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Iron and Steel Industry Office of Air and Radiation September 2012 AVAILABLE AND EMERGING TECHNOLOGIES FOR REDUCING GREENHOUSE GAS EMISSIONS FROM THE IRON AND STEEL INDUSTRY Available and Emerging Technologies for Reducing Greenhouse Gas Emissions from the Iron and Steel Industry Prepared by the Sector Policies and Programs Division Office of Air Quality Planning and Standards U.S. Environmental Protection Agency Research Triangle Park, North Carolina 27711 September 2012 Table of Contents Tables .............................................................................................................................................. v Figures............................................................................................................................................ vi Abbreviations and Acronyms ....................................................................................................... vii EPA Contact................................................................................................................................... ix I. Introduction ................................................................................................................................. 1 II. Purpose of this Document .......................................................................................................... 1 III. Organization of This Document................................................................................................ 1 IV. Description of the Iron and Steel Industry ................................................................................ 1 V. Energy Programs and Management Systems ............................................................................. 5 A. Formal Energy Programs .................................................................................................. 5 B. Energy Performance Benchmarks on Plant- and Industry-specific Basis ......................... 8 C. Industry Energy Efficiency Initiatives .............................................................................. 8 VI. Summary of GHG Control Measures ....................................................................................... 8 VII. Energy Efficiency Improvement Measures for the Steel Industry………………..………….9 A. Sintering at Integrated Iron and Steel Plants ................................................................... 13 B. Cokemaking .................................................................................................................... 15 C. Blast Furnace at Integrated Iron and Steel Plants ........................................................... 17 D. Basic Oxygen Furnace at Integrated Iron and Steel Plants ............................................. 20 E. Casting .......................................................................................................................... 21 F. Rolling Mills, General Measures ..................................................................................... 23 G. Hot Rolling Mills ............................................................................................................ 24 H. Cold Rolling Mills .......................................................................................................... 28 I. Finishing Operations......................................................................................................... 28 J. General Measures for Energy Efficiency Improvements ................................................. 29 K. Energy Efficiency Options for Electric Arc Furnace Steelmaking ................................. 30 VIII. References ............................................................................................................................ 37 Appendix A. Emerging Techniques for GHG Control ............................................................... A-1 A.1 Long-Term Opportunities to Reduce CO 2 Emissions ................................................ A-1 A.2 Near-Term Technologies ............................................................................................. A-2 A.3 Energy Improvement Technologies from U.S. Department of Energy ...................... A-4 Appendix B. The U.S. Steel Industry ......................................................................................... B-1 B.1 Plants and Locations .................................................................................................... B-1 B.2 Energy Intensity .......................................................................................................... B-4 Appendix C. Detailed Estimates of Energy Costs and Savings .................................................. C-1 Appendix D. Processes and Emissions in the Iron and Steel Industry ....................................... D-1 D.1 Overview of Processes in the Iron and Steel Industry ................................................ D-1 D.1.1 Sinter Production………………………………………………………………D-1 D.1.2 Blast Furnace Iron Production…………………………………………………D-2 D.1.3 Basic Oxygen Furnaces Steelmaking Process……………………... ……...….D-3 D.1.4 Electric Arc Furnace Steelmaking…………………………………………..…D-4 D.1.5 Casting and Finishing……………………………………………………….....D-4 D.1.6 Other Steel Finishing Processes and Combustion Sources…………………....D-5 iii D.1.7 Coke Production………………………………………………………………D-6 D.2 Greenhouse Gas Emissions from Steelmaking Processes............................................D-8 D.2.1 GHG Emissions from Sinter Plants…………………………………………...D-8 D.2.2 GHG Emissions from Blast Furnaces……………………………………........D-8 D.2.3 GHG Emissions from Basic Oxygen Furnaces……………………………......D-8 D.2.4 GHG Emissions from Electric Arc Furnace………………………………...…D-9 D.2.5 GHG Emissions from Coke Plants……………………………………….…....D-9 iv Tables Table 1. Energy Efficiency Technologies and Measures Available for Integrated Steel and Coke Production in the U.S. ....................................................................................................................................... 10 Table 2. Energy Efficiency Technologies and Measures Available for Electric Arc Furnace Steel Production inthe U.S. ........................................................................................................................................ 12 Table B-1. List of Coke Plants by City and State ............................................................................................... B-1 Table B-2. List of Integrated Iron and Steel Plants by City and State ................................................................ B-2 Table B-3. List of EAF Steel Plants by City and State ....................................................................................... B-3 Table B-4. Electricity Generation in the Iron and Steel Industry ……………………………………………...B-6 Table B-5. U.S. Slab Casting Units Installed 1994–2000................................................................................... B-7 Table C-1. Energy Efficiency Technologies and Measures Applied to Integrated Steel Manufacturing in the U.S. ....................................................................................................................................................... C-2 Table C-2. Energy Efficiency Technologies and Measures Applied to EAF Steel Production in the U.S. ..................................................................................................................................................... C-5 Table D-4. Estimates of GHG Emissions in 2010 for Iron and Steel Sector Using Emission Factors ……..….D-10 v Figures Figure 1. Routes to steelmaking.................................................................................. ……………2 Figure B-1. Historical energy consumption in the Iron and Steel industry……………….....….B-5 vi Abbreviations and Acronyms °C degrees Celsius °F degrees Fahrenheit AC alternating current ACCCI American Coke and Coal Chemicals Institute AISI American Iron and Steel Institute AIST Association for Iron & Steel Technology Al 2O3 aluminum oxide ANSI American National Standards Institute AOD argon-oxygen decarburization BACT best available control technology BFG blast furnace gas BOF basic oxygen furnaces Btu British thermal unit CaO calcium oxide CCAP Center for Clean Air Policy cm centimeter CCS carbon capture and sequestration CHP combined heat and power CFD computational fluid dynamics CH 4 methane CO carbon monoxide CO 2 carbon dioxide COG coke oven gas DC direct current DOE United States Department of Energy DRI direct reduced iron EAF electric arc furnaces EMS energy management systems EPA United States Environmental Protection Agency FeO iron oxide Ft feet ft 3 cubic foot g/m 3 grams per cubic meter GHG greenhouse gas GJ gigajoule gr/ft 3 grains per cubic foot hr hour in inch(es) IPCC Intergovernmental Panel on Climate Change ISO International Standards Organization kg kilogram vii kVA kilovolt amps kWh kilowatt hour lb pounds m meter(s) m3 cubic meter MMBtu million British thermal units MgO magnesium oxide mm millimeters NO x nitrogen oxide PM particulate matter -6 PM 2.5 particulate matter with a diameter less than 2.5 micrometers (10 m) PSD prevention of significant deterioration PSH paired straight hearth R&D research and development scf standard cubic feet SiO 2 silicon dioxide SOx sulfur oxide ton ton (short, English) tonne metric ton (equal to 1.102 short tons) tpy tons (short) per year UHP ultra-high power ULCOS ultra-low CO 2 steelmaking U.S. United States VSD variable-speed drive yr year viii EPA Contact Dr. Donna Lee Jones (D243-02)
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