TECHNOLOGIES CUSTOMIZED LIST version 1.0

Transcription

1 TECHNOLOGIES CUSTOMIZED LIST version 1.0 For Transfer to Philippines Iron and Steel Industry With regard to EnergySaving, Environmental Protection, and Recycling DEVELOPED AT ASEANJAPAN STEEL INITIATIVE

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3 Technologies Customized List & Technologies One by One Sheets Ver.1.0 For Philippines Iron and Steel Industry Table of s 1. Technologies Customized List 3 2. Technologies OnebyOne Sheet 9 ANNEX 1. Other Recommended Technologies for the future for Philippines 21

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7 selection criteria 30 technologies, based on the Technologies Customized List are considered to be significant countermeasures to tackle with energy conservation issues of ASEAN iron and steel industry. These 30 technologies were chosen by filtering under [Major premises]. These conditions are described below. Major premises Scope of AJSI activities: Energy saving, Environment protecting and Recycling technologies for steel plants operating with Electric Arc Furnace (EAF) P.1 Technologies under development in Japan are considered NOT to be eligible. P.2 Technologies mainly intended to improve quality of steel products and steel making processes are considered NOT to be eligible in order to keep the healthy competition in the market. P.3 Noncommercialized technologies which engineering suppliers have not brought to market as commercial products yet and suppliers are unable to provide, are NOT to be eligible. 5

8 PreConditions for Calculations of Effects Equipment List of Model Steel Plant Annual Production 500,000 ton/year EAF RHF Equipment Name Value Equipment Name Value Nominal capacity 80 ton Type Walking beam TTT 52 minutes Nominal capacity 100 ton/h Iron source 100 % scrap Heated material 135 SQ billet Scrap preheating none Heating temperature 1100 degc Scrap charging 3 times Fuel Natural gas, LHV 44 MJ/m3N Ladle furnace used Combustion air preheating around 300 degc with low grade recuperator NG burner used only to facilitate melting Computer control to set furnace temperature with heat transfer simulation none O2 and C lances installed only at slagdoor side, watercooled type Hot charge and/or direct rolling Process control by exhaust none Insulation firebrick gas analysis and/or computer Electricity consumption 430 kwh/ton Heat consumption 1,450 MJ/tonsteel Oxygen consumption 30 m3n/ton Natural gas consumption 20 m3n/ton Coke consumption 15 kg/ton Product Mild steel less than 0.2 % C Tapping temperature 1620 degc none Operating Environment Electricity Cost Fuel Cost CO2 Emission Factor Value Reference US$ / kwh (2013) JETRO website: US$ / GJ (2013) JETRO website: kgco2 / MWh CO2 EMISSIONS FROM FUEL COMBUSTION Highlights (2013 Edition) IEA Average rate of

9 A. Energy Saving for Electric Arc Furnace (EAF) 1 A1 2 A3 3 A7 4 A8 5 A12 6 B1 7 D1 High temperature continuous scrap preheating EAF High efficiency oxyfuel burner/lancing for EAF Optimized power control for EAF Operation support system with EAF meltdown judgment Energy saving for dedusting system in EAF meltshop Exhaust gas treatment through gas cooling, carbon injection, and bag filter dedusting for EAF Process control for reheating furnace Technologies Customized List for Energy Saving, Environmental Protection, and Recycling for Steel Industry in Philippines No. ID Title of technology Technical description Combination of the technologies of Air tight structure High temperature scrap preheating (over 700 degc) Continuous preheated scrap charging Automatic process control by using data logging Postcombustion of generated CO gas Dioxin decomposition by secondary combustion Supersonic or coherent burner Accelerate scrap melting during melting stage Facilitate slag foaming during refining stage over the bath Data logging and visualization of melting process Automatic judgement on meltdown and additional scrap charge Automatic phase power independent control for wellbalanced melting Automatic Rapid Melting system Data logging Optimum electric power control Alloy calculation Automatic meltdown Judgment Damper openings and exhaust fan rotation are controlled in consonance Combination of VVVF and proper damper opening B. Environmental Protection for Electric Arc Furnace D. Energy Saving for Reheating Furnace Thermal Electricity CO energy 2 saving reduction saving (kwh/t of product) (GJ/t of product) (kgco 2/t of product) Decomposition and reduction of dioxin, dispersing dust, & noise [*5] 2.9 Improved design configuration of the direct evacuation for treating hot unburned gas from much fuel use Minimize dust and gas dispersion from EAF with enough capacity and suitable control Setting furnace temperature by targeted billet temperature curve Precise air ratio control and O2 analysis in exhaust gas Expected effects of introduction Environmental Better working floor & atmosphere Better workfloor & environment Co Low electrode consumption ( kg/tonproduct at AC) Reduction of nitorgen in steel for quality improvement Productivity increase Manpower saving Productivity increase Manpower saving Operation standardization Assumed Profit/Oper investment ation Cost cost [*1] [*2] US$/t of product, Philippines million US$ in Philippines Assumed Payback time year in Philippines [*3] [*4] Main Japanese supplier JP Steel Plantech Nikko JP Steel Plantech JP Steel Plantech Daido Steel JP Steel Plantech Daido Steel JP Steel Plantech Daido Steel ChugaiRo 8 D2 9 D3 10 D4 Low NOx regenerative burner total system for reheating furnace High temperature recuperator for reheating furnace Air conditioning by absorption type refrigerating by using reheating furnace exhaust gas High efficient and durable burner system Heat transfer area is expanded Special material tube is used instead of stainless Low thermal conductivity High temperature change response (low thermalinertia) [*1] Opearation cost is indicated in minus () [*2] Co are not taken account into profits and operation costs [*3] Assumed investment cost is the revamping cost of existing conventional EAF [*4] Assumed investment cost is the adoption cost to existing EAF [*5] Assumed electricity consumption for building dedusting is 24 kwh/tonproduct, and 25 % power saving is expected 0.19 CO2 & NOx Reduction Reduction of Heat accumulation ChugaiRo Nippon Furnace ChugaiRo ChugaiRo 7

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13 A1 A. Energy Saving for Electric Arc Furnace (EAF) High temperature continuous scrap preheating EAF 2. Preheating scraps with hightemperature exhaust gas is possible because the preheating shaft and melting chamber are directly and rigidly connected, so the scraps are continually present, from the steel to preheating areas. This enables hightemperature preheating of the scraps, resulting in a significant reduction of power consumption. The melting chamber is sealed off from outside air, to prevent the excess air inlet. It prevents over oxidation of scrap under high temperature preheating.as this equipment keeps always flat bath operation, electrode consumption is significantly improved. Furthermore, the electric facilities necessary to meet power quality regulation can be drastically reduced on it may not even unnecessary depending on required regulation. Dioxins are decomposed through an exhaust gas combustion chamber and rapid quench chamber in the exhaust gas duct system. Not only dioxins but also a volatile material that causes foul odors and white smoke will be decomposed and the dispersal of them are also prevented.the furnace prevents diluting of exhaust gasses. Therefore, the CO within the exhaust gas can be used as fuel, reducing the amount of fuel gas consumed.flat bath operation dramatically reduces noise during operation. The reduction of power consumption also contributes to the reduction of emission of greenhouse gasses during power generation. Co Profit 150 kwh/tonproduct 72.5 kgco2/tproduct Decomposition and reduction of dioxin, dispersing dust, & noise Low electrode consumption ( kg/tonproduct at AC) 28.5 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 28.2 million US$ (assuming 80 ton EAF revamping) 5. Assumed Payback Time 2.0 years (28.2 million US$ / 28.5 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech 7. Technologies Reference SOACT 2nd Edition ("Ecological and Economical Arc Furnace"), Diagram from JP Steel Plantech 8. Comments <Precondition on calculation of investment cost> Assumed investment cost is the revamping cost of existing conventional EAF 11

14 A3 A. Energy Saving for Electric Arc Furnace (EAF) High efficiency oxyfuel burner/lancing for EAF 2. High efficiency thermal effect technologies of Scrap melting during melting stage Alternative Energy Input by OxyFuel / Lancing Burner Multi Injection Technologie of Carbon / Alloy powders Slag Management for foaming slag Bottom Stirring (by Ar or N2 gas) for uniformed rapid melting Co Profit 14.3 kwh/tonproduct 6.9 kgco2/tproduct Reduction of nitorgen in steel, quality improvement 2.7 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 1.5 million US$ (assuming 80 ton EAF revamping) 5. Assumed Payback Time 1.1 years (1.5 million US$ / 2.7 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier Nikko, JP Steel Plantech 7. Technologies Reference SOACT 2nd edition (Add the word "High efficiency" to SOACT item for uptodate oxygen use), Diagram from Nikko 8. Comments <Source of "Electricity saving"> 0.14 GJ/ton in SOACT > 0.14 x 9.8/1000 = 14.3 kwh/ton 12

15 A7 A. Energy Saving for Electric Arc Furnace (EAF) Optimized power control for EAF Statistical analysis Slag foaming detection Heat loss supervision Power supply control for each phase 2. Data logging and visualization of melting process Automatic meltdown and additional scrap charging judgement Automatic phase power independent control for wellbalance melting Co Profit 15 kwh/tonproduct 7.2 kgco2/tproduct Productivity increase Manpower saving 2.9 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 1.1 million US$ 5. Assumed Payback Time 0.8 years (1.1 million US$ / 2.9 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech 7. Technologies Reference SOACT 2nd Edition ("Improved Process Control (Neural Networks)"), Diagram from JP Steel Plantech 8. Comments 13

16 A8 A. Energy Saving for Electric Arc Furnace (EAF) Operation support system with EAF meltdown judgment 2. Automatic rapid melting system for EAF Optimum electric power control Reporting, Data logging and online data communications Automatic meltdown Judgment Power supply and electrode position control for each phase Co Profit 6 kwh/tonproduct 2.9 kgco2/tproduct Productivity increase Manpower saving 1.1 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 0.4 million US$ 5. Assumed Payback Time 0.7 years (0.4 million US$ / 1.1 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier Daido Steel 7. Technologies Reference May contact to Daido Steel 8. Comments <Preconditions on calculating investment cost> Assumed investment cost is the adoption cost to existing EAF 14

17 A12 A. Energy Saving for Electric Arc Furnace (EAF) Energy saving for dedusting system in EAF meltshop 2. Damper openings and exhaust fan rotation are controlled in consonance with the furnace operation pattern Combination of VVVF and proper damper opening Co Profit 6 kwh/tonproduct 2.9 kgco2/tproduct Better working floor and atmosphere 1.1 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 0.6 million US$ (adding VVVF system to main fans) 5. Assumed Payback Time 1.0 years (0.6 million US$ / 1.1 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech, Daido Steel 7. Technologies Reference Diagram from JP Steel Plantech, May contact to suppliers 8. Comments <Preconditions on calculating effects> Assumed electricity consumption for building dedusting is 24 kwh/tonproduct, and 25 % power saving is expected. 15

18 B1 B. Environmental Protection for Electric Arc Furnace Exhaust gas treatment through gas cooling, carbon injection, and bag filter dedusting for EAF 2. Improved design configuration of the direct evacuation for treating hot unburned gas from much fuel use Minimize dust and gas dispersion from EAF with enough capacity and suitable control Much fossil fuel use becomes possible to save electricity. Co Operation Cost Better workfloor environment Not Announced 4. Assumed Investment Cost 3 million US$ (assuming 80 ton EAF revamping) 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier JP Steel Plantech, Daido Steel 7. Technologies Reference SOACT 2nd Edition, Diagram from Daido Steel 8. Comments <Suitable site> Enough evacuation capacity for 30 m3n/ton O2, 20 m3n/ton NG, and 15 kg/ton carbon 16

19 D1 D. Energy Saving for Reheating Furnace Process control for reheating furnace Furnace temp. Billet temp. 2. Setting furnace temperature by targeted billet temperature curve Precise air ratio control and O2 analysis in exhaust gas Co Profit 0.02 GJ/tonproduct (1 % fuel saving from the base line of 1,450 MJ/ton) Not Announced 0.5 US$/tonproduct (assumed fuel price = US$/GJ) (Rounded off to one decimal place) 4. Assumed Investment Cost 0.4 million US$ for 100 ton/h reheating furnace (adding new function to the existing furnace) 5. Assumed Payback Time 1.7 years (0.4 million US$ / 0.5 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier ChugaiRo 7. Technologies Reference May contact to ChugaiRo 8. Comments 17

20 D2 D. Energy Saving for Reheating Furnace Low NOx regenerative burner total system for reheating furnace 2. Co Profit While one of the burners is burning, the other burner will work as an exhaust outlet. The exhaust gas is discharged from the system after the waste heat of the gas is recovered so that the temperature of the gas will be lowered to the extent that there will be no condensation in the regenerator. The combustion air receives heat from the regenerator. Therefore, the combustion air will be preheated to a superhigh temperature (i.e., 90% of the temperature of the exhaust gas or over) before the combustion air is supplied the burner. When the preset cycle time elapses, the burners exchange their roles of combustion and exhaustion GJ/t (about 13%) Not Announced CO2 & NOx Reduction 6.4 US$/tonproduct (assumed fuel price = US$/GJ) (Rounded off to one decimal place) 4. Assumed Investment Cost 3.0 million US$ 5. Assumed Payback Time 0.9 years (3.0 million US$ / 6.4 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier ChugaiRo, Nippon Furnace 7. Technologies Reference Diagram from Chugai Ro, May contact to suppliers 8. Comments 18

21 D3 D. Energy Saving for Reheating Furnace High temperature recuperator for reheating furnace Fuel : Natural Gas Heating Temperature : 1,100 deg C Air ratio : 1.10 The existing recuperator of twopass type will be changed to highefficiency recuperator of fourpass type in order to raise the preheating air temperature. 2. Co Profit For this purpose, the following shall be needed. Modification of Recuperator room Change of air duct Increase of discharge pressure of blower High efficiency recuperator 0.10 GJ/t (about 7%) Not Announced CO2 & NOx Reduction 3.4 US$/tonproduct (assumed fuel price = US$/GJ) (Rounded off to one decimal place) 4. Assumed Investment Cost 1.5 million US$ 5. Assumed Payback Time 0.9 years (1.5 million US$ / 3.4 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier ChugaiRo 7. Technologies Reference Diagram from Chugai Ro, May contact to Chugai Ro 8. Comments <Preconditions on calculating effects> When 300 degc air temperature is raised to 500 degc 19

22 D4 D. Energy Saving for Reheating Furnace Fiber block for insulation of reheating furnace 2. Furnace roof, wall and charging end face shall be insulated with ceramic fiber block. Steel plate shall be equipped with the furnace roof and ceramic fiber block shall be installed. Furnace wall has the existing steel plate and ceramic fiber block shall be installed on it. Co Profit 0.02 GJ/t (about 2%) Not Announced Reduction of Heat accumulation 0.7 US$/tonproduct (assumed fuel price = US$/GJ) (Rounded off to one decimal place) 4. Assumed Investment Cost 1.5 million US$ 5. Assumed Payback Time 4.0 years (1.5 million US$ / 0.7 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier ChugaiRo 7. Technologies Reference Diagram from Chugai Ro, May contact to Chugai Ro 8. Comments <Preconditions on calculating effects> assumed surface area of 100 ton/h furnace : 1350 m2 atmosphere temperature : 30 degc surface temp. and heat loss of brick lining case : 110 degc, 5.91 GJ/h surface temp. and heat loss of brick lining case : 70 degc, 2.47 GJ/h ( ) /100 (ton/h) = GJ/ton 20

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25 <Remarks> Technologies listed below are either being interested to introduce in other ASEAN countries (Malaysia, Indonesia, Vietnam, Singapore, and Thailand) or being recommended to introduce in Philippines by Japanese steel experts. The list of these technologies would be your useful reference to get an idea in case introducing new technoloies to steel plants in Philippines. No. ID Title of technology Technical description A. Energy Saving for Electric Arc Furnace (EAF) 1 A2 2 A4 3 A5 4 A6 5 A9 6 A10 7 A11 8 A13 9 A14 Medium temperature batch scrap preheating EAF Eccentric bottom tapping (EBT) on existing furnace High melting efficiency batch charging type EAF with SPH. Preheated scrap temperature is about degc. Fully enclosed automatic charging system to keep working floor clean. Minimize scrap oxidation by temperature controlling Material limitation free Slag free tapping Reliable stopping and scraping mechanism Electricity saving (kwh/t of product) Thermal energy saving (GJ/t of product) CO 2 reduction (kgco 2/t of product) Reduction of dioxin emission, dispersing dust, & noise Long arc by high voltage and low ampere operation Ultra highpower Water cooled wallpanel to protect refractories transformer for EAF Optimizing slag foaming in EAF Low NOx regenerative burner system for ladle preheating Oxygen burner system for ladle preheating Waste heat recovery from EAF [*5] Bottom stirring/stirring gas injection Induction type tundish heater Proper chemical ingredients of slag High efficient burner and/or lance Controlled O2 & C injection into EAF proper position Keeping slag thickness with airtight operation Regenerating burner use High Energy Saving Automatic control FDI Combustion Rapid and high temperature ladle heating by oxygen burner Automatic control Noise reduction & working floor cleaning No limit of material for high quality products as like stainless steel. Increase in Fe & alloy yield, productivity Improve steel quality Productivity increase US$/t of product, Philippines 40% NOx reduction million US$ in Philippines year in Philippines [*3] [*4] Vertical: 0.4 Horizontal: % NOx reduction Waste heat boiler based on the OG boiler technology Specified for splash and dust containing Inject inert gas (Ar or N2) into the bottom of EAF Better heat transfer steel quality Application of induction heating Possible to uniformize temperature in 3 minutes after power supply B. Environmental Protection for Electric Arc Furnace Analyze air flow in EAF building 10 B2 11 B3 12 B4 13 B5 14 B6 Floating dust control in EAF meltshop Packaged cartridges of activated carbon fixed at the exit of Dioxin adsorption bagfilter adsorbs and removes dioxins and heavy metals to by activated carbon an extremely low level for EAF exhaust gas Dioxin adsorption by mixing EAF exhaust gas with building dedusting gas Dioxin adsorption by 2 step bagfilter technology for EAF exhaust gas PKS charcoal use for EAF Cooling direct evacuation gas by mixing with building dedusting gas 2 step bag system can remove over 99% DXN's from EAF. This system provide a clean working environment. Effective evacuation decrease the consumption of electricity Fe yield increase 0.5 % [*6] Charcoal made from PKS can be used instead of injected coke into EAF. Expected effects of introduction Environmental Restrict dust loading on working floor to less than 5 mg/m3 Dioxin will be lower than 0.1 ng TEQ/m3N Dioxin will be lower than 5.0 ng TEQ/m3N Dioxin will be lower than 0.5 ng TEQ/m3N 39,000 tonco2/y GHG reduction Co Assumed Profit/Oper investment ation Cost cost [*1] [*2] Assumed Payback time 0.1 [*7] [*8] [*9] 0.7 Main Japanese supplier Daido Steel JP Steel Plantech Daido Steel JP Steel Plantech Nikko JP Steel Plantech Daido Steel ChugaiRo Nippon Furnace ChugaiRo JP Steel Plantech JP Steel Plantech JP Steel Plantech Fuji Electric JP Steel Plantech Daido Steel JFE Engineering JP Steel Plantech Daido Steel JP Steel Plantech Daido Steel JP Steel Plantech 23

26 <Remarks> Technologies listed below are either being interested to introduce in other ASEAN countries (Malaysia, Indonesia, Vietnam, Singapore, and Thailand) or being recommended to introduce in Philippines by Japanese steel experts. The list of these technologies would be your useful reference to get an idea in case introducing new technoloies to steel plants in Philippines. No. ID Title of technology Technical description C. Material Recycle for Electric Arc Furnace 15 C1 16 C2 EAF dust and slag recycling system by oxygenfuel burner EAF slag agglomeration for aggregate use D. Energy Saving for Reheating Furnace 17 D5 Air conditioning by absorption type refrigerating by using reheating furnace exhaust gas E. Common systems and General Energy 18 E1 19 E2 Inverter (VFD; Variable Frequency Drive) drive for motors Energy monitoring and management systems Zn recovery rate will be expected to be 95% Fe in EAF dust cannot be recovered as metal Molten slag is rapidly cooled by jet air, and becomes mm heavy and strong ball. Suited to use aggregate mixed with cement Use reheating furnace exhaust gas at the outlet of recuperator, about degc Applying the MultiLevel Drive for motors enables to save energy cost from vane and valve control (constant speed motor). EcoFriendly Power Source Friendly Less Maintenance Motor Friendly Energy data are collected in process computer for evaluation Electricity saving (kwh/t of product) Thermal energy saving (GJ/t of product) CO 2 reduction (kgco 2/t of product) Expected effects of introduction Environmental Slag satisfies the safety code Co Zn material and concrete aggregate can be gained from EAF dust Saved processing time: 10 minutes Assumed Profit/Oper investment ation Cost cost [*1] [*2] US$/t of product, Philippines million US$ in Philippines Assumed Payback time year in Philippines 1.5 [*10] [*11] % CO2 Reduction 550,000/ year [*12] Main Japanese supplier Daido Steel Nikko Hitachi Infrastructur e Systems Company Hitachi Major electric equipment suppliers Major electric equipment suppliers 20 E3 Management of compressed air delivery pressure optimization Energy saving in compressors requires consideration of the following points. * Selection of the appropriate capacity * Reduction in delivery pressure 285 MWh/y Major electric equipment suppliers [*1] Opearation cost is indicated in minus () [*2] Co are not taken account into profits and operation costs [*3] Assumed investment cost is additional cost from the cost of a conventional EAF investment [*4] Assumed investment cost is the revamping cost of existing conventional EAF [*5] Suited to DRI continuous charging EAF, not scrap EAF [*6] Assumed plasma type tundish heater is installed. Effect is calculated comparing to electricity consumption of plasma type heater [*7] Investment cost of 0.1 million US$ is the 3D flow analysis fee [*8] Investment cost is addition cost of building dedusting system to the independent direct dedusting system [*9] Install direct baghouse and booster blower for direct EAF exist dedusting system [*10] Assumed ZnO selling price : 500 US$/ton [*11] Compared to the air cooled electric chiller COP:3.5/ consider the auxiliaries consumption as 90kwh [*12] Assumed Annual operation : 3,600 h/y 24

27 A2 A. Energy Saving for Electric Arc Furnace (EAF) Medium temperature batch scrap preheating EAF 2. High melting efficiency batch charging type EAF with SPH. Preheated scrap temperature is about degc. Fully enclosed automatic charging system to keep working floor clean. Minimize scrap oxidation by temperature controlling Material limitation free Co Profit 40 kwh/tonproduct 19.3 kgco2/tproduct Reduction of dioxin emission, dispersing dust, & noise No limit of material for high quality products as like stainless steel. 7.6 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 7.4 million US$ (assuming 80 ton EAF revamping) 5. Assumed Payback Time 2.0 years (7.4 million US$ / 7.6 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier Daido Steel 7. Technologies Reference May contact to Daido Steel 8. Comments <Precondition on calculating investment cost> Assumed investment cost is additional cost from the cost of a conventional EAF investment. 25

28 A4 A. Energy Saving for Electric Arc Furnace (EAF) Eccentric bottom tapping (EBT) on existing furnace 2. Slag free tapping Reliable stopping and scraping mechanism Co Profit 15 kwh/tonproduct 7.2 kgco2/tproduct Increase in Fe & alloy yield, and productivity Improve steel quality 2.9 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 3.0 million US$ (assuming 80 ton EAF revamping) 5. Assumed Payback Time 2.1 years (3.0 million US$ / 2.9 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech, Daido Steel 7. Technologies Reference EPABACT (Sep. 2014), Diagram from JP Steel Plantech 8. Comments <Preconditions on calculating effects and investment costs> Values of "Electricity saving" and "Investment cost" are based on the EPABACT (Sep. 2014) & equipment supplier's rough estimation "Profit" does not include such other advantages than electricity saving Assumed investment cost is the revamping cost of existing conventional EAF 26

29 A5 A. Energy Saving for Electric Arc Furnace (EAF) Ultra highpower transformer for EAF The Impedance characteristics of Transformer 2. In the conventional system, series reactor was used for the early melting stage in order to stabilize arc and control of a flicker. Since HighEfficiency Furnace Transformer provides high impedance at early melting stage, series reactor is not required, though the same performance is achieved. Reduce electric power consumption Reduce electrode consumption Shorten tap to tap time Co Profit 15 kwh/tonproduct 7.2 kgco2/tproduct Increase productivity 2.9 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 4.2 million US$ (assuming 80 ton EAF revamping) 5. Assumed Payback Time 2.9 years (4.2 million US$ / 2.9 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech, Nikko 7. Technologies Reference EPABACT ("Transformer efficiency ultrahigh power transformers"), Diagram from Nikko 8. Comments <Preconditions on calculating effects and investment costs> "Electricity saving" 15 kwh/tonproduct comes from EPABACT, assuming that 44 MVA transformer for 80 ton EAF is revamped to 55 MVA. 27

30 A6 A. Energy Saving for Electric Arc Furnace (EAF) Optimizing slag foaming in EAF 2. Proper chemical ingredients of slag (Basicity , FeO %) High efficient burner and/or lance Controlled O2 & C injection into EAF proper position Keeping slag thickness with airtight operation Co Profit 6 kwh/tonproduct 2.9 kgco2/tproduct Noise reduction & working floor cleaning 1.1 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 1.1 million US$ (adding coherent burner and accurate C&O2 charging system) 5. Assumed Payback Time 2.0 years (1.1 million US$ / 1.1 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech, Daido Steel 7. Technologies Reference SOACT 2nd Edition (Delete the word "Exchangeable Furnace and Injection "), Diagram from JP Steel Plantech 8. Comments <Source of "Electricity saving"> (1) % energy saving in SOACT > 430 kwh/ton x 0.03 = 12.9 kwh/ton (2) The phenomenum is explained by several factors, 6 kwh/ton is reasonable (Japanese experts). <Preconditions on calculating investment costs> "Investment cost" is based on equipment supplier's rough estimation. 28

31 A9 A. Energy Saving for Electric Arc Furnace (EAF) Low NOx regenerative burner system for ladle preheating 2. Co Profit While one of the burners is burning, the other burner will work as an exhaust outlet. The exhaust gas is discharged from the system after the waste heat of the gas is recovered so that the temperature of the gas will be lowered to the extent that there will be no condensation in the regenerator. The combustion air receives heat from the regenerator. Therefore, the combustion air will be preheated to a superhigh temperature (i.e., 90% of the temperature of the exhaust gas or over) before the combustion air is supplied to the burner. When the preset cycle time elapses, the burners exchange their roles of combustion and exhaustion. 40% fuel saving is expected comparing to existing preheater Not Announced Low NOx Improving meltshop atmosphere by reducing hot gas which disturbs dirty gas suction at the canopy 40% fuel saving is expected comparing to existing preheater 4. Assumed Investment Cost Vertical: 0.4 million US$ Horizontal: 0.3 million US$ 5. Assumed Payback Time 3~4 years (Supplier's estimation based on experience) 6. Japanese Main Supplier ChugaiRo, Nippon Furnace 7. Technologies Reference Diagram from Chugai Ro, May contact to suppliers 8. Comments 29

32 A10 A. Energy Saving for Electric Arc Furnace (EAF) Oxygen burner system for ladle preheating 2. Oxygen combustion achieve rapid heating by high flame temperature. High flame temperature achieve high wall temperature, therefore it can be possible low temperature feeding of melted metal in to the ladle. Co Profit 40% fuel saving is expected comparing to existing preheater Not Announced Low NOx 40% fuel saving is expected comparing to existing preheater 4. Assumed Investment Cost 0.2 million US$ 5. Assumed Payback Time 2.0 years (Supplier's estimation based on experience) 6. Japanese Main Supplier ChugaiRo, JP Steel Plantech 7. Technologies Reference Diagram from Chugai Ro, May contact to suppliers 8. Comments 30

33 A11 A. Energy Saving for Electric Arc Furnace (EAF) Waste heat recovery from EAF 2. Waste heat boiler based on the OG boiler technology Specified for splash and dust containing Main boiler is radiative type, and convective type super heater is located at the downstream of boiler to avoid clogging. Co Profit 132 kwh/tonproduct 63.8 kgco2/tproduct 25.1 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 44.5 million US$ for two 150 ton EAFs for DRI 5. Assumed Payback Time 3.5 years (44.5 million US$ / 25.1 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech 7. Technologies Reference Diagram from JP Steel Plantech, May contact to JP Steel Plantech 8. Comments <Preconditions on calculating effects> Power generation is 248,000 MWh/year with two 150 ton EAFs for DRI Assumed annual production by two 150 ton EAF = 500,000 / 80 x 150 x 2 = 1,875,000 ton/y Unit power generation = 248,000 x 1,000 / 1,875,000 = 132 kwh/tonproduct Suited to DRI continuous charging EAF, not scrap EAF 31

34 A13 A. Energy Saving for Electric Arc Furnace (EAF) Bottom stirring/stirring gas injection 2. Inject inert gas (Ar or N2) into the bottom of EAF Better heat transfer steel quality Co Profit 18 kwh/tonproduct 8.7 kgco2/tproduct Fe yield increase 0.5 % 3.4 US$/tonproduct (assumed electricity price = US$/kWh) (Rounded off to one decimal place) 4. Assumed Investment Cost 0.2 million US$ (assumed 80 ton EAF revamping) 5. Assumed Payback Time 0.1 years (0.2 million US$ / 3.4 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier JP Steel Plantech 7. Technologies Reference EPABACT, May contact to JP Steel Plantech 8. Comments <Preconditions on calculating effects> "Electricity saving" 15 kwh/tonproduct comes from EPABACT 32

35 A14 A. Energy Saving for Electric Arc Furnace (EAF) Induction type tundish heater 2. Co Profit Application of induction heating Realizing 90 % heating efficiency Possible to remove inclusion within molten steel Step control method Possible to uniformize temperature in 3 minutes after power supply Temperature control with high accuracy through temperature feedback 3 kwh / tonproduct (Effect is calculated comparing to electricity consumption of plasma type heater) Productivity increase Quality improvement 0.6 US$/tonproduct (assumed electricity price = US$/kWh) 4. Assumed Investment Cost Not Announced 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier Fuji Electric 7. Technologies Reference May contact to Fuji Electric <Preconditions on calculating effects> Assumed plasma type tundish heater is installed Ladle capacity: 200 ton Operated days: 30 days/month Electricity intensity of heater: 13.7 kwh/ton Heat efficiency: 70% 8. Comments Pouring amount: 2.5 ton/min Dissolution time: 80 min/charge Rised temperature: 40 degeree C Number of charges: 8 charges/day Monthly production: 48,000 ton Annual production: 576, 000 ton 33

36 B2 B. Environmental Protection for Electric Arc Furnace Floating dust control in EAF meltshop Floating dust detector Dust loading after 30 sec. of scrap charge 2. Co Operation Cost In modern EAF meltshop, fully enclosed building is required to avoid dust dispersion to the outside environment. Enclosed building raises workfloor pollution which affects workers health. Proper design and operation of dedusting system based on the flow analysis and real dust data are essential. Restrict dust loading on working floor to less than the value specified by Industrial Safety and Health Act (for ex. 5 mg/m3) Restrict dust loading on working floor to less than 5 mg/m3 Not Announced 4. Assumed Investment Cost 0.1 million US$ 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier JP Steel Plantech, Daido Steel 7. Technologies Reference Diagram from JP Steel Plantech, May contact to suppliers 8. Comments <Precondition on calculating investment cost> Investment cost of 0.1 million US$ is the 3D flow analysis fee. Building and suction system revamping shall be executed based on the flow analysis. 34

37 B3 B. Environmental Protection for Electric Arc Furnace Dioxin adsorption by activated carbon for EAF exhaust gas 2. Co Operation Cost A new dioxinremoval system passes exhaust gas through a layer of granular activated carbon with outstanding adsorption performance. Highperformance activated carbon was developed exclusively for the system. Packaged cartridges with a unique structure allowing the system to adsorb and remove dioxins and heavy metals to an extremely low levels. A cartridge with a unique structure ensures improved contact efficiency between activated carbon and exhaust gas. Consequently, the filled quantity of activated carbon is considerably reduced allowing unparalleled compact size. In addition, amount of consumed activated carbon would be substantially reduced comparing to previous Activated Carbon Adsorption Tower. Furthermore, it would save electricity consumption of blower since its pressure loss would be lower than 0.5kPa (Approx. 50 mmaq) per a cartridge comparing to previous equipment. Dioxin will be lower than 0.1 ng TEQ/m3N Not Announced 4. Assumed Investment Cost 5.2 million US$ 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier JFE Engineering 7. Technologies Reference Diagram from JFE Engineering, May contact to JFE Engineering 8. Comments 35

38 B4 B. Environmental Protection for Electric Arc Furnace Dioxin adsorption by mixing EAF exhaust gas with building dedusting gas 2. Cooling direct evacuation gas by mixing with building dedusting gas Co Operation Cost Dioxin will be lower than 5.0 ng TEQ/m3N Not Announced 4. Assumed Investment Cost 11.1 million US$ 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier JP Steel Plantech, Daido Steel 7. Technologies Reference Diagram from Daido Steel, May contact to suppliers 8. Comments <Preconditions on calculating investment cost> Investment cost is addition cost of building dedusting system to the independent direct dedusting system. 36

39 B5 B. Environmental Protection for Electric Arc Furnace Dioxin adsorption by 2 step bagfilter technology for EAF exhaust gas Activated Carbon 2. The direct dust collector or the dust collecting route in the building can be switched over to collect the dust efficiently corresponding to the status of operation of the electric arc furnace so that clean operating environment can be offered. It is possible to select the appropriate volume of suction gas according to the operation pattern of the electric arc furnace so that the power required for the equipment can be reduced. It is possible to remove 99% or more of dioxins by the use of the 2step bug house with activated carbon system. Dioxin will be lower than 0.1 ng TEQ/m3N if activated carbon is injected. (Additional cost of US$ 1.0 mil required) Co Operation Cost Dioxin will be lower than 0.5 ng TEQ/m3N 0.2 US$/tonproduct 4. Assumed Investment Cost 3.0 million US$ 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier JP Steel Plantech, Daido Steel 7. Technologies Reference Diagram from Daido Steel, May contact to suppliers 8. Comments <Preconditions on calculating investment cost> Install direct baghouse and booster blower for direct EAF exist dedusting system. 37

40 B6 B. Environmental Protection for Electric Arc Furnace PKS charcoal use for EAF 2. Co Operation Cost Charcoal made from PKS (Palm Kernel Shell) has similar quality with coke commonly used for carbon injection into EAF Higher heating value, lower sulfur content than fossil fuel coke CO2 generated from charcoal is not counted as GHG (Green House Gas) PKS charcoal is produced for the production of activated carbon in a small scale Equipmet is very simple and can be constructed by local technology Japanese supplier will provide with knowhow 39,000 tonco2/y GHG reduction from 500,000 ton/y EAF plant Not Announced 4. Assumed Investment Cost 0.7 million US$ 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier JP Steel Plantech 7. Technologies Reference Diagram from JP Steel Plantech, May contact to JP Steel Plantech 8. Comments <Preconditions on calculating effects> Replaced coke at EAF : 25 kg/tonsteel C content in coke : 85 % CO2 generation from coke = 0.85 x 44 / 12 = 3.12 tonco2/toncoke GHG reduction = 500,000 tonsteel/y x x 3.12 = 39,000 tonco2/y 38

41 C1 C. Material Recycle for Electric Arc Furnace EAF dust and slag recycling system by oxygenfuel burner 2. As dust and slag are melted down completely at high temperature, it is very effective against dioxin. Produced valuable substances are completely harmless and can meet all environmental standards. More than 99% of dioxin can be removed by high temperature treatment in the furnace and strong rapid cooling mechanism. Besides electrical furnace dust and reduced slag, it is expected that this system will be applied to other waste treatments. The equipment is simple and compact because of unnecessary pretreatment such as dust granulation and so forth. Through simple design, excels in operability and suitable for onsite processing. Co Profit Zn material can be gained from EAF dust Concrete aggregate can be gained from EAF dust 1.5 US$/ ton (Operation cost will be less than profit.) 4. Assumed Investment Cost 13.3 million US$ (for 6 ton/hr. capacity DSM) 5. Assumed Payback Time 24 years (Supplier's estimation based on experience) 6. Japanese Main Supplier Daido Steel 7. Technologies Reference Diagram from Daido Steel, May contact to Daido Steel 8. Comments <Preconditions on calculating profit> ZnO selling price : 500 US$/ton 39

42 C2 C. Material Recycle for Electric Arc Furnace EAF slag agglomeration for aggregate use Treatment Process for Electric Arc Furnace Slag Air 2. Molten slag is rapidly cooled by jet air, and becomes 0.35mm size of spherical structure, Create strong & heavy fine aggregate material for concrete Enviromental friendly material Suitable & meet with JIS A for Electric arc furnace oxidizing slag aggregate. Require smaller space than normal slag treatment area. Co Profit Reduce disposal cost of industrial waste Processing time for one heat of EAF : 10 minutes Not Announced 4. Assumed Investment Cost 0.7 million US$ for 2 ton/h plant (onsite in 500,000 ton/y EAF plant) 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier Nikko 7. Technologies Reference Diagram from Nikko, May contact to Nikko 8. Comments <Notice> When using this technology, slag analysis data should be confirmed to meet the environmental regulation <Preconditions on calculating effects> Slag generation : 80 kg/tonproduct Yield of granulated slag with this process : 6070 % 40

43 D5 D. Energy Saving for Reheating Furnace Air conditioning by absorption type refrigerating by using reheating furnace exhaust gas 2. Co Profit This is a waste heat recovery system by using the absorption chiller. If there is a waste heat more than 200 deg. C, it can utilize for the double effect absorption chiller and can generate chilled water for air conditioning, etc. This chiller efficiency is about COP*:1.45 and it can reduce electrical type chiller power consumption. It requires close attention in case the exhaust gas contains corrosive components. *COP(Coefficient Of Performance) : Heat supplied(w) / Power consumption(w) 3.0 kwh/tonproduct (compared to the air cooled electric chiller COP:3.5 / considering the auxiliaries consumption as 90kWh) 1.4 kgco2/tproduct 0.6 US$/tonproduct US$/y income based on 5,000 hour operation in one year (Rounded off to one decimal place) 4. Assumed Investment Cost 0.7 million US$ for 100 ton/h reheating furnace (only equipment) 5. Assumed Payback Time 2.3 years (0.7 million US$ / 0.6 US$/tonproduct * 500,000 tproduct/year) 6. Japanese Main Supplier HITACHI Infrastructure Systems Co. 7. Technologies Reference Diagram from HITACHI Infrastructure Systems Co., May contact to HITACHI Infrastructure Systems Co. 8. Comments <Preconditions on calculating effects> compared to the air cooled electric chiller COP:3.5/ consider the auxiliaries consumption as 90kWh 41

44 E1 E. Common systems and General Energy Inverter (VFD; Variable Frequency Drive) drive for motors 2. EcoFriendly Total efficiency of 97% is achieved. 2030% of energy can be saved with fans and pumps. Separated installation is available for Transformer section. Power Source Friendly Current harmonic at the power source conforms to IEEE guidelines. Less Maintenance Reliable, available and serviceable of maintenance tool are widely arranged. Motor Friendly Series connected IGBT produce sinusoidal waveform of output voltage and current. It is best for to retrofit with existing motors. Co Profit 13% (Depending on the country and conditions of the facility) Not Announced CO2 Reduction Approximately 550,000 US$/ year ( as of currency exchange rate of Oct., 2014) 4. Assumed Investment Cost Approximately 1.3 million US$ (including construction cost, differ from conditions of the facility) 5. Assumed Payback Time 2~3 years (Depending on the country and conditions of the facility) 6. Japanese Main Supplier Hitachi, Ltd., Major electric equipment companies 7. Technologies Reference Diagram from Hitachi, Ltd., May contact to Hitachi, Ltd. 8. Comments <Preconditions on calculating effects> Annual operation : 3,600 h/y 42

45 E2 E. Common systems and General Energy Energy monitoring and management systems Daily and monthly reports of energy balance Online monitoring and logging system for energy currents Electric Power Steam Fuel Oxygen 2. This measure includes site energy management systems for optimal energy consumption in the plant. Online monitoring: This is often used for the most important energy flows at the site. The data are stored for a long time so that typical situations may be analyzed. It is very important to monitor for all energy sources on online. It is the main technique used to avoid energy losses. Continuous monitoring systems: Since all energyrelated process parameters are used to optimize process control and to enable instant maintenance, undisrupted production process could be achieved. Reporting and analyzing tools: Reporting tools are often used to check the average energy consumption of each process. In connection with cost controlling, controlling energy is the basis for optimizing energy consumption and cost savings. An energy controlling system enables to compare actual data with historical data (e.g. charts) Co 0.12 GJ/tsteel [*1, 2] Not Announced Profit 4. Assumed Investment Cost 4.1 US$/tonproduct It depends on system structure, from data monitoring network to whole control computer system. One example in Netherlands (was aquired by Tata Steel, and nominal capacity is 6.3Mt/y.) is 0.6 million US$ 5. Assumed Payback Time 0.3 years (Depends on cost of fuel and electricity of each site) 6. Japanese Main Supplier Major electric equipment suppliers 7. Technologies Reference *1 Farla, J.C.M., E. Worrell, L. Hein, and K. Blok, Actual Implementation of Energy Conservation Measures in the Manufacturing Industry , The Netherlands: Dept. of Science, & Society, Utrecht University. *2 ETSU, Reduction of Costs Using an Advanced Energy Management System, Best Practice Programme, R&D Profile 33, Harwell, UK: ETSU 8. Comments 43

46 E3 E. Common systems and General Energy Management of compressed air delivery pressure optimization 2. 'The delivery pressure of compressors is generally 100 kpa or higher. Compressors have been developed for a variety of applications. Table shows the types of compressors available, and their range of applications. Energy saving in compressors requires consideration of the following points. * Selection of the appropriate capacity * Reduction in delivery pressure Since the required motive power increases with increased delivery pressure, delivery pressure should be reduced as much as possible, while at the same time being sufficient for the receiving equipment (Fig. ), however it should be noted that motive power does not decrease with delivery pressure in the case of turbo compressors. * Prevention of leakage * Reduction in temperature of the compressed air * Reduction in intake air resistance Intake air resistance increases with intake filters, silencers, and valves in piping etc, and will increase the required motive power if excessive. Care is required to reduce pressure losses in the intake air system through periodic cleaning of filters to eliminate clogging. * Reduction in piping resistance Co Profit 285 MWh/y Not Announced Not Announced 4. Assumed Investment Cost Not Announced 5. Assumed Payback Time Not Announced 6. Japanese Main Supplier Major electric equipment suppliers 7. Technologies Reference Energy saving Diagnosis Examples Common Equipment Volume, Energy conservation Center, Japan 8. Comments <Preconditions on calculating effects> Number of compressors; Total of 17, *Delivery pressure; 0.8MPa, Equipment capacity; 823 kw, *Onload operation load; 60%, Daily operation; 24 h/d, *Annual operation; 241 days' Unit cost of power : US$/kWh 44

47 Contact Points of Supplier Companies Company Contact Points Chugai Ro Co., Ltd. Akira SHINOZUKA Overseas Sales Sect, Sales Dept, Plant Division Address: Sakai Works, 24 Chikko Shinmachi, NishiKu, Sakai , JAPAN A9. Low NOx regenerative burner system for ladle preheating A10. Oxygen burner system for ladle preheating D1. Process control for reheating furnace D2. Low NOx regenerative burner total system for reheating furnace D3. High temperature recuperator for reheating furnace D4. Fiber block for insulation of reheating furnace Tel: Daido Steel Co., Ltd Kunio MATSUO Melt Engineering Sect, Machinery Engineering Dept., Machinery Division Address: 9 Takiharucho, MinamiKu, Nagoya, JAPAN, kmatsuo@ac.daido.co.jp Tel: Katsunari HASHIMOTO Asean Area Manager. Machinery Division Adress: 1635 Kounan, Minato, Tokyo, JAPAN, ; khashimoto@bw.daido.co.jp Tel: A2. Medium temperature batch scrap preheating EAF A4. Eccentric bottom tapping (EBT) on existing furnace A6. Optimizing slag foaming in EAF A8. Operation support system with EAF meltdown judgment A12. Energy saving for dedusting system in EAF meltshop B1. Exhaust gas treatment through gas cooling, carbon injection, and bag filter dedusting for EAF B2. Floating dust control in EAF meltshop B4. Dioxin adsorption by mixing EAF exhaust gas with building dedusting gas B5. Dioxin absorption by 2 step bagfilter technology for EAF exhaust gas C1. EAF dust and slag recycling system by oxygenfuel burner Fuji Electric Co., Ltd. Masato IDE Assistant General Manager, Sales Dept. IV, Global Plant Sales Div., Sales Group Address: Gate City Ohsaki, East Tower 112, Osaki 1 Chome, ShinagawaKu, Tokyo , JAPAN idemasato@fujielectric.co.jp Tel: A14. Induction type tundish heater Hitachi, Ltd Hitachi Infrastructure Systems Company Taisuke SHIMAZAKI Assistant Manager, Industrial Systems and Solutions Division Heavy Industry Dept. Hitachi, Ltd. (Tokyo Head Office) taisuke.shimazaki.xz@hitachi.com TEL: FAX: D4. Air conditioning by absorption type refrigerating by using reheating furnace exhaust gas E1. Inverter (VFD; Variable Frequency Drive) drive for motors JFE Engineering Corporation JP Steel Plantech Co. Nagayoshi SUZUKI B3. Dioxin adsorption by activated carbon for EAF exhaust gas Manager, Environmental Plant Sec., Engineering Department, Overseas Business Sector Address: 21, Suehirocho, Tsurumiku, Yokohama, JAPAN suzukinagayoshi@jfeeng.co.jp Tel: +81(45) Fax: +81(45) Masao MIKI Green Business Dept. Sales & Marketing Division Address: 31, Kinkocho, Kanagawaku,Yokohama JAPAN mikim@steelplantech.co.jp Tel: +81(0) Fax: +81(0) A1. High temperature continuous scrap preheating EAF A3. High efficiency oxyfuel burner/lancing for EAF A4. Eccentric bottom tapping (EBT) on existing furnace A5. Ultra highpower transformer for EAF A6. Optimizing slag foaming in EAF A7. Optimized power control for EAF A10. Oxygen burner system for ladle preheating A11. Waste heat recovery from EAF A12. Energy saving for dedusting system in EAF meltshop A13. Bottom stirring/stirring gas injection B. Exhaust gas treatment through gas cooling, carbon injection, and bag filter dedusting for EAF B2. Floating dust control in EAF meltshop B3. Dioxin adsorption by mixing EAF exhaust gas with building dedusting gas B4. Dioxin absorption by 2 step bagfilter technology for EAF exhaust gas B5. PKS charcoal use for EAF Nikko Industry Co., Ltd. Nippon Furnace Co., Ltd. Akiyoshi OKAMOTO Director, Engineering and Marketing Division Address: 410, 2chome, Nunobikicho, Chuoku, Kobe, , JAPAN aokamoto@nikkojapan.co.jp Tel: Susumu MOCHIDA Director, General Manager, & Engineering Division Address: 153, Shitte 2Chome, Tsurumiku, Yokohama , JAPAN s_mochida@furnace.co.jp Tel: A3. High efficiency oxyfuel burner/lancing for EAF A5. Ultra highpower transformer for EAF C2. EAF slag agglomeration for aggregate use A9. Low NOx regenerative burner system for ladle preheating D2. Low NOx regenerative burner total system for reheating furnace 45