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Energy Efficiency inChina Iron and Steel Industry
International Workshop on Industrial Energy Efficiency
January. 27-28, 2010 New DelhiHuang Dao
China Iron & Steel Association
Who is the text one develop quickly in steel industry �Japan�China�India
The Main Steel Making countries
Germany
Russia
USA
China
Japan
ItalyUkraineBrazilIndiaKorea
570504489421356China Steel output(MT�
20092008200720062005Year
The profitable space in Iron & Steel Industry had been shrink
Iron & Steel Industry of
China
Price of ore and coal
raised
Monetary Policy
become tight
Exportation of steel is restricted
Environmental protection pressure increased
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65 ≤ 55 ≤ 60
460 ≤ 390 ≤ 41510 ≤ - 8 ≤ 0
� � 215 ≤ 180 ≤ 190� � 325 ≤ 280 ≤ 300
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Production Processes
Major ProductionProcesses
Blast Furnase
Electric cooker
BOF-Basic Oxygen Furnace
Sintering
Quota Target Admittance
KgCe/Tsteel KgCe/Tsteel KgCe/Tsteel
Note�
Forced Commend Forced
The norm of energy consumption per unit product of steel making processes
The norm of energy consumption per unit product of major procedure of crude steel manufacturing process
Heavy industrialization stage is inevitable during the whole process of industrialization
Heavy industrialization will continue. Energy conservation is our common responsibility and long term challenge.
China’s steel industry has made great contributions to socio-economic development, but it’s also confronted with the imbalance between economic growth and environmental protection and resources conservation
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Large share of industrial energy consumption
Industrial energy structure
USA JapanChina
IndustryIndustry
Industry
The trend of integrated energy consumption per ton steel in China
1980~2005� � � � � � �
0.728
0.0
0.5
1.0
1.5
2.0
2.519
8019
8119
8219
8319
8419
8519
8619
8719
8819
8919
9019
9119
9219
9319
9419
9519
9619
9719
9819
9920
0020
0120
0220
0320
0420
0520
0620
0720
0820
0920
10
80� � � � � � � � � � � � � 90� � � � � � � � � � � 21� � � � � � � � � � � � �
tce/t-s
� � � �� � � � � � � � � � �
1980~2005
Steel industryLarge and middle size Steel industry
In 80’s, unit and procedureenergy saving
In 90’s, systemic energy saving and flow optimize
In 21 century, energy recycle and conversion
�����������
• Energy consumption in Main process
Coking Sinter BF
EAF Rolling
BOF
Second energy reusing ratio in CHN Steel
Coking Coal Gas BOF Coal GasBF Coal Gas
•Coal gas is about 41% of total energy consumption.
•Emission of coal gas exists.
•if blast furnace gas emission reduce 1%: 530 thousand tce
•If BOF gas reuse reach 80m3/t-s: save 8 Mtce
•If BOF gas reuse reach 100m3/t-s: save 1000 Mtce
By product of coal gas
60’s 70’s 80’s 90’s
Direct discharge
Dilute and discharge
End treat Cleaner production
�National cleaner production contents of Key Industry��First batch�• CDQ • PC and rich O2 for BF • Sintering with small ball • Looping cooler with heat
recovery • Electrofilter with sinter
fume • COG desulfur with H.P.F• Liquid CO2 recovery from
lime-kiln gas• Ore dressing from ore
tailing• Bag-type dust collector
with BFG • BOF gas clean and
recycle with LT • Hot-pressed compact
technology from LT dust • Reduced iron powder
from rolling iron scale • BFG uesed in boiler fuel
�Second batch�• TRT• Double preheat regenerative
oven in rolling process• BOF combined blow, splashing
slag and long-life line• High efficiency CC• Hot transfer and hot charge for
CC to hot Rolling• AC motor frequency conversion • Automatic control for BOF• Power supply optimization for
EAF• Dust cleaning for coke oven• System optimization for
cleaning steel production• Permanent magnetism for
magnetic separator• High efficiency integrated
technology for BF• Recycle and utilization for BOF
dust nud• BOF evaporation cooling
system supply steam for vacuum refining
21 century
Circulatingeconomy
“zero”discharge
�Third batch�• Waste plastic
treatment with coke oven
• Pickle recovery from cold rolling
• A/O biologic denitriding for coke waste water
• High efficiency use for low heat value gas
• BOF production with negative energy consumption
Technology and Best Practices Pollution control Course
in China steel industry
Sustain technology work in China steel industry
energySteel
productswater
material
4 �Waste reuse and resources
3� material efficiency
2 �Waste Water Reuse
1� Energy efficiency & conservation
5�product efficiency
Wastesolid�slag &dust�
Waste gas
Waste
water
6� Information systems
Choose the technology in 6 type�Key of them in recent years are�1 Dry dedust in BF2 Dry dedust in BOF3 CDQ4 Water saving5 electricity generation 6 Slag comprehensive use
To provide technology support for steel industry development, pollutant control and project design.
Technology and Best Practices
BOF Dry dust treatment and the gas waste heat reused�More than 30 sets.
TRT�Over 560 TRT had been built �> 2000m3BF had been TRT 100%used�>1000m3 BF TRT95.6%.
CC
PP
CDQ:More than 76sets running�about 73Mt/a CDQ treatment capability had been .
More than 10 companies in China Steel section�more than 15 sets CCPP put intoproduction.
1616
Dry Type TRT
270kPa170�
263kPa155�
10kPa40�
24,600�W
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270kPa170�
263kPa155�
10kPa40�
24,600�W
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• For the gas de-dusted by the wet dust catcher � the dust content change with the top pressure fluctuation of BF�lot of water spray lost heat energy and add water content in the gas.
• Compared with wet the dry type TRT lost gas resistance and temperature drop is small. The recovery power of TRT could be improved by 25~45%. Lot of de-dusting water saved, the energy saving is remarkable.
Dry Type TRT succeed in 5500 M3
Blast furnace in ShouGang
2006�12�19-20����������������TRT����
2006����250�������TRT�����1000M3
����TRT������90%���������TRT���������������������100����
2009�10�18�����TRT������
���������500������TRT�����1000M3
����TRT������100%�
�����������Z&J������������5250m3����TRT���������“3H-TRT��” ���������
������450������
�����1��2�4200M3������TRT�������2�5���
�����114������
����TRT���
APP members shared The State-of-the-Art Clean Technologies �SOACT�relating to environmental protection and energy saving.
SinteringCokemaking
Iron making
BOFSteelmaking
EAF Steelmaking
Casting RecyclingCommon System
General Measures Total
11 6 11 9 6 1 4 11 5 64
The SOACT is posted on the APP website in January, 2008 and now available to the public.
URL�http://www.asiapacificpartnership. org/
Flagship Project 1Flagship Project 1��SOACT HandbookSOACT Handbook��
- 22 of environmental protection technologies - 42 of energy saving technologies
Next StepUpdate the SOACT Handbook after the Showcase (to accommodate new showcasedtechnologies)Issue Version 2.0 before the Fall 2009 APP Task Force meeting 20
The waste heat of the gas is still have potential
� � � �43.66%
� � � � �5%
� � � �9.02%
� � � �22.29%
� � � � � �3.76%
� � � �3.92%
� � � � �5.59%
� � � � �4.26%
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The waste heat reuse in sinter process
BOF energy consumption and recycle
Energy flow of BOF
The waste heat reuse in steel making process
Energy Efficiency Options for the Iron & Steel Industry
Overall Measures (measures apply to both integrated and secondary plants) Preventative maintenance Energy monitoring and management systems Variable speed drives for flue gas control, pumps, and fans Cogeneration Integrated Steel Making Measures Secondary Steel Making Measures Casting and Rolling (apply to integrated and
secondary plants unless otherwise specified) Iron Ore Preparation (Sintermaking) Electric Arc Furnace Casting Sinter plant heat recovery Improved process control (neural networks) Adopt continuous casting Use of waste fuels in the sinter plant Flue gas monitoring and control Efficient ladle preheating Reduction of air leakage Transformer efficiency measures Thin slab casting Increasing bed depth Bottom stirring/gas injection Rolling Improved process control Foamy slag practices Hot charging Coke Making Oxy-fuel burners/lancing Recuperative burners in the reheating furnace Coal moisture control Programmed heating
Post-combustion Eccentric bottom tapping (EBT)
Controlling oxygen levels and variable speed drives on combustion air fans
Variable speed drive on coke oven gas compressors Direct current (DC) arc furnaces Process control in the hot strip mill Coke dry quenching Scrap preheating Insulation of furnaces Iron Making - Blast Furnace Consteel process Energy efficient drives in the hot rolling mill Pulverized coal injection (medium and high levels) Fuchs shaft furnace Waste heat recovery from cooling water Injection of natural gas Twin shell DC arc furnace Heat recovery on the annealing line (integrated only) Top pressure recovery turbines (wet type) Automated monitoring & targeting system Recovery of blast furnace gas Reduced steam use in the pickling line Hot blast stove automation Recuperator on the hot blast stove Improved blast furnace control Steel Making - Basic Oxygen Furnace BOF gas & sensible heat recovery (supressed combustion) Variable speed drive on ventilation fans
Benchmarking in large enterprisesWe lack of recent international
comparable data
� � � � � �
� � � � � , 627.4� � � � � , 603.6 � � � , 651.3
� � � , 647.9
� � , 743� � , 711.9
� � , 679.76 650
� � , 768.81 733.86
� � , 858.79 769
400
500
600
700
800
900
� � � � � � � �
2000 2001 2002 2003 2004 2005
kgce/ t
Benchmarking analysis table(objective: find the weak point)
Enterprise
International level
Reached or not
Theoretical value
Gap National standard
Reached or not
process
Cindering
Iron prod.
Steel prod.......
Comparison of Energy consumption of main equipments�for example. blast furnace�
Thermal wind temperature
.TRTpower generation
Power consumption
Fuel ratio Power consumption
Water consumption
>2000 m3
>3000 m3
>4000 m3
Analysis on the process of not reaching standard
Enterprise
Tech A Tech B Tech C Tech D Tech E..... Summary
process Coverage of technologies
Energy Saved
Energy saving potential
Ratio of iron to steel in 2005 Year
USA Germany
Japan
China World World(excluding China)
Iron/steel 0.392
0.649 0.738 0.968 0.7 0.567
Energy intensity per
ton steel
676 765.5 719.41
741*
EAF steel ratio 55% 30.7% 25.6%
12.9%
35% 56%
Energy intensity gap in China Steel Industry
China‘s steel reserves were only 51.6%of the USA�and 87.4%of Japan.
Energy Structure of Iron & Steel Industryindifferent countries
•Coal occupies 70% of total consumption
•Low quality of coal
•Cause intensity gap 15~20 kgce/t-s�
3.20%
7.00%
20.70%
19.90%
17.00%
26.40%
16.00%
15.30%
23.70%56.40%
55.80%
60%
69.90%
8.20%
0.50%
0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00%
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Coal based energy structure caused low efficiency
Petroleum and gas could increase efficiency
China is restricted by resource condition Promote R&D cleaning energy using technology
Based on China’s own status, scientific development concept and requirement of industrial policy, based on structure optimization, decreasing consumption, environment protection and improve economic benefit, China’s Iron and Steel Industry will provide iron and steel with multiple specification, high quality, and competitive price to all steel demanding industries, to satisfy the goal of building a well-off society and realizing quadrupled GDP per capital steel making.
Process optimization brings indirect energy saving rate up to 67%�with systematic saving and structure optimization , annual saving rate will be 4.44%.
Strategic Position of China Iron & Steel industryFuture Development:
Thank you!
CISACISADepartment of Development, TechnologyDepartment of Development, Technology
and environment protectionand environment protection
Huang DaoHuang Dao
[email protected]@188.com
I believe India and I believe India and China will have a lot of China will have a lot of cooperation in the cooperation in the field of energy field of energy efficiency work in the efficiency work in the Iron & Steel industryIron & Steel industry