Steel Making

2007 RITE International Symposium -Technologies for mitigating global warming and the role of Japan-
Challenges for GHG Reduction in Steel Industry

January 18, 2007 Toru Ono Nippon Steel Corporation
Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.
Table of Contents
Contents
1) Introduction 2) Voluntary Action Plan 3) Energy-Saving Technologies 4) Utilization of Waste Materials 5) Challenges for the Future 6) International Collaborations 7) Conclusions
Introduction
Iron & Steel Making Process Flow

Raw Materials Iron Making Steel Making Hot Rolling Cold Rolling & Finishing Steel Products
Raw Materials Coal
Iron Making
Boiler
Energy Plants
Power Plant Oxygen Plant
Coke Oven Iron Ore Steel Scrap Sinter Plant Blast Pig Iron Furnace BOF Molten EAF Steel
Steel Making Continuous Crude Steel Caster
Long Products Continuous Galvanizing Plate
Heating Furnace Heating Furnace Heating Furnace
Continuous Annealing
Hot coil
Steel Products
Finishing
Cold Rolling
Hot Rolling
Process Boundary
Introduction
From the Point of View of Energy,

Waste Plastics, etc. Raw Materials
Coal Coke Oven Iron Ore Steel Scrap Sinter Plant
Highly Energy integrated process

Iron Making
By-pro. Gas
Blast Pig Iron Furnace
Energy Cascade
BOF Molten EAF Steel
Energy Power Oxygen Boiler Plant Conversion Plant
Energy Plants
Steel Making Continuous Crude Steel Caster
Waste Heat CO2 Energy Supply
Waste Energy Recovery

Continuous Galvanizing
Long Products Plate
Heating Furnace Heating Furnace Heating Furnace
Continuous Annealing
Hot coil
Finishing
Cold Rolling Process Boundary
Hot Rolling
Introduction
Energetic CO2 Emission in Japan by Sectors

GDP 450Tyen Crude Steel Production 112Mt
1,059 217 409
503(+11.9%) 113(+0.9%)
1,206 257
Total Energetic CO2 Emission : +143Mt-CO2 (+13.9%) Transportation : +40Mt-CO2 (+18.4%) House-H-holding & Business : + 118Mt-CO2 (+40.5%)
291
Industry Sector : -16Mt-CO2 (-3.3%) Steel Sector : -13Mt-CO2 (-6.9%)

Energy Conversion : + 6Mt-CO2 (+8.8%)
*Grid power is distributed to each sector with national average CO2 emission by power generation
482
195
466
182
68 1990FY
74 2005FY
Voluntary Action Plan
Voluntary Action Plan of JISF
*JISF:Japan Iron and Steel Federation
In 1996 the Japan Iron and Steel Federation launched its voluntary initiatives with the following action plans.
1) Challenge to save energy in the process by -10 between 1990 and 2010 2) Challenge to use 1 million tons of waste materials in the process under the condition of establishing classification and collecting scheme by local government. (equals to -1.5% of energy). 3) Further utilization of unused waste energy in the local communities. 4) Contribution to energy-saving in the communities through Eco-products and byproducts. 5) Contribution to world wide energy-saving through technology transfer.
Achievement of the Activities

EnergyEnergy-Saving
PJ
2600
Contributions through Products
Energy Consumption 2519 -4.2% -7.1%
-6.5%
-7.6 Million ton-CO2
2500 2400 2300 2200
2402 2340 2354

t-CO2 1000 900 800
Assumption of Calculation Conversion from Cement to Slag : 450kg-slag/t-cement CO2 Reduction Effect : 312kg-CO2/t-cement
2010Target 2267PJ (-10%) Mt-CO 2

200 190 180 170 160 150 1990 1995 2000 2005
186.1 180.9 181.9
1990
195.3
1995 2000 2 Emission CO
2005
-4.7%
-7.4%
-6.9%
924
Domestic Export 578 511
700 600 500 400 300 200 100 0 47 1990 53 1995 464 525
715 483
Domestic 4.8Mt
550
2010Target 177.7Mt (-9%)
Export 4.4Mt
165 2000 2005
441
Kyoto Mechanism -5.6 Million ton-CO2

Crude Steel Production (Mt) 1990 1995 2000 112 100 107
2005 113
Keidanrens Voluntary Action Plan

Targeting no increase in CO2 emission in 2010 from that in 1990 35 industrial sectors participants in the 2006FY follow-up. Covering 44% of the national total and 83% of industrial sector in Japan.
Industrial sector in Japan 1. Iron and Steel Federation 2. Car manufacturing 3. Car parts 4. Petroleum Association 5. Chemical I. Association 6. Paper Association 7. Cement Association 8. Power companies (portion) 9. Electric appliances etc 10. Other sectors 11. Non-energy CO2 Keidanren Total 1990 Mt-CO2 195.3 7.6 7.2 33.0 68.3 25.4 27.4 31.0 11.8 39.0 62.1 508.2 2005 Mt-CO2 182.0 5.7 7.4 44.7 75.2 25.1 21.8 38.8 18.7 33.4 52.4 505.1 Change Mt-CO2 -13.4 -1.9 0.2 11.7 6.8 -0.4 -5.7 7.8 6.9 -5.6 -9.6 -3.1 Rate % -6.9 -24.4 3.1 35.3 10.0 -1.4 -20.6 25.2 58.0 -14.4 -15.5 -0.6
EnergyEnergy-Saving Technologies
Efforts to Energy Saving

70s
Process Innovation 2Process Optimization
80s
CC, C.A.P.L etc. HCR, ACC etc.
90s
PCI, CMC etc. AI, SCN etc. Gas Holder, ACC Regenerative Burner etc.
00s
10s
SCOPE-21 etc.
never ending improvement H2 Supply, CO2 Capture Low Temp. Recovery and Use Biomass
3Enhancement of Bypro. Gas Recovery 4Waste Heat Recovery TRT, CDQ, etc
5Waste Material Utilization

Gross Energy Consumption Net Consumption
Plastics, Tires
Process Innovation Process Optimization
Recovery
By-pro. Gas recovery
Waste heat recovery Utilization of Wastes
73
80
90
00
10
Coke Dry Quenching (CDQ)

Waste-heat recovery from hot coke Improvement in coke quality
Cooling Chamber
Coke Basket 1050deg.C
Waste-heat boiler
860deg.C
Turbine Generator
High-pressure Steam 9MPa, 510 deg.C, 50t/H
Coke Oven
Coke Dust Collector 95t/H Cooling gas 130kNm3/H 130deg.C Pre heater 200deg.C Circulation Fan Coke Carrier Conveyer Cooled Coke 180deg.C
HT
Deairator
LP
Cooling Water Process steam
Energy Recovery System in BF

BFG DC Blast Furnace VS VS TRT To Gas holder
Blast Blower Hot Stove
195 85 BFG Air Heat Medium Circulation Tank Pump
Hot Stove WasteWaste-heat Recovery System
TopTop-pressure Recovery Turbine

10
Energy Recovery System in BOF

Recovered Steam Drum Direct Heat Exchang er Primary Radiator Upper Hood Pump BOF Lower Hood IDF
BOF gas is collected by OG system.

OG System
Water
Sensible heat of BOF gas is recovered by a waste-heat boiler equipped in the OG system.
Dust Collector BOF Gas
11
Trends of Waste-heat Recovery

Power generated by waste-heat

125 100 75 50 25
20 15 10 5
0 0 200 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 120 180 100 160 140 80 120 60 100 80 40 60 40 20 20 (t/H) (t/H) 0 0 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03
Fiscal Year
(MW (MW) )
()
Steam generated by waste-heat
Waste-heat steam rate over total demand (%)

()
Waste-heat power rate over total demand (%)

150
Results in Kimitsu Works of Nippon Steel 25
12
ACC for Byproduct Gas
Advanced Combined Cycle Capacity : 300MW Fuel : mixed BFG (4.4MJ/Nm3) Gas temp. : 1300deg.C Efficiency : 47.5%
Waste-heat Recovery Boiler Air Filter
LP Steam MP Steam HP Steam Gas Compressor Steam Turbine Gas Turbine Generator
Power to grid
Cooling Water
Combustion Chamber
BFG+COG Gas Filter
Gas Cooler
From Kimitsu Cooperative Thermal Power Company Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.
13
Advanced Coke Oven (SCOPE-21)

Hot briquetting machine Emission free coal charging Dust collecting system Highly sealed oven door Emission free coke discharging Emission free coke travelling system Coke upgrading chamber
CDQ
Coal plug conveying system
Pneumatic preheater
Emission free coke pushing Coking chamber

Medium temp. carbonization Super denced brick & thin wall Pressure control
Coal
Fine coal
Coarse coal
Fluidized bed dryer
Coke Coke quenching car
Blast furnace
Coal Pre-treatment
High performance Coke Oven
Coke Treatment
14
Utilization of Waste Materials
Cross Sector Approach

Civil Life
(Serious needs for waste disposal)
Iron/steel making process

(Big potential for effective uses of wastes)
Cost PA NIMBY
Incineration is the major method for waste disposal in Japan.
High temp./reducing Ideal reaction processes Products can be used by present processes
CO2 Emissions Solution for social problems High economic performance Global Warming Problem
Social system design Rule establishment
To realize a material recycling society system across sectoral borders

15
Evaluation of Utilization of Waste Materials

Coal, fuel (E) Steel mill Coke Oven Blast Furnace Waste plastics Waste tires Coal, fuel (E) Waste plastics Waste tires
System Extension
Incinerator Coke Oven Blast Furnace Incinerator
CO2 (A) + CO2 (B) CO2 (A) +
ZERO
Saving Natural Resources Reduction of Total CO2 Emission

16
Methodology of Waste Plastic Utilization-1

Material Preparation Process
From local governments Pre-crusher Waste plastic Primary selector CB eliminator Secondary crusher Pelletizer Magnetic selector
Pre-treatment
Compressed Package 1m x 1m x 1m 200 300 kg Secondary Crushed tips 20 x 20 mm Plastic Pellets 25 mmD x 40 mmL Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.
17
Methodology of Waste Plastic Utilization-2

Chemical Decomposition Process Products and Reuses
40% COG
Power Plant Fuel Cell (in future)
40% Oils
Plastic Materials Paints etc.
20% Coke
Reducing Agent for BF
Coke Oven
18
Trend of Utilization of Waste Plastics

kt
500 400 300 200 100 30 0 1997 1998 1999 2000 2001 2002 2003 2004 2005
Packaging Materials Recycling Law Stated Apr. 1, 2000
420 350
440
270 150 70 30
290
19
Social System Design by Nippon Steel

Social System Design by Nippon Steel
Local Government Gas(Fuel Recovery ) Collection Waste Coal Plastic Products
Main Flow
Coke Oven
Sub Flow
Products
Iron Making Coal+Iron ore
Raw Material Virgin Plastic
In 2002, Good Design Award was granted to Nippon Steel for its Social System Design of Waste Plastic recycling.
20
Challenges for the Future
A Scenario for Hydrogen Based Society in Japan

Japanese government disclosed a scenario for establishing a hydrogen based society in the future. In 2030, 15 million FCVs and 12.5 GW FCGs are planed to be installed. Hydrogen supply is one of the major concerns.
12.5GW FCGs
15million FCVs
Coke oven gas in steel plant becomes a promising candidate for hydrogen source.
21
Potential of COG as a Hydrogen Source

CO2 3% CmHn 3% N2 3% CO 6%
COG Dehydrater Off gas PSA H2 Compressor H2 Gas Holder
CH4 30%
H2 H2 Composition 55% 55 vol%
COG
H2 Compressor Desulfurizer H2 Liquifier Liquified H2 Tank
Easy equipment Wide spread of location
Huge amount of resource
FCV Demonstration in EXPO2005 Served from Nagoya Works 1) Number of FC bus 8 2) Total mileage 124,500km 3) Service term 185days 4) Total passengers 1million 5) Hydrogen consumption 11,430kg
JHFC FCV Demonstration Project Served from Kimitsu Works

22
CO2 Capture from Blast Furnace Gas

BFG
Composition vol% CO2 22 CO 23 N2 51 H2 4
High concentration of CO2 in BFG Improve efficiency of power plant

Power Plant
Reuse as a reducing agent in BF

CO2 absorbent CO2 absorber
Blast Furnace
Steel Process CO2 discharger Unused waste-heat
Captured CO2
Potential of utilization of unused waste heat
23
An Image of Future Iron/Steel Plant

Wastes Steel Plant Iron Ore Coal Energy Power, Gas, Steam etc
Waste Plastics Waste Biomass
Iron/Steel Making Process Byproduct Gases
Hydrogen
Energy Saving
Unused Waste Energy High Performance Products Byproducts
CCS
H2 Society
Global Warming
Society with
High Energy Efficiency Material Recycling
24
International Collaborations
Trend of World Steel Production

2005: China growth
1200
Mt
World Population 6.5Billion World Steel Production 1130Mt 1990: Base year of Kyoto World Population 5.3Billion Steel Production 770Mt 1974: After the 1st Oil Crisis World Population 4.0Billion Steel Production 710Mt 1950: After WW-II World Population 2.5Billion Steel Production 189.6Mt
1000
China Growth
800
Fall of the Berlin Wall Plaza Agreement
600
400
1913: A year before WW-I World Population 1.7Billion Steel Production 79.5Mt
2nd Oil Crisis 1 Oil Crisis

st
WW-I
200
Economic Panic
WW-II
0
19 10 19 15 19 20 19 25 19 30 19 35 19 40 19 45 19 50 19 55 19 60 19 65 19 70 19 75 19 80 19 85 19 90 19 95 20 00 20 05
25
Trend of National Steel Production

400 350 300 250 200
Mt China Growth
Year 1996 2000 2001 2002 2003 2004 2005 Crude Steel Production (million t) 101 Over 100 million tons 127 End of 20th Century 151 +24 182 +31 222 +40 Rapid Growth 272 +50 350 +78
CIS
150 100 50 0
19 10 19 15 19 20 19 25 19 30 19 35 19 40 19 45 19 50 19 55 19 60 19 65 19 70 19 75 19 80 19 85 19 90 19 95 20 00 20 05
USA France Germany
China
Jpn Japan Korea India
26
Economic Growth and Steel Consumption

Domestic steel consumption and GDP/capita between 2000 and 2005
1200
Domestic Steel Consumption 2000 2001 Korea 851 839 Japan 627 592 EU15 430 415 USA 484 402 China 109 133 CIS 161 173 India 30 30 World 151 151 2002 953 578 406 410 159 162 32 159 2003 991 599 408 362 198 189 33 168 kg-steel/capita 2004 2005 1018 1002 629 648 423 406 419 378 228 264 200 207 35 38 183 189
Domestic Steel Consumption (kg/capita)
1000 800
Korea
600
Japan Germany OECD EU15 China CIS

India
USA
400 200
France World average UK
0 0 10000
Real GDP is calculated based on the annual GDP and exchange rates of 2000. Domestic steel consumption is defined as National production + import export.
20000
30000
40000
50000
GDP ($/capita)
27
Energy-Saving Model Projects

Governmental Project 13 (500kt-CO2/year) Private Project 7 (900kt-CO2/year) 310 580 Korea
290
China
20 India 7 Thai
10 Malaysia unit: kt-CO2
Projects by Nippon Steel

Technology Installed BF-HS Waste Heat Recovery Coal Moisture Control Coke Dry Quenching BOFG Recovery BF-HS Waste Heat Recovery BF-HS Waste Heat Recovery Host Country Year Compreted CO2 reduction China China China China China Indea 1995 1995 2000 2001 2001 2003 Total 29.8 18.6 68.3 40.0 17.8 22.4 196.9 kt-CO2/year
28
Status of Major Energy-Saving Technologies

Coke Dry Quenching
() 0 50 100
TopRecovery Top-pressure Turbine

() 0 50 100
BOF Gas Recovery

() 0 50 100 100 25 11 18
Japan
Korea US UK Germany 50
8 5 Japan Korea US 2 UK 33 Germany 0 0 24
100 1 0 0Japan
100 1 0 0Korea
US UK 0 Germany
0 0
The data above were gathered in 1996. Efforts for updating the data are intensely carried out by IISI, IEA and APP to estimate potentials to be improved.
29
Future Potential of CO2 Reduction

CIS 2120 (2)
Potential of CO2 Reduction researched by NEDO
East Euro. 1240 (8)
Middle East 27 (1)
Asia 3390 (17)
Africa 59 (2) Latin America 73 (5)
JI Candidates3370kt-CO2(10Projects) CDM Candidates 4970kt-CO2(25Projects)
kt-CO2/year (# of Project)
30
Japan-China Steel Industry Advanced Technology Exchange Meeting in Environmental Protection & Energy-Saving
July 4-5, 2005 :The first meeting held in Beijing, China Nov. 1-2, 2006 :The second meeting held in Beppu, Japan
Common Understanding Importance of technical exchanges in the area of environmental preservation and energy-saving technologies, from the standpoint of the effective use of resources and the preservation of the global environment. Agreement To realize the above, the Japan Iron and Steel Federation and the China Iron and Steel Association will continue exchanges of information and experts on environmental preservation and energy-saving.
31
Asia Pacific Partnership (APP)

Established in 2005 6 partners: Australia, China, India, Japan, Korea, US To cope with both increasing energy needs and climate change Focus on technology To complement Kyoto Protocol
Cleaner fossil energy/ Renewable energy and distributed generation/ Power generation and transmission / Steel / Aluminum/ Cement/ Coal mining/ Buildings and Appliances
Steel Task Force chaired by Japan 2nd Steel TF Meeting and 1st WS, Sep. 27-29, 2006, Tokyo, Japan
Project# Pro.-1 Pro.-2 Pro.-3 Pro.-4 Pro.-5-1 Pro.-5-2 Contents APP Steel workshop Status Review of Steel Industry Related Indicators for Energy Saving etc Performance Indicators Setting Performance Diagnosis State-of-the-art Clean Technology Handbook Technology Deployment Chair Host Country Japan Korea China, India USA (co-chair JPN) Australia
Next meeting Mar.14-16,2007 Calcutta, India
32
SOACT Handbook
SOACT Handbook is under compiling to be shared state-of-art technologies relating environmental protection and energy saving by the member countries.
SOACT:State-of-Art Clean Technology)
By the end of 2006, 53 of environmental protection technologies and 48 of energy saving technologies are compiled. 63 technologies are presented by Japan.
33
International Collaborations Appendix
Importance of International Sectoral Approach

1,130Mt/year
Others Australia India Korea USA 130 10 40 50 90
650Mt/year
1,000Mt/year
460Mt/year
P AP : i es r t n ou c 6
n: n gh o u i t a tio l: thro n c a r A al: a e e k l r t a y e g a r t e in nta i-l Br la -Chin t S l y 2 B an Mu CO olu V p I Ja IIS China 350 460Mt/year
Japan CIS Canada Other EU EU15
110 110 20 60 160
World Total Coverage 100%
Kyoto 40%
Japan-China 40%
APP 60%
Kyoto+APP 90%
34
IISIs CO2 Breakthrough Program

Phase-1: Seeds research and developmentuntil 2008 Phase-2: Pilot project25years Phase-3: Demonstration Plant
North American Program
EU
ULCOS
*Ultra Low CO2 Steelmaking
Korea Program
Japan Program JISF

CO2 separation
South American Program
Hydrogen production etc.
35
Conclusions
Future Directions
Past Present Future
Performance Improvement (eg.HITEN) Process Innovation (eg.SCOPE-21) APP, Bilateral etc. IISI CO2 Breakthrough Waste Material Utilization
(Waste Plastics/Tires, Dust/Sludge)
Energy Saving through Steel Products and Byproducts
Energy-Saving in Process
International Collaboration
Cross Sector Approach
Hydrogen Supply
Low-Temp. Waste Heat Utilization CCS

36
Toru Ono Nippon Steel Corporation Otemachi 2-chome, 6-3, Chiyoda-ku, Tokyo 100-8071, Japan e-mail ono.tooru@hq.nsc.co.jp +81-3-3275-5471
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2007 RITE International Symposium -Technologies for mitigating global warming and the role of Japan-

Challenges for GHG Reduction in Steel Industry

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.

Iron & Steel Making Process Flow

Raw Materials Coal

Steel Making Continuous Crude Steel Caster

Long Products Continuous Galvanizing Plate

Heating Furnace Heating Furnace Heating Furnace

From the Point of View of Energy,

Highly Energy integrated process

Blast Pig Iron Furnace

Energy Power Oxygen Boiler Plant Conversion Plant

Steel Making Continuous Crude Steel Caster

Waste Heat CO2 Energy Supply

Waste Energy Recovery

Long Products Plate

Heating Furnace Heating Furnace Heating Furnace

Cold Rolling Process Boundary

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.

Energetic CO2 Emission in Japan by Sectors

Industry Sector : -16Mt-CO2 (-3.3%) Steel Sector : -13Mt-CO2 (-6.9%)

Voluntary Action Plan

Voluntary Action Plan of JISF

*JISF:Japan Iron and Steel Federation

Voluntary Action Plan

Achievement of the Activities

Contributions through Products

Energy Consumption 2519 -4.2% -7.1%

-7.6 Million ton-CO2

2500 2400 2300 2200

2402 2340 2354

-9.2 Million ton-CO2

2010Target 2267PJ (-10%) Mt-CO 2

1995 2000 2 Emission CO

Domestic Export 578 511

2010Target 177.7Mt (-9%)

-13.4 Million ton-CO2

Kyoto Mechanism -5.6 Million ton-CO2

Voluntary Action Plan

Keidanrens Voluntary Action Plan

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.

Efforts to Energy Saving

5Waste Material Utilization

Process Innovation Process Optimization

By-pro. Gas recovery

Waste heat recovery Utilization of Wastes

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.

Coke Dry Quenching (CDQ)

Coke Basket 1050deg.C

Cooling Water Process steam

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.

Energy Recovery System in BF

Blast Blower Hot Stove

195 85 BFG Air Heat Medium Circulation Tank Pump

Hot Stove WasteWaste-heat Recovery System

TopTop-pressure Recovery Turbine

Energy Recovery System in BOF

BOF gas is collected by OG system.

Dust Collector BOF Gas

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved.

Trends of Waste-heat Recovery

Steam generated by waste-heat

Waste-heat steam rate over total demand (%)