Introduction. Indian steel industry. In this context, contents of these booklets are useful tools for development of policies and measures.

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3 Introduction Contents of Technologies Customized List & Technologies One by One Sheets were developed at The Public and Private Collaborative Meeting between Indian and Japanese Iron and Steel Industry. Guidebook for diffusion of technologies on Technologies Customized List is an instruction manual for the contents of Technologies Customized List and Technologies One by One Sheet. Public and private experiences of the Japanese steel industry which achieves the highest energy efficiency in the world and the needs of the Indian steel industry are reflected in these booklets. Contents should be revised at the future Public and Private Collaborative Meeting between Indian and Japanese Iron and Steel Industry conforming to the situation at the time. Technologies on Technologies Customized List, Technical Description and Annex 2 (environmental technologies requested by Indian steel industry) should be transferred to the Indian steel industry. In this context, contents of these booklets are useful tools for development of policies and measures. 1) Discussion at the Collaborative collaborative Meeting meeting focuses on technological issues. Useful tools for development of policies and measures Development of Policies and measures for diffusion of the technologies on Technologies Customized List and its Annex 2 (environmental technologies requested by Indian steel industry) at formal occasion 2) Connection between Technologies Customized List and policies and measures shall be discussed at formal occasion by governments in charge. As a result of discussion among MEA, MoEF, METI and JISF on 25 th July 2012, the followings have been confirmed; 1) Discussion at the Collaborative Meeting focuses on technological issues. 2) Connection between Technologies Customized List and policies and measures shall be discussed at formal occasion by governments in charge. Technologies Customized List & Technologies One by One Sheets Ver.1 and Guidebook for diffusion of technologies on Technologies Customized List Ver.1 were authorized by the Collaborative Meeting on 5 th February 2013 in Tokyo, Japan. Taking into account the subsequent India s technical needs and the result of diagnosis in India s steel plant in 2013, Technologies Customized List was revised as Technologies Customized List & Technologies One by One Sheets Ver.2 Version 2 3 rd February,

4 Collaborative Meetings November 2011 in New Delhi, India November 2012 in New Delhi, India February 2013 in Tokyo, Japan 2 2

5 Technologies Customized List & Technologies One by One Sheets Ver.2 1. Technologies Customized List 5 2. Technologies One-by-One Sheet 9 3. Technical Description ANNEX 4. Full List of Technologies 5. Environmental technologies requested by Indian steel industry

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7 1 Technologies Customized List Technologies Customized List & Technologies One by One Sheets Ver.2 5

8 Technology selection criteria 19 technologies, based on the The Technologies Customized List are considered to be significant countermeasures to tackle with energy conservation issues of Indian iron and steel industry. These 19 technologies were chosen by filtering under [Prior Condition] and conditions A, B, and C. These condition s descriptions are below. [Prior Condition] Scope of our activities: Energy saving technologies of steel industry P1 P2 P3 Annex Technologies with no/little experience, under development in Japan or out of scope are considered not to be eligible. Technologies related to quality of products of steel and steel making processes, such as production rate, consumer s request and raw material restriction, are considered not to be eligible in order to keep the healthy competition in the market. Non-commercialized technologies: Only technologies, which engineering suppliers have brought to market as commercial products and suppliers are able to provide, could be included in Technologies Customized List. On the other hand, these technologies have enough possibly to be dealt with on individual basis. Technologies for environmental protection: not eligible as energy saving technologies but important for Indian steel industry. Included in Technologies Customized List Annex. *Technology One by One Sheet of these technologies on the Annex will not be made. - A is the evaluation of the technologies energy saving effect level. - B is the evaluation showing the completeness from the technology s commercial level point of view in Japan. This indicates the rate of diffusion of these technologies. For Japan to give technological cooperation, it is important to have plenty of knowledge and experience in Japanese iron & steel industry. From that point of view, we compiled a ranking of the technologies which can be considered as being able to contribute to energy saving. To be specific, F ranking was given to those technologies which are well known and familiarized, and A ranking was given to those technologies which are widely spread and mostly applied at steel plants. And the selection condition was that the technology should be evaluated as Rank F and A. - C is the evaluation which indicates the possibility of introducing a technology considering the Indian circumstances and environment. The indices are the rate of diffusion of technology, energy saving effect by the technology introduction, infrastructure facility for introducing the technology and the need for maintenance, possibility of financial support to introduce the technology, regulations and incentives etc. All this information was acquired by conducting a questionnaire survey carried out with 5 major steel companies in India in last fiscal year. Please refer to Guidebook for diffusion of technologies on Technologies Customized List ver.1 (P5-6) for more information on development methodology of Technologies Customized List. 6 5

9 No Sintering Sinter Plant Heat Recovery (Steam Recovery from Sinter Cooler Waste Heat) Sinter Plant Heat Recovery (Power Generation from Sinter Cooler Waste Heat) High Efficient (COG) Burner in Ignition Furnace for Sinter Plant Electricity Savings kwh/t of product kwh/t-sinter - Fuel Savings GJ/t of product /t-sinter /t-sinter 23.9 /t-sinter 19.9 /t-sinter 0.50 /t-sinter SOx, NOx, Dust Electricity Saving CO2 Reduction Productivity Quality Water Saving Financial Technical Retrofitting Financial Technical A 34 2 NA NA NA NA 2 NA F 0 NA NA NA NA NA NA NA NA NA NA - F NA NA NA NA Cokemaking 4 Coke Dry Quenching (CDQ) /t-coke /t-coke kwh/t-coke /t-coke - A 35 1 NA NA 1 1 NA Coal Moisture Control (CMC) Ironmaking Top Pressure Recovery Turbine (TRT) Pulverized Coal Injection (PCI) System 50 kwh/t-pig iron 8 Hot Stove Waste Heat Recovery - Steelmaking 9 Converter Gas Recovery Device Converter Gas Sensible Heat Recovery Device Ecological and Economical Arc Furnace 12 Waste Heat Recovery from EAF Title of Technology Recycling and Waste Reduction Rotary Hearth Furnace Dust Recycling System kwh/t-steel 87.7 kwh/t-steel /t-coke /t-pig iron (at 125kg coal inj.) 0.08 /t-pig iron 0.84 /t-steel /t-steel /t-pig iron Common Systems Inverter (VVVF; Variable Voltage Valuable Frequency) Drive for Motors Regenerative Burner Total System for reheating furnace /t-billet General Energy Savings & Environmental Measures Energy Monitoring and Management Systems Cogeneration (include Gas Turbine Combined Cycle (GTCC)) Management of Compressed Air Delivery Pressure Optimization Power Recovery by Installation of Steam Turbine in Steam Pressure Reducing Line Table Recommended Customized List of Energy Saving Technologies which lead to CO2 Emission Reduction in Indian Steel Industry 27.6 /t-coke 45.0 /t-pig iron 147 /t-pig iron 7.8 /t-pig iron 79.8 /t-steel 12.0 /t-steel 135 /t-steel 78.9 /t-steel 22.8 /t-pig iron - F 10 1 NA 1 NA NA 1 1 NA A 28 2 NA NA NA NA 2 NA A 65 NA NA NA NA NA NA NA NA NA NA - A NA NA NA 2 1 NA A - DXN, Dust, Noise A [*6] 63 [*3] No data NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA F 0 NA NA NA NA NA NA NA NA NA NA - F 0 NA NA NA NA NA NA NA NA NA NA Dust 42% A % (HHV) [*5] 285 MWh/y 4,308 MWh/y 0.12 /t-steel - Customization Conditions for Indian Steel Industry B ; Profic CO2 Cobenefits n Rate Diffusio iency Reduction Level of kg- CO2/t of Technolo of product gy in 7 Technol Major ogy in Steel Japan Compani [*1] A ; Effect of Technologies Introduction /t-billet 11.4 /t-steel 56.1 /t-steel F No data No data NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NOx F 0 1 NA NA NA NA 1 NA NA A - F F F No data No data No data No data Needs for Technologies Introduction NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 1 1 NA NA NA NA 1 NA 1 1 NA NA NA NA NA NA NA NA NA NA NA: Not applicable or No answer *1) Defined from JISF information; A: widely spread and mostly applied, F: well known and familiarized *2) Number of company replied to the questionnaire *3) Diffusion rate of OG boiler is Zero. *4) Diffusion rate is estimated as (production capacity by applied technologies)/(total production capacity in 7 major steel works) Values were calculated from the answer for questionnaire and independent survey (King's report) *5) /4,400 kj/m3-n dry (LHV) (By COG heat increased BFG) *6) Gas sensible heat recovery system are commomly installed combined with converter gas recovery in Japan. es,% [*4] C; Conditions in India [*2] Barrier against Technologies Introduction Counter measures expected 1 6 7

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20 9 Item Steelmaking Converter Gas Recovery Device Content 1. Process Flow 2. Technology Definition/Specification 3. Investment Cost & Operating Life 4. Effect of Technology Introduction 5. Direct Effect ( Annual Operating Cost ) 6. Indirect Effect (Cobenefits) 10. Preconditions Reduction of CO2 Emission Fuel Savings Electricity Savings Economic Effect (payback time) Productivity Improvement Maintenance Cost Reduction Effect for converter operations Product Quality Improvement SOx, Dust Decrease Water-saving Converter Gas Recovery Device[NEDO] Molten steel is produced by the converter process. This device recovers and uses the high temperature waste gas generated in large quantity during blowing in the converter (basic oxygen furnace: equipment used to produce crude steel from pig iron, steel scrap, etc.) Accompanying this process, about 100Nm3 of high temperature gas (CO) with a heating value of approximately 2,000 kcal/nm3 is generated. Heat recovery methods are classified as (1) combustion method (boiler method) and (2) non-combustion method (method of recovering gas in an unburned condition: OG method. The advanced type is called the closed OG method). Recently, the closed OG method has become the main stream. The OG facilities are designed to recover about 70% of the latent heat and sensible heat. The converter gas recovered is mixed with other by-product gases (coke oven gas, blast furnace gas), then used by the heating equipment of the ironworks. Steam is mainly used by the degassing equipment of the steel making factory. Today, gas recovery system are installed on every BOF in Japan. Equipment cost: 600-1,100 million Crore (equipment for 110 t/charge converter scale; includes construction cost) converter capacity: 110 t/charge.[nedo] Operating Life : increased life by regular maintenance 79.8kg-CO2/t-CS [NEDO] 0.84GJ/t-CS [NEDO] LDG : 100Nm3/t-CS 2,000kcal/Nm3-OG (latent heat only) - Payback time : 3.6years [NEDO] 4.7years The investment required in 2007 was EUR 30.5 million for an ongoing project consisting of a gasholder of 80,000 m3, blower fans, gas ducts, three way valves in the off-gas systems, security measures, erection and engineering, etc. About 80 % of the BOF gas will be recovered resulting in an annual energy savings of 2600 TJ/yr = approximately EUR 12/GJ investment. Payback is about five years taking into account the savings in the purchase of natural gas, exploitation costs. (EU-BAT) Not announced * The OG-type system is frequently used because of its operational stability. The OG-type cooling system makes it possible not only to recover the sensible heat of exhaust gas as steam, but also to increase the IDF efficiency by lowering the temperature of the exhaust gas by use of a cooling device. * As the steam is produced discontinuously, it cannot always be fully utilized. The use of recovered BOF gas with suppressed combustion is much more flexible. The use of BOF gas in conjunction with blast furnace gas and coke oven gas, allows for the replacement of considerable amounts of primary energy resources, such as natural gas. Increases the IDF efficiency by lowering the temperature of the exhaust gas, achieving high-speed oxygen feeding[soact] Not announced * suppressed combustion reduces the quantity of flue-gas and thus reduces the cost of fans and dust removal.[ *1] Reduced water requirement for off-gas cooling[ *1] 7. Proficiency Level of Technology Widely spread and mostly applied in Japan 8. Japanese Main Supplier * Nippon Steel & Sumikin Engineering Co., Ltd. * JP Steel Plantech Co. 9. Technologies Reference: *1 EU-BAT : * Investment cost, pay-back time and other important values are revised with referring to various values in the table of Technologies Customized List ver.1, and revised ones are indicated in. * Pay-back time is defined as (Investment cost / Economical merit) in this project

21 10 Item Steelmaking Converter Gas Sensible Heat Recovery Device Content 1. Process Flow 2. Technology Definition/Specification 3. Investment Cost & Operating Life 4. Effect of Technology Introduction 5. Direct Effect ( Annual Operating Cost ) 10. Preconditions Reduction of CO2 Emission 12.0kg-CO2/t-CS [NEDO] Fuel Savings 0.126GJ/t-CS [NEDO] LDG : 100Nm3/t-CS 30,000kcal/t-cs Electricity Savings - Economic Effect (payback time) Productivity Improvement Maintenance Cost Reduction Effect for converter operations Product Quality Improvement SOx, Dust Decrease Water-saving Converter Gas Sensible Heat Recovery Device[NEDO] Molten steel is produced by the converter process. This device recovers and uses the high temperature waste gas generated in large quantity during blowing in the converter (basic oxygen furnace: equipment used to produce crude steel from pig iron, steel scrap, etc.) Accompanying this process, about 100Nm3 of high temperature gas (CO) with a heating value of approximately 2,000 kcal/nm3 is generated. This device recovers and makes efficient use of the converter gas sensible heat. While the converter waste gas recovery device recovers the waste gas itself, this device burns the converter waste gas to transform latent heat to sensible heat and recovers the energy as sensible heat. Therefore, it is structured to have a sufficient space between the converter and the hood so that sufficient air can be supplied from the secondary air blower for combustion. Principal equipments are the brackish water drum, the accumulator, and the boiler etc. Equipment cost: 600 million 35 Crore (equipment for 110 t/charge converter scale; includes construction cost) converter capacity: 110 t/charge.[nedo] Operating Life : increased life by regular maintenance Payback time : 44years [NEDO] Energy recovery by means of full combustion systems or suppressed combustion systems is widely applied at oxygen steel plants around the world. There is a tendency towards suppressed combustion systems, mainly.[ *1]) because of logistic advantages compared to full combustion systems.(eu-bat Not announced No need for additional components other than conventional waste heat boiler. Additional safety engineering measures are not needed other than conventional boiler technologies. Not announced Not announced 6. Indirect Effect (Cobenefits) Not announced Reduce temperature of waste water for off-gas cooling 7. Proficiency Level of Technology Gas Sensible Heat Recovery System are commomly installed combined with converter gas recovery in Japan. in Japan 8. Japanese Main Supplier Nippon Steel & Sumikin Engineering Co., Ltd., JP Steel Plantech Co. 9. Technologies Reference: *1 EU-BAT : * Important values were revised with referring to various values in FYI, and revised ones were underlined. Especially as for investment cost and payback time, revised values were indicated in with underline. * Payback time is defined as (Investment cost / Economical merit) in this project. * Refer to

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28 17 Item General Energy Savings & Environmental Measures Cogeneration ( include Gas Turbine Combined Cycle (GTCC)) Content 1. Process Flow 2. Technology Definition/Specification Ironworks by-product gas, single-fuel-firing, high-efficiency, combined generator set This equipment is a high-efficiency(47.5%, HHV Base) combined generator set using the by-product gas produced during iron and steel manufacturing process as the fuel. This equipment is an iron and steel by-product gas fired combined generator set, in which the gas turbine is operated by high-temperature gas (1,300 ) generated by mixing the blast furnace gas with the coke oven gas to be gas with a heat amount of 4,400kJ/m3N and burning it after the pressure is increased to about 1.4MPa. At the same time the steam turbine is operated by the steam generated by directing the high-temperature (appprox. 550 ) gas discharged from the gas turbine to the exhaust heat recovery boiler.[ *1] 3. Investment Cost & Operating Life 4. Effect of Technology Introduction 5. Direct Effect ( Annual Operating Cost ) 6. Indirect Effect (Cobenefits) Reduction of CO2 Emission Economic Effect (payback time) Productivity Improvement Maintenance Cost Reduction Product Quality Improvement SOx, NOx, Dust Decrease Water-saving Reduction of power purchase. Not announced 7. Proficiency Level of Technology well known and familiarized in Japan 8. Japanese Main Supplier * Mitsubishi Heavy Industries Turbine systems : approx. $1000/kW. Total investment costs estimated to be $14.5/t crude steel.[soact] The type and size of CHP system utilized depends on a variety of site-specific factors including the amount and quality of off-gases from the coke oven, blast furnace, and BOF; the steam requirements of the facility, and the economics of generating power on-site versus purchasing power from the grid.(chp;combined heat and power) CHP capital costs can range from $900 to $2,500/kW depending on size and technology. [*2] Operating Life : increased life by regular maintenance 56.1kg-CO2/t-PI [SOACT] Fuel Savings - Increased electricity generation of 1.1 GJ/t crude steel (primary energy) [SOACT] Electricity Savings 47.5 % (HHV)[*1] World-largest gas turbine: Achieved an inlet gas temperature of 1,300 and realized the world-largest output as a blast furnace gas fired gas turbine by employing the most advanced technology to provide the vane with a forced cooling structure and anti-corrosion coating [*1] Not announced Low NOx emissions of 25 ppm[soact] Not announced 9. Technologies Reference: *1 Practical example: Kimitsu Cooperative Thermal Power Company, Inc / 4,400 kj/m3-n dry (LHV) (By COG heat increased BFG) / (Japanese) *2 EPA "AVAILABLE AND EMERGING TECHNOLOGIES FOR REDUCING GHG EMISSIONS FROM THE IRON & STEEL INDUSTRY": IV.A9 p Preconditions * Refer to and

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30 19 Item General Energy Savings & Environmental Measures Power Recovery by Installation of Steam Turbine in Steam Pressure Reducing Line Content 1. Process Flow 2. Technology Definition/Specification 3. Investment Cost & Operating Life 4. Effect of Technology Introduction Reduction of CO2 Emission Electricity Savings Economic Effect (payback time) 5. Direct Effect (Annual Operating Cost) Monetary equivalent of energy savings Maintenance Cost Reduction 6. Indirect Effect (Co-benefits) Product Quality Improvement 7. Diffusion Rate of Technology in Japan 8. Japanese Main Supplier 9. Technologies Reference: 10. Preconditions Fig. 1 Steam pressure reducing system before improvement Outline : In cases where high pressure steam generated by a boiler is used by pressure reduction, this technology reduces refrigerator power consumption by installing a steam turning in place of the steam pressure reducing valve and driving the refrigerator with the power recovered by the steam turbine. Although steam consumption is increased somewhat, a total energy saving is achieved. Principle, operation and features of technology: In this example in Fig.1, the capacity of the boiler which had been installed was approximately steam pressure: 12 kg/cm2 and steam output: 50 t/h. However, this steam was used as process steam after pressure reduction. In one case, the reduced-pressure conditions were 10 kg/cm2 and 28t/h, and in another, 4 kg/cm2 and 22t/h (approximate values). That is, steam at a pressure of 12 kg/cm2 was reduced to 10 kg/cm2 and 4 kg/cm2 by pressure reducing valves. In this example in Fig.2, a steam turbine is used in place of a pressure reducing valve, and the system was modified so that a refrigerator is driven by the rotational force of the turbine using steam as a power source. Pressure reducing valves reduce pressure by causing a pressure loss when the valve port in the valve is restricted, utilizing the difference in enthalpy drop due to adiabatic restriction. The principle of the steam turbine is the same as this, in that power is generated by utilizing the difference in enthalpy drop. The energy saving by adoption of this system is as follows: Reduction of electric power consumption fuel for increase of steam consumption = Energy saving approx. 50 million (Equipment), approx. 20million (Construction) Not announced 544 (approx.) kw 544kW*24h*330d/y=4308 MWh/y Demerit: Increase of steam consumption, approx.0.8 (t-steam/h) 6,197.6(Gcal/y)=(Electricity Savings=114,00.2Gcal/y )-(Increase of Steam consumption=5,202.6gcal/y) Reduction in crude oil equivalent: t-crude oil/y (approx.) Equipment only : 0.7 years (approx.) 5.8years, Including construction cost: 1.0 years (approx.) 8.1years 68 million/y 0.5 Crore/y Not announced Not announced Numerous examples of implementation of similar technologies at main plants in Japan. Kobe Steel, LTD. Fig. 2 System after improvement by introduction of steam turbine FY2000 Study Report Survey of Energy Saving in Japan, New Energy and Industrial Technology Development Organization (NEDO), March 2001 Collected Examples of Energy Saving, p. 1,095, 1984 (in Japanese) * Important values were revised with referring to various values in FYI, and revised ones were underlined. Especially as for investment cost and payback time, revised values were indicated in with underline. * Cost of power: 17.99/kWh Cost of C heavy oil: 1.81/1,000kcal Overall boiler efficiency: 0.8 Electricity conversion factor: 2646kcal/kWh Steam conversion factor: 656.9kcal/kg-steam 28 26

31 For your information Contact points of the suppliers which were interviewed for the public and private meeting, Company Contact Points Technology Chugai Ro Co., Ltd. JP Steel Plantech Co. Mitsubishi Heavy Industries, Ltd. Mitsui Engineering & Shipbuilding Co., Ltd. For your information Yoshihiko ADACHI Address: 618,CWing,215Atrium,Andheri-KurlaRoad Andheri(East),Mumbai , Maharashtra, INDIA Tel: Fax: Mobile: (India) Mobile: (Japan) Masao Miki (General Manager) Norihiko Inoue (General Coordinator) Green Business Dept. Sales & Marketing Division JP Steel Plantech Co Address: 3-1, Kinko-cho, Kanagawa-ku,Yokohama JAPAN Tel: +81-(0) Fax: +81-(0) Power Systems Project Engineering Department Power Systems Project Management Division Engineering Headquarters Address: 3-1, Minatomirai 3-Chome, Nishi-Ku, Yokohama JAPAN Tel: Madhu Ram Madhavan V.K. Managing Director, Representing Operations Manager of MES ME Consultancy Pvt. Ltd.(MEC) Address: D-3, Brownstore Apartments, Mahalingapuram, Chennai , Tamil Nadu, India TEL: : Regenerative Burner Total system for reheating furnace 1: Sinter Plant Heat Recovery (Steam Recovery from Sinter Cooler Waste Heat) 2: Sinter Plant Heat Recovery (Power Generation from Sinter Cooler Waste Heat) 3: High Efficient (COG) Burner in Ignition Furnace for Sinter Plant 4: Coke Dry Quenching (CDQ) 6: Top Pressure Recovery Turbine (TRT) 7: Pulverized Coal Injection (PCI) System 8: Hot Stove Hear Recovery 9: Converter Gas Recovery Device 10: Converter Gas Sensible Heat Recovery Device 11: Ecological and Economical Arc Furnace 12: Waste Heat Recovery from EAF 18: Management of Compressed Air Delivery Pressure Optimization 17: Cogeneration (include Gas Turbine Combined Cycle (GTCC)) 6: Top Pressure Recovery Turbine (TRT) Nippon Steel & Sumikin Engineering Co, Ltd. Nippon Furnace CO., LTD Tsukishima Kikai CO., LTD. Kobe Steel, Ltd. Mitsui Engineering & Shipbuilding Co., Ltd.(MES) 6-4, Tsukiji 5-Chome, Chuo-ku, Tokyo , Japan Tel: M. Dobashi, S. Maruyama, A.Okuda, Shunichi Takeda (Managing Director), Takuya Nazumi (Deputy General Manager) Nippon Steel Engineering India Plant & Machinery Pvt.Ltd. Address: The Millennium 4 th Floor,235/2A AJC Bose Road, Kolkata, Tel: +91-(0) Kazuhiko Masui Group Manager Plant & Process Engineering Sales Group Sales Division Address: 1-53,Shitte 2-Chome,Tsurumi-ku,Yokohama, Japan Tel: Fax: sales@furnace.co.jp Mrs. Meena TSK Mumbai Liaison Office Address: 602B,Excel Ark, Mercy Nagar, Ramdev Park Road, Mira Road (E),Thane , Maharashtra, India Tel: meena@tsktmo.com Tatsuro Shibata Rotating Machinery Marketing Dept. Machinery Business Address: 9-12, 5-chome, Kita-shinagawa, Shinagawa-ku, Tokyo JAPAN TEL: shibata.tatsuro@kobelco.com 4: Coke Dry Quenching (CDQ) 5: Coal Moisture Control (CMC) 6: Top Pressure Recovery Turbine (TRT) 7: Pulverized Coal Injection (PCI) System 8: Hot Stove Waste Heat Recovery 9: Converter Gas Recovery Device 10: Converter Gas Sensible Heat Recovery Device 13: Rotary Hearth Furnace Dust Recycling System 15: Regenerative Burner Total system for reheating furnace 15: Regenerative Burner Total system for reheating furnace 5: Coal Moisture Control (CMC) 19: Power Recovery by Installation of Steam Turbine in Steam Pressure Reducing Line 27 29

32 Used values and applied preconditions 1. Electricity (Power) Conversion Factor 2. Fuel Calorific Value 3. Energy Cost 4. CO2 Emission Factor 5. Current Exchange Rate Items Electricity Oil (Crude Oil) unit GJ/MWh (kcal/kwh) Values used in 2011 Values used for Revision Value Reference Value Reference 9.8 (2,341) worldsteel /IEA 11.4 (2,717) kcal/kg 10,000 NEDO 10,000 PAT_Rules_English.pdf(2012/3),p37 Ministry of Power Notification S.O.394(E), 12th March, 2007 Coal kcal/kg 6,200 NEDO 6917* referred to Answer Sheet from India Electricity unit/kwh SOACT/NEDO 4.48 ** Rs/kWh Annual Report on the working of State Power Utilities & Electricity Departments, Planning Commission, Government of INDIA October, 2011,p150 C Heavy Oil unit/mcal 1.81 SOACT/NEDO 2.04Rs Energy Prices and Taxes / IEA Statistics/2012 Coal unit/mcal 0.61 SOACT/NEDO 1.4Rs* referred to Answer Sheet from India Electricity t CO2/MWh CO2 Baseline Database for the Indian Power worldsteel /IEA/ 0.90 Sector user_guide_ver7, January 2012, 0.76 Plant Suppliers Government of India, p1 Coke Oven Gas t CO2/GJ Coke t CO2/ t coke Coal t CO2/GJ worldsteel /IEA referred to Answer Sheet from India Steam t CO2/ t steam Unspecified Fuel t CO2/GJ Rs/ 0.59 Rs/$ Rs/Won 0.05 at the current exchange rate in 20th Jan.,2013 * : average value ** : average value in all power plants supplying electricity to Steel Works

33 3 Technical Description Technologies Customized List & Technologies One by One Sheets Ver.2

34 Technical Description Taking into account the discussion at "1. The Public and Private Collaborative Meeting between the Indian and Japanese Iron and Steel Industry" in 2012, "2. India-Japan Workshop on Promotion of Energy Efficiency and Conservation/Capacity Building under PAT held in August 2013 and 3. Energy saving diagnosis in SAIL Bhilai steel plant, technical description regarding the following technologies has been added. Name of technology Effective Utilization of Waste Plastics at Coke-Oven/Blast Furnace By-Product Gas Generator Set These technologies are not listed on "Technologies Customized List & Technologies One by One Sheets"

35 Effective Utilization of Waste Plastics at Coke-Oven/Blast Furnace 1. Collection System of Waste Plastics in Community Plastics disposed from in-house are gathered by a collection system in community. Wasted plastics are separated and sorted, then pressed and packed. Baled waste plastics are transported into steel plant. (Fig.1) For technology introduction of waste plastics injection into blast furnace and its stable operation, it is indispensable that the waste plastics collection system functions stably and some amount of waste plastics can be constantly collected. 2. Plastics Recycling by the Coke-Oven (1) Purpose: Fig.1 Collection system of waste plastics from in-house through community to steel plant. [*1] 1) Effective utilization of waste plastics, which are generally disposed by incineration or land-filling, as part of metallurgical coal. 2) Reduction in emission of CO2 by avoiding incineration of the waste plastics and applying into chemical recycling which brings higher recycling ratio than that of material. 3) Contribution to energy and resources saving, and environmental harmony. (2) Feature of Technology: Municipal waste plastic containers and packaging are agglomerated by using pretreatment equipment, whose process flow is shown in Fig.2. In the pretreatment process, waste plastic is first crushed into pieces about 100 mm in size by a primary crusher and then any metals, heavy objects and other foreign matter are removed using a combination of magnetic and pneumatic separators. They are then crushed into pieces of less than 20 mm in size by a secondary crusher in order to make it easier to transport crushed waste plastics to a coke oven. 1 to 2% by mass of down sized and agglomerated waste plastic, together with the coal, is charged into the coke oven for carbonization. In a coke oven, it is converted into tar/light oil (about 40%), coke (about 20%) and coke oven gas (about 40%). Thus, it is confirmed that almost the entire amount of waste plastic could be utilized effectively. [*2] Fig.2 Waste plastics pre-treating and recycling process / Nippon Steel & Sumitomo Metal Co., [*2] 3. Plastics Injection into Blast Furnace (1) Purpose: 1) Effective utilization of waste plastics, which are generally disposed by incineration or land-filling, as part of metallurgical coal. 2) Reduction in emission of CO2 by avoiding incineration of the waste plastics and applying into chemical recycling which brings higher recycling ratio than that of material. 3) Contribution to energy and resources saving, and environmental harmony. (2) Feature of Technology: Figure 3 [*3] shows process flow of waste plastics for utilizing in Blast Furnace. 1) Film waste plastics are formed into solid matter with grain sizes appropriate for blast furnace injection through being cut down by a shredder and granulated by a pellet machine through polyvinyl chloride (PVC) separator. 2) Solid waste plastics, such as bottles and containers, are cut down by a shredder and formed into uniform grain sizes appropriate for injection into blast furnace. 3) Feed plastics formed into specific grain sizes are stored in a storage bin and then transferred to an injection station adjacent to a blast furnace. These plastics are transferred to blast furnace tuyeres by high-pressure air flow and injected into the blast furnace along with hot blast. 4) Injected feed plastics are instantaneously turned into reducing gas (CO, H2) due to high temperature in the furnace exceeding 2,000 C. This gas flows upward in the furnace and reduces iron ores. 5) The reaction that takes place in the tuyere zone is equivalent to the mechanism where reducing gas is formed by the gasification of coke and pulverized coal; thus, injected feed plastics work in place of coke. Fig.3 Process flow from the material preparation till waste plastics injection into Blast Furnace [*3] Technologies Reference: *1: *2 :Nippon Steel Technical Report No.94,July 2006, p.75 *3:

36 General Energy Savings & Environmental Measures By-Product Gas Generator Set Fig.1 Example of By-Product Gas Generator Set of Integrated Ironworks[*1:p.95} The power station boiler of integrated ironworks is operated by using by-product gas such as blast furnace gas as the main fuel, supplying most of the power consumed at the ironworks. Then, facility and operation improvement measures are taken as energy-saving strategy. Fig. 1 shows a case example of By-Product Gas Generator Set of integrated ironworks. (1) Recovery of waste heat from boilers [*1 : p.4] By preheating the water supply with the economizer, the temperature of the water supply at the inlet to the boiler is increased, reducing the amount of heat necessary to generate steam. (2) "High efficiency steam Energy saving by turbine" introducing new [*1 : p.213] facilities or improving the present facilities Figure shows the conventional-type blade and improved-type blade, including the Schlict blade, the Controlled Vortex Nozzle, the Multiple Fin Seal, stator, and elliptical packing. (3) Conversion of existing thermal power plant to exhaust gas returning-type combined cycle plant[*1 : p.217] By installing high efficiency gas turbine generating equipment and using the high temperature exhaust gas from the gas turbine as combustion air for the existing boiler, an aging thermal power plant is improved to a gas turbine combined cycle power plant. Energy saving by improving the operability (1) Enhancement of combustion management [*1 : p.8] Minimizing the amount of air while ensuring that incomplete combustion does not occur is therefore an important requirement for energy conservation. (2) Enhancement of steam leak prevention and heat retention measures (3) Enhancement of condenser heat exchange tube contamination rate control The ratio of fuel savings when the air ratio is reduced for a selection of exhaust gas temperatures. Technologies Reference: *1 : NEDO ; Japanese Technologies for Energy Savings/ GHG Emissions Reduction <2008 Revised Edition> 34 32

37 Annex 1 Full List of Technologies 136 energy saving technologies steel industry Technologies Customized List & Technologies One by One Sheets Ver.2 35

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41 Annex 2 Environmental Technologies Requested by India at the selection process of Technologies Customized List Technologies Customized List & Technologies One by One Sheets Ver.2

42 Environmental technologies requested by Indian Steel Industry Technologies for environmental protection requested by Indian Steel Industry are out of scope of Technologies Customized List on energy efficiency. However, both Indian and Japanese steel industry believe that these technologies should be transferred. Therefore, these technologies are included in Annex considering the growing demand for environmental technologies in India. Transfer of these technologies on this Annex will be discussed in future. *Technology One-by-One Sheet of these technologies is not prepared. Candidate Environmental Technologies No. Name of technologies Remarks Full List No. 1 Waste Water Treatment. 16 *1 2 Reduction of SO2 from Coke Oven gas by Desulphurization 19 3 Dust Emissions Control 4 4 Exhaust Gas Treatment through Denitrification, Desulfurization, and Activated Coke Packed Bed Absorption *2 5 5 Blast Furnace Gas and Cast House Dedusting 37 *1 : Requested by India *2 : Recommended from Japan based on request by India in FY

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