United States Office of Air Quality EPA-450/3-87-006
Environmental Protection Planning and Standards April 1987
Agency Research Triangle Park NC 27711
Air
Survey of New
Industrial Boiler
Projects —
1981-1984
-------
EPA-450/3-87-006
Survey of New
Industrial Boiler Projects —
1981 - 1984
Emission Standards and Engineering Division
U.S. Environmental Protection Agency
Office of Air and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park NC 27711
April 1987
-------
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 NC 27711, or from National Technical
Information Services, 5285 Port Royal Road, Springfield VA 22161.
-------
TABLE OF CONTENTS
Page
Section
LIST OF TABLES 1V
EXECUTIVE SUMMARY V
1
1.0 INTRODUCTION ...............................................
l
2.0 COLLECTION OF DATA
Description of the Survey Form
Development of the Mailing List
Data Management Procedures
Description of All Projectsjurveyed 3
3.0 DESCRIPTION OF NEW BOILER PROJECTS .......................... 3
Description of All Projects Surv
Representativeness of Data Base.
4.0 ANALYSIS OF NEW BOILER PROJECTS ............................. 7
Primary Reasons for New Boiler Projects ..................... 7
Factors Affecting Boiler Decisions .......................... JJ
Cost Sensitivity of Projects ................................ }«
Existing Boiler Data and Status Changes ..................... i&
5.0 SULFUR DIOXIDE EMISSIONS FROM CATEGORY I BOILER PROJECTS.... 18
Emission Rate
Total Annual Emissions
6.0
IMPACT OF LOWER ENERGY PRICES 24
APPENDIX 1: BOILER REPLACEMENT SURVEY QUESTIONNAIRE
APPENDIX 2: EMISSION CALCULATION PROCEDURES
m
-------
LIST OF TABLES
Table Page
1 Description of All New Boilers Covered by Survey 4
2 Description of New Boiler Projects >100 MMBtu/hr and Using
Coal, Oil, Natural Gas, or Wood as Primary Fuel 6
3 Primary Reason for Project (All Projects) 8
4 Primary Reason for Project (Category I Projects) 9
5 Factors Affecting Decisions for Category I Projects 13
6 Percent of Projects That Would Have Proceeded as Designed
If Cost Increased 14
7 Existing Boiler Information for Category I Projects 16
8 Changes in Status of Existing Boilers (Category I
Projects) 17
9 S0? Emission Rates From New and Existing Boilers
(Category I Projects) 19
10 Annual S0« Emission Impact (Category I Projects) 21
IV
-------
EXECUTIVE SUMMARY
This report presents an analysis of data collected through a written
survey of firms purchasing new industrial boilers between 1981 and 1984.
The purpose of the survey was to collect data which could be used to assess
the reasons for new industrial boiler purchases, the percentage of these
boilers which are used for new applications versus replacement of existing
boilers, and the impact of new boiler purchases on S02 emissions.
A total of 168 surveys covering 229 new industrial boilers with 47,750
million Btu/hour heat input capacity were collected and entered into a
computerized data base. Of these, 151 units were equal to or larger than
100 million Btu/hour and designed to fire coal, oil, natural gas, or wood as
the primary fuel; aggregate heat input capacity of these boilers was 38,657
million Btu/hour. Most of the analysis in the report is based on these 151
units. Comparison with boiler sales data gathered by the American Boiler
Manufacturers Association (ABMA) suggests that these units represent greater
than 95 percent of the industrial boilers in this category sold between 1981
and 1984.
Analysis of the data identified five primary reasons for installation
of new boilers: 1) desire to use fuels other than those currently used by
existing boilers (34 percent of the total), 2) need for additional boiler
capacity at an existing plant (22 percent), 3) poor condition qf an existing
boiler (16 percent), 4) need for steam at a new plant (14 percent), and 5)
desire to cogenerate electricity (14 percent). Factors affecting the design
of the new boiler and the cost sensitivity of the boiler purchase decision
were evaluated as a function of these five reasons. Less than 10 percent of
the purchasers indicated they would have changed the project if costs had
increased by 10 percent; if costs increased by 30 percent roughly one-half
of the boiler projects would have been changed. Boilers installed for the
primary purpose of fuel switching and cogeneration were the most cost
sensitive, while boilers installed due to poor condition of the existing
boiler were the least sensitive.
-------
Data on 291 existing boilers that were in some way affected by
installation of the new boilers were also examined. These boilers tend to
be much smaller in size and fire relatively greater amounts of oil and
natural gas than the new boilers. Roughly 50 percent of the existing
boilers were shutdown or dismantled as part of the new boiler project while
the remaining 50 percent continued operating, generally at reduced load. Of
the 50 percent reported as shutdown or dismantled, the boiler owners
indicated that about one-third could have been rebuilt to extend their
useful life.
The above five reasons were also used to classify boilers as
replacement versus new application and as mandatory versus discretionary
purchases. Based on this analysis, the number of replacement and new
application boilers are almost equal (50 percent each) while discretionary
purchases account for roughly 60 percent of sales versus 40 percent for
mandatory purchases.
Analysis of S02 emissions found that although the new coal- and
oil-fired boilers have average emission rates that are 40 to 50 percent
lower than the existing boilers firing the same fuel, the average emission
rate for all boilers remained virtually unchanged because of changes in the
mix of fuels fired, specifically increased use of coal and decreased use of
natural gas. This fact combined with the overall increase in total boiler
capacity results in an increase in total annual S02 emissions of roughly 70
percent compared to baseline emissions before the new boilers were
installed. This increase results from 1) installation of new boilers that
are not replacing existing boilers, 2) replacement of existing boilers with
new boilers that are significantly larger, 3) fuel switches from natural gas
and oil to coal, and 4) continued operation of the existing boilers,
although at reduced load.
Of the total annual SO- emissions occurring after installation of all
the new boilers (i.e., replacement and new installations), roughly one-
fourth were emitted by existing boilers that remained in operation after
installation of the new boilers. Of the emissions increase, roughly
one-half came from projects where the new boiler was installed as a
replacement, with the other half coming from new applications. If only
vi
-------
those boilers defined as mandatory (i.e., driven by factors largely
independent of boiler cost) were installed, emissions would have increased
by roughly 20 percent.
Based on current fuel prices, the number of coal-fired boiler purchases
associated with fuel switching is expected to be lower in the future than in
the 1981-84 time period. To evaluate the impact of lower oil and natural
gas prices on potential S02 emissions, data from projects installed for
reasons other than fuel switching projects were tabulated. Significantly,
when fuel switching is exluded from the analysis, the percentage of new
boilers installed as replacements for existing boilers decreases from
roughly one-half (as discussed above) to about one-fourth and the increase
in emissions declines from about 70 percent to about 40 percent. If current
low fuel prices were to also discourage construction of cogeneration boilers
(also found to be sensitive to project economics) as well as fuel switching
boilers, replacement boilers would represent roughly one-third of new boiler
installations; total S02 emissions would be about 20 percent higher than
from the existing boilers alone.
In summary, under all of the situations examined, the survey data
indicates that total emissions of S02 are higher after installation of new
boilers than they were previously. Major reasons for this are 1) instal-
lation of new boilers to satisfy increased steam demands at new and existing
plants, 2) changes in the relative use of coal versus natural gas, and 3)
continued operation of many existing boilers (although at reduced loads)
after the new boilers are installed. Because of this increased steam demand
(and associated energy use), total annual S02 emission increase despite the
fact that new coal- and oil-fired boilers have lower average emission rates
per million Btu of fuel fired than did the existing boilers.
vn
-------
-------
SURVEY OF NEW INDUSTRIAL BOILER PROJECTS
1981-1984
1.0 INTRODUCTION
This report presents the analysis of data collected through a written
survey of firms purchasing new industrial boilers between 1981 and 1984.
The purpose of the survey was to collect data which could be used to assess
the reasons for new industrial boiler purchases, the percentage of these
boilers which are used for new applications versus replacement of existing
boilers, and the impact of new boiler purchases on S02 emissions.
Section 2 of the report reviews the data collection and management
procedures. Section 3 summarizes general statistics on the boilers
surveyed; this information includes boiler size, fuel use, fabrication
methods, and methods of S02 control. A comparison of the surveyed boilers
relative to boiler sales data gathered by the American Boiler Manufacturers
Association (ABMA) for the same time period is also presented. Section 4
presents an analysis of why these new boilers were built, factors
influencing boiler decisionmaking, the sensitivity of the boiler purchase to
increased costs, and the impact of the new boiler on existing boilers at the
same site. Section 5 evaluates changes in S02 emission rates and total
annual emissions resulting from the overall new boiler project, including
operational changes in existing boilers already at the site. Section 6
examines possible impacts on the survey's findings resulting 'from current
energy prices which are lower than those during the 1981-84 time period.
2.0 COLLECTION OF DATA
Information on boiler replacements was collected using a written survey
form sent to recent purchasers of industrial boilers. The following three
sections describe the survey form used to obtain data, the development of a
mailing list of recent boiler purchasers, and data management procedures
used to handle the survey forms after they were completed.
-------
Description of the Survey Form
A survey form (Appendix 1) was developed to collect data on each new
boiler project; a project can consist of one or more new boilers. The
survey form is divided into four major sections:
o Part I, containing general information on the boiler purchaser;
o Part II, describing the reason(s) for undertaking the new boiler
project;
o Supplement A, providing detailed information on each new boiler
installed as part of the overall project; and,
o Supplement B, providing detailed information on each existing
boiler located at the site of the new boiler project (or an
adjacent site in the case of several "third-party" cogenerators)
which was affected in some way by installation, of the new
boiler(s).
Parts I and II were completed for the entire project, while separate Supple-
ments A and B were completed for each individual boiler included in the
project.
Development of the Mailing List
Information on new boiler orders was obtained from two data listings
collected by the U. S. Department of Energy (DOE): Form ERA-97 (Boiler
Manufacturers Report) and Form EIA-97 (Boiler Order Report). These two
reports contain essentially the same information; EIA-97 is the more recent
of the two and has superseded ERA-97.
These forms are used by DOE to collect quarterly data from U. S. bo'iler
manufacturers, their foreign affiliates and subsidiaries, and U. S. boiler
rental companies on orders received from electric utilities and industrial
firms operating in the U.S. (including territories and administered areas).
Information is required to be submitted for all boilers having a rated
capacity of 40,000 or more pounds of steam per hour (approximately
50 million Btu/hr heat input capacity) and includes: boiler function, rated
capacity, fuels burned, date ordered, date delivered, and the name and
address of the purchasing/operating company.
A list of the name, address, and telephone number of companies ordering
boilers rated at 80,000 pounds of steam and larger between January 1982 and
-------
September 1984 was obtained from the Form EIA-97 database. Similar
information was obtained from Form ERA-97 for boilers ordered between
January 1977 and March 1982. Both data sets were presorted to eliminate
non-industrial purchasers (e.g., electric utilities and institutional users
such as hospitals and universities) and waste heat boilers. For use in the
survey, the database was further sorted to eliminate boilers ordered prior
to January 1981.
As an additional check, the boiler inventory was screened to eliminate
boilers sold to rental companies, which would not be permanently installed
at a site. Information on the remaining boilers was confirmed through
•telephone calls to each purchaser listed. This was done to verify
installation of the boiler and to obtain a correct name and address for
survey mail out purposes. Survey forms were then sent to 185 companies.
Data Management Procedures
Responses were received from all 185 companies receiving the survey
form. Several of the respondents did not complete the survey, indicating
that the boiler was ordered prior to 1981, had been cancelled, or was below
the 100 million Btu per hour threshold established for the survey. Data
from the remaining 168 survey forms were entered into a computerized data
base, and then manually reviewed for missing data and keypunch errors to
eliminate possible problems in subsequent analysis. Statistical analyses of
the data were conducting using MICRO-SAS software developed by SAS, Inc.
(located in Gary, NC).
3.0 DESCRIPTION OF NEW BOILER PROJECTS
Description of All Pro.iects Surveyed
A total of 168 surveys were entered into the data base, covering 229
boilers with a total heat input capacity of 47,750 million Btu/hour
(assuming 1,176 Btu of fuel fired per pound of steam generated). Summary
statistics for the new boilers included in these projects are provided in
Table 1. Note that 7 percent of the total capacity and 23 percent of the
number of boilers surveyed are less than 100 million Btu/hour. Coal-fired
-------
TABLE 1. DESCRIPTION OF ALL NEW BOILERS COVERED BY SURVEY
Total Number of Projects:
Total Number of New Boilers:
Total New Boiler Capacity (MMBtu/hr
Average Size of New Boiler (MMBtu/hr
Frequency Distribution (Percentage)
heat input):
heat input):
by:
-- Capacity (MMBtu/hr): Capacity 1%} No.
<100
100-150
150-200
200-250
250-400
400-600
>600
Primary Fuel:
Coal
Oil
Natural Gas
Wood
Other
Fabrication Method:
Package
Field
Number of Boilers Per Project:
1
2
3
4
5
-- Method of S02 Control:
Low-Sulfur Fuel
Flue Gas Desulfurization
Fluidized Bed Combustion
No Response
7.0
12.7
12.4
5.8
13.8
21.0
27.3
42.6
2.0
23.4
16.6
15.2
--
--
--
--
--
--
--
--
--
--
- --
47
Units
23.1
25.3
17.0
6.6
10.0
10.9
7.0
•
39.0
3.9
29.8
13.6
13.6
36.8
63.2
76.2
16.7
2.4
4.2
0.6
74.2
1.7
13.5
10.5
168
229
,750
209
(%)
-------
boilers predominate (accounting for 43 percent of the capacity and 39
percent of the units). These were followed in decending order by natural
gas, wood, other (consisting primarily of byproduct fuels such as black
liquor and refinery off-gas), and oil. Almost 90 percent of the respondents
indicated they practiced some form of S02 control, primarily use of
low-sulfur fuels (74 percent of the boilers) followed by fluidized bed
combustion (14 percent).
A subset of the data base was constructed containing only those
projects (hereafter referred to as Category I projects) that included one or
more new boilers equal to or greater than 100 million Btu/hour heat input
capacity (85,000 pounds of steam/hour) and that burned coal, oil, natural
gas, or wood as the primary fuel. The Category I data base is summarized in
Table 2. It includes 158 new boilers with a total capacity of 38,657
million Btu/hour. Of these 158 boilers, 151 meet the above size and primary
fuel criteria. The remaining seven boilers were installed as part of
projects involving one or more of these 151 units, but are smaller than 100
million Btu/hour or fire byproduct fuels. Units greater than 250 million
Btu/hour account for 64 percent of the capacity and 34 percent of the new
boilers by number. Fuel use is generally similar to the larger data base,
but contains a somewhat larger percentage of coal and wood-fired units.
Sulfur dioxide control statistics are also similar to the larger data base.
Representativeness of Data Base
The survey was designed to gather information on new industrial boilers
sold between 1981 and 1984. To evaluate the completeness of the survey, the
Category I data base (excluding the seven new boilers smaller than 100
million Btu/hr capacity) was compared to boiler sales data compiled by the
American Boiler Manufacturers Association (ABMA) for the corresponding time
period (January 1981-September 1984). The ABMA data were adjusted to
exclude electric utility auxilliary boilers and rental boilers (estimated at
20 and 15 boilers, respectively, based on information provided by ABMA) to
provide a common basis for comparison.
The adjusted ABMA sales data includes a total of 156 boilers: 79
coal-fired, 50 oil- and gas-fired, and 27 wood-fired. The Category I
boilers for the same fuels total 151: 76 coal-fired, 49 oil- and gas-fired,
-------
TABLE 2. DESCRIPTION OF NEW BOILER PROJECTS >100 MMBTU/HR AND
USING COAL, OIL, NATURAL GAS, OR WOOD AS PRIMARY FUEL
Total Number of Projects: 115
Total Number of New Boilers: 158
Total New Boiler Capacity' (MMBtu/hr heat input): 38,657
Average Size of New Boiler (MMBtu/hr heat input): 245
Frequency Distribution (Percentage) by:
Capacity (MMBtu/hr): Capacity (%) No. Units (%}
<100 0.6 1.9
100-150 12.9 30.4
150-200 15.4 24.7
200-250 7.2 9.5
250-400 14.0 12.0
400-600 21.5 12.6
>600 28.5 8.9
Primary Fuel:
Coal 49.2 48.1
Oil 2.3 5.1
Natural Gas 24.6 27.2
Wood 19.9 16.5
Other 3.9 3.2
Fabrication Method:
Package -- 25.3
Field - 74.7
Number of Boilers Per Project:
1 - 76.5
2 -- 15.7
3 - 2.6
4 - 4.3
5 -- 0.9
Method of S02 Control:
Low-Sulfur Fuel -- 72.2
Flue Gas Desulfurization -- 1-9
Fluidized Bed Combustion -- 15.8
No Response -- 10-1
-------
and 26 wood-fired. Based on these almost identical numbers, results derived
from the survey data are expected to closely reflect the total population of
industrial boilers sold between 1981 and 1984.
4.0 ANALYSIS OF NEW BOILER PROJECTS
Primary Reasons for New Boiler Pro.iects
One of the principal questions in the survey dealt with why the boiler
was purchased. This question was asked both as an "essay" question
(Question II-6) and by asking respondents to rank a list of factors on a
scale of 0 (unimportant), 1 (somewhat important), and 2 (very important)
(Question II-9). Based on review of the responses to these two questions,
five primary reasons were identified that accounted for all of the projects
surveyed:
o desire to change base fuel;
o need for additional boiler capacity at an existing plant;
o condition of the existing boiler;
o need for steam at a new plant site; and
o desire to cogenerate electricity.
Each of these primary reasons is briefly described below. Tables 3 and 4
present the percent of boilers falling into each primary reason category for
the entire data base and Category I boilers, respectively.
Fuel Switching--
Given relative fuel prices and availability during the time period
covered by the survey, many boiler owners were faced with the decision to
continue operation with a fuel considered to be expensive and unreliable
(e.g., oil) or convert to a fuel considered cheaper and more secure (e.g.,
coal). As shown in Tables 3 and 4, respectively, the survey respondents
indicated 28 percent of all projects and 34 percent of the Category I
projects were for the primary reason of fuel switching--the most frequent
response given for any of the above reasons.
-------
TABLE 3. PRIMARY REASON FOR PROJECT (ALL PROJECTS)
1. Fuel Switch
2. Additional Capacity Needed
Number
of Projects
47
43
Percent
of Total
28.0
25.6
- Primary (36)
- Backup (7)
Boiler Condition 34 20.2
- Unreliable (29)
- Unsafe (2)
- Unable to Comply with Air Regs (3)
4. New Plant
5. Cogeneration
REPLACEMENT (Fuel Switch, Boiler Condition)
NEW APPLICATION (Additional Capacity,
New Plant, Cogeneration)
DISCRETIONARY (Fuel Switch, Backup Capacity,
Repairable Boiler Condition, Cogeneration)
MANDATORY (Primary Capacity, Unrepairable
Boiler Condition, New Plant)
25
19
168
81
87
168
86
82
168
14.9
11.3
TooTo
48.2
51.8
ToO
51.2
48.8
TooTo
-------
TABLE 4. PRIMARY REASON FOR PROJECT (CATEGORY I PROJECTS)
Number
of Projects
1. Fuel Switch 39
?. Additional Caoacitv Needed 25
Percent
of Total
33.9
21.7
- Primary (19)
- Backup (6)
3. Boiler Condition 19 16.5
- Unreliable (16)
- Unsafe (2)
- Unable to Comply with Air Regs (1)
4. New Plant
5. Cogeneration
REPLACEMENT (Fuel Switch, Boiler Condition)
NEW APPLICATION (Additional Capacity,
New Plant, Cogeneration)
DISCRETIONARY (Fuel Switch, Backup Capacity,
Repairable Boiler Condition, Cogeneration)
MANDATORY (Primary Capacity, Unrepairable
Boiler Condition, New Plant)
16
16
Us
58
57
Tl5
67
48
Tl5
13.9
13.9
ToO
50.4
49.6
ToO
58.3
41.7
TooTo
-------
Additional Capacity--
The need for additional boiler capacity—either to meet increased steam
demand at an existing industrial plant (defined as primary capacity in
Tables 3 and 4) or to increase the flexibility/reliability of steam
generation at the plant (defined as backup capacity)--was the second most
frequent reason for installing new boilers.
Boiler Condition--
Replacement of existing boilers due to their condition was the third
most frequent reason given for new boiler projects. This category includes
projects in which the existing boiler was unreliable (e.g., high percentage
of downtime, high O&M costs), unsafe (e.g., unable to pass a safety
inspection), or unable to comply with existing environmental regulations.
This category was further subdivided into six projects in which the boiler
owner said the existing boiler could have been repaired or rebuilt (but was
replaced with a new boiler anyway) and thirteen projects in which the boiler
owner stated repair or rebuild was not economically feasible (Question
B-10).
New PI ant--
The fourth most frequent reason for installation of new boilers was
steam demand at new manufacturing plants where a boiler did not previously
exist.
Cogeneration--
Partially as a result of economic incentives provided under the Public
Utility Regulatory Policy Act (PURPA), the desire to cogenerate both
electricity and process steam was the fifth most frequent reason given for
constructing new boiler projects.
Boilers installed for these five reasons were then combined and
redivided according to two alternative groupings: first, whether the new
boiler replaced an existing boiler or was a new application and second,
10
-------
whether installation of the boiler was discretionary (i.e., decision was
based on the economics of a new versus existing boiler) or mandatory (i.e.,
required by factors other than boiler economics). The first of these
alternative groupings was made based on the following interpretation of the
primary reason for each project:
o Replacement--.fuel switching and boiler condition,
o New application—additional capacity, new plant, and cogeneration.
The second of these alternative groupings was based on the following
interpretation of the primary reason:
o Discretionary--fuel switching, backup capacity, repairable boiler
condition, and cogeneration,
o Mandatory—primary capacity, unrepairable boiler condition, and
new plant.
As shown in Table 3, of all the projects surveyed, replacement projects and
new application projects were roughly equal in number (48 percent versus 52
percent). A similar split also occurred between discretionary versus
mandatory projects (51 percent versus 49 percent). For the Category I
projects (see Table 4), the split between replacement versus new application
remained roughly equal (50.4 percent versus 49.6 percent) while the
frequency of discretionary projects increased to 58 percent versus 42
percent for mandatory projects.
Factors Affecting Boiler Decisions
Information was also provided by the survey respondents on the factors
affecting the design of the new boiler project (Question 11-10). This
information was provided by ranking the listed factors as either 0, 1, or 2
(using the same definitions discussed above). The individual responses on
each factor were then averaged for the projects within each of the five
NOTE: In a few cases, existing boilers were affected by cogeneration, but
in most cases were not. In all cases, however, a primary factor in the
project design was the production of electricity, rather than simply
replacement of existing boilers.
11
-------
primary reasons discussed above. The results of this analysis are presented
in Table 5.
Capital cost and fuel cost were among the three highest rated factors
for each of the primary reason categories except boiler condition. Compa-
tibility with existing fuel handling facilities was the primary factor
affecting the design of projects undertaken due to poor condition of the
existing boiler (this factor was also important—scoring fourth—for
additional capacity projects). Frequently mentioned as unimportant were
corporate policy and environmental regulations.
Cost Sensitivity of Pro.iects
To estimate the economic sensitivity of projects to changes in project
cost, the respondents were asked whether their decision to build the project
would have changed if the projected cost of steam increased by 10, 20, 30,
or 50 percent (Question II-8). The data in Table 6 indicate the percentage
of industrial boiler projects that would continue as designed even if the
costs were increased by these percentages.
In general, most projects were insensitive to a 10 percent increase in
cost (only 7 out of 89 projects--8 percent--would have changed their
decision). If costs increased by 20 to 30 percent, an increasing number of
projects would have changed; roughly one-half of the projects would have
been altered if project costs increased by 30 percent. However, additional
increases in cost up to 50 percent resulted in few additional changes.
The two most cost sensitive project groups were those undertaken
primary to fuel switch (60 percent would have changed their decision if
costs increased by 30 percent) and cogeneration (64 percent). The least
cost sensitive were those undertaken primarily because of the condition of
the existing boiler (35 percent). These results tend to support the view
that fuel switching and cogeneration are highly discretionary, and are
therefore most sensitive to cost increases. On the other hand, boiler
projects tied to the existing boiler condition or need for additional
NOTE: The low rating of corporate policy may have reflected the lack of
corporate policies related to boiler purchase decisions, rather than the
unimportance of policies which did exist.
12
-------
TABLE 5. FACTORS AFFECTING BOILER DECISIONS FOR CATEGORY I PROJECTS
Reason
Top Three Factors
Bottom Three Factors
New Plant
Fuel Costs
Fuel Security/Reliability
Capital Costs
Existing System Components
Compatibility w/Existing
Fuels
Space/Land Available
Additional
Capacity
Fuel Costs
Operating Flexibility
Capital Costs
Interest Rates
Corporate Policy
Space/Land Available
Boiler
Condition
Compatibility w/Existing
Fuels
Maintenance Costs
Boiler Efficiency
Corporate Policy
Interest Rates
Environmental Regulations
Fuel Switch
Capital Costs
Fuel Costs
Corporate Funds
Availability
Corporate Policy
Environmental Regulations
Existing System Components
Cogeneration
Capital Costs
Fuel Costs
Boiler Efficiency
Corporate Policy
Environmental Regulations
Minimize Personnel
NOTE: The low rating of corporate policy may have reflected the lack of
corporate policies related to boiler purchase decisions, rather than the
unimportance of policies which did exist.
13
-------
TABLE 6. PERCENT OF PROJECTS THAT WOULD HAVE PROCEEDED AS
DESIGNED IF COST INCREASED
Primary
Reason
New Plant
Additional
Capacity
Number of
Projects
(100%)
12
19
Percent of Projects Proceeding
If Costs Increased Bv
10%
92
100
20%
67
79
30%
42
53
50%
42
47
Boiler 17 94 71 65 65
Condition
Fuel Switch 30 90 77 40 30
Cogeneration 11 82 64 36 36
TOTAL 89* 92 73 47 43
*26 of the 115 respondents did not answer this question.
14
-------
capacity are undertaken for mandatory reasons, and as a result were the
least sensitive to cost increases. These results are consistent with the
results presented previously in Table 5.
Existing Boiler Data and Status Changes
A total of 115 projects make up the Category I data base. These
projects include 158 new boilers and 291 existing boilers that were in place
and affected in some way by the new boiler. Data on these existing boilers
are presented in Table 7. These data include existing boilers affected by
"third-party" cogenerators who sold steam to an existing plant.
Although most of the existing boilers (53 percent) covered by the
survey are over 100 million Btu per hour, their average size is signifi-
cantly smaller than the new boilers--109 million Btu/hour for the existing
boilers versus 245 million Btu/hour for the new Category I boilers. Also, a
much greater percentage of the existing boilers fire oil and natural gas.
Oil-fired boilers make up only 5 percent of the new boilers, but comprise 24
percent of the existing boilers. Natural gas was used in 27 percent of the
new boilers and 56 percent of the existing boilers. Correspondingly, coal-
fired boilers comprise only 10 percent of the existing boilers compared to
48 percent of the new boilers.
Of the existing plants installing new boilers, 86 percent had existing
boilers which were in some way affected by installation of a new boiler.
Table 8 presents data on how and why the status of the existing boilers
changed as a result of the new boiler installation. The summation of
individual percentages to more than 100 percent reflects respondents
checking more than one answer. Almost 50 percent of the existing boilers
that were affected were either shut down without being dismantled (20
percent) or were dismantled (29 percent). The remaining 50 percent
continued operating after installation of the new boiler, but generally for
fewer hours or at lower load than before.
The major reason given for changes in the status of existing boilers
was the need to reduce fuel costs associated with the operation of the
existing boiler (63 percent). Thirteen percent of the existing boilers had
their status changed due to high operating and maintenance costs. Excess
15
-------
TABLE 7. EXISTING BOILER INFORMATION FOR CATEGORY I PROJECTS
Total Number of Projects: 79
Total Number of Existing Boilers: 291
Total Existing Boiler Capacity (MMBtu/hr heat input): 31,617
Average Size of Existing Boiler (MMBtu/hr heat input): 109
Frequency Distribution (Percentage) by:
Capacity (%)
17.8
22.
18.
15,
Capacity (MMBtu/hr):
<100
100-150 22.3
150-200 18.7
200-250 15.9
250-400 12.0
400-600 8.0
>600 5.3
Fuel type:
Coal 13.1
Oil 28.5
Natural Gas 42.9
Wood 7.4
Other 8.0
Fabrication Method:
Package
Field
Number of existing boilers per project:
Number of Boilers
Per Pro.iect
1
2
3
4
5-10
Fred
10
23
21
14
8
3
No. Units (%}
J
.7
.7
46
22
13
8.9
4.8
2.1
1.0
9.6
23.7
56.0
6.5
4.1
40.2
59.8
Percent
12.7
29.1
.6
.7
26.
17.
10.0
3.8
Percent of existing plant projects that involved changes in one
or more existing boilers: 86.0
16
-------
TABLE 8. CHANGES IN STATUS OF EXISTING BOILERS (CATEGORY I PROJECTS)
How did status change (for boilers that did change)
% Yes*
Shutdown (w/o dismantling) 19.6
Dismantled 29.2
Used as backup/peaking
boiler 43.0
Reduced hours of operation 3.1
Switched fuels 1.0
Other 8.2
Why. did status change (for boilers that did change)
% Yes*
High fuel costs 62.5
High O&M Costs 13.0
Excess boiler capacity 12.4
Mechanical problems 7.9
Obsolete (age, operating
pressure, size, poor
reliability) 6.5
Environmental restrictions 5.2
Inadequate space 2.4
Other 1.7
For those boilers that were shutdown/dismantled percent
that could have had useful life extended:
34.7
*
% by number of units.
17
-------
boiler capacity after installation of the new boiler was the reason for 12
percent of the changes. Environmental restrictions, primarily related to
S02 emissions, accounted for another 5 percent. Other individual responses
accounted for less than 10 percent of the changes.
In order to gain some insight as to the options available to the boiler
owner/operator, a question (Question B-ll) was posed as to whether those
boilers that were shut down or dismantled could have had their useful life
extended. According to the survey respondents, only about one-third
(35 percent) of the existing boilers that were shut down or dismantled could
have been economically repaired or rebuilt to extend their useful life.
5.0 SULFUR DIOXIDE EMISSIONS FROM CATEGORY I BOILER PROJECTS
Sulfur dioxide emissions- from both the new and existing boilers
involved in each project were estimated on a "before project" and "after
project" basis. Emission estimates are presented in two ways: pounds per
million Btu of heat input and total annual emissions (i.e., tons/year).
Calculation of annual emissions from each boiler is based on the quantity
and sulfur content of both the base fuel and backup fuel.
Emission Rate
Table 9 summarizes sulfur dioxide emission rate data for the existing
and new Category I boilers firing coal, oil, and all fuels (whether firing
coal, oil, natural gas, or wood) as a base fuel. Average emission rates for
the existing coal-fired boilers after completion of the new boiler projects
were lower than they were before the projects: 2.49 compared to 2.89 Ibs
SO-/MMBtu. Whether this decrease resulted from shutting down existing
boilers with high emission rates or changing the quality of the coal used in
the existing boilers was not examined. New coal-fired boiler emission rates
averaged 1.47 Ibs S02/MMBtu, significantly lower than the average emission
rate for the existing boilers. Of these new boilers, 67 percent have an
emission rate equal to 1.2 Ibs S02/MMBtu or less (this rate equals the
federally regulated limit [40 C.F.R. Part 60, Subpart D] then in effect for
SO- emissions from coal-fired industrial boilers >250 million Btu/hour).
Another 26 percent have an emission rate of 1.3-2.4 Ibs S02/MMBtu. The
18
-------
TABLE 9. SO- EMISSION RATES FROM NEW AND EXISTING BOILERS
2 (CATEGORY I PROJECTS)
Number of Average Emission Rate
Boilers f#SQ2/MMBtu)
Coal-Fired Boilers
Existing Boilers
--- Before the Project 28 2.89
--- After the Project 16 2.49
New Boilers 76 1.47
Oil-Fired Boilers
Existing Boilers
--- Before the Project 73 1.99
--- After the Project 37 1.92
-- New Boilers 7 1.14
All Boilers (Coal, Oil, Natural Gas, and Wood)
Existing Boilers
--- Before the Project 279 0.81
--- After the Project 141 0.79
-- New Boilers 151 0.80
Frequency Distribution (Percent) of New Boilers by Emission Rate:
#S02/MMBtu
<0.8
0.9-1.2
1.3-1.8
1.9-2.4
2.5-3.0
3.1-4.0
Coal
5
62
17
9
1
5
Oil
43
29
0
29
0
0
NOTE: See Appendix 2 for discussion of calculation procedures and number of
boilers included in analysis.
Percentages do not sum to 100 due to independent rounding.
19
-------
remaining 7 percent have an emission rate greater than 2.4 Ibs S02/MMBtu.
Average emission rates for the existing oil-fired boilers after the
projects were also lower than they were before the projects: 1.92 compared
to 1.99 Ibs S02/MMBtu. New boiler emission rates averaged 1.14 Ibs
S02/MMBtu, with 43 percent (three out of seven boilers) at 0.8 Ibs S02/MMBtu
or less (this rate equals the federally regulated limit [40 C.F.R. Part 60,
Subpart D] then in effect for S02 emissions from oil-fired industrial
boilers >250 million Btu/hour) and 72 percent at 1.2 Ibs S02/MMBtu or less.
None of the new oil-fired boiler emission rates exceeded 2.4 Ibs S02/MMBtu.
As noted in Section 4, however, the primary fuels fired by the new
boilers is significantly different from that of the existing boilers.
Specifically, natural gas-fired boilers (which cause essentially no S02
emissions) decrease from 56 percent of the existing boilers to 27 percent of
the new boilers. At the same time, the percentage of coal-fired boilers,
which represented 10 percent of the existing boilers, increased to 48
percent of the new boilers. As a result, although new coal- and oil-fired
boilers have lower emission rates than existing boilers firing the same
fuel, the average emission rate for all the new boilers (i.e., the composite
emission rate for boilers firing coal, oil, natural gas, and wood) is
virtually the same as for the existing boilers.
Total Annual Emissions
Table 10 summarizes the number of new and existing boilers included in
the analysis and the total annual S02 emissions before and after the
projects as a function of primary reason for the project, fuel type, and new
versus existing boiler classification. The number of boilers is classified
by base fuel type, whereas S02 emissions are based on the fuel's use both as
the base and backup fuel. For example, S02 emissions from oil reflects both
its firing as a base fuel as well as a backup fuel in boilers primarily
firing coal, natural gas, or wood. The far right column of Table 10
indicates the net change in the S02 emissions. The number of new boilers
and the annual emissions associated with replacement versus new application
and discretionary versus mandatory boiler projects (as previously defined)
are summarized at the bottom of the table.
20
-------
TABLE 10. ANNUAL S02 EMISSION IMPACT (CATEGORY I PROJECTS)
REASON
NEW PLANT
ADDITIONAL
CAPACITY
BOILER
CONDITION
FUEL SWITCH
COGENERATION
ALL
REPLACEMENT
NEW APPLICATION
DISCRETIONARY
MANDATORY
BOILER
NEW
EXISTING
TOTAL
NEW
EXISTING
TOTAL
NEW
EXISTING
TOTAL
NEW
EXISTING
TOTAL
NEW
EXISTING
TOTAL
NEW
EXISTING
TOTAL
FUEL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
COAL
OIL
NO. OF
BOILERS
13
0
0
0
13
7
1
17
1
24
5
6
10
23
44
39
0
0
44
83
10
1
1
2
14
74
8
28
70
178
--
. _
- -
BEFORE
0
0
0
0
0
0
0
42854
2512
45366
0
0
16331
9051
25382
0
0
0
30037
30037
0
0
2720
333
3053
0
0
61905
41933
103838
55419
48419
49828
54010
ONS S02/YE
AFTER
18676
248
0
0
18924
9458
130
33427
1034
44049
9633
2871
7540
250
20294
60816
10756
0
2325
73897
15720
28
2047
1
17796
114303
14033
43014
3610
174960
94191
80769
111223
63737
AR
rtrx
CHANGE
18924
-1317
-5088
43860
14743
71122
38772
32350
61395
9727
NOTE: See Appendix 2 for discussion of calculation procedures and number of
boilers included in analysis.
21
-------
Overall S02 emissions increased by 71,122 tons of S02 per year—a net
increase of 68 percent as a result of new boiler projects. Of the total
emissions after the projects were completed, 73 percent (128,336 tons) was
from the new boilers; the remaining 27 percent (46,624 tons) was from
continued operation of the existing boilers. Emission changes associated
with each of the primary reasons for the projects are discussed below.
New PI ants--
New plants are a major source of sulfur dioxide emissions. Because
boilers installed at new plants are not replacements for existing boilers,
they add capacity and emissions where none existed previously. The total
S02 emissions from the surveyed new plants is 18,924 tons per year; this
represents 26 percent of the total S02 emission increase from all boiler
groups.
Additional Capacity--
New boilers were installed primarily to increase the steam capacity of
existing plants; in most cases, the fuel choice for the new boiler was the
same as that of the existing boilers at the same plant. Several of these
projects also consolidated or otherwise modified the operation of existing
boilers, thereby reducing emissions from the existing boilers. In more than
half the cases, the existing boiler remained in operation. The net change
in emissions from the new and existing boilers was a reduction of 1,317 tons
of S0? per year, or roughly 3 percent less than the emission level existing
before installation of the new boiler.
Boiler Condition--
These projects installed one or more new boilers because of the poor
condition of the existing boilers. Of the 33 existing boilers affected,
only 6 continued operation after the new boiler was installed. Although the
new boilers generally fire the same fuel as the original boiler and have
* See Appendix 2 for example calculations of S02 tonnages and percentages.
22
-------
lower emission rates per million Btu of heat input, they are also generally
larger than the boilers they replaced. Overall, net emissions from this
category decreased by 5,088 tons of S02 per year, or roughly 20 percent.
Fuel Switch--
The largest single category of boiler projects were undertaken to
change the base fuel of the plant. In most cases, the change was from oil
or natural gas to coal or coal-wood mixtures. The net result was an
increase of 43,860 tons of S02 per year, representing 61 percent of the
total annual emissions increase and an increase of 152 percent relative to
the emissions of the existing boilers before these projects were undertaken.
(See Section 6 for additional discussion of this issue.)
Cogeneration--
Cogeneration projects generally involved adding a new boiler and
increasing fuel consumption at the plant (or at an adjacent site in the case
of third-party cogenerators). Coal was the primary fuel. In some cases,
steam production from existing boilers was replaced in whole or in part by
the new cogeneration boiler. The net change in emissions was an increase of
14,743 tons of S02 per year, representing about 21 percent of the total
increase in annual SO- emissions from all categories. This represents an
almost six-fold increase in emissions compared to the existing boilers that
were affected by the cogeneration projects. (See Section 6 for additional
discussion of this issue.)
New Application vs. Replacement Boilers--
The annual emissions were also categorized for new application boilers
versus those primarily installed to replace existing boiler capacity. As
mentioned above, new applications include new plants, cogeneration
facilities, and boilers built to satisfy additional steam demand at an
existing plant. Of the total net increase in S02 emissions, new application
boilers accounted for 32,350 tons of S02 per year (45 percent) compared to
38,772 tons of S02 per year (55 percent) for replacement boilers.
23
-------
Discretionary vs. Mandatory Boilers--
Annual emissions impacts were also calculated on the basis of discre-
tionary versus mandatory boiler projects. Discretionary projects (fuel
switching, backup capacity, replacement of a repairable boiler, and
cogeneration) accounted for 61,395 tons (86 percent) of the total net
increase in annual S02 emissions. Mandatory projects (addition of primary
capacity, replacement of an unrepairable boiler, and new plants) accounted
for the remaining 9,727 tons (14 percent) of net annual S02 emissions. If
only those projects defined as mandatory had been built, S02 emissions would
have increased by 18 percent.- Discretionary boiler projects increased
emissions by 123 percent relative to the total before the project.
6.0 IMPACT OF LOWER ENERGY PRICES
Two of the major reasons given in the survey for new boiler purchases
were fuel switching and cogeneration, in aggregate accounting for 48 percent
of all Category I projects (see Table 4). Both of these reasons were
heavily influenced by the perceptions of future energy prices and national
energy policies during the 1981-1984 time period. During this period,
future oil and natural gas prices were generally expected to be quite
high—and the reliability of their supply low. In addition, economic
incentives under the Public Utility Regulatory Policies Act (PURPA) made
cogeneration projects attractive to many investors.
Given current perceptions of lower oil and natural gas prices in the
future, construction of new boilers for reasons of fuel switching is
expected to be significantly reduced. Lower fuel prices will also reduce
the economics of some cogeneration projects and thereby decrease the number
of new cogeneration boiler installations. To aid in interpreting the future
direction of boiler replacement decisions and S02 emissions, this section
briefly summarizes the survey results if fuel switching projects singly and
in combination with cogeneration projects are excluded from the analysis.
First, if only fuel switching projects are excluded, the total number
of Category I projects decreases from 115 to 76 (see Table 4). The split
between replacement and new application boilers changes from roughly 50/50
24
-------
to 25 percent for replacement (due to boiler condition) and 75 percent for
new applications (new plants, capacity additions at existing plants, and
cogeneration). Elimination of fuel switching projects reduces total S02
emissions to 73,801 tons before the projects and 101,063 tons afterward. Of
these 101,063 tons, 56,764 tons (56 percent) are from new boilers and 44,299
tons (44 percent) are from existing boilers.
Excluding fuel switching projects, the net increase in emissions is
27,262 tons (37 percent). The emissions increase attributable to boilers
that were built for mandatory reasons (primary capacity, unrepairable boiler
condition, and new plants) is 9,727 tons (35 percent). Emissions from the
remaining discretionary boilers (backup capacity, repairable boiler
condition, and cogeneration) increased by 17,535 tons.
Second, if both fuel switching and cogeneration projects are excluded
from the analysis, the total number of Category I projects decreases from
115 to 60 (see Table 4). The split between replacement and new application
boilers changes from roughly 50/50 to 33 percent for replacement and 67
percent for new applications. Total annual S02 emissions increase from
70,748 tons before the projects to 83,267 tons afterward. Of the 83,267
tons of SO- afterward, 41,016 tons (49 percent) are from new boilers and
42,251 tons (51 percent) are from existing boilers.
The net increase in emissions from new projects excluding fuel
switching and cogeneration projects is 12,519 tons per year (18 percent).
The emissions increase attributable to boilers that were built for mandatory
reasons is 9,727 tons (74 percent). Emissions from the remaining
discretionary boilers (now limited to backup capacity and repairable boiler
condition) increased by 2,792 tons.
Thus, although the increase in SO^ emissions is smaller when fuel
switching by itself or fuel switching in conjunction with cogeneration are
excluded from the analysis, the remaining new boilers would still result in
net S02 emission increases of 18 to 37 percent compared to emission levels
prior to their installation.
25
-------
APPENDIX 1
BOILER REPLACEMENT SURVEY QUESTIONNAIRE
-------
-------
OMB Clearance No.
2060-0136
GENERAL INSTRUCTIONS
1. This "questionnaire is designed to obtain information about industrial
boiler projects. It focuses on the factors that influence the decision
to undertake a boiler project and the factors that are considered in
the selection of boiler type and fuel. Therefore, it is important that
the individual(s) completing this questionnaire be the person(s) who
actually made these kinds of decisions [or as close to the person(s) as
possible for the project covered by this questionnaire]. If this person
is not you, please route this questionnaire to the most appropriate
individual in your organization.
2 The questionnaire is designed to obtain information on each boiler
project. For the purposes of this survey, a boiler project is defined
as a series of activities that were begun due to a decision and plan
to alter, expand, or in some way modify the boiler facilities at a
particular plant site. Consequently, a boiler project may involve a
number of boilers and may include construction of several new boilers
as well as reconstruction or rebuilding of several existing boilers.
If you have undertaken more than one boiler project over the last five
years (since January 1, 1981), please fill out a separate questionnaire
for each boiler project.
3. This questionnaire consists of two parts and two supplements. It is
necessary to carefully review both parts and both supplements of the
questionnaire. Please read the introduction to each part and each
supplement carefully and follow the instructions included in the
questionnaire itself. Items a-d below address each of these sections.
a. Part I covers general information. Even though the Part I
information will not be used in the analysis, the information
requested is necessary if additional communication is appropriate
to understand or clarify answers to various questions involved in
the questionnaire.
b. Part II is the main part of the survey. Please answer each question
completely. Where space is provided for comments or additional
information, please take the time to provide information that will
provide a good understanding of the reasons for your decision to
undertake a boiler project.
c. Supplement A is to provide detailed information about each new
boiler involved in the boiler project. Supplement A has one
general information page (page A-l) and a one-page questionnaire
(page A-2) for each new boiler involved in the project. Please
complete Supplement A by filling out the general information page
and then photocopying and completing a page A-2 for each new
boiler in the project.
-------
d Supplement B is to provide detailed information about each existing
' boiler which may have been reconstructed, rebuilt, modified, or
chanaed in any way as part of the overall boiler project. Even if
an^ist SgboiU? wasonly operated in a different manner or
just shutdown, as a result of the boiler project, please identify
and include this boiler in Supplement B. Supplement B has a general
information page (page B-l) and a three page JuJst1»;n«ftJ;pages B'2
through B-4) for each existing boiler involved in the boiler
project. Please complete Supplement B by filling out the general
information page and then photocopying and completing pages B-Z
through B-4 for each existing boiler involved in the boiler
project.
4. The questionnaire should be completed and returned by July 18, 1986.
5 If you have any questions or anticipate difficulties in either fully
responding or responding within the allotted time, please call the
following individual:
Ms Dianne Byrne
Environmental Protection Agency
(919) 541-5578
6. When the questionnaire is completed, please mail to:
Ms Dianne Byrne
Environmental Protection Agency
OAQPS, ESED, SOB (MD-13)
Research Triangle Park, NC 27711
-------
OMB Clearance No.
2060-0136
PART I: SURVEY OF INDUSTRIAL BOILER PROJECTS
This survey questionnaire is being sent to firms who have undertaken
one or more boiler projects within the last five (5) years. The results of
this survey are intended to provide information on why boiler projects are
undertaken, the factors influencing the selection of the type of boiler and
the fuel, and whether existing equipment can be used in these projects.
Please read the general instructions carefully before completing the
questionnaire.
Please complete the following questions. This information is necessary
if additional communication is required to clarify answers provided to
various questions in the questionnaire. The link between the name of the
particular plant and the information in the survey will not be provided
to the public in any type of summary report that may be generated from
the responses.
1. Name of firm:
2. Two-digit Standard Industrial Classification (SIC) Code:
3. Name of person completing form:
4. Phone Number (include area code): ( )
5. Position:
6. Plant site address
Street address:
City: State: Zip Code:
7. Project number [As mentioned in the general instructions, a
complete questionnaire needs to be completed for each separate
boiler project (i.e., not each boiler but each project).]
Consequently, if you are completing more than one questionnaire,
identify separate projects by a project number, i.e., 1, 2, 3,
etc. .—.
1-1
-------
PART II: SURVEY OF INDUSTRIAL BOILER PROJECTS
1. Project number (See instructions in Part I):
2. Is this new boiler located at a new "greenfield" manufacturing
plant? Yes No
3. Please complete Supplement A for each new boiler(s) included in
the boiler project.
4 Did this boiler project involve or include reconstruction, rebuilding,
modifying, or changes of any sort in any existing boilers, including
operation of existing boilers at lower capacity or shutting down of
existing boilers? Yes No
If yes, how many existing boilers were affected in some way as a result
of this boiler project?
5. Please complete Supplement B for each existing boiler that was changed
or affected in any way as a result of this boiler project.
6. Please describe your main reason for building a new boiler:
7 If your decision was based on a cost analysis, please include a copy
of the cost analysis if one is available. If your decision was based
on cost considerations, but an analysis isn't available, please describe
the major cost considerations that influenced your decision.
II-l
-------
8. Would your decision to build a new boiler change if projected costs
to produce steam increased by:
10X • Yes No
20* " Yes . No
30X Yes No
50% ' Yes No
9. To supplement your answer to question 6, Which of the following
factors were also considered in deciding that there was a need for
this boiler project? Please rate EACH factor from 0 to 2 (0 - not
considered or relatively unimportant; 1 - moderately important; 2 -
very important). If you considered factors that are not on the list,
please add them to the bottom of the list and rate them.
Factor Rating
a. additional boiler capacity was needed over and
above what the existing boilers could provide
b. insurance companies were no longer willing to provide
insurance coverage for existing boilers
c. existing boiler(s) could not be operated safely
without extensive repairs
d. existing boiler(s) could not be operated reliably
without extensive repairs
e. existing boiler(s) could no longer be operated in
• compliance with air pollution regulations
f. the boiler project allowed us to change our base fuel
(e.g., coal, oil, natural gas, wood, waste fuels, etc.)
g. the boiler project allowed us to use multiple fuels ^
h. boiler allowed us to consolidate boiler operations
(ie., replace several smaller boilers with one or more
large boilers)
i. new boiler provides us with more backup boiler capacity
j. the mode of operation for the boilers changed (bigger
load swings, more baseload, etc.)
k. steam quality (pressure, temperature) requirements
changed
1. desire to cogenerate electricity for on-site use
or resale
m. other (specify):
II-2
-------
PART II (continued)
10 In considering a boiler project or selecting the type of boiler/fuel
to use a number of factors are weighed in the decision. Some of the
most commonly considered factors are listed below. Please rate how
important each of these factors were in your boiler project. Please
rate EACH factor from 0 to 2 (0 - not considered or relatively unimportant;
1 - moderately important; 2 - very important). If you considered factors
that are not on the list, please add them to the bottom of the list and
rate them.
Factor
a. operating costs excluding fuel
b. maintenance costs excluding fuel
c. fuel costs
d. interest rates
e. capital cost of project
f. availability of corporate funds for capital improvements
g. operating flexibility or backup boiler capacity
h. boiler efficiency
i. compatibility with existing fuels at plant
j. security or reliability of fuel supply
k. space or land availability
1. ability to use existing system components -
m. ability to minimize need for additional operating or
maintenance personnel
n. corporate policy (specify):
o. environmental regulations
(specify): __ .
p. other (specify):
II-3
-------
11 Of the following system components that were present on-site at
the time of construction of the boiler project, which could continue
to be used to service either new boilers involved in the boiler
project or existing boilers that were modified or changed in any way
as part of the boiler project. (0 - could not be used at all; 1 -
could use as is or with minor modification; 2 - could use only with
major modification)
If the boiler project was part of a new "greenfield" plant, skip this
question. „ _ ^ .
Can Service Can Continue to Service
New Boilers Existing Boilers Changed
System Component Added or Modified in Some May
a. fuel storage
b. fuel handling
c. boiler house
d. boiler feedwater treatment
e. condensate return
f. boiler blowdown and treatment
g. solid waste handling and
disposal
h. air pollution control equipment
i. waste water treatment system
II-4
-------
SUPPLEMENT A — NEW BOILERS INVOLVED IN BOILER PROJECT
This supplement is intended to collect information about the new
boiler or boilers included in the project covered by this questionnaire.
This Supplement A consists of two (2) pages. This page (page A-l) contains
questions about all the new boilers installed. The following page (page A-2)
requests informaTToh about each new boiler. Consequently, please photocopy
and complete as many copies of page A-2 as necessary to identify and
describe each new boiler. For each new boiler, please complete a separate
page A-2.
1. Project number (same as Question 16 of Part I):
2. Number of new boilers included in this project:
3. Maximum (design) capacity of each new boiler:
Boiler II thousand pounds steam/hr
Boiler #2 ____ thousand pounds steam/hr
Boiler *3 thousand pounds steam/hr
Boiler #4 thousand pounds steam/hr
Total
NOTE: If more than four new boilers were installed, please identify
at the bottom of this page the maximum design capacity of
each additional new boiler.)
4 What was the total capacity of the boilers that were shut down
or modified in any way as a result of the new boiler project?
thousand pounds steam/hr.
A - 1
-------
SUPPLEMENT A — INFORMATION FOR EACH NEW BOILER
(For each new boiler, please answer the following questions. Use one
page for each boiler.)
1. This page is for boiler number:
[If you have more than one new boiler in this project, identify each
new boiler by a separate number (i.e., 1, 2, 3, etc.)]:
2. Type of boiler: Package or Field-erected
3. Maximum capacity of this boiler: (thousand pounds steam/hr)
4. Base fuel for this boiler (coal, oil, natural gas, wood bark, etc.):
5. Base fuel characteristics:
a. Weight % ash b. Weight % sulfur
c. Heat content d. Annual fuel consumption :
(Btu/lb, Btu/gal, or tons coal _^r^__
Btu/scf - please state) tons other solid fuel
gallons oil
cubic feet gas
6. Backup fuel for this boiler (coal, oil, natural gas, wood bark, etc.)
7. Backup fuel characteristics:
a. Weight % ash b. Weight % sulfur
c. Heat content d. Average annual fuel consumption
(Btu/lb, Btu/gTTor tons coal ^
Btu/scf - please state) tons other solid fuel
gallons oil
cubic feet gas
8. Regulatory limit for S02 that applies to this boiler: _
9. Emission control technique used to control S02 emissions: (please check)
a. Low sulfur fuel b. Flue gas desulfurization
c. Other (please specify)
10. If this is a coal boiler, type of fuel firing system:
a. Pulverized coal b. Stoker coal c. Other (specify)
A-2
-------
SUPPLEMENT B — EXISTING BOILERS INVOLVED IN BOILER PROJECT
This Supplement is intended to collect information about the existing
boiler or boilers that were involved in the boiler project in some way.
This may have been reconstruction or rebuilding of an existing boiler
or a change in the manner of its operation. Consequently, even if an
existing boiler was only operated at a lower capacity, shutdown, or
placed in a standby or back-up position, as a result of the boiler project,
please identify and include this existing boiler in completing this
supplement.
This first page (page B-l) contains questions about all the existing
boilers that were involved in the boiler project in some way. The remaining
paqes (pages B-2 through B-4), request information about each existing
boiler that was involved in the boiler project. Consequently, please
photocopy and complete as many copies of pages B-2 through B-4 as necessary
to identify each existing boiler involved in the boiler project. For
each existingUoiler, please complete a separate set of pages B-2 through
"6^47
1. Project number (same as Question 16 of Part I):
2. Number of existing boilers involved in this boiler project:
3. Maximum (design) capacity of each existing boiler affected
by the boiler project:
Boiler #1 thousand pounds steam/hr
Boiler #2 thousand pounds steam/hr
Boiler 13 thousand pounds steam/hr
Boiler #4 thousand pounds steam/hr
Total _^_____
NOTE: If more than four existing boilers were involved in this
boiler project in some way, please identify the maximum
design capacity of each additional existing boiler that
was involved at the bottom of this page.
4 At the conclusion of the boiler project, what percent of this
total capacity was replaced, shut-down, or placed in a stand-by
position:
% replaced or shut-down
% placed in stand-by position
B-l
-------
SUPPLEMENT B — INFORMATION FOR EACH EXISTING BOILER
(For each existing boiler, please answer the following questions. Please
photocopy and complete as many copies of the following pages (i.e., B-2,
B-3, and B-4) to provide information on each existing boiler.)
1. This page is for boiler number:
(If you have more than one existing boiler which was involved in the
boiler project, please identify each boiler by a separate number,
i.e., 1, 2, 3, etc.):
2. Age of boiler:
3. Type of boiler: Package or Field-erected
4. Maximum capacity of this boiler: thousand pounds steam/hr
5. Base fuel for this boiler (coal, oil, natural gas, wood bark, etc.):
a. Before project: b. Following project:
c. Base fuel characteristics:
Before Project After Project
i. Weight % ash
ii. Weight X sulfur
111'. Heat content
(Btu/lb, Btu/gal or
Btu/scf - please state)
iv. Annual fuel consumption
tons coal
tons other solid fuel
gallons oil
cubic feet gas
B-2
-------
Supplement B (continued)
6. Backup fuel for this boiler (please identify):
a. Before project: b. After project:
c. Backup fuel characteristics:
Before Project After Project
i. Weight X ash
ii. Weight X sulfur
iii. Heat content
(Btu/lb, Btu/gal or
Btu/scf - please state)
iv. Annual fuel consumption
tons coal
tons other solid fuel
gallons oil
cubic feet gas
7. Regulatory limit for SOe that applies to this boiler:
8. Emission control technique used by boiler to meet S0£ emission limit:
(Please check control technique used.)
Before Project After Project
a. Low sulfur fuel _ -
b. Flue gas desulfurization _ _
c. Other (please specify) _ -
9. How did the status of this boiler change because of the boiler project?
(You may check more than one)
_ Shut down
_ Used as backup boiler only
_ Used as a peaking unit only
Reduction in hours of operation
Change to a different fuel
Dismantled
Other (specify: _ )
B-3
-------
10. Why was this boiler's status changed (You may check more than one)?
Boiler failed safety inspection
Insurance could not be obtained
Maintenance costs too high
Estimated annual costs (optional)
Non-fuel operating costs too high
Estimated annual costs (optional)
Fuel costs too high
Estimated annual costs (optional)
Other (specify: )
11. For a boiler that was dismantled or completely shut down, could this
boiler have been rebuilt to extend its useful life?
Yes No
If yes, what kind of repairs would have been necessary?
12. (Optional)
Please provide any additional information about this boiler project
that you believe would be helpful for us to know in order to fully
understand the nature of the project.
B-4
-------
APPENDIX 2
EMISSION CALCULATION PROCEDURES
TABLE 9
Average emission rates for coal- and oil-fired boilers were calculated
by dividing the fuel sulfur content for each boiler by its heat content and
then multiplying by two to convert pounds of sulfur to S02. Emission rates
for individual boilers were then summed and divided by the number of units
to obtain average rates for coal- and oil-fired boilers. Average emission
rates for all boilers were calculated by multiplying the average emission
rates for for each fuel (coal, oil, natural gas, and wood) by its percentage
of the total boiler capacity (from Tables 2 and 7) after excluding "other"
fuels; natural gas and wood were assumed to be sulfur free.
TABLE 10
Annual emissions from coal and oil firing as both a base and backup
fuel were calculated for each boiler by converting fuel sulfur content to
the equivalent amount of S02 and then multiplying by the quantity of fuel
used (to convert the quantity of oil from gallons—as reported on the survey
form—to pounds, a conversion factor of eight pounds per gallon was used).
CALCULATION OF EMISSION CHANGES BEFORE AND AFTER THE PROJECTS
Annual emissions are subdivided in Table 10 by fuel type (coal and oil)
and age (new and existing). Many of the key numbers used in the text are
composites of these subsets. For example, the reported total emissions from
new boilers at the top of page 22 of 128,336 ton is the composite of
emissions from new coal- and oil-fired boilers (114,303 plus 14,033,
respectively). Percentage changes were calculated by subtracting the
"before" emissions from the "after" emissions and then dividing by the
"before" level. For example, the 68 percent increase in total emissions
resulting from the new projects was calculated by dividing the difference in
emissions "before" and "after" (174,960-103,838-71,122) by the emissions
"before" (103,838).
-------
NUMBER OF BOILERS INCLUDED IN ANALYSIS
Because of incomplete fuel data on three survey forms (representing six
boilers), small differences exist in the number of boilers reported on
Tables 9 and 10. For five of these six units (two new coal-fired boilers
and three exisitng oil-fired boilers included on Table 9, but not Table 10),
fuel sulfur content needed to estimate the S02 emission rate per million Btu
was reported, but the quantity of fuel used was omitted. The sixth boiler
(included on Table 10, but not Table 9) was a new oil-fired boiler installed
as emergency backup for two existing coal-fired boilers; on this unit, oil
sulfur content was omitted while the fuel usage was reported as zero.
Emissions from this unit were assumed to be zero.
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO. 2.
EPA-450/3-87-006
4. TITLE AND SUBTITLE
Survey of New Industrial Boiler Projects
1981 - 1984
7. AUTHOR(S)
David M. White, Radian Corporation
Research Triangle Park, NC 27709
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Office of Air Quality Planning and Standards
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
12. SPONSORING AGENCY NAME AND ADDRESS
Office of Air and Radiation
U.S. Environmental Protection Agency
401 M Street, S.W.
Washinntnn. Pf ?QAfin -»,-„ — ,
5. REPORT DATE
Aoril 1987
8. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-3816
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
EPA/200/04
15. SUPPLEMENTARY NOTES
This report presents an analysis of new industrial boilers sold
between 1981 and 1984. The analysis focuses on 151 new coal-, oil-,
natural gas-, and wood-fired boilers larger than 100 million Btu/hour
and 291 existing boilers. Specific issues examined in the report include
the reasons for purchasing new industrial boilers, the percentage of new
boilers used for new applications versus replacement of existing boilers,
and the impact of new boiler purchases on sulfur dioxide emissions.
17. KEY WORDS AND DOCUMENT ANALYSIS
3. DESCRIPTORS
Air Pollution
Steam Generating Units
Sulfur Dioxide
18. DISTRIBUTION STATEMENT
Release Unlimited
b.lOENTIFIERS/OPEN ENDED TERMS
Industrial Boilers
Air Pollution Control
19. SECURITY CLASS (This Report)
Unclassified
20. SECURITY CLASS (This page)
Unclassified
c. COSATl Held/Group
13B
21. NO. OF PAGES
A*\
22. PRICE
EPA Form 2220-1 <"•». 4-77) PREVIOUS EDITION is OBSOLETE
------- |