Characterization of the U.S. Industrial Commercial Boiler Population

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Unit Sales per year Unit Sales per Year 4,000 3,500 3,000 2,500 2,000 1,500 1,000 300 250 200 150 100 50 500 0 0 Figure 4-1 Sales of Boilers >10 MMBtu/hr – 1964-2002 Firetube Boilers Watertube 10-100 MMBtu/hr Watertube 100-250 Watertube >250 MMBtu/hr Figure 4-2 Sales of Large Watertube Boilers - 1964-2002 Watertube >250 MMBtu/hr Watertube 100-250 4-2 Energy and Environmental Analysis, Inc. 1964 1966 1968 1970 1972 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 1964 2000 1966 2002 1968 1970 1972 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002
Boiler Capacity (MMBtu/hr) 1,200,000 1,000,000 800,000 600,000 400,000 200,000 - Figure 4-3 Age Distribution of Boilers >10 MMBtu/hr Pre-1964 1964-1978 1969-1973 1974-1978 1979-1983 1984-1988 1989-1993 1994-1998 1999-2002 Approximately two thirds of the boilers in the 100 to 250 MMBtu/hr range are more than 30 years old. 4.2 Fuel Consumption - 1991 through 1998 The EIA Manufacturing Energy Consumption Survey (MECS) estimates industrial energy consumption every three to four years. This information can be used to estimate trends in industrial boiler fuel consumption. The 1991, 1994 and 1998 MECS data indicate that fuel consumption for boilers increased somewhat during this period despite numerous news reports on the closure of manufacturing facilities. Figure 4-4 shows that boiler fuel consumption increased by about 6 percent between 1991 and 1994 and increased 3.6 percent between 1994 and 1998. The largest increase in boiler fuel consumption occurred in the chemicals industry, which experienced a 23 percent (334 TBtu/year) increase between 1991 and 1998. Consumption in the paper industry increased by 13 percent over the same period. Most of this increased consumption is believed to be from increased utilization at existing boilers. Boiler fuel consumption at refineries decreased by about 7 percent between 1991 and 1998. Boiler fuel consumption was relatively unchanged in the other industries. Energy and Environmental Analysis, Inc. 4-3
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 26 and 27: Table 1-1 CHP Thermal Output/Input
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: 4 HISTORIC TRENDS 4.1 Boiler Sales
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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