Introduction
Overview“Technologies Customized List” is a technology reference containing energy-saving,environmental-protection 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) and Japan. The list is aimed at
identifying appropriate technologies for the ASEAN steel industry and the first version of
the list was published in November 2014.
The list reflects the knowledge acquired from public and private experiences of theJapanese steel industry, which achieves the highest energy efficiency in the world, and thetechnology 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 forprivate 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 employedon many occasions such as Steel Plant Diagnosis and Public and Private Collaborative
Workshops. Through these activities, additional technology needs were specified.
Technologies Customized List version 2 contains these new technologies and more detailed
explanations of the existing technologies.

What is ASEAN-Japan Steel Initiative?

1

Development process of Technologies Customized List
Technologies on Technologies Customized List were chosen from several
technology references in the world, based on three perspectives;
1) Technological knowledge of steel experts in ASEAN and Japan
2) Experience of Japanese steel industry
3) Circumstances in ASEAN steel industry<Reference List>
SOACT Handbook: http://www.jisf.or.jp/business/ondanka/eco/docs/SOACT-Handbook-2nd-Edition.pdf
NEDO Handbook: http://ietd.iipnetwork.org/sites/ietp/files/Japanese%20Technologies%20for%20Energy%20Saving.pdf
EU-IPCC BAT: http://eippcb.jrc.ec.europa.eu/reference/BREF/IS_Adopted_03_2012.pdf
USA-EPA-BACT: https://www.epa.gov/sites/production/files/2015-12/documents/ironsteel.pdf

Version 2.02

September, 2016

Technologies Customized List & Technologies One by One Sheets Version 2.0

Table of Contents

1. Technologies Customized List

5

2. Technologies One-by-One Sheet

11

ANNEX 1.

Full List of Technologies

49

ANNEX 2.

Technologies for Blast Furnace

55

ANNEX 3.

Financial support scheme of Japan

59

ANNEX 4.

Expected effects in each ASEAN country

65

3

1.

6

Technology selection criteria
33 technologies on the “Technologies Customized List version 2” are considered to contributeto energy saving and environmental protection in ASEAN steel industry. These technologies
were chosen based on the following criteria.


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



Availability: Target technologies should be commercially available. Technologies underdevelopment in Japan, which the supplier companies are not ready to diffuse in ASEAN
region, are not eligible for Technologies Customized List.

7

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

NG burner

O2 and C lances

Process control by exhaustgas analysis and/or
computerElectricity consumption
Oxygen consumption
Natural gas consumption
Coke consumption
Product
Tapping temperature

8500,000 ton/year
Value
80 ton52 minutes
100 % scrapnone
3 times

RHF
Equipment NameType
Nominal capacity
Heated material
Heating temperature
Fuel

used Combustion air preheatingused only tofacilitate melting

Computer control to set
furnace temperature withheat transfer simulation
installed only at Hot charge and/or directslag-door side, rolling
water-cooledtype
none Insulation

430 kWh/ton
30 m3N/ton
20 m3N/ton
15 kg/ton
Mild steel lessthan 0.2 % C
1620 degC

Heat consumption

Value
Walking beam
100 ton/h
135 SQ billet
1100 degC
Natural gas,
LHV 44 MJ/m3N
around 300 degCwith low grade
recuperator
none

none

firebrick

1,450
MJ/ton-steelTechnologies Customized List for Energy Saving, Environmental Protection,
and Recycling for ASEAN Steel Industry (ver.2.0)
Assumedinvestment cost

Expected effects of introduction

No.

ID

Title of technology

Technical description

Electricity
saving(kWh/t ofproduct)

Thermalenergysaving

Profit ofOperation
cost(GJ/t ofproduct)(US$/t ofproduct,
Japan)

Environmental
benefits

AssumedPayback
investmen
time
t costCo-benefits(million
US$ inJapan)

Main
Japanese
supplier(year inJapan)

A. Energy Saving for Electric Arc Furnace (EAF)

1

Combination of the technologies of- Air tight structure- High temperature scrap preheating (over 700 degC)
A-1 High temperature continuous - Continuous preheated scrap charging
scrap preheating EAF- Automatic process control by using data logging- Post-combustion of generated CO gas- Dioxin decomposition by secondary combustion2

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
bath

A-4

Eccentric bottom tapping(EBT) on existing furnace

5

A-5

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

6- Proper chemical ingredients of slag
- High efficient burner and/or lance
Optimizing slag foaming in
A-6 EAF- Controlled O2 & C injection into EAF proper position- Keeping slag thickness with air-tight operation

7

Optimized power control for
A-7
EAF

8

Automatic Rapid Melting system- Data logging
Operation support system
A-8 with EAF meltdown judgment - Optimum electric power control- Alloy calculation- Automatic meltdown Judgment

9- Regenerating burner use
Low NOx regenerative burner- High Energy Saving (about 40%)
A-9 system for ladle preheating- Automatic control- FDI Combustion- Data logging and visualization of melting process- Automatic judgement on meltdown and additional
scrap charge- Automatic phase power independent control for wellbalanced melting- Rapid and high temperature ladle heating by oxygen
burner
10 A-10 Oxygen burner system for - Automatic control
ladle preheating- High Energy Saving (about 40%)
Waste heat recovery from

- Waste heat boiler based on the OG boiler technology- Specified for splash and dust containing- Damper openings and exhaust fan rotation are
Energy saving for dedusting controlled in consonance

12 A-12 system in EAF meltshop
Bottom

13 A-13 injection

stirring/stirring

40.0

14.3

-

-

-

16.95

4.52

1.62

- Combination of VVVF and proper damper openinggas - Inject inert gas (Ar or N2) into the bottom of EAF- Better heat transfer steel quality- Low
electrodeconsumption(0.8 1.0 kg/tonproduct at
AC)- Reduction of -No limit ofmaterial fordioxinhigh quality
emission,
products
asdispersing
like stainless
dust, & noise
steel

-

- Reduction of
nitrogen insteel forquality
improvement- JP Steel
Plantech
38.00

4.5

- Daido
Steel
10.00

2.05

4.4

2.5

15.0

-

1.70

-

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

15.0

-

1.70

-

- Productivity
increase

5.66

6.7

-

1.50

4.4

- Slag free tapping- Reliable stopping and scraping mechanism

4

11 A-11 EAF

150.0

Decompositi
on andreduction ofdioxin,dispersing
dust, & noise

6.0

15.0

6.0

-

-

-

0.68

1.70

0.68

- Noisereduction &working floor
cleaning

-

-

- NOx
reduction
-

0.20

-

- NOx
reduction- Productivity
increase- Manpowersaving- Productivity
increase- Manpowersaving- Operation
standardization- Contribute tobetteratmospherearoundatworkfloor

4.00

4.7

- JP Steel
Plantech- DaidoSteel- JP Steel
Plantech- Nikko- JP Steel
Plantech- DaidoSteel- JP Steel
Plantech

2.50

2.9

- Daido
Steel
0.50

0.40

1.5

0.2

- Chugai-Ro- Nippon
Furnace- Contribute tobetteratmospherearoundatworkfloor

0.30

0.1

- Chugai-Ro- JP Steel
Plantech- JP Steel
Plantech

-

0.20

-

132.0

-

14.92

-

-

60.00

8.0

6.0

-

0.68

- Betterworking floor& atmosphere

-

0.80

2.4

18.0

-

2.03

-

- Fe yield
increase 0.5 %

0.26

0.3

3.0

-

0.34

-

-

1.00

5.9

- Application of induction heating

14 A-14 Induction type tundish heater - Possible to uniformize temperature in 3 minutes after- Nikko- JP Steel
Plantech- JP Steel
Plantech- DaidoSteel- JP Steel
Plantech- FujiElectric

power supply- Long size or low bulk-density scrap is shredded andpackedScrap pretreatment with scrap- Scrap pretreatment decreases the scrap-charging
15 A-15 shear
frequency, which will lead to energy saving[Newly-added technology]- By rotating furnace shell 50 degree back-and-force,
Arc furnace with shell rotation cold spot will be decreased to realize smooth melting
16 A-16 drive- Assumed investment cost is the increase from the[Newly-added technology]
newly constructed conventional EAF

20.0

32.0

-

-

2.26

3.62

-

-

- Fe yield
increase in
1.5 % (byNon-integrated
steel
producers'
association)- Decreasing
power-on time,
melting fuel,and refractorymaterial- Fuji Car
Manufacturi
ng
3.80

3.4

- Daido
Steel
6.00

3.3

9

Technologies Customized List for Energy Saving, Environmental Protection,
and Recycling for ASEAN Steel Industry (ver.2.0)
Assumed investment
cost

Expected effects of introduction

No.

ID

Title of technology

Technical description

Electricity
saving

Thermal Profit ofenergy Operation
cost
saving(kWh/t of (GJ/t ofproduct) product)(US$/t ofproduct,
Japan)

Environmenta
Co-benefitsl benefits

AssumedPayback
investmen
time
t cost(million
US$ inJapan)

Main
Japanese
supplier(year inJapan)

B. Environmental Protection for Electric Arc Furnace
17

Exhaust gas treatment
through gas cooling,B-1
carbon injection, and bag
filter dedusting for EAF

18

Floating dust control in
B-2
EAF meltshop

19

B-3 activated carbon for- Improved design configuration of the direct evacuation
for treating hot unburned gas from much fuel use- Minimize dust and gas dispersion from EAF withenough capacity and suitable control

-

-

-

- Analyze air flow in EAF building---- Packaged cartridges of activated carbon fixed at theexit of bag-filter adsorbs and removes dioxins and heavy
metals to an extremely low level

-

-

-

- Cooling direct evacuation gas by mixing with building
dedusting gas

-

-

-

21

Dioxin adsorption by 2
B-5 step bagfilter technology
for EAF exhaust gas- 2 step bag system can remove over 99% DXN's fromEAF.
- This system provide a clean working environment.
- Effective evacuation decrease the consumption ofelectricity.

-

-

-

22

B-6 PKS charcoal use for EAF- Charcoal made from PKS can be used instead of
injected coke into EAF.

-

-

-

Dioxin adsorption by
EAF exhaust gas
Dioxin adsorption by

20

B-4 mixing EAF exhaust gas
with building dedustinggas- Betterworkfloor &environment- Restrict dust
loading on
working
floor to lessthan 5- Dioxin will
be lower than
0.5 ng3
TEQ/m N
- Dioxin will
be lower than
5.0 ng3
TEQ/m N
- Dioxin will
be lower than
0.5 ng3
TEQ/m N- 39,000 tonCO2/y GHG
reduction

-

-

-

-

1.00

-

-

-

-

-

-

-

-

-

-

-

-

-

- JP Steel
Plantech- DaidoSteel- JP Steel
Plantech- DaidoSteel- JFEEngineering- JP Steel
Plantech- DaidoSteel- JP Steel
Plantech- DaidoSteel- JP Steel
Plantech

C. Material Recycle for Electric Arc Furnace
EAF dust and slag

23

C-1 recycling system by- Zn recovery rate will be expected to be 95%- Fe in EAF dust cannot be recovered as metal

oxygen-fuel burner

24

C-2

EAF slag agglomeration
for aggregate use- Molten slag is rapidly cooled by jet air, and becomes
0.5 - 3.0 mm heavy and strong ball
- Suited to use aggregate mixed with cement- Zn materialand concrete
aggregate
can be gained
from EAF- Savedprocessing
time: 10minutes- Daido
Steel
-

-

1.00

-

-

2.50

-

-

8.00

-

-

-

1.50

-

- Reductionof Heataccumulation

-

1.50

-

-

-

-

-

-

-

-

- Slagsatisfies thesafety code

-

0.050

1.01

-

-

0.189

3.82

-

0.100

2.02

-

0.039

0.79

- Nikko

D. Energy Saving for Reheating Furnace
Process control for
reheating furnace- Setting furnace temperature by targeted billet
temperature curve- Precise air ratio control and O2 analysis in exhaust gas

Low NOx regenerative- High efficient and durable burner system

25

D-1

26

D-2 burner total system for27

D-3 recuperator forreheating furnace

High temperature
reheating furnace
Fiber block for insulationof reheating furnace

28

D-4

29

Air conditioning byabsorption typeD-5
refrigerating by using
reheating furnace exhaust30

D-6 for direct rolling- Heat transfer area is expanded- Special material tube is used instead of stainless- Low thermal conductivity- High temperature change response (low thermalinertia)- Use reheating furnace exhaust gas at the outlet ofrecuperator, about 300-350 degC

- Chugai-Ro- Chugai-Ro- Nippon
Furnace- Chugai-Ro

3.0

Compensate temperature drop of billets transferred from
Induction type billet heater CC to rolling mill (from 950 degC to 1050 degC).
Advantages:[Newly-added technology] - Automatic control- Less exhaust gas (without reheating furnace)- CO2 &
NOx
Reduction

-40.0

-

1.45

0.34

24.80

- Betterworking floor& atmosphere- Chugai-Ro

-

-

0.90

1.00

-

- Hitachi
Infrastructur
e Systems
Company-- MES
PowerElectronics
IndustryCo., Ltd.

E. Common systems and General Energy Savings

31

Applying the Multi-Level Drive for motors enables tosave energy cost from vane and valve control (constant
speed motor).
Inverter (VFD; Variable
・Eco-Friendly
E-1 Frequency Drive) drive for ・Power Source Friendly
motors・Less Maintenance・Motor Friendly

32

E-2 Energy monitoring andmanagement systems

33- Energy saving in compressors requires consideration
Management of compressed of the following points.
E-3 air delivery pressure* Selection of the appropriate capacity* Reduction in delivery pressure
optimization

10- Energy data are collected in process computer forevaluation- CO2
Reduction
13%

-

285
MWh/y

-

0.120

-

-

2.43

-

-

-

-

-

-

1.50

-

-

-

-

-

- Hitachi- Majorelectric
equipment
suppliers- Majorelectric
equipment
suppliers- Majorelectric
equipment
suppliers

2.

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

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 underhigh temperature preheating. As this equipment keeps always flat bath operation, electrode consumption is significantly
improved.
Furthermore, the electric facilities necessary to meet power quality regulation can be drastically reduced on it may not evenunnecessary 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 the exhaustgas 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)

4. Japanese Main Supplier

JP Steel Plantech

5. Technologies Reference

SOACT 2nd Edition ("Ecological and Economical Arc Furnace"), Diagram from JP Steel Plantech

6. Comments-

13

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

14- 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.

4. Japanese Main Supplier

Daido Steel

5. Technologies Reference

May contact to Daido Steel

6. Comments-

A. Energy Saving for Electric Arc Furnace (EAF)

A-3High efficiency oxy-fuel burner/lancing 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

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 nitrogen in steel, quality improvement

4. Japanese Main Supplier

Nikko, JP Steel Plantech

5. Technologies Reference

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

15

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

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits

15 kWh/ton-product-4. Japanese Main Supplier

Increase in Fe & alloy yield, and productivity
Improve steel quality
JP Steel Plantech, Daido Steel

5. Technologies Reference

EPA-BACT (Sep. 2014), Diagram from JP Steel Plantech

6. Comments<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

・Co-benefits

16- Molten steel is tapped through the hole at the furnace bottom.
- Tilting angle for tapping is smaller than conventional spot tapping, and quick tapping 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

A-5

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Ultra high-power transformer for EAF

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
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

JP Steel Plantech, Nikko

5. Technologies Reference

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.

17

A-6

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Optimizing slag foaming in EAF

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

18- 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

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 phenomenon is explained by several factors, 6 kWh/ton is reasonable (Japanese experts).

A-7

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Optimized power control for EAF

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
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

JP Steel Plantech

5. Technologies Reference

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

6. Comments-

19

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits

6 kWh/ton-product-4. Japanese Main Supplier

Productivity increase
Manpower saving
Daido Steel

5. Technologies Reference

May contact to Daido Steel

6. Comments-

・Co-benefits

20

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

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
Introduction

While one of the burners is burning, the other burner will work as an exhaust outlet. The exhaust gas is discharged from thesystem 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, the combustion
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 roles of combustionand 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.

・Environmental
benefits

Low NOx

・Co-benefits

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.

4. Japanese Main Supplier

Chugai-Ro, Nippon Furnace

5. Technologies Reference-

6. Comments-

21

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

22

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 NOx
Higher brick temperature can allow lower tapping temperature for energy saving at EAF.

4. Japanese Main Supplier

Chugai-Ro, JP Steel Plantech

5. Technologies Reference

Diagram from Chugai Ro, May contact to suppliers

6. Comments

-

A-11

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Waste heat recovery from EAF

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
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

JP Steel Plantech

5. Technologies Reference

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

23

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

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

4. Japanese Main Supplier

JP Steel Plantech, Daido Steel

5. Technologies Reference

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.

A-13

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Bottom stirring/stirring gas injection

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

Inject inert gas (Ar or N2) into the bottom of EAF to agitate steel bath
Expected effects:- 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-productFe yield increase 0.5 %4. Japanese Main Supplier-

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

-

25

A-14

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Induction type tundish heater

1. Process Flow or Diagram＜Features for Induction Tundish heater＞
2. Technology
Definition/Specification

1. Uniformity of Element of Molten Steel: Agitation effect by electromagnetic force.
2. High Precision Temperature Control: Target Temp.±2.5degree.
3. High Heating Efficiency: More than 90% by channel type inductor.
4. Ease of maintenance: Water cooled feeder with quick connector. Self-cooled type Induction coil and so on.

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits-

4. Japanese Main Supplier

Productivity increase
Quality improvement
Fuji Electric

5. Technologies Reference

May contact to Fuji Electric

6. Comments<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- Raised temperature: 40 degree C- Number of charges: 8 charges/day- Monthly production: 48,000 ton- Annual production: 576, 000 ton

・Co-benefits

26

3 kWh / ton-product (Effect is calculated comparing to electricity consumption of plasma type heater)

A-15

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Scrap pretreatment with scrap shear

1. Process Flow or Diagram

Before scrap pretreatment (0.3 ton/m3)
2. Technology
Definition/Specification
・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

After scrap pretreatment (0.6 ton/m3)- Long size or low bulk-density scrap is shredded and packed- For example, bulk density of 0.3 m3/ton can be increased to 0.6 m3/ton 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 producers' association of Japan)
Fe yield increase in 1.5 %, TTT shortening

4. Japanese Main Supplier

Fuji Car Manufacturing

5. Technologies Reference-

6. Comments

-

27

A-16

A. Energy Saving for Electric Arc Furnace (EAF)

Item

Content

Arc furnace with shell rotation drive

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

28

Furnace shell is rotated 50 degree 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

4. Japanese Main Supplier

Daido Steel

5. Technologies Reference

May contact to Daido Steel

6. Comments-

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

3. Expected
Effect of・Electricity Saving
Technology
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 work floor environment-

4. Japanese Main Supplier

JP Steel Plantech, Daido Steel

5. Technologies Reference

SOACT 2nd Edition
Diagram from Daido Steel
Recent Progress of Steelmaking Technology in Electric Arc Furnace (1993, JISF)

6. Comments

-

29

B-2

B. Environmental Protection for Electric Arc Furnace

Item

Content

Floating dust control in EAF meltshop

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

30- In modern EAF meltshop, fully enclosed building is required to avoid dust dispersion to the outside, but enclosed building
raises work floor 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.
Restrict dust loading on working floor to less than 5 mg/m3-

4. Japanese Main Supplier

JP Steel Plantech, Daido Steel

5. Technologies Reference

Diagram from JP Steel Plantech, May contact to suppliers

6. Comments-

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
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 aunique structure allowing the system to adsorb and remove dioxins and heavy metals to an extremely low levels. A cartridgewith a unique structure ensures improved contact efficiency between activated carbon and exhaust gas. Consequently, thefilled quantity of activated carbon is considerably reduced allowing unparalleled compact size. In addition, amount ofconsumed 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

JFE Engineering

5. Technologies Reference

Diagram from JFE Engineering, May contact to JFE Engineering

6. Comments-

31

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

32- 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.
- Dioxin seems to be captured by the oily dust which is accumulated on the surface of filter.
- When gas temperature at the bag filter ascends up to about 110 degC, where oil is vaporised, dioxin concentration rapidly
increases even in a short time.
- Collected duct at bag filter should be carefully treated, as it contains much dioxin.
- This phenomenon is different from the case of incinerators, where the dust does not contains oily substances.
Dioxin will be lower than 5.0 ng TEQ/m3N-

4. Japanese Main Supplier

JP Steel Plantech, Daido Steel

5. Technologies Reference

Diagram from Daido Steel, May contact to suppliers

6. Comments-

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
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-step bag
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 or industrial
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

JP Steel Plantech, Daido Steel

5. Technologies Reference

Diagram from Daido Steel

6. Comments

-

33

B-6

B. Environmental Protection for Electric Arc Furnace

Item

Content

PKS charcoal use for EAF

1. Process Flow or Diagram

2. Technology
Definition/Specification

・Electricity Saving
3. Expected
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

34- 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- Equipment 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-

4. Japanese Main Supplier

JP Steel Plantech

5. Technologies Reference

Diagram from JP Steel Plantech, May contact to JP Steel Plantech

6. Comments<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

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

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

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 cooling mechanism.
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.
-・Environmental
benefits

4. Japanese Main SupplierZn material can be gained from EAF dust
Concrete aggregate can be gained from EAF dust
Daido Steel

5. Technologies Reference

Diagram from Daido Steel, May contact to Daido Steel・Co-benefits

6. Comments

35

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits-

4. Japanese Main Supplier

Reduce disposal cost of industrial waste
Processing time for one heat of EAF : 10 minutes
Nikko

5. Technologies Reference

Diagram from Nikko, May contact to Nikko

6. Comments<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 %・Co-benefits

36

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-Environmental friendly material-Suitable & meet with JIS A 5011-4 for Electric arc furnace oxidizing slag aggregate.
-Require smaller space than normal slag treatment area.

D. Energy Saving for Reheating Furnace

D-1

Process control for reheating furnace

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- Setting furnace temperature by targeted billet temperature curve- Precise air ratio control and O2 analysis in exhaust gas
0.015 GJ/ton-product (1 % fuel saving from the base line of 1,450 MJ/ton)-

4. Japanese Main Supplier

Chugai-Ro

5. Technologies Reference

May contact to Chugai-Ro

6. Comments-

37

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

38

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

Diagram from Chugai Ro, May contact to suppliers-

0.189 GJ/t (about -13%)
CO2 & NOx Reduction
Chugai-Ro, Nippon Furnace

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

For this purpose, the following shall be needed.
- Modification of Recuperator room
- Change of air duct
- Increase of discharge pressure of blower- High efficiency recuperator
0.100 GJ/t (about -7%)
CO2 Reduction-

4. Japanese Main Supplier

Chugai-Ro, Rozai Kogyo

5. Technologies Reference

Diagram from Chugai Ro

6. Comments<Preconditions on calculating effects>
When 300 degC air temperature is raised to 500 degC39

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
Effect ofTechnology
Introduction

・Thermal Energy
Savings
・Environmental
benefits
・Co-benefits

40

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 energy-saving operation

4. Japanese Main Supplier

Chugai-Ro

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

D. Energy Saving for Reheating Furnace

D-5

Air conditioning by absorption type refrigeratingby using reheating furnace exhaust gas

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

This is a waste heat recovery system by using the absorption chiller.
If there is a waste heat more than 200 deg. C, it can utilize for the double effect absorption chiller and can generate chilledwater for air conditioning, etc. This chiller efficiency is about COP*:1.45 and it can reduce electrical type chiller power
consumption. It requires close attention in case the exhaust gas contains corrosive components.
*COP(Coefficient Of Performance) : Heat supplied(W) / Power consumption(W)
3.0 kWh/ton-product (compared to the air cooled electric chiller COP:3.5 / considering the auxiliaries consumption as
90kWh)-

4. Japanese Main Supplier

HITACHI Infrastructure Systems Co.

5. Technologies Reference

Diagram from HITACHI Infrastructure Systems Co., May contact to HITACHI Infrastructure Systems Co.

6. Comments<Preconditions on calculating effects>- compared to the air cooled electric chiller COP:3.5/ consider the auxiliaries consumption as 90kWh41

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

42Compensate 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

MES Power-Electronics Industry Co., Ltd.

5. Technologies Reference-

6. Comments-

E. Common systems and General Energy Savings

E-1

Inverter (VFD; Variable Frequency Drive) drive for motors

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- Eco-Friendly
Total efficiency of 97% is achieved. 20-30% of energy can be saved with fans and pumps.
Separated installation is available for Transformer section.
- Power Source Friendly
Current harmonic at the power source conforms to IEEE519-1992 guidelines.
- Less MaintenanceReliable, available and serviceable of maintenance tool are widely arranged.
- Motor Friendly
Series connected IGBT produce sinusoidal waveform of output voltage and current.
It is best for to retrofit with existing motors.
13% (Depending on the country and conditions of the facility)
CO2 Reduction-

4. Japanese Main Supplier

Hitachi, Ltd., Major electric equipment companies

5. Technologies Reference*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

6. Comments<Preconditions on calculating effects>- Annual operation : 3,600 h/y- Unit cost of power : 0.145 US$/kWh

43

E. Common systems and General Energy Savings

E-2

Energy monitoring and management systems

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

44This 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 time sothat typical situations may be analyzed. It is very important to monitor for all energy sources on online. It is the maintechnique 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.
-

4. Japanese Main Supplier

Major electric equipment suppliers

5. Technologies Reference-

6. Comments-

E. Common systems and General Energy Savings

E-3

Management of compressed air delivery pressure optimization

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

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, appropriate 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 cleaningof 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 additionally adopted instead ofpressure reducing valves.
285 MWh/y (=823 kW x 60 % x 10 % x 24 h/d x 241 days/y)-

4. Japanese Main Supplier

Major electric equipment suppliers

5. Technologies Reference

Japanese Technologies for Energy Savings/GHG Emissions Reduction 《2008 Revised Edition》, edited by NEDO

6. Comments<Preconditions on calculating effects>- Number of compressors; Total of 17,- Equipment capacity; 823 kW,- Daily operation; 24 h/d,

*Delivery pressure; 0.8MPa,*On-load operation load; 60%,
*Annual operation; 241 days'

45

46

Contact Points of Supplier Companies
Company

Contact Points
Akira SHINOZUKA
Overseas Sales Section, Sales Dept, Plant Division
Address: Sakai Works, 2-4 Chikko Shinmachi, Nishi-Ku,
Sakai 592-8331, JAPAN
Email: Akira_Shinozuka@n.chugai.co.jp
Tel: +81-72-247-2108

Technology
A-9. Low NOx regenerative burner system for ladle preheating
A-10. Oxygen burner system for ladle preheatingD-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

Daido Steel Co., Ltd

Kunio MATSUO
General Manager, Machinery Engineering Dept.,
Machinery Division
Address: 9 Takiharu-cho, Minami-Ku, Nagoya, JAPAN, 4578712
Email: k-matsuo@ac.daido.co.jp
Tel: +81-52-613-6819
Katsunari HASHIMOTO
Export Sales Manager (Asean Area Manager), Machinery
Division
Adress: 1-6-35 Kounan, Minato, Tokyo, JAPAN, 108-8478
Email; k-hashimoto@bw.daido.co.jp
Tel: +81-3-5495-1282

A-2. Medium temperature batch scrap preheating EAF
A-4. Eccentric bottom tapping (EBT) on existing furnaceA-6. Optimizing slag foaming in EAF
A-8. Operation support system with EAF meltdown judgment
A-12. Energy saving for dedusting system in EAF meltshop
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 absorption by 2 step bagfilter technology for EAF exhaust gas
C-1. EAF dust and slag recycling system by oxygen-fuel burner

Fuji Car
Manufacturing Co.
Ltd.

Mr. Satoshi MATSUMURA
Environmental Plant & Equipment Sales Division 1
Address: Shibapark Bldg. A-10F, 2-4-1, Shibakouen, Minatoku, Tokyo, 105-0011, Japan
Email: s-matsumura@fujicar.co.jp
Tel: +81-3-6402-4184
Fax: +81-3-6402-4185

A-15. Scrap pretreatment with scrap shear

Fuji Electric Co., Ltd.

A-14. Induction type tundish heater
Masato IDE
Assistant General Manager, Sales Dept. IV, Global Plant Sales
Div., Sales Group
Address: Gate City Ohsaki, East Tower 11-2, Osaki 1- Chome,
Shinagawa-Ku, Tokyo 141-0032, JAPAN
Email: ide-masato@fujielectric.co.jp
Tel: +81-3-5435-7062

Hitachi, Ltd.
Hitachi Infrastructure
Systems Company

D-4. Air conditioning by absorption type refrigerating by using reheating furnace
Taisuke SHIMAZAKI
Assistant Manager, Industrial Systems and Solutions Division, exhaust gas
E-1. Inverter (VFD; Variable Frequency Drive) drive for motors
Heavy Industry Dept., Tokyo Head Office

Chugai Ro Co., Ltd.

JFE Engineering
Corporation

Email: taisuke.shimazaki.xz@hitachi.com
TEL: +81-90-1690-4507
FAX: +81-3-5928-8745
Nagayoshi SUZUKIManager, Environmental Plant Section, Engineering
Department, Overseas Business Sector

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

Address: 2-1, Suehiro-cho, Tsurumi-ku, Yokohama, 230-8611
JAPAN
Email: suzuki-nagayoshi@jfe-eng.co.jp
Tel: +81(45)505-7821
Fax: +81(45)505-7833

JP Steel Plantech Co.

A-1. High temperature continuous scrap preheating EAF
Masao MIKI
General Manager, Section 1, Overseas Sales & Marketing Dept. A-3. High efficiency oxy-fuel burner/lancing for EAF
Address: 2-6-23, Shinyokohama, Kohoku-ku,Yokohama
222-0033 JAPAN
Email: mikim@steelplantech.co.jp
Tel: +81-(0)45-471-3917
Fax: +81-(0)45-471-4002

A-4. Eccentric bottom tapping (EBT) on existing furnaceA-5. Ultra-high-power transformer for EAF
A-6. Optimizing slag foaming in EAF
A-7. Optimized power control for EAF
A-10. Oxygen burner system for ladle preheating
A-11. Waste heat recovery from EAF
A-12. Energy saving for dedusting system in EAF meltshop
A-13. Bottom stirring/stirring gas injection
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-3. Dioxin adsorption by mixing EAF exhaust gas with building dedusting gas
B-4. Dioxin absorption by 2 step bagfilter technology for EAF exhaust gas
B-5. PKS charcoal use for EAF

MES PowerElectronics Industry
Co., Ltd.

Takahiro AO
Manager, Design Sect. Engineering Dept.
Address: 1-1,Tama 3-chome, Tamano, Okayama 706-8651,
Japan
Email: tao@mes.co.jp
Tel: +81-863-23-2439
Fax: +81-863-23-2784

D-6. Induction type billet heater for direct rolling

Nikko Industry Co.,Ltd.

Akiyoshi OKAMOTO
Director, Engineering and Marketing Division
Address: 4-10, 2-chome, Nunobiki-cho, Chuo-ku, Kobe, 6510097, JAPAN
Email: a-okamoto@nikko-japan.co.jp
Tel: +81-78-222-1688

A-3. High efficiency oxy-fuel burner/lancing for EAF
A-5. Ultra high-power transformer for EAF
C-2. EAF slag agglomeration for aggregate use

Nippon Furnace Co.,Ltd.

Susumu MOCHIDA
Director, General Manager, Technology & Engineering
Division
Address: 1-53, Shitte 2-Chome, Tsurumi-ku, Yokohama 2308666, JAPAN
Email: s_mochida@furnace.co.jp
Tel: +81-45-575-8008

A-9. Low NOx regenerative burner system for ladle preheatingD-2. Low NOx regenerative burner total system for reheating furnace

47

ANNEX 1.

136 energy saving, environment and recycle technologies
of steel industry

Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry
Expected Effect of Technologies Introduction[*3]

Technologies
Reference[*2]No

Title of Technology (SOACT base）[*1]

EU- EPASOACT NEDOBAT BACT

Sintering○1

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

2

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

3
4

District Heating Using Waste Heat
Dust Emissions Control○○

5

Exhaust Gas Treatment through Denitrification, Desulfurization, andActivated Coke Packed Bed Absorption

○

○

○

○

CO2
Reduction

Energy Savings(Electricity/ Fuel)kg- CO2/tof productGJ/tof productCo-benefits(Reduction of
Water, Dust,
SOx, etc.)23.8(N)/0.55, 0.25（N）

SOx, NOx, Dust

16.9

22.1kWh/t /0.245/800TJ/y(S)Dust
NOx, DXN, Hg

6Exhaust Gas Treatment through Selective Catalytic Reduction

○

SOx

7

Exhaust Gas Treatment through Low-Temperature Plasma

○

DXN

8

High Efficient (COG) Burner in Ignition Furnace for Sinter Plant [*4]○9Exhaust Gas Treatment Through Additive Injection and Bagfilter
Dedusting○

10 Sintering machine ignition oven burner (NEDO)
11 Partial recycling of waste gas (EU-BAT)

0.46(N)○○

12 Coke Dry Quenching○○

13 Coal Moisture Control
14 High Pressure Ammonia Liquor Aspiration System
15 Stripping of ammonia from the waste water (EU-BAT)○○○

Waste water treatment (EU-BAT)
Modern Leak-proof Door
Cleaning of oven doors and frame seals (EU-BAT)
Reduction of SO2 by coke oven gas desulphurisation (EU-BAT)
20 Land Based Pushing Emission Control System

○

○

○
○
-

Ironmaking○

Top Pressure Recovery Turbine
Pulverized Coal Injection (PCI) System
Pulverized coal injection to 225 kg/ton iron (EPA-BACT)
Oxy-oil injection (EU-BAT)
30 Gas injection (EU-BAT)
31 Injection of COG and BOF gas (EPA-BACT)
32 Plastic injection (EU-BAT)

33

36 Charging carbon composite agglomerates (EPA-BACT)
37 Blast Furnace Gas and Cast House Dedusting

38 Blast furnace gas recycling (EPA-BACT)
39 B-gas （fueling） Regenerative Reheating Furnace
40 B-gas （fueling） Ignition Burner of Sinter

41

○
○

44 Hydrocyclonage of blast furnace sludge (EU-BAT)
45 Slag Odor Control

97.5(S)

1.47(N)/1.2(S)○27.5(S)/0.3(S)

Fume
Water
Water
Fume
Fume
SOx
Fume (Dust)

○
○

○
○

○
○
○

○
○
○
○
○
○

3.8

/0.17
630-700KWh/t(S)/

25(S)
212(N)

0.49(S)//2.33(N: 200 kg inj.)

34.7

/0.57

54.9

○
○
○
○
○
○

○

/9tWater/t-iron

Water

○
-

Direct injection of used oils, fats and emulsions as reducing agents andof solid iron residues (EU-BAT)

42 Cast House Dust Suppression
43 Treatment and reuse of scrubbing water (EU-BAT)

○
○

○
○

Direct injection of used oils, fats and emulsions as reducing agents andof solid iron residues (EU-BAT)

34 Improve Blast Furnace Charge Distribution
35 Use of high quality ores (EU-BAT)○○VSD COG compressor (EPA-BACT)
Coke Plant – Automation and Process Control System
COG-non-recovery Coke Battery [*4]Waste Plastics Recycling Process Using Coke Ovens

26
27
28
29

○

SOx, NOx, Dust

○
○
○
○
○
○
○

Variable pressure regulation of ovens during the coking process (EU21
BAT)

22
23
24
25

/0.01[30%] (N)○Coke making

16
17
18
19

/0.01(S), 30%(S)

○
○

○

○
○
○
○

○

19.5

/0.18

Odor

51

Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry
Expected Effect of Technologies Introduction[*3]

Technologies
Reference[*2]No

Title of Technology (SOACT base）[*1]

EU- EPASOACT NEDOBAT BACT

46 Slag heat recovery (EPA-BACT)○48 Blast Furnace – Increase Blast Furnace Top Pressure (>0.5 Bar Gauge)
49 Improvement of combustion in hot stove (EPA-BACT)○

50 Blast Furnace Heat Recuperation○

51 Optimized Blast Furnace Process Control with Expert System○

Alternative Ironmaking: Direct Reduction (DRI/HBI) and Direct
52
Smelting○

54 Direct Reduction Processes
55 Coal Based Rotary Hearth Furnace Type Ironmaking Process [*4]56 Paired Straight Hearth Furnace
57

Coal and Lump Ore Based Smelting-Reduction Type Ironmaking
Process [*4]58 Finex Process
59 Rotary Kiln Direct Reduction
60 Coal and Fine Ore Based DRI/HBI Production Process [*5]GJ/tof product

○

○

○

7.8(S)○

24.4/0.08, 0.08(S),0.126(N)
/0.4

○
○

○
○
○

○

○
○
○

○

Natural Gas Based Zero-Reforming DRI/HBI Production Process using
Fine Ore [*4]○62Coal Synthesis Gas and Lump Ore/Pellet Based Shaft Furnace TypeDRI/HBI Production Process [*4]○63

Natural Gas and Lump Ore/Pellet Based Shaft Furnace Type DRI/HBI
Production Process with CO2 Removal System [*4]○64 High-efficiency cupola (NEDO)○○

65 On-line Feedback Analyzer for Efficient Combustion [*4]○ProVision Lance-based Camera System for Vacuum Degasser - Real66
time Melt Temperature Measurement○

67 Hot Metal Pretreatment

○

68
69
70
71

○
○
○

○
○

○

○
○

12.0(N)/0.13(N)○○46
79.8(N)/0.92/0.84(N)○

0.51

0.003/

○

17.6

0.11/

○

23.5

0.14/

○

35.2

0.22, 0.126(N)/

○

35.3

0.44/-0.7

85 Twin-shell DC with scrap preheating (EPA-BACT)

○

11.1

0.07/

86 Bottom stirring/stirring gas injection (EPA-BACT)87 Eccentric bottom tapping on existing furnace (EPA-BACT)

○
○

11.7

0.07/

8.8

0.05/

88 Post-combustion of the flue gases (EPA-BACT)89 Engineered refractories (EPA-BACT)
90 Adjustable speed drives (ASDs) (EPA-BACT)○○○91 Transformer efficiency—ultra-high power transformers (EPA-BACT)○

Programmed and efficient ladle heating (EPA-BACT)
Increase Thermal Efficiency by Using BOF Exhaust Gas as Fuel
Use Enclosures for BOF
Control and Automization of Converter Operation
72 OG-boiler System (Non-combustion)/Dry-type Cyclone Dust Catcher
73 Exhaust Gas Cooling System (Combustion System)
74 Converter gas recovery device (NEDO)

75

Laser Contouring System to Extend the Lifetime of BOF Refractory
Lining76 BOF Bottom Stirring

○

○

○
○

○

77 VSD on ventilation fans (EPA-BACT)

78
79
80

81
82
83

84

Dust hot briquetting and recycling with recovery of high zincconcentrated pellets for external reuse (EU-BAT)
Elimination of Radiation Sources in EAF Charge Scrap
Improved Process Control (Neural Networks)
Hot DRI/HBI Charging to the EAF
Oxy-fuel Burners/Lancing
Scrap Preheating
New scrap-based steelmaking process predominantly using primaryenergy92 Control and Automation for EAF Optimization

52

kg- CO2/tof product○61

Steelmaking

Energy Savings(Electricity/ Fuel)○

47 Blast Furnace – Increase Hot Blast Temperature (>1100 Deg C)

53 Smelting Reduction Processes

CO2
Reduction

○
○
○

○
○
○

○

○

○

○

○

0.036/
0.05/
10

0.06/

Co-benefits(Reduction of
Water, Dust,
SOx, etc.)Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry
Expected Effect of Technologies Introduction[*3]

Technologies
Reference[*2]No

Title of Technology (SOACT base）[*1]

93 Slag Foaming, Exchangeable Furnace and Injection Technology
94 Airtight operation (EPA-BACT)
95

Exhaust Gas Treatment Through Gas Cooling, Carbon Injection andBagfilter Dedusting

96 Ecological and Economical Arc Furnace [*4]EU- EPASOACT NEDOBAT BACT○○○

101 Strip Casting Technology [*4]102 Thin Slab Casting and Hot Rolling
103 Hot Charging to Reheat Furnace of Rolling Mills
104 Near net shape strip casting (EU-BAT)
105 Near net shape casting - strip (EPA-BACT)

Recycling and Waste Reduction

○
○
○
○

○

0.02/

○
○

728.8

0.64/3.5/20MLwater/day(S)

22.8(S)/1400TJ/y(S)

Water
Dust
Dust
Dust
Dust
SOx

20-30%(S) /55,069t/y(S)(assessments
139)

993TJ/y(S)(assessments 139)/

3,022t/y(S)(assessments
36)

53TJ/y(S)(assessments 36) /273,638t/y(S)(assessments
225)

5375TJ/y(S)(assessments
225)/22％(S)1,472,115t/y(S)(assessments
306)

20148TJ/y(S)(assessments 306)/○

1.5

42％(S), 0.02/○

16.2-20(N)/20-50％(S),0.17-0.21(N)Air leak

○

○

119

Process Heating Assessment and Survey Tool – Identify Heat
Efficiency Improvement Opportunities○

120

Quick Plant Energy Profiler – First Step to Identify Opportunities forEnergy Savings○

124 Techniques to improve heat recovery (EU-BAT)

1.1

○

○

123 Regenerative Burner Total System for reheating furnace [*5]

0.72/

○

Fan System Assessment Tool – Efficiency Enhancement for Industrial
Fan Systems

Inverter (VVVF; Variable Voltage Variable Frequency) Drive forMotors [*4]DXN, Dust,
Noise

○

116

122

0.86/t-steel
0.32, 0.11(N)/○○121 Steam System Tools – Tools to Boost Steam System Efficiency

70.1
52.9

○

○

Combined Heat and Power Tool – Improved Overall Plant Efficiency
and Fuel Use

MotorMaster+ International – Cost-Effective Motor System Efficiency
Improvement
NOx and Energy Assessment Tool – Reduced NOx Emissions and118
Improved Energy Efficiency

1.5

○
○

115

117

77

○

Bag filter – combined or integrated reduction of solid and gaseous
pollutants (EU-BAT)

AIRMaster+ Software Tool – Improved Compressed Air System
114
Performance

0.07/
0.36/

○

108 Pressurization-type Steam Aging Equipment for Steel Slag
109 EAF slag processing (EU-BAT)
110 Treatment of high alloyed and stainless steel EAF slags (EU-BAT)
111 Rotary Hearth Furnace Dust Recycling System

Common Systems

10.6

○
○
○

○
○

113 Auditing Rotary Machines for Pump Efficiency

GJ/tof product○106 Reducing Fresh Water Use
107 Slag Recycling

112

kg- CO2/tof productCo-benefits(Reduction of
Water, Dust,
SOx, etc.)

DXN, Dust○○

100 Efficient caster ladle/tundish heating (EPA-BACT)

Casting

Energy Savings(Electricity/ Fuel)○○

97 Waste Heat Recovery from EAF
98 DC arc furnace (NEDO)
99 Shaft-type Continuous EAF [*4] (EPA-BACT)

Ladle Refining and Casting

○
○

CO2
Reduction

○

○

○

○

○

○

○

NOx

○

53

Table Full List of Technologies for CO2 Emission Reduction and Energy Saving in World Steel Industry
Expected Effect of Technologies Introduction[*3]

Technologies
Reference[*2]No

Title of Technology (SOACT base）[*1]

General Energy Savings & Environmental
Measures

CO2
Reduction

Energy Savings(Electricity/ Fuel)kg- CO2/tof productGJ/tof product○11.4(S)

0.01/0.12[0.5%](S),
0.11○

56.1(S)

1.1(S), 0.35/0.03

EU- EPASOACT NEDOBAT BACT

Co-benefits(Reduction of
Water, Dust,
SOx, etc.)○

125 Energy Monitoring and Management Systems○

126 Cogeneration (include Gas Turbine Combined Cycle (GTCC))
127 Technology for Effective Use of Slag
128 Hydrogen Production
129 Carbonation of Steel Slag
130 By-product generator set (NEDO)

○
○
○
○

○
○
○

340(S)○
1-7%(S)○○

Ironworks by-product gas, single-fuel-firing, high-efficiency,○
combined generator set (NEDO)Management of steam traps in steam piping and drain water recovery
1.5GJ/y(N)132○/1.5tWater/h](N)(NEDO)
Power recovery by installation of steam turbine in steam pressure
47,652GJ/y(N) /0.8t133○
steam/h(N)reducing line (NEDO)Management of Compressed Air Delivery Pressure Optimization [*4]285MW/h/y(N) /134○(NEDO)/840GJ/y(N)135 Improving thermal insulation in industrial furnace (NEDO)○
35.7
0..02/0.43
136 Preventive Maintenance (EPA-BACT)○[*1] Description within ( ) indicates the technologies reference name. The title without ( ) refers to SOACT.
[*2] SOACT; The State–of-the-Art Clean Technologies (SOACT) for Steelmaking Handbook (2nd Edition, 2010)
NEDO; Japanese Technologies for Energy Savings/GHG Emissions Reduction《2008 Revised Edition》
EU-BAT; Best Available Techniques (BAT) Reference Document for Iron and Steel Production (Draft version, 24 June 2011)
EPA-BACT; Available and Emerging Technologies for Reducing Greenhouse Gas Emissions from the Iron and Steel Industry (2010)[*3] Referred to EPA-BACT (pp.9-12), SOACT (S), and NEDO (N). In the case of EPA-BACT, there is no "( )" at the end of the value.
[*4] Arranged title after replacing trademark or trade name with technical terms[*5] Arranged in a comprehensible title

131

54

Water
Steam

ANNEX 2.

Technologies for Blast Furnace
No

Title of Technology

Technology Description

CO2
Reduction
kg- CO2/tof productExpected Effect of Introduction
Electricity
Fuel
Savings
Savings
GJ/t
GJ/t
of productof productCo-benefits(Reduction of
Water, Dust,
SOx, etc.)

Sintering1

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

This device recovers the sensible heat in the hot air with temperature of 250℃ to 450℃ from a sinter cooler.
The 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

23.8

―

0.25

SOx,
NOx,
Dust

2

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

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.

16.9

22.1
kWh/tsinter

0.245

―

0.46

―

0.010

―

97.5/tcoke

1.47/tcoke

1.2/t-coke―

3

High Efficient (COG) Burner in
Ignition Furnace for Sinter Plant

The multi-slit burner is designed to form a successive and uniform frame along a pallet width direction in theignition furnace. It consists of fuel exhaust nozzles and a slit-like burner 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 the frame. By lining up the burner block, theframe 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.

Cokemaking

4

Coke Dry Quenching

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 coolingchambers by counter-currently circulating an inert gas media in a closed circuit consisting of1) cooling chamber 2) dust collecting bunker 3) waste heat boiler 4) dust cyclones 5) mill fan6) blowing device (to introduce the cold air from the bottom) 7) circulating ducts8) Capacity ;The nominal capacity of a typical CDQ plant is less than 100 t/h/chamber.(EU-BAT)
260t/h(China/Shougang Jingtang/NSC-ENG)

5

Coal Moisture Control

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 the heat content of the coke oven gas or other waste heatsources.[SOACT]Generally, low-pressure steam is used as the humidity control heat source.[NEDO]

27.5/tcoke―

0.3/t-coke―

25.0/t-PI

0.49/t-PI――

Ironmaking

6

Top Pressure Recovery Turbine

This system generates electric power by employing blast furnace top gas to drive a turbinegenerator. Afterthe blast furnace gas is used in power generation, it is used as a fuel in iron and steel manufacturing
processes. This technology is a method of generating power by employing this heat and pressure to drive aturbinegenerator. 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 isremoved by Venturi scrubbers in the wet method and by a dry-type dust collector in the dry method.

7

Pulverized Coal Injection (PCI) System

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).

212/t-PI―

2.33/t-PI(at 200kg
coal inj.)―

8

Hot Stove Waste Heat Recovery

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.

7.8/t-PI―

0.08/t-PI―

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.)

79.8/t-CS―

0.84/t-CS―

This equipment is a high-efficiency (47.5%, HHV Base) combined generator set using the by-product gas
produced during iron and steel manufacturing process as the fuel.
This equipment is an iron and steel by-product gas fired combined generator set, in which the gas turbine isoperated by high-temperature gas (1,300℃) generated by mixing the blast furnace gas with the coke ovengas to be gas with a heat amount of 4,400kJ/m3N and burning it after the pressure is increased to about
1.4MPa. At the same time the steam turbine is operated by the steam generated by directing the hightemperature (approx. 550℃) gas discharged from the gas turbine to the exhaust heat recovery boiler.

56.1/t-CS

1.1/t-CS――

Dust recycling in the rotary hearth furnace (RHF) was applied at Nippon Steel’s Kimitsu Works in 2000.
The dust and sludge, along with iron oxide and carbon, are agglomerated into shaped articles and the iron
Rotary Hearth Furnace Dust Recycling oxide is reduced at high temperatures. Zinc and other impurities in the dust and sludge are expelled and11exhausted once into off-gas.
SystemThe exhaust gas containing zinc is cooled using a boiler and recuperator and then, the secondary dust
containing condensed zinc is collected in a precipitator.

22.8/t-PI―

0.21/t-PI

Dust

Steelmaking
9

Converter Gas Recovery device

General Energy Savings & Environmental Measures

10

Cogeneration (include Gas Turbine
Combined Cycle (GTCC))

Recycling and Waste Reduction

57

ANNEX 3.

59

60

Introduction
Japan is offering various financial support programs aiming at promoting diffusion of Japanesesuperior technologies and products in other countries, especially in the area where difficulties of
securing funds exist. The financial support offered by Japan includes:
Demonstration Project (NEDO)Export Loans (JBIC)

GREEN (JBIC) and etc.

Though it is expected that by mobilizing those financial support programs, in order tocontribute further diffusion of energy saving, environmental protection and recycling
technologies in steel industry, detailed policies are currently under discussion.

Demonstration Project (NEDO)
The purpose of New Energy and Industrial Technology Development Organization (NEDO)’s“Demonstration Projects” is to demonstrate the effectiveness of advanced Japanese clean energy
and environmental technologies through the introduction of such technologies in overseas
countries.
Under the Demonstration Project scheme, costs are shared between Japan and the host country.
In executing the Demonstration Project, with focus on technologies and systems in which Japanis strong, roles are shared with government of host country and related organization consideringneeds of government and industry of host country.

Demonstration Project consists of three projects namely “Feasibility Study (F/S)”, “Model
Project” and “Follow-up Activities”.

Feasibility Study (F/S)–

Verifying feasibility of the project.

Model Project–

Actually bringing in Japanese technologies and systems and verifying effect of thosetechnologies and systems as well as verifying new business model.

61Follow-up Activities–

Promoting diffusion of verified technologies and systems and collecting information forformation of new projects.

Export Loans (JBIC)
Japan Bank for International Cooperation (JBIC)’s “Export Loans” is provided to overseas
importers and financial institutions to support finance exports of Japanese machinery,equipment and technology mainly to developing countries.
In particular, products such as marine vessels, power
generation facilities and other types of plant equipment
incorporate a large amount of advanced technology, andtheir export contributes to enhancing the technological
base

of

Japaneseindustries.

Further,Japanese

shipbuilding and plant facilities industries have a broad
range of supporting industries including SMEs producing
parts and components. Export loans are also available todeveloped countries in eligible sectors.

62

GREEN (JBIC)
Japan Bank for International Cooperation (JBIC)’s “GREEN” (Global action for Reconciling
Economic growth and ENvironmental preservation) is a scheme which allows JBIC to support
for projects undertaken in developing countries that are having a favorable impact on thepreservation of the global environment. Under the GREEN scheme JBIC finances projects
aimed at preserving the global environment, such as projects that significantly reducegreenhouse gas (GHG) emissions.

Joint Crediting Mechanism (JCM)
The JCM is possible win-win scheme for both of Japan and host country in terms of low-carbon
technologies transfer and GHG emission reduction. The JCM facilitates diffusion of leading low
carbon technologies, products, systems, services, and infrastructure as well as implementationof mitigation actions, and contributing to sustainable development of developing countries. The
JCM scheme appropriately evaluate contributions to GHG emission reductions or removals fromJapan in a quantitative manner, by applying measurement, reporting and verification (MRV)
methodologies, and use them to achieve Japan’s emission reduction target. The JCM contributes
to the ultimate objective of the UNFCCC by facilitating global actions for GHG emission
reductions or removals, complementing the CDM.

63

64

ANNEX 4.
EXPECTED EFFECTS IN EACH
ASEAN COUNRY

65

66

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 costin Japan.



By using plant costs and energy prices, profit of operation and simple pay-backtime are calculated for each ASEAN country in the sheet of "Expected effects ineach ASEAN country". This calculation suggests that when 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 factorof electricity in each country and the common value of CO2 emission rate from fuel(63.1 kg-CO2/GJ).

Energy price, plant cost, and CO2 emission factor in ASEAN countries
Electricity pricefor industry use1)(US$/kWh)

Fuel gas pricefor industry use1)(US$/GJ)

Plant costindex2)(Japan = 100.0)

CO2 emission
factor3)(ton-CO2/MWh)Thailand

0.097

14.37

82.2

0.5472Indonesia

0.090

7.17

76.3

0.7577

Vietnam

0.064

23.81

69.9

0.5638

Philippines

0.130

25.79

77.4

0.5109

Malaysia

0.100

5.67

85.9

0.6681

Singapore

0.147

50.00

111.6

0.4862

Japan

0.113

20.22

100.0

0.4960Country

1) JETRO website (2016), fuel gas is assumed as LPG
2) Japan Machinery Center for Trade and Investment (2016.3)
3) Average of combined margin from CDM projects, IGES website (2016.3.28)

67

Expected effects in Thailand, Indonesia and Vietnam
ThailandIndonesia

Preconditions

ID

Title of technology

Preconditions

0.5472CO2 emission factor (ton-CO2/MWh) 1)

0.7577CO2 emission factor (ton-CO2/MWh) 1)

Electricity price (US$/kWh)

2)

0.097

Electricity price (US$/kWh)

2)

0.090

Electricity price (US$/kWh)

2)

0.064

Fuel gas price

2)

14.37

Fuel gas price

2)

7.17

Fuel gas price

2)

23.81

CO2 emission factor (ton-CO2/MWh) 1)

No.

Vietnam

Preconditions(US$/GJ) (LPG)(US$/GJ) (NG)0.5638(US$/GJ) (LPG)

CO2
reduction

Profit or 3)
Operation cost

Assumedinvestment
cost 4)

Pay backtime

CO2
reduction

Profit or 3)
Operation cost

Assumedinvestment
cost 4)

Pay backtime

CO2
reduction

Profit or 3)
Operation cost

Assumedinvestment
cost 4)

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)High temperature continuous
scrap preheating EAF

1

A-1

2

Medium temperature batch
A-2
scrap preheating EAF

3

A-3

High efficiency oxy-fuelburner/lancing for EAF

82.08

14.55

31.24

4.3

113.66

13.50

28.99

4.3

84.57

9.60

26.56

5.5

21.89

3.88

8.22

4.2

30.31

3.60

7.63

4.2

22.55

2.56

6.99

5.5

7.82

1.39

1.69

2.4

10.84

1.29

1.56

2.4

8.06

0.92

1.43

3.1

4

Eccentric bottom tapping
A-4(EBT) on existing furnace

8.21

1.46

3.29

4.5

11.37

1.35

3.05

4.5

8.46

0.96

2.80

5.8

5

Ultra high-power transformer
A-5
for EAF

8.21

1.46

4.65

6.4

11.37

1.35

4.32

6.4

8.46

0.96

3.96

8.2

6

Optimizing slag foaming in
A-6
EAF

3.28

0.58

1.23

4.2

4.55

0.54

1.14

4.2

3.38

0.38

1.05

5.5

7

Optimized power control for
A-7
EAF

8.21

1.46

2.06

2.8

11.37

1.35

1.91

2.8

8.46

0.96

1.75

3.6

8

Operation support system with
A-8
EAF meltdown judgment

3.28

0.58

2.06

7.1

4.55

0.54

1.91

7.1

3.38

0.38

1.75

9.1

9

Low NOx regenerative burner
A-9
system for ladle preheating

12.62

2.87

0.33

0.2

12.62

1.43

0.31

0.4

12.62

4.76

0.28

0.1

10

A-10

Oxygen burner system forladle preheating

12.62

2.87

0.25

0.2

12.62

1.43

0.23

0.3

12.62

4.76

0.21

0.1

11

Waste heat recovery from
A-11
EAF

72.23

12.80

49.32

7.7

100.02

11.88

45.78

7.7

74.42

8.45

41.94

9.9

12

Energy saving for dedusting
A-12
system in EAF meltshop

3.28

0.58

0.66

2.3

4.55

0.54

0.61

2.3

3.38

0.38

0.56

2.9

13

A-13

Bottom stirring/stirring gas
injection

9.85

1.75

0.21

0.2

13.64

1.62

0.20

0.2

10.15

1.15

0.18

0.3

14

A-14 Induction type tundish heater

1.64

0.29

0.82

5.6

2.27

0.27

0.76

5.7

1.69

0.19

0.70

7.3

15

Scrap pretreatment with scrap
A-15
shear

10.94

1.94

3.12

3.2

15.15

1.80

2.90

3.2

11.28

1.28

2.66

4.2

16

Arc furnace with shell rotation
A-16
drive

17.51

1.94

4.93

5.1

24.25

1.80

4.58

5.1

18.04

1.28

4.19

6.6

B. Environmental Protection for Electric Arc Furnace

17

B-1

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

-

-

-

-

-

-

-

-

-

-

-

-

18

B-2

Floating dust control in EAF
meltshop

-

-

-

-

-

-

-

-

-

-

-

-

19

B-3

Dioxin adsorption by activatedcarbon for EAF exhaust gas

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

20

21
22

Dioxin adsorption by mixing
B-4 EAF exhaust gas with building
dedusting gas
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
EAF dust and slag recycling
system by oxygen-fuel burner

23

C-1

24

EAF slag agglomeration for
C-2
aggregate use

D. Energy Saving for Reheating Furnace
25
26
27
28
29

30

Process control for reheating
furnace
Low NOx regenerative burner
D-2 total system for reheating
furnaceHigh temperature recuperator
D-3
for reheating furnace
D-1

Fiber block for insulation of
D-4
reheating furnace
Air conditioning by absorption
D-5 type refrigerating by using
reheating furnace exhaust gas
D-6

Induction type billet heater for
direct rolling

3.16

0.72

2.06

5.7

3.16

0.36

1.91

10.6

3.16

1.19

1.75

2.9

11.93

2.72

6.58

4.8

11.93

1.36

6.10

9.0

11.93

4.50

5.59

2.5

6.31

1.44

1.23

1.7

6.31

0.72

1.14

3.2

6.31

2.38

1.05

0.9

2.46

0.56

1.23

4.4

2.46

0.28

1.14

8.2

2.46

0.93

1.05

2.3

1.64

0.29

0.74

5.1

2.27

0.27

0.69

5.1

1.69

0.19

0.63

6.6

113.38

16.96

0.82

0.10

121.80

6.80

0.76

0.2

114.05

31.96

0.70

0.04

E. Common systems and General Energy Savings
31

E-1

Inverter (VFD; Variable
Frequency Drive) drive formotors

-

-

-

-

-

-

-

-

-

-

-

-

32

E-2

Energy monitoring andmanagement systems

-

-

-

-

-

-

-

-

-

-

-

-

E-3

Management of compressed
air delivery pressure
optimization

-

-

-

-

-

-

-

-

-

-

-

-

33

68

Expected effects in Philippines, Malaysia and Singapore
Philippines

Malaysia

Preconditions

ID

Title of technology

Preconditions

0.5109CO2 emission factor (ton-CO2/MWh) 1)

0.6681CO2 emission factor (ton-CO2/MWh) 1)

Electricity price (US$/kWh)

2)

0.130

Electricity price (US$/kWh)

2)

0.100

Electricity price (US$/kWh)

2)

0.147

Fuel gas price

2)

25.79

Fuel gas price

2)

5.67

Fuel gas price

2)

50.00

CO2 emission factor (ton-CO2/MWh) 1)

No.

Singapore

Preconditions(US$/GJ) (LPG)(US$/GJ) (NG)

0.4862(US$/GJ) (NG)CO2
reduction

Profit or 3)
Operation cost

Assumedinvestment
cost 4)

Pay backtime

CO2
reduction

Profit or 3)
Operation cost

Assumedinvestment
cost 4)

Pay backtime

CO2
reduction

Profit or 3)
Operation cost

Assumedinvestment
cost 4)

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)High temperature continuous
scrap preheating EAF

1

A-1

76.64

19.50

29.41

3.0

100.22

15.00

32.64

4.4

72.93

22.05

42.41

3.8

2

Medium temperature batch
A-2
scrap preheating EAF

20.44

5.20

7.74

3.0

26.72

4.00

8.59

4.3

19.45

5.88

11.16

3.8

3

High efficiency oxy-fuelA-3burner/lancing for EAF

7.31

1.86

1.59

1.7

9.55

1.43

1.76

2.5

6.95

2.10

2.29

2.2

4

Eccentric bottom tapping
A-4(EBT) on existing furnace

7.66

1.95

3.10

3.2

10.02

1.50

3.44

4.6

7.29

2.21

4.46

4.0

5

Ultra high-power transformer
A-5
for EAF

7.66

1.95

4.38

4.5

10.02

1.50

4.86

6.5

7.29

2.21

6.32

5.7

6

A-6

Optimizing slag foaming in
EAF

3.07

0.78

1.16

3.0

4.01

0.60

1.29

4.3

2.92

0.88

1.67

3.8

7

Optimized power control for
A-7
EAF

7.66

1.95

1.94

2.0

10.02

1.50

2.15

2.9

7.29

2.21

2.79

2.5

8

Operation support system with
A-8
EAF meltdown judgment

3.07

0.78

1.94

5.0

4.01

0.60

2.15

7.2

2.92

0.88

2.79

6.3

9

A-9

Low NOx regenerative burnersystem for ladle preheating

12.62

5.16

0.31

0.1

12.62

1.13

0.34

0.6

12.62

10.00

0.45

0.1

10

Oxygen burner system for
A-10
ladle preheating

12.62

5.16

0.23

0.1

12.62

1.13

0.26

0.5

12.62

10.00

0.33

0.1

11

Waste heat recovery from
A-11
EAF

67.44

17.16

46.44

5.4

88.19

13.20

51.54

7.8

64.18

19.40

66.96

6.9

12

Energy saving for dedusting
A-12
system in EAF meltshop

3.07

0.78

0.62

1.6

4.01

0.60

0.69

2.3

2.92

0.88

0.89

2.0

13

Bottom stirring/stirring gas
A-13
injection

9.20

2.34

0.20

0.2

12.03

1.80

0.22

0.2

8.75

2.65

0.29

0.2

14

A-14 Induction type tundish heater

1.53

0.39

0.77

4.0

2.00

0.30

0.86

5.7

1.46

0.44

1.12

5.1

15

Scrap pretreatment with scrap
A-15
shear

10.22

2.60

2.94

2.3

13.36

2.00

3.26

3.3

9.72

2.94

4.24

2.9

16

Arc furnace with shell rotation
A-16
drive

16.35

2.60

4.64

3.6

21.38

2.00

5.15

5.2

15.56

2.94

6.70

4.6

B. Environmental Protection for Electric Arc Furnace

17

B-1

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

-

-

-

-

-

-

-

-

-

-

-

-

18

B-2

Floating dust control in EAF
meltshop

-

-

-

-

-

-

-

-

-

-

-

-

19

B-3

Dioxin adsorption by activatedcarbon for EAF exhaust gas

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

20

21
22

Dioxin adsorption by mixing
B-4 EAF exhaust gas with building
dedusting gas
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
23

C-1

EAF dust and slag recycling
system by oxygen-fuel burner

-

-

-

-

-

-

-

-

-

-

-

-

24

C-2

EAF slag agglomeration for
aggregate use

-

-

-

-

-

-

-

-

-

-

-

-

D. Energy Saving for Reheating Furnace
25
26
27
28
29

30

Process control for reheating
furnace
Low NOx regenerative burner
D-2 total system for reheating
furnaceHigh temperature recuperator
D-3
for reheating furnace
D-1

Fiber block for insulation of
D-4
reheating furnace
Air conditioning by absorption
D-5 type refrigerating by using
reheating furnace exhaust gas
D-6

Induction type billet heater for
direct rolling

3.16

1.29

1.94

3.0

3.16

0.28

2.15

15.1

3.16

2.50

2.79

2.2

11.93

4.87

6.19

2.5

11.93

1.07

6.87

12.8

11.93

9.45

8.93

1.9

6.31

2.58

1.16

0.9

6.31

0.57

1.29

4.5

6.31

5.00

1.67

0.7

2.46

1.01

1.16

2.3

2.46

0.22

1.29

11.7

2.46

1.95

1.67

1.7

1.53

0.39

0.70

3.6

2.00

0.30

0.77

5.2

1.46

0.44

1.00

4.6

111.93

32.20

0.774

0.05

118.22

4.22

0.86

0.41

110.94

66.62

1.12

0.03

E. Common systems and General Energy Savings
31

E-1

Inverter (VFD; Variable
Frequency Drive) drive formotors

-

-

-

-

-

-

-

-

-

-

-

-

32

E-2

Energy monitoring andmanagement systems

-

-

-

-

-

-

-

-

-

-

-

-

E-3

Management of compressed
air delivery pressure
optimization

-

-

-

-

-

-

-

-

-

-

-

-

33

69

Comments
1) Average of combined margin from CDQ projects (source : IGEA website 2016.3)
2) Source : JETRO website “ http://www.jetro.go.jp/world/search/cost/ “
3) Operation cost for Environment Protection or Material Recycle is described as minas (-)4) Investent cost is assumed by multipying following factors to the assumed cost in Japan. (source : Japan Mac
Thailand
0.822
Indonesia
0.763
Vietnam
0.699
Philippines
0.774
Malaysia
0.859
Singapore
1.1165) Assumed annual production to calculate pay-back time is 500,000 ton/y (refer to sheet"TCL_all")6) 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

70

71