Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

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Renewable and Sustainable Energy Reviews

journal homepage: www.elsevier.com/locate/rser

A review of energy use and energy-efficient technologies for the iron and MARK
steel industry
⁎
Kun Hea, Li Wanga,b,
a
School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China
b
Beijing Engineering Research Center for Energy Saving & Environmental Protection, Beijing 100083, China

A R T I C L E I N F O A BS T RAC T

/Keywords: The iron and steel sector is energy-intensive, and it consumed 18% of the world's total industry final energy
Energy consumption consumption in 2013. At present, according to the statistical data of International Energy Agency (IEA)
Energy-efficiency technology published in 2012, the iron and steel industry has the technical potential to reduce its current total energy
Steel industry consumption by approximately 20% by applying the best available technology (BAT), and more than half of this
technical potential may be obtained in China, where more energy-efficiency technologies/measures should be
implemented in the steel plants. So a review of energy-efficiency technologies/measures in steel industry could
be helpful for steel plants to improve their energy efficiency. Therefore, this paper presents a list of energy-
efficiency technologies and practices applicable to the steel industry, which includes case studies around the
world and information of energy savings and cost when available. Also, a brief overview of the steel industry
around the world, details and energy use conditions of different steel manufacturing processes, types of energy
use and specific energy consumption of steel industry and details of secondary energy are also included in this
paper to give readers a clear understanding of the energy use situation of the steel industry.

1. Introduction an average annual growth rate of 6.9% [34]. Rapid expansion of

The production process for manufacturing steel is energy-intensive
and requires a large amount of resources. In 2013, the iron and steel
sector accounted for 18% of the world's total industry final energy
consumption [1]. The energy efficiency of steel industry has a direct
effect on overall energy consumption. As such, improving energy
efficiency should be a primary concern for iron and steel plants,
especially in times of high energy price volatility.
Industrial energy intensity can be reduced through technological
progress [2]. There are many existing researches on steel industry from
a technical point of view [3–9], and the energy saving potential of
China [10,11] (including Taiwan [12]), the U.S. [13], Germany [14],
India [15], and the EU [16,17] has been assessed in scientific papers.
Besides the aforementioned studies, several reports and publications
on energy issues and energy-efficient technologies and measures [18–
33] of the iron and steel industry are also available in the literature.
There is no doubt more widely use of best available technology (BAT)
would greatly reduce energy intensity. However, at present, the
popularity of energy-saving technology in iron and steel industry still
needs to be improved.
Global crude steel production grew 96% between 2000 and 2014,
production capacity has had generally positive effects on the energy
efficiency of the industry. New plants tend to be more energy-efficient
than old ones, but not all new plants apply the best available technology
(BAT). Based on the International Energy Agency (IEA)’s statistical
data published in 2012, the iron and steel industry has the technical
potential to reduce its energy consumption by approximately 20% of
the current total energy consumption of the sector, by applying BAT,
and over 65% of this technical potential may be obtained in China [19].
There are various energy-efficiency opportunities that exist in every
steel plant, many of which are cost-effective; however, even cost-
effective options are not often implemented in steel plants, and part of
the reason for this phenomenon is the limited information. On the
other hand, BATs are always changing due to continuous radical and
incremental innovation. So a review of latest energy-efficiency tech-
nologies/measures in steel industry could be helpful for steel plants to
improve their energy efficiency.
The work presented in this paper is a unique study for iron and steel
industry, as an extensive literature review was conducted in this study
to obtain information on the energy use and energy efficiency mea-
sures/technologies for the iron and steel industry. This study reviewed
case studies from iron and steel plants around the world, and presents

⁎
Corresponding author at: School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China.
E-mail addresses: hekun0805@163.com (K. He), liwang@me.ustb.edu.cn (L. Wang).

http://dx.doi.org/10.1016/j.rser.2016.12.007
Received 19 June 2015; Received in revised form 6 September 2016; Accepted 3 December 2016
Available online 13 December 2016
1364-0321/ © 2016 Elsevier Ltd. All rights reserved.
K. He, L. Wang
a long list of 158 iron and steel sector-specific energy-efficiency
measures and technologies, including energy savings and cost informa-
tion, when available; in addition, references about other cross-cutting
measures that are in principle applicable across all manufacturing
industries are also given in this paper. Most of references used in this
paper are from China, Japan and U.S., which are major steel produc-
tion countries. We hope this study could be useful reference for global
policy makers, researchers, and industrial energy users and help create
a strong awareness of energy savings in the iron and steel industry.
In addition, the paper also gives an overview of the development
and present situation of world crude steel production, steel production
routes, breakdown of energy consumption by end use and production
process, and major secondary energy to give readers a clear under-
standing of steel industry.
2. Overview of the iron and steel industry
2.1. Development of the iron and steel industry
Iron, the precursor of steel, fueled the industrial revolution that
began in 1750, enabling manufacturing of equipment in factories and
rail transport. Modern steelmaking was developed 150 years ago with
the invention of the Bessemer process, resulting in affordable mass
production of steel (an iron alloy). This development set off a second
industrial revolution and sustained economic growth [35].
Modern iron and steel metallurgy began in the middle of the 19th
century and rapidly developed in the 20th century. According to
statistical data of the World Steel Association [36], world crude steel
production was as high as 28.3 Mt in 1900, maintained at over 100 Mt
since 1936, exceeded 200 Mt in 1951, and reached 850 Mt in 2000. In
Fig. 1. World crude steel production (1961–2014) [37].
Table 1
Two periods of rapid development in the iron and steel industry [38].
The first period of rapid development of iron and steel industry
Cause European countries, North America and Japan reconstructed infrastructure and
industrialized after the second world war
Period from the mid-1950s to the mid-1970s
Time of duration About 20 years
Increment rate 19 million t/year
Population involved About 800 million
Technical perspective Independent innovation technology in developed countries, such as converter,
continuous casting, computer automation
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Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039
the 21st century, the world crude steel production began increasing
further and reached 1670 Mt in 2014 (Fig. 1).
World crude steel production remained relatively constant between
1975 and 2000. Two periods of rapid development in the iron and steel
industry occurred after the 1950s, namely, the mid-1950s to the mid-
1970s and the late 1990s to the early 21st century. (Table 1).
As technological developments in the iron and steel industry were
achieved, energy consumption in this industry has been reduced.
However, while the steel industry has reduced its energy consumption
per ton of steel produced by 60% over the last 50 years, the field still
presents large energy saving potential [39].
2.2. Present situation of the iron and steel industry
The steel industry directly employed over two million people
around the world in 2011, along with two million contractors and four
million supporting industries. Considering the position of steel as the
key product supplied to various industries such as the automotive,
construction, transport, power, and machine goods industries, the steel
industry remains the source of employment for millions of people (
Fig. 2) [35].
In 2014, the world total crude steel production was approximately
1665 million tons, of which China produced 49.4%. The top 10 largest
crude steel-producing countries (China, Japan, the U.S., India, South
Korea, Russia, Germany, Turkey, Brazil, and Ukraine) produce over
80% of the world crude steel production ( Table 2) [40].
More than 1.6 billion tons of steel is manufactured and used every
year. Currently, 49.4% of the steel available is produced and used in
mainland China. The volume of steel produced will continue to
increase, particularly in developing areas, such as Latin America,
The second period of rapid development of iron and steel industry
China and some other developing countries constructed
infrastructure and industrialized
from the late 1990s, and still continuing
It is expected to continue until the second decade of the 21st century
60 million t/year
About 1.3–1.4 billion
Applying the mature technology or introduced the advanced
technology of developed countries
K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

Table 3
Crude steel production by process in 2014 [40].

OBC – oxygen-blown EF – electric OHF – open hearth

converter. furnace. furnace.
(%) (%) (%)

China 93.9 6.1

Japan 76.8 23.2
United States 37.4 62.6
India 42.3 57.5 1.4
Russia 66.6 30.6 2.8
South Korea 66.2 33.8
Germany 69.6 30.4
Turkey 30.2 69.8
Brazil 75.5 23.0
Ukraine 73.4 6.2 20.5
World 73.9 25.6 0.5

3. Iron and steel metallurgical process

The iron and steel industry has a complex industrial structure.

However, only a limited number of processes are applied worldwide,
Fig. 2. Steel used by sector in 2011 [35]. and these processes use similar energy resources and raw materials.
Globally, steel is produced via two main routes, namely, the blast
furnace–basic oxygen furnace (BF-BOF) route and the EAF route (
Fig. 3). The BF-BOF route, which utilizes iron ore and scrap, uses
Table 2
between 70% and 100% of iron ore, with the balance being made up of
Leading producers and users of the iron and steel industry in 2014 [40].
scrap. The EAF route, which utilizes direct reduced iron (DRI), scrap,
Production (Crude steel) Use (finished steel equivalent) and cast iron, uses between 70% and 100% scrap material, with the
balance being made up of ore-based materials [18].
Amount (Mt) Share (%) Amount (Mt) Share (%)
The key difference between the routes is the type of raw materials
China 822.7 49.4 710.8 46.2 they consume. The raw materials of the BF-BOF route are predomi-
Japan 110.7 6.6 67.5 4.1 nantly iron ore, coal, and recycled steel. By comparison, the EAF route
United States 88.2 5.2 106.9 7.0 produces steel using mainly recycled steel and electricity. Depending
India 86.5 4.9 75.3 4.9 on the plant configuration and availability of recycled steel, other
South Korea 71.5 4.3 55.4 3.6
Russia 71.5 4.3 43.1 2.8
sources of metallic iron, such as DRI or hot metal, can also be used in
Germany 42.9 2.6 39.2 2.5 the EAF route [35].
Turkey 34.0 2.0 30.7 2.0 The scrap/EAF route is less energy-intensive (which uses 4–6 GJ/t
Brazil 33.9 2.0 24.6 1.6 of iron produced when using 100% scrap) than the BF-BOF route
Ukraine 27.2 1.6 4.3 0.3
(which uses 13–14 GJ/t of iron produced). In EAFs using higher levels
World 1665.0 100 1537.3 100
of ore-based iron, energy use is higher. Significant energy savings can
be achieved by switching from BF-BOF to scrap/EAF production.
However, such changes may be limited by barriers, such as the
Asia, Africa, and the Indian subcontinent, where steel is vital in availability of scrap and the demand for higher grades of steel. In
improving the welfare of developing societies. In these regions, over China, India, and other emerging industrial economies, the BF-BOF
60% of the steel consumption will be used to create new infrastructure route continues to dominate production [18].
[39]. Molten steel is solidified in continuous casting machines and
In 2014, basic oxygen furnace (BOF) steelmaking currently ac- undergoes a series of hot and cold processes to produce various shapes.
counts for approximately 73.9% of the world production. Electric arc These shapes, coated or uncoated, are sold to manufacturers who
furnace (EAF) steelmaking accounts for just over 25.6% of the world- produce a myriad of steel products, e.g., automobile bodies, appliances,
wide production [40]. Another steelmaking technology, the open building frames, and support beams.
hearth furnace (OHF), accounts for approximately 0.5% of the global
steel production. The OHF process is energy-intensive and has not 4. Breakdown of energy use
been extensively used because of its environmental and economic
disadvantages. 4.1. Breakdown of energy use by end use
Among the major crude steel production countries, China, Japan,
Germany, Russia, Brazil, Ukraine, and South Korea produce most In 2013, the world total industry final energy consumption was
crude steel through the BOF process. China, the largest crude producer, 113,131 PJ, of which the consumption of the iron and steel sector
manufactures approximately 90% its crude steel through the BOF accounted for 18%. Fig. 4 shows the shares of different fuels used in the
process. The U.S., India, and Turkey are EAF-based countries, and world iron and steel industry. As shown in the figure, coal is the major
OHF process only accounts for a small portion of production in Russia resource for power generation, accounting for over 60% of the final
and India. In Ukraine, 20.5% of the crude steel is produced through the energy use; 21% of the final energy use is from electricity, 11% is from
OHF process ( Table 3). natural gas, and approximately 8% is from other energy sources (such

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K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

Fig. 3. Steel production routes [35].

Fig. 4. World total industry final energy consumption of the iron and steel sector in 2013
[1].

as oil, biofuels, waste, and heat).

Among the major steel-producing countries worldwide, China and
the U.S. primarily use the BF-BOF and EAF routes, respectively. In
2013, BOF steelmaking accounted for over 90% of crude steel produc-
tion in China, and EAF steelmaking accounted for approximately 60%
of crude steel production in the U.S. Overall, the Chinese steel industry
is more energy-intensive than the U.S. steel industry. This finding is
primarily, but not only, due to differences in the structural composi-
tions of the two industries. The U.S., for example, produces a
significantly greater share of the less energy-intensive EAF steel than
Fig. 5. Total energy use (fuel and nonfuel) in the iron and steel industries of the U.S. and
China [41]. China [41].
Fig. 5 shows the shares of different fuels used (as fuel and nonfuel)
in the U.S. and Chinese iron and steel industries. As shown in the
figure, the types of fuels used in this industry significantly differ consumption is related to the blast furnace (BF) process at approxi-
between the two countries. For example, in the U.S., natural gas mately 10–13 GJ/t crude steel, including the hot stove. Other large
accounts for 34.5% of the final energy use. In China, however, natural uses of energy include sintering (2–3 GJ/t crude steel), coke making
gas only accounts for 0.45% of the final energy use. (0.75–2 GJ/t crude steel), and steel rolling (1.5–3 GJ/t crude steel).
Ladle metallurgy and casting are of secondary importance (0–1 GJ/t
steel). Production of DRI using natural gas requires approximately
4.2. Breakdown of energy use by process
12 GJ/t crude steel. Meanwhile, EAF uses 1–1.5 GJ of electricity per
ton of crude steel produced [21]. Cast iron is usually produced in small-
In the process of iron and steel production, most of the energy

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K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

Table 4
Energy intensity of the average and the best plants in China [43]. (Unit: kgce/tonne steel).

process Coke making Sintering Pelleting Ironmaking (BF) steelmaking steelmaking Rolling Comprehensive energy
(BOF) (EAF) consumption

Chinese advanced level in 2008 Xinyegang Xinyu Taiyuan Taiyuan Taiyuan Bao steel Zongheng Sanming
61.33 39.04 17.44 363.85 −12.95 37.19 27.32 556.64
China's key steel enterprises 105.89 52.65 29.39 407.76 −0.16 73.98 61.69 604.60
average level in 2010
Difference value 44.56 13.61 11.95 43.19 12.79 36.79 34.37 47.96

Note: Data in the table are not comparability with data of other countries, as the conversion factor of electricity and coal are different.

Fig. 6. Current energy savings potential for the iron and steel industry, based on the BATs (published in 2012) [19]. Note: COG=coke oven gas; CDQ=coke dry quenching (also includes
advanced dry quenching); GJ/t=gigajoules per ton; EJ/year=exajoules per year.

scale BFs, which feature low efficiency compared with large BFs for
steel production. Table 5
There are considerable differences in the energy efficiency of Standard conversion factor.
primary steel production among countries and even individual plants
Monetary exchange rate
[42]. For the BF-BOF process, the gap in energy efficiency between the 1US$ 6.262 CNY
top and bottom countries is approximately 50% because of variations in 1US$ 0.6631 GBP
plant size, level of waste energy recovery, quality of iron ore, and 1US$ 0.9338 EUR
quality control. A few plants still use outdated technologies, such as 1US$ 121.3 JPY

OHFs and iron and steel ingot casting. In China, a gap exists between Energy exchange rate
the average and best plants, part of which is due to BF size and the level 1Kcal 4.184KJ
of heat recovery ( Table 4). 1kgce 29.27MJ

4.3. Energy saving potential of the world iron and steel industry

Worldwide, the iron and steel industry has achieved important
efficiency gains during the past 20 years. Iron and steel manufacturing
in all countries presents improved efficiency. However, the global
average level has not improved substantially.
Several opportunities exist within the iron and steel industry to
reduce energy consumption while maintaining or enhancing plant
productivity. Studies in the iron and steel industry have validated the
existence of a substantial potential for energy efficiency improvement
in almost all facilities, whether primary or secondary steel producers
[32].
IEA estimates that there has been substantial improvement in iron
and steel energy intensity in the recent past, and iron and steel industry
has the technical potential to reduce its energy consumption by 5.4 EJ
(Fig. 6), about 20% of the sector's current total energy consumption, by
applying BAT. More than 65% of this technical potential is in China.
In Japan, which ranks first in efficiency, potential energy savings
total only 1.0 GJ/t steel. Potential savings of 2.3 GJ/t steel in the U.S.
and 1.6 GJ/t steel in Europe (Organization for Economic Co-operation
and Development (OECD) member nations) have been reported.
Potential savings in China is 6.4 GJ/t steel, although a number of
other countries have higher potential in terms of energy reductions per
unit of steel produced. The average global potential is 4.4 GJ/t of crude
steel.
5. Energy efficiency improvement opportunities in the iron
and steel industry
In this part, an overview of energy efficiency technologies is
provided to help energy managers select areas for energy efficiency
improvement. The technologies that can be implemented at a plant
depend on the specifications of the installed facilities, as well as its
energy management and integration with upstream (e.g., production of
primary steel) or downstream (e.g., forming of steel products) activ-
ities.
Quantitative values for energy savings and cost of energy-efficient
technologies are also provided, and in some cases, two or more
references from different countries are provided; however, in some
cases, such quantitative values could not be derived. At all times, the
reader must bear in mind that the values presented in this studies are
provided as guidelines. Actual payback periods and energy savings for
the measures may vary, depending on plant configuration and size,

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 K. He, L. Wang

Table 6
List of energy-efficiency measures and technologies for sintering and pelletizing progress.

No. Energy-efficiency technologies and measures Fuel saving Electricity savings Capital cost ($) Payback period References
in sintering and pelletizing progress (year)

1 Sinter Plant Heat Recovery 0.55 GJ/tonne 4.7/tonne 2.8 [29]

[44]
2 Sintering waste heat power generation 234.16 MJ/tonne 1.95 miliion /plant with capacity of 1million t/ 3.1 [45]
y [46]
3 Pellets waste heat Recovery 87.81 MJ/tonne 1.45/tonne 6.8 [47]
4 District Heating Using Waste Heat 800 TJ/ /year using sinter cooler waste heat heating 5000 22.3 million for 5000 houses [31]
houses
5 Improved (Segregated) Charging of Materials 79 MJ/tonne 0.91 million/plant with capacity of 1million t/y 2.4 [30]
6 Improved Process Control 0.05 GJ/ tonne 0.21/tonne 1.4 [29]
[48]
[49]
7 Reduction of air leakage 1.7 kW h/tonne (when air leakage rate 0.12/toone 2.1 [50]
decline 10%) [32]
[51]
8 Increasing bed depth 23.64 MJ/tonne (10 mm) 0.38 million (annual production 1 million t) 1.6 [52]
9 Sintering waste heat energy recovery drive Efficiency increased by 5% 8.0 million /5000Kw exhaust fan 1 [28]
technology

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10 Use of waste fuels in sinter plant 0.18 GJ/ tonne 0.29/tonne 0.5 [29]
11 Selective Waste Gas Recycling- EPOSINT Coke conusmption and ignition gas consumption is 16.06 million/plant with existing waste gas [33]
Process reduced by 2–5 kg/t sinter and 10 MJ/ tonne, system and a suction area of 250 m2 [53]
respectively.
12 Low Emissions and Energy Optimized Solid fuel consumption is reduced by 12.5% 14.99 million for a 420 m2 sinter plant [33]
Sintering Process
13 Emissions Optimized Sintering Reduced coke breeze consumption by 12 kg/t-sinter (20% The system increased electricity 18.21 million for a sinter plant with 1.2 [33]
reduction) consumption by 3–8 MJ/ tonne MNm3/h waste gas flow from three sinter
strands.
14 Mini-pelletized sintering solid fuel saving 10~15% 0.20/tonne 1.6 [54]
15 Low temperature sintering Sintering solid fuel consumption decreased by 9 kg/tonne 0.19 million/ plant with capacity of 1million t/ 0.7 [55]
y
16 Grate-kiln pelletizing production 292.7 MJ/tonne 40.24/tonne 8.5 [56]
17 Liquid seal in sinter circular cooler 2.7 kW h/tonne 4.0 million/420 m2 sinter circular cooler 4–6 [27]
18 Improvements in Feeding Equipment [31]
19 Segregation of Raw Materials on Pellets [31]
20 Multi-slit Burner in Ignition Furnace Total heat input for ignition was reduced by approximately [31]
30%
21 Equipment to Reinforce Granulation [31]
22 Sintering machine ignition oven burner Ignition energy is reduced by approx. 30% [30]
23 Catalytic Combustion [57]
Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039
K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

Table 7
List of energy-efficiency measures and technologies for coke making progress.

No. Energy-efficiency technologies and measures in coke Fuel saving Electricity Capital cost (US$) Payback References
making progress savings period (year)

24 Coal moisture control 0.3 GJ/tonne 79.6 > 50 [29]

[58]
25 Programmed heating 0.17 GJ/tonne 0.37/tonne 0.7 [29]
[30]
26 Coke dry quenching 300 kW h/tonne 28.85 million/system 3.6 [30]
[59]
[60]
27 Variable speed drive COG compressor 6–8 MJ/tonne 0.47/tonne 21.2 [29]
[61]
28 Automation and Process Control System [31]
[62]
29 Tamping coking technology Weak caking coal used 124.57/tonne（including coke 6 [63]
increased by15% ~ 20% dry quenching）
30 Coke Oven Gas recovery 6 to 8 GJ/tonne 1 [21]
31 Non-Recovery Coke Ovens 630–700 kW h/ 365million for a plant [31]
tonne producing 1.2 million tons of [33]
coke [64]
32 Super Coke Oven for Productivity and Energy consumption Reduction in production cost [30]
EnvironmentalEnhancement towards the 21st Century reduced by 21% by 18% and construction cost [31]
(SCOPE21) by 16% [65]
33 Coke Stabilization Quenching reduce coke consumption [33]
by 1–2%
34 Modern Leak-proof Door [31]
35 Single Chamber System [29]

plant location, plant operating characteristics, and local supply of raw
materials and energy.
For all energy efficiency measures presented in this energy guide,
individual plants must pursue further research on the economics of the
measures and the applicability of different measures to their own
unique production practices to assess the feasibility of measure
implementation. When collect information of energy-efficient technol-
ogies from different countries, some standard conversion factor are
shown in Table 5.
5.1. Energy-efficient technologies and measures in the sintering
process
Pelleting and sintering of iron ore are complementary process
routes for preparing iron oxide raw materials for primary ironmaking
and steelmaking. Feed material to the sintering process includes ore
fines, coke, reverts (including blast furnace dust, mill scale, and other
by-products of steelmaking), recycled hot and cold fines from the
sintering process, and trim materials [29]. The sinter feed materials are
fused together by a flame, fueled by natural gas and/or COG, plus the
ignition of coal and coke fines in the sinter feed. The product is a hard-
fused material called sinter that is suitable for charging to the blast
furnace. These routes are highly influenced by local conditions, such as
the availability and type of raw materials.
The energy consumption of sintering process accounts for about
12% of total metallurgical energy consumption [42,43]. Energy-effi-
cient technologies and measures, such as increasing bed depth and
reduction of air leakage, have been extensively applied. Energy con-
sumption reduction and waste heat utilization technologies are key
development directions of energy saving.
5.2. Energy-efficient technologies and measures in the coke making
process
Coal pyrolysis means the heating of coal in an oxygen-free atmo-
sphere to produce coke (solid), gases and liquids. In this process, the
temperature of the flue-gases from under firing is normally 1150–
1350 °C indirectly heating the coal up to 1000–1100 °C for 14–28 h.
The duration depends, e.g. on the width of the oven (in the case of
heating by the side), the density of coal and on the quality of the
desired coke (e.g. use in foundries or blast furnaces) [33]. Coke is used
in blast furnaces for the chemical reduction of iron ore. The production
of one tonne of coke typically requires 1.25–1.65 t of coal and
generates 300–360 m3 of coke oven gas (COG; 6–8 GJ/t coke) [21].
The largest energy consumption in the coke making process is coal
gas used for heating. Coke must be cooled quickly when it leaves the
oven, in order to prevent burn-off and to achieve a high mechanical
stability. Reducing heat consumption, strengthening the recycling of
waste heat, and reducing electricity, steam, and water consumption are
key development directions of energy saving in the coke making
process.
5.3. Energy-efficient technologies and measures in the ironmaking
(BF) process
A BF is a vessel where iron ore is chemically reduced and converted
into liquid hot iron metal. Iron is produced in blast furnaces by the
reduction of iron-bearing materials with a hot gas. The large, refrac-
tory-lined furnace is charged through its top with iron ore pellets
(taconite), sinter, flux (limestone and dolomite), and coke, which
provides the fuel and forms a reducing atmosphere in the furnace.
Among several major processes, energy consumption of the ironmaking
process is markedly higher than that of other processes. In China,
which is the world's largest iron and steel producing countries, the
energy consumption of BF process accounts for about 70% of total
metallurgical energy consumption [42,43].
Energy-efficient technologies and measures in the BF process focus
on reducing fuel consumption (such as pulverized coal/oil/natural gas
injection, preheating materials, and dehumidifying blast technology)
and improving secondary energy recycling (such as top pressure

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 Table 8
List of energy-efficiency measures and technologies for Blast Furnace (BF) progress.

No. Energy-efficiency technologies and Fuel saving Electricity savings Capital cost (US$) Payback period References
K. He, L. Wang

measures in Blast Furnace (BF) progress (year)

36 Recovery of BFG 0.07 GJ/tonne 0.47/tonne 2.3 [29]

37 Pulverized coal injection [30]
[66]
38 Injection of natural gas to 140 kg/ton 0.90 GJ/tonne 7.8/tonne 1.3 [29]
iron
39 Injection of oil [33]
40 Injection of Plastic Waste [67]
[68]
41 Producing Pre-reduced Agglomerates [69]
42 Injection of COG [70]
43 Top pressure recovery turbines (wet 0.11 GJ/ tonne 31.3/tonne 29.8 [29]
type) [31]
[71]
44 Top pressure recovery turbines (dry 6.59 million (Generating capacity: 7000 kW) 1.8 [30]
type)
45 Cyclone type top combustion hot stove thermal efficiency increased by 8–12% 9.58 million/2500 m3 blast furnace capacity of 2million 2–4 [27]
t/y
46 Blast furnace blower driven by TRT and 397.34 TJ/y (1060m3 blast furnace) 2.40 million/1060 m3 blast furnace 1 [28]
motor in one shaft（BPRT）
47 Hot stove waste heat recovery device 0.125 GJ/tonne 1.23 million/system (plate type; includes civil 2.8 [30]
construction and installation costs)
48 Hot-blast stove automation 0.37 GJ/tonne 0.47/tonne 0.4 [29]
[72]
49 Recuperator hot-blast stove 0.08 GJ/tonne 2.2/tonne 8.7 [29]

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50 Improved blast furnace control systems 0.40 GJ/tonne 0.56/tonne 0.4 [29]
[73]
51 Blast furnace dewetting blast technology 19.90 MJ/tonne (wind humidity 4.79million/2 blast furnace blower units transformation 2 [24]
decreased by 1 g/m3)
52 Double preheating for hot stove Reduce 20 kg coke consumption (Hot air 1.86/tonne 3.1 [74]
temperature increase 100 ℃)
53 Use of High Quality Ore [33]
54 Increased Blast Furnace Top Pressure ( Furnaces operating at high pressures can produce [33]
> 0.5 bar Gauge) electricity in order of 0.35 GJ/t-HM if the system has [31]
recovery turbines installed
55 Increased Hot Blast Temperature( > 0.5 GJ/ tonne [31]
1100 °C)）
56 Improve Blast Furnace Charge [31]
Distribution
57 Blast furnace concentrate Ironmaking coke consumption decline 1– [75]
1.5% (ore grade increased by 1%)
58 Blast furnace gas steam drive blowing 220 GJ/y (2500m3 blast furnace) Compared to medium temperature and pressure 3.1 [76]
condensing steam-driven blower technology, increased
by 2.7/1000 Nm3 wind
59 Dry Process of Dust Removal direct: 9.95;MJ/ tonne indirect Decreased by 0.8/tonne compared to wet type [77]
Technology in Blast Furnace Gas :178.55 MJ/ tonne [78]
60 Blast furnace slag comprehensive Saving 45% limestone and 50% energy 31.15 million/ slag powder production line 3.4 [79]
utilization technology producing cement
61 Top Combustion Hot Blast Stove reduce energy loss through heat radiation [80]
from the stove body by 30%
62 Improvement of combustion in hot [29]
stove
63 Exhaust Heat Recovery System for Hot 10% reduction in the energy amount [81]
Air Stoves equivalent in the use with a 5000 m3 blast
(continued on next page)
Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039
K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

References recovery turbines, BF gases, slag recovery and utilization), and

increased efficiency of hot stoves.

[31]

[31]
[31]
5.4. Energy-efficient technologies and measures in the steelmaking
Payback period

(BOF) process

The basic oxygen furnace (BOF) is charged with molten iron and
(year)

scrap. The main operation in this process is addition of oxygen to

remove carbon from the iron to fabricate steel. Oxygen is injected
through a water-cooled lance, resulting in a tremendous release of heat
through the oxidation of carbon in the molten iron, with the CO
providing vigorous mixing of the charge as it leaves the vessel. Aside
from the oxygen, there is no fuel source needed to provide additional
thermal energy.
Although the energy consumption of the BOF process is the least
among several major processes, the BOF process still has energy saving
potential to achieve more efficient energy conversion and recovery and
more efficient use of secondary energy.
Capital cost (US$)

5.5. Energy-efficient technologies and measures in the steelmaking

(EAF) process

EAF is used to melt scrap, DRI, or pig iron. Compared with the BOF
process, the EAF process presents marked advantages in investment,
energy conservation, environment protection, and sustainable devel-
opment. In the EAF steelmaking process, the coke production, pig iron
production, and steel production steps are omitted, resulting in much
lower energy consumption. Generally, the energy intensity of steel
crude produced by EAF process are 60% lower than that produced by
BY-BOF process [42]. But due to the limited production of its main raw
materials-scrap, the EAF process is still not widely used in China.
A theoretical minimum energy of 300 kW h/t is necessary to melt
steel scrap. Additional energy is required to provide superheat above
the melting point and for typical tap temperature requirements, with
the total theoretical energy required usually in the range of 350–370
Electricity savings

kWh/t [21]. This energy can be supplied from the electric arc by fossil
fuel injection or scrap feedstock oxidation. Energy distribution is highly
dependent on product mix, local material, and energy costs and unique
to the specific furnace operation.
In the EAF process, reducing the energy consumption of electric arc
furnace is the main direction of energy saving. There are also some
energy-efficient technologies and measures for EAF process, such as
eccentric bottom tapping, using ultra high power transformers, oxygen
blowing, full foamy slag operation, oxy-fuel burners, carbon injection
and scrap preheating.

5.6. Energy-efficient technologies and measures in the casting process

Casting is the production of solid steel forms from molten steel.

Fuel saving

Once the final steel quality has been achieved, the steel is conveyed in a
furnace

casting ladle to the casting machines.

Casting can be either continuous casting or thin slab/near net shape
casting. Energy is only used to dry and preheat the ladles, heat the
measures in Blast Furnace (BF) progress

tundish, and for motors to drive the casting equipment. Thin slab/near
Energy-efficiency technologies and

Blast Furnace Heat Recuperation

net shape casting is a more advanced casting technique which reduces

High Pressure Ammonia Liquor

the need for hot rolling because products are initially cast closer to
their final shape using a simplified rolling strand positioned behind the
Modern Leak-proof Door

caster's reheating tunnel furnace, eliminating the need for a separate

hot rolling mill [42].
Aspiration System

Under the trend of higher integration of downstream transforma-

Table 8 (continued)

tion, new technologies, which include thick slab casting for thick plates,
direct strip casting for sheets, and rod casting, are being adopted to
achieve near net shape production. The general idea behind these
processes is to proceed from the molten metal directly to the desired
No.

shape with the desired mechanical properties and geometric tolerances

64

65
66

with limited or even absent intermediate processing, thus saving

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 K. He, L. Wang

Table 9
List of energy-efficiency measures and technologies for BOF progress.

NO. Energy-efficiency technologies and Fuel saving Electricity savings Capital cost (US$) Payback period References
measures in Steelmaking (BOF) progress (year)

67 BOF gas recovery 0.83 GJ/ tonne 4.95–9.07 million (equipment for 110 t/charge 8.3–15.2 [30]
converter scale; includes construction cost) [82]
68 BOF gas sensible heat recovery 0.126 GJ/tonne [30]
[83]
69 Variable speed drive on ventilation fans 0.003 GJ/ton of product 0.31/ton of product 9.9 [29]
[84]
70 Steel Slag Use [21]
71 Improved process monitoring and control [32]
72 Converter Negative Energy Steelmaking 731.75 MJ/tonne 2.48 milliion/converter capacity of 1 million t/y 0.8 [85]
73 Mechanical Vacuum pumps for steel 273.38 MJ/tonne Compared with an increase of 2.79 million to 1.5 [27]
degassing traditional steam jet vacuum system

1031
74 BOF Bottom Stirring [31]
75 Improved Ladle Preheating Reducing the amount of carbon (coke) used to raise steel [32]
temperature in a converter by 16%
76 Converter Gas Dry Dedusting Technology recycling more than 15–30 m3/tonne converter gas total electrical load is 52% of wet 11.61 million/250 t converter capacity of 3 million 3.3 [86]
dedusting technology t/y (wet type transformed into dry type)
77 MultiGas Analyzer – On-line Feedback for Potentially lowering continuous emissions monitoring (CEM) [31]
Efficient Combustion operational energy use by 70%, labor savings of up to 80%.
78 Hot Metal Pretreatment [31]
79 Increase Thermal Efficiency by Using BOF 535–916 MJ/tonne 20/tonne [31]
Exhaust Gas as Fuel
80 Use Enclosures for BOF [31]
81 Laser Contouring System to Extend the [31]
Lifetime of BOF Refractory Lining
82 Programmed and efficient ladle heating [29]
Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039
 K. He, L. Wang

Table 10
List of energy-efficiency measures and technologies for EAF progress.

No. Energy-efficiency technologies and measures in EAF Fuel saving Electricity savings Capital cost (US$) Payback period References
progress (year)

83 EAF gas waste heat recovery 130 kW h/tonne (efficiency 2.3 [87]
30%)
84 Improved process control 40 kW h/tonne 1.05/tonne [88]
85 Adjustable speed drives 0.05 GJ/tonne 2.0/tonne 1–3 [29]
86 Transformer efficiency—ultra-high power transformers 0.06 GJ/tonne 4.3/tonne 5.2 [29]
87 Bottom stirring/stirring gas injection 0.07 GJ/tonne 0.94/tonne 0.2 [29]
88 Foamy slag practice 0.07 GJ/tonne 15.6/ton of product 4.2 [29]
[89]
89 Oxy-fuel burners Reduce energy consumption by 30–45% [90]
[91]
90 Flue gas monitoring and control 25 kW h/tonne 3.6/tonne [88]
91 Eccentric bottom tapping on existing furnace 0.05 GJ/tonne 5.0/tonne 6.8 [29]
92 DC twin-shell with scrap preheating 0.07 GJ/tonne 9.4/tonne 3.5 [29]
93 Direct Current (DC) Arc Furnace 25–30 kW h/tonne 19.78 million/system 22.2–26.7 [30]
94 Electric furnace raw material preheating device 25–30 kW h/tonne 5.77 million/system 5.6–7.8 [30]
95 Scrap preheating, post-combustion—shaft furnace −0.70 GJ/tonne 0.43 GJ/tonne 9.4/tonne [29]
96 Engineered refractories 0.036 GJ/tonne [29]

1032
97 Airtight operation 0.36 GJ/tonne [29]
[92]
98 Contiarc furnace 0.72 GJ/tonne [29]
[33]
99 Comelt Furnace [32]
100 Electric supply optimization techniques 10–30 kW h/tonne 80,000 for technology application [93]
101 Scrap pretreatment and classification 2 million (annual production 1 4.6 [94]
million t steel)
102 Treatment and comprehensive utilization of steel slag [95]
103 Oxy-fuel Burners/Lancing 0.14 GJ/tonne 4.80/t crude steel on an EAF of [31]
110 t
104 Post Combustion Shaft Furnace (SIMETAL EAF Shaft) 120 kW h/tonne 6/tonne [31]
105 Ecological and Economical High Efficiency Arc [96]
Furnace
106 Continuous Horizontal Sidewall (CHS) Scrap Charging [31]
107 New scrap-based steelmaking process predominantly 32% reduction of primary energy intensity for liquid steel production [29]
using primary energy compared to the conventional EAF
108 Post-combustion shaft furnace 120 kW h/tonne 6/tonne [31]
109 Engineered Refractories [29]
110 EAF dust recycling [97]
Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039
K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

Table 11
List of energy-efficiency measures and technologies for casting progress.

No. Energy-efficiency technologies and Fuel saving Electricity Capital cost (US$) Payback period References
measures in Casting progress savings (year)

111 Continuous Casting 0.627–0.836 GJ/tonne 20–30 kW h/ 22.26–37.92 million/system (Capacity: 19.4–27.8 [30]
tonne 200,000 t/y)
112 Efficient caster ladle/tundish heating 0.02 GJ/tonne 0.09/tonne 1.3 [29]
[98]
113 Near net shape casting - thin slab 3.5 GJ/tonne 0.64 GJ/tonne 234.9/tonne 3.3 [29]
[99]
114 Direct Rolling (Integrated Casting and 40% lower than that needed for a [32]
Rolling) traditional rolling mill
115 Ladle Preheating [100]
116 Strip Casting – Castrip® Process 2 GJ/tonne compared to thick slab [31,32]
casting [101]
117 Continuous Temperature Monitoring An improvement in energy [31]
and Control efficiency of up to 5%
118 Steelmaking and continuous casting Steelmaking cycle decreased by 0.7985 million (annual production 1 4.6 [102]
scheduling optimization 21–23% million t steel) [103]
119 Rapidfire Edge Heater Energy saving 28% Capital and installation costs more than [104]
90% lower than reheat furnaces

energy and increasing productivity.
5.7. Energy-efficient technologies and measures in the rolling and
fishing process
Rolling and finishing are the processes of transforming semi-
finished shapes into finished steel products, which are used by down-
stream customers directly or to make further goods. Operations can
include hot rolling, cold rolling, forming or forging.
The amount of finishing energy required depends on the product.
Steel reinforcement bars and steel plates need only hot rolling.
However, steel for cars and white goods requires hot rolling and cold
rolling, as well as galvanizing or coating. Typical energy use is 2–
2.4 GJ/t for hot rolling and 1–1.4 GJ/t for cold rolling [21].
The heating furnace is the main energy-consuming equipment in
the rolling process that directly affects the energy consumption level
and costs. As such, reducing the energy consumption of the heating
furnace is the main goal of energy saving in the rolling process.
5.8. Energy-efficient technologies and measures in general
A list of general energy efficiency measures that could be used in
integrated iron and steel and EAF plants, and the cross-cutting
industrial systems that are in principle applicable across all manufac-
turing industries are given bellow ( Tables 6–13).
Crosscutting industrial systems include: Boilers and Steam
Systems, Compressed Air systems, Distributed Energy/Combined
Heat and Power (CHP), Motor systems, Pump Systems, Fan systems,
and Process Heating systems. 70 measures and technologies of cross-
cutting industrial systems have been summarized in [126], for more
information, references are given in Table 14.
6. Secondary energy of the iron and steel industry
The iron and steel industry is a typical energy-intensive industry
that can produce a significant amount of residual heat and waste
energy during the production of goods along with significant consump-
tion of electricity and steam. Thus, using secondary energy resources,
such as coal gas and waste heat in the processing industry is important.
Combined heat and electricity is sufficient for heat and electricity
users in the processing industry. For example, in the iron and steel
industry, secondary energy resources, such as by-product gases, waste
heat, and top pressure of BF, are abundant. These resources can be
used to generate power or steam and as fuel in the production process.
Utilization of secondary energy is an important part of the energy
saving of iron and steel enterprises.
6.1. By-product gases
By-product gases are important secondary energy resources of the
iron and steel industry, and its amount can be up to 30–40% of the
total energy consumption of the iron and steel industry. By-product
gases mainly refer to BFG, LDG, and COG ( Table 15). The utilization
conditions of by-product gases differ in different countries. In China,
by-product gases are still flared away. By contrast, in Japan and
Germany, by-product gases are all recovered and used [139].
BF gas is a by-product of the furnace process. The low heating value
of BF gas limits its use for blast heating, hot mill reheating furnaces,
coke oven heating, power production, or recycling the BF. Significant
amounts of BF gas are still flared away during periods when supply
exceeds demand. Older power plants use BF gas together with natural
gas or oil, often in a steam cycle. Combined gas turbines and steam
cycles can produce electric efficiencies in excess of 42% in steel mill
applications, which represents an important efficiency gain.
Off-gases from BOF and EAF have temperatures greater than
1650 °C, low pressures, and amount to approximately 6–8 MJ/m3.
Off-gases have a low fuel value during the steelmaking cycle. Off-gases
are generated intermittently, present significant variations in tempera-
ture and carbon monoxide and nitrogen concentrations, and are dirty.
For this reason, off-gases are still flared away at many sites. However,
technologies that use the energy content of the gas exist. Larger gas
storage systems can be part of the solution.
COG is rich in hydrogen and, therefore, has a relatively high heating
value. At most steel plants, COG is used to heat the coke oven, fuel
equipment such as boilers, and reheat furnaces. Overall efficiency can
be improved if the coke oven is fired with BF gas and the COG is set to
higher-quality use, e.g., power generation. Some plants convert COG
into chemicals. Although COG-fired steam cycles achieve approxi-
mately 30% efficiency, combined cycles can yield over 42% electrical
efficiency.

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Table 12
List of energy-efficiency measures and technologies for rolling progress.

No. Energy-efficiency technologies Fuel saving Electricity savings Capital cost (US$) Payback References
and measures for rolling (GJ/tonne) period (year)

Energy-efficiency technologies and measures for rolling mills

120 Energy efficient drives in the hot 0.01 GJ/tonne 0.30/tonne 3.2 [29]
rolling mill [105]
121 Install lubrication system 0.016 GJ/tonne [29]
[32]
[106]
122 Variable frequency drive in 311817.6 kW h for 0.25 [107]
descaler unit One year

Energy-efficiency technologies and measures in hot rolling progress

123 Hot charging 0.25–0.51 GJ/tonne 0.34/tonne 2.2 [108]
[109]
124 Process control in hot strip mill 0.30 GJ/tonne 1.1/tonne 1.2 [29]
[110]
[111]
125 Insulation of furnaces 0.16 GJ/tonne 15.6/ton of product 31.0 [29]
126 Flameless burners [112]
127 Walking beam furnace 25% [29]
128 Controlling oxygen levels and/or 0.33 GJ/tonne 0.79/ton of product 0.8 [29]
speed on combustion air fans
129 Waste heat recovery (cooling 0.03 GJ/tonne 1.3/tonne > 50 [29]
water)
130 Regenerative Burners for 0.167–0.209/tonne 5.77 million/system 0.7 [30]
Reheating Furnaces (including furnace) [100]
131 Heat Recovery to the Product 50% reduction of the unit energy consumption at a [100]
temperature above 650 °C，and 70–80% reduction [113]
at charging temperature above 980 °C
132 Throughput Optimization in [114]
Rolling Mills
133 Thermochemical Recuperation Reduce the fuel consumption in the furnace by 25% [115]
for High Temperature Furnaces
134 Proper Reheating Temperature [116]
and time [117]
135 Preventing Scale Formation in [118]
Rolling
136 Multi-line Syncopate and 149.28 MJ/t 1.597 million for a 0.8 1.5 [27]
controlled rolling and cooling million t/y bar
production-line
137 Low temperature rolling 182 kW h/tonne 0.42/tonne 2.7 [119]
138 Endless Strip Production (ESP) Comprehensive energy saving 20% 25.70/tonne [32]
[120]
139 Direct quenching (DQ) 24.4% 13.29 million Heat 4.5 [121]
treatment capacity of 0.1
million tons）
140 Steel rolling oxide iron scale Sintering fuel consumption decreased by 3.4%( 7.33 million /system 3.4 [122]
recycling Sintering process with 3% addition oxide iron capacity of 0.15 million t
scale) oxide scale /y
141 Avoiding overload of reheat [123]
furnaces

Energy-efficiency technologies and measures in Cold Rolling and Finishing progress

142 Heat recovery on the annealing 0.30 GJ/tonne 0.02 GJ/tonne 4.2/tonne 4.0 [29]
line
143 Reduced steam use (pickling 0.19 GJ/tonne 4.4/tonne 7.3 [29]
line)
144 Automated monitoring and 0.21 GJ/tonne 1.7/tonne 0.8 [29]
targeting system
145 Inter-Electrode Insulation in [30]
Electrolytic Pickling Line [124]
146 Continuous Annealing 33% in a Japanese plant [32]
147 Reducing Losses on Annealing 25% [32]
Line
148 Process optimization [125]

6.2. Waste heat
Waste heat is another important secondary energy resource in the
iron and steel industry. In China, 8.44 GJ residual heat is generated per
ton of steel produced, of which only 28% is recovered. As such, waste
heat recovery and utilization in the iron and steel industry has
significant potential.
Waste heat is generally used in two ways, namely, power use and
heat utilization. Power use refers to the conversion of waste heat into
electricity or mechanical energy. Heat utilization refers to the use of
waste heat to preheat air and dry products and to supply hot water or
steam and heating [144] ( Tables 16–17).
7. Conclusions
The production process for manufacturing steel is energy-intensive

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K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

Table 14
References Cross-cutting industrial systems.

[127]

[128]
[129]
[130]
[131]
[29]

[30]
[28]
[26]
[27]
Cross-cutting industrial systems References
Payback period (year)

Boilers and Steam Systems [126]

[132]
Compressed Air systems [126]
[133]
Distributed Energy/Combined Heat and Power (CHP) [126]
[134]
Motor systems [126]
5.6

0.5
0.5

[135]
Pump Systems [126]
16.51 million for a 10 million t annual production enterprise

[136]
Fan systems [126]
[137]
Process Heating systems [126]
[138]
Lighting system [126]
0.56 million/1.5 million t heating furnace
1.72 million (Reform 4×50 MW units)

Table 15
By-product gas resources in the iron and steel industry [21,140–142].

Chemical composition Heat value Production/t product

Capital cost (US$)

4 million /system

3
BFG H: 4% 3000–3800/m 1400–1800 m3/ton of
0.02/tonne

CO: 25%, iron

855.2/kW

CO2: 20%
The rest is N.
LDG CO2: 15–20%, 7500–8000 kJ/m3 80–100 m3/ton of liquid
O2: ≤2.0%: steel
Electricity savings

CO: 60–70%
0.02 GJ/tonne

N2: 10–20%
H2≤1.5%.
COG H2: 45–64%; 16,000– 19,300 kJ/ 400–450 m3/ton of coke
CH4: 20–30%; m3
CO: 5–10%;
CO2: 2–5%;
Energy consumption decreased by 30%

O2: 0.1–4%;
38.05–64.39 MJ/t storage capacity

CnHm: 0.1–3%.
CCPP efficiency increased by 0.5%
Improve energy efficiency 2–5%

191.43 MJ/tonne

and requires a large amount of natural resources. There has been

0.43 GJ/tonne

significant investment in new products, plants, technologies and

Fuel saving

operating practices. The result has been a dramatic improvement in

the performance of steel products, and new plants tend to be more
energy-efficient than old plants. But not all plants apply the BATs and
there are still energy saving potentials, and part of the reason is the
Combustion system optimization of carbon ring-baking furnace

limited of information on energy-efficiency technologies and measures.

This study gives a review on the energy use and energy efficiency
The blast furnace gas boiler power generation technology
Energy-efficiency technologies and measures in general

measures/technologies for the iron and steel industry, and summarizes

List of energy-efficiency measures and technologies in general.

Waste water recycling (double-membrane process)

a large number of energy-efficient, cost-effective, and available tech-

nologies. Energy efficiency improvement opportunities that are applic-
Raw material yard dust suppression technique
Gas turbine pilot fuel alternative technologies
Energy monitoring and management system

able at the component, process, facility, and organizational levels are

Steel manufacturing process optimization

all included. In addition, typical investment payback periods and

Strengthen heating furnace radiation
High efficiency gas separation plant

references to further information in the technical literature are

provided, when available. At all times, the reader must bear in mind
that the values presented in this paper are offered as guidelines. Actual
payback periods and energy savings for the measures may vary,
Preventive maintenance

depending on plant configuration and size, plant location, plant

operating characteristics, and local supply of raw materials and energy,
and several other factors.

Acknowledgements
Table 13

NO.

149
150
151
152
153
154
155
156
157
158

The authors are grateful for the supports of the National Natural
Science Foundation of China (Grant no. 51276016) and the National

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K. He, L. Wang Renewable and Sustainable Energy Reviews 70 (2017) 1022–1039

Table 17

High temperature flue gas: coke oven gas, converter gas, electric furnace gas and heating furnace flue gas etc.;
Typical recovery and utilization of waste heat resources [145].

Blast furnace gas and sintering flue gas, exhaust gas recovery of waste heat from the primary after flue gas etc.
Technology Heat recovery Energy savings
efficiency (%) kgce/tonne
Waste steam and hot water, all kinds of low temperature flue gas and low temperature materials etc.

product)

High temperature solid: sintering materials, high temperature coke, high temperature steel etc. Effectiveness of product sensible heat recovery under different modes
Coke sensible heat power generation (coke 34% 51.5
dry quenching)
Sinter sensible heat producing low pressure 17% 10.2
High temperature liquid: iron slag, steel slag and high temperature water etc.;

steam
Sinter sensible heat grading recovery, 21 16.6
cascade utilization

Effectiveness of blast furnace slag sensible heat recovery under different

modes
hot water recovery by water quenching 12 3.8
method
Hot air and steam recovery by wind 49 8.0
quenching method
H2, CO recovery and power generation by 88 17.7
chemical method

Effectiveness of sensible heat recovery of low-temperature fume under

different modes
sintering circular Preheating sintering 34 8.4
cooler hot air raw material
power generation 23 4.9
steel rolling heating regenerative 59 15.4
furnace flue gas chamber
heat exchanger 25 8.6
Steelmaking Steam recovery for 33 6.6
converter flue gas power generation
Recovery of low 23 3.6
Description

pressure steam

Basic Research Program of China (973 Program, Grant no.

Rate of recovery (%)

2012CB720406).

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