Energy Efficiency in CHN Steel Huang Dao

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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460 ≤ 390 ≤ 41510 ≤ - 8 ≤ 0

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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

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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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263kPa155�

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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

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� � � �22.29%

� � � � � �3.76%

� � � �3.92%

� � � � �5.59%

� � � � �4.26%

� � � � �1.59%

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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

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400

500

600

700

800

900

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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

Energy Efficiency in CHN Steel Huang Dao

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