EPA-600/2 75 067
October 1975
Environmental Protection Technology Series
EVALUATION OF
NATIONAL BOILER INVENTORY
PRO^
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
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This report has been assigned to the ENVIRONMENTAL PROTECTION
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EPA-600/2- 75-067
EVALUATION OF
NATIONAL BOILER INVENTORY
by
A.A. Putnam, E.L. Kropp, andR.E. Barrett
Battelle-Columbus Laboratories
505 King Avenue
Columbus, Ohio 43201
Contract No. 68-02-1223, Task 31
ROAPNo. 21ADE-010
Program Element No. 1AB013
EPA Task Officer: C. C. Lee
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
October 1975
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EVALUATION OF NATIONAL BOILER INVENTORY
by
A. A. Putnam, E. L. Kropp, and R. E. Barrett
October 10, 1975
ABSTRACT
Using available data sources, a compilation of the
boiler inventory was made for the Continental United States.
Primary data sources included the National Emissions Data
Bank (NEDS) data, American Boiler Manufacturers Association
boiler sales data, and earlier reports to EPA. Residential,
commercial, industrial, and utility boilers were included in
the study.
Results are presented in the form of (1) cumulative
boiler installed capacity and cumulative actual boiler use
(by fuel and total), both plotted against boiler size; (2)
cumulative S0„, NO , and particulate emissions (by fuel and
2 x
total) plotted against boiler size; and (3) tables of boiler
number count, boiler installed capacity, boiler actual use,
SO emission, NO emission, and particulate emission by boiler
4 X
size and fuel.
ii
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TABLE OF CONTENTS
Page
INTRODUCTION 1
DEFINITIONS 2
Conversion Factors ..... 2
CLASSIFICATION OF POPULATION DISTRIBUTION 3
Division by Size 3
Division by Use 4
Division by Fuel Type 6
Choice of Year 7
ANNUAL LOAD FACTOR 8
Relationship of Annual Load Factors and Sulfur
Content of Fuel 10
TABULATION OF BOILER POPULATION 11
RESIDENTIAL HEATING SYSTEMS 22
GRAPHICAL SUMMARY OF BOILER POPULATION DATA 27
ESTIMATED EMISSIONS OF SO-, NO , AND PARTICULATE 33
2 x
REFERENCES 52
ACKNOWLEDGMENTS 54
APPENDIX A
DISTRIBUTION OF BOILER POPULATION A-l
APPENDIX B
COMPILATION OF BOILER POPULATION FOR SMALL BOILERS B-l
iii
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TABLE OF CONTENTS
(Continued)
Page
LIST OF TABLES
Table 1. Boiler Size Ranges Used to Classify NED Data. ... 5
Table 2. Compilation of Use Categories With Arbitrary
Nominal Ranges Often Used 6
Table 3. Compilation of Fuel Types or Burning Techniques . . 6
Table 4. Annual Load Factors as a Function of Use and
Fuel Type, Based on NEDS Data 9
Table 5. Number Count of Boilers and Total Installed
Capacity (10^ Btu/hr) of NEDS Data (Corrected
for Missing State Data) 12
Table 6. Compilation of Total Installed Capacities
in 1971(1) 15
Table 7. Number Count, Total Installed Capacity (10^ Btu/hr)
and Average Hourly Fuel Consumption (Annual Load
Factor Times Total Installed Capacity) (106
Btu/hr) as a Function of Design Firing Rate,
Fuel Type, and Use 19
Table 8. Residential Dwelling Unit Heating Plants 23
Table 9. Estimated Number of Dwelling Units Heated by
Various Fuels 23
Table 10. Estimated Number of Dwelling Units, by Type,
Heated by Various Fuels in December, 1974 ... 24
Table 11. Estimated 1971 Fuel Consumption for Residential
Space Heating 24
Table 12. Distribution of Number of Units (Upper Value)
and Design Firing Rate of Individual Units
(Lower Value) to Match Data in Tables 10 and
11 and Assumption of 20 Percent Annual Load Factor 26
Table 13. Number Count, Total Installed Capacity (10^ Btu/hr),
and Average Hourly Fuel Consumption (Annual Load
Factor Times Total Design Firing Capacity) (10^
Btu/hr) as a Function of Design Firing Rate and
Fuel Type for Residential Boilers 26
iv
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TABLE OF CONTENTS
(Continued)
Page
Table 14. Sulfur Dioxide Emissions (Tons/yr) by
Boiler Size Class 35
Table 15. Emissions of Oxides of Nitrogen (Tons/yr) by
Boiler Size Class 39
Table 16. Particulate Emissions (Tons/yr) by
Boiler Size Class 43
Table 17. Sulfur Dioxide Emissions (Tons/yr) from
Residential Units as a Function of Fuel
Type and Design Size Class 47
Table 18. N0X Emissions (Tons/yr) from Residential Units
as a Function of Fuel Type and Design Size Class . 47
Table 19. Particulate Emissions (Tons/yr) from Residential
Units as a Function of Fuel Type and Design
Size Class 48
Table B-l. Data on Small Boilers B-2
LIST OF FIGURES
Figure 1. Conversion Factor to Divide Into NEDS Data to ... .
Obtain Total Installed Capacities in Each Size Class. 16
Figure 2. Normalized Total Installed Capacities in 2:1 Size
Classes as a Function of Design Size 17
Figure 3. Total Installed Capacity in Each Boiler Size
Increment 28
Figure 4. Boiler Use Related to Boiler Size 29
Figure 5. Cumulative Installed Boiler Capacity for Coal,
Oil, and Gas-Fired Boilers . 30
Figure 6. Cumulative Actual Boiler Use (Or Average Hourly
Firing Rate) For Coal, Oil, And Gas-Fired Boilers. . 32
Figure 7. Cumulative SO2 Emissions for all Boilers Based on
Actual Boiler Use 49
Figure 8. Cumulative NO Emissions for all Boilers Based on
Actual Boiler Use 50
Figure 9. Cumulative Particulate Emissions for all Boilers
Based on Actual Boiler Use. . 51
v
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TABLE OF CONTENTS
(Continued)
Page
Figure A-l. Total Installed Capacity of Stoker-Fired
Boilers Normalized from NEDS Data A-3
Figure A-2. Total Installed Capacity of Pulverized Coal-
and Non-Natural Gas-Fired Boilers from
NEDS Data A-4
Figure A-3. Total Installed Capacity of Residual Oil-
Fired Boilers Normalized from NEDS Data .... A-5
Figure A-4. Total Installed Capacity of Distillate Oil-
Fired Boilers Normalized from NEDS Data .... A-6
Figure A-5. Total Installed Capacity of Distillate and
Residual Oil-Fired Boilers, Normalized from
NEDS Data A-7
Figure A-6. Total Installed Capacity of Natural Gas-Fired
Boilers, Normalized from NEDS Data A-8
vi
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EVALUATION OF NATIONAL BOILER INVENTORY
by
A. A. Putnam,
and R. E.
October
E. L. Kropp,
Barrett
10, 1975
INTRODUCTION
The aim of this program is to provide a data-base of boilers
and warm air furnaces in terms of a "popuLation-characceristics matrix",
so that (1) estimates can be made of national impacts of pollutants from
various sizes and types of boilers, and (2) selections can be made of
representative units (from a pollutant standpoint) for tests that would
cover the major boiler and warm air heat sources in the chosen range.
As part of another program, Battelie-Colutnbus prepared an
analysis of the population of industrial boilers,(based primarily on
NEDS data and American Boiler Manufacturers Association (ABMA) sales
data) which included a summary by boiler sizes and types In the
present task, that earlier industrial boiler analysis is extended to in-
clude boilers of larger and smaller capacities. Thus, all boilers, the
nominal utility, industrial, commercial, and residential size ranges,
are included in one boiler inventory and the total distribution of steam
and hot water boilers, plus hot air furnaces, are described in a relatively
uniform manner over the entire range of boiler capacities. Output of
the task includes tabular distributions of boiler nmmber count, boiler
installed capacity, and actual boiler use. Further, the boiler inventory
developed on this program is subdivided into various size, boiler type,
and fuel classes for convenient analysis of pollutant emissions. Finally,
the total emission output of various sizes of boilers are derived from
the distribution of the boiler fuels, boiler uses, and published emission
factors .
The primary output of this study consists of Figures 5 through
9 as follows:
Figure 5. Cumulation plot of total installed boiler capacity
versus boiler design firing rate
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2
Figure 6. Cumulative plot of actual boiler use versus
boiler design firing rate
Figure 7. Cumulative plot of S0„ emissions for actual boiler
use versus boiler design firing rate
Figure 8. Cumulative plot of N0x emissions for actual boiler
use versus design firing rate
Figure 9. Cumulative plot of particulate emissions for
actual boiler use versus design firing rate.
DEFINITIONS
Several terms that are used repeatedly in this report should
be defined to insure proper interpretation of the report and results.
These are:
Design firing rate -- the input firing rate of the boiler when
operating at rated load
Total installed capacity -- the sum of the design firing ra-tes
of all boilers within a group of boilers
Annual load factor — the annual fuel consumption divided
by design firing rate times hours per year
Average hourly fuel consumption or actual boiler use (for
a group of boilers) -- product of total installed capacity
and annual load factor (equivalent to annual fuel consumption
divided by number of hours in a year).
Conversion Factors
10^ Btu/hr (firing rate) = 700 lb/hr of steam (for 75 percent
boiler efficiency)
= 0,10 megawatt, electrical (for
34 percent station efficiency)
1.0 megawatt, electrical = 10^ Btu/hr firing rate (for
34 percent station efficiency).
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3
CLASSIFICATION OF POPULATION DISTRIBUTION
In general, one would like to maintain as few classifications
as possible in any analysis to reduce the amount of material that must be
comprehended, and to increase the count number in each classification,
and, thus, the accuracy of any deductions about the classification. On
the other hand, any factor which might cause a decided change in perti-
nent characteristics of a classification must be used to split the classi-
fication. Furthermore, each classification should not cover initially
too large a range in sizes, because there are often differences in boilers
that result from size alone, e.g., construction method, packaged versus
field erected, and these differences may affect boiler populations (two
package boilers may be installed instead of one field-erected unit due to
lower cost). For the present study, as a result of the viewpoint just pre-
sented, a consideration of the results of preliminary analyses of the
available data, and the results presented in Reference 1, the following
classifications have been considered.
Division by Size
In Reference 1, in classifying boiler data as a function of
boiler size, the total population of industrial boilers was divided into
, 4
5 size ranges (in lb/hr of steam generated) as follows: 1 to 2 x 10 ,
2f to 5 x 104, 5+ to 10 x 104, 1+ to 2 x 105, and 2f to 5 x 105. To
maintain consistency in form, the lower limit in each range, including
the lowest range, starts slightly above the division, e.g., 10,001,
20,001, etc. Divisions at these points were found to be consistent with
the literature. In the present study, these boiler capacities are con-
verted to Btu/hr and the range is extended to larger boiler sizes to cover
(2)
the entire range of NEDS data . (Residential units are treated separately
in a later section of the report.)
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4
Table 1 lists the size classifications used to cover the entire
range of NEDS data. It is seen that each size classification includes
boilers covering a size range of 2:1 or 2.5:1. It is obvious that boiler
size increments of 2.5:1 would contain more boilers than size increments of
2.0:1. Thus, some adjustment must be made to equate all size increments
for some calculations and plots in subsequent sections of the report, that
is, to adjust all size increment ranges to the equivalent of a uniform
boiler size increment, say 2.0:1. This might be done by multiplying the
boiler data in the 2.5:1 size ranges by 0.80 before plotting (since the
2.0:1 size range is only 0.80 times as large as the 2.5:1 size range).
However, a more mathematically proper method of making this adjustment is
on a log basis rather than on a linear basis. The normalizing ratios listed
in Table 1 were calculated on a log basis, in the same manner as log mean
temperature differences are calculated for heat transfer problems. In
figures presented later in this report where normalized boiler data are
plotted, the actual values plotted are the real boiler data divided by the
proper normalizing ratios. Therefore, Table 1 lists, in addition to the
nominal boiler ranges, the log mean boiler size and the normalizing ratios
for each size range*. To include the residential data, the size range in
jf 4.
Table 1 is extended downward to a design capacity of 2 x 10 Btu/hr.
Division by Use
Four boiler use categories might be considered, residential,
commercial, industrial, and utility. It is quite common to use an arbitrary
design capacity as the dividing line between use categories, as shown in
Table 2^'^. However, another recent study ^ has shown that the annual load
factor is more dependent on actual boiler use than on design size, or
even fuel. For example, commercial boilers of a given size have low
annual load factors (since they are used primarily for heating during the
winter) while industrial boilers of the same size have high annual load
factors (since they are used all year for generating process steam). As
a result, if a division ia not made on the basis of actual use, the annual
load factors will not be correct, with a resulting possible misinterpreta-
tion of results.
* The minimum number in NEDS data is 1 x 10 3tu/hr. Assuming a value
of 1 corresponds to a rounded off value 0.5 to 1.4, and so forth,
actual ranges are determined and used in computing log mean size and
normalizing ratio.
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5
TABLE I. BOILER SIZE RANGES USED TO CLASSIFY NEDS DATA
Nominal. Range
of Boiler Design
Firing Races In-
cluded in This
Size Classi-
Slze fication,
Identification Btu/hr Cinque1)
Actual 3oLler Size Ranges In-
,eluded Ln This Size Classifi-
cation in NEDS Data, Btu/hr
Min
TcT
Max (c)
Log Mean
Size,Cd)
3tu/hr
(input)
Normalizing
Ratios (e)
Size l*(a)
1 X
106
0.5
X
io6
1.4
X
L06
0.837
X
iob
1.485
l<*>
1+
-
2 x 106
1.5
X
106
2.4
X
io6
1.897
X
io6
0.678
2
2+
-
5 x 106
2.5
X
io6
5 .4
X
L06
3.674
X
106
I.Ill
3
5+
-
10 x 106
5.5
X
io6
L0.4
X
io6
7.563
X
io6
0.919
4
1+
-
2 x 107
10.5
X
L06
20.4
X
io6
1.464
X
107
0.958
5
2+
-
5 x 107
20.5
X
L06
50.4
X
106
3.214
X
107
1.298
6
5+
-
10 x 107
50.5
X
106
100.4
X
io6
7.121
X
107
0.991
7
1+
-
2 x 108
100.5
X
LO6
200.4
X
io6
1.419
X
io8
0.996
8
2+
-
5 x 103
200.5
X
io6
500.4
X
106
3.167
X
io8
1.319
9
5+
-
10 x 103
500.5
X
io6
1000.4
X
io6
7.076
X
io8
0.999
10
1+
-
2 x 109
1000.5
X
io6
2000.4
X
io6
1.415
X
io9
1.000
11
2+
-
5 x 109
2000.5
X
io6
5000.4
X
io6
3.163
X
io9
1.322
12
>
3
-
10 x 109
5000.5
X
106
10,000.4
X
IO6
7.072
X
io9
1.000
13
1+
-
2 x 1010
10,000.5
X
io6
20,000.4
X
106
1.414
X
io10
1.000
(14)
> 2
x 10
Mot Used
Not
Used
(1.322)
(a) Size 1* does not refer to a range, buc a specific sec of data with the minimum labeled
capacity m the NEDS data of L x L0° Btu/hr.
(b) Because NEDS data are recorded in the incremental values of 1, 2, 3, ... x IO6 Btu/hr,
this sec of data turns out to contain only boilers with laoeLed capacities of 2 x LOO Scu/hr.
(c) To accuracy of 0.1 x 10^ Btu/hr.
(d) Square root of product of maximum size in range and minimum size in range.
(e) Log nf ratio of maximum siza in ranse co minimum size in range, divided by log 2.
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6
Division by Fuel Type
The fuel divisions of main interests to this project are coal,
residual oil, distillate oil, and gas. However, because of the interest
in pollutants (which vary with firing method), the coal boilers are
split into pulverized fuel and cyclone in one classification, and all
other systems (stoker types) in the second classification. An examina-
tion of the preliminary runs also showed that by-product gas data
appeared to be anomalous. Therefore, the gas data are divided into two
classes with natural gas and liquified petroleum gas (LPG) in one classi-
fication and by-product gas (refinery off-gases, coke oven gases, etc.)
in the other. This results in six fuel categories, as shown in Table 3.
In the residential category, natural gas and LPG are considered separately.
TABLE 2. COMPILATION OF USE CATEGORIES
WITH ARBITRARY NOMINAL
RANGES OFTEN USED
Use Design Firing Rate,
Category Btu/hr
Utility > 5 x 10^
Industrial 10^ - 5 x 10^
Commercial 3.3 x 10^ - 107
Residential < 3.3 x 10^
TABLE 3. COMPILATION OF FUEL TYPES OR
BURNING TECHNIQUES
Pulverized coal and cyclone
Stoker and other coal not in item above
Residual oil
Distilled oil
Natural gas and liquified petroleum gas (LPG)
Other gases not in item above (primarily by-product gases)
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7
Choice of Year
The aim of this program was to develop a consistent distribution
of boilers and warm air heaters over a wide range of firing rates at one
recent time. The only available relatively complete boiler count is the
(2)
NEDS data , which were obtained principally in 1971. The other major
sources of daca are the Midwest Research Institute report on pulverized
coal-fired boilers the ABMA data on boiler sales (available on an
annual basis since 1965)^, and U.S. Department of Commerce data on
boiler sales'"7^. Since these data must be summed with an extrapolation
back in time, the enumeration time is arbitrary. Therefore, 1971 was
chosen as the time of reference.
Extrapolation to any arbitrary later year than 1971 can be
made by use of growth rates reported in current literature (or, in some
categories, sales data minus retirement data). However, because of the
large installed capacity compared to yearly sales, there will be little
change in relative distribution among categories over a few years. Thus,
for the main aims of this report, it was not necessary to carry out such
an extrapolation.
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8
ANNUAL LPAD FACTOR
An important item in estimating actual boiler use and emissions
is the annual load factor. The annual load factor was computed for each
boiler for which NEDS data were available by dividing the total fuel heat
input rate per year by the design firing rate and the number of hours per
year. In a number of instances (about 20 percent) the resulting value was
greater than unity, occasionally by a considerable amount. This indicated
some error in these data. For these boilers an annual load factor of 1.05
was arbitrarily assigned. This will result in some overestimation of actual
boiler use. However, neglect of these units will result in too low of values
for boiler capacity, fuel use, and pollutant emissions. Also, some boilers
are fired at above the design rate. Comparison of the portion of the data
developed for Reference 4 using the 1.05 load factor with the data of
Reference 8 indicates a difference of about 5 percent.
Next, for each category defined by size class, use, fuel classifi-
cation, and sulfur content (in two ranges -- less than or equal to 1 percent,
and greater than 1 percent), an average annual load factor was computed.
Within each category, the number-of-boiler weighting system* was used
rather than design firing rate; the increment of design firing rate within
each category is sufficiently small, however, that the choise has no signi-
ficant effect.
An examination of the annual load factor value for each boiler
category led to the conclusion that, in most instances, the annual load
factor was not a function of design firing rate of the boiler, within the
accuracy to which it could be determined. As a result, average values of
annual load factor for broader categories of boilers were determined as
shown in Table 4. It was possible to obtain each annual load factor for
broader categories of boilers by either number weighting or total-installed -
capacity weighting of the annual load factors for each subcategory. On the
basis that if all boilers were counted and data were available to determine
the annual load factor for every boiler, the total-installed-capacity-
* Sum of annual load factors for all boilers in a size class divided by
the number of boilers in that size class.
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9
TABLE 4. ANNUAL LOAD FACTORS AS A FUNCTION OF USE
AND FUEL TYPE, BASED ON NEDS DATA
Commercial Industrial Utility
Stoker coal(a) 0.305 0.426(c) 0.479
Pulverized coal 0.424 0.524^ 0.423
and cyclone
Residual oil 0.245 0.368 0.429 (low sulfur oil)
0.647 (high sulfur oil)
Distillate oil 0.206 0.330(e) 0.130(h)
Natural gas and LPG 0.318 0.518 0.474
Gases other than -- 0.630 (i)
natural gas
(f ,g)
(a) Stoker coal includes all coal firing except pulverized coal
and cyclone.
6 8
(b) For design firing rates of 1 x 10 to 5 x 10 Btu/hr. Value
ranges from 0.01 to 0.16 for few boiler data above this design
size range.
g
(c) For design firing rates up through 5 x 10 Btu/hr. For the few
few boilers above, use 0.268.
g
(d) For design firing rates up through 5 x 10 Btu/hr. For boilers
above, use 0.580.
g
(e) No data for boilers with design firing rates above 5 x 10 Btu/hr.
(f) Use industrial value for boilers with design firing rates up to
5 x 10 Btu/hr.
(g) Low sulfur oil is 5 1 percent sulfur, high sulfur is > 1 percent sulfur.
(h) All low sulfur oil.
(i) Very sparse population; suggest using industrial value.
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10
weighted basis would be the correct one to use to compute total emissions,
the total-installed-capacity basis was used for the computation.
There are no NEDS data from which the annual load factor for the
(9)
residential class may be obtained. The Walden report gives a range of
values from 0.05 for Florida to 0.31 for Maine, with an indicated average
of 0.20. No differentiation on fuel type is recorded.
To summarize, for most practical purposes, for the range of design
firing rates considered herein, from 10^ Btu/hr through 2 x 10^ Btu/hr,
the parameters that fix the annual load factor are the category of use and
the type of fuel. The annual load factor for commercial use runs from
0.6 to 0.8 of the annual load factor for industrial use. The utility
values are closer to the industrial, but there are still variations. It
follows then that, as boiler size increases and the primary boiler use
shifts from residential to commercial to industrial to utility application,
the overall annual load factor will increase; this explains past observations
indicating annual load factors as varying with design firing rate.
Relationship of Annual Load
Factors and Sulfur Content of Fuel
The annual load factor was used primarily for estimating emis-
sions. Sulfur content of the fuel is another factor affecting SO^ emissions.
Hence, the correlation between sulfur content and use factor was examined.
Only residual oil-fueled boilers with design firing rates above 5 x 10^
Btu/hr (mostly utility boilers) showed a significant difference in use
factors associated with fuels of different sulfur controls. The load
factor values for all boiler categories are shown in Table 4.
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11
TABULATION OF BOILER POPULATION
The boiler population is built up in four different ways.
(1) It is assumed that the NEDS data has the total
count on boilers with design firing rates above
5 x 10^ Btu/hr, and on utility boilers. (NEDS
data on boiler count and design firing rate for
all boiler size ranges are given in Table 5.*)
(2) For boilers with design firing rates in the range
of 10 through 5 x 10® Btu/hr; values from the
prior boiler study were adjusted to include hot
water boilers and were used in this study. (These values
are presented in Table 6.) The distribution of this
total boiler population among the fuel and use
categories are based on the NEDS data of Table 5.
NEDS data are incomplete for boilers in this size
range. Hence, ABMA sales data were used to estimate
total capacity in the various size categories.
Two basic approaches for making these distributions
are possible, either (A) to distribute the ABMA data
into fuel and use categories according to the NEDS
data, or (B) to adjust the NEDS data by a conversion
factor derived by comparing NEDS data with ABMA sales
data for the various size categories*". The latter
approach was used. The conversion factor is given
in Figure 1. Figure 2 shows total installed boiler
capacity (by boiler-size categories) as a function
of design firing rate for ABMA data and NEDS data.
Figures 1 and 2 are discussed in detail in
Appendix A.
* One is not to infer the degree of accuracy by the lack of rounding
off of number counts and capacity summations. It was merely more
convenient in handling the data not to continually round off the
values. As will be seen from the discussion, something like ir 10
percent might be a more reasonable order of accuracy.
** The conversion factor approaches 1.0 for boilers vith firing rates
above 7 x 10® Btu/hr (showing NEDS data are relatively complete for
the larger boilers); it is as low as 0.01 for boilers with firing
rates of 10^ Btu/hr (indicating only 1 percent of these boilers
are included in the NEDS data) .
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TABLE 5. NUMBER COUNT OF BOILERS AND TOTAL INSTALLED CAPACITY (10b BTU/HR)
OP NEDS DATA (CORRECTED FOR MISSING STATE DATA) ¦*
Design Firing Rate, BCu/hr
S lze
1+; 1x10 '
b lze 1:
-2xl06
S lze
1
+
CM
C4
5xl06
Size 3: 5+ -10xl06
Size 4
: 1+
2x10?
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Com. Ind.
Ut.
Coca.
Ind
Ut.
Stoker coal
70
25
1
31
18
1
79
63
6
144 120
3
132
19^
¦ n
70
25
1
62
36
2
322
279
26
1,202 948
17
2,054
3,105
244
Pulverized coal
0
4
0
1
7
0
0
11
0
I 12
0
6
41
t
0
4
0
2
14
0
0
41
0
7 95
0
87
664
:e
Residual oil
75
115
4
32
82
7
126
369
7
146 514
12
251
714
17
75
115
4
64
164
14
486
1,474
32
1,189 4,110
82
3,886
10.951
282
Distillate oil
285
202
2
124
144
4
183
268
14
112 176
5
82
169
5
285
202
2
248
288
8
693
1,043
58
839 1,379
36
1,138
2,575
90
By-product gas
0
6
0
0
8
0
0
14
0
0 9
0
0
8
0
0
6
0
0
16
0
0
49
0
0 80
0
0
126
0
Natural gaa
166
226
1
72
161
2
98
433
9
110 477
11
94
622
33
166
226
1
144
322
4
386
1,702
35
888 3,750
78
1,471
9,582
489
(a) New York data and part of West Virginia data were not complete on NEDS computer tapes available for this
project. Hence, the available NEDS data were corrected on the basis of fuel consumption.
-------
TABLE 5. (Continued)
UesLgn Firing Kate, btu/llr
Size 5
: 2+ -s*in
7
Size
6: 5+ -
10xl07
Size
7: 1+ -2x108
S lze
ti
CO
-5x108
Size
?: 5+-
lOxlo8
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Stoker coal
200
490
39
Ill
519
67
24
328
117
10
118
58
0
15
5
6,735
17,469
1,482
8,121
38,108
5,546
3,105
46,925
17,301
.*,873
33,814
lb,503
0
11,071
3,005
PuLverlzed coal
19
70
14
11
97
19
8
208
81
0
165
J02
0
51
235
625
2,679
593
831
8,144
1,549
1,137
30,679
12,517
0
49,927
103,282
0
33,022
168,744
Residual oil
366
961
53
205
589
82
77
379
168
31
214
243
4
44
163
12,358
32,136
2,030
14,523
43,496
5,497
10,666
54,279
25,930
9,757
65,013
74,605
4,209
30,273
111,307
Distillate oil
84
163
5
40
67
14
21
58
43
13
22
67
3
3
33
2,576
5,332
165
2,930
5,264
1,070
3,136
8,358
6.238
4,375
6,530
20,949
1,907
2,492
21,735
By-product gas
0
33
0
0
56
0
0
70
0
0
45
4
0
26
0
0
1,341
0
0
4,001
0
0
9,235
0
0
14,386
1,496
0
16,554
0
Natural gas
130
950
56
74
712
83
51
468
181
27
243
333
5
75
241
4,127
32,600
1,950
5,838
51,544
6,161
6,927
69,656
27,733
9,044
73,780
108,281
2,794
48,794
169,221
-------
TABLE 5. (Continued)
Design FlrtoR Rate, Dtu/hr
Size
io: r -
2x10*
S Lze
11;
2+ -
9
5x10
S i?e
12;
5+ -
•lOxlO9
Slrp
13r 1 +
-?vin10
SI" 14-
>'vin
10
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Com.
Ind
•
Ut.
Com.
Ind.
Ut.
Com.
Ind .
Ut
Stoker coal
0
5
2
0
2
2
0
0
0
0
0
0
0
0
0
0
6,851
3,123
0
7
,600
6,132
0
0
0
0
0
0
0
0
0
Pulverized coal
0
10
266
0
5
125
0
1
53
0
0
2
0
0
4
0
16,019
376,851
0
11
,945
378,536
0
5
,068
327
,022
0
0
22,466
0
0
-
Residual oil
0
12
83
0
1
43
0
5
0
0
0
0
0
0
0
17,450
114,113
0
3
,020
128,886
0
0
26
,906
0
0
0
0
0
0
Distillate oil
0
0
3
0
1
1
0
0
1
0
0
1
0
0
0
0
0
4,129
0
2
,240
2,854
0
0
5
,184
0
0
13,070
0
0
0
By-producc gas
0
4
0
0
0
0
0
0
0
0
0
0
0
0
0
0
5,604
0
0
0
0
0
0
0
0
0
0
0
0
0
Natural gas
4
32
174
1
11
80
0
5
17
1
4
I
1
2
1
6,301
46,063
242,621
2,626
28
,908
247,992
0
38
,964
101
,915
10,350 61
,550
10,957
-
-
-
-------
TABLE 6. COMPILATION OF TOTAL INSTALLED CAPACITIES IN 1971^
In Units of 10^ Btu/lir
Design Firing Rate. Btu/hr
Size 4: 1+ -2x10? Size 5: 2+ -5xl07 Size 6; 5+ -lOxlO7 Size 7: 1+ -2xl08
Gas and oil
453.5
460.0
542.8
340.7
Pulverized coal and cyclone
0.5
3.6
8.9
54.6
S tolcer
5.1
24.3
56.8
67.9
Coal total^
5.6
?7 , 9
65.7
1??. 5
Coal only, exclude multiple
fuel (a)
TOTAL
5.4
24.8
55. 1
94.3
459.1
487.9
608.5
463.2
(a) The present study classified on the basis of the major fuel usage. Thus, the numbers would
fall between these two If the saine assumptions were made as in Reference 1.
-------
0.1
u_
-------
¦ ABM A data as analyzed in Ret I
All boilers
Combined analysis of
ABMA dalo, Ret 4,and
USDC dalo, fief 7
Commercial and
Industrial boilers
(X
NCOS data, gas and oil
hied boilers from Table 5
Data missed by NEDS count;
source of correction factor
given in Figure
J L
I I
J I L
J I L
10"
10"
10 10
Design Firing Rata, Btu/hr
10
to
FIGURE 2. NORMALIZED TOTAL INSTALLED CAPACITIES IN 2:1 SIZE
CLASSES AS A FUNCTION OF DESIGN SIZE
-------
L8
g
(3) The range of boilers with firing rates from 10 through
10? is handled in a manner similar to that of the next
higher range, using ABMA and other data sources^>?). The
procedure is outlined in Appendix B. It might be noted
that in recent years hot air units have started to
make important inroads for firing rates up to 5 x 10&
Btu/hr, but no sales counts appear to be available for
these units and they could not be included.
(4) Residential heating systems are treated separately
(as reported in the next section).
Unfortunatelyj some utility boilers that are reported in Table 5
are not consistent with known boiler data. For example, the largest boilers
ever built are about 1200 to 1500 megawatts, equivalent to about 12 to
15 x 10 Btu/hr fuel input. However, Table 7 lists 8 units above this
size range. Obviously, these units do not exist. Unfortunately, the NEDS
computer tapes that were used as the primary data source on utility boilers
listed these "impossible" units. The scope of this task did not include
correcting the NEDS data and, hence, they are tabulated in Tables 5 and 7.
Although the "impossible" units were included in our number count of boilers,
their reported capacities (up to 54,000 megawatts) were not included in our
boiler capacity tables or figures. These boilers are omitted from calculations
and listings in subsequent tables, but do not significantly affect results.
Unfortunately, it is not so easy to identify possible NEDS errors
at the small-size end of the utility boiler population. Some small boilers
exist at power stations to serve as steam sources for powering auxiliaries
during station startup. Additionally, utilities may have reported data
on boilers used for space-heating of office facilities when the NEDS data
were being compiled. Thus, separating small utility boilers that are real
from NEDS errors i3 beyond the scope of this task and impossible without
a major effort. Again, the small capacity of the units will not affect the
general results reported in this study.
Table 7 is a compilation of the number count and the total installed
capacity in each range of sizes after all corrections have been made. Further-
more, the average hourly fuel consumption, based on the total installed
capacity of each boiler group times annual load factors, are presented. THIS
TABLE REPRESENTS OUR BEST ESTIMATE OF ACTUAL BOILER COUNT, INSTALLED FIRING
CAPACITY, AND AVERAGE HOURLY FUEL CONSUMPTION OR ACTUAL BOILER USE OF U.S.
BOILERS FOR COMMERCIAL, INDUSTRIAL, AND UTILITY APPLICATIONS. (Residential
data are reported in the next section and graphic displays of boiler popula-
tion are given in the following section.)
-------
TABLE 7. NUMBER COUNT, TOTAL INSTALLED CAPACITY (10 BTU/llR) AND AVERAGE
HOURLY FUEL CONSUMPTION (ANNUAL LOAD FACTOR TIML'S TOTAL INSTALLED
CAPACITY) (JO6 BTU/lttO AS A FUNCTION OF DESIGN FIRING RATE,
FUEL TYPE, AND USE.
VesLga Firing Rate, Blu/hr
Slzc 0;
5+ -10x10
5
Size
1: l+ -2xl06
:
2: ?+ -5xlOb
Slz» 3-
s+ -in*tn
b
i
Size 4:1
+ -JxlO7
Com.
I net.
Ut.
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Cora.
Ind.
Ut.
Com.
Ind.
Ut.
Stoker coal
4,910
1,754
1
3,387
1,967
1
4,998
3,946
6
3,917
1,264
3
1,378
2,004
14
4,910
1,754
1
6,774
3.934
2
20,166
17,473
26
32,699
25,789
17
21,441
32,411
244
1,498
747
0
2,066
1.676
1
6,151
7,443
12
9,973
10,986
8
6,540
13,807
117
Pulverized coal
0
281
0
109
765
0
0
689
0
27
326
0
63
428
2
0
281
0
218
1,536
0
0
2,568
0
190
2,584
0
908
6,931
28
0
147
0
92
802
0
0
1,346
0
81
1,354
0
385
3,632
12
Residual oil
5,261
8,067
4
3,496
8,959
7
7,891
23,109
7
3,972
13,983
12
2,620
7,453
17
5,261
8,067
4
6,992
17,918
14
30,437
92,313
32
32,345
111,806
82
40,564
114,311
282
1,28-9
2,969
1
1.713
6,594
5
7.457
33,971
22
7,925
41.145
30
9,938
42,066
104
Distillate oil
19,992
14,169
2
13,547
15,733
4
11,461
16,789
14
3,047
4,758
5
856
1,764
5
19,992
14,169
2
27,094
31,466
8
43,401
65,320
56
22,824
37,514
36
11,879
26,879
90
4,11.8
4,676
0
5.581
10,384
1
8,941
21,556
3
4,702
12,380
5
2,447
8,870
12
By-product gas
0
421
0
0
B74
0
0
877
0
0
245
0
0
84
0
0
421
0
0
1.748
0
0
3,064
0
0
2,176
0
0
1,315
0
0
265
0
0
1,101
0
0
1,933
0
0
1,371
0
0
828
0
Natural gas
11,644
15,853
1
7.866
17,590
2
6,137
27,118
9
2,992
12,976
11
981
6,493
33
11,644
15,853
1
15,732
35,1BO
4
24,174
106,591
35
24,157
102,013
78
15,355
100,021
489
3,703
¦ 8,212
0
5,003
IB.223
2
7.687
55.214
17
S? BGT
17
- Lt
-51,ai_L-
¦ 212-
Sum
41,807
40,545
8
28,405
45,888
14
30,487
72,528
36
13,955
35,582
31
5,898
18,226
71
41,807
40,545
8
56,810
91,782
28
118,178
287,333
151
112,215
281,882
213
90,147
281,868
1,133
10,608
17,016
1
14.455
38.7 80
9
30.236
121.463
49
30.363
120.079
80
24.193
121.014
477
Class sum
82,360
74,307
103,051
49,568
24,195
82,360
148,620
405,662
394,310
373,148
27,625
53,244
151,748
150.522
145,684
-------
TAflLE 7. (Continued)
Design Firing Race, Blu/lic
S tze
5: 2+ -
5*10?
Size
6: 5+ -10x107
S i ze
7: 1+ -2*108
Size 3:
2+ -5xl06
1 Size 9:
5+ -lOxlO8
Com.
lrd .
Ut.
Cora.
Ind,
Ut.
Com.
Ind.
Ut.
Com.
Ind.
Ut.
Com.
Ind,
Ut.
Stoker coal
1.053
2,579
39
336
1,573
67
47
643
117
13
157
58
0
15
5
35,447
91,937
1,482
24.609
115.979
5,546
6,088
92.010
17,701
3,831
45,085
lb,503
0
11,071
3,005
10,811
39,165
710
7,506
49,194
2,657
1,857
39,196
829
1,16a
19,206
7,905
0
2,967
1,439
Pulverized coal
LOO
368
14
33
294
19
16
409
81
0
220
302
0
51
235
3,289
14,100
592
2,518
24,679
1,549
2,229
60,155
12,517
0
66,569
103,283
0
33,022
168,744
1,395
7,388
250
1,068
12,932
655
945
31,521
5,295
0
34,882
43,688
0
19,152
71,379
Residual oil
1,926
5,058
17
621
1,785
82
151
743
168
41
285
243
4
44
163
65,042
169,137
282
44,009
131,806
5,497
20,914
106.429
25,930
13,009
86,684
74,605
4,209
30,273
111,307
1,593
62,242
104
10,782
48,505
2,023
5,124
39,166
9,542
3,187
31,900
27,455
1,031
11,140
57,165
Distillate oil
442
858
5
121
203
14
41
114
43
17
29
67
3
3
33
13,558
28,063
90
8,879
15,992
1,070
6,149
16,388
6,239
5,833
8,717
20,94 9
1,907
2,492
21,735
2,793
9,261
12
1,829
5,264
139
1,267
5,408
811
1,202
2,877
2,723
393
822
2,826
By-product gas
0
174
0
0
170
0
0
137
0
0
60
4
0
26
0
0
7,058
0
0
12,124
0
0
18,108
0
0
19,181
1,496
0
16,554
0
0
4,447
0
0
7,638
0
0
11,408
0
0
12,089
942
0
10,429
0
Natural gas
684
5,000
56
2 24
2,158
43
100
918
181
36
324
33
5
75
241
21,721
276,842
1,950
17,691
156,194
6,161
13,982
136,580
27,733
12,099
98,373
108,281
2,794
48,744
169,221
6,967
149,404
924
5,626
80,908
2,920
4,319
70,798
13,145
3,835
50,957
51,325
888
25,249
80,210
Sura
4,205
14,037
131
1,335
6,183
265
355
2,964
590
107
1,075
707
12
214
677
139,057
587,137
4,396
98,706
456,774
19,823
49,362
429,670
90,118
34,772
324,609
325,118
8,910
142, 161
474,012
23.559
271,907
2,000
26.811
204,441
8.394
13.512
197.497
29.622
9.392
151.911
134.038
2.312
69.759
213.019
Class sum
18,373
7,783
3,909
1,889
903
730,590
575,303
569,150
684,499
625,083
297,466
239,646
240,631
295,341
285,090
-------
0
0
0
4
0
0
0
0
0
0
0
0
0
I
5
1ABLE 7. (Continued)
Design Firing Rate, E
I tu/hr
Size 10:
+ 9
1-2x10*
Size 11:
2+-
9
5x10
Size 12:
+ 9
5 -10x10
Size 13
: 1+-2x1010
Com.
Ind.
Ut.
Corn.
lnd.
Ut.
Com.
Ind.
Ut.
Com.
Ind .
Ut.
0
5
2
0
2
2
0
0
0
. 0
0
0
0
6,851
3,123
0
7,
600
6,132
0
0
0
0
0
0
0
1,836
1,496
0
2,037
2,937
0
0
0
0
0
0
0
10
266
0
5
125
0
1
53
0
0
2
0
16,019
370,857
0
u,
995
378,536
0
5,068
327,022
0
0 22
,466
0
9,291
159,410
0
6,
928
160,121
0
2,939
138,330
0
0 9
,503
0
12
83
0
1
43
0
0
5
0
0
0
0
17,450
114,113
0
3,
020
128,886
0
0
26,906
0
0
0
0
6,422
57,910
0
1,
111
70,068
0
0
17,408
0
0
0
0
0
3
0
1
1
0
0
1
0
0
1
0
0
4,129
0
2.
274
2,854
0
0
5,184
0
0 13,070
0
0
537
0
750
371
0
0
674
0
0
1,699
0
4
0
0
0
0
0
0
0
0
0
0
0
5,604
0
0
0
0
0
0
0
0
0
0
0
3,531
0
0
0
0
0
0
0
0
0
0
4
32
174
1
11
80
0
5
17
1
4
1
6,301
46,063
242,621
2,626
28
,908
247,992
0
38,964
101,915
10,350
61,550
10,981
2,004
23.861
115.010
835
14
.474
117.548
0
20.183
48.308
3.291
31.883
5,191
4
63
528
1
20
251
0
6
76
1
4
4
6,301
91,987
734,837
2,626
53,797
764.400
0
44,032
461,027
10,350
61,550
46,517
2,004
44,941
354,404
835
25
,300
351,045
0
23,122
204,720
3,291
31,883
16,393
595
27 2
82
9
833,125
820
,823
505,059
118,417
401,349
377
,180
227,842
51,567
-------
22
RESIDENTIAL HEATING SYSTEMS
The residential sector includes dwelling units of all types.
The majority of dwelling units in the United States are single family
houses, but the sector also includes mobile homes; duplex, triplex,
and quadruples units; and apartment buildings of five or more dwelling
units. Vacation homes are not year-round residences and are not included.
The number of residential heating systems by type in April, 1970,
as determined by the Bureau of Census, is given in Table 8. In the Census
data, the size of unit was not included, and the fuel type was tabulated
separately. For the purpose of estimating and controlling emissions from
residential heating systems, the type of fuel is of greater significance
than the type of heating unit. Although there are some differences in
emissions among different types of heating units, these are generally small
compared to the differences among fuels. Hence, they were neglected.
The estimated number of residential dwelling units by fuel is
summarized in Table 9. In the multiple dwelling units, some have individual
heating systems and some utilize a central heating system. It is expected
that while most electrical heating systems in apartment houses are in-
dividual, most apartment gas- and petroleum-fueled systems are supplied
from a central boiler.
No specific data on the size of residential heating systems were
found during this study. Some inferences can be made from the estimates
of Table 10. Better estimates of size could be made by considering both
the type of dwelling and the geographic location. That level of detail
could be obtained in a more intensive study but was beyond the scope of
the present investigation.
Estimated fuel consumption for space heating by residential units
is summarized in Table 11. These estimates were based upon data from the
Bureau of Mines and the Stanford Research Institute^^ . The national
average fuel consumption per dwelling unit is also summarized in Table 11.
-------
23
TABLE 8. RESIDENTIAL DWELLING-UNIT
HEATING PLANTS(a) U J
In Thousands of Heating Units
All Units
Occupied
Units
Steam or hot water
13,820
13,211
Warm air furnace
28,772
27,515
Built in electric
3,520
3,236
Floor, wall, or pipeless furnace
5,878
5,552
Room heaters with flue
7,910
7,209
Room heaters without flue
3,949
3,558
Fireplaces, stoves, or portable
3,269
2,766
heaters
None
Total
581
67,699
398
63,445
(a) Includes all year-round living quarters—single family houses,
apartments and mobile homes.
TABLE 9. ESTIMATED NUMBER OF DWELLING UNITS
HEATED BY VARIOUS FUELS
In Millions of Dwelling Units
April,
1970
End,
1971
December,
1974
Natural gas
35.0
36.7
39.4
Oil
16.5
15.8
14.8
Electricity
4.9
5.7
8.8
Bottled or LP gas
3.8
\
Coal or coke
Wood
1.8
0.8
> 6.6
) 6.5
Other
0.2 j
)
No heat
OA
0.4
0.4
Total
63.4
65.2
69.9
-------
24
TABLE 10. ESTIMATED NUMBER OF DWELLING UNITS,
BY TYPE, HEATED BY VARIOUS FUELS
IN DECEMBER, 1974
In Thousands of Dwelling Units.
Single Family
Mobile
2-4
5+
All
Fuel
Dwelling
Home
Units
Units
Units
Natural gas
27,400
925
5,625
5,475
39,425
Oil
9,350
1,300
1,750
2,400
14,800
Electricity
5,000
450
625
2,700
8,775
Other
4,950
850
450
675
6,925
Total
46,700
3,525
8,450
11,250
69,925
(a) Other is about 75 percent LP gas.
TABLE 11. ESTIMATED 1971 FUEL CONSUMPTION
FOR RESIDENTIAL SPACE HEATING
Fuel Consumed Per
Fuel Consumed, Dwelling Unit,
1012 Btu 106 Btu
Natural gas
3,695
100
LP and bottle gas
530
139
Kerosine
380
153
Distillate fuel oil
2044
Residual fuel oil^a^
negligible
—
Coal(a)
negligible
—
(a) There was probably a small amount of residual fuel oil and coal
consumed in central heating systems of apartment buildings, but
this is believed to be negligible based on Reference 11.
-------
25
The available population data on residential heating systems is
not in a form compatible with the majority of the boiler analysis. To
put it in a compatible form, some assumptions have to be made that are
believed sufficiently accurate to complete the distribution picture. How-
ever it is obvious that size distributions of the small heating units
would be required to produce more reliable results.
To carry out the analysis, arbitrary distributions were made
in multiple family units between those having a single furnace per family
unit, and those having one furnace or boiler per complex. As a result the
number of heating units becomes less than the number of family units.
To estimate fuel consumption, an arbitrary, but reasonable,
design firing rate was assigned to the heating units in each class, and the
(9)
Walden annual load factor of 20 percent as an average for residential
units was applied to the data. The total consumption agreed with the
values given in Tables 10 and 11.
Tables 12 and 13 resulted from these assumptions. Further
refinement was not justified considering the data that are available.
Table 13 (residential data) is used to complement Table 7 (which con-
tains data on commercial, industrial, and utility boilers).
From the viewpoint of reducing emissions, the above data can
provide only general guidance. When combines with information presented
elsewhere in this report, it gives perspective on the relative magnitude
of emissions from residential heating systems as compared with utility,
industrial, and commercial boilers. If, in the judgment of EPA, residential
heating is a problem worthy of further investigation, a regional approach
is suggested. The requirements for residential heating are greatest in
the northern states, and the use of petroleum is greatest in. the northeast.
Combustion of petroleum fuels emits more atmospheric pollutants
than other residential heating methods. (The use of coal in residential
heating is negligible.) In addition, because heating is seasonal and the
health hazards of atmospheric emissions appear to depend upon relatively
short-term levels (hours to days), the use of heating systems in winter
would have greater meaning than the national year-round average. A more
meaningful study would consider the consumption of fuels in the winter
months in the northeast and possibly in other selected northern locations.
-------
26
TABLE 12. DISTRIBUTION OF NUMBER OF UNITS (UPPER VALUE) AND
DESIGN FIRING RATE OF INDIVIDUAL UNITS (LOWER VALUE)
TO MATCH DATA IN TABLES 10 and 11 AND ASSUMPTION
OF 20 PERCENT ANNUAL LOAD FACTOR
Single Family Furnace Multiple Family Fiirnace
Mobile Homes Small Units Large Units Small Units Intermediate Units Large Units
LPG
Natural Gas
Oil
637,500
50,000
925,000
40,000
1,300,000
50,000
3,704,250
50,000
32,336,000
50,000
4,880,000
80,000
852,000
100,000
2,064,000
100,000
5,940,000
120,000
0
0
350,000
240,000
220,000
320,000
C
0
225,000
360,000
150,000
480,000
0
0
150,000
540,000
100,000
720,000
TABLE 13. NUMBER COUNT, TOTAL INSTALLED CAPACITY (10 BTU/HR),
AND AVERAGE HOURLY FUEL CONSUMPTION (ANNUAL LOAD FACTOR
TIMES TOTAL DESIGN FIRING CAPACITY) (106 BTU/HR) AS A
FUNCTION OF DESIGN FIRING RATE AND FUEL TYPE FOR
RESIDENTIAL BOILERS
Boiler Design Firing Races. Btu/hr
2+-5xl04 5+-10xl04 l+-2xl05 2+-5xl05 5+-10xl05
Distillate oil
and kerosine
6,180,000
455,400
91,080
5,940,000
712,800
142,560
370,000
142,400
28,480
100,000
72,000
14 ,400
Natural Gas
925,000
37,000
7,400
32,336,000
1,616,800
323,360
2,064,000
206,400
41,280
575,000
165,000
33,000
150,000
81,000
16,200
LPG
4,341,750
217,088
43,418
852,000
85,200
17,040
TOTAL
925,000
37,000
7,400
42,857,950
2,289,288
457,858
8,856,000
1,004,400
200,880
945,000
307,400
61,480
250,000
153,000
30,600
Normalizing Hacio
1.322
1.000
1.000
1.322
1.000
-------
27
GRAPHICAL SUMMARY OF BOILER
POPULATION DATA
This section of the report contains several figures that
graphically portray the summary data on boiler population presented
in Tables 7 and 13.
Figure 3 presents the total installed capacity distribution
for 2:1 firing rate increments. Some increments tabulated in Table 7
cover a 2.5:1 firing rate increment; data for these increments were
normalized to a 2:1 design firing rate increment before plotting on
Figure 3. Figure 3 is intended to show graphically total installed
capacity versus design firing rate by small increments for all boilers.
Similar plots can be made for individual fuel and/or use, and for average
hourly fuel consumption or actual boiler use (design firing rate times
the annual load factor). The total installed capacity and actual boiler
use show a peak in the residential area, a low value at a design firing
rate of about 10 Btu/hr, climb smoothly to a peak at a design firing
9
rate of about 10 Btu/hr, and then drop rapidly. Instinctively, it is
felt that both peaks may be too sharp. It is known that data on com-
mercial warm air heaters are missing in the low part of the curve; though
the missing data would not eliminate this low region, it would make it
considerably less pronounced.
Figure 4 shows the distribution of design firing capacity based
on type of boiler use, compiled from Table 7. Because of the small number
of boilers at the high design firing rates, large fluctuations result and
the data are not shown. As expected, it is clear that the typical boiler
use changes with design firing rate. As boiler size increases, the appli-
cation of most boilers within a given size increment shifts from residential
to commercial, to industrial, and to utility for the largest size boilers.
Figure 5 presents the cumulative installed boiler capacity for
all boilers included in this study. Separate curves are shown for coal-
fired, oil-fired, and gas-fired boilers and for boilers fired by all
-------
22-9
'T i °
° o
o ° o
z
Unknown
quantity of ro
commericial 00
warm air furnaces0 0
should be added
here 0
o o Remaining boilers all
grouped here •-*
i—l! i i i lI i l i l! J i i lJ i i L_lJ ' I i i 1 I 111
I07 I08
Design Firing Rate, Btu/hr
I04 lO5 lO6 lO7 I08 io9 lO10 10"
FIGURE 3. TOTAL INSTALLED CAPACITY IN EACH BOILER SIZE INCREMENT
-------
29
.0
0.8
Utility
.6
Industr ial
0.4
Residential
0.2
Commercial
0
10
Oesign Capacity,Btu/hr
FIGURE 4. BOILER USE RELATED TO BOILER SIZE
-------
30
Boiler Design Firing Rate , megawatts (thermal)
O.Ol
100
1000
10,000
I 1,000
3200
10,300
3000
0,000
O - Coal
A - Oi I
Q - Gas
X - Sum of coal,oil, and gas
2800
9300
9 000
2600
8 300
2400
2200
7500
2 7000
2000 o
O 6500
o
a
o sooo
All fuels
1800 O
3 300
1600 a
o
3000
400
CD
<2 4300
1200
4 000
3 3300
000
Gas
3 000
800
2300
€00
2000
1300 -
400
1000
Coal
200
300
Residential
Industrial
Commercial
Boiler Design Firing Rate, Btu/hr
FIGURE 5. CUMULATIVE INSTALLED BOILER CAPACITY
FOR COAL, OIL, AND GAS-FIRED BOILERS
-------
31
fuels. The size ranges generally used to define boiler use are shown
across the bottom of the figure. (Early discussions showed that these
definitions are not adequate for defining actual boiler use as there is
considerable overlap in the use of many sizes of boilers.)
Examination of Figure 5 shows that gas- and oil-fired boilers
with firing rates below 10^ Btu/hr make up 36 percent of the total in-
stalled boilers capacity in the United States. Gas- and oil-fired boilers
continue to account for a sizeable portion of boiler capacity, even for
the larger sizes of boilers.
Figure 6 presents the cumulative actual boiler use (or average
hourly fuel consumption) for all boilers included in this study.
In examining Figure 6, it is found that gas- and oil-fired boilers
g
with firing rates below 10 Btu/hr contribute 21.6 percent of actual boiler
use (versus 36 percent of installed boiler capacity). From Figure 6 it is
seen that the curve for actual boiler use (all fuels) approaches a straight-
line (with a hump at about 2 x 10^ Btu/hr and a dip at about 3 x 10 Btu/hr).
The interpretation of this is that, from the viewpoint of total fuel use,
nearly all sizes of boilers consume nearly equal quantities of fuel. Hence,
small boilers have as significant an impact as large boilers. Of course,
there is a shift of fuels with the size of boilers. The smaller units
nearly all fire gas and oil; coal does not become a significant factor
until boiler design firing rates exceed 10^ Btu/hr.
-------
32
Boiler Design Firing Rate , megawatts (thermal)
0 01
100
1000
10,000
3800
3 600
1000
3400
O - Caal
A - Oil
a - Gas
X - Sum of coal, oil,and gcs
3200
900
3000
2300
800
2400
700 S
u 2 200
6 00 —
2000
All fuels
I 600
400 -
Gas
1200
3 00 °
1000
Oil
o
800
200
600
Coal
400
I 00
200
10s
Ccmmercia
Residential
Industria
Utility
Boiler Design Firing Rate , Btu/hr
FIGURE 6. CUMULATIVE ACTUAL BOILER USE (OR AVERAGE HOURLY
FIRING RATE) FOR COAL, OIL, AND GAS-FIRED BOILERS
-------
33
ESTIMATED EMISSIONS OF SO„, NO , AND PARTICULATE
2-> x-a
Tables 14, 15, and 16 are estimates of SO^, NO^, and particulate
emissions, respectively, for the total national boiler inventory of com-
mercial, industrial, and utility boilers. Tables 17, 18, and 19 are
estimates of SO , NO , and particulate emissions from residential units.
X (13)
These estimates were made using published EPA emission factors and
other recent emission data^^'^\ except for by-product gas fuels. Two
numbers are given for each boiler size and category. The top number is
an estimate of potential annual emissions based on the total installed
capacity of a given class of boilers. The second number is an estimate
of annual emissions based on annual fuel consumption or actual boiler use
(total installed capacity adjusted by the annual load factor) for the
respective class.
In the case of by-product gas, SO^ emissions were based on the
sulfur content of typical coke-oven gas. Precise estimates of N0x or
particulate emissions were not possible since emissions vary with fuel
composition and the actual fuel composition was unknown. Therefore, EPA
(13)
emission factors for natural gas combustion in industrial boilers
were used to estimate NO and particulate emissions from boilers fired
x
with gaseous fuels other than natural gas or LPG.
Figures 7, 8, and 9 show cumulative emissions of SO2, NO^,
and particulate, respectively, for all boilers based on actual boiler
use. On each figure, where pertinent, separate curves are shown for
gas-fired, oil-fired, and coal-fired boilers and for the sum for all
fuels. Interesting observations from these figures include:
-------
34
Figure 7 - About 11 percent of SO^ emissions are from boilers with
firing rates below 10? Btu/hr (the nominal "residential"
and "commercial" boilers)
- About 59 percent of SO^ and emissions are from boilers
with firing rates over 5 x 10^ Btu/hr (the nominal
"utility" boilers)
- Oil-fired boilers contribute greater SO^ emissions than
do coal-fired boilers for small boilers. For each firing
rate size increment above about 10^ Btu/hr, coal-fired
boilers contribute greater SO^ emissions than do oil-fired
boilers
Figure 8 - About 23 percent of NO emissions are from boilers with
firing rates below 10^xBtu/hr (the nominal "residential"
and "commercial" boilers)
- About 50 percent of NO emissions are from boilers with
firing rates over 5 x ^O® Btu/hr (the nominal "utility"
boilers)
- Except for small coal-fired units (where the number of units
is small), boilers firing all fuels contribute significantly
to NO emissions over nearly the entire range of firing
rates
Figure 9 - About 3.0 percent of particulate emissions are from boilers
with firing rates below 10? Btu/hr
- Coal-fired boilers account for nearly all particulate
emissions.
-------
TABLE 14. SULFUR DI0X1DU EMISSIONS (10NS/YH) BY BOILER S1ZL CLASS (a)
Top Number is Potential Emissions (based on Installed
Boiler Capacity}, Lower Number Is Actual Emissions
(Based on Annual Fuel Consumption Or Actual Holler Use)
Fue I
Size 0:
5+-10 x 105
Btu/hr
Size I;
l+-2 x 106
Btu/hr
Size 2;
2+- 5 x 106
Btu/hr
Size 3:
5+-10 x 106
Btu/hr
Com.
I nd.
Utility
Com.
I nd.
Utility
Com.
I nd
Utility
Coin.
1 nd.
Utl lity
Stoker Coal,
13,993.0
5,027.5
0
19,305.3
8,143.8
0
55.398.3
57,938.
0
186,993.2
74,815.7
0
Low Sulfur
4,269.3
2,509.3
0
5,887.9
4,065.8
0
16,897.5
24,661.8
0
57.032.1
31,871.?
0
Stoker Coal,
40,155.0
3,497.2
15.6
55,398.0
12.746.1
31.a
169,298.4
501.124.2
1.941.9
154,839.3
313,632.4
0
High Sulfur
12,250.0
1,489.1
0
16,896.1
5,430.2
15.6
51,638.9
213,466.7
896.2
47,224.6
133,605.8
0
Pulverized Coal,
0
944.8
0
821.2
5,164.4
0
0
8,578.6
0
735.0
11,718.2
0
Low Sulfur
0
494.3
0
346.5
2,696.5
0
0
4,496.2
0
313.4
6,140.3
0
Pulverized Coal,
0
3,118.0
0
0
17.043.5
0
0
27,816.6
0
0
0
0
lllgli Sulfur
0
1,087.4
0
0
8,899.0
0
0
14,580.8
0
0
0
0
Residual Oil,
12,299.0
27,378.0
0
16,345.4
60,836.2
40.9
92.259.0
354,549.5
211.4
63,543.9
302.675.7
544.5
Low Sulfur
2,394.8
10,080.0
0
3,182.6
22,388.1
14.7
22.603.5
130,473.5
79.2
15,569.0
11,135.7
199.3
Residual Oil,
39,770.0
78,760.0
39.2
52,855.4
174,938.2
19.6
85.125.3
1,050,932.6
52.4
1,074.148.4
1,245,368.0
165.5
lll£h Sulfur
9,744.3
28,987.0
9.9
12,949.5
64,379.7
6.9
2.055.4
386,741.1
19.8
263.184.3
4 58,300.0
60.4
Diac 11 lace Oil,
39,001.0
17,713.0
0.9
35,237.4
39.336.0
3.4
49.072.0
60,079.7
34.0
3J ,491.2
92,901.1
15. 7
Low Sulfur
5,355.6
5,845.5
0
7,258.4
12,981. 2
.4
9.834.9
12,377.0
4.9
6,899.6
30,658.3
2.2
DIs L11 lute Oil,
12.555.3
4,301.3
0
17,015.5
9,552.4
0
26,593.3
24,484.6
0
12,684.5
31,656.6
0
lllgli Sulfur
2,586.3
1,419.6
0
3.504.9
3,152.6
0
5,478.3
5,044.3
0
2.613.4
10,447.0
0
By-product Gas,
0
. 9.8
0
0
40. 5
0
0
71.0
0
0
41.8
0
Low Sulfur
0
6.1
0
0
25. 5
0
0
44.8
0
0
26.4
0
By-product Cds,
0
0
0
0
0
0
0
0
0
0
714.3
0
lllgli Sulfur
0
0
0
0
0
0
0
0
0
0
135.0
0
Natural Caa,
30.6
40.9
0
41.4
92. 5
0
63.6
280.3
0
63. 5
268.3
0
Low Sulfur
9.7
21.6
0
13.2
47.9
0
20. 2
145.2
0
20. 7
139.0
0
Natural Cas,
0
0
0
0
0
0
0
0
0
0
0
0
lllgli Sulfur
0
0
0
0
0
0
0
0
0
0
0
O
(a) Average sulfur contenc of fuels fired la each class of boilers obtained from NEDS daca (Reference 2).
-------
IAI1LI. 14. ((onLlnued)
Size 4: l*-2 x 107 Btu/lir Size 5. 2+-5 x iq7 Bt»/I>r Sice 6: 5*-I0 » 107 Btu/lir Size 7: l+-2 x 10B Btu/lir
Fuel Coin. Ind. Utility Com. Ind. Utility Com. Ind. Utility Coin. Ind. Utility
Stoker Coal,
49,
113.
2
101,
075.
7
8,
,488.
7
87,
,819.
6
187,
,626.
8
3,
,601.
2
66,
,312.
8
249,
,368.
1
25,
,293.
8
6,
,334.
6
254.
713.
7
60,
,o36.
2
Low Sulfur
14.
,980.
6
43,
058.
3
4,
,074.
9
26,
,784.
0
79,
,928.
7
759.
I
19,
,920.
6
105,
,772.
9
12,
,118.
1
I,
,932.
1
108,
,507.
3
2,
,839.
5
Stoker Codl,
206,
802.
6
561,
,292.
9
1
,980.
I
330,
,131.
8
1,429,
,050.
3
24,
,912.
2
2 57,
,673.
4
1.502,
,051.
4
52,
,515.
3
94,
,402.
6
1,092,
,888.
4
170,
,690.
9
High Sulfur
64,
,869.
7
238,
,886.
,4
948.
8
100,
,687.
8
608,
,772.
8
11
.934.
8
78,
,593.
9
637,
, 114.
0
25,
,158.
5
28,
,795.
5
465,
,567.
5
7,
,994.
5
Eulverlzed Coal,
0
36,
,825.
1
9.
3
14,
,272.
5
27,
,462.
6
I
,459.
4
3,
,816.
2
37,
,197.
8
I,
,724.
4
7,
,356.
2
130,
,612
4
11.
, 133.
0
Low Sulfur
0
19,
,297.
3
40.
0
6,
,053.
5
14,
,389.
6
616.
0
1,
,618.
5
19,
,869.
,5
729.
, S
3,
,118.
9
68,
,440.
7
4,
,709.
9
Pulverized Coal,
5,
,727.
32,
,045.
.2
222.
3
22,
,297.
2
179,
,053.
5
1
.993.
6
U,
,362.
4
314,
,961.
7
42,
.726.
6
10,
,351.
7
699,
,090.
0
264,
,865.
6
lllgli Sulfur
2,
,428.
.3
16,
791.
.9
95.
3
9,
,457.
4
93,
,818.
9
841.
8
4,
,823.
3
165,
,041.
7
18,
,068.
.6
4,
.472.
9
366,
,320.
11?,
,045.
8
Residual Oil,
79
.17 1.
.9
295,
,755.
.5
455.
7
107
,708.
6
333
. 207.
6
290.
.9
78
,357.
,5
321,
,849.
8
7
.562.
, 3
44
,111.
.5
244,
,067.
9
64,
,851
2
Low Sulfur
191
,396.
.6
108,
, 100.
.6
168.
9
2,
,637.
.9
122
.619.
,7
107.
.3
19
, 197.
2
11
, 844.
2
2
.783.
. 1
10
O
CO
®
.9
89,
,897.
2
23,
,864.
6
Residual Oil,
316,
,506.
.0
839,
,968.
.0
3
.320.
4
414,
, 158.
,7
1,300,
.827.
1
.949.
6
288,
,704.
,7
1,099,
,533.
39,
,487.
. 3
116
.918.
.4
739,
,378.
5
130,
.721.
8
High Sulfur
77,
,542.
.9
309,
,105.
1
.225.
1
10
,143.
8
478
.701.
8
719.
.0
70
,731.
. 1
404,
,632.
14
,532.
.4
28
.646.
.5
272,
,092.
4
48,
,104.
4
Distillate Oil,
9,
,435.
.5
38,
,537.
.8
83.
2
11,
,580.
.6
26
,111.
3
0
9,
,110.
.2
33,
,281.
.4
1
,438,
.7
10
.141.
.2
75,
,331.
1
7,
,774.
1
Low Sulfur
I,
,943.
6
12,
,717.
.4
11.
1
2
,385.
.7
8
,616.
.9
0
1
,876.
.7
10,
,955.
186.
.9
2
00
0
.6
24,
CD
I
1
,010.
5
Distillate Oil,
15,
,086.
.6
8,
,811.
.6
0
11
,001.
.8
48
,802.
. i
0
3
,499.
.1
32
,331,
. 1
4
,304
.5
2
,017.
.2
6
,358.
, 5
0
High Sulfur
3,
,107.
.8
2,
,907.
.6
0
2
,266.
.2
16
.105,
.4
0
720.
.6
10
,642,
.3
558,
.2
415
.6
2
.098.
.3
0
By-product Gas,
0
30,
.5
0
0
106,
.3
0
0
212
.8
0
0
314.
.6
0
Lou Sulfur
0
19
.2
0
0
67,
.0
0
0
134
. 1
0
0
198,
. 2
0
By-product Gas,
0
0
0
0
572.
.3
0
0
681
.0
0
0
1
,048.
.0
0
High Sulfur
0
0
0
0
360.
6
0
0
429,
.0
0
0
660.
. 7
0
Natural Gas,
AO.
4
263.
1.
3
57.
. 1
728.
5.
2
46.
.5
410.
.8
16.
.2
36.
.8
359.
72.
.9
Low Sulfur
12.
8
1,
,226.
.3
6.
1
18.
.3
392,
,9
2.
.4
14.
.8
212.
.8
7,
.7
11
.4
186.
34.
.6
Natural Cas,
0
0
0
0
0
0
0
0
0
0
0
0
High Sulfur
0
0
0
0
0
0
0
0
0
0
0
0
-------
TABLE 14* (Continued)
Fuel
Size 8:
2+-5 k 10®
Btu/hr
S Ize
9: 5+-10 x 101
' Btu/hr
Size 10: 1+-
2 * lo' Btu/hr
Com.
Ind.
Utility
Com,
I rid.
Utility
Com.
lnd.
Utlllty
Stoker Coal,
6,927.6
86,723.6
3,199.8
0
6.169.6
1,892.3
0
27,157.6
0
Low Sulfur
2,111.9
36,943.9
1,532.7
0
1,653.5
5,694.9
0
7,277.9
0
Stoker Coal,
59.889.0
227,296.1
268,163.2
0
471,614.2
41,765.2
0
46,209.7
158.391.8
High Sulfur
18,260.1
96,827.0
128,451.0
0
126.393.5
20,000.1
0
12,363.4
75,873.9
Pulverized Coal,
0
99.358.1
99.744.3
0
41,274.4
233,517.5
0
27.751.7
493,300.2
Low Sulfur
0
52,063.5
42,191.4
0
23,938.1
98,778.0
0
16,096.0
212,041.2
Pulverized Coal,
0
716.952.4
2.896.232.3
0
1 .568,542.4
4,439,993.3
0
253,371,6
9,026.003.0
High Sulfur
0
375.681.0
1,225.072.4
0
909.683.0
1,878,124.8
0
146,954.9
3,879,758.0
ResLdual Oil,
23,647.4
71,458.5
194,919.3
25,157.
2
57,840.4
346.274.4
0
15,705.8
205,602.5
Low Sulfur
5.793.0
26.297.0
71.731.2
6,162.
3
21,?84.4
177,839.5
0
5,780.0
104,339 0
Residual Oil,
36,086.9
756,032.4
494,003.2
0
203,247.9
471,242.3
0
90,857.1
234.660.3
111 git Sulfur
8,841.0
278,222.2
181,797.6
0
74,792.0
242,020. 2
0
33,438.0
119.085.3
Distillate Oil,
5,681.0
5,621.2
22,203.6
1,689.
8
1.709.2
21,967.0
0
0
17,016.4
Low Sulfur
1,170.7
1,855.3
2,886.1
348.
2
563.8
2,856 1
0
0
2,213. 1
Distillate Oil,
0
0
0
0
0
0
0
0
0
High Sulfur
0
0
0
0
0
0
0
0
0
By-product Cas,
0
412.6
0
0
0
0
0
0
0
Low Sulfur
0
260.1
0
0
0
0
00
0
0
By-product Cas,
0
1,110.9
69J. 2
0
3,835.1
0
0
1,298.3
0
High Sulfur
0
700. 2
436.5
0
2.416.1
0
0
818.0
0
Natural Gas,
71.8
258.7
284.8
7.
,3
128.0
445.0
16.6
121.1
638.0
Low Sulfur
10.0
134.0
135.0
2.
3
66.4
211 .0
5.3
62. 7
302. 5
Natural Cas,
0
0
0
0
0
0
0
0
0
High Sulfur
0
0
0
0
0
0
0
0
0
-------
TABLE 14. (Continued)
Fuel
Size
11: 2+-5 x
109 Btu/hr
Size
12: 5+ -lOxlO9 Btu/hr
Size
13: 1+
-2xl010 Rtu/
Com.
Ind.
Utility
Com.
Ind.
Utility
Com.
Ind.
Utility
Stoker Coal,
0
0
0
0
0
0
0
0
0
Lou Sulfur
0
0
0
0
0
0
0
0
0
Stoker Coal,
0
177,243.8
157,332.4
0
0
0
0
0
0
High Sulfur
0
47,506.0
75,356.4
0
0
0
0
0
0
Pulverised Coal,
0
0
1,019,488.0
0
0
593,083.0
0
0
0
Low Sulfur
0
0
43,124.5
0
0
?50,874.0
0
0
0
Pulverized Coal,
0
84,626.2
9,839,853.0
0
232,136.0
6,370.437.0
0
0
765,264.0
High Sulfur
0
48,993.4
4,162,264.0
0
134,613.0
2,694,689.0
0
0
323,703.0
Residual Oil,
0
0
407,225.9
0
0
0
0
0
0
Low Sulfur
0
0
221,385.3
0
0
0 0
0
0
0
Res IduaI Oil,
0
0
716,123.3
0
0
306.257.5
0
0
0
High Sulfur
0
0
389,316.1
0
0
198,146.6
0
0
0
Distillate Oil,
0
0
4,539.0
0
0
16,124.9
0
0
22,804.9
Low Sulfur
0
0
590.0
0
0
2,096.5
0
0
2,964.5
Distillate Oil,
0
0
0
0
0
0
0
0
0
High Sulfur
0
0
0
0
0
0
0
0
0
By-product Cas,
0
0
0
0
0
0
0
0
0
Low Sulfur
0
0
0
0
0
0
0
0
0
By-product Cas,
0
0
0
0
0
0
0
0
0
High Sulfur
0
0
0
0
0
0
0
0
0
Natural Cas,
6.9
76.0
652.2
0
102.5
268.0
27.2
161.9
28.9
Low Sulfur
2. 2
38.0
309.1
0
53. 1
127.0
8.7
83.8
13.7
Natural Gas,
0
0
0
0
0
0
0
0
0
High Sulfur
0
0
0
0
0
0
0
0
0
-------
(a)
TABLE 15. EMISSIONS OF OXIDES OF NI1ROCEN (TONS/YR) BY BOILER SIZE CLASS
Top Number la Potential Emissions (Based on Installed
Poller Capacity); Lower Number is Actual Emissions
(Based on Annual Fuel Consumption or Actual Boiler Use)
Fuel
Size 0:
S+ -10xl05
Bfu/lir
SUe 1:
1+ -2xl0b
Btu/lir
Size 2;
2+ -5xl0b Utu/lir
Size 3:
56 -10x106
Btu/hr
Com.
Ind.
Utility
Com.
Ind.
Utility
Cora.
Ind.
Utility
Corn.
Ind.
Utility
Stoker Coal
12,324.1
4,402.5
2.5
17,00^.7
9,874.3
5.0
50,616.7
43,857.2
65.3
82,074. 5
64,730.4
42.7
3,760.0
1.875.0
0
5,185.7
4.206.8
2.5
15,439.0
18,681.9
30. 1
25,032.2
27,574.9
20. 1
Pulverised Coal
0
845.8
0
656. 2
4,623.4
0
0
7.729.7
0
571.9
7,777.8
0
0
442.5
0
276.9
2.414.0
0
0
4,051.5
0
243.8
4.075.5
O
Residual Oil
9.206.7
14,121.3
12.3
12.236.0
31,356.5
43.0
53.264.8
161,547.8
98.3
56,603.8
195,660.5
251. 7
208.3
5,195.0
3. 1
2,997.8
11,539.5
15.4
13,049.6
59,449.3
36.8
13,868.8
72,003.8
92. 1
Distillate Oil
37.584.9
26,654.7
6.2
50.936.7
59,156.1
24.6
81,593.9
122.801.6
171.9
42,909. 1
70,526.3
110 5
7.741.9
8,790.9
0
10,492.3
19,521.9
3.1
16.809.1
40,525.1
24.6
8.839.8
23,274.4
15 4
By-product gaa
0
322.9
0
0
1.340.7
0
0
2,350.1
0
0
1,669.0
0
0
203.3
0
0
845.7
0
0
1,482 6
0
0
1,051.6
0
Natural Caa
5.100.0
12.159.3
2.6
6,890.6
26,983.1
10. 5
10,588.2
81,755.3
' 92.0
10,580.8
78,244 0
205. 1
1,621.9
6,298.6
0
2.191.3
13,977.0
5.3
3,366.9
42,149.1
44.7
3.J66.9
40.530.6
97.3
(a) Emission factors arc from Reference IJ.
-------
1AULK 15. (('out inued)
Fue I
« I r <• 4 •
»+ -?k107
S1tc 5:
-5x10*
Utii/lir
S1 ze
6: 5+ -10xl0?
Btu/hr
Size 7;
; 1+ -2xL06
Btu/hr
Coui.
T [id
Utility
Cora.
I nd.
Utility
Cora.
Ind
Utility
Com.
1 (id .
Utility
Stoker Coal
53,816.9
81,351.6
612.4
88,972.0
230.761.9
3,719.8
61,768.6
291 .107.3
13,920.5
15,280.1
230.945.0
44,429.5
16,415.A
34,655.6
293.7
27,135 6
98,304.2
1,782.1
18,840. 1
123,476.9
6,669. 1
4,661. 1
98,256.5
2,080.8
Pulverized Coal
2,733.1
20,862.3
84.3
9,899.9
42.441.0
1.781.9
7,579.2
74,283.8
4,662.5
6,709.3
181,066.6
37,676.2
1,158.9
10,932.3
36.1
4,199.0
22.237.9
752.5
3,214.7
38,925.3
1,971.6
2,844.5
94,878.2
15,938.0
Residual Oil
70,987.0
200,044.3
865.7
113,823.5
295,989.8
865.7
77,015.8
230.660.3
16,875.8
36,599.5
186.250.8
79,605. 1
17,391.5
73,615.5
319.3
2,787.8
108,923 5
319.3
18,868. 5
84,883.8
6.210.6
8,967.0
68.540.5
29,293.9
Dlstl llace Oil
22,332.5
50,532.5
276.3
25,489.0
52,758.4
276.3
16,692.5
30,065.0
3,284.9
11.560.1
30.715.4
19,153 7
4,600.4
16,675.6
36.8
5,250.8
17,410 7
36.8
3,438.5
9,896.3
426.7
2,382.0
10,167.0
2,489 8
By-product Gas
0
1.008.6
0
0
5,413.5
0
0
9,299 I
0
0
13,888.8
0
0
635.0
0
0
3,410.8
0
0
5,858.3
0
0
8,749 9
0
Natural Caa
6,725.5
76.716.1
1,286.0
9,513.8
212,337.8
5,128.0
7,748.7
119,800.8
16. 202.0
6,124.1
104,756.9
72,932 0
2,138.8
39,739.0
610.0
3,051.6
114,592.9
2,429.9
2.464. 2
62,056.4
7,679.0
1,891.7
54,30 2. 1
34,568.7
-------
TABLE 15. (Continued)
Fuel
Size B:
2+ -5x108 Btu/hr
Size
9: 5+ -10x108 Btu/hr
S Ize
10: 1+ -2x10* Btu/hr
Com.
Ind.
Utility
Cora.
Ind.
Utility
Com.
1 nd.
Uti lity
Stoker Coal
9,615.8
113,163.4
41,422.5
0
27,788.2
7,542.6
0
40,207.7
930.851.1
2,931.7
48,207.1
19,841.6
0
7,447.2
3,611.9
0
23,320.0
400,119. 1
Pulverized Coal
0
200,372.7
310,881.8
0
99,396.2
507,919.4
0
48,217.2
1,116,279.6
0
104,994.8
131,500.9
0
57 .647. 5
214,850.8
0
27,965.9
479,824.1
Residual Oil
22,765.8
151,697.0
2?9,037.4
7,365.8
52,977.8
341,712.5
0
30,537.5
350,326.9
5,577.3
55,825.0
84,286.9
1,804.3
19,495.0
175,496.6
0
11,238.5
177,783 7
Distillate Oil
10,966.0
16,388.0
64,313.4
3,585.2
4.685.0
66,726.5
0
0
12,676.0
2,259.8
5,408.8
8,359.6
738.8
1,545.4
8,675.8
0
0
1,648.6
By-product Gas
0
14,711.8
3,934.2
0
12,696.9
0
0
4,298.2
0
0
9,272.3
2,477.3
0
7,999.0
0
0
2,708.3
0
Natural Cas
5.299.4
75,452.1
284,7 57.4
1,223.8
37,386.7
445,017.4
2,759.8
35,330.0
6 3 8,044 .7
1,679.7
39,084.0
134,974.5
388.9
19,366.0
210,936.0
877.8
18,301.4
302,453.3
-------
TABLE 15. (Continued)
Fuel
Size
11: 2+ -5x10
® Btu/hr
S lie
12: 5+ -lOxlO9 Btu/hr
Size
13: 1+ -2xl010 Btu/hr
Com.
lad.
Utili ty
Com.
Ind.
Utility
Com.
Ind.
Ut lllty
Stoker Coal
0
19,076.0
15,391.3
0
0
0
0
0
0
0
5,112.9
7,371.9
0
0
0
0
0
0
Pulverized Coal
0
36,105.0
1,139,393.4
0
15,254.7
984,336.2
0
0
67,622.7
0
20,853.3
481,964.2
0
8,846.4
416,373.3
0
0
28,604.0
Residual Oil
0
5, 285.0
395,680.0
a
0
82,601.4
0
0
0
0
1,944.3
215,108.8
0
0
53,442.6
0
0
0
Distillate Oil
0
4,275.1
8,761.8
0
0
15,914.9
0
0
40,124.9
0
1,410.0
1,139.0
0
0
2,069.2
0
0
5,215.9
By-product Gas
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Natural Gas
1,150.
2
22,172.4
652,219.0
0
29,865.4
268,016.1
4,533.3
47,208.9
28,877.8
365.
7
11,101.6
309.151.0
0
15,480.4
127,040.4
1,441.5
24,454.3
13,651.3
-------
(a)
'1ABLE 16. PARI1CUI.A1 E EMISSIONS (10NS/YR) UY UOILER SIZE CLASS
Top Number Is Potential Emissions (Based on Installed
Boiler Capacity); Lower Number la Actual Emissions
(llused on Annual Fuel Consumption or Actual Uotler Use)
Fuel
Size 0; 5+
-10x105 Btu/hr
Size 1:
1^ -2x106 Btu/lir
Size 2;
2+ -5xl06 Btu/hr
Size 3:
5+ -10x106
btu/hr
Coin.
1 nd .
Utility
Com
ind.
Utility
Com
Ind.
Utility
Com.
Ind.
Utility
Stoker Coal,
78.505.5
13.203.7
0
108,310.
21,388.2
0
435.732.3
0
0
746,822.1
168,009.8
0
Lou Sulfur
23.952.1
5.623.8
0
33,033 2
9, 112.0
0
132,921.7
0
0
226.113.5
71 .574.2
0
Stoker Cool,
23,261.6
7,535.1
16.3
32,091.7
27,462.5
32.6
64,219.7
183,311.6
636.1
80,680.6
249,617.9
0
High Sulfur
7,096.4
3.208.4
0
9,787.8
11.699.8
16. 3
19,588.1
78,086.3
361.3
24,606.9
106,336.
0
Pulverised Coal,
0
4,511.7
0
29.2
24,662.0
0
0
31,989.6
0
6,355.5
297.3
0
Low Sulfur
0
2,360.2
0
12.3
12,876.9
0
0
16,766.5
0
2,709.5
155.8
0
Pulverized Coal,
0
1.879.9
0
0
10, 275.8
0
0
21.713.7
0
0
29,561 1
0
IILgh Sulfur
0
655.6
0
0
5.36S.4
0
0
11,381 B
0
0
15,489.6
0
Residual Oil
3.535.4
5.421.0
1.0
4.698.6
12.040.9
3.3
20.453.7
62,034.3
7.8
21.735.8
75.133.6
19. 2
866. 2
1,995.2
0. 2
1,151. 1
4,431 2
1.2
5,011.1
22,828.5
2.8
5,325.6
27.649.4
7.0
Distillate Oil
9,388.2
6,653.7
0. 2
12,723. 3
14,776.4
1.0
20.381.1
30,674.3
13. 1
10,718 1
17,616 6
8 4
1,933.8
2,195.8
0
2,620.8
4.876.3
0
4,198.7
10.122.7
1.9
2,208.0
5,813.6
1.2
Natural Gas
968.8
1 ,250.8
0. 1
1,308.9
2,775.6
0
2,011.3
6,410
2.3
2,009.9
8,048 8
5 1
308.0
647.9
0
416.2
1,437.8
0
639.6
4,356.4
1.1
639.1
4,169.3
2.4
By-produce Cas
0
33.2
0
--
--
--
—
—
--
0
20. 9
0
--
--
--
--
--
--
(a) Emission factors are from Reference 13.
-------
TABLE 16. (Continued)
Fuel
SUe 4;
1+ -2x10? Btu/hr
SUu 51
; 2+ -5*107
Btu/lir
S i za
6;
5+ - 10k 10? Utu/lir
Size 7:
1+ -2x108 Btu/hr
Co ID.
1 ltd .
Utl 1 lty
Com.
I nd .
Utility
Com.
Ind.
Utility
Com.
I nd.
Uti Illy
Stoker Coa1.
229,824 4
187,377.2
1,612.8
356,491.1
423,332 3
6.70J.3
170,974.
7
734,105.4
52,814.9
30,588.5
684,726.6
107,392.1
Lou Sulfur
70,101.5
79,822.7
774. 2
108,725.6
180,339.0
3,211.6
52, 147
8
311 .381.0
25,303.3
9,329.5
291,691.5
5.029.0
Stoker Coal,
183,014.5
320,570.8
2.961.2
325,679.6
1,155,661.3
JO,272.4
261, 1 50
4
1,334,784.8
40,220.3
74,743.6
928,134.2
224,567.8
High Sulfur
55.823.9
136,423 4
1.419.0
99.529.9
492,309.5
9,712.
79,654.
4
566.165.8
19,268.4
22,799 5
395,382.6
10,517.9
Pulverized Coal,
0
107,597.1
281.
47,712.4
98,881.3
8,496. 3
65,142.
8
138,229.7
5, 24 5. 1
31,971.5
409,667.8
54,429.8
Lou Sulfur
0
56,383.7
120.4
20,236.6
51.811.0
3,588 2
6,422
4
72.434.6
829. 2
13,555.3
214.665.2
23.027.
Pulverized Coal,
18,223.6
40,550.3
468.3
21.347.5
199,584.3
6,416 4
36,261
3
477,875.4
27,095.6
19.844.6
1,001,139 5
371,549.1
lllglt Sulfur
7,727.
21,248.7
200.7
9,054.6
104,576 5
2,709.5
15,392
7
250,409.4
11,458.5
8,412.1
52.463.7
157,176.
Residual Oil
27,259.
76,817.0
65.9
43,708.2
113,660.1
65.9
29.574
0
88,969.1
1,284.6
14,054.2
71,520 3
6,059 8
6,678.3
28,268.4
24.3
1.070.5
41 ,826 6
24.3
7,218.
6
32,595.4
472.8
3,443 4
26,319.6
2. 230
Distillate Oil
5,578.4
12,622.4
21.0
6,366.8
13.178.4
21.0
4.169
6
7,509 8
250.1
2.887 6
7,695.8
1,458.1
1,149.1
4, 165.4
2.8
1,311.6
4,349.0
2.8
858
9
2,472.
32.5
595.0
2.539.6
189.5
Natural Cas
1,275.9
7,891.7
32.1
1,807.2
21,842.8
128.1
1,471.
9
12,323.7
404.8
1,163.3
10,776.2
1,822 1
406.3
4,087.9
15. 2
579.7
11,788.
60.7
468.
1
6,383.6
191.8
359.3
5.585.3
863.6
by-product Cus
-------
TABLE 16. (Continued)
Fuel
Size 8:
2+
-5x10® Btu/hr
Size 9.
5+ -10x108
Btu/hr
Size
10: 1+ -2x109 Btu/hr
Com.
Ind.
Utility
Cora.
Ind.
Utility
Com.
Ind.
Utility
Stoker Coa1,
26,046.2
285,825.7
43,066.7
0
601.9
19,604.9
0
93,081.6
0
Lou Sulfur
7,940. 2
121,760.5
20,629. 2
0
161. 3
9,388.2
0
24,944.7
0
Stoker Coal,
77,897.8
542,094.0
259,665.0
0
164,320.4
49,012.3
0
46,560.3
84,894.8
High Sulfur
23,751.0
230,929.4
124,380.3
0
44,038.1
23.171.5
0
12.477.3
40,666.9
Pulverized Coal,
0
400,048 2
414,579.3
0
222,011. 7
650. 243.9
0
93, 235. 2
l,296,290.8
Low Sulfur
0
209,624.8
175.365.0
0
128,761.2
275,053.7
0
54,076.6
557, 200.3
Pulverized Coal,
0
1.
,218,977.7 3
.071,355.5
0
593,455. 2
4,722,404.8
0
266,310.5
1,026,902. 3
High Sulfur
0
638,740.9 1
.299,359.5
0
344,190.7
1,997,586.0
0
154,459.4
4,739,829.6
Residual Oil
8,742.0
58,251.6
17,435.2
2,828.4
20,343.5
26,012.4
0
11,726 4
26,668.2
2,141.7
21,436.8
6,416.2
692.8
7,486.1
13,359.4
0
4,315.6
13,533.6
Distillate Oil
2,739.2
4,093.5
4,895.8
895. 5
1.170.2
5.079.5
0
0
964.9
564.5
1,351.0
636.4
184.6
386.0
660.0
0
0
125.5
Natural Gas
1,006.6
7 ,761.6
7,114.1
232. 5
3,845.9
11.117.8
524.2
3,634.4
15,940.2
319.1
4,020.5
3,372.0
73.9
1,992.1
5,269.8
166.7
1,882.6
7,556.2
By-product Gas
-------
TABLE 16 (Continued)
Fuel
Size
11: 2+ -5x10® blu/lir
Size
12: 5+ -IOkIO9 btu/lir
Size
13: 1+
-2x1010 Utu/hr
Coia.
lnd .
Utlllcy
Com.
I rul.
Uti 11 ty
Coiu
lnd.
Utility
Stoker Coal,
0
0
0
0
0
0
0
0
0
Lou Sulfur
0
0
0
0
0
0
0
0
0
Stoker Coal,
0
206,596.5
166,690 .8
0
0
0
0
0
0
IHgli Sulfur
0
55,373.3
7 9,038.7
0
0
0
0
0
0
Pulverized Coal,
0
0
2.165,205.8
0
0
2,734,721.5
0
0
0
Lou Sulfur
0
0
915,884.4
0
0
1,156,784 6
0
0
0
Pulverized Coal,
0
401,232.8
10,444,953 1
0
305.144.3
9,155,847.5
0
0
1,052,082.8
lligli Sulfur
0
231,741.6
4,418,224.6
0
176,957.2
3,872,914.9
0
0
445,025.5
Residual Oil
0
2,029.4
30,120.7
0
0
6.287.9
0
0
0
0
746.6
16,374.9
0
0
4,068.2
0
0
0
Distillate Oil
0
1,067.9
667.0
0
0
1,211.5
0
0
3,054.5
0
352. 2
86.7
0
0
157.5
0
0
397.0
Natural Cu3
218.5
2,280.8
16,293.1
0
3,074.3
6,695.8
861.
1
4,856.
3 721.5
-
69.5
1,142.0
8,099.1
0
1.592.4
3,173.8
273.
8
2,515.
6 341.0
By-j)ioduct Gas
-------
47
TABLE 17. SULFUR DIOXIDE EMISSIONS (TONS/YR) FROM RESIDENTIAL UNITS
AS A FUNCTION OF FUEL TYPE AND DESIGN SIZE CLASS
Top Number is Potential Emissions (Based on Total Installed
Capacity), Lower Number is Actual Emissions (Based on Annual
Fuel Consumption or Actual Boiler Use)
Design Firing Rate
& +¦ & + 5 + 5 + 5
Fuel 2 -5 x 10 5 -10 x 10 1 -2 x 10 2 -5 x 10 5 -10 x 10
Distillate oil(a) — 443,241 693,768 138,598 70,073
and kerosine — 38,651 138,754 27,720 14,016
Natural gas Nil Nil Nil Nil tTil
Nil Nil Nil Nil Nil
LPG Nil Nil Nil Nil Nil
Nil Nil Nil Nil Nil
(a) Distillate oil and kerosme emission factors taken from Reference 14,
TABLE 18. NO EMISSIONS (TONS/YK) FROM RESIDENTIAL UNITS AS
A JUNCTION OF FUEL TYPE AND DESIGN SIZE CLASS
Top Number is Potential Emissions (Based on Total
Installed Capacity), Lower Number is Actual Emissions
(Based on Annual Fuel Consumption or Actual 3oiler Use
Design Firing Rate
Fuel 2+-5 x 104 5+-10 x 104 l+-2 x 105 2+-5 x 105 5+-10 x 105
Distillate ail -- 275,313 430,925 86,088 43,528
and kerosme — 56 , 06 2 . 86,135 1 7 , 218 8 , 706
Natural gas (b) 15,540 679,056 86,688 69,300 34,020
3,108 137,383 17,333 13,860 6,304
LPG(b) - 91.177 35,784
18,236 • 7,157
(a) Distillate oil and kerosine emission factors taken from Reference 14.
(b) Natural gas and LPG emission factors taken from Reference 15.
-------
48
TABLE 19. PARTICULATE EMISSIONS fTONS/YR) FROM RESIDENTIAL UNITS
AS A FUNCTION OF FUEL TYPE AND DESIGN SIZE CLASS
Top Number 13 Potential Emissions (Based on Total Installed
Capacity), Lower Number is Actual Emissions (Based on Annual
Fuel Consumption or Actual Boiler Use)
Design Firing Race
Fuel 2+-5 x 104 5+-10 x 10^ l+-2 x 105 2+-5 x 105 5^-10 x lO3
Distillate oil(a) — 34,414 53,866 10,761 5,441
and kerosine — 6,883 10,773 2,152 1,088
078 134,518 17,172 13,728 6,739
616 26,910 3,434 2,746 1,348
3,062 7,089
3,612 1,418
(b)
Nacural gas 3,078 134,518 17,172 13,728 6,739
LPG(b) — 13,062 7,089
(a) Distillate oil and kerosine emission factors taken from Reference 14.
(b) Natural gas and LPG emission factors taken from Reference 13.
-------
ioc
10'
tA
C
o
10*
M
c
o
tA
U»
£
ui
CJ
O
in
o
3
E
3
o
I03
All fuels
Coal: O
Oil: A
Gas: negligible
Residential emissions negligible
4>
vO
Reeldentlal-
Design Firing Rate, Blu/hr
Commercial Industrial
Utility
FIGURE 7. CUMULATIVE SC>2 EMISSIONS FOR ALL BOILERS BASED ON ACTUAL BOILER USE
-------
10°
Al I fuels x--—
Coal: o
Oil: A (negligible for residential boilers)
Gos: ~ (negligible for residential boilers)
i-n
O
J i I I
l II I
i l i I
_L
J I 1 I
I II I
J I I I
J I L
KT
10°
Residential
10
Commercial
107
Design Firing Rate, Btu/hr
—4- Industrial —
K)a
10
10
10'
Utility
FIGURE 8. CUMULATIVE NO EMISSIONS FOR ALL BOILERS BASED ON ACTUAL BOILER USE
x
-------
10°
10'
Coo): O
Oil: A (negligible for residential boiler's)
Gos: ~ (negligible for residential boiler's)
10®
itr
10*
All fuels
I03
±1
10"
10"
Residential
-L-A-
lO
I I I I
_L
I I I I
10' 10"
Design Firing Role. Btu/hr
Commercial »4-"» Industrial
I 1 I I I I
J I I I
10°
10
10
10"
Utility
FICUkE 9. CUMULATIVE PARTICULATE EMISSIONS FOR ALL UOILERS BASED ON ACTUAL UOILER USE
-------
52
REFERENCES
(1) Barrett, R. E., Putnam, A. A., Blosser, R. R., Jones, P. W.,
"Assessment of Industrial Boiler Toxic and Hazardous Emissions
Control Needs", Battelle-Columbus report to EPA (Contract No.
68-02-1329, Task 8), October 16, 1974.
(2) National Emissions Data System (NEDS), National Source Inventory
Section, Environmental Protection Agency, Durham, N,C.
(3) Locklin, D. W., Krause, H. H., Putnam, A. A., Kropp, E. L., Reid,
W. T., and Duffy, M. A., "Design Trends and Operating Problems in
Combustion Modification of Industrial Boilers", Final Report to
Environmental Protection Agency, Grant No. 802402, April, 1974.
(4) Choi, P. S., Kropp, E. L., Putnam, A. A., "SO^ Reduction in Area
Sources—Technical and Economic Comparison of Alternatives, Battelle-
Columbus report to Environmental Protection Agency (Contract No.
68-02-1323, Task 13), in preparation, 1975.
(5) "Hazardous Pollutants from Fossil Fuel Combustion", Draft Report,
Midwest Research Institute to Environmental Protection Agency,
Control Systems Laboratory.
(6) American Boiler Manufacturing Association (a) Stationary Watertube
Steam and Hot-Water Generating Sales (Year); (b) Data Compilations
on Watertube Boilers; (c) Data Compilation on Firetube Boilers.
(7) Steel Power Boiler Report, Series MA-34G (Year)-l, from 1962 through
1971, Bureau of Census, U.S. Department of Commerce.
(8) Paddock, R. E., and McMann, D. C., "Distribution of Industrial and
Commercial — Institutional External Combustion Boilers", Research
Triangle Institute Report to Environmental Protection Agency
(Contract No. 68-02-1325, Task 5), February, 1975.
(9) Ehrenfeld, J. R., Bernstein, R. H., R. H. Carr, K., Goldish, J. C.
Orner, R. G., and Parks, T., "Systematic Study of Air Pollution from
Intermediate Size Fossil-Fuel Combustion Equipment", Walden Research
Corporation Report to Environmental Protection Agency (Contract No.
CPA-22-69-85) , July, 1971.
(10) U.S. Department of the Interior, Bureau of Mines, 1972 U.S. Energy
Use, News Release, March 10, 1973,
(11) SRI Patterns of Energy Consumption in the U.S., January, 1972.
(12) Bureau of Census, 1970 Census of Housing, July, 1972.
-------
53
REFERENCES(Con t inue d)
(13) "Compilation of Air Pollutant Emission Factors", U.S. Environmental
Protection Agency, Office of Air Programs, Publ. No. AP-42, February,
1972.
(14) Barrett, R. E., Miller, S. E., and Locklin, D.W., "Field Investigation
of Emissions from Combustion Equipment for Space Heating", U.S. Environ
mental Protection Agency, Publ. No. EPA-R2-73-084a, June, 1973.
(15) DeWerth, D. W., "An Investigation of Emissions from Domestic Natural
Gas-Fired Appliances", Proc., How Significant are Residential Com-
bustion Emissions, APCA Publ. No. SP-8, p 42-58, 1974.
-------
54
ACKNOWLEDGMENTS
The authors wish to acknowledge the contributions of other
Battelle-Columbus staff to the conduct of this study and preparation
of this report. These Battelle staff include R. Clark, D. M. Jenkins,
D. W. Locklin, and T. J. Thomas. Additionally, the authors wish to
thank Paul Spaite (Consultant) and Dr. C. C. Lee (EPA Task Officer)
for their comments and suggestions as to how the report might be made
more useful.
-------
APPENDIX A
DISTRIBUTION OF BOILER POPULATION
-------
APPENDIX A
DISTRIBUTION OF BOILER POPULATION
The simplest way to determine the distribution of the various
fuel firing methods for the boilers included in the A8MA data (by use of
the NEDS distribution) is to determine a factor P from
^ = Q* + + Qr-'
g d r
where Q is the total ABMA design firing capacity (for all fuels) in size
range s and Qg, Q^, are the total installed capacities from NEDS (for
gas, distillate oil, and residual oil-fired boilers, respectively) in the
same size range. Then the total design firing rate for gas-fired boilers,
* .
Q = Q /P, and so forth for distillate and residual oil. This approach
g o
assumes that the fraction of boilers not counted by NEDS depends only on
the design firing rate. That is, the NEDS data does not preferentially
count boilers firing any one fuel.
A second method is to assume that the chance of observing a
boiler is related to its actual firing rate. If a linear relation is
assumed, one might include the annual load factors (ALF) in the relation
P'Q* = Q /ALF + Q./ALF. + Q /ALF
g g d d xr r
to determine P' where ALF , ALF,, and ALF are annual load factors for gas,
8 d r °
distillate oil, and residual oil-fired boilers, respectively. Then
it
Q = Q /?' ALF , and so forth.
2 g g
Finally, one might assume that the pollutant itself would have
an effect on the probability of observation. It would appear that the
only way to approach this problem would be to assume that P is a function
of (s x function ALF) and fuel. If Q is plotted for each fuel as a
function of s, then the curves could be shifted horizontally and vertically
to match shapes. Assuming that this is the only factor involved, then the
horizontal shift could be expressed as a numerical factor for each fuel.
This factor could be used to replace ALF in the treatment outlined above,
and values of P' determined for each size range.
-------
A-2
Figure A-l through A-6 present the normalized NEDS count on
design firing rate obtained from Table 5, using the normalizing ratio
from Table 1. It is interesting to note that the slope at the lower
capacities tends to be about 2:1 when there is a change in use, as for
example, in the case of the utility boilers. On the other hand, when
there is reason to believe that boilers are being missed because of low
capacity, low firing rate, and low pollution level, the slope tends to
be 1:1 as in the case of the commercial boiler firing oil (distillate
plus residual). It is also apparent that the peaks of the curves for
commercial, industrial, and utility boilers occur at progressively higher
design firing rates, as expected.
These figures were basically prepared to enable a choice to be
made among the three methods outlined above, to determine multiplying
factors to convert NEDS data at low design capacities to an equivalent
number basis with ABMA data. However, an examination of the curves failed
to show any particular consistency that would permit a choice. Therefore,
the simplest method, the first outlined, was used. The multiplying factor
was determined from the ratio of the curves shown in Figure 2. The multi-
plying factor as a function of size is presented in Figure 1. Because
of the apparent lack of influence of type of fuel or principal pollutant
on this factor, it was not felt that a previous assumption made in Ref-
erence 1, that all the coal-fired units down to some low size were counted,
could be made. Rather, the coal-fired units were determined by use of the
same multiplying factor as determined from the gas and oil data.
It should be noted that the assumption is made that all utility
units are counted in NEDS.
-------
A-3
Industrial
Commercial
* 10'
Utility
Design Firing Rate, Btu/hr
FIGURE A-l. TOTAL INSTALLED CAPACITY OF STOKER-FIRED
BOILERS NORMALIZED FROM NEDS DATA
-------
A-4
TTE3
Pulverized coal , utility
Industrial, by
product gas
^ 10
CL
£ \
-------
A-5
ca
Industrial
CM
Commercial
Utility
LULL
Mil
Design Firing Rale, Btu/hr
FIGURE A-3. TOTAL INSTALLED CAPACITY OF RESIDUAL OIL-
FIRED BOILERS NORMALIZED FROM NEDS DATA
-------
s
-------
A-7
Industrial
Commercial
Design Firing Rafe, Btu/hr
FIGURE A-5. TOTAL INSTALLED CAPACITY OF DISTILLATE AND RESIDUAL
OIL-FIRED BOILERS, NORMALIZED FROM NEDS DATA
-------
A-8
TTTT
TTTTTT
Industrial
Commercial
Utility
I Ml
s
7
10
,6
fl
9
Design Firing Rate, Bfu/hr
FIGURE A-6. TOTAL INSTALLED CAPACITY OF NATURAL GAS-FIRED
BOILERS, NORMALIZED FROM NEDS DATA
-------
APPENDIX B
COMPILATION OF BOILER POPULATION
FOR SMALL BOILERS
-------
APPENDIX B
COMPILATION OF BOILER POPULATION
FOR SMALL BOILERS
The number of water-tube boilers below 10^ Btu/hr is estimated
as a constant function of 0.066 of those in the range 1+ ¦ 10 x 107 Btu/hr.
This is based on the data in Reference 7. The entire capacity, computed
9
from the data of Reference 1 corrected for hot-water boilers, of 88.7 x 10
Btu/hr is assumed to be in the range 5+ - 10 x 10^ Btu/hr.
Fire-Tube Boilers in Small Sizes
Neither Reference 6 nor Reference 7 report all fire-tube boiler
sales. However, it is believed that Reference 6 includes a known fraction
(85 percent) of Scotch boilers. A comparison of the ratio of the total
sales (based on design firing rates) of Scotch boilers over a period of
years (1965-1971) from Reference 6 and 7 shows that there is little
variation from 0.55. That is, Reference 7 consistently reports only 55
percent of the Scotch boiler sales that are reported in Reference 6.
Thus the data from the two sources are proportional if not equal. The
data from Reference 7 on the total sales of all fire-tube boilers com-
pared to Scotch boiler sales gives a ratio of 1.26, with little variation
from 1962 through 1972. Thus, to determine the total sales of fire-tube
boilers in 1971 for a given size range, assuming the above factors are
not a function of size (this assumption could not be checked), the sales
of Scotch boilers in that range (according to ABMA data, Reference 6 ) can
be multiplied by 1.26/0.85, where 0.85 corrects the ABMA data for the
estimated fraction missed in the compilation^.
The ABMA sales data for Scotch boilers were examined for design
firing rates down to 5 x 10^ Btu/hr, in the increments shown in Table
B-l. These data covered 1965 through 1972. It was noted that, as
the design firing rate becomes less, the rate of sales increase becomes
less, and eventually reverses. The rate of sales was determined for each
(9)
size class, and combined with the observation in the Walden report that
-------
B-2
10 percent of the boilers were more than 24 years old to determine a
mean life. Combining these factors, it was possible to determine the
ratio of the Scotch boiler population in each size class to that in the
1 - 2 x 10 Btu/hr size range. (These values are tabulated in Table B-l.)
The product of this term, 1.26, and the reference Scotch-boiler installed
capacity in the 1+ to 2 x 10^ Btu/hr size range (corrected for missing
data) gives the installed capacity of fire-tube boilers for each size
range. The total fire-tube boilers installed capacities for small boiler
sizes are given in Table B-l.
Adding the water-tube boiler installed capacity in the 5+ -
10 x 10 Btu/hr size class gives the total installed capacity for all
boilers in the 5 x 10^ to 10 x 10^ Btu/hr size ranges. The total in-
stalled capacities for various sizes of small fire-tube and water-tube
boilers are listed in the last column of Table B-l.
TABLE B-l. DATA ON SMALL BOILERS
5 x
tO3 co 10 x 106
Bcu/lir Firing Races
Firing
Race
Design,
3cu/hr
Design
Size,
/Scotch Boilers
In Size Range
of Incereac
I Scocch Boi.lers in
1+ -2x10? Bcu/hrj
Size Raima
local
?Ira-Tube Boiler
ensealled Capacity.
109 Dcu/hr
local Boiler
Installed Caoadcy,
10' Bcu/hr
3 x 10
10 x 10
2 x 106
15
20, 23, 30
40, 30, 60
2+ - 3 x 10& 70 - 150
i* - 10 x 106 200, 230, 300
0.022
0.286
0.390
1.328
1.161
3.7
74.2
101.2
3&4.6
301.2
5.7
74.2
101.2
344.6
389.9
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71
TECHNICAL REPORT DATA
/Please read luurueitons on the reverse before completing)
i a£OOflT no 2
EPA-600/2-75-067
3 RECIPIENT'S ACCeSSlO.VNO.
4 TITLE ANO SUBTITLE
Evaluation of National Boiler Inventory
5 REPORT OATE
October 1975
6. PERFORMING ORGANIZATION COOE
7 AUTHOfl(S)
A.A. Putnam, E.L. Kropp, R.E. Barrett
8. PERFORMING ORGANIZATION REPORT NO
9 PERFORMING ORGANIZATION NAME ANO AOORESS
Batte lie-Columbus Laboratories
505 King Avenue
Columbus, Ohio 43201
io program element no
1AB013: ROAP 21ADE-010
11 contract/grant NO.
68-02-1223, Task 31
12 SPONSORING AGENCY NAME ANO AOORESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT ANO PERIOO COVERED
Task Final: 4/15-10/10/75
14 SPONSORING AGENCY COOE
13 supplementary notes
is assthact T^e rep0rt gjves a compilation of the boiler inventory for the Continental
United States, using available data sources. Primary sources included the National
Emissions Data Bank data, American Boiler Manufacturers Association boiler sales
data, and earlier reports to the EPA. Residential, commercial, industrial, and
utility boilers are included. Results are presented as: cumulative boiler installed
capacity and cumulative actual boiler use (by fuel and total), both plotted against
boiler size; cumulative S02, NOx, and particulate emissions (by fuel and total),
plotted against boiler size; and tables of boiler number count, boiler installed
capacity, boiler actual use, S02 emission, NOx emission, and particulate emission,
by boiler size and fuel.
17 KEY WORQS ANO OOCUMENT ANALYSIS
a. descriptors
b lOENTt F1ERS/OPEN ENOED TERMS
c. COSATl Field/Croup
Air Pollution Natural Gas
Boilers Nitrogen Oxides
Population (Statistics)
Coal Dust
Emission Sulfur Dioxide
Fuel Oil
Stationary Sources
Boiler Population
Commercial Boilers
Industrial Boilers
Residential Heaters
Utility Boilers
Particulate
13 B
13A 07B
12 A
2 ID 11G
13 OtSTRiauTlON STATEMENT
Unlimited
19 SECURITY CLASS {This Report)
Unclassified
21 NO OF PAGES
71
20 SECURITY CLASS (This page)
Unclassified
22 PRICE
EPA Form 2220-1 (9-73)
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