Overview and EE&C of Steel Industry in Japan
Overview and EE&C of Steel Industry in Japan
Overview and EE&C of Steel Industry in Japan
November, 2006 Hideyuki TANAKA Program Leader, International Engineering Dept. The Energy Conservation Center, Japan
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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
Converter EAF ratio EAF, Special steel Open hearth EAF, Ordinary steel
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Continuous Rolling
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Type 1 Type 2
EAF (Power) EAF (Chemical ReactionO2OilOthers) Auxiliaries of Steel Making Shop (Power) Burner (Ladle+Tundish) Burner (Re-heating Furnace)
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3.2 2.8
110
390
20
95 85
345 325
28
2.3
32
1.8
63
Hot metal operation Night time operation Utilization of waste materials 200 6
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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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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
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Energy (kWh/t)
Power
Metal
Metal oxidation
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Input
Output
11
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
3 kWh/t
Oxygen 1m3N/t
(m3N/t)
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13
(7) Relation between Transformer Capacity and Tap to Tap Time of EAF
160 140
120 100 80 60 40 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 14
Shaft Furnace
Effect: 70kWh/t
(Reported value)
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15
Refining Control
Slag foaming guidance Thermal model calculation Metallurgical model calculation
Effect:
Fuel Reduction Ratio = 51%
[Condition] Ladle Capacity: 100 t Heating Period: 10 hours
Conventional
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Regenerative Burner
19
Hot charge
200-600
Cold charge
20-200
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20
2002~
21 ECCJ
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22
Blower
Burner
Recuperator
(metal)
Fuel
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Blower
Combustion air
23
Burner
Regenerator (Ceramic)
Blower
24
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
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27
(Billet) or Bar
Plane
28
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(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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100
1996
Thank You