technologies customized list

Introduction

Contents of “Technologies Customized List & Technologies One by One Sheets” were developed at The Public and Private Collaborative Meeting between Indian and Japanese Iron and Steel Industry. “Guidebook for diffusion of technologies on Technologies Customized List” is an instruction manual for the contents of “Technologies Customized List and Technologies One by One Sheet.”

Public and private experiences of the Japanese steel industry which achieves the highest energy efficiency in the world and the needs of the Indian steel industry are reflected in these booklets. Contents should be revised at the future Public and Private Collaborative Meeting between Indian and Japanese Iron and Steel Industry conforming to the situation at the time.

Technologies on Technologies Customized List, Technical Description and Annex 2 (environmental technologies requested by Indian steel industry) should be transferred to the Indian steel industry. In this context, contents of these booklets are useful tools for development of policies and measures. As a result of discussion among MEA, MoEF, METI and JISF on 25th July 2012, the followings

have been confirmed; 1) Discussion at the Collaborative Meeting focuses on technological issues. 2) Connection between Technologies Customized List and policies and measures shall be discussed at formal occasion by governments in charge.

“Technologies Customized List & Technologies One by One Sheets Ver.1” and “Guidebook for diffusion of technologies on Technologies Customized List Ver.1” were authorized by the Collaborative Meeting on 5th February 2013 in Tokyo, Japan.

Taking into account the subsequent India’s technical needs and the result of diagnosis in India’s steel plant in 2013, “Technologies Customized List” was revised as “Technologies Customized List & Technologies One by One Sheets Ver.2”

Version 2 3rd February, 2014

Development of Policies and measuresfor diffusion of the technologies on Technologies Customized List and its Annex 2 (environmental technologies requested by Indian steel industry)

at formal occasion

Useful tools for developmentof policies and

measures

1) Discussion at thecollaborative meeting focuses on technological issues.

2) Connection between Technologies Customized List and policies and measures shall be discussed at formal occasion by governments in charge.

Discussion at the Collaborative Meeting focuses on technological issues.

1

1

Collaborative Meetings November 2011 in New Delhi, India

November 2012 in New Delhi, India

February 2013 in Tokyo, Japan

2

2

Technologies Customized List & Technologies One by One Sheets Ver.2

1. Technologies Customized List 5 2. Technologies One-by-One Sheet 9 3. Technical Description

ANNEX

4. Full List of Technologies 5. Environmental technologies requested by Indian steel industry

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5

9

31

35

39

5

TechnologiesCustomized List1

Ver.2Technologies Customized List & Technologies One by One Sheets

Technology selection criteria

19 technologies, based on the “The Technologies Customized List” are considered to be significant

countermeasures to tackle with energy conservation issues of Indian iron and steel industry. These 19 technologies were chosen by filtering under [Prior Condition] and conditions A, B, and C. These condition’s descriptions are below.

- A is the evaluation of the technologies energy saving effect level. - B is the evaluation showing the completeness from the technology’s commercial level point of

view in Japan. This indicates the rate of diffusion of these technologies. For Japan to give technological cooperation, it is important to have plenty of knowledge and experience in Japanese iron & steel industry. From that point of view, we compiled a ranking of the technologies which can be considered as being able to contribute to energy saving. To be specific, ‘F’ ranking was given to those technologies which are well known and familiarized, and ‘A’ ranking was given to those technologies which are widely spread and mostly applied at steel plants. And the selection condition was that the technology should be evaluated as Rank ‘F’ and ‘A’.

- C is the evaluation which indicates the possibility of introducing a technology considering the

Indian circumstances and environment. The indices are the rate of diffusion of technology, energy saving effect by the technology

introduction, infrastructure facility for introducing the technology and the need for maintenance, possibility of financial support to introduce the technology, regulations and incentives etc.

All this information was acquired by conducting a questionnaire survey carried out with 5 major steel companies in India in last fiscal year.

Please refer to “Guidebook for diffusion of technologies on Technologies Customized List ver.1” (P5-6)

for more information on development methodology of Technologies Customized List.

[Prior Condition] Scope of our activities: Energy saving technologies of steel industry P1 Technologies with no/little experience, under development in Japan or out of scope are

considered not to be eligible. P2 Technologies related to quality of products of steel and steel making processes, such as

production rate, consumer’s request and raw material restriction, are considered not to be eligible in order to keep the “healthy competition” in the market.

P3 Non-commercialized technologies: Only technologies, which engineering suppliers have brought to market as “commercial products” and suppliers are able to provide, could be included in Technologies Customized List. On the other hand, these technologies have enough possibly to be dealt with on individual basis.

Annex Technologies for environmental protection: not eligible as energy saving technologies but important for Indian steel industry. Included in Technologies Customized List Annex. *Technology One by One Sheet of these technologies on the Annex will not be made.

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6

Electricity Savings

FuelSavings

CO2 Reduction

kWh/tof product

GJ/tof product

kg- CO2/t of product

Elec

trici

ty S

avin

g

CO

2 R

educ

tion

Prod

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Qua

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Wat

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avin

g

Fina

ncia

l

Tech

nica

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Ret

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Fina

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Tech

nica

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Sintering

1Sinter Plant Heat Recovery(Steam Recovery from SinterCooler Waste Heat)

- 0.251/t-sinter

23.9/t-sinter

SOx,NOx,Dust

A 34 2 NA NA NA NA 2 NA 1 2 1

2Sinter Plant Heat Recovery(Power Generation from SinterCooler Waste Heat)

22.1kWh/t-sinter - 19.9

/t-sinter- F 0 NA NA NA NA NA NA NA NA NA NA

3 High Efficient (COG) Burner inIgnition Furnace for Sinter Plant - 0.011

/t-sinter0.50

/t-sinter- F 45 1 1 NA NA NA NA 1 1 1 1

Cokemaking- 1.9

/t-coke135

/t-coke150

kWh/t-coke - 74.9/t-coke

5 Coal Moisture Control (CMC) - 0.3/t-coke

27.6/t-coke

- F 10 1 NA 1 NA NA 1 1 NA 1 1

Ironmaking

6 Top Pressure Recovery Turbine(TRT)

50kWh/t-pig iron - 45.0

/t-pig iron- A 28 2 NA NA NA NA 2 NA 1 2 1

7 Pulverized Coal Injection (PCI)System -

1.55/t-pig iron

(at 125kg coal inj.)

147/t-pig iron

- A 65 NA NA NA NA NA NA NA NA NA NA

8 Hot Stove Waste Heat Recovery - 0.08/t-pig iron

7.8/t-pig iron

- A 25 2 1 NA NA NA 2 1 NA 2 2

Steelmaking

9 Converter Gas Recovery Device - 0.84/t-steel

79.8/t-steel

- A 63[*3]

NA NA NA NA NA NA NA NA NA NA

10 Converter Gas Sensible HeatRecovery Device - 0.126

/t-steel12.0

/t-steel - A[*6]

Nodata


11 Ecological and Economical ArcFurnace

150kWh/t-steel - 135

/t-steel

DXN,Dust,Noise

F 0 NA NA NA NA NA NA NA NA NA NA

12 Waste Heat Recovery from EAF 87.7kWh/ｔ-steel - 78.9

/t-steel- F 0 NA NA NA NA NA NA NA NA NA NA

Recycling and Waste Reduction

13 Rotary Hearth Furnace DustRecycling System - 0.21

/t-pig iron22.8

/t-pig ironDust F No

dataNA NA NA NA NA NA NA NA NA NA

Common Systems

14Inverter (VVVF; VariableVoltage Valuable Frequency)Drive for Motors

42% - - - A Nodata


15 Regenerative Burner TotalSystem for reheating furnace - 0.17-0.21

/t-billet16.2-20.0/t-billet

NOx F 0 1 NA NA NA NA 1 NA NA 1 1

General Energy Savings & Environmental Measures

16 Energy Monitoring andManagement Systems - 0.12

/t-steel11.4

/t-steel- A No


17Cogeneration (include GasTurbine Combined Cycle(GTCC))

47.5 % (HHV)[*5] - 56.1

/t-steel- F No


18 Management of Compressed AirDelivery Pressure Optimization

285MWh/y - - - F No

data 1 1 NA NA NA NA 1 NA 1 1

19Power Recovery by Installationof Steam Turbine in SteamPressure Reducing Line

4,308MWh/y - - - F No


NA: Not applicable or No answer*1) Defined from JISF information; A: widely spread and mostly applied, F: well known and familiarized*2) Number of company replied to the questionnaire*3) Diffusion rate of OG boiler is Zero.

Countermeasuresexpected

Needs for TechnologiesIntroduction

Coke Dry Quenching (CDQ) A- NA4 11NANA

Co-benefits

35 1 1

*6) Gas sensible heat recovery system are commomly installed combined with converter gas recovery in Japan.

Barrier againstTechnologiesIntroduction

B ;ProficiencyLevel

ofTechnology inJapan[*1]

1

*5) /4,400 kJ/m3-N dry (LHV) （By COG heat increased BFG）

*4) Diffusion rate is estimated as (production capacity by applied technologies)/(total production capacity in 7 major steel works)　　Values were calculated from the answer for questionnaire and independent survey (King's report)

Customization Conditions for Indian Steel Industry

A ; Effect of Technologies Introduction

1 1

Table Recommended Customized List of Energy Saving Technologieswhich lead to CO2 Emission Reduction in Indian Steel Industry

No. Title of Technology

Diffusion Rate

ofTechnolo

gy in 7MajorSteel

Companies,%

[*4]

C; Conditions in India [*2]

6

7

9

TechnologiesOne by One Sheet2


11 8

10

12 9

11

13 10

12

14 11

13

15 12

14

16 13

15

17 14

16

18 15

17

・Reduction of CO2Emission

・Fuel Savings

・Electricity Savings

・Economic Effect（payback time）

・ProductivityImprovement

・Maintenance CostReduction

・Effect forconverter operations・Product QualityImprovement・SOx, DustDecrease・Water-saving

10. Preconditions* Investment cost , pay-back time and other important values are revised with referring to various values in thetable of Technologies Customized List ver.1, and revised ones are indicated in 【】.* Pay-back time is defined as (Investment cost / Economical merit) in this project.

7. Proficiency Level of Technologyin Japan Widely spread and mostly applied

8. Japanese Main Supplier * Nippon Steel & Sumikin Engineering Co., Ltd. * JP Steel Plantech Co.

9. Technologies Reference: *1 EU-BAT : 7.3.7

5. DirectEffect ( AnnualOperatingCost )

Payback time : 3.6years [NEDO]【 4.7years 】The investment required in 2007 was EUR 30.5 million for an ongoing project consisting of a gasholder of80,000 m3, blower fans, gas ducts, three way valves in the off-gas systems, security measures, erection andengineering, etc. About 80 % of the BOF gas will be recovered resulting in an annual energy savings of 2600TJ/yr = approximately EUR 12/GJ investment. Payback is about five years taking into account the savings in thepurchase of natural gas, exploitation costs. (EU-BAT)

Not announced

* The OG-type system is frequently used because of its operational stability. The OG-type cooling system makesit possible not only to recover the sensible heat of exhaust gas as steam, but also to increase the IDF efficiency bylowering the temperature of the exhaust gas by use of a cooling device.* As the steam is produced discontinuously, it cannot always be fully utilized. The use of recovered BOF gaswith suppressed combustion is much more flexible. The use of BOF gas in conjunction with blast furnace gasand coke oven gas, allows for the replacement of considerable amounts of primary energy resources, such asnatural gas.Increases the IDF efficiency by lowering the temperature of the exhaust gas, achieving high-speed oxygenfeeding[SOACT]

6. IndirectEffect（Co-benefits）

Not announced

* suppressed combustion reduces the quantity of flue-gas and thus reduces the cost of fans and dust removal.[*1]Reduced water requirement for off-gas cooling[ *1]

2. TechnologyDefinition/Specification

Molten steel is produced by the converter process. This device recovers and uses the high temperature waste gasgenerated in large quantity during blowing in the converter (basic oxygen furnace: equipment used to producecrude steel from pig iron, steel scrap, etc.)Accompanying this process, about 100Nm3 of high temperature gas (CO) with a heating value of approximately2,000 kcal/Nm3 is generated.Heat recovery methods are classified as (1) combustion method (boiler method) and (2) non-combustion method(method of recovering gas in an unburned condition: OG method. The advanced type is called the closed OGmethod). Recently, the closed OG method has become the main stream. The OG facilities are designed to recoverabout 70% of the latent heat and sensible heat. The converter gas recovered is mixed with other by-product gases(coke oven gas, blast furnace gas), then used by the heating equipment of the ironworks. Steam is mainly used bythe degassing equipment of the steel making factory. Today, gas recovery system are installed on every BOF inJapan.

3. Investment Cost　　　　　& Operating Life

Equipment cost: ￥600-1,100 million【35-65 Crore 】(equipment for 110 t/charge converter scale; includes construction cost)converter capacity: 110 t/charge.[NEDO]Operating Life : increased life by regular maintenance

4. Effect ofTechnologyIntroduction

79.8kg-CO2/t-CS [NEDO]

0.84GJ/t-CS [NEDO]LDG : 100Nm3/t-CS 2,000kcal/Nm3-OG (latent heat only)

-

1. Process Flow

Converter Gas Recovery Device[NEDO]

9 SteelmakingConverter Gas Recovery Device

Item Content

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18

・Reduction of CO2Emission

・Fuel Savings



・ProductivityImprovement・Maintenance CostReduction・Effect forconverter operations・Product QualityImprovement・SOx, DustDecrease・Water-saving

10. Preconditions

1. Process Flow

Converter Gas Sensible Heat Recovery Device[NEDO]

10 SteelmakingConverter Gas Sensible Heat Recovery Device

Item Content


12.0kg-CO2/t-CS [NEDO]

0.126GJ/t-CS [NEDO]LDG : 100Nm3/t-CS 30,000kcal/t-cs

-


Molten steel is produced by the converter process. This device recovers and uses the high temperature waste gasgenerated in large quantity during blowing in the converter (basic oxygen furnace: equipment used to producecrude steel from pig iron, steel scrap, etc.) Accompanying this process, about 100Nm3 of high temperature gas (CO) with a heating value of approximately2,000 kcal/Nm3 is generated.This device recovers and makes efficient use of the converter gas sensible heat. While the converter waste gasrecovery device recovers the waste gas itself, this device burns the converter waste gas to transform latent heat tosensible heat and recovers the energy as sensible heat. Therefore, it is structured to have a sufficient spacebetween the converter and the hood so that sufficient air can be supplied from the secondary air blower forcombustion. Principal equipments are the brackish water drum, the accumulator, and the boiler etc.

3. Investment Cost　　　　　& Operating Life

Equipment cost: ￥600 million【35 Crore 】(equipment for 110 t/charge converter scale; includes construction cost)converter capacity: 110 t/charge.[NEDO]Operating Life : increased life by regular maintenance

* Important values were revised with referring to various values in FYI, and revised ones were underlined.Especially as for investment cost and payback time, revised values were indicated in 【】 with underline.* Payback time is defined as (Investment cost / Economical merit) in this project.* Refer to http://www.nedo.go.jp/content/100107259.pdf

7. Proficiency Level of Technologyin Japan Gas Sensible Heat Recovery System are commomly installed combined with converter gas recovery in Japan.

8. Japanese Main Supplier Nippon Steel & Sumikin Engineering Co., Ltd., JP Steel Plantech Co.

9. Technologies Reference: *1 EU-BAT : 7.3.7

Not announced

Reduce temperature of waste water for off-gas cooling


Payback time : 44years [NEDO]Energy recovery by means of full combustion systems or suppressed combustion systems is widely applied atoxygen steel plants around the world. There is a tendency towards suppressed combustion systems, mainlybecause of logistic advantages compared to full combustion systems.(EU-BAT.[ *1])

Not announced

• No need for additional components other than conventional waste heat boiler.• Additional safety engineering measures are not needed other than conventional boiler technologies.

Not announced


Not announced

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19

20 18

11

20

21 19

12

21

22

20

13

22

22

20

23 21

14

23

24 22

15

24

25 23

16

25

・Reduction of CO2Emission・Fuel Savings


・Economic Effect（payback time）・ProductivityImprovement

・Maintenance CostReduction

・Product QualityImprovement・SOx, NOx, DustDecrease・Water-saving

10. Preconditions * Refer to http://asiapacificpartnership.org/japanese/soact2nd.aspx and http://www.nedo.go.jp/content/100107259.pdf

7. Proficiency Level of Technologyin Japan well known and familiarized

8. Japanese Main Supplier * Mitsubishi Heavy Industries

9. Technologies Reference:

*1 Practical example: Kimitsu Cooperative Thermal Power Company, Inc /4,400 kJ/m3-N dry (LHV) （By COG heat increased BFG）/http://www.tgn.or.jp/kmk/plant/machine05.html (Japanese)*2 EPA "AVAILABLE AND EMERGING TECHNOLOGIES FOR REDUCING GHG EMISSIONS FROM THE IRON & STEELINDUSTRY": IV.A9 p.31


Reduction of power purchase.

Not announced

World-largest gas turbine: Achieved an inlet gas temperature of 1,300℃ and realized the world-largest output asa blast furnace gas fired gas turbine by employing the most advanced technology to provide the vane with aforced cooling structure and anti-corrosion coating [*1]


Not announced

Low NOx emissions of 25 ppm[SOACT]

Not announced


This equipment is a high-efficiency(47.5%, HHV Base) combined generator set using the by-product gasproduced during iron and steel manufacturing process as the fuel.This equipment is an iron and steel by-product gas fired combined generator set, in which the gas turbine isoperated by high-temperature gas (1,300℃) generated by mixing the blast furnace gas with the coke oven gas tobe gas with a heat amount of 4,400kJ/m3N and burning it after the pressure is increased to about 1.4MPa. At thesame time the steam turbine is operated by the steam generated by directing the high-temperature (appprox.550℃) gas discharged from the gas turbine to the exhaust heat recovery boiler.[ *1]

3. Investment Cost & OperatingLife

Turbine systems : approx. $1000/kW. Total investment costs estimated to be $14.5/t crude steel.[SOACT]The type and size of CHP system utilized depends on a variety of site-specific factors including the amount andquality of off-gases from the coke oven, blast furnace, and BOF; the steam requirements of the facility, and theeconomics of generating power on-site versus purchasing power from the grid.(CHP;combined heat and power)CHP capital costs can range from $900 to $2,500/kW depending on size and technology. [*2]Operating Life : increased life by regular maintenance


56.1kg－CO2/t-PI [SOACT]

-

Increased electricity generation of 1.1 GJ/t crude steel (primary energy) [SOACT]47.5 % (HHV)[*1]

1. Process Flow

Ironworks by-product gas, single-fuel-firing, high-efficiency, combined generator set

17 General Energy Savings & Environmental MeasuresCogeneration ( include Gas Turbine Combined Cycle (GTCC))

Item Content

24

26

27 25

18

27

General Energy Savings & Environmental MeasuresPower Recovery by Installation of Steam Turbine

in Steam Pressure Reducing LineContent

Outline : In cases where high pressure steam generated by a boiler is used by pressure reduction, this technologyreduces refrigerator power consumption by installing a steam turning in place of the steam pressure reducing valveand driving the refrigerator with the power recovered by the steam turbine. Although steam consumption isincreased somewhat, a total energy saving is achieved.

approx. 50 million (Equipment), approx. 20million (Construction)

・Reduction of CO2Emission Not announced

・Electricity Savings 544 (approx.) kW →　544kW*24h*330d/y=4308 MWh/yDemerit: Increase of steam consumption, approx.0.8 (t-steam/h)


6,197.6(Gcal/y)=(Electricity Savings=114,00.2Gcal/y )-(Increase of Steam consumption=5,202.6Gcal/y)Reduction in crude oil equivalent: 619.8 t-crude oil/y (approx.)Equipment only : 0.7 years (approx.) 【5.8years】 , Including construction cost: 1.0 years (approx.)【8.1years】

・Monetary equivalentof energy savings ￥68 million/y 【 0.5 Crore/y】

・Maintenance CostReduction Not announced

6. Indirect Effect(Co-benefits)

・Product QualityImprovement Not announced

Numerous examples of implementation of similar technologies at main plants in Japan.

Kobe Steel, LTD.

・FY2000 Study Report “Survey of Energy Saving in Japan,” New Energy and Industrial TechnologyDevelopment Organization (NEDO), March 2001・“Collected Examples of Energy Saving,” p. 1,095, 1984 (in Japanese)* Important values were revised with referring to various values in FYI, and revised ones were underlined.Especially as for investment cost and payback time, revised values were indicated in 【】 with underline.* http://www.nedo.go.jp/content/100107259.pdfCost of power：¥17.99/kWhCost of C heavy oil：¥1.81/1,000kcalOverall boiler efficiency: 0.8Electricity conversion factor: 2646kcal/kWhSteam conversion factor: 656.9kcal/kg-steam

19

Principle, operation and features of technology: In this example in Fig.1, the capacity of the boiler which hadbeen installed was approximately steam pressure: 12 kg/cm2 and steam output: 50 t/h. However, this steam wasused as process steam after pressure reduction. In one case, the reduced-pressure conditions were 10 kg/cm2 and28t/h, and in another, 4 kg/cm2 and 22t/h (approximate values). That is, steam at a pressure of 12 kg/cm2 wasreduced to 10 kg/cm2 and 4 kg/cm2 by pressure reducing valves. In this example in Fig.2, a steam turbine is usedin place of a pressure reducing valve, and the system was modified so that a refrigerator is driven by the rotationalforce of the turbine using steam as a power source. Pressure reducing valves reduce pressure by causing a pressureloss when the valve port in the valve is restricted, utilizing the difference in enthalpy drop due to adiabaticrestriction. The principle of the steam turbine is the same as this, in that power is generated by utilizing thedifference in enthalpy drop. The energy saving by adoption of this system is as follows: Reduction of electricpower consumption – fuel for increase of steam consumption = Energy saving

7. Diffusion Rate of Technology in Japan

10. Preconditions

8. Japanese Main Supplier


5. Direct Effect (Annual OperatingCost)

3. Investment Cost & Operating Life


1. Process Flow

2. Technology Definition/Specification

Item

Fig. 1 Steam pressure reducing systembefore improvement

Fig. 2 System after improvement byintroduction of steam turbine

26

28

General Energy Savings & Environmental MeasuresPower Recovery by Installation of Steam Turbine

in Steam Pressure Reducing LineContent

Outline : In cases where high pressure steam generated by a boiler is used by pressure reduction, this technologyreduces refrigerator power consumption by installing a steam turning in place of the steam pressure reducing valveand driving the refrigerator with the power recovered by the steam turbine. Although steam consumption isincreased somewhat, a total energy saving is achieved.

approx. 50 million (Equipment), approx. 20million (Construction)

・Reduction of CO2Emission Not announced

・Electricity Savings 544 (approx.) kW →　544kW*24h*330d/y=4308 MWh/yDemerit: Increase of steam consumption, approx.0.8 (t-steam/h)


6,197.6(Gcal/y)=(Electricity Savings=114,00.2Gcal/y )-(Increase of Steam consumption=5,202.6Gcal/y)Reduction in crude oil equivalent: 619.8 t-crude oil/y (approx.)Equipment only : 0.7 years (approx.) 【5.8years】 , Including construction cost: 1.0 years (approx.)【8.1years】

・Monetary equivalentof energy savings ￥68 million/y 【 0.5 Crore/y】

・Maintenance CostReduction Not announced

6. Indirect Effect(Co-benefits)

・Product QualityImprovement Not announced

Numerous examples of implementation of similar technologies at main plants in Japan.

Kobe Steel, LTD.

・FY2000 Study Report “Survey of Energy Saving in Japan,” New Energy and Industrial TechnologyDevelopment Organization (NEDO), March 2001・“Collected Examples of Energy Saving,” p. 1,095, 1984 (in Japanese)* Important values were revised with referring to various values in FYI, and revised ones were underlined.Especially as for investment cost and payback time, revised values were indicated in 【】 with underline.* http://www.nedo.go.jp/content/100107259.pdfCost of power：¥17.99/kWhCost of C heavy oil：¥1.81/1,000kcalOverall boiler efficiency: 0.8Electricity conversion factor: 2646kcal/kWhSteam conversion factor: 656.9kcal/kg-steam

19

Principle, operation and features of technology: In this example in Fig.1, the capacity of the boiler which hadbeen installed was approximately steam pressure: 12 kg/cm2 and steam output: 50 t/h. However, this steam wasused as process steam after pressure reduction. In one case, the reduced-pressure conditions were 10 kg/cm2 and28t/h, and in another, 4 kg/cm2 and 22t/h (approximate values). That is, steam at a pressure of 12 kg/cm2 wasreduced to 10 kg/cm2 and 4 kg/cm2 by pressure reducing valves. In this example in Fig.2, a steam turbine is usedin place of a pressure reducing valve, and the system was modified so that a refrigerator is driven by the rotationalforce of the turbine using steam as a power source. Pressure reducing valves reduce pressure by causing a pressureloss when the valve port in the valve is restricted, utilizing the difference in enthalpy drop due to adiabaticrestriction. The principle of the steam turbine is the same as this, in that power is generated by utilizing thedifference in enthalpy drop. The energy saving by adoption of this system is as follows: Reduction of electricpower consumption – fuel for increase of steam consumption = Energy saving

7. Diffusion Rate of Technology in Japan

10. Preconditions

8. Japanese Main Supplier


5. Direct Effect (Annual OperatingCost)

3. Investment Cost & Operating Life


1. Process Flow

2. Technology Definition/Specification

Item

Fig. 1 Steam pressure reducing systembefore improvement

Fig. 2 System after improvement byintroduction of steam turbine

26

For your information Contact points of the suppliers

which were interviewed for the public and private meeting, 2012 -2013 Company Contact Points Technology

Chugai Ro Co., Ltd.

15: Regenerative Burner Total system for reheating furnace

JP Steel Plantech Co.

Yoshihiko ADACHI Address: 618,CWing,215Atrium,Andheri-KurlaRoad

Andheri(East),Mumbai-400059, Maharashtra, INDIA Tel: +91-22-6708-4313 Fax: +91-22-6708-4317 Mobile: +91-96191-46575 (India) Mobile: +81-90-5509-5285 (Japan) Email:[email protected] Masao Miki (General Manager) Norihiko Inoue (General Coordinator) Green Business Dept. Sales & Marketing Division JP Steel Plantech Co Address: 3-1, Kinko-cho, Kanagawa-ku,Yokohama 221-0056 JAPAN Tel: +81-(0)45-440-5908 Fax: +81-(0)45-440-5842

1: Sinter Plant Heat Recovery (Steam Recovery from Sinter Cooler Waste Heat)

2: Sinter Plant Heat Recovery (Power Generation from Sinter Cooler Waste Heat)

3: High Efficient (COG) Burner in Ignition Furnace for Sinter Plant

4: Coke Dry Quenching (CDQ) 6: Top Pressure Recovery Turbine (TRT) 7: Pulverized Coal Injection (PCI) System 8: Hot Stove Hear Recovery 9: Converter Gas Recovery Device 10: Converter Gas Sensible Heat Recovery

Device 11: Ecological and Economical Arc Furnace 12: Waste Heat Recovery from EAF 18: Management of Compressed Air Delivery

Pressure Optimization Mitsubishi Heavy Industries, Ltd.

Power Systems Project Engineering Department Power Systems Project Management Division Engineering Headquarters Address: 3-1, Minatomirai 3-Chome, Nishi-Ku, Yokohama 220-8401

JAPAN Tel: +81-3-6716-3111

17: Cogeneration (include Gas Turbine Combined Cycle (GTCC))

Mitsui Engineering & Shipbuilding Co., Ltd.

Madhu Ram Madhavan V.K. Managing Director, Representing Operations Manager of MES ME Consultancy Pvt. Ltd.(MEC) Address: D-3, Brownstore Apartments, Mahalingapuram,

Chennai-600034, Tamil Nadu, India TEL: +91-860-600-6263 E-mail: [email protected] Mitsui Engineering & Shipbuilding Co., Ltd.(MES) 6-4, Tsukiji 5-Chome, Chuo-ku, Tokyo 104-8439, Japan Tel: +81-3-3544-3951 Email: M. Dobashi, E-mail:[email protected]

S. Maruyama, E-mail:[email protected] A.Okuda, E-mail:[email protected]

6: Top Pressure Recovery Turbine (TRT)

Nippon Steel & Sumikin Engineering Co, Ltd.

Shunichi Takeda (Managing Director), Takuya Nazumi (Deputy General Manager) Nippon Steel Engineering India Plant & Machinery Pvt.Ltd. Address: The Millennium 4th Floor,235/2A AJC Bose Road, Kolkata,

700 020 Tel: +91-(0)33-4006-0927

4: Coke Dry Quenching (CDQ)5: Coal Moisture Control (CMC) 6: Top Pressure Recovery Turbine (TRT) 7: Pulverized Coal Injection (PCI) System 8: Hot Stove Waste Heat Recovery 9: Converter Gas Recovery Device 10: Converter Gas Sensible Heat Recovery

Device 13: Rotary Hearth Furnace Dust Recycling

System 15: Regenerative Burner Total system for

reheating furnace Nippon Furnace CO., LTD

Kazuhiko MasuiGroup Manager Plant & Process Engineering Sales Group Sales Division Address: 1-53,Shitte 2-Chome,Tsurumi-ku,Yokohama,230-8666 Japan Tel: +81-45-575-8007 Fax: +81-45-575-8131 Email: [email protected]

15: Regenerative Burner Total system for reheating furnace

Tsukishima Kikai CO., LTD.

Mrs. Meena TSK Mumbai Liaison Office Address: 602B,Excel Ark, Mercy Nagar, Ramdev Park Road, Mira Road

(E),Thane – 401 107, Maharashtra, India Tel: + 91-22-2815-2784 Email: [email protected]

5: Coal Moisture Control (CMC)

Kobe Steel, Ltd.

Tatsuro ShibataRotating Machinery Marketing Dept. Machinery Business Address: 9-12, 5-chome, Kita-shinagawa, Shinagawa-ku, Tokyo 141-8688

JAPAN TEL: +81-3-5739-6771 Email: [email protected]

19: Power Recovery by Installation of Steam Turbine in Steam Pressure Reducing Line

27

For your information

29


Used values and applied preconditions

Items unit Valuesusedin2011 ValuesusedforRevisionValue Reference Value Reference

1.Electricity(Power)

ConversionFactor

Electricity GJ/MWh(kcal/kWh)

9.8(2,341) worldsteel /IEA 11.4

(2,717) PAT_Rules_English.pdf(2012/3),p37

2.FuelCalorificValue

Oil(CrudeOil) kcal/kg 10,000 NEDO 10,000 MinistryofPowerNotificationS.O.394(E),12th

March,2007Coal kcal/kg 6,200 NEDO 6917* referredtoAnswerSheetfromIndia

3.EnergyCost

Electricity unit/kWh ￥15‐15.3 SOACT/NEDO 4.48**Rs/kWh

AnnualReport2011‐2012ontheworkingofStatePowerUtilities&ElectricityDepartments,PlanningCommission,GovernmentofINDIA

October,2011,p150CHeavyOil unit/Mcal ¥1.81 SOACT/NEDO 2.04Rs EnergyPricesandTaxes/IEAStatistics/2012

Coal unit/Mcal ¥0.61 SOACT/NEDO 1.4Rs* referredtoAnswerSheetfromIndia

4.CO2EmissionFactor

Electricity t‐CO2/MWh 0.504‐ 0.76

worldsteel /IEA/PlantSuppliers 0.90

CO2BaselineDatabasefortheIndianPowerSectoruser_guide_ver7,January2012,

GovernmentofIndia,p1CokeOven

Gas t‐CO2/GJ 0.044

worldsteel /IEA

0.044

referredtoAnswerSheetfromIndiaCoke t‐CO2/t‐coke 3.257 3.257Coal t‐CO2/GJ 0.095 0.095Steam t‐CO2/t‐steam 0.195 0.195

UnspecifiedFuel t‐CO2/GJ 0.095 0.095

5.CurrentExchangeRate

Rs/￥ 0.59atthecurrentexchangerate

in20thJan.,2013Rs/$ 53.70Rs/Won 0.05

*:averagevalue**:averagevalueinallpowerplantssupplyingelectricitytoSteelWorks

PDF と差し替え



Items unit Valuesusedin2011 Valuesusedfo n

11.4(2,717)

10,000

6917*

4.48**Rs/kWh2.04Rs1.4Rs*

0.90

0.044

3.2570.0950.195

0.095

0.5953.700.05

rRevisioValue Reference Value Reference


ConversionFactor


9.8(2,341) worldsteel /IEA PAT_Rules_English.pdf(2012/3),p37


Oil(CrudeOil) kcal/kg 10,000 NEDO MinistryofPowerNotificationS.O.394(E),12th

March,2007Coal kcal/kg 6,200 NEDO referredtoAnswerSheetfromIndia

3.EnergyCost

Electricity unit/kWh ￥15‐15.3 SOACT/NEDOAnnualReport2011‐2012ontheworkingofStatePowerUtilities&ElectricityDepartments,PlanningCommission,GovernmentofINDIA

October,2011,p150CHeavyOil unit/Mcal ¥1.81 SOACT/NEDO EnergyPricesandTaxes/IEAStatistics/2012

Coal unit/Mcal ¥0.61 SOACT/NEDO referredtoAnswerSheetfromIndia

4.CO2EmissionFactor


worldsteel /IEA/PlantSuppliers




worldsteel /IEA referredtoAnswerSheetfromIndiaCoke t‐CO2/t‐coke 3.257Coal t‐CO2/GJ 0.095Steam t‐CO2/t‐steam 0.195

UnspecifiedFuel t‐CO2/GJ 0.095


Rs/￥atthecurrentexchangerate

in20thJan.,2013Rs/$Rs/Won


29 28

30

TechnicalDescription3




Items unit Valuesusedin2011 ValuesusedforRevisionValue Reference Value Reference


ConversionFactor


9.8(2,341) worldsteel /IEA 11.4

(2,717) PAT_Rules_English.pdf(2012/3),p37


Oil(CrudeOil) kcal/kg 10,000 NEDO 10,000 MinistryofPowerNotificationS.O.394(E),12th

March,2007Coal kcal/kg 6,200 NEDO 6917* referredtoAnswerSheetfromIndia

3.EnergyCost

Electricity unit/kWh ￥15‐15.3 SOACT/NEDO 4.48**Rs/kWh

AnnualReport2011‐2012ontheworkingofStatePowerUtilities&ElectricityDepartments,PlanningCommission,GovernmentofINDIA

October,2011,p150CHeavyOil unit/Mcal ¥1.81 SOACT/NEDO 2.04Rs EnergyPricesandTaxes/IEAStatistics/2012

Coal unit/Mcal ¥0.61 SOACT/NEDO 1.4Rs* referredtoAnswerSheetfromIndia

4.CO2EmissionFactor


worldsteel /IEA/PlantSuppliers 0.90




worldsteel /IEA

0.044

referredtoAnswerSheetfromIndiaCoke t‐CO2/t‐coke 3.257 3.257Coal t‐CO2/GJ 0.095 0.095Steam t‐CO2/t‐steam 0.195 0.195

UnspecifiedFuel t‐CO2/GJ 0.095 0.095


Rs/￥ 0.59atthecurrentexchangerate

in20thJan.,2013Rs/$ 53.70Rs/Won 0.05


PDF と差し替え



Items unit Valuesusedin2011 Valuesusedfo n

11.4(2,717)

10,000

6917*

4.48**Rs/kWh2.04Rs1.4Rs*

0.90

0.044

3.2570.0950.195

0.095

0.5953.700.05

rRevisioValue Reference Value Reference


ConversionFactor


9.8(2,341) worldsteel /IEA PAT_Rules_English.pdf(2012/3),p37


Oil(CrudeOil) kcal/kg 10,000 NEDO MinistryofPowerNotificationS.O.394(E),12th

March,2007Coal kcal/kg 6,200 NEDO referredtoAnswerSheetfromIndia

3.EnergyCost

Electricity unit/kWh ￥15‐15.3 SOACT/NEDOAnnualReport2011‐2012ontheworkingofStatePowerUtilities&ElectricityDepartments,PlanningCommission,GovernmentofINDIA

October,2011,p150CHeavyOil unit/Mcal ¥1.81 SOACT/NEDO EnergyPricesandTaxes/IEAStatistics/2012

Coal unit/Mcal ¥0.61 SOACT/NEDO referredtoAnswerSheetfromIndia

4.CO2EmissionFactor


worldsteel /IEA/PlantSuppliers




worldsteel /IEA referredtoAnswerSheetfromIndiaCoke t‐CO2/t‐coke 3.257Coal t‐CO2/GJ 0.095Steam t‐CO2/t‐steam 0.195

UnspecifiedFuel t‐CO2/GJ 0.095


Rs/￥atthecurrentexchangerate

in20thJan.,2013Rs/$Rs/Won


29 28

TechnicalDescription3


Technical Description

Taking into account the discussion at "1. The Public and Private Collaborative Meeting between the Indian and Japanese Iron and Steel Industry" in 2012, "2. India-Japan Workshop on Promotion of Energy Efficiency and Conservation/Capacity Building under PAT” held in August 2013 and “3. Energy saving diagnosis in SAIL Bhilai steel plant”, technical description regarding the following technologies has been added.

Name of technology

Effective Utilization of Waste Plastics at Coke-Oven/Blast Furnace By-Product Gas Generator Set

These technologies are not listed on "Technologies Customized List & Technologies One by One Sheets".

30

32

Technical Description

Taking into account the discussion at "1. The Public and Private Collaborative Meeting between the Indian and Japanese Iron and Steel Industry" in 2012, "2. India-Japan Workshop on Promotion of Energy Efficiency and Conservation/Capacity Building under PAT” held in August 2013 and “3. Energy saving diagnosis in SAIL Bhilai steel plant”, technical description regarding the following technologies has been added.

Name of technology

Effective Utilization of Waste Plastics at Coke-Oven/Blast Furnace By-Product Gas Generator Set

These technologies are not listed on "Technologies Customized List & Technologies One by One Sheets".

30

1. Collection System of Waste Plastics in Community

2. Plastics Recycling by the Coke-Oven(1) Purpose:

(2) Feature of Technology:

Fig.2 ‘Waste plastics pre-treating and recycling process’ / Nippon Steel & Sumitomo Metal Co., [*2]

3. Plastics Injection into Blast Furnace(1) Purpose:

(2) Feature of Technology:

Fig.3　 Process flow from the material preparation till waste plastics injection into Blast Furnace [*3]

Technologies Reference:*1: http://www.jfe-plr.co.jpbusinessindex.html*2 :Nippon Steel Technical Report No.94,July 2006, p.75*3: http://www.jfe-steel.co.jp/recycle/index.html

3) Feed plastics formed into specific grain sizes are stored in a storage bin and then transferred to an injection station adjacent to a blast furnace. These plastics are transferred to blastfurnace tuyeres by high-pressure air flow and injected into the blast furnace along with hot blast.4) Injected feed plastics are instantaneously turned into reducing gas (CO, H2) due to high temperature in the furnace exceeding 2,000°C. This gas flows upward in the furnace andreduces iron ores.5) The reaction that takes place in the tuyere zone is equivalent to the mechanism where reducing gas is formed by the gasification of coke and pulverized coal; thus, injected feedplastics work in place of coke.

Effective Utilization of Waste Plastics at Coke-Oven/Blast Furnace

Fig.1 　Collection system of waste plastics from in-house through community to steel plant. [*1]

Figure 3 [*3] shows process flow of waste plastics for utilizing in Blast Furnace.1) Film waste plastics are formed into solid matter with grain sizes appropriate for blast furnace injection through being cut down by a shredder and granulated by a pellet machinethrough polyvinyl chloride (PVC) separator.2) Solid waste plastics, such as bottles and containers, are cut down by a shredder and formed into uniform grain sizes appropriate for injection into blast furnace.

Municipal waste plastic containers and packaging are agglomerated by using pretreatment equipment, whose process flow is shown in Fig.2. In the pretreatment process, wasteplastic is first crushed into pieces about 100 mm in size by a primary crusher and then any metals, heavy objects and other foreign matter are removed using a combination of magneticand pneumatic separators. They are then crushed into pieces of less than 20 mm in size by a secondary crusher in order to make it easier to transport crushed waste plastics to a coke oven.1 to 2% by mass of down sized and agglomerated waste plastic, together with the coal, is charged into the coke oven for carbonization. In a coke oven, it is converted into tar/light oil(about 40%), coke (about 20%) and coke oven gas (about 40%). Thus, it is confirmed that almost the entire amount of waste plastic could be utilized effectively. [*2]

Plastics disposed from in-house are gathered by a collectionsystem in community. Wasted plastics are separated and sorted,then pressed and packed. Baled waste plastics are transported intosteel plant. (Fig.1) For technology introduction of waste plastics injection into blastfurnace and its stable operation, it is indispensable that the wasteplastics collection system functions stably and some amount ofwaste plastics can be constantly collected.

1) Effective utilization of waste plastics, which are generally disposed by incineration or land-filling, as part of metallurgical coal.2) Reduction in emission of CO2 by avoiding incineration of the waste plastics and applying into chemical recycling which brings higher recycling ratio than that of material.3) Contribution to energy and resources saving, and environmental harmony.

1) Effective utilization of waste plastics, which are generally disposed by incineration or land-filling, as part of metallurgical coal.2) Reduction in emission of CO2 by avoiding incineration of the waste plastics and applying into chemical recycling which brings higher recycling ratio than that of material.3) Contribution to energy and resources saving, and environmental harmony.

31

33

(1) ”Recovery of waste heatfrom boilers”[*1 : p.4]

　By　preheating the water supplywith the economizer, thetemperature of the water supply atthe inlet to the　boiler is increased,reducing the amount of heatnecessary to generate steam.

(2) "High efficiency steamturbine"[*1 : p.213]

Figure shows the conventional-typeblade and improved-type blade,including the Schlict blade, theControlled Vortex Nozzle, theMultiple Fin Seal, stator, andelliptical packing.

(3) ”Conversion of existingthermal power plant” toexhaust gas　returning-typecombined cycle plant[*1 :p.217]

By installing high efficiency gasturbine generating equipment andusing the high temperature exhaustgas from the gas turbine ascombustion air for the existingboiler, an aging thermal power plantis improved to a gas turbinecombined cycle power plant.

(1) Enhancement ofcombustion management[*1 : p.8]

Minimizing the amount of air whileensuring that incompletecombustion does not occur istherefore an important requirementfor energy conservation.

TechnologiesReference:

By-Product Gas Generator SetGeneral Energy Savings & Environmental Measures

(2) Enhancement of steam leak prevention and heat retention measures

(3) Enhancement of condenser heat exchange tube contamination rate control

The ratio of fuel savings when the air ratio is reduced for a selection of exhaust gas temperatures.

Fig.1 Example of By-Product Gas Generator Set of Integrated Ironworks[*1:p.95}

*1 : NEDO ; Japanese Technologies for Energy Savings/ GHG Emissions Reduction <2008 Revised Edition>

Energy saving byintroducing newfacilities or improvingthe present facilities

Energy saving byimproving theoperability

The power station boiler of integrated ironworks is operated by using by-product gas such as blast furnace gas as the main fuel, supplying most of the power consumed at the ironworks.Then, facility and operation improvement measures are taken as energy-saving strategy. Fig. 1 shows a case example of By-Product Gas Generator Set of integrated ironworks.

32

34

(1) ”Recovery of waste heatfrom boilers”[*1 : p.4]

　By　preheating the water supplywith the economizer, thetemperature of the water supply atthe inlet to the　boiler is increased,reducing the amount of heatnecessary to generate steam.

(2) "High efficiency steamturbine"[*1 : p.213]

Figure shows the conventional-typeblade and improved-type blade,including the Schlict blade, theControlled Vortex Nozzle, theMultiple Fin Seal, stator, andelliptical packing.

(3) ”Conversion of existingthermal power plant” toexhaust gas　returning-typecombined cycle plant[*1 :p.217]

By installing high efficiency gasturbine generating equipment andusing the high temperature exhaustgas from the gas turbine ascombustion air for the existingboiler, an aging thermal power plantis improved to a gas turbinecombined cycle power plant.

(1) Enhancement ofcombustion management[*1 : p.8]

Minimizing the amount of air whileensuring that incompletecombustion does not occur istherefore an important requirementfor energy conservation.

TechnologiesReference:

By-Product Gas Generator SetGeneral Energy Savings & Environmental Measures

(2) Enhancement of steam leak prevention and heat retention measures

(3) Enhancement of condenser heat exchange tube contamination rate control

The ratio of fuel savings when the air ratio is reduced for a selection of exhaust gas temperatures.

Fig.1 Example of By-Product Gas Generator Set of Integrated Ironworks[*1:p.95}

*1 : NEDO ; Japanese Technologies for Energy Savings/ GHG Emissions Reduction <2008 Revised Edition>

Energy saving byintroducing newfacilities or improvingthe present facilities

Energy saving byimproving theoperability

The power station boiler of integrated ironworks is operated by using by-product gas such as blast furnace gas as the main fuel, supplying most of the power consumed at the ironworks.Then, facility and operation improvement measures are taken as energy-saving strategy. Fig. 1 shows a case example of By-Product Gas Generator Set of integrated ironworks.

32

35

Full List of Technologies136 energy saving technologies steel industry

Annex 1


33 34

36

34 35

37

35 36

38

Annex 2

Environmental TechnologiesRequested by India at the selection process ofTechnologies Customized List


Environmental technologies requested by Indian Steel Industry

Technologies for environmental protection requested by Indian Steel Industry are out of scope of Technologies Customized List on energy efficiency. However, both Indian and Japanese steel industry believe that these technologies should be transferred. Therefore, these technologies are included in Annex considering the growing demand for environmental technologies in India. Transfer of these technologies on this Annex will be discussed in future. *Technology One-by-One Sheet of these technologies is not prepared.

Candidate Environmental Technologies

No. Name of technologies Remarks Full ListNo.

1 Waste Water Treatment. *1 16 2 Reduction of SO2 from Coke Oven gas by Desulphurization 19 3 Dust Emissions Control

*2

4

4 Exhaust Gas Treatment through Denitrification, Desulfurization, and Activated Coke Packed Bed Absorption 5

5 Blast Furnace Gas and Cast House Dedusting 37 *1 : Requested by India *2 : Recommended from Japan based on request by India in FY2012

38

40

technologies customized list

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