The report also includes analysis of boiler fuel consumption and the age of boiler units. It does not include an inventory of individual boilers. ES-1. Combined
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Acknowledgement The authors wish to thank Merrill Smith of the U.S. DOE and Patti Garland, Steve Fischer and Barry Olander of the Oak Ridge National Laboratory for their support and helpful comments in the development of this report. We also thank Bob Bessette of the Council of Industrial Boiler Owners and Randy Rawson of the American Boiler Manufacturers Association for their helpful comments in the development of the report. Notice This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completene ss, or usefulness of any information, apparatus, product or process disc losed or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trad emark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency ther eof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.
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Table Contents EXECUTIVE SUMMARY .. 1ES-1 COMBINED BOILER INVENTORY 1ES-2 INDUSTRIAL BOILER INVENTORY . 2ES-3 NONMANUFACTURING BOILER INVENTORY 3ES-4 COMMERCIAL BOILER INVENTORY . 3ES-5 ENERGY CONSUMPTION IN BOILERS .. 4ES-6 AGE OF BOILERS .. 5ES-7 THE MARKET IN 10 MMB TU/HR AND SMALLER UNITS 51 INTRODUCTION . 11.1 OVERVIEW . 11.2 BOILER BASICS 21.3 BOILER TYPES .. 31.3.1 Heat Exchange r Configuration ..41.3.2 Fuel Firing Types . 51.4 CHP T ECHNOLOGIES 82 CHARACTERIZATION OF INDUSTRIAL BOILERS . 2-1 2.1 OVERVIEW . 2-1 2.2 BREAKDOWN BY INDUSTRY .. 2-1 2.2.1 Food Industry . 2-2 2.2.2 Paper Industry 2-3 2.2.3 Chemicals Indus try.. 2-3 2.2.4 Refining Industry .. 2-4 2.2.5 Primary Metals Industry 2-4 2.2.6 Other M anufacturing..2-5 2.3 BREAKDOWN BY FUEL .2-5 2.4 REGIONAL BREAKDOWN .2-7 2.5 NONMANUFACTURING BOILERS .. 2-8 3 CHARACTERIZATION OF COMMERCIAL BOILERS 3-1 3.1 OVERVIEW . 3-1 3.2 BREAKDOWN BY SECTOR 3-1 3.3 BREAKDOWN BY FUEL .3-2 3.4 BREAKDOWN BY REGION 3-5 4 HISTORIC TRENDS . 4-1 4.1 BOILER SALES TRENDS 4-1 4.2 FUEL CONSUMPTION – 1991 THROUGH 1998. 4-3 APPENDIX AADDITIONAL BACKGROUND ON THE DATA SOURCES A-1 A.1 ABMA S ALES DATA .. A-1 A.2 MECS . A-4 A.3 EEA™S 1996 A NALYSIS OF THE INDUSTRIAL BOILER POPULATION .. A-5 A.4 MIPD D ATABASE . A-6 A.5 EPA™ S ICCR DATABASE .. A-7 A.6 EPA™ S ICI DATABASE A-9 A.7 EPA™ S BOILER MACT D ATABASE A-11 A.8 ECONOMIC CENSUS A-12 A.9 CBECS A-12
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APPENDIX BMETHODOLOGY FOR CALCULATING THE BOILER INVENTORY . B-1B.1 METHODOLOGY FOR CALCULATING THE INDUSTRIAL BOILER INVENTORY . B-1B.2 METHODOLOGY FOR CALCULATING THE COMMERCIAL BOILER INVENTORY . B-3APPENDIX C ACRONYMS .. C-1APPENDIX D MAP OF U.S. CENSUS REGIONS . D-1
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List of Tables Table 1-1 Combined Boiler Inventory .. 2Table 1-1 CHP Thermal Output . 10Table 2-1 Industrial Boiler Inventory ΠNumber of Units ..2-1Table 2-2 Industrial Boiler Inventory РBoiler Capacity.. 2-2Table 3-1 Commercial Boiler Inventory..3-2Table A-1 ABMA Sales 1992-2002 .. 1Table A-2 ABMA Sales Data by SIC 1992-2002 .. 3Table A-3 MECS Boiler Fuel Summary .. 4Table A-4 MECS Fuel Consumption in Boilers by Industry . 5Table A-5 Percentage Facilities by Number of Employees . 12Table A-6 CBECS Space Heating Technologies by Building Vintage . 13Table B-1 Incremental Industrial Boilers 2
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EXECUTIVE SUMMARY The U.S. industrial and commercial sectors consume large quantities of energy. Much of this energy is used in boilers to generate steam and hot water. EEA estimates that there are almost 163,000 industrial and commercial boile rs in the U.S. with a total fuel input capacity of 2.7 million MMBtu/hr. These bo ilers consume about 8,100 TBtu per year, accounting for about 40 percent of all energy consumed in these sectors. This report characterizes the boilers in th e industrial and commercial se ctor in terms of number of units, aggregate capacity, unit capacity, pr imary fuel, application and regional distribution. The report also includes analysis of boiler fu el consumption and the age of boiler units. It does not include an inventory of individual boilers. ES-1 Combined Boiler Inventory The combined inventory of industrial a nd commercial boilers includes about 163,000 boilers with an aggregate capacity of 2.7 million MMBtu/hr (fuel input basis). Table ES-1 lists the summary statistics for the co mbined inventory including a breakdown by unit capacity. The inventory includes 43,000 industrial boilers with a total capacity of 1.6 million MMBtu/hr and 120,000 commercial boilers with a total capacity of 1.1 million MMBtu/hr. Industrial boilers tend to be larger than commercial units. There are 19,500 industrial boilers larger than 10 MMBtu/hr, including more than 1,300 larger than 250 MMBtu/hr. Commercial facilities have 26,000 boilers larger than 10 MMBtu/hr but only about 130 larger than 250 MMBtu/hr. The va st majority of commercial boilers are smaller than 10 MMBtu/hr. Overall, the size of the average industrial boiler is 36 MMBtu/hr, compared to 9.6 MMBtu/hr for the average commercial boiler. In addition to the industrial boilers included in the primar y analysis, EEA estimates that there are approximately 16,000 industrial boilers in the nonmanufacturing sector with an aggregate capacity of 260,000 MMBtu/hr. Because these units are not well characterized, they were not included in the industrial boiler results listed in the analysis. Over 70 percent of the boiler units are less than 10 MMBtu/hr heat input, mostly in the commercial sector. These boilers account for only15 percent of boiler capacity and typically have lower utilization than the larger industrial boilers. Due to the small size of these boilers and the lack of detailed information on them, this report focuses primarily on boilers larger than 10 MMBtu/hr. Energy and Environmental Analysis, Inc. ES-1
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