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2007 RITE International Symposium

-Technologies for mitigating global warming and the role of Japan-

Challenges for GHG Reduction


鉄鋼業におけるエネルギー有効利用と
in Steel Industry
地球温暖化問題への取り組み

January 18, 2007


Toru Ono
Nippon Steel Corporation

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved. 0


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

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved. 1


Introduction

Iron & Steel Making Process Flow


Cold Rolling
Raw Materials Iron Making Steel Making Hot Rolling Steel Products
& Finishing

Raw Materials Energy Plants


Iron Making
Power
Boiler Oxygen
Coal Plant
Plant
Coke Oven
Blast Steel Making
Iron Pig Iron
Furnace
Ore
BOF
Continuous Crude Steel
Sinter Plant Molten Caster
Steel
Scrap EAF Steel

Heating
Long Products Furnace

Heating
Continuous Galvanizing Plate Furnace

Heating
Furnace
Continuous Annealing Hot coil
Finishing Cold Rolling Hot Rolling
Steel Products

Process Boundary
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Introduction

From the Point of View of Energy,


Waste
Plastics,
Highly Energy integrated process
etc.
Raw Materials Iron Making By-pro. Gas Energy Plants
Energy
Power
Coal Boiler
Conversion
Plant Oxygen
Plant
Coke Oven Energy Cascade
Blast Steel Making
Iron Pig Iron
Furnace
Ore
BOF
Continuous Crude Steel
Sinter Plant Molten Caster
Steel
Scrap EAF Steel
Waste
Waste Energy Heating
Heat Recovery Long Products Furnace

Heating
Continuous Galvanizing Plate Furnace
CO2
Heating
Furnace
Energy Continuous Annealing Hot coil
Cold Rolling Hot Rolling
Supply Finishing

Process Boundary

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Introduction

Energetic CO2 Emission in Japan by Sectors


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

482 466 Steel Sector :


-13Mt-CO2 (-6.9%)
195 182
Energy Conversion :
68 74 + 6Mt-CO2 (+8.8%)
1990FY 2005FY *Grid power is distributed to each sector with national average
CO2 emission by power generation
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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.
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Voluntary Action Plan

Achievement of the Activities


Energy-
Energy-Saving Contributions through Products
PJ Energy Consumption
2600
-7.6 Million ton-CO2
2519 -4.2% -7.1% -6.5%
2500

2400
2402
2354
2300 2340 Contributins through Byproducts
2010Target 2267PJ (-10%)
2200 -9.2 Million ton-CO2
Mt-CO 2 1990 1995 2000 2005
CO 2 Emission t-CO2 Assumption of Calculation

-6.9%
Conversion from Cement to Slag : 450kg-slag/t-cement
200 195.3
1000 CO2 Reduction Effect : 312kg-CO2/t-cement 924
-4.7% -7.4% 900
Domestic
800 Export 715
190 700 483
600 578
511 Domestic –4.8Mt
186.1 500
180 181.9 400
550
180.9 525
300 464
2010Target 177.7Mt (-9%) 200 441
Export –4.4Mt
170 100 165
0 47 53
1990 1995 2000 2005
160 -13.4 Million ton-CO2
150
1990 1995 2000 2005 Kyoto Mechanism
Crude Steel Production (Mt)
1990 1995 2000 2005
112 100 107 113
-5.6 Million ton-CO2

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Voluntary Action Plan

Keidanren’s 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.
1990 2005 Change Rate
Industrial sector in Japan
Mt-CO2 Mt-CO2 Mt-CO2 %
1. Iron and Steel Federation 195.3 182.0 -13.4 -6.9
2. Car manufacturing 7.6 5.7 -1.9 -24.4
3. Car parts 7.2 7.4 0.2 3.1
4. Petroleum Association 33.0 44.7 11.7 35.3
5. Chemical I. Association 68.3 75.2 6.8 10.0
6. Paper Association 25.4 25.1 -0.4 -1.4
7. Cement Association 27.4 21.8 -5.7 -20.6
8. Power companies (portion) 31.0 38.8 7.8 25.2
9. Electric appliances etc 11.8 18.7 6.9 58.0
10. Other sectors 39.0 33.4 -5.6 -14.4
11. Non-energy CO2 62.1 52.4 -9.6 -15.5
Keidanren Total 508.2 505.1 -3.1 -0.6

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Energy-
Energy-Saving Technologies

Efforts to Energy Saving


’70s ’80s ’90s ’00s ’10s
1)Process Innovation CC, C.A.P.L etc. PCI, CMC etc. SCOPE-21 etc.

2)Process Optimization HCR, ACC etc. AI, SCN etc. never ending improvement

3)Enhancement of Bypro. Gas Recovery Gas Holder, ACC H2 Supply, CO2 Capture

4)Waste Heat Recovery TRT, CDQ, etc Regenerative Burner etc. Low Temp. Recovery and Use

5)Waste Material Utilization Plastics, Tires Biomass


Net Consumption
Gross Energy Consumption

Process Innovation
Process Optimization
Recovery

By-pro. Gas recovery

Waste heat recovery

Utilization of Wastes
‘73 ‘80 ‘90 ‘00 ‘10
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Energy-
Energy-Saving Technologies

Coke Dry Quenching (CDQ)

Waste-heat recovery from hot coke


Improvement in coke quality

Cooling Chamber

Coke Basket Waste-heat boiler Turbine Generator


1050deg.C 860deg.C
High-pressure Steam
9MPa, 510 deg.C, 50t/H
Coke Oven
Coke Dust Collector
95t/H Cooling gas
130kNm3/H
HT LP G

130deg.C Pre heater


200deg.C Deairator
180deg.C
Cooling
Circulation Fan Water
Coke Carrier
Conveyer Process steam
Cooled Coke

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Energy-
Energy-Saving Technologies

Energy Recovery System in BF


BFG

DC

Blast VS
Furnace To Gas holder
Blast Blower Hot Stove VS

M BL
TRT G

195℃ 85℃

BFG

Air

Heat Medium Pump


Circulation
Tank

Hot Stove Waste-


Waste-heat Recovery System Top-
Top-pressure Recovery Turbine

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Energy-
Energy-Saving Technologies

Energy Recovery System in BOF

BOF gas is collected


Recovered Steam by OG system.

OG System
Drum
Water
接触
Direct
伝熱部
Heat
Sensible heat of BOF Exchang
gas is recovered by a er
Dust Collector
waste-heat boiler
Primary BOF Gas
equipped in the OG Radiator
system.
Upper Hood

Pump Lower Hood


下部フー
IDF
IDF

BOF

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Energy-
Energy-Saving Technologies

Trends of Waste-heat Recovery


Results in Kimitsu Works of Nippon Steel
150 25
Power generated

Waste-heat power rate


over total demand (%)
排 排
by waste-heat
熱 125 20 熱
回 回
100 収
収 15
発 発
75 電
電 10 比
量 50

25 5
(MW
(MW) (%)
) 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 年度
Steam generated

Waste-heat steam rate


over total demand (%)
排 160 100 排
by waste-heat

熱 熱
140 80 回

収 120 収

蒸 100 60

気 80 比
量 60 40

40 20
(t/H)
(t/H) 20
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
年度
Fiscal Year

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Energy-
Energy-Saving Technologies

ACC for Byproduct Gas Advanced Combined Cycle

Capacity : 300MW
Fuel : mixed BFG (4.4MJ/Nm3)
Gas temp. : 1300deg.C
Efficiency : 47.5%
LP Steam
MP Steam
Waste-heat Recovery Boiler HP Steam

Gas Compressor
Air Filter
Steam Turbine Power to grid
Gas Turbine Generator

Combustion
Chamber
Cooling Water

BFG+COG
Gas Filter

Gas Cooler

From Kimitsu Cooperative Thermal Power Company

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Energy-
Energy-Saving Technologies

Advanced Coke Oven (SCOPE-21)

Hot briquetting machine


Emission free
coal charging
Coal plug Dust collecting system
conveying system
Highly sealed oven door
Emission free
coke discharging
Pneumatic Emission free
preheater coke pushing
Emission free coke
Coking chamber travelling system

・Medium temp. carbonization


Coke upgrading
・Super denced brick & thin wall chamber
Fine Coarse ・Pressure control
Coal coal coal CDQ

Coke Blast
Fluidized bed dryer Coke quenching car furnace

High performance Coke Treatment


Coal Pre-treatment
Coke Oven

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Utilization of Waste Materials

Cross Sector Approach


Civil Life Iron/steel making process
(Serious needs for waste disposal) (Big potential for effective uses of wastes)

Cost Incineration is the High temp./reducing …


major method for
PA Ideal reaction processes
waste disposal in
Japan.
NIMBY Products can be used by
CO2 Emissions present processes

Solution for social problems


Social system design
High economic performance
Rule establishment
Global Warming Problem

To realize a material recycling society system


across sectoral borders
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Utilization of Waste Materials

Evaluation of Utilization of Waste Materials

Waste plastics Waste plastics


Coal, fuel (E) Waste tires Coal, fuel (E’) Waste tires
Steel mill System
Extension
Coke Oven Coke Oven
Incinerator Incinerator
Blast Furnace Blast Furnace

×
CO2 (A) + CO2 (B) CO2 (A’) + ZERO

Saving Natural Resources


Reduction of Total CO2 Emission
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Utilization of Waste Materials

Methodology of Waste Plastic Utilization-1


Material Preparation Process
供給コンベア Magnetic
磁力選別機 selector
From local
自治体ヤードより
governments
積込・輸送

Pre-crusher

Waste plastic
廃プラ受入

Primary selector CB eliminator Secondary crusher Pelletizer


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

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Utilization of Waste Materials

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

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Utilization of Waste Materials

Trend of Utilization of Waste Plastics


kt
500
420 440
Packaging Materials Recycling Law
400
Stated Apr. 1, 2000 350
290
300 270

200
150

100 70
30 30
0
1997 1998 1999 2000 2001 2002 2003 2004 2005

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Utilization of Waste Materials

Social System Design by Nippon Steel

Social System Design by Nippon Steel


Local Government
Gas(Fuel
Recovery ) Collection
Coal Waste
Plastic

Main Coke Sub


Products Products
Flow Oven Flow

Iron Making Raw Material


Coal+Iron ore Virgin Plastic

In 2002, Good Design Award was


granted to Nippon Steel for it’s Social
System Design of Waste Plastic
recycling.

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Challenges for the Future

A Scenario for Hydrogen Based Society in Japan

Japanese government
disclosed a scenario for
establishing a hydrogen based 15million FCVs

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
Coke oven gas in steel plant
becomes a promising
candidate for hydrogen source.

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Challenges for the Future

Potential of COG as a Hydrogen Source


N2
CO2 3%
3%
CmHn Dehydrater
3% CO H2 Compressor
6% Off gas
H2 Gas Holder
PSA
COG

COG H2 H2
H2

CH4 Composition 55%


30% vol% 55% 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 JHFC FCV Demonstration Project
5) Hydrogen consumption 11,430kg Served from Kimitsu Works
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Challenges for the Future

CO2 Capture from Blast Furnace Gas


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

Potential of utilization of unused waste heat


Captured CO2

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Challenges for the Future

An Image of Future Iron/Steel Plant

Steel Plant Iron Ore


Wastes Coal Energy
Waste Plastics Power, Gas,
Waste Biomass Iron/Steel Making Process Steam etc
Byproduct Gases
Hydrogen Energy Saving CCS

Unused Waste Energy
High Performance
Products
Byproducts
H2 Society Global Warming
Society with
High Energy Efficiency
Material Recycling
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International Collaborations

Trend of World Steel Production


2005: China growth
Mt World Population 6.5Billion
1200 World Steel Production 1130Mt

1990: Base year of Kyoto


World Population 5.3Billion
1000 Steel Production 770Mt
China
1974: After the 1st Oil Crisis Growth
World Population 4.0Billion
800 Steel Production 710Mt

1950: After WW-II


World Population 2.5Billion Fall of the Berlin Wall
600 Steel Production 189.6Mt
Plaza Agreement
1913: A year before WW-I 2nd Oil Crisis
World Population 1.7Billion st
Steel Production 79.5Mt 1 Oil Crisis
400

WW-I Economic WW-II


Panic
200

0
10

15

20

25

30

35

40

45
50

55

60

65

70

75

80

85

90

95
00

05
19

19
19

19

19

19

19

19

19

19

19

19
19

19

19

19

19

19

20

20
Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved. 25
International Collaborations

Trend of National Steel Production


Mt
400
China Growth
Year Crude Steel Production (million t)
350
1996 101 Over 100 million tons
2000 127 End of 20th Century
2001 151 +24
300
2002 182 +31
2003 222 +40 Rapid Growth
250 2004 272 +50
2005 350 +78

200
CIS
150
USA China
Jpn
Japan
100
France
Germany
50 Korea
India
0
10

15

20
25

30

35
40

45

50

55

60

65

70

75
80

85

90
95

00

05
19
19

19

19

19
19

19

19

19
19

19

19
19

19

19

19

19

19

20
20
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International Collaborations

Economic Growth and Steel Consumption


Domestic steel consumption and GDP/capita between 2000 and 2005
Domestic Steel Consumption kg-steel/capita
1200 2000 2001 2002 2003 2004 2005
Korea 851 839 953 991 1018 1002
Japan 627 592 578 599 629 648
Korea EU15 430 415 406 408 423 406
1000
Domestic Steel Consumption

USA 484 402 410 362 419 378


China 109 133 159 198 228 264
CIS 161 173 162 189 200 207
India 30 30 32 33 35 38
800 World 151 151 159 168 183 189
(kg/capita)

Japan
600
Germany
OECD
EU15 USA
400
China France
CIS UK
200 World average
Real GDP is calculated based on the annual GDP and exchange rates of 2000.
India Domestic steel consumption is defined as “National production + import – export”.
0
0 10000 20000 30000 40000 50000
GDP ($/capita)
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International Collaborations

Energy-Saving Model Projects


Governmental Project
13 (500kt-CO2/year)

Private Project
7 (900kt-CO2/year) 580
290 310
Korea
China

20

India 7
Thai

10 Projects by Nippon Steel


Malaysia Technology Installed Host Country Year Compreted CO2 reduction
BF-HS Waste Heat Recovery China 1995 29.8
(unit: kt-CO2) Coal Moisture Control China 1995 18.6
Coke Dry Quenching China 2000 68.3
BOFG Recovery China 2001 40.0
BF-HS Waste Heat Recovery China 2001 17.8
BF-HS Waste Heat Recovery Indea 2003 22.4
Total 196.9
kt-CO2/year
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International Collaborations

Status of Major Energy-Saving Technologies

コークス Top-
Top-pressure Recovery
Coke 乾式消火設備
Dry Quenching 高炉炉頂圧回 転炉ガス回収設備
BOF Gas Recovery
( CDQ) Turbine
収設備( TRT)
(%) 0 50 100 (%) 0 50 100 (%) 0 50 100

Japan
日本 8 5 Japan
日本 100 1 0 0Japan
日本 100

Korea
韓国 50 韓国
Korea 100 1 0 0Korea
韓国 25

米国
US 0 米国
US 2 米国
US 11

イギリス イギリス 00 イギリス


UK 0 UK UK 18

Germany
ドイツ 33 Germany
ドイツ 24 Germany
ドイツ 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.

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International Collaborations

Future Potential of CO2 Reduction

Potential of CO2 Reduction researched by NEDO


CIS
2120 (2)
East Euro.
1240 (8)

Middle East Asia


27 (1) 3390 (17)

Africa
59 (2)

Latin America
73 (5)

JI Candidates:3370kt-CO2(10Projects)

CDM Candidates :4970kt-CO2(25Projects)


kt-CO2/year (# of Project)

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International Collaborations

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.

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International Collaborations

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# Contents Chair
Pro.-1 APP Steel workshop Host Country Next meeting
Pro.-2 Status Review of Steel Industry Related Indicators for Energy Saving etc Japan
Pro.-3 Performance Indicators Setting Korea
Mar.14-16,2007
Pro.-4 Performance Diagnosis China, India
Pro.-5-1 State-of-the-art Clean Technology Handbook USA (co-chair JPN)
Calcutta, India
Pro.-5-2 Technology Deployment Australia

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International Collaborations

SOACT Handbook SOACT:State-of-Art Clean Technology)

SOACT Handbook is
under compiling to be
shared state-of-art
technologies relating
environmental
protection and
energy saving by the
member countries.

By the end of 2006,


53 of environmental protection technologies and 48 of energy
saving technologies are compiled. 63 technologies are
presented by Japan.

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved. 33


International Collaborations
Appendix

Importance of International Sectoral Approach

1,130Mt/year
Others 130 650Mt/year 1,000Mt/year
Australia 10
India 40
Korea 50
USA 90 460Mt/year
ugh io n: n
l: thro a t tio P
e ra k l e n A c
r al: a : AP
a t a g r y e i es
lt i-l Br e
S in nta
y-la -Chin
t
n tr
Mu CO 2
V olu B an
p cou
I Ja 6
IIS
China 350 460Mt/year
Japan 110

CIS 110
Canada 20
Other EU 60

EU15 160

World Total Kyoto Japan-China APP Kyoto+APP


Coverage 100% 40% 40% 60% 90%

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International Collaborations

IISI’s CO2 Breakthrough Program


Phase-1: Seeds research and development(until 2008)
Phase-2: Pilot projectト(2~5years)
Phase-3: Demonstration Plant

EU
North
ULCOS
American
Program
*Ultra Low CO2 Steelmaking
Korea Japan
Program Program
JISF
CO2 separation
Hydrogen production etc.
South
American
Program

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Conclusions

Future Directions
Past Present Future
Energy Saving through Performance Improvement
Steel Products and Byproducts
(eg.HITEN)

Process Innovation
Energy-Saving in Process
(eg.SCOPE-21)
APP, Bilateral etc.
International Collaboration
IISI CO2 Breakthrough
Waste Material Utilization
(Waste Plastics/Tires, Dust/Sludge)
Cross Sector Approach Hydrogen Supply

Low-Temp. Waste Heat Utilization


CCS

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved. 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 Wind farm in Hibikinada Coast

Copyright (C) 2005 NIPPON STEEL Corporation All Rights Reserved. 37

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