Table 4 Compiled data of 36 energy-conservation and emission-reduction measures
Technology | Product (Mt) | Fuel savings (kgce/t) | Electricity savings (kWh/t) | Capital cost ($/t) | O&M cost ($/t) | Lifetime (Year) | Current adoption rate k (%) | Data source | |
|---|---|---|---|---|---|---|---|---|---|
Coke making | |||||||||
1 | Coal moisture control (CMC) | 145.1 | 15.0 | 0 | 13.53 | 5.01 | 20 | 50 % | |
2 | Coke dry quenching (CDQ) | 145.1 | 0 | 75.0 | 36.69 | 11.00 | 18 | 50 % | |
Sinter | |||||||||
3 | Generation of sinter waste heat | 808.9 | 0 | 65.0 | 3.96 | 0.12 | 10 | 21 % | |
4 | Cooler fluid sealing ring | 808.9 | 0 | 3.0 | 2.01 | n/a | 20 | 3 % | |
5 | Improved process control in sintering | 808.9 | 0.34 | 0 | 0.95 | n/a | 20 | 90 % | |
6 | Small pellet sintering process | 808.9 | 9.0 | 0 | 0.21 | 0.19 | 20 | 50 % | |
7 | Reduction of leakage rate in sintering process | 808.9 | 0 | 2.0 | 0.12 | 0.40 | 20 | 80 % | |
8 | Low temperature sintering technology | 808.9 | 9.0 | 0 | 0.19 | 0.40 | 20 | 75 % | |
9 | Low carbon and thick sinter-bed sintering | 808.9 | 2.0 | 0 | 0.38 | 0.08 | 20 | 80 % | |
Pellet | |||||||||
10 | Grate-Kiln | 232.7 | 9.9 | 0 | 39.62 | n/a | 15 | 48 % | |
11 | Recovery of waste heat in pelletizing process | 232.7 | 3.0 | 0 | 1.43 | 0.18 | 10 | 60 % | |
Iron making | |||||||||
12 | Top-pressure recovery turbines (TRT) | 657.9 | 0 | 50.0 | 2.38 | 0.63 | 15 | 62 % | |
13 | Recovery of BFG gas | 657.9 | 1.37 | 0 | 0.44 | n/a | 10 | 94 % | |
14 | Dehumidification blast | 657.9 | 8.0 | 0 | 2.69 | 0.71 | 10 | 10 % | |
15 | Cyclone type top combustion hot stoves | 657.9 | 7.96 | 0 | 34.80 | n/a | 20 | 50 % | |
16 | Injection of pulverized coal | 657.9 | 4.3 | 0 | 9.33 | −0.01 | 20 | 60 % | |
17 | CCPP | 657.9 | 16.0 | 0 | 15.06 | n/a | 15 | 20 % | |
18 | Process control of blast furnace | 657.9 | 12.3 | 0 | 9.98 | n/a | 20 | 30 % | |
19 | Waste plastic injected into blast furnace | 657.9 | 3.76 | 0 | 9.51 | n/a | 20 | 3 % | |
Steel making-BOF | |||||||||
20 | Recovery of BOF gas | 643.5 | 0 | 9.0 | 3.96 | 0.92 | 20 | 48 % | |
21 | Converter steelmaking with negative energy consumption | 643.5 | 25.0 | 0 | 23.77 | 0.55 | 20 | 48 % | |
Steel making-EAF | |||||||||
22 | Scrap preheating | 72.5 | 0 | 61.0 | 7.13 | −3.49 | 20 | 10 % | |
23 | Generation of EAF waste heat | 72.5 | 12.0 | 0 | 5.94 | n/a | 20 | 3 % | |
24 | Improved process control | 72.5 | 0 | 13.9 | 60.22 | n/a | 20 | 50 % | |
25 | UHP transformer | 72.5 | 0 | 58.3 | 29.16 | n/a | 20 | 40 % | |
Casting | |||||||||
26 | Integrated casting and rolling | 704.7 | 8.53 | 42.0 | 2.38 | 0.24 | 20 | 50 % | |
27 | Thin slab casting (TSC) | 704.7 | 0 | 25.0 | 6.34 | 7.13 | 20 | 15 % | |
Hot Rolling | |||||||||
28 | Regenerative burners | 716.7 | 0 | 85.0 | 1.58 | 0.36 | 10 | 22 % | |
29 | Process control in hot rolling | 716.7 | 10.24 | 0 | 1.39 | n/a | 10 | 0 % | |
30 | Enhanced radiation technology | 716.7 | 6.5 | 0 | 0.48 | n/a | 10 | 10 % | |
31 | Recovery of hot-rolling waste heat | 716.7 | 1.02 | 0 | 3.71 | 0.32 | 20 | 80 % | |
Cold Rolling | |||||||||
32 | Recovery of cold-rolling waste heat | 123.9 | 10.24 | 3.0 | 4.29 | 0.19 | 15 | 45 % | |
33 | Multi rolling technique on the bar rolling | 123.9 | 5.12 | 0 | 1.98 | n/a | 20 | 10 % | |
34 | Continuous annealing technology | 123.9 | 12.97 | 0 | 17.61 | n/a | 20 | 5 % | |
General measures | |||||||||
35 | Energy management and system optimization | 657.9 | 10.9 | 2.78 | 4.75 | n/a | 20 | 90 % | |
36 | Preventative maintenance | 657.9 | 14.7 | 5.56 | 3.96 | 1.30 | 20 | 90 % | (MIIT, 2012a, 2012b; Hasanbeigi et al. 2013; Morrow et al. 2014) |