Direction of Steel Industry Development against a Low ... Nakano_E.pdf · Direction of Steel...

N.NAKANO SUMITOMOMETAL 0

Asia Steel Forum 2011

Naokazu NAKANO (Sumitomo Metal Industries,Ltd.)

Shanghai, September 26-28,2011

Direction of Steel Industry Development

against a Low-carbon Backdrop Production technology view point

Chair for Energy Technology Committee

Of

The Japan Iron and Steel Federation


Steel industry is CO2 intensive and thirty percent of CO2 emission of

industry is from steel. Global warming is one of the most important issue

for every steel producer all over the world

Steel industry has achieved significant improvement in energy intensity

through technology development and brought to reduction in CO2

emission intensity of steel production

The improvement rate is reducing due to maturity of the technologies,

while steel industry recognizes the necessity of innovative steel

production technology.

This presentation will explain current efforts of save energy and CO2

emission reduction of steel production process, and then innovative

technology mainly about Japanese steel industry

And finally the importance of deployment of existing state of the art

technologies coupled with continuous effort of technological improvement

Outline


0

5

10

15

20

25

30

35

40

0

50

100

150

200

250

300

350

400

1750 60 70 80 90 1800 10 20 30 40 50 60 70 80 90 1900 10 20 30 40 50 60 70 80 90 2000 02 03 04 05 06 07

Gas,Others

Oil

Coal

CO2 concentration

ＣＯ２ emission from fuel combustion and ＣＯ２ concentration in the

air

Source: CDIAC「Global Fossil-Fuel Carbon Emissions」

CO2 emission

[ bn ton-CO2 ] CO2 Concentration

[ ppm ]

CO2 concentration (ppm)

World total CO2 emission from

fuel combustion

30.7

384ppm

(2007)

[year]

Diverse discussion have been conducted on global warming

CO2 concentration has increased as CO2 from fuel combustion

increased

Gas, Others

Oil

Coal

GHG

GHG

sunlight

sunlight

earth

earth

IR

IR


UN Negotiation on Climate Change / COP

COP13 (Bali) Indonesia Dec.2007

COP15 (Copenhagen) Denmark Dec.2009

COP16 (Cancun) Mexico Dec.2010

COP17 (Durban) South Africa Dec.2011

COP18 Korea or Qatar Dec.2012

COP19 ? Dec.2013

COP13 :Bali Action Plan was agreed to establish new international framework to combat global warming by COP15

COP15, COP16 : New beyond Kyoto framework was not finalized. But Cancun agreement include core elements of major areas such as REDD, finance and technology in a balanced manner

More discussion is required to establish

“new frame work”

While, each participating country share

the view that reducing GHG emission is

vital for decreasing the risk of global

warming

Ky

oto

Pe

rio

d

2008 ｜

2012

Po

st K

yo

to


製造・建設

20%

Transport 23%

Electricity 41%

Others11%

その他エネル

ギー5%

CO2 Emission in the World

Source: Energy technology perspective(2010)

CO2 emissions from fuel

combustion by sector CO2 emissions in industry by sector

Steel

30%

Chemical

17%

Aluminum

2%

Cement26%

Paper-Pulp 2%

Others 23%

Other energy 5%

Industry-

Construction

20%

30%of CO2 emission from industry is originated from steel industry

Global warming is one of the most important issue for every steel producer

all over the world

Source: CO2 emissions from fuel combustion (2010 edition)


1.Steel production by scrap re-melting gives lower CO2 emission. However,

it is limited by scrap supply. - Life cycle of steel products are long (40–60 years or more)

- It is unrealistic to increase EAF route due to limitation on scrap supply as the figure shows

Therefore, steel production from iron ore ,BF-BOF route, will remain a main

process for decades.

Steel Production Process

Crude Steel production by process

BF-BOF

EAF

Hundred million ton

Crude Steel production / world

5% PA

1% up 100 million tons in

30 years

5-7% PA

source source CY CY


Coke is indispensable for iron making

by blast furnace

Coke as

Iron Making by Blast Furnace

Ｆｅ２Ｏ３＋３ＣＯ＝２ＦｅＯ＋３ＣＯ２

ＦｅＯ＋Ｃ＝Ｆｅ＋ＣＯ

１５０℃～２００℃

１２００℃～１４００℃

1500℃

Reducing agent

Spacer for air flow

Hot metal

1500℃

Hot metal

Hot air

Fe2O3 C 鉄鉱石コークス

BF-Gas

Cohesive zone


Reducing Agent Ratio and Energy intensity Improvement in Japan

300

350

400

450

500

550

600

650

1950 1960 1970 1980 1990 2000 2010

Distribution control High-pressure

operation

High-temperature blast Compound blast

Oil

Coke Rate

Pulverized coal

Reducing Agent Rate

RA

R [

kg

/t ]

100 98

89

80

100 95

90

50

60

70

80

90

100

110

1500

2000

2500

3000

1973 75 80 85 90 00 05

(PJ)

FY

(1973=100)

Energy consumption

(1990=100)

Energy intensity

Source：JISF note：Index of 1973FY～85FY are correction value based on 73FY production condition after 1990FY Voluntary action plan

Reducing agent ratio(RAR)

was improved but saturated in

1980s. But energy intensity

has been improved up to now.

Trends in Energy consumption and unit energy consumption

in the Japanese steel industry

Improved raw-material aspect


Environmental Protection & Energy – Saving technologies in steel works

Common Efforts Lightning Optimization : Na lamp etc. Steam drain reduction

Improvement of LDG recovery VVVF for OG –IDF and blowers Heat Insulation in Slab transfer Yard Optimization of blowers and pumps Hot Grinder Coolant pump optimization (downsizing, low-lift pump)

Continuous Caster

CMC(Coke Moisture Control) CDQ(Coke Dry Quenching) SCOPE21 Waste plastics

OG Boiler

Waste Heat Boiler

Recovery of exhaust heat from coolers

Hot Charging Direct Hot Charge Rolling

Coking Coal

PCI TRT HS Heat Recovery Dust recycle Waste plastics

Electric power plant

PCI BOF

○

blooms slabs

Hot rolling

Reheating furnace

Continuous Galvanizing Line

Automation of combustion control of individual coke

High efficiency power generation【ＡＣＣ・ＵＳ

Ｃ】

Leak Protection Blower Capacity Optimization Motor Speed Control SPME waste heat recovery

Pressure Balance Gas Recovery Blower optimization Sectionalized Dust Collector

Leak Protection Pressure Loss Minimization Heat Insulation

Replacement to High Efficiency Plant Efficiency improvements in Blowers and Compressors

CDCM Auxiliaries Optimization Replacement to AC Motors Coolant pump optimization (downsizing, low-lift pump)

Upgraded Cooling Water System (plunger pump, downsizing, low-lift pump) VVVF of Blowers and pumps Auxiliaries optimization

Slab yard heat insulation Efficiency increase in recuperate Remodeling Furnace Body Optimization of heating pattern Low temp Slab extract

High-Efficiency Continuous Annealing Process

Heavy Oil

By-product gas

BOF gas latent/sensible heat recovery

Regenerative Burner

Fuel

BOF gas (LDG) Oxygen

Electricity

Cold rolling

Iron Ore

Sintering

Coke Oven

COG BFG

Oxygen

Blast Furnace

Torpedo Car Blast

Blower


General Aspect of Technology Diffusion

Remarkable improvement in steel material yield and shorter process time,

continuous casting ratio is almost 100% in major steel making countries.

A lot of technology on continuous casting has been developed under hard

competition among steel producers.

Diffusion start point is different from country to country. But Diffusion rate in each

country is similar, 20 years for full penetration. Early start is important for faster

penetration of ‘new’ technology.

Continuous Casting rate

Source: worldsteel etc.

%

0

10

20

30

40

50

60

70

80

90

100

1974

1976

1978

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

2004

2006

JapanKor eaChi naW.GermanyFr anceUKFSUUSA

- Continuous Caster-

Ingot casting and continuous casting

Ingot Casting

Continuous Casting


Steel Production Process Technology Improvement Way

・Long period is required to develop , to materialize and to deploy new

technology throughout the industry even the developed technology is the

excellent one

・This is remarkable in case of steel industry because the steel works is

composed of many extremely large plants ・The energy efficiency improvement of the conventional BF-BOF process is

thought to be almost saturated in technological viewpoint . But innovative

technologies which improve the efficiency drastically are in R&D stage.

・Therefore, we have to conduct

and at the same time to conduct

in parallel.

－ Full deployment of existing commercialized excellent

technologies

－ Technology development including surrounding process like

by-product gas power generation, based on current BF-BOF

process

－ Innovative technology development


Improved energy intensity 1973-1990FY 1990-2005FY ～2020FY

CO2 reduction target

About 30％ 20％ 8.4％ Maximum reduction

potential3％

●Save energy activities has been strongly promoted triggered by “the Oil Shock” in1973

●Almost of all major producer finish providing the state of the art save energy technologies which gives highest energy efficiency to Japanese steel industry. But it means little save energy potential remains.

●Toward 2020, deployment of newly materialized technologies, which still have save energy potential, will be promoted coupled with steady save energy activity at site.

●Innovative development is required for future drastic decrease in CO2 emission from steel production process from iron ore. Then Japan has started new project called COURSE50.

Approach Direction of

improvement

Key technologies

1970’s－2000’s

～2020 2030～

Innovative technologies

Improving of

process

efficiency

Advantage of scale

continualization

New process

development

Upgrade automatic

control system

Efficiency power

equipment

Continuous caster,

Direct hot charge rolling,

Continuous annealing process,

PCI, ausforming, DC Electric Furnace,

AI control,

High- efficiency large inverter

Improvement in coke oven

efficiency

Improve efficiency of

equipment powered by

electricity(replace electricity

powered equipment at steel

mills with more efficiency)

COURSE50

Direction of improvement

CO2 emission reduction

Utilization of unused waste

heat

Key technologies

hydrogen reduction

CO2 separation

energy recovery from

unused waste heat

Increase the hydrogen in

the coke oven gas

Technologies to capture –

separate and recovery

Enhancemen

t of energy

recovery

Enhanced by-product gas recovery

Usage efficiency improvement

Enhanced sensible heat recovery

Enhanced pressure recovery

Large size gas holder, control the supply and

demand balance, High-efficiency turbine,

combined power generation, CDQ,

Regenerative Burner, low-temperature-heat

power generation systems, TRT

Higher efficiency for internal

and joint power generation

equipment

Increase the use of energy

conservation equipment

Material

Recycle

Recycling of

community waste

waste plastic, waste tire Increasing chemical

recycling

（waste plastic etc.）

Energy Efficiency Improvement/ Up to Now and Hereafter –Japan-


～2020

Coal Pre-treatment High performance

Coke Oven Coke Treatment

Advanced Coke Oven ≪SCOPE-21≫


～2020

From Kimitsu Cooperative Thermal Power Company

Power to grid

Gas Compressor

Gas Turbine Generator

Steam Turbine

BFG+COG Gas Filter

Gas Cooler

Combustion Chamber

Air Filter

Waste-heat Recovery Boiler

Cooling Water

LP Steam

MP Steam

HP Steam

Advanced Combined Cycle

・Exhaust gas from gas turbine is re-used for

generation of steam for steam turbine

・Technology to utilize “Lean gas/ BFG” has

been developed

Capacity : 300MW

Fuel : mixed BFG

(4.4MJ/Nm3)

Gas temp. : 1300deg.C

Efficiency : 47.5%

ACC(Advanced Combined Cycle) for Byproduct Gas


Methodology of Waste Plastic Utilization

～2020

Chemical Decomposition Process by Coke Oven

Coke Oven

40% COG

40% Oils

20% Coke

Power Plant

Fuel Cell (in future)

Plastic Materials Paints etc.

Reducing Agent for BF

Products and Reuses

Coking Chamber


Time Table of Technology Development

Phase 1 Step 1 (2008～12）

Phase 1 Step 2 (2013-17）

Phase 2

2008 2009 2010 2011 2012

2010 2020 2030 2040 2050

Phase 1 Step 1 (2008～12）

NEDO Project

0.6 2 –3 2 –3 2 – 3 2 – 3 (billion yen)

Coal is used to reduce iron ore in steelmaking process.

Even with enhanced energy-saving, emission of CO2 is unavoidable.

COURSE 50 aims at developing technologies to decrease CO2 emissions by approximately 30% through reduction of iron ore by hydrogen as well as capture – separation and recovery – of CO2 from blast furnace gas.

The initiative targets establishing the technologies by ca. 2030 with the final goal of industrializing and transferring them by 2050, taking advantage of renewing blast furnaces and relevant facilities.

1. Total Budget : approximately 10 billion yen (planned) 2. Term for R&D : Step 1 of Phase 1 for 5 years (Fy 2008 – Fy2012) 3. R&D Targets

(1) Development of technologies to reduce CO2 emissions from blast furnace (2) Development of technologies to capture - separate and recover - CO2 from blast furnace gas (BFG)

(CO2 Ultimate Reduction in Steelmaking Process by Innovative Technology for Cool Earth 50)

Innovative Steelmaking Process <COURSE 50>

Industrialization & Transfer


Sub Projects

1. Development of technologies to utilize hydrogen for the reduction of iron ore.

2. Development of technologies to reform coke oven gas (COG) through the amplification of

3. Development of technologies to produce coke for hydrogen reduction of iron ore.

4. Development of technologies to capture – separate and recover – CO2 from blast furnace gas (BFG).

5. Development of technologies to recover unused sensible heat.

6. Development of holistic evaluation technologies for the processes.

examples of simulating

hydrogen enriched gas

injection into blast furnace

<COURSE 50> Target/Sub Projects


～～ ℃

鉄鉱石

ＣＯ

ＣＯ２

(1) 高炉からのＣＯ２排出削減技術開発

カリーナサイクル

発電システム

BFG


Source：JFE Group ENVIRONMENTAL SUSTAINABILITY REPORT 2010]

Ferro-Coke Technology Development Outline

Improve the efficiency

of iron ore reduction

and decrease reducing

agent by Ferro-Coke

by JFE, NSC, SMI,

KSL


ＪＩＳＦ

1-ULCOS 1-JISF

1-COURSE50

2-POSCO

1-AISI

1- 2003 1-Canada

2- 2004

3- 2005

4- 2008

1- HIsmelt

3- Brazil

3- BSC

3- Australia

4- CSC

5- 2009

5- India

Participation in the CO2 Breakthrough Program

Objective： Established this program at worldsteel for the purpose of facilitating international cooperation so

the global steel industry can work on ways to achieve a dramatic reduction in CO2 emissions.

(Since 2003: Started with the participation of the EU, U.S., Canada and Japan.

Objective is to conduct efficient development activities by exchanging information among the

development programs in different countries and regions.

Development steps and framework for cooperation Phase I: Distribution of information about development programs in different countries and regions and exchange of opinions (2003-2008)

Phase II: Perform comparative evaluations of technology development activities and exchange information and encourage development

involving the following five themes.

1) CO2 separation and recovery, mainly for blast furnaces

2) CO2 separation and recovery based on smelting reduction

3) Hydrogen reduction

4) Biomass steelmaking

5) Molten electrolytic refining

The worldsteel CO2 Breakthrough Program


How to contribute toward CO2 mitigation in steel production?

The energy efficiency improvement of the conventional BF-

BOF process is thought to be almost saturated in technological

viewpoint . But energy saving potential by deploying these

technologies is large worldwide as a whole.

Newly constructed steel works at green field provides all state

of the art technologies worldwide. Steel industry is obliged to

do so.

But it is also the obligation to make full efforts to improve the

energy efficiency of existing plant by introducing the existing

state of the art technologies. Generally, so called “retrofit” is

more difficult to get sufficient return for investment but we have

to challenge.


:Large save energy/CO2 mitigation potential is expected by diffusion of these technologies

CO2 Mitigation Potential by technology diffusion (APP)

:Save energy technologies are well established and available

Widely acknowledged

0 10 20 30 40

BOF Gas sensible Heat Recovery

BOF Gas Recovery

Hot Stove Waste Heat Recovery

PCI

TRT

BFG Recovery

Sinter Waste Heat Recovery

COG Recovery

Coal moisture control

CDQ

5.17

10.13

0.86

3.65

5.42

36.10

5.22

36.09

5.39

20.89

SOACT million ton/year

Potential Total

129.0 million t-CO2/year

Estimation of current CO2 mitigation technical potential from steel industry of seven APP countries

APP Fourth Policy and Implementation Committee Meeting Gold Coast, Australia 19 May, 2009


Overview (GSEP)

Purpose:

• Encourage industrial facilities and commercial buildings to pursue

continuous improvements in energy efficiency

• Promote public-private partnerships for cooperation on specific

technologies or individual energy-intensive industry sectors

13 Participating Governments:

Canada Denmark European Commission Finland France India

Japan Korea Mexico Russia South Africa Sweden United States

CLEAN ENERGY MINISTERIAL PREPARATORY MEETING

UPDATE ON GLOBAL SUPERIOR ENERGY PERFORMANCE PARTNERSHIP (GSEP)

14 - 15 February 2011


Transition of APP into IPEEC/GSEP (Relation diagram)

《Chair》

〈Co-Chair〉

Cabinet ministers meeting（Co-Chair: Host country ＋USA）

Cool Roofs &

Pavements

etc 《USA》

Asia-Pacific Partnership on Clean Development and Climate (APP)

Secretariat ：U.S. Department of State

Secretariat : IPEEC（Paris）

IPEEC Policy Committee （Chair

USA）

Steel 《Japan 》

〈India〉

Cleaner

Fossil Energy

《 Australia

》

<China >

Aluminum

《 Australia

》

< USA>

Renewable Energy

and Distributed

Generation

《Canada》

< Australia >

Coal Mining

《 USA 》

< India >

Buildings and

Appliances

《 Korea 》

< USA >

Cement

《Japan》

〈Canada〉

Power Generation

and Transmission

《 USA 》

〈China〉

At the Clean Energy Ministerial in

Washington, D.C., on July 20th,

government and corporate leaders

announced a new public-private

partnership, Global Superior

Energy

Performance(GSEP).

他のタスクグループ

（現在６グループ）他のタスクグループ

（現在６グループ） Existing Task Groups

（six groups at

present. ）

Global Superior Energy

Performance Partnership （GSEP）

Steel 《Japan 》

Cement

《Japan》

Some TF would

be under IPEEC in

future, while other

international

frameworks can

be to consider.

International Partnership for Energy Efficiency Cooperation

（IPEEC）

Under exam

《adjustment 》 Under exam

《adjustment 》 Under exam

《adjustment 》

IPEEC Executive Committee （Chair

Japan ）

Policy and Implementation Committee (Chair USA)

CHP Power

《Japan》


:Save energy effect and investment cost of save energy technologies are well analyzed

:Deployment of currently available save energy technologies has been accomplished with return on the investment among Japanese steel industry.

:Cost and effect of save energy /CO2 emission reduction technology is often expressed by CO2 abatement cost curve as below. It must be noted that save energy technologies listed in APP SOACT handbook is in the range of “negative cost “. Steel industry can generally make profit through investment in these technologies in the negative cost range.

CO2 Emission Reduction by Existing Technologies

Example of

cost curve


Compact High

productivity

Innovation

Hot Metal

Advanced 2ndary

Refining

De-P converter

Revamping of steel Making Plant

従来

Bloom CC

25 Retrofit – Wakayama Steel Works of Sumitomo Metal Ind.

Advanced Pre-Treatment of Hot Metal

High Speed refining

Round

CC

Slab CC

De-C converter Previous

19min

New

9min

Oxygen flow (Nm3/ min)

(min

/ch

)


Material Flow Innovation Achieved by Technology Development

Shipping

pier

BF

New

Converter

Works

New Round

CC

New Pipe

Mill(Middle

size)

Before Round CC

Pipe Mill

Shipping

pier

BF

１km

Converter

works Blooming

mill

20.5km

8.5km

Before(1996) Innovation(2000) Improvement %

Energy Intensity 31.6 GJ 24.7 GJ 6.9 GJ ▲22%

CO2 Emission Intensity 2.76 t 2.16 t 0.61 t ▲22%

2007 Improvement %

1.83 t 0.93 ▲34%

Total effect

Innovation


Technological Development along with Deployment of Technology

Started 1974 1987 1988

Capacity

(t-coke/h)

56 75 110 118 150 180 175 200 190

Profile

Turbine type Wet radial

flow

Wet radial

flow

Wet axial

flow

Dry axial

flow

Pressure control Septum valve TRT TRT TRT

Generated electric power

From same amount of BFG

10,330KW

(100%)

13,773KW

(133%)

15,609KW

(151%)

20,605KW

(199%)

CDQ

TRT

Source: JISF 2006

Great development is often induced during deployment of new technology.


ＡＰＰ(Asia Pacific Partnership)/Outcome of Steel Taskforce

【SOACT Handbook】

64 state of the art

technology on save

energy and

environment control

from seven countries

are compiled

Environment：22

Save energy：42

【Energy Efficiency 】

【ＣＯ２Mitigation

potential】

Energy efficiency indicator

development

CO2 mitigation potential

estimation by diffusion of

save energy technology by

taking account of each

country circumstances

【Performance

Diagnosis】

Energy and

environmental survey

on selected sites by

experts

Actual saving

potential analysis in

detail

【Barrier

Analysis】

Technical,

financial, or

other barrier

analysis on

introduction

of the

technologies

CDQ

Theoretical CO2 mitigation potential estimated from the first diffusion survey.

ＣＯ２ Mitigation Potential（May , ２００９,）

0 10 20 30 40

BOF Gas sensible Heat …

BOF Gas Recovery

Hot Stove Waste Heat …

PCI

TRT

BFG Recovery

Sinter Waste Heat …

COG Recovery

Coal moisture control

CDQ

5.17

10.13

0.86

3.65

5.42

36.10

5.22

36.09

5.39

20.89

Theoretical reduction potential

0.13bnt/y


Global warming is one of the most important issue for energy intensive steel

industry all over the world

Steel industry has made excellent achievement to improve energy

efficiency and CO2 emission intensity by developing and materializing save

energy technologies

Large improvement potential exists by these technologies with negative

cost. Steel industry can generally make profit through investment in these

technologies and is responsible for introduce them.

International cooperation could accelerate the deployment. APP like

activity is vital for steel industry. GSEP is one of the vital candidate for this.

Innovative technology developments are conducted worldwide which

enable to reduce energy consumption or CO2 emission drastically. Since

long period is expected to achieve these developments, constant effort to

promote them is highly expected.

Conclusion


以下、予備

Thank You! 谢谢！ 감사합니다！ありがとうございます! Sumitomo Metal Industries, Ltd. Naokazu

NAKANO

September 27, 2011

Direction of Steel Industry Development against a Low ... Nakano_E.pdf · Direction of Steel...

Documents

Transcript of Direction of Steel Industry Development against a Low ... Nakano_E.pdf · Direction of Steel...