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# OAR Box 1851 Prepped byKeeiaRichards



### Document

Number: 

# 40 ) ll-A-1 4 Docket Number: 

# A-90-1 9

Printed 11/19/200811:19:52 AM Sheet 40of 41P. 2 

# A-90-1 9 ll-A-1 4

FPAAI R DOCKE T 

# Populatio n an d Characteristics o f Industrial/Commercia l Boiler s i n th e U.S .

b y T . Devitt , P. Spaite , an d L Gibb s PEDC o Environmental , Inc . 1149 9 ChesterRoa

d Cincinnati , Ohi o 4524 6 Contrac tNo . 68-02-260 3 Task No . 1 9 Program ElementNo . EHE624 A

M' AI'I<P|IM: I OHic.n i Chiiiln u J dMillyiii m Industria l Environmenta l Researc h Laborator y Office o fEnergy, Minerals , an d Industr y Researc h Triangl e Park

, NC 2771 1
Prepare d fo r U.S . ENVIRONMENTA L PROTECTIO N AGENC Y Office o fResearc h an d Development Washington , DC

-2046 0P. 3

1

Thi s repor t wa s furnishe d t o th e U.S . Environmenta l Protectio nAgenc yb yPEDC o Environmental , Inc. , Cincinnati , Ohio , i nfulfillmen t o f Contrac t No . 68-02-2603 , Assignmen t No . 19 . Th e content s o f thi s repor t are reproduce d herei na s receive d fro

m the contractor . Th e opinions , findings , an d conclusion s expresse d ar e thos e o f th e autho r an d no t neces saril ythos e o f th e Environmenta l Protectio nAgency .

i iCONTENT S P. 4

Figure s Table s Acknowledgemen t Executiv e Summary 1 . Introductio n Reference s 2 . th e Industrial/Commercia l Boile r Populatio nan d 'Fue l Consumptio n 2. 1 Boile r Classificatio n 2. 2 Presen t Boile r Populatio n 2. 3 Fue l Consumptio n 2. 4 Growt hProjection s fo r Industrial/Commercia l Boile r Populatio n Reference s 3 . Atmospheri c Emission s 3. 1 Emissio nFactor s 3. 2 Curren t Level s o f Uncontrolle d Emission s 3. 3 Emissio nProjection s t o 200 0 Reference s 4 . Representativ e Ne wBoiler s an d Characteristic s 4. 1 Typica l Industria l Boiler s 4. 2 Boile r Characteristic s Reference s 5 . Basi s fo r Cos t Evaluation s 5. 1 Cos t Element s 5. 2 Cos t Estimatin g Forma t 5. 3 Uni t Cos t Recommendation s Reference s Pag e vi i vii i xii i xi v 1 5

6 8 2 9 3 7 5 1 5 2 5 2 6 9 7 6 8 7 8 8 8 8 9 1 11 1 11 2 11 3 11 8 12 3 12 5P. 5

SECTION2 TH E INDUSTRIAL/COMMERCIAL BOILE RPOPULATIONAND FUE L CONSUMPTION Th e populatio no f industrial/commercia l boiler s consist s o f man ydifferen t type s o f units , whic hus e variou s fuel s an d method s o f hea t transfer . Th e following subsection s presen t the categorie s o f classificatio nfo r industrial/commercia l boilers , th e populatio no f eac hcategory , tho fuel s consume d i neac h category , an

d the projection s o f growt ho f fue l consumptio nb y th e boile r populatio nthroughth e yea r 2000 . 2. 1 BOILE RCLASSIFICATION Boiler s ca nb e an

d hav e bee nclassifie d i na numbe r o f ways , using suc hbase s o f categorizatio na s boile r type , fue l use , an d metho d o f manufacture . Tw o mai nfactor s wer e considere d i n selecting the parameter s o f classificatio nfo r thi s study . First , consideratio nwa s give nt o whethe r variatio ni nth e param ete r wa s likel yt o produc e a significan t chang e i nai r emis
sions . Th e second consideratio nask s whethe r th e paramete r had bee nregarde d a s a nimportan t variabl e i ncollecting an d storing the dat a neede d t o construc t boile r populatio nestimates . Th e fina l lis t o f parameter s wa s develope d fromanalysi s o f pas t wor k an d reflect s comment s o f reviewer s wh o ar e associate d wit hboile r manufacturin g organization s an d kno wwha t dat a ar e available . Th e basi c boile r classification s appea r i nTabl e 2-1 . A s th e tabl e shows , unit s wer e categorize d b yconstructio nmetho d an d hea t transfe r configuration , the nb yfiring mechanis man d fuel . Description s o f th e variou s type s o f boiler s show ni n Tabl e 2- 1 ar e presente d i nAppendi xA . Eac htyp e o f industrial/commercia l boile r wa s furthe r subcategorize d b

yhea t transfe r mechanism , typ e o f use , an d size , using th e following classificatio nscheme . 6P. 6

TABL E 2-1 . CATEGORIE S O F INDUSTRIAL/COMMERCIAL BOILER S

Field-erected/Water-tub e Pulverize d coa l Spreader-stoke r Overfeed-stoke r coa l Underfeed-stoke r coa l Residua l oi l Distillat e oi l Natura l ga s Packag e Boilers/Water-tub e Pulverize d coa l Spreader-stoke r coa l Overfeed-stoke r coa l Underfeed-stoke r coa l Residua l coa l Distillat e oi l Natura l ga s Package/Fire-tub e Coal/Horizonta l Retur nTubula r (HRT ) Coal/Firebo x Coal/Scotc h Coal/Othe r Residua l oil/Horizonta l Retur nTubula r (HRT ) Residua l oil/Fi::ebox Residua l oil/Scotc h Residua l oil/Othe r Distillat e oil/Horizonta l Retur nTubula r (HRT ) Distillat e oil/Firebo x Distillat e oil/Scotc h Distillat e oil/Othe r Natura l gas/Horizonta l Retur nTubula r (HRT ) Natura l gas/Firebo x Natura l gas/Scotc h Natura l gas/Othe r Package/Cas t Iro n Coa l Residua l oi l Distillat e oi l Natura l Ga sP. 7

Hea t transfe r medium : Supercritica l stea

m High-pressur e stea

m Low-pressur e stea

m Ho t wate r Use : Commercial/institutiona l spac e heating Industria l spac e heating Industria l proces s hea t Size : MWtherma l (Btu/h ) Equa l t o o r unde r 0. 1 Ove r 0. 1 - 0. 4 Ove r 0. 4 - 2. 9 Ove r 2. 9 - 7. 3 Ove r 7. 3 - 14. 7 Ove r 14. 7 - 29. 3 Ove r 29. 3 - 73. 3 Ove r 73. 3 - 146. 5 Ove r 146. 5 - 439. 5 Ove r 4 39. 5 (Equa l t o o r unde r 0. 4 x10 6 ) (over 0. 4 x10 6 - 1. 5 x10 6 ) (over 1. 5 x10 6 - 1 0 x10 6 ) (ove r 1 0 x10 6 - 2 5 x10 6 ) (over 2 5 x10 & - 5 0 x10 6 ) (ove r 5 0 x10 6 - 10 0 x10 6 ) (ove r 10 0 x10 ^ - 25 0 x10 6 ) (ove r 25 0 x10 6 - 50 0 x10 6 ) (ove r 50 0 x10^ - 150 0 x10^) . (ove r 150 0 x10 6 ) Possibl e combination s o f th e classification s use d i nthi s stud yar e illustrate d i nFigur e 2-1 . During th e cours e o f the study , manyrearrangement s o f th e dat a wer e use d t o compar e the relativ e significanc e o f variou s categories , wit hregar d t o suc hfactor s a s tota l capacity , fue l consumption , an

d emissions . Th e nex t sectio ndescribe s the boile r populatio naccording t o the fina l classification s selected . 2. 2 PRESENT BOILE RPOPULATION Estimate s o f th e numbe r an d capacit yo f presen t industrial / commercia l boiler s ar e derive d fromcombining dat a i nstudie s b y Battell e (Lockli ne t al. , 1974 ; Putname t al. , 1975 ) an d Walde n (Ehrenfel d e t al. , 1971 ) wit hsale s record s o f the America nBoile r Manufacturer s Associatio n(ABMA ) an d th e Hydronic s Institut e (HI ) . Th e tota l numbe r o f boiler s categorize d b yfue l type , size , typ e o f use , hea t transfe r configuration , an d metho d o f constructio n 8P. 8

PULVERIZE D 

### WATEHyi i FIELD-ERECTE D

•PACKAG E COAL RESIDUALOI L DISTILLAT EOI NATURALGA S STOKE R

L SPREADE R

OVERFEE D UNDERFEE D

FIRE-TUB Ef " PACKAG E COAL RESIDUALOI L DISTILLAT EOI L NATURALGA S HORIZONTALRETURN TUBULAR SCOTC H FIREBOX OTHE R COA L
PACKAG E CAS T IRO N RESIDUALOI L

DISTILLAT EOI L NATURALGA S
Figur e 2-1 . Possibl e combination s o f characteristic s associate d wit hU.S . industrial/commercia l boilers .P9 ^

(i.e. , packag e versu s field-erected ) ar e discusse d i nthe follow
in g subsections . Th e method s use d t o develo p th e estimate s ar e explaine d i nAppendi xB . Dat a sheet s fo r al l boile r type s an d subcategorie s ar e presente d i nAppendi xC . Th e tota l numbe r an d capacit yo f industrial/commercia l boiler s according t o fue l use d ar e show ni nTabl e 2-2 . Th e variou s fuel s ar e burne d i nboiler s tha t diffe r widel yi nsize , us e (e.g. , spac e heating an d electri c generation) , an d typ e o f hardwar e (e.g. , fire-tube , water-tube , an d cas t iron) . I norde r t o focu s o nthes e differences , i t i s necessaryt o examin e variou s subcategories . Th e nonutilit yboiler s being considere d ca nb e separate d int o two broad sectors , commercia l an d industrial . Commercia l boiler s ar e generall ythe smalle r o f th e two , an d ar e use d primaril yfo r spac e heating i ncommercia l an d institutiona l buildings . Industria l boiler s ar e use d t o generat e proces s steam , spac e heating , an d electricity . Th e distributio nbetwee n th e two sector s i s show ni nTabl e 2-3 . TABL E 2-2 . SUMMARYO F TH E TOTAL BOILE RPOPULATIONB YFUE L USE D Fue l Coa l Residua l oi l Distillat e oi l Natura l ga s Numbe r o f bo i 214,40 0 389,10 4 244,20 6 954,35 0 ler s Tota l

MWtherma l 239,11 0 358,57 0 127,04 0 588,59 0 capacity, 3

(10 6 Btu/h ) (815,830 ) (1,223,800 ) (433,600 ) (2,008,800 ) Throughou t thi s sectio ntotal s fo r capacit yd o no t alway s agre e becaus e figure s ar e rounded . TABL E 2-3 . DISTRIBUTIONO F NONUTILIT YBOILER S BYSECTOR Secto r Commercia l Industria l Numbe r o f boiler s 1,295,13 0 506,93 0 Tota l

MWtherma l 402,78 0 910,48 0 capacity ,

(10 6 Btu/h ) (1,374,690 ) (3,107,440 ) 1 0P.1 0

the siz e o f a boile r candirectl yrelat e t o the auantityo f pollutant s discharge d an d the feasibilit yan d ;^ c o f control , i t i s necessaryt o distribut e the tota l economic s
, . ia i/commercia l populatio nb ysize . Tabl e 2- 4 present s industr- 1

- 0 a display . A s show ni nthi s table , 1,094,00 0 M Wtherma l 73 3 80 0 x10 6 Btu/h) , o r 8 3 percen t o f th e industrial/com
- ; a l boile r capacity , i s comprise d o f unit s whos e siz e i s les s mercioJ
7 3 2 5 M Wtherma l (25 0 x10 ° Btu/h) , the lowe r limi t fo r th e existin g Ne wSourc e Performanc e Standard s fo r boilers . TABL E 2-4 . DISTRIBUTIONO F COMMERCIAL/INDUSTRIAL BOILER S BYSIZ E Size , M Wtherma l (10 6 Btu/h) ' Equa l t o o r unde r 0. 1 (equal t o o r unde r 0.4 ) Ove r 0. 1 t o 0. 4 (ove r 0. 4 t o 1.5 ) Over 0. 4 t o 2. 9 (ove r 1. 5 t o 10 ) Over 2. 9 t o 7. 3 (ove r 1 0 t o 25 ) Over 7. 3 t o 14. 7 (ove r 2 5 t o 50 ) Over 14. 7 t o 29. 3 (ove r 5 0 t o 100 ) Over 29. 3 t o 7 3. 3 (ove r 10 0 t o 250 ) Over 73. 3 t o 146. 5 (ove r 25 0 t o 500 ) Over 146. 5 t o 439. 5 (ove r 50 0 t o 1500 ) Over 439. 5 (ove r 1500 ) Numbe r o f boiler s Tota l capacity ,

M Wtherma l (10 ^ Btu/h ) 970,98 0 568,41 5 208,65 9 25,08 1 16KJ83 .

1,01 8 25 3 6 5 69,18 0 143,82 0 240,27 0 126,77 0 178,35 0 147,38 0 185,16 0 98,28 0 56,08 0 68,05 0 (236,100 )

(490,700 ) (820,000 ) (432,600 ) (608j.700 ) (503,000 ) (632,000 ) (335,400 ) (191,400 ) (232,200 )

1 1Abasi c an d importan t wayt o classif yboiler s i s according t o hea t transfe r configuration , i.e. , water-tube , fire-tube , an d cas t iron . I nwater-tub e boilers , the wate r being heate d flow s throughtube s an

d the ho t gase s circulat e outsid e o f the tubes . I nfire-tub e boilers , the opposit e i s true . I ncas t iro nboilers , the ga s i s als o containe d insid e th e tube s tha t ar e surrounde d b y the wate r being heated , bu t the unit s ar e constructe d o f cas t iro n rathe r thansteel . Classificatio nb ytyp e i s importan t becaus e water-tub e boiler s ar e generall ymuc hlarge r tha nfire-tub e o r cas t iro nboilers . Th e potentia l emission s ar e differen t fo r th e variou s type s o f boilers . Table s 2- 5 through2- 7 provid e th e distribution s fo r the thre e type s o f boiler s according t o the siz e rang e an d fue l used . I t wil l b e note d tha t Tabl e 2- 5 provide s a subcategorizatio nfor
coal-fire d unit s according t o firing mechanism . I nTable s 2- 8 through2-13 , thes e distribution s ar e presente d individuall yfo r th e commercia l secto r an d th e industria l sector . Tabl e 2-1 4 summarize s th e result s an d clearl yindicate s tha t water-tub e boiler s represen t ove r hal f th e tota l capacity . Furthermore , th e averag e siz e o f water-tub e boiler s exceed s tha t o f fire-tub e boiler s b ymor e than1 0 times . I nsummary , th e derive d dat a indicat e th e following char
acteristic s o f th e boile r population : ° Natura l ga s i s th e predominan t fuel , accounting fo r 4 5 percen t o f th e capacity . 0 Rankin g o f th e othe r fuel s b ycapacit yi s residua l oi l a t 2 7 percent , coa l a t 1 8 percent , an d distillat e oi l a t 1 0 percent . 0 Distributio no f th e industrial/commercia l boile r pop ulatio ni s 6 9 percen t o f th e capacit yi nindustria l application s an

d 3 1 percen t i ncommercia l applications . 0 Fort ypercen t o f th e industrial/commercia l boile r capacit yi s i nth e rang e o f 1 t o 7 3 MWthermal . Seven tee npercen t o f th e capacit yi s abov e 7 3 MWthermal , an d 4 4 percen t i s belo w7 MWthermal .
1 2TABL E 2-5 . DISTRIBUTIO NO F U.S . WATER-TUB E BOILER S B YCAPACIT YAN D FUE L TYP E

u > ra. 1 MlMaSa to fonlt o tota l capacity . M M tkaima l <I0 « •»«/» » Mtaaka ro fwil l Tota l capacity . M M tharaa l 110 * ato/ M waaarlaoo-atoao i coa l Mariaa ! o fualt a SotA l rapacity . M M tharaa l (10 * Otu/a. ) Oaatfaoa-atoaa tcoa l MMMOJOKo fualt a Tota l capacity . "• » tharaa l UO * ata/b. ) •aolaua l oi l Kao n o fualt a •aaa l capacity . M M tharaa l (10 * Ma/k l Olatlllat a oi l Muafea ro fualt a Tota l capacity . I9t tharaa l IIO * Mto/k l Natura l aa * MufUaaro faalt a Tota l capacity . M M tharaa l 110 * Otu/h l Tota l al l foal * Muasa c o fualt a Tota l capacity . M P tharaa l 110 0 Otu/a l 0 J t o 0. 4 10. 4 t o 1.1 )

0

•

11 1 IS O IS00 I
1 0 1 0

1.17 1 41 0 11.400 1 1.01 0 l.OI O O.SOO I
1.41 4 oso 11.000 1
7.07 1 1.41 0 10.110 1 0. 4 t o 1. *

I I S t o 10 1

0

10 1 IS O 1100 )
01 0 1.41 0 14,000 1
11 4 to o 1400 1
1.1I S 4.01 0 II*.»00 l
1.41 0 1.44 0 III.OOO )
1.01 4 4.01 0 lit.000 1
10.01 4 •4.OS O ISI.000 I 1. 0 l o 7 . 1

11 0 t o 1S I

0

; 14 1 ' 71 0 ; 12.400 1 1 •* ' 1.11 0 1 111.000 1

O f 44 0 \ 11.100 1
1.11 1 11.01 0 144,400 1
41 0 2.0* 0 110.100 1
1.11 1 11.4) 0 141.100 1 4.Oi l 11.00 0 llll.100 1 Capacit yranq a

7. 1 t o 14. 7 11 1 t o 10 1

0 

### i„ T 1.01 0 110.000 1 1.10 0 I 14.74 0 / 117.1001 1

1 I 40 1 j 4.41 0 111.1001 , 1.01 1 11.14 0 11*2.000 1 01 4 0.11 0 111.000 1
4.00 1 12.71 0 1170,000 1
11.21 1 • 141.40 0 < 1404.700 1 14. 7 t o 11. 1

11 0 t o 100 1 *

14 1 7.44 0 121,400 1
•s o 20,00 0 171.000 1 24 0 1.17 0 110.100 1
2.20 1 47.11 0 11*2.200 1
20 0 4.11 0 122.000 1
2.70 S 10.14 0 1201.200 1 *.4« 0 147.14 0 1101.000 ) M

M tharaa l 110 * Otu/h ) l«. l t o 71. 1 110 0 t o 110 )

4* 1 10.11 0 170.00* 1
10 4 11.1* 0 111.700 )
10 0 7.11 0 121.700 ) 0 0 1.70 0 112,000 )
1.21 7 11.12 0 1102.00* 1
20 2 0.01 0 110,200 )
1.10 4 40.10 0 1217.100 1 4,14 * 1*1.14 0 1*11.000 1 71. 1 t o 14*. 1

111 0 t o 100 1

10 1 10.4* 0 141.000 )
0 1 7.10 0 111.(00 )
1 0 1.4* 0 111.000 ) I t 2,11 0 10.000 1
10 0 20.24 0 I00.M0 I
4 1 4.21 0 114.100 1
1 1 * 12.** * (1)1.404 ) 1.0) 4 40,10 0 (1)1.400 ) 114. 1 t o 411. 1

110 0 t o 1100 )

4 1 11.** * 147.7*4) 1 • 2.14 * (7.10* 1

1.11 0 O.OOO ) 1 7 1 * 12.IM )

• 2 11.0* 0 l«».40* 1
7 1.12 * 11.100 1
10 1 22.1* 0 177,100 )
21 1 It.00 0 11*1.400 1 

### 1

41*. 1 1 II100 1

1 1 7.71 0 11*.4*0 )
1 1,01 0 14.144 1
1 01 0 11.100 1 1 11.14* 1
0 1.41 * 11*.144 )
1 47 0 12.100 1
4 0 10.4) 0 |171.*0( ) 4 1 40.01 0 17)2,10* ) Total .

71 1 **.4« * 1207.100 1
1.70 0 47.11 0 1141.100 )
4.00 0 11.I* * 11*0.000 ) 1.00 1 II.*1 * 141.0)0 1 11.01 1 111.41 0 (711.700 )
0.00 0 10.74 4 1112.100 ) 14,14 1 104.44 0 11.011.000 ) 10.4* 1 747.4) 0 11.111.110 )

# p TABL E 2-6 . DISTRIBUTIO NO F U.S . FIRE-TUB E BOILER S B YCAPACIT YAN D FUE L TYP E

Fue l Siz e range , M Wtherma l (1 0 ' ntu/h ) 0. 1 t o 0. 4 (0. 4 t o 1.5 ) 0. 4 t o 2.9 ) (1. 5 t o 10 ) 2. 9 t o 7. 3

(1 0 t o 25 ) 7. 3 t o 14. 7

(2 5 t o 50 ) Total s Coa l Numbe r o f unit s Tota l capacity , M W therma l (10 & Btu/h ) Residua l oi l Numbe r o f unit s Tota l capacity , M W therma l <10 & Btu/h ) Distillat e oi l Numbe r o f unit s Tota l capacity , M W therma l (10 6 ntu/h ) Natura l ga s Numbe r o f unit s Tota l capacity , M W therma l (10 ° Btu/h ) Tota l al l fuel s Numbe r o f unit s Tota l capacity , M W therma l (10 & Btu/h ) 19,22 7 5,63 0 (19,200 )
46,26 7 13,57 0 (46,300 )
30,19 1 8.85 0 (30,200 )
83.48 3 24,47 0 (83,500 )
179,16 8 52,52 0 (179,200 ) 5,21 0 8,79 0 (30,000 )
21,51 1 34,63 0 (118,200 )
14,08 9 22,68 0 (77,400 )
33,57 7 54.62 0 (186,400 )
74,38 7 120.72 0 (412,000 ) 1,53 3 7, 8 0 0 (26,800 )
5,07 2 26,05 0 (88,900 )
3,31 8 17,05 0 (58,200 )
8,34 5 42,84 0 (146,200 )
18,26 8 93,79 0 (320,100 ) 35 8 3.93 0 (13,400 )
83 3 9,14 0 (31,200 )
54 3 5,98 0 (20,400 )
1,51 8 16,70 0 (57,000 )
3,25 2 35,75 0 (122,000 ) 26,32 8

26,20 0 (89,400 )
73,68 3 83,39 0 (284,600 )
48,14 1 54,56 0 (186,200 )
126,92 3 138,63 0 (473,100 )
275,07 5 302,78 0 (1,033,300 )U I TABL E 2-7 . DISTRIBUTIO NO F U.S . CAS T IRO NBOILER S B YCAPACIT YAN D FUE L TYP E

Fue l Coa l Numbe r o f unit s M Wtherma l inpu t (10 $ Btu/h ) Residua l oi l Numbe r o f unit s M Wtherma l inpu t (10 6 Btu/h ) Distillat e oi l Numbe r o f unit s M Wtherma l inpu t (10 6 Btu/h ) Natura l ga s Numbe r o f unit s M Wtherma l inpu t (10 6 Btu/h ) Tota l al l fue l Numbe r o f unit s M Wtherma l inpu t (10 6 Btu/h ) Siz e <0. 1 (<0.4 )
113,28 7 6,01 0 (20,500 )
203,56 9 15,03 0 (51,300 )
127,83 3 9,43 0 (32,200 )
526,29 1 38,71 0 (132,100 )
970,98 0 69,18 0 (236,100 ) range , M Wtherma l (10 6 Btu/h )

0. 1 t o 0. 4 1 (0. 4 t o 1.5 )
46,76 0 12,31 0 (42,000 ) 71,61 4 16,09 0 (54,900 )
44,97 9 10,08 0 (34,400 ) 218,81 9 50,34 0 (171,800 )
382,17 2 88,82 0 (303,100 ) 0. 4 t o 2. 9 1

(1. 5 t o 10 ) 19,78 2 13,27 0 145,300 ) 24,28 5 22,65 0 (77,300 )
15,24 5 14,21 0 (48,500 )
64,02 6 54,47 0 (185,900 )
123,33 8 104,60 0 (357,000 ) Tota l 179,82 9 31,59 0 (107,800 ) 299,46 8 53,77 0 (183,500 ) 188,05 7 33,72 0 (115,100 ) 809,13 6 143,52 0 (489,800 )
1,476,49 0 262,60 0 (896,200 )

# . J

TABL E2-8 . DISTRIBUTIO NO FU.S . WATER-TUB ECOMMERCIALBOILER S B YCAPACIT YAN

D FUE LTYP E

O N t+ir-i: —

rua l Puluanaa a coa l Phalli —o fualt a tota l capacity . 07 4 tharaa l II* *otu/k l apraaOag-otoko rcoa l aaaa i o l ualt a Tota l capacity . M M tkarm a 1 11* 4 otu/k l Ua»arlood-atoka rcoa l Muvihac o fualt a ta>ta l capacity . 40) tharaa l II* **jta/h l Ouarfuaa-ataka i coa l OasHM Wo fualt a nata l capacity . •* • tharaa l 110 **tu/h l •>1MM | Oi l •UJMM M o fualt a •Ma i capacity , m tharaa l II* *ata/h ) •latlllat a oi l *>•**> •o fualt a ••ta l capacity , rot tharaa l II* **tu/k l aatowa l aa a OaOa ro fualt a Dota l capacity . M M tharaa l II* **tu/k l tota l al l fual a BXoaa*to funit * tota l capacity . M M tkanaa l 110 4 atu/b ) 0. 1 t o 0. 4 10. 4 t o 1.1 1

0
•

11 1 10 1 1)10 )
2 * 1 12* 1
• 0 * 14 * 14*0 1
111 1 11 0 11040 1

•0 1 11 0 110)0 ) 111 * 111 0 11700 1 0. 4 t o 19

I I . 1 l o 10 1

0

1 7 0 0 1100 1
11 0 77 1 12.440 1
4 1 10 0 1110 )
77 2 1 . 14 0 ll.ttO ) 1.1* 1 1 . 1* 0 14.720 )
72 1 * * 1 I I . 1*0 1
1 . 10 0 4.40 0 111.1*0 1 2 * l o 1. 1

11 0 l o I M

0

1 1 24 0 11*0 1
24 1 1.1* 1 14.070 )
1 1 1* 0 11*0 1
71 0 1.10 0 111.140 1 20 4 42 0 II.110 )
11 0 1.44 0 11.400 )
1.17 1 7.11 1 121.1*0 ) ' I j

7 . 1 t o 14 . I 11 1 t o SO I

0

14 4 1. 4 1 0 11.170 1
42 1 4.44 0 11*.020 1
I I I 1.24 0 14.210 1
1.40 * 11.00 0 111.100 1 10 2 1.07 0 110.4*0 )
11 1 1.00 0 110.7*0 )
1.41 1 11.4) 0 1107.1*0 1 fjrit yr.n-ie .

14. > t o 11. ) I'. O t o 100 1

0

S O 1.24 1 14.120 1
14 2 J.M S 112.070 1
4 2 * l l 11.110 1
11 1 11.00 0 140.110 1 10 7 1.41 1 10.240 )
20 0 1,*1 S I2r,120 )
1.10 0 1S.»4 S 1*0.410 ) H

Wtht-t«* l ( ) I Vi l.. 71 . ) 110 0 t o 2S0 I

1 4 41 1 12.100 1
1 0 1.24 1 14.410 1
1 1 41 0 II.HO I
1 22 1 1770 1
14 0 0.1) 0 11*.120 1
1 2 2.44 0 10.440 1
14 1 4.24 0 111.170 1
4I I l*.4S S 147.140 1 0 ' otu/k l

7 ) 1 t o 144. S I2S 0 t o 100 1

4

J 40 0 I1.0S0 I > 20 0 l*S0 l
1 1* 0 1440 1
1 4 1.40 0 lli.*70 )
1 * 1.10 0 IS.0*0 1
1 7 1.41 0 112,1*0 )
10 4 10.10 0 1)4.100 ) 144 . " . t o 4)4. S

110 0 t o 1S00 I

0

0

0
• * 1 . 1* 0 14.740 1 ) 41 1 11.24* 1 > 1.1* 0 11.40* 1
I.*! * 111.14* 1 41*. 1

11100 1

0

0

0

0

•
•

4 l.** l 17.1** l
4 1,41 ) 117.1** ) Total *

1 * 41 1 12.1*0 1
11 1 1.11 0 111.11* 1
1.72 4 11.41 0 117.440 1
17 0 1.4) 1 (4.444 1
4.M l 41.2* 0 1114.140 )

11.17 * 144.»4* > 1.41 1 11.12 ) (104.100 1 11.70 * 1**.)* ) 1)72.4** 1TABL E 2-9 . DISTRIBUTIO N O F U.S . WATER-TUB E INDUSTRIA L BOILER S B YCAPACIT YAN DFUE L TYP E

0. 1 t o 0. 4 10. 4 t o I.I I t o 2 4 1 t o 1* 1 2 . *t o 7 . )

I I *t o 21 1 Capacit ytantia . M M tharpa l UQ 4 *tu/h ) 1. 1 t o 14. 7 12 1 t o SO I 14. 7 t o 2* 1

I S *t o 100 1 11. 1 t o 71. 1

110 *t o ISO ) 71. ) t o 144. 1 144. 1 l o 114. 1

121 0 t o 100 ) 110 0 t o 1100 ) 414. 1 11100 )
PuluatlOQ M coa l •uaao ro fualt a tota l capacity . MM tharaa l III *ata/a ) •pcoaaar-ataao rcoa l •aaha ro fualt a tota l capacity . M M tharaa l II* *ato/ M —aarfaaa-otoka c coa l Muro m o fualt a fata l capacity . MM tharaa l II* *Bta/a l Ouocfoaa-atoka tcoa l •uaaa ro foalt o fata l capacity . <• § tharaa l <l« *ata/fc ) aaalaua l al l

o faalt a

- e !l» - m tharaa l II* *Ma/h l hlatlllat a al l

t a l capacity . MM a l lift * ata/a l fata l oi l fual a tota l capacity . M M tharaa l 11* 4 *tu/h l 14 * 4 1 111* 1

1 11* 1
77 * 27 * 1*2* 1 1)7 * 4 M 11*4* 1 1)2 1 1 4 * uaM l 1*1 * I 140 M'.SO I 4 4 7 0 1220 1 41 0 4 ) 1 12.1** ) I I • • 127* )
2.44 ) 1.47 0 112.14* 1 1.77 1 2.00 0 11.00* 1
1.44 1 l.*l l 111.440 1
7.41 * 10.41 0 111 . HO I 0 * 41 0 11.110 1
41 4 2.01 1 Il.tM l
1 * 2 * * 1*4* 1 2,*2 I *.*! • 112.*** )
41 1 2,*4 * (4.47* )
2.20 1 10.4* 0 117.100 1
1.24 0 11.42 1 104.710 ) 17 1

4.20 0 114.110 ) 1.00 4 11. 0 7 0 141.1(0 1
10 * 1.1* 0 110.*7* |
1.41 4 10.14 0 ID).410 ) 4) 2 *.24 * 121.11* 1
4.12 * 4*.*I 0 1140.110 1
10 . 101 . 111. 1 11 1 I II4.4JD I 20 1

4.17 1 121.000 1
73 0 17,14 1 ll*.*10 )
10 7 4.41 1 111.1*0 1
1.41 4 11.44 0 1121.410 1
1* 1 4.1* 1 11*.MS I
l.ftl l 11.4* 1 1101.000 )
1.441 1 iii.«r , 1414.)»0 I 4 ) 1

1*.** 1 l*7.*00 l
47 4 20.2* 1 14*.2*0 )
14 * 7.00 0 174.140 )
0 1 1.11 1 112,1)0 ) 1,01 * 44.7* 0 (1)2.000 1
17 0 4 , 17 0 121.740 1
1.44 1 4 ) . 12 0 1214. I 10 1
..i:.. * 1* 1

10.14 0 141.000 1
7 4 4.40 0 111.110 1
1 1 I.11 0 1)0.410 1
1 4 1.14 0 17.1*0 )
1* 1 11.44 0 1*4.(1* 1
I S 2.SS 0 (1.7*0 )

> 0J 2 4 . 14 0 1100.210 1
oo.ftl o Iino.to m 4 4 11.44 0 141,70* 1 * 1.24 * 17.700 1
1 1.11 0 11.000 1
1 11 0 11.100 1 1 * 11.I M (41.44* 1
4 •4 1 I2.t** l

* • 21.01 * 171.7M I
21 7 11.41 1 I 174.010 1 I I

7,71 0 124.44* 1
1 1.01 0 I * . IM 1
I * l * II.1M 1 I 42 * I2.1M I

II*.2*0 1
I 47 * I2.1M I ) « 11.14 1 ID) . 12* 1 4 1 42.44 1 JH.420 I 40.0 "

(70S.000 1 I . >i i 4 1 . .'0 0 1) 4 >.»70 1
1.01 4 44 . H O 1111 . 140 1 71 4 11.0) 1 (11.I'O I 11.(7 1 174 . I 1 0 1*01.140 1 4.40 * 11.14 0 ((7 . HO I 11.1) 4 271.11 ) 1*1* . 120 )
17.44 4 4 '*.H" >
, : > vsto iTABL E 2-10 . DISTRIBUTIO NO F U.S . COMMERCIA L FIRE-TUB E BOILER S BYCAPACIT YAN D FUE L TYP E

o o Fue l

Coa l Numbe r o f unit s Tota l capacity , M M therma l (10 * Btu/h ) Residua l oi l Numbe r o f unit s Tota l capacity , HW

1 (10 * Btu/h ) th e pistillat e oi l Numbe r o f unit s Tota l capacity , M W therma l (10 * Btu/h ) Natura l ga s Numbe r o f unit s Tota l capacity , M M then-a l UO * Btu/h ) Tota l al l fuel a 4 • » Numbe r o f unit s Tota l capacity , M W therma l (10 * Btu/h ) Siz e range , M W therma l (1 0 Btu/h ) 0 . (0 . 1 t o 0. 4 4 t o l.S )
13,45 9 3,94 0 (13.S00 )
15,73 1 4,61 0 (15,700 )
16,00 1 4,69 0 (16.000 )
30,88 9 9,05 0 (30,900 )
76,08 0 22,29 0 (76,100 ) 0. 4 t o 2. 9

(1. 5 t o 10 )
2,86 6 4,83 0 (16,500 )
5.16 3 8,31 0 (28.400 )
5.63 6 9,07 0 (31,000 )
6,71 5 10.92 0 (37.300 )
20,38 0 33,13 0 (113,200 ) 2. 9 t o 7. 3

(1 0 t o 25 )
56 7 2,90 0 (9,900 )
1.31 9 6,77 0 (23,100 )
1,02 9 5,29 0 (18.000 )
1,08 5 5,57 0 (19,000 )
4,00 0 20,53 0 (70,000 ) 7. 3 t o 14. 7

(2 5 t o 50 )
10 0 1,10 0 (3,800 )
23 3 2,56 0 (8,700 )
17 9 1.97 0 (6,700 )
16 7 1,84 0 (6,300 )
67 9 7,47 0 (25,500 ) Total s

16,99 2 12.77 0 (43.700 )
22,44 6 22,25 0 (75.900 )
22.84 5 21.02 0 (71,700 )
38,85 6 27,38 0 (93.500 )
101.13 9 83,42 0 (284,800 )TABL E 2-1 1 DISTRIBUTIO NO F U.S . INDUSTRIA L FIRE-TUB E BOILER S B YCAPACIT YAN D FUE L TYP E

h-t Fue l

Coa l Numbe r o f unit s Tota l capacity , M W therma l (10 * Btu/h ) Residua l oi l Numbe r o f unit s Tota l capacity , M W therma l (10 * Btu/h ) Distillat e oi l Numbe r o f unit s Tota l capacity , M

M therma l (10 6 Btu/h ) Natura l ga s Numbe r o f unit s Tota l capacity , M

W therma l (10 * Btu/h ) Tota l al l fuel s Numbe r o f unit s Tota l capacity . M W therma l (10 * Btu/h ) 0. 1 t o 0. 4 (0. 4 t o 1.5 )

Siz e range , MWtherma l (1 0 Btu/h ) 2
5,76 8 1,69 0 (5,700 )
30.53 6 8,96 0 (30,600 ) 14,19 0 4,16 0 (14,200 ) 52,59 4 15,42 0 (52,600 ) 103,08 8 30,23 0 (103.100 ) 0. 4 t o 2. 9

(1. 5 t o 10 ) 2,34 4 3.96 0 (13,500 ) 16,34 8 26,32 0 (89,800 )
8.45 3 13,61 0 (46,400 ) 26,86 2 43,70 0 (149,100 ) 54,00 7 87,59 0 (298,800 ) . 9 t o 7. 3

(1 0 t o 25 )
96 6 4,95 0 (16,900 ) 3,75 3 19,28 0 (65,800 ) 2,28 9 11.76 0 (40,200 ) 7,26 0 37,27 0 (127,200 ) 14,26 8 73,2fi 0 (250,100 ) 7. 3 t o 14. 7

(2 5 t o 50 )
25 8 2,83 0 (9,600 )
60 0 6,58 0 (22,500 )
36 4 4,01 0 (13,700 ) 1,35 1 9,23 0 (50,700 ) 2,57 3 28,28 0 (96,500 ) Total s

9,33 6 13,43 0 (45,700 ) 51,23 7 61,14 0 (208,700 )
25.29 6 33.54 0 (114.500 ) 88,06 7 111,25 0 (379,600 ) 173,93 6 219,36 0 (748,500 )Tabl e 2-12 . DISTRIBUTIO NO F U.S . COMMERCIAL/INSTITUTIONA L CAS T IRONBOILER S B YCAPACIT YAND FUE L TYP E 

# ~ l

r o o •

Fue l Coa l Numbe r o f unit s M Wtherma l inpu t (10 6 Btu/h ) Residua l oi l Numbe r o f unit s M Wtherma l inpu t (10 * Btu/h ) Distillat e oi l Numbe r o f unit s M Wtherma l inpu t (10 * Btu/h ) Natura l ga s Numbe r ot * unit s M Wtherma l inpu t (10 6 Btu/h ) Tota l al l fue l Numbe r o f unit s M Wtherma l inpu t (10 6 Btu/h ) Siz e <0. 1 (<0.4 ) 90,63 0 4,81 0 (16,400 ) 162,85 5 12,01 0 (41,000 ) 102,26 6 7,53 0 (25,700 ) 421,03 3 30,97 0 (105,700 ) 776,78 4 55,32 0 (188,800 ) range , M Wtherma l (10 6 Btu/h )

0. 1 t o 0. 4 (0. 4 t o 1.5 ) 37,40 8 9,84 0 (33,600 ) 57,29 1 12,86 0 (43,900 ) 35,98 3 8,09 0 (27,600 ) 175,05 5 40,26 0 (137,400 ) 305,73 7 71,05 0 (242,500 ) 0. 4 t o 2. 9

(1. 5 t o 10 ) 15,82 6 10,61 0 (36,200 ) 19,42 8 18,14 0 (61,900 ) 12,19 6 11,37 0 (38,800 ) 51,22 1 43,57 0 (148,700 ) 98,67 1 83,69 0 (285,600 ) Tota l

143,86 4 25,26 0 (86,200 ) 239,57 4 43,01 0 (186,800 ) 150,44 5 26,99 0 (92,100 ) 647,30 9 114,80 0 (391,800 )

I 1.181,19 2 210,06 0 (716,900 )t o TABL E 2-13 . DISTRIBUTIO NO F U.S . INDUSTRIA L CAS T IRO NBOILKR S B YCAPACIT YAN D FUE L TYP E

Fue l Coa l Numbe r o f unit s Tota l capacity , M W therma l (10 6 Btu/h ) Residua l oi l Numbe r o f unit s Tota l capacity , MW therma l (10* 5 Btu/h ) Distillat e oi l Numbe r o f unit s Tota l capacity , M W therma l (lO ^ Btu/h ) Natura l ga s Numbe r o f unit s Tota l capacity , M W therma l (10 ^ Btu/h ) Tota l al l fuel s Numbe r o f unit s Tota l capacity , M W therma l (10 6 Btu/h ) Siz e range , M Wtherma l (1 0 ntu/h ) <0. 1 (<0.4 ) 22,65 7 1,20 0 (4,100 )
40,71 4 3,02 0 (10,300 )
25,56 7 1,88 0 (6,400 )
105,25 8 7,74 0 (26,400 )
194,19 6 13,84 0 (47,200 ) 0 . 1 t o 0. 4

(0. 4 t o 1.5 ) 9,35 2 2,46 0 (8,400 ) 14,32 3 3,22 0 (11,000 ) 8,99 6 2,02 0 (6,900 ) 43,76 4 10,08 0 (34,400 ) 76,43 5 17,78 0 (60,700 ) 0 . 4 t o 2. 9

(1. 5 t o 10 ) 3,95 6 2,67 0 (9,100 ) 4,85 7 4,54 0 (15,500 )
3,0 4 9 2,84 0 (9,700 ) 12,80 5 10,90 0 (37,200 ) 24,66 7 20,95 0 (71,500 ) 35,96 5 6 , 33 0 (21,600 ) 59,89 4 10,78 0 (36,800 ) 37,61 2 6,74 0 (23,000 ) 161,82 7 28,72 0 (98,000 ) 295,29 8 52,57 0 (179,400 )

# 1 P.2 1

TABL E 2-14 . BOILE RPOPULATIONDISTRIBUTE D BY

HEAT-TRANSFE RCONFIGURATION Hea t transfe r configuratio n Numbe r o f boiler s Tota l capacity , MWtherma l (10 6 Btu/h ; Water-tub e Fire-tub e Cas t iro n 50,49 5 275,07 5 1,476,49 0 747,93 0

302,78 0 262,60 0 (2,552,500 )

(1,033,300 ) (896,200 )

2 2 .

_^a*J||i
_P.2 2

Distributio no f the industria l commercia l boile r capacit yb

ythe thre e majo r type s i s 5 7 percen t water tube , 2 3 percen t fire-tube , an d 2 0 percen t cas t iron . Giventhe significanc e o f water-tub e boilers , i t i s appro - •.•. * t o examin e furthe r detail s o f the population . pria t e Based onsale s dat a fro mth e ABM

Aan d HI , i t wa s determine d

, t abou t 2 0 percen t o f th e water-tub e boile r capacit ycurrentl y plac e i s les s than7 year s old . (Th e sale s dat a fromABM A
wer e availabl e onl yfo r th e pas t 7 years) . Abou t 2 5 percen t o f th e curren t capacit yo f fire-tub e an d cas t iro nboiler s i s les s tha n1 0 year s old . Abou t 6 2 percen t o f industrial/commercia l water-tub

e boile r capacit yi s field-erected . Th e res t ar e pack
ag e unit s (i.e. , fabricate d i nthe shop an d transporte d i non e piec e t o the plan t site) . I ncontrast , al l fire-tub e an d cas t iro nboiler s ar e packag e units . Table s 2-1 5 an d 2-1 6 provid e a distributiono f the water-tub e boiler s b ysiz e an

d fue l typ e fo r th e field-erecte d an

d packag e units . Althoug hthere are thre e time s a s man

ypackag e units , thes e onl yrepresen t a thir d o f th e tota l capacity . The majorit yo f th e tota l water-tub e boile r capacit yi s represented b

yboiler s belo w73. 3 MWtherma l (25 0 x10 6 Btu/h) , th e presen t lowe r limi t fo r unit s subjec t t o NSPS . Th e dis
tributio nb ysize , (excerpte d fromTabl e 2-5 ) is : Size , Tota l capacity , M Wtherma l (10 * Btu/h ) MWtherma l (1Q 6 Btu/h ) Equa l t o o r unde r 7. 3 (equal t o o r unde r 25 ) 50,38 0 (171,800 ) Over 7. 3 - 14. 7 (ove r 2 5 - 50 ) 142,60 0 (486,700 ) Ove r 14. 7 - 29. 3 (ove r 5 0 - 100 ) 147,38 0 (503,000 ) Ove r 29. 3 - 73. 3 (ove r 10 0 - 250 ) 185,16 0 (632,000 ) Over 73. 3 (ove r 250 ) 222,41 0 (759,000 ) Onl y6. 7 percen t o f the tota l water-tube capacity i s belo

w 7. 3 M W therma l (2 5 x10 6 Btu/h) . Water-tube unit s belo w 73. 3 M Wtherma l accoun t for nearl y 4 9 percen t o f th

e boiler s no t Presentl

y coveredb

y NSPS . 2 3TABL E 2-15 . DISTRIBUTIO NO F U.S . FIELD-ERECTE D WATER-TUB E BOILER S B YCAPACIT YAN D FUE L TYP E

talaatlaaa ' coa l aaaea ro f*M.I4 a Vata l capacity . M M tharaa l (l» » ata/a t aawaa«ar-a4oaa roaa l aaaaa to faait a Tot. I capacity , M M • I lit * i tharaa l (!• •tta/k l •aaatfaaa-atoaa rcoa l •uraa to faatt o fata l capacity , 41 4 tkaiaa l II* *ata/a l e—,fao4-atoaa « S i r o aaaaa to faalt a tota l caaacity . MM tharaa l IIP *Ma/k l i l al l
aaaa l aapaclty . M M taataa l (It * a ta/ a I »4»tlllat a al l •aaaa i o faalt a t l caaacity . M

M araa l lit * •ta/a l Matata l w t •t o fMalt a

•ta/a l tota l caaacity . M M taaraa l II* * tota l al l foot * Mtaaaavo fwall a tota l capacity . W taataa l Ila 4 ato/a t l'.»l>.cit yi^iKi* . M Witi-ra^ l 110 4 otu/h l (0. 4 t o I 0. 4 l o 1 4

11. 1 t o 10 1 1. 4 It i 1. 1

11 0 t o I M

4 1 21 0 (10» l
1* 1 •1 0 (1.100 1
1 4 11 0 1400 )

•1 * 1.40 0 tll.lM l
1* 1 • t o 11.040 1
14 0 1.10 0 tll.tOO ) 2.04 1 ».4t 0 111.400 1 7 . 1 t o II. 1 14. 1 t o 24. 1

U S t o S0 | IS O t o 100 1

H I 1.14 0 (••••0 1 I M S.*4 * (11.240 1
12 0 1.12 0 I4.SO0 )
1.40 1 14.04 0 1*4.440 1
11 4 2.1( 0 (».»00 l
1.44 * IS.(2 0 1*4.000 1 l.*1 0 41.14 0 1144.000 1 12 0

1.41 0 14.400 1
I I I 1,41 0 llS.SOO l ( 1 1.44 0 (4.400 1
11 1 14.44 0 (S4.400 I
10 4 2 , 14 0 ••.••0 1
» 1 * 20,41 0 111.1*0 1 2 . 14*' 41,11 0 1114.100 1 2*. I i n 11. 1

110 0 t o 2*0 )

14 0 I S . 14 0 IS2.S00 I
17 * 14.10 0 I4S.100 1
I I S S.4S 0 II*.100 1
4 7 2.14 0 I*.100 1
41 1 :».*» • 1114.440 )
1S I 4.42 0 122.400 1
1.14 * 42.11 0 111*.100 ) 1 . 14 * II*.41. 0 1414.000 1 11. 1 t o 144. S 144. S t o 41*. S

(24 1 t o SO U (SO * t o ISO* )

1* 0 I I . 11 * 141,10* 1
1 2 1.41 0 124,100 )
1 7 1.40 0 (11,41* 1
I S 2.24 * (7.7** )
2 * * 21.»* » (*4.*** l
4 * 4.14 * 114,2*0 1
11 1 12.10 0 (111.000 ) 1,00 * » ! . IS * llll.*10 l 1 1 14 1

2 1 1

1 ( 1

1 2

1 1 14 1

1 ( S

2 2 41 1

4 4 1* 1 4 4 .44 0 .10* 1 * ,24 0 .1*0 )

S .11 * ,*B* I
1 11 0 S44 )
4 2 • • • 444 )
1 41 4 104 )
14 1 44 0 111 )
24 1 01 0 401 1 4 14. 4

(ISOO I tol a l a

I I 1,74 0 I24.4M )
t l.*4 * I4.1M 1 I •I * O.IM 1
I 4 2 * I1.1M I
4.41 1 «!*.)•*)
I 4 7 * U.tao ) 4 * S4.41 1 1112 ,

* S 44.*S 1 12)2.2** ) 41 4

44. 4 1 0 (144.100 )
74 1 II.10 0 (110.200 1
1.14 1 14.44 0 (I).100 1
12 4 4.77 0 111.100 1
4.1 4 1 124.04 0 (424,100 )
77 4 ll.*7 0 144.100 1
4.1 4 7 174.4) 0 (417.400 1 12.4) 1 44..4S 0 ll.414.ii>0 >^•'**«***apw*mam*artaawi ll^)U^l"V"l»l l WVMt'.' l •»»*H4t2»»2M ^ ^ TABL E 2-16 . DISTRIBUTIO NO F U.S . PACKAG E WATER-TUB E BOILER S B YCAPACIT YAN D FUE L TYP E

thciiu l1104itu/h l u. li. . 0. 4 10. 4l oI.S I 0 4 >• > 2. 4 I I S t o 10 1 2 . * t o1. 1

II * t o2S I 1. 1 t o 14. 1

I I S t o SO I 14. 7t o2*. I

IS * t o1*0 1 2*. 1 t o II. I

110 0 t o 2S0 I 11. 1 t o I44. S

I2S 0 t o 400 1 I44. S t o 11* . S

I S M t o 1SM I 41*. S

11401 )
Pai»at.4a a coa l aaaaa c o foatt a fata l capacity . M M tharaa l (11 *ata/ M apraaaat-atoaa tcoa t

r o •MPaa to faalt a

fata l capacity . MM •harai l (I* *ata/h ) O.aifaoa'-atota tcoa l Baaaa ra faalt a fata l capacity . M M tharaa l IIP *ata/h l •aalaaa l al l
•aaa i aapaclty . M M tharaa l II* *ata/a l lollllat a al l •aaha s a faalt a • I capacity . M

M •raa l »»• *»ta/h | •atata l %am •aaha ra taalt a fata l aapaclty . M M tharaa l IIP *ata/h l fata l al l foal a
•ill l a faalt a fata l capacity . "* » a l <!• * ata/a l S1 2 I S * ISM I
1 * 1 * II* ) 111 1 41 * II4M I
2*2 * 1*1 * (IS** )
241 4 •4 * I1100 I
707 S 144 0 1 4 114 1 10 1

I', * ISM I

1.41 0 14.40* 1
11 4 14 1 I4M )
1.21 4 4,11 0 II*.S M
2.44 4 1.44 * Ill.tM )
1.41 4 4.41 0 114.IM ) 10.41 1 14.14 0 141.1M I » »

so o II.7M I
44 * 2.24 * I1.1M I
4 1 12 0 11.111 ) 1.41 2 4.11 0 I1I.IM I 44 2 2.0* 0 I1.1M I

I.77 S 1.14 1 IM.1M I 4.17 1 21.12 0 (71.M0 ) 14 4 4. 0 7 0 111.400 ) 1.04 4 11.72 * I4*.*M > 2* 2 1.11 0 110.4** 1
I.M S II.SO * llll.OM )
44 0 4.SI 0 (22.10* 1
1.40 4 14.1* 0 (11S.*M I
*.24 l *t.*2 0 (140.100 1 2 2 I

4.01 0 114.S*0 )
41 7 11.11 0 I4S.M0 I 14 2 1.4* 0 (II.M* )
1. 4 1 4 11.11 0 I10S.4M )
1* 1 4.11 * ll«.*0* l 1,(1 4 14.71 0 1112.IM )

4.44 S Li].:... . i n

S , 11 0 117.4*0 1
12 4 S . I« 0 II*.400 1 44 1.11 0 10.400 1
2 ) 14 0 11.200 1
10 * I I . 11 0 I4S.400 I
4 1 2, 2 1 0 (7,400 1
1*7 17,40 0 IS*.400 )
I .0 4 7 (isllooo . I 4 0 (100 1 1 4 0 (100 )
I 4 0 I 100 1 I 4 0 llbO i
2 2* 0 11*0* 1
1 4 0 1)00 1
1 2* 0 11010 1 Mil 4 11 1

IS . 141 .
1 . 10 . 1104 .

1 (2 7
1 1 4 4 (11 1
7 1 * (4 1
1 1 10 7 1)4 1
1 1 24 ) (14 4 11 4 22 0 400 1
4I S 0) 0 100 1
4 1 * • 4 0 200 )
471 14 0 110 )
SOO ISO 400 1
211 7* 0 SOO )
41 4 41 0 100 1
41 1 14 0 110 1P.2 5

Th e capacit yrepresente d b yboiler s betwee n7. 3 an d 73. 3 M

W therma l (2 5 an

d 25 0 x10 6 Btu/h ) i s larg e fo r bot hfield-erecte d an d packag e water-tub e boilers . Approximatel y93. 5 percen t o f the capacit yo f packag e boiler s i s i nthi s range . Fo r field
erecte d boilers , the distributio nis :

Size , M Wtherma l (10 6 Btu/h ) Equa l t o o r unde r 7. 2 (equa l t o o r unde r 25 ) Ove r 7. 2 - 73. 2 (2 5 - 250 ) Ove r 73. 2 (over 250 ) Tota l capacity , % 2. 1 50. 3 47. 6 Th e distributio no f capacit yb yfue l fo r al l water-tub e boiler s (excerpted fromTabl e 2-5 ) is : Fue l Tota l capacity , MWtherma l (1Q 6 Btu/h ) Natura l ga s Residua l oi l Coa l ; Distillat e oi l 306,44 0 (1,045,900 ) 221,41 0 (755,700 ) 181,32 0 (618,600 ) 38,76 0 (132,300 ) Water-tub e boiler s accoun t fo r onl y2 7 percen t o f th e over al l capacit yo f commercia l units ; th e balanc e come s from fire
tub e an d cas t iro nboilers . I nsummary , th e industrial/commercia l water-tub e boile r populatio nha s th e following characteristics : ° I t represent s th e majorit yo f tota l capacity . 0 I t represent s th e fewes t boilers . 0 Th e averag e boile r siz e i s th e larges t o f the thre e types . 0 Th e majorit yo f th e tota l water-tub e boile r capacit yi s field-erected . 0 Mos t unit s ar e industria l rathe r tha ncommercial .


### 2 6?_ 6 presente d the tota l estimate d fire-tub e capacit y Tab± e d fuel . Onl y11. 8 percen t o f thi s capacit yi s provide d siz ea.. - 6 y" elarge r

tha n7. 3 M

Wtherma l(2 5 x10 uBtu/h) . w boil e r s y+ - fire-tub eboiler s hav eacapacit ybetwee n0. 4 an d7. 3 Hos t n i C - ma l (1* 5 anc i ^ x^ Btu/h) . Water-tub e unit s als o i. for som

e capacit yi nthe smal l siz e ranges ; bu t fo r accoun t i u l , unde r 7. 3 MWtherma l (2 5 x1 0 Btu/h) , fire-tub e unit s boil ® sent five time s a s muc hcapacit ya s water-tub e boilers . boil er s wit hdifferen t hea t transfe r configuration s pre •„ a +- p indifferen t siz e ranges , dominat e Table s 2-1 0 an

d 2-1 1 presente d the distributio no f fire-tub e cit ybetwee ncommercia l an d industria l boilers . Approxi
te l y2 1 percen t o f th e tota l commercia l boile r capacit ycome s fro mfire-tube units . Mos t fire-tub e boilers , however , ar e use d b yindustry . The tota l capacit yo f cas t iro nboiler s wa s presente d b y siz e an d fue l i nTabl e 2-7 . Al l industrial/commercia l unit s belo w0. 1 M Wtherma l (0. 4 x1 0 Btu/h ) ar e cas t iron . Abov e thi s siz e throug

h2. 9 MWtherma l (1 0 x1 0 Btu/h) , cas t iro nan d fire
tub e boiler s overlap considerably . N o cas t iro nunit s ar e large r tha n2. 9 M Wtherma l (1 0 x1 0 Btu/h) . Table s 2-1 2 an

d 2-1 3 presente d estimate s o f cas t iro n boiler capacit yi ncommercia l an d industria l applications . Th e table s sho

wtha t 8 0 percen t o f al l cas t iro nboile r capacit yar e use d commercially . I t shoul d b e note d tha t thi s rati o wa s base d o nestimate s b

yWalde nan

d coul d no t b e verifie d independentl yi n thi s study . Th e same i s tru e o f th e fire-tub e an d water-tub e boiler distribution s discusse d previously . I nal l cases , th e rati o o f commercia l t o industria l capacit ywa s assume d i nthi s stud yt o b e independen t o f fuel . Thi s assumptio nma yhav e intro
duce d error s i nth e industrial/commercia l distributio nbu t woul d no t significantl yaffec t th e overal l siz e an d fue l distributions . Th e classificatio no f tota l boile r populatio nb ytyp e o f industr yi s a nimportan t parameter . Sale s dat a fromABM Afo r water-tube boiler s sol d durin g th e perio d 196 6 t o 197 7 ar e classi
fie d b yth e Standar d Industria l Classificatio n(SIC) . Tabl e 2-1 7 2 7P.2 7

TABL E2-17 . DISTRIBUTIO NB YSI C O

F WATER-TUB

EBOILERS SOL D I NPERIOD 196 5 THROUG H197 7

t i c M

I S
2 0

12

2 1

2 *

2 1

2 1

1 0 ) )

J 7 I t

» > 1 2
M

• J latuatr y aonaanu facta , i n a
Officii , •hoppin g cantara . aall a roo d

tiitil . aill i

Loaba ran d aoe d product a tapir , allia d product !
CMiueili , *lli* 4 proauct t
Patrolau a rafinina , nlit M indultna i
tubba rproduct *

•naar yaata l Triniportitlo n

Nucalltaoov l aanafactarln * tpirfiit * •aila rraavtl i •aaplttli . aMlca l aaatar* . Maa * •ahaal i aa * •alaaroltla * ruo i Coi l Oi l Ca t t u ttota l Oi l Ca . tu b tota l Coa l O H Ga a tu b tota l Coa l O i l Ga t tut ) toti l Coa l Oi l 61 4 tu b tota l Coa l O H 6* 4 >u » tota l Coa l Oi l 6* 4 tu b toti l Coa l Oi l 6* 1 tu b tota l Oi l Caa tu b tot * I Coa l Oi l Ca t tu b tota l Coa l Oi l 6* 1 oa k tota l Coa l O H Ga i ta b tota l 0* 1 ta b t*t* l O i l 6* 1 ta b tau l Caa l O i l •4 4 fta> tota l O M l O i l a* * ta b tota l tor n Ho . e fboilir i 2 4 14 * 12 1 1.20 ) 2 1 0 1 2 1 1 14 0 << • 4S4 I S 12 4 24 4 40 5 ) ) ) 1 7 7 ) 1 4 12 1 11 4 2S4 4 1 :o s M O I I ) 2 14 ) 21 ) ) t t J ) 10 4 1S 7 t 1 4 li e 1SS 2 4 S t 11 ) 2 1 ' .' t 21 1 4) 4 •7 4 1 1 1 1 M I t 1 1 * 2 1 I t l Tt ) l.tt o

- 2 1 4 l - t •7 4 t.t4 0 Capacit y

h a tharaa l inpu t (16 *It./ M 41 2 11,444 1 t.12 4 (10,114 1 12,1* 4 144,001 1 22.20 0 (7S.74I I 2) 4 (ISO ) 1* 1 11.000 1 •2 7 11,100 ) 1,11 4 (1,410 ) 1.77 1 (».457 i t.)4 4 I)l.tl2 l 1).2) 2 (4S,l»» l 5) 1 11,UO , l.H J lt,S2t l 1.41 2 11).441 > t.)t 7 121,7** . I t(*0 ! tt S (1.»»« J St ) (2.01) : 1.20 4 14,19* ) 1.1! ) 14.744 1 2.11 1 11).ISO ) l.tt l (11,147 ) t,)0 ) (21.7S1 I 2,)l t(11.Ill ) t,)) 4 tll.tti l lt.tt t(SO.01* 1 27.10 4 (t).lt) ! 4 4 (ISO ) 4,)) 4 I21.42S ) 7.)* 4 (25.211 1 11.77 4 (47.011 ) 1.01 2 13.451 ) 1.74 C 15.472 1 2.74 2 (4.424 1 I t t(540 1 1.0* 4 ().4)0 1 1.M 7 (10,47) 1 4,li t(14.741 1 1.27 2 14.140 1 1,44 * (S.014 I 1 2,14 0 It.414 1 l.tl ) llt.ttt l 1.0* 7 (1.741 ) 4.44 4 (11,*1» ) t.Sl t()2.414 ) 11,17 * (S2.144 I l i t1440 ) l i t1440 ) 1,14 2 I),til l 1.24 ) 17,724 ) 1,41 4 111,441 1 11 1 Kit ) l.tS l It,11 1 I 7.11 *(24.M7 ) 1*.4* 4 (It.Mi l M I ii.ta* ) 1.11 *11*.1*4 ) «.** * (It,1*4 ) 1*,M ) (14.414 ) Itt.tt t14*7,*7t l Papcan t b yind.atr y

14. 2
0. 4

t . l

4. 4

0. 1

1. 4

11. 7

t . 4
1 . *

1. 0

1. 1

10. 4 • i l
2 . 1

1. 1

t . t tt. t 2 8P.2 8

bulationo f the ABM Asale s dat a b

yfue l typ e an

d SI C pr ese nC 5 th e nonm anufacturin g secto r (i.e. , commercial /

. . Boil er s coo e ' ., ar e denote d wit ha SI C cod e o f zero . cr itutiona D ar e in 5 , j-,+- a indicate , th e chemical , petroleu m refinery , an

d A S th e a° t o • e s a r e the larges t purchaser s o f ne wwater-tub e industr J. C n r f th e chemica l industrypurchase d twic e the capacit yo f ilers , an a the r tw o industries . foo d b o th e o 2 3 . FUE L CONSUMPTIO

N Th e majo r fuel s consume d b yindustria l an

d commercia l are - coal , residua l oil , distillat e oil , an d natura l gas . jailers «* i

C th e othe r fuel s burne d ar e woo d wastes , liquifie d petroleu m asDhalt , an

d kerosene . Sinc e the four majo r fuel s con gaS ; as p •tut e th e vas t majorit yo f al l fuel s burne d (estimated a t eate r tha n90%) / an

d sinc e the us e o f othe r fuel s i s site
cifi c anc j difficul t t o document , th e consumptio nfigure s o f onl vth e fou r majo r fuel s wer e compile d an d analyzed . Figure s fo r th e consumptio no f fue l i nindustrial/commercia l boilers wer e derive d fro mstatistica l report s compile d b ythe Department o f Energy . Th e procedur e i s full ydescribe d i n AppendixD . Th e summar

ypresente d i nTabl e 2-1 8 show s tha t ga s i s the mos t widelyused boile r fuel , an d tha t residua l oi l i s burne d i n industrial/commercia l boiler s i ngreate r quantitie s thancoal . TABL E 2-18 , ANNUAL FUE L CONSUMPTIONBYINDUSTRIAL /

COMMERCIAL BOILER S Fue l typ e Ga s Residua l oi l Distillat e oi l Coa l Tota l Tota l energy , 10 1 5 J (10 1 2 Btu ) 6,734. 5 (6,381.2 ) 1,861.0 . (1,762.3 ) 1,192. 9 (1,129.6 ) 1,163. 3 (1,101.6 ) 10,951. 7 (10,374.7 ) 2 9TABL E 2-19 . ESTIMATE D FUE L CONSUMPTIO NBY INDUSTRIAL AN D COMMERCIA L BOILERS , 19 7 5

u > o Secto r

Industria l Coa l Residua l oi l Distillat e oi l Natura l ga s Tota l Commercia l Coa l Residua l oi l Distillat e oi l Natura l ga s Tota l Consumptio n Quantit y 33,90 6 G g (39,37 4 x10 3 tons ) 19,88 1 x10 3 m 3 (125,06 7 x10 3 bbl ) 728 1 x10 3 m 3 (45,79 9 x10 3 bbl ) 112,23 7 x10 6 m 3 (3,963,63 5 x10 6 ft 3 )
457 5 Gg (5,04 3 x10 3 tons ) 24,65 7 x10 3 m 3 (155,10 3 x10 3 bbl ) 23,52 1 x10 3 m 3 (147,95 9 x10 3 bbl ) 64,23 3 x10 6 m 3 (2,268,12 8 x10 6 ft 3 ) Hea t content , 1 0 1 5 Joule s (10 1 2 Btu ) 1031. 0 (976.5 ) 830. 8 (786.7 ) 282. 0 (267.0 ) 4282. 3 (4058. 8 ) 6426. 1 (6089.0 ) 132. 1 (125.1 ) 1030. 2 (975.6 ) 910. 9 (862.6 ) 2452. 5 (2322.4 ) 4525. 7 (4285.7 )P.3 0

rthe r distributio nint o industria l and commercia l sector s

. . industria l boiler s consum e mor e fue l overal l ( a littl e tha» - * • * nt " " fl percen t o f th e total ) bu t tha t commercia l boiler s d o con - ° V substantiall yt o tota l consumption , and tha t the yus e a rabl e am0 un t o f "dirty " fue l (i.e. , coa l an d residua l Thes e dat a ar e presente d i nTabl e 2-19 . Th e figure s fo r consumptio no f majo r fuel s wer e subdivide d ndustria l consumptio nint o quantitie s use d fo r generatio no f tricity * proces s steam , an d spac e heating . Th e distributio n base d upo nend-use-fue l estimate s obtaine d fro mth e Depart o f Energ ysurve yo f Majo r Fue l Burnin g Installation s (MFBI) , cons oil )

(DOE , 197.5 ) . Thes e end-us e distribution s wer e applie d t o th e ta l industria l fue l consumptio nfigure , reporte d i nth e Minera l industr ySurvey s (Burea u o f Mines , 197 6 a , b , c ) usin g th e pro cedure s describe d i nAppendi xD . Th e result s ar e show ni nTabl e 2-20 . TABL E 2-20 . FUE L CONSUMPTIO NFO RINDUSTRIA L BOILER S =-" — Fue l Coa l Residua loi l Distillat eoi l Natura lga s Tota lener q Electri c generatio n 257. 8 (244 ) 108. 8 (102 ) 38. 4(36 ) 475. 8 (451 ) 880. 8 (833 ) 1 5 1 2

y , 10 1 DJ(lO 1 ^ Process _ stea m 618. 6(586 ) 606. 5 (574 ) 90. 8 (86 ) 3330. 6(3157 ) 4646. 5 (4403 ) Btu ) Spac e hea t 154. 6(147 ) 115. 5 (111 ) 152. 8 (145 ) 475. 8 (451 ) 898. 7(854 ) Th e MFB I data , however , ar e les s thancompletel ysatis
factory . Onl yboiler s havin ga capacit yove r 2 9 M W(10 0 x1 0 Btu/h ) wer e included , andth e numbe r o f boiler s (3670 ) wa s limited . Al l th e boiler s i nthi s siz e rang e ar e water-tub e boilers , andth e presen t study estimate s tha t 560 3 water-tub e boiler s hav e a capacit y greate r than2 9 M W (10 0 x1 0 Btu/h) . Thus , the DO E surve y accounte dfo r onl y 6 5 percen t o f th e estimate d


### 3 1P.3 1

boile r population . I naddition , the MFB I dat a containe d obviou s error s tha t in

* validate d some o f the dat a an d cas t doub t o nthe validit yo f th e remaining information . A nattemp t wa s mad e t o verif yth e percen t distribution s fo r eac husag e b

ycomparing the MFB I base d finding wit hthos e re porte d b

yStanfor d Researc hInstitut e (Stanford , 1970) . Th e basi s fo r th e Stanfor d stud ydiffere d i ntha t i t combine d indus
tria l proces s stea

man d spac e hea t int o on e category , an d tha t i t reporte d a tota l fo r petroleu m products . Tabl e 2-2 1 present s th e result s o f th e compariso no f th e two differen t studies .

TABL E 2-21 . COMPARISONO F FUE L AN D US E ESTIMATE S 

### Fue l Coa l Oi l Natura l Ga s Stud

y Stanfor d stud

y Presen t stud

y Stanfor d stud

y Presen t stud

y Stanfor d stud

y Presen t stud

y Electri c

generatio n 3.8 % 26.8 % 3.7 % 13.4 % 3.9 % 11.1 % Proces s stea man d spac e hea t 96.2 % 71.2 % 96.3 % 86.6 % 96.1 % 88.9 % Th e fue l usag e estimat e fo r generatio no f electricity , derive d fromMFB I data , i s consistentl yhighe r thanth e usag e estimate d b

yStanford . Th e Stanfor d stud ydoe s no t stat e ho wth e distributio nbetwee nelectri c generatio nan d othe r industria l use s wa s determined , bu t th e similarit ybetwee nvalue s fo r dif
feren t fuel s suggest s tha t a singl e facto r wa s use d fo r al l fuels . Sinc e th e MFB I stud yfocuse d o nboiler s ove r 2 9 MW(10 0 x 1 0 Btu/h) , an

d i t i s thi s boile r Capacit ycategorytha t i s likel yt o accoun t fo r almos t al l o f th e electricit ygeneratio nb y industria l boilers , applying th e MFB I fue l usag e distributio nt o th e tota l industria l fue l consumptio ncreate s a nunrealisticall y highestimat e fo r th e percen t o f fue l being use d t o generat e electricity . Adjustin g thes e value s t o reflec t fue l consumptio n b yal l type s an

d size s o f industria l boiler s shoul d yiel d value s

3 2P.3 2

e n1 0 an d 1 5 percen t o f consumptio no f coa l fo r the generatio n i e ctricit yan

d 5 t o 1 0 percen t o f consumptio nfo r ga s an d N o furthe r attemp t wa s mad e a t reconciling the difference s
a o nth e MFB I generate d an d Stanford values . Ther e ar e jjetwee n re icient dat a t o permi t calculatio no f fue l consumptio nb y insut L

X si n f boile r (needed t o determin e actua l enduse-fue l distribu
t ion ) an

d furthe r effort s t o reconcil e th e value s ar e no t
• t-ifie d i nligh t o f th e limite d utilit yo f suchfindings . Th e estimate s o f fue l consumptio nan d capacit ypermitte d th e offlputatio

no f overal l load factors . Th e result s o f thi s compu tatio nar e show

ni nTabl e 2-22 . TABL E 2-22 . ESTIMATE D LOA D FACTOR S FORINDUSTRIAL AND COMMERCIAL BOILER S B YFUE L industria l fue l Capacity , M Wtherma l (10 6Btu/h )

Commercia l fue l Coa l Residua loi l Distillat eoi l Gas 181,60 1 (619,800 )

248,46 4 (848,000 ) 66,27 7 (226,200 ) 433,40 6 (1,479,200 )
57,92 6 110,78 3 61,47 1 (197,700 )

(378,100 ) (209,800 ) Consumption , 101 5 J (101 2Btu ) 1,031. 2 830. 8 282. 0 4,282. 0 (976.5 )

(786.7 ) (267.0 ) (4,058.8 ) Calculate d

loa d facto r

Tota l 169,09 0(577,100 )

1,329,01 9 (4,535,900 ) 132. 1 (125.2 ) 1,030. 2(975.6) . 910. 9 (862.6 ) 2,452. 5 (2,322.4 ) 0.18 0 0.10 6 0.13 5 0.31 3

10,951. 7 (10,374.7 ) 0.07 2 0.29 5 0.46 9 0.45 9 0.26 1 The figure s i nsome categorie s ar e lowcompare d wit hpreviou s estimates , an

d th e weightedaverage o f 26. 1 percen t i s lower tha n th e estimat e o f 3 5 percen t fro m a previou s boile r stud y (Ehrenfel d e t al. , 1971) . Estimate s fro m Battell e (Putna

m e t al. , 1974 ) ar e i nTabl e 2-2 3 wit hth e comparabl e value fro m th e presen t study . 

### 3 3P.3 3

TABL E 2-23 . COMPARISONO F BATTELL E AND PEDC O LOA D FACTOR S Estimate d load factor s b yfue l

Pulverize d coa l an d cyclon e Othe r coa l fire d Residua l oi l Distillat e oi l Natura l ga s Commercia l Battell e 0.42 4 0.30 5 0.24 5 0.20 6 0.31 8 PEDC o

0.07 2 0.29 5 0.46 9 0.45 9 Industria l Battell e 0.52 4 0.42 6 0.36 8 0.33 0 0.51 8 PEDC o

0.18 0 0.10 6 0.13 5 0.31 3 Th e Battell e estimate s wer e derive d fromdat a containe d i n the EPANationa l Emission s Dat a System (NEDS) . Thes e dat a hav e know nlimitation s (e.g. , Ne wYor k Stat e i s no t included) , an d contain-some errors . Battell e reported , fo r example , tha t fo r some bbiler s th e reporte d capacit yan d fue l consumptio nproduce d a load : facto r greate r than1.0 . Thu s th e Battell e load factors , althoughgenerall yconsidere d a s th e bes t available , ar e no t base d o n complet e data ; difference s wit hthemd o no t necessaril y diminis hthe credibilit yo f th e dat a use d t o deriv e nationa l averag e load factor s fo r thi s study . Nevertheles s th e value s derive d i n thi s stud yfo r industria l unit s appea r low . Thi s i s probabl ybecaus e o f assumption s con cerning replacemen t rates . Base d upo ndiscussion s wit hboile r manufacturers , i t wa s assume d tha t 2 7 percen t o f th e sale s o f water-tub e an

d fire-tub e boiler s and 5 0 percen t o f th e sale s o f cas t iro nboiler s wer e replacements . Thes e assumption s directl y affec t th e tota l boile r capacit ycalculation s (e.g. , 2 7 percen t o f th e ne wcapacit yaddition s fo r water-tub e boiler s replac e existing unit s yielding a ne t increas e i n capacit yo f 7 3 percen t o f th e sales) . Furthermore , th e assumption s d o no t facto r i n replacemen t o f coal-fire d unit s b yne woil
- an

d gas-fire d capac ity(i.e. , i f a ne woil
- o r gas-fire d uni t i s purchase d t o re plac e a coal-fire d unit , n o correspondin g reductio ni n th e coal
fire d capacit ywa s incorporate d i n th e study) . Th e sale s dat a 

### 3 4P.3 4

-tube an

d fire-tub e boiler s wer e obtaine d fro mABM Afo r e n r water*" 1

- £ ° „y. i975 , an d the dat a o ncas t ironboiler s wer e obtaine d 106 6 throug hi*'- "

uvdronic s Institut e fo r 196 5 through1975 . Sale s o f fro m tn e H y f e d boiler s wer e quit e lowfo r the perio d covered ; hence , C ume

d retiremen t rat e wa s als o low . Th e averag e boile r ag e

_ en te d i nTabl e 2-2 4 sugges t tha t the assumptio nled t o data pre»<= *.^m^tes o f existing coal-fire d boilers , sinc e the percen t overestimate s capacityfo r coal-fire d unit s i s muc hlowe r thanfo r othe r o f ne wi
- f fuels
O nth e othe r hand , th e figure s mayindicat e tha t a substan
- • i numbe r o f boiler s ar e o nstandby . Th e relativel ylowloa d etor s for boiler s firing residua l oi l mayb e explaine d i nthe manner , sinc e sale s o f water-tub e boiler s (whichar e b yfar th e larges t class ) wer e lowi nrelatio nt o the tota l numbe r o f water-tub

e boilers . Th e lowload facto r fo r boiler s firing dis
tillat e oi l i nindustria l servic e an d the highload facto r fo r thos e incommercia l servic e sugges t tha t some assumption s mad e abou t typ e o f servic e mayb e invalid . Th e load factor s fo r ga s ar e no t unreasonable , excep t tha t th e facto r fo r industria l servic e wa s expecte d t o b e highe r thantha t fo r commercia l service . Th e us e o f interruptibl e ga s b yindustria l concern s may b e a partia l explanation , however , o r th e ratio s presente d b y Battell e an

d use d i nthi s stud yfo r industria l versu s commercia l boiler s (Putna

m e t al. , 1974 ) mayno t b e applicabl e t o th e pre sen t populatio no f boilers . Additiona l wor k i s require d t o resolv e the replacement , retirement , an

d standb

yissue s i norde r t o generat e bette r esti
mate s o f capacity ; th e require d informatio ncoul d probabl yb e obtained mos t effectivel yb ycanvassin g th e boile r manufacturer s an d contacting th e ABMA . Althoughconsiderabl e effor t wa s expende d i nthi s stud yt o develo p goo d estimate s o f capacity , th e retiremen t an d replace
men t issu e coul d no t b e pursue d furthe r withi nth e existin g stud y constraints . Furthermore , th e calculate d load factor s ar e no t use d directl yi nothe r part s o f th e stud ysinc e emissio nestimate s 35
-P.3 5

': f

•H i 

### i n i l I 

## 4 

# I fI TABL E

Boile r typ e Water-tub e Coa l Residua l oi l •Distillat e oi l Natura l ga s Fire-tub e Coa l Residua l oi l Distillat e oi l Natura l ga s Cas t iro n Coa l Residua l oi l Distillat e oi l Natura l ga s Al l boiler s Coa l Residua l oi l Distillat e oi l Natura l ga s : 2-24 .

170,40 0 177,10 0 33,00 0 220,30 0 26,20 0 52,70 0 34,30 0 101,10 0 30,50 0 30,50 0 19,60 0 100,50 0 227,10 0 260,30 0 86,90 0 421,90 0 COMPARISONO F BOILER S

Boile r M Wtherma l Ol d (581,600 ) (604,400 ) (112,500 ) (752,000 ) (89,400 ) (179,800 ) (117,200 ) (345,100 ) (104,200 ) (104,100 ) (66,800 ) (343,000 ) (775,200 ) (888,300 ) (296,500 ) (1,440,100 ) BYAG E

capacity , (10 6 Btu/h ) New a 9,70 0 43,40 0 5,70 0 86,10 0
0 30,70 0 20,20 0 37,50 0 1,10 0 23,30 0 14,30 0 43,00 0 10,80 0 97,40 0 40,20 0 166,60 0 (33,100 )

(148,100 ) (19,400 ) (293,800 ) (0 ) (104,800 ) (69,000 ) (127,900 ) (3,600 ) (79,500 ) (48,700 ) (146,800 ) (36,700 ) (332,300 ) (137,100 ) (568,500 ) % Ne w

5. 4 19. 7 14. 7 28. 1
0 36. 8 37. 1 27. 0
3. 3 43. 3 42. 2 30. 0
4. 5 27. 2 31. 6 28. 3
Ne wrepresent s capacit yadde d betwee nth e year s 196 7 an d 197 7



### 3 6P.3 6

e d onfue l consumptio nstatistics , an d furthe r analysi s o f o f the pas t 1 0 year s woul d no t necessaril yprovid e addi
1 insight o ncurren t an d futur e practice . GROWT HPROJECTION S FO RINDUSTRIAL/COMMERCIA LBOILER . 2 , 4POPULATIO N Th e majo r factor s affecting the futur e growt ho f the indus
-

. , /commercia l boile r populatio nar e th e economi c growt ho f the tion , technologica l advancement s i nenergyproductio nan d use , e l us e patterns , an d energyan

d environmenta l regulatory trends . Althoughth e projection s containe d i nthi s sectio nar e base d onlyo neconomi c growth , the qualitativ e effec t o f the othe r factor s wil l b e discussed . I nthe industrialize d states , Stat e Implementatio nPlan (SIP ) requirement s fo r fossil-fuel-fire d boiler s includ e regu lation s governing emission s o f particulat e matte r an d sulfu r dioxid e (S02 ) fromindustria l boilers . Atypica l equatio nbase d o nth e Illinoi s SI P fo r allowabl e particulat e emission s is : E = 5.1 8 Q-°' 7 1 5 wher e E i s allowabl e particulat e emission s i nlb/1 0 Bt u Q i s hea t inpu t rat e i n10 6 Btu/h . The allowabl e particulat e emissio nrat e range s fro m 43 0 t o 4 3 ng/ J (1. 0 t o 0. 1 lb/10 6 Btu ) a s th e hea t inpu t varie s from2. 3 t o 73.2 5 M

Wtherma l (1 0 t o 25 0 x10 6 Btu/h) . Regulation s governin g SO 2 emission s varyfo r eac htyp e o f fuel . Fo r coa l firing , SO 2 regulation s varyfrom8 6 t o 258 0 ng/ J (0. 2 t o 6. 0 lb/10 6 Btu) . Fo r fue l oi l firing , th e regulation s (normall yexpresse d a s a limitatio no nth e sulfu r conten t i nth e fuel ) ar e equivalen t t o 8 6 t o 34 4 ng/ J (0. 2 t o 0. 8 lb/10 6 Btu) . T o dat e n o Federa l regulation s hav e bee npromulgate d fo r ne w boiler installation s unde r 73. 3 MWtherma l (25 0 x10 6 Btu/h ) hea t input , an

d manufacturer s o f industria l boiler s hav e no t ye t had to dea l extensivel ywit hemissio nlimitatio nproblems . Th e 

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