Recommended technologies for energysaving, environmental protection andrecycling in ASEAN iron and steel industry

The Japan Iron and Steel Federation

Introduction
Overview“Technologies Customized List” is a technology reference containing energy-saving, environmentalprotection and recycling technologies, developed under a collaborative scheme of ASEAN-Japan Steel Initiative(AJSI) between ASEAN 6 countries (Indonesia, Malaysia, Philippines, Singapore, Thailand and Vietnam) andJapan. The list is aimed at identifying appropriate technologies for the ASEAN steel industry and the firstversion of the list was published in November 2014.
The list reflects the knowledge acquired from public and private experiences of the Japanese steel industry,
which achieves the highest energy efficiency in the world, and the technology needs of ASEAN steel industry.
In this context, contents of the list are informative 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.
After the publication of the Technologies Customized List Version 1, the list was employed on manyoccasions such as Steel Plant Diagnosis and Public and Private Collaborative Workshops. Through these
activities, additional technology needs were specified. In particular, in response to the growing introduction of
BF-BOF type steel plants in ASEAN countries, Technologies Customized List 2022 version is developed as a
two-part series. Technologies Customized List v.3.2 Part-1 is for EAF plants, and v.4.0 Part-2 is for BF-BOF
plants.

What is ASEAN-Japan Steel Initiative?
AJSI is a public and private partnership program between ASEAN and Japan1

Development process of Technologies Customized List
Technologies on the Technologies Customized List are considered to contribute to energy saving andenvironmental protection in ASEAN steel industry. They were chosen from several technology references*1 inthe world, based on the following criteria.
1.

Coverage: Technologies Customized List contains the technologies for energy saving, environmental
protection and recycling in the steel plants in ASEAN region. Technologies for other purposes, such as
quality improvement and production increase, are not covered in Technologies Customized List.

2.

Availability: Target technologies should be commercially available. Technologies under development inJapan, which the supplier companies are not ready to diffuse in ASEAN region, are not eligible forTechnologies Customized List.

3.

Experience: Steel experts in Japan have technological knowledge and experiences.

2022 versionpart-2: BF-BOF (v.4.0)
January, 2022

*1 Reference List
 The State–of-the-Art Clean Technologies (SOACT) for Steelmaking Handbook
 NEDO Handbook
 EU-IPCC BAT
USA-EPA-BACT
2

Technologies Customized List & Technologies One by One Sheets
2022 version part-2: BF-BOF (v.4.0)

Table of Contents
1. Energy-Saving Technologies
1-1.

Technologies Customized List

4

1-2.

Technologies One-by-One Sheet

8

2. Environmental Protection Technologies
2-1.

Technologies Customized List

35

2-2.

Technologies One-by-One Sheet

37

Contact Points of Suppliers

56

ANNEX 1. Guidance for calculating the profit, assumed investment cost andpayback time for your country59

3

1. Energy-Saving
Technologies
1-1. Technologies Customized List

4

Pre-Conditions for Calculations of Effects
In the technologies customized list, the values of electricity saving and fuel saving are drawn from thetechnology references*2. The sources of each value are noted for each technology in the technologies one-byone sheets. For the calculation of CO2 reduction effects, following factors are applied:

For calculating CO2 reduction from electricity saving, country-specific CO2 emission factors areused, because the emission factors vary from country to country based on the grid mix.

Country
ThailandIndonesia
VietnamPhilippines
Malaysia
SingaporeJapan

CO2 emission factor for electricity
CO2 emission factor
Source(ton-CO2/MWh)
0.548
0.771
average of combined
0.599
margin from CDM
projects, IGES website
0.512(2021.2.23)
0.670
0.486
0.434
TEPCO, 2021

For calculating CO2 reduction from fuel saving, CO2 emission factors from ISO 14404 part 1 wasused. Unlike for electricity, CO2 emission factors for these items are unlikely to vary from country tocountry, so a common emission factor is used for all countries.
CO2 emission factors for non-electricity energy sources
CO2 Emission Factor
Item
Source(kg-CO2/GJ)
Natural Gas
56.1
Coke Oven Gas
44.00
Coke
108.21
ISO 14404
Coal
95.02
Steam
51.32

Unlike Technologies Customized List Part 1 (for EAF plants), this Part 2 (for BF-BOF plants) does notprovide information on economic effects such as profit, assumed investment cost and payback time due tolimited information. However, for your reference, the Technologies One-by-One Sheet for each technology
contains such information for the case of Japan, when available. For this calculation, following factors areapplied. Savings from reduction of fuels other than coal are calculated assuming the unit energy cost of heavy
oil.
Unit Energy Cost

Item

Unit Energy Cost

Unit

SourceElectricity
C Heavy Oil
Coal

17.99
432.31
145.7

JPY/kWh
JPY/GJ
JPY/GJ

SOACT/NEDO

Guidance for estimating the profit of operation cost, assumed investment cost and payback time based on
the Japan case is provided in Annex 1.

*2 Reference List
 The State–of-the-Art Clean Technologies (SOACT) for Steelmaking Handbook
 NEDO Handbook
 EU-IPCC BAT
USA-EPA-BACT
5

Technologies Customized List of Energy Saving Technologies
for ASEAN Steel Industry 2022 version part-2: BF-BOF (v.4.0)
Expected Effects of Introduction
No.

Title of Technology

Technical Description

Electricity
Savings
kWh/t ofproduct

Fuel
Savings
GJ/t ofproduct

CO2 Reduction
kg- CO2/t of product

Estimation
Details

Co- benefits-

SOx, NOx,
Dust

-

-

-

-

assuming
steam
substitution
assuming
electricity
substitution

-

-

-

-

-

Thailand Indonesia Vietnam Philippines Malaysia Singapore
Sintering (product: sinter)

A-1

Sinter Plant Heat Recovery The device recovers the sensible heat in(Steam Recovery fromthe hot air with temperature of 250C to
Sinter Cooler Waste Heat) 450C from a sinter cooler.

-

0.25

A-2

Sinter Plant Heat Recovery This is a waste gas sensible heat recovery(Power Generation fromsystem from sinter cooler to generate
Sinter Cooler Waste Heat) electric energy.

22.10

-

A-3

High Efficient (COG) Burner The multi-slit burner can form a successivein Ignition Furnace for Sinter and uniform frame in the ignition furnace
Plantusing coke oven gas.

-

0.01

0.44
(emission factor: COG)

-

1.9

97.51
(emission factor: steam)

150-

Coal moisture control uses the waste heatfrom the coke oven gas to dry the coalused for coke making. Coal moisture ischanged from 8-9% to 3-5%, which
reduces fuel consumption in the coke oven.

-

0.29

A-6

Top Pressure Recovery
Turbine (TRT)This system generates electric power by
employing blast furnace top gas to drive aturbine generator. Blast furnace gas
passed through TRT is used as a fuel iniron and steel making processes.

50

-

A-7

Multi-Vessel Electrostatic
Precipitator

This system cleans the blast furnace gasthat goes into TRT power generation
system through removing dust and water
drops by electrostatic field.

64.8
MWh/day

12.9
tonCO2/day--

No Water
consumption

A-8

Pulverized Coal Injection(PCI) System

This technology is for injecting pulverizedcoal directly through the blast furnace
tuyeres as a partial substitute for the cokeused in the blast furnace.

-

1.39

132.1
(emission factor: steam coal)assuming
125kg coal
injection-

A-9

Hot Stove Waste Heat
RecoveryThis device recovers the sensible heat of
the flue gas generated in the hot stove anduses this heat in preheating fuel andcombustion air for the hot stoves.

-

0.083

7.89
(emission factor: steam coal)

A-10

Top Combustion type Hot
Stove with Metallic Burners

23.85(emission factor: steam coal)

12.11

17.04

13.24

11.32

14.81

10.74

Cokemaking (product: coke)

A-4

A-5

The heat recovered by inert gas from the
hot coke is used to produce steam, which
Coke Dry Quenching (CDQ)
may be used on-site or to generate
electricity.

Coal Moisture Control
(CMC)

82.2

115.65

89.85

76.8

100.5

72.9

27.56
(emission factor: steam coal)

Ironmaking (product: pig iron)

27.40

38.55

29.95

25.60

33.50

24.30

-

Coming Soon

Steelmaking (product: steel)
A-11

Converter Gas Recovery
DeviceLow NOx regenerative
A-12 burner system for ladlepreheating

A-13

Converter Gas Sensible
Heat Recovery Device

This device recovers and uses the hightemperature waste gas generated during
blowing in the converter (basic oxygen
furnace).

-

0.84

79.8
(emission factor: steam coal)-

Contribute tobetteratmospherearound atworkfloor- Regenerating burner use- High Energy Saving (about 40 %)- Automatic control- FDI Combustion

-

0.20

12.62

This device recovers and uses the hightemperature waste gas generated during
blowing in the converter (basic oxygen
furnace). This device burns the converter
waste gas to transform latent heat tosensible heat and recovers the sensible
heat

-

0.126

11.97
(emission factor: steam coal)-In the RHF, the dust and sludge along withiron oxide and carbon are agglomerated
into shaped articles and iron oxide is
reduced into DRI, which reduces coke
consumption in the blast furnace.

-

0.21

22.72
(emission factor: steam coal)

Dust

-

Recycling and Waste Reduction
Rotary Hearth Furnace
A-14 (RHF) Dust Recycling
System6

Expected Effects of Introduction
No.

Title of Technology

Technical Description

Electricity
Savings
kWh/t ofproduct

Fuel
Savings
GJ/t ofproduct

CO2 Reduction
kg- CO2/t of product

Estimation
Details

Co- benefits

Thailand Indonesia Vietnam Philippines Malaysia Singapore
Processing (product: steel products)

Process control for
reheating furnace- Setting furnace temperature by targetedbillet temperature curve- Precise air ratio control and O2 analysis
in exhaust gas

Regenerative Burner Total
A-16 System for reheating
furnace

While one of the burners is burning, theother burner will work as an exhaust outlet.
The combustion air will be preheated to asuperhigh temperature.

High temperature
A-17 recuperator for reheating
furnace

A-15

0.05

3.16

-

-

-

0.19

10.66
(emission factor: natural gas)

Fuel saving
and CO2
reduction are
averagevaluesNOx- Heat transfer area is expanded- Special material tube is used instead ofstainless

-

0.1

6.31

-

-

- Low thermal conductivity
Fiber block for insulation of- High temperature change response (lowreheating furnace
thermal-inertia)

-

0.039

2.46

-

-

Induction type billet heaterfor direct rolling

Compensate temperature drop of billets
transferred from CC to rolling mill (from 950
degC to 1050 degC).
Advantages :- Automatic control- Less exhaust gas (without reheating
furnace)

-40

1.45

113.42

122.34115.46111.98118.30110.94--Oxygen enrichment for
combustion air

Thermal energy will be reduced with thedecrease in the volume of exhaust gas.
Assumed oxygen percentage in
combustion air is 39 % in the study.
Equipment of oxygen generator is not
estimated, it is sometime rental use. Only
electric power to generate pxygen is
examined (0.5 kWh/m3N)

-23.6

0.26

29.34

34.60

30.54

28.49

32.22

27.88

-

-

Highly efficient combustion
A-21 system for radiant tube
burnerSilicon-carbide parts are inserted into theradiant tube to promote heat transfer fromhot gas to the tube, which improve thermal
efficiency of the furnace. Production of thetarget plant is assumed as 594,000 ton/y(CGL) with natural gas use.

-

0.0896

5.03(emission factor: natural gas)

-

-

13%

-

-

-

-

-

0.12

11.4
(emission factor: steam coal)

A-18

A-19

A-20

-

General Energy Saving & Environmental Measures
Applying the Multi-Level Drive for motors
enables to save energy cost from vane andInverter (VVVF; Variable
valve control (constant speed motor).
A-22 Voltage Valuable
・Eco-Friendly
Frequency) Drive for Motors ・Power Source Friendly
・Less Maintenance・Motor Friendly

Energy Monitoring andManagement Systems

This measure includes site energy
management systems for optimal energy
recovery and distribution between various
processes and plants.

Cogeneration (include Gas
A-24 Turbine Combined Cycle(GTCC))

This equipment is a high efficiency
combined generator set using the byproduct gas produced during iron and steel
making process.

Management of
A-25 Compressed Air Delivery
Pressure Optimization

Energy saving in compressors requiresconsideration of the points like (1)selection of the appropriate capacity, (2)reduction in delivery pressure.

285
MWh/y

-

-

-

Power Recovery byInstallation of SteamA-26
Turbine in Steam Pressure
Reducing Line

This technology reduces refrigerator power
consumption by installing a steam turningin place of the steam pressure reducing
valve and driving the refrigerator with thepower recovered by the steam turbine.

4308
MWh/y

-

-

-

A-23

-

Coming Soon

7

1. Energy-Saving
Technologies
1-2. Technologies One by One Sheet

8

A-1
Item

Sintering

Sinter Plant Heat Recovery(Steam Recovery from Sinter Cooler Waste Heat)
Content

1. Process Flow

Steam recovery systemfrom sintering machine

2. Technology
Definition/Specification

This device recovers the sensible heat in the hot air with temperature of 250 C to 450 C from a sinter cooler.
It comprises mainly;a) boiler/economizer,b) pure water feed device,c) deaeratord) steam drum, etc.
After heat exchange with sintered ores of 500 C to 700 C in the cooler, the exhaust gas is introduced to theboiler/economizer to generate steam and is recycled to the cooler. Unit recovery of waste heat is on the orderof 60,000 kcal/t-sinterThe 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

3. Investment Cost & Operating
Equipment cost ： approx.￥3,000 million (annual sinter production : 1 mil. ton/y) 【177 Crore】
Construction cost： approx. ￥500 million 【30 Crore】
Life・Reduction of CO2
4. Effect of
23.86kg-CO2/t-sinterEmission
Technology
0.251GJ/t-sinter [NEDO] ： 60,000 kcal/t-sinter/ 1,000,000 * 4.186
Introduction
・Fuel Savings
payback time [NEDO]: Equipment only
: approx. 22.1 years 【11.6 years】:
Includingconstruction
cost: approx. 25.8 years 【13.5 years】
・Economic Effect
5. Direct Effect （payback time）
Annual steam recovery: 60,000 * 106 kcal/y( Annual
Reduction in crude oil equivalent : 7,500 t-crude oil/yEconomic effect:￥135.8 mil./y (=60,000 * (1.81/0.8) / 1,000) 【153 Crore】
Operating Cost)
・Productivity
Not announced
Improvement
・Maintenance Cost
Not announced
Reduction
6. Indirect
・Product Quality
Not announced
EffectImprovement（Co・SOx, Dust
Not announced
benefits）
Decrease
7. Diffusion Rate of Technology inwidely spread and mostly appliedJapan
JP Steel Plantech Co.
8. Japanese Main Supplier
Nippon Kokan Technical Report, 1980, No.84, 25
9. Technologies Reference:

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* Payback time was defined as (Investment cost / Economical merit) in this project.
* annual sinter production : 1 mil. ton/y* CO2 emission factor of coal : 0.095* unit cost of C heavy oil : ￥1.81/ 1,000 kcal [NEDO]
overall boiler efficiency : 0.8
Economic effect : 60,000 * 1.81 /0.80 = ￥136 mil./y9

Sintering

A-2

Sinter Plant Heat Recovery(Power Generation from Sinter Cooler Waste Heat)

Item

Content

Sintering machine
Hood

Stack

Main
blowerCoolerEP

1. Process Flow

Dust
collector

Waste
heat
boilerCirculation

Turbine andfan

Generator

Sinter cooler waste heat recovery system

2. Technology
Definition/Specification

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 bysteam turbine.
The figures listed below are obtained from a system configuration of two identical sintering machines,
coolers each equipped with waste heat recovery boiler and one unit of electric power generator, to which thesteam from two boilers is led.

3. Investment Cost & Operating Lifeapprox.￥5 billion at 5.9Mt/y 【295 Crore】

4. Effect ofTechnology
Introduction

・Reduction of CO2
Emission・Fuel Savings
・Electricity Savings
・Economic Effect（payback time）

5. Direct Effect( Annual
・Productivity
Operating Cost ) Improvement
・Maintenance Cost
Reduction
・Product Quality
6. Indirect Effect Improvement（Co-benefits）
・SOx, Dust
Decrease
7. Diffusion Rate of Technology inJapan

19.96 kg-CO2/t-sinter0.253GJ/t-sinter= 17,400kWh/h * 2,717kcal/kWh /1,000,000 /(393 t-Sr/h * 2) * 4.186 GJ/Gcal
22.1 kWh/t-sinter= 17,400 kWh/(393t-Sr/h * 2)
2.9 years 【5.5 years】(Reduction in crude oil equivalent：32,500 Toe/y = 17,400 kWh/h * 24h/D * 365 D/Y * 0.85 * 0.95 * 2,646kcal/kWh /10,000 kcal)
Not announced
Not announced
Not announced
Not announced
well known and familiarized

8. Japanese Main Supplier

JP Steel Plantech Co.

9. Technologies Reference:

2006 NEDO project report, No.06002211-0

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied
preconditions." Especially as for investment cost and payback time for the case of India, revised values wereindicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.
1. Sinter operation conditions- production
393 t/h × 2 units- sinter qty in cooler
540 t/h × 2 units- sinter surface temperature at cooler exit
＜125 C- sinter layer height in cooler
1,000 mm- circulating waste gas volume
650,000 Mm3/h × 2 units
2. Electricity recovered 17,400 kWh / 2 units or 129,560,400 kWh/y (equivalent to 310 days)
3. Reduction in crude oil equivalent
32,500 Toe/y4. Electricity savings￥1.7 billion/y (Electricity price : 14 ￥/kWh = 0.123 US$/kWh *113 ￥/US$)
5. Payback time
2.9 years (Investment cost /(Ele. savings running cost)

10

A-3
Item

SinteringHigh Efficient (COG) Burner in Ignition Furnace forSinter Plant
Content

1. Process Flow

2. Technology Definition/Specification

3. Investment Cost & Operating Life
4. Effect ofTechnology
Introduction

Outline of multi-slit burner
The multi-slit burner is designed to form a successive and uniform frame along a palletwidth direction in the ignition furnace. It consists of fuel exhaust nozzles and a slit-likeburner 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 theframe.
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.
No data・Reduction of CO2
Emission

0.44kg-CO2/t-sinter・Fuel Savings

0.010GJ/t-sinter : 2.5Mcal/t-sinter/1,000 * 4.186 [NEDO]
30% decrease in heat input for ignition [SOACT]

・Economic Effect
5. Direct Effect （payback time）( Annual
・Productivity
Operating Cost Improvement)
・Maintenance Cost
Reduction
・Product Quality
6. Indirect
Improvement
Effect（Co-benefits） ・SOx, Dust Decrease

Not announced
Not announced
Not announced
Not announced
Not announced

7. Diffusion Rate of Technology inJapanwell known and familiarized

8. Japanese Main Supplier

JP Steel Plantech Co.

9. Technologies Reference:

Refer to http://asiapacificpartnership.org/japanese/soact2nd.aspx and "JapaneseTechnologies for Energy Savings/ GHG Emissions Reduction 《2008 Revised Edition》(NEDO, 2008)"

10. Preconditions* Payback time is defined as (Investment cost / Economical merit) in this project.

11

A-4

Cokemaking

Coke Dry Quenching

Item

Content

1. Process Flow

‘ Coke Dry Quenching’ / Nippon Steel Engineering Co., [*1]

The heat recovered by inert gas is used to produce steam, which may be used on-site 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
2. Technology Definition/Specification 1) cooling chamber 2) dust collecting bunker 3) waste heat boiler 4) dust cyclones 5) mill fan6) blowing device (to introduce the cold air form the bottom) 7) circulating ducts8) Capacity ;The nominal capacity of a typical CDQ plant is less than 100 t/h/chamber.(EU-BAT)[*1]
260t/h(China/ Shougang Jingtang/NSC-ENG) [*3]3. Investment Cost
& Operating Life

4. Effect ofTechnology
Introduction

5. Direct Effect( Annual
Operating Cost )New plant costs are estimated to be $50/t coke, based on the construction costs of a recently built plant inGermany.[SOACT]
Equipment cost: ￥3,000 million (approx.) 【177 Crore】; construction cost: ￥500 million (approx.) 【30 Crore】 [NEDO]
Operating Life : increased life by regular maintenance・Reduction of CO2
Emission

97.5 kg-CO2/t-coke (assuming fuel substitution)
135.45 kg-CO2/t-coke (assuming electricity substitution)

・Fuel Savings

1.9 GJ/t-coke : heat usage (500 kg-steam/t-coke)= 0.5 t-steam/t-coke * 3.8 GJ/t-steam (Energy conversion factor of water vapor : 3.8 GJ/t-steam)・Electricity Savings

150kWh/t-coke : electric usage(300KWh/t-steam)( 500kg-steam/t-coke)[NEDO]

・Economic Effect（payback time）

payback time [NEDO]: Equipment only
: approx. 3.1 years: Including construction cost : approx. 3.6 years (annual coke production : 450000 t, electricity price : 17.99 ￥/kWh)【4.7years】
4.4 years [EU BAT](Payback is rather sensitive to electricity prices and can vary within the EU-27 between 3 and 8
years. In addition, taking into account some European energy saving schemes such as ‘Tradable Certificates forEnergy savings’, which have been implemented in some European countries,the above payback is expected to bemuch shorter)[ *3]・Productivity
Improvement

Not announced

・Maintenance Cost
Reduction

According to an actual operational record in Japan, Maintenance is usually carried out during the periodic maintenanceof the coke ovens. Only a small amount of additional maintenance time is required.[EU][ *1]

Better quality coke produced, improved strength of coke by 4%[SOACT]
Nippon Steel's performance record shows that the use of coke manufactured by dry quenching reduces the amount ofcoke consumption in the blast furnace by 0.24 MMBtu/ton molten iron./EPA [*4]During final collecting by bag filters, emission factors of dust of less than 3 g/t coke are achievable, corresponding toless than 20 mg/Nm3. SO2 emissions are at a level of 200 mg/Nm3. Emissions to surface water are close to zero.
6. Indirect EffectCollected coke dust is supplied as fuel to the sinter plant.[SOACT]（Co-benefits）
・SOx, Dust Decrease The handling of dry quenched coke can cause more dust emissions than the handling of wet quenched coke.The
electrical power consumption of fans, the operation of various dedusting devices, etc. is not negligible. However, net
energy output will be rather positive, due to the recovery of waste heat which is usually transferred into the electrical
power.[EU ][*1]・Product Quality
Improvement

・Water-saving

Increased water efficiency[SOACT]

7. Proficiency Level of Technology inJapanwidely spread and mostly applied

8. Japanese Main Supplier*JP Steel Plantech Co. * Nippon Steel Engineering Co., Ltd * Paul Wurth IHI Co., Ltd.

9. Technologies Reference:*1 : EU BAT5.3.14 *2 : Reference : 290 / NSC-ENG Personal Communication, 2008.
*3 :"Establishment of coke dry quenching technology with a maximum coke throughput of 200T/H".
KATAOKA S, et.,al : Proc 6th Int Iron Steel Congr 1990 Vol 2 Page.337-344 (1990)*4 EPA "AVAILABLE AND EMERGING TECHNOLOGIES FOR REDUCING GHG EMISSIONS FROM THE IRON & STEEL INDUSTRY":
IV.A2.p.21

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.
* Refer to http://asiapacificpartnership.org/japanese/soact2nd.aspx and "Japanese Technologies for Energy Savings/
GHG Emissions Reduction 《2008 Revised Edition》(NEDO, 2008)"

12

A-5

Cokemaking

Coal Moisture Control

Item

Content

1. Process Flow

Variation of CMC Drying Method [ *1]
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 8-9% for good coking coal. Drying further reduces the coal moisture
content to a constant 3-5%, which in turn reduces fuel consumption in the coke oven. The coal can be dried using theheat content of the coke oven gas or other waste heat sources.[SOACT]Generally, low-pressure steam is used as thehumidity control heat source.[NEDO]

Comparison of CMC Drying Method

2. Technology Definition/Specification

3. Investment Cost
& Operating Life
4. Effect ofTechnology
Introduction

Coal humidity control cost in Japan: Approx. $21.9/t-steel[SOACT,NEDO]
Equipment cost: ￥2,000 million 【118 Crore】; construction cost: ￥500 million 【30 Crore】/ 450,000t-coke/y[NEDO]
Operating Life : increased life by regular maintenance・Reduction of CO2
Emission

27.55 kg-CO2-/t-coke

・Fuel Savings

Fuel savings of approximately 0.29 GJ/t-coke[SOACT]

・Electricity Savings

Not announced

・Economic Effect
5. Direct Effect （payback time）( Annual
Operating Cost ・Productivity Improvement)
・Maintenance Cost
Reduction
・Product Quality
6. Indirect
Improvement
Effect・SOx, Dust Decrease（Cobenefits）
・Water-saving

Cheaper lean coal blend ratio increase[ *1]payback time: Not announced
Coke production increase (about 10%)/Shorter cooking times[SOACT,NEDO]
Careful attention needed to corrosion znd abrasion for STD and CIT
Coke quality improvement (about 1.7%)[SOACT,NEDO]
Not announced
Decrease in water pollution (ammonia reduction)[SOACT]

7. Proficiency Level of Technology in Japan well known and familiarized
8. Japanese Main Supplier* Nippon Steel Engineering Co., Ltd * Tsukishima Kikai CO., LTD.

9. Technologies Reference:*1 : SOACT Appendix2a10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* Refer to http://asiapacificpartnership.org/japanese/soact2nd.aspx and "Japanese Technologies for Energy Savings/
GHG Emissions Reduction 《2008 Revised Edition》(NEDO, 2008)"
13

A-6

Ironmaking
Top Pressure Recovery Turbine

Item

Content
Wet Type Dust Cleaner

Dry Type Dust Cleaner

1. Process Flow

2. Technology Definition/Specification

3. Investment Cost
& Operating Life
4. Effect ofTechnology
Introduction

・Reduction of CO2
Emission・Fuel Savings
・Electricity Savings

Assuming pig iron production of 1 million t/y, the blast furnace capacity is 1,500m3 (daily production
scale: 3,000t) and B-gas generation is 212,500m3/h. The possible generating capacity with the gas
volume is approximately 7,000kW (dry type). [ NEDO ]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.
Blast furnace gas (BFG) has a pressure of 0.2-0.236MPa (2-2.41 kg/cm2) and temperature of
approximately 200°C at the furnace top. 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 B-gas purification method. Dust is removed by
Venturi scrubbers in the wet method and by a dry-type dust collector in the dry method. When dust istreated by the dry method, the gas temperature drop is small in comparison with the wet method, andas a result, generated output is at maximum 1.6 times greater than with the wet method[NEDO]
Equipment cost : 7,000kW Generator ; ￥1,400million (approx.) 【83 Crore】,
Construction cost : ￥400million (approx.) 【24 Crore】[NEDO]
Operating Life : increased life by regular maintenance
45.15 kg-CO2/t-PI
50 kWh/t-PI (= (40+60)/2 kWh/t-PI) [SOACT]
More expensive than wet type, $28/t hot metal. NEDO from Japan gives 1.8 years for the payback
period of VS-ESCS (Venturi Scrubber- Electrostatic Space Clear Super) (including the construction
costs)[SOACT]
payback time [NEDO]: Equipment only
: approx. 1.4 years: Including construction cost : approx. 1.8 years (=1.8billion/(7000*24*330*17.99)) 【3.6 years】

・Economic Effect
5. Direct Effect （payback time）( Annual
Operating Cost)
・Productivity Improvement Not announced
・Maintenance Cost
Reduction
・Product Quality
Improvement

6. Indirect
Effect・SOx, Dust Decrease（Co-benefits）
・Water-saving

Excellent operational reliability, abrasion resistant[SOACT]
Not announced
Not announced
Lower water consumption compared with wet type[SOACT]

7. Proficiency Level of Technology inJapanwidely spread and mostly applied

8. Japanese Main Supplier* Mitsui E&S Machinery Co., Ltd. * Nippon Steel Engineering Co., Ltd

9. Technologies Reference:

Refer to "Japanese Technologies for Energy Savings/ GHG Emissions Reduction 《2008 Revised
Edition》(NEDO, 2008)"

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied
preconditions." Especially as for investment cost and payback time for the case of India, revised values
were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.

14

A-7

Ironmaking
Multi-Vessel Electrostatic Precipitator

Item

Content

2. Technology Definition/Specification

Multi-vessel electrostatic precipitator (MVEP), instead of the existing 2-stage venturi scrubber, is arrangedin the system, and dust and water drops are removed by electric energy in MVEP located in the gas
turnover/rising section in each vessel, which generates clean gas. Since the temperature drop andpressure loss is reduced as compared to 2-stage venturi scrubber, TRT power generation is increased by
20~30%, with realizing the dust content at the outlet of the system of 5 mg/Nm3 or lower. And, since there
is no temperature limitations as compared to bag filter, this system has excellent durability at hightemperature gas inlet by operation fluctuations.

3. Investment Cost & Operating Life

Investment Cost : Depending on a project caseOperating Life : Equivalent to twice time blast furnace life

1. Process Flow

4. Effect ofTechnology
Introduction

5. Direct Effect(AnnualOperating Cost)

6. Indirect Effect(Co-benefits)

・Reduction of CO2
Emission

8.36 kg-CO2/ton-pig iron・Electricity Savings

9.26 kWh/ton-pig iron or 64.8 MWh /day saving, Improvement of Electricity generation is about 21% (15.8
MW at MVEP by TRT / 13.1 MW at Wet GCP by TRT).

・Economic Effect（payback time）

TRT power generation is increased by 20~30% than Wet GCP・Monetary equivalentof energy savings(15.8 [MW]-13.1 [MW])*24[hr./day]*350[work-day/year]*5000[Rs./MWh ≒ 11.3 [Cr./year]

・Maintenance Cost
Reduction

Equivalent with Wet GCP ( No need to replace filter cloth required with dry bag filter )・Product Quality
Improvement

No water consumption at MVEP

7. Diffusion Rate of Technology inJapan

One pilot plant in Japan

8. Japanese Main Supplier

Nippon Steel Engineering Co., Ltd.

9. Technologies Reference:

NIPPON STEEL & SUMIKIN ENGINEERING CO., LTD. TECHNICAL REVIEW vol.10 (Published:
May.2019)

10. Preconditions

Calculations are based on a 3000 m3 class blast furnace producing 7000 ton of pig iron per day, and theCO2 reduction amount is calculated using CO2 emission factor for grid electricity, 0.903 t-CO2/MWh(average of combined margin from CDM projects, IGES website, 2018). Both are trial values, which are
not guaranteed.

15

A-8

Ironmaking

Pulverized Coal Injection (PCI) System

Item

Content

1. Process Flow

System diagram of PCI equipment [NEDO]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 isinjected directly, the corresponding amount of coke is unnecessary, making it possible to reduce energy
consumption for coke making (coke dry distillation energy).
This equipment comprises (1) coal receiving equipment, (2) pulverizing/drying equipment, (3) pulverized coal
2. Technology Definition/Specification injection equipment and the instrumentation system.
Noncoking coal is used as a partial substitute for coke (i.e., for coking coal). This coal is pulverized to a size of
approximately 74μm, classified using a bag filter, and conveyed to the pulverized coal storage silo. It is thensupplied at the timing of injection in accordance with the injection rate. The injection tank is pressurized with acompressor, and the pulverized coal is conveyed to the blast furnace tuyeres (charging holes) and injected into
the blast furnace using this pressure. However, the type of coal used and the size of the pulverized coal will
differ depending on the injection equipment and the blast furnace.
3. Investment Cost
& Operating Life

4. Effect ofTechnology
Introduction

Equipment cost: ￥1,500 million ; construction cost: ￥500 million (approx.) / Based on blast furnace with 1
million t/y production[NEDO](Investment of coal grinding equipment estimated at $50-55/t coal injected [SOACT])
Operating Life : increased life by regular maintenance・Reduction of CO2
Emission

147 kg CO2/t-PI (at 125 kg/t-PI)

・Fuel Savings

1.55 GJ/t-PI=125*(1/0.7-1)*6200*4.186/1000000(PCI rate: 125 (=(50+200)/2) kg/t-PI /coke yield : 0.7 / coal heat : 6,917 kcal/kg-coal)・Electricity Savings
・Economic Effect（payback time）

5. Direct Effect( Annual
Operating Cost ) ・Productivity
Improvement

Increased costs of oxygen injection and maintenance of BF and coal grinding equipment offset by lower
maintenance costs of existing coke batteries and/or reduced coke purchase costs, yielding a net decrease inoperating and maintenance costs..[SOACT]
Furthermore, coal injection can allow the use of coals of a lower quality compared to coking coals. [*1]payback time; 15.3 years at 125 kg/t-PI years [NEDO] 【20 years】
Increased productivity[SOACT]

・Maintenance Cost
Reduction

High reliability and easy operation[SOACT]
Decreased frequency of BF relining[SOACT]

・Product Quality
Improvement

Not announced

6. Indirect Effect ・SOx, Dust
（Co-benefits） Decrease
・Water-saving

Not announced
Not announced

7. Diffusion Rate of Technology inJapanwell known and familiarized

8. Japanese Main Supplier* JP Steel Plantech Co. * Nippon Steel Engineering Co., Ltd

9. Technologies Reference:*1 EU-BAT : 6.3.12.1

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied
preconditions." Especially as for investment cost and payback time for the case of India, revised values wereindicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.
*Average unit cost of power; ￥15.3/kWh* Refer to "Japanese Technologies for Energy Savings/ GHG Emissions Reduction 《2008 Revised Edition》(NEDO, 2008)"

16

A-9

Ironmaking

Hot Stove Waste Heat Recovery

Item

Content

1. Process Flow

Flow of heat medium-type waste heat recovery device [NEDO]

2. Technology Definition/Specification

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.
This device (system) comprises two heat exchangers. One is a heat-receiving side heat exchanger
which receives the flue gas discharged from the hot stove; the second is a heating side heatexchanger which preheats the combustion air and fuel using the sensible heat of the flue gas
received by the heat-receiving side heat exchanger. The preheated combustion air and fuel gas aresupplied to the hot stoves. Heat exchange methods are classified as (1) rotary type, (2) plate type,and (3) heat pipe type, depending on the type of heat exchanger. The recovery rate of hot stove fluegas sensible heat with this device is 40-50%.

3. Investment Cost
& Operating Life

Equipment: ￥150 million (approx.) 【8.9 Crore】/Blast furnace: 1 million t/y(plate type; includes civil construction and installation costs)[NEDO]
Operating Life : increased life by regular maintenance

4. Effect ofTechnology
Introduction

・Reduction of CO2
Emission

7.89 kg-CO2/t-CS

・Fuel Savings

Hot Blast Stove: Fuel savings vary between 83 (=(80+85)/2) MJ/t hot metal [SOACT]
Hot Blast Stove: Fuel savings vary between 125 MJ/t hot metal [NEDO]・Electricity Savings
・Economic Effect（payback time）

5. Direct Effect( Annual
・Productivity
Operating Cost Improvement)
・Maintenance Cost
Reduction
・Product Quality
Improvement

6. Indirect
Effect・SOx, Dust Decrease（Co-benefits）
・Water-saving

Efficient hot blast stove can run without natural gas [*1]payback time： 2.8 years [NEDO] 【3.6 years】= 150*4.186/125/1.81
Not announced
Not announced
Not announced
It might be expected that preheating of the fuel media and a reported increase of the flue-gas
temperature would lead to higher NOX emissions from the hot stoves. The application of modern
burners may reduce NOX emissions.[*2]Not announced

7. Proficiency Level of Technology inJapanwidely spread and mostly applied

8. Japanese Main Supplier* Nippon Steel Engineering Co., Ltd.

9. Technologies Reference:*1 USA-BAT:V.A3.10*2 EU-BAT: 6.3.14

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied
preconditions." Especially as for investment cost and payback time for the case of India, revised
values were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.
* Refer to http://asiapacificpartnership.org/japanese/soact2nd.aspx and "Japanese Technologies forEnergy Savings/ GHG Emissions Reduction 《2008 Revised Edition》(NEDO, 2008)"

17

A-10

Ironmaking

Top Combustion type Hot Stove with Metallic Burners

Item

Content

1. Process Flow

2. Technology
Definition/Specification

3. Investment Cost
& Operating Life

4. Effect ofTechnology
Introduction

・Reduction of CO2
Emission・Fuel Savings

Coming Soon

・Electricity Savings

・Economic Effect（payback time）

5. Direct Effect・Productivity( Annual
Improvement
Operating
Cost )
・Maintenance Cost
Reduction

6. Indirect
Effect（Cobenefits）

・Effect for converter
operations
・Product Quality
Improvement
・SOx, Dust
Decrease
・Water-saving

7. Proficiency Level of Technology
in Japan
8. Japanese Main Supplier
9. Technologies Reference:
10. Preconditions

18

A-11

Steelmaking

Converter Gas Recovery Device

Item

Content

1. Process Flow

Converter gas recovery device[NEDO]

2. Technology
Definition/Specification

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.)
Accompanying this process, about 100Nm3 of high temperature gas (CO) with a heating value of approximately
2,000 kcal/Nm3 is generated.
Heat recovery methods are classified as (1) combustion method (boiler method) and (2) non-combustion method(method of recovering gas in an unburned condition: OG method. The advanced type is called the closed OG
method). Recently, the closed OG method has become the main stream. The OG facilities are designed torecover about 70% of the latent heat and sensible heat. The converter gas recovered is mixed with other byproduct gases (coke oven gas, blast furnace gas), then used by the heating equipment of the ironworks. Steamis mainly used by the degassing equipment of the steel making factory.

3. Investment Cost
& Operating Life

Equipment cost: ￥600-1,100 million 【35～65 Crore】(equipment for 110 t/charge converter scale; includes construction cost)converter capacity: 110 t/charge.[NEDO]
Operating Life : increased life by regular maintenance

4. Effect ofTechnology
Introduction

・Reduction of CO2
Emission

79.8 kg-CO2/t-CS

・Fuel Savings

0.84 GJ/t-CS [NEDO]=100*2000*4/186/1000000
LDG : 100Nm3/t-CS 2,000kcal/Nm3-OG

・Electricity Savings

・Economic Effect（payback time）

・Productivity
5. Direct EffectImprovement( Annual
Operating
Cost )
・Maintenance Cost
Reduction

6. Indirect
Effect（Cobenefits）

Payback time : 8.3～15.2 years (annual crude steel production : 200000 t) [NEDO]
The investment required in 2007 was EUR 30.5 million for an ongoing project consisting of a gasholder of
80,000 m3, blower fans, gas ducts, three way valves in the off-gas systems, security measures, erection andengineering, etc. About 80 % of the BOF gas will be recovered resulting in an annual energy savings of 2600
TJ/yr = approximately EUR 12/GJ investment. Payback is about five years taking into account the savings in thepurchase of natural gas, exploitation costs. (EU-BAT)
Not announced* The OG-type system is frequently used because of its operational stability. The OG-type cooling system makes
it possible not only to recover the sensible heat of exhaust gas as steam, but also to increase the IDF efficiency
by lowering the temperature of the exhaust gas by use of a cooling device.
* As the steam is produced discontinuously, it cannot always be fully utilized. The use of recovered BOF gas with
suppressed combustion is much more flexible. The use of BOF gas in conjunction with blast furnace gas andcoke oven gas, allows for the replacement of considerable amounts of primary energy resources, such as
natural gas.
・Effect for converter Increases the IDF efficiency by lowering the temperature of the exhaust gas, achieving high-speed oxygen
feeding[SOACT]
operations
・Product Quality
Not announced
Improvement* suppressed combustion reduces the quantity of flue-gas and thus reduces the cost of fans and dust removal.[・SOx, Dust
*1]
Decrease

・Water-saving
7. Proficiency Level of Technology
in Japan

Reduced water requirement for off-gas cooling[ *1]8. Japanese Main Supplier* JP Steel Plantech Co. * Nippon Steel Engineering Co., Ltd

9. Technologies Reference:*1 EU-BAT : 7.3.7

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.

Widely spread and mostly applied

19

A-12

Steelmaking
Low NOx regenerative burner system for ladle preheating

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected ・Thermal Energy
Savings
Effect ofTechnology
Introduction ・Environmental
benefits
・Co-benefits
4. Japanese Main Supplier

While one of the burners is burning, the other burner will work as an exhaust outlet. The exhaust gas isdischarged from the system after the waste heat of the gas is recovered so that the temperature of the gas will belowered to the extent that there will be no condensation in the regenerator. The combustion air receives heat fromthe regenerator. Therefore, the combustion air will be preheated to a super-high temperature (i.e., 90% of thetemperature 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.

40 % fuel saving is expected comparing to existing preheater with conventional burner.
900 m3N natural gas in 6 hour burning for 80 ton ladle consumes about 40 GJ ---> 0.5 GJ/ton-steel x 40 % = 0.2
GJ/ton-steel save
Low NOｘ
Higher brick temperature can allow lower tapping temperature for energy saving at EAF.
Improving meltshop atmosphere by reducing hot gas which disturbs dirty gas suction at the canopy
Chugai Ro Co., Ltd.

Nippon Furnace CO., LTD

5. Technologies Reference
6. Comments

-

20

A-13

Steelmaking

Converter Gas Sensible Heat Recovery Device

Item

Content

1. Process Flow

Converter gas sensible heat recovery device[NEDO]

2. Technology
Definition/Specification

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.)
Accompanying this process, about 100Nm3 of high temperature gas (CO) with a heating value of approximately
2,000 kcal/Nm3 is generated.
This device recovers and makes efficient use of the converter gas sensible heat. While the converter waste gas
recovery device recovers the waste gas itself, this device burns the converter waste gas to transform latent heatto sensible heat and recovers the energy as sensible heat. Therefore, it is structured to have a sufficient space
between the converter and the hood so that sufficient air can be supplied from the secondary air blower for
combustion. Principal equipments are the brackish water drum, the accumulator, and the boiler etc.

3. Investment Cost
& Operating Life

Equipment cost: ￥600 million 【35 Crore】(equipment for 110 t/charge converter scale; includes construction cost)converter capacity: 110 t/charge.[NEDO]
Operating Life : increased life by regular maintenance

4. Effect ofTechnology
Introduction

・Reduction of CO2
11.97kg-CO2/t-CS
Emission
0.126 GJ/t-CS [NEDO]= 30000*4.186/1000000
・Fuel Savings
LDG : 100Nm3/t-CS 30,000kcal/t-cs
・Electricity Savings
・Economic Effect（payback time）

Payback time : 44years [NEDO]
Energy recovery by means of full combustion systems or suppressed combustion systems is widely applied atoxygen steel plants around the world. There is a tendency towards suppressed combustion systems, mainly.[ *1]
because of logistic advantages compared to full combustion systems.(EU-BAT )5. Direct Effect・Productivity( Annual
Not announced
Operating Cost Improvement)
・Maintenance Cost • No need for additional components other than conventional waste heat boiler.
• Additional safety engineering measures are not needed other than conventional boiler technologies.
Reduction・Effect for
Not announced
converter operations
6. Indirect
Effect（Cobenefits）

・Product Quality
Improvement
・SOx, Dust
Decrease
・Water-saving

Not announced

Reduce temperature of waste water for off-gas cooling

7. Proficiency Level of Technology
Gas sensible heat recovery system are commomly installed combined with converter gas recovery in Japan.
in Japan
8. Japanese Main Supplier

JP Steel Plantech Co.

Nippon Steel Engineering Co., Ltd

9. Technologies Reference:*1 EU-BAT : 7.3.7

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.
* Refer to "Japanese Technologies for Energy Savings/ GHG Emissions Reduction 《2008 Revised Edition》(NEDO, 2008)"

21

A-14

Recycling and Waste Reduction

Rotary Hearth Furnace Dust Recycling System

Item

Content

1. Process Flow

General process flow of RHF [SOACT]
2. Technology
Definition/Specification

Dust recycling in the rotary hearth furnace (RHF) was applied at Nippon Steel’s Kimitsu Works in 2000. The dust andsludge, along with iron oxide and carbon, are agglomerated into shaped articles and the iron oxide is reduced at hightemperatures. Zinc and other impurities in the dust and sludge are expelled and exhausted once into off-gas.
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.
Comparison of steel mill waste treatment process [ *1]3. Investment Cost & Operating Life

Fixing investment cost is difficult due to large effect of plant scale.
Operating Life : increased life by regular maintenance

4. Effect ofTechnology
Introduction

・Reduction of CO2
Emission

22.5 kg-CO2/t-PI [SOACT & NSC]
= 0.23 (kg-coke/kg-DRI) x 30(kg-DRI/t-PI) x 3.257(kg-CO2/kg-coke)[WS Guidebook]

・Fuel Savings

0.21GJ/t-PI [SOACT & NSC]
=0.23(kg-coke/kg-DRI) x 30(kg-DRI/t-PI) x 30.1(MJ/kg-coke) x 0.001(GJ/MJ)[WS Guidebook]
・Decrease in fuel(coke) ratio to BF is up to 0.23(kg-coke/kg-DRI) [SOACT] ,・NCV(Net Calorific Value) of coke : 30.1(MJ/kg-coke)[WS Guidebook]・(DRI;30(kg/t-PI))[* 1]・Electricity Savings
・Economic Effect
5. Direct Effect （payback time）
・Productivity( Annual
Operating Cost Improvement)
・Maintenance Cost
Reduction
・Product Quality
Improvement

6. Indirect
Effect（Cobenefits）

Operating Life : increased life by regular maintenanceNot announced
Not announced
Not announced

・SOx, Dust
Decrease• Waste reduction and decreased disposal costs• Extended landfill life
• Recovery of unused resources (recycling iron, nickel, zinc, carbon, etc.)[SOACT]
In the sinter or cold pellet process, almost all the zinc contained in the raw material is directly transferred to the product.
Because of the above limits on the permissible amount of zinc that can be contained in the blast furnace burden, dust
containing a large amount of zinc could not be used as a raw material and hence was simply discarded. After the dust
recycling plants, employing an RHF, were put into operation, it has become possible to remove zinc from the dust andhence recycle almost all the dust and sludge generated within the works.[*1]・Water-saving

Not announced

7. Proficiency Level of Technology
in Japanwell known and familiarized

8. Japanese Main Supplier* Nippon Steel Engineering Co., Ltd.

9. Technologies Reference:*1 : NIPPON STEEL TECHNICAL REPORT No. 86 p.35(July 2002)
https://www.nipponsteel.com/en/tech/report/nsc/pdf/8608.pdf

10. Preconditions* Refer to http://asiapacificpartnership.org/japanese/soact2nd.aspx

22

A-15

Processing
Process control for reheating furnace

Item

Content

Furnace
Furnace
temp.
BilletBillettemp.
temp.

1. Process Flow or Diagram

2. Technology
Definition/Specification- Setting furnace temperature by targeted billet temperature curve- Precise air ratio control and O2 analysis in exhaust gas

・Electricity Saving 3. Expected ・Thermal Energy
Effect of Savings
Technology
・Environmental
Introduction
benefits
・Co-benefits

0.05 GJ/ton-product (3.5 % fuel saving from the base line of 1,450 MJ/ton)-

4. Japanese Main Supplier

Chugai Ro Co., Ltd.

Rozai Kogyo Kaisha Ltd.

5. Technologies Reference

May contact to Chugai-Ro

6. Comments

-

23

A-16
Item

Processing

Regenerative Burner Total System for reheating furnace
Content

1. Process Flow

Application of regenerative burner [SOACT]

2. Technology
Definition/Specification

An unit, Burner with Regenerator, ensures highly efficient, selectable thermal storage:
・The burner body is compact and of mono-block construction incorporating a valve to select air or
exhaust gas.
・The whole system can be downsized with a reduction in cost.
・This product is applicable to compact high-temperature furnaces where the introduction of
conventional regenerative systems is difficult.
・The regenerative media uses an alumina ball that is economical and excellent in heat resistance andcorrosion resistance.
・The product is ideal for forge furnaces, open flame heat treatment furnaces, nonferrous metal melting
furnaces, and other high-temperature furnaces that are comparatively compact in capacity.

3. Investment Cost & Operating Life Not announced
4. Effect ofTechnology
Introduction
5. Direct Effect( Annual
Operating Cost )・Reduction of
CO2 Emission

10.66 kg-CO2/t-CS

・Fuel Savings

0.19 (=(0.17+0.21)/2) GJ/t-CS 【1.9 Crore】

・Economic EffectNot announced（payback time）

・Productivity
Improvement
6. Indirect Effect ・Environmental
effect（Co-benefits）
7. Diffusion Rate of Technology inJapan

Expected・Quiet operation [*1]・NOx decrease
well known and familiarized

8. Japanese Main Supplier

Chugai Ro Co., Ltd. [*1]
Nippon Furnace CO., LTD [*2]
Nippon Steel Engineering Co., Ltd

9. Technologies Reference:*1: http://www.chugai.co.jp/*2: http://www.furnace.co.jp/

10. Preconditions

・Basic condition; amount of productionis 0.2 million ton of billet per year at EAF plant* Important values were revised with referring to various values in "1-4. Used values and applied
preconditions." Especially as for investment cost and payback time for the case of India, revised values
were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.

24

Rozai Kogyo Kaisha Ltd.

A-17

Processing

High temperature recuperator for reheating furnace

Item

Content

1. Process Flow or Diagram

Heat transfer area of the existing recuperator shall be increased (for example, by changing two-pass to four-pass)in order to raise the preheated combustion air temperature.
2. Technology
Definition/Specification

For this purpose, the followings may or may not be needed.
- Modification of Recuperator room
- Change of air duct
- Increase in discharge pressure of blower- High grade recuperator material・Electricity Saving 3. Expected ・Thermal Energy
Effect of Savings
Technology ・Environmental
Introduction benefits
・Co-benefits

0.100 GJ/t (about -7%)
CO2 Reduction-

4. Japanese Main Supplier

Chugai Ro Co., Ltd.

5. Technologies Reference

Diagram from Chugai Ro

6. Comments<Preconditions on calculating effects>
When 300 degC air temperature is raised to 500 degC

Rozai Kogyo Kaisha Ltd.

25

A-18

Processing

Fiber block for insulation of reheating furnace

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Ceramic fiber is lighter in weight and has the lower thermal conductivity than conventional brick or castable.
Ceramic fiber can be used for the insulation of furnace roof and side wall.

・Electricity Saving 3. Expected ・Thermal Energy
Effect of Savings
Technology ・Environmental
Introduction benefits
・Co-benefits

0.039 GJ/t (about 2.7 %)Reduction of Heat accumulation
Quick heat-up and cool-down of the furnace temperature for smooth and energy-saving operation.

4. Japanese Main Supplier

Chugai Ro Co., Ltd.

5. Technologies Reference

Diagram from Chugai Ro and JP Steel Plantech

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 : 130 degC, 7.96 GJ/hsurface temp. and heat loss of brick lining case : 90 degC, 4.08 GJ/h
(7.96 - 4.08) /100 (ton/h) = 0.0388 GJ/ton ---> 0.039 GJ/ton saving<Notice>
High-sulphur fuel may cause problem due to the corrosion of fixing pins.

Rozai Kogyo Kaisha Ltd.

26

A-19

Processing

Induction type billet heater for direct rolling

Item

Content

Induction coil

Hot billet

Heating Curve
Temperature(℃)

1. Process Flow or Diagram

1300
1200
1100
1000
900
800
700

Center ofSide
CornerCenter0

2. Technology
Definition/Specification
・Electricity Saving
3. Expected ・Thermal Energy
Effect of
Savings
Technology ・Environmental
benefits
Introduction
・Co-benefits

5

10
15
Time(s)20

25Compensate temperature drop of billets transferred from CC to rolling mill (from 950 degC to 1050 degC).
Advantages :- Automatic control- Less exhaust gas (without reheating furnace)
40 kWh/ton-product increase (electrical energy for billet heating)1.45 GJ/ton-product (Cold charge to reheating furnace is replaced.)
Better working floor and atmosphere-

4. Japanese Main Supplier

Mitsui E&S Power Systems Inc.

5. Technologies Reference-

6. Comments

MESPS Tokyo Office:TEL 03-6806-1075
FAX 03-5294-1121

27

Processing

A-20

Oxygen enrichment for combustion air

Item

1. Process Flow or Diagram

Content
When oxygen is mixed into combustion air to increase the O2 percentage, thermal energy will be reduced with thedecrease in the volume of exhaust gas. In many EAF plants, oxygen is generated by PSA or VPSA process,therefore, new equipment for oxygen generation is not considered in this sheet. Only the electric power to generate
oxygen is studied to estimate its economical effect.
Effects of oxygen enrichment are studied for the model RHF of 100 ton/h 1,100 degC billet heating (500,000 ton/y).
The upper list shows the required fuel (thermal energy) and volume of oxygen. When oxygen percentage is raised to
42 %, exhaust gas volume from the furnace reduces to 45 % with 19.5 % fuel saving. The list also shows the required
oxygen volume. The oxygen is assumed to be generated by VPSA process, with the purity of 93 %.
The bottom list shows the economical effect of oxygen enrichment. Required electric power is assumed as 0.5
kWh/m3N-O2 of 0.1 MPa pressure. Energy price is based on the latest Japanese values of 17.11 US$/GJ and 0.123
US$/kWh.

2. Technology
Definition/Specification

・Electricity Saving When oxxygen percentage is raised to 39 %, 23.6 kWh/ton of electricity is needed.

3. Expected
・Thermal Energy
Effect of
Savings
Technology
・Environmental
Introductio
benefitsn・Co-benefits

When oxxygen percentage is raised to 39 %, 0.26 GJ/ton of thermal energy is saved.
-

4. Japanese Main Supplier

Chugai Ro Co., Ltd.

Nippon Furnace CO., LTD

5. Technologies Reference-

6. Comments

Furnace manufactureres can arrange the oxygen control system and piping revamping.

28

Rozai Kogyo Kaisha Ltd.

A-21

Processing

Highly efficient combustion system for radiant tube burner

Item

Content

Silicon Carbide
Heat Exchanger

Silicon-Carbide Inserts
for heat radiation

Radiant
Tube

Burner

1. Process Flow

Combustion air flow on thesilicon-carbide heat exchanger

2. Technology
Definition/Specification

Exhaust gas flow on thesilicon-carbide heat exchanger

Radiant tube burner which consists of 1)Radiant tube(U shape or W shape), 2)Gas Burner, 3)3-D formed silicon-carbide
Inserts for heat radiation, and 4)Heat exchanger made of 3-D formed silicon carbide.
These 3-D formed silicon carbide elements have high thermal conductivity and wide surface area, which allow approx. 10%
improvement in heat recovery compared to conventional radiant tube burners with heat exchanger made of steel.
Any industrial furnace with radiant tube burner will potentially be applicable and typical applicable furnace will be CGL,
Continuous Galvalizing Line or CAL, Continuous Annealing Line, with approx. 100-200 radiant tube burners of 210420MJ/hour of rated combustion volume.
*Radiant tube burner is often used for the industrial furnaces such as heat treatment furnace which requires indirect heating.

3. Investment Cost
& Operating Life

4. Effect ofTechnology
Introduction

The cost of adding this system into existing furnace will be approximately 1.6 million JPY for one burner which have
420MJ/hour of combustion rate. This includes the cost for installation work and combustion adjustments.
Operating life for silicon carbide elements is considered to be semipermanently.

2,654t-CO2/year under assumptions below.
1) 10% of Fuel substitution will be achieved by replacing conventional recupecator into DINCS (Daido Innovative Neo
Combustion System) to the CGL with 200 radiant tube burners.
2) Each burners have 420MJ/h of rated combustion volume, and combusted at 80% rate on average.
・Reduction of CO2 3) Furnace operation is 330days/year, 24 hours/day.
Production capacity is assumed as 594,000 ton/y (75 ton/h x 24h x 330 day/y)Emission
4) The effect is calculated as comparison with steel heat exchanger system
5) Natural gas is used as for combustion.
53222(𝐺𝐺𝐺𝐺⁄𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦) × 0.0136(𝑡𝑡𝑡𝑡 ⁄𝐺𝐺𝐺𝐺) × 44�12 = 2,654(𝑡𝑡𝑡𝑡𝑡𝑡𝑡⁄𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦)
・Fuel Savings

53,222GJ/year under assumptions same as above
0.0896 GJ/ton saving (= 53,222 GJ/y / 594,000 ton-product/y)・Electricity Savings N/A・Economic Effect（payback time）

Approx. 4.9 years under assumptions same as above.
Cost for installation work and combustion adjustment are included (1,600,000JPY) and the price of thermal enrgy isassumed to be 19.11 US$/GJ (2,100 JPY/GJ).
Annual profit = 53,222 GJ/y x 19.11 US$/GJ / 594,000 ton/y = 1.71 US$/ton-product<Calcuation>
Payback time = (1,600,000 JPY x 200 units) / (53,222 GJ/y x 2,100 JPY/GJ) = 2.86 year

5. Direct Effect( Annual
Operating Cost)
・Productivity
Improvement

Since this system transfers the heat effectivly into the furnace or into product, line speed of the furnacecan be increased
which results in productivity improvement, if there is no restrictions for the equpment other than the combustion system.

・Maintenance Cost Conventional heat exchanger made of steel usually requires replacement every 3-4 years, but silicon carbide elements will
not deteriorate over time and last semipermanently.
Reduction
6. Indirect
Effect（Cobenefits）

・Product Quality
Improvement
・SOx, Dust
Decrease

N/A
N/A

・Water-saving
7. Proficiency Level of Technology
in Japan

N/A

8. Japanese Main Supplier

Daido Steel Co., Ltd.

9. Technologies Reference:

Japanese patent No.6587411 (Radiant tube type heating device)
Japanese patent No.6790554 (Radiant tube type heating device)

10. Preconditions

Investment cost and benefit vary depending on furnace specification, operation condition, fuel cost, etc of each customer.

Applied to more than 30 heat treatment furnaces.

29

A-22

General Energy Saving & Environmental Measures
Inverter (VVVF; Variable Voltage Valuable Frequency) Drive for Motors

Item

Content

1. Process Flow

Relationship between airflow under airflow control and the required Electric power

An inverter is a variable speed device controlling frequency and voltage to allow precise control of rotation.
The commercial AC voltage is converted to DC in the converter control unit, which then controls the inverter togenerate a three-phase variable voltage and variable frequency current.
A high-pressure inverter as an energy-saving device can directly drive a high-speed electric motor without using abooster transformer.
High-pressure IGBT (Insulated Gate Bipolar Transistor) inverter device outputs high voltage of 3.3kV and 6.6kV,
depending on the single-phase inverter multiple connection technology.
2. Technology Definition/Specification

3. Investment Cost & Operating Life
4. Effect of Technology
Introduction

Energy saving effect : Conversion of six 55kW electric motors with eddy current coupling, and reduction in power
consumption
Calculation conditions/NEDO :* Overall efficiency of conventional electric motors with eddy current coupling : 0.65
* Overall efficiency of electric motors converted to inverter control : 0.80
* Reduction in power consumption by lowering motor speed : 15% (assumed)* Annual operation : 3,600 h/y* Unit cost of power : ￥15/kWh￥2,000,000/unit(assumed) [NEDO] 【0.12 Crore/unit】

・Reduction of CO2
Emission

Not announced

・Electricity Savings

90,000 kWh/y [NEDO] 【0.04 Crore/unit】

・Economic Effect（payback time）
5. Direct Effect・Productivity( Annual Operating Cost ) Improvement
・Maintenance Cost
Reduction
6. Indirect Effect・Product Quality
Improvement（Co-benefits）

1.5 years [NEDO] 【2.9 years】
Not announced
Not announced
Not announced

7. Diffusion Rate of Technology in JapanNo data

8. Japanese Main Suppliermajor electric equipment suppliers

9. Technologies Reference:

Energy savings Diagnosis Examples-Common Equipment Volume', Energy conservation Center, Japan
Sumiyasu Kodama, et al. "High-performance AC Drive Series for Industrial Use", Toshiba Review, 52, 9, 1997,
p.36-39

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.
* annual operation : 3,600 h/y* unit cost of power : ￥15/kWh* Note : SOACT data
- Electricity savings 42 %- payback time : 3.4 years ( 3 pence/kWh under US 1994 conditions)* Refer to http://asiapacificpartnership.org/japanese/soact2nd.aspx and "Japanese Technologies for Energy
Savings/ GHG Emissions Reduction 《2008 Revised Edition》(NEDO, 2008)"

30

A-23

General Energy Saving & Environmental Measures
Energy Monitoring and Management Systems

Item

Content

1. Process Flow

Energy Monitoring and Management Systems

This measure includes site energy management systems for optimal energy recovery and distribution between
various processes and plants.
The aim of energy management should be to maximize the productive use of gases arising from the processes,
thereby minimizing the necessity of importing supplementary energy sources into the system and optimizing thespecific energy consumption within the inherent constraints of the system. In order to achieve the goal, there must
be an adequate system dealing with the technical possibilities and costs on the one hand, and on the organizationon the other hand.
1.Optimizing energy consumption: Typically, a change in the energy supply of one process in the steel plant
influences several other processes (e.g. the use of coke oven gas in the blast furnace can result in a higher
caloric value in the BF top gas). Optimizing tools that consider the whole integrated site may be preferable toones that consider each process as a standalone unit.

2. Technology Definition/Specification[*1]

2. Online monitoring.: This is often used for the most important energy flows and combustion processes at thesite. The data are stored for a long time so that typical situations may be analyzed. Very important is the online
monitoring for all gas flares. It is the main technique used to avoid energy losses in the flares and combustion
processes.
3. Continuous monitoring systems: For all energy-related process parameters can be used to optimize processcontrol and enable instant maintenance, thus achieving an undisrupted production.
4. Reporting and analyzing tools.: Reporting tools are often used to check the average energy consumption ofeach process. In connection with cost controlling, controlling energy is the basis for optimizing energy
consumption and cost savings. An energy controlling system offers the possibility of comparing actual data withhistorical data (e.g. charts)
5. Techniques to optimize process gas utilization：Some potential process-integrated techniques used to improveenergy efficiency in an integrated steelworks by optimizing process gas utilization include:(1) the use of gas holders for all by-product gases or other adequate systems for short-term storage and pressure
holding facilities for maximizing the recovery of process gases.
(2) increasing pressure in the gas grid if there are energy losses in the flares – in order to utilize more processgases with the resulting increase in the utilization rate.
(3)reheating fire furnaces with process gas in order to maximize the use of process gases and reduce the need topurchase natural gas or electrical power.
(4)use of a computer-controlled caloric value control system. This measure includes site energy management
systems for optimal energy recovery and distribution between various processes and plants.

3. Investment Cost & Operating Life
4. Effect ofTechnology
Introduction

・Reduction of CO2
Emission・Fuel Savings
・Electricity Savings

5. Direct Effect ・Economic Effect（payback time）( Annual
Operating・Maintenance Cost
Cost )
Reduction
6. Indirect
Effect（Cobenefits）

・Product Quality
Improvement

It depends on system structure, from data monitoring network to whole control computer system. One example in
Netherlands (was aquired by Tata Steel, and nominal capacity is 6.3Mt/y.) is $0.8M. 【4.3 Crore】
11.4 kg-CO2/t-steel
0.12 GJ/t-steel [*2, 3]
Not announced
Depends on cost of fuel and electricity of each site.
Not announced
Not announced

7. Diffusion Rate of Technology in Japan widely spread and mostly applied
8. Japanese Main Supplier

Major electric equipment suppliers

9. Technologies Reference:*1 EU-BAT 2.5.2.1 9.1.2, USA-BAT IV.A9.2*2 Farla, J.C.M., E. Worrell, L. Hein, and K. Blok, 1998. Actual Implementation of Energy Conservation Measuresin the Manufacturing Industry 1980-1994, The Netherlands: Dept. of Science, Technology & Society, Utrecht
University.
*3 ETSU, 1992. "Reduction of Costs Using an Advanced Energy Management System," Best Practice
Programme, R&D Profile 33, Harwell, UK:ETSU

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.

31

A-24

General Energy Saving & Environmental Measures

Item

Content

Cogeneration ( include Gas Turbine Combined Cycle (GTCC))

1. Process Flow

2. Technology
Definition/Specification

3. Investment Cost & Operating Life

4. Effect ofTechnology
Introduction

Coming Soon

・Reduction of CO2
Emission・Fuel Savings
・Electricity Savings

・Economic Effect（payback time）
5. Direct Effect・Productivity( Annual
Improvement
Operating Cost)
・Maintenance Cost
Reduction
・Product Quality
Improvement
6. Indirect・SOx, NOx, Dust
Effect（Co-benefits） Decrease
・Water-saving
7. Proficiency Level of Technology
in Japan
8. Japanese Main Supplier

9. Technologies Reference:

10. Preconditions

32

A-25

General Energy Saving & Environmental Measures

Item

Content

Management of Compressed Air Delivery Pressure Optimization

1. Process Flow

2. Technology
Definition/Specification

The delivery pressure of compressors is generally 100 kPa or higher. Compressors have been developed for avariety 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 resistanceIntake 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 resistanceCalculation conditions;*Number of compressors; Total of 17, *Delivery pressure; 0.8MPa,*Equipment capacity; 823 kW,*On-load operation load; 60%,
*Daily operation; 24 h/d,
*Annual operation; 241 days

3. Investment Cost & Operating Life Not announced
・Reduction of CO2
4. Effect of
Not announced
Emission
Technology
Introduction
・Electricity Savings 285 MWh/y (=823 kW * 60 % * 10 % * 24 h/d * 241 days/y)

5. Direct Effect(AnnualOperating Cost)

・Economic EffectNot announced（payback time）
・Monetaryequivalent of energy ￥4,370,000/y 【0.5 Crore/year】
savings
・Maintenance Cost
Not announced
Reduction

6. Indirect Effect ・Product Quality
Improvement(Co-benefits)
7. Diffusion Rate of Technology inJapan

Not announced
well known and familiarized

8. Japanese Main Supplier

Major electric equipment suppliers

9. Technologies Reference:‘Energy saving Diagnosis Examples – Common Equipment Volume’, Energy conservation Center, Japan

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* Payback time is defined as (Investment cost / Economical merit) in this project.
* Average unit cost of power; ￥15.3/kWh

33

A-26

General Energy Saving & Environmental Measures

Item

Content

Power Recovery by Installation of Steam Turbine
in Steam Pressure Reducing Line

1. Process Flow

Fig. 1 Steam pressure reducing systembefore improvement

Fig. 2 System after improvement byintroduction of steam turbine

Outline : In cases where high pressure steam generated by a boiler is used by pressure reduction, thistechnology reduces refrigerator power consumption by installing a steam turning in place of the steam pressure
reducing valve and driving the refrigerator with the power recovered by the steam turbine. Although steam
consumption is increased somewhat, a total energy saving is achieved.

2. Technology Definition/Specification

3. Investment Cost & Operating Life
4. Effect ofTechnology
Introduction

5. Direct Effect(AnnualOperating Cost)

6. Indirect Effect(Co-benefits)

Principle, operation and features of technology: In this example in Fig.1, the capacity of the boiler which had
been installed was approximately steam pressure: 12 kg/cm2 and steam output: 50 t/h. However, this steam wasused as process steam after pressure reduction. In one case, the reduced-pressure conditions were 10 kg/cm2
and 28t/h, and in another, 4 kg/cm2 and 22t/h (approximate values). That is, steam at a pressure of 12 kg/cm2
was reduced to 10 kg/cm2 and 4 kg/cm2 by pressure reducing valves. In this example in Fig.2, a steam turbine isused in place of a pressure reducing valve, and the system was modified so that a refrigerator is driven by therotational force of the turbine using steam as a power source. Pressure reducing valves reduce pressure bycausing a pressure loss when the valve port in the valve is restricted, utilizing the difference in enthalpy drop due
to adiabatic restriction. The principle of the steam turbine is the same as this, in that power is generated byutilizing the difference in enthalpy drop. The energy saving by adoption of this system is as follows: Reduction ofelectric power consumption – fuel for increase of steam consumption = Energy saving
approx. 50 million (Equipment), approx. 20million (Construction)

・Reduction of CO2
Emission

Not announced

・Electricity Savings

544 (approx.) kW → 544kW*24h*330d/y=4308 MWh/y
Demerit: Increase of steam consumption, approx.0.8 (t-steam/h)・Economic Effect（payback time）

6,197.6(Gcal/y)=(Electricity Savings : 114,00.2Gcal/y )-(Increase of Steam consumption : 5,202.6Gcal/y)Reduction in crude oil equivalent: 619.8 t-crude oil/y (approx.)
Equipment only : 0.7 years (approx.)【5.8 years】, Including construction cost: 1.0 years (approx.)【8.1 years】

・Monetary equivalent￥68 million/y 【0.5 Crore/y】
of energy savings
・Maintenance Cost
Reduction

Not announced

・Product Quality
Improvement

Not announced

7. Diffusion Rate of Technology inJapan

Numerous examples of implementation of similar technologies at main plants in Japan.

8. Japanese Main Supplier

Kobe Steel, Ltd.

9. Technologies Reference:・FY2000 Study Report “Survey of Energy Saving in Japan,” New Energy and Industrial Technology
Development Organization (NEDO), March 2001
・“Collected Examples of Energy Saving,” p. 1,095, 1984 (in Japanese)

10. Preconditions* Important values were revised with referring to various values in "1-4. Used values and applied preconditions."
Especially as for investment cost and payback time for the case of India, revised values were indicated in 【】.
* "Japanese Technologies for Energy Savings/ GHG Emissions Reduction 《2008 Revised Edition》(NEDO,2008)"
Cost of power：¥17.99/kWh
Cost of C heavy oil：¥1.81/1,000kcal
Overall boiler efficiency: 0.8
Electricity conversion factor: 2646kcal/kWh
Steam conversion factor: 656.9kcal/kg-steam

34

2. Environmental
Protection Technologies
2-1. Technologies Customized List

35

Technologies Customized List of Environmental Protection Technologies
for ASEAN Steel Industry 2022 version part-2: BF-BOF (v.4.0)
No.

Title of Technology

Technical Description

Expected Effects of Introduction

Waste Water Treatment- Injection of polymer and optimized agitating time to produce
high density pellets- Removing suspended solids (SS)- Combined cleaning w ith the air and w ater cleans the filter
w ell and restores it completely- Removing suspended solids (SS)- The multi staged fluidized bed all allow s for continuous feedand extraction of activated carbon- Removing organic substance and oil- Decoloration of colored w astew ater

B-4 High-Speed Air Flotation System- Ten times larger upflow velocity than the conventional
system, leading to drastic reduction in installation space- Removing oily and suspended matters

B-5 Cooling Tow er- Equipped w ith the blow er module consisting of reliableblow er/ speed reducer/ motor and filling materials of high heat - Removing naphthalene and dust
exchange efficiency

B-6 Electrochlorination System- This system reduces the volume of acid cleaning w aste
w ater, w ith the recycle system of MGPS

B-1

High-Speed Coagulating Sedimentation
Equipment

B-2 High-Speed Filtration Equipment

B-3

Multi-Staged Fluidized-Bed Activated Carbon
Absorption Equipment- Reduction of acid cleaning w aste w ater

Reduction of SO2 from Coke Oven gas by Desulphurization
B-7

Reduction of SO2 from Coke Oven gas by
Desulphurization- The NNF Process is the latest desulfurization process for- Minimizing SO2 emission
COG, w hich does not produce the contaminated w aste w ater

Dust Emissions Control
B-8 Wet type Electrostatic Precipitator for COG- Tar separation from COG w ith stable performance andcontinuous operation- Low outlet dust (tar) concentration < 1 mg/
Nm3

B-9 Dry type Electrostatic Precipitator- The precipitator structure and dimensions have beenstandardized to uniform the gas flow distribution- Low outlet dust concentration < 10-50 mgdust/Nm3- A moving electrode mechanism and a new method thatremoves dust by means of brushes w ere developed- Cleaning exhaust gas (dust and ultrafinedust) from sintering machines

B-10

Moving Electrode Electrostatic Precipitator:
MEEP

B-11

Wet type Electrostatic Precipitator for Scarfing - Dust, mist and submicron particulate are collected on
Machinecollecting plates and w ashed aw ay by w ater sprays- Cleaning exhaust gas (dust and mist) from
scarfing machines to less than 1 mg/m3

B-12

Wet type Electrostatic Precipitator for ByProduced Gas Turbine- Effective for SO3, PM 2.5 and heavy metals- Using w ater in removing the collected dust, the w et EP canachieve high dust removal efficiency less than 1 mg/Nm3

Exhaust Gas Treatment through Denitrification, Desulphurization
B-13

Dry Activated Coke Exhaust Gas Treatment
Facilities- This method is capable of eliminating DXNs and heavy metals - Eliminating DXNs and heavy metals such as
such as Hg in exhaust gas
Hg in exhaust gases

Blast Furnace Gas and Cast House Dedusting
B-14 Multi-Vessel Electrostatic Precipitator (MVEP)- Dust and w ater drops are removed by electric energy in- Realizing the dust content at the outlet of 5
MVEP located in the gas turnover/rising section in each vessel,
mg/Nm3 or low er
w hich generates clean gas

B-15 Ring Slit Washer (RSW) Wet Gas Scrubber- Achieved excellent dust collection performance w ith its low
load differential pressure and liquid-gas ratio

B-16 Pulse type Bag Filter- Compressed air is discharged through the pulsing nozzle and- Eliminating dust, DXNs and others
creates shock w ave breaking the dust cake deposition

B-17 High temperature filter bag(nanolof HT)- High temperature resistance up to Max 350℃
- Non-flammable material (High resistance for sparks)- High strength (approximately 30% stronger than regular filterbag)- Easy handling and installation compared to ceramic forming
filter bag.

- Realizing the dust content at the outlet of 5
mg/Nm3 for BFG or 20 mg/Nm3 for LDG- Less damage from sparks.
- Energy and utility cost saving can beachieved due to omission or dow nside ofexisting cooling facility.

General Technology
B-18 Gas Analyzer- Measures the NO, SO2, CO2, CO, CH4, N2O and O2- Quantitative grasp of substances ofcomponents in sample gas by detecting the amount of infraredatmosphere that cause global w armingrays absorbed by a Measuring cell, w ith Mass flow sensor.

36

2. Environmental
Protection Technologies
2-2. Technologies One by One Sheet

37

B-1
Item

Waste Water Treatment

High-Speed Coagulating Sedimentation
Equipment
Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

1. Suitable coagulants are selected according to wastewater property in order to generate highdensity flocks.
2. Injection of polymer and optimized agitating time to produce high-density pellets.
3. Sedimentation & settlement process
A slurry blanket layer is formed to quicken the sedimentation of the consolidated pellets

3. Field of Application

Removing SS from various types of wastewater

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law)
Environmental Water Quality Standard
http://www.env.go.jp/en/water/

5. Benefits

Not Announced

6. Co-benefits

・No sludge thickener is required. Sludge is thickened to a high concentration (approx. 30,000
milligram/liter) by consolidation.

7. Japanese Main Supplier

Mitsubishi Heavy Industries Power Environmental Solutions, Ltd.

8. Technologies Reference

https://power.mhi.com/group/es/products/rainwater/outline

38

B-2

Waste Water Treatment

High-Speed Filtration Equipment

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification- Excellent filter cleaning
Combined cleaning with the air and water cleans the filter well and restores it completely.
- Easy operation management
All operations are automatically controlled, which makes the operation management so easy.

3. Field of Application

This is most commonly used at a steel plant for blooming and continuous caster, and theirequipment can be backed up with stability.

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law)
Environmental Water Quality Standard
http://www.env.go.jp/en/water/wq/wp.pdf

5. Benefits

Stable operation : With strong tolerance against variation of inflow raw water quality, the system
can obtain filtered water stably, which can make the operation so stable.

6. Co-benefits
7. Japanese Main Supplier
8. Technologies Reference

Not Announced
Kobelco Eco-Solutions Co., Ltd
https://www.kobelco-eco.co.jp/english/product/pdf/industrial_water_treatment/superfilter.pdf

39

B-3
Item

Waste Water Treatment

Multi-Staged Fluidized-Bed Activated Carbon
Absorption Equipment
Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

The multi-staged fluidized bed allows for continuous feed and extraction of activated carbon.
It achieves smaller space and lower cost than the conventional fixed-staged fluidized-bed activated carbon
absorption equipment, and provides many advantages including easy operation and maintenance.

3. Field of Application- Treatment of factory effluent containing organic substances (for chemical, food, iron, paper, medicine, etc.)- Decoloration of colored wastewater- Oil removal from wastewater containing oil (oil refinement wastewater, petrochemistry wastewater, etc.)

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law)
Environmental Water Quality Standard
http://www.env.go.jp/en/water/wq/wp.pdf

5. Benefits- Lower operating cost : This equipment provides higher usage and contact efficiency of activated carbon to
reduce the running cost, compared with the fixed-bed type.
- Addresses variation of wastewater quality : By adjusting the feed quantity of activated carbon, the quality oftreated water can be kept constant even when the wastewater quality changes.
- Saves space and reduces facilities cost : Being different from the fixed-bed type, continuous operation for
the entire tower is available and the absorption speed is high, reducing the equipment size and cost.
- Backwash is not necessary : the fluidized-bed does not suffer from blocking By contaminating materials
contained in the wastewater as seen with the fixed-bed type, eliminating need for backwash.

6. Co-benefits- Saves labor : Unmanned operation allows for easy operation and management, enables significantly laborsaring

7. Japanese Main Supplier
8. Technologies Reference

Kobelco Eco-Solutions Co., Ltd
https://www.kobelco-eco.co.jp/english/product/pdf/industrial_water_treatment/multiactos.pdf

40

B-4

Waste Water Treatment

High-Speed Air Flotation System

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

As a result of the improvement of the structure of the floatation tank, we achieved ten times larger upflow
velocity than the conventional system, leading to drastic reduction in installation space required for the unit. It
could cut install space by 90%. As specification of the system, easy bubble generation control and fewer
components to achieve easy Operations & Maintenance

3. Field of Application* High Performance* High dissolving efficiency by Micro Bubble Generator* High efficient floatation of oily and suspended matters

4. Regulatory and/or
administrative frameworks
in Japan(Basic Environment Law)
Environmental Water Quality Standard
http://www.env.go.jp/en/water/wq/wp.pdf

5. Benefits
6. Co-benefits
7. Japanese Main Supplier
8. Technologies Reference

Not Announced
Not Announced
Mitsubishi Heavy Industries Power Environmental Solutions, Ltd.
https://power.mhi.com/group/es/products/rainwater/outline

41

B-5

Waste Water Treatment

Cooling Tower

Item

Content

1. Process Flow or Diagram

COG Cooling System with Double
Contact Tower

2. Technology
Definition/Specification

Our cooling tower for industry is equippedwith the blower module consisting of reliableblower/speed reducer/motor and fillingmaterials of high heat exchange efficiency.
We can select the best suited cooling tower
from our ample line up suited according tocustomer's demand of specifications such as
quantity of water/quality of water/temperature
condition/setting space, and others.

We have various types of COG cooling apparatus, equipped with adirect or an indirect heat exchange system in the cooling tower. The
picture shows a cooling tower which has a double contact direct
cooling system, avoiding cooler clogging by dissolving thenaphthalene precipitate by coal tar in coolant.

3. Field of Application

A cooling tower for industry is applied in thefield of every industry such as ironmanufacture /chemistry/oil
refining/generation/paper
manufacture/cement.

A cooling tower of Coke Oven Gas (COG)

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law)
Environmental Water Quality Standard
http://www.env.go.jp/en/water/wq/wp.pdf

5. Benefits

Not Announced

Not Announced

6. Co-benefits

Not Announced

1) Compact configuration.
2) Economical combination of a direct and an indirect cooling system.

7. Japanese Main Supplier

Kobelco Eco-Solutions Co., Ltd

Nippon Steel Engineering Co., Ltd

8. Technologies Reference

https://www.kobelcoeco.co.jp/english/product/cooling_tower/

https://www.eng.nipponsteel.com/english/whatwedo/steelplants/

42

B-6

Waste Water Treatment

Electrochlorination System

Item

Content

Mitsubishi MGPS® (Marine Growth Preventing
System), a representative technology ofelectrochlorination system, has the environmental
friendly process.
Sodium hypochlorite solution produced in the Bi-polarcell unit is transported to the cell unit again withseawater, while some portion of it is discharged into
the seawater inlet channel.
1. Process Flow or Diagram

Mitsubishi MGPS® is the best solution for maintaining the efficiency of coolingsystems in your plant !

2. Technology
Definition/Specification①Proven Technology
MITSUBISHI MGPS® has over 50 years experience since 1965.
②Safety and harmless
Produced sodium hypochlorite is almost consumed and discharged into the seawater③High Durability
High chlorine generation efficiency achieved for a long time by original highly durable
electrode coating.
④High Availability & Maintainability
Mitsubishi MGPS® can reduce the frequency of acid cleaning to 1/12.
Mitsubishi MGPS® can be applied to variouis kinds of plants on the sea!
Wide capacity for any scales of plants

3. Field of Application●Iron Mills●Coal-fired Thermal Power Plant●Gas Turbine Combind Cycle Thermal Power Plant●Nuclear Power Plant●LNG/LPG Terminals●Seawater Desalination Plants●Oil Refinery Plants●Chemical Plants (Fertilizer, Ammonia, Methanol, etc.)●Coastal Sewage Treatment Plants●Offshore Structure ( Offshore Oil Platform, etc.)

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law) / Ministry of Environment
ambient air quality standard
http://www.env.go.jp/en/air/aq/aq.html

5. Benefits

・Reliable adhesion prevention by electro chrolination technology
・Stable and improved plant operation rate by protection of cooling system
・Reduction of LCC (Life Cycle Cost) through energy-saving and chemical-saving technologies.
Waste liquid treatment costs also can be reduced by over 90%.

7. Japanese Main Supplier・Eco-Technology for the local environment
・Safe Operation for plant operators
Mitsubishi Heavy Industries Environmental & Chemical Engineering Co., Ltd.

8. Technologies Reference

Trackrecord : More than 165 Plants all over the world.
https://www.mhiec.co.jp/products/electrolysis/menes/menes_technologie.html

6. Co-benefits

43

B-7

Reduction of SO2 from Coke Oven gas by Desulphurization

Reduction of SO2 from Coke Oven gas by
Desulphurization

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

The NNF Process, the latest desulfurization process for coke oven gas which does not produce thecontaminated waste water, is able to produce the conc.-H2SO4 from contaminated waste water including
elemental sulfur and ammonium salt. This process is at an advantage over the other wet oxidation
processes or the absorption/stripping processes in desulfurization efficiency and operating costs, theoptimum solution in terms of economy, SO2 emission minimizing & environmental protection.

3. Field of Application

The removal of Hydrogen Sulfate from COG

4. Regulatory and/or
administrative frameworks inJapanAmbient air quality standard
http://www.env.go.jp/en/air/aq/aq.html

5. Benefits

Not Announced

6. Co-benefits

The liquid oxidation section, because of exothermic reactions in the reaction tower, does not need to beheated from the outside.

7. Japanese Main Supplier

Nippon Steel Engineering Co., Ltd.

8. Technologies Reference

https://www.eng.nipponsteel.com/english/whatwedo/steelplants/

44

B-8

Dust Emissions Control

Wet type Electrostatic Precipitator for COG

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Low outlet dust(Tar) concentration < 1mg/Nm3
Wire & Weight Type Discharge Electrode Perforate Segment Sllurry Sump

3. Field of Application

Tar separation from coke oven gas
Stable performance and continuous operation with countermeasures for corrosion, explosive and high pressure gas(1,500mmAq ~ 2,000mmAq)

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law)
Environmental Water Quality Standard
http://www.env.go.jp/en/water/wq/wp.pdf

5. Benefits

Not Announced

6. Co-benefits

Not Announced

7. Japanese Main Supplier

Mitsubishi Heavy Industries Power Environmental Solutions,
Sumitomo Heavy Industries,Ltd.
Ltd.
https://www.shi.co.jp/english/products/environment/electricity/ind
ex.html

8. Technologies Reference

45

B-9

Dust Emissions Control

Dry type Electrostatic Precipitator

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification*The ESP incorporates a three-stage gas distribution systemin the splitter in the gas entry section to ensure that the gas* The precipitator structure and dimensions have been
is evenly distributed for entry to the energizing chamber.
standarized to actualize the gas flow distribution to be*The discharge electrode provide the excellent discharge
uniform, so that flow distribution test at site fis not neededcharacteristics due to the optimum shape, and has good
*Unique lattice-type gas distribution plate, which isstablity with the strength and rigidity of electrode. The
configured to prevent dust adhesion and clogging, can be
possibility of breakage is minimaized.
used without rapping*The discharge electrodes of high mechanical strength and *The Unique shape collecting electrode, called sigma III, has
the cross section strength withstand rapping impact. At thesuperior discharging properties are used according to dust
same time it can acheive high rapping efficiency and uniform
concentration and properties in each section, to ensure
distribustion of the electrical field.
optimum energization conditions* Component except for the driving motor are built in, thus no *The Rapping systems feature low rapping reentrainmentand high rapping effect to calculate the appropriate rapping
noise is emitted.
* Support insulators are protected at all times by seal air and force.
heater, avoiding damage caused by dust sticking or moisture *Puse enegization system is installed to obatain thesignificant improvement in the performance of ESP against
condensation.
to the dust which has high electirical resitivity and under the* Discharge electrodes are extremely strong speciallyback ionization.
molded electrodes, short in length and fixed to the support*Advanced energizaiton control system can be adopted withframe (pipe), so as to prevent energization failure due toindividual configuration developed by ourself and latest
vibration or breakage due to fatigue.
digital signal process remote control.

3. Field of Application* Sinter main gas treatment are highly evaluated by customers under strict conditions such as high negative pressure (1,000～2,500mmAq), high dust resistivity, flammable,corrosive,etc⇒10～50mg-dust/Nm3

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law) / Ministry of Environment
ambient air quality standard
http://www.env.go.jp/en/air/aq/aq.htm

5. Benefits

Not Announced

6. Co-benefits

Not Announced

7. Japanese Main Supplier

Mitsubishi Heavy Industries Power Environmental Solutions,
Sumitomo Heavy Industries,Ltd.
Ltd.

8. Technologies Reference

https://power.mhi.com/products/aqcs/lineup/dust-collector

46

https://www.shi.co.jp/english/products/environment/electricity/index.html

B-10

Dust Emissions Control

Moving Electrode Electrostatic Precipitator : MEEP

Item

Content

1. Process Flow or Diagram

Structural Diagram of Moving Electrode Unit

2. Technology
Definition/Specification

Electrostatic precipitators are devices that collect dust by drawing it to the dust collecting electrode by using adischarge electrode to electrostatically charge the dust in the gas included in the flue emissions. With conventional
fixed electrode electrostatic precipitators, the collection plate is hammered at regular intervals to knock off thecollected dust. However, it is difficult to sufficiently remove highly adhesive, high resistivity dust from the plate. As aresult, the surface of the collecting plate becomes covered by layers of adhered high-resistivity dust. If operation
continues under these conditions, high-resistance obstruction and the back corona phenomenon will occur due to thedust covering the collecting plate. The corona current from the discharge electrode will be abated, and the dust
deposited on the collecting electrode will cause dielectric breakdown, seriously degrading the dust collection
performance.
For the moving electrode electrostatic precipitator, a moving electrode mechanism and a new method that removes
dust by means of brushes were developed, enabling the efficient collection of high-resistivity dust and a space-saving
footprint.
* High performance
Since high-resistivity dust and ultrafine dust collected on the collecting electrode can be efficiently removed bybrushes, dust collection efficiency is high. Also, because dust removal takes place outside of the dust collection area,
there is no reentrainment and high performance can be maintained.
* Space saving and power saving
Since dust collection efficiency is high, the apparatus can be made significantly smaller and power consumption canbe reduced, enabling energy-saving operation.

3. Field of Application

Cleaning exhaust gas from sintering machines

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law) / Ministry of Environment ambient air quality standard
http://www.env.go.jp/en/air/aq/aq.html

5. Benefits

Not Announced

6. Co-benefits

Not Announced

7. Japanese Main Supplier

Mitsubishi Heavy Industries Power Environmental Solutions, Ltd.

8. Technologies Reference

https://power.mhi.com/products/aqcs/lineup/dust-collector

47

Dust Emissions Control

B-11

Wet type Electrostatic Precipitator
for Scarfing Machine and Gas Cutting Machine

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Dust and mist, including submicron particulate, arecollected on collecting plates and then washed away bywater sprays. Offering minimal water consumption, theHitachi Plant Construction's wet ESP is designed with theconfiguration that is optimal for the customer's specificsystem. This enables high performance - reducing theoutlet dust concentration to less than 1 mg/m3 - from acompact wet ESP capable of handling high gas velocity.
In addition, this system has following specification;(1) Reduced outlet dust concentration(2) Compact configuration(3) Reduced water consumption for washing the collecting
electrodes and effectiveness with high gas velocity(4) Reduced use of industrial water(5) Total water treatment planning

Dust and mist, including submicron particulate, are collected oncollecting plates and then washed away by water sprays.
The Wet Electrostatic Precipitator(WESP), which was developed by
Sumitomo Heavy Industries, Ltd.(SHI), has following specification;(1) Excellent dust removal performance.
(2) Wide range of applications under such the corrosive andexplosive conditions(3) Less breakdowns considering the staructure with disconnecitingof discharge electrode and breakage of insulators(4) Low running cost regarding the optimum energization control
system and water consumption(5) Space-saving, Compact considering the properties of the waste
flue gas and the lack of reentrainment.

3. Field of Application
4. Regulatory and/or
administrative frameworks inJapanCleaning exhaust gas from scarfing machines, Wet type ESP for gas cutting machine

5. Benefits

Not Announced

6. Co-benefits

Not Announced

7. Japanese Main Supplier

Mitsubishi Heavy Industries Power
Environmental Solutions, Ltd.

Sumitomo Heavy Industries,Ltd.

8. Technologies Reference

https://power.mhi.com/products/aqcs/lineup/dust-collector

https://www.shi.co.jp/english/products/environment/electricity/index.
html(Basic Environment Law) / Ministry of Environment ambient air quality standard
http://www.env.go.jp/en/air/aq/aq.html

48Dust Emissions Control

B-12

Wet type Electrostatic Precipitator
for By-Produced Gas Turbine

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification* Using water in removing the collected dust, the wet EP can achieve high dust removal efficiency (less than over equal
to1mg/m3N at wet type EP outlet is also possible) without being affected by the high or low electrical resistivity of dust.
* Using an excellent atomization electrode washing nozzle, the discharge electrodes and collecting electrodes can be
washed* In case significant corrosion is evident due to the gas property or quality of water, corrosion-resistant design such as
stainless steel, FRP, and flake lining is being considered.

3. Field of Application* Wet type EP for by-produced gas turbine for power generation remove solid particulate matters contained in the fuel,actualizing ultralow concentration in order to protect compressors for gas turbines.
* Effective for SO3, PM2.5, and Heavy metals

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law) / Ministry of Environment
ambient air quality standard
http://www.env.go.jp/en/air/aq/aq.html

5. Benefits

Not Announced

6. Co-benefits

Not Announced

7. Japanese Main Supplier
8. Technologies Reference

Mitsubishi Heavy Industries Power Environmental Solutions, Ltd.
https://power.mhi.com/products/aqcs/lineup/dust-collector

49

B-13

Exhaust Gas Treatment through Denitrification, Desulfurization

Dry Activated Coke Exhaust Gas Treatment Facilities

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

The activated coke in the moving bed moves slowly in a vertical direction (top to bottom). As it moves it comes
into contact with the exhaust gases that flow in a horizontal direction, eliminating pollutants. This method isreferred to as the cross flow moving bed method and also provides a dust collecting function.
This method is capable of eliminating DXNs and Heavy Metals such as Hg in exhaust gases.

3. Field of Application* Sintering Machines in steel plants* Pulverixed coal fired power plants* Incinerater

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law) / Ministry of Environment
ambient air quality standard
http://www.env.go.jp/en/air/aq/aq.html

5. Benefits

Not Announced

6. Co-benefits- Various harmful components included in exhaust gases can be eliminated- No changes to the temperature of exhaust gases- Small amount of service water used
- Byproducts (sulfuric acid, gypsum, etc.) can be selected to suit the installation location- Small amount of waste materials generated

7. Japanese Main Supplier

J-POWER EnTech, Inc.

Nippon Steel Engineering Co., Ltd.

8. Technologies Reference

50

B-14

Multi-Vessel Electrostatic Precipitator

Item

Content

Blast Furnace Gas and Cast House Dedusting

1. Process Flow or Diagram

2. Technology
Definition/Specification

Multi-vessel electrostatic precipitator (MVEP), instead of the existing 2-stage venturi scrubber, is arranged in
the system, and dust and water drops are removed by electric energy in MVEP located in the gas
turnover/rising section in each vessel, which generates clean gas. Since the temperature drop and pressure
loss is reduced as compared to 2-stage venturi scrubber, TRT power generation is increased by 30%, withrealizing the dust content at the outlet of the system of 5 mg/Nm3 or lower. And, since there is notemperature limitations as compared to bag filter, this system has excellent durability at high temperature gas
inlet by operation fluctuations.

3. Field of Application

Blast Furnace

4. Regulatory and/or
administrative frameworks in
Japan

Strategic Energy Plan
Act on Promotion of Global Warming Countermeasures

5. Benefits- TRT power generation is 10% larger than bag filter type, and 30% larger than wet type.
- Conpact, saving space system compared to bag filter type
- Achieved exellent dust collection performance

6. Co-benefits
7. Japanese Main Supplier

Lower water consumption compared with wet-type
Nippon Steel Engineering Co., Ltd.

8. Technologies Reference

PMD NEWS 2013(Published: May.2013)https://www.eng.nipponsteel.com/english/whatwedo/steelplants/

51

B-15

Blast Furnace Gas and Cast House Dedusting

Ring Slit Washer (RSW) Wet Gas Scrubber

Item

Content

CONVERTER GAS

BFG

1. Process Flow or Diagram

The RSW jointly contains an auxiliary spray tower-type scrubber in its upper part and a variable throattype venturi scrubber called RSE in its lower part.
When this system is applied to the blast furnace, an axis flow mist separator is installed in thedownstream to separate air and liquid and realizes the dust content at the outlet of the system of 5
mg/Nm3 or lower.
When this system is applied to the converter, gas from the gas cooler is cooled down again to 70 deg C
by the saturator and 99.9% of dust, which is contained high concentrated in the gas, is removed at dust
collector(RSE)
2. Technology
Definition/Specification

In addition, this system has following specification;* Compact, space-saving system.
* Achieved excellent dust collection performance with its low load differential pressure and liquid-gas
ratio.
* When this system applied to BF, the load differential pressure is 30 kPa, and the dust content at theoutlet of the RSW is 5 mg/Nm3 or lower .
* When this system applied Converter, the load differential pressure is 15 - 20 kPa, and the dust content
at the outlet of the RSW is 20 mg/Nm3 or lower.
* Realized excellent blast furnace top pressure control performance.
* Realized excellent converter throat pressure control performance, results high gas recovery
efficiency(70-90%)

3. Field of Application

The Ring Slit Washer (RSW) wet gas scrubber is used widely with various dust collection devices,
including its use for cleaning the gas emitted by blast and converter furnaces.

4. Regulatory and/or
administrative frameworks in
Japan

Strategic Energy Plan
Act on Promotion of Global Warming Countermeasures

5. Benefits
6. Co-benefits
7. Japanese Main Supplier
8. Technologies Reference

Not Announced
Not Announced
JP Steel Plantech Co. (SPCO)
http://steelplantech.com/product/rsw/

52

B-16

Blast Furnace Gas and Cast House Dedusting

Pulse type Bag Filter

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

When the diaphragm valve is opened, compressed air is discharged through the pulsing nozzle. It creates shock
wave which break the deposition of dust cake.
Reduction in the number of parts and components, such as the filtering cloth, leads to a reduced number of
replacement parts and therefore the costs involved in work for exchanging parts and components are reduced.
Also, the adoption of a high-speed filtration and long length filtering cloth achieved space saving.

3. Field of Application* Coke Plant
Coal charging car
Coke guide
PusherFlue gases from coke oven
* Sintering Plant
Sinter cooler* Blast Furnace
Coal Pulverization for BF Injection* House dedusting

4. Regulatory and/or
administrative frameworks inJapan(Basic Environment Law) / Ministry of Environment
ambient air quality standard
http://www.env.go.jp/en/air/aq/aq.html

5. Benefits

Not Announced

6. Co-benefits

Not Announced

7. Japanese Main Supplier

Nihon Spindle Manufacturing, Sumitomo Heavy
Industries, Ltd

8. Technologies Reference

http://www.spindle.co.jp/product/dust.html
https://www.shinwatec.co.jp/products/air_pollution_contr
http://www.shi.co.jp/english/products/environment/dust/in ol_systems/
dex.html
https://www.shinwatec.co.jp/en/pollution/

53

Shinwa Corporation

B-17

Blast Furnace Gas and Cast House DedustingHigh temperature filter bag(nanolof HT)

Item

Content

350℃

1. Process Flow or Diagram

Using nanolof HT, it is NOT necessary to lower the gas temperature below 200℃
by cooling equipment before dedusting system.
(Normal filter bags can be used only at200℃ for regular use, and up to 230℃ for a moment.)

2. Technology
Definition/Specification

・High temperature resistance up to Max 350℃
・Non-flammable material (High resistance for sparks)
・High strength (approximately 30% stronger than regular filter bag)・Easy handling and installation compared to ceramic forming filter bag.

3. Field of Application

Waste gas treatment facilities relating to incinerator, steel factory, power plant, waste treatment plant andchemical plant.

4. Regulatory and/or
administrative frameworks inJapan
5. Benefits

Bag filter can be operated at high temperature condition(300℃ or more) and less damage from sparks.
Energy and utility cost saving can be achieved due to omission or downside of existing cooling facility.

6. Co-benefits

More waste heat recovery can be achieved after dedusting.

7. Japanese Main Supplier

Shinwa corporation

8. Technologies Reference

54

B-18

General Technology

Item

Content

Gas Analyzer

1. Process Flow or Diagram

2. Technology
Definition/Specification

Gas Analyzer is capable of measuring the NO, SO2, CO2, CO, CH4, N2O and O2 components in sample
gas by detecting the amount of infrared rays absorbed by a Measuring cell, with Mass flow sensor. There arevarious types of gas analyzers for each applications and it is used to support environmental preservation andcontrol atmospheric pollution as well as monitor the atmosphere to help maintain a cleaner naturalenvironment. Fuji Electric produce the whole equipment including the sensor, which is an important part ofGas Analyzer.

3. Field of Application

Blast furnace, Converter funacer, Heat treatment furnace, Sintering (pallet equipment), Coke oven (CDQ)

4. Regulatory and/or
administrative frameworks in
Japan(The Basic Environment Law) / Ministry of Environment
Environmental Quality Standards
http://www.env.go.jp/en/air/aq/aq.html

5. Benefits

Quantitative grasp of substances of atmosphere that cause global warming

6. Co-benefits

Balancing economic activities and environmental conservation by a basic data provided by Gas Analyzer

7. Japanese Main Supplier

Major electric equipment suppliers

8. Technologies Reference

https://www.fujielectric.com/products/instruments/products/anlz_gas/top.html

55

Contact Points of Suppliers

56Company

Energy-Saving Technologies

Environmental Protection Technologies

Contact Points

A-12: Low NOx regenerative burner system for ladlepreheating
A-15: Process control for reheating furnace
Chugai Ro Co., Ltd.

A-16: Regenerative Burner Total system for reheating

3-6-1 Hiranomachi, Chuo-ku, Osaka 541-0046, Japanfurnace

TEL:+81-6-6221-1251 FAX:+81-6-6221-1411

A-17: High temperature recuperator for reheating

https://chugai.co.jp/en/

furnace
A-18: Fiber block for insulation of reheating furnace
A-20: Oxygen enrichment for combustion air
1-10, Higashisakura 1-chome, Higashi-ku, Nagoya,
Daido Steel Co., Ltd.

A-21: Highly efficient combustion system for radiantAichi, 461-8581, Japan

tube burner

TEL:+81-52-963-7501 FAX: +81-52-963-4386
https://www.daido.co.jp/en/index.html
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome,

Fuji Electric CO.,LTD.

A-23: Energy Monitoring and Management Systems

B-18: Gas Analyzer

Shinagawa-ku, Tokyo 141-0032, Japan
https://www.fujielectric.com/contact/?ui_medium=gl_glnavi

A-1: Sinter Plant Heat Recovery (Steam Recovery from
Sinter Cooler Waste Heat)
A-2: Sinter Plant Heat Recovery (Power Generation from
Sinter Cooler Waste Heat)
Kaneko 2nd Building 4-9F 2-6-23 Shin-yokohama,A-3: High Efficient (COG) Burner in Ignition Furnace for
JP Steel Plantech

Sinter Plant

Co.

A-4: Coke Dry Quenching (CDQ)

B-15: Ring Slit Washer (RSW) Wet Gas Scrubber

Kohoku-ku, Yokohama 222-0033 JAPAN
TEL:+81-45-471-3911 Fax:+81-45-471-4002
https://steelplantech.com/en/

A-8: Pulverized Coal Injection (PCI) System
A-11: Converter Gas Recovery Device
A-13: Converter Gas Sensible Heat Recovery Device
A-25: Management of Compressed Air Delivery Pressure
Optimization

Daiwa NishiShimbashi Building (4F), 3-2-1, NishiJ-POWER EnTech,

B-13: Dry Activated Coke Exhaust Gas Treatment

Inc.

Facilities

shinbashi, Minato-ku, Tokyo, 105-0003 Japan
TEL:+81-3-3434-7081 FAX:+81-3-3434-7086
Email:mail-box@jp-entech.co.jp
https://www.jp-entech.co.jp/en/
ON Building, 9-12, Kita-Shinagawa 5-chome,

Kobe Steel, Ltd.

A-26: Power Recovery by Installation of Steam Turbine

Shinagawa-ku, Tokyo, 141-8688, Japanin Steam Pressure Reducing Line

TEL:+81-3-5739-6000 FAX:+81-3-5739-6903
http://www.kobelco.co.jp/english/machinery/inquiry/
B-2: High-speed filtration Equipment

4-78, 1-chome, Wakinohama-cho, Chuo-ku, Kobe, 651-

Kobelco Eco-

B-3: Multi-Staged Fluidized-Bed Activated Carbon

0072, Japan

Solutions Co., Ltd

Absorption Equipment

TEL:+81-78-232-8018 FAX:+81-78-232-8051

B-5: Cooling Tower

https://www.kobelco-eco.co.jp/english/(Mitsubishi Group)

Mitsubishi Heavy

MITSUBISHI HEAVY INDUSTRIES. LTD.

Industries
B-6: Electro Chlorination System(MGPS)

Environmental &Chemical

2-3,Marunouchi 3 Chome, Chiyoda-ku, TOKYO 1008332 JAPANTEL: +81-3-6275-6199 FAX: +81-3-6275-6474

Engineering Co., Ltd.

https://www.mhi.com/
B-1: High-Speed Coagulating Sedimentation Equipment
B-4: High-Speed Air Floatation System
B-8: Wet type Electrostatic Precipitator

Mitsubishi Heavy

B-9: Dry type Electrostatic Precipitator

Industries Power

B-10: Moving Electrode Electrostatic

Environmental

Precipitator(MEEP)

Solutions, Ltd.

B-11: Wet type Electrostatic precipitator for Scarfing
Machine and Gas Cutting Machine

NISSEKI YOKOHAMA Bldg. 1-8, Sakuragicho 1-Chome
Naka-Ku, Yokohama 231-0062, Japan
TEL: +81-(0)45-232-4948
FAX: +81-(0)45-307-3400
URL: https://power.mhi.com/jp/group/es/

B-12: Wet type Electrostatic Precipitator for ByProduced Gas Turbine
1-1 Tama 3-chome, Tamano, Okayama, JAPANMitsui E&S
Machinery Co., Ltd.

Sales Gr. Plant Machinery Service Dept. Technoservice
A-6: Top Pressure Recovery Turbine (TRT)Div.
TEL: +81-863-23-2586
https://www.mes.co.jp/machinery/english/

Mitsui E&S Power
Systems Inc.

MESPS Tokyo Office:
A-19: Induction type billet heater for direct rolling

TEL:+81-3-6806-1075 FAX:+81-3-5294-1121
https://www.mesps.co.jp/contact/index.html

57Company

Energy-Saving Technologies

Environmental Protection Technologies

Nihon Spindle
Manufacturing Co.,

B-16: Pulse type Bag Filter

Ltd.

Nippon Furnace CO.,LTD

Contact Points
Sumitomo Fudosan Ueno Building No. 5, 1-10-14 KitaUeno Taito-ku, Tokyo 110-0014
TEL: +81-3-5246-5610
http://www.spindle.co.jp/en/index.html

A-12: Low NOx regenerative burner system for ladle

2-1-53, Shitte, Tsurumi-ku, Yokohama City, Kanagawa

preheating

Prefecture, 230-8666 Japan

A-16: Regenerative Burner Total system for reheating

TEL:+81-45-575-8111 FAX:+81-45-575-8046

furnace

Email:webmaster@furnace.co.jp

A-20: Oxygen enrichment for combustion air

http://www.furnace.co.jp/en.html

A-4: Coke Dry Quenching (CDQ)
A-5: Coal Moisture Control (CMC)
A-6: Top Pressure Recovery Turbine (TRT)
A-7: Multi-Vessel Electrostatic Precipitator
A-8: Pulverized Coal Injection (PCI) System
Nippon SteelEngineering Co., Ltd.

A-9: Hot Stove Waste Heat Recovery
A-10: Top Combustion type Hot Stove with Metallic
Burners
A-11: Converter Gas Recovery Device
A-13: Converter Gas Sensible Heat Recovery Device

B-5: Cooling Tower
B-7: Reduction of SO2 from Coke Oven gas by

Osaki Center Building, 1-5-1 Osaki, Shinagawa-ku,

Desulphurization

Tokyo 141-8604 Japan

B-13: Dry Activated Coke Exhaust Gas Treatment

TEL: +81-3-6665-2000

Facilities

https://www.eng.nipponsteel.com/english/

B-14: Multi-vessel Electrostatic Precipitator

A-14: Rotary Hearth Furnace Dust Recycling System
A-16: Regenerative Burner Total system for reheating
furnaceToyosu Center Bldg. 9F, 3-3 Toyosu 3-chome, Koto-ku,
Paul Wurth IHI Co.,Ltd.

Tokyo 135-6009 Japan
A-4: Coke Dry Quenching (CDQ)

TEL:+81-3-6630-4786 FAX:+81-3-3536-4014
Email:contact@ihi-pw.jp
https://www.ihi.co.jp/ihipw/en/index.html

A-15: Process control for reheating furnace
A-16: Regenerative Burner Total system for reheating
Rozai Kogyo Kaisha
Ltd.

2-14, Minamihorie 1-chome, Nishiku, Osaka, Japan 550-

furnace0015

A-17: High temperature recuperator for reheating

TEL:+81-6-6534-3609 Fax:+81-6-6534-3602

furnace

http://www.rozai.co.jp/en/company/index.html

A-18: Fiber block for insulation of reheating furnace
A-20: Oxygen enrichment for combustion air

Harmony Tower, 1-32-2 Honmachi, Nakano- ku, Tokyo
Shinwa Corporation

B-16: Pulse type Bag Filter

164-0012 JAPAN

B-17: High temperature filter bag

Email:info@shinwatec.co.jp
https://www.shinwatec.co.jp/en/

B-8: Wet type Electrostatic Precipitator
Sumitomo Heavy

B-9: Dry type Electrostatic Precipitator

Industries, Ltd.

B-11: Wet type Electrostatic precipitator for Scarfing
Machine and Gas Cutting Machine

ThinkPark Tower, 1-1 Osaki 2-chome, Shinagawa-ku,
Tokyo 141-6025, Japan
http://www.shi.co.jp/english/contact/index.html
3-5-1, Harumi, Chuo-ku, Tokyo 104-0053(Head Office)Tsukishima Kikai
CO., LTD.

TEL:+81-3-5560-6531 FAX:+81-3-5560-6596 (Industrial

A-5: Coal Moisture Control (CMC)

Sales Dept.)
TEL:+81-3-5560-6535 FAX: +81-3-3536-0575
https://www.tsk-g.co.jp/en/

58Annex 1. Guidance for calculating the profit, assumed
investment cost and payback time for your country

The information on economic effects such as profit of operation cost, assumed investment cost andpayback time are provided for some technologies on the technologies one-by-one sheet for Japan’scase. As the plant costs and energy prices may change from country to country, such information foryour country can be calculated following this guidance.
The list of "Electricity price, fuel price and plant cost index in ASEAN countries" is given below.

Electricity price, fuel price and plant cost index in ASEAN countries

SourceCountry

Electricity price forindustry use 1)(US$/kWh)

Fuel gas price forindustry use 1)(US$/GJ)

Plant cost index2)(Japan = 100.0)

Thailand

0.111

20.62

81.4

Indonesia

0.070

9.68

76.1

Vietnam

0.076

24.98

70.2

Philippines

0.200

25.89

74.4

Malaysia

0.077

7.49

77.4

Singapore

0.130

48.61

97.4

Japan

0.143

19.11

100.0

1) JETRO website (2021)
2) 2019PCI_LF_summary.pdf, Japan Machinery Center for Trade and Investment
3) average of combined margin from CDM projects, IGES website (2021.2.23)

Exchange Rate: The economic values in technologies one-by-one sheet is given in Japanese Yen(JPY). The electricity price and fuel price are given in US dollar (USD). Please use the relevant
exchange rate at the time of analysis to convert to the currency of your preference.

Investment Cost: Investment cost in each country can be calculated by multiplying "plant cost index" tothe total investment cost in Japan.

Annual Profit: Annual Profit from energy saving can be calculated as follows.
Annual profit from electricity saving ($/y)= amount of electricity saved per year (kWh/y) x electricity price for your country ($/kWh)Annual profit from fuel saving ($/y)= amount of fuel energy saved per year (GJ/y) x electricity price for your country ($/GJ)



Payback Time: simple payback time can be calculated using following equation.
Simple Payback Time (y)= investment cost ($) / annual profit ($/y)

Please note that these values are for reference only, as they vary widely depending on various local
conditions.
59Technologies Customized List
2022 version Part 2 : BF-BOF (v.4.0)