings, it is usually generated from a central source via steam. This steam comes from high-speed steam generators and boiler systems and is a key component of industrial infrastructure. It is used for a variety of technical processes, such as in the textile, food and beverage industries. Steam as an energy carrier has many favourable properties, such as high energy absorption capacity. In the long term, steam will be irreplaceable as an energy source.
Since steam generators typically use normal tap water, they face a major problem - corrosion, which leads to significant economic costs and environmental problems. Tap water contains about 8-10 mg/l oxygen (O2) and 9-12 mg/l carbon dioxide (CO2). Once the cold water is heated, its O2 and CO2 content is released for oxidation > and this leads to corrosion.
In order to avoid this corrosion, O2 and CO2 must be removed from the water. Currently, two basic processes are available: a chemical process (chemical degassing - use of oxygen scavengers) and a thermal process (thermal degassing - requires the boiling point of water). For the chemical process a high dosage of chemicals (sulphides) is added and for the thermal process a considerable amount of energy is required. Both processes are neither ecologically nor resource-efficient nor economically viable.
The EKOWA start-up has succeeded in developing a third way: a compact and cost-efficient system based on an innovative physical process for degassing cold soft water - the membrane filtration process. The system, called EDS 2500 (TRL 6), is now ready to be launched on the European market. Compared to conventional processes, the EDS 2500 is economically highly efficient (short payback period). It is a small and compact instrument that is easy to use, sustainable and environmentally friendly (no chemicals or high temperatures).
All those who have lost steam in their processes are potential customers. The total market volume is estimated at € 300 - 400 million.
As a result of the feasibility analysis an economic, political and legal feasibility of a project implementation could be determined. The EKOWA created all the organisational prerequisites for broad international establishment, which now have to be implemented. A sales and marketing department was established within the company within the year 2018/2019. The further planning of the establishment of a suitable manufacturing capacity will take place together with a manufacturing partner and is currently in the final implementation phase.
Work performed
The work within the scope of the feasibility study (SME Phase 1) included:
• Analysis and presentation of the user market
• Analysis and presentation of technical feasibility on the basis of user needs, analysis of technical risks
• Business segment analysis, evaluation of business concept and market positioning, presentation of business segments, analysis of potential new attractive business models and innovative further developments
• Entwicklung eines Konzeptes für die industrielle Produktion (Zusammenarbeit mit einem Fertigungspartner)
The target group of the EDS2500 are users of steam generators. In particular, customers with existing room steam boilers (use of thermal boilers). Potential customers are small and medium-sized companies from a wide variety of industries that use steam generators (laundries), e.g. food and beverage companies, vulcanisers, hospitals and retirement homes. In the course of 2018, the customer base was significantly expanded with the acquisition of SME Phase 1.
The market situation for intelligent degassing systems (extended version of the EDS2500, which is to be offered in the portfolio) for monitoring operating conditions can be seen as growing in the future. Due to the new technology of processor-controlled data transmissions and new electronic high-performance modules, we see very interesting application possibilities in the area of trend analysis.
In order to reach the markets, customers have the following technological requirements: compact system, consistently high industrial quality, low-maintenance technology > upgrading of steam boilers for predictable maintenance, reduction of O2 and CO2 content without the use of personnel autonomously at various points, energy-efficient - and resource-saving.
The market launch strategy provides for intensive customer acquisition with high customer loyalty. EKOWA benefits here from the high technical competence of the employees, which can be communicated to the customers. At the beginning of 2019, EKOWA was able to expand its personnel capacities.
A sales concept was developed for market implementation. An important approach is participation in conferences and symposia. The EKOWA wants to present itself with corresponding lectures in which the EDS 2500 is introduced.
Final results
The EDS 2500 is a device which deals with the physical degassing of soft water. The core innovation of the EDS 2500 is an innovative process for water pre-treatment. First, a vacuum is applied to the device. The soft water then flows through the module and is degassed. Technologically, O2 and other gases (especially CO2) are extracted from the water through the interaction of a large surface area and the presence of a negative pressure. To operate the vacuum pump, treatment and cooling water is required, which is held in a storage tank (feed water tank). The treatment water is cooled by a heat exchanger, which thermally connects it with the soft water inlet. The vacuum to be achieved or the degassing performance depends directly on the cooling water temperature, i.e. the colder the soft water, the better the degassing performance of the EDS 2500. Under optimum conditions (tap water temperature, perfect degassing module), a vacuum of up to 30mbar can be achieved. The EDS 2500 is installed via a bypass.
We at EKOWA are currently the only company to offer such a device for the physical degassing of soft water for small to medium-sized applications on the basis of the new process procedure. This makes it possible to reduce the O2 content in tap water to only 0.03 mg/l and thus virtually prevent corrosion.
The positive economic effects of the project are that the service life of steam boiler systems and water supply networks will be significantly increased. The new process offers a high quality and simple method to minimise damage to the water infrastructure caused by corrosion.
Website & more info
More info: https://ekowa.de/.