eastern asia steel research

8/18/2019 Eastern Asia Steel Research

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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


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


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)


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)


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


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Japan Energy Saving Measures

6


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


8/27

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)


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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


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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.


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


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 )


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


Myanmar 0.0

Brunei Darussalam 0.0

Lao PDR 0.0

Cambodia 0.0

ERIA Total 255,235.1


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 )


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)


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 )



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


Myanmar 0.0


Lao PDR 0.0

Cambodia 0.0

ERIA Total 29.8


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


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


Lao PDR 0.0

Cambodia 0.0

ERIA Total 2,506


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)


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


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 )



18

China 193.1

Japan 0.0


Australia 1.8

Malaysia 2.0

Thailand 1.7

Indonesia 1.2

Vietnam 0.7

New Zealand 0.3


Myanmar 0.0


Lao PDR 0.0

Cambodia 0.0

ERIA Total 237.0


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


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


Myanmar 0.0

Brune i Darus salam 0.0

Lao PDR 0.0

Cambodia 0.0

ERIA Total 13,313


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


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


Lao PDR 0.0

Cambodia 0.0

ERIA Total 3,258.0


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


Myanmar 1.0


Lao PDR 0.0

Cambodia 0.0

ERIA Total 271,053.6


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)


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.


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


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.


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.


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.

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