E.ON Denmark, Heat Pump / Waste water

E.ON Danmark group produces and supplies electricity, gas and heat in Denmark. E.ON also has one of the country's largest networks of charging stations for electric cars and opened the first of a series of gas filling stations.
E.ON also produces district heating for households.

2,750 tons of CO₂ saved annually

“The FoulingCure system maintain a high heat exchanger efficiency, reduces our need for chemical CIP / manual service, and eliminates the need for a redundant exchanger. It flushes the exchanger every hour during full operation.
The whole Heat Pump setup is expected to save more than 2,750 tons of CO₂ per year. It’s truly a pleasure to go to work when you can contribute to such a positive environmental impact.”
– Camilla Nelly Jensen, Project Manager at E.ON Denmark

In #Frederikssund, E.ON’s new 2.5 MW wastewater heat pump - delivered by Aalborg CSP - extracts heat from wastewater from Novafoss and turns it into green district heating for up to 770 households.

 At FoulingCure, we’re proud to contribute with our add-on system that turns any plate heat exchanger into a self-cleaning unit – maintaining more than 95% efficiency 24/7, without shutdowns.

✔️ Automatic Flushing and BackFlush every hour
✔️ Continuous, optimized heat recovery
✔️ Less (or no) chemicals
✔️ Fast automatic CIP if or when needed

FoulingCure ensures a clean plate heat exchanger in order to maintain a high COP value for the consumers to get the most possible MWh of district heating from the MWh of power supplied to the heat pump.

Egedal Fjernvarme Denmark, Heat Pump / Sewage water - Installed 2024

The new heat pump makes it possible for Egedal Fjernvarme to utilize energy from the sewage water in Stenløse Treatment Plant for heat in the district heating network.

The heat pump ensure sufficient heating capacity to supply both current and future district heating customers with a maximum performance of approx. 1,5MW

In Stenløse, the heat pump extracts the energy from the sewage water before discharging into Stenløse river. The low-temperature energy from the sewage water is subsequently converted into 75 °C via the heat pump. 

FoulingCure cleans two plate heat exchangers in order to maintain a high COP value for the heat pump.

Odsherred Forsyning Denmark, Heat Pump / Sewage water

The new heat pump makes it possible for Odsherred Forsyning to utilize the energy in the sewage water for the district heating network in Fårevejle.

"With us, it will be a 1.5 MW water-to-water heat pump, which will especially benefit in winter - because the waste water's constant temperature of 8-10 degrees is a significantly better source of heat than the cold outside air" explains Fanny Villadsen.

Contractor of the project is Tjæreborg Industries

FoulingCure cleans the plate heat exchanger in order to maintain a high COP value for the heat pump.

King Fish Zeeland Holland, Landbased Fish Farming RAS Energy Recovery

From 50% loss to 95% efficiency – How The Kingfish Company transformed Heat Recovery with FoulingCure.

The Kingfish Company is a first-mover in technology driven re circulation aquaculture system for Yellowtail Kingfish with an aim is to be the market leader in the sustainable production of high value Marine Seafood. 1st site is located in the Netherlands with full cycle hatchery, an on site R&D facility, and an advanced grow-out system; and a 2nd site in development in Jonesport Maine for the US market

Since installing the FoulingCure system, The Kingfish Company — has maintained a consistent heat exchange performance of 95% in their heat recovery system. That is a dramatic turnaround from the previous 50% loss caused by biofouling.

“After installing FoulingCure, we automatically rinse and backflush every hour. The result is much better performance with no need for manual cleaning,” says Christiaan De Wet, Head of Design and Engineering, The Kingfish Company.

Before FoulingCure biofouling posed a major operational challenge. The initial heat recovery system was designed for 2.5 MW, and the team had to manually clean 10 plate heat exchangers every week — a full-time task for one operator. The average heat recovery performance was 50% due to biological buildup.

It wasn’t just time-consuming — manual cleaning also meant significant energy loss, requiring additional gas burners to compensate for reduced efficiency.

FoulingCure is integrated into The King Fish Company's heat recovery system design. After completing the expansion project, doubling their output capacity, FoulingCure is installed on 18 heat recovery exchangers (total capacity of 8 MW).

FoulingCure has been in operation for four years since the initial installation. Improvements have been both operational and environmental:

📉 No more manual cleaning
⚡ Recovered energy = increased efficiency
🌱 No need for gas back up = reduced carbon footprint
⏱️ Payback time: under 1 year

FoulingCure is proud to support The Kingfish Company in their mission to lead the market in sustainable, technology-driven marine seafood production.

18 FoulingCure systems installed

Payback time <  under 1  year

Scottish Salmon Company (Bakkafrost) UK, RAS - Energy Recovery - Installed 2022

Scottish is a salmon smolt facility with state of the art re circulation aquaculture system.

RAS technology is an indoor land based aquaculture system which allows fish to be reared for longer in freshwater tanks before being moved to marine sites. Greater control of the freshwater rearing environment means that farmers can produce larger smolt (juvenile salmon), reducing the marine production cycle which in turn cuts down the biological risk of rearing in the marine environment

Natural bacteria growth – bio fouling - are found in the re-circulated fish water resulting in clogging of the exchangers.

After a two weeks without cleaning, the energy recovery were reduced 30% and cleaning were required

Cleaning the plate heat exchangers were done manually by opening up the exchangers.

One FoulingCure systems were installed as a trial and 6 systems more have been ordered.

Tytlandsvik Aqua Norway , Salmon Landbased Fish Farming RAS , Cooling - Installed 2022

Tytlandsvik Aqua is a salmon smolt facility with state of the art re circulation aquaculture system. The plan is to become the leading smolt producers with a capacity of 4500 tons “large smolt”. Larger smolt reduces the grow out period in the ocean from 22 months to 10 months. This double the ocean grow out capacity without further environmental impact.

The fish tanks are cooled via plate heat exchangers using 8°C water from 100m depth in the nearby Fjord.

Natural bacteria growth – bio fouling - are found in the re-circulated fish water resulting in clogging of the heat exchangers. After 1-2 weeks without cleaning, the cooling is down below required capacity.

Tytlandsvik Aqua do not use chemical CIP in order to minimize any risk for contamination of the RAS water.

Cleaning of plate heat exchangers were done manually by opening up the exchangers every 2nd week.

Two FoulingCure systems were installed as a trial to increase the cooling capacity and reduce man power cost.

Sterling White Halitbut Norway,  Landbased Fish Farming RAS,  Installed 2023

Sterling White Halibut AS are the world leader of farmed halibut with headquarter in Hjelmeland, Norway.
Their production facilities are dotted along the Norwegian coast, with a hatchery in Rørvik, Trøndelag, a growing facility in Vindafjord, Rogaland, and sea facilities in Hjelmeland.

SterlingWhit Halibut deliver 1.5 million kilos of premium Sterling ® halibut to discerning customers all over the world. Their biggest markets are Norway, UK, Sweden, US, Be-Ne-Lux, and Germany.

From eggs to 1500 grams the halibuts are farmed in landbased fish tanks. After they are transported to sea facilities where they stay for 2 - 2.5 years, until they reach 4 - 5 kilos and are ready to be harvested.

The fish tanks are temperature regulated via plate heat exchangers from cooling/heating pumps.

The challenges is the natural bacteria growth – bio fouling - are found in the re-circulated fish water resulting in clogging of the heat exchangers. After a few weeks without cleaning, the capacity is down.

Two FoulingCure systems are installed to avoid the loss of cooling/heating capacity and to reduce the man power cost for traditional cleaning.

Breda Court House, Holland - HVAC  Cooling / Heating Pump,  Installed 2023

The new built court house from 2018 is using canal water for cooling/heating the HVAC system in the building.

The canal water kept building up fouling (bio & particles) in the 1 MW heat exchanger for the heat pump.
The COP value for the heat pump were significant reduced and every 3 months, the heat exchanger had to be opened for a service.

FoulingCure system with BackFlush application were installed.

The FoulingCure system is running 7 minutes every 1 hour and has kept the heat exchanger clean from fouling.

District Heating Plant, Denmark, Flue Gas Condensation Energy Recovery - Installed 2020

This district heating company supplies heating and hot water to a community of approx. 8,200 households and businesses. The plant has two  biomass boilers, each with a nominal capacity of 15 MWh and it is equipped with a heat recovery system based on flue gas condensation. Via a plate heat exchanger, the recovered energy is re-directed into the heating supply system.

Despite cyclones and filters, particles and bacteria are found in the condensate. In fact, data showed fouling reduced the heat recovery significantly. After 24 weeks, performance was down by 15%. Further, the data showed that the total energy loss due to fouling was 3,077 MWh per year.

A FoulingCure system was installed, and after 20 weeks of operation, no fouling was detected in the plate heat exchanger for heat recovery. Performance was close to 100%. 

Potential annual heat recovery: 3,077 MWh

Potential annual savings, primary energy: approx. 66,000 EUR = 80,000 USD.

Additionally, the plate heat exchanger no longer needs full service once a year.

Annual savings, service: approx. 16,000 EUR = 20,000 USD.

Annual operational savings: 82,000 EUR = 100,000 USD.

Energnisten Esbjerg Denmark, Power & District Heating Plant , Flue Gas Condensation - 2022

Waste burning Power plant with a capacity of 215.000 tons/year.
Producing 460.000 MWh heat and 150.000MWh electricity
– equals consumption at 25.500 households

The boiler is equipped with a heat recovery scrubber system / flue gas condensation. Via a plate heat exchanger, the recovered energy is re-directed into the district heating system.

Despite filters, fouling has been detected in the condensate system. Data showed fouling reducing the heat recovery with 7%.

As a trial for recovering a dirty exchanger, a FoulingCuresystem was installed without making a full service of the plate heat exchanger. After running non-stop for 2 weeks and a CIP, the heat recovery went up from 93% to 98%

= 1MWh extra output

Estimate Payback < 5 months

Power and District Heating Plant, Flue Gas Condensation, Energy Recovery - Installed 2020 

The district heating company supplies heating and hot water to a community of approx. 36,000 households and businesses. The plant has two biomass boilers, each with a nominal capacity of 95 MWh. Flue gas condensate is used as fluid in the plate heat exchangers – to optimize heat production and primary energy consumption.

Despite electrostatic precipitators in the flue gas system, particles accumulate in the condensate and settle in  heat exchangers. Data showed that fouling reduced the heat recovery after only six weeks of operation. After 16 weeks, performance was down by 10%, and after 20 weeks by 15%. Calculations revealed that the total energy loss due to fouling was 12,000 MWh per year.

Potential annual heat recovery: 12,000 MWh

The foulingCure application was installed, and the performance of the plate heat exchanger was monitored on a weekly basis. After 16 weeks, data showed that fouling had occurred, resulting in a heat transfer reduction of 5%. Further inspections and analyses were carried out. There was still fouling in the form of bacteria growth settling on the plates. After 24 weeks, performance was down by 9%.

CIP with disinfectants was carried out in combination with a FoulingCure flushing for 30 minutes. Within 24 hours the plate heat exchanger was back at 100% performance.

Annual operational savings: 404,000 EUR = 476,000 USD

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