United States Steam Boiler System Market Overview, 2030

The U.S. steam boiler systems market has a long and storied history, deeply interwoven with the nation's industrialization and technological advancements from the 19th century onwards. Steam boiler systems, at their core, are enclosed pressure vessels designed to heat water to generate steam, primarily for industrial processes, electric power generation, and commercial/institutional heating. The expansion of existing industrial facilities and the construction of new ones in key manufacturing hubs contribute to market demand. Stringent environmental regulations, especially those targeting coal-fired boilers, often necessitate costly conversions, retrofits, or outright decommissioning, impacting traditional segments. The broader shift towards renewable energy sources for electricity generation, while primarily impacting utility-scale power boilers, can also influence industrial choices. Issues faced by market participants include navigating complex and sometimes evolving state and federal regulations, managing the increasing cost of raw materials, addressing a shortage of skilled labor for installation and maintenance, and maintaining competitiveness against both domestic and international suppliers. Low Pressure boilers, typically operating below 15 psi and the value in bar is 1.03 bar for steam or 160 psi and the value in bar is 11.03 bar for hot water, are commonly used in the U.S. for commercial and institutional heating applications, such as schools, hospitals, hotels, and smaller industrial processes. Medium Pressure boilers, operating between 15 psi and 150 psi and the value in bar is 1.03-10.34 bar, find extensive use in a broader range of industrial processes requiring moderate steam volumes, including food processing, laundries, and light manufacturing. High Pressure boilers, functioning above 150 psi, are critical for heavy industries, including large power generation plants, oil refineries, petrochemical complexes, and large pulp & paper mills, where vast quantities of high-temperature, high-pressure steam are essential for turbines and complex chemical reactions.

According to the research report “US Steam Boilers System Market Overview, 2030,"" published by Bonafide Research, the US Steam Boilers System market is anticipated to grow at more than 4.54% CAGR from 2025 to 2030. The competitive structure of the U.S. market is robust and fragmented, featuring a mix of large global manufacturers with significant domestic operations, specialized American boiler companies, and numerous smaller fabricators and service providers. Key players include Cleaver-Brooks, a long-standing American manufacturer known for its comprehensive range of packaged boilers for various industries. Other prominent players include Babcock & Wilcox, particularly strong in utility and large industrial boilers, Foster Wheeler, and international giants like Siemens Energy and Mitsubishi Power, as well as Bosch Commercial and Industrial and Viessmann in the commercial and smaller industrial segments. Competitive strategies adopted by market leaders often involve significant investment in R&D to develop highly efficient, low-NOx, and fuel-flexible boiler systems that comply with the latest EPA and state-specific regulations. They also focus on providing extensive service networks, offering comprehensive lifecycle support from installation and commissioning to ongoing maintenance and optimization, and leveraging digitalization for remote monitoring and predictive maintenance. Actionable recommendations for market participants, investors, and stakeholders in the U.S. include prioritizing R&D in decarbonization technologies such as hydrogen-ready boilers and advanced carbon capture integration. Investing in digital services for remote monitoring, data analytics, and predictive maintenance will be crucial.

Natural gas is by far the most used fuel for industrial and commercial steam boilers across the U.S. Its widespread availability through an extensive pipeline network, relatively low cost due to hydraulic fracturing, and cleaner combustion properties compared to coal and fuel oil have made it the primary choice for new installations and the conversion of existing boilers. Natural gas-fired boilers offer high efficiency and significantly lower emissions of particulate matter, sulfur dioxide, and nitrogen oxides, aligning with tightening environmental regulations. Coal-fired boilers, historically a cornerstone of U.S. power generation and heavy industry, have seen a drastic decline in usage, particularly in the utility sector. While some industrial and institutional facilities may still operate older coal-fired units, new installations are extremely rare, and many existing ones are being retired or converted due to stringent EPA emissions regulations and economic disadvantages. Oil-fired boilers, primarily using distillate fuel oil or residual fuel oil, are utilized in the U.S., often as a secondary or backup fuel for dual-fuel boilers, or in regions where natural gas access is limited. Their usage has decreased due to higher operating costs, price volatility, and a heavier carbon footprint. Biomass-fired boilers represent a growing niche, particularly in industries with access to organic waste streams. Driven by renewable energy incentives and sustainability goals, biomass offers a carbon-neutral solution when sourced sustainably. Electric boilers are a smaller but emerging segment, mainly for specialized applications where very clean steam is required, or where renewable electricity is abundant and the cost of electricity for large-scale steam generation is viable.

Water-Tube Boilers are widely used and represent the dominant type for large-scale industrial applications and utility power generation in the U.S. Their design, where water circulates inside tubes heated externally by combustion gases, allows for the generation of high-pressure and superheated steam in massive quantities. This makes them indispensable for core U.S. industries such as power plants, large chemical complexes, oil refineries, and large pulp and paper mills, all of which require continuous, high-quality steam for their processes. Water-tube boilers are chosen for their superior efficiency, faster response to load changes, and ability to handle the demanding conditions of high-pressure and high-temperature steam production. Fire-Tube Boilers, also known as shell boilers, are extensively utilized across the U.S. for small to medium-sized industrial processes and various commercial and institutional applications. Their simpler design, ease of operation, and relatively lower initial cost make them a popular choice for industries such as food and beverage processing, laundries, hospitals, schools, and general manufacturing facilities where moderate steam volumes and lower pressures are sufficient. They are valued for their robustness, reliability, and ease of maintenance. Electric Boilers have a growing, albeit still smaller, presence in the U.S. steam boiler market. They are primarily used for smaller-scale applications where direct emissions are undesirable, such as in laboratories, pharmaceutical facilities, or where excess renewable electricity is available, offering a clean, compact, and precise steam generation solution. While fire-tube boilers cater to a broad range of general industrial and commercial uses, water-tube boilers are the backbone of the U.S.'s heavy industries and utility-scale power generation, with electric boilers serving a specific niche driven by sustainability and operational flexibility.

Boilers in the 10–150 BHP range are highly common across the U.S., serving a vast array of small and medium-sized enterprises and various commercial establishments. These units are frequently found in bakeries, small food processing units, laundries, hotels, hospitals, and light manufacturing facilities, where the demand for steam is consistent but not excessively high. Their compact footprint, relatively lower initial investment, and ease of operation make them an ideal choice for these sectors, with a focus on energy efficiency for operational savings. Boilers within the 151–300 BHP range cater to medium-scale industrial applications. These are typically deployed in more substantial manufacturing plants, larger food and beverage production facilities, and some chemical processes that demand a more significant and consistent steam supply. This range offers a balance between considerable steam output and operational efficiency, making them versatile for a broader spectrum of U.S. industrial requirements, where industries prioritize robust performance and adaptability to ensure uninterrupted production cycles. The 301–600 BHP segments of boilers is crucial for heavier industrial operations in the U.S. These high-capacity units are essential for sectors such as large-scale food manufacturing, parts of the automotive industry, and various process industries where continuous, high-volume steam is integral to their core operations. The demand in this segment focuses on high efficiency, durability, and the ability to operate under stringent environmental compliance. The boilers with Above 600 BHP represent the largest scale of steam generation in the U.S. market. These colossal units are predominantly utilized in major industrial complexes, including large power generation plants, vast oil refineries, large petrochemical facilities, and major pulp and paper mills.

Considered in this report
• Historic Year: 2019
• Base year: 2024
• Estimated year: 2025
• Forecast year: 2030

Aspects covered in this report
• Steam Boiler Systems Market with its value and forecast along with its segments
• Various drivers and challenges
• On-going trends and developments
• Top profiled companies
• Strategic recommendation

By Fuel Type
• Coal-Fired
• Oil-Fired
• Gas-Fired
• Biomass-Fired
• Electric
• Others(Hydrogen-Fired,Hybrid)

By Boiler Type
• Fire-Tube Boilers
• Water-Tube Boilers
• Electric Boilers

By Horsepower
• 10–150 BHP
• 151–300 BHP
• 301–600 BHP
• Above 600 BHP Show more