· "Gas quality" CEN/AFNOR/WG 197 Date: 2010-12-29 Doc. Number: N 230 Assistant: Marie BOURBIGOT Direct line: + 33 (0)1 41 62 87 20 [email protected] Your contact: Sylvie

"Gas quality" CEN/AFNOR/WG 197 Date: 2010-12-29

Doc. Number:

N 230Assistant: Marie BOURBIGOT Direct line: + 33 (0)1 41 62 87 20 [email protected]

Your contact: Sylvie FERNANDEZ Direct line : + 33 (0)1 41 62 86 59 [email protected]

GASQUAL DELIVERABLE APPROVED BY CEN/BT WG 197 "GAS QUALITY"

D1.2 "Final WP1 report with methodology and results"

The deliverable D1.2 was presented to CEN/BT WG 197 members commented, and approved on 2010-02-08/09 by the resolution 02/2010: Resolution 02/2010 – Deliverable D.1.2 Final report on study by country of appliances population (document N136) BT WG197 accepts the deliverable with a number of comments listed in an addendum presented in document N184. The document and the addendum will be circulated to the sector forum gas for information and to the relevant following CEN/TCs: 48, 49, 58, 62,106, 109, 131, 180, 234, 238, 299

With the following observations on the document: CENBT WG197 Addendum to document N 136 Deliverable D1-2" Final report on study by country of appliance population": CENBTWG197 formulates the following observations on the document: - It is appreciated that the information on the non-domestic market is very limited, both with respect to the market size and the various combustion systems in use post GAD. Especially the information gathered by phone interview to trade associations are missing. - Mandate M/400 did not envisage testing of non-domestic GAD-compliant appliances. A consequence of this constraint on GASQUAL is that no detailed information on the tolerance of these appliances to changes in gas quality will be obtained in WP5. The results of this market study, however, suggest that the size of this appliance population is substantial, yet detail is not readily available on their sensitivity to gas quality changes.

- There is only partial knowledge of some types of burners and appliances, so additional information shall be provided about the appliances included in the sample of the testing programme. Gasqual has to bring very precise description about appliances they propose to test, with additional information from manufacturers. -The restriction on pressure governor is not specific to France but to 2E+ gas group. -The term " air ratio control" is too general and in the segmentation precise description has to be made (especially identifying those with feed back and no feed back)

Association Française de Normalisation 11, rue Francis de Préssensé F – 93 571 La Plaine Saint Denis cedex http://www.afnor.fr SIRET 775 724 818 00205

GASQUAL.EU

ANSWER TO THE CALL FOR TENDER ON

GAS QUALITY- PHASE 1 OF THE MANDATE M/400

INVESTIGATIONS ON NEW ACCEPTABLE EU LIMITS FOR GAS QUALITY.

INFLUENCE ON THE PERFORMANCE OF NEW AND INSTALLED GAS APPLIANCES.

STUDY PROJECT

DELIVERABLE D1.2

Installation and Inspection Rules and Practices Study

GQWP1_08_D1.2_Final WP1 Report.pdf

Deliverable

N°

Work

packag

e N°

Deliverable name Type of

deliverable

Lead

participant

Limit date

of issue

D1.2 WP1 D1.2 Final WP1 report with

methodology and results

Final Report

v2.0

BRG

ADVANTICA

GL

20.10.2009

AUTHOR(S): MICHAEL DENISON-PENDER, MARCIN PAWESKA, TERRY WILLIAMS, LEN EASTELL

DATE: 20.10.2009

VERSION: CEN, AFNOR FINAL VERSION

GASQUAL PROJECT, WORK PACKAGE 1, FINAL REPORT│BRG Consult for European Commission 2

Document Version Control:

Vers By Status Date Comments

1.0 BRGC Final Draft 15.08.2009 Final Draft to CEN

2.0 BRGC & GL Final Report 20.10.2009 Final Report with:

More explanation on Methodology Section 1.2.1Revised burner classification Fig. 2.2.2Revised park by burner type Fig. 4.2252.1Commercial boiler park & commentary Fig 9.1.2Commercial cooker burner types Fig 9.3.3

Clarification & alignment with WP3 regardingmanufacturer adjustment to reflect country ofdestination (gas group, ref gas, supply pressure)

Tables detailing appliance populations segmentedwith country by country breakdown (Appendix D)


Executive Summary

This report has been produced for review by CEN/BT/WG 197 to record theconclusions of work completed by the GASQUAL consortium on WorkPackage 1 (WP1) Market Study.

This is one of six work packages being undertaken by GASQUAL to provideinformation for CEN in the production of a harmonised European Standard forgas quality. WP1 has studied the current European market for domestic gasappliances. Also, some studies have taken place regarding the Europeanmarket for commercial gas–fired equipment.

The primary objectives of the WP1 Market Study have been to develop aclassification to segment the gas appliance market, provide a country bycountry analysis of the appliance populations in the market and to provide alist of domestic gas appliance categories that should be considered inGASQUAL WP4 for testing in WP5.

It was specifically requested that the appliance classification should relate tothe relevant EN classifications, and this BRGC has attempted to do.However, the EN classifications do not necessarily segment the marketsufficiently to cover all the variables that need to be taken intoconsideration. In most cases it has been necessary to sub-segment the ENclassifications in order to make sure that critical variables are notoverlooked.

The report sets out a “long list” of possible domestic appliance categories thatshould at least be screened for their specific relevance to the test programme.BRGC is not necessarily recommending that every one of the listedappliances should be tested, but rather that each should be taken intoaccount during WP4. It may even be that there are further sub-segmentations that need to be made. On the other hand it is likely thatsome of the categories can be grouped together once it starts to becomeclear exactly where the sensitivities lie.

It will be noted that in order to facilitate the analysis, the pre-agreed“Levels” of segmentation are not necessarily taken in numerical order.Similarly the vertical order of the categories reflects in part the need to groupcertain categories together for the purposes of quantification (e.g. Low NOxnon-condensing boilers).

The final tables in Appendix D have been collated by GL from the data givenin the report. These tables detail appliance populations country by country inan agreed segmentation for boilers, water heaters, cookers and spaceheaters and these will be reflected in the final WP3 and WP4 reports such thatappliance populations, possible field adjustment and an overall riskassessment will be presented as part of the final appliance selection for theGASQUAL test programme.


GASQUAL PROJECT

WORK PACKAGE 1: MARKET STUDY

FINAL REPORT (REVISED VERSION)

BRG CONSULTCP HOUSE

97-107 UXBRIDGE ROAD

EALING

LONDON W5 5TKUNITED KINGDOM


DISCLAIMER

BRG accepts no liability for any material orimmaterial, direct or indirect damage resulting from the

use of this report or its content.

COPYRIGHT

Please note that the quantified data on the Boiler and Water Heatermarkets are derived from sources that are the intellectual property

of BRG CONSULT.

The data on foodservice establishments presented in Fig. 9.3-1 arethe intellectual property of:

GIRA FOODSERVICE18, avenue Marcel Anthonioz

BP 28F - 01220 Divonne-les-Bains

Tel: +(33) 4 50 20 16 35Fax: +(33) 4 50 20 29 28

1.1 OBJECTIVES AND SCOPE


CONTENTS

PART I: DEFINING THE PROJECT ................................................................................................................ 9

1 INTRODUCTION ..................................................................................................................................... 10

1.1 OBJECTIVES AND SCOPE .................................................................................................................... 101.11 Objectives..................................................................................................................................... 101,12 Scope ............................................................................................................................................ 12

1.2 OVERVIEW OF METHODOLOGY .......................................................................................................... 181.21 General Observations .................................................................................................................. 181.22 Boilers and Water Heaters ........................................................................................................... 201.23 Other Domestic Appliances......................................................................................................... 231.24 Commercial Appliances ............................................................................................................... 251.25 Results and Confidence Limits ..................................................................................................... 27

2. CLASSIFICATIONS, DEFINITIONS AND TECHNICAL VARIABLES ........................................... 30

2.1 OVERALL APPROACH......................................................................................................................... 302.2 BURNERS ........................................................................................................................................... 322.3 FLUES ................................................................................................................................................ 362.4 APPLIANCES AND APPLIANCE SPECIFIC VARIABLES .......................................................................... 38

2.41 Boilers .......................................................................................................................................... 382.42 Water Heaters .............................................................................................................................. 462.43 Room Heaters and Gas Warm Air Systems .................................................................................. 482.44 Cookers ........................................................................................................................................ 502.45 Other Gas Appliances .................................................................................................................. 52

PART II: MARKET DATA................................................................................................................................ 54

3. GAS APPLIANCE POPULATIONS: EU OVERVIEW....................................................................... 56

3.1 DOMESTIC APPLIANCE POPULATIONS ................................................................................................ 563.11 All Domestic Appliances .............................................................................................................. 563.12 Total Park by Member State......................................................................................................... 57

3.2 COMMERCIAL APPLIANCE POPULATIONS........................................................................................... 58

4. DOMESTIC GAS BOILER MARKET.................................................................................................. 60

4.1 QUANTIFYING THE EU DOMESTIC GAS BOILER PARK BY COUNTRY ................................................. 604.11 Defining the Domestic Boiler Market .......................................................................................... 604.12 Methodology for Quantifying the Park......................................................................................... 61

4.2 TECHNICAL SEGMENTATION OF THE PARK ........................................................................................ 644.21 General Approach........................................................................................................................ 644.22 First Segmentation: Levels 1, 2 & 3............................................................................................. 784.226 Newer Technologies ................................................................................................................... 1024.2262 Gas Heat Pumps.................................................................................................................... 103

4.3 FUTURE TRENDS .............................................................................................................................. 1054.31 Drivers ....................................................................................................................................... 1054.32 Technological Developments ..................................................................................................... 106

5. DOMESTIC GAS WATER HEATERS .............................................................................................. 115

5.1 QUANTIFYING THE EU DOMESTIC GAS WATER HEATERS PARK BY COUNTRY................................ 1155.11 Product Definitions .................................................................................................................... 1155.12 Quantifying the Park of Gas Water Heaters .............................................................................. 117

5.2 TRENDS......................................................................................................................................... 121

6 GAS ROOM HEATERS AND DRY SYSTEM HEATING ................................................................ 123

6.1 PRODUCT DEFINITIONS .................................................................................................................... 1236.2 MARKET DATA ................................................................................................................................ 123

6.21 Market Segments ........................................................................................................................ 1236.22 UK .............................................................................................................................................. 127

6.3 BURNERS ......................................................................................................................................... 129



6.4 SUPPLY ............................................................................................................................................ 130

7. DOMESTIC GAS COOKERS .............................................................................................................. 134

7.1 PRODUCT DEFINITIONS .................................................................................................................... 1347.11 Cooker Types.............................................................................................................................. 1347.12 Burner Types .............................................................................................................................. 137

7.2 QUANTIFYING THE DOMESTIC GAS COOKER PARK.......................................................................... 1427.3 TRENDS............................................................................................................................................ 145

8. OTHER DOMESTIC GAS APPLIANCES.......................................................................................... 146

9. COMMERCIAL GAS APPLIANCES .................................................................................................. 148

9.1 COLLECTIVE AND COMMERCIAL BOILERS ....................................................................................... 1489.2 COMMERCIAL WATER HEATERS...................................................................................................... 1529.3 COMMERCIAL CATERING EQUIPMENT ............................................................................................. 1549.4 OTHER COMMERCIAL GAS APPLIANCES .......................................................................................... 158

9.41 Commercial Laundry Equipment ............................................................................................... 1589.42 Non Domestic Space and Air Heaters ........................................................................................ 158

PART III: CONCLUSIONS AND RECOMMENDATIONS ........................................................................ 160

10 CONCLUSIONS: LISTING OF APPLIANCES TO BE CONSIDERED FOR TESTING............. 161

10.1 INTRODUCTION ................................................................................................................................ 16110.2 DOMESTIC GAS BOILERS ................................................................................................................. 16510.3 OTHER DOMESTIC GAS APPLIANCES ............................................................................................... 171APPENDIX A ............................................................................................................................................... 181

SUPPLEMENTARY ANALYSES BY COUNTRY OF THE PARK OF BOILERS <70 KW INSTALLED1993-2007 .......................................................................................................................................................... 181

APPENDIX B................................................................................................................................................ 190

SUPPLEMENTARY ANALYSES BY COUNTRY OF THE DOMESTIC WATER HEATERSINSTALLED 1993-2007 ................................................................................................................................. 190

APPENDIX C................................................................................................................................................ 192

MAIN RANGES OF COMMERCIAL BOILERS AVAILABLE IN SELECTED MEMBER STATES 1997........................................................................................................................................................................... 192

APPENDIX D ............................................................................................................................................... 213

APPLIANCE POPULATIONS, SEGMENTED AND COUNTRY BY COUNTRY.................................. 213





PART I: DEFINING THE PROJECT



1 INTRODUCTION


1.11 OBJECTIVES

This document contains the final report on:

- PROJECT GASQUAL: WORK PACKAGE 1 MARKET STUDY.

The report has been prepared by the Contractor BRG CONSULT (BRGC)in conjunction with the Project Leader for WP1 (GL-GROUP, previouslyADVANTICA).

The WP1 Market Study was launched at the outset of the GASQUALProject and was conducted over the first 6 months of the Project (Januaryto June 2009).

The original Proposal quotes the objectives of the Market Study as set outin the Call for Tender:

“This work package shall give a view of the existing market of appliances

and its trend. It shall identify for all the countries included in the study the

types of appliances present on the market complying with Directive

90/396/EEC and certified to burn gases within the H group. […] This work

package shall include domestic and non-domestic appliances. […] This

work package shall give an estimate of the number of appliances in each

segment identified. For each type of appliances at least the trend i.e.

stable, growing or diminishing number of appliances in this segment and

an estimation of the size and composition by age of the installed appliance

population should be given unless more precise figures are available.”

Further on in the Proposal the deliverables of the WP1 Market Study aresummarized as follows:

“Final report on Study by Country of Appliance Populations

The report will at least include:

- A description of the methodology used to realize this study publicdocuments used as sources will be included as annexes of this report.

- The list of type of appliances identified with the motivation forsegmentation.



- The tables of results by country with results of number of appliances inthe different technology segments.

Fig. 1.121-1 16 SELECTED EU COUNTRIES: DWELLINGS CONNECTED TO GAS

Connected to gasCountry TOTAL Dwellings

Total Total %

Austria 4 187 1 396 33%

Belgium 4 903 3 574 73%

Denmark 2 710 345 13%

France 31 455 11 010 35%

Germany 38 751 17 579 45%

Greece 5 619 31 1%

Ireland 1 369 525 42%

Italy 27 012 19,300 71%

Portugal 5 271 744 14%

Spain 23 935 6 132 26%

UK 25 612 22 794 89%

Czech Republic 4 090 3 120 76%

Hungary 4 172 3 106 74%

Poland 13 000 7 100 55%

Romania 8 260 2 600 31%

Slovakia 1 899 1 466 77%

Other EU Countries 24 825 9 576 39%

TOTAL EU 16countries

203 168 100 760 50%

TOTAL EU 227 993 110 336 48%

% EU 16 89% 91%



- The list of sources and organisations that have contributed to themarket study.

- The list of publications that have been used for the market study (+copy in annex).

- The type of user i.e. domestic, non-domestic or both for each segmentof appliances.

- An estimation of the size and composition by age of the installedappliance population.

- The forecasted evolution of the number of appliances for eachsegment.

- The accuracy of the data given.

- A synthesis table grouping the information by technologies.

- A highlight of the group(s) of countries/segments of appliances withsimilar profile.”

1,12 SCOPE

1.121 Geographical Scope

In principle the study covers the current EU 27 with the exception of theNetherlands (which only consumes L gas and therefore does not comewithin the scope of the GASQUAL Project).

However the Call for Tender required the focus of the study to be on the16 Member States that (always excluding the Netherlands) represent thegreat majority of gas consumption in the EU:

- Germany

- UK

- Italy

- France

- Spain

- Belgium

- Poland

- Hungary



- Czech Republic

- Austria

- Slovakia

- Denmark

- Finland

- Ireland

- Portugal

- Greece.

In practice, of the above Member States, Finland has little relevance to thestudy since there is virtually no gas distribution to households (only c.35,000 dwellings are connected). The gas is used mainly for electricitygeneration. It was therefore decided to substitute Romania (which has asignificant domestic gas network) for Finland.

Dwellings in the 16 selected Member States account for 89% of all EUdwellings but 91% of dwelling connected to gas (Fig 1.121-1).

1.122 Appliance Scope

The Proposal sets out the appliance scope as follows:

“It is expected that that domestic boilers and water heaters will have

major relevance among gas burning appliances in the countries

considered. Therefore, it is suggested that the project will cover

extensively domestic boilers (below 70 kW) and water heaters. For these

products detailed analyses of the appliance population, annual markets

and forecasted evolution will be carried out.

Cookers will also be subject to special attention due to the size of the

market.

Other appliances, including probably space heaters, new appliances

such as micro CHP and heat pumps and possibly less used technologies

such as gas washing machines, tumble dryers, etc will be considered less

extensively. Approximate population and market figures will be sought

through desk-top studies and contacts with manufacturers and trade

associations, in order to allow for an impact assessment.



Larger plants (e.g. commercial heating, commercial catering, commercial

laundry) will only be included if falling under the GAD. The market study

will not cover industrial plants like gas turbines and gas engines that do

not fall under the GAD.

Regarding the two latter product groups (other appliances and larger

plants) preliminary analyses and past experience suggest that the

availability of market data can be very limited and patchy, however, best

efforts will be made in order to reach a satisfactory picture of the relevant

markets, within the time and budget constraints outlined for the present

project.

As far as commercial products are concerned, approaching the relevant

manufacturing sectors and trade associations would establish which

appliances would be sensitive to any broadening of the gas quality bands.

Then relevant benchmark products will be identified for future testing (if

this is feasible). Industrial processes will be studied in theory only, as an

indication of where issues with gas quality variation may occur, but as

already mentioned they will not be part of the market study.

As regards boilers and water heaters, existing data will be used for

appliance classification such as that presented in the EC study on the

boiler directive (92/42) [4]. However, some additional work will need to be

carried out in order to include additional segmentation based on relevant

combustion parameters, such as possibly:

- atmospheric vs. premix burner

- air/gas ratio control

- combustion control (e.g. Scot)

- separate forced air burner (called jet burner in the BED report).

- the share of boilers that are condensing / not condensing

- power burners (fan premixed) or fan-assisted (fan in the exhaust)(incase this plays a relevant role)

- for the atmospheric burners: Percentage of "partially" premixed(bunsen-type) and premixed (Cf. Polidoro and Worgas)

- for the "jet burners": share of premixed and non-premixed

As it can be difficult and costly to get the detailed share by subcategory

and as in the case of this project a very high accuracy on all details of the

market is not necessary, some assumptions and models will be applied.



As regards other appliances, a possible list of types of appliances

identified could include:

- Cookers (hobs and ovens)

- Space heaters: (flued and unflued):

• domestic gas fires - flue and flueless types (to include balanced flueas well)

• convector wall heaters - fan flued and natural draught types

• warm air heaters - ducted and free-blowing types

• radiant tube heaters - mainly commercial

• decorative fuel effect fires - flue and flueless types

• live fuel effect fires - flue and flueless types

- Micro Combined Heat and Power appliances

- Heat pumps

- Washing machines (domestic)

- Commercial laundry appliances

• Dryers

• Commercial catering (hobs and ovens).

For these products accurate market shares are not very relevant and the

efforts to get the data will be adjusted during the execution phase of the

project to the estimated amount of appliances that are installed. For that

reason the boilers, water heaters and cookers will have a higher priority.

In addition, the study will take into account the importance of national

market characteristics and the importance of those characteristics for the

gas quality influence, for example: power burners are (at least in

Germany) adjusted to CO2-maximum on site. So, for example, such a

category will be very sensitive to gas quality changes in Germany and

other countries.

In general for the appliances considered, the study must take account of

different technologies and installation requirements such as:

- modulating/burner type

- air/gas ratio control

- gas exhaust (flued and unflued)



- flame control device (sensor) and type

- pressure control.”

In the report that follows:

- domestic appliances are treated separately from (and in more detailthan) commercial appliances. Indeed domestic appliances form themain focus of the study, since they are the only ones that are due to betested in WP5 of the Project. For domestic appliances, separatechapters (see Part II) are presented for:

• gas boilers (Section 4)

• gas water heaters (Section 5)

• gas room heaters (Section 6)

• gas cookers (Section 7)

• other domestic gas appliances (Section 8)

- commercial products are all covered in Section 9.

Product definitions are set out in Section 2. During the early part of thestudy a set of classifications were agreed (see Section 2), and BRGC hasattempted to follow these classifications while at the same time relatingthem to the appliances and components actually found on the market.

Although not specifically required by the proposal, BRGC was requestedduring the course of the study to relate the appliances and technicalvariables to the EN classifications, and wherever relevant and possible thishas been done.

1.123 Market Scope

In terms of market quantification, the study is concerned more with thepark (population) of appliances than with annual sales data. The Proposalstates:

“For each of the segments we shall make an estimate of:

- the composition by age for each country

- the type of user (domestic / non-domestic)

- the forecast evolution of the number of appliances by segment andcountry”.



As already stated, the domestic and commercial markets have beenanalysed separately. There are some instances (especially for boilers)where the distinction between the two is not entirely clear cut, and thecriteria used are explained in Section 2.

1.2 OVERVIEW OF METHODOLOGY



1.21 GENERAL OBSERVATIONS

Before considering the methodologies employed for each of the appliancefamilies, it is worth making some general observations about theprocesses of assembling the data required for the current project.

Although this part of Work Package 1 is called a “market study”, thequantification required was not what a market research consultancy suchas BRGC would normally consider as “market data” (i.e. annual sales intothe market) but was in fact “park” or “population” data which is a verydifferent challenge.

There are only three possible approaches to assembling park data:

- to conduct sample household ownership surveys

- to construct models based on historical sales data

- to search for any existing data that might be available in the publicdomain.

Conducting sample household studies was obviously way beyond thebudget available (even in one Member State, let alone 16). In any case toobtain the technical details required would be impossible since thehouseholders would not know all the answers. In some countries thereare broad brush government statistics on the park of heating (e.g. by fueltype and/or system type) but these nowhere near go into the technicalvariables required, and often they are out of date there was a niceexercise done by INSEE on the 1995 park in France). Such data can beused for reality checks for the modelling.

The modelling approach does require having access to annual salesdata going back at least to 1992. Fortunately BRGC had been collectingsuch data on domestic boilers and water heaters for the past 20 years,and had already done part of the modelling work for its own forecastingprojects. BRGC also has some softer historical data on commercialboilers, albeit not necessarily based strictly on the 70 kW threshold. Forroom heaters, BAXI VALOR was able to supply similar data for the allimportant UK market.



Even with the benefit of such historical sales data, it is not possible to plotevery variable by every other variable. For example BRGC had fordomestic boilers assembled over the years data by flue type and again byfunctionality, but not for the two combined. Where no such historical dataexist, estimating the park becomes very difficult. It is not possible toreconstruct such data where they do not already exist. This also meansthat the “park” data that can be compiled to not necessarily conformexactly to the classifications that best suit the GASQUAL Project (e.g.conforming precisely to the EN classifications, or to the burner categoriesthat the GASQUAL Project ideally wishes to adopt.

Relevant existing park data tend to be few and far between:

- some countries broad brush data on heating in the housing stock,but not in anything like the detail required for the GASQUAL project.However such data can provide a useful reality check.

- for cookers BRGC did find existing broad data on ownership in mostcountries, plus splits free standing/built-in for the largest countries

- for “commercial” appliances very few data exist at all:

• for commercial boilers BRGC had been following the salestrends based on rather soft industry data since 1997, which gavesome basis for estimating the park

• for commercial catering equipment BRGC was able to findsome data on appliances in Germany and Italy. Otherwise contactswith CISA and EFCEM revealed that no market data are collectedby them or the other national associations. BRGC has howeverbeen able to provide unique data (not so far available to EFCEM)on the number of catering establishments per sector andcountry, courtesy of GIRA FOOD SERVICE.

There were certain technical variables for which no historical sales datahad been assembled, e.g.:

- for boilers, burner types, modulation and special combustion controls

- for cookers, critical burner categories (for hobs, ovens and grills).

To try to fill these gaps BRGC conducted personal interviews with keycomponent manufacturers.



1.22 BOILERS AND WATER HEATERS

1.221 BRGC In-House Data

As far as boilers and water heaters are concerned, BRGC has been ableto draw on sales data that have been built-up over 20 years. In particular,BRGC has a database of annual sales (in number of pieces) from 1990 to2007, split as follows for gas boilers:

- boilers:

• wall hung gas

•• non condensing

•• condensing

• floor standing gas

•• non condensing

•• condensing

• jet burner boilers (includes oil and gas).

Supplementary analyses split the wall hung boiler markets between“heating only” and “combis”. Additional segmentations (although basedof somewhat softer estimates) distinguish the above categories byoutput (kWh) and flue type, and also showing the share on low NOxmodels within non-condensing boilers

- gas water heaters

• instantaneous

• storage

Supplementary analyses split these markets by output/capacity.

These data have formed the basis of BRGC’s annual multi-clientprogramme to which much of the European heating products industrysubscribes on a regular basis. The data, compiled mainly from researchwith manufacturers, cross checked as relevant and critically againstindustry association data, remain the intellectual property of BRGC. Forboth boilers and water heaters, additional information is contained withinthe texts and tables of BRGC’s past multi client reports, and reference hasbeen made to these as appropriate.



Some data based on the above BRGC sources are in the public domain,including those presented in the 1996 EC BED study on the boiler directive(92/42), and those presented in the EC EUP Eco Design Studies (Lots 1 &2). However for this GASQUAL WP1 Market Study BRGC has gone backto its original (now updated) data.

1.222 Other Sources Used

Even for boilers and water heaters, there are certain technical variablesthat needed to be considered that have not been systematically coveredby BRGC’s past work, including:

- burner types

- modulation

- the use of special combustion controls

- pressure controls.

For burners in particular, initial segmentations were provided by HowardLevinsky (GASUNIE) and Petra Nitschke-Kowsky (E.ON RUHRGAS)

In order to fill the remaining information gaps, BRGC conducted a series ofpersonal interviews with the relevant component suppliers, including:

- burner manufacturers (BEKAERT, POLIDORO, WORGAS)

- controls manufacturers (HONEYWELL, SIEMENS, SIT).

This research was supported by contacts with boiler and water heatermanufacturers (RIELLO, ARISTON, VAILLANT, BAXI, VIESSMANN,BOSCH), some of who also completed matrices showing the technicalspecifics or their current models.



1.223 Analytical Methodology

1.2231 Domestic Boilers

Although the main objective of the WP1 Market Study is to provide park(population) data, for these appliances BRGC’s in-house data are mainlyin the form annual sales of pieces. Furthermore, independent existingdata on the park of appliances in most Member States is generallyincomplete, out of date or non-existent. None of available sources providethe technical detail required for the present study. Thus there was a needto convert BRGC’s historical sales data into park estimates. The fact thatBRGC’s sales data had been systematically collected on an annual basissince 1990 was obviously a substantial advantage.

Even prior to becoming involved in the GAQUAL project, BRGC hadalready undertaken some work of this kind for its own forecastingpurposes. Indeed some simple park estimates were included in the 2006BED report. Nonetheless a good deal of original work needed to becarried out for the present study.

This required a modeling approach that BRGC had already evolved for itsown park model (Fig. 1.2231-1).

Fig. 1.2231-1 METHODOLOGY FOR CALCULATING BOILER PARK DATA

The analysis did involve eliminating:

- boilers installed pre-GAD (pre 1993)

- boilers on L gas (especially in northern Germany)

- boilers on LPG and town gas (but taking into account possibleconversions from LPG to natural gas).



1.2231 Domestic Water Heaters

A similar approach was used for water heaters, although here there is anadditional consideration in that some dwellings may use more than onesingle point/secondary water heater. For this reason (rather than fortechnical reasons) the analysis distinguishes “primary” and “secondary”water heaters.

For instantaneous gas water heaters, it is particularly important to take outthe still large park of appliances running on LPG (notably in Spain andPortugal) and to make some assumptions about conversion from LPG tonatural gas.

1.23 OTHER DOMESTIC APPLIANCES

For appliances other than boilers and water heaters, BRGC did not startwith the benefit of an in-house data resource, and all market informationhad to be compiled from original research.

1.231 Cookers

The following sources have been used to conduct research on domesticcookers:

- telephone interviews with cooker manufacturers and personalinterviews with cooker burner manufacturers (SABAF andCASTFUTURA)

- EUROSTAT time series

- IGU Database

- gas usage/gas connection statistics

- other:

• BAK, 1997; CEREN, 1998; Dansk Naturgas, 1999; DETR, 1996;Distrigas, 1999; Doxa S.p.A., 1998; EnergieNed, 1998; EVA, 1997;Finergy/Sener, 1998; GasTec, 1996; GdF, 1999; IEC, 1996; ISR,pers. comm., 1999; Konsumenverket, pers. comm., 1998; LEEP,1996; PdM, pers. comm., 1998; Ruhrgas, 1999; Statistics Finland,1998; VDEW, 1996; Wolf and Kronsteiner, 1995

• STAT, INS, Statistics Denmark , INSEE, SB, Ruhrgas, Fyrogenis,CSO, ISTAT, ISR

• US FCS and US DoS, 1997; Ecofys, 1999; ISR, 1999



• Environmental Change Institute, University of Oxford, Labellingdomestic ovens study

• a programme of telephone interviews was conducted with industryassociations (Fig. 1.231-1).

Fig. 1.231-1 COOKER INDUSTRY ASSOCIATIONS CONTACTED

Country Association Website

Austria FEEI www.feei.at

Belgium AGORIA www.agoria.be

Belgium FEE www.feebel.be

CzechRepublic

CECED CZ www.cecedcz.cz

Germany ZVEI www.zvei.org

Denmark FEHA www.feha.dk

Spain ANFEL www.anfel.org

Spain FAPE www.e-fape.com

France GIFAM www.gifam.fr

Greece SVEIS www.sveis.el

Hungary CECED Magyarország www.cecedhu.hu

Italy ANIE www.anie.it

Portugal AGEFE www.agefe.pt

Poland CECED Polska www.cecedpolska.pl

Slovakia CECED Slovakia www.cecedslovakia.sk

UK AMDEA www.amdea.org.uk

UK TEHVA www.beama.org.uk

1.232 Gas Fires and Room Heaters

For room heaters and gas fires, very little market monitoring of any sort isconducted except in the UK and the Netherlands (the latter in any casebeing excluded from the GASQUAL study). Consequently:

- personal interviews were conducted with the gas fire manufacturersVALOR and FABER

- a telephone interview was conducted with ORANIER



- discussions about burners for this products was included in theinterviews with the burner manufacturers mentioned in Section 1.212above.

1.233 Other

The markets for other domestic appliances such as gas tumble driers andgas washing machines are so small that there are no published dataavailable. BRGC has contacted manufacturers in order to obtain someidea of the scale of these markets.

1.24 COMMERCIAL APPLIANCES

1.241 Boilers

The “commercial and collective” boiler markets are notoriously poorlydocumented, and past studies conducted by BRGC have revealed thateven the market leaders in these sectors have made little attempt toquantify these markets.

However BRGC has over the years attempted to keep track of the maindevelopments in this part of the boiler market, including estimates thesales of boilers above the normally accepted output thresholds, as well asestimates of the penetration of collective heating in the housing stock.Thus it has been possible to use these data to estimate the scale of thecommercial and collective boiler stock based on in-house data, even ifthese estimates are considerably “softer” than those for the domestic park.

1.242 Water Heaters

BRGC has treated all instantaneous gas water heaters as being“domestic”. It is true that there is some “light commercial” use of theseproducts, but the appliances are the same as those in domestic use, so forthe practical purposes of the GASQUAL project, there is nothing to begained from any attempt to distinguish between the two market sectors.

As far as gas storage water heaters are concerned, BRGC regularlycollects sales data split between “up to 80 litres” and “>80 litres”, and themakes the assumption that all appliances >80 litres are commercial.However the EN classifications put the threshold at 70 kW but consideringand it is this threshold (equating to around 220 litres) that has been usedfor the present report.



1.243 Commercial Cookers and Catering Equipment

Contacts with CISA/EFCEM revealed that very few data are collected oncommercial catering equipment markets, with figures available only onGermany and Italy.

Under the circumstances, it was decided to undertake a modeling exercisebased on catering establishment data kindly made available to theGASQUAL project on special terms by the market research companyGIRA FOODSERVICE. GIRA FOODSERVICE has a position in the foodservice market similar to that enjoyed by BRGC in the heating sector.Under the terms of the agreement, BRGC has undertaken not to place thefull raw GIRA data in the public domain.

In addition, telephone interviews were conducted with NationalAssociations:

- Europe, EFCEM

- France, SYNEG

- Germany, HKI

- Italy, CECED Italia

- Spain, FELAC

and with the catering equipment manufacturer FAGOR INDUSTRIAL.

1.244 Other Sectors

No published data are available on other non domestic gas appliancemarket, and BRGC has been obliged to conduct a pragmatic programmeof contacts within the relevant industries.

Phone interviews/visits with manufacturers and associations wereconducted, including:

- GOGAS

- ELVHIS

- ICOM ENERG (via GL)

- Kris de Wit (ARGB – KVBG) for Belgium.



1.25 RESULTS AND CONFIDENCE LIMITS

1.251 Domestic Boilers

With the detailed sales data series that come from the BRGC databaseand reports, verified manufacturer market shares and modelling exercises,BRGC has a strong belief that the information for domestic individual boilerpark is substantially accurate. However there are specific areas wheresofter estimated has proved necessary:

- Germany L-gas using boilers have been subtracted using proportionalrule (+/- 1.5% of boiler park)

- the extent of Spanish dwellings converted from LPG to natural gas isdifficult to measure (+/- 1.5% of boiler park)

- data on park of boilers installed before 1992 (and therefore eliminatedfrom the final figures as being pre-GAD) are less accurate than thepark data for period 1992-2007

- for jet burner boilers (other than “units”) the oil/gas split is difficult toestimate accurately and other reasons (+ /- 2% of boiler park)

- the share of full modulation in heating only boilers, especially thoseinstalled pre-2000.

Overall, BRGC considers its domestic boiler numbers to be accurate within±5%.

1.252 Domestic Water Heaters

With the detailed sales data series that come from the BRGC databaseand reports, complemented by manufacturer market shares and modellingexercises BRG has strong believe that information for domestic waterheater park is fairly accurate. However there are specific areas whererelatively softer estimating has necessarily been applied:

- the extent of Spanish and Portuguese dwellings converted from LPG tonatural gas is difficult to measure, especially since such estimatingneeds to take into account conversions of existing water heaters, thereplacement of existing water heaters, and the displacement of waterheaters by combi boilers



- for instantaneous gas water heaters, BRGC’s regular monitoring of themarket has not historically segmented sales by flue types or electronicversus water activated modulation. However, BRGC is aware of thebroad patterns and trends, and believes that the estimates aresufficiently reliable for the purposes of identifying appliances that justifytesting.

- The share of products on LPG versus natural gas has been based onBRG internal reports as well as any other data available from publicsources / discussions with manufacturers.

Overall, BRGC considers its domestic boiler numbers to be accurate within±8%

1.253 Domestic Cookers

This is not a market that BRGC has previously studied, and with little dataavailable from secondary sources on the park and sales, combined with afairly fragmented industry, it was impossible to quantify certain technicalcharacteristics, as outlined in INIG segmentation document

To better understand burner and combustion technology BRGC conductedinterviews with SABAF and CASTFUTURA, the largest OEM suppliers ofburners to cooker manufacturers (~30%- 40% of OEM market across EU).BRGC also contacted number of large cooker manufacturers that produceown burners.

Numbers on the total population of gas cookers are less accurate thanthose for boilers and water heaters and include mixed electric/gas hobsand mixed fuel free standing products. There are also softer estimates inrelation to LPG.

Overall, BRGC considers its domestic boiler numbers to be accurate within±10%

1.254 Domestic Gas Fires and Room Heaters

The extent and quality of the data available reflects to a large extent thegeographical characteristics of these markets.

The only two substantial markets in the EU are UK and the Netherlands,and it is only in these countries that any systematic attempt is made tomonitor the markets. The Netherlands is of course excluded from theGASQUAL project, although exports from the Netherlands of EN 613products make up a significant part of the small continental EU H gasmarket for such appliances.



For the UK market, BRGC is greatly obliged to VALOR FIRES (BAXIGROUP) for the very substantial inputs they have provided. Somequantified sales data were provided subject to a confidentiality undertaken.While these data have been used as the basis for what BRGC believesare substantially reliable park estimates, it is not possible to reveal the rawsales data in this report.

For the much smaller (and wholly undocumented) Continental markets,BRGC much appreciates the inputs from FABER, ORANIER as well asARGB-KVBG. However, with the possible exceptions of the room heaters(ORANIER type) in Germany and the wall hung EN 613 convectors inHungary, the volumes are so small that it is not worth attempting toquantify each Member State separately.

1.255 Other Domestic Products

Estimates of these very small markets are inevitably soft, but no amount ofanalysis would come to any other conclusion than that these appliancesneed to be covered by whatever policy the GASQUAL Project decides toadopt towards very small niche markets.

1.256 Non-Domestic Markets

The non domestic markets form easily the most difficult part of WP1 from aresearch point of view, and a great deal of soft estimating is involved:

- for collective and commercial boilers, BRGC is confident that from itshistorical research it is able to provide the best estimates that could bemade available within the budget, even if the strength of the data isconsiderably lower than for domestic boilers

- commercial water heaters are hardly an issue, apart from the largestorage models on which BRGC has some historical data on sales ofappliances >80 litres

- for domestic catering equipment, access to the GIRA data provides abasis for estimating that is not generally available to the cateringequipment industry. Even so, the estimates (except in Italy andGermany) are based on the application of assumptions rather than ondirect market data. BRGC does not see any way of quantifying themarket for the listed catering appliances other than cookers within thebudget available

- other space heating equipment markets are also very difficult toquantify.

2.1 OVERALL APPROACH


2. CLASSIFICATIONS, DEFINITIONS AND TECHNICAL VARIABLES

2.1 OVERALL APPROACH

During the early stages of the study a set of classifications were agreed asthe basis of the market analysis. It was also agreed that as far as possiblethe analyses should be based on the EN classifications.

For the most part the technical variables on which the classifications arebased are product specific (see Section 2.4 below). However, some,including:

- burner types (see Section 2.2)

- flue types (see Section 2.3)

apply to all or several product categories, and a specific set ofclassifications is needed for each.

It should be note that the Proposal also requires the Market Study to takeinto consideration the penetration of special heating controls. However,since these are so far only fitted to boilers, coverage of them is confined tothe boiler analysis.

The agreed classifications are set out in Sections 2.2-2.4. In order toarrive at a market analysis based on the agreed classifications, it has beennecessary:

- to relate these classifications to the appliances and components thatare actually found on the market

- to make the best use of the market data that is available.

GASQUAL PROJECT, WORK PACKAGE 1, PRELIMINARY REPORT│BRG Consult for European Commission 31

Fig. 2.2-1 E.ON RUHRGAS CLASSIFICATION OF GAS BURNER FOR MARKET ANALYSIS /1

2.2 BURNERS


2.2 BURNERS

The classification of gas burners was based on inputs from:

- Petra Nitschke-Kowsky (E.ON Ruhrgas) who submitted the matrixshown in Fig. 2.2-1

- Howard Levinsky (GASUNIE).

In April 2009 the resulting basic classifications adopted were as shown inFig. 2.2-2 below (left hand column). These classification were used as thebasis for BRGC, research and analysis. However, since the first version ofthis report was circulated in August 2009, it has been proposed that aslightly different set of classifications for boiler burners. These basicallyseparate the original category “Partial Premix” into:

- atmospheric

- fan assisted.

These revised classifications also introduce some slightly differentterminologies. Fig. 2.2-2 attempts to reconcile the various different sets ofclassifications:

2.2 BURNERS


Fig. 2.2-2 H. LEWINSKY & E.ON CLASSIFICATIONS OF GAS BURNERS FOR MARKET ANALYSIS

H. Levinsky(adopted April2009)

E.ON RuhrgasClassifications(ref Fig. 2.2-1)

RevisedClassifications

and Terminology(October 2009)

Characteristics

Non-premix Not included Not includedGas and air are notmixed prior tocombustion

Atmospheric(Natural Draught)Partially Aerated

“Partial premix”or“Conventional”

1,2,6,7

Fan AssistedPartially Aerated

Bunsen type: only partof the air necessary forcombustion goesthrough the burner.The rest goes roundthe burner.

Atmosphericpremix

3,4,5,8,9*

Atmospheric(Natural Draught)Fully Aerated

Usually slightly over-stoichiometric. Oftenflat/butterfly wingflame, rod cooled orwater cooled*

Premix burner 10Fan Assisted FullPremix

The air goes throughthe burner. Usuallyfanned.

Jetburner/Forcedair burner

13Fan Assisted NonPremix (JetBurners)

Fan driven horizontalflame. Gas version ofoil burner.

Note*: since the submission of the first version of this report in August2009, BRGC has been advised that the water cooled ribbed burnersshould be a sub-category of “partial premix” and not “atmospheric premix”.This implies that they are not in fact slightly over-stoichiometriic assuggested in Fig. 2.2-1.

Working to the above classifications, BRGC conducted personal interviewswith burner manufacturers. These revealed that:

- “no premix” is not really a relevant category for the appliances understudy

- the vast majority of appliances use partial premix Bunsen type burners,which come in a variety of constructions (these are described in moredetail in the relevant parts of Section 2.4)

2.2 BURNERS


Fig. 2.2-1 E.ON RUHRGAS CLASSIFICATION OF GAS BURNER FOR MARKET ANALYSIS /2

2.2 BURNERS


- atmospheric premix burners are used primarily in low NOx noncondensing boilers. Broadly speaking since the early 1990’s there hasbeen a progression from rod cooled to flat (butterfly-wing) flames(OVO/OVAL type) to water cooled (for wall hung boilers). Asmentioned above, BRGC has since been advised to include the ribbedwater cooled burners as a sub category of “partial premix” rather thanof “atmospheric premix”

- fully premix burners are used in most condensing boilers (apart fromsome SEDBUK B models in the UK and possibly some other, early,condensing models, although this latter group may be largely in theNetherlands and/or pre GAD)

- gas jet burners may be fitted to “gas units” (jet burner boilers withfactory fitted gas burners), or (further down the distribution chain) to“oil/gas boilers” which do not have the jet burner fitted n the factory.The share of gas is difficult to quantify for the latter type sincemanufacturers do not know which fuel type will eventually be used.There is even a possibility of gas burners replacing oil burners later inthe life of the boiler.

2.3 FLUES


2.3 FLUES

Apart from condensing boilers with fully premix burners and jet burnerboilers, the EN classifications for domestic gas boilers are closely linked tothe flue type. The flue classifications follow these EN standards:

Fig. 2.3 BASIC CLASSIFICATIONS OF FLUES

Type Description

Type AFlueless (applies to some UK gas fires and some waterheaters).

Type BOpen flue: draws air for combustion from inside theroom, and usually evacuates the waste gasses throughthe chimney or through a special outlet in the roof.

Type C

Room sealed: draws air for combustion from inside thebuilding. Two main types are fanned (C32 and C33which gives greater flexibility in siting the boiler,because up to 3 metres of flue can be used) orbalanced flue (C11 which needs the appliance to bepositioned near an outside wall). Used mainly in theUK and for gas fires throughout Europe. Sometimesfor gas fires a longer version of the balance flue isused, which it is reported does not fit easily with thecurrent test standards.


Fig. 2.41-1 CLASSIFICATION OF DOMESTIC BOILER BY TYPE /1

LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5Sector /

Product TypeEN Standard Product System Burner Controls

Flue Sensor

Air / Gas ControlConventionalModulation type

Flue Sensor

Air / Gas Control

Heating only

Atmosphericpremixed

Modulation type

Flue Sensor


Flue Sensor

Air / Gas Control

Wall-hung non-condensing

EN625Combination

Atmosphericpremixed

Modulation type

Flue Sensor


Flue Sensor

Air / Gas Control

Heating only

AtmosphericPremixed

Modulation type

Flue Sensor


Flue Sensor

Air / Gas Control

DOMESTICBOILER

EN 297BOILERType B

Floor-standing non-condensing (Excl Jet

Burners)

EN625Combination

AtmosphericPremixed

Modulation type

2.4 APPLIANCES AND APPLIANCE SPECIFIC VARIABLES


2.4 APPLIANCES AND APPLIANCE SPECIFIC VARIABLES

2.41 BOILERS

The agreed classifications for domestic boilers are summarized in Figs.2.41-1, 2.41-2, 2.41.3 and 2.41.4.



LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5

Sector / Product Type EN Standard Product System Burner Controls

Flue SensorAir / Gas ControlConventionalModulation typeFlue SensorAir / Gas Control

AtmosphericPremixed Modulation type

Flue SensorAir / Gas Control

Heating Only

Fully premixedModulation typeFlue SensorAir / Gas ControlConventionalModulation typeFlue SensorAir / Gas Control



Wall-hung Non-Condensing

EN625Combination




Heating Only




DOMESTIC BOILEREN 483 BOILER

Type C

Floor-StandingNon-Condensing(Excl Jet Burners)

EN625Combination

Fully premixedModulation type



LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5Sector / Product Type EN Standard Product System Burner Controls

Flue Sensor

Air / Gas ControlHeating OnlyFully

PremixedModulation type

Flue Sensor

Air / Gas Control

Wall Hung

CombinationEN625

FullyPremixed

Modulation type

Flue Sensor

Air / Gas ControlHeating OnlyFully

PremixedModulation type

Flue Sensor

Air / Gas Control

EN 677 BOILERSCondensing (equippedwith a premix burner)

Floor- Standing

CombinationEN625

FullyPremixed

Modulation type

Flue Sensor

Air / Gas Control

Jet burnerboiler non-condensing

Heating Only Jet BurnerModulation type

Flue Sensor

Air / Gas Control

DOMESTIC BOILER

EN 303-3 BOILERS(equipped with forced

draught burners) Jet burnerboiler

condensingHeating Only Jet Burner

Modulation type


Fig. 2.41-4 CLASSIFICATION OF NON DOMESTIC BOILER BY TYPE /1

Levels 1 & 2: the main focus has been on domestic boilers, which BRGCclassifies as boilers that provide central heating for a single dwelling unit,the great majority of which are <60 kW. It should be noted that thoseclassified as “commercial” boilers (Fig. 2.41.5) include both those used fornon-housing and those used for the collective heating of multi-dwellingbuilding. In practice, distinguishing between “domestic” and “commercial”boilers is never absolutely precise in that:

- different countries use different output levels as thresholds (e.g. Italy35 kW, UK 44 kW, Germany 60 kW and France 70 kW). BRG,following EN classification, made estimates which would take 70kW asthreshold for domestic products.

- some boilers that are sold primarily for “domestic” use are also fitted insmall non-housing premises (“light commercial”)

- in the “commercial” boiler market there is a growing trend towardsinstalling “cascades” of wall hung condensing boilers. Individuallythese units may fall below the normally accepted output thresholds for“commercial” boilers, but they are always installed in groups. It isassumed that these are treated as domestic boilers in the ENclassification, but it may be worth considering whether a cascadeinstallation should be tested.

Level 3: while it has been argued that the distinction between “wall hung”and “floor standing” boilers may not be critical to the GASQUAL project, inreality the distinction is valid because of the different construction ofburners used for each category (especially with regard to low NOx modelsusing atmospheric premix burners or water cooled burners).

LEVEL 1 LEVEL 2

Sector / ProductType

EN Standard

EN 656Floor Standing (70-300kW)

EN 13836Floor Standing (300-1000kW)NON DOMESTIC

BOILER

EN 303-7 BOILER (equippedwith a forced draught

burners)


Level 4:

- System: this classification relates to the sanitary hot water provisionfunction of the boiler:

• combination boilers include only those with direct production ofinstantaneous hot water, although some models may havesupplementary built-in storage tanks or pre-heat/“microaccumulation” facilities. The great majority of combi boilers are wallhung, but there are some floor standing combis sold, notably in theUK. BRGC believes that this definition (used historically by BRGCfor its market analyses) corresponds to the EN 625 definitions

• heating only boilers do not produced directly heated sanitary hotwater, but many (probably most) are connected to a hot watercylinder that is indirectly heated using a secondary circuit.

Combination boilers were the main drivers of the development ofcontinuous modulation.

- Burners (see also Section 2.2 above): with a few exceptions, thepatterns of burner use are fairly straightforward:

• non condensing boilers (other than low NOx models) useconventional partial premix Bunsen type burners (mainly bladed forwall hung and tubular for floor standing). Most wall hung noncondensing Low NOx boilers use water cooled bladed burners. It isunderstood that this type of burner should be included as asubcategory of atmospheric partial premix rather than atmosphericfully premix

• non condensing low NOx models use some form of atmosphericpremix burner (generally with rods or “oval” types for floor standing).There are also mesh/matrix type burners. As mentioned above,most wall hung low NOx boilers have water cooled rib type burners,but there are some with rod or mesh type cooling

• condensing boilers (apart from some SEDBUK B models in the UKand maybe some very early condensing boilers elsewhere) usefanned premix burners. There are some non condensing boilerswith fan assisted burners (e.g. ECOFLAM, IMAR and BALTUR inItaly and some VIESSMANN boilers in Germany) but it is not clearwhether these should be classified as fanned premix or fan assistedpartial premix.

Flue types: Type A is not relevant to boilers. The overall trend for wallhung non condensing boilers has been away from Type B towardsType C. Within Type C, balanced flues (C11) are found mainly in theUK, but the trend has been away from theses towards fanned flues(C31). In can be assumed that all condensing boilers use Type Cflues, especially designed for condensing use.


Level 5:

- Modulation: this is a poorly documented area. Modulation (and inparticular continuous modulation) was introduced above all as a meansof reducing the water content of wall hung combi boilers, and the greatmajority of combis are now continuously modulating. There may besome low priced models still in the park that are step modulating. Thepenetration of modulation in heating only boilers (and especially floorstanding models) was slower, but today almost all heating only boilerssold are continuously modulating (the few open vented cast iron boilersstill sold in the UK may be exceptions)

- Special combustion controls: these included flame signal gasadaptors (e.g. SCOT and SIETHERM PRO), and flue sensor adaptors.In practice such supplementary controls are fitted only to a smallnumber of condensing wall hung boilers

- the proposal also requires air/gas ratio controls to be covered.However BRGC understands that pneumatic air/gas ratio controls arethe standard modulating controls that are sold by HONEYWELL andSIT. These are not designed to broaden the range of gasses that canbe used, but rather they need to be set for the gasses that are used ineach country/region in which the boiler is to be sold. There are alsoelectronic air/gas ratio controls but BRGC’s understanding that evenwhere these are fitted the boiler needs to be adapted to the quality ofgas used. Since the circulation of the original version of this report ithas been pointed out (by the UK representative on the CEN 197Committee) that both for boilers and water heaters there are manyGAD compliant appliances that are still in use that do not have air/gascontrols but have simple controls consisting of an appliance governoror throttle

- the proposal also mentions pressure controls. Pressure governorsare fitted as standard to the modulating controls supplied by SIT andHONEYWELL; also there are special restrictions on how they are usedin France.



Fig. 2.42-1 DOMESTIC WATER HEATER CLASSIFICATIONS

LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5

Sector / Product Type EN Standards Condensation Flue Controls

Type B Modulation typeEN26 Instantaneous Non-Condensing

Type C Modulation type

Type B Modulation typeCondensing

Type C Modulation type

Type B Modulation type

DOMESTIC WATERHEATER

EN89 Storage

Non-CondensingType C Modulation type

Fig. 2.42-2 NON-DOMESTIC WATER HEATER CLASSIFICATION

LEVEL 1 LEVEL 2

Sector Product Type EN Standard

NON DOMESTIC WATER HEATEREN89

Storage


2.42 WATER HEATERS

The categories of gas water heater covered are shown in Fig. 2.42-1 andFig. 2.42-2.

It is assumed that all instantaneous gas water heaters are for domesticuse. In general those <10 litres per minute are single point and are notnecessarily the primary source of sanitary hot water for the dwelling(although they may be, especially in Spain and Portugal). Models of 10+litres per minute are generally multi-point and therefore are often theprimary source of hot water for the dwelling. One challenge is to estimatethe substantial proportion of instantaneous gas water heaters, againespecially in Spain and Portugal, that use LPG rather than H Gas. Also, itis known that many of those originally using LPG have been converted toH gas when the gas network arrived, and this is probably an ongoingprocess. This has resulted in the need for some rather “soft” estimating.

For gas storage water heaters, BRGC has in the past generally assumedthat those up to 80 litres capacity are for domestic use and those >80 litresare for commercial use. There is a significant usage of such appliances in“light commercial premises that need a plentiful supply of hot water suchas hairdressers and restaurants. However, the EN classification gives thethreshold at 70 kW, which is thought to be closer to a 220 litre capacity.For the GASQUAL project BRGC has adopted this threshold.

In instantaneous gas water heaters, most appliances have water activatedmodulation. Some of the premium models are continuously modulating(electronic) but the precise share of these is difficult to quantify.


Fig. 2.43-1 EN CLASSIFICATIONS FOR DOMESTIC SPACE AND AIR HEATERS

LEVEL 1 LEVEL 2

SectorProduct

TypeEN Standard

EN 613 (including BS7977-1)Independent space heaters without fan

EN 1266Independent space heaters with fan

EN 509Fuel effect

EN 14438Gas-fired insets for heating more than one room

EN 13278Open fronted independent space heaters

SPACEHEATERS

EN 14829Flue-less space heaters

EN 778Forced convection air heaters <70kW

EN 1319Forced convection with fan assisted burner

<70kW

DOMESTIC

AIRHEATERS

EN 1196Condensing air heaters


2.43 ROOM HEATERS AND GAS WARM AIR SYSTEMS

The EN classifications for this family of appliances are shown in Fig. 2.43-1.The descriptions given for each category are those provided in a listingsubmitted by AFNOR. However, some further explanation about the productactually tested under some of these EN categories may be helpful,especially in relating the EN numbers to the UK’s SBGI classifications whichform the basis of BRGC’s statistical analysis of the very large UK market (forgas fires the only other substantial market is the Netherlands which isexcluded because it is based on L gas):

- EN 613 (independent space heaters without fan) covers most balanced andopen flue gas fires and room heaters, including glass fronted “live fuel effectfires” sold in continental Europe, wall hung convectors (e.g. in Hungary andSBGI “wall heaters” in the UK), floor standing room heaters (e.g. ORANIERtype in Germany). In the UK, the majority of “radiant convectors” (SBGI,mainly old style ceramic gas fires) and “live fuel effect fires” (SBGI “insetliving flame”, “outset living flame” and “balanced flue”) are installed inbuilders openings rather than having a directly fitted flue as required by EN613. For this reason they are tested under BS7977-1, which nonethelesscomes within the auspices of the GAD). On the Continent, it seems thatalmost all gas fires and room heaters are tested under EN 613

- EN 1266 (independent space heaters with fan) probably covers the relativelysmall market for fanned flue products (mainly continental). This Standarddoes not seem to be used in the UK, where most of the fanned flue productscome under EN 13278. BRG still researches market for EN 1266

- EN 509 (fuel effect): this is very much a UK product, classified by SBGI as“decorative gas fires”. These open fronted gas fires have more of adecorative than a heating function, and products tested under EN 509 arenot allowed to claim any efficiency levels

- EN 14438 (gas fired insets for heating more than one room). Logically thiswould include models such the FABER PELGRIM KOMPAKT and SELECTmodels, but few are sold outside the Netherlands, and it seems that theseproducts are tested mainly under EN 613

- EN 13278 (open fronted independent space heaters): includes SBGI “fannedflue” (mainly live fuel effect fires)

- EN 14829 (flueless space heaters) applies mainly in the UK (SBGI “fluelessfires”). These products claim 100% efficiency but need a catalytic converterto process the waste gasses.

- EN 788: (forced convection air heaters <70 kW). This is used in the UK foropen flue gas warm air systems (whole dwelling)

- EN 1319: (forced convection air heaters <70 kW with fan assisted burner).This is used in the UK for room sealed gas warm air systems (wholedwelling).


Fig. 2.44-1 DOMESTIC COOKER CLASSIFICATIONS

LEVEL 1 LEVEL 2 LEVEL 3Sector /Product

TypeEN Standard Product

Freestanding cookers

HotplatesEN 30-1-1,3,4

Gas cooking appliances

Others gas cookingappliances

DOMESTICCOOKER

EN 30-1-2 and EN 30-2-2Forced Convection ovens

and/or grillsOvens/grills

Fig. 2.44-2 NON-DOMESTIC COOKER CLASSIFICATIONS

LEVEL 1 LEVEL 2 LEVEL 3


Open burners and wokburners EN 203-2-1

Chargrills EN 203-2-10

Pasta cookers EN 203-2-11

Ovens EN 203-2-2

Boiling pans EN 203-2-3

Fryers EN 203-2-4

Hot water heaters forbeverage EN 203-2-6

Salamanders androtisseries EN 203-2-7

Brat pans and paellacookers EN 203-2-8

NON DOMESTIC

CATERINGEQUIPMENT

EN 203-1 & EN 203-2-1 to 11

Solid tops, warming platesand griddles EN 203-2-9


2.44 COOKERS

The EN Classifications (Fig. 2.44-1) for domestic gas cookers are:

- domestic cookers: EN30-1-1, 3,4 & EN 30-2-1

- forced-convection ovens and/or grills.

In practice, available data on this market are so thin that it has only beenpossible to quantify all EN 30 appliances together, giving the splitbetween:

- built-in

- free standing.

This split is relevant since built-in ovens (being generally smaller) are likelyto be more sensitive to gas quality. Some reference is made in the reportto the distinctions between high level (open) grills and grills built into theoven cavity. Within the latter, the trend towards ovens designed for use ofthe grill with the oven door closed is also relevant.

As far as burners are concerned, all cooker burners (for hob, oven andgrill) “take air from outside” and are therefore classified as partial premixBunsen type. There are some sub-categories for hob burners:

- fricative vs. ring (ring more stable but more expensive)

- single vs. double or triple ring. Multiple ring are likely to be moresensitive to gas quality.


Fig. 2.45-1 OTHER DOMESTIC GAS APPLIANCES

LEVEL 1 LEVEL 2

Sector / Product Type EN Standard

EN 12752-1 & EN 12752-2Tumble dryers <20kW

EN 1458-1 & EN 1458-2Tumble dryers <6kW

EN 12309-1 & 2Heat Pump

EN 12244-1 & EN 12244-2Washing machine

DOMESTICOTHER

No EN number forMicro CHP yet


2.45 OTHER GAS APPLIANCES

The markets for other gas appliances (see Fig. 2.45-1) are either verysmall or very difficult to quantify or both. There are particular difficulties inquantifying the non-domestic/commercial market, and these are allcovered in a single section of the report (Section 9).


Fig. 2.45-2 OTHER NON DOMESTIC GAS APPLIANCES /1

LEVEL 1 LEVEL 2


EN 525 Direct forcedconvection <300kW

EN 621 Forced convection airheaters <300kW

EN 1020 Indirect forcedconvection <300kW

EN 1196 Condensing airheaters

AIR HEATER

EN 12669 Air heaters for greenhouse applications

EN 416-1 &EN 416-2 Overheadradiant-tube heaters

EN 777-1 to 4 Overheadradiant-system heaters

NON DOMESTIC

RADIANT HEATER

EN 419-1 & EN 419-2 Overheadluminous radiant heaters

Fig. 2.45-2 OTHER NON DOMESTIC GAS APPLIANCES /2

LEVEL 1 LEVEL 2

Sector / Product Type EN Standard

EN 12244-1 &EN 12244-2Commercial laundryappliances (Washing

machines)NON DOMESTICOTHER

no EN numberMicro CHP


PART II: MARKET DATA


Fig 3.11-2 TOTAL PARK 2007 FOR DOMESTIC GAS APPLIANCES* IN 16 SELECTED EU COUNTRIES

Country I. Boiler II. Water Heater III. Cookers IV. Space heaters Other Total

United Kingdom 21 434 1 184 10 843 11 966(1)

*** 45 427

Italy 13 116 3 174 24 445 *** *** 40 736

France 9 000 2 950 12 866 *** *** 24 816

Spain 4 342 7 913 3 980 *** *** 16 234

Germany 8 140 2 217 2 168 829 *** 13 354

Poland 1 466 2 179 7 191 *** *** 10 836

Hungary 1 495 848 2 600 3 500 *** 8 443

Czech Republic 1 568 467 2 451 *** *** 4 485

Belgium 1 870 1 386 600 250 *** 4 106

Portugal 198 3 115 *** *** *** 3 314

Slovak Republic 633 193 1 290 *** *** 2 117

Romania 1 556 214 *** *** *** 1 770

Austria 701 195 539 *** *** 1 434

Ireland 613 36 *** *** *** 649

Denmark 329 9 96 5 *** 439

Greece 115 22 30 *** *** 167

Total 66 577 26 103 69 098 16 550 *** 178 327

* all numbers in (‘000). The figures refer to the total park, including appliances installed pre 1993. Subsequent analyses refer mainly to the post 1992 (GAD) park.*** BRG expects these markets to be relatively small.(1): Number includes 480,000 ducted gas warm air systems.

3.1 DOMESTIC APPLIANCE POPULATIONS


3. GAS APPLIANCE POPULATIONS: EU OVERVIEW


3.11 ALL DOMESTIC APPLIANCES

The total estimated park of domestic H-gas using appliances gas acrossthe 16 EU Member States specifically covered by the study is around178.3 million (Fig. 3.11-1). It is estimated that this figure represents closeto 95% of domestic H-gas appliances installed in the EU. BRGC’sanalysis has attempted to exclude L-Gas consuming appliances (this hasinvolved excluding the Netherlands from the project) and also appliance onLPG. The analysis, presented in later parts of report also attempts toexclude all appliances still in use but installed pre-1993. Fig. 3.11-1includes total park of appliances as of the end of 2007.

Fig. 3.11-1 TOTAL PARK OF GAS USING APPLIANCES IN 2007

37%

15%

39%

9%

TOTAL PARK 2007* : 178 327

I. Boiler II. Water Heater III. Cookers IV. Space heaters

* all numbers ‘(000)



Fig. 3.11-1 clearly illustrates the relative importance of boilers and cookers,which between them account for 76% of the total park. There is also park ofradiant heaters in UK in Fig. 3.11-1 included in others. Fig. 3.11-1 does notinclude the “others category which is too small to show up. “other”appliances include:

- washing machines

- tumble driers

- heat pumps

- micro-CHP.

3.12 TOTAL PARK BY MEMBER STATE

Fig. 3.12-1 shows that the top 6 countries (UK, Italy, France, Spain,Germany and Poland) together account for 85% of the park of appliancesin the 16 countries covered. The UK is easily the largest market for boilers(UK, Italy, France and Germany account for 78% of the gas boiler park)and space heaters (UK >70%), while Italy is clear leader in gas cookers(Italy, France, UK and Poland account for >80%).

In terms of trends:

- in most of the larger markets the domestic boiler park is nearingsaturation, but trends favour wall hung against floor standing and thereis a rapid move towards condensing which should accelerate if andwhen the EUP Eco-Design proposals are implemented. There is stillscope for enlarging the park in countries where the gas networks arestill being extended, but for climatic and other reasons such growth inthe uptake of gas central heating may be limited (Spain, Portugal,Greece). In Eastern Europe much will depend on policy towardsdistrict heating. The domestic boiler park could even be eroded insome of the larger markets if policy swings towards district heating(local CHP) or back towards collective heating (starting in Italy)

- the gas water heater market is now largely a replacement market, withthe park generally declining in favor of combi boilers and othersolutions linked to central heating. Against this, there may be somescope for the H-gas park to gain share from LPG, notably in Spain andPortugal

- the gas fires/room heater markets are probably loosing share both tocentral heating and to electricity, and in some cases (e.g. EN 509 in theUK) to solid fuel. EUP process has started, which could againstproducts such as EN 509. There is an argument that increasingly wellinsulated houses may shift from central to room heating (+ perhapssolar for water heating) but this is marginal so far

3.2 COMMERCIAL APPLIANCE POPULATIONS


- the gas cookers population is now losing to electricity because of thetechnological advances that have been made on the electrical side.The trend is towards built-in appliances


Quantifying the populations of commercial appliances has, as anticipated,proved to be extremely difficult. This is largely because few such marketsare statistically monitored by the industries involved.

BRGC tentatively estimates the following total populations (16 countries1993-2007 installations):

Product Boilers >70kW

Gas StorageWater Heaters

>70 kW

CateringEquipment

Other (mainlyradiant & air

heaters)

‘000 pieces 863 241 [1,872 cateringestablishments]

2.5-3.5 million



4.1 QUANTIFYING THE EU DOMESTIC GAS BOILER PARK BY COUNTRY


4. DOMESTIC GAS BOILER MARKET


4.11 DEFINING THE DOMESTIC BOILER MARKET

BRGC defines the domestic boiler market as being the market for boilersbelow 70 kW. In general these provide central heating for a single dwellingunit, whether this be:

- an individual house (detached, semi-detached or terraced)

- a single apartment within an apartment building.

The definition does not include collective heating for dwellings (i.e. whereone boiler or group of boilers heats more than one dwelling unit). Boilersfor the collective and block heating of apartments are grouped by BRGCtogether with commercial boilers (for non housing) classified as “collectiveand commercial boilers”, including the elements of cascade systems (seeSection 9).

Within the German definitions, BRGC’s definition of individual (orautonomous) domestic central heating includes:

- all Etagenheizung in apartment buildings

- Zentralheizung in 1 and 2 dwelling houses (assuming that eachdwelling in a 2 dwelling house has its own boiler), but not in apartmentbuildings.

Most such “domestic” boilers are likely to be under 70 kW (in practice thegreat majority are <35 kW). Thus the domestic gas boiler park can broadlybe quantified in terms of the number of dwellings on autonomous H-gascentral heating.

However not all such boilers are domestic. There is a “light commercial”market. However, BRGC has not attempt to separate out the lightcommercial market where the appliances used are the same as those inthe autonomous domestic market.



4.12 METHODOLOGY FOR QUANTIFYING THE PARK

The requirements of the GASQUAL Market Study within WP1 are forquantifying the park (population) of domestic boilers rather than the annualsales figures. This BRGC has attempted to do this for base year 2007.Since, as explained below, estimating the national park of boilers by therequired technical segmentations, BRGC has undertaken the exercise forthe 16 Member States that make up close to 98% of the EU gas boilerpark (excluding the Netherlands which is omitted from the study becauseof its use of L gas). Perhaps surprisingly given its importance within theoverall energy consumption in each country, data on the park of domesticheating available in the public domain are scarce, intermittent andincomplete in terms of the segmentations required for the current project.Some data have appeared during the period under review. In Francethere was a significant INSEE studying 1996. In Italy useful overview datafrom DOXA were made available to BRGC by SNAM, but none have beenforthcoming since 1995. In Germany some data is prepared by theChimney Sweepers Association, but we have never seen these presentedin a useful format. GfK is known to monitor the market in UK andGermany, but these data are not in the public domain and would bebeyond the budget of this project.

In view of the above, the only methodology available is:

- to use whatever incomplete data that is available as a reality check

- to calculate the park on the basis of BRGC’s unique database ofannual boiler sales from 1990-2007.

It is this exercise (herein referred to as “BRGC Park Model”) that has beencarried out by BRGC for the 16 selected countries (in order of size of parkthese are UK, Italy, France, Spain, Germany, Belgium, Poland, Hungary,Czech Republic, Austria, Ireland. Slovakia, Denmark, Greece, Romania).

The historical sales data which form the basis of the modeling exercise arebased primarily on information received from boiler manufacturers,crossed checked against total market estimates and incorporatingestimates for non-responding manufacturers. The data have beencollected from the industry in different ways according to the technicalvariables involved:

- actual returns of individual manufacturers’ sales for boiler types:

• wall hung non condensing

• wall hung condensing

• floor standing gas non condensing (excluding jet burner)

• floor standing gas condensing (excluding jet burner)


• jet burner boilers:

•• gas “units”

•• oil/gas boilers (for these it is not possible to tell whatproportion will eventually be gas as opposed to oilbecause the burner is not fitted by the manufacturer.BRGC has assumed the share of gas to be 15%)

- consensus of opinion on annual trends in the shares of:

• combi vs. heating only

• flue types (Type B vs. Type C)

• low NOx models within the non-condensing boiler categories

• sales by output (kWh)

• other variables that are not so relevant to the current study share asheat exchanger materials and ignition types.

It is stressed that the above inputs to the “BRGC Park Model” are drawnfrom BRGC’s ongoing multi client research programme and remain theintellectual property of BRGC.

This leaves some technical variables on which data have not beensystematically collected over the years, and for which BRGC has beenobliged to conduct research specifically for the present study:

- segmentation by burner types

- the penetration of special combustion controls

- trends in modulation (fixed flame vs. step modulation vs. continuousmodulation).


4.2 TECHNICAL SEGMENTATION OF THE PARK



4.21 GENERAL APPROACH

4.211 Industry Characteristics

BRGC’s remit for WP1 is to segment the EU park of domestic gas boilersaccording to certain technical variables that have been agreed within theConsortium (based largely on EN classifications) during the early part ofthe project.

However in order to arrive at the analysis required it is necessary to gothrough the stage of relating these defined parameters to what isphysically out there in the market and boiler park. The main objective ofthe WP1 Market Study is to support the selection of appliances to betested. This implies evaluating the relative importance of each of thetechnical variables and identifying clusters of products or models typesthat match these variables. This in turn should facilitate the selection ofmodels for testing that can confidently be considered as technicallyrepresentative of these clusters.

A step towards clustering the types and models of boilers in the EU park isto identify specific or shared characteristics (historical and current) ofnational markets and of boiler manufacturers. It is the manufacturers andtheir component suppliers who have driven the technologicaldevelopments that have created today’s product segments, but thepatterns of technological development have differed between differentparts of the European boiler industry. To make the market analysis moremanageable, BRGC has divided the industry into a number of differentcategories of manufacturer within each of which there are likely to beshared characteristics. Because of the numerous acquisitions that havetaken place over the years, several of the larger holding companies in theindustry have subsidiaries that fall into different groupings.

A summary of market shares per product categories across the 16countries can be found in Fig. 4.211-1 to Fig. 4.211-4 while Figs 4.211-5 to4.211-11 provide more detail on the structure and evolution of each of themain industry groupings. These Figs. make reference to the burnercategories submitted by EON RUHRGAS (see Fig. 2.2-1). It should benoted that for analytical purposes the French, Italian and Spanish wallhung boiler manufacturers have many shared characteristics, and couldeffectively be merged into one grouping. BRGC has not prepared a Fig.for the east European industry yet all. Amongst the manufacturers with gasboiler that are based in the newer Member States in Eastern Europeranges are:



- PROTHERM (VAILLANT via SAUNIER DUVAL) manufacturing mainlywall hung boilers in Slovakia

- ATTACK, manufacturing gas and solid fuel boilers in Slovakia

- VIADRUS (ZDB) in the Czech Republic whose main strength is in solidfuel boilers but which also offers wall hung and floor standing gasboilers

- DAKON (BOSCH) in the Czech Republic which is strong in solid fuelbut also in gas boilers.

Although the groupings in the Figs. 4.211-1 to 11 do not form part of thefinal analysis required for WP1, they will be referred to in the chapters thatfollow as a convenient way of explaining the technical evolution of the EUboiler market.

Fig. 4.211-1 WALL HUNG CONDENSING SHARES: 16 COUNTRIES 1993-2007

Fig. 4.211-2 WALL HUNG NON-CONDENSING SHARES: 16 COUNTRIES 1993-2007

HOLDING (1) COMPANY / BRAND NAME Park Share 1993-2007

VAILLANT GROUP VAILLANT (2) 19%

WORCESTER 10%

BUDERUS 7%BOSCH

JUNKERS 4%

BAXI BAXI HEATING UK 8%

ISG IDEAL 8%

VIESSMANN VIESSMANN 7%

Other 35%

* Includes GLOW WORM and S-DUVALNote: (1) based on 2008 ownerships. (2) includes SAUNIER DUVAL and GLOW WORM

HOLDING COMPANY / BRAND NAME Park Share 1993-2007

VAILLANT 8%VAILLANT GROUP

SAUNIER DUVAL 7%

JUNKERS 6%

WORCESTER 4%BOSCH

ELM LEBLANC 3%

BAXI BAXI 5%

ARISTON CHAFFOTEAUX ET MAURY 4%

IMMERFIN IMMERGAS 4%

RIELLO BERETTA 3%

ISG IDEAL 3%

Others 54%



Fig. 4.211-3 FLOOR STANDING NON-CONDENSING SHARES: 16 COUNTRIES 1993-2007


BAXI 7%

POTTERTON 3%

BAXI FRANCE 2%BAXI

BAXI HEATING UK 4%



GLOW-WORM 4%

BOSCH BUDERUS 6%

ISG IDEAL 3%

REMEHA DE DIETRICH 3%

CENTROTEC WOLF 2%

Other 53%

Fig. 4.211-4 FLOOR STANDING CONDENSING SHARES: 16 COUNTRIES 1993-2007


BAXI HEATING UK 12%BAXI

BAXI FRANCE 2%


ISG IDEAL 4%

BOSCH WORCESTER 3%

VAILLANT GROUP VAILLANT 3%

Others 69%

BRGC believes it is important to point out that the supply of boilers hasbecome very international, certainly since the GAD came into force in1992. While there are still national peculiarities, BRGC believes that theseare few enough to allow all the significant ones to have been identified inthe analysis that follows.

The above comments are particularly relevant to new newer memberstates that joined the EU after the GAD came into force. While it might beargued that the study should only consider boilers installed in thesecountries post-accession, in practice the vast majority of gas boilersinstalled in these countries since 1993 were either manufactured inexisting Member States or in local subsidiaries of holdings based inexisting Member States.



Fig. 4.211-5 EU BOILER INDUSTRY: STATUS AND EVOLUTION OF THE GERMAN THERMEN SECTOR

Structural Overview

Sector comprises the two German companies with an instantaneous gas water heater/lightweight wall hung boiler ("Thermen") ancestry. Both have subsequently expanded byacquiring boiler manufactures that have different ancestries. Note that the market shares given below refer only to the VAILLANT and JUNKERS (including BOSCH and VULCANO)brands, not to the total group sales.

Holding VAILLANT BOSCH

Brand/Range VAILLANT JUNKERS/BOSCH/VULCANO

Historical Perspective

Up to the mid 1990’s (when condensing boilers started to gain share in Germany), wall hung boiler supply to the German market was effectively shared between two producers,VAILLANT and BOSCH THERMOTEKNIK (JUNKERS brand) selling "Thermen" type boilers under DIN 3368. These two also dominated instantaneous gas water heater production. Therewas a clear distinction (both in terms of DIN standards and in terms of installers) between the “Thermen” sector (wall hung boilers and instantaneous gas water heaters) and the“Heizkessel” sector (floor standing boilers, both dedicated gas and jet burner oil and gas). VAILLANT and JUNKERS currently hold some 75% of the German non-condensing wall hungboiler market, but face much stronger competition in the condensing sector, where their combined share is <30%. VAILLANT and JUNKERS both export wall hung boilers all overEurope. They also sell floor standing gas boilers in Germany (VAILANT more than JUNKERS) but exports of these products is limited. Both produce their boilers in Germany, but havemoved their instantaneous gas water heater production abroad (BOSCH to Portugal and Turkey and VAILLANT to Spain).

Technical Characteristics

Overview

The two “Thermen” producers were slow to develop suitable condensing boilers, and it was the accelerating uptake of condensing oilers from the mid 1990’sthat opened the door to the Heizkessel producers (and to some importers) to challenge the wall hung duopoly of VAILLANT and JUNKERS. The German Thermenwall hung boilers were generally considered more sophisticated than the French and Italian types. We believe that VAILLANT and BOSCH produce some of theirown burners, and all products were sold as “low temperature” (Niedertemperatur). The Germans pushed low NOx in non condensing boilers, and most noncondensing burners are classified as premix (but not fan assisted). After a slow start the two manufacturers have seen their sales move increasingly towardscondensing. In Germany for wall hung boilers the proportion of there sales taken by condensing boilers grew. Internationally, VAILLANT and JUNKERS have soldwall hung boilers produced in Germany, but with less emphasis on the low temperature and low NOx aspects. Both companies also in the 1990's introducedlower priced lines to compete with the French and Italian (VAILLANT with the "Euroline" TURBOBLOCK and JUNKERS with the NOVATHERM produced in itPortuguese VULCANO plant. There may also have been some JUNKERS imports from Turkey.

Burner types

Non condensingwall hung (Germanmarket)

BRGC’s recollection is that by the mid 1990’s these German wall hung boilers were increasingly sold as “low NOx" and “premix” (but were not fan assisted).The EON chart suggests that all non-condensing wall hung boilers would use the rib type, but that the German boilers would have progressed from 6 through to9, while the French, Italian and Spanish products would have remained mainly with type 6. For low NOx VAILLANT has its own water cooled burner, but BOSCHis thought to source from POLIDORO. Both in Germany and internationally the combis will have been fully modulating, and today the heating only models are aswell.

Non condensingwall hung(international)

6-9, but probably with a higher proportion remaining longer on 6. Combis (and now heating only) fully modulating (possible that the BOSCH NOVATHERM wasstep modulating).

Condensing wallhung

Both in Germany and internationally, the condensing boilers are fitted with the fan assisted premix type 11 (modulating). VAILLANT has one model using type12 with flue sensors. BOSCH reportedly decided against special combustion controls.

Floor standing gasnon condensing

VAILLANT more important than JUNKERS, with concentration on German market (therefore low temperature). VAILLANT is thought to have opted for the rodcooled low NOx burner.

Floor standing gascondensing

VAILLANT more important than JUNKERS, with concentration on German market. Condensing models used fully premix burners.

Jet burner Not in VAILLANT or JUNKERS/BOSCH ranges.



Fig. 4.211-6 EU BOILER INDUSTRY: STATUS AND EVOLUTION OF THE FRENCH WALL HUNG SECTOR

Structural Overview

Sector comprises the three French companies (all of whom have now been acquired by foreign boiler manufacturers) with an instantaneous gas water heater/lightweight wall hungboiler ancestry. Together with the two German "Thermen" companies, these three French manufacturers effectively created the European lightweight wall hung boiler (and especiallythe combi boiler) market. Also included in this group is a fourth French wall hung boiler manufacturer, FRISQUET. FRISQUET has a much smaller international presence than the otherthree, and has rather distinctive models with an exclusive type of burner.

Holding VAILLANT BOSCH MTS FRISQUET

Brand/Range SAUNIER DUVAL ELM LEBLANC CHATTOTEAUX ET MAURY FRISQUET


French wall hung boiler manufacturers: the French non-condensing wall hung boiler market has long been dominated by 4 indigenous producers:- SAUNIER DUVAL (now owned by VAILLANT)- CHAFFOTEAUX ET MAURY (now owned by MTS/ARISTON and rebranded simply as "CHAFFOTEAUX")- ELM LEBLANC (now owned by BOSCH)- FRISQUET.The first three were amongst the pioneers of the mass market combi boilers, and made a large contribution to the development of that market not only in France, but also in the UK,Italy and Spain. Indeed, the Italian and Spanish industries are thought largely to have followed the French (even though the Germans were also active on their markets). The French(and subsequently the Italian) wall hung boilers were generally perceived as being less sophisticated than the German ones. The main French wall hung boiler manufacturers sell alimited range of floor standing boilers. FRISQUET stands out from the other three in that it has special models that are very little sold outside France. FRISQUET offers a range ofrelatively high priced copper wall hung boilers with pre-heat cylinders and special burners. It has recently launched a condensing range.


Overview

With the exception of FRISQUET, French wall hung boiler producers emerged from the instantaneous gas water heater industry. Both inFrance and internationally they were largely responsible (from the 1980's), developing a mass market for wall hung combi boilers that wereprobably less sophisticated than the German models. Until recently the products were fixed water temperature non condensing. Theyfollowed the Italians into combis with storage, and since the late 1990s they have pioneered the "micro accumulation" concept. Over the pastfew years (probably partly as a defensive measure against anticipated Eco-Design recommendations), an increasing proportion of their boilersare offered (and tested) as "low temperature" boilers. It is thought that the great majority of their non condensing models use copper heatexchangers. As condensing boilers gained ground internationally they have all introduced condensing models. The share of condensing is nowgrowing rapidly in France (24% in 2007).

Burner types

Non condensing wall hungMainly Type 6. SAUNIER DUVAL is thought to produce many of its own burners, and CHAFFOTEAUX used to do so prior to its acquisition byMTS

Condensing wall hung Both in France and internationally, the condensing boilers are fitted with the fan assisted premix (type No. 10).

Floor standing gas non condensing Very limited involvement.

Floor standing gas condensing Very limited involvement.

Jet burner Not supplied



Fig. 4.211-7 EU BOILER INDUSTRY: STATUS AND EVOLUTION OF THE ITALIAN WALL HUNG SECTOR

Structural Overview

In terms of the number of producers/assemblers, Italy has the largest and most fragmented gas boiler industry in Europe, with dozens of mainly family owned companies. These aregrouped around a relatively small number of component manufacturers, including WORGAS and POLIDORO in burners, SIT and now BERTELLI in controls, GIANNONI in heat exchangersetc. There is only space below to list a few of the largest boiler manufacturers. It should be noted that BRGC has not attempted to analysis separately the Italian floor standing gasboiler industry since it overlaps to a large extent with the wall hung industry. Much of the now declining floor standing boiler industry was dependent on the few manufacturers thatmaintained their own foundries (FERROLI, SIME, BIASI, IDEAL CLIMA and GRUPPO IMAR).

Holding RIELLO IMMERFIN MTS BAXI FERROLI BIASI

Brand/Range BERETTA/SYLBER/VOLKERA RIELLO/THERMITAL IMMERGAS/ALPHA/HYDROTHERMARISTON& others

BAXIFERROLI/FER/STARCLIMA

BIASI/SAVIO


After the Italian wall hung boiler market had been pioneered mainly by the French and Germans, and encouraged by rapid gasification in the early 1990’s, a large and fragmentedItalian wall hung boiler industry developed, led by BERETTA/RIELLO, but with IMMERGAS, FERROLI, MTS etc growing rapidly. Italy became Europe’s largest wall hung boiler market,with sales consistently running at close to one million pieces a year. There were said at one time to be over 100 producers (or more accurately assemblers).The Italians have developed a substantial export business, and are present in almost every EU market. In particular they were very active in the UK, but have lost ground since theswitch to condensing in 2005.Many of the Italians offer floor standing gas boilers (notably RIELLO, FERROLI, IMMERGAS, SIME etc. These are both steel, cast iron and copper, with the last named type being closeto a floor standing combi.It should be noted that there are some Italian wall hung boiler producers whose products diverge from the normal patterns in using fan assisted premix burners for non condensingboilers (ECOFLAM, IMAR and BALTUR).


Overview

The industry grew (mostly in the North Eastern quarter of the country) based on a few major component suppliers, of which WORGAS andPOLIDORO were dominant in burners, supplying, it is thought, overwhelmingly type 6 burners to the Italian industry. The main product wasthe (relatively simple) non-condensing combi. The Italians did pioneer the combi with a 40 litre storage tank, but sales stagnated at around10% of the market. As in France (and for the same reasons), the Italian manufacturers have recently moved rapidly towards presenting theirboilers as “low temperature”. Most of the Italians now offer condensing models. The condensing market is now developing quite rapidly aftera slow start, accounting for some 20% of sales in 2007. One specific of the Italian market is that many wall hung boilers are installed onbalconies. Perhaps 20% of sales of wall hung boilers in Italy are of models specifically designed for such siting, but it is reported that othermodels are also installed on balconies.

Burner types

Non condensing wall hung Overwhelmingly Type 6 supplied by WORGAS and POLIDORO. ECOFLAM, IMAR and BALTUR closer to Type 10, even for non-condensing.

Condensing wall hungBoth in Italy and internationally, the condensing boilers are fitted with the fan assisted premix type No. 10). Pioneered by the Dutch

BEKAERT, these premix burners are now offered by both WORGAS and POLIDORO.

Floor standing gas non condensing Two main types: cast iron and copper (the latter with integrated hot water production). Probably mainly Type No. 1.

Floor standing gas condensing Very limited involvement.

Jet burner Limited involvement (e.g. RIELLO, FERROLI, SIME).

Cast iron wall hung (UK) SIME & FERROLI had models (outsourced?)



Fig. 4.211-8 EU BOILER INDUSTRY: STATUS AND EVOLUTION OF THE IBERIAN WALL HUNG SECTOR

Structural Overview

There are four significant Spanish producers of wall hung boilers. Two of these, ROCA (now owned by BAXI) and COINTRA (now owned by FERROLI) were originally supplying the verylarge instantaneous gas water heater market. ROCA CALEFACCION (previously) part of the ROCA bathroom group), was initially a radiator and then a floor standing boiler producer,which established a wall hung boiler plant in 1995. MANAUT was originally a radiator specialist. The floor standing gas boiler market is very small and is dominated by ROCA (Spanishproduction) and FERROLI (importing from Italy). The Portuguese market is still very small. BOSCH has its VULCANO instantaneous gas water heater plant there, which produces somelow cost wall hung boilers.

Holding MCC BAXI FERROLI MANAUT

Brand/Range FAGOR BAXI ROCA COINTRA MANAUT


The Spanish wall hung boiler market was developed mainly by the French, Germans and then the Italian manufacturers. The early Spanish manufacturers emerged from the verylarge instantaneous gas water heater sector:• in the 1980’s the only Spanish producer of wall hung gas boilers was the water heater and domestic appliance producer COINTRA (quite recently acquired by FERROLI)• once gasification started the water heater and domestic appliance co-operative MCC (FAGOR) brand also entered with wall hung boilers. VAILANT established its instantaneous gaswater heater production in Spain in partnership with MCC• in Portugal the VULCANO instantaneous gas water heater factory, having been acquired by BOSCH, started producing a very simple and low cost wall hung boiler for the very pricesensitive Spanish contract market (NOVATHERM). BOSCH already had a low priced range or the Spanish market (NECKAR) part of which may have been imported from its Turkish jointventure• ROCA (whose heating business was later acquired by BAXI) was not in instantaneous gas water heaters, but had a long standing range of (mainly oil fired) floor standing boilers.They started by importing CHAFFOTEAUX wall hung boilers, but went into production in its own right in 1995, based on technology supplied by the Italian INTERKLIM (which went out ofbusiness at the end of 1995)• the radiator manufacturer MANAUT also started to assemble wall hung boilers.There have been few exports outside Spain and Portugal.


OverviewTechnologically the Spanish industry has closely followed that of Italy. Condensing boilers have still hardly made any impact. One

important consideration is possibility that there are still wall hung gas boilers in use that are run of LPG. For example in 1996 some20% of the wall hung boilers sold were LPG models (in the same year some 60% of instantaneous gas water heaters sold were LPG).

Burner types

Non condensing wall hung. Overwhelmingly Type 6 supplied by WORGAS and POLIDORO. Generally a very low priced market.

Condensing wall hung Condensing boilers are still hardly seen in Iberia.

Floor standing gas non condensing Very little floor standing gas (mainly ROCA/BAXI)

Floor standing gas condensing Minimal involvement.

Jet burner Limited involvement (e.g. ROCA/BAXI).



Fig. 4.211-9 EU BOILER INDUSTRY: STATUS AND EVOLUTION OF THE BENELUX WALL HUNG AND FLOOR STANDING SECTOR

Structural Overview

The Dutch effectively pioneered the condensing boiler (mainly loft sited wall hung) in the EU, and there is a significant and sophisticated condensing oriented industry comprisingmanufacturers such as NEFIT, REMEHA, INTERGAS, ATAG, AWB, etc. The Netherlands market is of course excluded from the GASQUAL project, but Dutch condensing boilers are foundin other EU countries, most notably NEFIT boilers in Germany. In Belgium the largest wall hung boiler factory, that of RADSON, was closed in 2000 following the acquisition by BOSCH.The two main boiler producers are now SAINT ROCH COUVIN (mainly floor standing) and ACV (strongest in floor standing using its tank-in-tank hot water system, but now also in wallhung condensing.

Holding BOSCH BOSCH REMEHA ATAG ACV ENERTECH

Brand/Range RADSON NEFIT REMEHA/BROAG/OERTLI ATAG ACV ST ROCH COUVIN/ZAGEL HELD


Although the Netherlands are not included in the GASQUAL project, the Benelux industry needs to be taken into account. After the French stopped supporting condensing boilers in1989, it was the Dutch who were the main champions of such boilers, and the presence of Dutch manufacturers is felt in other EU countries, most notably NEFIT which supplied, andthen was acquired by, BUDERUS, which itself joined the BOSCH Group. REMEHA acquired the French DE DIETRICH. From Belgium, RADSON was the first main supplier of condensingboilers to BOSCH/JUNKERS. Although the Belgian plant was closed in 2000, there are still many RADSON produced boilers in use in Belgium and Germany. SAINT ROCH COUVAIN isstrongest in floor standing cast iron boilers, supplying mainly the Belgian market (the ZAGEL HELD brand is exported to France). ACV is a leader in floor standing boilers and nowimports condensing wall hung boilers into Belgium. It is best known for its stainless steel "tank-in-tank" hot water systems, and it has an international position in commercial boilers.


Overview

The Dutch industry is of interest since it has long been the technological pace setter in wall hung condensing boilers.BEKAERT (previously known as FURIGAS), pioneered and for a long time dominated the supply of premix burners forcondensing boilers. Now it competes in this field with POLIDORO and WORGAS in Italy. In Belgium RADSON was producingcondensing wall hung boilers with aluminium heat exchangers up to 2000. SAINT ROCH is mainly in cast iron floor standingboilers.

Burner types

Non condensing wall hung (Belgium & international) 6-9.

Condensing wall hung The condensing boilers are fitted with the fan assisted premix (type No. 10).

Floor standing gas non condensing SAINT ROCH COUVIN probably has significant stock of Type 1 in Belgium.

Floor standing gas condensing REMEHA significant in this sector.

Jet burner ACV.



Fig. 4.211-10 EU BOILER INDUSTRY: STATUS AND EVOLUTION OF THE GERMAN HEIZKESSEL SECTOR

Structural Overview

Prior to the GAD the German Heizkessel industry was seen as being quite distinct from the Thermen industry, with different DIN standards and a different installer trade (Heizungsbauer). The sector was dominatedby VIESSMANN and BUDERUS, with BRÖTJE third. WOLF grew during the 1990's through aggressive pricing and marketing, which probably hastened the demise of some smaller players. WEISHAUPT is best knownas a jet burner manufacturer, but also sold "units" and since about 2000 wall hung condensing boilers produced in Switzerland.

Holding VIESSMANN BOSCH CENTROTECH BAXI WEISHAUPT

Brand/Range

VIESSMANN BUDERUS/SIEGER WOLF BRÖTJE WEISHAUPT


The German Heizessel industry, selling mainly floor standing boilers under DIN 4702, which by the time of unification was led by:• VIESSMANN (which was always seen as highly individualist with its bimetal heat exchangers and its introduction in the mid 1990’s of its Matrix gas burner). VIESSMANN also has a floor standing boiler factory in

France, of which much of the output is exported to German• BUDERUS (now owned by BOSCH), which moved into wall hung condensing boilers through being supplied by, and the acquiring, the Dutch market leader NEFIT. BUDERUS sells largely through its integrated

distribution network, but it has a second brand, SIEGER, which targets the wholesaler trade• BRÖTJE (now owned by BAXI). For a long time BRÖTJE had its own distribution network, but this has now been sold and the company has a special (but not exclusive) relationship with GC GRUPPE• WOLF (CENTROTECH) which in the 1990’s was seen as something of an interloper with its aggressive pricing policies• MHG (MAN) which was previously EWFE, which market had been an early pioneer of condensing boilers in Germany• WEISHAUPT is leader in jet burners, but also produces some floor stand "units" and now condensing wall hung boilers• FRÖLING, which is probably best known as leader in solid fuel boilers in Germany, but which also produces gas and oil boilers• ROTEX (DAIKIN) in condensing floor standing boilers

There were other brands, such as SBS and SCHÄFFER which have now disappeared. Up to the time of unification the Heizkessel industry was treated as a different sector from the Thermen industry, with differentDIN standards and a separate installer trade (Heizungsbauer). However during the 1990's, and especially after condensing boilers started to gain a significant share, the Heizkessel producers started to introduce wallhung gas boilers (although these were still classified as "Heizkessel"). By the end of the 1990's the distinctions were becoming blurred, with the Heizungsbauer moving into the territory of the "Gaz -und WasserInstallaturen" and vice versa. This process was probably encouraged by mergers and by the overriding of the DIN standards by CE standards. It is important to note that VAILLANT, though classified as a "Thermen"producer, has long had an important position in the German floor standing gas boiler market (not jet burner).


Overview

Although the German industry, until the mid 1990's, was slow to move into condensing boilers, the product range was relatively sophisticated, reflecting the need to conform tothe requirements of the Blauer Engel and in some cases to the Hamburger Forderprogram. All products have since the 1980's sold in Germany as “low temperature”(Niedertemperatur). The Germans pushed low NOx in non condensing boilers, and most non condensing burners are classified as atmospheric premix. After a slow start theGerman manufacturers have seen their sales move increasingly towards condensing. In Germany for floor standing gas boilers (excluding jet burner) the proportion of their salestaken by condensing boilers grew from 4% in 1996 to 11% in 2000 and to 47% in 2007 (although the overall market size in 2007 was 83% lower than in 1996). For jet burnerboilers, BRGC's 2008 report suggests that all gas units were non condensing, while 40% of oil units were condensing.

Burner types

Non condensing wallhung (German market)

The non-condensing wall hung boilers launched by the "Heizkessel" industry during the 1990's were seen more as Heizkessel than as Thermen. The VIESSMANN range began touse the "Matrix" ceramic mesh burner. It is not clear whether the other Heizkessel wall hung boilers used burners in the range 1-5 or 6-9 (probably mainly 9: water cooled). Bythe mid 1990’s these German wall hung "Heizkessel" were increasingly sold as “low NOx".

Non condensing wallhung (international)

6-9, but probably with a higher proportion remaining longer on 6.

Condensing wall hungBoth in Germany and internationally, the condensing boilers are fitted with the fan assisted premix (mainly type No. 10, but WEISHAUPT and some VIESSMANN products use the

Scot system, and some BRÖTJE boilers use the SIETHERM PRO (i.e type 12).

Floor standing gas noncondensing

By the mid 1990’s these German floor standing boilers were increasingly sold as “low NOx". The VIESSMANN range began to use the "Matrix" ceramic mesh burner. WhileVAILLANT (from the Thermen sector) was using cooling rods, it is thought that most of the other Heizkessel manufacturers were using "butterfly-wing" flame burners such as theBEKAERT OVAL, the POLIDORO OVO and the WORGAS low NOx equivalent. This type of burner is thought to be highly sensitive to gas quality.

Floor standing gascondensing

Use fanned premix burners (Type 10).



Fig. 4.211-11 EU BOILER INDUSTRY: STATUS AND EVOLUTION OF THE UK BOILER SECTOR

Structural Overview

The UK boiler industry has been shaped by the previous dominance of open vented cast iron products that are not found in continental Europe. There were four leading brands of such boilers, ofwhich two (BAXI and POTTERTON) now have a joint ownership. GLOW WORM is now part of VAILLANT and IDEAL is owned by ISG (previously known as CARADON). By contrast WORCESTER (nowowned by BOSCH) was never in cast iron, but moved from its oil-fired base into combis.

Holding BOSCH VAILLANT BAXI ISG GLEN DIMPLEX

Brand/RangeWORCEST

ERGLOW

WORMBAXI/POTTERTON

IDEAL/KESTON

HALSTEAD


The UK has an industry that developed primarily through supplying the cast iron open vented gas boilers (wall hung, floor standing and back boiler units) that are unique to the UK market and thatreflect the previous Water Bye Laws that forbade more than 15 litres of hot water to be stored under mains pressure. The emergence of the combi boiler since the late 1970's, the repeal of the ByeLaw in 1989, and the revisions to Part L in 2005 have more or less killed sales of these products, but the park remains large. The four UK cast iron producers:• POTTERTON MYSON (BAXI)• BAXI (dominant in back boiler units)• IDEAL (ISG)• GLOW-WORM (VAILLANT)have all moved into lightweight wall hung boilers (especially combis, including some floor standing combis) and now condensing boilers. These are partly home produced and partly imported. Howeverit was WORCESTER, coming from the oil fired sector, that was the first UK producer to start seriously to challenge the flood of imported combis.


Overview

Although sales have fallen to a residual level, some 36% of the UK park of domestic gas boilers is still made up of relatively simple open vented castiron boilers. These are not connected directly to the pressurised mains water supplied, but the sanitary hot water is fed from an open tank in the loft,and there is also an open header tank rather than an expansion vessel such as would be found in a sealed system. There are three main categories ofsuch products: cast iron wall hung, floor standing atmospheric gas, and back boiler units (BBU). The last named category is a boiler set under thechimney with an open gas fire in front (typically used in social housing). The products are not efficient but they are simple and long lived. Initiallymost had open or balanced (short horizontal) flues, but room sealed fanned flues gained ground rapidly from the late 1980's. There are no condensingversions, so when the revised Part L regulations came into force in 2005, sales of this type of boiler almost ceased. From the late 1970's, the cast ironwall hung boilers were increasingly challenged by sealed system lightweight wall hung boiler, and especially by combis. The share of condensingboilers grew steadily, especially in the subsidised social sector. They then took off when it was decided to revise the Part L Building Regulations, andthe UK market is now overwhelmingly for condensing boilers (although a law preventing the continuous running of pumps means that most UKcondensing boilers run at well above the optimum return temperature).

Burner types

Cast iron open vented boilers.These products are produced by BAXI, ISG and VAILLANT's GLOW-WORM. WORCESTER used to outsource some but never had a significant share in

these products. It is understood that these boilers typically use a "box burner", which functionally is closely related to burner Type 1 (or type 6, butwith only 1 rib). It is thought that these burners were all on/off rather than modulating.

Non condensing lightweight wall hung

The great majority of lightweight wall hung boilers sold in the UK over the past 20 years are combis, but heating only "system" boilers (i.e. sealedsystem) and up to a few years ago "fabricated" open vented boilers were also sold. The UK manufacturers covered by this analysis mostly producedtheir own boilers, but following a spate of mergers these manufacturers increased the proportion of such products that they imported (BAXImanufactures at it POTTERTON plant as well as importing from its ex-OCEAN Italian plant, ISG manufactures itself and now also owns the UK producerKESTON as well as importing some combis from SAVIO in Italy, VAILLANT's GLOW-WORM produces but may also import from its parent company,which has a significant share of the UK market in its own right). The burners are probably mainly Type 6. Sales of non condensing boilers are now at alow level.

Condensing wall hungSince 2005 the market is overwhelmingly for condensing boilers (mainly combis but also some heating only, both "system" and open vented). Again

the UK producers rely on a mix of UK production and imports. These use Type 10 burners.

Floor standing gas non condensing The old style cast iron boilers are covered above. There are some floor standing combis in the park (e.g. WORCESTER).

Floor standing gas condensing These are mostly cast iron. Type 10 burners.

Jet burner There are some gas units sold. Since 2007 these are mainly condensing.



4.212 Classification of Domestic Gas Boiler Park

The form of classification that was agreed early on in the project is as setout in Section 2.4. While BRGC was reasonably comfortable withinsegmenting the park by each variable separately, to do so in a linearmanner (i.e. each variable by each variable) is a daunting task, especiallysince it is necessary to go back further than most people in the industryremember or have readily accessible records.

It is worth noting that one of the difficulties of focusing on ENclassifications is that it gives a high priority to flue types as againstcombustion and burner types. In reality the type of burner is fundamentallylinked to the Product Type (Level 2), whereas the system type (at least forwall hung boilers) and flue types tend to emerge as variants within a familyof models.

It will also be seen that jet (forced air) boilers are shown as a separatecategory within Level 2 rather than within Level 3 because of the specialdifficulties of segmenting this sector.

During the 1990’s, the penetration of continuous modulation (in Level 4)was liked primarily to the system type, with modulation having beendeveloped primarily as a solution for wall hung combis. Similarly the stillvery low penetration of special combustion controls and sensors is entirelywithin the wall hung condensing sector.



Fig. 4.221-1 1993-2007 TOTAL PARK DOMESTIC BOILERS* 16 EU COUNTRIES DIVIDED BY AGE OF APPLIANCE AND EN STANDARDS

16 EU COUNTRIES (‘000 boilers)LEVEL 2- EN Standard*

1993-1997 1998-2002 2003-2007 TOTAL PARK ‘93-07TOTAL PARK %

share ‘93-’07

EN 483- Boiler Type C 5 629 12 103 12 113 29 844 51%

EN 297- Boiler Type B 6 199 7 327 5 116 18 641 32%

EN 677- Boiler Condensingequipped with premixedburner (1)

484 1 564 7 600 9 648 16%

EN 303-3 Boilers equippedwith forced draught burner

315 336 218 869 1%

Grand Total 12 627 21 329 25 047 59 003 100%

Note (1): The park numbers in this row refer to all gas condensing boilers <70 kW (except jet burner), and may includesome that do not have fully premix burners, including c. 1.5 million SEDBUK B boilers in the UK and maybe some oldercondensing boilers elsewhere.



Fig.4.222-1 TOTAL PARK (INCL. PRE 1993) OF INDIVIDUAL GAS BOILERS 2007 (EU excl. NL, Luxembourg, Malta & Cyprus)

Park 2007 ('000boilers)

Dwellings Connectedto GasCountry

Total %

TotalDwellings

('000)

% of DwellingStock on

Individual Gas '000 %Comments

UK 21 434 32.1% 25 612 83.7% 22 794 89.0% Individual gas central heating prevalent where gas available. Gasification starting in Northern Ireland

Germany 8 140 12.2% 38 751 21.0% 17 579 45.4% Significant use of collective heating in ABL and district heating (esp. NBL)

Italy 13 116 19.6% 27 012 45.8% 19 300 71.4% Uptake of autonomous gas CH high. Some scope for increased penetration in Centre & South

France 9 000 13.5% 31 455 28.6% 11 010 35.0% Gas central heating has strong competition from dry electric

Poland 1 466 2.2% 13 000 11.3% 7 100 54.6% Large district heating infrastructure.

Spain 4 342 6.5% 23 935 18.1% 6 132 25.6% Gasification started in 1990's. Uptake strongest in urban centres & new build, excl. South.

Belgium 1 870 2.8% 4 903 38.1% 3 574 72.9% Limited gas supply in Walloon region.

Czech Republic 1 568 2.3% 4 090 38.3% 3 120 76.3% Large district heating infrastructure.

Hungary 1 495 2.2% 4 172 35.8% 3 540 84.9% Significant DH network (esp.Budapest). Wall convectors also significant.

Slovakia 633 0.9% 3 798 16.7% 1 466 38.6% Significant DH network .

Austria 701 1.0% 4 187 16.7% 1 396 33.3% Strong competition from DH and biomass

Portugal 198 0.3% 5 271 3.8% 744 14.1% Gasification has started but CH uptake very low.

Ireland 613 0.9% 1 369 44.8% 575 42.0% Gasification expanding. Combis not favoured.

Denmark 329 0.5% 2 710 12.1% 345 12.7% Very strong district heating infrastructure.

Greece 115 0.2% 5 619 2.0% 31 0.6% Gasification developing.

Romania 1 556 2.3% 8 260 18.8% 2 600 31.5% District heating dominates, but households have attempted to switch to gas if allowed.

Sub Total: Selected Countries 66 576 99.6% 203 168 32.4% 100 760 48.0%

Lithuania 87 0.1% 1 313 6.6% 1 090 83.0% Significant DH network .

Latvia 46 0.1% 1 035 4.4% 869 84.0% Significant DH network .

Estonia 19 0.0% 633 3.0% 500 79.0% Significant DH network .

Slovenia 62 0.1% 796 7.8% 105 13.2% Significant DH network .

Sweden 18 0.0% 5 158 0.3% 52 1.0% Very limited domestic gas supply. District heating and heat pumps prevail.

Bulgaria 30 0.0% 3 738 0.8% 37 1.0% Limited gas supply.

Sub Total: Other Countries 262 0.4% 12 673 2.1% 2 653 20.9%

Total 66 838 100.0% 215 841 30.6% 103 413 47.9%

Selected Countries % 99.6% 94.1% 97.4%



FIG. 4.22-2 PARK OF DOMESTIC GAS BOILERS 1993-2007 AND PRE 1993* BY COUNTRY (16 COUNTRIES)

Gas Wall HungCondensing

Gas Wall Hung Non-Cond.

Gas Floor Stand. NonCond

Gas Floor Stand. Cond JB gas Total

CountryPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

Total

Austria 6 237 243 13 305 317 46 70 116 1 20 21 3 1 4 68 633 701

Belgium 0 275 275 106 834 940 151 444 595 0 7 7 29 24 53 287 1 583 1 870

CzechRepublic

0 66 66 0 898 898 102 476 578 0 11 11 6 9 15 107 1 460 1 568

Denmark 0 143 143 41 126 166 8 9 17 0 2 2 0 1 2 49 280 329

France 2 404 406 293 5 956 6 248 907 1 028 1 935 0 35 35 99 277 376 1 300 7 700 9 000

Germany 27 2 097 2 123 233 2 666 2 899 901 1 348 2 249 6 76 82 495 291 787 1 662 6 479 8 140

Greece 0 3 3 0 93 93 0 1 1 0 0 0 0 18 19 0 115 115

Hungary 0 25 25 0 970 970 133 363 497 0 2 2 1 0 1 134 1 361 1 495

Ireland 0 32 32 7 540 548 11 22 33 0 0 0 0 0 0 18 594 613

Italy 0 668 668 0 10 418 10 418 628 993 1 621 0 49 49 221 140 361 849 12 268 13 116

Poland 0 103 103 0 1 030 1 030 18 198 216 0 7 7 47 63 110 65 1 401 1 466

Portugal 0 1 1 0 182 182 0 11 12 0 0 0 1 3 4 2 197 198

Romania 0 31 31 16 1 403 1 419 3 56 59 0 1 1 18 28 46 37 1 519 1 556

SlovakRepublic

0 46 46 0 238 238 7 338 345 0 4 4 0 0 0 7 626 633

Spain 0 15 15 0 4 229 4 229 2 75 77 0 0 0 8 12 20 10 4 332 4 342

UnitedKingdom

18 5 206 5 224 53 11 488 11 541 2 909 1 677 4 586 0 82 82 0 1 1 2 980 18 454 21 434

TOTAL 52 9 351 9 404 761 41 375 42 136 5 827 7 110 12 937 7 297 304 928 869 1 797 7 575 59 00266

*all numbers in ‘000



4.22 FIRST SEGMENTATION: LEVELS 1, 2 & 3

Please note that more detailed estimates of technical segmentations percountry can be found in Appendix A of this report.

4.221 Overview

Fig. 4.221-1 summarizes the scale of the EU (16 country boiler) parkaccording to Classification Levels 1 (all boilers) and 2 (EN Standards). Ofthe totals:

- for jet gas burner boilers (EN 303-3) Germany and France make upalmost 70% of the park

- for EN 677 (in the absence of the condensing dominated Netherlands)the UK (thanks to the recent Part L revisions) and Germany (where thesignificant uptake of condensing boilers started in the early 1990’s)make up almost 80% of the park, but the penetration of condensingboilers is now accelerating in other countries

- the trend towards room sealed flues (EN 438) and away from openflues (EN 297) has been seen across all countries, with Italy and Spainswitching fastest towards room sealed.

4.222 Levels 1 to 3: Total Domestic Boiler Park

The relative share of the gas boiler park held by each country depends ofcourse to a large extent on population and numbers of households, butalso on the penetration of such factors as (see Fig. 4.222-1):

- the penetration of central heating (partly related to latitude and climate)

- gasification and the household penetration of mains gas

- the existence and uptake of heating systems other than autonomousgas boilers.

The numbers in Fig. 4.222-1 are for the total park of domestic gas boilersin 2007, including those that remain from before the GAD (pre 1993). Fig.4.222-2 shows separately by country the park of domestic boilers by typeinstalled in 1993-2007.

An understanding of these factors is important for the forecasting of trendsrequired for WP1 (see Section 4.3).

Areas that are difficult to treat within the analysis required for WP1 are:



- boilers installed before 1992 (especially floor standing and jet burnerboilers in Germany and open vented cast iron boilers in the UK)

- boilers that are on L gas in northern Germany and Belgium

- boilers on originally LPG that have been converted to natural gas(especially in Spain, but impossible to quantify: but this is a muchbigger issue for water heaters).

Wall Hung vs. Floor Standing

Although it has been suggested that the distinction between wall hung andfloor standing boilers may not be inherently significant to the GASQUALproject, it is almost impossible to achieve the other segmentations that arerequired for the project without first making this split:

- almost all statistical data available on the boiler market (including theall important BRGC database) are segmented in this way

- the historical development of burners for non-condensing boilers hasbeen different for wall hung and floor standing, with some of theburners that are likely to be most sensitive to gas quality being specificto floor standing boilers

- wall hung boilers have historically moved more rapidly to room sealedflues (EN 483) than have floor standing.

- because within the domestic gas boiler market there has been a veryclear and prolonged trend in favor of wall hung (which has this haseven accelerated in recent years), most of the recent productdevelopment efforts have gone into wall hung, and there is now areluctance to invest in improving floor standing models. This alsomeans that the floor standing park is ageing. Since the majority of floorstanding gas boilers have cast iron heat exchangers, the tend to belong lived, and indeed there may be a significant park of such boilersthat pre-date the 1992 threshold.

Wall hung boilers now account for some 86% of the total gas post 1993boiler park, and indeed they hold a majority share in all countries.



The UK as a Special Case

From the bald analysis it emerges that the UK is the largest market forboth wall hung and floor standing gas boilers (excluding jet burnerboilers). However, it must be noted that a substantial part of the UK parkof both types is made up of the cast iron open vented models that areexclusive to the UK (and on a very small scale, Ireland) and which were arequirement of the old Water Bye-Laws which up to 1989 forbade thestorage of more than 15 lires of hot water under mains pressure. Sealedsystems came in with the combis (which did not need to hold as much as15 litres. Although the Bye Laws were revised in 1989, a substantialdemand for these open vented boilers continued right up to the Part Lrevisions of 2005. Since then sales of these products have effectivelydied. The relative importance of these UK specific models is illustrated inFigs. 4.222-3 and 4.222-4. These products (which can also be found inIreland) have different burner types (“box burners”) and also are mostlyon/off rather than modulating.

If the UK cast iron wall hung boilers are excluded, the most import marketsfor “lightweight” wall hung boilers (Fig. 4.222-5) are UK, Italy, FranceGermany and Spain, which between them account for 83% of the 16country park of such boilers.

Other peculiarities of the UK market are:

- the presence of floor standing combi boilers. This is a niche marketthat is difficult to quantify since manufacturers have always beenreluctant to provide separate sales figures for these models

- the presence of lower spec. SEDBUK B rated condensing boilers.These above reflect an effort to offer the lowest priced boilers thatcould conform to the revised Part L requirements introduced in April2005. It is thought that some or all of these do not have full premixburners. BRGC calculates that there are some 1.5 million of theseboilers in use in the UK.

Floor Standing Boilers

Floor standing boilers account for some 20% of the total 16 countrydomestic gas boilers park excluding jet burner boilers. However, since30% of the floor standing park is pre-1992, in the 1993-2007 park theshare of floor standing is only 13% (or 14% if gas jet burner boilers areincluded).



Apart from the UK, the most significant floor standing gas boiler parks arein Germany and (some way behind) France. Indeed, if jet burner boilersare added to the totals (Fig. 4.222-6) Germany accounts for an estimated21% of the 16 country floor standing gas boiler park (partly reflecting theonce obligatory existence of basements in 1 and 2 family houses), and thisis important to note because of the relatively high share of non-condensinglow temperature and low NOx floor standing boilers (and more recently theincreasing share of condensing floor standing boilers) in order to meet theBlaue Engel requirements.

The French floor standing boiler manufacturers (especially DE DIETRICH)have long been conscious of German standards, but the penetration of lowNOx models is lower in France.

In the UK, as already shown, a large part of the park of floor standing gasboilers is made up of the old cast iron open vented boilers and of backboiler units. There is also an identifiable park of floor standing combis.

In Italy, the floor standing market comprises mainly conventional cast ironmodels but there are steel gas boilers as well as copper models that areeffectively combis.



Fig. 4.222-3 UK SPECIFIC BOILER MODEL PARK 1993-2007*

TOTAL PARK in UKLEVEL 3 Product* Model

1993-1997 1998-2002 2003-2007TOTAL

1993-2007%

Cast Iron 1535 1807 1589 4931 30%

Lightweight 2119 3668 5976 11763 70%Wall Hung

TOTAL ('000) 3654 5475 7565 16694 100%

Back Boilers 549 376 109 1034 59%

Conventional 337 283 105 725 41%Floor Standing

TOTAL ('000) 886 659 214 1759 100%

Fig. 4.222-4 UK SPECIFIC BOILER MODEL SALES TRENDS 1993-2007*

LEVEL 3Product*

Type 1993 1997 2003 2007

Back Boilers 150 96 39 1Floor Standing

Conventional 85 70 50 19

Cast Iron 278 339 296 8Wall Hung

Lightweight 368 550 1 140 1 609

Total 881 1 055 1 526 1 638

Fig. 4.222-5 LIGHTWEIGHT WALL HUNG BOILER PARK 1993-2007 IN 16 COUNTRIES*

Fig. 4.222-6 FLOOR STANDING PARK 1993-2007 IN 16 COUNTRIES*

*all numbers (‘000)

Country*Park "lightweight"Wall Hung boilers 1993-2007

Share in 16 EU Countries

United Kingdom 11 764 26%

Italy 11 086 24%

France 6 360 14%

Spain 4 245 9%

Germany 4 763 10%

Others 7 580 17%

Total 45 798 100%

Floor Standing 1993-2007 ParkCountry* Jet Burner as part

of Floor StandingFloor Standing Park excludingJet Burner

France 16% 14%

Germany 21% 20%

United Kingdom 21% 24%

Total 8 275 7 407



Fig. 4.224-1 SHARE OF NON-CONDENSING AND CONDENSING BOILER PARK 1993-2007* INSELECTED 16 EU COUNTRIES


Fig. 4.224-2 CONDENSING / NON-CONDENSING SALES TRENDS 1993-2007* IN SELECTED 16EU COUNTRIES




4.224 Non-Condensing vs. Condensing

Given that the Netherlands (easily the most important pioneer ofcondensing boilers) is excluded from the study, the condensing boiler parkis relatively young, and the condensing share in 1993-2007 park,excluding jet burners is 17% (Fig. 4.224-1) by no means reflects theircurrent share of sales (48% in the same 16 countries in 2007: see Fig.4.224-2). The condensing share of floor standing boilers is much lower.Basically the increased penetration of the condensing technology hascoincided with the rapid decline in floor standing boiler sales.

The penetration and pace of growth of condensing has varied markedlybetween countries (Fig. 4.224-3), and this has been linked to a largeextent to legislation and incentives. After the Netherlands had shown theway in the 1980’s:

- Germany saw a shift in emphasis from non-condensing lowtemperature/low NOx to condensing progressively after unification asthe demands of the Blaue Engel and the Hamburg Forderprogrammeintensified (though much of the early demand for condensing camefrom the NBL armed with newly converted Deutsch Marks)

- in the UK the big switch to condensing came rapidly and suddenly withthe revisions to the Part L Building Regulation in 2005. However thereare doubts about the energy saving effectiveness of this move since itappears that many condensing boilers are factory set to run at 75o C

- Denmark took much the same line as the UK and has now goneentirely to condensing. However the boiler market is small because ofthe massive penetration of district heating

- Austria largely followed the Swiss LRV’92 provisions

- other countries have been slower to take up condensing, butpenetration is now growing significantly in Italy and France.

The uptake of condensing is likely to accelerate if the current EUP Eco-Design recommendations are implemented, but the consultation process isproving tough.



Fig. 4.224-3 TOTAL OF CONDENSING AND NON CONDENSING BOILERS* BY COUNTRY IN ’93-’07 PARK.

Country Condensing Non-Condensing Total

United Kingdom 5 288 13 165 18 453

Italy 716 11 411 12 128

France 439 6 984 7 423

Germany 2 173 4 014 6 187

Spain 15 4 304 4 320

Belgium 282 1 277 1 559

Romania 32 1 459 1 491

Czech Republic 77 1 375 1 453

Hungary 27 1 333 1 360

Poland 111 1 227 1 338

Austria 256 375 631

Slovak Republic 50 576 626

Ireland 32 563 594

Denmark 145 134 279

Portugal 1 193 194

Greece 3 94 97

Total 9 648 48 486 58 134


The subsequent analyses assume (based on research conducted for the GASQUALproject) that all condensing boilers have Type C flues and premix burners. HoweverBRGC has been informed at a late stage in the project that:

- there are some condensing boilers installed with Type B flues

- SEDBUK B condensing boilers in the UK do not have fully premix burners.



4.225 Level 4: Burner Classification

4.2251 Identification of Burners Within Each Classification

The basic burner classifications adopted for the study emerged from asubmission by RUHRGAS/EON (as already shown in Fig. 2.21) and asubsequent presentation from GASUNIE which led to the adoption of fivebasic categories of burners:

- no premix (not relevant to the appliances covered by this study)

- atmospheric partial premix (Bunsen type), also known as “atmosphericpartially aerated burners”. Since the completion of the market study ithas been proposed that this category be split between “naturaldraught” and “fan assisted”

- atmospheric fully premix, also known as “atmospheric (natural draught)fully aerated burners”

- fan assisted full premix

- jet burner, also known as “fan assisted non premix burners”.

On this basis BRGC conducted an exercise aimed at relating the adoptedclassifications to burners actually on the market. This proved especiallyimportant since it quickly became apparent that the key to analyzing theburner penetration within the park was to talk to the burner manufacturersthemselves. This outcome of this analysis is summarized in Fig. 4.2251-1.Of course the burners mentioned in this matrix are also for products otherthan boilers, but the matrices are placed here because boilers are the onlyproduct category using more than just Bunsen type burners.

As far as boilers are concerned, the key findings are:

- that almost all conventional boilers (non-condensing boilers that arenot specifically sold as “low NOx”) use partially premix/conventionalBunsen type burners:

• for wall hung boilers these are usually bladed construction.Identified exceptions are:

•• FRISQUET in France whose non condensing boilers use thecompany’s own tubular construction (4 tubes) burners, believedto be fan assisted

•• certain Italian manufacturers (ECOFLAM, GRUPO IMAR andBALTUR) who are thought to use fanned premix burners in noncondensing boilers



•• the UK-specific cast iron wall hung boilers. Historically all ofthese used a multi-bladed Bunsen type burner but with a singleinjector for the whole burner (“box burners”) and non-modulating. This is in contrast with the typical Italian bladedBunsen burner which has an injector/venturi for each blade.Towards the end AEROMATRIX came out with a fanned premixfor the UK cast iron boilers of boiler that was fitted to e.g. thePOTTERTON PRIMA. It is thought that it was also taken up byBAXI and CARADON and maybe GLOW WORM

• for floor standing boilers, these are generally tubular construction.Identified exceptions are:

•• UK back burner units and possibly some old open vented castfloor standing boilers that use the same type of single injectormulti bladed burners as the wall hung cast iron models



Fig. 4.2251-1 BURNER CLASSIFICATIONS OF MANUFACTURERS BY TYPE /1

WORGAS Classifications H. Levinsky Classifications

Main category Sub-category Non-premixedPartially premixed/

conventional("Bunsen" type)

Atmospheric premixLean-premixed/ fully

premixed

Round Burners – X

Traditional X

Low NOx and CO X

Yellow flame (alsooval burners)

XTubular Burners

"Elite" & other fanassisted

X

Traditional & Lownoise

X

Bladed burners

Low NOx and CO X

Fiber X

Cylindrical metal XPremix burners

Flat X



Fig. 4.2251-1 BURNER CLASSIFICATIONS OF MANUFACTURERS BY TYPE /2

POLIDORO Classifications H. Levinsky Classifications




premixed

Round BurnersMULTIGAS C51,C65, C120, C160,C220

X

Burners for Log FirePlaces and SpaceHeaters

X X

MULTIGAS Tubularburners for boilersand stoves

XTubular burners

OVO low Nox/COemmissions.

X

NP model burners X

Bladed burnersBNOx model burners(water cooled) [1]

X

SEMIPREMIX(cylindrical)

XPremix burners

PREMIX (cylindrical) X

Note [1]: The POLIDORO water cooled bladed burners (and the similar VAILLANT burners) were included under “atmospheric premix” in the first version ofthis report. BRGC has since been advised that these burners should be considered as “partial premix”. However this does present some problems inquantifying the market by the agreed burner classifications since BRGC’s historical sales data segment the wall hung non condensing boiler market between“conventional” and “low NOx”, and not specifically by burner type.



Fig. 4.2251-1 BURNERS CLASSIFICATIONS OF MANUFACTURER BY TYPE /3

BEKAERT/FURIGAS Classifications H. Levinsky Classifications




premixed

FURINIT (round orflat)

X

ACONIT (flat) XPremix burners withBEKNIT material.

DUONIT X

Cylindrical premixburners

FURIPAT X

Tubular burner OVAL X



- that non-condensing low NOx models represent the most complexgroup of boilers as far as burner types are concerned. In general theseuse burners that may be classified as “atmospheric premix”, but manydifferent types have been tried:

• for wall hung:

•• today the most used solution is the most widely used solution isthe water cooled bladed burner. As an OEM supplierPOLIDORO has the exclusive rights to this type (BNOx range).However VAILLANT has its own version. These water cooledburners should not strictly speaking be classified as“atmospheric premix” but for statistical reasons it has beennecessary to group together all the non-condensing low NOxwall hung boilers

•• there are also flattened “butterfly-wing flame” versions(WORGAS has one) but the uptake has been very low for wallhung

•• it may be that some of the solutions tried for floor standing gasboilers (see below) have also been incorporated into the“Heizkessel” type wall hung boilers launched when the GermanHeizkessel manufacturers first tried to break into the wall hungmarket. This may include the VIESSMANN Matrix burner

• for floor standing a great variety of burners have been used,generally with the objective of flattening the flame. These include:

•• tubular burners with cooling rods. These were introduced in thelate 1980’s/early 1990’s as German Heizkessel manufacturers(which at that time were hesitant about going down thecondensing route) sought ways of conforming to the BlaueEngel NOx emission requirements (at that time set at 70 ppm).The rod technology proved adequate for 70 ppm, but when theSwiss and the Hamburg Forderprogram set the limit at 40 ppm,something new was required. For this reason rod cooling,though still fitted to some boilers, is now seen as an oldtechnology.

•• various types of ceramic of fibre mesh solutions. TheVIESSMANN Matrix burner fits into this category



•• butterfly-wing flame tubular burners (e.g. POLIDORO OVO,BECKAERT OVAL and WORGAS Low NOx butterfly wing).These are thought to have been widely adopted by the GermanHeizkessel manufacturers, while VAILLANT tended to favour therod technology. Burner manufacturers suggest that this typehas a low operating range and could be very sensitive tochanges in gas quality (when the pressure drops, the flame cantouch burner surface, giving rise to cracks or flashbacks with theflaming turning inside the burner and starting a fire). Theseburners are still on the market, but demand for the floor standingboilers that take these has for the types of boilers to which theyare fitted is plummeting. It is reported that the main demand isnow coming from Eastern Europe

•• burners that can be fan assisted (e.g. WORGAS ELITE)

- that almost all condensing boilers use fanned fully premix burners,which can be:

• cylindrical steel (e.g. BEKAERT FURIPAT, WORGAS CylindricalMetal Premix, POLIDORO PREMIX)

• flat metal (e.g. WORGAS BISCOTTI)

• fibre in various shapes, including cylindrical, flat or conical (e.gBEKAERT FURINIT and WORGAS TEXI).

The fans are not supplied by the burner manufacturers, but aresourced separately (EBM appears to be the dominant supplier) and arefitted by the boiler manufacturer.

It is understood that some condensing boilers are not fitted with fullpremix burners. These are mainly:

•• some or all of the SEDBUK B boilers in the UK, of which BRGCestimates around 1.5 million are in use in the UK. It should benoted that the UK representative on CEN Committee 197 hasraised the possibility of other “specials” in the UK, mentioning inparticular the GLOW-WORM ENERGY SAVER (which existed inboth condensing and non-condensing, but is now discontinued) andthe GLOW-WORM FLEXICOM (condensing boiler currentlyavailable in both sealed system and open vented versions which issaid to have a very high port loading)

•• possibly some early condensing boiler models. However it isthought that most of these are either in the Netherlands (notincluded in this study), or are pre-GAD.



4.2252 Park by Type of Burner

As suggested above, the available historical sales data required to makeestimates of the park of boilers do not necessarily cooespond exactly tothe agreed burner classifications. Based on applying the aboveobservations to the BRGC database numbers, Fig. 4.2252-1 sets out theestimates of the 16 country park by type of burner to the extent that theavailable information allows. Please note that:

- “conventional” includes all atmospheric partial premix burners except:

• water cooled burners for wall hung non condensing low NOxboilers. These are included under low NOx wall hung. It is difficultto estimate what percentage of the park of these boilers have watercooled bladed burners, but it is certainly the great majority.Assuming it is about 90%, then a further 4,150 boilers would betransferred to the “conventional” category

• some or all of the SEDBUK, which are included under “fan assistedpremix and other condensing”. It is possible that up to 1.5 million ofthese are not full premix, but it is not quite clear whether or not theyshould be added to any “atmospheric partial premix” total

• any older condensing boilers that do not have full premix burners.These are also included under “fan assisted premix and othercondensing”. BRGC has no basis for estimating the park of these,but believes it is very small given that the Netherlands and all preGAD boilers are excluded

Thus it is possible that a comprehensive “atmospheric partial premix”category might encompass a park of up to 45.6 million boilers.

Fig. 4.2252-1 ESTIMATION OF THE 1993-2007 BOILER PARK BY LEVEL 4: BURNER TYPE

TOTAL PARK 1993-2007LEVEL 4 – BURNER(‘000 pieces) 1993-

19971998-2002

2003-2007

TOTALPARK ‘93-07

TOTAL PARK % shares‘93-’07

Conventional 9 614 16 726 13 602 39 942 71%

Fan assisted premix &other condensing

8 240 14%

- SEDBUK B 1 500 3%- non condensing

619 1 675 7 845

400 <1%

Low NOx (wall hung) 4605 8%

Low NOx (floorstanding)

2 079 2 591 3 3811694 3%

Jet Burner (inc.condensing)

315 336 218 869 1%

Total 12 627 21 328 25 047 59 003 100%



4.2253 Heating Only vs. Combi

In this analysis:

- “combi” refers to boilers incorporating directly heated sanitary hotwater, and tested under EN 625, including:

• combi boilers supplying instantaneous sanitary hot water only

Fig. 4.2253-1 16 COUNTRY PARK OF BOILER BY WATER HEATING FUNCTION


Fig. 4.2253-2 HEATING ONLY AND COMBI BOILER SHARES IN TOTAL 1993-2007 PARK, (16COUNTRIES)

CountryEN 625- Boilers with

sanitary waterHeating only boilers Total Park 1993-2007

United Kingdom 10 533 7 921 18 454

Italy 10 969 1 299 12 268

France 5 780 1 919 7 700

Spain 4 189 142 4 332

Germany 1 783 4 695 6 479

Romania 1 315 204 1 519

Belgium 966 617 1 583

Poland 758 644 1 401

Hungary 681 680 1 361

Czech Republic 803 657 1 460

Ireland 57 537 594

Austria 191 441 633


Denmark 5 275 280

Greece 33 82 115

Portugal 132 65 197

Total 38 328 20 674 59 003

LEVEL 2- EN Standards LEVEL 3 - Product PARK 1993-2007*

Gas Floor Standing 246EN 625- Boilers with sanitary water

Gas Wall Hung 38 082

Gas Floor Standing 7 161

Gas Wall Hung 12 644NON EN 625- Boilers with sanitary water

JB gas 869

Total 59 003



• combi boilers with instantaneous hot water productionsupplemented by a built-in storage cylinder (typically 40 litres)

• combi boilers incorporating a pre-heat arrangement (including theFrench “micro-accumulation” models).

- heating only boilers do not provide directly heated sanitary hot water,but more often than not they are connected to some form of indirectwater heating, including:

• a separate hot water cylinder:

•• on the continent these are all under mains pressure

•• in the UK many are fed from a loft tank rather than directly fromthe mains (classically single walled copper cylinders). Althoughthe Water Byelaw preventing more than 15 litres being storeunder mains pressure was rescinded in 1989, such open ventedsystems have continued to be installed, albeit with a decliningshare of the market

• a cylinder that is supplied along with the boiler. This includes therelatively new wall hung condensing boilers that are positioned ontop of a floor standing cylinder

• some models with built-in indirect water heating (e.g. the ACV-typetank-in-tank systems or the French “bain-marie” models).

In general combis are wall hung, but there are some floor standingmodels, e.g.: WORCESTER HIGHFLOW and BAXI POWERMAX) andpossibly the copper floor standing boilers in Italy (e.g. FERROLITANTAQUA NF). However it is not sure that any of these are tested underEN 625.

Within the Member States covered by this project:

- the majority of 1993-2007 domestic boiler park, including floor standingand jet burner boilers (65% of the current park) are combis (Figs.4.2253-1 and 4.2253-2), obviously this share is the result of wall hungcombis uptake (within wall hung 1993-2007 park share of combis is75%).

- the major exceptions to this pattern are:



• Germany and Austria, which have long been less enthusiastic aboutthe concept of combs than the rest of Europe. Of the total 1993-2007 park of wall hung boilers in these countries, some 63% areheating only, while due to high share of floor standing models inoverall 1993-2007 boiler park the penetration of heating only is72%. This pattern has become even more marked as the share ofcondensing boilers has grown. In 2007, 72% of wall hungcondensing boilers sold in Germany and 88% of those sold inAustria were heating only (this includes wall hung condensingboilers positioned on a floor standing cylinder)

• the penetration of combis is very low within the small Danish boilermarket (heating is dominated by district heating). The main reasonis reportedly the hard water which does not suit combis

• the UK and Ireland, where the park of cast iron heating boilersremains significant accounting for some 30% of the park of wallhung boilers in the UK. Heating only lightweight wall hung boilerssuch as those sold as “system boilers” are also significant.

- for the rest of the EU (excluding the Netherlands) combis account forsome 79% of the wall hung boiler park. In general in countries such asItaly, Spain and France, heating only models are offered as a variantwithin each main family of wall hung boiler models, rather than asseparate families of models.

It should be mentioned that during BRGC’s discussions with the industry,no prima facie evidence emerged that sensitivity to gas quality would beaffected as such by whether the boiler was a combi or a heating onlymodel. However, continuous modulation was developed primarily as asolution for wall hung combis. Although nearly all heating only boilers soldtoday have continuous modulation, there share of modulation in the parkremains much higher for combis than for heating only boilers.

4.2254 Flue Types

As far as boilers are concerned, the EN standards recognize two basic fluetype for boilers:

- Type B: open flue that draws air for combustion from the room, andusually evacuates the waste gasses through the chimney or through aspecial opening in the roof

- Type C: room sealed flue that draws air from outside the building(rather than from the room) is found in two forms:



• fanned flue (Types C32 and C33), which uses a fan to evacuate thewaste gasses. This gives greater flexibility in siting the boiler,because up to 3 metres can be used, which usually allowsevacuation through a chimney or elsewhere through the roof

• balanced flue (Type C11) which uses a balanced opening andclosing system. Balanced flues have to be very short (limiting sitingoptions) and are usually put through the back wall of the house orapartment. The disadvantage is that they tend to discharge wastegasses at low levels.

The broad trend since the early 1990’s (especially for wall hung) has beenaway from Type B towards the fanned version of Type C. In particular:

- For its statistical analysis BRGC has assumed, based the research forthe GASQUAL Project, that all condensing boilers (now gaining sharerapidly) use Type C flues. However, recent feedback from the industrysuggests that there are “condensing boilers installed as type B takingcombustion air from the installation room; mainly B23P and B53Pconfigurations which are critical configurations for cold starts”. It isunderstood that these have tended to be installed in unoccupied areassuch as basements and boiler rooms, and thus are probably foundmostly in countries where these are common (e.g. Germany, France,Belgium, Denmark). Above all they are typical where boilers areinstalled in cascades

- for non-condensing wall hung boilers, the estimated split of the park is31% Type B and 69% Type C (Fig. 4.2254-1). However current salesare considerably more slanted towards Type C

- Type C balanced flues are found mainly in the UK (Fig. 4.2254-2), butthey have lost share to fanned Type C flues since 1990, and with theswitch to condensing since 2005 fanned flues now account for thegreat majority of sales

- floor standing gas boilers have been slower to move towards Type Cbecause of the lesser need for flexibility of sitting.



Fig. 4.2254-1 PARK OF NON-CONDENSING WALL HUNG BOILERS BY TYPE OF FLUE

TOTAL PARK 1993-2007LEVEL 2- EN Standards

1993-1997 1993-1997 1993-1997

TOTALPARK ‘93-07

TOTAL PARK %shares ‘93-’07

EN 483- Boiler Type C 5 178 11 592 11 802 28 571 69%

EN 297- Boiler Type B 3 253 5 300 4 251 12 805 31%

Total 8 431 16 892 16 053 41 376 100%


Fig 4.2254-2 PARK OF EN 483 TYPE C NON-CONDENSING BOILERS IN UK

TOTAL UK PARK 1993-2007LEVEL 2- EN Standards

1993-1997 1993-1997 1993-1997

TOTAL UKPARK ‘93-

07

TOTAL UKPARK %

shares ‘93-’07

Type C Balanced 874 679 324 1 877 16%

Type C Standard 2 866 4 443 2 504 9 812 84%

Total EN 483 Boiler Type C 3 740 5 122 2 828 11 690 100%




4.2255 Modulation

Boiler burners can be:

- fixed flame

- step modulating

- continuously modulating.

The purpose of modulation is to reduce the volume of water that needs tobe held in the boilers, while maintaining or improving the comfortperformance of the boiler.

The introduction of continuous modulation was triggered above all by theintroduction of the combi boiler. The supply of modulating controls for wallhung combis is dominated by two companies, HONEYWELL and SIT.They informed BRGC that virtually all combis (i.e. boilers producinginstantaneous directly heated sanitary hot water) have continuouslymodulating burners. Today these typically modulate within a range of100% down to 40%. As part of a general trend to seek higher efficiency atlow cost, manufacturers are reported to be seeking to widen the range ofmodulation. In the opinion of one controls manufacturer, 30% is probablythe achievable limit, while another talked of going down to 10%. Suppliersalso expressed the opinion that this type of fine tuning of boilers is likely toincrease the sensitivity to variations in gas quality (“It can be argued thatmanufacturers are moving in the opposite direction to GASQUAL”)

It is acknowledged that a few low cost combis are still in the park (possiblyARISTON META and BOSCH NOVATHERM) have step modulation, butthis is thought to represent a very small share of the park. In general stepmodulation has proved unsatisfactory in terms of the comfort levelsprovided, and they are probably now hardly sold, at least as far as combisare concerned.

The situation with heating only boilers is less clear cut. It is thought thatthe great majority of heating only boilers on sale today have continuousmodulation, but the situation in the park is more mixed:

- in the German speaking countries, low temperature boilers (andtherefore continuous modulation) has been more or less standard sincewell back into the 1980’s, but it has been difficult to establish whetherall such heating only wall hung and the floor standing LT boilers havecontinuous modulation

- it seems logical that in the combi-dominated countries outsideGermany, heating only variants of models that are mainly combis willhave continuous modulation



- the great majority of UK open vented cast iron boilers are on/off(except possibly for some more recent models that were fitted with theAEROMATRIX fanned premix burner)

- it has proved difficult to obtain a precise view of modulation in floorstanding boilers. Clearly the penetration of continuous modulationdeveloped far more slowly than for wall hung boilers, partly becausethere are so few floor standing combis. It is thought that most floorstanding gas boilers sold today have continuous modulation, but this isa fairly recent development. On the other hand the largest market forfloor standing boilers (Germany) has been installing low temperatureboilers more or as standard since the 1980’s which presumably impliessome form of modulation. It is believed that there was a good deal ofstep modulation

- it is assumed that all floor standing condensing boilers have continuousmodulation.

4.2256 Special Controls

The Market Study is required to quantify the penetration of additionalcontrols including:

- combustion controls. These can be classified as “gas adaptors” andcan be based on:

• flame signal sensors (SCOT and similar).

• flue sensors

- air/gas ratio controls, which come in the form of:

• pneumatic controls. These are the standard HONEYWELL and SITtype modulating controls and are not concerned with handlingdifferent gas qualities. The boiler must be set for the gas quality tobe used

• electronic, which, according to the manufacturers, still need theboiler to be adjusted or the gas to be used

The initial perception is that such controls could make it easier for theboilers in question to handle variable gas qualities.

However, the overall picture is that the penetration of such controls to datehas been so low that they would hardly show up within the total EU parknumbers. Cost and cost effectiveness appear to have been the mainbarrier.



Combustion Controls (Gas Adaptors)

There are several such systems (which control the modulation dependingon the combustion quality, and detects whether the current is too rich ortoo lean) on the market:

- the SCOT System (flame signal) was developed by STIEBEL ELTRONfor RUHRGAS (EON) some 15 years ago. It enables the boiler toadjust in response to varying gas qualities, in order to be able to takegas from e.g. Norway, Russia, North Africa etc. ELSTER(KROMMSCHROEDER) now has exclusive rights to the SCOT system.It is reported that the uptake has been very low, and has mainly beenfor the wall hung condensing boilers of:

• VIESSMANN (some models). VIESSMANN is reported to be thebiggest user of SCOT

• WEISHAUPT, which apparently fits SCOT to all the wall hungcondensing boilers it produces in its Swiss factory

- SIEMENS has the SIETHERM PRO system, which is known to beused to some extent by BRÖTJE

- HONEYWELL has its own system (SQUARE) but so far it is not in use

- WORGAS has the WTC system (but it is not evident in the market)

- BERTELLI PARTNERS in Italy is reported to coming out with system,but it is thought that this is not yet in use.

It is reported RUHRGAS originally hoped that all new boilers would beequipped with the SCOT System. However in practice the uptake hasbeen low. The downside reportedly has been the R&D costs at the boilermanufacturer level. It takes time to adjust the controls to suit eachindividual model. It is understood that some trials were made on floorstanding boilers (BUDERUS?), but the use of this type of control isreportedly more or less confined to wall hung condensing boilers. It wouldprobably require legislation to increase the uptake significantly.

Flue Sensors

Again the uptake is low. VAILANT has a flue sensor offered with its.However, in general the feedback from the industry is not encouragingabout its use being extended further. BOSCH reportedly tried it but wasnot happy with the performance. The total combustion goes wrong if thesystem is not well adjusted. The need is to find a low cost solution. Workis being done to de to develop a laser sensor for flue gasses to detect CO2

levels at <€50.



Air/Gas Ratio Controls

BRGC’s advice from the industry is that air/gas ratio controls merely mix toa pre adjusted setting, and therefore would not help with handling variablegas qualities Wall hung boilers mostly have a ratio of 1 (in other wordsstoichiometric) equal quantity of air and gas (over stoichiometric meansmore air than gas). SIT has a product with 2 diaphragms which iscommonly used, but it is not a combustion optimization product. It is stillnecessary to know the gas quality.

There appear to be two types:

- pneumatic, which are the basic modulating controls fitted to mostcombis and some heating only boilers, produced mainly by SIT andHONEYWELL

- electronic.

In addition, it is reported that there are still GAD compliant boilers in usethat do not have air/gas control but have simple controls consisting of anappliance governor or throttle.

Pressure Controls

The modulating controls supplied by companies such as SIT andHONEYWELL have pressure controls fitted as standard. BRGC wasinformed that there is a particular issue related to the market in France,where variable pressure controls are not permitted and the controls mustbe set at maximum.

4.226 NEWER TECHNOLOGIES

4.2261 Micro CHP

To date the only micro-CHP appliance available on a commercial scale isthe BAXI/SENERTEC DACHS range (internal combustion) which isintended for non-domestic use (see Section 9.1), even though it might fallinto the “domestic” category according to the EN standards. As of 2009about 13,000 appliances are in place, with Germany as easily the largestmarket. VAILLANT has a similar product (ECOPOWER).

A number of domestic models are expected to be launched from 2009(see Fig. 4.2261-1), but these launches have repeatedly been put backreflecting a difficulty in getting these products ready for market. It isanticipated that the UK and the Netherlands will take the lead inencouraging the uptake of these products.



DG TREN is in the process of incorporating micro CHP appliances into theEUP Eco-Design process (Lot 1), and the assessment appears to bereasonably favorable.

4.2262 GAS HEAT PUMPS

The only product known to be on the market is the ROBUR commercialmodel. BRGC understands that by the end of 2008 some 4,000appliances had been installed. Italy is easily the largest market, followedby Germany. These are basically light commercial gas absorbtionproducts for heating and cooling. ROBUR is understood to have receivedfunding from GDF to develop a smaller domestic model (BUDERUS is alsoa partner), but the launch is probably 4 years away. There is also an EONconsortium of which VAILLANT, BTT and VIESSMANN are members.



Fig. 4.2261-1 MICRO CHP APPLIANCES IN DEVELOPMENT 2009

Company Model Partners Technology OutputExpectedLaunch

CERES POWERMoving from "Alpha" to"Beta" phase

BRITISH GAS Fuel Cell 2011

CERAMIC FUELCELLS

GENNEX/BLUE GEN

E.On (UK),EWE/BRUN (D),GDF SUEZ/DEDIETRICH (F)

Fuel Cell 2kWe 2009

BAXI ECOGEN BRITISH GAS Stirling1.1kWe/24kWthermal

2009

DISENCOHOMEPOWERPLANTmCHP

Stirling 3kWe/18kW thermal 2009

ENERGETIX GENLEC GENELECDAALDEROP (NL),E.On (UK), STIEBELELTRON (D)

Rankine Cycle Up to 3kWe 2009 (?)

WORCESTER BOSCH E.On Stirling 1kWe, 7kWh

WHISPERGEN WHISPERGENMONDRAGON &MERIDIAN ENERGY

Stirling 2009

BROAG-REMEHA REMEHA CHP Stirling 1kWe, 18kWh 2010

VAILLANTBased onMICROGEN

Stirling MECengine

VIESSMANNBased onMICROGEN

Stirling MECengine

ARISTON/ELCO INFINIA (USA) Stirling

4.3 FUTURE TRENDS


4.3 FUTURE TRENDS

4.31 DRIVERS

Forecasting future trends in the domestic gas boiler market involves takinginto account a complex mix of drivers. BRGC has developed an approachthat attempts to take into account these different variables, broadlyspeaking along the following lines:

Fig. 4.31 KEY DRIVERS INFLUENCING BOILER TRENDS

Type ofDriver

Specific Driver Comments

Saturation

Scope for additional first time installation.Effective saturation occurs at lower level ofcentral heating penetration in warmerclimates

GasificationWhere gasification is still developing thereis scope for growth scope for growth, butconsumer attitudes will affect actual uptake.

Underlyingtrend drivers

Replacementpatterns

Replacement rates (linked to appliance lifecycle) will influence uptake of newertechnologies in the existing dwelling stock

Product mix

Substitution from within the domestic gasboiler market; e.g. condensing from non-condensing, Type C flues from Type Bflues.

Substitution

System /fuel typesubstitution

Substitution from outside the individual gasboiler market; e.g. competition fromcollective heating, district heating, differentfuel types, heat pumps etc.

Macro-economic

Housing constructionCyclicaldrivers

Other (incl. weather,energy prices)

Cyclical drivers are in principle short termand reversible. The current economicdownturn is an example. It is not alwayseasy to distinguish cyclical trends fromunderlying trends. Cyclical factors can forexample delay underlying trends.

Political

Macro-economicEvents

Legislation/incentives

Legislation and incentives are easily themost important of these “artificial” drivers.Their impact can be to bring forwardtechnological substitution. GASQUALcould in itself, like EUP, become an “event”

4.3 FUTURE TRENDS


4.32 TECHNOLOGICAL DEVELOPMENTS

4.3211 Technological Trends (Product Substitution)

4.32111 Boilers

Within the domestic boiler sector itself, the most important “productsubstitution” trends are likely to be:

- a continuing shift in favour of condensing boilers. Apart from thecountries where there is already a strong momentum in this direction(UK, Denmark, Germany, Austria, Belgium), the EUP Eco-Designprocess (although its final requirements are still in doubt) is expected toact as a catalyst in the countries that have shown more reluctance(France, Italy, Spain) and also in eastern Europe where economicconsiderations have so far been the main constraint

- the shift towards condensing will obviously help to prolong the longterm shift from open flues (Type B) towards room sealed (Type C)

- there is also a strong shift away from floor standing boilers towards wallhung, and much of the R&D work is now being focused on wall hungrather than the dying floor standing sector. In general terms, much ofthis R&D effort is being directed towards improving the performanceand energy efficiency of existing boilers while keeping the cost of doingso to a minimum. Such efforts reportedly include:

• further refining the adjustments made to boilers pre-shipping toaccommodate the gas qualities in the country of end use

• searching for modulation through a range wider than 100% to 40%.With the demise of the UK open vented cast iron boiler, continuousmodulation itself is now more or less standard

• searching for effective combustion controls/flue gas sensors thatmight facilitate the use of more variable gas qualities without aprohibitive hike in costs (the search was mentioned for a lasersensor for flue gasses to detect CO2 levels costing <€50 a piece).As things stand there is little expectation of any significant increasein the fitting of either the Scot/SiethermPro type controls or ofsensors without either targeted incentives or coercive legislation.

4.3 FUTURE TRENDS


4.32112 Micro CHP

Although (apart from the light commercial internal combustion models fromBAXI/SENERTEC and VAILLANT) it has taken far longer than mostplayers had anticipated to bring domestic micro CHP to market on acommercial scale, there is so much activity at the moment (see Section4.2231) that it is impossible to reach any other conclusion than that theGASQUAL project will need to take into account each of the maintechnologies that are being developed, i.e.:

- internal combustion engines

- Stirling engines

- Rankine Cycle

- fuel cells

however difficult it is to predict what the uptake will be. The SterlingEngine and Rankine Cycle technologies have emerged reasonablyfavourably has a result of their being added to the EUP Eco Designproposals (it is understood that fuel cells have not been taken intoconsideration).

4.32113 Gas Heat Pumps

Gas heat absorption heat pump technology as emerged mainly from theair conditioning sector, but in spite of positive expectations no domesticsized product has yet come to market. The small ROBUR product is saidto be some 4 years away from launch. Thus for the moment this can onlybe earmarked as a product to watch out for (unless it is decided that theexisting ROBUR appliance should be classified as domestic rather thancommercial).

4.3212 System/Fuel Type Substitution

Assuming that micro CHP and gas heat pumps are considered as a typeof gas boiler, BRGC sees the main substitution issues from outside thegas boiler are:

- positive for H gas boilers:

• continued trend away from LPG and oil in favour of natural gas

• continued trend towards wall hung which is overwhelmingly naturalgas (apart from a small share of LPG and of electric boilers)

4.3 FUTURE TRENDS


• in France, any reversal of the recent trend in favour of dry electric innew build (now standing at record levels). This could happen asFrance’s nuclear capacity starts to approach the end of its life cycle,and also as a result of the generally negative implication of the EUPon electric heating (especially water heater which forms part of ant“toute électique” system). On the other hand the wish to avoid thecost of installing individual condensing boilers in new build couldfavour alternatives including electric, collective or district heating

- neutral for H as boilers:

• BRGC does not expect any significant threat to gas boilers fromdomestic biomass boilers. Where there is substitution, it is morelikely to be from oil to biomass, but BRGC believes that there is inany case that the prospect of further biomass boiler growth is verylimited

- negative for H gas boilers:

• a much greater threat comes from electric heat pumps, whethergeothermal, air-to-water or air-to-air (reversible air conditioning)with the biggest immediate threat coming for high temperature air-to-water heat pumps, which are subject to intense market activity atpresent

• linked to the EPBD requirements there is some indication of apossible swing back to:

•• collective heating in new build (easier to combine with solarthermal in multi-family buildings)

•• local CHP district heating (but in some of the new MemberStates, including Romania and The Czech Republic there hasbeen pressure from home occupiers to switch from districtheating to gas central heating, which has generally beendiscouraged by the authorities)

• any move towards “passive” or “carbon neutral” new housing.

4.3213 Underlying Trend Drivers

4.32131 Replacement Rates

The rate of replacement does not in itself (if like-for-like) impact on theoverall size of the domestic gas boiler park, but it will affect the pace ofproduct substitution (e.g. non-condensing to condensing) or systemsubstitution. Perhaps most importantly for the GASQUAL project, thereplacement rate will influence the pace at which pre-GAD appliances arereplaced with new appliances.

4.3 FUTURE TRENDS


4.32132 First Time Installation/Saturation

The scope for increasing the size of the domestic gas boiler park dependsto a large extent on the level of equipment of central heating (whether gasor other, and whether autonomous or collective/district) that already exists.Any continuing first time installation of individual gas boilers will have apositive impact on the total park, even if the level of first time installation isfalling (which is the case in most countries). The anticipated realisticsaturation level for central heating ownership will vary between countriesand regions, depending mainly on the climate

4.32133 Gasification

Gasification has obviously been the most powerful driver of the gas boilersmarket in past years, but the pace of gasification has inevitably slowed assaturation approaches. In some countries (Southern Italy, SouthernSpain, Portugal, Greece) gasification is taking place largely in areas wherefor climatic reasons central heating is not a priority. In eastern Europe,much of the gasification has taken place in urban arrears already equippedwith district heating. There remain scope for growth in Bulgaria, butprogress is slow in the current economic climate. Gasification isproceeding in Ireland and Northern Ireland within the UK. There is no signof any significant extension of the very small gas networks in Sweden orFinland.

4.3 FUTURE TRENDS


4.3214 Events

Legislation and incentives are key factors influencing the market. Inaddition to the many measure that are already in place, the two mostimportant events over the next few years are likely to be:

- legislation linked to the EPBD, which will vary by Member State. Insome countries (e.g. Italy and Spain) this may encourage a swing backto collective and district heating in new apartment building. A recast ofthe EPBD to extend it to smaller individual existing dwellings is underway. This is likely to encourage the replacement of pre-GAD boilers,and should in theory favour the more efficient gas boilers

- the implementation of the EUP Eco-Design (Lot 1) proposals. Theseare almost certain to accelerate the shift towards condensingtechnology, but could also stimulate the uptake of micro CHP and heatpumps.

The impact of the above trends will probably be reinforced by theindividual National Energy Efficiency Action Plans, and NationalRenewable Energy Action Plans (required respectively by the “EnergyServices” Directive 2006/32/EC and the “Renewable Energies” Directive2009/28/EC) to be published or updated over the coming years.

4.3215 Cyclical Drivers

It is sometimes difficult to make a distinction between the impact of cyclicaldrivers and the impact of underlying drivers. There is no doubt that inrecent years the cyclical drivers have depressed the market (in terms ofannual sales) in most countries. Replacement rates have fallen in favourof repairs, and new housing construction has fallen. This will notnecessarily reducing the size of the park in a measurable way, but it willcause the park to age. In Spain, where so much of the growth in the parkhas been linked to new build, the recession has undoubtedly held back thegrowth of the park.

While levels of new housing construction can be considered as a cyclicaldriver when forecasting boiler sales levels, in general any continuedinstallation of autonomous gas boilers in new dwellings will generate anabsolute increase in the park, since new construction normally outweighsdemolitions. Changes in the share of individual gas systems within newbuild (see Section 4.3212 above) can be considered more as anunderlying driver.

4.3 FUTURE TRENDS


4.34 Expected Future Trends

Figs. 4.341-1 & 2 summarize BRGC’s view of the most likely future trendsin the domestic gas boiler park.

4.3 FUTURE TRENDS


Fig. 4.34-1 PARK OF DOMESTIC GAS BOILERS 2007 ('000 boilers/dwellings)

Gas Wall HungCondensing

Gas Wall Hung Non-Cond.

Gas Floor Stand. NonCond

Gas Floor Stand. Cond JB gas Total

CountryPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

TotalPre

19931993-2007

Total

Austria 6 237 243 13 305 317 46 70 116 1 20 21 3 1 4 68 633 701

Belgium 0 275 275 106 834 940 151 444 595 0 7 7 29 24 53 287 1 583 1 870

CzechRepublic

0 66 66 0 898 898 102 476 578 0 11 11 6 9 15 107 1 460 1 568

Denmark 0 143 143 41 126 166 8 9 17 0 2 2 0 1 2 49 280 329

France 2 404 406 293 5 956 6 248 907 1 028 1 935 0 35 35 99 277 376 1 300 7 700 9 000

Germany 27 2 097 2 123 233 2 666 2 899 901 1 348 2 249 6 76 82 495 291 787 1 662 6 479 8 140

Greece 0 3 3 0 93 93 0 1 1 0 0 0 0 18 19 0 115 115

Hungary 0 25 25 0 970 970 133 363 497 0 2 2 1 0 1 134 1 361 1 495

Ireland 0 32 32 7 540 548 11 22 33 0 0 0 0 0 0 18 594 613

Italy 0 668 668 0 10 418 10 418 628 993 1 621 0 49 49 221 140 361 849 12 268 13 116

Poland 0 103 103 0 1 030 1 030 18 198 216 0 7 7 47 63 110 65 1 401 1 466

Portugal 0 1 1 0 182 182 0 11 12 0 0 0 1 3 4 2 197 198

Romania 0 31 31 16 1 403 1 419 3 56 59 0 1 1 18 28 46 37 1 519 1 556

SlovakRepublic

0 46 46 0 238 238 7 338 345 0 4 4 0 0 0 7 626 633

Spain 0 15 15 0 4 229 4 229 2 75 77 0 0 0 8 12 20 10 4 332 4 342

UnitedKingdom

18 5 206 5 224 53 11 488 11 541 2 909 1 677 4 586 0 82 82 0 1 1 2 980 18 454 21 434

TOTAL 52 9 351 9 404 761 41 375 42 136 5 827 7 110 12 937 7 297 304 928 869 1 797 7 575 59 003 66 577

4.3 FUTURE TRENDS


Fig. 4.34-2 TOTAL PARK OF DOMESTIC H-GAS BOILERS 2007 AND FORECAST FUTURE TRENDS ('000 boilers/dwellings)

Total Central Heating Park Total Dwellings

Domestic H-Gas BoilersCountry

Pre1993

1993-2007

Total

OtherCentral

Heating (1)

Nocentralheating

'000%

w/oCH

% onGas

Expected Future Trends

Austria 68 633 701 2 737 749 4 187 17.9% 33.3% Condensing set to grow, but total gas boiler park may fall. Much of non equipped park out of reach of gas. Growing competition from district heating, biomassand possibly heat pumps.

Belgium 287 1 583 1 870 1 851 1 182 4 903 24.1% 72.9%Rapid growth in condensing likely to continue, but pace of growth depends on continued incentivisation. Modest park growth should come from extension of

gas (first time installation) and new build. No expected competition from district heating. Heat pump uptake still low.

Czech Republic 107 1 460 1 568 1 931 591 4 090 14.4% 63.6%Prospect of modest but slowing growth in gas boiler park from first time installations and new build. However gasification is slowing. District heating (35% of

dwellings) not expanding and there are some defections in favour of gas. Already some impetus behind growth in condensing share and this should accelerate ifEUP proposals implemented.

Denmark 49 280 329 1 978 403 2 710 14.9% 65.0%Although some 65% of dwellings are connected to gas, only some 12% used individual gas boilers, while 61% are on district heating. There is little prospect of

significant growth in the park of gas boilers, especially given the emergence of demand for air-to-air heat pumps. The park will however shift rapidly towardscondensing boilers, since the sale of non-condensing is no longer permitted

France 1 300 7 700 9 000 19 187 3 268 31 455 10.4% 35.0%

Gas boilers in France have long faced intense competition from dry electric systems based on France's large nuclear power capacity. Currently the park of gasboilers is scarcely growing as the share of dry electric in new build is running at record levels (<70%). There was a brief enthusiasm for solid fuel, but the growthof heat pumps looks more serious, especially in new build and as replacements for the rapidly declining floor standing boilers. France has been slow toencourage condensing boilers, but condensing should now gain share at an accelerating pace. It would take a significant swing away from electric to enable thegas boiler park to grow, but is not impossible if the EUP programme threatens electric water heaters and as the current nuclear capacity approaches the end ofits life cycle. However it could be that district heating rather than gas will be the beneficiary.

Germany 1 662 6 479 8 140 27 177 3 434 38 751 8.9% 45.4%

Germany has traditionally favoured collective rather than autonomous heating for apartments. In 1 & 2 family houses there is a relatively large share ofbasement sited floor standing boilers. There could be some growth in the park of individual gas boilers as wall hung gas displaces floor standing oil, but there iscompetition from heat pumps and (sporadically) from biomass. The district heating network (especially important in the NBL) has not grown much sinceunification, but there could be an ESCO led upswing in local CHP. Condensing boilers (especially wall hung) will gain share rapidly in the park.

Greece 0 115 115 2 663 2 841 5 619 50.6% 0.6%While there is plenty of scope for the gas boiler park to increase along with gasification, this is currently happening at only a modest pace, mainly in

Thessalonica. The Athens market has yet to gather momentum. It will probably take strong legislation and/or incentives to achieve more than a marginal sharefor condensing, but this may come with the EUP implementation.

Hungary 134 1 361 1 495 754 1 923 4 172 46.1% 85.0%

On the face of it Hungary is far from being a mature heating market. Central heating penetration, as defined by BRGC, is only around 55%, although this doesnot include the dwellings (c. 25%) using the gas radiators that are a particular feature of the Hungary. Currently about 16% of dwellings are on district heating(mainly in Budapest), 4% are on collective heating, 35% are on autonomous central heating (compared with 22% in 1990) 25% are on gas radiators and 20% areon other forms of room heating. With the gasification programme approaching saturation and much of the switch from solid fuel to gas having taken place,growth in the gas boiler park would need to come from displacing wall convectors. The growth in condensing should accelerate.

Ireland 18 594 613 611 145 1 369 10.6% 42.0%The park has grown very rapidly since the mid 1990's, helped by gasification and a booming economy. Saturation is now approaching, but there is still scope

for gas to displace peat boilers. The condensing share should grow with the new Part L, especially at the expense of open vented cast iron.

Italy 849 12 268 13 116 8 500 7 013 27 012 26.0% 71.6%

Central heating penetration is approaching 75% (compared with some 60% in 1990), which may be close to saturation given the warm climate in the South andIsles. The biggest underlying drivers have been the gasification process, and (in addition to first time installations) the accompanying wave of conversions fromcollective to autonomous (mainly wall hung combis) heating. All these drivers are now well past their peak. Some 90% of dwellings are in gas supply areas andover 70% are connected. Any park growth from new build and first time installation could be offset by a swing back to collective and district heating. After a slowstart condensing is now growing, and this should accelerate in anticipation of the EUP measures.

Poland 65 1 401 1 466 8 604 2 930 13 000 22.5% 54.6%

Poland still has a considerable park of dwellings with no central heating (estimated at some 25% of dwellings), mostly in rural areas, which is being equipped ata rather slow pace (1-2% per year). However, given the continuing improvements of standards of living in the country it is considered that this trend shouldcontinue to provide a moderate but steady underlying growth for the years to come. Poland has a relatively low share of natural gas within its energy mix, due togreat reliance on coal. Gasification is still under way, although at a rather slow pace, and it is not expected to have any dramatic impact on the number ofconnections for domestic heating in the forecasting period.

Portugal 2 197 198 79 4 994 5 271 94.7% 14.1%In spite of the relatively recent gasification, especially in Lisbon and Porto, the uptake of central heating has been slow and confined mainly to new build. The

park should grow, but slowly and from a low base.

Romania 37 1 519 1 556 1 831 4 873 8 260 59.0% 35.0%The boiler market developed largely because of dissatisfaction with the old district heating networks. Between 2001 and 2004 a total of 776,360 disconnections

from the district heating were made, causing the proportion of the dwelling stock on district heating to fall from 31% to 23%. Although the authorities acted tostem the flow of disconnections from 2005, there is still scope for further growth from disconnections and gasification.

Slovak Republic 7 626 633 2 379 786 3 798 20.7% 38.6%

During the 1990s the Slovak market was characterised by a shift away from solid fuel and towards gas (initially floor standing, then mostly wall hung). Thetrend is now partly reversing, with solid fuel having gradually regained a substantial share since 1998. Within the gas segment, floor standing models aredeclining rapidly, and condensing is growing at a rather fast pace. District heating supplies some 40% of all dwellings. There have been some disconnectionsfrom the network, with people preferring the independence of individual gas systems. However it appears that this trend is now slowing down. Similarly, there hasbeen a trend away from collective systems, but this seems to be now reversing, especially in smaller buildings.

Spain 10 4 332 4 342 6 394 13 199 23 935 55.1% 25.6%

The proportion of dwellings with central heating increased from around 19% in 1990 to nearly 50% by 2007. The gasification process revealed a preference forautonomous heating over collective, although there was not the same type of massive programme of conversions that occurred in Italy. Thus the main under lyingdrivers over this period have been the increasing uptake of central heating in Spain's very large new housing sector, and first time installations linked to thegasification process. The park still has scope to grow further, but this is likely to be at a slower pace as saturation approaches and as new build levels fall. TheEPBD could cause a swing back to collective. It will take legislation to generate a substantial condensing boiler market.

United Kingdom 2 980 18 454 21 434 3 462 716 25 612 2.8% 89.0%The UK gas boiler park is virtually saturated, with scope for growth coming mainly from the gasification of Northern Ireland. The share of condensing in the

park has been increasing rapidly since the Part L revisions of 2005. The share of cast iron boilers is declining, but the rate is constrained by the long life of theseproducts. The UK s a country to watch for micro CHP

TOTAL 7 575 59 003 66 577 90 137 49 047 203 168 23.8% 48.0%

4.3 FUTURE TRENDS


5.1 QUANTIFYING THE EU DOMESTIC GAS WATER HEATERS PARK BY

COUNTRY


5. DOMESTIC GAS WATER HEATERS

5.1 QUANTIFYING THE EU DOMESTIC GAS WATER HEATERS PARK BY COUNTRY

5.11 PRODUCT DEFINITIONS

The products covered here are gas dedicated water heaters. This meansthat their sole function is to provide sanitary hot water. Boilers that bothrun the central heating and provide sanitary hot water (whether directly orindirectly) are covered in Section 4 above.

There are two relevant categories of domestic gas water heaters:

- instantaneous gas water heaters (conforming to EN 26) that do notstore hot water but which provide it instantaneously on demand. Thesewater heaters are generally sub-segmented by water flow rate:

• 5 to <10 litres per minute

• 10 to <13 litres per minute

• 13+ litres per minute.

Typically water heaters in the first of these categories are used assingle point water heaters (i.e. just the kitchen or just the bathroom)and as such can usually be considered as secondary water heaters (i.ethey have a supplementary role and or not the main source of hotwater for the house). On the other hand water heaters providing 10 ormore litres per minute are most often multi-point water heaters andtherefore represent the primary source of sanitary hot water for thedwelling. However it is believed that within the large park ofinstantaneous gas water heaters in Spain and Portugal, it is thoughtthat a 5 to <10 litres per minute water heater may in many cases be thesole form of water heating for the dwelling.

In the UK there is a small market for instantaneous gas water heatersspecifically for caravans and boats (PALOMA brand imported byMORCO from FAGOR).

There are no condensing models. The main product development inwhat is now largely a replacement market has been from pilot toelectronic ignition as well as movement towards water initiatedmodulation.


COUNTRY


Fig. 5.12-1 1993-2007* TOTAL PARK OF WATER HEATERS IN 16 EU COUNTRIES DIVIDED BYAGE OF APPLIANCE AND EN STANDARD

TOTAL PARK '93-07LEVEL 2- ENStandard 1993-

19971998-2002

2003-2007

TOTAL Park'93-07

TOTAL % Share'93-07

EN26-Instantaneous

7 024 6 782 6 842 20 648 87%

EN89- Storage 1 032 1 089 925 3 046 13%

TOTAL 8 056 7 870 7 767 23 693 100%


Fig. 5.12-2 1993-2007* TOTAL PARK OF WATER HEATERS IN 16 EU COUNTRIES PERCOUNTRY

Country 1993-1997 1998-2002 2003-2007

Spain 2 219 2 284 2 418

Italy 938 1 026 1 199

Portugal 804 1 035 826

France 1 106 886 793

Poland 655 697 735

Belgium 378 412 495

Germany 1 083 559 333

Hungary 206 300 320

United Kingdom 397 308 245

Czech Republic 120 163 135

Romania 34 53 127


Austria 75 54 39

Ireland 8 11 11

Greece 3 4 7

Denmark 2 2 3

Total 8 056 7 870 7 767



COUNTRY


It should be stressed that in several countries, but above all in the verylarge markets in Spain and Portugal, a substantial proportion of thepark of instantaneous gas water heaters were sold for use with LPG.BRGC has attempted to exclude these from the numbers, but it isknown that some (notably in Spain) will have been converted from LPGto natural gas when the gas network was developed

- gas storage water heaters (EN 89) which is a much smaller market,with most sales having been concentrated in Germany, Italy, andFrance. It is generally considered that models up to 80 litres capacityare for domestic use (mainly primary/multi-point) while those >80 litresare commercial (to a large extent in small commercial premises).However, EN89 sets the threshold at 70 kW which is equal and above220 litres, and this has been used in the BRGC analysis.

A small market for condensing models (almost entirely in >70 kWmodels) has emerged in recent years, probably based on imports fromthe USA.

5.12 QUANTIFYING THE PARK OF GAS WATER HEATERS

Figs. 5.12-1 and 5.12-2 set out BRGC’s estimates of the park of domesticgas water heaters in total and by country. Please note that estimates ofthe water heater park by type per country can be found in Appendix B ofthis report. The water heater market is less complex than the boilermarket, with fewer significant manufacturers (Figs. 5.12-3 and 5.12-4):

- the instantaneous gas water heater industry has a large overlap withthe wall hung boiler industry, but with fewer players. It is dominated by:

• the two German “Thermen” manufacturers, both of whom havelocated their production the Iberian Peninsular (BOSCH to itsVULCANO plant in Portugal and VAILLANT to a joint venture withFAGOR in Spain). There was an eastern German producer,DESSAUER GASGERÄTE, that expanded rapidly during the postunification boom, but then folded. Some of its appliances areprobably still in use in the NBL, but they can probably beconsidered as pre-GAD

• the three main French wall hung boiler manufacturers SAUNIERDUVAL (VAILLANT), CHAFFOTOEAUX (ARISTON) and ELMLEBLANC (BOSCH)

• the Spanish FAGOR and COINTRA (FERROLI)

• the Italian SYLBER (RIELLO)

• BAXI in the small UK market.


COUNTRY


Fig. 5.13 INSTANTANEOUS GAS WATER HEATER MARKET SHARES IN 1993-2007PARK ACROSS SELECTED 16 EU COUNTRIES

HOLDING COMPANY / BRAND NAMEGAD Appliancemarket shares

JUNKERS 38%BOSCH

ELM LEBLANC 3%


SAUNIER DUVAL 6%

MCC FAGOR 12%

FERROLI COINTRA 7%

ARISTON THERMO GROUP CHAFFOTEAUX 4%

TERMET TERMET 4%

SYLBER 2%RIELLO

BERETTA 1%

Others 10%

Fig. 5.14 STORAGE GAS WATER HEATER MARKET SHARES IN 1993-2007 PARKACROSS SELECTED 16 EU COUNTRIES

HOLDING COMPANY / BRAND NAMEGAD Appliancemarket shares

ARISTON 23%ARISTON THERMO GROUP

OTHER ATG BRANDS 6%

VAILLANT GROUP VAILLANT 12%

WIKORA WIKORA 6%

QUANTUM QUANTUM 5%

Others 27%


COUNTRY


Although water heater park has less variables to work on, the dataavailable is more scarce as well. In particular there is little information onshare of LPG in total sales of water heaters and BRG based its estimates,where available, on BRG internal reports. Later some of key industrymanufacturers, such as RIELLO, were contacted to understand better theshare of LPG in total sales of gas dedicated water heater and ultimatelypark of H-gas using products. For water heaters the situation is even morecomplex as in southern Europe (in particular Spain and Portugal and to alesser extent Italy), where dedicated water heaters are most popular, oncegas arrived some of LPG water heaters have been adapted to use H-gas(changing the gas injector), while some have been substituted by combiboilers. Quantifying these processes is almost impossible and there areno official statistics to support such quantifications. Therefore the accuracyof H-gas water heater park is lower than this of boilers and BRG estimatesit to be within + 10% / - 10%.


COUNTRY


5.121 Flue Types

Traditionally the great majority of flues for instantaneous gas water heatershave Type B. However fanned flues (Type C) were progressivelyintroduced during the 1990’s. The situation seems to differ acrosscountries, for instance in Italy approximately 30%-40% of water heatersare type C, while in UK over last years Type C has been predominant,following the Part L revisions. Late information suggests that there is aclose correlation between flue types and modulation, with the greatmajority of water activate models having Type B flues, and almost allelectronically modulating models having Type C flues. It is known thatsome water heaters have been installed without flues (especially in Spain).

5.122 Burners

Here the situation is clear cut:

- all instantaneous gas water heaters use Bunsen type burners (bladedconstruction e.g. POLIDORO NP). No evidence has been found ofspecial low NOx models or of the use of premix burners

- gas storage water heaters use round Bunsen type burners.

5.123 Modulation

The standard method of modulating in instantaneous gas water heaters isthe water activated method. Full electronic modulation was introduced forpremium models in the mid 1990’s (VAILLANT and JUNKERS), but thisstill only accounts for a minority of sales. It is difficult to quantify preciselyBRGC is assuming around 10% of the park and 25% of current sales(maximum) been electronically modulating.

5.124 Combustion Controls

No special combustion controls are used.

5.2 TRENDS


5.2 TRENDS

Dedicated gas water heaters have increasingly become a replacementmarket as first time installation increasingly favours water heating linked tothe boiler (whether combis or indirect water heating). In the replacementmarket itself dedicated water heating itself has tended to lose through ashift in favour of central heating. In warmer climates where there is lessdemand from central heating, solar is likely to gain share. It is possiblethat gas water heaters will benefit from the generally negative outcome ofthe EUP Eco-Design process for electric storage water heaters, butecologists would prefer to see the benefits going to solar.

In general BRGC expects to see a steady decline in the park of dedicatedgas water heaters (Fig. 5.2).

Fig 5.2 1993-2007* TRENDS IN SALES OF DEDICATED WATER HEATERS

0

500

1000

1500

2000

2500

3000

1993 1997 2000 2002 2004 2007

2 053 1 907 1 928 1 819 1 757 1 662

257257 284

249 228207

EN89 Gas Storage EN26 Gas Instantaneous

2 165 1 9852 0682 310 2 211 1 869


5.2 TRENDS


Fig. 6.1-1 GAS FIRED SPACE HEATERS: MAIN PRODUCTS FOUND ON THE MARKET

Category Description Picture Flue Standard Comments

Radiant gas fires

This category correspond to the SBGI "Radiant' category, whichincludes ceramic type open gas fires that are mainly radiant but someof which also include some convection. They can be open or glassfronted. VALOR models include FIRELITE OXYSAFE, ESQUIRE,BRAVA, CHARM and BLACK BEAUTY RADIANT.

Open flue

EN 613 fordirect flueconnections. BS 7977-1for closureplateinstalls.

Independent space heaters

Radiant gas fires are the original gas fires that have been onthe market since approximately 1967. They are morefunctional than decorative. Most now include someconvection as well, and can claim efficiencies (NCV) of 79%.80-90% are sold to social housing including EAGA DecentHomes, which may be phased out in 2012.

Decorative fuel effectfires

Decorative fuel-effect gas fires are designed to simulate a solid fuelopen fire primarily for decorative purposes and intended to be installedso that the products of combustion pass unrestricted from the firebed tothe flue. We assume that this corresponds to the SGBI "Decorative GasFires". Includes VALOR models DGF WITH QUATTRO, , DGF WITHMAJESTIC, ARC (open basket type) and SPANISH BASKET.

Open flue. EN509

EN509 products cannotmake claims for efficiencylevels. AFNOR's listingdescribes this category as"fuel effect" but in the marketplace "fuel effect" is usedmore to describe the EN 613gas fires (see below).

EN509 products came on to the market relatively late (late1980's?), and they are seen primarily as decorativeproducts. The typical product is an open grate inset fire.Efficiencies are generally low (<40%). They may be bannedas a result of the current EUP Eco-Design process. Stillhigh sales but losing to electric, solid fuel and more efficientLive Fuel Effect fires.

Live fuel effect fires are designed to look like a solid fuel fire, just likedecorative fires, but it includes a flue box which is, in combination withthe front fret and overall design, restricts the flow up the chimney .These are significantly more efficient than a decorative ones.

Live fuel effect fires

This correponds to SBGI "outset L.F.E", " inset L.F.E.", "BalancedFlue", and "Fanned or Powered Flue". Includes VALOR modelsADORN, VISAGE, WESTMINSTER, DREAM, ULTIMATE, HERITAGE,DECADENT, CAPRI, BLENHEIM, TRANQUILITY, ICON, ARTURA,VISIA, LIBERTY, ENVY, OBSESSION, SEATTLE, HOMEFLAME(EMINENCE, HARMONY and DREAM - all open flue) and BLACKBEAUTY UNIGAS, ULTIMATE BALANCED FLUE, SEATTLEBALANCED FLUE, DREAM BALANCED FLUE, DECADENTBALANCED FLUE, DREAM FAN FLUE, BLACK BEAUTY SLIMLINEand HEARTBEAT.

Open, Balanced orFanned Flue

EN13278and EN 613(+ BS7977-1)

Covered by both EN 613 andEN 13278 - but most ofVALOR's approvals would becertified against BS7977-1:2002, which falls under theG.A.D. as they are notdirectly connected to a flueconnection, but are installedinto the builders opening.

These products are effectively the immediate successors ofthe radiant gas fire, and were introduced when decorativegas fires started to become popular. They haveprogressively become more efficient. These are also themain type of decoarative gas fire export from theNetherlands by, for example, FABER and DRU.

Flueless gas fires

These products have no flue and evacuate the waste gasses (usuallytreated by a catalytic converter) into the room. VALOR does notproduce them. The UK market leader is FOCAL POINT, which sells alot through B&Q (including EUPHORIA). Flueless not picked up bySBGI?

Appear to be mainly glassfronted LFE designs.

Flueless EN14829Separate EN Code forflueless.

Not sold by VALOR. 3 UK producers. Product marketed as100% efficient (NCV). Market c. 20,000 pieces maximum ayear. B&Q an important distributor.

A convector heater is a heater which operates by air convectioncurrents circulating through the body of the appliance, and across itsheating element. This heats up the air, causing it to increase in area.Wall heaters emit both radiant and convected heat.

Convector wallheaters

Assume classified as "Wall Heaters" by SBGI.

Balanced Flue EN613Independent space heaters(with or without fan).

In UK now sold largely to the EAGA Decent Homes contract,which may be phased out in 2012. A variant is common nthe Hungarian market

Type C

Ducted EN778

Type BWarm air heatersThe warm air heaters is a dry system. The air is warmed directly by thegas as it passes through a simple heat exchanger, the air is thencirculated through ducts within the property.

Free Blowing EN1319

Most first time installations in 1960's/70's. There is still asignificant park in the UK (c.500,000 dwellings?). JOHNSON& STARLEY still sell replacement appliances.



6 GAS ROOM HEATERS AND DRY SYSTEM HEATING


In terms of EN classifications (see also Section 2.43), this section coversthe following:

- EN 613: independent space heaters without fan but with directlyconnected flue (in the UK many radiant and decorative gas fires areinstalled in the builders opening which provides an open route for thewaste gasses without the need for a directly connect flue. These aretest under BS7977-1 which comes within the GAD, rather than underEN 613)

- EN 1266: independent space heaters with fan

- EN 509: decorative fuel effect gas fires

- EN 14438: gas fired insets for heating more than one room

- EN 13278: open fronted independent space heaters

- EN 14829: flueless space heaters

- EN 778: forced convection air heaters <70kW

- EN 1319: forced convection air heaters <70kW with fan assisted burner

- EN 1196: condensing air heaters.

Fig. 6.1-1 illustrates some of the actual products found on the market.

6.2 MARKET DATA

6.21 MARKET SEGMENTS

In terms of markets, the most important segments are:

- gas fires, for which demand within the EU is very much concentrated inthe UK (easily the largest market) and in the Netherlands (the latter isof course not included in the GASQUAL project). There are someexports (mainly from manufacturers in the Netherlands such as FABERand DRU VERWARMING) to other EU Member States, but the scale issmall (perhaps 20,000 units a year, with 10-20% going to the UK). Themain product sub categories are:

6.2 MARKET DATA


• radiant gas fires which are open flue and would normally fall withinEN 613. However, most of them are installed directly in the buildersopening, and do not require a directly connected flue. For thisreason they are tested under BS7977-1 rather than EN 613.Radiant gas fires are specific to the UK, and were the original gasfires that have been on the market since before WWII. They areceramic type open (still the largest category) or glass fronted gasfires that are mainly radiant but some of which also include someconvection. Most now include some convection as well, and canclaim efficiencies (NCV) of 79%. In the UK 80-90% are now sold tosocial housing including EAGA Decent Homes, which may bephased out

• live fuel effect fires (most which, if they are balanced or open flue,are covered by EN 613, with fanned flue coming under EN 132278)which are designed to look like a solid fuel fire, just like decorativefires (see below), but which include a flue box which, in combinationwith the front fret and overall design, restricts the flow up thechimney. These are significantly more efficient than the decorativeones.

There is a substantial market in the UK, where the SBGIdistinguishes between “inset” and “outset” (open flue) and “nochimney” (balanced or fanned flue). However, most of the “inset”and “outset” and outset models are installed directly in the buildersopening, and do not require a directly connected flue. For thisreason they are tested under BS7977-1 rather than EN 613.

Most of the gas fires exported to other Member States from theNetherlands fall into this category. They are all tested under EN613, and the vast majority are glass fronted with balanced flues. Inaddition FABER has developed a hybrid product (long balancedflue) which does not really fit into existing classifications for testpurposes. One notified body gave an appliance a 93% efficiencyrating not taking into account the specifics of this type of flue, whileanother gave it 68% taking into account the longer flue.

These products are effectively the immediate successors of theradiant gas fire, and were introduced during the late 1990’s whendecorative gas fires started to become popular. They haveprogressively become more efficient. There are also Type Bmodels which tend to be older models that are often manufacturedlocally. It seems that, whether with balanced flue or fanned flue,these products are tested under EN 613 on the continent

6.2 MARKET DATA


• decorative fuel effect gas fires (EN509) are designed to simulate asolid fuel open fire primarily for decorative purposes and intended tobe installed so that the products of combustion pass unrestrictedfrom the firebed to the flue. This category is specific to the UK,where a strong underlying growth seems to have peaked in 2003.EN509 products came on to the market relatively late (late1980's?), and they are seen primarily as decorative products. Thetypical product is an open grate inset fire. Efficiencies are generallylow (45%-65%), and EN509 products are not allowed to publishefficiency levels. Some believe they may be banned as a result ofthe current EUP Eco-Design process. Sales in the UK are still highbut the product is losing ground to electric & solid fuel. Theseproducts are hardly sold on the Continent. It is thought they mayuse non-premix burners

• flueless gas fires (EN14829). These products have no flue andevacuate the waste gasses (treated by a catalytic converter) intothe room. VALOR does not produce them. The UK market leader isFOCAL POINT, which sells a lot though B&Q (includingEUPHORIA). The product is offered as 100% efficient (NCV).Concern was expressed during the research about the possibility ofvarying gas qualities causing soot build up that in turn could affectthe operation of the catalytic converter, with potentially dangerousconsequences. The product was first sold in 1998, and the marketis quite small (possibly 20,000 pieces a year in the UK) but it isthought to be growing

- room heaters, which are covered by EN 613 (without fan) and EN 1266(with fan). Within this category BRGC has identified:

• convector wall heaters sold in the UK. A convector heater is aheater which operates by air convection currents circulating throughthe body of the appliance, and across its heating element. Thisheats up the air, causing it to increase in area. VALOR has such aproduct, which is now sold largely o the EAGA Decent Homescontract, which may be phased out

6.2 MARKET DATA


• there is also a range of balanced flue wall hung convector heatersor gas radiators that a above all associated with the market inHungary. It is likely that many of those in use predate 1992, andcertainly the vast majority will predate Hungary’s accession to theEU in 2004, and even the transition period before that. Apart fromindigenous production FABER in the Netherlands came out with arange (GWH Series; balanced flue EN 613) originally with theHungarian market in mind, but now of the 40,000 to 50,000 a yearsold by FABER, most go to Russia where they are well able to copewith the low gas pressures. BRGC estimates that in Hungary closeto 25% of dwellings (i.e. around 1 million dwellings) use this type ofheating, implying some 3.5 million convectors in use. Most havebeen supplied by local producers FÉG and LAMPART, but it is notpossible to evaluate how many have been installed since Hungarycame under the auspices of the GAD

• the German ORANIER is thought to be the leading EU producer of“Gasheizautomaten” which are both wall hung and floor standingconvector type room heaters. Sales of these products have fallenfrom about 150,000 pieces a year in the mid 1990’s to some 20,000in 2008. Much of the demand comes from Germany, Austria andEastern Europe. ORANIER also produces a range of theseproducts for VAILLANT’s VGR range

• in the Netherlands, DRU has a range of wall hung and floorstanding room heaters, but it is not clear to what extent these areexported (they appear in the French and German catalogues butnot in the UK one)

• ROBUR in Italy produces a range of gas space heaters (both non-condensing and condensing) but it is believed that these are mainlyfor commercial use. They do however offer gas radiators fordomestic and commercial use.

6.2 MARKET DATA


- in the UK there are still some 480,000 homes (40% private, 60%public) which have ducted gas warm air. Although there has little firsttime or new build installation for many years (the systems wereoriginally installed mainly in the 1960’ and 1970’s, there is a significantreplacement market, and some 230,000 systems have been installedsince 1993. The average product life is estimated to be 27 years in theprivate sector and 17 years in the public sector. The products usepartial premix “Bunsen” type burners (tubular construction sourcedfrom Italy). The burners do not modulate (modulation refers to the fan,not the burner). Originally there were balanced flue installations, but itis thought that these are now rare in the park. Since 1992 the trendhas been from open to fanned flues, and current sales are roughlyevenly split between the two. Outputs range from 7.3 kW to 26.4 kW.These appliances can also offer indirectly heated hot water (EN 483indirect cylinder), and facilities for air filtration. The product has beenadapted to conform to the 2005 Part L revisions, but this did not involvelaunching a condensing model. However, one is expected to appearover the net few years (they are widely used in the USA). This will betested under an extension of EN 1319.

6.22 UK

The UK is so easily the largest and most complex market amongst thecountries covered for these products that it is worth considering the UKseparately from the rest of Europe. Various different sets of market datahave been submitted to BRGC during the research (including estimatesfrom GASTEC), not all of which are compatible. In BRGC’s view the mostreliable figures are those complied on annual sales over the period 1993-2008. It is probably reasonable to assume that the cumulative sales1993-2008 are close to the current park of appliances installed post GAD.On this basis, the park estimates are given in Fig. 6.22-1.

6.2 MARKET DATA


Fig. 6.22-1 ESTIMATED UK PARK OF GAS FIRES, ROOM HEATERS AND GAS WARM AIR SYSTEMS INSTALLED 1993-2008

Appliance Type EN ClassificationPark 1993-2008 ('000

pieces)Comments Expected Future Trends

Radiant Gas Fires EN 613 2 270

Market in long term decline. GASTEC estimatesthe total park at some 5.7 million (70% boxradiant and 30% glass fronted). This implies alarge remaining park of pre-1993 fires still in use.

Market decline expected to continuedue to loss of share to electric andend of Decent Homes scheme in2012.

Live Fuel Effect Gas FiresEN 613 & 13278 +BS7977-1

4 695 GASTEC estimates 3,250,000.

Open Flue Outset EN 613+ BS7977-1 790 Steady decline in sales since 1993

Open Flue Inset EN 613+ BS7977-1 3 250Strong growth in sales which peaked in 2003.Since then sales have fallen sharply.

No Chimney EN 613 & 13278 655 Market fairly steady.

Market continues to decline in face ofcompetition from solid fuel andelectric

Decorative Gas Fires EN 509 970GASTEC shows 2.6 million (but includes someEN 613?). Strong growth up to 2003 when salespeaked.

Threatened by EUP?

Total Flued Gas Fires EN 613, 13278 & 590 7 935

Flueless EN 14829 120Not included in SBGI. Market c. 20,000 pa.GASTEC had 172,000 park in 2005

Market thought to be growing.

Wall Heaters EN 613 485GASTEC has 443,000 for balance flueconvectors in 2005. Steady decline in sales since1993

Market likely to become residual afterend of Decent Homes scheme in1012.

Gas Warm Air Systems EN 778 & 1319 230

Total park c.450,000. Most systems installed forthe first time in 1960'/70's, but there is areplacement market. Products adapted to 2005Part L revisions. Condensing version in pipeline.

Continued decline in sales.

6.3 BURNERS


6.23 Continent

Given that the Netherlands are excluded from the study, the market fordomestic room heaters on Continental Europe is so small that it is notpossible to analyse it by country. To summarise:

- about 20,000 live fuel effect EN 613 gas fires are exported a year fromthe Netherlands, of which perhaps 15,000 go to continental EUMember States. Germany and Belgium are the largest markets

- in Germany, there is estimated to be a park of 836,000 gas fires androom heaters (nearly all EN 613), roughly evenly split between openand balanced flue

- in Belgium there is a significant park of around 250,000 gas fires androom heaters (EN 613)

- there is still a significant usage of gas stoves in the new MemberStates of eastern Europe, but most of these are pre-GAD

- in Hungary, there is a long established usage of wall hung gasconvector balanced flue radiators. In total BRGC estimates that some25% of dwellings are heated in this way. Assuming an average of 3.5radiators per dwelling, this gives a park of some 3.5 million radiators.This form of heating was already widely used during the communistera, and given the fact that Hungary joined the EU only in 2001, mostof this park must be considered as pre GAD. However there will havebeen replacement sales made since 2001.

6.3 BURNERS

As far as is known all products covered by this section of the report usesome type of partial premix Bunsen type burner. It was suggested thatsome EN 509 products use secondary air only, but this was denied by theUK market leader. Italy appears to be the major source of supply for theUK industry, while FABER in the Netherlands has burners produced totheir own design by a UK manufacturer.

One feature of the market is the importance of the appearance of theflame for the gas fires with a decorative function. It is believed that thisinvolves quite fine adjusting, and this aspect could be affected byvariations in gas quality.

In terms of sensitivity to changes in gas quality:

- glass fronted fires run more risk of soot/carbon deposits. This isalready a major cause of call-outs

6.4 SUPPLY


- there may be safety risks if flueless products have their catalystsclogged up.

In terms of other sensitivities to changes in gas quality:

- glass fronted fires run more risk of soot/carbon deposits. This isalready a major cause of call-outs

- there may be safety risks if flueless products have their catalystsclogged up.

6.4 SUPPLY

The production of gas fires and room heaters can be considered in threegroups:

- the UK industry supplying the UK market which is easily the largest inthe EU, comprising:

• VALOR (BAXI Group) which is probably the market leader with itstwo brands VALOR and WONDERFIRE. VALOR does notproduce flueless models

• FOCAL POINT is probably No.2 (and is leader in flueless).

• ROBINSON WILLEY which also owns GRATEGLOW FIRES

• BFM which owns FLAVEL, KINDER and VERINE.

• others including:

•• JETMASTER

•• YEOMAN STOVES

•• LEGEND

•• MAGIGLOW

Plus DRU GASSAR and BURLEIGH in flueless

- the Netherlands industry, which mainly supplies its home market (thesecond largest after the UK, but excluded from the present study) butwhich also exports perhaps 20,000 live fuel effect gas fires a year toother EU fires (including the UK which may take 10-20% of theseexports. The two largest players are:

• FABER INTERNATIONAL BV (GLEN DIMPLEX) which hascommercial subsidiaries in UK, Belgium and Germany, and partnersin Austria, Denmark, France, Greece, Hungary, Ireland, Italy, Latviaand Spain

6.4 SUPPLY


• DRU VERWARMING B.V. which owns SPARTHERM in Germanyand DRU GASSAR in the UK

- local manufacturers in the other Member States including:

• ORANIER in Germany which sells room heaters (convector type)mainly to Germany and Austria. ORANIER also supplies an ownlabel range to VAILLANT

• local manufacturers in Belgium and in eastern Europe (possiblymainly MORATOP for wall mounted and KARMA CESKY BROD forfloor standing in the Czech Republic) who are thought to besupplying mainly open flue appliances. There are also producers ofgas radiators in Hungary, including FÉG and LAMPART.

JOHNSON & STARLEY now dominates the supply of domestic gas warmair systems in the UK.

6.4 SUPPLY


6.4 SUPPLY


Fig. 7.121-1: ILLUSTRATIONS OF BURNERS USED FOR DOMESTIC COOKERS (HKI COMPILATION 2009)…/1

Burner Type(group)

Burner Type(subgroup)

Image Defintion/DescriptionProducedsince (ca.)

Produced byUsed

in*

Load range(of appliances)

(kW)

Sensitivity tochanging

Gasquality

atmosphericburner

single ring burner,primary air fromabove the hotplate

hotplate burner,gives different emission behaviour depending onmounting conditions (flat or deep mounted) and the pansupport, no air adjustement

min. since1990

B

min. output0,3 - 0,6

max. output1,0 - 3,2

not clear

atmosphericburner



min. since2000

B



not clear

atmosphericburner



min. since2005

B



not clear

atmosphericburner

triple ring burner,primary air fromabove the hotplate


min. since1990

B



not clear,more sensitive thansingle ring burners

atmosphericburner



min. since1990

B 1,0 - 3,2 not clear

atmosphericburner



min. since1990


atmosphericburner



min. since1990

B 0,3-2,0 not clear

atmosphericburner



min. since1990


atmosphericburner

double ring burner,primary air fromabove the hotplate


min. since1995

B 0,5 - 2,5not clear,more sensitive thansingle ring burners

atmosphericburner

double ring burner,primary air fromabove the hotplate


min. since1995


atmosphericburner

triple ring burner,primary air fromabove the hotplate


min. since1995


atmosphericburner

triple ring burner,seperate supply of innerring, primary air fromabove the hotplate


min. since2000


B: Hotplate



7. DOMESTIC GAS COOKERS


7.11 COOKER TYPES

To quantify the park, BRGC has been obliged to rely on the rather limitedpark data that has been available via the industry. For the most part theonly segmentation available has been between free standing and built-inappliances (but in the case of ovens this is a relevant segmentation for theGASQUAL project).

In terms of combustion there are three different functions:

- hobs

- ovens

- grills

although not all installations incorporate all three.

Statistically:

- free standing cookers are treated as a single unit. The grill may beseparate from the oven (high level), or integrated into the oven. Somecookers have two ovens

- for built-in, the hob and oven are counted as two units (sometimes agas hob may be used with an electric oven, and a separate high levelgrill would be treated as a third unit. However where the grill is builtinto the oven, the oven+grill are treated as one unit.



Fig. 7.121-1: ILLUSTRATIONS OF BURNERS USED FOR DOMESTIC COOKERS (HKI COMPILATION 2009)…/2

Burner Type(group)

Burner Type (subgroup) Image Defintion/DescriptionProducedsince (ca.)

Produced byUsedin

Load range(of appliances)(kW)

Sensitivity tochangingGasquality

atmosphericburner

triple ring burner,seperate supply of inner ring,primary air from above thehotplate

hotplate burner,gives different emission behaviour dependingon mounting conditions (flat or deep mounted)and the pan support, no air adjustement

min. since2005

B ?

not clear,more sensitivethan single ringburners

atmosphericburner

4 ring burner,primary air from above thehotplate


min. since2000

B ?


atmosphericburner

single ring fish burner,primary air from above thehotplate


min. since1990

B 0,6 - 1,9

not clear, moresensitive thannormal single ringburners in low rate

atmosphericburner

single ring burner,primary air from above thehotplate


min. since1990

B

min. output0,3 - 0,6max. output1,0 - 3,0

not clear

atmosphericburner



1998 B


not clear

atmosphericburner

triple ring burner,seperate supply of inner ring,primary air from above andbelow the hotplate


1998 B 0,3 - 4,5


atmosphericburner

single ring burner,primary air from below thehotplate


1999 Gaggenau B 0,6 - 2,8 not clear

atmosphericburner



1999 Gaggenau B 0,4 - 1,9 not clear

atmosphericburner

double ring burner,seperate supply of inner ring,primary air from below thehotplate

hotplate burner,gives different emission behaviour dependingon mounting conditions (flat or deep mounted)and the pan support, primary air adjustmentpossible

1993 Isphording B 0,2 - 4,2


atmosphericburner



1993 Isphording B 0,16 - 3,6


atmosphericburner



1993 Isphording B 0,11 - 3,6




atmosphericburner



min. since1990

Isphording B 0,6 - 2,8 not clear

atmosphericburner



2008 Isphording B


not clear

atmosphericburner


hotplate burner,gives different emission behaviour dependingon mounting conditions (flat or deep mounted)and the pan support, primary air adjustmentpossibe

1996 Gaggenau B 0,25 - 6,0


atmosphericburner



2007 BSHG B 0,3 - 6,0


atmosphericburner



2003 Gaggenau B 0,165 - 4,0


atmosphericburner



2003 Gaggenau B 0,165 - 2,0


atmosphericburner



min. since1990

ATAG/NL B


not clear

atmosphericburner

radiant grill burner,located in oven

s.r.MonteMorenze23804 LeccoItaly

E not clear

Oven Burner CastFutura A 2,4 kW not clear

atmosphericburner

single ring burner, orimary airfrom below the hotplate

hotplate burner, no air adjustement 1994 Palux AG B 0,8 bis 3,5 very low

atmosphericburner

double ring burner, primary airfrom below the hotplate

hotplate burner, no air adjustement 1994 Palux AG B 1,2 bis 7 very low

atmosphericburner

standard version, round form radiant grill burner, located in oven 2007 Palux AG E 5.2 very low

A Oven B Hotplate C Open burner D Covered burner E Grill



7.12 BURNER TYPES

A gas cooker installation may include three different burner types:

- hob (typically 4 per hob)

- oven

- grill.

-

All of them can be classified as “Partial premix/Bunsen type” under theLevinsky format, but obviously the construction of each is different.Fig.7.121-1 presents an illustrated diagram submitted by Haus-, Heiz- undKüchentechnik e.V. (HKI Industrie Verband)



FIG 7.121-2 CHARACTERISTIC OF THE COOKER BURNERS, PREPARED BY INIG FOR GASQUAL



7.121 Hob Burners

These are generally round burners working in the open with plenty ofaccess to secondary air. There are many different models (see also Fig7.121-2) but it has not been possible to segment the park in such detail.

The burners are normally in three parts:

- injector holder (fixed base). BRANDT integrates this into the surface ofthe cooker)

- spreader

- lid.

Burners may also be classified as “fricative” or “ring”:

- ring burners provide a more stable flame (but are more expensive)because the pilot flame is a continuous circle below actual flames (seeFig. 7.121-3), whereas fricative have small pilots in between mainflames (see Fig. 7.121-4), so easier for pilots to go off, or easier tohave flame lift

- fricative are in aluminum, molded

- ring burners have 4 parts, the copper cover being the additional oneand most expensive to manufacture.

Of the total market it is estimated that 95% fricative, 5% ring.

Perhaps from the point of view of the GASQUAL project, the mostimportant distinction to be made is between single and multiple ringburners. Double/triple or more are more unstable, even with today’s gases.They are subject to flame lift and flashback, so would be very sensitive tochanges in gas quality. This is critical. If the worst gases work with multi-rings, then they will work with the single ring ones too.

Multiple burners have been produced since about 10 years ago. Theirshare has grown rapidly but has now stabilized now to about 10% of salesand BRG estimates these products constitute approximately 6% of thehobs park.



Fig. 7.121-3 RING HOB BURNER

Fig. 7.121-4 FRICATIVE HOB BURNER

MAIN FLAME

PILOT FLAME

MAIN FLAME

PILOT FLAME



Since the mid 1990’s there has been a trend towards cookermanufacturers outsourcing the production. The largest specialist hobburner producers are:

- SABAF (Italy)

- SOMIPRESS: SOCIETA METALLI INIETTATI (Italy)

- DEFENDI (Italy).

Some cooker manufacturers, including ELECTROLUX andBRANDT/FAGOR, still produce their own burners.

Where the burner production is outsourced, the burner manufacturer willadapt the injector according to the country and local gas quality. Theircustomers will order batches for specific countries. Then the cooker islabeled according to the gas type that is suitable for it.

However often largest customers will order high volumes of the burnerssuitable for the most common gases (eg G20), and then will changethemselves the injector required for gases for which small volumes arerequired.

7.122 Oven and Grill Burners

All oven and grill burners are basically Bunsen type partially premix(generally 70% primary air and 30% secondary). According to the industrythere are no exceptions. Within this category there are many designs.Most seem to be tubular, either straight and “formed’ (seewww.castfuturagroup.com for illustrations).

Ovens are tested (EN 30 .1.1) at 2000 C. The flame modulates 1.3 (notless).

There are certain differences between the requirements of the UK and theContinent. In the UK:

- the oven burner is generally at the back

- the top part of the oven is expected to be the hottest, while on theContinent the hottest part is on the bottom

- open high level grills are probably mainly found in the UK

- there are special tests for the UK (not under any EN standard). Thisseems to be something to do with English housewives wanting to bakebread rapidly. There are specially designed burners for the UK.

7.2 QUANTIFYING THE DOMESTIC GAS COOKER PARK


As for hob burners, the trend has been for cooker manufacturers tooutsource the production of their oven and grill burners. The two leadingspecialist oven and grill burner producers are CASTFUTURA andFLAMGAS, both in Italy. Again, the burner manufacturers normally carryout the adjustments to the burners in relation to the country in which thecooker is to be installed. According to one burner manufacturer, there aretoo many gasses already (they mentioned 22 different types for Europe).They say it takes 2 weeks for one set-up for Europe but only 1 week forthe USA.

Certain types of cooker may prove more sensitive than others, notably:

- burners for built-in ovens are more difficult than those for free standingbecause the cavities for the former are generally smaller, givingreduced access to secondary air

- a relatively new but growing type of oven is one that is specificallydesigned to allow grilling with the oven door closed. Again lack of air isa problem.


BRG has extensive data on sales of boilers and water heaters, includingmarket segmentations per certain technical characteristics as well asmanufacturers’ market shares. Domestic cookers, which is not targetmarket for BRG multi-client market studies BRG has prepared parkestimates relying primarily on external sources. Thus, as presented in Fig.1.221-1 BRG contacted number of European gas cooker associations aswell as largest manufacturers of domestic cookers, such asELECTROLUX in an attempt to gather data on sales time series, park orboth. BRG also used information from Danish Gas Technology Centredatabase as well as dig through numerous publicly available reports anddata from statistics offices. As result BRG has found that data availabilitydiffers significantly across countries (see Fig. 7.2-1). In addition BRG hasseparated cookers using natural gas, from cookers running LPG accordingto any data available from secondary sources.



Fig. 7.2.2 PARK OF H-GAS DOMESTIC COOKERS IN THE 16 SELECTED COUNTRIES BYCOUNTRY

Country Total

Italy 24 445

France 12 866

United Kingdom 10 843

Poland 7 191

Spain 3 980

Hungary 2 600

Czech Republic 2 451

Germany 2 168

Slovak Republic 1 290

Belgium 600

Austria 539

Denmark 96

Greece 30

Portugal N/D

Romania N/D

Ireland N/D

Total 69 098

Fig. 7.2.3 PARK OF H-GAS DOMESTIC COOKERS IN THE 5 MAJOR COUNTRIES BYCOUNTRY AND EN CLASSIFICATIONS

Country LEVEL 3 Classification Total

Free standing gas cookers 4 320France

Built-in (separate) gas hobs / mixed hobs / gas ovens 8 546

Free standing gas cookers 1 573Germany

Built-in (separate) gas hobs / mixed hobs / gas ovens 595

Free standing gas cookers 10 743Italy


Free standing gas cookers 1 511Spain


Free standing gas cookers 7 062

Built-in (separate) gas hobs / mixed hobs 3 020UK

Built-in (separate) gas ovens 760

Total 54 301



The table below provides summary of data quality for gas cooker, where:

***- Reliable data with additional splits for free standing and built-inmodels

**- Reliable data; total park of domestic gas using appliances

*- Data estimated based on numerous sources including H-gas totalhousehold connections, share of electricity versus gas in total cookersales, EUROSTAT time series and other

n/a- Insufficient data for estimates

Fig. 7.2-1 DATA RELIABILITY FOR ESTIMATING DOMESTIC COOKER PARK

Figs. 7.2-2 and 7.2-3 present estimates of the park of H-gas using cookersacross 16 selected EU countries.

For free standing appliances, the three functions (hob, oven and grill) arecombined into a single statistical unit. By contrast for built-in appliances,the hobs and ovens (usually with grills incorporated into the ovens) arecounted as separate pieces, but except in the UK it has not been possibleto obtain separate figures for hobs and ovens.

It must therefore be acknowledged that the form in which the data on built-in appliances are available is only partly helpful in terms of supporting theformulation of the GASQUAL test programme. In Section 10 of this reportBRGC has assumed that separate testing would be required for hobs,ovens and grills. For hobs, it is probably not significant whether they areon a free standing appliance or separate. However, it is thought that built-in ovens may be more sensitive than those in free standing appliances.Thus it would have been helpful to have separate numbers for built-inovens.

Country Data Quality

Austria *

Poland **

Ireland n/a

Greece n/a

Slovak Republic **

Romania n/a

Portugal n/a

Country Data Quality

France ***

UK ***

Germany ***

Italy ***

Spain **

Belgium **

Czech Republic *

Hungary *

7.3 TRENDS


BRGC’s research suggests that typically on the Continent, only some 10%oven built-in gas hobs are used in conjunction with gas ovens (the rest useelectric ovens). This provides some basis for estimating the scale of thebuilt in ovens park. BRGC is working on the basis of some 3.5 millionpieces for the 16 countries.

7.3 TRENDS

Cooker markets are reported generally to be stable. There may howeverbe some loss of share to electric reflecting the improvements in electricaltechnology (e.g. induction).

7.3 TRENDS


8. OTHER DOMESTIC GAS APPLIANCES

The proposal requires BRG to cover:

- gas tumble dryers (EN 12752 for <20kW and EN 1458 for <6 kW)

- gas washing machines (EN 12244-1)

These are small markets and there appear to be a mainly residual park.According to one major manufacturer these appliances are now hardlysold because of the difficulties of installation. It was suggested that in thepast the main markets were UK and Germany (+ the Netherlands), andthat the burners could well be sensitive to gas quality.

In respect of gas tumble driers, the following helpful observation werereceived from the UK Member of the CEN 197 Committee:

- “The gas tumble dryer model suggested for assessment is a MIELET9820 residential tumble dryer. This was only ever sold in very smallvolumes when MIELE tried out the market and we believe has sincebeen withdrawn from sale. We would recommend that White KnightECO43A (3kW burner) and White Knight BG44A (4.7kW burner)models are both assessed as part of this exercise. Variations on thesemodels have been sold in Europe to UK, Spain, Italy, Netherlands andGermany with an overall population of around 150K pieces and arecurrently being produced and sold unlike the proposed model.”

Another niche market (mainly in the UK) is for boiler-cookers.

Patio heaters are also covered by the GAD, but these have not beenincluded in the study since it is thought that almost all are for use withLPG. They generally use round Bunsen type burners similar to those usedfor gas storage water heaters.

Please note that micro-CHP and gas heat pumps have already beencovered in Section 4.226.


Fig. 9.1-1 ESTIMATED PARK OF "COMMERCIAL" GAS BOILERS 2007 FOR 16 SELECTED COUNTRIES

CountryThreshold

(kW)Total Comments

Germany 50 243 127

Great majority sold 2007 (excluding jet burner) arecondensing. Park figures exclude wall hung. Some 10,500wall hung boilers >50 kW sold in 2007, so there may be apark of >100,000.

UK 44 212 825In 2007 35% of sales were 44-75 kW. Wall hung (includingcascades) are gaining share. Most sales now condensing.

Italy 35 104 727C.60% >50 kW. Cascades gaining share. Aside from jetburner, condensing share approaching 50% of sales.

France 70 73 130Condensing started in 2003 and now has majority of sales.Cascades gaining share.

Poland 50 63 725"Commercial" boilers losing share rapidly to wall hungcascades.

Belgium 70 38 880Majority condensing sold in 2007. Also some 11,700 wallhung boilers (mainly condensing) sold for use in cascades in2007.

Austria 60 37 225 Sales >50% condensing by 2007.

Spain 50 31 831 Condensing penetration still negligible.

Romania 70 17 123 Market declining.

Czech Republic 70 13 200 Smaller wall hung boilers for cascades gaining share.

Slovakia 70 7 363 Smaller wall hung boilers for cascades gaining share.

Denmark 60 6 108 39% condensing in 2007 sales (78% excluding jet burner).

Greece 70 5 200 Mainly jet burner. Gas still has only a small share.

Hungary 70 4 831 Small market: little collective heating in apartments.

Ireland 44 2 382 Gas has small share.

Portugal 70 1 333Gas has small share, but market developing based oncondensing.

Total 863 009

9.1 COLLECTIVE AND COMMERCIAL BOILERS


9. COMMERCIAL GAS APPLIANCES


There are numerous problems involved in quantifying the park of“commercial” boilers. In most cases the markets are poorly documented.BRGC has been attempting to monitor these markets within its multi-clientprogrammes since the mid 1990’s, and thus has some basis for estimatingroughly the size of the park in each country. However there are alsoproblems of classification and definition. The EN classifications adopt thefollowing definitions:

- EN 656 (gas boilers 70-300 kW)

- EN 13836 (gas boilers 300-1000 kW)

- Gas boilers within EN 303-7 (boilers equipped with a forced draughtburner).

Thus the threshold for “commercial boilers” adopted by the ENclassifications is 70 kW. However, the thresholds commonly used in eachMember State (and hence the bases of BRGC’s analyses) vary.

However, please note that:

- these boilers are used both for non-domestic applications and for thecollective heating of apartment buildings

- while the EN classifications adopt an output threshold of 70 kW, it hasnot always been possible strictly to adhere to this threshold. Thisapplies particularly in the UK, which is one of the better documentedmarkets, but where the threshold has long been set at 44 kW

- there are obvious difficulties in splitting jet burners sales (other thangas “units” between gas and oil)

- the numbers do not include the increasingly important category of“cascade” boilers. These are banks of, usually, wall hung condensingboilers which individually would (it is assumed) come under EN 677and be considered as “domestic”, but would be installed in groups thatin aggregate would be >70 kW. GASQUAL WP4 may wish to considerwhether or not these should be included as a separate category in theWP5 test programme. This solution is gaining share in many countries,causing sales of “commercial” gas boilers to decline. They probablyrepresent the largest group of condensing boilers <70 kW that areinstalled with Type B rather than Type C flues.

In practice this is a highly complex sector with a wide range of models,technologies and outputs.



Fig. 9.2-1 ESTIMATED PARK OF GAS STORAGE WATER HEATERS >70 kW

CountryPark 93-07 ('000

pieces)

France 80 844

Italy 66 446

United Kingdom 44 773

Germany 15 564

Ireland 9 089

Belgium 6 200

Hungary 4 625

Spain 2 985

Czech Republic 2 606

Poland 1 921

Slovak Republic 1 895

Austria 1 550

Portugal 1 158

Greece 811

Romania 582

Denmark 98

TOTAL 241 147



Supply is fairly fragmented. The German “Heizkessel” manufacturers(notably VIESSMANN and BUDERUS) are present in most countries, andWOLF, BRÖTJE and WEISHAUPT are also significant. Other importantsuppliers are REMEHA, IGNIS (B). DE DIETRICH, BAXI and ATLANTICGUILLOT are important in France, as are RIELLO, IDEAL CLIMA,FERROLI, ICI CALDAIE and UNICAL in Italy. FERROLI and BAXI lead inSpain. UK market for gas commercial boilers is dominated by ISG/IDEAL,HAMWORTHY, POTTERTON COMMERCIAL, BROAG and MHS.

Fig. 9.1-2 presents estimates of “commercial” boiler market shares for the16 EU Member States covered by this study. The purpose including thisTable in the report is to identify the leading brands, so that if a subsequentproject is undertaken to identify models for testing, web searches ofproduct ranges can be undertaken. This said, the Table needs to be usedwith caution within the context of the GASQUAL project:

- the shares are based on the thresholds commonly used in eachcountry (as shown in Fig. 9.1-1) and not on the EN 70 kW threshold

- the jet burner shares include gas and oil

- the rankings are by brand rather than holding, since this is the bestguide to seeking out the product ranges

- being 2008 shares, the Table only reflects the current position, andobviously not the historical situation.

Following on from the last mentioned point, BRGC is also presenting inAppendix C to this report some charts illustrating the main ranges ofcommercial boilers that were on the market in Belgium, France, Germany,Italy, Netherlands, Spain and UK in 1997.



Fig. 9.1-2 ESTIMATED BRAND SHARES FOR COMMERCIAL BOILERS IN 16 EU COUNTRIES2008 (% volume)

Holding Brand/Company (Country) Jet Burner Floor Standing Gas Total

VIESSMANN VIESSMANN (D) 12.87% 15.51% 14.00%DE DIETRICH REMEHA DE DIETRICH (F) 4.45% 8.89% 6.36%ISG IDEAL/KESTON (UK) 8.28% 3.68% 6.31%BOSCH BUDERUS (D) 6.95% 4.45% 5.87%RIELLO RIELLO (I) 5.02% 5.39% 5.18%FERROLI FERROLI (I) 5.67% 4.17% 5.03%DE DIETRICH REMEHA BROAG (NL) 5.00% 2.99% 4.14%ATLANTIC HAMWORTHY (UK) 3.28% 2.99% 3.15%ATLANTIC ATLANTIC GUILLOT (F) 1.79% 4.34% 2.89%WEISHAUPT WEISHAUPT (D) 3.62% 0.05% 2.09%BAXI POTTERTON COMMERCIAL (UK) 2.80% 0.92% 1.99%VAILLANT VAILLANT (D) 0.03% 4.15% 1.79%HOVAL HOVAL (A) 1.68% 1.48% 1.60%BIASI BIASI (I) 1.78% 1.31% 1.58%BAXI ROCA (E) 2.07% 0.69% 1.48%ACV ACV (B) 2.05% 0.60% 1.43%IDEAL CLIMA IDEAL CLIMA (I) 1.29% 1.49% 1.38%UNICAL UNICAL (I) 1.67% 0.80% 1.30%ATG ELCO (D) 0.25% 2.67% 1.29%CENTROTEC WOLF (D) 1.95% 0.23% 1.21%ICI CALDAIE ICI CALDAIE (I) 0.00% 2.76% 1.18%BAXI BRÖTJE (D) 0.38% 1.92% 1.04%MODULAR HEATING GROUP MHS (UK) 1.21% 0.69% 0.99%MCC DOMUSA (E) 1.41% 0.11% 0.85%ATLANTIC YGNIS (B) 0.69% 0.99% 0.82%DE DIETRICH REMEHA REMEHA (NL) 0.10% 1.69% 0.78%FONDERIE SIME SIME (I) 0.51% 1.15% 0.78%BAXI BAXI FRANCE (F) 0.90% 0.46% 0.71%ARCA ARCA (I) 0.69% 0.51% 0.61%CLYDE ENERGY SOLUTIONS CLYDE (UK) 0.86% 0.23% 0.59%FIREBIRD BOLIERS FIREBIRD (IRL) 1.04% 0.00% 0.59%ATG ECOFLAM (I) 0.91% 0.00% 0.52%BALTUR BALTUR (I) 0.35% 0.69% 0.49%MHG MHG (D) 0.60% 0.28% 0.46%ENERTECH ST ROCH COUVIN (B) 0.52% 0.30% 0.42%THERMONA THERMONA (CZ) 0.00% 0.86% 0.37%VIADRUS VIADRUS (CZ) 0.10% 0.70% 0.36%DE DIETRICH REMEHA OERTLI (F) 0.31% 0.41% 0.35%BAXI BAXI ITALY (I) 0.00% 0.80% 0.34%FACODY FACODY (E) 0.60% 0.00% 0.34%BOSCH JUNKERS (D) 0.00% 0.69% 0.30%GRANT ENGINEERING GRANT (IRL) 0.52% 0.00% 0.30%LACAZE TRANSTUB (F) 0.17% 0.43% 0.28%STREBELWERK STREBEL (A) 0.43% 0.00% 0.25%ALUFI ALUGAS/ALDINGAS (E) 0.00% 0.57% 0.25%STOKVIS INDUSTRIAL BOILERS STOKVIS/RENDAMAX (NL) 0.35% 0.00% 0.20%ADISA ADISA (E) 0.00% 0.46% 0.20%ERESAN ERESAN (RO) 0.33% 0.00% 0.19%BLOWTHERM BLOWTHERM (I) 0.14% 0.25% 0.19%ATG CHAFFOTEAUX (F) 0.00% 0.41% 0.18%COSMOGAS COSMOGAS (I) 0.00% 0.41% 0.18%SILE SILE (I) 0.22% 0.09% 0.17%VICKING GROUP PERGE (F) 0.24% 0.00% 0.14%RADIANT BRUCIATORI RADIANT (I) 0.05% 0.18% 0.11%BAXI BAXI DENMARK (DK) 0.09% 0.11% 0.10%COMERCIAL QUEMOIL COMERCIAL QUEMOIL (E) 0.17% 0.00% 0.10%FATECA LASIAN (E) 0.15% 0.00% 0.08%THERMOSTAHL THERMOSTAHL (RO) 0.14% 0.00% 0.08%SANT'ANDREA SANT'ANDREA (I) 0.11% 0.00% 0.06%GOLDPOL TORIS (PL) 0.10% 0.00% 0.06%BOSCH GEMINOX (F) 0.00% 0.11% 0.05%VARA VARA-FÉG (H) 0.00% 0.11% 0.05%PIFATI PIFATI (RO) 0.05% 0.00% 0.03%BOSCH DAKON (CZ) 0.00% 0.05% 0.02%UNITED TECHNOLOGIES ALARKO (T) 0.02% 0.00% 0.01%HÖTECHNIKAI HÖTERM (H) 0.00% 0.02% 0.01%CTD COLLARD & TROLART (F) 0.00% 0.02% 0.01%TIFELL TIFELL (E) 0.01% 0.00% 0.00%Others/not identified 13.02% 14.74% 13.76%Total 100.00% 100.00% 100.00%

Source: BRG CONSULT

9.2 COMMERCIAL WATER HEATERS


9.2 COMMERCIAL WATER HEATERS

This section covers only gas storage water heaters >70 kW (EN 98), whichis assumed to correspond to appliances >220 litres.

Based on BRGC’s annual sales estimates for such appliances 1993-2007,the park by country is as shown in Fig. 9.2-1. Please note that:

- the figures include a small number of condensing models

- also included are combined residential solar + gas storage waterheaters (<1%)

It may be surprising to find the UK so high on the list, given the very smalldomestic market for these products. Most gas storage water heaters soldin the UK are for commercial use (even those below 220 kW.).

All instantaneous gas water heaters are assumed to be “domestic”. Whilesome are certainly used in commercial premises, the models are the sameso from a testing point of view there is no point in attempting to segmentthe market between “domestic” and “commercial”.


Fig. 9.3-1 TOTAL FOOD SERVICE ESTABLISHMENTS: 16 EU COUNTRIES 2008

Segment A B CZ DK F D GR H IRL I PL P RO SK E UK Total

COMMERCIAL 35 899 44 272 28 484 14 534 175 865 236 890 32 286 26 731 18 433 197 764 76 808 76 304 24 153 16 926 237 306 196 681 1 439 336

Hotels & Lodging Places 15 275 1 975 3 900 1 075 35 070 44 800 6 700 1 930 4 150 36 850 4 055 1 325 3 435 1 115 10 105 48 600 220 360

Restaurants 13 518 15 080 5 400 5 000 88 080 130 105 14 650 7 150 3 550 64 730 23 815 24 150 5 500 11 770 62 585 44 500 519 583

QSR Outlets (inc. Fast Food) 6 650 26 475 18 700 7 780 47 690 57 900 10 350 17 390 10 410 91 820 48 050 49 780 14 538 3 715 161 225 72 150 644 623

Transport Foodservice 386 272 242 201 1 220 2 561 361 140 29 2 184 338 464 550 326 1 091 526 10 891

Leisure & Event Catering 70 470 242 478 3 805 1 524 225 121 294 2 180 550 585 130 65 2 300 1 750 14 789

SOCIAL FOODSERVICE 7 922 12 987 15 301 8 082 78 807 74 720 3 322 7 743 3 750 41 889 43 209 20 539 14 428 6 848 18 317 83 136 441 000

Business & Industry 1 570 2 814 3 551 2 871 7 805 17 440 620 1 396 1 148 4 850 3 505 1 705 3 886 983 1 465 21 750 77 359

Education 5 135 6 113 9 810 2 836 49 310 33 960 2 200 5 245 1 900 24 457 36 415 11 070 7 352 5 190 8 635 28 420 238 048

Health & Welfare 1 090 3 525 1 630 2 271 20 195 22 275 467 1 035 620 10 080 2 414 7 414 2 907 577 7 455 32 110 116 065

Other Social Foodservice 127 535 310 104 1 497 1 045 435 67 82 2 502 875 350 283 98 762 856 9 928

TOTAL FOODSERVICE 43 821 57 259 43 785 22 616 254 672 311 610 35 608 34 474 22 183 239 653 120 017 96 843 38 581 23 774 255 623 279 817 1 880 336

Source: GIRA FOODSERVICE

Fig. 9.3-4 PARK OF COMMERCIAL GAS CATERING EQUIPMENT IN ITALY AND GERMANY

Country Product No pieces

Gas ovens 90 000

Boiling pans, frytop, open burners 289 600

Gas cooking appliances 32 061Italy (2004)

Total 411 661

Roast-, grill- and griddleplates/-equipment 3 000

Combi steamer 7 000

Commercial cookers 6 000

Multi-purpose cooking pan 3 000

Cooking machines, (pressure-) boiling pan 2 000

Fryer, frying machines 2 000

Germany

Total 23 000

9.3 COMMERCIAL CATERING EQUIPMENT



In spite of extensive research, it has only been possible to find quantifieddata for commercial catering equipment in Italy and Germany. In order tomake some progress on this sector it was decided to purchase data fromthe specialist food service market research consultancy GIRA SIC. GIRASIC prepares every year detailed statistics on the number of non-housingestablishments with kitchen facilities in most European countries (includingall EU Member States except Bulgaria). A summary of the data for 2008for the 16 countries is given in Fig. 9.3-1. The source data gives far moredetailed splits by sub segments, as well as time series, but BRGC hasagreed to restrict the divulgation of these data.

While these numbers give a good idea of the scale of the sector, thereremain a number of steps between them and quantifying the park of gasappliances. To do this it would be necessary to have some basis forestimating:

- the average number of appliances per kitchen in each user segment(preferably be type), based on the EN classifications (Figs. 9.3-2)

- the % share of gas vs electricity.

As far as the latter point is concerned, the numbers available for Italy andGermany (Fig. 9.3-3) clearly illustrate the huge differences that can befound between Member States.

Fig. 9.3-2 NON-DOMESTIC COOKER CLASSIFICATIONS

LEVEL 1 LEVEL 2 LEVEL 3


Open burners and wok burners EN 203-2-1

Chargrills EN 203-2-10

Pasta cookers EN 203-2-11

Ovens EN 203-2-2

Boiling pans EN 203-2-3

Fryers EN 203-2-4

Hot water heaters for beverage EN 203-2-6

Salamanders and rotisseries EN 203-2-7

Brat pans and paella cookers EN 203-2-8

NON DOMESTIC

CATERINGEQUIPMENT

EN 203-1 & EN

203-2-1 to 11

Solid tops, warming plates and griddles EN 203-2-9

In terms of technical characteristics, the illustrated chart (submitted byHKI) shows some of the main burner types used on commercial cookers(Fig. 9.3-3).



Fig. 9.3-3 EXAMPLES OF BURNERS USED FOR COMMERCAL COOKERS (HKI COMPILATION 2009)…/1

Burner Type(group)

Burner Type(subgroup)

No Image Defintion/Description

Produced

since(ca.)

Produced by Used inLoad range

(of appliances)(kW)

Sensitivity tochanging

Gasquality

Atmosphericburner (rip form)

standard/oldversion 6

burner is composed of several singleburner rips 1986 Junkers Combisteamer 18-36 low

Premixed burner(Surface burner)

Standard version 10Air is blown by a fan into the burner, gasis mixed with into the air stream by anozzle

1997 Rational AG Combisteamer 10-54 medium


Standard version 10

Air is blown by a fan into the burner, gasis mixed with into the air stream beforethe burner with an overstoichiometricmixture

2004 Rational AG Combisteamer 10-60 medium

atmosphericburner

old version of burner in combisteamer 1992 Eloma GmbH combi-steamer 10-20 medium


Standard versionAir and gas mixture is blown by a faninto the burner, gas is mixed with airstream by a nozzle

2001 Eloma GmbH combi-steamer 10-40 high

atmosphericburner

double ringburner,primary air frombelow the coverplate

Open burner, used in gas range, there isdifferent emission behavior, dependanton the rust, primary air adjustment at theMixing tube possible

1999 C 2,1 - 7,0

internal ringsensitively; nozzleand Venturi tube mustbe adapted,sensitively liquid gaswith low inletpressure

atmosphericburner

single ring burner,primary air frombelow the coverplate


1995 C 1,4 - 5,6

nozzle and Venturitube must beadapted, sensitivelyliquid gas with lowinlet pressure

atmosphericburner

single ring burner,primary air frombelow the coverplate


1995 C 0,7 - 3,5

nozzle and Venturitube must beadapted, sensitivelyliquid gas with lowinlet pressure



Fig. 9.3-3 EXAMPLES OF BURNERS USED FOR COMMERCAL COOKERS (HKI COMPILATION 2009)…/2

atmosphericburner

Staff burnerCovered burner,used in gas deep fat fryer

1995 D8,016,0

not clear

atmosphericburner

Round burnerHotplate burner,used in gas solid top range

1995 B 12.5 not clear

atmosphericburner

Round burner

Covered burner,used in gas baking-oven,used in gas broiler,used in gas lava stone grill

1993 D7,07,016,0

nozzle and Venturi tube must beadapted, sensitively liquid gaswith low inlet pressure

atmosphericburner

Staff burner

Covered burner,used in gas tilting bratt pan,used in gas baking-oven,used in gas griddle plate

1995 D

12,017,05,67,014,0

nozzle must be adapted

pre mix burner

Aconit®cylindrical premixburnerflat pre mix burner,

Covered burner,used in gas combi steamer,used in gas quick boiling kettle,used in gas cooking kettle

2004 D

11,0/17,018,0/26,036,0/52,0

15,0/20,0/26,024,0/30,0/38,0

CO2 Calibration,if necessary nozzle must beadapted



9.4 OTHER COMMERCIAL GAS APPLIANCES


9.4 OTHER COMMERCIAL GAS APPLIANCES

9.41 COMMERCIAL LAUNDRY EQUIPMENT

Up to the time of the deadline for WP! It had not been possible to obtainany quantified data on commercial gas laundry equipment, althoughBRGC still has enquiries out in the market place. It is assumed that, as inthe domestic sector, the vast majority of the market is for electricalappliances.

9.42 NON DOMESTIC SPACE AND AIR HEATERS

A significant sector of non domestic gas appliances is that of space and airheaters. Not surprisingly market data are scarce, but according to SBM inFrance there is a European market of about 300,000 pieces a year sold toindustrial and commercial premises (agriculture is not included) coveringall the EN categories listed in Fig. 9.42-1 (plus EN 778 and 1319 which aretreated as domestic and include mainly gas warm air systems in the UK forwhich the market is some 15,000 units a year). It also includes about70,000 overhead luminous radiant heaters (EN 419)

The market in France is for 30,000 pieces a year (includes 7,000 EN 419),and the park is estimated at 450,000, including 200,000 EN 419).Extrapolating these figures it is likely that the 16 country total park for allthese products is in the order of 2.5-3.5 million.

Fig. 9.42-1 OTHER NON DOMESTIC GAS APPLIANCES

LEVEL 1 LEVEL 2


EN 525 Direct forced convection <300kW

EN 621 Forced convection air heaters <300kW

EN 1020 Indirect forced convection <300kW

EN 1196 Condensing air heaters

AIR HEATER

EN 12669 Air heaters for green house applications

EN 416-1 &EN 416-2 Overhead radiant-tube heaters

EN 777-1 to 4 Overhead radiant-system heaters

NONDOMESTIC

RADIANTHEATER

EN 419-1 & EN 419-2 Overhead luminous radiant heaters



PART III: CONCLUSIONS AND RECOMMENDATIONS


10 CONCLUSIONS: LISTING OF APPLIANCES TO BE CONSIDERED FOR

TESTING

10.1 INTRODUCTION

The primary objective of the WP1 Market Study has been to provide a listof domestic gas appliance categories that should be considered in WP4for testing in WP5. It was specifically requested that this list should relateto the relevant EN classifications, and this BRGC has attempted to do.

However, the EN classifications do not necessarily segment the marketsufficiently to cover all the variables that need to be taken intoconsideration. In most cases it has been necessary to sub-segment theEN classifications in order to make sure that critical variables are notoverlooked.

Figs. 10.2-1 & 2 and 10.3-1 & 2 set out a “long list” of possible domesticappliance categories that in BRGC’s view should at least be screened fortheir specific relevance to the test programme. BRGC is not necessarilyrecommending that every one of the 88 listed appliances should be tested,but rather that each should be taken into account during WP4. Thecomposition of the list is summarized in Fig. 10.1-1. It may even be thatthere are further sub-segmentations that need to be made. On the otherhand it is likely that some of the categories listed in Figs. 10.2 and 10.3can be grouped together once it starts to become clear exactly where thesensitivities lie.

It will be noted that in order to facilitate the analysis, the pre-agreed“Levels” are not necessarily taken in numerical order. Similarly the verticalorder of the categories reflects in part the need to group certain categoriestogether for the purposes of quantification (e.g. Low NOx non condensingboilers).

10.1 INTRODUCTION


Fig. 10.1-1 INITIAL PROPOSED PRODUCT SEGMENTATION FOR TESTING

10.1 INTRODUCTION


Pre-Adjustments to Appliances

One set of possibly critical variables that is not taken into account at all in Figs. 10.2and 10.3 is the adjustments made by or on behalf of manufacturers prior to shipping,or by installers in the field, to reflect the H gas qualities found in the countries wherethe appliances are to be installed.

This is a topic that comes under the scope of WP3 rather than of WP1, but duringthe WP1 research it was repeatedly claimed by appliance, burner and controlsmanufacturers that pre-adjusting prior to shipping is common practice. The WP3findings suggest that the manufacturer adjustments are solely to account for H, L orE-gas groupings in the country of destination, BRGC feels bound to record that thisis not the impression gained during BRGC’s own research.

The information given to BRGC (in discussion rather than in writing) is that:

- in the case of boilers, water heaters and space heaters, theadjustments are made by the appliance manufacturers themselves.According to one boiler manufacturer the countries for which suchadjustments are needed include France, Belgium, Poland andHungary. Problems in Denmark were also mentioned. The practicewas cited by one controls manufacturer as being part of a general trendtowards trying to extract the maximum levels of performance fromexisting boilers by fine tuning rather than by more costly innovation

- for cookers (both hobs and ovens+ grills), the adjustments are made bythe burner manufacturers on behalf of the appliance manufacturers.

10.1 INTRODUCTION


Since the submission of the first version of this report, the following clarification wasoffered by one of the boiler and water heater manufacturers represented on theGASQUAL Consortium:

“G20 is the reference gas for Group H and Group E; it means that, in theory, gasappliances in categories I2H and I2E using G20 at 20 mbar should have the sameadjustment but this is not true because:

a - Hungary has I2H gas category, the reference gas is G20 but a supply pressure of25 mbar instead of 20 mbar so some appliances need a specific adjustment atassembly lines

b - Denmark has I2H gas category, the reference gas is G20 but the actuallydistributed gas has a higher Wobbe index than in other countries so standard boilersneed a specific adjustment at assembly lines

c - France has several gas categories (I2E+, I2Esi , I2Er), the reference gas is G20at 20 mbar but the gas appliances can be supplied also with G25 at 25 mbar; in thiscase the gas appliances need a specific design and a specific adjustment so theyare quite different from similar appliances for other countries

d - similar situation in Belgium where gas categories are I2E+ and I2E(S)B and thereference gas is G20 at 20 mbar but the gas appliances can be supplied also withG25 at 25 mba

rAs can be seen by those simple cases, appliances for Hungary, Denmark, France,Belgium have G20 as reference gas but their adjustments (in some cases theirdesign) can be completely different and gas appliances for France can't be installedin Hungary or viceversa.”

10.2 DOMESTIC GAS BOILERS



EN Classifications (Level 2)

Figs.10.2-1 and 10.2-2 lists some 50 categories of domestic gas boilers.

Giving priority to EN classifications obliges the analysis to segment between:

- flue types (EN 297 vs EN 483)

- combis (EN 265) vs “heating only”

- condensing (EN 677) vs non condensing

- jet burners (EN 303-3) vs other gas boilers.

These distinctions have been made, except in respect of some very small nichemarkets:

- boilers with special combustion controls, for which combis and heatingonly are taken together

- floor standing combis, where Type B and Type C flues are takentogether.

Flue Type (Level 2)

Prioritising the EN classfications places considerable emphasis on flue types.

For non condensing boilers, the main distinction is between:

- Type B (open/atmospheric) flues

- Type C (room sealed) flues. For boilers the vast majority of these arefanned flues, but there are still some balanced flues in place in the UK.



Non Condensing vs Condensing (Level 3)

This is a reasonably straightforward classification, and several of the other variablesare partially dependent on this split. It was assumed for the basic analyses that allcondensing boilers:

- use Type C flues

- use full premix fanned burners.

However it has emerged that there are some significant exceptions to these generalrules:

- there are some condensing boilers, usually sited in boilers room orbasements, that are installed with Type B flues. The most importantgroup of such boilers are the “cascade” systems, many of which haveType B flues

- there are some condensing boilers that do not have full fanned premixburners. The most important group of these is the SEDBUK B ratedcondensing boilers in the UK. BRGC estimates that there are some1.5 million of these in use, but it is not clear exactly how their burnersshould be classified, or indeed under which EN Classification they aretested. They are listed as a separate category in Fig. 10.2-1.

Combi vs Heating Only (Level 4)

The term “combi” refers to boilers providing directly heated instantaneous sanitaryhot water (even where there may be supplementary built-in storage or pre-heatfacilities). This should conform to EN 625.

Where “heating only” boilers also supply sanitary hot water, it is via a secondarycircuit heating an indirect hot water cylinder.

The vast majority of combis are wall hung.

There are some floor standing combis in use in the UK (including the BAXIPOWERMAX CPSU and the WORCESTER HEATSLAVE; there are nowcondensing versions, but these are not listed as a separate category), and there aresome borderline cases elsewhere (notably the copper floor standing boilers sold byseveral of the Italian manufacturers + perhaps Bain Marie types in France). Boththese types have been included in the list in Fig. 10.2-1, but it may be that the factthat they are floor standing is not relevant.

The combi/heating only split has been very relevant to the evolution of continuousmodulation (Level 5), which was first introduced primarily for wall hung combis(although, especially since around the year 2000, it has spread to most heating onlyand floor standing boilers). Nonetheless in the park today a far higher proportion ofcombis than of heating only boilers have continuous modulation. There have been avery few low priced combis sold in the past with fixed or step modulation.



Wall Hung vs Floor Standing (Level 3)

It has been argued that the distinction between wall hung and floor standing is not initself relevant to the GASQUAL project. However in practice the technical andquantitative evolution of the two types of boiler have been so different that it isvirtually impossible to analyse the market without treating them separately.

In particular, the construction of the burners is very different between the twocategories.

Burner Types

Apart from jet (forced draught) burners, the EN classifications do not directly classifyboilers by burner type (although all condensing boilers coming under EN 677 havefull premix fanned burners).

It was agreed that the market study should (based on the H. Levinsky/GASUNIErecommendations) distinguish between 5 categories of burner (no premix, partialpremix/Bunsen type, atmospheric premix, full fanned premix and jet burner), butBRGC has sub-segmented some of this categories (based in part on Petra Nitschke-Kowsky/EON RUHRGAS analysis).

No premix burners are not relevant to boilers.

Atmospheric Partial premix (Bunsen type) burners are used in the vast majorityof non-condensing, non low NOx boilers. The most common types are:

- multi-blade burners used for most non-condensing, non low NOx wallhung boilers

- tubular burners used for most non-condensing, non low NOx floorstanding boilers.

There are some smaller additional categories:

- most wall hung low NOx boilers are fitted with the water cooled bladedburners of POLIDORO and VAILLANT. It is understood that theseshould be classified as “atmospheric partial premix” rather than begrouped under “atmospheric premix” along with the other types of lowNOx burner

- “box burners” used for most of the UK open vented cast iron boilers(floor standing, wall hung and back boiler units). These are bladedburners with a single injector for the whole burner. There may indeedbe other “specials” in the UK

- special 4 tube burners used by the French wall hung boilermanufacturer FRISQUET.



Atmospheric premix burners, which have been taken to include most of thsolutions that have been tried for non-condensing low NOx boilers. This is arelatively small and declining segment, but it is also the most complex and possiblythe most sensitive to gas quality:

- for wall hung boilers, the most used solution is the water cooled bladedburners of POLIDORO and VAILLANT. How these are considered tobe “atmospheric partial premix” burners. There may be some rodcooled or mesh type burners in wall hung boilers, but these can also befound and tested in floor standing boilers

- for floor standing boilers a lot of types were tried during the postunification boom in Germany, when the Blaue Engel NOx emissionsrequirements were being reduced from 70 ppm to 40 ppm, and beforeGermant really embraced the condensing boiler. These solutionsincluded:

• rod cooling, favoured by VAILLANT. It was suggested during theresearch that this type could be sensitive to gas quality because theheight of the flame in relation to the rod is important

• various mesh types (ceramic, metal) including the VIESSMANNMatrix burner

• “butterfly-wing flame” burners, including the BEKAERT OVAL, thePOLIDORO OVO and the WORGAS Low NOx. This type has beenused by a number of German and other floor standing boilermanufacturers, probably including BUDERUS, BRÖTJE and WOLF.It is still used in what is now a declining market segment. It wasrepeatedly stressed that this could be the type of burner that is mostsensitive to gas quality. If the flame gets too low, the burner itselfburns up.

Full premix fan assisted burners, which are now more or less standard forcondensing boilers, apart from at least some UK SEDBUK B boilers. There are alsosome non condensing boilers that use fanned premix burners (ECOFLAM, IMAR,BALTUR).

Jet burner boilers, which is a difficult category to quantify. Jet burners are used farmore for oil than gas, and the gas burners tend towards the higher output. Jetburner boilers as a whole fall into a Level2 category (EN 303-3). BRGC has furthersegmented this into:

- non-condensing and condensing

- “units” (where the burner is factory fitted and is specific to the boilermodel) and “oil/gas boilers” (where the burner is fitted further down thesupply chain, and the manufacturer does not necessarily know whetherthis will be oil or gas).

For “oil/gas” boilers the test houses will need to select both a burner and a boilermodel.



Modulation (Level 5)

To avoid having too many categories, the analysis just distinguishes between:

- continuous modulation

- step modulation and fixed flame (no modulation).

Continuous modulation was introduced around the late 1980’s/early 1990’s primarilyas a means of limiting the volume of water that needed to be held in wall hung combiboilers. Thus almost all wall hung combis now in use (with the exception of a smallnumber of very low cost models) have continuous modulation, typically controlled bySIT or HONEYWELL modulation controls (which also incorporate pressure controls).

Progressively continuous modulation has spread to heating only wall hung and floorstanding boilers, including the great majority of such boilers being sold today (andsince about 2000). However, there are many such boilers in the park that do nothave continuous modulation, including the majority of pre 2000 floor standing boilersand nearly all the UK open vented cast iron products that use “box” burners.

Continuous modulation today is typically in the range of 100% down to 40%.However development work is taking place to widen the range (some see 30% asthe likely limit, while others talk of going down to 10%). This (like the fine adjustingof boilers to suit the gas quality of their country of destination) is all part of a trend totry to get the best possible performance out of existing boiler types. It is a trend thatmay be going in the opposite direction from what is convenient for GASQUAL.

Combustion Controls

The uptake of special combustion controls has so far been minimal:

- WEISHAUPT fits SCOT to all its wall hung condensing boilers(probably around 10,000 in use)

- VIESSMANN fits SCOT to certain models

- BRÖTJE fits the SIETHERM PRO to some boilers

- VAILLANT has a flue sensor on offer with one model.

The industry is seeking to develop an effective low cost laser sensor, but the generalview is that it would take legislation significantly to extend the use of such controls.

Figs. 10.2-1 and 10.2-2 do not list separately any older boilers that are reportedlyGAD compliant do not have air/gas control but have simple controls consisting of anappliance governor or throttle. It has not been possible to quantify the park of these,but it may be that they will need to be considered when the final test programme isdrawn up.



Other Variables: Balcony Siting

The question was raised during discussions on the test protocols as to whether it isnecessary to test as a separate category wall hung boilers that are sold (mainly inItaly) specifically form external siting on balconies. These need to operate intemperatures of Max 40/60°C; min -10/-15°C.

The situation is not very clear cut. It is estimated that some 10-11% of combis soldin Italy are specifically designed for external use. These can be both Type B andType C (fanned). It is not thought that balanced flues are used.

Many combis that are not intended for external siting are nonetheless installed onbalconies. It is possible that 20% of all combis sold are so sited. Rough estimatesindicate up to 50/60% of boilers in Italy, one of the largest markets in EU, areinstalled outside (i.e balcony siting)

There is a trend towards selling boilers that can be sited either indoors or on abalcony.

Other Variables: Cascades

There is a growing trend towards installing wall hung (usually condensing) boilers ingroups or cascades, especially for the collective heating of apartments. This variantis included in Fig. 10.2-1 because the individual boiler units are mostly below the 70kW threshold for “commercial” boilers. It has not been possible to quantify the park,but it certainly runs into hundreds of thousands in the 16 countries covered. Asalready indicated, a significant proportion of these might be installed with Type Bflues rather that the Type C flues that are more or less standard for other types ofcondensing boilers.

10.3 OTHER DOMESTIC GAS APPLIANCES



Figs. 10.3-1 and 10.3-2 lists 40 categories of domestic gas appliancesother than boilers that might be screened for testing in WP4. It will benoted under Level 5 that there is no column for combustion controls. Thisis because no such special controls are used on any of the productcategories covered.

Gas Water Heaters

There are only two Level 2 and Level 3 categories:

- instantaneous (EN 26)

- storage (EN 89).

Instantaneous Gas Water Heaters

For instantaneous, models of 10 litres + per minute are normally considered as multipoint/primary water heaters (i.e. they are the main source of sanitary hot water forthe whole dwelling) while those of <10 litres per minute are generally singlepoint/secondary. However, it is thought that in many Iberian homes water heaters of<10 litres per minute are the sole source of sanitary hot water. These outputclassifications are useful for quantifying the market, but they are not thought to berelevant to the test programme (no specific “commercial” models were found).

One challenge to quantifying the relevant park is to estimate the proportion(especially in Spain and Portugal) that run on LPG rather than H gas (especiallygiven that some have been converted from LPG to natural gas).

There are no EN numbers to distinguish between open flues (Type B) and fannedflues (Type C). There are even some flueless products (Type A). Traditionally thegreat majority were Type B, but the share of Type C has grown steadily.

All burners are partial premix Bunsen type (bladed).

Traditionally most appliances had water activated modulation, but the share ofelectronic continuous modulation has grown at the premium end of the market.Continuous modulation may now account for 25% of sales and 10% of the park.

As for boilers, Fig. 10.3-1 does not list separately any older water heaters that arereportedly GAD compliant do not have air/gas control but have simple controlsconsisting of an appliance governor or throttle. It has not been possible to quantifythe park of these, but it may be that they will need to be considered when the finaltest programme is drawn up.



Gas Storage Water Heaters

For gas storage, it is assumed that those of <70 kW are domestic and those of 70kW+ are commercial.

There are a very few condensing models on the market, but BRGC’s researchsuggests that these are all right at the upper end of the commercial range. It ispossible that they are imported from the USA. There would appear to be no reasonto test them as a domestic product.

Both Type B and Type C flues are offered, but it has not so far been possible toquantify the share of each.

All burners are partial premix/Bunsen type (round burners especially designed forgas storage water heaters).

All are on/off (non modulating).

Gas Fires, Space Heaters and Warm Air Heaters

With the Netherlands excluded from the GASQUAL project, the UK is by far thelargest market for this group of products.

It should be noted that EN 613 covers a wide variety of different balanced and openflue gas fires and space heaters, so Fig. 10.3-1 sub-segments this particular ENclassification to a considerable extent.

Radiant Gas Fires (EN 613 + BS 7977-1)

This is the oldest category of gas fires in the UK. There is still a large park of pre-1993 appliances, so the total park is much larger than the estimated post 1993 park.

Independent Space Heaters with Fan (EN 1266)

BRGC has not come across anyone claiming to sell appliances under this category.May apply to a very small number of fanned flue radiant gas fires.

Live Fuel Effect Gas Fires (EN 613 & EN 132678 + BS 7977-1)

These have both a heating and decorative function. They are able to claim efficiencylevels (unlike EN 509).

There is a large UK market, mainly for open flue (chimney). The fanned andbalanced flue market is small.

This is also the main product exported by the Netherlands producers to otherMember States. These are nearly all balanced flue (EN 613). Volumes are small(<20,000 p.a. exported).



Decorative Gas Fires (EN 509)

This is a UK specific product, which is more decorative than for heating. It is notpermitted to claim efficiency levels for this product.

Flueless Gas Fires (EN 14829)

UK specific product. Uses catalytic converter. Can claim 100% efficiency. Smallmarket, with a large part of the sales channeled through DIY stores.

Could be a critical “special case” for GASQUAL, because of fears that variable gasqualities could cause soot build up and jeopardise function of catalytic converter.

Gas Fired Insets for Heating More Than 1 Room (EN 14438)

This category was not specifically discussed during the research. FABER in theNetherlands has products that appear to fit the description, but it is not certainwhether they are tested under EN 14438 or under EN 613, or whether there aresignificant sales outside the Netherlands.

Floor Standing Gas Room Heaters (EN 613)

These balanced flue products are associated mainly with the German speakingmarket, and above all with the German manufacturer ORANIER (which also suppliesthe VAILLANT range). They are described by ORANIER as “Gasheizautomaten”.There is thought to be some market in Eastern Europe. Sales peaked in the 1990’s.

Gas Wall Heaters (EN 613)

In the UK, there is a significant but declining market for wall hung gas convectorheaters (balanced flue).

In Hungary there is a much larger market for gas radiators (also balanced flue) whichmay account for 25% of the total domestic heating park (implying 3.5 million piecesassuming an average of 3.5 units per equipped dwelling). However, only a smallpart of this park will have been installed since Hungary came under the GAD.

Gas Warm Air Systems (EN 778 & 1319)

In European terms this is a UK specific product (although there are marginal sales inFrance and Belgium), but it is very widely used in the USA. The main period ofinstallation was in the 1960’s and 1970’s, but there has been a continuingreplacement market since the GAD in 1992.

The dominant producer JOHNSON & STARLEY adapted the product to meet therequirement of the revised Part L regulations of 2005, but a condensing version isstill in development. EN 778 is for open flue and EN 1319 for room sealed (includingcondensing when it appears).



Cookers (EN 30): Hobs

The listing in Fig. 10.3-2 assumes that:

- for both built-in and free standing cookers, the hob burners would betested separately from the oven/grill burners. Thus the distinctionbetween free standing and built-in is probably not relevant for hobs

- the first distinction is between the cheaper but less stable fricativeburners (c.95% of the markets) and the more expensive ring burners(c.5%). The pilot flames referred to are feeder flames that light onignition. They are not permanent pilots such as used to be a feature ofgas boilers in the past

- there is also a sub-segment of multiple ring burners (double and triple).These are considered to be especially sensitive to gas quality, andcover about 10% of current sales (6% of the park).

Generally the pre-delivery adjustments to accommodate the gas quality in thecountry of end-use are done by the burner manufacturer.

Cookers (EN 30): Oven and Grill Burners

Here the distinctions between:

- built-in and free standing

- grill inside oven and separate (high level) grill

are significant:

- built-in ovens generally have a smaller cavity than those in freestanding cookers, and therefore have more restricted access tosecondary air. This could make them more sensitive to gas quality

- where the grill is inside the oven, the user is advised to leave the ovendoor open when using the grill. However, there is a new type of ovenavailable that is specifically designed to allow the grill to be used withthe oven door closed. The there is limited access to secondary air, andthis type could be the most sensitive of all to gas quality.

Again, the pre-delivery adjustments to accommodate the gas quality in the country ofend-use are done by the burner manufacturer.

Gas Tumble Driers (EN 1752 and EN 1458)

Very small market.

Gas Washing Machines (EN 12244-1)

Very small market.



Micro CHP (no EN No. as yet)

Internal combustion models have been on the market for some years, but theystraddle the light commercial and domestic markets.

Stirling Engine Micro-CHP has been in development for some years, but it has takena long time to bring them to market. Many companies, including leading boilermanufacturers, are planning launches some from late 2009

The ENERGETIX/GENLEC Rankine Cycle product is also due for launch in 2009.

Micro CHP has recently been added to the EUP Eco-Design process (Lot 1) andseems to be emerging reasonably well, with the possibility of rankings slightly aheadof the best condensing boilers on a primary energy consumption basis. Howevermuch depends on how the products are installed and set up

Fuel cell models are also in development.

Gas Heat Pumps (EN 12309) for Heating & Cooling

ROBUR has a product on the market, but like internal combustion Micro CHP theystraddle the light commercial and domestic markets.



Fig. 10.2-1 SUMMARY OF DOMESTIC GAS APPLIANCES TO BE CONSIDERED FOR TESTING IN WP4: LIGHTWEIGHT WALL HUNG GAS BOILERS

LEVEL 5 Modulation &Combustion Controls

EstimatedPark (1993-

2007)LEVEL 1LEVEL 2 EN

ClassificationLEVEL 3 PRODUCT TYPE LEVEL 4 System

LEVEL 2 FlueType

LEVEL 4 Burner Type

ModulationCombustion

Controls('000 pieces)

CommentsLEVEL 6 Manufacturers (not

comprehensive)

EN 297 Wall Hung Non Condensing Heating only Type B Partial Premix (bladed) Continuous Standard } 375 Tends to be variant within ranges that are mainly combis. Most wall hung boiler producers.

EN 297 Wall Hung Non Condensing Heating only Type B Partial Premix (bladed) Fixed or step } negligible Very few if any left.

EN 483 Wall Hung Non Condensing Heating only Type C (Fanned) Partial Premix (bladed) Continuous Standard 970 Tends to be variant within ranges that are mainly combis. Most wall hung boiler producers.

EN 483 & 625 Wall Hung Non Condensing Combi Type B Partial Premix (bladed) Continuous Standard 7 700 Large park, but losing to Type C. Most wall hung boiler producers.

EN 483 & 625 Wall Hung Non Condensing Combi Type C (Fanned) Partial Premix (bladed) Continuous Standard 18 000 Now the largest category of boilers internationally Most wall hung boiler producers.

EN 297Wall Hung Non Condensing(low NOx)

Heating only Type B Partial premix (water cooled) Continuous Standard } Mainly Germany VAILLANT


Heating only Type B Atmospheric premix (rod cooled) Continuous Standard } Mainly Germany. Few in wall hung. Just test floor standing? BUDERUS (?)


Heating only Type B Atmospheric premix (mesh type) Continuous Standard } Mainly Germany. Includes Matrix burner. Few Type B VIESSMANN


Heating only Type C (Fanned) Partial premix (water cooled) Continuous Standard }Mainly Germany but also now main type of low NOxinternationally

Most wall hung boiler producers.


Heating only Type C (Fanned) Atmospheric premix (rod cooled) Continuous Standard } Mainly Germany. Few in wall hung. Just test floor standing? BUDERUS (?)


Heating only Type C (Fanned) Atmospheric premix (mesh type) Continuous Standard }

4 605

Mainly Germany. Includes Matrix burner. VIESSMANN

EN 483 & 625Wall Hung Non Condensing(low NOx)

Combi Type B Partial premix (water cooled) Continuous Standard }Mainly Germany but also now main type of low NOxinternationally

VAILLANT


Combi Type B Atmospheric premix (rod cooled) Continuous Standard } Mainly Germany. Few in wall hung. Just test floor standing? BUDERUS (?)


Combi Type B Atmospheric premix (mesh type) Continuous Standard } Mainly Germany. Includes Matrix burner. VIESSMANN


Combi Type C (Fanned) Partial premix (water cooled) Continuous Standard }Mainly Germany but also now main type of low NOxinternationally

Most wall hung boiler producers.


Combi Type C (Fanned) Atmospheric premix (rod cooled) Continuous Standard } Mainly Germany. Few in wall hung. BUDERUS (?)


Combi Type C (Fanned) Atmospheric premix (mesh type) Continuous Standard }

1 694

Mainly Germany. Includes Matrix burner. VIESSMANN

EN 297 (A6) & 625 Wall Hung Non Condensing Combi (for balcony) Type B Partial Premix (bladed) Continuous Standard }

EN 297 (A6) 483 &625

Wall Hung Non CondensingCombi (for siting onbalcony)

Type C (Fanned) Partial Premix (bladed) Continuous Standard }2 200

Especially Italy. Many wall hung boilers not specifically forexternal siting are also sited on the balcony. Trend towardsextra slimline versions.

Especially Italian manufacturersbut also those importing into Italy

EN 483 & 625 Wall Hung Non CondensingCombi & HeatingOnly

Type C (Fanned) Full premix Continuous Standard 400Non condensing fanned burners specific to certain Italianproducers.

IMAR, ECOFLAM, BALTUR.

EN 483/297 & 625 Wall Hung Non CondensingCombi & HeatingOnly

Type B & C(Fanned)

Partial Premix (specific FRISQUETtype)

Continuous Standard 500 France only. FRISQUET

EN 677 Wall Hung Condensing Heating only Type C (Fanned) Full Premix Continuous Standard } 4 114International, but especially UK (including open vented andSEDBUK A &B) and Germany.

Especially VAILLANT, BOSCHand UK producers

EN 677 Wall Hung Condensing Heating only Type C (Fanned) Full Premix Continuous With flue sensor } very few Only one VAILLANT model in Germany VAILLANT

EN 677 Wall Hung Condensing Heating only Type C (Fanned) Full Premix ContinuousWithSCOT/SIEMENS

} very fewAll WEISHAUPT wall hung & some VIESSMANN (SCOT),some BRÖTJE (SIEMENS)

WEISHAUPT, VIESSMANN,BROETJE

EN 677 & 625 Wall Hung Condensing Combi Type C (Fanned) Full Premix Continuous Standard } 5 237

Gaining share throughout Europe. May be some specials in UK,including SEDBUK B (which may not all have fully premixburners) and open vented. There are some condensing boilerswith Type B flues.

Most boiler manufacturers

EN 677 & 625 Wall Hung Condensing Combi Type C (Fanned) Full Premix Continuous With flue sensor } very few Only one VAILLANT model in Germany VAILLANT

EN 677 & 625 Wall Hung Condensing Combi Type C (Fanned) Full Premix ContinuousWithSCOT/SIEMENS

} very fewAll WEISHAUPT wall hung & some VIESSMANN (SCOT),some BRÖTJE (SIEMENS)

WEISHAUPT, VIESSMANN,BRÖTJE

EN 677 & 625 Wall Hung CondensingHeating only &combi

Type C (Fanned) Partial premix (SEDBUK B UK) Continuous Standard

c. 1.5millionincludedin totalsabove

At least some SEDBUK B condensing boilers do not have fullpremix burners.

BAXI/POTTERTON, IDEAL,GLOW WORM

Do

mesti

cB

oil

ers

EN 677 Wall Hung CondensingHeating only (incascades)

Type C (Fanned)and Type B

Full Premix Continuous Standard …Growing market for wall hung boilers installed in "cascades"especially for collective heating of apartments.

Many condensing boilermanufacturers





Fig. 10.2-2 SUMMARY OF DOMESTIC GAS APPLIANCES TO BE CONSIDERED FOR TESTING IN WP4: FLOOR STANDING AND CAST IRON WALL HUNG GAS BOILERS

LEVEL 5 Modulation &Combustion Controls

EstimatedPark (1993-

2007)LEVEL 1LEVEL 2 EN

ClassificationLEVEL 3 PRODUCT

TYPELEVEL 4System

LEVEL 2 FlueType

LEVEL 4 Burner Type

ModulationCombustion

Controls('000 pieces)

CommentsLEVEL 6 Manufacturers

(not comprehensive)

EN 297Floor Standing NonCondensing

Heating only Type B Partial Premix (tube) Continuous Standard 450 Most floor standing boilers sold now outside Germany.Most floor standing boilerproducers.


Heating only Type B Partial Premix (tube) Fixed or step Standard 2 428 International. Mainly pre 2000 models.Most floor standing boilerproducers.

EN 297Floor Standing/Wall hung NonCondensing

Heating only (UKcast iron openvented)

Type B Partial Premix ("box") Fixed or step Standard 2 000UK: includes wall hung cast iron, floor standing cast iron,BBU's.


EN 483Floor Standing/Wall hung NonCondensing

Heating only (UKcast iron openvented)

Type C (balanced &fanned)

Partial Premix ("box") Fixed or step Standard 4 690UK: includes wall hung cast iron, floor standing cast iron,BBU's.



Heating only Type C (Fanned) Partial Premix (tube) Continuous Standard 315 International. Type C mainly post 2000 models.Most floor standing boilerproducers.

EN 297Floor Standing NonCondensing (Low NOx)

Heating only Type B Atmospheric premix (rod cooled) Continuous Standard } Mainly Germany, but also internationally on a small scale Especially VAILLANT


Heating only Type B Atmospheric premix (mesh type) Continuous Standard } Mainly Germany. Includes Matrix burner. VIESSMANN


Heating only Type BAtmospheric premix (OVO/OVALButterfly-wing flame)

Continuous Standard }Mainly Germany, but also internationally on a small scale.Special case for sensitivity.

Probably BUDERUS, BRÖJTE,WOLF


Heating only Type C (Fanned) Atmospheric premix (rod cooled) Continuous Standard } Mainly Germany. Especially VAILLANT


Heating only Type C (Fanned) Atmospheric premix (mesh type) Continuous Standard } Mainly Germany. Includes Matrix burner. VIESSMANN


Heating only Type C (Fanned)Atmospheric premix (OVO/OVALButterfly-wing flame)

Continuous Standard }

1 752

Mainly Germany, but also internationally on a small scale.Probably low numbers for Type C. Special case forsensitivity.

Probably BUDERUS, BRÖJTE,WOLF

EN 483 & 625Floor Standing NonCondensing

Combi UK Type C (Fanned) Partial Premix (tube) Continuous Standard 256 Small park in UK. WORCESTER


Italy copper withlarge built-in cylinder

Type C (Fanned) Partial Premix (type?) Continuous Standard 200Mainlly in Italy. Integrated hot water production. Tested underEN 625 (?)

E.g. FERROLI TANTAQUA NF,RIELLO COLONNA 130

EN 677 Floor Standing Condensing Heating only Type C (Fanned) Full Premix Continuous Standard } 297International, but especially (including open vented andSEDBUK A &B) and Germany.

VAILLANT, German Heizkessel,UK producers

EN 677 & 625 Floor Standing Condensing Combi UK Type C (Fanned) Full Premix Continuous Standard } very few Niche UK market. WORCESTER, ISG

EN 303-3Floor Standing Jet BurnerNon Condensing

Heating only (burnersupplied separatey)

Type B Jet burner (forced draught) } Esp. Germany and France.


Heating only (gasunits)

Type B Jet burner (forced draught) } Esp. Germany and France.



Type C Jet burner (forced draught) } Esp. Germany and France.



Type C Jet burner (forced draught) }

869

Esp. Germany and France.

German Heizkessel + FrenchFloor Standing Manufacturers

EN 303-3Floor Standing Jet BurnerCondensing


Type C (?) Jet burner (forced draught) } Esp. Germany

Do

mesti

cB

oil

ers

EN 303-3Floor Standing Jet BurnerCondensing


Type C (?) Jet burner (forced draught) }

very few,but willgrow Esp. Germany

German Heizkessel



Fig. 10.3-1 SUMMARY OF DOMESTIC GAS APPLIANCES TO BE CONSIDERED FOR TESTING IN WP4: DOMESTIC GAS WATER HEATERS AND SPACE HEATERS

LEVEL 5Modulation

Estimated Park

LEVEL 1LEVEL 2 EN

ClassificationLEVEL 3 PRODUCT

TYPELEVEL 4 System

LEVEL 2 FlueType

LEVEL 4 Burner Type

Modulation ('000 pieces)


comprehensive)

EN 26 InstantaneousDedicated WaterHeating

Type APartial Premix(bladed)

WaterActivated

} few (?)


Type BPartial Premix(bladed)

WaterActivated

} 18 600


Type BPartial Premix(bladed)

Modulating(electronic)

}negligible

(?)


Type C(Fanned)

Partial Premix(bladed)

WaterActivated

} few (?)


Type C(Fanned)


Modulating(electronic)

} 2 048


Type C(Fanned)


Forexternalsiting

} few (?)

Now mainly a replacement market. Spain, Portugal, Italy and France together account for 67% of the park. There are some fluelessinstallations, but it has not been possible to quantify these. It is thoughtthat all fully modulating appliances are type C, and most water activatedones are Type B. There are some balcony models in Italy (e.g.SYLBER DERVYL POLAR).

VAILLANT, BOSCH, SAUNIERDUVAL, CHAFFOTEAUX, ELMLEBLANC, FAGOR, COINTRAdominate, + RIELLO/SYLBER inItaly

EN 89Storage NonCondensing

Dedicated WaterHeating

Type BPartial Premix(round)

Fixed }

DomesticGas WaterHeaters

EN 89Storage NonCondensing

Dedicated WaterHeating

Type C(Fanned)

Partial Premix(round)

Fixed }

3 046Germany, Italy and France together account for some 56% of themarket. Other significant countries are Hungary, Poland and CzechRepublic.

A.O. SMITH, VAILLANT, ARISTONTHERMO, WIKORA

BS 79771 +EN 613

Radiant Gas Fires Room HeatingType B or BS79771 opening

Partial Premix Fixed 2 270The original UK gas fire. Open or glass fronted. Now most have someconvection.

VALOR, FOCAL POINT,ROBINSON WILLEY etc.

EN 1266Independent SpaceHeaters with Fan

Room HeatingType C(fanned)

Partial Premix Fixed negligible? None found during study. None identified.

BS 79771 +EN 613

Live Fuel Effect GasFires

Room Heating +decorative

Type C(balanced)

Partial Premix Fixed } 1 655Significant UK market (c. 655,000 park), and also the main type ofdecorative gas fire exported from the Netherlands.

VALOR and other UK. FABER andDRU (NL)

EN 613Live Fuel Effect GasFires


Type C (FABERlong balancedflue)

Partial Premix Fixed } fewSpecial flue developed by FABER which has produced varied testresults.

FABER



Type B (Open) Partial Premix Fixed 4 400Main UK category. Most are do not have a directly connected flue (EN613) but are installed into a builders's opening (BS 7977-1 within GAD).

VALOR, FOCAL POINT,ROBINSON WILLEY etc.



Type C(fanned)

Partial Premix Fixed few Minority UK category VALOR etc.

EN 590 Decorative Gas Fires Mainly Decorative Type BPartial Premix (someno premix?)

Fixed 970UK specific. More decorative than heating. Cannot claim effiency levelsfor this product.

VALOR etc. and many generic.

EN 14829 Flueless Gas FiresRoom Heating +decorative

Type A Partial Premix Fixed 120UK specific. Special case for GASQUAL because of fears of sootaccumulation affecting catalytic converter.

FOCAL POINT, DRU GASSAR,BURLEIGH

EN 14438Gas Fired Insets forheating more than 1room

Heating several rooms Type A (?) Partial Premix Fixed negligible? Very small sector. Possibly not much sold outside Netherlands. FABER has in range.

EN 613Room Heaters (floorstanding)

Room Heating Type B Partial Premix Fixed 500 Significant in Germany. ORANIER

EN 613Wall Heaters/Wall HungConvectors

Wall Hung GasConvectors and GasRadiators

Type C(balanced)

Partial Premix Fixed 5 000Significant but declining market for wall heaters in the UK (c. 485,000park), and Germany (est. 350,000). Large and long established marketfor gas radiators in Hungary (c.3.5 million units in 1 million homes)

VALOR (UK), FÉG (H), LAMPART(H), FABER (NL)

EN 778Forced convection airheaters <70 kW

Ducted warm air <70kW whole dwellingheating: open flue

Type B Partial Premix Fixed 150UK specific. Main period of installation in 1960's/70's, but replacementssold post 1993.

Gas Fires,SpaceHeaters andWarm AirHeaters

EN 1319Forced convection airheaters <70 kW withfan assisted burner

Ducted warm air <70kW whole dwellingheating: room sealed

Type C (?) Partial Premix Fixed 80UK specific. Main period of installation in 1960's/70's, but replacementssold post 1993. Mainly fanned flue. Few balanced flue now marginal.

JOHNSON & STARLEY dominates.Some from BRINK (NL),MULTICALOR (B) and USA.



Fig. 10.3-2 SUMMARY OF DOMESTIC GAS APPLIANCES TO BE CONSIDERED FOR TESTING IN WP4: COOKERS AND OTHER APPLIANCES

LEVEL 5Modulation

Estimated Park

LEVEL 1LEVEL 2 EN

ClassificationLEVEL 3 PRODUCT TYPE LEVEL 4 System

LEVEL 2Flue Type

LEVEL 4 BurnerType

Modulation ('000 pieces)


comprehensive)

EN 30Domestic gas cookers: hobs (built in &free standing) fricative single ring

Cooking (open) No flue Partial Premix Manual 51 525Cheaper less stable burner: small pilot in between flames. c.95% ofmarket

EN 30Domestic gas cookers: hobs (built in &free standing) ring single ring

Cooking (open) No flue Partial Premix Manual 2 700More stable and more expensive: Pilot flame is a continuous circle belowthe actual flames. C. 5% of market

EN 30Domestic gas cookers: hobs (built in &free standing) fricative and ring:multiple ring

Cooking (open) No flue Partial Premix Manual 2 250Double & triple ring. Could be especially sensitive to gas quality. C. 10%of current sales and 6% of market.

All main cooker manufacturers.SABAF, SOMIPRESS, DEFENDIare main burner manufacturers.

EN 30Separate (High Level) Grill (freestanding)

Grilling No flue Partial Premix Manual }Grill is separate and open. Plenty of access to secondary air. Probablymost common in UK.

EN 30 Oven (free standing: no grill) Oven No flue Partial PremixOvenmodulates1:3

}

EN 30Oven (free standing:with grill for usewith open door)

Oven + grilling No flue Partial PremixOvenmodulates1:3

}

EN 30Oven (free standing:with grill for usewith closed door)


}

34 000

Small new sector, but probably highly sensitive.

EN 30 Oven (bult-in:no grill) Oven No flue Partial PremixOvenmodulates1:3

}

EN 30Oven (built-in:with grill for use withopen door)


}

The great majority of built-in hobs in Europe are used in conjuction withelectric ovens. BRGC estimates that roughly 10% of built-in ovens aregas. These are likely to be more sensitive to gas quality than oven onfree standing cookers.

DomesticGas Cookers

EN 30Oven (built-in:with grill for use withclosed door)


}

3 500

Small new sector, but probably highly sensitive.

All main cooker manufacturers.CASTFUTURA and FLAMMGASare main burner manufacturers.

EN 12752 Type B Tumble Dryers <20 kW Laundry Drying Not known Not known Not known few

EN 1458 Type B22 & B23 Tumble Dryers <6 kW Laundry Drying Not known Not known Not known few

DomesticGas TumbleDryers &WashingMachines

EN 12244-1 Domestic Gas Washing Machines Laundry Not known Not known Not known few

Appears now to be a residual park. Very few such appliances are nowsold because of the difficulties of installing such products.

MIELE and other domesticappliance manufacturers.

None Specific Micro-CHP: Stirling EngineSpace Heating &ElectricityGeneration

Not known Not known Not knownNot yet

on marketIt is taking a long time to bring to market, but launches planned for 2009

BAXI, DISENCO, BOSCH,VAILLANT, REMEHA,VIESSMANN, ARISTON

None Specific Micro-CHP: Rankine CycleSpace Heating &ElectricityGeneration


on marketLaunch planned for 2009 ENERGETIX GENLEC

None Specific Micro-CHP: Internal CombustionSpace Heating &ElectricityGeneration

Not known Not known Not known 13 Already on market, but more light commercial than domestic BAXI/SENERTEC, VAILLANT

None Specific Fuel CellsSpace Heating &ElectricityGeneration


on marketIn development

CERES POWER, CERAMIC FUELCELLS

Micro-CHPand HeatPumps

EN 12309 Gas Heat PumpsSpace Heating &Cooling

Not known Not known Not known 4 Already on market, but more light commercial than domestic ROBUR

APPENDIX A


APPENDIX A

SUPPLEMENTARY ANALYSES BY COUNTRY OF THE PARK OF BOILERS <70 KWINSTALLED 1993-2007

APPENDIX A


Fig. A.1: 1993-2007 PARK OF DOMESTIC GAS BOILERS DIVIDED BY FLUE IN 16 SELECTED EU COUNTRIES /1

Country Flue LEVEL 2- EN Standard Product 1993-1997 1998-2002 2003-2007 TOTAL PARK 93-07

Gas floor standing non condensing 35 24 11 70EN 297- Boiler type B

Gas wall hung non condensing 46 71 57 173Open

EN 303-3 Boilers equipped with forced draught burner Jet burner gas 1 0 0 1Gas floor standing non condensing 0 0 0 0

Room sealed (balanced) EN 483- Boiler type CGas wall hung non condensing 0 0 0 0

EN 303-3 Boilers equipped with forced draught burner Jet burner gas 0 0 0 0

Gas floor standing non condensing 0 0 0 0EN 483- Boiler type C

Gas wall hung non condensing 23 50 59 131Gas floor standing condensing 4 7 8 20

Austria

Room sealed (fanned)

EN 677- Boiler condensing equipped with premixed burnerGas wall hung condensing 48 85 104 237






EN 483- Boiler type CGas wall hung non condensing 65 142 244 451

Gas floor standing condensing 0 3 4 7

Belgium


EN 677- Boiler condensing equipped with premixed burnerGas wall hung condensing 2 34 239 275Gas floor standing non condensing 266 140 44 451

EN 297- Boiler type BGas wall hung non condensing 103 199 184 486Open




EN 483- Boiler type CGas wall hung non condensing 82 167 147 396Gas floor standing condensing 0 2 9 11

Czech Republic








Denmark



APPENDIX A





Gas wall hung non condensing 1 141 1 151 928 3 221Open





Gas wall hung non condensing 584 1 015 1 136 2 735Gas floor standing condensing 0 1 35 35

France


EN 677- Boiler condensing equipped with premixedburner Gas wall hung condensing 12 26 366 404

Gas floor standing non condensing 768 411 112 1 291EN 297- Boiler type B

Gas wall hung non condensing 946 548 354 1 849Open

EN 303-3 Boilers equipped with forced draught burner Jet burner gas 134 97 44 275EN 303-3 Boilers equipped with forced draught burner Jet burner gas 0 0 16 16



Germany


EN 677- Boiler condensing equipped with premixedburner Gas wall hung condensing 280 744 1 073 2 097







Greece






Gas floor standing non condensing 0 0 0 0Room sealed (balanced) EN 483- Boiler type C

Gas wall hung non condensing 0 0 0 0EN 303-3 Boilers equipped with forced draught burner Jet burner gas 0 0 0 0



Hungary









Ireland



APPENDIX A





Gas wall hung non condensing 172 1 538 1 138 2 848Open





Gas wall hung non condensing 281 3 233 4 056 7 570Gas floor standing condensing 0 9 40 49

Italy









Poland










Portugal








EN 483- Boiler type CGas wall hung non condensing 42 361 957 1 361Gas floor standing condensing 0 0 1 1

Romania



APPENDIX A











Slovak Republic



EN 297- Boiler type BGas wall hung non condensing 310 595 467 1 371Open




EN 483- Boiler type CGas wall hung non condensing 174 1 045 1 639 2 858Gas floor standing condensing 0 0 0 0

Spain






Gas wall hung non condensing 513 450 275 1 237EN 303-3 Boilers equipped with forced draught burner Jet burner gas 0 0 0 0


Gas wall hung non condensing 2 866 4 402 2 480 9 747Gas floor standing condensing 0 9 73 82

United Kingdom


EN 677- Boiler condensing equipped with premixed burnerGas wall hung condensing 110 449 4 648 5 206Total 12 627 21 329 25 047 59 003

Source : BRG Consult

APPENDIX A


Fig. A.2: 1993-2007 PARK OF DOMESTIC GAS BOILERS DIVIDED BY FUNCTIONALITY IN 16 SELECTED EUCOUNTRIES

Country Functionality LEVEL 2- EN Standard Product1993-1997

1998-2002

2003-2007

TOTALPARK 93-07

Combi EN 625- Boilers with sanitary water Gas wall hung 35 75 82 191

Gas floor standing 39 31 20 90Gas wall hung 82 130 138 350

AustriaHeating only NON EN 625- Boilers with sanitary water

Jet burner gas 1 0 0 1



BelgiumHeating only NON EN 625- Boilers with sanitary water




CzechRepublic Heating only NON EN 625- Boilers with sanitary water




DenmarkHeating only NON EN 625- Boilers with sanitary water


Combi EN 625- Boilers with sanitary water Gas wall hung 1 626 2 067 2 087 5 780

Gas floor standing 358 405 300 1 063Gas wall hung 111 126 343 579

FranceHeating only NON EN 625- Boilers with sanitary water


Combi EN 625- Boilers with sanitary water Gas wall hung 820 540 423 1 783

Gas floor standing 781 448 195 1 424

Gas wall hung 764 1 085 1 130 2 980Germany

Heating only NON EN 625- Boilers with sanitary waterJet burner gas 134 97 60 291



GreeceHeating only NON EN 625- Boilers with sanitary water



Gas floor standing 182 114 69 366

Gas wall hung 146 80 88 314Hungary




IrelandHeating only NON EN 625- Boilers with sanitary water


Gas floor standing 50 87 109 246Combi EN 625- Boilers with sanitary water

Gas wall hung 438 4 734 5 551 10 723Gas floor standing 405 260 130 796Gas wall hung 23 142 198 363

ItalyHeating only NON EN 625- Boilers with sanitary water




PolandHeating only NON EN 625- Boilers with sanitary water




Gas wall hung 6 1 44 51Portugal


Combi EN 625- Boilers with sanitary water Gas wall hung 41 330 943 1 315


RomaniaHeating only NON EN 625- Boilers with sanitary water




Gas wall hung 12 53 86 152

SlovakRepublic Heating only NON EN 625- Boilers with sanitary water


Combi EN 625- Boilers with sanitary water Gas wall hung 472 1 619 2 098 4 189


SpainHeating only NON EN 625- Boilers with sanitary water


Combi EN 625- Boilers with sanitary water Gas wall hung 1 730 3 374 5 429 10 533

Gas floor standing 886 659 214 1 759Gas wall hung 1 924 2 101 2 136 6 161

UnitedKingdom Heating only NON EN 625- Boilers with sanitary water


Total 12 627 21 328 25 047 59 003

Source : BRG Consult

APPENDIX A


Fig. A.3: 1993-2007 PARK OF DOMESTIC GAS BOILERS DIVIDED BY BURNER IN 16 SELECTED EU COUNTRIES /1

Country Burner LEVEL 2- EN Standard Product 1993-1997 1998-2002 2003-2007 TOTAL PARK 93-07

Gas floor standing non condensing 3 2 1 5Conventional EN 483- Boiler type C / EN 297- Boiler type B

Gas wall hung non condensing 51 89 40 180

Gas floor standing non condensing 0 0 0 0EN 483- Boiler type C / EN 297- Boiler type B


Fan assisted premixEN 677- Boiler condensing equipped with premixed burner

Gas wall hung condensing 48 85 104 237

Gas floor standing non condensing 32 22 10 65Low Nox EN 483- Boiler type C / EN 297- Boiler type B


Austria

Jet Burner EN 303-3 Boilers equipped with forced draught burner Jet burner gas 1 0 0 1


Gas wall hung non condensing 182 248 273 704Gas floor standing non condensing 0 0 0 0

EN 483- Boiler type C / EN 297- Boiler type BGas wall hung non condensing 0 0 0 0

Gas floor standing condensing 0 3 4 7Fan assisted premix




Belgium









Gas wall hung non condensing 0 33 37 69Low NoxEN 677- Boiler condensing equipped with premixed burner Gas wall hung condensing 0 0 0 0

Czech Republic








Low Nox EN 483- Boiler type C / EN 297- Boiler type BGas wall hung non condensing 0 16 17 33

Denmark



Gas wall hung non condensing 1 725 2 158 2 044 5 926Gas floor standing non condensing 54 0 21 75






France




EN 483- Boiler type C / EN 297- Boiler type B Gas floor standing non condensing 0 0 0 0

Gas floor standing condensing 13 29 35 76Fan assisted premixEN 677- Boiler condensing equipped with premixed burner

Gas wall hung condensing 280 744 1 073 2 097

Germany

Low Nox EN 483- Boiler type C / EN 297- Boiler type B Gas floor standing non condensing 705 398 154 1 256

APPENDIX A



Country Burner LEVEL 2- EN. Standard Product 1993-1997 1998-2002 2003-2007 TOTAL PARK 93-07




Gas wall hung non condensing 0 0 0 0Gas floor standing condensing 0 0 0 0Fan assisted premix




Greece



Gas wall hung non condensing 211 352 374 937Gas floor standing non condensing 5 1 0 6


Gas floor standing condensing 0 0 2 2Fan assisted premixEN 677- Boiler condensing equipped with premixedburner Gas wall hung condensing 0 3 22 25



Hungary









Ireland



Gas wall hung non condensing 440 4 443 4 317 9 200



Gas floor standing condensing 0 9 40 49Fan assisted premixEN 677- Boiler condensing equipped with premixedburner Gas wall hung condensing 8 106 555 668


Gas wall hung non condensing 14 304 743 1 060

Italy








Gas wall hung non condensing 0 10 55 65Low Nox

EN 677- Boiler condensing equipped with premixedburner


Poland


APPENDIX A



Country Burner LEVEL 2- EN Standard Product 1993-1997 1998-2002 2003-2007 TOTAL PARK 93-07








Portugal



Gas wall hung non condensing 43 365 967 1 375Gas floor standing non condensing 0 0 0 0






Romania









SlovakRepublic



Gas wall hung non condensing 484 1 562 1 722 3 768Gas floor standing non condensing 0 0 0 0






Spain


Gas floor standing non condensing 886 650 141 1 677Conventional EN 483- Boiler type C / EN 297- Boiler type B

Gas wall hung non condensing 3 499 5 027 2 888 11 414




Gas wall hung condensing 110 449 4 648 5 206



UnitedKingdom


Total 12 627 21 328 25 047 59 003

Source: BRG consult

APPENDIX B


APPENDIX B

SUPPLEMENTARY ANALYSES BY COUNTRY OF THE DOMESTIC WATER

HEATERS INSTALLED 1993-2007

APPENDIX B


Fig B.1: 1993-2007 PARK OF WATER HEATER EN26 INSTANTANEOUS IN 16 SELECTED COUNTRIES

Country 1993-1997 1998-2002 2003-2007 Total Total

Spain 2 200 2 263 2 389 6 853 33.2%

Italy 761 873 1 063 2 697 13.1%

Portugal 801 1 029 821 2 650 12.8%

France 933 722 659 2 313 11.2%

Poland 594 596 650 1 840 8.9%

Belgium 359 391 475 1 225 5.9%

Germany 673 296 188 1 158 5.6%

United Kingdom 359 269 205 834 4.0%

Hungary 143 149 151 443 2.1%

Romania 34 53 125 211 1.0%

Czech Republic 73 59 57 190 0.9%

Austria 67 48 35 150 0.7%

Slovak Republic 20 24 14 58 0.3%

Greece 3 4 5 12 0.1%

Ireland 2 2 2 7 0.0%

Denmark 1 2 2 6 0.0%

Total 7 024 6 782 6 842 20 648 100.0%

Fig B.2 : 1993-2007 PARK OF WATER HEATER EN89 STORAGE IN 16 SELECTED COUNTRIES

Country 1993-1997 1998-2002 2003-2007 Total Total

Germany 25 410 263 698 28.6%

France 44 173 164 381 15.6%

Italy 11 177 153 341 14.0%

Hungary 11 63 151 226 9.2%

Poland 44 61 100 206 8.4%

United Kingdom 80 37 38 155 6.4%

Czech Republic 4 47 103 154 6.3%

Belgium 82 19 21 122 5.0%

Slovak Republic 0 6 53 60 2.4%

Spain 4 19 20 43 1.8%

Ireland 7 6 8 21 0.9%

Austria 5 8 6 19 0.8%

Portugal 2 3 6 11 0.4%

Denmark 1 1 0 3 0.1%

Romania 0 0 1 1 0.0%

Greece 0 0 0 0 0.0%

Total 321 1 032 1 089 2 441 100.0%

Source: BRG Consult

APPENDIX C


APPENDIX C

MAIN RANGES OF COMMERCIAL BOILERS AVAILABLE IN SELECTED MEMBER

STATES 1997

APPENDIX C

GASQUAL PROJECT, WORK PACKAGE 1, FINAL REPORT │BRG Consult for European Commission 193

Fig C.1-1 BELGIUM: RANGE OF POWER FOR GAS ATMOSPHERIC AND CONDENSING BOILERS 1996/7…/1

APPENDIX C


Fig C.1-1 BELGIUM: RANGE OF POWER FOR GAS ATMOSPHERIC AND CONDENSING BOILERS 1996/7…/2

APPENDIX C


Fig C1-2 BELGIUM: RANGE OF POWER FOR JET BURNER BOILERS 1996/7…/1

APPENDIX C


Fig C1-2 BELGIUM: RANGE OF POWER FOR JET BURNER BOILERS 1996/7…/2

APPENDIX C


Fig.C.2-1 FRANCE: SELECTED RANGES OF ATMOSPHERIC GAS BOILERS WHICH GO >40kw 1996/7

APPENDIX C


Fig. C.2-2 FRANCE: SELECTED RANGES OF JET BURNER BOILERS WHICH GO >40 Kw 1996/7

APPENDIX C


Fig. C.3-1 GERMANY: RANGE OF POWER OF ATMOSPHERIC GAS BOILERS >50KW 1996/7 BY MANUFACTURER

APPENDIX C


Fig. C.3-2 GERMANY: RANGE OF POWER OF OIL/GAS JET BURNER FLOOR STANDING BOILERS >50KW 1996/7 BY MANUFACTURER

APPENDIX C


Fig. C.3-3 GERMANY: RANGE OF POWER OF GAS UNIT FLOOR STANDING BOILERS >50KW BY MANUFACTURER 1996/7

APPENDIX C


Fig C.4-1 ITALY: SELECTED RANGES OF FLOOR STANDING ATMOSPHERIC GAS BOILERS WHICH GO >35 kW 1996/7

APPENDIX C


Fig C.4-2 ITALY: SELECTED RANGES OF CAST IRON JET BURNER BOILERS WHICH GO >35kW 1996/7

APPENDIX C


Fig C.4-3 ITALY: SELECTED RANGES OF STEEL OIL/GAS BOILERS WHICH GO >35kW 1996/7

APPENDIX C


Fig C.4-4 ITALY: SELECTED RANGES OF GAS JET BURNER UNITS/GRUPPI TERMICI WHICH GO >35 kW 1996/7

APPENDIX C


Fig. C.5-1 NETHERLANDS: RANGE OF POWER OF COLLECTIVE/ COMMERCIAL ATMOSPHERIC GAS BOILERS, INCLUDING BOILERS TO BE USED INCASCADE SYSTEMS 1996/7

APPENDIX C


Fig. C.5-2 NETHERLANDS: RANGE OF POWER OF JET BURNER BOILERS 1996/7

APPENDIX C


Fig C.6-1 SPAIN: EXAMPLES OF RANGES OF ATMOSPHERIC GAS BOILERS AVAILABLE ON THE SPANISH MARKET 1996/97

APPENDIX C


Fig C.6-2 SPAIN: EXAMPLES OF RANGES OF JET BURNER BOILERS >40 kW AVAILABLE ON THE SPANISH MARKET 1996/97

APPENDIX C


Fig. C.7-1 UK: SELECTED RANGES OF "COMMERCIAL" ATMOSPHERIC GAS BOILERS 1996/1997

APPENDIX C


Fig C.7-2 UK: SELECTED RANGES OF "COMMERCIAL" JET BURNER BOILERS 1996/1997…/1

APPENDIX C


Fig C.7-2 UK: SELECTED RANGES OF "COMMERCIAL" JET BURNER BOILERS 1996/1997…/2

APPENDIX D


APPENDIX D

APPLIANCE POPULATIONS, SEGMENTED AND COUNTRY BY COUNTRY

APPENDIX D


COMMENTARY

The following tables have been produced taking data from the main report, in orderto use the agreed segmentation for the different generic appliance types and toidentify individual country by country appliance populations. Tables have beendeveloped for boilers, water heaters, cookers and space heaters. Populations forother generic appliance types are very small and did not warrant further detailedanalysis.

The same table formats are being used for the WP3 (installation & service practice)and WP4 (appliance selection) reports.

This will enable the production of a spreadsheet for each generic appliance type(Level 1) in which a risk value will be calculated for the segmented appliance types(Levels 2 and 3).

This will be the methodology used to select the appliance types for the GASQUALtesting programme based on the following risk assessment methodology:

Risk Value = Probability of Failure x Consequence

Risk = [Sum by Country (Population x Likelihood of Adjustment)] x ConsequenceWeightings

Country Population - taken from WP1 tables on populations

Country Likelihood of Adjustment - taken from WP3 tables on adjustment of air/gasratio and/or burner pressure

Consequence Weightings – taken from an assessment of the controls (Level 5) oneach appliance type and response to gas quality variation regarding BurnerInstability, High Emissions, Overheating and Loss of Safety Devices.

The ranking of the risk values will indicate the appliance types most at risk andcandidates for the GASQUAL test programme.

APPENDIX D


WP1 MARKET SEGMENTATION AND APPLIANCE POPULATIONS BY COUNTRY

EN 297 - Central heating boilers - type B11 and B11BS boilers fitted with atmospheric burners of nominal heat input not exceeing 70 kW

L1 Boilers EN 483 - Central heating boilers - type C boilers of nominal heat input not exceeding 70 kW

EN677 - Central heating boilers - specific requirements for condensing boilers with a nominal heat input not exceeding 70 kW and EN 15417 for 70-1000 kW

EN 303-3/303-7 - Central heating boilers - assembly comprising a boiler body and a forced draught burner

L5 Controls Key - O=On/Off P= Pressure Regulator Q= Modulation R = Air/Gas Ratio N/D = No Data Available All Population Data x 1000

L2 EN Std/Flue L3 Burner Type L4 Floor/Wall

L5

Controls TOTAL 93-07 AUS BEL CZ R DEN FRA GER GRE HUN IRE ITA POL POR ROM SLO SPA UK

EN 297 No PreMix Floor O, P 0

Open Flued Wall O, P 0

Partial PreMix/Conv Floor O, P, Q 2292 3 268 323 0 385 72 1 326 1 291 143 7 3 260 25 184

Wall O, P, Q 12107 117 436 566 0 3438 52 16 764 21 2944 866 124 83 181 1243 1256

Partial PreMix Fanned Floor O, P N/D

Wall O, P N/D

Low NOx Partial PreMix Floor O, P, Q 1273 64 7 4 0 167 980 0 11 0 3 35 0 0 2 0 0

Wall O, P, Q 2804 56 80 48 0 17 2028 0 28 0 339 59 0 2 6 141 0

Atmos. Full PreMix Floor O, P N/D

Wall O, P N/D

Full premix Floor P, Q, R 79 0 0 1 0 44 0 0 5 0 24 0 0 0 5 0 0

Wall P, Q, R 82 2 0 6 0 0 0 0 0 1 50 3 0 0 1 11 8

Jet burner Floor 0

Wall 0


Room-sealed Wall O, P 0

Partial PreMix/Conv Floor O, P, Q, R 2990 2 164 145 4 279 20 0 52 21 618 16 4 52 70 50 1493

Wall O, P, Q, R 23907 63 268 255 67 2489 15 77 140 497 6157 96 58 1292 48 2526 9859


Wall O, P N/D

Low NOx Partial PreMix Floor O, P, Q 455 35 4 2 4 121 276 0 2 0 6 4 0 1 0 0 0

Wall O, P, Q 1666 31 50 21 33 13 472 0 5 0 721 6 0 26 2 286 0


Wall O, P N/D


Wall P, Q, R 246 1 0 2 25 0 0 0 0 21 107 0 0 0 1 23 66

Jet burner Floor 0 0 0 0

Wall 0 0 0 0

APPENDIX D



Condensing Wall O, P 0

Boilers Partial PreMix/Conv Floor O, P, Q, R 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Wall O, P, Q, R 500 0 0 0 0 0 100 0 0 0 100 0 0 0 0 0 300


Wall O, P N/D

Low NOx Partial PreMix Floor O, P 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Wall O, P 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0


Wall O, P N/D


Wall P, Q, R 9354 238 275 66 144 404 2097 3 25 32 668 103 1 31 46 15 5206

Jet burner Floor 0

Wall 0

EN 303-3 Jet burner Floor P, Q, R 868 1 24 9 1 277 291 18 0 0 140 63 3 28 0 12 1

Forced Draught Wall P, Q, R 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

TOTALS 59003 633 1583 1460 280 7700 6479 115 1361 594 12268 1401 197 1519 626 4332 18455

APPENDIX D



EN 26 - Gas-fired instantaneous water heaters for the production of domestic hot water, fitted with atmospheric burners

L1 Water Heaters EN 483 - Gas-fired storage water heaters for the production of domestic hot water

L5 Controls Key - O=On/Off P= Pressure Regulator Q= Modulation All Population Data x 1000

L2 EN Std/Flue L3 Burner Type L4 Floor/Wall

L5

Controls TOTAL 93-07 AUS BEL CZ R DEN FRA GER GRE HUN IRE ITA POL POR ROM SLO SPA UK

EN 26 Instantaneous Partial PreMix/Conv Wall P, Q 18600 135 1102 171 5 2082 1042 11 399 6 2427 1656 2385 190 52 6168 751

Open Flued

EN26 Instantaneous Partial PreMix/Conv Wall P, Q 2048 15 123 19 1 231 116 1 44 1 270 184 265 21 6 685 83

Room-sealed

EN89 Storage Partial PreMix/Conv Floor O, P 2319 18 116 146 3 362 663 0 215 324 20 196 10 1 57 41 147

Open Flued

EN89 Storage Partial PreMix/Conv Floor O, P 122 1 6 8 0 19 35 0 11 17 1 10 1 0 3 2 8

Room Sealed

TOTALS

23089

APPENDIX D



EN30 - 1.1 General Safety

L1 Cookers EN30 - 1.2 Forced Convection Ovens/grills

EN30 - 1.4 Automatic controls

EN30 – 2.1 Efficiency

EN30 – 2.2 Rational use of energy for Fanned Ovens All Population Data x 1000

L4 Construction Sensitive constructions are: Burner positioned below hob level (Deep Inset) or Burner close to Pan Support (Small B-P Dist) N/D = No Data Available

L2 Type L3 Burner Type L4 Construction

L5

Controls TOTAL 93-07AUS BEL CZ R DEN FRA GER GRE HUN IRE ITA POL POR ROM SLO SPA UK

Built-in

Hob

Atmospheric

Partially Aerated

– Single Ring Deep Inset FSD

No FSD

Small B-P Dist FSD

No FSD

Atmospheric

Partially Aerated

– Multi-Ring Deep Inset FSD

No FSD

Small B-P Dist FSD

No FSD

Built-in

Oven

Partially Aerated

Oven Burner Convection Fan

No Convection Fan

Free-Standing

Cooker

Partially Aerated


No Convection Fan

Partially Aerated

Surface Combustion Built-in Grill Door Open

Door Closed

Partially Aerated

Ribbon Burner Built-in Grill Door Open

Door Closed

Partially Aerated

Surface Combustion Eye Level Grill

Partially Aerated

Ribbon Burner Eye Level Grill

69,098 539 600 2451 96 12866 2168 30 2600 N/D 24445 7191 N/D N/D 1290 3980 10842

34000 N/D N/D N/D N/D 1511 7062N/D N/D N/D N/D 10743 N/D4320 1573

N/D

N/D

N/D N/D N/D

N/D

N/D

N/D492 N/D N/D

N/D N/DN/D N/D N/D N/DN/D 1366

N/D N/D N/D N/D

N/D N/D N/D N/D

136

760

2134

87

248

2884514

21

60

11844N/D N/D N/D

N/D N/D N/D307

852

30339

1259

3500

N/D N/D N/D 7387N/D

APPENDIX D



EN30 - 1.1 General Safety

L1 Cookers EN30 - 1.2 Forced Convection Ovens/grills

EN30 - 1.4 Automatic controls

EN30 – 2.1 Efficiency

EN30 – 2.2 Rational use of energy for Fanned Ovens All Population Data x 1000

L4 Construction Sensitive constructions are: Burner positioned below hob level (Deep Inset) or Burner close to Pan Support (Small B-P Dist) N/D = No Data Available

L2 Type L3 Burner Type L4 ConstructionL5

ControlsTOTAL 93-07 AUS BEL CZ R DEN FRA GER GRE HUN IRE ITA POL POR ROM SLO SPA UK

Built-in

Hob

Atmospheric

Partially Aerated

– Single Ring Deep Inset FSD

No FSD

Small B-P Dist FSD

No FSD

Atmospheric

Partially Aerated

– Multi-Ring Deep Inset FSD

No FSD

Small B-P Dist FSD

No FSD

Built-in

Oven

Partially Aerated


No Convection Fan

Free-Standing

Cooker

Partially Aerated


No Convection Fan

Partially Aerated

Surface Combustion Built-in Grill Door Open

Door Closed

Partially Aerated

Ribbon Burner Built-in Grill Door Open

Door Closed

Partially Aerated

Surface Combustion Eye Level Grill

Partially Aerated

Ribbon Burner Eye Level Grill

69,098 539 600 2451 96 12866 2168 30 2600 N/D 24445 7191 N/D N/D 1290 3980 10842

34000 N/D N/D N/D N/D 1511 7062N/D N/D N/D N/D 10743 N/D4320 1573

N/D

N/D

N/D N/D N/D

N/D

N/D

N/D492 N/D N/D

N/D N/DN/D N/D N/D N/DN/D 1366

N/D N/D N/D N/D

N/D N/D N/D N/D

136

760

2134

87

248

2884514

21

60

11844N/D N/D N/D

N/D N/D N/D307

852

30339

1259

3500

N/D N/D N/D 7387N/D

Documents

· "Gas quality" CEN/AFNOR/WG 197 Date: 2010-12-29 Doc. Number: N 230 Assistant: Marie BOURBIGOT Direct line: + 33 (0)1 41 62 87 20 [email protected] Your contact: Sylvie