TECHNOLOGIES CUSTOMIZED LIST version 1.0

Transcription

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

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3 Introduction Overview Contents of Technologies Customized List were developed under a collaborative scheme of ASEANJapan Steel Initiative (AJSI) between ASEAN 6 countries (Indonesia, Malaysia, Philippines, Singapore, Thailand and Vietnam) and Japan. The List is intended to be developed to identify appropriate technologies for iron and steel industry regarding energy saving, environmental protection and recycling in these ASEAN countries. Knowledge acquired from public and private experiences of the Japanese steel industry which achieves the highest energy efficiency in the world, and the needs of ASEAN country s steel industry are reflected in the list. In this context, contents of the list are useful for public sectors for development of policies and measures, as well as for private sectors for the plan of the technology introduction and improvement of energy management activities in steel plants. Contents of the list should be revised at the future Public and Private Collaborative Meeting between ASEAN and Japanese Iron and Steel Industry conforming to a situation at the time. What is ASEANJapan Steel Initiative? 1

4 Development process of Technologies Customized List Technologies on Technologies Customized List were chosen from technology reference existing in the world, based on three perspectives; 1) Technological knowledge of steel experts in ASEAN and Japan, 2) Experience of Japanese steel industry, 3) Circumstances in ASEAN. More detailed information about selection criteria of technologies for Technologies Customized List will be introduced in page 6. <Reference List> SOACT Handbook: NEDO Handbook: EUIPCC BAT: USAEPABACT: Technologies Customized List is developed by steel experts who ACTUALLY operate steel plants in ASEAN and Japan so that you would find appropriate solutions on improvement of energy efficiency and environment protection for your steel plant. Version th November,

5 ASEANJapan Public and Private Collaborative Meeting in Jakarta, Feb 2014 Steel Plant Diagnosis in Malaysia, Aug 2014 Steel Plant Diagnosis in Thailand, Sep 2014 Steel Plant Diagnosis in Singapore, Sep 2014 Steel Plant Diagnosis in Philippines, Oct 2014 Steel Plant Diagnosis in Vietnam, Oct 2014 Steel Plant Diagnosis in Indonesia, Oct

6 Technologies Customized List & Technologies One by One Sheets Ver.1.0 Table of Contents 1. Technologies Customized List 5 2. Technologies OnebyOne Sheet 11 ANNEX 1. Full List of Technologies 45 ANNEX 2. Technologies for Blast Furnace 51 ANNEX 3. Financial support scheme of Japan 55

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8 Technology 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. 6

9 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 7

10 No. A. Energy Saving for Electric Arc Furnace (EAF) 1 A1 2 A2 High temperature continuous scrap preheating EAF Medium temperature batch scrap preheating EAF Technologies Customized List for Energy Saving, Environmental Protection, and Recycling for ASEAN Steel Industry 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 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 Electricity saving (kwh/t of product) Thermal energy saving (GJ/t of product) Expected effects of introduction Environmental benefits Decomposition and reduction of dioxin, dispersing dust, & noise Reduction of dioxin emission, dispersing dust, & noise Cobenefits Low electrode consumption ( kg/tonproduct at AC) No limit of material for high quality products as like stainless steel. Main Japanese supplier JP Steel Plantech Daido Steel 3 A3 4 A4 5 A5 6 A6 High efficiency oxyfuel burner/lancing for EAF Eccentric bottom tapping (EBT) on existing furnace Ultra highpower transformer for EAF Optimizing slag foaming in EAF Supersonic or coherent burner Accelerate scrap melting during melting stage Facilitate slag foaming during refining stage over the bath Slag free tapping Reliable stopping and scraping mechanism Long arc by high voltage and low ampere operation Water cooled wallpanel to protect refractories 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 Noise reduction & working floor cleaning Reduction of nitorgen in steel for quality improvement Increase in Fe & alloy yield, productivity Improve steel quality Productivity increase Nikko JP Steel Plantech JP Steel Plantech Daido Steel JP Steel Plantech Nikko JP Steel Plantech Daido Steel 7 A7 8 A8 9 A9 10 A10 11 A11 Optimized power control for EAF Operation support system with EAF meltdown judgment Low NOx regenerative burner system for ladle preheating Oxygen burner system for ladle preheating Waste heat recovery from EAF 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 Regenerating burner use High Energy Saving Automatic control FDI Combustion Rapid and high temperature ladle heating by oxygen burner Automatic control Waste heat boiler based on the OG boiler technology Specified for splash and dust containing Productivity increase Manpower saving Productivity increase Manpower saving Operation standardization 40% NOx reduction 40% NOx reduction JP Steel Plantech Daido Steel ChugaiRo Nippon Furnace ChugaiRo JP Steel Plantech JP Steel Plantech 12 A12 13 A13 Energy saving for dedusting system in EAF meltshop Bottom stirring/stirring gas injection Damper openings and exhaust fan rotation are controlled in consonance Combination of VVVF and proper damper opening Inject inert gas (Ar or N2) into the bottom of EAF Better heat transfer steel quality 6.0 Better working floor & atmosphere 18.0 JP Steel Plantech Daido Steel JP Steel Fe yield increase 0.5 Plantech % 14 A14 Induction type tundish heater Application of induction heating Possible to uniformize temperature in 3 minutes after power supply 3.0 [*1] Fuji Electric 8

11 No. Technologies Customized List for Energy Saving, Environmental Protection, and Recycling for ASEAN Steel Industry ID Title of technology Technical description B. Environmental Protection for Electric Arc Furnace 15 B1 16 B2 17 B3 18 B4 19 B5 Exhaust gas treatment through gas cooling, carbon injection, and bag filter dedusting for EAF 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 Electricity saving (kwh/t of product) Thermal energy saving (GJ/t of product) Floating dust control in EAF Analyze air flow in EAF building meltshop Dioxin adsorption by activated carbon 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 20 B6 PKS charcoal use for EAF C. Material Recycle for Electric Arc Furnace 21 C1 22 C2 EAF dust and slag recycling system by oxygenfuel burner EAF slag agglomeration for aggregate use D. Energy Saving for Reheating Furnace 23 D1 24 D2 25 D3 26 D4 Packaged cartridges of activated carbon fixed at the exit of bagfilter adsorbs and removes dioxins and heavy metals to an extremely low level 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. Charcoal made from PKS can be used instead of injected coke into EAF. 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 Setting furnace temperature by targeted billet Process control for reheating temperature curve furnace Precise air ratio control and O2 analysis in exhaust gas Low NOx regenerative burner total system for reheating furnace High temperature recuperator for reheating furnace Fiber block for insulation of reheating furnace Expected effects of introduction Environmental benefits Better workfloor & environment Cobenefits Restrict dust loading on working floor to less than 5 mg/m 3 Dioxin will be lower than 0.5 ng TEQ/m 3 N Dioxin will be lower than 5.0 ng TEQ/m 3 N Dioxin will be lower than 0.5 ng TEQ/m 3 N 39,000 tonco2/y GHG reduction 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) 27 D5 Air conditioning by absorption type refrigerating Use reheating furnace exhaust gas at the outlet of by using reheating furnace recuperator, about degc exhaust gas E. Common systems and General Energy Savings 28 E1 29 E2 30 E3 Inverter (VFD; Variable Frequency Drive) drive for motors Energy monitoring and management systems Management of compressed air delivery pressure optimization 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 Energy saving in compressors requires consideration of the following points. * Selection of the appropriate capacity * Reduction in delivery pressure Slag satisfies the safety code Zn material and concrete aggregate can be gained from EAF dust Saved processing time: 10 minutes CO2 & NOx Reduction Reduction of Heat accumulation % CO2 Reduction MWh/y [*1] Assumed plasma type tundish heater is installed. Effect is calculated comparing to electricity consumption of plasma type heater Main Japanese supplier JP Steel Plantech Daido Steel JP Steel Plantech Daido Steel JFE Engineering JP Steel Plantech Daido Steel JP Steel Plantech Daido Steel JP Steel Plantech Daido Steel Nikko ChugaiRo ChugaiRo Nippon Furnace ChugaiRo ChugaiRo Hitachi Infrastructure Systems Company Hitachi Major electric equipment suppliers Major electric equipment suppliers Major electric equipment suppliers 9

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15 A1 Item A. Energy Saving for Electric Arc Furnace (EAF) High temperature continuous scrap preheating EAF Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 150 kwh/tonproduct Decomposition of dioxin, reducing dispersing dust, & noise Low electrode consumption ( kg/tonproduct at AC) 4. Japanese Main Supplier JP Steel Plantech 5. Technologies Reference SOACT 2nd Edition ("Ecological and Economical Arc Furnace"), Diagram from JP Steel Plantech 6. Comments 13

16 A2 Item A. Energy Saving for Electric Arc Furnace (EAF) Medium temperature batch scrap preheating EAF Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 40 kwh/tonproduct Reduction of dioxin emission, dispersing dust & noise No limit of material for high quality products as like stainless steel. 4. Japanese Main Supplier Daido Steel 5. Technologies Reference May contact to Daido Steel 6. Comments 14

17 A3 Item A. Energy Saving for Electric Arc Furnace (EAF) High efficiency oxyfuel burner/lancing for EAF Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 14.3 kwh/tonproduct Reduction of nitorgen in steel, quality improvement 4. Japanese Main Supplier Nikko, JP Steel Plantech 5. Technologies Reference SOACT 2nd edition (Add the word "High efficiency" to SOACT item for uptodate oxygen use), Diagram from Nikko 6. Comments <Source of "Electricity saving"> 0.14 GJ/ton in SOACT > 0.14 x 9.8/1000 = 14.3 kwh/ton 15

18 A4 Item A. Energy Saving for Electric Arc Furnace (EAF) Eccentric bottom tapping (EBT) on existing furnace Content 1. Process Flow or Diagram 2. Technology Definition/Specification Slag free tapping Reliable stopping and scraping mechanism Electricity Saving 15 kwh/tonproduct 3. Expected Effect of Technology Introduction Thermal Energy Savings Environmental benefits Cobenefits Increase in Fe & alloy yield, and productivity Improve steel quality 4. Japanese Main Supplier JP Steel Plantech, Daido Steel 5. Technologies Reference EPABACT (Sep. 2014), Diagram from JP Steel Plantech 6. Comments <Preconditions on calculating effects and investment costs> Values of "Electricity saving" are based on the EPABACT (Sep. 2014) & equipment supplier's rough estimation "Profit" does not include such other advantages than electricity saving 16

19 A5 Item A. Energy Saving for Electric Arc Furnace (EAF) Ultra highpower transformer for EAF Content 1. Process Flow or Diagram The Impedance characteristics of Transformer 2. Technology Definition/Specification 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 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 15 kwh/tonproduct Increase productivity 4. Japanese Main Supplier JP Steel Plantech, Nikko 5. Technologies Reference EPABACT ("Transformer efficiency ultrahigh power transformers"), Diagram from Nikko 6. Comments <Preconditions on calculating effects> "Electricity saving" 15 kwh/tonproduct comes from EPABACT, assuming that 44 MVA transformer for 80 ton EAF is revamped to 55 MVA. 17

20 A6 Item A. Energy Saving for Electric Arc Furnace (EAF) Optimizing slag foaming in EAF Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 6 kwh/tonproduct Noise reduction & working floor cleaning 4. Japanese Main Supplier JP Steel Plantech, Daido Steel 5. Technologies Reference SOACT 2nd Edition (Delete the word "Exchangeable Furnace and Injection Technology"), Diagram from JP Steel Plantech 6. 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). 18

21 A7 Item A. Energy Saving for Electric Arc Furnace (EAF) Optimized power control for EAF Content Statistical analysis Slag foaming detection 1. Process Flow or Diagram Heat loss supervision Power supply control for each phase 2. Technology Definition/Specification Data logging and visualization of melting process Automatic meltdown and additional scrap charging judgement Automatic phase power independent control for wellbalance melting 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 15 kwh/tonproduct Productivity increase Manpower saving 4. Japanese Main Supplier JP Steel Plantech 5. Technologies Reference SOACT 2nd Edition ("Improved Process Control (Neural Networks)"), Diagram from JP Steel Plantech 6. Comments 19

22 A8 Item A. Energy Saving for Electric Arc Furnace (EAF) Operation support system with EAF meltdown judgment Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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 Electricity Saving 6 kwh/tonproduct 3. Expected Effect of Technology Introduction Thermal Energy Savings Environmental benefits Cobenefits Productivity increase Manpower saving 4. Japanese Main Supplier Daido Steel 5. Technologies Reference May contact to Daido Steel 6. Comments 20

23 A9 Item A. Energy Saving for Electric Arc Furnace (EAF) Low NOx regenerative burner system for ladle preheating Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 40% fuel saving is expected comparing to existing preheater Low NOx Improving meltshop atmosphere by reducing hot gas which disturbs dirty gas suction at the canopy 4. Japanese Main Supplier ChugaiRo, Nippon Furnace 5. Technologies Reference Diagram from Chugai Ro, May contact to suppliers 6. Comments 21

24 A10 Item A. Energy Saving for Electric Arc Furnace (EAF) Oxygen burner system for ladle preheating Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 40% fuel saving is expected comparing to existing preheater Low NOx 4. Japanese Main Supplier ChugaiRo, JP Steel Plantech 5. Technologies Reference Diagram from Chugai Ro, May contact to suppliers 6. Comments 22

25 A11 Item A. Energy Saving for Electric Arc Furnace (EAF) Waste heat recovery from EAF Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 132 kwh/tonproduct 4. Japanese Main Supplier JP Steel Plantech 5. Technologies Reference Diagram from JP Steel Plantech, May contact to JP Steel Plantech 6. 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 23

26 A12 Item A. Energy Saving for Electric Arc Furnace (EAF) Energy saving for dedusting system in EAF meltshop Content 1. Process Flow or Diagram 2. Technology Definition/Specification Damper openings and exhaust fan rotation are controlled in consonance with the furnace operation pattern Combination of VVVF and proper damper opening 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 6 kwh/tonproduct Better working floor and atmosphere 4. Japanese Main Supplier JP Steel Plantech, Daido Steel 5. Technologies Reference Diagram from JP Steel Plantech, May contact to suppliers 6. Comments <Preconditions on calculating effects> Assumed electricity consumption for building dedusting is 24 kwh/tonproduct, and 25 % power saving is expected. 24

27 A13 Item A. Energy Saving for Electric Arc Furnace (EAF) Bottom stirring/stirring gas injection Content 1. Process Flow or Diagram 2. Technology Definition/Specification Inject inert gas (Ar or N2) into the bottom of EAF Better heat transfer steel quality 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 18 kwh/tonproduct Fe yield increase 0.5 % 4. Japanese Main Supplier JP Steel Plantech 5. Technologies Reference EPABACT, May contact to JP Steel Plantech 6. Comments <Preconditions on calculating effects> "Electricity saving" 15 kwh/tonproduct comes from EPABACT. 25

28 A14 Item A. Energy Saving for Electric Arc Furnace (EAF) Induction type tundish heater Content 1. Process Flow or Diagram 2. Technology Definition/Specification Electricity Saving 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) 3. Expected Effect of Technology Introduction Thermal Energy Savings Environmental benefits Cobenefits Productivity increase Quality improvement 4. Japanese Main Supplier Fuji Electric 5. Technologies Reference 6. Comments 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% 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 26

29 B1 Item B. Environmental Protection for Electric Arc Furnace Exhaust gas treatment through gas cooling, carbon injection, and bag filter dedusting for EAF Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits Better workfloor environment 4. Japanese Main Supplier JP Steel Plantech, Daido Steel 5. Technologies Reference SOACT 2nd Edition, Diagram from Daido Steel 6. Comments <Suitable site> Enough evacuation capacity for 30 m3n/ton O2, 20 m3n/ton NG, and 15 kg/ton carbon 27

30 B2 Item B. Environmental Protection for Electric Arc Furnace Floating dust control in EAF meltshop Content Floating dust detector 1. Process Flow or Diagram Dust loading after 30 sec. of scrap charge 2. Technology Definition/Specification 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 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. Building and suction system revamping shall be executed based on the flow analysis 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 4. Japanese Main Supplier JP Steel Plantech, Daido Steel 5. Technologies Reference Diagram from JP Steel Plantech, May contact to suppliers 6. Comments 28

31 B3 Item B. Environmental Protection for Electric Arc Furnace Dioxin adsorption by activated carbon for EAF exhaust gas Content 1. Process Flow or Diagram 2. Technology Definition/Specification 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 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 4. Japanese Main Supplier JFE Engineering 5. Technologies Reference Diagram from JFE Engineering, May contact to JFE Engineering 6. Comments 29

32 B4 Item B. Environmental Protection for Electric Arc Furnace Dioxin adsorption by mixing EAF exhaust gas with building dedusting gas Content 1. Process Flow or Diagram 2. Technology Definition/Specification Cooling direct evacuation gas by mixing with building dedusting gas 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits Dioxin will be lower than 5.0 ng TEQ/m3N 4. Japanese Main Supplier JP Steel Plantech, Daido Steel 5. Technologies Reference Diagram from Daido Steel, May contact to suppliers 6. Comments 30

33 B5 Item B. Environmental Protection for Electric Arc Furnace Dioxin adsorption by 2 step bagfilter technology for EAF exhaust gas Content Activated Carbon 1. Process Flow or Diagram 2. Technology Definition/Specification 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) 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits Dioxin will be lower than 0.5 ng TEQ/m3N 4. Japanese Main Supplier JP Steel Plantech, Daido Steel 5. Technologies Reference Diagram from Daido Steel, May contact to suppliers 6. Comments 31

34 B6 Item B. Environmental Protection for Electric Arc Furnace PKS charcoal use for EAF Content 1. Process Flow or Diagram 2. Technology Definition/Specification 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 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 4. Japanese Main Supplier JP Steel Plantech 5. Technologies Reference Diagram from JP Steel Plantech, May contact to JP Steel Plantech 6. 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 32

35 C1 Item C. Material Recycle for Electric Arc Furnace EAF dust and slag recycling system by oxygenfuel burner Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. Electricity Saving 3. Expected Effect of Technology Introduction Thermal Energy Savings Environmental benefits Cobenefits Zn material can be gained from EAF dust Concrete aggregate can be gained from EAF dust 4. Japanese Main Supplier Daido Steel 5. Technologies Reference Diagram from Daido Steel, May contact to Daido Steel 6. Comments 33

36 C2 Item C. Material Recycle for Electric Arc Furnace EAF slag agglomeration for aggregate use Content 1. Process Flow or Diagram Treatment Process for Electric Arc Furnace Slag Air 2. Technology Definition/Specification 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. Electricity Saving 3. Expected Thermal Energy Effect of Savings Cobenefits Technology Environmental Introduction benefits Reduce disposal cost of industrial waste Processing time for one heat of EAF : 10 minutes 4. Japanese Main Supplier Nikko 5. Technologies Reference Diagram from Nikko, May contact to Nikko 6. 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 % 34

37 D1 Item D. Energy Saving for Reheating Furnace Process control for reheating furnace Content Furnace temp. 1. Process Flow or Diagram Billet temp. 2. Technology Definition/Specification Setting furnace temperature by targeted billet temperature curve Precise air ratio control and O2 analysis in exhaust gas 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits GJ/tonproduct (1 % fuel saving from the base line of 1,450 MJ/ton) 4. Japanese Main Supplier ChugaiRo 5. Technologies Reference May contact to ChugaiRo 6. Comments 35

38 D2 Item D. Energy Saving for Reheating Furnace Low NOx regenerative burner total system for reheating furnace Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. Electricity Saving 3. Expected Effect of Thermal Energy GJ/t (about 13%) Technology Savings Introduction Environmental CO2 & NOx Reduction benefits Cobenefits 4. Japanese Main Supplier ChugaiRo, Nippon Furnace 5. Technologies Reference Diagram from Chugai Ro, May contact to suppliers 6. Comments 36

39 D3 Item D. Energy Saving for Reheating Furnace High temperature recuperator for reheating furnace Content 1. Process Flow or Diagram 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. Technology Definition/Specification Electricity Saving 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 3. Expected Effect of Technology Introduction Thermal Energy Savings Environmental benefits Cobenefits 4. Japanese Main Supplier ChugaiRo GJ/t (about 7%) CO2 & NOx Reduction 5. Technologies Reference Diagram from Chugai Ro, May contact to Chugai Ro 6. Comments <Preconditions on calculating effects> When 300 degc air temperature is raised to 500 degc 37

40 D4 Item D. Energy Saving for Reheating Furnace Fiber block for insulation of reheating furnace Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits GJ/t (about 2%) Reduction of Heat accumulation 4. Japanese Main Supplier ChugaiRo 5. Technologies Reference Diagram from Chugai Ro, May contact to Chugai Ro 6. 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 38

41 D5 Item D. Energy Saving for Reheating Furnace Air conditioning by absorption type refrigerating by using reheating furnace exhaust gas Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 3.0 kwh/tonproduct (compared to the air cooled electric chiller COP:3.5 / considering the auxiliaries consumption as 90kWh) 4. Japanese Main Supplier HITACHI Infrastructure Systems Co. 5. Technologies Reference Diagram from HITACHI Infrastructure Systems Co., May contact to HITACHI Infrastructure Systems Co. 6. Comments <Preconditions on calculating effects> compared to the air cooled electric chiller COP:3.5/ consider the auxiliaries consumption as 90kWh 39

42 E1 Item E. Common systems and General Energy Savings Inverter (VFD; Variable Frequency Drive) drive for motors Content 1. Process Flow or Diagram 2. Technology Definition/Specification 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. 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 13% (Depending on the country and conditions of the facility) CO2 Reduction 4. Japanese Main Supplier Hitachi, Ltd., Major electric equipment companies 5. Technologies Reference Diagram from Hitachi, Ltd., May contact to Hitachi, Ltd. 6. Comments <Preconditions on calculating effects> Annual operation : 3,600 h/y Unit cost of power : US$/kWh 40

43 E2 Item E. Common systems and General Energy Savings Energy monitoring and management systems Content Daily and monthly reports of energy balance 1. Process Flow or Diagram Online monitoring and logging system for energy currents Electric Power Steam Fuel Oxygen 2. Technology Definition/Specification 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) Electricity Saving 3. Expected Effect of Technology Introduction Thermal Energy Savings Environmental benefits Cobenefits 0.12 GJ/tsteel [*1, 2] 4. Japanese Main Supplier Major electric equipment suppliers 5. 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, Technology & Society, Utrecht University. *2 ETSU, Reduction of Costs Using an Advanced Energy Management System, Best Practice Programme, R&D Profile 33, Harwell, UK: ETSU 6. Comments 41

44 E3 Item E. Common systems and General Energy Savings Management of compressed air delivery pressure optimization Content 1. Process Flow or Diagram 2. Technology Definition/Specification '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 3. Expected Effect of Technology Introduction Electricity Saving Thermal Energy Savings Environmental benefits Cobenefits 285 MWh/y 4. Japanese Main Supplier Major electric equipment suppliers 5. Technologies Reference Energy saving Diagnosis Examples Common Equipment Volume, Energy conservation Center, Japan 6. 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 42

45 Contact Points of Supplier Companies Company Contact Points Technology 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, Technology & 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 43

46

47 ANNEX energy saving, environment and recycle technologies of steel industry

48

49 Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry Technologies Expected Effect of Technologies Introduction Reference[*2] [*3] No Title of Technology (SOACT base)[*1] SOACT NEDO EU BAT EPA BACT CO2 Reduction kg CO2/t of product Energy Savings (Electricity/ Fuel) GJ/t of product Cobenefits (Reduction of Water, Dust, SOx, etc.) 1 Sintering Sinter Plant Heat Recovery (Steam Recovery from Sinter Cooler Waste Heat) 23.8(N) /0.55, 0.25(N) SOx,NOx,Dust 2 Sinter Plant Heat Recovery (Power Generation from Sinter Cooler Waste Heat) kWh/t / District Heating Using Waste Heat /800TJ/y(S) 4 Dust Emissions Control Dust 5 Exhaust Gas Treatment through Denitrification, Desulfurization, and Activated Coke Packed Bed Absorption NOx,DXN,Hg 6 Exhaust Gas Treatment through Selective Catalytic Reduction SOx 7 Exhaust Gas Treatment through LowTemperature Plasma DXN 8 High Efficient (COG) Burner in Ignition Furnace for Sinter Plant [*4] 0.46(N) /0.01(S), 30%(S) 9 Exhaust Gas Treatment Through Additive Injection and Bagfilter Dedusting 10 Sintering machine ignition oven burner (NEDO) /0.01[30%] (N) 11 Partial recycling of waste gas (EUBAT) SOx,NOx,Dust Cokemaking 12 Coke Dry Quenching 97.5(S) 13 Coal Moisture Control 27.5(S) /0.3(S) 14 High Pressure Ammonia Liquor Aspiration System Fume 15 Stripping of ammonia from the waste water (EUBAT) Water 16 Waste water treatment (EUBAT) Water 17 Modern Leakproof Door Fume 18 Cleaning of oven doors and frame seals (EUBAT) Fume 19 Reduction of SO2 by coke oven gas desulphurisation (EUBAT) SOx 20 Land Based Pushing Emission Control System Fume(Dust) 21 Variable pressure regulation of ovens during the coking process (EU BAT) 1.47(N) /1.2(S) 22 VSD COG compressor (EPABACT) 23 Coke Plant Automation and Process Control System 3.8 / COGnonrecovery Coke Battery [*4] KWh/t(S)/ 25 Waste Plastics Recycling Process Using Coke Ovens Ironmaking 26 Top Pressure Recovery Turbine 25(S) 0.49(S)/ 27 Pulverized Coal Injection (PCI) System 212(N) /2.33(N:200kg inj.) 28 Pulverized coal injection to 225 kg/ton iron (EPABACT) 29 Oxyoil injection (EUBAT) 34.7 / Gas injection (EUBAT) 31 Injection of COG and BOF gas (EPABACT) Plastic injection (EUBAT) 33 Direct injection of used oils, fats and emulsions as reducing agents and of solid iron residues (EUBAT) 34 Improve Blast Furnace Charge Distribution 35 Use of high quality ores (EUBAT) 36 Charging carbon composite agglomerates (EPABACT) 37 Blast Furnace Gas and Cast House Dedusting /9tWater/tiron Water 38 Blast furnace gas recycling (EPABACT) 39 Bgas (fueling) Regerenative Reheating Furnace 40 Bgas (fueling) Ignition Burner of Sinter 41 Direct injection of used oils, fats and emulsions as reducing agents and of solid iron residues (EUBAT) 19.5 / Cast House Dust Suppression 43 Treatment and reuse of scrubbing water (EUBAT) 44 Hydrocyclonage of blast furnace sludge (EUBAT) 45 Slag Odor Control Odor 47

50 Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry Technologies Expected Effect of Technologies Introduction Reference[*2] [*3] No Title of Technology (SOACT base)[*1] SOACT NEDO EU BAT EPA BACT CO2 Reduction kg CO2/t of product Energy Savings (Electricity/ Fuel) GJ/t of product Cobenefits (Reduction of Water, Dust, SOx, etc.) 46 Slag heat recovery (EPABACT) 47 Blast Furnace Increase Hot Blast Temperature (>1100 Deg C) 48 Blast Furnace Increase Blast Furnace Top Pressure (>0.5 Bar Gauge) 49 Improvement of combustion in hot stove (EPABACT) 50 Blast Furnace Heat Recuperation 7.8(S) /0.08, 0.08(S), 0.126(N) 51 Optimized Blast Furnace Process Control with Expert System 24.4 / Alternative Ironmaking: Direct Reduction (DRI/HBI) and Direct Smelting 53 Smelting Reduction Processes 54 Direct Reduction Processes 55 Coal Based Rotary Hearth Furnace Type Ironmaking Process [*4] 56 Paired Straight Hearth Furnace 57 Coal and Lump Ore Based SmeltingReduction Type Ironmaking Process [*4] 58 Finex Process 59 Rotary Kiln Direct Reduction 60 Coal and Fine Ore Based DRI/HBI Production Process [*5] 61 Natural Gas Based ZeroReforming DRI/HBI Production Process using Fine Ore [*4] 62 Coal Synthesis Gas and Lump Ore/Pellet Based Shaft Furnace Type DRI/HBI Production Process [*4] 63 Natural Gas and Lump Ore/Pellet Based Shaft Furnace Type DRI/HBI Production Process with CO2 Removal System [*4] 64 Highefficiency cupola (NEDO) Steelmaking 65 Online Feedback Analyzer for Efficient Combustion [*4] 66 ProVision Lancebased Camera System for Vacuum Degasser Realtime Melt Temperature Measurement 67 Hot Metal Pretreatment 68 Programmed and efficient ladle heating (EPABACT) 69 Increase Thermal Efficiency by Using BOF Exhaust Gas as Fuel 70 Use Enclosures for BOF 71 Control and Automization of Converter Operation 72 OGboiler System (Noncombustion)/Drytype Cyclone Dust Catcher 12.0(N) /0.13(N) 73 Exhaust Gas Cooling System (Combustion System) 46 / Converter gas recovery device (NEDO) 79.8(N) /0.84(N) 75 Laser Contouring System to Extend the Lifetime of BOF Refractory Lining 76 BOF Bottom Stirring 77 VSD on ventilation fans (EPABACT) / 78 Dust hot briquetting and recycling with recovery of high zinc concentrated pellets for external reuse (EUBAT) 79 Elimination of Radiation Sources in EAF Charge Scrap 80 Improved Process Control (Neural Networks) / 81 Hot DRI/HBI Charging to the EAF 82 Oxyfuel Burners/Lancing / 83 Scrap Preheating , 0.126(N)/ 84 New scrapbased steelmaking process predominantly using primary energy / Twinshell DC with scrap preheating (EPABACT) / 86 Bottom stirring/stirring gas injection (EPABACT) / 87 Eccentric bottom tapping on existing furnace (EPABACT) / 88 Postcombustion of the flue gases (EPABACT) 89 Engineered refractories (EPABACT) 0.036/ 90 Adjustable speed drives (ASDs) (EPABACT) 0.05/ 91 Transformer efficiency ultrahigh power transformers (EPABACT) / 92 Control and Automation for EAF Optimization 48

51 Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry Technologies Expected Effect of Technologies Introduction Reference[*2] [*3] No Title of Technology (SOACT base)[*1] SOACT NEDO EU BAT EPA BACT CO2 Reduction kg CO2/t of product Energy Savings (Electricity/ Fuel) GJ/t of product Cobenefits (Reduction of Water, Dust, SOx, etc.) 93 Slag Foaming, Exchangeable Furnace and Injection Technology / 94 Airtight operation (EPABACT) 0.36/ 95 Exhaust Gas Treatment Through Gas Cooling, Carbon Injection and Bagfilter Dedusting DXN, Dust 96 Ecological and Economical Arc Furnace [*4] DXN, Dust, Noise 97 Waste Heat Recovery from EAF /tsteel 98 DC arc furnace (NEDO) , 0.11(N)/ 99 Shafttype Continuous EAF [*4] (EPABACT) 0.72/ Ladle Refining and Casting 100 Efficient caster ladle/tundish heating (EPABACT) / Casting 101 Strip Casting Technology [*4] 102 Thin Slab Casting and Hot Rolling 103 Hot Charging to Reheat Furnace of Rolling Mills 104 Near net shape strip casting (EUBAT) / Near net shape casting strip (EPABACT) Recycling and Waste Reduction 106 Reducing Fresh Water Use /20MLwater/day(S) Water 107 Slag Recycling Dust 108 Pressurizationtype Steam Aging Equipment for Steel Slag 109 EAF slag processing (EUBAT) Dust 110 Treatment of high alloyed and stainless steel EAF slags (EUBAT) Dust 111 Rotary Hearth Furnace Dust Recycling System 22.8(S) /1400TJ/y(S) Dust 112 Bag filter combined or integrated reduction of solid and gaseous pollutants (EUBAT) Common Systems 113 Auditing Rotary Machines for Pump Efficiency 2030%(S) / 55,069t/y(S) AIRMaster+ Software Tool Improved Compressed Air System 993TJ/y(S) 114 (assessments Performance (assessments 139)/ 139) Combined Heat and Power Tool Improved Overall Plant Efficiency 115 and Fuel Use 116 Fan System Assessment Tool Efficiency Enhancement for Industrial Fan Systems MotorMaster+ International CostEffective Motor System Efficiency 117 Improvement NOx and Energy Assessment Tool Reduced NOx Emissions and 118 Improved Energy Efficiency Process Heating Assessment and Survey Tool Identify Heat Efficiency Improvement Opportunities Quick Plant Energy Profiler First Step to Identify Opportunities for Energy Savings 121 Steam System Tools Tools to Boost Steam System Efficiency 122 Inverter (VVVF; Variable Voltage Valiable Frequency) Drive for Motors [*4] 3,022t/y(S) (assessments 36) 273,638t/y(S) (assessments 225) 1,472,115t/y(S) (assessments 306) Regenerative Burner Total System for reheating furnace [*5] (N) 124 Techniques to improve heat recovery (EUBAT) 53TJ/y(S) (assessments 36) / 5375TJ/y(S) (assessments 225)/22%(S) 20148TJ/y(S) (assessments 306)/ 42%(S), 0.02/ /2050%(S), (N) SOx Air leak NOx 49

52 Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry Technologies Expected Effect of Technologies Introduction Reference[*2] [*3] No Title of Technology (SOACT base)[*1] SOACT NEDO EU BAT EPA BACT CO2 Reduction kg CO2/t of product Energy Savings (Electricity/ Fuel) GJ/t of product Cobenefits (Reduction of Water, Dust, SOx, etc.) General Energy Savings & Environmental Measures 125 Energy Monitoring and Management Systems 11.4(S) 0.01/0.12[0.5%](S), Cogeneration (include Gas Turbine Combined Cycle (GTCC)) 56.1(S) 1.1(S), 0.35/ Technology for Effective Use of Slag 340(S) 128 Hydrogen Production 129 Carbonation of Steel Slag 17%(S) 130 Byproduct generator set (NEDO) Ironworks byproduct gas, singlefuelfiring, highefficiency, 131 combined generator set (NEDO) Management of steam traps in steam piping and drain water recovery 1.5GJ/y(N) 132 (NEDO) /1.5tWater/h](N) Power recovery by installation of steam turbine in steam pressure 47,652GJ/y(N) /0.8tsteam/h(N) 133 reducing line (NEDO) Management of Compressed Air Delivery Pressure Optimization [*4] 134 (NEDO) 285MW/h/y(N) / 135 Improving thermal insulation in industrial furnace (NEDO) /840GJ/y(N) 136 Preventive Maintenance (EPABACT) /0.43 [*1] Description within ( ) indicates the technologies reference name. The title without ( ) refers to SOACT. [*2] SOACT; The State oftheart Clean Technologies (SOACT) for Steelmaking Handbook (2nd Edition, 2010) NEDO; Japanese Technologies for Energy Savings/GHG Emissions Reduction 2008 Revised Edition EUBAT; Best Available Techniques (BAT) Reference Document for Iron and Steel Production (Draft version, 24 June 2011) EPABACT; Available and Emerging Technologies for Reducing Greenhouse Gas Emissions from the Iron and Steel Industry(2010) [*3] Referred to EPABACT(pp.912), SOACT(S), and NEDO(N). In the case of EPABACT, there is no "( )" at the end of the value. [*4] Arranged title after replacing trademark or trade name with technical terms [*5] Arranged in a comprehensible title Water Steam 50

53 ANNEX 2.

54

55 Technologies for Blast Furnace No Title of Technology Technology Description Sintering CO2 Reduction kg CO2/t of product Expected Effect of Introduction Electricity Fuel Savings Savings GJ/t GJ/t of product of product Cobenefits (Reduction of Water, Dust, SOx, etc.) 1 Sinter Plant Heat Recovery (Steam Recovery from Sinter Cooler Waste Heat) This device recovers the sensible heat in the hot air with temperature of 250 to 450 from a sinter cooler. The sensitive heat can be recovered by one or more of the following ways: steam generation in a waste heat boiler hot water generation for local heating preheating combustion air in the ignition furnace power generation SOx, NOx, Dust 2 Sinter Plant Heat Recovery (Power Generation from Sinter Cooler Waste Heat) This is a waste gas sensible heat recovery system from sinter cooler to generate electric energy. The system is composed of dust collector, waste heat recovery boiler as steam, circulation fan and power generator by steam turbine kwh/tsinter High Efficient (COG) Burner in Ignition Furnace for Sinter Plant Cokemaking The multislit burner is designed to form a successive and uniform frame along a pallet width direction in the ignition furnace. It consists of fuel exhaust nozzles and a slitlike burner tile containing these nozzles. The fuel, coke oven gas, supplied from the fuel exhaust nozzles reacts with the primary air inside the burner tile, then with the secondary air supplied to the periphery area of the frame. By lining up the burner block, the frame can cover the whole surface of the bed along the width direction. By controlling the primary/secondary air ratio, the length of the frame can be controlled to minimize the energy consumption for ignition Coke Dry Quenching The heat recovered by inert gas is used to produce steam, which may be used onsite or to generate electricity. Hot coke from the coke oven is cooled in specially designed refractory lined steel cooling chambers by countercurrently circulating an inert gas media in a closed circuit consisting of 1) cooling chamber 2) dust collecting bunker 3) waste heat boiler 4) dust cyclones 5) mill fan 6) blowing device (to introduce the cold air from the bottom) 7) circulating ducts 8) Capacity ;The nominal capacity of a typical CDQ plant is less than 100 t/h/chamber.(eubat) 260t/h(China/ Shougang Jingtang/NSCENG) 97.5/tcoke 1.47/tcoke 1.2/tcoke 5 Coal Moisture Control Coal moisture control uses the waste heat from the coke oven gas to dry the coal used for coke making. The moisture content of coal varies, but it is generally around 89% for good coking coal. Drying further reduces the coal moisture content to a constant 35%, which in turn reduces fuel consumption in the coke oven. The coal can be dried using the heat content of the coke oven gas or other waste heat sources.[soact]generally, lowpressure steam is used as the humidity control heat source.[nedo] 27.5/tcoke 0.3/tcoke Ironmaking 6 Top Pressure Recovery Turbine This system generates electric power by employing blast furnace top gas to drive a turbinegenerator. After the blast furnace gas is used in power generation, it is used as a fuel in iron and steel manufacturing processes. This technology is a method of generating power by employing this heat and pressure to drive a turbinegenerator. The system comprises dust collecting equipment, a gas turbine, and a generator. Generating methods are classified as (1) wet or (2) dry depending on the Bgas purification method. Dust is removed by Venturi scrubbers in the wet method and by a drytype dust collector in the dry method. 25.0/tPI 0.49/tPI This system comprises a technology and equipment for injecting pulverized coal directly through the blast furnace tuyeres as a partial substitute for the coke used in the blast furnace. Because pulverized coal is 7 Pulverized Coal Injection (PCI) System injected directly, the corresponding amount of coke is unnecessary, making it possible to reduce energy consumption for coke making (coke dry distillation energy). 212/tPI 2.33/tPI (at 200kg coal inj.) 8 Hot Stove Waste Heat Recovery Steelmaking 9 Converter Gas Recovery device This device recovers the sensible heat of the flue gas generated in heating the hot stoves which supply hot blast to the blast furnace and uses this heat in preheating fuel and combustion air for the hot stoves. Installation of this device improves the combustion efficiency of the hot stoves, thereby saving energy. 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.) 7.8/tPI 0.08/tPI 79.8/tCS 0.84/tCS General Energy Savings & Environmental Measures 10 Cogeneration (include Gas Turbine Combined Cycle (GTCC)) This equipment is a highefficiency(47.5%, HHV Base) combined generator set using the byproduct gas produced during iron and steel manufacturing process as the fuel. This equipment is an iron and steel byproduct gas fired combined generator set, in which the gas turbine is operated by hightemperature 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 hightemperature (appprox. 550 ) gas discharged from the gas turbine to the exhaust heat recovery boiler. 56.1/tCS 1.1/tCS Recycling and Waste Reduction 11 Rotary Hearth Furnace Dust Recycling System Dust recycling in the rotary hearth furnace (RHF) was applied at Nippon Steel s Kimitsu Works in The dust and sludge, along with iron oxide and carbon, are agglomerated into shaped articles and the iron oxide is reduced at high temperatures. Zinc and other impurities in the dust and sludge are expelled and exhausted once into offgas. The exhaust gas containing zinc is cooled using a boiler and recuperator and then, the secondary dust containing condensed zinc is collected in a precipitator. 22.8/tPI 0.21/tPI Dust 53

56

57 ANNEX 3.

58

59 Introduction Japan is offering various financial support programs aiming at promoting diffusion of Japanese superior technologies and products in other countries, especially in the area where difficulties of securing funds exist. The financial support offered by Japan includes: Demonstration Project (NEDO) Export Loans (JBIC) GREEN (JBIC) and etc. Though it is expected that by mobilizing those financial support programs, in order to contribute further diffusion of energy saving, environmental protection and recycling technologies in steel industry, detailed policies are currently under discussion. Demonstration Project (NEDO) The purpose of New Energy and Industrial Technology Development Organization (NEDO) s Demonstration Projects is to demonstrate the effectiveness of advanced Japanese clean energy and environmental technologies through the introduction of such technologies in overseas countries. Under the Demonstration Project scheme, costs are shared between Japan and the host country. In executing the Demonstration Project, with focus on technologies and systems in which Japan is strong, roles are shared with government of host country and related organization considering needs of government and industry of host country. Demonstration Project consists of three projects namely Feasibility Study (F/S), Model Project and Followup Activities. Feasibility Study (F/S) Verifying feasibility of the project. Model Project Actually bringing in Japanese technologies and systems and verifying effect of those technologies and systems as well as verifying new business model. 57

60 Followup Activities Promoting diffusion of verified technologies and systems and collecting information for formation of new projects. Export Loans (JBIC) Japan Bank for International Cooperation (JBIC) s Export Loans is provided to overseas importers and financial institutions to support finance exports of Japanese machinery, equipment and technology mainly to developing countries. In particular, products such as marine vessels, power generation facilities and other types of plant equipment incorporate a large amount of advanced technology, and their export contributes to enhancing the technological base of Japanese industries. Further, Japanese shipbuilding and plant facilities industries have a broad range of supporting industries including SMEs producing parts and components. Export loans are also available to developed countries in eligible sectors. 58

61 GREEN (JBIC) Japan Bank for International Cooperation (JBIC) s GREEN (Global action for Reconciling Economic growth and ENvironmental preservation) is a scheme which allows JBIC to support for projects undertaken in developing countries that are having a favorable impact on the preservation of the global environment. Under the GREEN scheme JBIC finances projects aimed at preserving the global environment, such as projects that significantly reduce greenhouse gas (GHG) emissions. Joint Crediting Mechanism (JCM) The JCM is possible winwin scheme for both of Japan and host country in terms of lowcarbon technologies transfer and GHG emission reduction. The JCM facilitates diffusion of leading low carbon technologies, products, systems, services, and infrastructure as well as implementation of mitigation actions, and contributing to sustainable development of developing countries. The JCM scheme appropriately evaluate contributions to GHG emission reductions or removals from Japan in a quantitative manner, by applying measurement, reporting and verification (MRV) methodologies, and use them to achieve Japan s emission reduction target. The JCM contributes to the ultimate objective of the UNFCCC by facilitating global actions for GHG emission reductions or removals, complementing the CDM. 59