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Energy saving and environmentalEnergy saving and environmental
protection in Chinese Steel Industryprotection in Chinese Steel Industry(a typical process industry)(a typical process industry)
Activity 3.2Activity 3.2
DaqiangDaqiang CANGCANGSchool of Metallurgical and Ecological EngineeringSchool of Metallurgical and Ecological Engineering
University of Science and Technology BeijingUniversity of Science and Technology Beijing
Key Lab of Ecology and Circle Metallurgy,Key Lab of Ecology and Circle Metallurgy,Ministry of EducationMinistry of Education
ChinaChina
Contract number: CN/ASIAContract number: CN/ASIA--LINK/016(103LINK/016(103--187)187)
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ContentContent
1. Preface1. Preface
2. Chinese steel industry2. Chinese steel industry 3. Present situation of energy consumption3. Present situation of energy consumption
in Chinese steel industryin Chinese steel industry
4. Environmental protection in Chinese steel4. Environmental protection in Chinese steel industryindustry
5. New tech. on Energy Saving &5. New tech. on Energy Saving &
Environmental Protection for steel industryEnvironmental Protection for steel industry
6. Conclusions6. Conclusions
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BF LD CC Hot rolling Cold rolling
Products
Coking
Sintering
Scrap
Power generation
Gas
Cement
Slag
Wasted plastic
Steel industrial processSteel industrial process
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1.Preface1.Preface * Steel still is the* Steel still is the main material, but is amain material, but is a
energy intensive and heavier pollutedenergy intensive and heavier polluted
industry.industry.
* A huge domestic market in China.* A huge domestic market in China.
* Some gap between China and the others:* Some gap between China and the others:
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Production of crude steel:Production of crude steel: 420420 million tons,million tons,20062006(~1/3 of the world). 18.5% increase(~1/3 of the world). 18.5% increase
comparing to 2005.comparing to 2005.
Domestic crude steel consumption:Domestic crude steel consumption: 384384
million tons,million tons, 2006,2006, 30.98% in the whole world.30.98% in the whole world.
2. Chinese steel industry2. Chinese steel industry
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China Steel Output In Recent 5 Years
0
500010000
15000
2000025000
30000
35000
40000
45000
2002 2003 2004 2005 2006
O
u
t
u
t
(
1
00
0
0
t
on
s
)
Steel output
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China steel output in the past 16 yearsChina steel output in the past 16 years
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The Characteristics of Chinese steelThe Characteristics of Chinese steelproduction, 2006production, 2006
The structure of Chinese steel productsThe structure of Chinese steel products
changed.changed.
The production and proportion of highThe production and proportion of high--level products increased.level products increased.
The production of specialThe production of special--purpose steelpurpose steel
products increased.products increased.
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Some steel products adjusted inSome steel products adjusted in
20062006
67.68%529.88Stainless steel
34.8%654Shipbuildingplate
60.5%73.2Bridge plate
65%217.5Container plate
Special-purpose
products
53.1%1314.57Cold rolling
sheet
36.54%15402.46plateHigh-level
products
Growthproportion
Output (10000tons)
Class
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New policyNew policy------Chinese steel productionChinese steel production
Change the steel industry from big size toChange the steel industry from big size to
higher level.higher level.
Improve the technology and hardware.Improve the technology and hardware.
Increase the proportion of highIncrease the proportion of high--levellevelproducts.products.
Strengthen steel enterprisesStrengthen steel enterprises centralizationcentralization
and reorganizing.and reorganizing.
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3. Present situation of energy consumption3. Present situation of energy consumption
in Chinese steel industryin Chinese steel industry
Pictures fromPictures from BaosteelBaosteel, Shanghai, China, Shanghai, China
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Energy consumption in 2006Energy consumption in 2006
Gross energy consumptionGross energy consumption:: 198 million tons198 million tons cece (standard coal)(standard coal) increased 15 million tonsincreased 15 million tons
cece than 2005than 2005about 8.45%(production:18.5% increased).about 8.45%(production:18.5% increased).
Comprehensive energy consumptionComprehensive energy consumption ::
645.12645.12 kgec/tkgec/treduced 7.06%reduced 7.06% than 2005.than 2005. Comparable energy consumptionComparable energy consumption 623.04623.04 kgec/tkgec/treduced 6.19%reduced 6.19% than 2005.than 2005.
Fresh water consumptionFresh water consumption:: 6.56t/t6.56t/treduced 14.9%reduced 14.9% than 2005.than 2005.
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The energy consumption between 1990 andThe energy consumption between 1990 and
20002000The data after 2000 are from large and middle sized steelThe data after 2000 are from large and middle sized steel
enterprisesenterprises
0
50000
100000
150000
200000
250000
1990
1992
1994
1996
1998
2000
2002
2004
year
amountofenergy
consumption,0.
01million
tec
0
2
4
6
8
10
12
14
16
18
energyconsump
tionofsteel
making/nationwideenergy
consumpt
ion
%
nationwide energy consumption,0.01million tec
total energy consumption of iron and steel making industry ,0.01million tecenergy consumption of steelmaking industry /nationwide energy consumption,%
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The constitution of energy consumption
in Chinese steel industry, 2004
Electricity power,26.40%
Coal, 69.90%
Naturalgas,0.50%Fuel oil,3.02%
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Steel industry energy structureSteel industry energy structure
in some countriesin some countries
23.7 %15.3 %16.0 %26.4 %Electricity
power
8.2 %17.0 %0.5 %Natural gas
19.9 %20.7 %7.0 %3.2 %Fuel oil
56.4 %55.8 %60 %69.9 %Coal
JapanGermanyUSAChina
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-25.0%-24.3%25.8%-11.2%-2.0%-5.9%-8.6%-20.3%Change
rate
-29.43-64.577.46-17.99-9.28-4.07-67-179
The
variation
quality
of 2005to 2000
88.52201.0236.34142.21456.7964.83714741
92.91209.8926.57142.21466.2066.38701761
96.29213.7323.56148.51464.6866.42709780
101.49228.9424.01150.32455.1367.07698815
107.52230.0928.03153.9868.60747876
117.95265.5928.88160.20466.0768.90781920
RollingEAFLFCockingIron
makingSinter
Comparable
energy
consumption
Comprehensive
energy
consumption
Changes of the process energy consumption inChanges of the process energy consumption in2000~20052000~2005 ((kgce/tkgce/t))
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227.476.5152.532.538.695.531.937.4
The gap
between
lagging
indicator andaverage%
41.232.4107.412.215.737.49.08.3
The gap
betweenadvanced and
average%
289.78354.9091.75605.1089.87278.06994.21018
Lagging
indicator
(kgce/t)
289.78135.89-2.7396.7054.6889.02650.00679.76
Advanced
level (kgce/t)
88.52201.0236.34456.7964.83142.21714741
Key
enterprises
(kgce/t)
RollingEAFLFIron
making
SinterCocking
Comparable
Energy
consumption/tsteel
Comprehensive
Energy
Consumption/tsteel
The energy consumption gap between steel enterprises in CThe energy consumption gap between steel enterprises in Chinahina
20052005 , (, (kgce/tkgce/t))
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9.60153.682.2748.1714.690.496.06
The proportion
of total energy
consumption()
Hot-rolling47.82
Cold-rolling80.28198.6-8.88437.93128.158.89
International
advancedlevel(1999)
117.32O396.789.0260.55Baosteel (first
season)
88.82201.0236.34456.79142.2164.83The domestic
key enterprises
RollingPowerEAFLFIron
makingCockingPelletingSinteringProcess
The gap between China(2005) and international advanced leveThe gap between China(2005) and international advanced level(1999)l(1999)
((kgce/tkgce/t))
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Some new energy savingSome new energy saving
technology applied in Chinatechnology applied in China
There are more and more energy saving tech. wereThere are more and more energy saving tech. were
used in Chinese steel industry, the followingused in Chinese steel industry, the following are some of them which start to be used in the pastare some of them which start to be used in the past
few year.few year.
(1) Coke Dry Quenching (CDQ)(1) Coke Dry Quenching (CDQ)
1)1) Recovery sensible heat from red coke : 80%Recovery sensible heat from red coke : 80%
2)2) Produce 0.5t/t ,steam pressure: 4MPa, 450Produce 0.5t/t ,steam pressure: 4MPa, 450 ..
3)3) Improve environmental quality .Improve environmental quality .
4)4) Improve coke strength, with M40 increase 3~8%, M10 reduce 0.3~Improve coke strength, with M40 increase 3~8%, M10 reduce 0.3~0.8%.0.8%.
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(2) Heat Recovery Technology from Hot(2) Heat Recovery Technology from Hot
Sinter product for Steam and electricitySinter product for Steam and electricity
generationgeneration
Recovery 76kg steam /per ton sinter product in BaostRecovery 76kg steam /per ton sinter product in Baosteeleel..
(3) Blast Furnace Top Gas Pressure(3) Blast Furnace Top Gas Pressure
Recovery Turbine UnitRecovery Turbine Unit TRTTRT
which can generate 37kwh electricity/ ton of product inwhich can generate 37kwh electricity/ ton of product in BaosteelBaosteel..
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(4) HTAC (High temperature air combustion)(4) HTAC (High temperature air combustion)
Fuel oilBurner
nozzle ABurner
nozzle B
Fuel oil
Hot air
1000o
CTemperature 1200oC
High
temperature gas
Left regenerative
chamberLeft regenerative
chamber
Cold flue gas
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4.4. Environmental protection inEnvironmental protection inChinese steel industryChinese steel industry
(for gas, solid, liquid phase pollutants)(for gas, solid, liquid phase pollutants)
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The proportion of the pollutants ofThe proportion of the pollutants ofChinese steel industry to theChinese steel industry to the
gross national pollutantsgross national pollutants
Based on the data of the National Bureau ofBased on the data of the National Bureau of
Statistics of China, The proportion of the steelStatistics of China, The proportion of the steel
industry pollutants to the national total pollutantsindustry pollutants to the national total pollutantsare as follows:are as follows:
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Gross National
emissions
Steel industry
emissions
Proportion (%)
Waste gas(cubic meters)
268025 57134 21.31
SO2
(10 thousandtone)
2549 146.5 7.4
Smoke (10thousand tone)
1183 71 8.3
Dust (10
thousand tone)828.1 129.6 15.65
Waste water (10million tone)
5633 18.4173 8.53
The proportion of the steel industry pollutants toThe proportion of the steel industry pollutants to
the gross national pollutantsthe gross national pollutants
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Index 2003 2004 2005 (statistic
incompletely)
Reused industrial
water (%)
90.73 92.28 94.4
New water consumption
per tone steel (cubic
meters)
13.73 11.27 8.06
Outfall waste water
capacity per tone
steel (cubic meters)
7.7 7.23 5.02
Waste water
disposing ratio (%)
99.52 99.58 99.6
The ratio of disposed
water (%)
98.08 98.25 98.6
Utilization ratio of
the coking gas (%)
96.64 98.17 98.3
Main indexes of environmental protection and pollutants utilization inmain steel enterprises recently
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Index 2003 2004 2005 (statistic
incompletely)%
Utilization ratio of the
blast furnace gas (%)91.61 95.85 96.1
Utilization ratio of the
converter gas (%)
87.07 84.08 89.7
Utilization ratio of the
dust and sludge (%)98.46 98.66 99.7
Utilization ratio ofthe waste dregs (%) 58.07 60.48 67.9
Utilization ratio of
the furnace slag (%)
92 95.68 97
Utilization ratio of
the steel slag (%)
87.39 90.05 Converter slag 10
Utilization ratio of
the waste acid (%)
90.01 95 Sulfuric 76
Hydrochloric 98
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The major problems of environmentalThe major problems of environmental
protection for Chinese steel industryprotection for Chinese steel industry
.(1) Wasted water from coke making process.(1) Wasted water from coke making process
(2) SO(2) SO22 andand NOxNOx in Sinter flue gasin Sinter flue gas
(3) High temperature(3) High temperature dedustingdedusting
(4) Dioxin remove from sinter plan(4) Dioxin remove from sinter plan (5) Organic pollutant remove from water(5) Organic pollutant remove from water
(6) BOF and EAF slag utilization(6) BOF and EAF slag utilization
(7) Tailing from iron ore mine(7) Tailing from iron ore mine
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The goal of energy saving and environmentThe goal of energy saving and environment
protection afterprotection after the tenth fivethe tenth five--yearyear--projectsprojects..Several important target of clean production in large and middle-size enterprises in
2005 and 2010
Year 1million
t/a cokeoven dry
quenchin
g
proportio
n (%)
BF over
1000m
3
TRT
proportio
n (%)
New
waterconsump
tion per
tone
steel
(m3)
Proporti
on ofconverte
r gas
utilizatio
n (%)
Waste
waterand gas
standardi
ng rate
(%)
Decrease
of mainpollutant
discharg
e amount
(%)
Compreh
ensiveenergy
consump
tion per
tone
steel
(kg/t)
2005 60 100 12 70 100 15 750
2010 100 50(BF
between300 to
1000m3
TRT
proportio
n)
8 90 100 30 650
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Strengthen the EnvironmentStrengthen the Environment
Impact AssessmentImpact Assessment
Minimizing pollutantMinimizing pollutant
Improve the energy utilization efficiencyImprove the energy utilization efficiency
Improve the water utilization efficiencyImprove the water utilization efficiency
Improve the material utilization efficiencyImprove the material utilization efficiency
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Some concerned activities in China:Some concerned activities in China:
Cleaner productionCleaner production (CP)(CP)
Recycle economyRecycle economy (RC)(RC)
Industrial ecologyIndustrial ecology (IE)(IE) The principle:The principle:
3R3R :: RReduce,educe, RReuse,euse, RRecycleecycle
From theFrom the resource sideresource side minimizing theminimizing thepollutant emission, energy consumptionpollutant emission, energy consumptionand resource consumption.and resource consumption.
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5.New technologies and approaches5.New technologies and approaches
New approachesNew approaches for energy saving:for energy saving:
(1)process innovation: Continuous casting instead(1)process innovation: Continuous casting instead
of model casting, etc.of model casting, etc.
(2) short process instead of long process.(2) short process instead of long process.
(3) small size(3) small size ------large size enterprises.large size enterprises. (4) develop more super steel products.(4) develop more super steel products.
(5) industrial ecology (industrial group system).(5) industrial ecology (industrial group system).
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New approachesNew approaches for environment protection:for environment protection:
(1)Treat wastes before process, in process and(1)Treat wastes before process, in process and
after process.after process.
(2)Waste treatment with wastes.(2)Waste treatment with wastes. (3)Industrial ecology: use wastes as a new(3)Industrial ecology: use wastes as a new
resource (for another industry or enterprise).resource (for another industry or enterprise).
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New tech.:New tech.:
For energy saving:For energy saving: (1) Low temperature ,dispersed, batch emitted wasted heat(1) Low temperature ,dispersed, batch emitted wasted heat
for power generation. (organized a national symposium infor power generation. (organized a national symposium in
China)China) (2) Energy saving materials development :(2) Energy saving materials development :
NanoNano fluid,fluid, nanonano coating, copper stave for BFcoating, copper stave for BF
(3)Physical fields to change the chemical and physical(3)Physical fields to change the chemical and physical
properties or the process (patens).properties or the process (patens).
(4) Super(4) Super--critical conditions for new energy production.critical conditions for new energy production.
(5) High temperature slag heat recovery(5) High temperature slag heat recovery..
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New tech. for environment protection:New tech. for environment protection:
(1)In process control (not end of pipe control):(1)In process control (not end of pipe control):
e.g. fixed SOe.g. fixed SO22 in solid sinter product, not inin solid sinter product, not in
flue gas etc).flue gas etc). (2) Slag reform: change crystal structure and(2) Slag reform: change crystal structure and
composition for new application etc.composition for new application etc.
(3) High temperature(3) High temperature dedustingdedusting (4) H(4) H22 metallurgymetallurgy
(5) Water saving(5) Water saving
(6) Waste treat waste: coking wasted water treats(6) Waste treat waste: coking wasted water treats
SOSO22 in sinter flue gas andin sinter flue gas and
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ConclusionsConclusions
1) Different countries have different1) Different countries have different
conditions and requirement under differentconditions and requirement under differentdeveloping stage, some tech. be used maybedeveloping stage, some tech. be used maybe
different in different countries.different in different countries.
2)2) Recycle economyRecycle economy is a good way foris a good way for
energy saving, environment protection andenergy saving, environment protection and
resource utilization effectively.resource utilization effectively.
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Many thanks!Many thanks!