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 7 countries (Indonesia, Malaysia, Philippines, Singapore, Thailand, Vietnam andMyanmar) and Japan. The list is aimed at identifying appropriate technologies for the ASEAN steel industry andthe first version 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 andmeasures, 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 2023 version is developed as a
two-part series. Technologies Customized List v.4.0 Part-1 is for EAF plants, and v.4.1 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,environmental protection and recycling in ASEAN steel industry. They were chosen from several technology
references*1 in the 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.

2023 version Part-1: EAF (v.4.0)
March, 2023

*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
2023 version part-1: EAF (v.4.0)

Table of Contents
1. Technologies Customized List

4

2. Technologies One-by-One Sheet

8

Contact Points of Suppliers

43

ANNEX 1. Expected effects in each ASEAN country45

31. Technologies
Customized List

4

Pre-Conditions for Calculations of Effects

Capacity and performance of the model steel plant to study costs and effects of energy saving project are
assumed as below:
1) 100 % scrap use EFA plant to produce mild steel for construction use
2) Annual production is 500,000 ton/y with 80 ton EAF
3) Unit electricity consumption of EAF is 430 kWh/ton-billet
4) Unit thermal consumption of reheating furnace is 1,450 MJ/ton-billet
5) The plant possesses conventional facilities, without advanced technologies

Equipment List of Model Steel Plant
500,000 ton/year 1)

Annual Production
EAF
Equipment Name
Nominal capacity
TTT
Iron source
Scrap preheating
Scrap charging
Ladle furnace

NG burner

O2 and C lances

RHF
Equipment Name

Value
80 ton 2)
52 minutes
100 % scrapnone
3 times

Type
Nominal capacity
Heated material
Heating temperature
Fuel

used Combustion air preheating

Air ratio for combustion

used only tofacilitate melting

installed only at Computer control to set
slag-door side, furnace temperature withwater-cooled heat transfer simulation
type

none

none Hot charge and/or directrolling

none

Process control by exhaustgas analysis and/or
computerElectricity consumption

430 kWh/ton

Insulation

Oxygen consumption

30 m3N/ton

Heat consumption

Natural gas consumption
Coke consumption
Product
Tapping temperature
Atmosphere condition
1)

2)

Value
Walking beam
100 ton/h
135 SQ billet
1100 degC
Natural gas,
LHV 44 MJ/m3N
around 300 degCwith low grade
recuperator
1.20 for all zones

20 m3N/ton
15 kg/ton
Mild steel lessthan 0.2 % C
1620 degC
25 degC with relative humidity 60 %The following technologies have different assumptions;A-11：1,875,000 ton/year
A-14：576,000 ton/year
E-4：594,000 ton/year
The following technology have a different assumption;
A-11：Two 150-ton EAF

5firebrick
1,330
MJ/ton-steelTechnologies Customized List for Energy Saving, Environmental Protection,
and Recycling for ASEAN Steel Industry 2023 version (v.4.0) part 1: EAF
Expected effects of introduction

No.

ID

Title of technology

Technical description

Electricity
saving

Thermalenergysaving

Profit of 2)
Operation
cost

Environmental
benefits

Assumed investment cost
Assumed investment
cost 4)

Payback time

(million US$
in Japan)(year in Japan)

Co-benefits(kWh/tofproduct)(GJ/tofproduct)(US$/t ofproduct,
Japan)High temperature continuous
scrap preheating EAF

Combination of the technologies of- Air tight structure- High temperature scrap preheating (over 700 degC)- Continuous preheated scrap charging- Automatic process control by using data logging- Post-combustion of generated CO gas- Dioxin decomposition by secondary combustion

150.0

-

21.45

- Decomposition and- Low electrodereduction of dioxin,
consumption (0.8 - 1.0
dispersing dust, & noise kg/ton-product at AC)

38.00

3.5

40.0

-

5.72

- Reduction of dioxin
emission, dispersing
dust, & noise-No limit of material forhigh quality products as
like stainless steel.

10.00

3.5

14.3

-

2.04

-

- Reduction of nitorgenin steel for quality
improvement

2.05

2.0

A. Energy Saving for Electric Arc Furnace (EAF)

1

A-1

2

A-2

Medium temperature batch
scrap preheating EAF- High melting efficiency batch charging type EAF with SPH.
- Preheated scrap temperature is about 250 - 300 degC.
- Fully enclosed automatic charging system to keep working
floor clean.
- Minimize scrap oxidation by temperature controlling- Material limitation free3

A-3High efficiency oxy-fuelburner/lancing for EAF- Supersonic or coherent burner- Accelerate scrap melting during melting stage- Facilitate slag foaming during refining stage over the bath4

A-4

Eccentric bottom tapping (EBT) - Slag free tappingon existing furnace- Reliable stopping and scraping mechanism

15.0

-

2.15

-

- Increase in Fe & alloyyield, productivity- Improve steel quality

4.00

3.7

5

A-5

Ultra high-power transformer
for EAF- Long arc by high voltage and low ampere operation- Water cooled wall-panel to protect refractories

15.0

-

2.15

-

- Procuctivity increase

5.66

5.3

6

A-6

Optimizing slag foaming in EAF- Proper chemical ingredients of slag
- High efficient burner and/or lance- Controlled O2 & C injection into EAF proper position- Keeping slag thickness with air-tight operation

6.0

-

0.86

- Noise reduction &working floor cleaning

-

1.50

3.5

7

A-7

Optimized power control for
EAF- Data logging and visualization of melting process- Automatic judgement on meltdown and additional scrap charge- Automatioc phase power independent control for wellbalanced melting

15.0

-

2.15

-

- Productivity increase- Manpower saving

2.50

2.3

8

A-8

Operation support system with
EAF meltdown judgment

Automatic Rapid Melting system- Data logging- Optimum electric power control- Alloy calculation- Automatic meltdown Judgment

6.0

-

0.74

-

- Productivity increase- Manpower saving- Operation
standardization

0.65

1.5

9

A-9

Low NOx regenerative burnersystem for ladle preheating- Regenerating burner use- High Energy Saving (about 40 %)- Automatic control- FDI Combustion

-

0.20

- NOx reduction

Contribute to better
atmosphere around at
workfloor

0.40

0.2

10

A-10

- Rapid and high temperature ladle heating by oxygen burner
Oxygen burner system for ladle- Automatic control
preheating- High Energy Saving (about 40 %)

-

0.20

- NOx reduction

Contribute to better
atmosphere around at
workfloor

0.30

0.2

11

A-11 Waste heat recovery from EAF- Waste heat boiler based on the OG boiler technology- Specified for splash and dust containing

132.0

-

18.88

-

-

60.00

6.4

12

A-12

Energy saving for dedusting
system in EAF meltshop- Damper openings and exhaust fan rotation are controlled inconsonance- Combination of VVVF and proper damper opening

6.0

-

0.86

- Better working floor &atmosphere

-

0.80

1.9

13

A-13

Bottom stirring/stirring gas
injection- Inject innert gas (Ar or N2) into the bottom of EAF- Better heat transfer steel quality

18.0

-

2.57

-

- Fe yield increase 0.5
%

0.26

0.2

14

A-17

NS-Tundish Plasma Heater(NS-TPH)- Heats molten steel within the tundish by generating a plasmaarc between the molten steel and a plasma torch

22.0

-

3.15

-

- Higher productivity- Improvemet of castquality

3.85

2.4

15

A-14 Induction type tundish heater- Application of induction heating- Possible to uniformize temperature in 3 minutes after power
supply(compared toplasma heater)-(compared toplasma heater)

-

-

1.00

4.7

16

A-15

Scrap pretreatment with scrap
shear- Long size or low bulk-density scrap is shredded and packed.
- Scrap pretreatment decreases the scrap-charging frequency,
which will lead to energy saving.

20.0

-

2.86

-

Fe yield increase in 1.5% (by Non-integrated
steel producer's
association)

3.80

2.7

17

A-16

Arc furnace with shell rotation
drive- By rotating furnace shell 50 degree back-and-force, cold spot
will be decreased to realize smooth melting.
- Assumed investment cost is the increase from the newly
constructed conventional EAF.

32.0

-

4.58

-

- Decreasing power-on
time, melting fuel, andrefractory material

6.00

2.6

3

0.43

6

Expected effects of introduction

No.

ID

Title of technology

Technical description

Electricity
saving(kWh/tofproduct)

B. Environmental Protection for Electric Arc Furnace

Thermalenergysaving(GJ/tofproduct)(compared toplasma heater)

Profit of 2)
Operation
cost(US$/t ofproduct,
Japan)

Environmental
benefits

Assumed investment cost
Assumed investment
cost 4)

Payback time

(million US$
in Japan)(year in Japan)

Co-benefits(compared toplasma heater)

18

B-1

- Improved design configuration of the direct evacuation for
Exhaust gas treatment throughtreating hot unburned gas from much fuel use
gas cooling, carbon injection,- Minimize dust and gas dispersion from EAF with enoughand bag filter dedusting for EAF
capacity and suitable control

-

-

-

- Better workfloor &environment

-

-

19

B-2

Floating dust control in EAF
meltshop---- Restrict dust loading
on working floor to less3
than 5 mg/m

-

1.00

20

B-3

- Packaged cartridges of activated carbon fixed at the exit of
Dioxin adsorption by activatedbag-filter adsorbs and removes dioxins and heavy metals to an
carbon for EAF exhaust gas
extremely low levels

-

-

-

- Dioxin will be lower
3
than 0.5 ng TEQ/m N

-

-

21

B-4

Dioxin adsorption by mixing
EAF exhaust gas with building
dedusting gas- Cooling direct evacuation gas by mixing with building
dedusting gas

-

-

-

- Dioxin will be lower
3
than 5.0 ng TEQ/m N

-

-

22

B-5

Dioxin absorption by 2 step
bagfilter technology for EAF
exhaust gas- 2 step bag system can remove over 99% DXN's from EAF.
- This system provide a clean working environment.
- Effective evacuation decrease the consumption of electricity.

-

-

-

3

-

-

23

B-6

PKS charcoal use for EAF- Charcoal made from PKS can be used instead of injected coke
into EAF.

---- 39,000 ton-CO2/y
GHG reduction--- Zn material and heavy
aggregate can be gained
from EAF dust-

- Analyze air flow in EAF building- Dioxin will be lower
than 0.5 ng TEQ/m N

C. Material Recycle for Electric Arc Furnace
24

C-1

EAF dust and slag recycling
system by oxygen-fuel burner- Zn recovery rate will be expected to be 95%-Remove heavy metals from dust and turn into harmless

-

-

-

25

C-2

EAF slag agglomeration for
aggregate use- Molten slag is rapidly cooled by jet air, and becomes 0.5 - 3.0mm heavy and strong ball.
- Suited to use aggregate mixed with cement

-

-

-

-

- Slag satisfies the safety - Saved processing time:code
10 minutes

1.00

D. Energy Saving for Reheating Furnace
26

D-1

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

-

0.050

0.96

-

-

2.50

5.2

27

D-2

Low NOx regenerative burner
total system for reheating
furnace- High efficient and durable burner system

-

0.189

3.61

- CO2 & NOx
Reduction

-

8.00

4.4

28

D-3

High temperature recuperator
for reheating furnace- Heat transfer area is expanded- Special material tube is used instead of stainless

-

0.100

1.91

-

-

1.50

1.6

29

D-4

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

-

0.039

0.75

- Reduction of Heataccumulation

-

1.50

4.0

30

D-6

Induction type billet heater for
direct rolling

-40.0

1.45

21.99

- Better working floor &atmosphere

-

1.00

0.1

31

D-7

Oxygen enrichment for
combusiotn air

-23.6

0.26

1.59

- Smaller exhaust gas
volume from the stack

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

Thermal energy will be reduced with the decrease 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 togenerate pxygen is examined (0.5 kWh/m3N)-

E. Common systems and General Energy Savings
Applying the Multi-Level Drive for motors enables to saveenergy cost from vane and valve control (constant speed motor).
・Eco-Friendly
・Power Source Friendly
・Less Maintenance・Motor Friendly

13%

-

-

- Energy data are collected in process computer for evaluation

-

0.120

2.29

285
MWh/y

-

-

-

0.0896

1.71

32

E-1

Inverter (VFD; Variable
Frequency Drive) drive formotors33

E-2

Energy monitoring andmanagement systems

34

E-3

- Energy saving in compressors requires consideration of theManagement of compressed air following points.
delivery pressure optimization* Selection of the appropriate capacity* Reduction in delivery pressure

35

E-4

Highly efficient combustion
system for radiant tube burner

Silicon-carbide parts are inserted into the radiant tube topromote heat transfer from hot gas to the tube, which improve
thermal efficiency of the furnace. Production of the target plant
is assumed as 594,000 ton/y (CGL) with natural gas use.

-

1.50

-

-

-

-

-

- CO2 Reduction- CO2 Reduction

1) Baseline to study energy saving effect is shown in p.5
2) Enegy cost in Japan is assumed as below (JETRO website 2021)
Elecricity (US$/kWh) 0.143
Fuel price (US$/GJ) 19.11
3) Operation cost for Environment Protection or Material Recycle is described as minas (-)4) Assumed investment costs is not guranteed by suppliers, they should be fixed according to local conditions.

7

-

2.90

2.9

2. Technologies
One by One Sheets8A. Energy Saving for Electric Arc Furnace (EAF)

A-1

High temperature continuous scrap preheating EAF

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

Preheating scraps with high-temperature exhaust gas is possible because the preheating shaft and melting chamber are
directly and rigidly connected, so the scraps are continually present, from the steel to preheating areas.
This enables high-temperature preheating of the scraps, resulting in a significant reduction of power consumption.
The melting chamber is sealed off from outside air, to prevent the excess air inlet. It prevents over oxidation of scrap
under high temperature preheating.As this equipment keeps always flat bath operation, electrode consumption issignificantly improved.
Furthermore, the electric facilities necessary to meet power quality regulation can be drastically reduced on it may noteven unnecessary depending on required regulation.
Dioxins are decomposed through an exhaust gas combustion chamber and rapid quench chamber in the exhaust gas ductsystem. Not only dioxins but also a volatile material that causes foul odors and white smoke will be decomposed and thedispersal of them are also prevented.The furnace prevents diluting of exhaust gasses. Therefore, the CO within theexhaust gas can be used as fuel, reducing the amount of fuel gas consumed.Flat bath operation dramatically reduces noise
during operation. The reduction of power consumption also contributes to the reduction of emission of greenhouse gasses
during power generation.
150 kWh/ton-productDecomposition of dioxin, reducing dispersing dust, & noise
Low electrode consumption (0.8 - 1.0 kg/ton-product at AC)
JP Steel Plantech
SOACT 2nd Edition ("Ecological and Economical Arc Furnace"), Diagram from JP Steel Plantech

6. Comments

9A. Energy Saving for Electric Arc Furnace (EAF)

A-2

Medium temperature batch scrap preheating EAF

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference- High melting efficiency batch charging type EAF with SPH.
- Preheated scrap temperature is about 250 - 300 degC.
- Fully enclosed automatic charging system to keep working floor clean.
- Minimize scrap oxidation by temperature controlling- Material limitation free
40 kWh/ton-product
Reduction of dioxin emission, dispersing dust & noise
No limit of material for high quality products as like stainless steel.
Daido Steel

6. Comments

10

A. Energy Saving for Electric Arc Furnace (EAF)

A-3High efficiency oxy-fuel burner/lancing for EAF

Item

Content

New type of burner has beenused to inject carbon and oxygenfrom side wall and closed slag
door.
The buener can realize evenly
distributed slag-foaming and

1. Process Flow or Diagram

Coherent buner can make long and sharp oxygen jet,which works instead of oxygen lance.
Oxygen jet from the center hole is resricted to
expand by the combustion around the jet, thecombustion is generated by the fuel and oxygen from

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits'Conventional oxygen lances inserted through slag door causes;- Local oxygen input near the slag door
- Uneven slag foaming through the bath
- Uneven post-combustion of generated CO- Much hot gas escape caused by the cold air infiltration through the slag door

14.3 kWh/ton-product
Reduction of nitorgen in steel, quality improvement

4. Japanese Main Supplier
5. Technologies Reference

Daido Steel, Nikko, JP Steel Plantech
SOACT 2nd edition (Add the word "High efficiency" to SOACT item for up-to-date oxygen use), Diagram from Nikko

6. Comments<Source of "Electricity saving">
0.14 GJ/ton in SOACT ---> 0.14 x 9.8/1000 = 14.3 kWh/ton

11

A. Energy Saving for Electric Arc Furnace (EAF)

A-4

Eccentric bottom tapping (EBT) on existing furnace

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification- Molten steel is tapped through the hole at the furnace bottom.
' - Tilting angle for tapping is smaller then conventional sput tapping, and quick tappping and returning are possible.
' - Tapping hole is plugged with silicon sand after tapping, which is held by stopping mechanism.
' - Slag free tapping is possible- Reliable stopping and scraping mechanism to avoid leakage

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

6. Comments

15 kWh/ton-productIncrease in Fe & alloy yield, and productivity
Improve steel quality
JP Steel Plantech, Daido Steel, Nikko
EPA-BACT (Sep. 2014), Diagram from JP Steel Plantech<Preconditions on calculating effects and investment costs>- Values of "Electricity saving" are based on the
EPA-BACT (Sep. 2014) & equipment supplier's rough estimation- "Profit" does not include such other advantages than electricity saving

12

A. Energy Saving for Electric Arc Furnace (EAF)

A-5

Ultra high-power transformer for EAF

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

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

In the conventional system, series reactor was used for the early melting stage in order to stabilize arc and control of a
flicker .
Since High-Efficiency Furnace Transformer provides high impedance at early melting stage, series reactor is not
required, though the same performance is achieved.
- Reduce electric power consumption- Reduce electrode consumption- Shorten tap to tap time
'In addition, it will conduct a fine-grained control by adding a reactor.
15 kWh/ton-productIncrease productivity

4. Japanese Main Supplier
5. Technologies Reference

Fuji Electric, JP Steel Plantech, Daido, Nikko
EPA-BACT ("Transformer efficiency - ultra-high power transformers"), Diagram from Nikko

6. Comments<Preconditions on calculating effects>- "Electricity saving" 15 kWh/ton-product comes from EPA-BACT,
assuming that 44 MVA transformer for 80 ton EAF is revamped to 55 MVA.

13

A. Energy Saving for Electric Arc Furnace (EAF)

A-6

Optimizing slag foaming in EAF

ItemContent

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits- Proper chemical ingredients of slag (Basicity 1.5 - 2.2, FeO 15 - 20 %)- High efficient burner and/or lance- Controlled O2 & C injection into EAF proper position- Keeping slag thickness with air-tight operation
6 kWh/ton-product
Noise reduction & working floor cleaning-

4. Japanese Main Supplier

JP Steel Plantech, Daido Steel, Nikko

5. Technologies Reference

SOACT 2nd Edition (Delete the word "Exchangeable Furnace and Injection Technology"), Diagram from JP Steel
Plantech

6. Comments<Source of "Electricity saving">(1) 2.5 - 3 % energy saving in SOACT ---> 430 kWh/ton x 0.03 = 12.9 kWh/ton(2) The phenomenum is explained by several factors, 6 kWh/ton is reasonable (Japanese experts).

14

A. Energy Saving for Electric Arc Furnace (EAF)

A-7

Optimized power control for EAF

Item

Content

Statistical analysis

Slag foaming detection

Heat loss supervision

Power supply control for each phase

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits- Data logging and visualization of melting process- Automatic meltdown and additional scrap charging judgement- Automatic phase power independent control for well-balance melting

15 kWh/ton-productProductivity increase
Manpower saving-

4. Japanese Main Supplier
5. Technologies Reference

JP Steel Plantech
SOACT 2nd Edition ("Improved Process Control (Neural Networks)"), Diagram from JP Steel Plantech

6. Comments-

15

A. Energy Saving for Electric Arc Furnace (EAF)

A-8

Operation support system with EAF meltdown judgment

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

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

Automatic rapid melting system for EAF- Optimum electric power control- Reporting, Data logging and online data communications- Automatic meltdown Judgment- Power supply and electrode position control for each phase
6 kWh/ton-product-4. Japanese Main Supplier
5. Technologies Reference

Productivity increase
Manpower saving
Daido Steel
Daido Steel

6. Comments-

Co-benefits

16

A. Energy Saving for Electric Arc Furnace (EAF)A-9

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
Effect of Savings
Technology
Environmental
Introduction
benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference
6. Comments

While one of the burners is burning, the other burner will work as an exhaust outlet. The exhaust gas is discharged fromthe system after the waste heat of the gas is recovered so that the temperature of the gas will be lowered to the extent that
there will be no condensation in the regenerator. The combustion air receives heat from the regenerator. Therefore, thecombustion air will be preheated to a super-high temperature (i.e., 90% of the temperature 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 rolesof 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/tonsteel save
Low NO
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, Nippon Furnace-

17

A. Energy Saving for Electric Arc Furnace (EAF)

A-10

Oxygen burner system for ladle preheating

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

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

Oxygen combustion achieve rapid heating by high flame temperature. High flame temperature achieve high wall
temperature, therefore it can be possible low temperature feeding of melted metal in to the ladle.

40 % fuel saving is expected comparing to existing preheater
Low NO
Higher brick temperature can allow lower tapping temperature for energy saving at EAF.

4. Japanese Main Supplier

Chugai-Ro, Nippon Furnace

5. Technologies Reference

Diagram from Chugai Ro, May contact to suppliers

6. Comments-

18

A. Energy Saving for Electric Arc Furnace (EAF)

A-11

Waste heat recovery from EAF

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits- Waste heat boiler based on the OG boiler technology- Specified for splash and dust containing- Main boiler is radiative type, and convective type super heater is located at the downstream of boiler to avoid clogging.
132 kWh/ton-product-4. Japanese Main Supplier
5. Technologies Reference

JP Steel Plantech (yoshidah@steelplantech.co.jp, tel +81-45-471-3917 fax +81-45-471-4002)
Diagram from JP Steel Plantech, May contact to JP Steel Plantech

6. Comments<Preconditions on calculating effects>- Power generation is 248,000 MWh/year with two 150 ton EAFs for DRI- Assumed annual production by two 150 ton EAF= 500,000 / 80 x 150 x 2 = 1,875,000 ton/y- Unit power generation = 248,000 x 1,000 / 1,875,000 = 132 kWh/ton-product- Suited to DRI continuous charging EAF, not scrap EAF

19

A. Energy Saving for Electric Arc Furnace (EAF)

A-12

Energy saving for dedusting system in EAF meltshop

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification
Electricity Saving
3. Expected
Effect ofTechnology
Introduction

Thermal Energy
Savings
Environmental
benefits
Co-benefits- Damper openings and exhaust fan rotation are controlled in consonance with the furnace operation pattern- Reducing fan rotation with VVVF sytem enables to save motor power, comparing to the simple damper control sytem.
6 kWh/ton-product (25 % of assumed unit power consumption)
Better working floor and atmosphere-

4. Japanese Main Supplier
5. Technologies Reference

Fuji Electric, JP Steel Plantech, Daido, Nikko
Diagram from JP Steel Plantech

6. Comments<Preconditions on calculating effects>
Assumed electricity consumption for building dedusting is 24 kWh/ton-product, and 25 % power saving is expected.

20

A. Energy Saving for Electric Arc Furnace (EAF)

A-13

Bottom stirring/stirring gas injection

Item

Content

1. Process Flow or Diagram

Schematic sketch ofgas injection nozzle 2)

2. Technology
Definition/Specification

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

Inject inert gas (Ar or N2) into the bottom of EAF to agitate steel bath
Expected effects : 2)
- homogenize chemical composition and temperature in steel bath- accelerate chemical reaction between steel and slag
- shorten tap-tap-time- save electrical energy- increase yields of iron and alloys
18 kWh/ton-product 1)
Fe yield increase 0.5 % 1)

4. Japanese Main Supplier

Nikko, Daido Steel

5. Technologies Reference

1) EPA-BACT2) Bottom-stirring in an electric-arc furnace:Performance results at ISCOR Vereeniging Works(The Journal of The South African Institute of Mining and Metallurgy, January 1994

6. Comments

21

A. Energy Saving for Electric Arc Furnace (EAF)

A-17

NS-Tundish Plasma Heater (NS-TPH)

Item

Content

1. Process Flow or Diagram<Application of NS-TPH><Steel Temperature at Steel Making

Faced with growing demands for improvements in productivity and slab quality in recent years, NIPPON STEELENGINEERING CO., LTD. offers a solution to our clients' problems through the provision of the world's only Tundish
Plasma Heater technology (NS-TPH). NS-TPH is a device that heats molten steel within the tundish by generating aplasma arc between the molten steel and a plasma torch that is inserted from the upper part of the tundish.
2. Technology
Definition/Specification

3. Investment Cost
& Operating Life

<Effects>(1) Lower energy consumption of steelmaking plant(2) Stabler cast quality(3) Higher productivity(4) Less emergency cast stop

Reduce production cost and CO2 emission

Investment Cost : 500million JPY(approx.) (3.85 Mil USD @ 130 JPY/USD)
Operation Life : increased life by regular maintenance. (*Consumable parts life : Carbon electrode's life about
20~30hours of use)

Reduction of CO2 4,800 t-CO2/Y at 500,000 t-steel/Y* 9.6 kg-CO2/t-steel (at 0.434 t-CO2/MWh)
Emission
4. Effect ofTechnology
Introduction

5. Direct
Effect(AnnualOperating
Cost)

Fuel Savings-

Electricity Savings

11,000MWh/Y at 500,000 t-steel/Y* 22 kWh/t-steel

Economic Effectpayback time

Profit from electricity savings:
22(kWh/steel) × 0.143(USD/kWh) = 3.15 (USD/steel)3.15(USD) ×500,000 = 1.58 Mil USD
Payback time:
3.85 Mil USD / 1.58 Mil USD = 2.4 years at 500,000 ton-steel/Y (approx.)

Productivity
Improvement

Higher productivity by controlling constant temp and therefore increasing casting speed.

Maintenance Cost
Reduction of refractories cost at Steelmaking plant by lower tapping temperature.
Reduction
Improvemet of cast quality(*) by implementing narrow range temperature control.
Product Quality
6. Indirect* : Non-metallic Inclusion, Center segregation
Improvement
EffectSOx,
Dust(Co-benefits)
Water-saving
7. Proficiency Level of Technology
widly spread and mostly applied.
in Japan
8. Japanese Main Supplier*Nippon Steel Engineering Co., Ltd.

9. Technologies Reference:

Nippon Steel Engineering Co., Ltd. HP
https://www.eng.nipponsteel.com/english/whatwedo/steelplants/casting/ns_tundish_plasma_heater/

10. Preconditions-

22

A. Energy Saving for Electric Arc Furnace (EAF)

A-14

Induction type tundish heater

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

6. Comments

Features for Induction Tundish heater
1.Uniformity of Element of Molten Steel:Agitation effect by electromagnetic force.
2.High Precision Temperature Control:Target Temp.±2.5degree.
3.High Heating Effciency More than 90% by channel type inductor.
4.Ease of maintennance:Water cooled feeder with quick connector.Self-cooled type Induction coil and so on.
3 kWh / ton-product (Effect is calculated comparing to electricity consumption of plasma type heater)
1.Productivity increase
2.Quality improvement
Fuji ElectricFuji Electric<Preconditions on calculating effects>- Assumed plasma type tundish heater is installed- Ladle capacity: 200 ton- Operated days: 30 days/month- Electricity intensity of heater: 13.7 kWh/ton- Heat efficiency: 70%- Pouring amount: 2.5 ton/min- Dissolution time: 80 min/charge- Rised temperature: 40 degeree C- Number of charges: 8 charges/day- Monthly production: 48,000 ton- Annual production: 576, 000 ton

23A. Energy Saving for Electric Arc Furnace (EAF)

A-15

Scrap pretreatment with scrap shear

Item

Content

1. Process Flow or Diagram

Before scrap pretreatment (0.3 ton/m3)

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

After scrap pretreatment (0.6

- Long size or low bulk-density scrap is shredded and packed.
- For example, bulk density of 0.3 m3/ton can be decreased to 0.6 with 1250 ton shear x 2 for 80 ton EAF.
- Scrap pretreatment decreases the scrap-charging frequency, which will lead to energy saving.

20 kWh/ton-product (reported by Non-integrated steel producer's association of Japan)- Fe yield increase in 1.5 %, TTT shortening
Fuji Car Manufacturing

6. Comments

24

A. Energy Saving for Electric Arc Furnace (EAF)

A-16

Arc furnace with shell rotation drive

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

Furnace shell is rotated 50 dgree back-and-force
Uniform scrap melting with furnace shell rotation- Shortening power-on time
- Reduction in cooling water energy loss
- Reduction in scrap cutting oxygen- Reduction in refractory repairing materials
32 kWh/ton-product- No limit of material for high quality products- Reduction of refractory consumption
Daido Steel

6. Comments25

B. Environmental Protection for Electric Arc Furnace

B-1

Exhaust gas treatment through gas cooling, carbon
injection, and bag filter dedusting for EAF

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected
Effect ofTechnology
Introduction

Thermal Energy
Savings
Environmental
benefits
Co-benefits- Improved design configuration of the direct evacuation for treating hot unburned gas from much fuel use- Minimize dust and gas dispersion from EAF with enough capacity and suitable control- Much fossil fuel use becomes possible to save electricity.

- When capacity increase is applied to the standard size EAF (30 m3N-O2/ton-steel, 20 m3N-natural gas/ton-steel,and 15 kg-carbon/ton-steel), expected electrical energy saving becomes as:
4 - 5 kWh/m3N-O2
8 - 9 kWh/m3N-natural gas
8 - 9 kWh/kg-carbon- Decrease in yield is assumed as 1 - 2 % per 10 m3N-O2/ton-steel.

Better workfloor environment-

4. Japanese Main Supplier

JP Steel Plantech, Daido Steel, Nikko

5. Technologies Reference

SOACT 2nd Edition
Recent Progress of Steelmaking Technologiy in Electric Arc Furnace (1993, JISF)

6. Comments

26

B. Environmental Protection for Electric Arc Furnace

B-2

Floating dust control in EAF meltshop

Item

Content

Transient analysis of flow and dust density in meltshop builiding

1. Process Flow or Diagram

Floating dust density around EAF (by laser-scattering dust indicator)

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference- In modern EAF meltshop, fully enclosed building is required to avoid dust dispersion to the outside,
but enclosed building raises workfloor pollution which affects workers health.
- Proper design and operation of dedusting system based on the flow analysis and real dust data are essential.
- Building and suction system revamping shall be executed based on the flow analysis.
- Target value of dust loading on working floor should be less than 5 mg/me, for example, specified
in Industrial Safety and Health Act. in Japan
Restrict dust loading on working floor to less than 5 mg/m3
JP Steel Plantech, Daido Steel
Diagram from JP Steel Plantech, May contact to suppliers

6. Comments

27

B. Environmental Protection for Electric Arc Furnace

B-3

Dioxin adsorption by activated carbon for EAF exhaust gas

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

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

A new dioxin-removal system passes exhaust gas through a layer of granular activated carbon with outstanding
adsorption performance. High-performance activated carbon was developed exclusively for the system. Packaged
cartridges with a unique structure allowing the system to adsorb and remove dioxins and heavy metals to an extremely
low levels. A cartridge with a unique structure ensures improved contact efficiency between activated carbon and exhaustgas. Consequently, the filled quantity of activated carbon is considerably reduced allowing unparalleled compact size. In
addition, amount of consumed activated carbon would be substantially reduced comparing to previous Activated Carbon
Adsorption Tower. Furthermore, it would save electricity consumption of blower since its pressure loss would be lower
than 0.5kPa (Approx. 50 mmAq) per a cartridge comparing to previous equipment.
Dioxin will be lower than 0.1 ng TEQ/m3N-

4. Japanese Main Supplier
5. Technologies Reference

JFE Engineering
Diagram from JFE Engineering

6. Comments-

28

B. Environmental Protection for Electric Arc Furnace

B-4

Dioxin adsorption by mixing EAF exhaust gas
with building dedusting gas

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference- Dioxin concentration in the EAF exhaust gas at the exit of bag filter is strongly susceptible to the gas temperature.
- In order to comply with the regulated value of 5.0 ngTEQ/m3N (applied to the existing EAF in JAPN), common
technology is to mix the hot process gas with the in-house dedusting gas to cool down the gas through the bag filter.
- Diokin seems to be captured by the oily dust which is accumulated on the surface of filter.
- When gas temperature at the inlet of bag filter ascends up to about 110 degC, where oil is vaporised, dioxin
concentration
rapidly increases after bag filter even in a short time.
- Collected duct at bag filter should be carefully treated, as it contains much dioxin.
- This phenomenon is diffirent from the case of incinerators, where the dust does not contains oily substances.
Dioxin will be lower than 5.0 ng TEQ/m3N
JP Steel Plantech, Daido Steel, Nikko

6. Comments

29

B. Environmental Protection for Electric Arc Furnace

B-5

Dioxin adsorption by 2 step bagfilter technology
for EAF exhaust gas

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits- In order to comply with the more stringent regulation of 0.5 ngTEQ/m3N (applied to the new EAF in JAPN), two-stepbag filter system is applied with the careful temperature control.
- When 0.1 ngTEQ/m3N is requested from the authorities, for the cases of installation at dense-population are orindustrial
wastes treatment, activated carbon injection into the exhaust gas line is effective.
- Dust loading in the process gas is much higher than that of in-house dedusting gas, therefore, activated carbon is
injected
into the gas which is dedusted with the primary bag filter. This activated carbon powder is accumulated on the filters of
secondary bag filter and adsorbs dioxin.
Dioxin will be lower than 0.5 ng TEQ/m3N-

4. Japanese Main Supplier
5. Technologies Reference

JP Steel Plantech, Daido Steel, Nikko
Diagram from JP Steel Plantech

6. Comments-30

B. Environmental Protection for Electric Arc Furnace

B-6

PKS charcoal use for EAF

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

6. Comments- Charcoal made from PKS (Palm Kernel Shell) has similar quality with coke commonly used for carbon injection into
EAF
- Higher heating value, lower sulfur content than fossil fuel coke
- CO2 generated from charcoal is not counted as GHG (Green House Gas)
- PKS charcoal is produced for the production of activated carbon in a small scale- Equipmet is very simple and can be constructed by local technology- Japanese supplier will provide with know-how
39,000 ton-CO2/y GHG reduction from 500,000 ton/y EAF plant
JP Steel Plantech<Preconditions on calculating effects>
Replaced coke at EAF : 25 kg/ton-steel
C content in coke
: 85 %
CO2 generation from coke = 0.85 x 44 / 12 = 3.12 ton-CO2/ton-coke
GHG reduction = 500,000 ton-steel/y x 0.025 x 3.12 = 39,000 ton-CO2/y

31

C. Material Recycle for Electric Arc Furnace

C-1

EAF dust and slag recycling system by oxygen-fuel burner

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

As dust and slag are melted down completely at high temperature, it is very effective against dioxin.
Produced valuable substances are completely harmless and can meet all environmental standards.
More than 99% of dioxin can be removed by high temperature treatment in the furnace and strong rapid coolingmechanism.
Besides electrical furnace dust and reduced slag, it is expected that this system will be applied to other waste treatments.
The equipment is simple and compact because of unnecessary pretreatment such as dust granulation and so forth.
Through simple design, excels in operability and suitable for on-site processing.
Also this system can recover expected 95% Zn from EAF dust as Zn law material.

Electricity Saving-

Thermal Energy
Savings-

3. Expected
Effect ofTechnology Environmental
Introduction benefits

Co-benefits
4. Japanese Main Supplier
5. Technologies Reference-

Zn material can be gained from EAF dust
Heavy aggregate can be gained from EAF dust
Daido Steel
Diagram from Daido Steel, May contact to Daido Steel2

6. Comments-

32

C. Material Recycle for Electric Arc Furnace

C-2

EAF slag agglomeration for aggregate use

Item

Content

1. Process Flow or Diagram

Treatment Process for Electric Arc Furnace Slag Air

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

6. Comments

Molten slag is rapidly cooled by jet air, and becomes 0.3-5mm size of spherical structure,-Create strong & heavy fine aggregate material for concrete-Enviromental friendly material-Suitable & meet with JIS A 5011-4 for Electric arc furnace oxidizing slag aggregate.
-Require smaller space than normal slag treatment area.
Electricity consumption : 6 - 8 kWh/ton-slag
Reduce disposal cost of industrial waste
Processing time for one heat of EAF : 10 minutes
Nikko
Diagram from Nikko<Notice>
When using this technology, slag analysis data should be confirmed to meet the environmental regulation<Preconditions on calculating effects>- Slag generation : 80 kg/ton-product- Yield of granulated slag with this process : 60-70 %33

D. Energy Saving for Reheating Furnace

D-1

Process control for reheating furnace

Item

Content

Furnace temp.
Billet temp.

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected Thermal Energy
Effect of Savings
Technology Environmental
Introduction benefits
Co-benefits- Setting furnace temperature by targeted billet temperature curve- Precise air ratio control and O2 analysis in exhaust gas
0.05 GJ/ton-product (3.5 % fuel saving from the base line of 1,450 MJ/ton)-

4. Japanese Main Supplier
5. Technologies Reference

Chugai-Ro, Rozai Kogyo
May contact to Chugai-Ro

6. Comments-

34

D. Energy Saving for Reheating Furnace

D-2

Low NOx regenerative burner total system
for reheating furnace

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

While one of the burners is burning, the other burner will work as an exhaust outlet.
The exhaust gas is discharged from the system after the waste heat of the gas is recovered so that the temperature of the gas
will be lowered to the extent that there will be no condensation in the regenerator. The combustion air receives heat from theregenerator.
Therefore, the combustion air will be preheated to a superhigh temperature (i.e., 90% of the temperature of the exhaust gas
or over) before the combustion air is supplied the burner. When the preset cycle time elapses, the burners exchange theirroles of combustion and exhaustion.

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

6. Comments-

0.189 GJ/t (about -13%)
CO2 & NOx Reduction
Chugai-Ro, Nippon Furnace, Rozai Kogyo
Diagram from Chugai Ro, May contact to suppliers

35

D. Energy Saving for Reheating Furnace

D-3

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

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

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

4. Japanese Main Supplier
5. Technologies Reference

Chugai-Ro, Rozai Kogyo
Diagram from Chugai Ro

6. Comments<Preconditions on calculating effects>
When 300 degC air temperature is raised to 500 degC, 7 % enrgy saving is expected.

36

D. Energy Saving for Reheating Furnace

D-4

Fiber block for insulation of reheating furnace

Item

Content

1. Process Flow or Diagram

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

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.

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

4. Japanese Main Supplier
5. Technologies Reference

Chugai-Ro, Rozai Kogyo
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.

37

D. Energy Saving for Reheating Furnace

D-6

Induction type billet heater for direct rolling

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected
Effect ofTechnology
Introduction

Thermal Energy
Savings
Environmental
benefits
Co-benefits

4. Japanese Main Supplier
5. Technologies Reference

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 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
Mitsui E&S Power Systems Inc.
-

6. Comments

38

D. Energy Saving for Reheating Furnace

D-7

Oxygen enrichment for combusiotn air

Item

Content

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected
Effect ofTechnology
Introduction

Thermal Energy
Savings
Environmental
benefits

When oxygen is mixed into combusiotn air to increase the O2 percentage, thermal energy will be reduced with the decrease in thevolume of exhaust gas. In many EAF plants, oxygen is generated by PSA or VPSA process, therfore, new equipment for oxygen
generation is not considered i n 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 id 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 MPapressure. Energy price is based on the latest Japanese values of 17.11 US$/GJ and 0.123 US$/kWh.

When oxxygen percentage is raised to 39 %, 23.6 kWh/ton of electricity is needed.
When oxxygen percentage is raised to 39 %, 0.26 GJ/ton of thermal energy is saved.

Co-benefits
4. Japanese Main Supplier
5. Technologies Reference

Chugai-Ro, Rozai Kogyo, Nippon furnace

6. Comments

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

39

E. Common systems and General Energy Savings

E-1

Inverter (VVVF; Variable Voltage Valuable Frequency) Drive for Motors

Item

Content

1. Process Flow or Diagram- Pumps are running at point a in the current situation, and will be runningat point b after adoption of an inverter system.
- Power for pumps is proportional to flow rate
total pressure ,and motor input ratio before and after installation is the ratio of Q0
P1 and Q0

P0.

Fig.2 Relationship between airflow and required
electric power relating to the type of control *2

Fig.1 Relationship between flow rate and total pressure
before/after adoption of an inverter system. *1* Problems with the current situation: Generally, flow rate of centrifugal pumps and fans is controlled byvalves because of uncontollable motor rotaion speed, resulting in great power loss (see Fig.1 I and A).
* Improvement measures: An inverter system will be adopted in pumps and fans, in order to control therotation speed according to the load (flow rate) with valves fully open. This results in electricity savings(see Fig.1 I and A). *1
2. Technology Definition/Specification

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

5. Direct Effect( Annual Operating Cost )6. Indirect EffectCo-benefits

Reduction of CO2
Emission
Electricity Savings
Economic Effectpayback time
Productivity
Improvement
Maintenance Cost
Reduction
Product Quality
Improvement

An inverter is a variable speed device controlling frequency and voltage to allow precise control ofrotation.
Energy saving effect : Conversion of six 55kW electric motors with eddy current coupling,
and reduction in power consumption. *2
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)
2,000,000/unit(assumed) [NEDO]
Not announced
125,000 kWh/y =55kW/unit x 0.7(assumed aveerage motor power) x 6units x 3600h/y x 0.15
1.5 years [NEDO]
Not announced
Not announced
Not announced

7. Diffusion Rate of Technology in JapanNo data

8. Japanese Main Supplier

Fuji Electric

9. Technologies Reference:

10. Preconditions*1 Guidebook on Energy Conservation for Factories (2010/2011), ed. by The Energy Conservation Center,Japan*2 Energy savings Diagnosis Examples-Common Equipment Volume', Energy conservation Center, Japan* Payback time is defined as (Investment cost / Economical merit) in this project.
* annual operation : 3,600 h/y,
* unit cost of power : 15/kWh40

E. Common systems and General Energy Savings

E-2

Energy monitoring and management systems

Item

Content

Daily and monthly
reports of energybalance
1. Process Flow or Diagram

Online monitoring and logging system for energy
currents
ElectricPower

2. Technology
Definition/Specification

Electricity Saving
3. Expected
Effect ofTechnology
Introduction

Thermal Energy
Savings
Environmental
Benefits
Co-benefits

4. Japanese Main Supplier

Steam

Fuel

OxygenThis measure includes site energy management systems for optimal energy consumption in the plant.
- Online monitoring: This is often used for the most important energy flows at the site. The data are stored for a long timeso that typical situations may be analyzed. It is very important to monitor for all energy sources on online.
It is the main technique used to avoid energy losses.
- Continuous monitoring systems: Since all energy-related process parameters are used to optimize process control and toenable instant maintenance, undisrupted production process could be achieved.
- Reporting and analyzing tools: Reporting tools are often used to check the average energy consumption of each process.
In connection with cost controlling, controlling energy is the basis for optimizing energy consumption and cost savings.
An energy controlling system enables to compare actual data with historical data (e.g. charts)

Energy saving effect depends on the local conditions, therefore, quantitative estimation is difficult.
Fuji Electric

5. Technologies Reference

6. Comments

41

E. Common systems and General Energy Savings

E-3

Management of compressed air delivery pressure
optimization
Content

Item

1. Process Flow or Diagram

2. Technology
Definition/Specification

Electricity Saving
3. Expected
Effect ofTechnology
Introduction

Thermal Energy
Savings
Environmental
benefits
Co-benefits

4. Japanese Main Supplier
5. Technologies Reference

6. Comments

Energy saving in compressors requires consideration of the following points.
* Selection of the appropriate capacity* Reduction in delivery pressure by keeping the required working power
Since the required motive power increases with increased delivery pressure, appropreate delivery pressure should beselected in consideration of the items below.
* 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 resistance
From the figure above, when delivery pressure is reduced to 0.098MPa, load on the electric motor can be reduced byapproximately
10 %. When low pressure air is sufficient, low pressure unit should be addtionally adopted instead of pressure
reducing valves.
285 MWh/y (=823 kW x 60 % x 10 % x 24 h/d x 241 days/y)Major electric equipment suppliers
Japanese Technologies for Energy Savings/GHG Emissions Reduction 2008 Revised Edition , editted by NEDO
Preconditions for trail calculating above>- Number of compressors; Total of 17,*Delivery pressure; 0.8 MPa,
- Equipment capacity; 823 kW,*On-load operation load; 60 %,- Daily operation; 24 h/d,
*Annual operation; 241 days'

42

E. Common systems and General Energy Savings

E-4

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

Fuel Savings

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.
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)4) The effect is calculated as comparison with steel heat exchanger system
5) Natural gas is used as for combustion.
53222()
× 0.0136() × 44 12 = 2,654()

Electricity Savings

N/A

Reduction of CO2
Emission
4. Effect ofTechnology
Introduction

Economic Effectpayback time

53,222GJ/year under assumptions same as above
0.0896 GJ/ton saving (= 53,222 GJ/y / 594,000 ton-product/y)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 )6. Indirect EffectCo-benefits

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.

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
Reduction

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.

Product Quality
Improvement

N/A

SOx, Dust Decrease 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.

43

Contact Points of SuppliersCompany

Contact Points

Technologies

JP Steel Plantech Co.

Kaneko 2nd Building 4-9F 2-6-23
Shin-yokohama, Kohoku-ku,
Yokohama 222-0033 JAPAN
Phone: +81-45-471-3911 Fax: +8145-471-4002
https://steelplantech.com/en/

Daido Steel Co., Ltd．

1-10, Higashisakura 1-chome,
Higashi-ku,
Nagoya, Aichi, 461-8581, Japan
TEL:+81-52-963-7501 FAX: +8152-963-4386
https://www.daido.co.jp/

Nikko Industry Co.,Ltd.

2-4-10, Nunobiki-cho, Chuo-ku,
Kobe-city,
Hyogo 651-0097. Japan
TEL：+81-78-222-1688 FAX：+8178-222-2916
https://www.nikkojapan.co.jp/home_en/
E-mail：nikko@nikko-japan.co.jp

Chugai Ro Co., Ltd.

3-6-1 Hiranomachi, Chuo-ku, Osaka
541-0046, Japan
TEL: +81-6-6221-1251 FAX: +816-6221-1411
https://chugai.co.jp/en/

Nippon Furnace Co.,Ltd.

2-1-53, Shitte, Tsurumi-ku,
Yokohama City, Kanagawa
Prefecture, 230-8666 Japan
TEL.+81-45-575-8111 FAX.+8145-575-8046
http://www.furnace.co.jp/en.html
E-mail.webmaster@furnace.co.jp
Gate City Ohsaki, East Tower, 11-2,
Osaki 1-chome, Shinagawa-ku,
Tokyo 141-0032, Japan
https://www.fujielectric.com/contact/?ui_medium=gl_glnavi

A-1: High temperature continuous scrap preheating EAF
A-3: High efficiency oxy-fuel burner/lancing for EAF
A-4: Eccentric bottom tapping (EBT) on existing furnace
A-5: Ultra high-power transformer for EAF
A-6: Optimizing slag foaming in EAF
A-7: Optimized power control for EAF
A-11: Waste heat recovery from EAF
A-12: Energy saving for dedusting system in EAF meltshop
B-1: Exhaust gas treatment through gas cooling, carbon
injection, and bag filter dedusting for EAF
B-2: Floating dust control in EAF meltshop
B-4: Dioxin adsorption by mixing EAF exhaust gas
with building dedusting gas
B-5: Dioxin adsorption by 2 step bagfilter technology
for EAF exhaust gas
B-6: PKS charcoal use for EAF
A-2: Medium temperature batch scrap preheating EAF
A-3: High efficiency oxy-fuel burner/lancing for EAF
A-4: Eccentric bottom tapping (EBT) on existing furnace
A-5: Ultra high-power transformer for EAF
A-6: Optimizing slag foaming in EAF
A-8: Operation support systemwith EAF meltdown judgment
A-12: Energy saving for dedusting system in EAF meltshop
A-13: Bottom stirring/stirring gas injection
A-16: Arc furnace with shell rotation drive
B-1: Exhaust gas treatment through gas cooling, carbon
injection, and bag filter dedusting for EAF
B-2: Floating dust control in EAF meltshop
B-4: Dioxin adsorption by mixing EAF exhaust gas
with building dedusting gas
B-5: Dioxin adsorption by 2 step bagfilter technology
for EAF exhaust gas
C-1: EAF dust and slag recycling systemby oxygen-fuel burner
A-3: High efficiency oxy-fuel burner/lancing for EAF
A-4: Eccentric bottom tapping (EBT) on existing furnace
A-5: Ultra high-power transformer for EAF
A-6: Optimizing slag foaming in EAF
A-13: Bottom stirring/stirring gas injection
B-1: Exhaust gas treatment through gas cooling, carbon
injection, and bag filter dedusting for EAF
B-4: Dioxin adsorption by mixing EAF exhaust gas
with building dedusting gas
B-5: Dioxin adsorption by 2 step bagfilter technology
for EAF exhaust gas
C-2: EAF slag agglomeration for aggregate use
A-9: Low NOx regenerative burner system
for ladle preheating
A-10: Oxygen burner system for ladle preheating
D-1: Process control for reheating furnace
D-2: Low NOx regenerative burner total system
for reheating furnace
D-3: High temperature recuperator for reheating furnace
D-4: Fiber block for insulation of reheating furnace
D-7: Oxygen enrichment for RHF combustion air
E-4: Highly efficient combustion system for radiant tube burner
A-9: Low NOx regenerative burner system
for ladle preheating
A-10: Oxygen burner system for ladle preheating
D-2: Low NOx regenerative burner total system
for reheating furnace
D-7: Oxygen enrichment for RHF combustion air

Fuji Electric Co., Ltd.

Fuji Car
Manufacturing Co.,Ltd.

13-1 Chishiro-cho, Moriyama-city,
Shiga,
JAPAN 524-0034
TEL +81-77-583-1235 / FAX +8177-582-8805

44

A-5: Ultra high-power transformer for EAF
A-12: Energy saving for dedusting system in EAF meltshop
A-14: Induction type tundish heater
Ｅ-1: Inverter (VVVF; Variable Voltage Valuable Frequency)
Drive for Motors
E-2: Energy monitoring and management systems
A-15: Scrap pretreatment with scrap shear

JFE Engineering
Corporation
Rozai Kogyo Kaisha
Ltd.

Mitsui E&S Power
Systems Inc.

NipponSteelEngineering Co.,Ltd.

http://www.fujicar.com/ENG_fujicar/
2-1,Suehiro-cho,Tsurumiku,Yokohama
230-8611, JAPANhttp://www.jfe-eng.co.jp/en/
2-14, Minamihorie 1-chome, Nishiku, Osaka,
Japan 550-0015
Phone: +81 6-6534-3609 / Fax: +81
6-6534-3602
http://www.rozai.co.jp/en/company/index.html
MESPS Tokyo Office:TEL +81-3-6806-1075 FAX +81-35294-1121
https://www.mesps.co.jp/contact/ind
ex.html
Osaki Center Building, 1-5-1 Osaki,
Shinagawa-ku,Tokyo 141-8604
JapanTEL: +81-3-66652000https://www.eng.nipponsteel.com/english/45

B-3: Dioxin adsorption by activated carbon for
EAF exhaust gas

D-1: Process control for reheating furnace
D-2: Low NOx regenerative burner total system
for reheating furnace
D-3: High temperature recuperator for reheating furnace
D-4: Fiber block for insulation of reheating furnace
D-7: Oxygen enrichment for RHF combustion air
D-6: Induction type billet heater RHF for direct rolling

A-17: NS-Tundish Plasma Heater (NS-TPH)
D-2: Low NOx regenerative burner total system
for reheating furnace

ANNEX 1.
Expected Effects
in Each ASEAN Country46Pre-Conditions for Calculations of Effects
As the plant costs and energy prices may change country to country, the differences are shown in the list of"Energy price, plant cost, and CO2 emission factor in ASEAN countries".

Plant cost in each country is calculated by multiplying "plant cost index" to the cost in Japan.



By using plant costs and energy prices, profit of operation and simple pay-back time are calculated for each
ASEAN country in the sheet of "Expected effects in each ASEAN country". This calculation suggests thatwhen energy price is high, energy saving project is profitable even though the plant cost is expensive.

CO2 emission reduction is also calculated for each country by using emission factor of electricity in eachcountry and the common value of CO2 emission rate from fuel. LPG is assumed to calculate CO2 emission
from fuel combustion as: 47.3 GJ/ton-LPG & 2,985 kg-CO2/ton-LPG ---> 63.1 kg-CO2/GJ

Energy price, plant cost, and CO2 emission factor in ASEAN countries

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

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

Plant cost index 2)(Japan = 100.0)

CO2 emission factor 3)(ton-CO2/MWh)Thailand

0.111

20.62

81.4

0.548

Indonesia

0.070

9.68

76.1

0.771

Vietnam

0.076

24.98

70.2

0.599

Philippines

0.200

25.89

74.4

0.512

Malaysia

0.077

7.49

77.4

0.670

Singapore

0.130

48.61

97.4

0.486

Japan

0.143

19.11

100.0

0.434 4)

Country

Source1) 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)
4) Tokyo Electric Power Company website (2021)

47

Expected effects in Thailand, Indonesia and Vietnam
ThailandIndonesia

Preconditions

Vietnam

Preconditions

Preconditions

CO2 emission factor (ton-CO2/MWh)

0.548

CO2 emission factor (ton-CO2/MWh)

0.771

CO2 emission factor (ton-CO2/MWh)Electricity price (US$/kWh)

0.111Electricity price (US$/kWh)

0.070

Electricity price (US$/kWh)

0.076

Fuel gas price

20.62

Fuel gas price

9.68

Fuel gas price

24.98

Title of technology(US$/GJ) (LPG)(US$/GJ) (LPG)

0.599(US$/GJ) (LPG)

CO2
reduction

Profit or
Operation cost

Assumedinvestment
cost

Pay backtime

CO2
reduction

Profit or
Operation cost

Assumedinvestment
cost

Pay backtime

CO2
reduction

Profit or
Operation cost

Assumedinvestment
cost

Pay backtime(kg-CO2/
ton-product)(US$/tonproduct)(millionUS$)(year)(kg-CO2/
ton-product)(US$/tonproduct)(millionUS$)(year)(kg-CO2/
ton-product)(US$/tonproduct)(millionUS$)(year)

A. Energy Saving for Electric Arc Furnace (EAF)

1

A-1

2

A-2

3

A-3

4

A-4

5

A-5

6
7
8
9
10
11
12
13
14

High temperature continuous scrap
preheating EAF
Medium temperature batch scrap
preheating EAFHigh efficiency oxy-fuelburner/lancing for EAF
Eccentric bottom tapping (EBT) on
existing furnace
Ultra high-power transformer for
EAF

82.20

16.65

30.93

3.7

115.65

10.50

28.92

5.5

89.85

11.40

26.68

4.7

21.92

4.44

8.14

3.7

30.84

2.80

7.61

5.4

23.96

3.04

7.02

4.6

7.84

1.59

1.67

2.1

11.03

1.00

1.56

3.1

8.57

1.09

1.44

2.6

8.22

1.67

3.26

3.9

11.57

1.05

3.04

5.8

8.99

1.14

2.81

4.9

8.22

1.67

4.61

5.5

11.57

1.05

4.31

8.2

8.99

1.14

3.97

7.0

A-6 Optimizing slag foaming in EAF

3.29

0.67

1.22

3.7

4.63

0.42

1.14

5.4

3.59

0.46

1.05

4.6

A-7 Optimized power control for EAF

8.22

1.67

2.04

2.4

11.57

1.05

1.90

3.6

8.99

1.14

1.76

3.1

Operation support system with
A-8
EAF meltdown judgment
Low NOx regenerative burner
A-9
system for ladle preheating
Oxygen burner system for ladle
A-10
preheating

3.29

0.67

0.53

1.6

4.63

0.42

0.49

2.4

3.59

0.46

0.46

2.0

12.62

4.12

0.33

0.2

12.62

1.94

0.30

0.3

12.62

5.00

0.28

0.1

12.62

4.12

0.24

0.1

12.62

1.94

0.23

0.2

12.62

5.00

0.21

0.1

A-11 Waste heat recovery from EAF

72.34

14.65

48.84

6.7

101.77

9.24

45.66

9.9

79.07

10.03

42.12

8.4

3.29

0.67

0.65

2.0

4.63

0.42

0.61

2.9

3.59

0.46

0.56

2.5

9.86

2.00

0.21

0.2

13.88

1.26

0.20

0.3

10.78

1.37

0.18

0.3

12.06

2.44

3.13

2.6

16.96

1.54

2.93

3.8

13.18

1.67

2.70

3.2

Energy saving for dedusting system
A-12
in EAF meltshop
Bottom stirring/stirring gas
A-13
injection
NS-Tundish Plasma Heater (NSA-17
TPH)

15

A-14 Induction type tundish heater

1.64

0.33

0.81

4.9

2.31

0.21

0.76

7.2

1.80

0.23

0.70

6.2

16

A-15 Scrap pretreatment with scrap shear

10.96

2.22

3.09

2.8

15.42

1.40

2.89

4.1

11.98

1.52

2.67

3.5

17

A-16 Arc furnace with shell rotation drive

17.54

2.22

4.88

4.4

24.67

1.40

4.57

6.5

19.17

1.52

4.21

5.5

B. Environmental Protection for Electric Arc Furnace
18
19
20
21

22
23

Exhaust gas treatment through gas
B-1 cooling, carbon injection, and bag
filter dedusting for EAF
Floating dust control in EAF
B-2
meltshopDioxin adsorption by activatedB-3
carbon for EAF exhaust gas
Dioxin adsorption by mixing EAF
B-4 exhaust gas with building dedustinggas
Dioxin absorption by 2 stepB-5 bagfilter technology for EAF
exhaust gas
B-6 PKS charcoal use for EAF

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

C. Material Recycle for Electric Arc Furnace
24
25

EAF dust and slag recycling systemby oxygen-fuel burner
EAF slag agglomeration for
C-2
aggregate use
C-1

D. Energy Saving for Reheating Furnace
26

D-1

27

D-2

28

D-3

29

D-4

30

D-6

31

D-7

Process control for reheating
furnace
Low NOx regenerative burner total
system for reheating furnace
High temperature recuperator forreheating furnace
Fiber block for insulation ofreheating furnace
Induction type billet heater for
direct rolling
Oxygen enrichment for combustion
air

3.16

1.03

2.04

3.9

3.16

0.48

1.90

7.9

3.16

1.25

1.76

2.8

11.93

3.90

6.51

3.3

11.93

1.83

6.09

6.7

11.93

4.72

5.62

2.4

6.31

2.06

1.22

1.2

6.31

0.97

1.14

2.4

6.31

2.50

1.05

0.8

2.46

0.80

1.22

3.0

2.46

0.38

1.14

6.0

2.46

0.97

1.05

2.2

113.42

25.46

0.81

0.1

122.34

11.24

0.76

0.1

115.46

33.18

0.70

0.0

29.34

2.74

0.86

4.70

-

-

34.60

-

-

30.54

-

-

E. Common systems and General Energy Savings
32

E-1

33

E-2

34

E-3

35

E-4

Inverter (VFD; Variable Frequency
Drive) drive for motors
Energy monitoring andmanagement systems
Management of compressed air
delivery pressure optimization
Highly efficient combustion system
for radiant tube burner

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

5.65

1.85

2.36

2.2

48

5.65

0.87

2.21

4.3

5.65

2.24

2.04

1.5

Expected effects in Philippines, Malaysia and Singapore
Philippines

Malaysia

Preconditions

Singapore

Preconditions

Preconditions

CO2 emission factor (ton-CO2/MWh)

0.512

CO2 emission factor (ton-CO2/MWh)

0.670

CO2 emission factor (ton-CO2/MWh)Electricity price (US$/kWh)

0.200Electricity price (US$/kWh)

0.077

Electricity price (US$/kWh)

0.130

Fuel gas price

25.89

Fuel gas price

7.49

Fuel gas price

48.61

Title of technology(US$/GJ) (LPG)(US$/GJ) (LPG)

0.486(US$/GJ) (LPG)

CO2
reduction

Profit or
Operation cost

Assumedinvestment
cost

Pay backtime

CO2
reduction

Profit or
Operation cost

Assumedinvestment
cost

Pay backtime

CO2
reduction

Profit or
Operation cost

Assumedinvestment
cost

Pay backtime(kg-CO2/
ton-product)(US$/tonproduct)(millionUS$)(year)(kg-CO2/
ton-product)(US$/tonproduct)(millionUS$)(year)(kg-CO2/
ton-product)(US$/tonproduct)(millionUS$)(year)

A. Energy Saving for Electric Arc Furnace (EAF)

1

A-1

2

A-2

3

A-3

4

A-4

5

A-5

6
7
8
9
10
11
12
13
14

High temperature continuous scrap
preheating EAF
Medium temperature batch scrap
preheating EAFHigh efficiency oxy-fuelburner/lancing for EAF
Eccentric bottom tapping (EBT) on
existing furnace
Ultra high-power transformer for
EAF

76.80

30.00

28.27

1.9

100.50

11.55

29.41

5.1

72.90

19.50

37.01

3.8

20.48

8.00

7.44

1.9

26.80

3.08

7.74

5.0

19.44

5.20

9.74

3.7

7.32

2.86

1.53

1.1

9.58

1.10

1.59

2.9

6.95

1.86

2.00

2.1

7.68

3.00

2.98

2.0

10.05

1.16

3.10

5.4

7.29

1.95

3.90

4.0

7.68

3.00

4.21

2.8

10.05

1.16

4.38

7.6

7.29

1.95

5.51

5.7

A-6 Optimizing slag foaming in EAF

3.07

1.20

1.12

1.9

4.02

0.46

1.16

5.0

2.92

0.78

1.46

3.7

A-7 Optimized power control for EAF

7.68

3.00

1.86

1.2

10.05

1.16

1.94

3.4

7.29

1.95

2.44

2.5

Operation support system with
A-8
EAF meltdown judgment
Low NOx regenerative burner
A-9
system for ladle preheating
Oxygen burner system for ladle
A-10
preheating

3.07

1.20

0.48

0.8

4.02

0.46

0.50

2.2

2.92

0.78

0.63

1.6

12.62

5.18

0.30

0.1

12.62

1.50

0.31

0.4

12.62

9.72

0.39

0.1

12.62

5.18

0.22

0.1

12.62

1.50

0.23

0.3

12.62

9.72

0.29

0.1

A-11 Waste heat recovery from EAF

67.58

26.40

44.64

3.4

88.44

10.16

46.44

9.1

64.15

17.16

58.44

6.8

3.07

1.20

0.60

1.0

4.02

0.46

0.62

2.7

2.92

0.78

0.78

2.0

9.22

3.60

0.19

0.1

12.06

1.39

0.20

0.3

8.75

2.34

0.25

0.2

11.26

4.40

2.86

1.3

14.74

1.69

2.98

3.5

10.69

2.86

3.75

2.6

Energy saving for dedusting system
A-12
in EAF meltshop
Bottom stirring/stirring gas
A-13
injection
NS-Tundish Plasma Heater (NSA-17
TPH)

15

A-14 Induction type tundish heater

1.54

0.60

0.74

2.5

2.01

0.23

0.77

6.7

1.46

0.39

0.97

5.0

16

A-15 Scrap pretreatment with scrap shear

10.24

4.00

2.83

1.4

13.40

1.54

2.94

3.8

9.72

2.60

3.70

2.8

17

A-16 Arc furnace with shell rotation drive

16.38

4.00

4.46

2.2

21.44

1.54

4.64

6.0

15.55

2.60

5.84

4.5

B. Environmental Protection for Electric Arc Furnace
18
19
20
21

22
23

Exhaust gas treatment through gas
B-1 cooling, carbon injection, and bag
filter dedusting for EAF
Floating dust control in EAF
B-2
meltshopDioxin adsorption by activatedB-3
carbon for EAF exhaust gas
Dioxin adsorption by mixing EAF
B-4 exhaust gas with building dedustinggas
Dioxin absorption by 2 stepB-5 bagfilter technology for EAF
exhaust gas
B-6 PKS charcoal use for EAF

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C. Material Recycle for Electric Arc Furnace
24
25

EAF dust and slag recycling systemby oxygen-fuel burner
EAF slag agglomeration for
C-2
aggregate use
C-1

D. Energy Saving for Reheating Furnace
26

D-1

27

D-2

28

D-3

29

D-4

30

D-6

31

D-7

Process control for reheating
furnace
Low NOx regenerative burner total
system for reheating furnace
High temperature recuperator forreheating furnace
Fiber block for insulation ofreheating furnace
Induction type billet heater for
direct rolling
Oxygen enrichment for combustion
air

3.16

1.29

1.86

2.9

3.16

0.37

1.94

10.3

3.16

2.43

2.44

2.0

11.93

4.89

5.95

2.4

11.93

1.42

6.19

8.7

11.93

9.19

7.79

1.7

6.31

2.59

1.12

0.9

6.31

0.75

1.16

3.1

6.31

4.86

1.46

0.6

2.46

1.01

1.12

2.2

2.46

0.29

1.16

7.9

2.46

1.90

1.46

1.5

111.98

29.54

0.74

0.1

118.30

7.78

0.77

0.2

110.94

65.28

0.97

0.03

28.49

2.01

0.13

9.57

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32.22

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27.88

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E. Common systems and General Energy Savings
32

E-1

33

E-2

34

E-3

35

E-4

Inverter (VFD; Variable Frequency
Drive) drive for motors
Energy monitoring andmanagement systems
Management of compressed air
delivery pressure optimization
Highly efficient combustion system
for radiant tube burner

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5.65

2.32

2.16

1.6

49

5.65

0.67

2.24

5.6

5.65

4.36

2.82

1.1

Technologies Customized List
2023 version Part 1 : EAF (v.4.0)