Tahara Presentation

1

InLCA/LCM 2006 meeting 2006/10/05

Development of Steel Products Inventory Database from Statistics

and PRTR Data in Japan

Kiyotaka TAHARA ([email protected])Toshio ONOYEAtsushi INABA

Research Center for Life Cycle Assessment, National Institute of Advanced Industrial Science and Technology (AIST)

2


INTRODUCTION

• LCA: Inventory analysisInventory analysis + Impact analysis

– Lack of Inventory dataForeground data

Need to developa database

Background dataForeground Data

Fuels

Back ground Data

ElectricityMining

DisposalManufacturing Use

Material

Foreground Data

Fuels

Back ground Data

ElectricityMining

DisposalManufacturing Use

Material

3


OBJECTIVE

• To establish an LCA technique to evaluate the environmental load from steel products based on statistics on steel and PRTR*

• To develop the LCI database of Japan’s steel products

PRTR*: Pollutant Release and Transfer Register (a.k.a. TRI in the United States)

4


Production flow of Iron and Steel

5


CokeSinter Pellet

FerroalloyBurntlime Iron (BF)

Foundryiron

Crude steel(LD)

Crude steel(EF)

Billet, bloom & slab

Hot rolling

Cold rolling

Surfacefinishing

Weld (pipe)

Oridinarysteel (LD)

Kinds ofsteel

Ironore

Otherores

Coal(foke)

Coal(non-coke)

Otherfuels Electricity

Ordinarysteel (EF)

Ordinarysteel (ave)

Specialsteel (LD)Special

steel (EF)

Specialsteel (ave)

Receipt

Final products

Burnatdolomite

CarbonElectrode

Considering chemical composition of steel and production yield for final product. (In practice, composition of steel is prepared at crude steel production)

Flow of main materials

Flow of main energy

Process / products

Fromingprocess

Received raw

materials

Ferrousscrap

System boundary in this study

6


Statistics on Iron and Steel IndustryCode Industry No. of

establishment

Shipments, bil.JPY

2310231123122313

IRON INDUSTRIES - Iron industries, with blast furnaces - Iron smelting, without blast furnaces - Ferro-alloys

38 16 1

21

3,989 3,849

Undiscl.Undiscl.

2320 STEEL, WITH ROLLING FACILITIES 74 2,0482330233123322333233423352336233723382339

STEEL MATERIALS- Hot rolling - Cold rolling - Cold rolled steel shapes - Steel pipes and tubes - Re-rolled steel products - Cold finished steel bars - Pipes and tubes drawing - Wire drawing - Miscellaneous steel materials

459 31 38 32 66 12 56 32 186

6

2,111 235 634 70 411 25 162 57 516

1 From Statistics Table by Industry of the 2000 Census, METI

7


Statistics on Iron and Steel Industry (Cont’d) Code Industry No. of

establishment

Shipments, bil.JPY

2340234123422349

COATED STEEL - Galvanized steel sheets - Coated steel pipes - Miscellaneous coated steel

76 21 6

49

199 142 11 46

2350

23512352235323542355

FERROUS METAL MACHINE PARTS AND TOOLING PRODUCTS - Iron castings- Malleable iron castings - Steel castings - Secondary forgings - Steel forgings

1,601

1,017 75 92 407 10

1,324

654 130 135 351 54

23902391239223932399

MISCELLANEOUS IRON AND STEEL - Iron and steel shearing and slitting - Iron and steel scrap preparation for smelting - Cast iron pipe - Iron and steel, n.e.c.

2,906 1,737 628 72 469

2,256 1,542 328 179 208

8


Raw Material Statistics~ Receipt & shipment ~

Receipt Consumption

Purchase Other Iron & steel sectors

Other

Pig iron scrap

Carbon steel scrapAlloy steel scrap

Iron ore

��

Sinter ImportDomestic

Pellet ImportDomestic

Manganese ore

Chromium ore

��

Steel scrap

InventoryProduction or generation

Item

Kind of raw material

Pig iron scrapSteel scrap (carbon steel, alloy steel)Iron oreIron-manganese oresIron sandOther iron materialsSinter (Import, domestic)Pellet (Import, domestic)Manganese oresSilica stoneChromium oresNickel oresFluoriteTungsten oresMolybdenum oresVanadium oresMetallic manganeseMolybdenum trioxide briquette

Unit : t

9


Raw Material Statistics~ Consumption of iron & steel sectors ~

For iron making For steel makingGrand total

For sintering

Blast furnace

Otherfurnace

LD con-verter

Electricfurnace

Pig iron scrap

Carbon steel scrapAlloy steel scrap

Iron ore

��

Sinter ImportDomestic

Pellet ImportDomestic

Manganese ore

��

Carbon electrodes

Steel scrap

Other steel sections

For ferro-alloys

Item

Kind of raw material

Pig iron scrapSteel scrap (carbon steel, alloy steel)Iron oreIron-manganese oresIron sandOther iron materialsSinter (Import, domestic)Pellet (Import, domestic)Manganese oresSilica stoneChromium oresNickel oresFluoriteLimestoneLimeSerpentinesDolomiteBurnt dolomiteCarbon electrodes

Unit : t

10


Material flow of steel production

11


Statistics of Energy Consumption~ Fuel materials receipt & shipment ~

Consumption forFuel Unit Receipt(Purchase / other)

Generation, recovery,production

Raw materials

Direct heating

Other

Shipment

Oil based fuels

Non-oil based fuels

Kerosene

Gas oils

Fuel oils

��

Coal (coking)Coal(non-coking)COG

��

LNG

Oxygen

Boiler Co-generation

Inventory

Oil based fuelsKeroseneGas oilsFuel oils (A, B, C)Hydrocarbon oilLiquefied petroleum oil (LPG)Petroleum coke

Non-oil based fuelsCoal (coking, non-coking)Coal cokeTarCoke oven gas (COG)Blast furnace gas (BFG)Converter gas (LDG)Electric furnace gas (EFG)LNGTown gasOxygen

12


Statistics of Energy Consumption~ Consumption by sectors ~

Iron & steel sectors forSteelmakingSinter Blast

furnaceFerroalloy LD EF

Rolling & pipe

Power gen. etc

Coke making sectors

Other sectors

Fuel Unit

Kerosene

Non-oil based fuels

Electricity

Oil based fuels

Steam

Gas oils

Fuel oils

��

Coal (coking)Coal(non-coking)COG

��

LNG

Oil based fuelsKeroseneGas oilsFuel oils (A, B, C)Hydrocarbon oilLiquefied petroleum oil (LPG)Petroleum coke

Non-oil based fuelsCoal (coking, non-coking)Coal cokeTarCoke oven gas (COG)Blast furnace gas (BFG)Converter gas (LDG)Electric furnace gas (EFG)LNGTown gasOxygen

ElectricitySteam

Iron & steel sectorsSinterPelletsGas oilsIron making

Blast furnaceOther furnaces

Ferro-alloySteel making

LD converterElectric furnace

ForgingCastingRolling & pipePower generation, boiler & cogenerationOther sectors

Coke making sectorsOther sectors

13


Statistics of Energy Consumption for electricity and steam

Private power generationPurchaseThermal power

Cogeneration

Hydraulic power

BFTRT Others

50,178 19,604 1,526 357 3,335 3,180 69,252 8,930

Consumption

Sold

~ Electric power receipt & shipment ~ Unit: GWh

~ Steam receipt & shipment ~

3,87810,75366,16629,77525,5902,61978,2134,489

OtherPrivate power generation

Production process

OthersCogeneration

Primary steam

Shipments

Consumption forSteam generationReceipt

Unit: kt

BFRTRT: Blast furnace top-pressure energy Recovery Turbine

14


BoilerPrivate power

generation

Other processes

Fuel for boiler Steam Electricity

Fuel for cogeneration

Electricity

Steam

Fuel for process

Electricity

Steam

12,048 ktElectricity for boiler & congeneration

1,671 GWh

19,605 GWh

1,526 GWh

6,874 GWh

fromHydropower� � 357 GWhBFTRT� 3,336 Gwh

78,214 kt

2,619 kt

25,590 kt

66,166 kt

Co-generation

Other processes

Allocated

Electricity and steam flow

Compared the amounts of fuel consumption and CO2 emissions in cases:(1)where fuel consumption is allocated to boiler and co-generation, and (2)where no allocation was performed and the fuel was consumed for private power

generation alone

15


Allocated to electricity and steam Not allocated

Private power generation

Steam Private power generation

Kerosene Fuel oils AFuel oils BFuel oils CLPGCoalTarCOGBFGLDGEFGLNGTown gas

llll

kgkgkg

Nm3

Nm3

Nm3

Nm3

kgNm3

0.0005 0.0035 0.0000 0.0137 0.0050 0.0860 0.0008 0.0495 1.0390 0.0704 0.0014 0.0010 0.0048

0.000 0.002 0.000 0.006 0.002 0.028 0.000 0.016 0.373 0.025 0.000 0.000 0.003

0.0006 0.0046 0.0000 0.0170 0.0059 0.1028 0.0010 0.0591 1.2579 0.0853 0.0016 0.0013 0.0064

Electricity kWh 0.0522 0.019 0.0635

ElectricitySteam

kWhkg

1.0000 -

-1.0000

0.8024 0.5570

CO2 kg 1.349 0.483 1.633

Output

Input

Items Unit

Inventory data of private power generation and steam

1.6330.4831.349kgCO2

0.8024 0.5570

-1.0000

1.0000 -

kWhkg

ElectricitySteam

Output

0.06350.0190.0522kWhElectricity

0.0006 0.0046 0.0000 0.0170 0.0059 0.1028 0.0010 0.0591 1.2579 0.0853 0.0016 0.0013 0.0064

0.000 0.002 0.000 0.006 0.002 0.028 0.000 0.016 0.373 0.025 0.000 0.000 0.003

0.0005 0.0035 0.0000 0.0137 0.0050 0.0860 0.0008 0.0495 1.0390 0.0704 0.0014 0.0010 0.0048

llll

kgkgkg

Nm3

Nm3

Nm3

Nm3

kgNm3

Kerosene Fuel oils AFuel oils BFuel oils CLPGCoalTarCOGBFGLDGEFGLNGTown gas

Input

Private power generationSteamPrivate power

generation

Not allocated Allocated to electricity and steam UnitItems

16


Energy flow of steel production

17


Inventory of iron-1�Statistics on materials, energy & products �

Input materials Un. Amount Input materials Unit AmountIron oreIron-manganese o.Other iron mat.SinterPelletSilica stoneLimestoneLimeSerpentineDolomite

kgkgkgkgkgkgkgkgkgkg

24,390,17111,971

603,31597,946,967

8,848,595243,587136,066

50,778255,013112,019

CoalCoal cokeTarCoke oven gasBlast furnace gasConverter gasLNGTown gasOxygenSteam

ttt

1000m3

1000m3

1000m3

t1000m3

1000m3

t

10,990,25831,212,626

42,7591,533,700

31,657,6981,097,780

3,3372,500

3,038,0617175081

Fuel oil C kl 20,264 Electricity MWh 5,291,273LPG t 20,750

Petroleum coke t 601,745 Output products Unit AmountIronBlast furnace gasBF slag

t1000m3

t

81,068,260132,380,51823,498,000

18


Inventory of iron-2�Calculated inventory �

Input materials Unit Amount Input materials Unit AmountIron oreIron-manganese o.Other iron mat.SinterPelletSilica stoneLimestoneLimeSerpentineDolomite

kgkgkgkgkgkgkgkgkgkg

0.30090.00010.00741.20820.10910.00300.00170.00060.00310.0014

CoalCoal cokeTarCoke oven gasBlast furnace gasConverter gasLNGTown gasOxygenSteam

kgkgkg

Nm3

Nm3

Nm3

kgNm3

Nm3

Kg

0.13560.38500.00050.01890.39050.01350.00000.00000.03750.0885

Fuel oil C l 0.0002 Electricity kWh 0.0653LPG kg 0.0003Petroleum coke kg 0.0074 Output products Unit Amount

IronBlast furnace gasBF slag

kgNm3

kg

1.00001.63300.2899

19


Inventory of iron-3�Carbon balance except electricity�

Materials Amount Amount of carbonLimestoneDolomiteCoal cokeCoalPetroleum cokeFuel oil CTar

0.0017 kg0.0014 kg0.3850 kg0.1356 kg0.0074 kg0.0002 l0.0005 kg

0.000 kg-C0.000 kg-C0.341 kg-C0.091 kg-C0.007 kg-C0.000 kg-C0.000 kg-C

LPGCoke oven gasBlast furnace gasConverter gasLNGTown gas

0.0003 kg0.0189 Nm30.3905 Nm30.0135 Nm30.0000 kg0.0000 Nm3

0.000 kg-C0.004 kg-C0.094 kg-C0.006 kg-C0.000 kg-C0.000 kg-C

Sub-total (A) 0.544 kg-CIronBlast furnace gasCO2

1.0000 kg1.6330 Nm30.3930 kg

0.045 kg-C0.392 kg-C0.107 kg-C

Sub-total (B) 0.544 kg-CBalance (A-B) 0 kg-C

Output

Input

20


Process sheet of iron in AIST-LCA

21


Data sheet of iron in AIST-LCA

22


0.0

0.5

1.0

1.5

2.0

2.5

3.0

Steel s

hape

sStee

l bars

Steel w

ire &

rods

Steel p

lates

Hot rol

led sh

eets

& strip

s

Cold ro

lled s

heets

& st

rips

Electric

al sh

eets

& strip

s

Surfac

e fini

shed

stee

l she

ets

Steel p

ipes &

tube

sC

O2

emis

sion

[kg-

CO

2/kg

]

Fig. CO2 emission of various ordinary steels

23


0.0

1.0

2.0

3.0

4.0

5.0

Specia

l stee

l sha

pes

Specia

l stee

l bars

Specia

l stee

l wire

&rod

sSpe

cial s

teel p

lates

Hot rol

led sh

eets

& strip

s

Cold ro

lled s

heets

& st

rips

Steel p

ipes &

tube

s

CO

2 em

issi

on [k

g-C

O2/

kg]

Fig. CO2 emission of various special steels

24


Inventory on PRTR target pollutants of Crude Steel~ Releases ~

PRTR Chemicals Air emission Water bodies Land Landfillszinc compounds (water-soluble) 1.12E-08 1.20E-07bis(2-ehtylhexyl) adipate 1.78E-102-aminoethanol 7.52E-11 3.01E-08antimony and its compounds 1.29E-09

dichloromethane; methylene dichloride 5.20E-06styrene 2.89E-07selenium and its compounds 3.19E-10dioxins 8.85E-13 1.44E-15 9.39E-17thiourea 1.69E-08tetrachloroethylene 2.91E-06copper salts (water-soluble, except complex salts) 3.01E-09 2.82E-10trichloroethylene 3.68E-061,3,5-trimethylbenzene 2.17E-07toluene 1.13E-05lead and its compounds 1.26E-08 1.80E-08 8.46E-11 1.78E-07nickel 1.43E-09 1.97E-10 1.32E-10nickel compounds 6.17E-08 1.85E-07 9.31E-07barium and its water-soluble compounds 9.39E-12bis(2-ethylhexyl) phthalate 3.10E-10 1.32E-08hydrogen fluoride and its water-soluble salts 1.97E-07 3.46E-06 2.72E-06benzene 2.48E-06 0

Unit: kg/kg-crude steel

46 substances

25


Inventory on PRTR target pollutants of Crude Steel~ Transfers ~ Unit: kg/kg-crude steel

PRTR Substances Air emission Water bodies Land Landfillszinc compounds (water-soluble) 1.53E-07 1.65E-06bis(2-ehtylhexyl) adipate 2.31E-092-aminoethanol 1.76E-11 7.03E-09antimony and its compounds 1.44E-08asbestos 1.22E-084,4'-isopropylidenediphenol; bisphenol A 3.38E-09polymer of 4,4'-isopropylidenediphenol and 1-chloro-2,3-epoxypropane (liquid)

3.58E-09

ethylbenzene 1.63E-07ethylene glycol 3.96E-07 1.04E-07ethylenediamine 3.95E-08cadmium and its compounds 1.14E-07xylene 1.86E-06toluene 1.51E-06

formaldehyde 2.87E-09manganese and itsw compounds 1.19E-06 8.06E-06 1.39E-04mercaptoacetic acid 3.12E-11 7.01E-09molybdenum and and its compounds 6.10E-09 1.70E-06 4.27E-07tris(dimethylphenyl) phosphate 1.41E-07

45 substances

26


Concept of LIME� Life -cycle Impact assessment Method based on Endpoint modeling

CO2

SOx

NOx

Lead

Total N

Total P

NMVOC

Waste

Oil

Coal

Iron Ore

etc.

Total: 1,000 materials

Urban air pollution

Chemical substances

Ozonelayer depletion

Global warming

Ecotoxicity

Acidification

Eutrophication

Photo. oxidantcreation

Land use

Waste

Resource consumption

Total : 11 categories

Social welfareSocial welfare

BiodiversityBiodiversity

PrimaryproductionPrimary

production

Single indexSingle index

Inventory Safeguard subject Single index

Weighting

DALY

Yen

EINES

NPP

Eco-index Yen

Damage assessmentCharacterization

Human healthHuman health

LCIA steps:

Impact category

27


0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

Cru

de S

teel

Cru

de s

teel

cons

ider

ing

rele

ases

Cru

de s

teel

cons

ider

ing

rele

ases

&tra

nsfe

rs

Inde

x by

LIM

E [J

PN

/kg-

Ste

el] Air pollution in urban area

Resource consumptionLand useSolid wastePhotochemical oxidantEutrophicationAcidificationEcotoxicityHazardous chemical substancesOzone depletionGlobal warming

Fig. Effect of PRTR substances on Impact Assessment of Crude Steel

28


CONCLUSION

• The inventory database for the production of Japan’s steel products was developed using statistics data and PRTR data

• PRTR target pollutants do not have significant influence

• The database is available with LCA software (AIST-LCA Ver.4, JEMAI-LCA Pro)

Date post:	13-Dec-2015
Category:	Documents
Upload:	ariel-mark-pilotin
View:	17 times
Download:	5 times

Tahara Presentation

Documents