Overview and EE&C of Steel Industry in Japan

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Overview and EE&C of Steel Industry in Japan

November, 2006 Hideyuki TANAKA Program Leader, International Engineering Dept. The Energy Conservation Center, Japan
ECCJ 1

1. Recent status of Energy Conservation in Mini Mill Industry in Japan 2. EE & C Activities in EAF 3. EE & C Activities in CC 4. Energy Conservation in Rolling Mill Process 5. Transition of Total Energy Intensity (Crude oil equivalent) - Example ECCJ 2

(1) Trend of Crude Steel Production, Operation Status in Japan


kton EAF ratio = (EAF steel) / (All steel)

Converter EAF ratio EAF, Special steel Open hearth EAF, Ordinary steel

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(2) Energy Saving Technologies in Mini Mill Process


Decrease of Input Power Decrease of Heat Loss Scrap Scrap Preheater VVVF Bag Filter
Ladle & Tundish

EAF Regenerative Burner Furnace

Continuous Caster Decrease of Holding Time

Billet Heat insulator

DHCR (Direct Hot Charge Rolling)


Rolling Mill

Furnace Operation Rod, Bar & Coil

Continuous Rolling
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Type 1 Type 2

Connecting of Billet Connecting of Bar


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(3) Energy Use in Mini Mill Factory


(Products: Steel Bars for Concrete Reinforcement)
13% 10% 4% 52% 9% 12% Ratio

EAF (Power) EAF (Chemical ReactionO2OilOthers) Auxiliaries of Steel Making Shop (Power) Burner (Ladle+Tundish) Burner (Re-heating Furnace)
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Rolling Mill Shop (Power)

(1) Transition of Technical Development


(EAF-CC)
Period ~ 1976 1976~ 1978 1979~ 1980 1981~ 1984 Introduction of new Technologies Traditional operation method LF installation Burners on wall Furnace water cooling Wider water cool area High power factor operation Carbon injection SPH installation Oxygen rich operation (PSA) New casting machine EBT installation Installation of more wall burners Bottom stirring DC furnace (More than 20 fces) Aluminum arm, Slag detector Powder casting or nozzle casting Large tundish, EMS Mist cooling Ecoarc (Shaft furnace and continuous operation) Power Consum. Oxygen Tap-Tap m3N/t (kWh/t) Time (min) 176 147 560 497 10 12 Oil L/t --

3.2 2.8

110

390

20

95 85

345 325

28

2.3

1985~ 1988~ 2000

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1.8

63

Hot metal operation Night time operation Utilization of waste materials 200 6

2001~ 2006 ECCJ

(2) Trend in Operation Indices of EAF


Power Unit Consumption of EAF
Tap to Tap Time (min)

Tap to Tap Time

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Power Unit Consumption of EAF (kWh/t-good steel)


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(3) Energy Conservation Activities in EAF Process


1) Energy conservation in EAF shop
(EAF: Electric Arc Furnace (AC, DC)) a) Increase of input energy Enrichment of O2 According to above countermeasure Increase of Oil (Burner), Carbon, Low cost alloys (Aluminum ash, Bundle made from Can, etc. )
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b) Increase of efficiency in input energy


Power

Common (DC, AC ): VVVF control of electrode lifting Introduction of Inverter control system Foaming slag control in refining stage, etc. AC Al-arm, Reactor (in case of enough capacity of power station and high voltage operation), etc Other Post combustion (Shaft furnace), Supersonic lance, etc.
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c) Decrease of output energy


Increase of Heat size Decrease of Tap to Tap time and waiting time

of the time after tapping (from tapping to the start of scrap charge) Decrease of heat loss by slag Hot recycle of slag, Control of scraps dust, etc. Scrap preheating Shaft furnace with decreasing technology of dioxin

2) Others

Power saving in auxiliaries


VVVF control of dust collecting fan motor, etc.
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(4) Energy Balance-1


700 600 500 380 400 300 C-combustion 200 100 0 210 Metal oxidation 100 37 100 140 Slag Furnace loss Off gas 370

Energy (kWh/t)

Power

Metal

Metal oxidation
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Input

Output

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(5) Enriched Oxygen Operation (Example)


Melting Stage Melt down and Refining Stage Coke Slag Foaming Detector Coke

O2 O2 Manipulator / EBT Water Cooled Lance Fe + 1/2 O2 = FeO 1.15Mcal/kg-Fe FeO + C = Fe + CO - 0.68Mcal/kg-Fe C + 1/2 O2 = CO 2.2Mcal/kg-C
#1 Ch. Burner Oxygen Carbon 5.3kA 700V 700V 5.3kA 675V #1 Me. #2 Ch. #2 Me. Refining and Heating Tap

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Time (min) 12

(6) Influence of Oxygen and Reheat on Power Consumption

3 kWh/t

Oxygen 1m3N/t

(m3N/t)
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(7) Relation between Transformer Capacity and Tap to Tap Time of EAF
160 140

Tap to Tap Time (min)

120 100 80 60 40 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 14

Transformer Capacity / Charge Weight (MW/Ch-t)


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(8) Scrap Preheater


Several Types of Recent Scrap Preheater
Consteel
Effect: 45kWh/t
(Reported value)

Shaft Furnace
Effect: 70kWh/t
(Reported value)

Twin Shell Furnace


Effect: 30kWh/t
(Reported value)

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(9) Effect of VVVF


(Example of Power saving calculation)
(80t furnace) Without VVVF With VVVF 9700.85(min/60) 9700.85[111/60 = 960kWh/ch. + 0.85 310/60 + 0.753 49/60] = 520kWh/ch. 960/80 = 12kWh/t 520/80 = 6.5kWh/t 5.5kWh/t
Operation rate: 100% 85% 75%

Blower Motor of Direct Dust Collector (970kW) Power Consumption Difference

1 charge = 70 min: 11 + 10 + 49 min


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(10) Energy Control System


Standardized Operation and Reduction of Production Cost in EAF Melting Control
Power control Melting profile calculation Raw/Submaterial feed control Additional scrap charging & meltdown determination

Refining Control
Slag foaming guidance Thermal model calculation Metallurgical model calculation

Data Management Statistical data analysis


Operation tracking and reporting (Electricity & fuel: daily & monthly report)
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Other Functions Trend graph of kWh/t


Correlation between kWh & oxygen Etc.
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(1) EE&C Activities in CC


(1) Energy conservation in Ladle and CC Regenerative burner for ladle & tundish Matching of the productivity between EAF and CC (Continuous Casting) (2) Energy conservation after CC Billet heat insulating equipment DHCR (Direct Hot Charge Rolling), etc. Matching of the productivity between CC and Rolling Mill
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(2) Regenerative Burner for Ladle


(Same System for CC Tundish)
Exhaust Gas Exhaust Gas Switching Valve Fuel Gas 920Mcal/h Regenerator (Ceramics) Fuel Gas 600Mcal/h

Effect:
Fuel Reduction Ratio = 51%
[Condition] Ladle Capacity: 100 t Heating Period: 10 hours

Conventional
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Regenerative Burner
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(3) Billet heat insulating equipment


This equipment maintain the billet temperature in hot at waiting to the reheating furnace.
Steel Making Shop

Billet Yard Heat insulating Direct Hot Charge Rolling


600-800

Hot charge
200-600

Cold charge
20-200

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Reheating Furnace ( Hot rolling Mill Shop)

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(1) Transition of Technical Development


(Rolling Mill)
Period Introduction of new Technologies Regenerative burner DHCR (Direct Ht Charge rolling), and subsidiary furnace (Heat keeping furnace) Endless rolling Power Consum. (kWh/t) Oil L/t Oil reduction: 20~29% Oil reduction: 52%

1995~ 2001~ 2001~

2002~

Hot eddy current inspection

21 ECCJ

(2) Energy Conservation Measures in Rolling Mill Factory


(1) Matching of the productivity between CC and Mill (2) DHCR (Direct Hot Charge Rolling), etc. (3) Reheating furnace: Application of regenerative burner system (4) Energy saving of fluid machinery: Pump, Fan, Air Compressor, etc.

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(3) Application of Regenerative Burner


Regular Industrial Furnace
High temperature exhaust! Fuel Burner Exhaust

High-performance Industrial Furnace (1)


Metal type heat exchanger Exhaust

Blower
Burner

Recuperator
(metal)

Fuel

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Blower

Combustion air

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High-performance Industrial Furnace


Alignment of a pair of burners with a built-in ceramic storage heat exchanger, combustion and exhausting in turn, temperature preheated of combustion air Fuel switching valve

Burner

Regenerator (Ceramic)

Induced draft fan


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Switching valves for air supply & exhaust

Blower
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Merit of Regenerative Burner in Furnace Energy saving


Effect of high temperature combustion air over 1,000 (Reduction of fuel = - 20%)

Uniform heating
Effect of the stirring of waste gas by cyclic combustion

Compact equipment
Shortening of the furnace length by installing burners along the full length of the furnace
ECCJ 25

(4) Effect of Heat Pattern Change in Re-hearing Furnace


Temperature Temperature of re-hearing furnace 1200 1000 800 600 400 200 0 Time
ECCJ 26

Temperature of heated material Heat pattern Fuel usage 1.0 0.93

(5) Endless Bar Rolling System


Loss reduction by eliminating of cutting off at both ends of bars Reduction of the idle time before feeding each new billet and the factors for rolling errors Drastic reduction in products of wrong dimension or insufficient length Reduction in energy cost 3%

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Endless Bar Rolling - Welding


Flash Butt Welding Preheat Rough Mill Crop shear FBW Intermediate Mill

(Billet) or Bar

(Billet) or Bar Preset

Flash butt Welding

Plane
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(6) Energy Conservation System


Accumulation and analysis of the energy consumption data Control and management of energy consumption & intensity Application of existing system examples Energy monitor and analysis system
Local devices

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Energy Intensity (Crude oil equivalent L/t)

(1) Transition of Total Energy Intensity (Crude oil equivalent) - Example (50t/heat EAF) 250 221 200 190 150 Performance of energy conservation for 5 years = 10.5% Performance of energy conservation for 3 years = 8.1% 50 Electricity / total = 85 0 1995
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185 173 171 159 154 143

100

Energy conservation effect by continuous rolling = 4.1% (FY2002)

Electricity / total = 88 1997 1998 1999 Fiscal Year 2000

Electricity / total = 93 (estimate) 2001 2002


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1996

Thank You

31 The Energy Conservation Center, Japan

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