Characterization of the U.S. Industrial Commercial Boiler Population

Table Contents
EXECUTIVE SUMMARY .......................................................................................................................... 1
ES-1 COMBINED BOILER INVENTORY................................................................................................... 1
ES-2 INDUSTRIAL BOILER INVENTORY ................................................................................................. 2
ES-3 NONMANUFACTURING BOILER INVENTORY ................................................................................. 3
ES-4 COMMERCIAL BOILER INVENTORY .............................................................................................. 3
ES-5 ENERGY CONSUMPTION IN BOILERS ............................................................................................ 4
ES-6 AGE OF BOILERS .......................................................................................................................... 5
ES-7 THE MARKET IN 10 MMBTU/HR AND SMALLER UNITS ............................................................... 5
1 INTRODUCTION............................................................................................................................... 1
1.1 OVERVIEW ........................................................................................................................................ 1
1.2 BOILER BASICS ................................................................................................................................. 2
1.3 BOILER TYPES................................................................................................................................... 3
1.3.1 Heat Exchanger Configuration...............................................................................................4
1.3.2 Fuel Firing Types ................................................................................................................... 5
1.4 CHP TECHNOLOGIES ........................................................................................................................ 8
2 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 Industry.............................................................................................................. 2-3
2.2.4 Refining Industry ................................................................................................................. 2-4
2.2.5 Primary Metals Industry...................................................................................................... 2-4
2.2.6 Other Manufacturing........................................................................................................... 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 SALES DATA .................................................................................................................... A-1
A.2 MECS........................................................................................................................................... A-4
A.3 EEA’S 1996 ANALYSIS OF THE INDUSTRIAL BOILER POPULATION............................................... A-5
A.4 MIPD DATABASE ......................................................................................................................... A-6
A.5 EPA’S ICCR DATABASE .............................................................................................................. A-7
A.6 EPA’S ICI DATABASE .................................................................................................................. A-9
A.7 EPA’S BOILER MACT DATABASE ............................................................................................. A-11
A.8 ECONOMIC CENSUS..................................................................................................................... A-12
A.9 CBECS....................................................................................................................................... A-12