DOE/EIA-0358

Report on 

the 1980 

Manufacturing 

Industries Energy 

Consumption 

Study and Survey 

of Large 

Combustors

Energy Information Administration

Washington, D.C.

January 1983
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Report on 

the 1980 

Manufacturing 

Industries Energy 

Consumption 

Study and Survey 

of Large 

Combustors

Energy Information Administration

Office of Energy Markets and End Use

U.S. Department of Energy 

Washington, D.C. 20585

January 1983

DOE/EIA-0358

This report was prepared by the 

Energy Information Administra 

tion, the independent statistical 

and analytical agency within the 

Department of Energy. The in 

formation contained herein 

should not be construed as 

advocating or necessarily reflect 

ing any policy position of the 

Department of Energy or any 

other organization.
Contacts

The following information is provided in case questions arise concerning 

this report:

This report was prepared in the Energy Information Administration (EIA), 

Office of Energy Markets and End Use under the directorship of Wray Snucl- 

(202/252-1617). General supervision of the report was provided by Lynd;3 

Carlson, Acting Director of the Energy End Use Division (202/252-1112),

This report was prepared by Stephen Jo Dienstfrey (202/252-1128) with 

assistance from John L. Preston (202/252-1124).

A major guiding force in this survey was Kenneth A. Vagts who was the 

Director of the Energy End Use Division until October 1, 1982. Other 

participants in the design and implementation of this survey were John. '!, 

Makens, Robert B. Latta, and Thomas H. Woteki. Additional assistance was 

provided by Westat, Inc., of Rockville, Maryland, which also served as 

the collection agent.

For further information regarding additional copies of this report, 

contact:

U.S. Department of Energy 

National Energy Information Center 

1000 Independence Avenue, S.W. 

Room 1F-048

Washington, B.C. 20585 

(202) 252-8800

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Connbustors 

Energy Information Administration
Preface

The 1980 Manufacturing Industries Energy Consumption Study and Survey of 

Large Combustors (EIA-463) was designed to collect information on large 

combustors in the United States and the manufacturing establishments 

operating them. The survey was mailed to a list of respondents in late 

November and early December 1980. On February 20, 1981, the Secretary 

of Energy received notice from the Office of Management and Budget that 

authority for the information collection activity had been withdrawn and 

that the information already collected should be treated in a confidential 

manner. The Energy Information Administration (EIA) proceeded to carry 

out these instructions to insure the maximum confidentiality of the data.

At that time, responses had been received from approximately 76 percent 

of the final survey frame, and even though this represented a respectable 

response rate, the usefulness of the survey was substantially diminished 

for the following reasons:

 The results of this survey are probably somewhat biased due 

to systematic nonresponse error.

« Because of the withdrawal of authority for this survey, the 

EIA was unable to undertake a followup of respondents to 

resolve problems of missing and seemingly questionable data.

This report presents an overview of the data collected by this study. 

This will be the only report prepared covering the entire study. Other 

reports from this study include a methodological report, Methodological 

Report on the 1980 Manufacturing Industries Survey of Large Combustors 

(EIA-463) DOE/EIA-0306, and the Report on Alternative-Fuel Burning 

Capabilities of Large Boilers, DOE/EIA-0304.

Report on the 1980 Manufacturing industries Energy 

Consumption Study and Survey of Large Comfeustcsrs 

Energy Information Administration

Tables

Contents

PREFACE ..... 

INTRODUCTION

Page 

ill

SUMMARY OF FINDINGS

Characteristics of Establishments and Combustors ................

Standard Industrial Classification Breakdown Characteristics.....

Regional Characteristics ........................................

FUEL AND ENERGY USE AT THE ESTABLISHMENT LEVEL

ENERGY USE IN LARGE BOILERS

The Role of Large Boilers in Industry 

Fuels Used ...........................

Boiler Utilization ...................

Heat Recovery Equipment ..............

APPENDIXES

A. Questionnaire and Other Materials ................

B. Letter from the Office of Management and Budget .. 

C. Steps Taken to Minimize the Potential to Identify 

Respondents ......................................

Number of Establishments and Large Boilers Together with Total 

and Average Amount of Fuel Consumed (Trillion Btu) by Standard 

Industrial Classification (SIC) Code ..........................

General Characteristics of Large Boilers by Standard Industrial 

Classification (SIC) Code .....................................

Number of Combustors with a Maximum Design Firing Rate of 

One-Million Btu-Per-Hour or More by Type of Combustor and 

Standard Industrial Classification (SIC) Code .................

Number of Combustors with a Maximum Design Firing Rate of 

One-Million Btu-Per-Hour or More by Maximum Design Firing 

Rate and Standard Industrial Classification (SIC) Code ...

.9.

Number of Establishments and Large Boilers Together with Total 

and Average Amount of Fuel Consumed (Trillion Btu) by Region ..

General Characteristics of Large Boilers by Region and Selected 

Standard Industrial Classification (SIC) Code .................

Number of Combustors with a Maximum Design Firing Rate of

One-Million Btu-Per-Hour or More by Type of Combustor

and Region ....................................................

Number of Coobustors with a Maximum Design Firing Rate of 

One-Million Btu-Per-Hour or More by Maximum Design Firing 

Rate and Region ...............................................

Establishment Fuel Use by Standard Industrial Classification 

(SIC) Code Unweighted Data (Trillion Btu) ....................

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

2

2

12

17

27

27

32

38

40

43

57

61

10

11

12

13

15

16

18
r

Tables (continued!

Contents (continued)

L'aj-e

10. Establishment Fuel Use by Standard Industrial Classification

(SIC) Code Weighted Data (Trillion Btu) ...................... :°

11.. Establishment Fuel Use by Region (Trillion Btu) ............... ;:0

12.. Electricity Generated and Used Onsite by Standard Industrial

Classification (SIC) Code (Trillion Btu) ...................... /I

13« Electricity Generated and Used Onsite by Region

(Trillion Btu) ................................................ 23

14. Steam Balance by Standard Industrial Classification

(SIC) Code (Trillion Btu) ..................................... J 4

15. Steam Balance by Region (Trillion Btu) ........................ ?.5

16. Number of Large Boilers by Maximum Design Firing Rate and

Standard Industrial Classification (SIC) Code ................. 23

17. Number of Large Boilers by Maximum Design Firing Rate and

Region ........................................................ 29

18. Percent of Large Boilers by Maximum Design Firing Rate and Year

of Installation .............................................. 50

19. Fuel Consumption in Large Boilers by Standard Industrial Classi 

fication (SIC) Code Unweighted Data (Trillion Btu) ........... 33

20. Fuel Consumption in Large Boilers by Standard Industrial

Classification (SIC) Code Weighted Data (Trillion Btu) ....... 34

21. Fuel Consumption in Large Boilers by Region (Trillion Btu) .... 35

22. Fuel Use in Large Boilers by Maximum Design Firing Rates

(Trillion Btu) ................................................ 36

23. Fuel Use in Large Boilers by Year of Installation

(Trillion Btu) ................................................ 37

24. Mean Fuel Consumption for a Typical Large Boiler by Maximum 

Design Firing Rate and Year of Installation Categories 

(Trillion Btu) ................................................ 33

25. Average Calculated Large Boiler Utilization by Maximum Design

Firing Rate and Year of Installation .......................... 39

26. Percentage of Large Boilers with Heat Recovery Equipment by

Maximum Design Firing Rate and Year of Installation ........... £0

1. Number of Establishments and Large Boilers and the Amount of Fuel 

Consumed in Establishments and Large Boilers by Major Industrial 

Classification ..................<............................. <;

2. Electricity Generated and Used Onsite by Major Industrial

Classification (Unweighted) ................................... 11

3. Percent of Large Boilers of Various Size by Year of

Installation .................................................. 31.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Introduction

During 1979, total annual industrial energy consumption, including 

electrical energy losses in the United States, was 31.5 quadrillion Btu. 

This amounts to almost 40 percent of the energy consumed in the final 

consuming sectors of the economy.'- Manufacturing is by far the largest 

energy consuming component, totaling 12.9 quadrillion Btu of purchased 

fuels and electricity for heat and power during 1979. Of this amount, 

10.5 quadrillion Btu was accounted for by purchased fuels alone (fuel 

oil, coal, natural gas, etc.).

From the data collected in this survey,^ it is estimated that all 

establishments which operate large combustors'* consumed 12.1 quadrillion 

Btu in 1979. Of this amount, 7.2 quadrillion Btu was purchased fuels 

and 4.9 quadrillion Btu was nonpurchased fuels, such as woodchips, pulping 

liquor, and process off-gases. Establishments which operate large combustors consumed almost 70 percent of the purchased fuels and 40 percent 

of the nonpurchased fuels were consumed in the manufacturing subsector.

Of the estimated 12.1 quadrillion Btu used in establishments with large 

combustors, slightly more than 50 percent, or 6.2 quadrillion Btu, was 

used in these combustors. This amount includes an estimated 3.8 

quadrillion Btu of purchased fuel and 2.4 quadrillion Btu of nonpurchased 

fuels.

This report covers the energy consumption characteristics of respondents/ 

establishments that operate large combustors. The energy consumption 

characteristics of large boilers, the predominant combustor, are also 

covered.^

-"-The industrial sector includes manufacturing, mining, construction, and 

agriculture. The amount of energy consumed is reported in the Energy 

Information Administration's 1980 Annual Report to Congress, DOE/EIA0173(80).

^U.S. Department of Commerce, Bureau of the Census. 1979 Annual Survey 

of Manufactures, Fuels and Electric Energy Consumed, M79(AS)-4.1.

-'The 1980 Manufacturing Industries Energy Consumption Study and Survey 

of Large Combustors, Form EIA-463 appears in Appendix A. The survey design 

is detailed in the Methodological Report of the 1980 Manufacturing 

Industries of Large Combustors (EIA-463), DOE/EIA-0306, March 1982.

^For the purpose of this study, large combustors are defined as boilers, 

gas turbines, combined cycle units, or internal combustion engines with a 

maximum design firing rate of 50 million Btu-per-hour or more.

-'Due to the cancellation of this study, coverage of the intended universe 

is not complete. See the methodology report for details concerning 

coverage.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

Characteristics of 

Establishments and 

Combustors

Standard Industrial 

Classification Breakdown 

Characteristics

of

Responses to this study were received from 7,983 establishments. Of this 

number, 2,498 reported having one or more large combustors for a total of 

7,680.' While 7,510 of these combustors were classified as boilers, 102 

were found to have a maximum design firing rate (MDFR) of less than 50 

million Btu (MMBtu) per hour.^ This report will consider only the 

remaining 7,408 boilers unless otherwise indicated.-'

The establishments responding to the survey reported consuming 8,518.5 

trillion Bta of energy. Almost 63 percent of this amount was purchased 

fuel with the balance made up of nonpurchased byproduct or waste stream 

fuels and a negligible amount of nontraditional energy sources such as 

solar, hydropower, etc. When this figure is adjusted to account for 

those establishments, which did not respond, the total fuel consumption 

is estimated to be 12,089.6 trillion Btu but the purchased fuel component 

drops to slightly less than 60 percent.

In addition, these establishments used 857.5 trillion Btu of electricity, 

of which 26 percent is generated onsite. The amount of electricity con 

sumed increases to 1,130.4 trillion Btu after adjusting for nonresponse. 

This adjustment does not substantially change the proportion generated 

onsite.

Approximately 63 percent of the fuel consumed in large boilers consists of

coal, natural gas, or fuel oil. This figure remains constant after

adjusting for nonresponse.

This section of the report indicates that, based on various measures of 

size, energy consumption among establishments with large combustors is 

concentrated in five industries: Food and Kindred Products, Paper and 

Allied Products, Chemicals and Allied Products, Petroleum and Coal 

Products, and Primary Metals. These five industries are not the same 

five industries which the 1979 Annual Survey of Manufactures reported as 

the most energy intensive. The Stone, Clay, and Glass Products industry, 

the third most energy intensive in terms of purchased fuels consumed in 

1979,^ is not among the most energy intensive industries as reported 

in this study. As will be seen later in Tables 1, 3, and 4 of this 

report, the 33 establishments included In this study from this industry 

reported 4,832 combustors with an MDFR of at least one million Btu-perhour. Only 574 were boilers of which only 84 had an MDFR of 50 million 

Btu-per-hour or more. So while this industry has a large number of 

combustors, they do not have a large number of large boilers.

-^Individual reports were received for 7,386 boilers, 116 gas turbines, 

and 25 internal combustion engines. In addition, from information 

provided by partially completed questionnaires, an additional 124 com 

bustors were classified as boilers, 2 as gas turbines, and 7 as internal 

combustion engines. The remaining 20 combustors are unclassified due to 

a lack of information.

^They were either separately filed components of combined cycle units 

or were erroneously reported.

^A public use data tape covering all data from this study is available 

from the National Technical Information Service of the U.S. Department 

of Commerce, 5285 Port Royal Road, Springfield, Virginia 22161.

^U.S. Department of Commerce, Bureau of the Census, 1979 Annual Survey 

of Manufactures, Fuels and Electric Energy Consumed, 1979(AS) 4.1.

Report on the 19SQ Manufacturing industries Energy 

Consumption Study .and Survey of Large Combustors 

Energy Information Administration
Summary of Findings (continued)!

The four largest industry groups in terms of fuel used-" at the 

establishment level are chemicals, paper, petroleum, and primary metals 

(Table 1). These four industries account for 85 percent of the fuel 

consumed at the establishment level but less than half of the establish 

ments responding to this survey. These high-energy-use industries also 

report the highest amounts of energy consumed per establishment (Figure 

1).

The food industry is the fifth largest energy consuming industry at the, 

establishment level. Fuels consumed in this industry accounted for 

only about one-third as much as the fourth largest industry, primary 

metals. When the food industry is added to the four largest, these five: 

industries account for 90 percent of the fuel consumed at the establish 

ment level and 66 percent of the establishments with large boilers 

(Figure 1).

Table 1 provides similar information for large boilers. The five largefi: 

industry groups, which consume the most energy at the establishment 

level, are also the five largest industries in terms of energy con 

sumption at the boiler level. These five industries account for 66 

percent of the establishments reported and comprise 74 percent of the 

boilers. Further, they consumed 90 percent of the reported energy at 

the establishment level, and 89 percent of the fuel reported for boilers,

^Several steps were taken to avoid the disclosure of the individual 

respondents. These are detailed in Appendix C.

Report on the 1980 Manufacturing Industrie! Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Table 1. Number of

Establishments and Large

Boilers, Together with Total

and Average Amount of Fuel

Consumed (Trillion Btuj by

Standard Industrial Classification

(SICJ Code

Industry

SIC 

Code Number

Fuels

Total

Consumed

Average

Fuels Consumed

Number Total Average

Summary of Findings (continued)

Establishments Large Boilers

Food and Kindred 

Products............ 20

Tobacco............. 21

Textile Mill 

Products............ 22

Apparel............. 23

Lumber and Wood..... 24

Furniture........... 25

Paper and Allied 

Products............ 26

Printing and 

Publishing.......... 27

Chemicals........... 28

Petroleum........... 29

Rubber and

Plastics............ 30

Leather............. 31

Stone, Clay and

Glass............... 32

Primary Metals...... 33

Fabricated Metals... 34

Machinery........... 35

Electronic

Equipment........... 36

Transportation 

Equipment........... 37

Instruments......... 38

Miscellaneous....... 39

Other Nondurables a .. NA

Other Durables'3 ..... NA

Unclassified d ....... NA

462 445.7 0.96 1,122 321.0 0.29

See Other Nondurables 49 6.9 0.14

186 152.0 0.82 382 70.9 0.19

See Other Nondurables 14 1.5 0.11

142 163.7 1.15 240 134.6 0.56

See Other Durables 13 1.4 0.11

370 1,994.5 5.39 1,239 1,575.2 1.27

See Other Nondurables 10 2.5 0.25

518 2,004.9 3.87 1,783 1,223.1 0.69

163 1,847.3 11.33 653 467.4 0.72

97 80.5 0.83 

See Other Nondurables

33 52.4

134 1,385.3

50 27.7

1.59

10.34

0.55

81 102.4 1.26

63 47.3 0.75

112 121.4 1.08

See Other Durables

See Other Durables

38

33

16

33.4

60.0

20.4

0.88

1.82

1.28

224

5

84

647

115

221

165

331

61

13

C 78

C 87

37

62.3 

0.8

0.28

0.16

26.1 0.31

565.2 0.87

17.2 0.15

41.5

32.1

0.19

0.19

59.8 0.18

35.3 0.58

12.8 0.98

C 11.7 C 0.15

C 49.5 C 0.57

13.6 0.37

Total. NA 2,498 8,538.9 3.42 7,408 4,671.2 0.63

a SIC codes 21, 23, 27, and 31.

bSIC codes 25, 38, and 39.

cNot included in column totals since they are already in the table 

above.

^From the information requested, it was impossible to determine the 

industry group.

NA = Not Applicable.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries 

Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Figure 1. Number of 

Establishments and Large Boilers 

and the Amount of Fuel Used in 

Establishments and Large Boilers 

by Major Industrial Classification3

Summary of Findings (continued

Chemical

Paper

Petroleum 

Primary Metal

Food

Other Durable

Other Nondurable

518 

21%

310 

15%

163 

6%

134 

5%

462 

19%

514 

21%

321

13%

Number 

of 

Estab 

lish 

ments

*"--..

\ 

\

l, \ 

\ \

\

\\

\ \ 

\ \

\ \ 

\ \ 

I \ X

\ V '

\ \

\ \ 

\ \ 

\ \

\ \

X \

X ^ 

X

X

2.0C4.9 

25%

1,994 5

23%

1,847.3

!,385 3 

16%

5%,

574.4 

7%

265.9 3%

Fuel 

Used at 

the 

Estab 

lish 

ment 

'IWMBtuI

s

/ 

/

/ !

" 1

1 

/

1 /

*

/

s

1,783 

24%

1,239 

17%

653 

9%

647 

9%

1122

15%

1243

17%

684 

9%

Mumber 

of 

Boilers

\

\

, \

\\

\ \ 

\ \

\ \

\

1 \

\\

\

\

X

1,223.1 

26%

1,575.2

34%.

467.4

10%

565.2

12%

321.0

7%

360.6 

8%

144.4 3%

Fuel

Used in 

Boilers 

(MMBtu)

aThe percentages on this figure have been rounded. Those establishments and large comtaustcrs .yii.ti coulc 

not be classified by Standard Industrial Classification (SIC) Code are not shown. The 16 establis-ir ;HK in this 

category represent 0.6 percent of the establishments and consume 20.4 trillion Btu, or 0.2 percer: :f ::he tots 

fuel consumption at the establishment level. The 37 large boilers which could not be classified b<. S C Code 

represent 0.5 percent of the large boilers and consume 13.6 trillion Btu, or 0.3 percent of the ti;t,- fuel 

consumption at the boiler level.

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy Enr :.se 

Division, I960 Manufacturing Industries Energy Consumption Study and Survey of Large Corrc^ic:-;

Report on the 19SO Manufacturing Industries Energy 

Consumption Study and Survey of Large Ccrnfoustors 

Energy Information Administration
Summary of Findings (continued)

As will be discussed in the section on the role of larger boilers in 

industry, the size of boiler varies considerably by industry. Table 2 

highlights this point. This fact means that two industries which have 

the same number of boilers may consume vastly different amounts of energy 

due to the size of the boilers. For example, the food and paper indus 

tries (as shown in Table 1) have approximately the same number of boilers, 

yet the paper industry uses almost five times as much fuel (as shown in 

Table 2) because its boilers are considerably larger.

Table 2 presents some general characteristics of boilers. The industries 

with the largest number of boilers per establishment are primary metals, 

petroleum, paper, and chemicals. The lumber and wood industry reported 

the fewest number of boilers per establishment.

Nationwide, the median size of large boilers in operation during 1979 was 

123 million Btu-per-hour. Some industries, particularly paper, primary 

metals, chemicals, and petroleum, have a median size considerably higher 

than the national average.

The median year of installation for large boilers nationally is 1962. 

However, there is a fairly wide range for this date. The oldest boilers 

are in the stone, clay, and glass; and primary metals industries where 

the median years of installation are 1951 and 1952, respectively.

Report on the 1980 Manufacturing Industries Energy

Consumption Study and Surwey of Large Comburton 

Energy Information Administration
Table 2. General Characteristics

of Large Boilers by Standard

Industrial Classification

(SIC) Code

Summary of Findings (continued)

Industry

SIC 

Code

Number 

of Estab 

lishments

Number

of

Large 

Boilers

Mean

Number of 

Large 

Boilers

Median 

Maximum

Design Medlar 

Firing Year o:f

Per Estab- Ratea Instal 

lishment (MMBtu/hr.) laeiori

Food and Kindred

Products............ 20 462

Tobacco............. 21 c

Textile Mill

Products............ 22 186

Apparel............. 23 c

Lumber and Wood..... 24 142

Furniture........... 25 c

Paper and Allied

Products............ 26 370

Printing and 

Publishing.......... 27 c

Chemicals........... 28 518

Petroleum........... 29 163

Rubber and

Plastics............ 30 97

Leather............. 31 c

Stone, Clay, and 

Class............... 32 33

Primary Metals...... 33 134

Fabricated Metals... 34 50

Machinery........... 35 81

Electronic

Equipment........... 36 63

Transportation

Equipment........... 37 112

Instruments......... 38 c

Miscellaneous....... 39 c

Other Nondurables... NA 38

Other Durables...... NA 33

Unclassified 6 ....... NA 16

Total......... NA 2,498

1,122

49

382

14

240

13

1,239

10

1,783

653

224

5

84

647

115

221

165

331

61

13

d 78

37

7,408

2.43 

c

2.05 

c

1.69

3.35

c

3.44 

4.01

2.31 

c

2.55

4.83

2.30

2.73

2.62

2.96 

c

2.05

2.64

2.31

2.97

96

88

83

77

95

77

184

86

149

143

75

115

163

94

89

84

96

138

175

84

126

94

121

1961

1967

1965

1966

aThis column is based on a total of 7,204 boilers due to the exclusion 

of 167 boilers which could not be classified by maximum design firing 

rate.

^This column is based on a total of 7,027 boilers due to the exclusion 

of 344 boilers which could not be classified by year of installation.,

c ln order to avoid the possible identification of respondents, estab 

lishments in SIC codes 21, 23, 27, and 31 are reported in "Other Nondura 

bles" and establishments in SIC codes 25, 38, and 39 are reported in 

"Other Durables." "Not included in column totals since they are already 

in the table above.

eFrom the information requested, it was impossible to determine the 

industry group.

NA = Not Applicable.

Source: Energy Information Administration, Office of Energy Markets aid 

End Use, Energy End Use Division, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries; Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Summary of Findings (continued)

In an effort to determine the population of both process and nonprocess 

combustors, respondents were asked to indicate the number and MDFR size 

class of all combustors with a maximum design firing rate greater than 

one MMBtu per hour.^ Almost 63,000 combustors were reported. Table 3 

presents these combustors divided into the eleven categories by SIC 

code. 7

The primary metals industry reported 16,898 combustors. This is 

approximately 27 percent of all combustors reported. A little less 

than one fourth of these combustors were identified as heat treaters, 

with an almost equal number of reheaters. The chemicals industry reported 

8,529 combustors, or a little less than 14 percent of the total reported. 

A little more than one in five of these combustors were identified as 

boilers. 8

Table 4 shows the distribution of all combustors by maximum design 

firing rate and SIC code. While the primary metals industry has the 

largest number of combustors, they are relatively small. On the other 

hand, the paper industry has only 15 percent as many combustors as the 

primary metals industry, but the typical combustor in the paper industry 

is almost 9 times larger as measured by the MDFR. Other industries with 

high median MDFR among those industries reporting 2,000 or more corabustors 

are the petroleum, food, and chemicals industries.

^Of the 7,983 establishments which responded to this survey, 6,550 

reported at least one combustor.

''The detailed data from which Tables 3, 4, 7, and 8 were extracted are 

part of the public use data tape.

 The reader is reminded that due to the cancellation of this study (see 

Appendix B), the number of combustors reported by an industry is less 

than the number actually in use. However, the relative proportion of the 

types of combustors, particularly in industries with a large number of 

reporting establishments, may more accurately represent the true 

distribution of combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Summary of Findings (con tin wed

Vfe ^Wr j k«9 ^HWx £ »/:t^'::';?f^ESB^ JL jP

Table 3. Number of Combustors 

with a Maximum Design Firing 

Rate of One-Million Btu-per-hour 

or More by Type of Combustor3 

and Standard Industrial 

Classification (SIC) Code

Industry

Primary Metal. .

Stone, Clay,

Fabricated

Transportation.

Electrical

Textile.. ......

Rubber and 

Plastic. .......

Lumber and

Printing and 

Publishing. .... 

Miscellaneous. .

Unclassified0 .. 

Total..........

SIC 

Code

. 33 

. 28

. 29

. 32

. 20

. 34

. 37 

. 35

. 26

. 36

. 22

. 30

. 24

. 25

. 38

. 27 

. 39 

. 23

. 21

. 31

. NA 

. NA

Total 

Com 

bus 

tors

16,898 

8,529 

7,002

4,892 

4,661

3,783 

3,595 

2,719 

2,576

2,496 

2,018 

842

767 

344 

316

257 

220 

144 

118 

89 

450

62,716

Gas 

TurBoilers bines

1,571 19 

3,700 62 

1,173 80

574 5 

2,732 8

744 

1,245 15 

793 12 

1,788 7

725

821 

543 3

525 

118 

232 5

76 

105 4 

48 

99 

60 

100 5

d !7,778 225

Inter 

nal 

Combus 

tion 

Engines

301 

607 

913

63 

132

21 

91 

94 

18

36 

4 

23 

8 

44

14 

7 

4 

2,380

Fluid 

Heat 

ers

1,416 

1,495 

3,852

66 

186

457 

632 

119 

43

138 

32 

72

19 

118 

1

13 

19 

8 

1 

5 

242

8,939

Dryers

727 

858 

614

725 

1,134

552 

574 

267 

510

472 

1,048 

122

169 

64 

28

144 

55 

59 

11 

16 

81

8,230

Cal- Reacciriers tors

180 3,169 

300 1,219 

40 260

933 40 

82 66

15 63 

8 121 

10 38 

163 23

15 112 

3 9 

0 23

13 

13 

2 4

19 2

12 4

1 2 

6 1

1,789 5,182

Melters

1,251 

81 

2

593 

4

99 

98 

59 

5

83 

4 

10

1 

3 

2

3 

2,298

Heat ReTreat- heat 

ers ers

4,073 3,914 

111 52 

25 34

1,789 35 

310 4

1,121 702 

755 52 

1,065 255

11 5

875 22 

86 5 

46

33 

19 12

1 1 

4 

12 15

2

5 *~

10,343 5,108

Sinand 

Pell!: - 

iaeri; Other"

27V 

4C 4

.:: 4

•>'; u 

:\ 2

0 

3 1 

1 2 

1. 8 

1

418 2

aSee the Glossary in Appendix A for the definitions of the types of corabustors.

"Includes 21 combustors which were either boilers, gas turbines, or Internal combustion engines and 5 which t.sre rot 

identifiable.

cFrom the information reported, it was Impossible to determine the industrial group.

^Includes 10,370 boilers with a maximum design firing rate between 1 and 49 MMBtu per hour as well as the 

7,408 larger boilers with an MDFR of 50 MMBtu or more per hour reported elsewhere in this report.

"-" = None

NA = Not applicable.

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use Division, 

1980 Manufacturing Industries Energy Consumption Study and Survey of Large Corabustors.

10 Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Table 4. Number of Combustors

with a Maximum Design Firing

Rate of One-Million Btu-per-hour

or More by Maximum Design

Firing Rate and Standard

Industrial Classification

(SIC) Code

Summary of Findings (continued)

Industry

SIC

Code Total 1-9 10-24

Maximum Design Firing Rate (MMBtu per hoar)

25-49 50-99 100-249 250 +50+a Unknown Median

Primary Metals. 33 16,898 10,361

Chemicals........ 28 8,529 3,488

Petroleum........ 29 7,002 2,476

Stone, Clay,

and Glass. ....... 32 4,872 2,677

Food............. 20 4,661 1,670

Fabricated 

Metals. ........

Transportation. 

Machinery. .....

Paper..........

Electronic 

Equipment. .....

Textile.........

Rubber and 

Plastic.........

Lumber and Wood. 

Furniture.......

Instruments.....

34 3,783 2,768

37 3,595 2,569

35 2,719 2,012

26 2,576 554

36 2,496 1,816

22 2,018 1,042

30 842 416

24 767 259

25 344 244

38 316 161

Printing......... 27 257 194

Miscellaneous.... 39 220 114

Apparel.......... 23 144 84

Tobacco.......... 21 118 23

Leather.......... 31 89 46

Unclassified0 .... NA 220 279

2,970

1,654

1,269

994

1,039

576

486

277

302

368

331

108

131

54

67

37

61

27

26

28

41

1,476

895

1,072

462

686

175

173

158

326

143

255

82

118

31

23

16

31

18

15

8

33

689 954

949 1,109

1,096 872

328

707

86

199

177

436

123

292

163

144

14

28

7

5

11

35

6

54

321

460

167

141

85

544

40

84

60

93

1

26

3

5

2

16

1

41

441

405

200

92

53

1

20

10

389

7

13

11

2

29

16

18

42

5

7

25

3

11

6

9

Total. KA 2,716 33,253 10,846 6,196 5,549 5,025 1,654 178

7

17

22

9

20

7

7

7

62

10

11

24

7

10

7

10

9

42

9

15

a From the information reported, It was possible only to determine an MDFR greater than 50 MMBtu/hr. 

This column was not included in the median calculations.

''From the information reported, it was impossible to determine the MDFR. 

c Frora the information reported, it was impossible to determine the industry group. 

"-" = None

N/A = Not applicable.

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use 

Division, 1980 Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Contfeustors 

Energy Information Administration

I!
Regional Characteristics

Table 5. Number of

Establishments and Large Boilers

Together with Total and

Average Amount of Fuel

Consumed (Trillion Btu)

by Region

12

Summary of Findings (continued)

The data reported in the previous section focused on standard industrial 

classification. The focus of this section is on regions of the country.

The data presented in this section will repeatedly show that while the 

North Central region of the country traditionally thought of as the 

industrial center of the country -- has the largest number of establish 

ments and combustors, the South Central region uses considerably more, 

energy. While this report should not be considered as conclusive evident.i: 

of this fact, it is a further indication that the new industrial 

centerland may well be in the South.

Table 5 presents similar information as presented in Table 1. The trend, 

mentioned above, is very obvious. As can be seen, energy use varied 

substantially across the five regions of the country. The North Central 

region stands out because it has the largest number of establishments 

and the largest number of boilers. However, the South Central region, 

with two-thirds as many establishments and 88 percent as many boilers, 

consumes 41 percent more energy at the establishment level and 54 percent 

more fuel at the combustor level. The average establishment in the 

South Central region consumes more than twice as much energy as the ave :a,i;

Region

____Establishments____ ____Large Boilers_____ _

Fuel Consumed Fuel Consumed

Number Total Average Number____Total Average

Northeast........ 388 1,015.0 2.62 1,080 494.3

North Central.... 630 1,857.2 2.95 1,811 921.5

South Atlantic... 342 937.4 2.74 990 722.3

South Central.... 426 2,624.3 6.16 1,593 1,423.4

West. ............ 299 1,038.6 3.47 819 523.7

Other 3 ........... 413 1,066.4 2.58 1,115 585.6

_Total.......... 2,498 8,538.9 3.42 7,408 4,670.8 0.63

aThis category includes those establishments and combustors which, in 

order to avoid disclosure, are reported in 2 or more regions. Also 

included in this category are 8 establishments with 18 boilers which were 

not classified by region.

Source: Energy Information Administration, Office of Energy Markets en: 

End Use, Energy End Use Division,, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

"in an effort to protect the confidentiality of the respondents, the 

regional divisions chosen were the four regions defined by the U.S. Bureau 

of the Census with the Southern region further divided into the South 

Atlantic and South Central regions. For the purposes of this report , 

the geographic regions are made up of the following States: Northeast: 

Maine, New Hampshire, Vermont, Massachusetts, Connecticut, Rhode Island, 

New York, New Jersey, and Pennsylvania; North Central: Ohio, Indiana, 

Illinois, Michigan, Wisconsin, Minnesota, North Dakota, South Dakota,, 

Iowa, Nebraska, Missouri, and Kansas; South Atlantic: Delaware, Maryland, 

District of Columbia, Virginia, West Virginia, North Carolina, South 

Carolina, Georgia, and Florida; South Central: Kentucky, Tennessee, 

Alabama, Mississippi, Arkansas, Louisiana, Texas, and Oklahoma; West: 

Montana, Wyoming, Idaho, Colorado, Utah, New Mexico, Arizona, California.. 

Nevada, Oregon, Washington, Alaska, and Hawaii. See Appendix C.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combuxtors 

Energy Information Administration
Table 6. General Characteristics

of Large Boilers by Region and

Selected Standard Industrial

Classification (SIC) Code

Summary f Findings (continued)

establishment In the North Central region. The average combustor in 

the South Central region consumes 75 percent more energy than the average 

combustor in the North Central region.

Table 6 continues to highlight the difference between the North Central 

and South Central regions. While the North Central region has the most 

boilers, they tend to be among the smallest in terms of median MDFR and 

oldest in terms of median year of installation. The boilers in the 

South Central region, on the other hand, are among the largest and 

newest.

The biggest contributing factor to this difference comes from the boilers 

used in the paper and chemical regions. The largest boilers for these two 

industries are in the South Central region. These boilers are also among 

the newest.

Region

Food.... ..........

Other Nondurables. 

North Central.......

Other Nondurables. 

South Atlantic... ...

Other Nondurables. 

South Central.. .....

Other Nondurables.

Numbe r of 

Establish 

ments

388

38

98

59

13

25

104

51 

630

150

103

103

39

43

176

16

342

29

43

84

9

20

157 

426

69

57

156

51

52

41

Number of 

Large 

Boilers

Mean 

Number of 

Large 

Boilers 

Per Estab 

lishments

1,080 2.78 

100 2.63 

244 2.49 

164 2.78 

62 4.77 

148 5.92 

274 2.63 

88 1.73

1,811 2.87 

355 2.37 

262 2.54 

263 2.55 

151 3.87 

257 5.98 

495 2.81 

28 1.75

990 2.89 

97 3.34 

203 4.72 

312 3.71 

12 1.33

27 1.35 

339 2.16

1,593 3.74 

188 2.72 

275 4.82 

686 4.40 

252 4.94

94 1.81 

98 2.39

Median 

Maximum 

Design 

Firing 

Rate 

(MMBtu/Hr.

99 

102 

105 

102 

134 

179 

90 

79

99 

92 

136 

97 

135 

177 

90 

79

122 

131 

238 

133

130

95 

86

172 

91 

312 

191 

161

126 

80

End Notes Appear at End of Table.

Report on the 1980 Manufacturing industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

Median 

Year of 

Instal- 

) a lationb

1958 

1961 

1959 

1961 

1951 

1948 

1958 

1961

1959 

1964 

1955 

1964 

1953 

1953 

1957 

1959

1964 

1968 

1959 

1962 

1971

1967 

1966

1964 

1966 

1963 

1964 

1957

1971 

1967

13
Table 6. General Characteristics

of Large Boilers by Region and

Selected Standard Industrial

Classification (SIC) Code

[continued)

14

Summary of Findings (continued

Region

Number of Number of

Establish- Large

merits Boilers

Mean 

Number of

Large 

Boilers 

Per Estab 

lishments

Median 

Maximum 

Design 

Firing

Rate 

(MMBtu/Hr.) a lat.xc

West.................. 299 819 2.74

Food................ 106 244 2.30

Paper............... 44 176 4.00

Chemicals........... 19 59 3.11

Petroleum........... 34 138 4.06

Primary Metals...... 10 35 3.50

Other Durables...... 82 156 1.90

Other Nondurables... 4 10 2.50

Other0 ................ 413 1,115 2.70

Food................ 70 138 1.97

Paper............... 25 79 3.16

Chemicals........... 97 299 3.08

Petroleum........... 17 38 2.24

Primary Metals...... 56 207 3.70

Other Durables...... 80 197 2.46

Other Nondurables. .. 52 121 2.33

Unclassified d ....... 16 37 2.31

Total..............2,498 7,408 2.97

121

1C5

182

96

133

142

93

92

104

90

186

122

89

138

98

86

94

121 1961

a The calculations in this column are based only on those boilers u'h.i.r:! 

could be classified by MDFR.

D The calculations in this column are based only on those boilers wh:i.::l 

could be classified by year of installation.

c This category includes those establishments and combustors which, i -. 

order to avoid disclosure, are reported in 2 or more regions. Also 

included in this category are 8 establishments with 18 boilers which we "e 

not classified by region.

"From the information reported, it was impossible to determine the 

industrial group. Also included in this category is one large boiler 

which is incorrectly identified on the data tape as being in the West 

region.

"-" = None

Source: Energy Information Administration, Office of Energy Markets avul 

End Use, Energy End Use Division, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

Table 7 provides a regional distribution of all process and nonorocess 

combustors with an MDFR of at least one million MMBtu per hour.J-0 Boiler 

predominate in each region as the most common type of combustor. However 

the mix of combustors varies widely. Boilers range from a high of 34,3 

percent of all combustors in the South Atlantic to a low of 25.9 percent 

in the North Central. Other types of combustors have an even larger rarg-~ 

than the 8.4 percentage points seen among boilers. The range for heat 

treaters, the second most common combustor, is 15.6 points while the raigi 

for fluid heaters, the third most common combustor, is 13.5 points.

combustors reported in Tables 7 and 8 are reported in only on; 

region. The data used to develop these tables exist only in an aggre 

gated format either by Standard Industrial Classification or by region, 

rather than in a micro-level establishment format.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
IT wi 

^^^kflHWrjkvv L Jr «l VvisS^swAi/ % %^s:y?» I^K^BBF'Sfc Jft. Jx

Table 7. Number of Combustors 

with a Maximum Design Firing 

Rate of One-Million Btu-perHour or More by Type of 

Combustor and Regions

Region

North Central, i..

South Atlantic...

South Central. . . . 

Wes t

Otherd ...........

Total. ...........

Total 

Com 

bus 

tors

b!3,569 

(100.0)

21,387 

(100.0)

7,021 

(100.0)

12,618 

(100.0)

7,691 

(100.0)

430 

(100.0)

62.7166 

(100.0)

Boilers

3,720 

(27.4)

5,541 

(25.9)

2,412 

(34.3)

3,419 

(27.1)

2,581 

(33.6)

105 

(24.4)

17,778 

(28.3)

Summary of Findings (continued)

Gas 

Tur 

bines

48 

(0.4)

26

(0.1)

12 

(0.2)

91 

(0.7)

38 

(0.5)

10 

(2.3)

225 

(0.4)

Inter 

nal 

Combus- Fluid 

tion HeatEngines ers Dryers

172 

(1.3)

447 

(0.1)

119 

(1.7)

1,034 

(8.2)

603 

(7.8)

5 

(1.2)

2,380 

(3.8)

1,375 1,220 

(10.1) (9.0)

2,460 2,966 

(11.5) (13.9)

593 1,704 

(8.4) (24.3)

2,764 1,382 

(21.9) (10.9)

1,506 914 

(19.6) (11.9)

241 44 

(56.0) (10.2)

8,939 8,230 

(14.3) (13.1)

Cal- Reacciners tors

370 1,607 

(2.7) (11.3)

381 1,718 

(1.8) (8.0)

242 229 

(3.4) (3.3)

412 1,268 

(3.3) (10.0)

376 358 

(4.9) (4.7)

8 2 

(1.7) (0.5)

1,789 5,182 

(2.8) (8.3)

Melters

532 

(3.9)

841 

(3.9)

250 

(3.6)

400 

(3.2)

272 

(3.5)

3 

(0.7)

2,298 

(3.7)

Heat 

Treatera

2,890 

(21.3)

4,700 

(22.0)

1,036 

(14.8)

1,213 

(9.6)

492 

(6.4)

12 

(2.8)

10,343 

(16.5)

Sinterers 

Re- and 

heat- Peliters izers Otherc

1,565 

(11.5)

2,174 

(10.2)

399 

(5.7)

576 

(4.6)

394 

(5.1)

(-)

5,108 

(8.1)

64 

(0.5X0

124 

(0.6)

23 

(0.3)

53 

(0.5)

154 

(2.0)

(-)

418 

(0.7)

6 

.1)

9 

(*)

2 

(*)

6 

(*)

3 

(*)

(-)

26 

(*)

a The tabulations reported in this table are based on separate files of the responses of 7,946 establishments. 

Of this number, 1,605 were in the Northeast, 2,323 were in the North Central, 1,237 were in the South Atlantic, 

1,520 were in the South Central, 1,222 were in the West, and 39 were unclassified.

''The top figure in each cell is the number of combustors of that type in that region. The bottom figure is the 

percent of the total combustors in that region.

c lncludes 21 combustors which were either boilers, gas turbines, or internal combustion engines and 5 which were not 

identifiable.

^This category includes only those combustors in establishments which could not be classified by region.

e lncludes 10,370 boilers with a maximum design firing rate between 1 and 49 MMBtu per hour as well as 

the 7,408 large boilers with an MDFR of 50 MMBtu or more per hour reported elsewhere in this report. 

"-" = None 

"*" = Less than 0.05 percent

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use Division, 1980 

Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

15
Table 8. Number of Combustors

with a Maximum Design Firing

Rate of One-Million Btu-perHour or More by Maximum

Design Firing Rate and Region

Summary of Findings (continued)

The regional distribution of corabustors by capacity (i.e., MDFR) is 

presented in Table 8. Here again is an indication of the differences 

between the North Central and South Central regions. The median MDFR 

for combustors in the North Central region is among the lowest at 9 

MMBtu per hour, whereas the South Central region is the highest at 

16 MMBtu per hour.

Just as the distribution of types of combustors varied by region, so 

does the distribution by MDFR. The largest combustors, those of 250 

MMBtu per hour or more, comprise 2.6 percent of all combustors in the 

Nation. However, these combustors are only 1.5 percent of the corabusto: 

in the Northeast; 2.1 percent of the corabustors in the North Central; 

2.6 percent in the West; 3.1 percent in the South Atlantic region; and 

4.6 percent in the South Central region.

The South Central region has over 15 percent more combustors of 100 or 

more MMBtu per hour than any other region. This region has 1-1/2 times 

as many combustors as the Nation's average for combustors of this size. 

Further, this region has the smallest proportion of combustors of under 

9 MMBtu per hour. This is a further indication of the energy 

intensiveness of this region.

Maximum Design Firing Rate (MMBtu per hour)

Region3

North Central.... 

South Atlantic... 

South Central.... 

West. ............

Other6 ... ........

Total. ...........

Total

di i SAP

(100.0)

21,387 

(100.0)

7,021 

(100.0)

12,618 

(100.0)

7,691

(100.0) 

430

(100.0) 

62,716

(100.0)

1-9

7,851

(57.7)

12,792 

(59.8)

3,279 

(46.7)

5,344 

(42.3)

3,688

(47.9) 

299

(69.5) 

33 253

(53.0)

10-24

2 232

(16.4)

3,476 

(16.3)

1,279 

(18.2)

2,471 

(19.6)

1,365

(17.7) 

23

(5.4) 

10,846

(17.3)

25-49

1 242

(9.2)

1,802 

(8.4)

787 

(11.2)

1,463 

(11.6)

882

(11.5)

20

(4.7) 

6,196

(9.9)

50-99

1 022

(7.5)

1,542 

(7.2)

784 

(11.2)

1,297 

(10.3)

866

(11.3) 

38

(8.8) 

5,549

(8.9)

100-249

979

(7., 2)

1,275 

(6.0)

641 

(9.1)

1,411 

(11.2)

681

(8.9) 

38

(8.. 8) 

5,025

(8.0)

250 +

209

(1.5)

444 

(2.1)

216 

(3.1)

575 

(4.6)

198

(2.6) 

12

(2.8) 

1,654

(2.6)

50 +b

26

(0.2)

51 

(0.2)

35 

(0.5)

55 

(0.4)

11

(0.1)

(-)

178

(0.3)

Unknown 0 Med:

8

(0.1)

5 

(*)

1 

(-)

2 1 

<*)

(-)

(--)

15

(*)

aThis table is based on a separate file of the responses from 7,946 establishments. Of this number, 1,605 

were in the Northeast, 2,323 were in the North Central, 1,237 were in the South Atlantic, 1,520 were in the 

South Central, 1,222 were in the West, and 39 were unclassified.

^From the information reported, it was possible only to determine an MDFR of at least 50MMBtu/hr. 

c From the information reported, it was impossible to determine the M'DFR.

^The top figure in each cell Is the number of combustors of that type in that region. The bottom figure Is 

the percent of the total combustors in the region.

e This category includes only those combustors from establishments which could not be classified by region, 

"-" = None 

"*" = Less than 0.05 percent

NA = Not applicable

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use Division, 

1980 Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

16 Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Fuel and Energy Use

at the Establishment Level

As shown in Table 9, establishments responding to the survey consumed 

8,518.5 trillion Btu of fuel in 1979. This includes 5,345.7 trillion Btu, 

or 62.8 percent, of purchased fuels, 3,172.1 trillion Btu or 37.2 percent 

of nonpurchased or byproduct fuels, and 0.7 trillion Btu or 0.008 percent 

of energy from hydropower, wind, geothermal, solar, or other energy 

sources. In general, industry uses more purchased than nonpurchased 

fuels. The petroleum industry is the exception because of its heavy 

consumption of refinery off-gases. Other industries which consume rela 

tively larger amounts of nonpurchased fuels are the paper (pulping 

liquor), primary metals (coke oven gas), and wood and lumber (wood waste) 

industries. The data reported in Table 10 are weighted to account for 

the nonresponse of establishments. This table shows estimated total 

fuel consumption as 12,089.6 trillion Btu. Of this amount, 7,212.2 

trillion Btu came from purchased, fuels; 4,907.4 trillion Btu from nonpur 

chased fuels; and 1.0 trillion Btu from nontraditional energy sources.

Natural gas accounts for 58 percent of all purchased fuels. Almost 36 

percent of the natural gas is consumed in the chemical industry. Residual 

oil accounts for 17 percent of purchased fuel consumption. The paper 

industry is the largest user of residual oil. The third most consumed 

purchased fuel is coal which accounts for 15 percent.

Table 11 presents establishment fuel use by region. Only in the West 

region is the proportion of purchased fuel less than the proportion of 

nonpurchased fuel. This is possibly due to the high concentration of 

lumber and paper industries in the West. The highest use of nonpurchased 

fuel occurs in the South Central region due to the large number of 

petroleum, chemical, and paper establishments.

-' The 1979 Annual Survey of Manufactures, Fuels and Electric Energy 

Consumed reports that natural gas accounts for 57 percent of all purchased 

fuels; 26 percent of the natural gas was consumed in the chemical industry; 

residual oil accounts for 10 percent of purchased fuel consumption; and 

coal accounts for 11 percent.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

17
Table 9.. Establishment Fuel Use 

by Standard Industrial 

Classification (SIC) CodeUnweighted Data (Trillion BtuJ

Fuel and Energy Use at the 

Establishment Level (continued)

Purchased Fuels

Industry

Food. ..............

Lumber and Wood. . 

Transportation. . .

Stone, Clay, and 

Glass. ...........

Electric

Fabricated Metal. 

Other Durables 13 . .

Nondurable Goods... 

Text i le .....

Rubber and 

P 1 a s t ic

Other NonUnc lasslf i ed^

Total. .............

SIC

28 

26 

29 

33

20

NA 

24 

37 

35

32

36 

34 

NA

NA 

22

30 

NA 

NA 

NA

Totals 

All 

Fuels Total

2,004. 

1,994. 

1,847. 

1,385.

445.

574. 

163. 

121. 

102.

52.

47. 

27. 

60.

265. 

152.

80. 

33. 

20. 

8,538.

9 1,689.9 

5 1,052.3 

3 679.8 

3 773.2 

7 395.6

9 490.7 

7 85.5 

4 121.4 

4 102.3

4 49.2

3 45.6 

7 27.7 

0 59.0

9 264.2 

0 152.0

5 80.2 

4 32.0 

4 20.4 

9 5,366.2

Coal

297.0 

226.0 

5.6 

89.6 

83.0

80.0 

1.6 

19.8 

15.1

10.6

8.4 

2.1 

22.4

44.1 

22.1

19.4 

2.6 

3.5 

828.8

Other 

Solid

7.3 

116.4 

8.9

10.6 

10.5

57.5 

53.4 

0.1 

0.1

2.8 

0.7 

0.4

1.9 

1.9

* 

213.1

Dis 

tillate

30.4 

12.2 

6.2 

15.3 

16.4

7.8 

0.4 

2.0 

2.5

0.6

0.9 

0.9 

0.5

6.9

1.6

5.1 

0.2 

.5 

95.7

Resid 

ual

191.9 

338.7 

122.1 

93.2 

51.9

65.4 

10.3 

16.3 

13.2

4.1

11.9 

2.7 

6.9

48.0 

23.3

19.9 

4.8 

.2 

911.4

Other Natural 

Liquid Gas

7,7 1,116.4 

7.0 348.1 

8.9 456.4 

5.2 527.6 

2.1 227.7

2.4 269.9 

16.5 

2.4 80.2 

* 67.8

31.1

* 23.6 

* 21.9 

* 28 . 8

* 161.9 

* 102.1

* 35.5 

24.3 

2,1 14.0 

35.5 3,122.0

Other 

Gas

39.1 

4.0 

71.7 

31.8 

4.0

7.8 

3.4 

0.7 

3.5

0.1 

0.1 

*

1.2 

0.9

0.3 

*

159.6

NonPur 

chased

314.6 

942.0 

1,167.5 

612.1

50.0

84.1 

78.1 

*

0.1 

3.2

1.7 

NA 

1.0

1.8 

0.1

0.3 

1.4

3,172,1

isk: ''.I II

i.:i:aiiUoaal*

a lncludes energy derived from hydropower, wind, geothermal, solar, or any other energy source.

b SIC Codes 25,38, and 39.

C SIC Codes 21,23, 27, and 31.

d From the information reported, it was Impossible to determine the industrial group.

"-" = None

"*" = Less than 0.05 trillion Btu.

NA = Not Appliclable

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use Division, 

Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

18 Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Fuei arid Energy Use at the t^ttj^iwwtx* Establishment Level (contlnyed)

Table 1 0. Establishment Fuel Use 

by Standard industrial 

Classification (SIC) CodeWeighted Data (Trillion Btu)

Purchased Fuels

Industry

Lumber and Wood. . 

Transportation. . .

Stone, Clay, and 

Glass. ...........

Electric

Fabricated

Other Durables*5 . .

Nondurable Goods... 

Text ile

Rubber and 

Pla s t ic

Other NonT ncla ssif ied^

Total.. ............

SIC

28 

26 

29 

33 

20

NA 

24 

37 

35

32 

36

34

NA

NA 

22

30 

NA 

NA 

NA

Totals 

(All 

Fuels)

2,622.9 

2,418.2 

3,828.1 

1,662.9

541.9

743.3 

197.4 

195.9 

120.2

65.0 

56.2

36.8 

71.8

302.3 

170.5

92.3 

39.5 

21.3 

12,140.9

Total

2,213.9 

1,272.1 

1,379.6 

923.9 

482.4

639.9 

101.9 

195.8 

120.1

60.8 

53.9

36.8 

70.6

300.4 

170.4

91.9 

38.1 

21.3 

7,233.5

Coal

383.4 

281.5 

10.5 

108.0 

102.4

111.1 

1.8 

37.2 

19.9

12.7 

9.0

3.5 

27.0

50.0 

25.2

21.8 

3.0 

4.0 

1,050.9

Other 

Solid

7.9

139.7 

13.9 

12.0 

12.5

70.2 

64.5 

0.1 

0.1

3.9

1.0

0.6

2.1 

2.1

* 

258.3

Dis 

tillate

40.2 

15.1 

13.5 

19.0 

20.2

10.2 

0.5 

3.3 

2.8

0.8 

1.0

1.1 

0.7

7.7 

1.8

5.6 

0.3 

0.5 

126.4

Residual

241.4 

403.9 

245.5 

108.7 

63.7

81.9 

11.3 

23.5 

15.4

5.3 

14.8

3.4 

8.2

55.4 

26.7

22.9 

5.8 

0.3 

1,200.8

Other Natual 

Liquid Gas

9.9 1,478.3 

8.1 419.0 

11.4 917.9 

6.8 630.1 

2.7 275.9

3.7 352.5 

19.1 

3.7 126.8 

* 77.7

38.0 

* 28.0

* 28.6 

* 34.2

* 183.8 

* 113.5

* 41.3 

29.0 

2.1 14.4 

44.7 4,271.9

Other 

Gas

52.9 

4.8 

166.9 

39.3 

5.0

10.3 

4.7 

1.1 

4.3

*

0.1

0.1 

*

1.4

1.1

0.3 

*

280.6

NonPur 

chased

408.4 

1,145.8 

2,448.6 

739.0 

59.5

103.2 

95.4 

*

0.1 

4.2 

2.3

1.2

1.8 

0.1

0.3

1.4

4,906.3

Nontraditional 3

0.6 

0.3

0.1 

*

* 

*

* 

*

* 

1.0

a lncludes energy derived from hydropower, wind, geothermal, solar, or any other energy source.

bSIC Codes 25,38, and 39.

C SIC Codes 21, 23, 27, and 31.

^From the information reported, it was impossible to determine the industrial group.

"-" = None

"*" = Less than 0.05 trillion Btu.

NA = Not Appliciable

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use Division, 

1980 Manufacturing Industries Energy Consumption Study of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

19
Table 11. Establishment Fuel Use 

by Region (Trillion Btu)

Fuel and Energy Use at the 

Establishment Level (continued)

Region

Totals

All 

Fuels Total

Unweighted Data

Northeast...... 1,015.0 705.4

North Central.. 1,857.2 1,205.5

South Atlantic. 937.4 614.8

South Central.. 2,624.3 1,522.3

West. .......... 1,038.6 512.5

Otherb......... 1,066.4 800.9

Total........... 8,538.9 5,356.1

Weighted Data

Northeast...... 1,421.1 940.3

North Central.. 2,653.7 1,620.1

South Atlantic. 1,147.3 754.0

South Central.. 3,837.1 2,146.6

West. .......... 1,732.0 778.0

Otherb ......... 1,349.6 994.4

Total0 .......... 12,140.8 7,233.4 :

Coal

Other 

Solid

Purchased Fuels

Dis 

tillate Residual

Other 

Liquid

Natural 

Gas

Other 

Gas

NonPur 

chased

Wontradi 

tion 

 na.". a

93.9

242.5

180.4

118.4

52.4

118.9

7.1

12.6

41.6

53.7

68.9

28.9

18.7

24.4

11.2

17.4

7.3

16.7

826.7 213.0 95.8

251.4

137.6

201.6

137.5

65.8

116.8

911.4

5.1 

4.9 

2.7 

11.5 

4.5 

6.9

304.5

733.1

162.8

1,147.7

305.2

467.1

24.7

50.3

14.5

36.0

8.5

25.6

309.5

651.5

322.2

1,102.0

526.1

256.8

o, :i.

0, /: 

0,4

35.5 3,122.0 159.6 3,172.1

122

317

220

147

70

173

1,050

. 1

.0

.6

.5

.2

.4

.8

8.4

16.8

49.3

68.4

81 ."3

34.0

258.2

25. 1

30.8

13.2

23.2

10.6

23.4

126.3

334.

199.

250.

177.

88.

150.

1,200.

5

7

3

9

1

4

9

6.8

6.8

3.2

13.9

5.9

8.1

44.7

399.

962.

193.

1,647.

501.

567.

4,272.

7

3

5

2

4

9

0

43.7

86.6

23.9

68.5

20.6

37.3

280.6

1

1

4

480.6

,033.5

392.7

,690.5

953.9

355.2

,906.4

0 i. 

0. 2 

0 6

a lncludes energy from hydropower, wind, geothermal, solar, or any other energy source.

 This category includes the corabustors from 2 or more regions in a given SIC which, for disclosure purposes 

were combined. These combustors are reported in all regions represented.

cDifferences between the total reported in this table and those reported in Table 9 and 10 occur due to 

rounding.

"*" = Less than 0.05 trillion Btu.

Source: Energy Information Administration, Office of Energy Markets and End Use Division, Energy End Use 

Division, 1980 Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

20 Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Table ?2. Electricity Generated

and Used Onsite by Standard

Industrial Classification

(SIC) Code (Trillion Btu)

Fyel and Energy Use at the 

Establishment Level (continued)

Table 12 shows the amount of electricity which is used by the establish 

ment and the amount generated onsite. Overall, slightly more than 

one-fourth of the electricity needs of establishments are generated 

onsite. Among the industries which are the largest electricity users, 

the paper industry generates 57 percent of its electricity needs. Some 

of this information is shown graphically in Figure 2. Table 13 shows 

these data by Region.

Unweighted

Industry SIC

Generated 

Onsite

Weighted

Used Generated Used 

Onsite Onsite Onsite

Chemicals......

Paper..........

Primary Metals. 

Petroleum......

Food...........

Durable Goods...........

Transportation........

Machinery.............

Electrical Equipment.. 

Lumber and Wood.......

Fabricated Metals.....

Stone, Clay and Glass. 

Other Durables 3 .......

Nondurable Goods......

Rubber and Plastic..., 

Textile Mills........

Other Nondurables^....

Unclassified0 .

Total.

28

26

33

29

20

NA 

37

35

36 

24 

34 

32 

NA

NA 

30 

22 

NA

NA 

NA

32.7

115.4

38.4

13.0

12.1

11.8 

1.6 

1.3 

0.7 

2.9 

0.2 

0.9 

4.2

3.0 

1.7 

1.2 

0.1

2.0

228.4

246.3

201.1

165.1

71.1

39.1

94.7

30.0

16.6

13.2

12.6

6.2

5.8

10.3

40.9

20.3

16.8

3.8

2.0

860.3

45.8

140.5

46.6

26.9

14.6

14. 

2. 

1.

0.8 

3.5 

0.2 

1.3 

4.8

3.3

1.9 

1.3 

0.1

2.3

320.6

243.0

196.8

145.5

48.3

128.8

49.2

20.7

15.2

15.0

8.6

7.3

13.0

47.2

23.5

19.0

4.7

2.0

294.6 1,132.2

a SIC Codes 25, 38, and 39. 

b SIC Codes 21, 23, 25, and 31.

c From information reported, it was Impossible to determine the 

industrial group.

NA = Not applicable

"*" = Less than 0.05 trillion Btu of electricity.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

21
Figure 2. Electricity Generated

and Used Onsite by Major

Industrial Classification

(Unweighted)3

Fuel and Energy Use at the 

Establishment Level (continued)

Chemical

Paper

Primary Metal

Petroleum

Food

Other Durable

Other Nondurable

Trillion Btu

aThis figure does not include the 16 establishments which could not be classified by Standard Ins'i.. ;fr: a 

Classification code. These establishments use 2.0 trillion Btu of electricity, all of which was general::-.1 :' c r

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End ...w 

Division, 1980 Manufacturing Industries Energy Consumption Study and Survey of Large Conibustc ';

H

Used

Generated 1

1

0 4

1

0 80

i

120

1

160

_ 1 ........

200

._.. L.....

240

J

280

22 Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Table 13. Electricity Generated

and Used Onsite by Region

(Triiiion Btu)

Region

Generated 

Onsite

Used 

Onsite

Generated Used 

Onsite Onsite

Fuel and Energy Use at the

Level (continued)

Unweighted Weighted

Northeast. .....

North Central.. 

South Atlantic. 

South Central.. 

West...........

Other3 .........

Total c

25.9

39.7

39.7

55.2

23.0

44.8

228.3

106.9

198.3

107.0

32.7

220. 

88.

139.1

860.3

49.7

47.5

77.0

30.0

57.8

136.4

268.0

130.7

299.7

124.0

173.3

294.7 1,132.1

aFor disclosure purposes, the establishments and combustors from 2 or 

more regions in a given SIC grouping were combined. They are reported 

in all regions represented. Also included in this category are 8 

establishments and 6 boilers which were not classified by region.

"Differences between the total reported in this table and those 

reported in Table 12 occur due to rounding.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

Steam use by industry is shown in Table 14. For 1979, industry was able 

to generate more steam onsite than was required. Less than 1 percent 

of the reported steam used was purchased. With the exception of three 

industries petroleum, food, and rubber more steam was sold or trans 

ferred offsite than was purchased or received. It appears that only in 

rare instances is industry unable to meet its own steam needs.

The chemicals and paper industries account for almost 60 percent of 

industrial steam use. When adjustments are made for nonresponse, over 

three-quarters of the estimated steam used by industry in 1979 was used 

in the chemicals, paper, and petroleum industries.

These data are shown by region in Table 15. This table continues to 

demonstrate the South Central region's dominance of energy consumption. 

This region consumes over one-third of the steam used in industry in the 

Nation.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

23
tflFl^fciflB"flh ^^^^"- t $f/$z '%>-. <* 3-xy% JPS^KX ^r ^^BAA J%^'W^^^'>% / i -P *!

 ^BtfiB^^s-'^^^^PtvCOy 41 I

L JBtAl m^mmimKm^.^ J

^H^^^r Wjh«w ''•'f'iv^vffif-' ''•• fy. ^X'^ ^iB^i^W. JK. 9

Table 14. Steam Balance by 

Standard Industrial Classification 

(SIC) Code (Trillion Btu)

Industry

Electrical Equipment. 

Stone, Clay,

Fabricated Metals....

Ruber and Plastic.... 

Textile Mills ........

Other Nondurables b .. .

Fuel and Energy Use at the 

Establishment Level (continued)

Purchasec 

or 

SIC Received

28 

26 

29 

33 

20

NA 

24 

37 

35 

36

32

34 

NA

NA 

30 

22

NA

NA 

NA

12.6 

5.6 

10.6 

6.9 

4.1

5.1 

2.5 

2.6

*

2.5 

2.5

47.4

Unweighted Data Weighted Data

Generated Sold or Used 

Onsite Transferred Onslte

1,586.5 

1,374.0 

753.7 

501.0 

301.6

310.0 

83.5 

70.0 

42.9 

29.8

17.5 

14.4 

51.9

151.3 

69.8 

72.2 

9.3

21.6 

4,999.7

33.0 

15.5 

6.3 

8.6

2.7

11.1 

3.3 

2.6 

0.9 

2.0

2.2 

0.1

2.6 

0.2 

2.4 

*

0.1 

79.9

1,566.1 

1,364.-

758.0 

499.3 

303.0

304.0 

82.7 

70.0 

42.0 

27.8

17.5 

12. 2 

51.8

151.2 

72.1 

69.8 

9.3

21.5 

4,967.2

Purchased 

or 

Received

16.2 

6.7 

24.0 

9.9 

4.9

6.6 

2.8 

3.8

*

2.9 

2.9

71.2

Generated Sold or Usoo 

Onsite Transferred Onsil:

2,110.5 

1,677.2 

1,545.4 

600.1 

371.5

406.3 

101.3 

114.1 

53.2 

33.8

22.2 

19.7 

62.0

173.6 

80.6 

81.7 

11.3

22.5 

6,907.1

44.8 1, 0151 

18.1 1,655 

16.1 1,553 

10.6 5') 9 

2.9 3:' 3

14.6 3<>6 

4.2 99 

3.9 IL<; 

1.0 12 

2. 3 11

_ ? 7

3.0 .6

o. i a

3.0 1/3 

0.2 !!3 

2.8 /8 

*

o.i n

110.1 6,866

a SIC Codes 25, 38, and 39.

b SIC Codes 21, 23, 27, and 31.

c From the information reported, it was impossible to determine the industrial group.

"-" = None

NA = Not applicable

"*" = Less than 0.05 trillion Btu

Source: Energy Information Administration, Office of Energy Markets and Knd Use, Energy End Use Division, 

1980 Manufacturing Industries Energy Consumption Study and Survey of Large Conibustors.

24 Report on the 1980 Manufacturing Industrie.! Energy 

Consumption Study and Survey of Large Combuitors 

Energy Information Administration
Table 15. Steam Balance 

by Region (Trillion Btu)

Region

Purchased 

or 

Received

Generated 

Onsite

Sold or 

Transferred

Used 

Onsite

Fuel and Energy Use at the 

Establishment Level (continued)

Unweighted Data 

Northeast......

North Central.. 

South Atlantic. 

South Central.. 

West...........

Othera .........

Total.

Weighted Data 

Northeast......

North Central.. 

South Atlantic. 

South Central.. 

West...........

Other3 .........

Totalb .

3.1

5.8

5.8

18.9

10.5

3.3

47. A

4.6

8.1

10.4

27.0

16.8

4.3

71.2

525.7

865.1

644.0

1,701.8

534.8

718.5

4,999.9

736.5

1,196.4

800.2

2,417.1

823.8

933.2

6,907.2

5.9

14.3

11.7

21.2

8.7

18.2

80.0

8.2 

18.4 

13.8 

35.8 

11.S 

22.1

110.1

522.9

856.6

638.1

1,699.5

536.6

713.6

4,967.3

732.9

1,186.1

796.8

2,408.3

828.8

915.4

6,868.3

aTo prevent disclosure, the establishments and combustors from 2 or 

more regions in a given SIC grouping were combined. They are reported in 

all regions represented. Also included in this category are 8 establish 

ments and 13 boilers which were not classified by region.

''Differences between the total reported in this table and the totals 

reported in Table 14 occur due to round!ng.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries 

Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

25

The Role of Large 

Boilers In Industry

in Boilers

As was shown earlier in this report, a few industries have most of the 

large industrial boilers. This information is repeated in Table 16 with 

more details. About 56 percent of all large industrial boilers are in 

three industries: chemicals, paper, and food. After adding the petroleum 

and primary metals industries, these five industries account for almost 

three-fourths of the boilers under consideration. With the exception 

of the food industry, the remaining four industries are among the 

highest in terms of the median maximum design firing rate of boilers.

Approximately 44 percent of large industrial boilers reported in this 

study have an MDFR of between 50 and 99 MMBtu per hour. An additional 40 

percent have an MDFR of between 100 and 249 MMBtu per hour. Of the 

remaining 16 percent, there are approximately three times as many boilers 

in the 250 to 499 MMBtu per hour range as the 500 and above range.

Table 17 presents this information by region. The South Central region, 

repeatedly shown as the dominant energy-consuming section of the country, 

has more boilers with an MDFR of 100 MMBtu per hour or more than any other 

region.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy information Administration

27
Table 16. Number of Large

Boilers by Maximum Design

Firing Rate and Standard

Industrial Classification

(SIC) Code

28

Energy Use in Large Boilers 

(continued)

Group

SIC 50-99 100-249 250-499 500 + 

Code Total MMBtu/Hr. MMBtu/Hr. MMBtu/Hr. MMBtu/H:

Chemicals............. 28 1,755 618 803 275

Paper and Allied

Products.............. 26 1,216 331 496 253

Food and Kindred

Products.............. 20 1,080 593 436 44

Primary Metals........ 33 645 207 275 116

Petroleum............. 29 642 241 277 99

Textile Mill

Products.............. 22 371 286 83 2

Transportation

Equipment............. 37 324 178 136 10

Lumber and Wood....... 24 231 128 90 13

Machinery............. 35 221 142 73 6

Rubber and Plastics... 30 218 152 59 5

Electronic

Equipment............. 36 162 118 41 3

Fabricated Metals..... 34 110 62 48

Stone, Clay and

Glass. ................ 32 66 30 30 6

Instruments........... 38 61 24 26 6

Tobacco............... 21 49 33 16

Furniture............. 25 13 12 1

Miscellaneous......... 39 13 4 5

Apparel............... 23 12 11 1

Printing Publishing... 27 10 7 3

Leather............... 31 55

Unclassified3 ......... NA 37 21 14 2

Total b ................ NA 7,241 3.2C3 2,913 840

Percent of Total...... NA 100.0 44.2 40.2 11.6

59

136

a From the information report, it was Impossible to determine the 

industrial group.

 This total excludes 167 boilers which are unclassified by industry. 

Of these, 23 are in the Paper industry, 28 in Chemicals, 42 in Fooc, 2 

in Primary Metals, 11 in Petroleum, 11 in Textile Mills, 7 in 

Transportation Equipment, 9 in Lumber and Hood, 6 in Rubber and Plastics 

3 in Electrical Equipment, 5 in Fabricated Metals, 18 in Stone, Clay. 

and Glass, and 2 in Apparel. These boilers may be included in other 

tables in this report as appropriate.

"-" = None

NA = Not Applicable.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries E;ie:: 

Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries (Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Table 17. Number of Large

Boilers by Maximum Design

Firing Rate and Region

Energy Use in Large Boilers 

(continued)

Region

50-99 100-249 250-499 500 + 

Total MMBtu/Hr. MMBtu/Hr. MMBtu/Hr. MMBtu/Hr.

Northeast......

North Central.. 

South Atlantic. 

South Central.. 

West...........

Othera.........

1,062

1,775

962

1,554

809

1,079

Totalb ............. 7,241

543

903

423

447

359

526

3,203

406

683

394

692

318

420

2,913

94

155

104

293

100

94

840

19

34

41

122

32

37

285

aFor disclosure purposes, the establishments and combustors from 2 

or more regions in a given SIC grouping were combined. They are 

reported in all regions represented. Also included in this category 

are 8 establishments and 18 boilers which were not classified by region.

^This total does not include 167 boilers for which size classification 

was not available but which apparently had a maximum design firing rate 

of at least 50 MMBtu/hr. Of these boilers, 18 are in the Northeast 

region, 3-6 are in the North Central Region, 28 are in the South Atlantic 

Region, 39 are in the South Central Region, 10 are in the West, and 36 

are in the Other category.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries 

Energy Consumption Study and Survey of Large of Combustors.

Table 18 shows boilers by MDFR and year of installation. This 

information is shown graphically in Figure 3. Overall, the number of 

boilers installed has decreased slightly over the last decade. It is 

interesting to note from this table that in 1979, one boiler in four had 

been operating for 30 years or more, and slightly less than 1 in 2 had 

been operating for 20 years or more. Boilers installed between 1940 and 

1974 vary only slightly in terms of MDFR. However, those installed 

prior to 1940 are appreciably smaller while those installed after 1974 

are considerably larger.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

29
Table 18. Percent of Large

Boilers by Maximum Design

Firing Rate and Year of

Installation

30

Energy Use in Large Boilers 

(continued)

Maximum Design 

Firing Rate

50-99 MMBtu/hr. . . .

100-249 MMBtu/hr..

250-499 MMBtu/hr..

500 + MMBtu/hr.. . .

All Large

Total

a 3,095 

(100)

2,845 

(100)

830 

(100)

279 

(100)

by 049

(100)

1939 or 

Earlier

a 355 

(12)

274 

(10)

53 

(6)

5 

(2)

687

(10)

1940- 

1949

476 

(15)

542 

(19)

138 

(17)

8 

(3)

1,164

(16)

1950- 

1959

623 

(20)

521 

(18)

197 

(24)

38 . 

(14)

1 17Q

(20)

1960- 

1969

870 

(28)

729 

(26)

260 

(31)

96 

(34)

1 Q S S

(28)

1970- 

1974

479 

(15)

435 

(15)

90 

(11)

57 

(20)

1,061

(15)

1975 t 

Later

292 

(9)

34i

(12;

92 

(11)

/ .:i 

(27)

803

(11)

Median MDFR. 123 129 119 122 118

aThe top number in each cell is the actual number of boiler in the 

given size and year of installation class. The bottom number, in paren 

theses, is the percent of- boilers in a given class that were installed 

in a given group of years.

''This total does not include 359 boilers which were unclassified by 

size and/or year of installation.. Of this number, 108 are in the 50-99 

MMBtu/hr. size class, 68 are in the 100-249 MMBtu/hr. size class, 10 

are in the 250-499 MMBtu/hr. size class, 6 are in the 500 + MMBtu/hr. 

size class, 5 were installed before 1939, 2 were installed between 1940 

and 1949, 3 were installed between 1950 and 1959, 1 was installed betwee 

1960 and 1969, 3 were installed between 1970 and 1974, and 1 was install 

in 1975 or later. The remaining 152 were not classified by both size 

and year of installation.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries 

Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Figure 3. Percent of Large

Boilers of Various Size by

Year of Installation

Energy Use in Large Boilers 

(continued)

30

20

10

500+ MMBtu/hr. 

250-499 MMBtu/hr 

100-249 MMBtu/hr 

50-99 MMBtu/hr

Year of Installation

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use 

Division, 1980 Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

31
nil """T83H

Fuels Used

32

Energy Use in Large Boilers 

{[continued)

Fuels Used

As detailed in Table 19, natural gas is the most widely used fuel in 

large industrial boilers, accounting for 29.5 percent of the Btu consumer 

The second most widely used fuel is coal-'- accounting for 17.1 percent 

of large boiler fuel use. This is followed by fuel oil, both distillate' 

and residual; pulping liquor; waste gases;2 wood waste; and other fuels. 

Fuel use by SIC code is also shown in this table.

Table 19 also shows that the fourth most common fuel in large industrial 

boilers, accounting for 14.2 percent of total fuel consumption, is 

pulping liquor. This fact should not be interpreted as meaning that 

this fuel is widely used in industry. Such a conclusion would be 

incorrect. Almost 99 percent of all pulping liquor is used in the paper 

industry. In fact, only 242 boilers, 3.3 percent, reported using this 

fuel in 1979.

The paper industry is followed in total fuel use by chemicals with about 

one fourth of the fuel reported in this survey. The five largest fuel 

consuming industries, which, as shown earlier, account for some threefourths of the boilers, use slightly less than 90 percent of the fuel 

use reported in Table 19.

Table 20 presents the fuels used in large boilers after adjusting for 

nonresponse. Table 21 offers these data, both unweighted and weighted, 

by region.

1-For the purpose of this report, coal includes anthracite, bituminous 

coal, lignite, coke, and breeze. This category, however, is 

overwhelmingly dominated by bitlminous coal.

furnace gas, coke oven gas, and refinery off-gas.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Comfouartors 

Energy Information Administration
Table 19. Fuel Consumption in

Large Boilers by Standard

Industrial Classification

(SIC) Code Unweighted Data

(Trillion Btu)

Energy Use in Large Boilers 

(continued)

Group SIC

Percent of 

Boilers

All Natural 

Fuels b Gas Coal

Fuel 

Oil

Pulping 

Liquor

Waste 

Gases Wood Other

Paper................... 26 17

Chemicals............... 28 24

Primary Metals.......... 33 9

Petroleum............... 29 9

Food.................... 20 15

Lumber and Wood......... 24 3

Textile Mills........... 22 5

Rubber and Plastic...... 30 3

Transportation

Equipment............... 37 4

Machinery............... 35 3

Instruments............. 38 1

Electrical Equipment.... 36 2

Stone, Clay, and

Glass................... 32 1

Fabricated Metals....... 34 2

Miscellaneous. .......... 39 *

Tobacco................. 21 1

Printing................ 27 *

Apparel................. 23 *

Furniture............... 25 *

Leather................. 31 *

Unclassifiedd ........... NA *

Total................... NA 100

Percent of All Fuel..... NA NA

1,575.2

1,223.1

565.2

467.4

321.0

134.6

70.9

62.3

59.8

41.5

35.3

32.1

26.1

17.2

12.8

6.9 

2.5 

1.5 

1.4 

0.8 

13.6

256.6

590.0

117.0

108.5

145.1

11.1

27.6

28.2

26.5

16.2

5.3 

13.5

9.7

11.9

0.8

2.2 

0.5 

0.8 

0.4 

0.4 

6.2

193.9

302.8

105.4

6.3

59.7

1.7

20.5

14.6

17.8

14.8

23. 

7.

4,671.2 1,378.5

100.0 29.5

9.9

2.1

11.1

2.2

0.3 

0.3

3.8

798.2

17.1

283.9

164.7

45.9

93.1

58.7

9.5

21.1

19.3

15.4

10.5

5.9 

8.9

3.4 

3.3 

0.8

2.5 

0.9 

0.3

0.3 

0.8

749.2

16.0

654.0

5.0

2.2

185.0

28.3 7.7 

295.8

209.2 1.2 

*

107.9

1.6

0.1

C1.5 C 0.6

2.7

1.8

124.6

1.3

49.2

57.4

2.2 

0.1 

0.1

0.1

0.6

*

0.4

662.7

14.2

1.1

0.5 0.1 

* 2.8

536.0 305.7 240.6 

11.5 6.5 5.2

Differences in the fuel consumption reported in this Table and that reported in the alternate fuels report are 

caused by a combination of rounding error, the exclusion of unusual fuels from the Report on Alternative-Fuel Burning 

Capabilities in Large Boilers, the exclusion of boilers unclassified by industry from this Table, and the error 

innoculation procedure reported earlier in this report.

''This column may differ from the sum of the individual fuels due to rounding.

c lt is possible that the boilers reporting consumption of pulping liquor and wood, should be classified in SIC 26. 

However, no such changes have been made in this report.

^From the Information reported, it was impossible to determine the industrial group.

"-" = None

NA = Not Applicable.

"*" = Less than 0.5 percent.

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use Division, 

1980 Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

33
34

Table 20. Fuel Consumption in

Large Boilers by Standard

Industrial Classification

(SIC) Code Weighted Data

(Trillion Btu)

Energy Use in Large Boilers 

(continued)

Group SIC

All Natural 

Fuels 3 Gas Coal

Fuel 

Oil

Pulping 

Liquor_

Waste 

Gases Wood Other

Paper.................... 26 1,910.7 312.5 242.7 339.4 793.4 - 220,2 2.4

Chemicals................ 28 1,616.4 795.3 396.3 208.8 5.3 39.4 8.4 162.9

Primary Metals........... 33 678.1 141.5 126.2 54.3 - 354.7 - 1.3

Petroleum................ 29 938.8 215.2 11.5 193.7 - 441.0 1.4 76=0

Food..................... 20 395.5 180.3 74.2 72.3 * 6.8=8

Lumber and Wood.......... 24 162.7 12.6 1.9 10.5 2.3 - 132.5 2.9

Textile Mills. ........... 22 80.1 30.8 23.3 24.0 - - 1.8 0.1

Rubber and Plastic....... 30 71.5 32.7 16.6 22.0 - - 0.1 0.1

Transportation

Equipment... .............. 37 100.4 43.7 33.4 23.1 - 0.1

Machinery................ 35 51.4 20.0 19.4 12.2 - *

Instruments.............. 38 42.0 6.8 27.6 6.9 - 0.7

Electrical Equipment..... 36 36.9 15.1 8.1 10.8 b 2.0 - b0.8 *

Stone, Clay, and Glass... 32 33.5 12.4 12.7 4.4 - 3.5 - 0.3

Fabricated Metals........ 34 23.6 15.8 3.6 4.2

Miscellaneous............ 39 15.8 1.2 13.5 1.1 -

Tobacco. ................. 21 8.2 2.8 2.5 2.9 -

Printing................. 27 2.8 0.6 NA 1.0 - - 1.1

Apparel. ................. 2.3 1.8 1.0 0.4 0.4 - -

Furniture................ 25 1.6 0.4 0.4 - 0.6 0.2

Leather.................. 31 0.9 0.5 NA 0,4

Unclassified0 ............ NA 14.5 6.6 4.3 0.8 - _ _ ...

Total.................... NA 6,187.2 1,847.8 1,018.6 993.2 803.0 838.6 366.9 318,5

Percent of All Fuel...... NA 100.0_____29.9_____16.4 16.1 13.0_____13.6_____5_.l_____5._]_

a This column may differ from the sum of the individual fuels due to rounding.

bit is possible that the boilers reporting consumption of pulping liquor and wood should be classified 

in SIC 26. However, no such changes have been made in this report.

c From the Information reported, it was impossible to determine the Industrial group.

"-" = None

NA = Not Applicable.

"*" = Less than 0.5 percent.

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End Use 

Division, 1980 Manufacturing Industries Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combditors 

Energy Information Administration
Table 21. Fuel Consumption in

Large Boilers by Region

(Trillions of Btu)

Energy Use in Large Boilers 

(continued)

Region

Percent of 

Boilers

All 

Fuels3

Natural 

Gas Coal

Fuel 

Oil

Pulping 

Liquor

Waste 

Gases Wood Other

Unweighted Data 

Northeast. .....

North Central.. 

South Atlantic. 

South Central.. 

West...........

Otherb.........

Total c .

Weighted Data 

Northeast......

North Central.. 

South Atlantic. 

South Central.. 

West...........

Otherb .........

14. 

24. 

13. 

21. 

11. 

15.

494.3

921.5

722.3

1,423.4

523.7

585.6

61.0

291.6

91.1

616.8

136.5

181.4

97.

239.

157.

125.0

38.1

140.9

216.2

98.4

165.3

112.6

51.5

105.2

28,

23.

207.

239.

120.

79.2

100.0

MA 

NA 

NA 

NA 

NA 

NA

4,670.8 1,378.4 798.1 749.2

43.3

662.8

669.4

1,239.5

878.0

1,962.7

714.2

723.2

82.1

381.6

108.1

859.9

193.1

222.9

127.4

311.1

191.8

163.5

51.3

173.3

304.5

142.1

204.

142.

67.

131.

33.8

29.0

248.

291.

145.

55.

Total0 . 6,187.0 1,847.7 1,018.4 993.6 803.1

214.6

2.6

131.0

42.9

65.7

536.0

104.8

301.8

5.9

256.0

90.2

80.0

838.7

6.4

9.0

63.0

92.5

105.5

29.2

305.7

7.7

11.0

73.8

111.9

127.4

35.2

367.0

5.5

44.9

35.5

106.2

28.7

20.0

240.8

9.2

62.9

45.5

136.7

39.4

25.0

318.7

aThis column may differ from the sum of the individual fuels due to rounding.

bpor disclosure purposes, the establishments and combustors from 2 or more regions in a given SIC 

grouping were combined. They are reported in all regions represented. Also included in this category 

are 8 establishments and 6 boilers which were not classified by region.

cDifferences between the total reported in this Table and those reported in Tables 19 and 20 occur 

due to roundl ng.

"NA"=Not applicable since no effort has been made to estimate the number of large industrial 

boilers not included due to nonresponse.

Source: Energy Information Administration, Office of Energy Markets and End Use, Energy End 

Use Division, 1980 Manufacturing Industries Energy Consumption Study and Survey of Large Combustors,

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

35
Table 22. Fuel Use In Large

Boilers by Maximum Design

Firing Rates (Trillion Btu)

36

Energy Use In Large Boilers 

[continued)

Table 22 shows the types of fuel consumed by size of boilers. Among all. 

boilers, natural gas is the most commonly used fuel. The use of natural 

gas, however, decreases substantially as MDFR increases from A3 percent 

(283.6 trillion Btu) of all fuels consumed in the 50-99 MMBtu per hour 

size class to 16 percent in the 500 or more MMBtu per hour class. 

Consumption of coal, the second most-consumed fuel, remains relatively 

constant over all.

All Large 50 - 99 100 - 244 250 - 499 500 + 

FUEL ___________Boilers MMBtu/Hr. MMBtu/Hr. MMBtu/Hr. MMBtu/HNatural Gas....... a l,374.9

(30)

Coal.

Fuel Oil.

Pulping Liquor.

797.5 

(17)

748.0 

(16)

662.9 

(14)

535.2 

(11)

304.9 

(7)

240.7 

(5)

4,663.6 

(100)

Number of

Boilers. .......... C 7,241

Other.

283.6 

(43)

89.6 

(14)

150.8 

(23)

9.4

(1)

48.8 

(7)

58.0 

(9)

16.2 

(3)

656.4 

(100)

3,203

582.9 

(35)

280.6 

(17)

336.4 

(20)

79.7

(5)

188.8 

(11)

101.9

(6)

103.0 

(6)

1,673.2 

(100)

2,913

352.2 

(25)

247.4 

(18)

150.7 

(11)

262.7 

(19)

195.9 

(14)

91.6 

(7)

80.5 

(6)

1,381.0 

(100)

840

156.0 

(16)

178,9 

(18)

110.1 

(12)

311.1. 

(33)

102.5 

(11)

53.4 

(6)

41.0 

(4)

953.0 

(100)

aThe top number in each cell is the Btu consumption of the fuel by 

boilers of given MDFR. The bottom number, in parentheses, is the percent 

of total Btu consumed in the size class of the fuel.

''The total may be different than the sum of the values in the column 

due to rounding.

cThe table does not include the 167 boilers which were not classified 

by size. These boilers account for 7.3 trillion Btu of all fuels.

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Table 23. Fuel Use in Large

Boilers by Year of Installation

(Trillion Btu)

Energy Use in Large Boilers 

(continued)

size classes. The use of fuel oil also decreases In terms of percent 

of fuels consumed as MDFR increases. Almost twice as much fuel oil is 

used as the two smaller size categories than in either of the two larger 

size categories.

The most dramatic change takes place with the consumption of pulping 

liquor. The use of this fuel increases substantially as MDFR increases 

from 1 percent in 50-99 MMBtu/per hr. boilers to 33 percent in MMBtu/per 

hr. boilers with an MDFR of 500 or more. As was seen in Table 19, the 

paper industry accounts for almost all of this.

Several interesting facts are apparent when fuel use patterns are examined 

by the date of installation (Table 21). Natural gas consumption appears 

to increase with new boilers until the latter half of the 1970's. Coal 

usage seems to exhibit an opposite pattern. The consumption of fuel oil 

does not vary in any discernible pattern. However, the use of waste fuels, 

i.e. pulping liquor, waste gases, wood, and other fuels, has increased. 

Such fuels account for almost half of all fuel consumed in the newest 

boilers.

Fuel

1939

All Large or 1940- 1950- 1960- 1970- 1975 

Boilers Earlier 1949 1959 1969 1974 or Later

Natural Gas. a l,355.5 57.3 

(30) (20)

Coal. 793.2 

(17)

72.4 

(25)

Fuel Oil.

Pulping Liquor.

741.9 60.9 

(16) (21)

660.1 

(14) (-)

Waste Gases.

Wood.

Other.

534.1 

(12)

289.2 

(6)

236.9 

(5)

66.4 

(23)

16.4 

(6)

12.8 

(5)

182.0 267.2

(28) (27)

158.1 240.1

(25) (24)

125.2 141.0

(19) (14)

23.8 107.8

(4) (11)

118.9 145.0

(18) (15)

478.0 214.8 156.2 

(34) (33) (25)

209.7 

(15)

39.2 

(6)

73.7 

(12)

192.0 126.0 96.8

(13) (19) (16)

266.7 133.9 127.9

(19) (21) (21)

17.3 

(3)

20.0 

(3)

62.3 

(6)

29.0 

(3)

102.8

86.4 

(6)

57.6 

(9)

41.3 

(6)

43.4 

(7)

65.5 

(ID

87.9 40.7 46.8 

(6) (6) (8)

Total b . 4,611.3 286.2 

(100) (100)

645.4 992.4 1,423.5 653.5 610.3 

(100) (100) (100) (100) (100)

Number of

Boilers .......... C 7,064 692 1,166 1,382 1,956 1.064 804

aThe top number in each cell is the actual number of Btu of the fuel 

consumed in a boiler of the given age. The bottom number in parentheses 

is the percent of total Btu consumed in the age group of the fuel.

"The total may be different than the sum of the values in the column 

due to rounding.

cThis table does not include 344 boilers not classified by age. These 

boilers account for 59.6 trillion Btu of all fuels.

"-" = None

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries 

Energy Consumption Study and Survey of Large Combustors.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Table 24. Mean Fuel

Consumption for a Typical Large

Boiler by Maximum Design

Firing Rate and Year of

Installation Categories3

(Trillion Btu)

Boiler Utilization

33

Energy Use in Large Boilers 

(continued)

Tables 22 and 23 showed fuel mix by size and year of installation. 

Table 24 shows the mean Btu consumption by a typical boiler in a given 

MDFR and age class.

Maximum Design 

Firing Rate

1975

1939 or 1940- 1950- 1960- 1970- or 

Total Earlier 1949 1959 1969 1974 Later

50-99 MMBtu/hr.. 

100-249 MMBtu/hr. 

250-499 MMBtu/hr. 

500 + MMBtu/hr...

0.21

0.58

1.65

3.34

0.20

0.52

1.15

1.63

0.22

0.62

1.21

2.83

0.22

0.73

1.76

3.27

0.20

0.53

1.95

3.72

0.20

0.45

1.73

3.61

0,. IS 

0,6! 

1..3C 

3.0!

Total. 0.65 0.42 0.55 0.72 0.73 0.62

aThe calculations in this table do not include 64.5 trillion Btu of 

fuel consumed in those boilers which were not classified by size or year 

of installation. (See footnote b in Table 17 for details.)

Source: Energy Information Administration, Office of Energy Markets; 

and End Use, Energy End Use Division, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

The amount of fuel consumed in boilers in the range of 50 to 99 MMBtu per 

hour apparently has no relationship to the year of installation. Boilers 

in the 100 to 249 MMBtu per hour range show increased usage (as measured 

by mean fuel consumption) as age decreases, that is, as year of instal 

lation approaches the present, through the decade of the 1950's. Begin 

ning with boilers installed in the 1960's, the consumption decreases 

substantially through the mid-1970's, when it increases once again. 

Boilers in the two largest size categories show an increase in fuel 

consumption through the 1960's.

It is interesting to note that the newest boilers do not have the highest 

fuel consumption.

The questionnaire used in this study did not ask for any direct measure, 

of boiler utilization. An approximate measure was constructed 

using the data reporting the usual firing rate and the number of houn3 of 

operation during 1979.

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustont 

Energy Information Administration
Table 25. Average Calculated

Large Boiler Utilization by

Maximum Design Firing Rate

and Year of Installation^

Energy Use In Large Boilers 

(continued)

Respondents were asked to report the usual firing rate of the boiler. 

This information was converted to the percent of the MDFR and rounded to 

the nearest 5 percent with a range of 0 percent to 110 percent.^ Hours 

of operation are reported to the nearest hundred hours with a range of 0 

to 88, even though the maximum number of hours is 8,760 (365 days times 

24 hours per day). The utilization measure compares the actual use of 

the boiler as measured in terms of usual firing rate and hours of use 

against a theoretical maximum.

This utilization measure was calculated for the 6,504 boilers which had a 

value for both variables used in the formula and which could be classified 

by size and year of installation. The calculated utilization rate ranged 

from a low of 0 to a high of 1.06. Table 25 reports the average 

calculated utilization rate for size and year of installation categories.

Overall, the mean boiler utilization is 39 percent. As would be expected, 

the largest boilers have the highest utilization rates. In terms of year 

of installation, the boilers with the highest utilizations were installed 

in the 1950's. The least utilized boilers were installed before 1940 

and the first half of the 1970's. The deviation from this pattern among 

those boilers with the largest MDFR is possibly a function of the small 

number of boilers, particularly among the oldest age classes.

Maximum Design 

Firing Rate

50-99 MMBtu/hr. . . . . .

100-249 MMBtu/hr..... 

250-499 MMBtu/hr..... 

500 + MMBtu/hr.......

Total

33

40 

53 

59

39

1939 or

Earlier

30

39 

38 

65

34

1940- 

1949

34

42 

48 

53

40

1950- 

1959

36

48 

58 

61

44

1960- 

1969

33

38 

58 

62

40

1970- 

1974

31

34 

50 

58

35

1975 or 

Later

32

40 

49 

54

40

aThis table is based on the 7,049 boilers which had both size and year 

of installation data. (See footnote b on Table 7 for details.)

Source: Energy Information Administration, Office of Energy Markets 

and End Use, Energy End Use Division, 1980 Manufacturing Industries 

Energy Consumption Study and Survey of Large Combustors.

 ^A small number of respondents reported usual firing rates in excess 

of the reported MDFR. These values were excepted since it was impossible 

to verify these figures. Of the 7,408 large boilers included in this 

study, 174 reported a usual firing rate that rounded to 100 percent, 14 

to 105 percent and 6 to 110 percent.

following formula was used to calculate the utilization index.

Usual Firing Rate

as a Percent of

Maximum

Number of Hours in 

X Use Rounded to the 

Nearest Hundred

Utilization Index 100 X 

(The theoretical maximum 

usual firing as a percent 

of maximum design firing 

rate)

(The maximum number 

of hours rounded to 

the nearest hundred 

a boiler can operate)

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

39
Heat Recovery Equipment

Table 26. Percentage of Large

Boilers with Heat Recovery

Equipment by Maximum Design

Firing Rate and Year of

Installation3

Energy Use in Large Boilers 

(continued)

As energy costs increase, it becomes increasingly important to use energy 

fully. Waste heat recovery equipment which may not have been feasible 

at the lower energy costs of the past, may now be economically attractive. 

As Table 26 indicates, the use of waste-heat recovery equipment has 

increased considerably in all boilers of all sizes installed during the 

last half of the 1970's.

Nationwide, 60 percent of the boilers in operation during 1979 had 

some sort of heat recovery equipment. The presence of heat recovery 

equipment increases as size increases in all age groupings. Of more 

interest, however, is the pattern of the existence of heat recovery equip 

ment over time.

Maximum Design 

Firing Rate

50-99 MMBtu/hr.....

100-249 MMBtu/hr. . .. 

250-499 MMBtu/hr. ... 

500 + MMBtu/hr. .....

Total... ............

Total

41

70 

83 

86

60

1939 or 

Earlier

39

76 

83 

100

58

1940- 

1949

46

71 

85 

75

63

1950- 

1959

42

72 

86 

84

61

1960- 

1969

36

68 

87 

90

57

1970- 

1974

37

59 

73 

82

52

1975 o 

La t e r

55

78 

85 

87

72

aThis table is based on the 7,049 boilers which had both size and year 

of installation data. See footnote b on table 17 for details.

Source: Energy Information Administration, Office of Energy Markets and 

End Use, Energy End Use Division, 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors.

For the 30 years starting in 1940, the presence of heat recovery equipment 

remained relatively constant. Boilers installed during the first half of 

the 1970's show the lowest rate of the use of heat recovery equipment. 

However, those boilers installed starting in 1975 show the highest use. 

This pattern reflects both the Increased cost of energy and the several 

year lead time required from the time a boiler is designed until it is in 

operation.

Report on the 1980 Manufacturing Industrie! Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Appendix 

A Questionnaire and 

Other Materials

UNITED STATES

DEPARTMENT OF ENERGY

ENERGY INFORMATION ADMINISTRATION

1980 Manufacturing Industries 

Energy Consumption Study and 

Survey of Large Combustors

FORM APPROVED

OMB NUMBER 038-S80011

This report /s mandatory under the Federal Energy Administration Act of 1974, 

P.L 93-275, and the Powerp/ant and Industrial Fuel Use Act of 1978, P.L 95-620. 

Failure to respond may result in criminal fines, dvi! penalties and other sanctions, 

as provided by taw.

The information reported on these forms may be !i; information that is exempt from disclosure to the public under the 

exemption for trade secrets and confidential commercial information specified in the Freedom of Information Act, 5 USC 

552 (b) 14) (FOIAX or fii) prohibited from public release by 18 USC 1905. However. beforejggPellierminaiion can be made that 

particular information is within the coverage of either of these statutory provisions, the pjjjgn submitting the information must 

make 8 showing, satisfactory to the Department of Energy, concerning its confidential nati 

Therefore, respondents wishing to claim such exemption must stale specifjCj!5v1JKkan eierrfl^fag^ifement basis, if possible!

a letter accompanying submission of this form, why they consid' 

proprietary information, whether such information is customarily Jn 

the industry, and the type of competitive harm that would 

provisions of 10 CFR 1004.11, D0£'s Freedom of Inforrnatroi 

submitted should be withheld from public disclose 

substantive justification that the information submit 1 respondent does not object to disclosure t>

The provisions of Section 711!a) of P.L. 3! 

reference the provisions of 5ecii«tey id! 

apply to the information subrj^prflfh this 

to the Attorney Gsngrat, the 

and other applicable authority? 

of the Congress and to the Gen;

'6 a trade secret or other 

i. tat ton by these companies and 

-e of nmorrriation, In accordance with the 

 ns, DOE will determine whether the information 

iponses and does not receive a request with 

>d to the public. DOE may assume that the 

ion submitted by it on the forms.

me! industrial Fuel Use Act of 1978, which incorporate by 

Energy Supply and Environmental Coordination Act of 1974, 

'equest, therefore, DOE must provide information obtained on this iorm 

iteriof, and the Federal Trade Commission in accordance with the cited statutes 

must also be made available upon request to the Congress or any committee

inling Office.

WHAT TO FILL OUT:

s Complete Section ' ion yellow paper) only once; il sppiies to your establishment (shown on mai^ label below; as a whole.

9 Complete a separate copy of Section \\ (on blue paper) for;

 each boiler, gas turbine, and iniernal combustion engine with a maximum < 

Btu/hr or greater, and

 each fired component of a combined cycle unit in which the components 1 million Btu/hr or greater.

* If your company did not operate this establishment at any time in 1973 answer 

18 of Section I. Then complete Section II forms required.

items 1 through 7 and 14 through

SEE SECTION II, PAGE 4 FOR ADDITIONAL INSTRUCTIONS

SECTiON ! - ESTABLISHMENT (PLANT) REPORT

1. Name and physical location of estabiishmen

CiTY. TOWN. VIUAGF FT'

(Please correct any e'fOr if 

label, including zip code.)

43

Report on the 1980 {Manufacturing industries Energy

Consumption Study and Survey of Large Combustors 

Energy Information Adrnir-lstrst'or?
44

Questionnaire and Other Materials 

(continued)

2. Currenl Employer Identification Number IEIN; 'pjis r's the number used by this establishment on tfrs 

latest Quarterly Federal Tax Return Form 341.)

3. Primary Standard Industrial Classification ;S!C' code far !h:s establishment.

5. Is this establishment owned 01 coiU'Oi'c.rt bv 3"\c"l~i=.t organization at company^1 

(11 No igo to item 61

6. Is this a seasonal operation 7

(1) No (2! | !

|79 or 1980.

12' I Started as a new business iV.e-.. 1979 or 1 38C> was rhe iniia! yest o f operation of this estab!:$ r 

Specify month and year started ._. ...... ___..__.___

(4) Establishment was sold or lueis-cd to a-ioiher company in 1979 or 1930

Specify month and year m which sod cr leased: __...._____._..___

NevOperator:

FOPM FiA 463 SECTION I

Report on the 1980 Manufacturing Bndustrfes Energy 

Consumption Study and Survey of Large Combusitors 

Energy Information Administration
Questionnaire and Other Materials

(continued)

Fill out the following table for fuels used by this establishment during calendar year 1979 for heat, power, 

and/or generation of electricity. Actual shipment of fuels may have occurred earlier than 1979.

S3QO uo esn

513 o

I,

g

D.

5

D

W

Z

o

0

UJ

* fill out all portions thai apply; leave others blank. 

» Include: - purchased fuels.

 non-purchased fuels, such as irrterptant transfers.

 fuels mined or extracted onsiie and used at the site.

* Do not include: - fuels produced as byproduct ol onsite operations (these are to be reported in item 9i.

 fuels used for transportation equipment.

- fuels used for feedstocks Isee Glossary for "feedstocks").

» Note thai the amount of "wood, bark, wood waste" is asked for on a "50 percent moisture" basis Adjustments 

may be necessary in estimating the amount used.

* Figures for amounts in excess of 100,000 may be rounded to thousands, if you prefer, however, yo 

esact amounts.

f this establishment used 1256,630 me! of natural gas in 1979. report either

Mil THOU UNITS M'i. fHQli 'JWTS

[256 ! m&t °' . * I < 257

may report

Example: If t

AMOUNT USED FOR

HEAT, POWER AND/OR

GENERATION OF

ELECTRICITY

AVERAGE 

% SULFUR

(BY 

WEIGHT)

SOLIDS

{11! Anthracit.

{12) Bituminous coal

(non-metallurgical uses!

113) Lignit

LIQUIDS

[21,' Motor gasoline

(for stationary engines!

1221 Distillate fuel oils

II, 2, 4 a light diesall

123) Residual fuel oils

IS, 6 ft heavy niesell

Other liquid fuels {specify!

__ ___ per gal ____% 

_ ^_ _ _ ^ per gal ____%

GASES

131) Natural gas

{32} LPG, butane, propane

Other gaseous fuels (specify!

___ per cu ft 

[ per cu ft

FORM EIA-463 SECTION I Page 3

(CCW7WUE OH REVERSE SIDE'

45

Report on the 1980 Manufacturing industries Energy 

Consumption Study and Survey of Large CombusSors 

Energy Information Administration
46

Questionnaire and Other Materials 

(continued)

Please Jill out the fallowing table for fue s whicr1 were produced onsite as byproducts of establishrnen 

operations during 1979.

No fuels produced as byproducts in 1979 igo to item Wa & b)

AMOUNT USED AT

SITE FOR HEAT. POWER

AND/OR GENERATION OF

ELECTRICITY

AVERAGE

Btu CONTENT

(HIGHER HEATING

VALUE)

LMTS

AMOUNT SOLD Ol::

TRANSFERRED

OFFSITE

i Refinery off gas [__

Other process 

gases (specify!

.' per cu ft ,____

[31 Amount of electricity sold or transferred offsite :-n 1979. ........ __ ___________. _

[4] E;ectricity used onsite in 1979

I this figure should be the same as n: - ,2i - i3l! . ........... _ _i_____ _ _.

10b. Of the total amount of electricity generated onsite \r 1979 [the amount reported in 10a '2K please 

report the amounts generated by each of the following:

[ZJ No elec!nc " v generated (go ro nerr lt>

(1) Steam ....................... ...... ... ..... _ _____ __ _|^

(2) Gas turbines......... ........ ......... .......... _

13] Internal combustion engines ..... ........ .... ._________

(4) Hydro. ............ ... . . . .............. ..... , ___ ____ _ ___

(5) Other (specify) .. ._...._... ._ .

FORM EIA-463 SECTION I

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
nil! Questionnaire and Other Materials

FORM EIA 463 SECTION

47

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
i!

48

Questionnaire and Other Materiab 

(continued)

FFICE USE

ONLY

15. Indicate the current number of all other combusto-s at this establishment (i.e.. combusiors not repcn 

item 14} in each category.

 Do not report combustors with a maxin

 Under "internal combustion enyines" 

do not include sell-propelled vehicle;;; 

do include equipment such as portable 

generators with a maximum firing rate 

o) 1 million Btii'hr or greater

i design firing rate of less Ihan 1 i

NUMBER OF OTHER COMBUSTORS

Telephone No.

17. Disclosu'6 Statement

(1] |__, K'o Igo ro i'.err Yes (continue with item 17t>f

b Have you attached a written jusiif.c<i:ion fo- exeirpnon from Freedon of Information Act, 5 USC 

552(b)(4p (see page If

This report is substantially accurate and has been prepared in accordance with instructions, and 

the period ._._.. ..___..__.___.____... to ____

FORM EIA.i63 SECTION I

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Questionnaire and Other Materials 

(continued)

FORME.A«3 UNITED STATES 

SECTION ii DEPARTMENT OF ENERGY 

ENERGY INFORMATION ADMINISTRATION

S

1980 Manufacturing Industries 

Energy Consumption Study and 

Survey of Large Combustors

FORM APPROVED 

0MB NUMBER 038-S80011

ID NO.:

SECTION II - INDIVIDUAL COMBUSTOR REPORT

THIS REPORT IS MANDATORY (see page 4 of Section ft. General Instructions) 

Assign sequential numbers to each boiler, gas turbine, internal combustion engine and each fired componeni of a combined cycle unir for 

which you are reporting. As an example, H you are reporting for four boilers and one combined cycle unit with two fired components the 

numbers should go from 01 through 06 (01 through 04 would identify individual bo ers; 05 and 06 would identify the two components of 

the combined cycle unit).

IDENTIFICATION

KIND OF COMBUSTOR

BOttER OPERATION

SHAFT POWER

la. Enter the sequential number assigned to this combustor. L 1_J 

1b. Name or identfficatr'on number assigned to this combuslor in your company's records:

2a. Is this combustor part of a combined cycle unit? 

(1) | | No (go to item 3} Ij^Lji 

2b. Please list the numbers (as assigned in /tem^Kofllpt

^f

Bts (contnBbjjtKih item 2b/ 

TaB^ljreomponents of this combined cycle unit.

3. What kind of combustor or ^W>OH^K>f SSebinnbined cycle unit is this? (mark one box only) 

1 | Boiler fcoSBH^^y/rft ^Bk ^P^ ... i ~\ . . _ , . _ . , . .., 

11) i __ j -fe/ns 4a K ^i»m_ «fe ' lmernal Combustion Engine (go to item 5)

4a. What is ^Att^r's design (rated) steam/hot water: 

(!) Pressure? psig !2i Temperature 7 F

MIL THOU UNITS M = L THOU UNITS

(3) Flow Rate? [ ____ j __ _ _ L1^22^ ib/f1r (steam!, or, , _ , __ j ____ |, ,\ , _ _ Btu'hr (hot water 

boilers only)

4b. For this boiler, what is the annual average steam/hot water: 

(1) Pressure? psig (2) Temperature7 F

4c. Is the steam or hot water produced by this boiler used for: (mark all that apply) 

r-,\ 1 ! Space heating, ventilating, or ... 1 j .... 

">l_l air conditioning? {3) LJ Etectncrtv gener 3 uon?

(2) 1 1 Process heat> (4) j \ Mechanical dfive lothef than electricity 

1 1 ! i generation)?

tNQW GO TO ITEM 6?

6. "Indicate below whether this gas turbine/internal combus 

mechanicai drive (mark one box only). Also indicate the 

USE

(11 [ j Electricity generation .......................

tion engine is used for electricity generation or 

rated output of this unit. 

RATED OUTPUT

THOU SJ.-JiTS

............ | ____ j ____ kW

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

49
50

Questionnaire and Other Materials 

(continued)

a S

O a

7. In column CO of the following table-. incicate 

has been modified, to use tmsrk at' rA»,y! , »>,-_ 

in this combustor in 1979.

SOLIDS

(111 Anthracite

H2" Bituminous coal

(13) Lignite

(14.' Coke and breeze

:he fuel(s) that this combustor was initial y designed, ondica:e in column (2) the amount of each fuel jsed

DESIGNED OR 

MODIFIED TO USE

|Z 4 a itgm 

His '5, 6 ft heav.' o:e3c>< 

(24; Pulping liquor (bone dry basis! 

Other liquid fuels (specify

GASES

(31! Natural gas

(32I LPG, butane, propane

(33) Blast furnace gas

(34) Coke oven gas 

(351 Refinery off gas

Differ gaseous fuels (specify/

OTHER (specify) .__.

 u

FORM ElA-463 SECTION I

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

iEnergy Information Administration

AMOUNT 

USED IN 1979

121

_.__Jv,^ : :p[
Questionnaire and Other Materials

(continued)

If this cornbustor was either designed, or has been modified, to use a solid f 

sulfur and Btu content of that fuel?

I_| Not appficabie

jei, what was the design

What is this combuslor's current maximum design firing raie ?

10. At what firing rate i 

when not banked)

RANGE: From 

USUAL RATE.

11a. Approximatelv what is the temperature of 

the usual firing rate 7 dhe rate indicated

combustor whife in use at

"beyond this exit? imark at! friar apply) 

(4) 1 : Economizer (7! Other (specify/

12." if. your company did net operate this plant in 1979. or if mis combustor was installed after 1979, 

check box below.

Skip items 13 & 14

13. Please estimate the number of hours in 1979 this combustor was in use at approximately the usual 

firing rate.

14. During 1979, approximately how many days each month was this combustor not in use ? icount only 

days on which this combustor was shut down for s 24 hour period,'

(1) January [

(21 February |

(3f March [

NOTES OR COMMENTS:

FORM EIA-163 SECTION II Page 3

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy information Administration

51
52

Questionnaire and Other Materials 

(continued)

GENERAL ENSTRUCTIONS

This report is mandatory under the Federal Energy Administration Act of 1974, 

P.L 93-275, and the Powerptent and Industrial Fuel Use Act of 1978, P.L 95-620. 

Failure to respond may result in criminal fines, civil penalties and other sanctions, 

as provided by law.

The information reported on these forms may be (i) information that is exempt Irom disclosure to the public under the

exemption for trade secrets and confidential commercial information specified in the Freedom of Information Act, 5 USC b52

(bl (4) IFOIAI, or (ii) prohibited from public release by 18 USC 1905. However, before (he determination can be made tlai

particular information is within the coverage of either of these statutory provisions, the person submitting the in'sr-nalror r-j:

make a showing, satisfactory io the Department of Energy, concern.ng is confidential nature.

Therefore, respondents wishing lo claim such exemption rrusl sta^e spec fically [on an element by element basis, '* possoi^ 1

a letter accompanying submission of this form, why they consider the : nforrnalion concerned to be a trade secret cr other

proprietary information, whether such information is customarily treated as confidential information by these companies and

the industry, and the type of competitive harm thai would result (rom disclosure of the information. In accordance with mt

provisions of 10 CFR 1004.11, DOE'S Freedom of Information Act Hecu : aiions. DOE will c

submitted should be withheld from public disclosure If DOE receives the responses ar\

substantive justification thai the information submitted should not be .'eleased to the pil

respondent does not object to disclosure to the public of any nlor

The provisions of Section 71! la) of P.L- 95-620, the Po^er plant a

reference the provisions of Section 11 id) of P.L. 93-319. The Eneri

apply to the information submitted on this form. Upon r

to the Attorney General, the Secretary of the Interior, and 1

and other applicable authority. The information muaj

of the Congress and to the General Accounting 0(

/heiher the nformaticn 

)t receive a request with 

may assume that the

. Complete a separate ci

 each boiler, gas turbi 

greater, and

 each fired component 

Or greater.

A. If records are not available for an item, carefully derived estimates g.-c acceptable. 

5. The Glossary explains key terms used in the forms.

7 For additional copies of the forms write or call:

Mr, Stephen J. Dienstlrey, Industrial Survey Manager

U.S. Department of Energy

P.O. Box 2100

Rockville, MD 20852

8QO-638-65&4

or you may duplicate as many cop.es of the forms, as needed H you make duplicate copies, pfease be sure thai the- pm 

iD number which appears on page ' is clearly leg:b!e cr ail reprocuced copies.

8. If you wish to amend or correct any items alter returning your completed forms, send the corrections to Mr Dsenstfiey ,• 

the address above. Clearly identify the itemlsi to be amended or correctec.

EIA 463 SECTION1 I

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combuston 

Energy Information Administration
ims Questionnaire and Other Materials 

(continued)

GLOSSARY

Anthracite - ASTM class I coal.

Bituminous Coa! ASTM classes II and Ml coal. Please note that sub-bituminous coal should be reported under 

this category.

Boiler A unit which heats water for the generation of steam and.-'or hot water. 

Bone Dry 0% moisture.

Calciner A combustor which heats solid material to a high temperature without fusing, its principal function is 

to decompose hydrates, carbonates, and other compounds and expe! volatile matter. This will primarily refer to 

the heating of unformed materials in a kiln such as a rotary cement kiln, lime kiln, or alumina kiln.

Coke The solid residue remaining from the destructive distillation of coal or other carbonaceous material such 

as pitch, petroleum, or petroleum residue. Coke which is used as a raw maTjMpSnn a blast furnace, cupola furnace 

or any other operation should not be reported as a fuel in this survey. ^jj|hnjg$^

Combined Cycle Unit An elect/ic or mechanical power generan1 ^jnit thlafcapfffets of a combination of one 

or more combustion turbine units and one or more boilers v^P^ffil^bffitetial poJTOn of the required energy input 

to the boilerts) provided by the exhaust gas of the conrjhus^Ktt^R^e^Hlr Use of supplemental firing for the 

boiler does not preclude the unit from being designawfccolBped cycre unit.

Combustor A unit which consumes fuels 

naces, ovens, combustion turbines, blasjjui

Dryer A combustor whii 

processed. Typical types of 

food dryers.

Establishment The def! 

Census; in general, that is

iiy to provide heat. Examples are boilers, fur- 

 mbustion engines, and combined cycle units.

water or other volatile compounds from the material being 

iry'rnineral dryers, shaft mineral dryers, paint drying ovens, or

it for this survey is the same as that used by the Bureau of 

 hysical location where manufacturing is performed.

Feedstocks Materials (which can also be used as fuels) which are consumed as raw materials in the production 

of intermediate or finished products. Feedstocks do not include materials used primarily for process heat. Coal 

used for coking, crude oil that is refined, and coke used in blast furnaces, are all considered feedstocks for this 

survey.

Firing Rate Fuel heat input rate. The rate at which fuel is supplied to a combustor. The firing rate calculation 

is based on the higher heating value of the fuelFluid heater A combustor that heats (or preheats) gases or liquids. Examples of fluid heaters are fired 

petroleum heaters and blast furnace stoves. Combustors where a chemical reaction takes place simultaneously 

with heating are considered reactors, not heaters.

Gas Turbine A heat engine that converts energy of fuel into work by using compressed hot gas as the

working medium. Usually delivers its mechanical output through a rotating shaft. Also known as a combustion

turbine.

Heat Treater A combustor that heats a material to create or remove specific properties in the material. Heat

treating is particularly widespread in the rnetais industries. Examples of heat treaters are glass annealing iehrs and

brick kilns.

Higher Heating Value The total heat obtained from the combustion of a specified amount of fuel and the

stoichiornetrically correct amount of air, both at 60 F when combustion starts, and the combustion products

being cooled to 60 C F before the heat release is measured. This is the heating value that is typically reported in

the United States.

Hot Water Boiler A boiler that can produce only hot water and not steam.

Internal Combustion Engine A prime mover in which the fuel is burned within the engine and the products

of combustion serve as the working medium.

Lignite ASTM class !V coal.

53

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

(Energy Information Administration
Questionnaire and Other Materials 

(continued)

GLOSSARY

Maximum Design Firing Rate The maximum firing rate that the combustor is designed to achieve over c 

period of continuous operation,

rncf One thousand cubic feet at 14.73 psia and 60" F.

Melter A combustor where the principal function is the conversion of a solid to a liquid at high temperature, 

Examples include glass melters, aluminum reverberatory melters and open hearth furnaces.

Metallurgical Coal Bituminous or coking coals which are used to produce coke for blast furnaces and cuool;i 

furnaces.

Onsite Pertains to operations which are performed on the grounds

Reactor ~ A combustor in which a chemical reaction takes place. Ex; 

pyrolysis furnaces in the chemical industry, or blast furnaces or^jke ov<

Recuperative Air Preheater A continuous heat ex 

the exiting flue gases, which are being cooled,

Regenerative Air Preheater A cyclical

over exchanger internals. This heat is re\- 

passes over the exchai

Reheater A com: 

appropriate for subseqj

Sinterer/Pelletizer 

Usual Rate The mo:

establishment itself.

elude reforming furnaces or 

steel industry.

jtTHsses through a surface separating 

fated, usually incoming combustion air.

'here the exiting flue gases give up heat as they DES 

being heated, usually incoming combustion air, as i 

of the cycle (includes heat wheels).

ion is to bring the temperature of a solid material to 3 leve 

ncluce steel reheating furnaces and soaking pits.

agglomerates ores, coke breeze, or metal powders without mehing. 

frequent rate of operation.

MULTIPLY

Barrels

Btu

Btu

Btu'hr

Btu/hr

Horsepower

Horsepower

Horsepower-hour

Kilowatt

Kilowatt

Kilowatt-hour

CONVERSION FACTORS

BY

42.0

0.000393

0.000293

0.000393

0.000293

2545.0

0.7457

2545.0

3412.0

1.34

3412.0

TO OBTAIN

Gallons

Horsepower-hour

kWh

Horsepower

Kilowatt

Btu/hr

Kilowatt

Btu

Btu/hr

Horsepower

Btu

54

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration
Appendix 

B Letter from the Office of 

Management and Budget

Letter from the Office of 

Management and Budget

EXECUTIVE OFFICE OF THE PRESIDENT 

OFFICE OF MANAGEMENT AND BUDGET

WASHINGTON. D.C. 20503

Honorable James B. Edwards 

Secretary

Department of Energy 

Washington, D.C. 20585

Dear Mr. Secretary:

On October 15, 1980, the Office of Management and Budget 

approved fora EIA-463, the "1980 Survey of Large Ccmbustors 

in Manufacturing Industries" for use through Decerr-ber 31, 1981. 

The estimated number of respondents was 10,000; the estimated 

total of respondent burden was 59,000 hours.

We understand this form is the first of many being developed 

to expand the Department's collection of energy consumption 

data. Subsequent to the issuance of the form, many respondents 

furnished data showing that the information requested is need 

lessly detailed and cannot be used for the pnrrrases intended.

We have reviewed -chase comments, and under the authority provided 

by 44 O.S.C. 3506, have determined that the collection is 

unnecessary and therefore unduly burdensome. Therefore, I hereby 

withdraw OMB's approval of this information collection activity 

and direct the Department of Energy not to engage in any further 

collaction of this information. We also expect you to treat the 

data already collected in a confidei>cial mannex.

Sincerel

David A. Stocfana-n 

Director

57

Report on the 1980 Manufacturing Industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

Appendix 

C Steps Taken to Minimize the 

Potential to Identify 

Respondents

Steps Taken to Minimize the 

Potential to Identify

Respondents

In an effort to fully comply with the directive from the Director of the 

Office of Management and Budget "to treat the data...collected in a con 

fidential manner (See Appendix B)", the following procedures were taken 

to modify the data in such a way as to minimize the potential to identify 

respondents while at the same time still allowing for a full range of 

potential analysis.

First, all links were broken between the sampling frame used for the 

study, the establishment reports, Section 1, and the individual combustor 

reports, Section 2. This was done in such a way as to make it impossible 

to group combustors for the same establishment together. In addition, a 

separate file was created for the information reported in Question 15 of 

Section 1, the number of process and nonprocess combustors with an MFDR 

of one million Btu/hr. or more.

Second, the Standard Industrial Classification code reported by the 

respondent was raised to a higher level, to 3-digit, etc., where the 

4-dlgit detail could allow for the identification of the respondent. 

Further, geographic detail was also collasped for the same reason.

In several cases, a given industrial designation and geographical class 

did not have a sufficient number or cases to meet the dominant rule 

established for public disclosure. In these instances, geographical 

classes with the same industrial designation were combined until the 

dominant rules were satisfied. The establishment and combustors in a 

combined region are identified as being located in all the geographical 

classes that were combined. (For the tables in this report, unless 

otherwise indicated, any establishment or combustor in a combined region 

is listed in the "other" category.)

Third, upper limits for the Btu value of all fuels, electricity and steam 

consumed, produced, purchased or transferred onsite, or sold or 

transferred off-site were established. The values reported in the data 

file for items reported above that limit are the mean value for all 

values reported above the upper limit for the particular item.

Fourth, all values below the upper limit mentioned above, were innoculated 

with normally distributed random error. The minimum error was _+ 5 percent 

of the originally reported value and the maximum is ^+ 40 percent. All 

values on a given report received the same amount of error so that the 

original proportions are preserved. The probabilities of the error 

ranges are as follows:

Ranges of Error (Percent)

 I 05% 1

I 05% - 10% I

I10% - 15%l

115% - 20%I

I 20% - 25%I

I 25% - 30%]

I 30% - 40%I

Probability

0.3820

0.2996

0.1836

0.0880

0.0332

0.0098

0.0036

In a few cases, this error innoculation resulted in values which exceed 

the upper unit described above. In order to maintain the consistency of 

the innoculation procedures, the innoculation values were reported even 

though they exceeded the upper limit established for raw data.

Report on the 1980 Manufacturing industries Energy 

Consumption Study and Survey of Large Combustors 

Energy Information Administration

61

 U.S. GOVERNMENT PRINTING OFFICE: 1983-380-903:24


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