p.1 

OAR Box 1870 

Prepped by Ollie Stewart 

Document Number: 

16) ll-A-21 

Docket Number: 

A-90-19 

Printed 11/28/2008 7:05:04 AM Sheet 16 of 67 
P.2 

£EPA 

United States , 

Environmental Protection 

Agency 

Office of Air Quality 

Planning and Standards 

Research Triangle Park NC 27711 

A-90-19 

ll-A-21 

Air 

Fossil Fuel Fired _ Draft 

Industrial Boilers- EIS 

Background Information 

Volume 1: Chapters 1-9 

'>/ y 
P.3 

This report has been reviewed by the Emission Standards and Engineering Division 

of the Office of Air Quality Planning and Standards, EPA, and approved for publication. 

Mention of trade names or commercial products is not intended to constitute endorsement 

or recommendation for use. Copies of this report are available through the Library 

Services Office (MD-35), U.S. Environmental Protection Agency, Research Triangle 

Park, N.C. 27711, or from National Technical Information Services, 5285 Port Royal 

Park, i-c.-s/. *.••--. -;, -. . Oo*i/,i 

Road, Springfield, Virginia 22161 

For sale by Superintendent of Documents 

U.S. Government Printing Office 

Washington, DC 20402 

W 
P.4 

This report has been reviewed by the Emission Standards and Engineering Division 

of the Office of Air Quality Planning and Standards, EPA, and approved for publication. 

Mention of trade names or commercial products is not intended to constitute endorsement 

or recommendation for use. Copies of this report are available through the Library 

Services Office (MD-35), U.S. Environmental Protection Agency, Research Triangle 

Park, N.C. 27711, or from National Technical Information Services, 5285 Port Royal 

Road, Springfield, Virginia 22161. 

For sale by Superintendent of Documents 

U.S. Government Printing Office 

Washington, DC 20402 
Table 3-4. INSTALLED CAPACITY OF U.S. WATERTUBE INDUSTRIAL BOILERS 

BY UNIT SIZE AND FUEL TYPE1* 

(MW thermal Input (10-5 Btu/hr)) 

(JO 

I 

Fuel 

Pulverized coal 

Spreader-stoker coal 

Under feed-stoker coal 

Overfeed-stoker coal 

Total coal 

Residual oil 

Distillate oil 

Total oil 

0 to 2.9 

(0 to 10) 

0 

(0) 

70 

(240) 

680 

(2,300) 

85 

(290) 

835 

(2,830) 

3,960 

(13.500) 

2,560 

(8.700) 

6.520 

(22.200) 

2.9 to 14.7 

(10 to 50) 

0 

(0) 

4.650 

(15.900) 

14,105 

(48,000) 

3,470 

(11,800) 

22,225 

(75,700) 

48,190 

(164,000) 

8,280 

(28,200) 

• 

56,470 

(192,200) 

Capacity by 

14.7 to 29.3 

(50 to 100) 

0 

(0) 

6,175 

(21,060) 

17,265 

(58,900) 

4,455 

(15,200) 

27.895 

(95,160) 

35.640 

(122,000) 

4,295 

(14,600) 

39,935 

(136,600) 

unit size 

29.3 to 73.3 

(100 to 250) 

19,895 

(67,800) 

20,295 

(69,000) 

7,080 

(24,200) 

3,555 

(12,100) 

50,825 

(173,100) 

44,790 

(153,000) 

6,370 

(21.700) 

51,160 

(174.700) 

>73.3 

(>250) 

40.180 

(137.000) 

11,010 

(37,600) 

5,230 

(17,800) 

3,510 

(12,000) 

59.930 

(204,400) 

43,570 

(148,600) 

4,085 

(13,900) 

47,655 

(162,500) 

Totals 

60,075 

(204,800) 

42.200 

(143.800) 

44,360 

(151.200) 

15,075 

(51,390) 

161,710 

(551,190) 

176,150 

(601.100) 

25.590 

(87.100) 

201,740 

(688,200) 

Natural gas 

Total all fuels 

4.475 

(15.300) 

11.830 

(40,330) 

57,900 

(197,500) 

136.595 

(465,400) 

53.505 

(182.800) 

121.415 

(414.560) 

63,320 

(216,000) 

165,305 

(563,800) 

95,935 

(327,200) 

203.520 

(694.100) 

275.215 

(938,800) 

638.665 

(2.178.190) 
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TABLE 3-5. INSTALLED CAPACITY 0FQINDUSTRIAL FIRETUBE BOILERS 

BY SIZE AND FUEL TYPEb 

[MW thermal input (10-5 Btu/hr)] 

Fuel 

Capacity by unit size 

0 to 2.9 

(0 to 10) 

2.9 to 14.7 

(10 to 50) Total 

Coal 

Residual oi l 

Distillate oil 

Natural gas 

5,650 

(19,270) 

35,280 

(120,330) 

17,770 

(60,610) 

59,120 

(201,630) 

7,780 

(26,530) 

25,860' 

(88,200) 

15,770 

(53,790) 

52,130 

(177,790) 

13,430 

(45,800) 

61,140 

(208,530) 

33,540 

(114,400) 

111,250 

(379,420) 

Total 117,820 

(401,840) 

101,540 

(346,310) 

219,360 

(748,150) 

Jjk 

3-13 
P.7 

TABLE 3-6. INSTALLED CAPACITY OF INDUSTRIAL 

CAST IRON BOILERS BY FUEL TYPE15 

[MW Thermal Input (IO6 Btu/hr)] 

Fuel Boiler Capacity3 

Coal 6,330 

(21,590) 

Residual oi l 10,780 

(36,770) 

Distillate oil 6,740 

(22,990) 

Natural gas 28,720 

(97,950) 

All cast iron boilers have a capacity less than 

4.0 MW thermal input (14 x IO6 Btu/hr). 

3-14 

fc 
P.8 

of watertube and firetube boilers and 50 percent of the sales of cast iron 

units are replacements for existing boilers that are being .retired. 

Seasonal and time-of-day changes in energy demand result in excess 

capacity during nonpeak demand periods. Section 3.1.4 discusses these 

variations in capacity utilization by industry. Since capacity utilization 

varies widely in industry, the installed capacity by itself is not an 

adequate measure of fuel consumption. This information must be obtained 

from actual fuel usage data. Summaries of industrial fuel consumption data 

are presented in the next subsection. 

3.1.4 Fuel Usage Patterns 

Table 3-7 gives fossil fuel consumption by the manufacturing industries 

in each EPA region. Region V (including Ohio, Michigan, Illinois, and 

Indiana) is a heavy consumer of fossil fuels, using nearly 40 percent of the 

national annual coal consumption by manufacturers and about 20 percent of 

the U.S. annual consumption of distillate oil and natural gas by the 

manufacturing industries. Region VI (including Texas and Louisiana) 

consumes 40 percent of the natural gas. In general, the largest end use of 

each fuel in each region is for process steam, accounting for about 

19 one-third of the fuel used by industry nationwide. Use of fuel as 

feedstock accounts for less than one-third of the manufacturing fuel use. 

Industrial process heating in furnaces and space heating accounts for most 

19 

of the remaining industrial fuel consumption. 

Table 3-8 lists the percent of industrial boiler fossil fuel consumption by industry and fuel type for 1974. The most energy intensive 

industries—chemicals and paper—account for over one-third of the 

industrial boiler fuel consumption. The other industries listed (petroleum 

refining, steel, aluminum, and food) account for much of the remaining 

industrial boiler fuel consumption. Other industries, using smaller but 

significant amounts of fuel in boilers, include textiles, lumber, rubber, 

metal fabrication, and transportation. 

Table 3-9 relates the share of fuel used in this country by industry to 

the quantities used by other sectors. In addition to manufacturing, the 

3-15 
P.9 

TABLE 3-7. REGIONAL FOSSIL FUEL CONSUMPTION BY THE MANUFACTURING 

INDUSTRIES IN 1976a 

[Exajoules (10lb Btu)] 

EPA 

Region 

I 

II 

III 

IV 

V 

VI 

VII 

VIII 

IX 

X 

Total 

Residual 

oil 

0.19 

(0.18) 

0.21 

(0.20) 

0.28 

(0.27) 

0.38 

(0.36) 

0.26 

(0.25) 

0.09 

(0.085) 

0.023 

(0.022) 

0.029 

(0.027) 

0.05 

(0.047) 

0.051 

(0.048) 

1.6 

(1.5) 

Distillate 

oil 

0.033 

(0.031) 

0.077 

(0.073) 

0.12 

(0.11) 

0.14 

(0.13) 

0.12 

(0.11) 

0.039 

(0.037) 

0.026 

(0.025) 

0.0095 

(0.009) 

0.023 

(0.022) 

0.023 

(0.022) 

0.61 

(0.58) 

Coal 

0.0071 

(0.0067) 

0.20 

(0.19) 

1.2 

(1.1) 

0.48 

(0.45) 

1.4 

(1.3) 

0.079 

(0.075) 

0.11 

(0.1) 

0.10 

(0.095) 

0.088 

(0.083) 

0.019 

(0.018) 

3.7 

(3.5) 

Natural 

gas 

0.081 

(0.077) 

0.18 

(0.17) 

0.51 

(0.48) 

- 0.69 

(0.65) 

1.4 

(1.3) 

2.7 

(2.6) 

0.32 

(0.3) 

0.14 

(0.13) 

0.48 

(0.46) 

0.19 

(0.18) 

6.7 

(6.4) 

Total 

0.31 

(0.29) 

0.67 

(0.63) 

2.1 

(2.0) 

1.7 

(1.6) 

3.2 

(3.0) 

2.9 

(2.8) 

0.48 

(0.45) 

0.28 

(0.26) 

0.64 

(0.61) 

0.28 

(0.27) 

13 

(12) 

aThe fuel consumption data include use in process heaters 

and as feedstock as well as in boilers. Reference 18. 

i 

3-16 
P.10 

Table 3-8. DISTRIBUTION OF INDUSTRIAL BOILER FOSSIL FUEL CONSUMPTION 

IN 1974 BY INDUSTRY AND FUEL TYPE20' 

(percent) 

Industry 

Chemicals 

Paper 

Steel and aluminum 

Food 

Petroleum refining 

Other manufacturing 

Total 

Coal, 

% 

4.5-5.6 

2.9-3.6 

2.6-3.3 

1.1-1.3 

0.07-0.09 

3.5-4.3 

15-18 

Fuel type 

Oil, 

% 

1.9-2.4 

6-7.4 

0.68-0.85 

1.3-1.6 

1.2-1.5 

6.1-8.5 

17-22 

Gas, 

% 

14-17 

4-5 

5.5-6.8 

4.8-5.9 

3.8-4.8 

14-35 

46-75 

Total, 

% 

20-25 

13-16 

8.8-11 

7.1-8.8 

5.1-6.4 

24-48 

100 

3-17 
3-18 

Consuming sector* 

Household and 

commercial 

Industrial 

Transportation 

Electrical 

generation 

Total 

Percent 

TABLE 3-9. 

» Coal 

0.31 

(0.29) 

4.44 

(4.2) 

0.01 

(0.01) 

9.15 

(8.67) 

13.9 

(13.2) 

18.0 

UNITED STATES PRIMARY ENERGY CONSIJMPTIOh 

SECTOR AND ENERGY SOURCE, 1974*' 

[Exajoules (1015 Btufl 

Petroleum 

6.75 

(6.39) 

6.38 

(6.04) 

18.6 

(17.6) 

3.64 

(3.45) 

35.4 

(33.5) 

45.9 

Natural gas 

7.51 

(7.1) 

11.75 

(11.1) 

0.70 

(0.66) 

3.51 

(3.23) 

23.5 

(22.2) 

30.4 

aExcludes use of electrical energy by household, commercial, 

and transportation sectors 

Includes all manufacturing sectors. 

Nuclear 

— 

— 

— 

1.24 

(1.17) 

1.24 

(1.17) 

1.6 

industrial 

BY CONSUMING 

Hydropower 

and 

geothermal 

— 

— 

— 

3.19 

(3.02) 

3.19 

(3.02) 

4.1 

• 

Total 

14.6 

(13.8) 

22.6 

(21.4) 

19.3 

(18.3) 

20.7 

(19.6) 

77.2 

(73.1) 

100.0 • 

i 

Percent 

18.9 

29.3 " 

25.0 

26.8 

100.0 
P.12 

subsections. Following these two subsections, emission factors for coalfired boilers are presented. ' 

3.2.2.1 Watertube Boilers. A watertube boiler is one in which the hot 

combustion gases contact the'outside of the heat transfer tubes, while the 

boiler water and steam are contained within the tubes. The tubes are 

interconnected to. common water channels and to a steam outlet or outlets. 

Watertube boilers can generate high-pressure, high-temperature steam, 

up to 12,000 kPa (1740 psi) and 810 K (1000°F), and are available in many 

sizes (see Table 3-4). The tubes are of relatively small diameter, 5 cm 

(2.0 inch), providing rapid heat transfer, good response to steam demands, 

39 

and high efficiency. 

There are two main types of coal-fired watertube boilers: pulverized 

coal and stoker-fired. Industrial size pulverized coal units range from 

29.3 MW to over 200 MW (100 to 700 x IO6 Btu/hr) heat input,14 and burn the 

coal in suspension. A stoker is a conveying system that serves both to feed 

the coal into the furnace and to provide a grate upon which the coal is 

burned. Since feed rates by stoker units are limited, stokers are generally 

used on units rated at less than 117 MW (400 x IO6 Btu/hr) heat input.14 

The three main types of stoker furnaces are spreader, overfeed or chaingrate, and underfeed. 

Pulverized Coal-Fired 

In pulverized coal-fired boilers the fuel is pulverized to the 

consistency of light powder and pneumatically injected through the burners 

into the furnace. Combustion begins at the burners and continues into the 

furnace volume. Wet-bottom furnaces are designed to operate at high 

temperatures and therefore keep the ash in the molten state until it 

collects in the bottom ash hopper. Dry-bottom furnaces, on the other hand, 

operate at lower combustion temperatures; consequently, the bottom ash 

remains in the solid state. Wet-bottom units are not expected to be 

40 manufactured and sold in the future. Figure 3-3 illustrates a typical 

58.6 MW (200 x 10 Btu/hr) heat input, dry-bottom pulverized coal unit with 

the corresponding mass and energy balances. Thirty percent-excess air and a 

3-27 
P.13 

TECHNICAL REPORT DATA 

(Please read Instructions on the reverse before completing) 

1. REPORT NO.

 : I 

EPA 450/3-82-006a,b 

3. RECIPIENT'S ACCESSION NO. 

4. TITLE. AND SUBTITLE 

Fossil Fuel-Fired Industrial Boilers 

Background Information 

5. REPORT DATE 

March 1982 

6. PERFORMING ORGANIZATION CODE 

7. AuTriORlS) I. PERFORMING ORGANIZATION REPORT NO. 

9. PERFORMING ORGANIZATION NAME ANO ADDRESS 

Office of Air Quality Planning and Standards 

U. S. Environmental Protection Agency 

Research Triangle Park, North Carolina 27711 

10. PROGRAM ELEMENT NO. 

11. CONTRACT/GRANT NO. 

68-02-3058 

12. SPONSORING AGENCY NAME ANO ADDRESS 

DAA for Air Quality Planning and Standards 

Office of Air, Noise, and Radiation 

U. S. Environmental Protection Agency 

Research Triangle Park, North Carolina 27711 

13. TYPE OF REPORT ANO PERIOO COVERED 

14. SPONSORING AGENCY CODE 

EPA/200/04 

15. SUPPLEMENTARY NOTES 

16. ABSTRACT 

This document provides background information for the fossil fuel-fired 

industrial boiler source category. Fossil fuels considered include coal, 

oil and natural gas. Background information for industrial boilers includes 

a survey of boiler types, sizes, operating characteristics, and existing 

State and Federal regulations. Uncontrolled emissions of particulate 

natter, sulfur dioxide and nitrogen 'oxides are quantified and factors 

affecting these emissions are discussed. Control technologies for 

particulate matter, sulfur dioxide and nitrogen oxides are identified and , 

discussed with respect to the technologies' applicability to industrial 

boilers, developmental status, and factors affecting performance. Emissions 

data for each technology are also presented. Finally, environmental, energy 

and cost impacts of applying these technologies to fossil fuel-fired 

industrial boilers are presented and discussed. This information was 

developed in support of potential new source performance standards for 

industrial boilers. 

KEY WORDS ANO DOCUMENT ANALYSIS 

DESCRIPTORS b.lOENTIFIERS/OPEN ENDED TERMS c. COSATI F'ield/Gioup 

Air pollution 

Pollution control 

•Standards of performance 

Fossil fuel-fired industrial boilers 

Fossil fuel-fired industrial 

bo i1ers 

Air pollution control 

18. D'STaiauT.ON STATEMEN T 

Release unlimited. Available from EPA 

Library (MD-35), Research Triangle Park, 

North Carolina 27711 

j 19. SECURITY CLASS (This Report/ 

unclassified 

21. NO. OF PAGES 

869 

'20. SECURITY CLASS iThit pagei 

unclassified 

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