p. 1


# OAR Box 

# 1870 Prepped byOllie Stewart



## Document

Number: 

# 16 ) ll-A-2 1 Docket Number: 

# A-90-1 9

Printed 11/28/20087:05:04AM Sheet 16 of 67P. 2 

# £EP A Unite d State s ,

Environmenta l Protectio n Agenc y Offic e ofAi rQualit y Plannin g an d Standard s Researc h Triangl e Par k N C 2771 1 

# A-90-1 9

ll-A-2 1 Ai r 

# Fossi l Fue l Fire d
_Draf t Industria l Boilers - EI S Backgroun d Informatio n Volum e 1 : Chapter s 1- 9

'>/ yP. 3



### Thi s repor t

ha s bee nreviewe db y th eEmissio nStandard s an dEngineerin g Divisio n o f th eOffic eof

Ai r Qualit y Plannin g an dStandards , EPA , an dapprove dfo r publication . Mentio no

f trad ename s o r

commercia lproduct s i s no t intende dt o constitut eendorsemen t o r recommendatio nfo r

use . Copie s o

f thi s repor t

ar eavailabl ethroug hth eLibrar y Service s Offic e(MD-35) , U.S . Environmenta lProtectio nAgency , Researc hTriangl e Park , N.C . 27711 , o r

fro mNationa lTechnica lInformatio nServices , 528 5 Por t Roya l Park , i-c.-s/. *.••-- . -; , - . . O

### o*i/, i Road , Springfield , Virgini a2216 1

Fo rsal e bySuperintenden to fDocument s U.S
. Governmen tPrintin g Offic e Washington , D C 2040 2 

# WP. 4



### Thi s repor t

ha s bee nreviewe db y th eEmissio nStandard s an dEngineerin g Divisio n o f th eOffic eof

Ai r Qualit y Plannin g an dStandards , EPA , an dapprove dfo r publication . Mentio nof

trad ename s o r

commercia lproduct s i s no t intende dt o constitut eendorsemen t o r recommendatio nfo r

use . Copie s of

thi s repor t

ar eavailabl ethroug hth eLibrar y Service s Offic e(MD-35) , U.S . Environmenta lProtectio nAgency , Researc hTriangl e Park , N.C . 27711 , o r

fro mNationa lTechnica lInformatio nServices , 528 5 Por t Roya l Road , Springfield , Virgini a22161 .

Fo rsal e b ySuperintenden to fDocument s U.S
. Governmen tPrintin g Offic e Washington , D C 2040 2

### Tabl e 3-4 . INSTALLE D CAPACIT YO F U.S . WATERTUB E INDUSTRIA L BOILER S BYUNI T SIZ E AND FUE L TYPE 1 

### *

(M W therma l Inpu t (10- 5 Btu/hr) )

(J O I Fue l Pulverize d coa l Spreader-stoke rcoa l Underfeed-stoke rcoa l Overfeed-stoke rcoa l
Tota l coa l
Residua l oi l Distillat e oi l
Tota l oi l 0 t o 2. 9 ( 0 t o 10) 0 (0 ) 7 0 (240 ) 680 (2,300 ) 8 5 (290 ) 835 (2,830 ) 3,96 0 (13.500 ) 2,56 0 (8.700 ) 6.52 0 (22.200 ) 2. 9 to 14. 7

(1 0 t o 50 )

0 (0 ) 4.65 0 (15.900 ) 14,10 5 (48,000 ) 3,47 0 (11,800 ) 22,22 5 (75,700 ) 48,19 0 (164,000 ) 8,28 0 (28,200 ) • 56,47 0 (192,200 ) Capacit yb y 14. 7 t o 29. 3 (5 0 t o 100) 0 (0 ) 6,17 5 (21,060 ) 17,26 5 (58,900 ) 4,45 5 (15,200 ) 27.89 5 (95,160 ) 35.64 0 (122,000 ) 4,29 5 (14,600 ) 39,93 5 (136,600 ) uni t siz e

29. 3 t o 73. 3 (10 0 t o 250 ) 19,89 5 (67,800 ) 20,29 5 (69,000 ) 7,08 0 (24,200 ) 3,55 5 (12,100 ) 50,82 5 (173,100 ) 44,79 0 (153,000 ) 6,37 0 (21.700 ) 51,16 0 (174.700 ) >73. 3

(>250 ) 40.18 0 (137.000 ) 11,01 0 (37,600 ) 5,23 0 (17,800 ) 3,51 0 (12,000 ) 59.93 0 (204,400 ) 43,57 0 (148,600 ) 4,08 5 (13,900 ) 47,65 5 (162,500 ) Total s

60,07 5 (204,800 ) 42.20 0 (143.800 ) 44,36 0 (151.200 ) 15,07 5 (51,390 ) 161,71 0 (551,190 ) 176,15 0 (601.100 ) 25.59 0 (87.100 ) 201,74 0 (688,200 ) Natura l ga

s
Tota l al l fuel s 4.47 5 (15.300 ) 11.83 0 (40,330 ) 57,90 0

(197,500 ) 136.59 5 (465,400 ) 53.50 5

(182.800 ) 121.41 5 (414.560 ) 63,32 0

(216,000 ) 165,30 5 (563,800 ) 95,93 5

(327,200 ) 203.52 0 (694.100 ) 275.21 5

(938,800 ) 638.66 5 (2.178.190 )P. 6

TABL E 3-5
. INSTALLE D CAPACIT Y0F Q INDUSTRIA LFIRETUB E BOILER S B YSIZ E AN D FUE LTYPE b 

### [M Wtherma linpu t

(10-5 Btu/hr) ]

Fue l Capacit yb yuni tsiz e 

### 0 t o 2. 9 ( 0 t o 10 ) 2. 9 t o 14. 7

(1 0 t o 50 ) Tota l Coa l Residua l oi l Distillat e oi l Natura l ga

s 

### 5,65 0

(19,270 ) 35,28 0 (120,330 ) 17,77 0 (60,610 ) 59,120 (201,630 ) 7,78 0

(26,530 ) 25,860 ' (88,200 ) 

### 15,77 0 (53,790 ) 52,13 0 (177,790 ) 13,43 0

(45,800 ) 61,14 0 (208,530 ) 33,54 0 (114,400 ) 111,25 0 (379,420 ) Tota l 117,82 0

(401,840 ) 101,54 0

(346,310 ) 219,36 0

(748,150 )



# Jj k 3-1 3P. 7



### TABL E 3-6 . INSTALLE DCAPACIT YO F INDUSTRIAL CAS T IRO N BOILER S BYFUE L TYPE 1 5 

### [M WTherma l Inpu t(IO 6 

### Btu/hr) ]
Fue l Boile rCapacity 3 

### Coa l 6,33 0 (21,590 ) Residua l oi l 10,78 0 (36,770 ) Distillat e oi l 6,74 0 (22,990 ) Natura l ga

s 28,72 0 (97,950 ) Al l cas tiro n boiler s hav e a capacit yles s tha n 4. 0 M Wtherma l inpu t(1 4 xIO 6 

### Btu/hr)
.

3-1 4 

# fcP. 8

o f watertub e and firetub e boiler s and 5 0 percen t o f th e sale s o f cas t iro n unit s ar e replacement s fo r existin g boiler s tha t ar e bein g .retired . Seasona l and time-of-da ychange s i nenerg ydeman d resul t i n exces s capacit ydurin g nonpea k deman d periods . Sectio n3.1. 4 discusse s thes e variation s i ncapacit yutilizatio nb yindustry . Sinc e capacit yutilizatio n varie s widel yi n industry , th e installe d capacit yb yitsel f i s no t an adequat e measur e o f fue l consumption . Thi s informatio n mus t b e obtaine d fro mactua l fue l usag e data . Summarie s o f industria l fue l consumptio n dat a ar e presente d i nth e nex t subsection . 3.1. 4 Fue l Usag e Pattern s Tabl e 3- 7 give s fossi l fue l consumptio n b yth e manufacturin g industrie s i n eac hEP Aregion . Regio nV (includin g Ohio , Michigan , Illinois , and Indiana ) i s a heavyconsume r o f fossi l fuels , usin g nearl y4 0 percen t o f th e nationa l annua l coa l consumptio n b ymanufacturer s and abou t 2 0 percen t o f th e U.S . annua l consumptio no f distillat e oi l and natura l ga s b yth e manufacturin g industries . Regio n V I (includin g Texa s and Louisiana ) consume s 4 0 percen t o f th e natura l gas . I n general , th e larges t en d us e o f eac hfue l i n eac hregio ni s fo r proces s steam , accountin g fo r abou t 1 9 one-thir d o f th e fue l use d b yindustr ynationwide . Us e o f fue l a s feedstoc k account s fo r les s tha none-thir d o f th e manufacturin g fue l use . Industria l proces s heatin g i n furnace s an d spac e heatin g account s fo r mos t 1 9 o f th e remainin g industria l fue l consumption . Tabl e 3- 8 list s th e percen t o f industria l boile r fossi l fue l consump tio n b yindustr yan d fue l typ e fo r 1974 . Th e mos t energ yintensiv e industries—chemical s and paper—accoun t fo r ove r one-thir d o f th e industria l boile r fue l consumption . Th e othe r industrie s liste d (petroleum refining , steel , aluminum , and food ) accoun t fo r muc ho f th e remainin g industria l boile r fue l consumption . Othe r industries , usin g smalle r bu t significan t amount s o f fue l i n boilers , includ e textiles , lumber , rubber , meta l fabrication , and transportation . Tabl e 3- 9 relate s th e shar e o f fue l use d i n thi s countr yb yindustr yt o th e quantitie s use d b yothe r sectors . I n additio n t o manufacturing , th e

3-1 5P. 9

TABL E 3-7 . REGIONA L FOSSI L FUE L CONSUMPTIO NBY TH E MANUFACTURIN G

INDUSTRIE S IN1976 a

[Exajoule s (10 l bBtu) ]

EP A Region 

### I I I 

### III I V 

### V V I 

### VII
VII I 

### I X 

### X

Tota l Residua l

oi l 0.1 9 (0.18 ) 0.2 1 (0.20 ) 0.2 8 (0.27 ) 0.3 8 (0.36 ) 0.2 6 (0.25 ) 0.0 9 (0.085 ) 0.02 3 (0.022 ) 0.02 9 (0.027 ) 0.0 5 (0.047 ) 0.05 1 (0.048 ) 1. 6 (1.5 ) Distillat e

oi l 0.03 3 (0.031 ) 0.07 7 (0.073 ) 0.1 2 (0.11 ) 0.1 4 (0.13 ) 0.1 2 (0.11 ) 0.03 9 (0.037 ) 0.02 6 (0.025 ) 0.009 5 (0.009 ) 0.02 3 (0.022 ) 0.02 3 (0.022 ) 0.6 1 (0.58 ) Coa l

0.007 1 (0.0067 ) 0.2 0 (0.19 ) 1. 2 (1.1 ) 0.4 8 (0.45 ) 1. 4 (1.3 ) 0.07 9 (0.075 ) 0.1 1 (0.1 ) 0.1 0 (0.095 ) 0.08 8 (0.083 ) 0.01 9 (0.018 ) 3. 7 (3.5 ) Natura l

ga s 0.08 1 (0.077 ) 0.1 8 (0.17 ) 0.5 1 (0.48 )

- 0.6 9 (0.65 ) 1. 4 (1.3 ) 2. 7 (2.6 ) 0.3 2 (0.3 ) 0.1 4 (0.13 ) 0.4 8 (0.46 ) 0.1 9 (0.18 ) 6. 7 (6.4 ) Tota l

0.3 1 (0.29 ) 0.6 7 (0.63 ) 2. 1 (2.0 ) 1. 7 (1.6 ) 3. 2 (3.0 ) 2. 9 (2.8 ) 0.4 8 (0.45 ) 0.2 8 (0.26 ) 0.6 4 (0.61 ) 0.2 8 (0.27 ) 1 3 (12 )

a Th e fue l consumptio n dat a includ e us e i n proces s heater s and a s feedstoc k a s wel l a s i n boilers . Referenc e 18 . 

# i 3-1 6P.1 0

Tabl e3-8 . DISTRIBUTIONO FINDUSTRIA

LBOILE RFOSSILFUE

LCONSUMPTIO

N I N197 4 B

YINDUSTR

YAN D FUE LTYPE 20 ' (percent )



### Industr y Chemical s Pape r Stee l and aluminu m Foo d Petroleu m refinin g Othe rmanufacturin g Tota l Coal , % 

### 4.5-5. 6 2.9-3. 6 2.6-3. 3 1.1-1. 3 0.07-0.0 9 3.5-4. 3 15-1 8 Fue l typ e

Oil , % 

### 1.9-2. 4 6-7. 4 0.68-0.8 5 1.3-1. 6 1.2-1. 5 6.1-8. 5 17-2 2 Gas ,

% 

### 14-1 7 4- 5 5.5-6. 8 4.8-5. 9 3.8-4. 8 14-35 46-7 5 Total ,

% 

### 20-2 5 13-1 6 8.8-1 1 7.1-8. 8 5.1-6. 4 24-4 8 10 0



### 3-1 73-18 Consumin g sector * Househol dan

d commercia l Industria l Transportatio

n Electrica l generatio

n
Tota l
Percent TABLE 3-9 .

» Coa l 0.3 1 (0.29 ) 4.4 4 (4.2 ) 0.0 1 (0.01 ) 9.1 5 (8.67 ) 13. 9 (13.2 ) 18. 0 UNITE

DSTATE S PRIMAR

YENERG Y CONSIJMPTIO

h SECTO RAN DENERG YSOURCE , 1974* ' [Exajoule s (10 1 5 Btuf l

Petroleu

m 6.7 5 (6.39 ) 6.3 8 (6.04 ) 18. 6 (17.6 ) 3.6 4 (3.45 ) 35. 4 (33.5 ) 45. 9 Natura l ga s

7.5 1 (7.1 ) 11.7 5 (11.1 ) 0.7 0 (0.66 ) 3.5 1 (3.23 ) 23. 5 (22.2 ) 30. 4

a Exclude s us e o f electrica l energ y b y household , commercial , an dtransportatio

nsector s Include s al l manufacturin g sectors . Nuclear

—

—

— 1.2 4 (1.17 ) 1.2 4 (1.17 ) 

### 1. 6 industria l B

YCONSUMIN

G

Hydropowe r an d geotherma l

—

—

— 3.1 9 (3.02 ) 3.1 9 (3.02 ) 

### 4. 1

• Tota l

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. 0P.1 2

subsections . Followin g thes e tw o subsections , emissio n factor s fo r coal

fire d boiler s ar e presented . ' 3.2.2. 1 Watertub e Boilers . Awatertub e boile r i s on e i n whic hth e ho t combustio ngase s contac t the'outsid e o f th e hea t transfe r tubes , whil e th e boile r wate r and stea mar e containe d withi n th e tubes . Th e tube s ar e interconnecte d to . commo nwate r channel s and t o a stea moutle t o r outlets . Watertub e boiler s ca ngenerat e high-pressure , high-temperatur e steam , up t o 12,00 0 kP a (174 0 psi ) and 81 0 K (1000°F) , and ar e availabl e i n man y size s (se e Tabl e 3-4) . Th e tube s ar e o f relativel ysmal l diameter , 5 c m (2. 0 inch) , providin g rapi d hea t transfer , goo d respons e t o steamdemands , 3 9 and hig hefficiency . Ther e ar e tw o mai n type s o f coal-fire d watertub e boilers : pulverize d coa l and stoker-fired . Industria l siz e pulverize d coa l unit s rang e fro m 29. 3 MWt o ove r 20 0 MW(10 0 t o 70 0 xIO 6 Btu/hr ) hea t input, 1 4 and bur n th e coa l i n suspension . Astoke r i s a conveyin g syste mtha t serve s bot ht o fee d th e coa l int o th e furnac e and t o provid e a grat e upo n whic hth e coa l i s burned . Sinc e fee d rate s b ystoke r unit s ar e limited , stoker s ar e generall y use d o n unit s rate d a t les s tha n 11 7 MW(40 0 xIO 6 Btu/hr ) hea t input. 1 4 Th e thre e mai ntype s o f stoke r furnace s ar e spreader , overfee d o r chain

grate , and underfeed . Pulverize d Coal-Fire d I n pulverize d coal-fire d boiler s th e fue l i s pulverize d t o th e consistenc yo f ligh t powde r and pneumaticall yinjecte d throug hth e burner s int o th e furnace . Combustio n begin s a t th e burner s and continue s int o th e furnac e volume . Wet-botto mfurnace s ar e designe d t o operat e a t hig h temperature s and therefor e kee p th e as hi n th e molte n stat e unti l i t collect s i nth e botto mas hhopper . Dry-botto m furnaces , o nth e othe r hand , operat e a t lowe r combustio ntemperatures ; consequently , th e botto mas h remain s i n th e soli d state . Wet-botto munit s ar e no t expecte d t o b e 4 0 manufacture d and sol d i nth e future . Figur e 3- 3 illustrate s a typica l 58. 6 MW(20 0 x1 0 Btu/hr ) hea t input , dry-botto m pulverize d coa l uni t wit h th e correspondin g mas s and energ ybalances . Thirt ypercent-exces s ai r and a

3-2 7P.1 3

TECHNICA L REPOR TDAT A (Please read

Instructions on the reverse before completing) 1 . REPOR TNO . : I EP A450/3-82-006a, b 3 . RECIPIENT' S ACCESSIO N NO . 4 . TITLE . AN D SUBTITL E Fossi l Fuel-Fire d Industria l Boiler s Backgroun d Informatio n 5 . REPOR TDAT E Marc h 198 2 6 . PERFORMIN G ORGANIZATIO N COD E
7 . AuTriORlS ) I . PERFORMIN G ORGANIZATIO N REPOR TNO .
9 . PERFORMIN G ORGANIZATIO N NAM E AN O ADDRES S Offic e o f Ai r Qualit yPlannin g an d Standard s U . S . Environmenta l Protectio nAgenc y Researc hTriangl e Park , Nort hCarolin a 2771 1 10 . PROGRA M ELEMEN TNO . 11 . CONTRACT/GRAN TNO . 68-02-305 8 12 . SPONSORIN G AGENC YNAM E AN O ADDRES S DA Afo r Ai r Qualit yPlannin g an d Standard s Offic e o f Air , Noise , an d Radiatio n U . S . Environmenta l Protectio nAgenc y Researc hTriangl e Park , Nort hCarolin a 2771 1 13 . TYP E O F REPOR TAN O PERIO O COVERE D 14 . SPONSORIN G AGENC YCOD E EPA/200/0 4 15 . SUPPLEMENTAR YNOTE S

16 . ABSTRAC T Thi s documen t provide s backgroun d informatio nfo r th e fossi l fuel-fire d

industria l boile r sourc e category . Fossi l fuel s considere d includ e coal , oi l an d natura l gas . Backgroun d informatio nfo r industria l boiler s include s a surve yo f boile r types , sizes , operatin g characteristics , an d existin g Stat e an d Federa l regulations . Uncontrolle d emission s o f particulat e natter , sulfu r dioxid e an d nitroge n'oxide s ar e quantifie d an d factor s affectin g thes e emission s ar e discussed . Contro l technologie s fo r particulat e matter , sulfu r dioxid e an d nitroge noxide s ar e identifie d and , discusse d wit hrespec t t o th e technologies ' applicabilit yt o industria l boilers , developmenta l status , an d factor s affectin g performance . Emission s dat a fo r eac htechnolog yar e als o presented . Finally , environmental , energ y and cos t impact s o f applyin g thes e technologie s t o fossi l fuel-fire d industria l boiler s ar e presente d an d discussed . Thi s informatio nwa s develope d i n suppor t o f potentia l ne wsourc e performanc e standard s fo r industria l boilers .

KE YWORD S AN O DOCUMEN TANALYSI S

DESCRIPTOR S b.lOENTIFIERS/OPE N ENDE D TERM S c. COSAT I F'ield/Giou p Ai rpollutio n Pollutio n contro l •Standard s o fperformanc e Fossi l fuel-fire d industria l boiler s Fossi l fuel-fire d industria l bo i1er s Ai rpollutio n contro l

18 . D'STaiauT.O N STATEMEN T Releas e unlimited . Availabl e fro mEP A Librar y(MD-35) , Researc hTriangl e Park , Nort hCarolin a 2771 1 j 19 . SECURIT YCLAS S (This Report/ unclassifie d 21 . NO . O F PAGE S 86 9 '20 . SECURIT YCLAS S iThit pagei unclassifie d 122 . PRIC E 5? AForm i:20. 1 (R-,, . 4_77 ) •*•->€ viOu S SC'T'O N i s OSSOL t T E