Japan

Research activity for energy conservation in

Eastern-Asian steel industry in fiscal year 2009.

Basic research for energy conservation

and environment protection
in Eastern-Asian steel industry.
(Final Report)
Presented at the 2nd ERIA Working Group Meeting
March 3, 2010
Jakarta, Indonesia

Yutaka Suzukawa
JFE Techno-Research Corporation, Japan

Japan

Purpose of the project

Research and analyze actual conditions of Eastern-Asian steel

industry in the field of energy conservation and environment

protection by referring to the Japanese countermeasures and to
specify effective energy saving and CO2 emission reduction
measures for each country. And build up the global database of
the Eastern-Asian steel mills, and execute trial calculation of the
potential CO2 emission reduction volume.
Target countries
Indonesia, Malaysia, Philippines, Singapore, Thailand, Brunei Darussalam,
Vietnam, Laos PDR, Myanmar, Cambodia, China, India, Republic of Korea,
Australia, New Zealand and Japan.

Japan

Trend of Energy Conservation Activities

of Steel Industry in Japan
Source : The Japan Iron and Steel Federation (2008)

20% reduction achieved

Target : 10% reduction

Steel Making Process (Blast Furnace System)

Japan

(See Energy Saving Measures on Page 5)

Raw Material
Iron Ore
Cokes

Blast Furnace

Scrap

Limestone

Electric Arc Furnace

Coke Oven Sinter Plant

Converter

Energy Source
Electricity
Coke/Coal
Natural Gas
Oil
Others

Products
Rail

Continuous

Casting
Reheating Furnace Rolling Mills
Machine

Bar
Wire
Shaped Bar
Thick Plates
Hot Rolled Coil
Cold Rolled Coil
Galvanized Plates
Welded Pipes
Seamless Pipes
Other products

Japan

Steel Making Process (Electric Arc Furnace System)

(See Energy Saving Measures on Page 7)
Scrap

DRI

Electric Arc Furnace

Energy Source
Electricity
Coke/Coal
Natural Gas
Oil
Others
Products

Continuous

Casting
Reheating Furnace Rolling Mills
Machine

Bar
Wire
Shaped Bar
Thick Plates
Hot Rolled
Coil
Galvanized
Plates
Welded Pipes
Other products

Japan

Energy Saving Measures

Japan

Facility
Coke Oven

Sinter Plant
Blast Furnace

Converter
Electric Arc Furnace
Hot Rolling
Power Plant
Gas Holder

Energy Saving Measures

Energy Saving Measures
Coke Oven Gas Recovery
Coke Dry Quenching
Coal Moisture Control
Main Exhaust Gas Waste Heat Recovery
Cooler Exhaust Gas Waste Heat Recovery
Blast Furnace Gas Recovery
Top Pressure Recovery Turbine
Hot Stove Waste Heat Recovery
Top Pressure Equalizing Gas Recovery
Pulvarized Coal Injection
Converter Gas Recovery
Converter Gas Sensible Heat Recovery
Scrap Preheating
Reheating Furnace Exhaust Gas Waste Heat Recovery
Gas Turbine Combined Cycle
Gas Holder for Each Gas

No.

Japan

Steel Production of the World (2009)

Country
China
Japan
India
Republic of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
New Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total
World Total

Process (1,000t)
BF ( A ) DRI ( B ) EAF ( C )
543,748
24,094
66,943
20,591
29,646
21,035
5,927
27,278
21,320
4,370
879
0
6,000
0
5,000
0
3,500
200
1,800
608
157
0
700
0
750
0
25
0
0
0
0
0
0
672,793
21,035
90,743
899,825
52,176 267,714

Crude Steel (1,000t)

( A )+( B )+( C )
567,842
46.6%
87,534
7.2%
56,608
4.6%
48,598
4.0%
5,249
0.4%
6,000
0.5%
5,000
0.4%
3,500
0.3%
2,000
0.2%
765
0.1%
700
0.1%
750
0.1%
25
0.0%
0
0.0%
0
0.0%
0
0.0%
784,571
64.3%
1,219,715 100.0%

Steel Production of the World

Japan
Country
China
Japan
India
Republic of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
New Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total
World Total

2007
489,288 36.4%
120,203
8.9%
53,080
3.9%
51,517
3.8%
7,939
0.6%
6,895
0.5%
5,565
0.4%
4,160
0.3%
2,024
0.2%
845
0.1%
718
0.1%
640
0.0%
25
0.0%
0
0.0%
0
0.0%
0
0.0%
742,899 55.2%
1,345,822 100.0%

BF
543748
66943
29646
27278
4370
0
0
0
200
608
0
0
0
0
0
0
672793
899825

DRI
0
0
21035
0
0
0
0
0
0
0
0
0
0
0
0
0
21035
52176

2009
EAF
24,094
20,591
5,927
21,320
879
6,000
5,000
3,500
1,800
157
700
750
25
0
0
0
90,743
267,714

09/07
Total
567,842 46.6%
87,534
7.2%
56,608
4.6%
48,598
4.0%
5,249
0.4%
6,000
0.5%
5,000
0.4%
3,500
0.3%
2,000
0.2%
765
0.1%
700
0.1%
750
0.1%
25
0.0%
0
0.0%
0
0.0%
0
0.0%
784,571 64.3%
1,219,715 100.0%

116%
73%
107%
94%
66%
87%
90%
84%
99%
91%
97%
117%
100%
106%
91%

Japan

Energy Saving Measures and Potential

(IEA)

Energy saving potential in steel industry (Mostly Blast Furnace System)

reported by IEA 2008, based on the best available technology.
10

Energy Saving Potential

(Blast Furnace System)

3,500
3,000
2,500
2,000
1,500
1,000
500

China
Japan
India
Re public of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
Ne w Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

2,654.2
72.0
210.4
27.1
24.8
0.0
0.0
0.0
0.0
2.6
0.0
0.0
0.0
0.0
0.0
0.0
2,991.2

0
Ch
in
a
Ja
pa
Re
n
pu
In
bl
d
ic
o f ia
K
or
A ea
us
tra
l
M ia
al
ay
s
Th ia
ai
la
In n d
do
ne
sia
V
i
N etna
ew
m
Ze
a
Ph lan
d
ili
pp
in
es
Si
ng
ap
Br
M ore
un
ya
ei
nm
D
a
ar
us r
sa
la
La m
o
PD
R
Ca
m
ER bo d
IA ia
To
ta
l

Energy Saving Potential (PJ/year)

Japan

Calculation is based on IEA2008 potential data and 2007 production data. 11

Japan

CO2 Reduction Measures and Potential

(IEA)

Potential of CO2 reduction in steel industry (Mostly Blast Furnace System)

reported by IEA 2008, based on the best available technology.
12

CO2 Reduction Potential (1,000t CO2/year)

Japan

CO2 Reduction Saving Potential

(Blast Furnace System) China
Japan
India
Re public of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
Ne w Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

300,000
250,000
200,000
150,000
100,000
50,000

228,727.7
6,074.0
17,585.1
2,355.0
445.8
0.0
0.0
0.0
0.0
47.5
0.0
0.0
0.0
0.0
0.0
0.0
255,235.1

0
a
in
h
C

pa
Ja

ia
d
In
ub
p
Re

of
c
li

ea
or

ia
d
re
R
ia
m
ia
m
al
ar
nd
es
d
lia
t
o
s
s
n
a
a
a
n
D
l
a
m
e
o
l
y
a
l
tn
P
b
a
tr
n
ap
pi
To
sa
ea
a
g
on
ai
s
p
ie
o
al
m
i
us
y
Z
h
n
d
a
l
u
V
IA
A
M
T
L
ar
In
Si
M
Ca
hi
R
ew
P
D
E
N
ei
n
r
Bu

Calculation is based on IEA2008 potential data and 2007 production data. 13

Energy Saving Potential

of Electric Arc Furnace

Electricity Consumption (kWh/ton)

Japan

Japan
SEA countries

900
800
700

SEA 420 kWh/t

600
500
400
300

Japan 370 kWh/t

200
100
0
0

20

40

60

80

100

120

140

160

Furnace Capacity (ton/charge)

14

Energy Saving Potential

of Electric Arc Furnace

Energy Saving Potential (PJ/year)

Japan

35.0
30.0
25.0
20.0
15.0
10.0
5.0

China
Japan
India
Republic of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
New Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

6.1
0.0
2.9
10.5
0.7
3.3
2.6
2.0
0.9
0.1
0.3
0.3
0.0
0.0
0.0
0.0
29.8

0.0
a
in
h
C

pa
a
J

a
di
n
I
ub
p
Re

of
il c

or

ea

e
a
l
R
m
m
ar
nd
es
di
lia
ta
sia
or
nd
sia
a
a
a
n
D
l
e
o
m
l
a
y
o
i
p
n
rt a
l
a
t
P
b
a
T
ea
on
ga
an
ai
pp
ss
ie
o
al
m
i
us
y
h
Z
d
n
a
A
u
l
a
i
V
i
r
I
n
A
M
T
L
I
S
M
C
a
ew
Ph
ER
ie D
N
un
r
B

15

CO2 Reduction Potential

of Electric Arc Furnace

CO2 Reduction Potential (1,000t CO2/year)

Japan

3,000
2,500
2,000
1,500
1,000
500

China
Japan
India
Republic of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
New Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

510.9
0.0
247.8
883.2
62.8
275.8
222.6
166.4
74.2
6.6
28.7
25.6
1.0
0.0
0.0
0.0
2,506

0
ia tal
re
ar lam DR
na pan dia rea alia ysia and esia am land nes
d
o
i
m
o
tn e a
I n K o s tr
n
il
pi gap an
Ja
To
sa o P mb
la
Ch
e
o
a
s
p
i
a
i
u
in My aru La Ca
V w Z hil
IA
of
A
M
Th Ind
S
R
c
e
P
D
li
E
i
N
b
e
u
p
rn
u
Re
B

16

Energy Saving Potential

of Reheating Furnace

Fuel Consumption (MJ/ton)

Japan

Japan
SEA countries

2500

2000

SEA 1,440 MJ/t

1500

1000

Japan 1,000 MJ/t

500

0
0

50

100

150

200

250

Heating Capacity of Furnace (ton/h)

17

Energy Saving Potential

of Reheating Furnace

250
200
150
100
50

China
Japan
India
Republic of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
New Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

193.1
0.0
19.2
16.5
1.8
2.0
1.7
1.2
0.7
0.3
0.2
0.3
0.0
0.0
0.0
0.0
237.0

Ch
in
a
Ja
pa
Re
n
pu
In
bl
d
ic
of ia
K
or
A ea
us
tra
l
M ia
al
ay
s
Th ia
ai
la
In n d
do
ne
sia
V
i
N etna
ew
m
Ze
a
Ph lan
d
ili
pp
in
es
Si
ng
ap
or
Br
e
u n My
a
ei
nm
D
a
ar
us r
sa
la
La m
o
PD
R
Ca
m
ER bod
IA ia
To
ta
l

Energy Saving Potential (PJ/year)

Japan

18

CO2 Reduction Potential

of Reheating Furnace China
Japan

CO2 Reduction Potential (1,000tCO2/year)

Japan

India
Republic of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
New Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

14,000
12,000
10,000
8,000
6,000
4,000
2,000

10,811.7
0.0
1,077.8
925.3
99.9
132.0
107.0
78.0
39.0
14.6
13.3
14.3
0.0
0.0
0.0
0.0
13,313

0
ia
d
ia rea
re
ia
ia
ia
m and nes
al
ar lam DR
na pan
d
l
t
o
s
s
n
d
i
a
a
m
e
o
l
y
a
n
r
l
P
I n Ko
b
a
ap an
n
pi
Ja
To
sa
Ch
et Zea
st
g
o
ai
s
p
i
o
al
m
i
u
y
h
f
d
a
in M
V w
il
ru
IA
o
A
M
T
La
In
S
C
a
h
R
e
il c
P
E
iD
N
b
e
u
p
un
e
r
R
B

19

Energy Saving Potential (Total)

Energy Saving Potential (PJ/year)

Japan

China
Japan
India
Re public of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
Ne w Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

3,500
3,000
2,500
2,000
1,500
1,000
500

2,853.3
72.0
232.6
54.1
27.4
5.3
4.3
3.2
1.6
3.0
0.6
0.6
0.0
0.0
0.0
0.0
3,258.0

0
a
an
in
p
h
C
Ja

di
In

Re

bl
u
p

ic

of

a
re
o
K

st
u
A

l
ra

ia
al
M

si
y
a

a
a
Th

d
s
ia
R
al
ia
m
re
m
ar
n
e
t
s
d
a
a
D
o
l
a
n
m
o
P
n
ne
tn
bo
T
al
pi
ap
sa
a
e
o
e
p
o
g
s
i
i
m
y
l
d
A
a
n
u
Z
i
I
a
V
i
M
L
In
S
C
ar
w
Ph
ER
e
D
ie
N
un
r
B

nd
li a

20

CO2 Reduction Potential (Total)

CO2 Reduction Potential (1,000t CO2/year)

Japan

China
Japan
India
Republic of Korea
Australia
Malaysia
Thailand
Indonesia
Vietnam
New Zealand
Philippines
Singapore
Myanmar
Brunei Darussalam
Lao PDR
Cambodia
ERIA Total

300,000
250,000
200,000
150,000
100,000
50,000

240,050.3
6,074.0
18,910.7
4,163.5
608.6
407.8
329.6
244.4
113.2
68.7
42.0
39.9
1.0
0.0
0.0
0.0
271,053.6

0
C

na
hi

d
r
d
R d ia
e
s
al
ia e a
ia
ia am
ia
m
a
r
n
l
e
t
n
d
s
D
s
a
a
o
In
or stra lay aila
To
nm sal o P
ne etn eal pp in ap
bo
a
K
o
a
g
h
i
m
y
IA
us
M
T
V w Z h ili Sin
La C a
of
nd
Au
r
M
I
R
a
P
E
e
l ic
D
N
b
i
pu
ne
e
u
R
Br

an
p
Ja

21

Japan

Advanced Technology
Advanced Electric Arc Furnace integrated with highefficiency shaft-type scrap pre heater (Advanced EAF).
Electricity
Consumption
420 kWh/ton
(ERIA Countries)

370 kWh/ton
(Japan)

270 kWh/ton
(Advanced EAF)

22

Japan

Advanced Technology
Regenerative Burner Heating System for Reheating Furnaces.
Fuel

Fuel

Burner B

Burner A

Furnace temperature
1350 C

Billets 1250 C

Ceramic
Regenerator B

Air
Exhaust gas 200

Switch valve

Fuel Consumption 20% compared with

conventional burner heating system.

Ceramic
Regenerator
A

23

Japan

Standardization of Steel Data Collection

In many ERIA countries, energy consumption and CO2
emission data are not collected nor statistically analyzed.
CO2 Data Collection System
(Worldsteel)
Worldsteel has issued the
method as a guideline . And
actual data collection among
worldsteel members based
upon the guide started in
2007.
This standard stipulates the method of comparing and evaluating the
quantity and emission factor of CO2 emissions by the entire steel
production process. This means that regardless of the equipment
configuration of each steel plant, it is possible to compare and evaluate
CO2 emissions of steel production processes worldwide by the same
method

24

Environmental Issues

Japan

Most countries have their environmental standards.

Example of Air Quality Standards.
Country
SOx
Japan

q=K10-3He2

China

NOx

Dust

220 ppm

150 mg/N

2860 mg/N

240 mg/N

150 mg/N

India

800 mg/N

500 mg/N

50 mg/N

Malaysia

2000 mg/N

200 mg/N

Thailand

800ppm
(25,1atm,O2 7%)

Indonesia

800 mg/
(25,1atm)

1000 mg/
(25,1atm)

Vietnam

500 mg/N

850 mg/N

Philippines

200 mg/N

180ppm
(25,1atm,O2 7%)

500 mg/N

240 mg/
(25,1atm,O2 7%)
230 mg/
(25,1atm,O2 10%)
200 mg/N
200 mg/N

25

Japan

Environmental Issues
Followings are the proposals for environmental issues.
1. Stimulate more concerns on environment.
Managers should appoint a person to treat environmental
issues. Education for environmental protection is
recommended.
2. Environment friendly operation and maintenance of
environment protection facilities are recommended.
Adopt low dust emission operation and plan periodical
maintenance of filters.
3. Make laws for utilization of steel by-products.

Make plans for effective use of slug.

4. Environmental protection regulations should be technically
and economically adoptable.

If not adoptable, they may hinder economic growth.

26

Japan

Prevalence of the Results

The report has been translated into English, and it will be open to public.
The report will be sent to Iron and Steel Institute of ERIA countries, steel
companies who have accepted our visit and all the representatives of ERIA
countries.

Acknowledgements
We would like to thank SEAISI and Iron and Steel Institutes of ERIA
countries for providing us valuable information. We also would like to thank
some steel companies for accepting our site visit and giving us operation data.
The advices and suggestions from the members of ERIA Project Advisory
Board which is organized in Japan are highly appreciated and were helpful for
preparing our final report.

27