Characterization of the U.S. Industrial Commercial Boiler Population

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Table 1-1 CHP Thermal Output/Input Electric Output (kW) Power/ Heat Thermal Output (MMBtu/hr) 1-10 Energy and Environmental Analysis, Inc. Heat Input (MMBtu/hr) Small Microturbine 60 0.4 0.5 0.6 Fuel Cell 200 1.0 0.7 0.9 Large Microturbine 250 0.4 2.0 2.5 Reciprocating Engine 250 0.7 1.3 1.6 Reciprocating Engine 1,000 0.9 4 5 Reciprocating Engine 5,000 0.9 19 23 Small Combustion Turbine 1,000 0.4 8 10 Small Combustion Turbine 5,000 0.6 28 36 Small Combustion Turbine 12,000 0.6 68 85 Large Combustion Turbine 50,000 0.9 190 237
2 CHARACTERIZATION OF INDUSTRIAL BOILERS 2.1 Overview EEA estimates that there are approximately 43,000 industrial boilers in the United States with an aggregate capacity of 1.5 million MMBtu/hr input. Slightly more than half of these boilers are less than 10 MMBtu/hr capacity but these small boilers account for less than seven percent of the total capacity. The majority of the boilers and the largest boilers are located at facilities in the food, paper, chemicals, refining and primary metals industries. Almost 78 percent of boiler units and 56 percent of industrial boiler capacity are identified as natural gas-fired, although certain industries (refining, paper, primary metals) have large shares of boiler capacity that are fired with by-product fuels. Industrial boilers are found in every census region but are more concentrated in the East North Central (ENC), South Atlantic (SA) and West South Central (WSC) regions, 2 which contain more than 60 percent of the capacity. 2.2 Breakdown by Industry Table 2-1 (units) and Table 2-2 (capacity) present the summary statistics by industry for industrial boilers. Table 2-1 Industrial Boiler Inventory – Number of Units Boiler Units Food Paper Chemicals Refining Metals < 10 MMBtu/hr 6,570 820 6,720 260 1,850 10-50 MMBtu/hr 3,070 1,080 3,370 260 920 50-100 MMBtu/hr 570 530 950 260 330 100-250 MMBtu/hr 330 540 590 200 110 >250 MMBtu/hr 70 490 350 220 120 Total 10,610 3,460 11,980 1,200 3,330 2 A map of the census regions is included in Appendix D. Other Manufacturing Total 7,275 23,495 3,680 12,380 930 3,570 440 2,210 110 1,360 12,435 43,015 Energy and Environmental Analysis, Inc. 2-1
Page 1: Characterization of the U.S. Indust
Page 5 and 6: Table Contents EXECUTIVE SUMMARY ..
Page 7: List of Figures Figure 1-1 Boiler A
Page 11 and 12: EXECUTIVE SUMMARY The U.S. industri
Page 13 and 14: Natural gas is the most common fuel
Page 15: and other fuels (2 percent). The av
Page 18 and 19: 1.2 Boiler Basics Boilers use a hea
Page 20 and 21: Firetube units are typically the sm
Page 22 and 23: Stoker boilers are described by the
Page 24 and 25: Figure 1-7 Cut-Away View of a Fluid
Page 28 and 29: Table 2-2 Industrial Boiler Invento
Page 30 and 31: Consumption Survey (MECS) identifie
Page 32 and 33: Coal, oil and wood are important fu
Page 34 and 35: industry utilizing large black liqu
Page 36 and 37: MMBtu/hr total capacity) and 387,00
Page 38 and 39: Oil is the designated primary fuel
Page 41 and 42: 4 HISTORIC TRENDS 4.1 Boiler Sales
Page 43 and 44: Boiler Capacity (MMBtu/hr) 1,200,00
Page 45 and 46: APPENDIX A ADDITIONAL BACKGROUND ON
Page 47 and 48: the capacity is not assigned. Of th
Page 49 and 50: Table A-4 MECS Fuel Consumption in
Page 51 and 52: Boiler Units 10,000 8,000 6,000 4,0
Page 57: Total Square Feet (1,000,000 sq ft)
Page 60 and 61: Incremental Boiler Fuel (TBtu/year)
Page 62 and 63: does not fit the typical definition
Page 64 and 65: MMBtu Million British Thermal Units

Characterization of the U.S. Industrial Commercial Boiler Population

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