Discussion on the Green Transformation Path of China’s Industrial Boiler Industry

Historically, China’s energy policy has been heavily reliant on coal, driven by the nation’s energy endowment and economic development. As a result, China has become the global leader in the number of coal-fired industrial boilers. The coal consumption of industrial boilers in China is second only to that of power plants, surpassing energy-intensive industries like steel, petrochemicals, and cement in terms of consumption. This sector not only represents a significant energy user but is also one of the main contributors to air pollution and CO₂ emissions. In 2019, the coal consumption of industrial boilers reached approximately 500 million tons of standard coal, accounting for 17.8% of China’s total coal consumption. This resulted in CO₂ emissions of around 1.36 billion tons, contributing 13.8% of the nation’s total CO₂ emissions. In conjunction with the growing use of gas boilers, China’s industrial boiler industry is now a focal point for advancing the country’s “dual carbon” goals.

Achieving the carbon peak by 2030 and carbon neutrality by 2060 is central to China’s long-term strategic vision. This ambitious objective will have profound implications for the trajectory and transformation of key industries. Scholars like Xie Yanxiang and others have proposed several paths for carbon emission reduction, focusing on clean energy development and the transition of fossil fuels to meet these targets. Researchers such as Su Jian and others have studied energy development strategies by analyzing carbon reduction practices in developed countries, while Wang Lulu’s work highlights energy transformations in Chinese cities, especially in low-carbon pilot regions. These studies underscore the growing need for industrial sectors to adopt green and low-carbon technologies.

Industrial Boiler

The industrial boiler sector presents unique challenges for transitioning to low-carbon operations. Boilers, characterized by their large inventory, widespread distribution, high energy consumption, and variable fuel types, face more complexity in decarbonization compared to power station boilers. Scholars like Li Jun have recommended multi-faceted approaches to achieving green and low-carbon development for boilers. These include advancing technological innovation, improving public service systems, and enhancing laws and regulations. Researchers such as Zhao Qinxin have focused on emission reduction strategies throughout the boiler lifecycle, using gas-fired steam boilers as a case study. Meanwhile, Jin Jiongchen’s work analyzes low-carbon heating solutions for northern China. This article draws on these studies to examine the current status, challenges, and opportunities within China’s industrial boiler industry, particularly in light of the “dual carbon” goals. It also explores potential pathways for the industry’s green transformation and offers strategic recommendations for innovation priorities.

1. Development Status of China’s Industrial Boiler Industry

China is the world leader in both the production and use of industrial boilers. Through years of industrial effort, China has established a robust boiler market, with products spanning 8 categories, 38 series, 85 varieties, and more than 300 specifications by the 1990s. During its peak, the number of industrial boilers in operation across the country reached 600,000, and their coal consumption accounted for roughly one-third of the national total. Despite efforts to improve energy efficiency and reduce emissions, industrial boilers continue to rank second in terms of energy consumption and pollutant emissions within China’s industrial sectors. Emissions of particulate matter (PM), sulfur dioxide (SO₂), and nitrogen oxides (NOₓ) from this sector account for 40%, 26%, and 12% of national totals, respectively, highlighting its significant impact on energy use, environmental protection, and sustainable development.

Recent years have seen notable progress in the green transformation of the industrial boiler industry, largely due to the nation’s deepened energy conservation and emission reduction policies. These initiatives have led to improvements in product structure and combustion technology. Notable advancements include the optimization of fuel sources and the adoption of low-carbon technologies. These efforts have resulted in several key developments:

1.1 Fuel Transformation: From High Carbon to Low Carbon

For decades, coal has dominated as the primary fuel for industrial boilers in China. Despite ongoing energy conservation and emission reduction efforts, challenges such as outdated combustion technologies, low energy efficiency, and high pollutant emissions have persisted. In 2013, the Chinese government introduced the Action Plan for the Prevention and Control of Air Pollution, which emphasized the need to phase out small coal-fired boilers and improve the environmental performance of existing systems. Over time, numerous policies followed, including the Implementation Plan for the Comprehensive Improvement of Energy Conservation and Environmental Protection of Coal-fired Boilers and the Winter Clean Heating Plan for the Northern Region (2017–2021). These initiatives, particularly in coal-restricted regions, have accelerated the transformation of China’s industrial boiler landscape, resulting in a significant decrease in the number of small, inefficient coal-fired boilers.

By the end of 2020, the number of industrial boilers in operation nationwide had decreased by 44.5% compared to its peak in 2013, totaling approximately 342,000. Simultaneously, the proportion of coal-fired boilers in restricted regions continued to decline, with gas, biomass, and waste heat boilers seeing rapid growth. The evolving fuel structure now reflects a diverse mix, with natural gas, coal, biomass, and other fuels accounting for 51.1%, 24.4%, 15.5%, and 9.0% of newly installed industrial boilers, respectively. Notably, gas boilers now account for more than half of all new industrial boiler installations, representing a significant shift away from coal dependence.

1.2 Progress in Product Development: Towards Larger and More Efficient Boilers

Driven by policy mandates and technological innovation, the design parameters for industrial boilers have seen continuous advancements. The rated thermal power of coal-fired hot water boilers has now reached up to 168 MW—three times that of traditional units. Likewise, gas-fired hot water boilers can now achieve a maximum rated thermal power of 116 MW, and electric steam boilers have reached evaporation capacities of up to 80 t/h. These developments are indicative of a broader trend toward larger, more efficient industrial boilers.

To further enhance the energy efficiency of these systems, the Chinese government has issued standards such as GB 24500-2020, which sets energy efficiency limit values and grades for industrial boilers. Under these guidelines, a variety of high-efficiency and energy-saving products have been developed. For example, circulating fluidized bed boilers now achieve thermal efficiencies of 88.75%, natural gas boilers reach efficiencies of 96.67% (with condensing models reaching up to 98.91%), and biomass boilers have efficiencies of 87.85%. Electric heating boilers are also highly efficient, with a thermal efficiency of 98.05%. These improvements are helping to ensure that newly developed industrial boilers meet the third energy efficiency grade as specified by GB 24500-2020, advancing China’s transition to cleaner, more efficient industrial operations.

1.3 Effective Control of Pollutant Emissions

For many years, coal-fired industrial boilers in China were the second-largest source of coal-related pollution after power plants, contributing significantly to fine particulate matter (PM2.5) and PM10 emissions. In 2014, the Chinese government implemented GB 13271-2014, a new emissions standard for industrial boilers that set stricter limits on pollutants such as soot, SO₂, and NOₓ, as well as introducing restrictions on mercury and its compounds. Since then, China has intensified its efforts to combat pollution through a series of initiatives, including the Three-Year Action Plan to Win the Blue Sky Defense War and the Battle for Clean Air. These policies have led to the gradual elimination of small coal-fired boilers in key urban areas and the implementation of ultra-low emissions standards for retained boilers.

Furthermore, the introduction of advanced technologies such as low-nitrogen combustion, high-efficiency desulfurization, and integrated pollution control measures has significantly reduced emissions from industrial boilers. The result is that China’s industrial boiler industry now meets international air quality standards, reflecting its capability to manage pollutant emissions effectively.

1.4 Advancements in Digital and Intelligent Technologies

The transition from coal to cleaner fuels like gas and electricity has laid the foundation for the digitalization of industrial boilers in China. Technologies such as the industrial Internet, cloud computing, and artificial intelligence are beginning to be applied to the design, production, installation, and operation of industrial boilers. Research teams have developed new sensor technologies, intelligent algorithms, and mobile applications that enable more effective monitoring and optimization of boiler performance.

Despite these advancements, the industry still faces challenges in automation and real-time monitoring. Digital transformation remains in its early stages, and there are notable gaps in the adoption of online detection and control systems for industrial boilers. Continued investment in these technologies will be essential for optimizing boiler operations and supporting the green transformation of the sector.

The industrial boiler industry in China is at a critical juncture as it faces both challenges and opportunities in light of the nation’s ambitious “Dual Carbon” strategy, which aims to peak carbon emissions by 2030 and achieve carbon neutrality by 2060. This section of the article highlights the technological development status of China’s industrial boiler industry and identifies key challenges and opportunities associated with the industry’s transformation.

2. Technical Development Status of China’s Industrial Boiler Industry

The technological progress in China’s industrial boiler industry can be traced through scientific and technological literature. By analyzing the number of publications on industrial boilers from 1983 to 2022 in China National Knowledge Infrastructure (CNKI), the following trends were identified:

2.1 The Climbing Period (1983-2004)

  • The number of publications was modest, averaging around 100 per year, with a slow upward trend. This period marked the early stages of technological development for industrial boilers in China.

2.2 The Explosive Period (2005-2014)

  • There was rapid growth in research output, with the number of publications increasing at an average rate of more than 20 per year. In 2014, the number of publications peaked at 359, signaling an era of technological breakthroughs and increased interest in the industrial boiler sector.

2.3 The Decline Period (2015-Present)

  • Since 2015, the number of publications has decreased, indicating a slowdown in technological advancement and innovation in the sector. By 2022, the number of publications had fallen below 2005 levels.

This pattern of publication trends aligns with the S-curve theory of technological innovation, which suggests that industries go through a life cycle of growth, maturity, and decline. Currently, China’s industrial boiler industry appears to be in the decline phase of this cycle, with limited room for further growth unless external factors, like national policies or technological breakthroughs, stimulate a new cycle of innovation.

Technological Innovation Needs

  • The declining trend in publications highlights the stagnation in core technological developments. However, the current “Dual Carbon” strategy presents an opportunity for a fresh wave of innovation, particularly in areas such as energy efficiency, low-carbon technologies, and intelligent systems.

3. Challenges and Opportunities Faced by China’s Industrial Boiler Industry

3.1 Challenges

The industrial boiler industry faces several significant challenges as it moves toward the goal of carbon neutrality:

3.1.1 Coal Restriction Policies
  • Coal restriction policies are narrowing the market for coal-fired boilers, especially in key urban areas and regions with strict environmental regulations. These policies are directly affecting the demand for coal-fired industrial boilers, as seen in cities like Shenyang and regions like Inner Mongolia, where coal-fired boilers are being eliminated or transformed into cleaner alternatives.
3.1.2 Diversified Energy Use
  • The rapid development of alternative energy sources, such as nuclear, solar, geothermal, and cogeneration technologies, is diverting demand away from traditional industrial boilers. For instance, Haiyang City in Shandong has implemented a zero-carbon heating system, replacing coal-fired boilers, and setting a precedent for the future of urban heating.
3.1.3 Insufficient R&D for Low-Carbon Technologies
  • While there has been progress in adopting clean technologies, R&D in low-carbon solutions for industrial boilers is still underdeveloped. Key areas such as CO₂ capture, utilization, and storage (CCUS) and co-firing hydrogen-rich fuels remain insufficiently explored due to the high costs associated with these technologies. Boiler users, especially in cost-sensitive industries, are reluctant to adopt these high-cost solutions.

3.2 Opportunities

Despite the challenges, there are several opportunities for the industrial boiler industry to align with the “Dual Carbon” strategy:

3.2.1 Energy Efficiency Improvements
  • Many industrial boilers in China still have relatively low energy efficiency. As such, there is significant potential for energy conservation and carbon reduction through technological upgrades and efficiency improvements. This potential presents an opportunity for manufacturers to develop and promote energy-efficient and low-carbon boiler technologies.
3.2.2 Expanding Heating Markets in Southern China
  • With rising living standards, the demand for heating in southern China during the winter is growing. This expansion creates a large market for industrial boilers that are energy-efficient and meet new environmental standards.
3.2.3 Intelligent Upgrades and Automation
  • The transition from coal to cleaner fuels (gas, biomass, electric) has paved the way for greater use of smart technologies in industrial boilers. These include advancements in automation, remote monitoring, and data analytics, which will be crucial in boosting the efficiency and performance of boilers. The need for intelligent upgrades offers a significant opportunity for companies in the industrial boiler sector to invest in digital transformation.

The industrial boiler industry in China faces a critical moment in its transformation. While it has made progress in adopting cleaner fuels, improving energy efficiency, and meeting stricter environmental standards, challenges such as coal restriction policies, competition from alternative energy sources, and insufficient R&D in low-carbon technologies remain significant obstacles. However, these challenges also present opportunities, particularly in the areas of energy efficiency, intelligent upgrades, and the development of new low-carbon technologies.

The industry must navigate these challenges while capitalizing on the opportunities presented by China’s “Dual Carbon” strategy. This requires a concerted effort to drive innovation, develop new technologies, and implement smart, energy-efficient solutions. The future success of the industrial boiler industry depends on its ability to adapt to changing energy landscapes and meet the nation’s ambitious environmental goals.

4. Green Transformation Path of the Industrial Boiler Industry

As part of China’s push for sustainable development, green and low-carbon technologies, along with digitalization, have emerged as central themes in the industrial sector. The industrial boiler industry is currently at a crossroads, facing a bottleneck in development while simultaneously being presented with a window of opportunity for innovation. To address these challenges, the industry must capitalize on the synergies between low-carbon and digital transformations, integrating them into the broader industrial transformation agenda.

4.1 Energy Transformation Path

The energy transformation strategy involves reducing carbon emissions while ensuring energy security. The main focus should be on the clean substitution of traditional fuels, such as coal, by alternative energy sources, with a particular emphasis on the following:

  1. Coal-fired Boilers: Shift towards large-scale, clean, and high-efficiency coal boilers, integrating advanced technologies like low-nitrogen burners and improving desulfurization methods.
  2. Gas-fired Boilers: Natural gas offers a cleaner alternative to coal, with lower emissions of pollutants like sulfur dioxide (SO₂) and soot. A transition to natural gas boilers would significantly reduce carbon emissions.
  3. Biomass Boilers: Biomass, a renewable resource, can be used to replace coal, achieving substantial carbon dioxide (CO₂) emission reductions. However, technical challenges such as ash deposition and fouling need to be addressed.
  4. Electric Boilers: Electric boilers are pivotal in moving towards zero-carbon heating. They will play a role in utilizing green electricity and renewable energy sources.

This approach requires strategic investments in technologies that can integrate renewable energy sources, such as hydrogen energy, and innovations in energy storage systems to support a clean energy future.

4.2 Digital Transformation Path

Digitalization is crucial for enhancing the efficiency, intelligence, and sustainability of industrial boilers. The industry must embrace modern technologies like artificial intelligence (AI), big data, cloud computing, 5G communication, and digital twins. These technologies enable real-time monitoring, predictive maintenance, and optimized energy usage, improving the entire lifecycle of industrial boilers—from research and development to design, manufacturing, and operation.

The key directions for digital transformation include:

  1. Collaborative Innovation: Integration of modern combustion technology, AI, smart systems, and new materials into the industrial boiler production process. This interdisciplinary collaboration will foster disruptive innovations and propel the industry toward higher efficiency and lower emissions.
  2. Intelligent Operation & Maintenance: The deployment of intelligent algorithms, digital twins, and data-driven solutions will enable optimized operation and maintenance of industrial boilers, reducing energy consumption and improving overall performance.
  3. Digitalization of the Full Lifecycle: The goal is to shift from a manufacturer to a full-service provider by offering “design + manufacturing + installation + maintenance” integrated solutions. This will help promote “green manufacturing” and establish intelligent services based on digital platforms.

4.3 Key Innovation Directions for Industrial Boilers

The industrial boiler industry must prioritize the following areas to achieve low-carbon and high-efficiency performance:

  1. Coal Clean Utilization Technologies:
    • Despite the push for cleaner fuels, coal will remain a significant fuel source for the foreseeable future. The development of high-efficiency, low-emission pulverized coal boilers and technologies to reduce NO₂ emissions (such as low-nitrogen burners and desulfurization techniques) are essential to reduce the carbon footprint of coal-fired systems.
  2. Natural Gas Substitution Technologies:
    • Transitioning to natural gas as a fuel source for industrial boilers can significantly reduce emissions. The development of advanced burners, optimized combustion technologies, and solutions to prevent corrosion from flue gas condensation are crucial for this transition.
  3. Biomass Boiler Technology:
    • Biomass resources in China are abundant, offering significant potential for CO₂ reduction. However, challenges like high alkali metal content in biomass fuels must be overcome. Innovations are needed to prevent ash deposition, fouling, and corrosion in boilers that use biomass fuels.
  4. Zero-Carbon Frontier Technologies:
    • Achieving zero-carbon emissions will require the development of regenerative electric boilers and hydrogen-doped natural gas boilers. Research must focus on high-efficiency and cost-effective hydrogen technologies, as well as improving the production, storage, and transportation of green hydrogen.
  5. Carbon Emission Lifecycle Assessment:
    • It is essential to develop comprehensive carbon accounting systems that track emissions from production to disposal. This will help identify reduction opportunities and set clear standards for carbon emissions in the industrial boiler lifecycle.
  6. Digital and Intelligent Technologies:
    • The integration of AI, machine learning, and big data into boiler management systems will allow for real-time monitoring and optimization of energy use, improving efficiency and reducing emissions across the entire boiler lifecycle.

5. Conclusion

Industrial boilers in China are a major source of CO₂ emissions, second only to coal-fired power plants. Over the past 40 years, the focus has been on energy conservation, environmental protection, and safety. However, as the country moves toward achieving its “Dual Carbon” goals, the industry has faced challenges in carbon emission reduction technologies and lacks sufficient technological momentum for transformation.

The adoption of energy and digital transformation strategies—along with the integration of low-carbon and digital solutions—offers a way forward for the industrial boiler sector. By focusing on cleaner technologies, energy efficiency, and digital innovation, the industry can contribute significantly to China’s goals of carbon peaking and neutrality.

The path to a green, low-carbon, and intelligent industrial boiler industry is not only essential for achieving national sustainability targets but also critical for ensuring the long-term competitiveness and growth of the sector.

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