Overview of Japan Steel Industry

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Overview and EE&C of Steel Industry in Japan Hideyuki TANAKA Program Leader, International Engineering Dept. The Energy Conservation Center, Japan November, 2006　　 　　　

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(1) Trend of Crude Steel Production, Operation Status in Japan

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(2) Energy Saving Technologies in Mini Mill Process

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(3) Energy Use in Mini Mill Factory (Products: Steel Bars for Concrete Reinforcement)

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(1) Transition of Technical Development Hot metal operation Night time operation Utilization of waste materials (EAF-CC)

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(2) Trend in Operation Indices of EAF

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(3) Energy Conservation Activities in EAF Process 1) Energy conservation in EAF shop (EAF: Electric Arc Furnace (AC, DC)) a)　 Increase of input energy ● Enrichment of O2 According to above countermeasure ■　Increase of Oil (Burner), Carbon, Low cost alloys (Aluminum ash, Bundle made from Can, etc. )

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b) Increase of efficiency in input energy ● Power Common (DC, AC ): ○ VVVF control of electrode lifting 　Introduction of Inverter control system 　　 ○ Foaming slag control in refining stage, etc. AC： Al-arm, Reactor (in case of enough capacity of power station and high voltage operation), etc ● Other Post combustion (Shaft furnace), Supersonic lance, etc.

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c) Decrease of output energy 　● Increase of Heat size ● Decrease of Tap to Tap time and waiting time of the time after tapping (from tapping to the start of scrap charge) ● Decrease of heat loss by slag Hot recycle of slag, Control of scrap’s dust, etc. ● Scrap preheating Shaft furnace with decreasing technology of dioxin 2) Others ● 　Power saving in auxiliaries VVVF control of dust collecting fan motor, etc.

(4) Energy Balance-1: 

(4) Energy Balance-1 Output Input Energy (kWh/t)

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(5) Enriched Oxygen Operation (Example) 　　　　　　　　　

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(6) Influence of Oxygen and Reheat on Power Consumption

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(7) Relation between Transformer Capacity and Tap to Tap Time of EAF

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Several Types of Recent Scrap Preheater (8) Scrap Preheater

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(9) Effect of VVVF (Example of Power saving calculation)

(10) Energy Control System: 

(10) Energy Control System Standardized Operation and Reduction of Production Cost in EAF

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(1) Energy conservation in Ladle and CC ● 　Regenerative burner for ladle & tundish ● Matching of the productivity between EAF and CC (Continuous Casting) (2) Energy conservation after CC ● Billet heat insulating equipment ● DHCR (Direct Hot Charge Rolling), etc. ●　Matching of the productivity between CC and Rolling Mill (1) EE&C Activities in CC

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(2) Regenerative Burner for Ladle (Same System for CC Tundish) Effect: Fuel Reduction Ratio = 51% [Condition] ・Ladle Capacity: 100 t ・Heating Period: 10 hours

(3) Billet heat insulating equipment: 

(3) Billet heat insulating equipment This equipment maintain the billet temperature in hot at waiting to the reheating furnace.

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(Rolling Mill) 1995~ Regenerative burner Oil reduction: 20~29% Oil reduction: 52% 2002~ 2001~ Endless rolling Hot eddy current inspection (1) Transition of Technical Development

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(1) Matching of the productivity between CC and Mill (2) DHCR (Direct Hot Charge Rolling), etc. (3) Reheating furnace: Application of regenerative burner system (4) Energy saving of fluid machinery: Pump, Fan, Air Compressor, etc. (2) Energy Conservation Measures in Rolling Mill Factory

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(3) Application of Regenerative Burner

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High-performance Industrial Furnace Alignment of a pair of burners with a built-in ceramic storage heat exchanger, combustion and exhausting in turn, temperature preheated of combustion air

Merit of Regenerative Burner in Furnace : 

Merit of Regenerative Burner in Furnace Energy – saving Effect of high temperature combustion air over 1,000℃ (Reduction of fuel = - 20%) Uniform heating Effect of the stirring of waste gas by cyclic combustion Compact equipment Shortening of the furnace length by installing burners along the full length of the furnace

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(4) Effect of Heat Pattern Change in Re-hearing Furnace

(5) Endless Bar Rolling System: 

(5) Endless Bar Rolling System Loss reduction by eliminating of cutting off at both ends of bars Reduction of the idle time before feeding each new billet and the factors for rolling errors Drastic reduction in products of wrong dimension or insufficient length Reduction in energy cost ≒ 3%

Endless Bar Rolling - Welding: 

Endless Bar Rolling - Welding

(6) Energy Conservation System: 

(6) Energy Conservation System Accumulation and analysis of the energy consumption data Control and management of energy consumption & intensity Application of existing system examples Energy monitor and analysis system Local devices

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(1) Transition of Total Energy Intensity (Crude oil equivalent) - Example -

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Thank You