Energy saving and environmental protection in Chinese Steel Industry

(a typical process industry) Activity 3.2

Daqiang CANG
School of Metallurgical and Ecological Engineering University of Science and Technology Beijing Key Lab of Ecology and Circle Metallurgy, Ministry of Education China
Contract number: CN/ASIA-LINK/016(103-187)
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Content
1. Preface 2. Chinese steel industry 3. Present situation of energy consumption in Chinese steel industry 4. Environmental protection in Chinese steel industry 5. New tech. on Energy Saving & Environmental Protection for steel industry 6. Conclusions
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Steel industrial process

Power generation Gas Coking BF LD CC Hot rolling Cold rolling

Wasted plastic

Slag Scrap Sintering Cement Products

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1.Preface
* Steel still is the main material, but is a energy intensive and heavier polluted industry. * A huge domestic market in China. * Some gap between China and the others:

2. Chinese steel industry

Production of crude steel: 420 million tons, 2006(~1/3 of the world). 18.5% increase comparing to 2005. Domestic crude steel consumption: 384 million tons, 2006, 30.98% in the whole world.

China Steel Output In Recent 5 Years 45000 40000 35000 30000 25000 20000 15000 10000 5000 0 2002 2003 2004 2005 2006

Output(10000 tons)

Steel output

China steel output in the past 16 years

The Characteristics of Chinese steel production, 2006

The structure of Chinese steel products changed. The production and proportion of highlevel products increased. The production of special-purpose steel products increased.

Some steel products adjusted in 2006

Class plate Cold rolling sheet Container plate Specialpurpose products Bridge plate Shipbuilding plate Stainless steel Output (10000 tons) 15402.46 1314.57 217.5 73.2 Growth proportion 36.54% 53.1% 65% 60.5%

High-level products

654 529.88

34.8% 67.68%
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New policy---Chinese steel production

Change the steel industry from big size to higher level. Improve the technology and hardware. Increase the proportion of high-level products. Strengthen steel enterprises centralization and reorganizing.

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3. Present situation of energy consumption in Chinese steel industry

Pictures from Baosteel, Shanghai, China

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Energy consumption in 2006

Gross energy consumption:
198 million tons ce (standard coal) increased 15 million tons ce than 2005about 8.45%(production:18.5% increased).

Comprehensive energy consumption :

645.12 kgec/treduced 7.06% than 2005.

Comparable energy consumption

623.04 kgec/treduced 6.19% than 2005.

Fresh water consumption:

6.56t/treduced 14.9% than 2005.
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The energy consumption between 1990 and 2000

The data after 2000 are from large and middle sized steel enterprises
nationwide energy consum ption,0.01m illion tec total energy consumption of iron and steel m aking industry ,0.01million tec energy consumption of steelmaking industry /nationwide energy consum ption,%

amount of energy consumption,0.01million tec

250000 200000 150000 100000 50000 0

19 90 19 92 19 94 20 00 19 96 20 02 19 98 20 04

18 16 14 12 10 8 6 4 2 0

year

energy consumption of steel making/nationwide energy consumption%

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The constitution of energy consumption in Chinese steel industry, 2004

Fuel oil,3.02% Naturalgas,0.50% Electricity power,26.40%

Coal, 69.90%

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Steel industry energy structure in some countries

China
Coal Fuel oil Natural gas Electricity power 69.9 % 3.2 % 0.5 % 26.4 %

USA
60 % 7.0 % 17.0 % 16.0 %

Germany
55.8 % 20.7 % 8.2 % 15.3 %

Japan
56.4 % 19.9 % 23.7 %

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Year 2000 2001

Comprehensive energy consumption 920 876

Comparable energy consumption 781 747

Sinter 68.90 68.60

Iron making 466.07

Cocking 160.20 153.98

LF 28.88 28.03

EAF 265.59 230.09

Rolling 117.95 107.52

2002 2003 2004 2005 The variation quality of 2005 to 2000 Change rate

815 780 761 741

698 709 701 714

67.07 66.42 66.38 64.83

455.13 464.68 466.20 456.79

150.32 148.51 142.21 142.21

24.01 23.56 26.57 36.34

228.94 213.73 209.89 201.02

101.49 96.29 92.91 88.52

-179

-67

-4.07

-9.28

-17.99

7.46

-64.57

-29.43

-20.3%

-8.6%

-5.9%

-2.0%

-11.2%

25.8%

-24.3%

-25.0%

Changes of the process energy consumption in 2000~2005 (kgce/t)

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Comprehensive Energy Consumption/t steel Key enterprises (kgce/t) Advanced level (kgce/t) Lagging indicator (kgce/t) The gap between advanced and average% The gap between lagging indicator and average% 741

Comparable Energy consumption/t steel 714

Cocking

Sinter

Iron making

LF

EAF

Rolling

142.21

64.83

456.79

36.34

201.02

88.52

679.76

650.00

89.02

54.68

396.70

-2.7

135.89

289.78

1018

994.2

278.06

89.87

605.10

91.75

354.90

289.78

8.3

9.0

37.4

15.7

12.2

107.4

32.4

41.2

37.4

31.9

95.5

38.6

32.5

152.5

76.5

227.4

The energy consumption gap between steel enterprises in China 2005 , (kgce/t)

Process

Sintering

Pelleting

Cocking

Iron making

LF

EAF

Power

Rolling

The domestic key enterprises

64.83

142.21

456.79

36.34

201.02

88.82

Baosteel (first season) International advanced level(1999) The proportion of total energy consumption()

60.55

89.02

396.7

117.32

58.89

128.1

437.93

-8.88

198.6

Hot-rolling47.82 Cold-rolling80.28

6.06

0.49

14.69

48.17

2.27

3.68

15

9.60

The gap between China(2005) and international advanced level(1999) (kgce/t)

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Some new energy saving technology applied in China

There are more and more energy saving tech. were used in Chinese steel industry, the following are some of them which start to be used in the past few year. (1) Coke Dry Quenching (CDQ)
1) 2) 3) 4) Recovery sensible heat from red coke : 80% Produce 0.5t/t ,steam pressure: 4MPa, 450 . Improve environmental quality . Improve coke strength, with M40 increase 3~8%, M10 reduce 0.3~0.8%.
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(2) Heat Recovery Technology from Hot Sinter product for Steam and electricity generation
Recovery 76kg steam /per ton sinter product in Baosteel.

(3) Blast Furnace Top Gas Pressure Recovery Turbine Unit TRT
which can generate 37kwh electricity/ ton of product in Baosteel.

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(4) HTAC (High temperature air combustion)

Fuel oil Hot air 1000oC

Burner nozzle A

Fuel oil Burner nozzle B High temperature gas

Temperature 1200oC Cold flue gas<200oC

Left regenerative chamber

Left regenerative chamber

Rom temperature air

Directional control valve

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4. Environmental protection in Chinese steel industry

(for gas, solid, liquid phase pollutants)

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The proportion of the pollutants of Chinese steel industry to the gross national pollutants
Based on the data of the National Bureau of Statistics of China, The proportion of the steel industry pollutants to the national total pollutants are as follows:

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Gross National emissions Waste gas (cubic meters) SO2 (10 thousand tone) Smoke (10 thousand tone) Dust (10 thousand tone) Waste water (10 million tone)

Steel industry emissions

Proportion (%)

268025 2549 1183 828.1 5633

57134 146.5 71 129.6 18.4173

21.31 7.4 8.3 15.65 8.53

The proportion of the steel industry pollutants to the gross national pollutants
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Index

2003

2004

2005 (statistic incompletely) 94.4

Reused industrial water (%)

New water consumption per tone steel (cubic meters)

90.73

92.28

13.73

11.27

8.06

Outfall waste water capacity per tone steel (cubic meters) Waste water disposing ratio (%) The ratio of disposed water (%) Utilization ratio of the coking gas (%)

7.7

7.23

5.02

99.52

99.58

99.6

98.08

98.25

98.6

96.64

98.17

98.3

Main indexes of environmental protection and pollutants utilization in 25 main steel enterprises recently

Index

2003

2004

2005 (statistic incompletely)% 96.1

Utilization ratio of the blast furnace gas (%) Utilization ratio of the converter gas (%) Utilization ratio of the dust and sludge (%)

91.61

95.85

87.07

84.08

89.7

98.46

98.66

99.7

Utilization ratio of the waste dregs (%) Utilization ratio of the furnace slag (%) Utilization ratio of the steel slag (%) Utilization ratio of the waste acid (%)

58.07

60.48

67.9

92

95.68

97

87.39

90.05

Converter slag 10

90.01

95

Sulfuric 76 Hydrochloric 98
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The major problems of environmental protection for Chinese steel industry

.(1) Wasted water from coke making process (2) SO2 and NOx in Sinter flue gas (3) High temperature dedusting (4) Dioxin remove from sinter plan (5) Organic pollutant remove from water (6) BOF and EAF slag utilization (7) Tailing from iron ore mine

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The goal of energy saving and environment protection after the tenth five-year-projects.
Several important target of clean production in large and middle-size enterprises in 2005 and 2010
Year 1million t/a coke oven dry quenchin g proportio n (%) 60 BF over 1000m3 TRT proportio n (%) New water consump tion per tone steel (m3) 12 8 Proporti on of converte r gas utilizatio n (%) Waste water and gas standardi ng rate (%) Decrease of main pollutant discharg e amount (%) Compreh ensive energy consump tion per tone steel (kg/t) 750 650

2005

100

70 90

100

15

2010

100

50(BF between 300 to 1000m3 TRT proportio n)

100

30

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Strengthen the Environment Impact Assessment

Minimizing pollutant Improve the energy utilization efficiency Improve the water utilization efficiency Improve the material utilization efficiency

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Some concerned activities in China: Cleaner production (CP) Recycle economy (RC) Industrial ecology (IE)
The principle: 3R : Reduce, Reuse, Recycle From the resource side minimizing the pollutant emission, energy consumption and resource consumption.
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5.New technologies and approaches New approaches for energy saving: (1)process innovation: Continuous casting instead of model casting, etc. (2) short process instead of long process. (3) small size ---large size enterprises. (4) develop more super steel products. (5) industrial ecology (industrial group system).

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New approaches for environment protection: (1)Treat wastes before process, in process and after process. (2)Waste treatment with wastes. (3)Industrial ecology: use wastes as a new resource (for another industry or enterprise).

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New tech.: For energy saving:

(1) Low temperature ,dispersed, batch emitted wasted heat for power generation. (organized a national symposium in China) (2) Energy saving materials development : Nano fluid, nano coating, copper stave for BF (3)Physical fields to change the chemical and physical properties or the process (patens). (4) Super-critical conditions for new energy production. (5) High temperature slag heat recovery.

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New tech. for environment protection:

(1)In process control (not end of pipe control): e.g. fixed SO2 in solid sinter product, not in flue gas etc). (2) Slag reform: change crystal structure and composition for new application etc. (3) High temperature dedusting (4) H2 metallurgy (5) Water saving (6) Waste treat waste: coking wasted water treats SO2 in sinter flue gas and
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Conclusions
1) Different countries have different conditions and requirement under different developing stage, some tech. be used maybe different in different countries. 2) Recycle economy is a good way for energy saving, environment protection and resource utilization effectively.

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Many thanks!

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