eastern asia steel research
TRANSCRIPT
-
8/18/2019 Eastern Asia Steel Research
1/27
Japan
Research activity for energy conservation in
Eastern-Asian steel industry in fiscal year 2009.
Basic research for energy conservationBasic research for energy conservation
and environment protectionand environment protection
in Easternin Eastern--Asian steel industry.Asian steel industry.(Final Report)(Final Report)
Presented at the 2nd ERIA Working Group Meeting
March 3, 2010
Jakarta, Indonesia
Yutaka Suzukawa
JFE Techno-Research Corporation, Japan 1
-
8/18/2019 Eastern Asia Steel Research
2/27
Japan
Research and analyze actual conditions of Eastern-Asian steelindustry in the field of energy conservation and environment
protection by referring to the Japanese countermeasures and to
specify effective energy saving and CO2 emission reduction
measures for each country. And build up the global database of
the Eastern-Asian steel mills, and execute trial calculation of the potential CO2 emission reduction volume.
Target countries
Indonesia, Malaysia, Philippines, Singapore, Thailand, Brunei Darussalam,
Vietnam, Laos PDR, Myanmar, Cambodia, China, India, Republic of Korea,
Australia, New Zealand and Japan.
Purpose of the project
2
-
8/18/2019 Eastern Asia Steel Research
3/27
Japan
3
Trend of Energy Conservation Activities
of Steel Industry in Japan
20% reduction achieved Target : 10% reduction
Source : The Japan Iron and Steel Federation (2008)
-
8/18/2019 Eastern Asia Steel Research
4/27
Japan Steel Making Process (Blast Furnace System)
Raw Material
LimestoneCokes
Iron Ore
Sinter PlantCoke Oven
Blast Furnace
Scrap
Electric Arc Furnace
Converter
Reheating Furnace Rolling Mills
Energy Source
☆ Electricity
☆
Coke/Coal
☆ Natural Gas
☆
Oil
☆
Others
Continuous
CastingMachine
ProductsRail
Bar
Wire
Shaped Bar Thick Plates
Hot Rolled Coil
Cold Rolled Coil
Galvanized Plates
Welded Pipes
Seamless Pipes
Other products 4
⑮⑯
④③②①
⑨⑧⑦⑥
⑤
⑭
⑬
⑫⑪
⑩
(①~⑯:See Energy Saving Measures on Page 5)
-
8/18/2019 Eastern Asia Steel Research
5/27
Japan Steel Making Process (Electric Arc Furnace System)
Scrap
Electric Arc Furnace
Reheating Furnace Rolling Mills
Energy Source
☆ Electricity
☆
Coke/Coal
☆ Natural Gas
☆
Oil
☆
Others
Continuous
CastingMachine
Products
Bar
Wire
Shaped Bar Thick Plates
Hot Rolled
Coil
Galvanized
Plates
Welded Pipes
Other products 5
⑭
⑬
(①~⑯:See Energy Saving Measures on Page 7)
DRI
-
8/18/2019 Eastern Asia Steel Research
6/27
Japan Energy Saving Measures
6
-
8/18/2019 Eastern Asia Steel Research
7/27
Japan Energy Saving Measures
7
Facility Energy Saving Measures No.
Coke Oven Gas Recovery ①Coke Dry Quenching ②
Coal Moisture Control ③
Main Exhaust Gas Waste Heat Recovery ④
Cooler Exhaust Gas Waste Heat Recovery ⑤
Blast Furnace Gas Recovery ⑥
Top Pressure Recovery Turbine ⑦Hot Stove Waste Heat Recovery ⑧
Top Pressure Equalizing Gas Recovery ⑨
Pulvarized Coal Injection ⑩
Converter Gas Recovery ⑪
Converter Gas Sensible Heat Recovery ⑫
Electric Arc Furnace Scrap Preheating ⑬Hot Rolling Reheating Furnace Exhaust Gas Waste Heat Recovery ⑭
Power Plant Gas Turbine Combined Cycle ⑮
Gas Holder Gas Holder for Each Gas ⑯
Coke Oven
Sinter Plant
Blast Furnace
Converter
-
8/18/2019 Eastern Asia Steel Research
8/27
Japan Steel Production of the World (2009)
8
Country
BF ( A ) DRI ( B ) EAF ( C )
China 543,748 24,094 567,842 46.6%Japan 66,943 20,591 87,534 7.2%
India 29,646 21,035 5,927 56,608 4.6%
Republic of Korea 27,278 21,320 48,598 4.0%
Australia 4,370 879 5,249 0.4%
Malaysia 0 6,000 6,000 0.5%
Thailand 0 5,000 5,000 0.4%
Indonesia 0 3,500 3,500 0.3%
Vietnam 200 1,800 2,000 0.2%
New Zealand 608 157 765 0.1%
Philippines 0 700 700 0.1%
Singapore 0 750 750 0.1%
Myanmar 0 25 25 0.0%
Brunei Darussalam 0 0 0 0.0%Lao PDR 0 0 0 0.0%
Cambodia 0 0 0 0.0%
ERIA Total 672,793 21,035 90,743 784,571 64.3%
World Total 899,825 52,176 267,714 1,219,715 100.0%
Crude Steel (1,000t)
( A )+( B )+( C )
Process (1,000t)
-
8/18/2019 Eastern Asia Steel Research
9/27
Japan
9
Steel Production of the World
Country 2007 09/07
BF DRI EAFChina 489,288 36.4% 543748 0 24,094 567,842 46.6% 116%
Japan 120,203 8.9% 66943 0 20,591 87,534 7.2% 73%
India 53,080 3.9% 29646 21035 5,927 56,608 4.6% 107%
Republic of Korea 51,517 3.8% 27278 0 21,320 48,598 4.0% 94%
Australia 7,939 0.6% 4370 0 879 5,249 0.4% 66%
Malaysia 6,895 0.5% 0 0 6,000 6,000 0.5% 87%
Thailand 5,565 0.4% 0 0 5,000 5,000 0.4% 90%Indonesia 4,160 0.3% 0 0 3,500 3,500 0.3% 84%
Vietnam 2,024 0.2% 200 0 1,800 2,000 0.2% 99%
New Zealand 845 0.1% 608 0 157 765 0.1% 91%
Philippines 718 0.1% 0 0 700 700 0.1% 97%
Singapore 640 0.0% 0 0 750 750 0.1% 117%
Myanmar 25 0.0% 0 0 25 25 0.0% 100%
Brunei Darussalam 0 0.0% 0 0 0 0 0.0% -Lao PDR 0 0.0% 0 0 0 0 0.0% -
Cambodia 0 0.0% 0 0 0 0 0.0% -
ERIA Total 742,899 55.2% 672793 21035 90,743 784,571 64.3% 106%
World Total 1,345,822 100.0% 899825 52176 267,714 1,219,715 100.0% 91%
Total
2009
-
8/18/2019 Eastern Asia Steel Research
10/27
Japan
10
Energy Saving Measures and Potential
( I E A )
Energy saving potential in steel industry (Mostly Blast Furnace System)
reported by IEA 2008, based on the best available technology.
-
8/18/2019 Eastern Asia Steel Research
11/27
Japan
0
500
1,000
1,500
2,000
2,500
3,000
3,500
C h i n a J a p a n I n d i a
R e p u b l i
c o f K
o r e a
A u s t r
a l i a
M a l a
y s i a
T h a i l a n d
I n d o n e s i a
V i e t n
a m
N e w Z e
a l a n d
P h i l i p
p i n e s
S i n g a p o r e
M y a n m a r
B r u n e i D a
r u s s a l a m
L a o P
D R
C a m b
o d i a
E R I A
T o t a l
Energy Saving Potential
(Blast Furnace System)
11
E n e
r g y S a v i n g P o t e n t i a l ( P J / y e a r )
Calculation is based on IEA2008 potential data and 2007 production data.
China 2,654.2
Japan 72.0
India 210.4
Re public of Kore a 27.1
Australia 24.8
Malaysia 0.0
Thailand 0.0
Indonesia 0.0
Vietnam 0.0
New Zealand 2.6
Philippines 0.0Singapore 0.0
Myanmar 0.0
Brune i Darussalam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 2,991.2
-
8/18/2019 Eastern Asia Steel Research
12/27
Japan
12
Potential of CO2 reduction in steel industry (Mostly Blast Furnace System)
reported by IEA 2008, based on the best available technology.
CO2 Reduction Measures and Potential
( I E A )
-
8/18/2019 Eastern Asia Steel Research
13/27
Japan
0
50,000
100,000
150,000
200,000
250,000
300,000
C h i n a
J a p a n I n d i a
R e p u b l i c
o f K o r e a
A u s t r a l i a
M a l a
y s i a
T h a i l a n d
I n d o n e s i a
V i e t
n a m
N e w
Z e a l a n d
P h i l i
p p i n e s
S i n g a p o r e
M y a n m a r
B u r n e i D a
r u s s a l a m
L a o P D R
C a m b o d i a
E R I A
T o t a l
CO2 Reduction Saving Potential
(Blast Furnace System)
13
C O
2 R e d
u c t i o n P o t e n t i a l ( 1 , 0
0 0 t C O
2 / y e a r )
Calculation is based on IEA2008 potential data and 2007 production data.
China 228,727.7
Japan 6,074.0
India 17,585.1Re public of Kore a 2,355.0
Australia 445.8
Malaysia 0.0
Thailand 0.0
Indonesia 0.0
Vietnam 0.0
New Zealand 47.5
Philippines 0.0Singapore 0.0
Myanmar 0.0
Brunei Darussalam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 255,235.1
-
8/18/2019 Eastern Asia Steel Research
14/27
Japan
E l e c
t r i c i t y C o n s u m p t i o n ( k W h / t o n )
Energy Saving Potential
of Electric Arc Furnace
14
0
100
200
300
400
500
600
700
800
900
0 20 40 60 80 100 120 140 160
Japan
SEA countries
SEA 420 kWh/t
Japan 370 kWh/t
Furnace Capacity (ton/charge)
-
8/18/2019 Eastern Asia Steel Research
15/27
Japan
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
C h i n a
J a p a n
I n d i a
R e p u b l i c
o f K o r e a
A u s t r a l i a
M a l a
y s i a
T h a i l a n d
I n d o n e s i a
V i e t n
a m
N e w Z e
a l a n d
P h i l i
p p i n e
s
S i n g a p o r e
M y a n m
a r
B r u n e i D a
r u s s a l a m
L a o P
D R
C a m b o
d i a
E R I A
T o t a l
E n e r g y S a v i n g P o t e
n t i a l ( P J / y e a r )
Energy Saving Potential
of Electric Arc Furnace
15
China 6.1
Japan 0.0
India 2.9Republic of Korea 10.5
Australia 0.7
Malaysia 3.3
Thailand 2.6
Indonesia 2.0
Vietnam 0.9
New Zealand 0.1
Philippines 0.3Singapore 0.3
Myanmar 0.0
Brunei Darussalam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 29.8
-
8/18/2019 Eastern Asia Steel Research
16/27
Japan
0
500
1,000
1,500
2,000
2,500
3,000
C h i n a
J a p a
n I n
d i a
R e p u b l i c
o f K o r e a
A u s t r a l i
a
M a l a
y s i a
T h a i l
a n d
I n d o n e s i a
V i e t n
a m
N e w Z e
a l a n d
P h i l i
p p i n e
s
S i n g a p
o r e
M y a n m
a r
B u r n e i D a
r u s s a l a m
L a o P
D R
C a m b o
d i a
E R I A
T o t a l
CO2 Reduction Potential
of Electric Arc Furnace
C O
2 R e d
u c t i o n P o t e n t i a l ( 1 , 0
0 0 t C O
2 / y e a r )
16
China 510.9
Japan 0.0
India 247.8
Republic of Korea 883.2
Australia 62.8
Malaysia 275.8
Thailand 222.6
Indonesia 166.4
Vietnam 74.2
New Zealand 6.6
Philippines 28.7
Singapore 25.6
Myanmar 1.0
Brunei Darussalam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 2,506
-
8/18/2019 Eastern Asia Steel Research
17/27
Japan
F u e l C o n s u m p
t i o n ( M J / t o n )
Heating Capacity of Furnace (ton/h)
Energy Saving Potential
of Reheating Furnace
17
0
500
1000
1500
2000
2500
0 50 100 150 200 250
Japan
SEA countries
SEA 1,440 MJ/t
Japan 1,000 MJ/t
-
8/18/2019 Eastern Asia Steel Research
18/27
Japan
0
50
100
150
200
250
C h i n a
J a p a n
I n d i a
R e p u b l i
c o f K
o r e a
A u s t r
a l i a
M a l a
y s i a
T h a i l
a n d
I n d o n
e s i a
V i e t n
a m
N e w Z e
a l a n d
P h i l i p
p i n e s
S i n g a p o
r e
M y a n m
a r
B r u n
e i D a
r u s s a l
a m
L a o P
D R
C a m b
o d i a
E R I A
T o t a l
E n e r g y S a v i n g P o t e
n t i a l ( P J / y e a r )
Energy Saving Potential
of Reheating Furnace
18
China 193.1
Japan 0.0
India 19.2Republic of Korea 16.5
Australia 1.8
Malaysia 2.0
Thailand 1.7
Indonesia 1.2
Vietnam 0.7
New Zealand 0.3
Philippines 0.2Singapore 0.3
Myanmar 0.0
Brunei Darussalam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 237.0
-
8/18/2019 Eastern Asia Steel Research
19/27
Japan
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
C h i n a
J a p a n
I n d i a
R e p u b l i c
o f K o r e a
A u s t r a l i a
M a l a
y s i a
T h a i l a n d
I n d o n e
s i a
V i e t
n a m
N e w Z e
a l a n d
P h i l i
p p i n e
s
S i n g
a p o r e
M y a n m
a r
B r u n e i D a
r u s s a l a
m
L a o P
D R
C a m b o
d i a
E R I A
T o t a l
CO2 Reduction Potential
of Reheating Furnace
C O
2 R e d u c t i o n P o t e n t i a
l ( 1 , 0
0 0 t C O
2 / y e a r )
19
China 10,811.7
Japan 0.0
India 1,077.8
Republic of Korea 925.3
Australia 99.9
Malaysia 132.0
Thailand 107.0
Indonesia 78.0
Vietnam 39.0
New Zealand 14.6
Philippines 13.3Singapore 14.3
Myanmar 0.0
Brune i Darus salam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 13,313
-
8/18/2019 Eastern Asia Steel Research
20/27
Japan
0
500
1,000
1,500
2,000
2,500
3,000
3,500
C h i n
a
J a p a
n I n
d i a
R e p u b l i c
o f K
o r e a
A u s t r a l i a
M a l a y s i a
T h a i l a
n d
I n d o
n e s i a
V i e t n a m
N e w Z e
a l a n d
P h i l i p
p i n e
s
S i n g a p
o r e
M y a
n m a r
B r u n
e i D a r u s s a l a
m
L a o P D
R
C a m b o
d i a
E R I A
T o t a l
Energy Saving Potential (Total)
E n e
r g y S a v i n g P o t e n t i a l ( P J / y e a r )
20
China 2,853.3
Japan 72.0
India 232.6Republic of Korea 54.1
Australia 27.4
Malaysia 5.3
Thailand 4.3
Indonesia 3.2
Vietnam 1.6
New Zealand 3.0
Philippines 0.6
Singapore 0.6
Myanmar 0.0
Brunei Darussalam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 3,258.0
-
8/18/2019 Eastern Asia Steel Research
21/27
Japan
0
50,000
100,000
150,000
200,000
250,000
300,000
C h i
n a
J a p a n
I n d i a
R e p u b l i c
o f K
o r e a
A u s t r a l i a
M a l a y s i a
T h a i l a
n d
I n d o n e
s i a
V i e t n a
m
N e w Z e
a l a n d
P h i l i p
p i n e
s
S i n g a p
o r e
M y a n m
a r
B r u n
e i D a r u s s a l a
m
L a o P D
R
C a m b o
d i a
E R I A
T o t a l
CO2 Reduction Potential (Total)
C O
2 R e d u c t i o n P o t e n t i a l ( 1 , 0
0 0 t C O
2 / y e
a r )
21
China 240,050.3
Japan 6,074.0
India 18,910.7Republic of Korea 4,163.5
Australia 608.6
Malaysia 407.8
Thailand 329.6
Indonesia 244.4
Vietnam 113.2
New Zealand 68.7
Philippines 42.0Singapore 39.9
Myanmar 1.0
Brunei Darussalam 0.0
Lao PDR 0.0
Cambodia 0.0
ERIA Total 271,053.6
-
8/18/2019 Eastern Asia Steel Research
22/27
Japan
22
Advanced Technology
Advanced Electric Arc Furnace integrated with high-
efficiency shaft-type scrap pre heater (Advanced EAF).
Electricity
Consumption
420 kWh/ton(ERIA Countries)
370 kWh/ton(Japan)
270 kWh/ton(Advanced EAF)
-
8/18/2019 Eastern Asia Steel Research
23/27
Japan
23
Advanced Technology
Ceramic
Regenerator B
Fuel
Burner A
Fuel
Burner B
Air
Switch valveExhaust gas 200℃
Ceramic
Regenerator
A
Furnace temperature
1350 C
Billets 1250Billets 1250 CC
Regenerative Burner Heating System for Reheating Furnaces.
Fuel Consumption ▲20% compared withconventional burner heating system.
-
8/18/2019 Eastern Asia Steel Research
24/27
Japan
CO2 Data Collection System
(Worldsteel)
Worldsteel has issued the
method as a guideline . And
actual data collection among
worldsteel members based
upon the guide started in
2007.
This standard stipulates the method of comparing and evaluating thequantity and emission factor of CO2 emissions by the entire steel
production process. This means that regardless of the equipment
configuration of each steel plant, it is possible to compare and evaluate
CO2 emissions of steel production processes worldwide by the same
method
Standardization of Steel Data Collection
In many ERIA countries, energy consumption and CO2
emission data are not collected nor statistically analyzed.
24
-
8/18/2019 Eastern Asia Steel Research
25/27
Japan Environmental Issues
25
Country SOx NOx Dust
Japan q=K ×10-3He2 220 ppm 150 mg/ N
China 2860 mg/ N 240 mg/ N 150 mg/ N
India 800 mg/
N 500 mg/
N 50 mg/
N
Malaysia ― 2000 mg/ N 200 mg/ N
Thailand 800ppm(25℃,1atm,O2 7%)
180ppm
(25℃,1atm,O2 7%)
240 mg/
(25℃,1atm,O2 7%)
Indonesia 800 mg/
(25℃,1atm)
1000 mg/
(25℃,1atm)
230 mg/
(25℃,1atm,O2 10%)Vietnam 500 mg/ N 850 mg/ N 200 mg/ N
Philippines 200 mg/ N 500 mg/ N 200 mg/ N
Most countries have their environmental standards.
Example of Air Quality Standards.
-
8/18/2019 Eastern Asia Steel Research
26/27
Japan Environmental Issues
26
Followings are the proposals for environmental issues.
1. Stimulate more concerns on environment. Managers should appoint a person to treat environmental
issues. Education for environmental protection is
recommended.
2. Environment friendly operation and maintenance of
environment protection facilities are recommended. Adopt low dust emission operation and plan periodical
maintenance of filters.
3. Make laws for utilization of steel by-products.
Make plans for effective use of slug.
4. Environmental protection regulations should be technicallyand economically adoptable.
If not adoptable, they may hinder economic growth.
-
8/18/2019 Eastern Asia Steel Research
27/27
Japan
27
Prevalence of the Results
The report has been translated into English, and it will be open to public.
The report will be sent to Iron and Steel Institute of ERIA countries, steel
companies who have accepted our visit and all the representatives of ERIA
countries.
Acknowledgements
We would like to thank SEAISI and Iron and Steel Institutes of ERIA
countries for providing us valuable information. We also would like to thank
some steel companies for accepting our site visit and giving us operation data.
The advices and suggestions from the members of ERIA Project Advisory
Board which is organized in Japan are highly appreciated and were helpful for preparing our final report.