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1
Feasibility Study project for the JCM
(FY 2014)
“Feasibility Study for developing future JCM
project applying effective Japanese excellent
energy saving technologies
to Vietnam Steel Industry “
Report
March, 2015
JFE Techno-Research Corporation
JFE Steel Corporation
Table of contents
1. The Purpose of the Project...................................................................................................1
2. Present conditions of the steel industry in Vietnam and Study of the energy-saving
7.1 Policy reccomendation on JCM in Vietnam ................................................................108
7.2 Summery, Suggestion and Proposal for the activity for next fiscal year.....................110
Annex1 Commentary on technologies positive list ...........................................................112
1
1. THE PURPOSE OF THE PROJECT
Japan has been working for solving the climate change issue, and has developed a lot of superior
technologies and products applicable to reducing greenhouse gas emissions overseas. “The Clean
Development Mechanism (CDM)” is now the sole global framework available for us to contribute to
reduction of greenhouse gas emissions in developing countries by promoting these technologies and
products. But there are still relatively few cases where those countries have adopted our low-carbon
technologies which are ones of Japan’s major strengths, such as the energy-saving technologies, the
new energy technologies, the technologies for high efficiency coal-fired power generation, etc.
Moreover, the CDM is difficult for smaller developing countries to utilize its system as it requires
difficult procedures and its validation process is complicated, and therefore it is insufficient
framework for Japan to contribute widely to reduction of greenhouse gas emissions in developing
countries by promotion of our low-carbon technologies and products.
The government of Japan has been building “the Joint Crediting Mechanism (JCM)” as a
complementary system for the CDM in order to push forward the global warming mitigation on a
worldwide scale by aggressive promotion of spreading the Japan’s world-class low-carbon
technologies and products in developing countries.
Japan signed the bilateral document for the JCM with countries in Asia and Africa, some of the
countries have started the implementations, and they are looking forward to the JCM and the spread of
the Japan’s low-carbon technologies.
This study includes introduction of Japan’s superior technologies to the steel industry in the Socialist
Republic of Vietnam (hereinafter referred to as “Vietnam”), field survey at two sites of steelworks in
the country, applicability study of the energy-saving technologies to the Vietnamese steel industry,
evaluation of cost performance and amount of CO2 reduction, and applicability study of the JCM.
2
2. PRESENT CONDITIONS OF THE STEEL INDUSTRY IN
VIETNAM AND STUDY OF THE ENERGY-SAVING
TECHNOLOGIES
2.1 PRESENT CONDITIONS OF STEEL INDUSTRY AND ENERGY SITUATION IN
VIETNAM
2.1.1 PRESENT CONDITIONS OF THE STEEL INDUSTRY IN VIETNAM
Figure 2.1-1 shows the trend of steel consumption, steel production and steel self sufficient ratio
in this decade in Vietnam. Steel consumption grew to double from 2004 through 2011 backed by
high growth of the economy of Vietnam. The government tight-money policy for inflation restraint
in 2011 collapsed a real-estate bubble and forced to slow down the steel consumption, but it
gradually increases again recently. The increasing rate of production exceeds that of consumption
from 2004 through 2011, and the self-sufficiency ratio tends to increase. In 2012 and 2013, the
self-sufficiency ratio decreases slightly, because low-priced import steel from China in particular
has increased.
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
Ste
el Cosu
mpt
ion, C
rude
Ste
el pr
odu
ct
steel
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
Self sufficient
Steel Cosumption
Crude Steel production
Self sufficient ratio
Figure 2.1-1 Transition of crude steel production rate, steel consumption rate and self sufficient
ratio1
One major issue of the steel industry in Vietnam includes imbalance between supply and demand.
Productive capacity of some products such as rebar and rod becomes superabundant.
1 Based on the data of worldsteel ”Steel Statistical Yearbook 2014”
3
Another major issue is the production cost. Outdated and small facilities are still left, and at the same
time new facilities have started in operation after 2000. It is said that old facilities cannot show their
efficiency, and new facilities cannot handle them sufficiently. This situation cannot control
competitive production cost. Meanwhile electric power price in Vietnam has been held down
politically. At present electric power price is 6 ~7 US cents/kwh, but it will be raised to 8 ~9 US
cents/kwh in 2020 according to Master Plan. On the other hand, low price steel from China tends to
increase. In order to overcome this situation, cost down of the steel production must be required from
now.
2.1.2 ENERGY SITUATION IN VIETNAM
Steel industry is one of the big energy consumng industry, and its energy saving activity can
contribute to big CO2 reduction. On the otherhand, profitability is important to introduce energy
saving technologies. Steel companies in Vietnam generally posess Electric Arc Furnace (hereinafter
referred to as “EAF”) and Reheating furnace (hereinafter referred to as “RHF”). EAF mainly
consumes electric power, and RHF maily consumes fuel such as coal, oil, natural gas etc. Accordingly
energy prices are key factor for production of steel..
Vietnam is blessed with energy resources, and the production of oil, natural gas, coal is an big scale
in the Southeastern Asian area. However, with recent economic growth, the energy demands increase
rapidly, and all these resources must be improted in the near future.
The master plan2 says that electric power price will be raised to 8~9 US Cents/kwh. Oil, natural gas,
and coal will be expected to be raised too. For example2 coal prices will be raised to 15% by 2020.
As mentioned above, in 2020 it is expected that electric power price will be raised by 30%, and oil,
natural gas, and coal will be raised by 15%.
2.1.3 ENERGY CONSUMPTION CONDITION OF STEEL INDUSTRY IN VIETNAM.
Through documents and a field work, the amount of energy saving and CO2 reduction potentials are
calculated when Japanese technologies are introduced.
UNIDO Vietnam Mission Report3 in 2011 and UNIDO Seminar4 in 2012 show energy intensity
(GJ/t-steel) and CO2 emission rate (kg-CO2/t-steel) of 18 steel companies joining Vietnam steel
association. Fig.2.1-2 shows both average value of CO2 emission and specific electric power
consumption calculated from energy intensity. CO2 emission and specific electric power consumption
is assumed to be almost 1.5 times as much as that of Japan.
In Figure 2.1-3, operation conditions and their operational indecis are arranged.
2 JETRO Hanoi Center March, 2011 3 UNIDO, "Energy and Resource Efficiency in the Vietnamese Steel Industry", July 2011 4 Green Industry Initiative and Promotion of Green Technologies 20120828-Green_Industry.pdf, (UNIDO Seminar, Tokyo (2012))
4
0
200
400
600
800
1000
1200
1400
1600
L E O M K Q G J N A H D P I F C R B Average Japan
Ele
ctr
ic p
ow
er,
、C
O2 E
mis
sion
Electric power, kWh/t-liquid steel (2011/7)
Electric power, kWh/t-liquid steel (updatedbaseline, 2012/8)
CO2, kg-CO2e/t-steel billet(2011/7)
(Hot metal ratio/50%)
Figure 2.1-2 Specific electric power consumption and CO2 emission rate of 18 steel companies
joining Vietnam Steel Association
(Unit of data in Japan is expressed as “per t-steel billet”)
5
Figure 2.1-3 EAF operation condition and its operational index of 18 steel companies joining Vietnam Steel Association
Production,x10,000t/y
EAFCapacity
,t/ch
SPH EBT CoolingPane
LadleFurnac
e
Warmor Hotcharge
EAF electric powerconsumption
,GJ/t-liquid steel(2011/7)
EAF electric powerconsumption,kWh/t-steel(2011/7) *3
*1: UNIDO, "Energy and Resource Efficiency in the Vietnamese Steel Industry", July 2011, *2: Total on and off site emissions *3: From Nguyen Thi Ngoc Tho (Energy Efficiency and Conservation Center of Ho Chi Minh City) "Overview of Steel and Paper Industry – Energy Saving Potential"2012,
and *1 (calculated with using 5.0GJ/MWh)。 *4: Handbook of Iron and Steel 5th edition, the 1st volume p.322 (2014), *5: Ferrum Vol.3 (1998) No.1, *6: Handbook of Iron and Steel 5th edition, the 6th volume p.216 (2014) *7: P.Dahlmann, R.Fandrich and H.B.Lüngen: Stahl Eisen, 132(2012), Nr.10, 29 *8: Green Industry Initiative and Promotion of Green Technologies 20120828-Green_Industry.pdf, (UNIDO Seminar, Tokyo (2012))
6
2.2 THE TECHNOLOGIES POSITIVE LIST
We selected here the proposals for energy saving technologies which are effective in applying to the
Vietnamese steel industry by careful study and organization of the energy saving technologies for
EAF steelmaking mainly in Japan, and by comparison with such lists as 'the List of Energy-Saving
Technologies’ which is one of the deliverables from “the Global Warming Mitigation Technology
Promotion Project” so far. The Positive List has been drawn up simultaneously with and is
substantially similar to the Customized List of “the Promotion of ISO14404 (Calculation method of
carbon dioxide (CO2) emission intensity from iron and steel production)” in the FY2014
“Fundamental Projects on International Standardization and Dissemination of Energy Savings (Joint
Research and Development and Promotion of International Standards on Energy Savings)”.
In the following, we explain a basic process for an EAF steel mill, the Positive List in which the
proposals for effective energy saving technologies are listed, and the technologies in the List which
are subject to application examination in this study.
2.2.1 OVERVIEW OF ELECTRIC FURNACE STEEL MILL
EAF steel mill consists of a steelmaking process and a rolling process. In the former process, an
electric arc furnace (EAF) and a ladle furnace (LF) are mainly used for manufacturing semi-finished
products, and in the latter, the semis are converted into finished products.
It can be said that the steelmaking process is a process for manufacturing semi-finished products by
electric furnace steelmaking method. Electric furnace steelmaking method is, different from blast
furnace steelmaking method, basically a batch process method. On the other hand, a rolling process is
a continuous operation process in the same way as that of a blast furnace method.
Figure 2.2-1 shows a flowchart illustrating the process for manufacturing carbon steel products at
EAF steel mill. The flowchart explains the process from raw materials to carbon steel products
through electric furnace steelmaking method. EAF steel mills use recycled scraps (from bridges,
buildings and vehicles, etc.) and/or domestic scraps originated from production plants as raw
materials, while integrated steel mills use iron ore. The domestic generation of scraps is low in
Vietnam, and for most of them Vietnam relies on imports from other advanced steelmaking countries
such as US. In a series of smelting and refining process (electric furnace steelmaking), these steel
scraps are melted in an EAF, impurities are removed and the molten steel is adjusted at given
components and temperature. In the next process, a continuous caster produces a few types of
semi-products (such as billets, blooms and slabs) as source materials for rolling from molten steel.
The semi products are rolled several times at each of rolling mills after reheated at RHF, and so on
and converted into finished products such as rebar, wire rods and flat bars.
7
(a) Process 1 (Steel making Process: from Scrap to Semi-product)
(b) Process 2 (Steel making Process: from Semi-product to final product)
Figure 2.2-1 Steel Process of Steel making plant with EAF5
2.2.2 SUPERIOR ENERGY SAVING TECHNOLOGIES AT EAF STEEL MILLS IN JAPAN
In this study, we screen suitable technologies for the Vietnamese steel industry from among the
superior energy saving technologies mainly for the electric furnace steelmaking method and the
reheating method at rolling process in Japan, and select applicable ones for the candidate steelworks
from among the suitable ones.
First of all, we organize and classify Japanese superior energy saving technologies into elemental
technologies.
5 Non- Integrated Steel Producers! Association : http://www.fudenkou.jp/manu_01.html
ビレット
ブルーム
スラブ
市中回収スクラップ(橋、ビル、自動車等)生産工場発生の加工スクラップ
バケット
電気炉へバケットでスクラップを装入
電炉工場へのスクラップ搬入
スクラップスクラップヤード
スクラップ配合 電気炉炉外精錬
(取鍋精錬)連続鋳造
鋳片(鋼片)半製品
出 鋼
ビレット
ブルーム
スラブ
市中回収スクラップ(橋、ビル、自動車等)生産工場発生の加工スクラップ
バケット
電気炉へバケットでスクラップを装入
電炉工場へのスクラップ搬入
スクラップスクラップヤード
スクラップ配合 電気炉炉外精錬
(取鍋精錬)連続鋳造
鋳片(鋼片)半製品
出 鋼
Scrap Scrapyard
Scrap mixing
EAFLadle
FurnaceContinuous
CastingSemi
Products
Tapping
ScrapBringing in
Scrap charging
billet
bloom
Slabbucket
Scrap gathering (Bridge, Building, Automobile, etc.Scrap from steel processing
加熱炉:1000~1200℃
小形棒鋼
線材
平鋼
棒鋼圧延機
線材圧延機
平鋼圧延機
粗圧延 中間圧延 仕上圧延
粗圧延機 中間圧延機仕上圧延機
(NTブロックミル) 冷水ゾーン
ステルモアクーリングコンベアー
粗圧延 中間圧延 仕上圧延
加 熱 炉 圧 延 機 主な製品
加熱炉:1000~1200℃
小形棒鋼
線材
平鋼
棒鋼圧延機
線材圧延機
平鋼圧延機
粗圧延 中間圧延 仕上圧延
粗圧延機 中間圧延機仕上圧延機
(NTブロックミル) 冷水ゾーン
ステルモアクーリングコンベアー
粗圧延 中間圧延 仕上圧延
加 熱 炉 圧 延 機 主な製品RHFSteel Rod Rolling Mill
Rolling Mill Major Products
Wire Rolling Mill
Flat Steel Rolling Mill
Rough Rolling Mill Middle Rolling Mill
Light steel bars
Finishing Rolling Mill
Rough Rolling Mill
Middle Rolling
Mill
Finishing Rolling
MillCoolingZone
CoolingConveyor
Rough Rolling Mill Middle Rolling Mill Finishing Rolling Mill
RHF :1000~1200 deg.C
Wire rod
Flat steel
8
(1) ENERGY SAVING TECHNOLOGIES FOR EAF STEELMAKING METHOD
As mentioned above, EAF steelmaking method is, different from blast furnace steelmaking method,
basically a batch process in which molten steel is tapped every 40 to 80 minutes. The key factors in
energy saving technologies for EAF steelmaking method are improvement of heat transfer efficiency
into scraps and molten steel as well as reduction of thermal radiation from the furnace body. In EAF
process, the early phase is the scrap melting period during which scraps are mainly melted, and the
later phase is the refining period during which the temperature of molten steel is increased and the
component of it is adjusted. Therefore, it is effective to utilize the appropriate technology in response
to each of the operational situations and it is important to properly control the appropriate technology
in accordance with the change of the process.
①Scrap Melting Enhancement Technology during scrap melting period
The scrap melting period is a period during which electrodes are plugged into, strike an arc on, and
melt the scraps charged in the furnace with the large current conducting in. Therefore, it is an
important operation technique to keep on flowing large and stable electrical current.
Regarding the technology for improving scrap melting efficiency, we have the auxiliary heating
burner technology as well as the hardware and software to supply large and stable electric current.
Generally, there is generated what is called “a cold spot” at the scraps in the furnace where electric
current is hard to flow, which causes delay in melting scraps, extension of the melting period and
increase in radiation loss of an arc. A burner for melting enhancement at “a cold spot” is usually
equipped in order to realize enhancement of scrap melting and reduction in radiation loss of an arc.
The burner for EAFs uses an auxiliary fuel such as heating oil, heavy oil and LNG, and supplements
scrap melting with high temperature flames obtained by burning the fuel effectively with enough
oxygen. The burner is set at “a cold spot” and solves the imbalance of partial melting. When the
burner is used during the scrap melting period, higher heat transfer efficiency is attained at “a cold
spot”. Melting period is also shortened by optimizing the position and the utilization of highly
efficient burner, and therefore energy efficiency is increased.
Figure 2.2-2 Image of inside-EAF and burners during scrap melting process
②Radiation Loss Reduction Technology from the end of melting period to refining period
The refining period is a period during which almost all of scraps are melted and the molten steel is
subject to adjustment of its component and temperature for tapping. From the end of the scrap melting
Burner
Fuel Oxygen
Cold Spot Scrap
9
period to the refining period, melting of scraps is almost completed, an arc from electrodes exposes in
the furnace, and thermal radiation of the arc often increases.
The slag foaming technology is utilized as a countermeasure against the thermal radiation. The
principle of the technology is explained as follows: carbon particles are blown with oxygen into the
molten slag on the molten metal, CO gas bubbles are generated in the molten slag, the slag foams with
the gas bubbles, electrodes are covered with the foamed slag, the thermal radiation of an arc decreases
and the efficiency of heat into the molten metal is increased. The technology can also enhance the
heat transfer into the molten steel and reduce the thermal radiation to the furnace body because high
temperature atmosphere is created in the furnace due to secondary combustion of CO gas which is
generated by blowing carbons and oxygen (Secondary Combustion Technology).
This requires introduction and installation of the carbon-oxygen blowing equipment, and it is a key
point to design the suitable blowing facilities according to the local situations because the effect will
change depending on the installation site and the number of burners.
Figure 2.2-3 Image of inside-EAF and carbon injection during refining process
③ Other Energy Saving Technologies
During powering of EAF steelmaking, exhaust gas is always emitted at some high temperature. The
applicable technologies are limited because EAF is a batch process, nevertheless Japan have the
technology for pre-heating of scraps before charging and that for direct recovery of energy from
exhaust gas.
Usually, a ladle is preheated just before molten steel is tapped into it in order to reduce the power
consumption of an EAF. The process of ladle preheating is also a batch one and the preheating
facilities often have no heat recovery system. Therefore, some energy saving technology is applicable
to the ladle preheating process.
Figure 2.2-4 shows the energy saving technologies supporting the electric furnace steelmaking
method in Japan.
Arc
Pulverized Coal
Oxygen
Foaming Slag
Arc
Pulverized Coal
Oxygen
Foaming Slag
10
Figure 2.2-4 Major Energy saving technologies for EAF
Classfied Energy
Saving Technologies
Tehcnologies Title Equipment and system for
technologies
① Scrap melting acceleration
technologies
High efficiency burner, High
efficiency oxygen lance
Scrap melting
technologies
② Radiation loss reduction
technologies during refining
process
High efficiency carbon injection,
High efficiency oxygen lance
EAF control system ③ Process control EAF for scrap
melting and refining
High efficiency power input control
system
Applecation of high
efficiency equipment
for EAF
④ Higher Power input
technologies
・High efficiency Transformer and
Reactance technologies
・Low impedance conducter arm
⑤ High temperature scrap
preheater
Environmental Economical arc
furnace
Waste recovery
technologies
⑥ Waste heat recovery
technologies of EAF
Waste heat recovery technologies
from EAF waste gas
Improvement of fuel
efficiency
⑦ High efficicncy preheater for
ladle preheating
Regenerative burner or oxygen/fuel
burner system for ladle preheating
(2) ENERGY SAVING TECHNOLOGIES FOR RHF
Major consumption sources of energy in a rolling process are the fuels at RHF and the electric power
required for rolling. RHF consumes more energy because billets or slabs must be heated to higher
than 1000 deg.C there. We suppose that advanced technologies are not sufficiently applied to fuel
saving at RHF, particularly in Vietnam. Figure 2.2-5 shows the technologies supporting energy
savings at RHFs in Japan.
Figure 2.2-5 Major Energy saving technologies for RHF
Classfied Energy Saving
Technologies
Tehcnologies Title Equipment and system for
technologies
Computer Control of
RHF
① Combustion control of RHF Optimum Air/fuel ratio
control, Optimum heat pattern
control
Improvement of fuel
efficiency
② Waste heat recovery system of
RHF
Regenerative burner system
These energy saving technologies for RHF are expected to be strong candidates applicable for the
11
Vietnamese steel industry, and they are listed in the Positive List as concretely applicable equipment,
in the same way as the technologies for EAF steelmaking method.
In the Positive List, there are listed the feasible technologies applicable for the Vietnamese steel
industry considering those energy saving technologies described above, in reference to the following
documents:
①FY2013 Global Warming Mitigation Technology Promotion Project
”Technologies Customized List & Technologies One by One Sheets (Ver.2)” regarding energy
saving, a deliverable from the report “A Study on Project Development Planning to Disseminate
Energy Saving Technologies in the Iron and Steel Industry in India”
②FY2012 Small and Medium-sized Enterprises Support Survey
“The Current State of the Technologies for Practical Use of Unused Sensible Heat and Waste
Thermal Energy at Electric Furnace Steel Mills (The Results of Questionnaire)”, a deliverable from
the report “Survey on the Actual Conditions of Iron & Steel Industry Regarding the Effective
Utilization of Waste Thermal Energy and the Saving of Energy”
③ The State-of-the-Art Clean Technologies (SOACT) for Steelmaking Handbook (2nd Edition), Dec.
2010, available at http://asiapacificpartnership.org/japanese/soact2nd.aspx.
④Japanese Technologies for Energy Savings/GHG Emissions Reduction, NEDO, 2008 Revised
Edition (hereinafter referred to as NEDO), available at http://www.nedo.go.jp/content/100107259.pdf
⑤Best Available Techniques (BAT) Reference Document for Iron and Steel Production, EU, Latest
Edition, Mar. 2012 (hereinafter referred to as EU-BAT), available at
IEA statistics, 2013 edition(average of '09-'11) *3
world*2
23
Figure 2.2-16 Technologies positive list for steel making plant with EAF (The number of each title corresponds to the number of Figure 2.2-6)
24
Figure 2.2-18 Presumed effect (power saving, CO2 reduction) of each technology from Technologies positive list
CO2Reductionkg-CO2/t
of productGJ/t
of productkWh/t
of product
1 Hot DRI/HBI Charging to the EAF 84.6 >150 ○
2 Scrap Preheating (ex. Ecological and Economical Arc Furnace) 84.6 150 1. reduction of DXN, Dust, Noise ○
3 Transformer efficiency—ultra-high power transformers 8.5 15 ○
4 Aluminium Alloy Conductor Arm for Supporting Electrode 1.6~3.3 3~6 *1
5 DC Electro Arc Furnace 5~10.1≦5%9~18
1.electrode consumption -(40-60)%2. reduction of flicker -(50-60)%, noise
○ ○
6 Oxy-fuel Burners/Lancing (together with enough capacity of direct suction type dust collector) 10.1~20.2 0.14 18~36 ○ ○
7 Eccentric Bottom Tapping (EBT) on existing furnace 3.9~1413.6
(7~25)1. 15-25% reduction of CaO(kg/t)2. shorter tap-to-tap times
○
8 Waste Heat Recovery from EAF 81.7 0.86 ○
9 Ladle Preheating9.1 -Regenerative Burner Total System 20.0 0.21 or 51% ○
9.2 -Oxygen/fuel Burner Total System ≧50% 1. life extension of refractory *2
10 Electrode Position Control for Power Optimization 10.4~16.9 0.11 301. electrode consumption -25%2. Productivity: +(9-12)%
○ ○
11 Control and Automation for EAF Optimization11.1 - by pattern presetting11.2 - by using Off-gas Analysis 19.7 35 ○ ○ *3
11.3 - Automatic Scrap Meltdown Timing Judgment System by Acoustic Spectrum Analysis for AC EAF 1.6~3.3 3-6 1. skill free *4
11.4 - Optimum Regulation System with multi-variable control using Fuzzy logic 10 *6
12 Carbon and Oxygen Injection System for foamy slag practice 2.8~3.90.04~0.05or 2.5~3%
5~7 ○ ○
13 Combustion Air Preheating for reheating furnace
13.1 - Preheating temperature ≧1000℃ by Regenerative Burner Total System 16.1~19.945%(S),
0.17-0.21(N)1. reduction of NOx ○ ○ ○
13.2 - Preheating temperature 600℃ by Recuperator using high heat resistance steel 10.7~13.3 30% ○
13.3 - Preheating temperature 400℃ by Recuperator 7.1~8.820% (S)0.7(E)
○ ○
14 Thermal insulation by Ceramic Fiber on inner wall of reheating furnace 15.2 2-5%, 0.16 ○ ○
15 Process Control for Reheating Furnace 19.9~79.8 0.21~0.84 ○
16 Air Conditioning by Hot Water Absorption Chiller utilizing Waste Heat 1.5 2.6 *5
17 Inverter (VVVF; Variable Voltage Variable Frequency) Drive for Motors 42% ○ ○ ○ ○
18 Energy Monitoring and Management Systems for Steel Plant with EAF 0.5% ○ ○ ○
Remarks;*1:*2:*3: Iron Steel Technol Conf Proc, vol.1, 2006, pp.509-518*4: Daido Steel*5:*6: NIKKO Industry CO.,LTD
estimated by JFE Techno-Research Corp. from data supplied from EBARA Refri. Equip. & Systems Co., Ltd.
CHUGAI RO Industry CO.,LTD, and http://www.klchem.co.jp/blog/2013/08/post_2094.phpNIKKO Industry CO.,LTD, and "Tekko-Binran" (Handbook of Iron and Steel) Vol.5, No.6, p.224
Miscellaneous
SO
AC
T
Indi
a T
CL
ver
.2No. Title of Technology
Technologies Reference
Mis
cell
aneo
us
Steelmaking
Reheating Furnace
Effect of Technologies IntroductionEnergy Savings
(Fuel)Co-benefits
EP
A-B
AC
T
NE
DO
EU
-BA
T
25
3. THE REVIEWS ON THE SPECIFIC PROJECT PLANNING FOR
COMMERCIALIZATION
Upon commencement of the field surveys, we requested the government of Vietnam (Heavy
Industry Dept., Ministry of Industry and Trade (hereinafter referred to as MOIT) to select the
steelworks which are willing to accept the study of the project on energy diagnosis and technology
introduction to EAF mills in Vietnam, and two companies were the candidates. Both of the companies
desired to receive energy diagnosis and study of the project, and we finally determined field surveys
on both of the companies. Hereinafter, the companies are referred to as A-Company and B-Company,
respectively.
These 2 companies locate in the north area in Vietnam. One is a steelworks with its long history, the
other is a comparatively new one which was established after 2000, and then they are contrast
steelworks to each other.
In surveying both the companies, we implemented field surveys and presentations according to the
schedule below:
1st visit (Sep. 2014), Preliminary field surveys on both EAF steelworks
Contents: Presentation of the project purpose (including introduction of JCM scheme),
Understanding of the actual conditions (plant tours and operation observations)
Discussion of the issues on energy, and refinement of applicable technology
2nd visit (Nov. 2014), Technical study of both EAF steelworks
Contents: Energy diagnoses of the electric furnaces and the RHF
Diagnoses of each of the processes on energy saving, and study of feasibilities of the
technology
Collection and estimation of data to evaluate energy saving
3rd Visit (Jan. 2015): Seminar
Presentation of the diagnosis results, the estimation of profitability for each technology,
and explanation of JCM
As for both of the EAF steelworks in Vietnam, we refined the equipment and the technology
applicable to them through actual condition surveys on the steelworks, and discussions with the
officers of the steelworks during our 1st visit. During the 2nd visit, we practically implemented
surveys and diagnoses, and during the 3rd visit, we held a seminar to present the results from the
surveys and the diagnoses and to focus on the profitability of the application of the technologies.
During the 2nd visit and diagnosis, we were accompanied by people from engineering firms
specializing in EAFs and RHFs in iron and steel making process, they also implemented diagnosis
and study based on applicability of the technologies to estimate the cost for the applicable
technologies and to do trial calculations of the merits together with us.
26
During the 1st and 2nd visits, we also explained to the relevant ministries and agencies to JCM in
Vietnam, the contents and activities of the project, and the details of JCM, which will be described
late in Chapter 5.
The contents of these three times of visits are described below.
27
3.1 THE REVIEW ON THE SPECIFIC PROJECT PLANNING FOR A-COMPANY
To A-Company, the 1st and 2nd visits were made by the members and on the schedule shown in Fig.
3.1-1.
Figure 3.1-1 Visit to A-Company
Period Delegation member
1st visit Sep. 11th to 12th ,2014
11th : Explanation of outline of this
project and Fact findings of EAF and
RHF
12th : Fact findings of iron making
process and discussion
JFE Techno-Research:2
JFE Steel:2
2nd visit Nov. 17th to 19th ,2014
Study and diagnosis for targeted
technologies application
JFE Techno-Research:2
JFE Steel:2
EAF Engineering maker:2
RHF Engineering maker:2
3rd visit Jan. 20th ,2015
Reporting the result at Seminar in Hanoi
JFE Techno-Research:2
JFE Steel:1
3.1.1 OVERVIEW OF A-COMPANY
Figure 3.1-2 shows an overview of A-Company steelworks.
Figure 3.1-2 Overview of the steel plant
No.2 EAFCapacity: 45ton/heatproduction
:300,000ton/y
Main Facilities
Reheating FurnaceNo.2 RHF
Capacity: 50ton/h
No.1 EAFCapacity: 20ton/heatproduction
:150,000ton/y
Reheating FurnaceNo.1 RHF
Capacity: 30ton/h
Blast Furnaces, Sintering Plant, Cokes ovens
BFSinterCoke Making
28
A-Company is a steelworks holding blast furnaces and coke ovens along the river, and behind them
an extensive site on which sintering furnaces and an electric furnace plant stand.
Its steelmaking process is an electric furnace one, and both scraps and hot metal from the blast
furnace are its iron sources. There are two units of EAFs as steelmaking equipment and two lines of
RHF and a rolling machine as rolling equipment in the plant, and the steelworks holds coke ovens,
sintering furnaces and blast furnaces in its upstream process. The steelworks is characterized by its
operation at the EAFs, where about a half of the iron source is hot metal from the blast furnaces and
the remainder relies on scraps.
The steelmaking plant holds two units of EAFs, the large scale No.2 EAF mainly produces molten
steel. Both of them are made in Chine and considerably old facilities.
Molten steel is treated at a ladle furnace (LF) and it is cast at a 4-strand continuous casting machine.
The cast products are transferred into RHF. There are two units of RHFs, one is the old and
Chinese-made No.1 RHF, and the other is the No.2 RHF which commenced operation in 1996.
A-Company intends that billets are supplied to No.2 RHF by hot charging from the steelmaking plant.
About 80 - 85% of the billets are supplied to the RHF at a temperature of 500 - 600℃, and the hot
charging is put into good practice (hot charging is not in operation at No.1 RHF).
Oil (Fuel Oil, F.O) is used as a fuel for both of No.1 and No.2 RHFs, however, we could not confirm
any information on type and property of the oil. No.1 RHF is a Chinese-made and old facility;
nevertheless, it is maintained sufficiently and kept in good condition. No.2 RHF is also kept up in
good condition.
This rolling process produces steel bars as finished products, which are shipped.
Meanwhile, the steelworks plans on expanding its annual production to about 1 million tons per year
in the future. The steelworks currently holds two blast furnaces, and a new blast furnace is under
construction. In line with this, the steelworks plans to construct a steelmaking plant as well as a
sintering plant and a coke oven. In addition, construction of new RHF is almost completed. It seems
that the steelworks enters a period of transition to some kind of integrated steelworks.
We describe the overviews of the EAF and the RHF below.
The following are the typical indices of operation for No.2 EAF and No.2 RHF which are finally
chosen as the facility subject to the study. The values below rely on the documents of A-Company
and the interviews with the officers.
EAF
・ Average tapping quantity: About 45 t-steel/heat
・ Average power consumption rate: 250 kwh/t-steel
・ Average oxygen consumption rate: 55 m3N/t-steel
・ Average coal consumption rate: 10 kg/t-steel
Much usage of hot metal gives the facility a feature that the power consumption is lower and the
oxygen usage is more than those of an average EAF.
RHF
29
・ RHF capacity: 50 ton/h (walking hearth type)
・ Hot charging ratio: 80 – 85% (at an assumed temperature of 500 – 600℃)
・ Fuel: Oil (details unknown)
・ Fuel consumption rate: 24 l/t-steel (210,000 kcal/t-steel, when hot charged)
31 l/t-steel (273,000 kcal/t-steel, when cold charged)
Where the energy conversion factor is assumed as 8,800 kcal/l, supposing that Oil is fuel oil
A (JIS K2205 Class).
・ Furnace temperature: 1150℃
It is a very conventional RHF, however, the fuel consumption rate is lower compared to an average
RHF because of its intention of hot charging.
3.1.2 SPECIFICATION OF ISSUES ON ENERGY SAVING TO STUDY
On the 1st visit, we presented the technology in Japan, took a tour of the whole steelworks, and had a
discussion focused on issues A-Company has with energy saving.
Figure 3.1-3 Meeting with A-Company at 1st visit
Based on the discussion with officials of A-Company and the current situations witnessed through
plant tour, following technologies are the issues for study of the technologies.
(1) Study of energy saving technologies for EAF:
oxygen lances, burners, coal injection, and reduction in electric power consumption rate by
application of the technologies such as the optimal control for an EAF.
(2) Study of fuel consumption reduction for RHF:
diagnosis of the current operation and reduction in fuel usage by introduction of the
regenerative burners.
30
(3) Utilization of gases in the whole steelworks:
gas balancing in the whole steelworks and effective utilization of B gas.
Based on the premise of study of the above items, we implemented surveys and study, and specified
technologies to introduce on the 2nd visit. The above item (3) is not likely linked to a practical project
at this moment. However, we considered it subject to the study because it is important to save energy
at the steelworks in future.
3.1.3 DIAGNOSIS ON ENERGY SAVING ISSUES AND ESTIMATION OF APPLICABLE
TECHNOLOGIES
As for the three items of issues as stated above, we implemented field study and diagnosis on the
2nd visit, accompanied by engineering makers specializing in EAFs and RHFs. In the field survey, we
observed operations at the plants, provided recommendations on improvement of the current
operations through observation of operations, and studied the optimal application of technologies. In
addition, the engineering firms studied the estimations and construction periods on the spot, and we
based them on our final estimation of economical evaluation.
We will describe the details on each of the technologies below.
(1) STUDY OF ENERGY SAVING TECHNOLOGIES FOR THE EAF:
On the study of technologies, we followed through such steps as witnessing the operation at the plant,
identifying issues, and studying appropriate technologies to introduce. We show the approximate
merits by introduction of the technologies below; nevertheless, further study in detail is required.
Figure 3.1-4 Photo of EAF under operation
① Observation of operation at the EAF plant
Figure 3.1-5 shows a result we obtained through the observation of an operation at the EAF.
31
Figure 3.1-5 operation observation of EAF at the site
Results of the observation are summarized as below:
・ Charging 10 tons of scraps (referred to as SC① in the figure), cutting the scraps with oxygen
for around 3 min, and charging 20 tons of hot metal (HM in the figure).
・ After that, raising the voltage to start scrap melting, and charging some scraps for the second
time at the point when the scraps were melted to some extent.
・ Subsequently, melting the scraps in the same way, and charging once more scraps for the third
time at the point when the scraps were melted to some extent.
・ After the third charging, blowing just oxygen (for about 16 min.), and entering the refining
period at the point when the scraps were thoroughly melted. Foaming slag by carbon injection,
and completing the refinement.
② Findings on the operation
The findings as described below are extracted through the observation of the operation.
Finding 1: As shown as “①Oxygen Supply” in Fig. 3.1-5, the operation period is elongated due to the
long period of oxygen supply without turning on the electric power.
Finding 2: As shown as “②Tap change” in Fig. 3.1-5, the electric power is temporarily turned off
every time the voltage is changed. Moreover, there is large fluctuations of electric current through
each of the electrodes (Figure 3.1-6), and high electric power can not be inputted stably, which leads
PEelec : CO2 emission from electricity, which is consumed at the EAF during the
project [t-CO2/ y]
PEcm : CO2 emission from carbon of the cold pig iron, which is consumed at the EAF
during the project [t-CO2/ y]
PEhm : CO2 emission from carbon of the hot pig iron, which is consumed at the EAF
during the project [t-CO2/ y]
PEcoal : CO2 emission from EAF coal, which is consumed at the EAF during the
project [t-CO2/ y]
PEng : CO2 emission from natural gas, which is consumed at the EAF during the
project [t-CO2/ y]
PEoil : CO2 emission from heavy oil, which is consumed at the EAF during the project
[t-CO2/ y]
PEo2 : CO2 emission from oxygen, which is consumed at the EAF during the project
[t-CO2/ y]
PEelec = EPeaf, y × EFelec
Where,
EPeaf, y : Consumption of electricity at the EAF during the project [MWh/ y]
EFelec : CO2 emission factor for the Viet Nam grid system [t-CO2/MWh]
PEcm = WPcm, y × 0.04 × (44/12)
Where,
WPcm, y : Consumption of cold pig iron at the EAF during the project [t/ y]
PEhm = WPhm, y × 0.04 × (44/12)
Where,
WPhm, y : Consumption of hot pig iron at the EAF during the project [t/ y]
PEcoal = WPcoal, y × EFcoal
Where,
WPcoal, y : Consumption of EAF coal at the EAF during the project [t/ y]
EFcoal : CO2 emission factor for the EAF coal [t-CO2/t]
74
PEng = QPng, y × EFng
Where,
QPng, y : Consumption of natural gas at the EAF during the project [km3N/ y]
EFng : CO2 emission factor for the natural gas [t-CO2/km3N]
PEoil = QPoil, y × EFoil
Where,
QPoil, y : Consumption of heavy oil at the EAF during the project [m3/ y]
EFoil : CO2 emission factor for the heavy oil [t-CO2/ m3]
PEo2 = (EPo2, y × EFelec + WPsteam, y × EFsteam)
×QPo2, y / (QPo2, y + QPo22, y)
Where,
EPo2, y : Consumption of electricity at the oxygen plant during the project
[MWh/ y]
EFelec : CO2 emission factor for the Viet Nam grid system [t-CO2/MWh]
WPsteam, y : Consumption of steam at the oxygen plant during the project [t/ y]
EFsteam : CO2 emission factor for the steam [t-CO2/ t]
QPo2, y : Consumption of oxygen at the EAF during the project [km3N/ y]
QPo22, y : Consumption of oxygen at the other process during the project [km3N/ y]
H. Calculation of emissions reductions
Emission reductions are calculated as the difference between the reference emissions and
project emissions, as follows.
DPRy = REy - PEy
Where,
DPRy :GHG emission reductions in year [t-CO2/y]
I. Data and parameters fixed ex ante
The source of each data and parameter fixed ex ante is listed as below.
Parameter Description of data Source
75
EFelec CO2 emission factor for
the Viet Nam grid system
The combined margin(CM) emission factor in Viet
Nam from "IGES CDM project data base"
(http://www.iges.or.jp/en/cdm/report.html)
EFcoal CO2 emission factor for
the EAF coal
1) The data is calculated from the carbon content of
the coal, which is measured by chemical analysis.
2) The data is sourced from "CO2 EMISSIONS
DATA COLLECTION, User Guide, Version 6"
(worldsteel).
(unless instructed by the Joint Committee)
EFng CO2 emission factor for
the natural gas
1) The data is calculated from the carbon content of
the natural gas, which is measured by chemical
analysis.
2) The data is sourced from "CO2 EMISSIONS
DATA COLLECTION, User Guide, Version 6"
(worldsteel).
(unless instructed by the Joint Committee)
EFoil CO2 emission factor for
the heavy oil
1) The data is calculated from the carbon content of
the heavy oil, which is measured by chemical
analysis.
2) The data is sourced from "CO2 EMISSIONS
DATA COLLECTION, User Guide, Version 6"
(worldsteel).
(unless instructed by the Joint Committee)
EFsteam CO2 emission factor for
the steam
1) The data is sourced from "CO2 EMISSIONS
DATA COLLECTION, User Guide, Version 6"
(worldsteel).
(unless instructed by the Joint Committee)
As an example, JCM Methodology Spreadsheets (Input sheet, Calculation process sheet) are shown in
Figure 4.1-1 and Figure 4.1-2.
76
Figure 4.1-1 Input sheet
JCM_VN_F_PMS_ver01.0
Joint Crediting Mechanism Proposed Methodology Spreadsheet Form (input sheet) [Attachment to Proposed Methodology Form]
Table 1: Parameters to be monitored ex post(a) (b) (c) (d) (e) (f) (g) (h) (i) (j)
Monitoringpoint No.
Parameters Description of dataEstimated
ValuesUnits
Monitoringoption
Source of data Measurement methods and proceduresMonitoringfrequency
Othercomments
(1) WPbillet,y Production of billets per ayear ex post
250,000 t-billet/y C Monitored data
- Counting the number of the produced billets divided intoeach billet size.- Having data of the weight per a billet of each billet sizeby direct mesuaring or by calculating using billet size anddencity.- Calculating "Pbillet,y" from the number of the producedbillets and the weight per a billet of each billet size
once at theend of theyearlymonitoring
(2) Epeaf, y Consumption of electricity atthe EAF
97,500 MWh/ y C Monitored data - Measuring the Watt-hour meter equipped to the EAFat the startand the endof the period
(3) WPcm, y Consumption of cold pig ironat the EAF
12,500 t/ y C Monitored data- Measuring the weight of the charged cold pig iron- Integration of the weights
at everycharge toEAF
(4) WPhm, y Consumption of molten pigiron at the EAF
0 t/ y C Monitored data- Measuring the weight of the charged molten pig iron- Integration of the weights
at everycharge toEAF
(5) WPcoal, y Consumption of EAF coal atthe EAF
6,250 t/ y C Monitored data- Reading the delivery amount of the EAF coal describedin the invoice
at everydelivery
(6) QPng, y Consumption of natural gasat the EAF
0 km3N/ y C Monitored data- Measuring the integrating flowmeter equipped to theEAF
at the startand the endof the period
(7) QPoil, y Consumption of heavy oil atthe EAF
0 m3/ y C Monitored data- Reading the delivery amount of the oil described in theinvoice
at everydelivery
(8) QPo2, y Consumption of oxygen atthe EAF
10,000 km3N/ y C Monitored data- Measuring the integrating flowmeter equipped to theEAF
at the startand the endof the period
(9) EPo2, y Consumption of electricity atthe oxygen plant
8,750 MWh/ y C Monitored data- Measuring the Watt-hour meter equipped to the oxygenplant
at the startand the endof the period
45 WPsteam, y Consumption of steam at theoxygen plant
1,563 t/ y C Monitored data- Measuring the integrating flowmeter equipped to theoxygen plant
at the startand the endof the period
(11) QPo22, y Consumption of oxygen atthe other plant
2,500 km3N/ y C Monitored data- Measuring the integrating flowmeter equipped to theother plant
at the startand the endof the period
(12) Ttap, y Tap temperature 1,600degreesCelsius
C Monitored data- Immersion thermocouple is used to measure thetemperature of steel bath at EAF- Average value during the project period
At least, oncea day duringoperation
77
Table 2: Project-specific parameters to be fixed ex ante
(a) (c) (d)
ParametersEstimated
ValuesUnits
EFelec 0.564 t-CO2/MWh
EFcoal 3.257 t-CO2/t
EFng 2.014 t-CO2/km3N
EFoil 2.907 t-CO2/m3
EFsteam 0.195 t-CO2/t
WRbillet 50,000 t-billet
EReaf 20,000 MWh
WRcm 2,500 t
WRhm 0 t
WRc 1,250 t
QRng 0 km3N
Qroil 0 m3
QRo2 2,000 km3N
ERo2 1,750 MWh
WRsteam 313 t
QRo22 500 km3N
Ttap, ref 1,601degreesCelsius
Table3: Ex-ante estimation of CO2 emission reductionsUnits
tCO2/y
[Monitoring option]Option AOption BOption C
Consumption of natural gas at the EAFduring the reference period
CO2 emission factor for the EAF coal
1) The data is calculated from the carbon content of the coal, which is measured bychemical analysis.2) The data is sourced from "CO2 EMISSIONS DATA COLLECTION, User Guide,Version 6"(worldsteel).(unless instructed by the Joint Committee)
CO2 emission factor for the natural gas
1) The data is calculated from the carbon content of the natural gas, which is measuredby chemical analysis.2) The data is sourced from "CO2 EMISSIONS DATA COLLECTION, User Guide,Version 6"(worldsteel).(unless instructed by the Joint Committee)
CO2 emission factor for the heavy oil
1) The data is calculated from the carbon content of the heavy oil, which is measured bychemical analysis.2) The data is sourced from "CO2 EMISSIONS DATA COLLECTION, User Guide,Version 6"(worldsteel).(unless instructed by the Joint Committee)
Consumption of cold pig iron at the EAFduring the reference period
Based on the amount of transaction which is measured directly using measuring equipments (Data used: commercial evidence such as invoices)
Consumptio of electricity at the EAF duringthe reference period
Monitored data.- Measuring the Watt-hour meter equipped to the EAF
Consumption of molten pig iron at the EAFduring the reference period
Monitored data.- Measuring the weight of the charged molten pig iron- Integration of the weights
Consumption of EAF coal at the EAF duringthe reference period
Monitored data.- Reading the delivery amount of the EAF coal described in the invoice
Consumption of heavy oil at the EAF duringthe reference period
Consumption of oxygen at the EAF duringthe reference period
Monitored data.- Measuring the weight of the charged cold pig iron- Integration of the weights
(e)
Source of data
The combined margin(CM) emission factor in Viet Nam from "IGES CDM project database"(http://www.iges.or.jp/en/cdm/report.html)
Based on the actual measurement using measuring equipments (Data used: measured values)
(b)
Description of data
CO2 emission reductions
1,409
CO2 emission factor for the Viet Nam gridsystem
Based on public data which is measured by entities other than the project participants (Data used: publicly recognized data such as statistical data and specifications)
(f)
Other comments
CO2 emission factor for the steamThe data is sourced from "CO2 EMISSIONS DATA COLLECTION, User Guide, Version6"(worldsteel).(unless instructed by the Joint Committee)
Production of billets during the referenceperiod
Monitored data.- Counting the number of the produced billets divided into each billet size.- Having data of the weight per a billet of each billet size by direct mesuaring or bycalculating using billet size and dencity.- Calculating "Pbillet,ref" from the number of the produced billets and the weight per abillet of each billet size
Monitored data.- Measuring the integrating flowmeter equipped to the EAF
Monitored data.- Reading the delivery amount of the oil described in the invoice
Monitored data.- Measuring the integrating flowmeter equipped to the EAF
Consumption of electricity at the oxygenplant during the reference period
Monitored data.- Measuring the Watt-hour meter equipped to the oxygen plant
Consumption of steam at the oxygen plantduring the reference period
Monitored data.- Measuring the integrating flowmeter equipped to the oxygen plant
Tap temperature during the reference period
Monitored data.- Immersion thermocouple is used to measure the temperature of steel bath at EAF- At least, once a day during operation- Average value during the referencce period
Consumption of oxygen at the other plantduring the reference period
Monitored data.- Measuring the integrating flowmeter equipped to the EAF
78
Figure 4.1-2 Calculation process sheet
JCM_VN_F_PMS_ver01.0
1. Calculations for emission reductions Fuel type Value Units Parameter
Emission reductions during the period of year y 1,410 tCO2/y DPRy
2. Selected default values, etc.
CO2 emission factor for the Viet Nam grid system ----- 0.564 t-CO2/MWh EFelec
CO2 emission factor for the EAF coal ----- 3.257 t-CO2/t EFcoal
CO2 emission factor for the natural gas ----- 2.014 t-CO2/km3N EFng
CO2 emission factor for the heavy oil ----- 2.907 t-CO2/m3 EFoil
CO2 emission factor for the steam ----- 0.195 t-CO2/t EFsteam
3. Calculations for reference emissions
Reference emissions during the period of year y 82,781 tCO2/y REy
Production of billets during the reference period ----- 50,000 t-billet WRbillet
Consumptio of electricity at the EAF during the reference period Electricity 20,000 MWh EReaf
Consumption of cold pig iron at the EAF during the reference period ----- 2,500 t WRcm
Consumption of molten pig iron at the EAF during the reference period ----- 0 t WRhm
Consumption of EAF coal at the EAF during the reference period Fossil Fuel 1,250 t WRc
Consumption of natural gas at the EAF during the reference period Fossil Fuel 0 km3N QRng
Consumption of heavy oil at the EAF during the reference period Fossil Fuel 0 m3 Qroil
Consumption of oxygen at the EAF during the reference period ----- 2,000 km3N QRo2
Consumption of electricity at the oxygen plant during the reference per Electricity 1,750 MWh ERo2
Consumption of steam at the oxygen plant during the reference period ----- 313 t WRsteam
Consumption of oxygen at the other plant during the reference period ----- 500 km3N QRo22
4. Calculations of the project emissions
Project emissions during the period of year y 81,371 tCO2/y PEy
Production of billets per a year ex post ----- 250,000 t-billet/y WPbillet,y
Consumption of electricity at the EAF Electricity 97,500 MWh/ y Epeaf, y
Consumption of cold pig iron at the EAF ----- 12,500 t/ y WPcm, y
Consumption of molten pig iron at the EAF ----- 0 t/ y WPhm, y
Consumption of EAF coal at the EAF Fossil Fuel 6,250 t/ y WPcoal, y
Consumption of natural gas at the EAF Fossil Fuel 0 km3N/ y QPng, y
Consumption of heavy oil at the EAF Fossil Fuel 0 m3/ y QPoil, y
Consumption of oxygen at the EAF ----- 10,000 km3N/ y QPo2, y
Consumption of electricity at the oxygen plant Electricity 8,750 MWh/ y EPo2, y
Consumption of steam at the oxygen plant ----- 1,563 t/ y WPsteam, y
Consumption of oxygen at the other plant ----- 2,500 km3N/ y QPo22, y
Joint Crediting Mechanism Proposed Methodology Spreadsheet Form (Calculation Process Sheet)
[Attachment to Proposed Methodology Form]
79
4.2 METHODOLOGY OF LADLE PREHEATING OXYGEN/FUEL BURNER
This methodology describes that retrofitting an existing burner into an oxygen/fuel burner can
improve fuel efficiency, resulting in reduction of CO2 emissions during ladle preheating.
JCM Proposed Methodology Form
Cover sheet of the Proposed Methodology Form
Form for submitting the proposed methodology
Host Country Socialist Republic of Vietnam
Name of the methodology proponents
submitting this form
JFE Steel
JFE Techno-Research
Sectoral scope(s) to which the Proposed
Methodology applies
4.Manufacturing industries
Title of the proposed methodology, and
version number
Oxygen/Fuel Burner System for Rapid Ladle
Preheating in Elevated Temperature Application
Version number: 1.0
List of documents to be attached to this form
(please check):
The attached draft JCM-PDD:
Additional information
Date of completion
History of the proposed methodology
Version Date Contents revised
80
A. Title of the methodology
Oxygen/Fuel Burner System for Rapid Ladle Preheating in Elevated Temperature Application
Version number: 1.0
B. Terms and definitions
Terms Definitions
Coal Gasification Furnace
(CGF)
Furnace to produce mixed gas from coal and air.
Coal Gas (CG) Mixed gas produced from coal in CGF. which consists
primarily of carbon monoxide (CO), hydrogen (H2), carbon
dioxide (CO2), methane (CH4), nitrogen (N2) and moisture
(H2O).
Ladle (LD) Vessel or container of molten steel
Oxygen/fuel Burner total
system for Ladle preheating
Burners designed to fire coal gas mixed with oxygen in high
temperature applications.
Electric Arc Furnace (EAF) A furnace that heats and melts steel scraps by means of an
electric arc charging between electrodes. The steel melt is
refined by blowing oxygen into melt.
Ladle Furnace (LF) Facility to refine and reheat molten steel in ladle to targeted
steel compositions and temperature after Electric Arc
Furnace.
Continuous Caster (CC) Facility to solidify molten steel into a semi-finished product,
billet, for subsequent rolling in hot rolling mills. (Continuous
Caster can also produce bloom, or slab, larger section than
billet.)
Billet Semis which rectangular or round steel bar in an intermediate
stage of manufacture. Bar, rod, wire, and etc. can be
produced from steel billets.
C. Summary of the methodology
Reduction of CO2 emission from ladle preheating furnace can be performed by improving fuel
efficinecy at ladle preheating. As co-benefits through an introduction of “Oxygen/Fuel Burner System
for Rapid Ladle Preheating in Elevated Temperature Application”, reduction of electricity
81
consumption in EAF by decreasing tapping temperature is expected as a result from preheating
temperature increase (ex. from 900 deg C. to 1400 deg C.) of ladle inner refractory. If an operation to
decrease tapping temperature is not applied in EAF, reduction of electricity consumption in LF is
expected by decreasing amount of temperature rising up to targeting temperature of steel melt in LF.
These co-benefits mentioned above strongly affect by operational conditions in EAF and LF, and it is
also difficult to quantitatively evaluate the co-benefits.
Therefore, a methodology in a boudary shown in figure below is focussed hereafter.
Items Summary
GHG emission reduction
measures
Reduction of fuel and electricity consumption in CGF by
efficiency improvement of ladle preheating through an
introduction of “Oxygen/fuel Burner System for Rapid Ladle
Preheating in Elevated Temperature Application.”
Calculation of reference
emissions
Calculated using CO2 emission originated from fuel and
electricity consumed at ladle preheating furnace (LPF) before an
introduction of “Oxygen/Fuel Burner System for Rapid Ladle
Preheating in Elevated Temperature Application.”
Calculation of project
emissions
Calculated from CO2 originated from oxygen, fuel, steam, and
electricity consumed at LPF after introduction of “Oxygen/Fuel
Burner System for Rapid Ladle Preheating in Elevated
Temperature Application.”
Monitoring parameters 1) Coal consumed in CGF produced as a fuel for LPF
2) Natural gas consumed for LPF
3) Heavy oil consumed for LPF
4) Electricity consumed at CGF and LPF
6.O2
10.Billet
LF
CC
9.Steel
temperature
before tapping
Oxygen
Production
Plant (OPP)
5.O2
7.Power
LD
LD
8.Steam EAF
steel flow
2.Natural gas
3.Heavy oil
Coal
Gasification
Furnace (CGF)1.Coal
4-1.Power
Oxygen/fuel
Burner
system
for Ladle
4-2.Power
Boundary
gas/oil flow
82
5) Oxygen consumed in oxygen production plant (OPP) for
ladle preheating
6) Oxygen consumed in OPP for other plant except for LPF
7) Electricity consumed in OPP
8) Steam consumed in OPP
9) Steel temperature before tapping from EAF
10) Production of billet
D. Eligibility criteria
This methodology is applicable to projects that satisfy all of the following criteria.
Criterion 1 Proposed methodology is applied to improve efficiency of preheating ladle by
retrofitting an existing burner into an “Oxygen/Fuel Burner System for Rapid
Ladle Preheating in Elevated Temperature Application” in billet production route
of EAF-LF-CC.
Criterion 2 At the beginning of project, existing burners for preheating ladle have been
already operated, and “Oxygen/fuel Burner System for Rapid Ladle Preheating
in Elevated Temperature Application” has not been introduced.
Criterion 3 Easily possible to be certificated by analyzing actual data that efficiency of
preheating ladle can be improved by an introduction of “Oxygen/fuel Burner
System for Rapid Ladle Preheating in Elevated Temperature Application.”
Criterion 4 A fuel to preheat ladle should be one of coal gasification gas, natural gas, or
heavy oil.
Criterion 5 Difference of tapping temperature of molten steel in EAF between reference and
project should be within ten degree centigrade.
E. Emission Sources and GHG types
Reference emissions
Emission sources GHG types
CO2 originated from electricity consumed at CGF and LPF CO2
CO2 originated from coal consumed in CGF as a fuel at LPF CO2
CO2 originated from natural gas consumed as a fuel at LPF CO2
CO2 originated from heavy oil consumed as a fuel at LPF CO2
Reference emissions
Emission sources GHG types
CO2 originated from electricity consumed at CGF and LPF CO2
83
CO2 originated from coal consumed in CGF as a fuel at LPF CO2
CO2 originated from natural gas consumed as a fuel at LPF CO2
CO2 originated from heavy oil consumed as a fuel at LPF CO2
CO2 originated from electricity and steam consumed at OPP CO2
F. Establishment and calculation of reference emissions
F.1. Establishment of reference emissions
1. Reference CO2 emissions can be converted and summarized following data measured during
at least three months. In this case, CO2 emission factors of coal, natural gas, heavy oil,
electricity, and steam at the time of project year can be applied.
1) Elecricity consumed at CGF and LPF
2) Fuel consumed at LPF
2. CO2 emissions due to billet manufacturing can be strongly influenced by not only electricity
efficiency of plant facilities but also fuel consumption at LPF and production amount of billet.
In consideration of the above,
3. Reference CO2 emissions of fuel consumed for ladle preheating are calculated by using
reference fuel consumption compensated with project production amount of billet.
4. Reference CO2 emissions of electricity consumed for ladle preheating are calculated by using
reference electricity consumption compensated with project production amount of billet.
F.2. Calculation of reference emissions
Reference CO2 emmisions are calculated based on following equations.
QOld,y:Oxygen produced in OPP for ladle preheating (m3N-o2 /y)
QOother,y:Oxygen produced in OPP for other plant except for LPF (m3N-o2 /y)
EOo2 plant,y:Electricity consumed in OPP(MWh/y)
PEsteam = WPsteam,y × EFsteam (t-CO2/y)
where,
86
WPsteam,y:Steam consumed for production of oxygen used at LPF( t-steam/y)
EFsteam :CO2 emission factor of steam(t-CO2/ t-steam)
WPsteam,y =[QOld,y/(QOld,y+QOother,y )] x WSy
where,
QOld,y:Oxygen produced in OPP for ladle preheating (m3N-o2 /y)
QOother,y:Oxygen produced in OPP for other plant except for LPF (m3N-o2 /y)
WSy:Project steam consumed in OPP( t-steam/y)
In case of purhased oxygen ;
EPo2,y = QOp,ld,y × UOP (MWh/y)
where,
QOp,ld,y:purchase oxygen consumed for ladle preheating (m3N-o2 /y)
UOP:Electricity equivalent value of oxygen (kWh/ m3N-o2)
H. Calculation of emissions reductions
Reduction of CO2 emmision is calculated based on a following equation.
DPRy = REy - PEy
where,
DPRy : Emission reductions during the period of year y(t-CO2/y)
REy : Reference emissions during the period of year y(t-CO2/y)
PEy : Project emissions during the period of year y(t-CO2/y)
I. Data and parameters fixed ex ante
The source of each data and parameter fixed ex ante is listed as below.
Parameter Description of data Source
EFcoal CO2 emission factor of coal due to the
project
1. Actual value
2. Value in “CO2 EMISSIONS DATA
COLLECTION, User Guide, Version 6”
published from worldsteel
EFng CO2 emission factor of natural gas due
to the project
1. Actual value
2. Value in “CO2 EMISSIONS DATA
COLLECTION, User Guide, Version 6”
published from worldsteel
87
EFoil CO2 emission factor of heavy oil due
to the project
1. Actual value
2. Value in “CO2 EMISSIONS DATA
COLLECTION, User Guide, Version 6”
published from worldsteel
EFelec CO2 emission factor of grid electricity
due to the project
1. Value (CM) in ”IGES CDM Project
database”
http://www.iges.or.jp/en/cdm/report.html
published from IGES
EFsteam CO2 emission factor of steam utilized
for producing oxygen due to the
project.
1. Actual value
2. Value in “CO2 EMISSIONS DATA
COLLECTION, User Guide, Version 6”
published from worldsteel
EFo2 CO2 emission factor of oxygen due to
the project
1. Actual value
2. Value in “CO2 EMISSIONS DATA
COLLECTION, User Guide, Version 6”
published from worldsteel
UOP Electricity consumption for production
of 1 km3N oxygen (electricity
consumed for production of steam
used for producing oxygen is not
included)
1. Actual value
2.Calculating as EFo2 / EFelec
Concrete examples of spreadsheet including “PMS(input)” and “PMS(calc_process)” are shown in
Figures 4.2-1 and 4.2-2.
88
Figure 4.2-1 An example of JCM spreadsheet “PMS(input)”
Table 1: Parameters to be monitored ex post(a) (b) (c) (d) (e) (f) (g) (h) (i) (j)
Monitoringpoint No.
Parameters Description of dataEstimated
ValuesUnits
Monitoringoption
Source ofdata
Measurement methods andprocedures
Monitoring frequencyOther
comments
1 WPcoal,yProject consumption of coal in coalgasification furnace(CGF) for ladlepreheating furnace(LPF)
1,020 drt t-coal/y CMonitoreddata
- Measuring the weight of the chargedcoal- Integration of the weights
at every charge to LPF
2 QPng,yProject consumption of natural gasfor LPF
0 km3N-ng/y CMonitoreddata
- Measuring the integrating natural gasflowmeter equipped to LPF
at the start and the end ofthe period
3 QPoil,yProject consumption of heavy oil forLPF
0 m3-oil/y CMonitoreddata
- Measuring the integrating oil flowmeterequipped to LPF
at the start and the end ofthe period
4-1 EPcgf,yProject consumption of elecricity forCGF
200 MWh/y CMonitoreddata
- Measuring the Watt-hour meterequipped to CGF
at every charge to CGF
4-2 EPld,yProject consumption of elecricity forLPF
400 MWh/y CMonitoreddata
- Measuring the Watt-hour meterequipped to LPF
at every charge to LPF
5 QOld,yProject consumption of oxygenproduced in oxygen productionplant(OPP) for LPF
300 km3N-o2/y CMonitoreddata
- Measuring the integrating O2flowmeter equipped to LPF
at the start and the end ofthe period
5 QOp,ld,yProject consumption of purchaseoxygen for LPF
0 km3N-o2/y CMonitoreddata
- Measuring the integrating O2flowmeter equipped to LPF
at the start and the end ofthe period
6 QOother,yProject consumption of oxygenproduced in OPP for other plantexcept for LPF
10,212 km3N-o2/y CMonitoreddata
- Measuring the integrating O2flowmeter equipped to the other plantexcept for LPF
at the start and the end ofthe period
7 EPo2 plant,yProject consumption of elecricity forOPP
2,064 MWh/y CMonitoreddata
- Measuring the Watt-hour meterequipped to OPP
at every charge to OPP
8 WSyProject consumption of steam forOPP
1,314 t-steam/y CMonitoreddata
- Measuring the integrating steamflowmeter equipped to OPP
at the start and the end ofthe period
9 TPtap,yProject average tappingtemperature of molten steel in EAF
1,600 deg C. CMonitoreddata
- Measuring molten steel tempareture inEAF before tapping from EAF
at every charge from EAF
10 WPbillet,y Project production of billet 220,000 t-billet/y CMonitoreddata
- Counting the number of the producedbillets divided into each billet size.- Having data of the weight per a billetof each billet size by direct mesuaring orby calculating using billet size anddencity.- Calculating "Pbillet,ref" from thenumber of the produced billets and theweight per a billet of each billet size
at the start and the end ofthe period
Table 2: Project-specific parameters to be fixed ex ante(a) (c) (d)
ParametersEstimated
ValuesUnits
EFcoal 3.257 t-CO2/dry t-coal
EFelec CO2 emission factor of grid electricity 0.564 t-CO2/MWh
EFo2 CO2 emission factor of oxygen 0.355 t-CO2/km3N-o2
EFng CO2 emission factor of natural gas 2.014 t-CO2/km3N
EFoil CO2 emission factor of heavy oil 2.907 t-CO2/m3
EFsteam CO2 emission factor of steam 0.195 t-CO2/t-steam
WRbillet 250,000 t-billet
WRcoal 1,700 dry t-coal
QRng 0 km3N-ng
QRoil 0 m3-oil
ERcgf 200 MWh
ERld 400 MWh
ERld 400 MWh
TRtap,y 1,600 deg C.
Table3: Ex-ante estimation of CO2 emission reductions
Unitst-CO2/y
[Monitoring option]Option AOption BOption C
Reference elecricity consumed at LPFMonitored data,- Measuring the Watt-hour meter equipped to LPF
Reference average tapping temperature of moltensteel in EAF
Monitored data,- Measuring molten steel tempareture in EAF before tapping
The data is sourced from "CO2 EMISSIONS DATA COLLECTION,User Guide, Version 6"(worldsteel) unless instructed by the JointCommittee.
Monitored data,- Measuring the integrating natural gas flowmeter equipped to LPFMonitored data,- Measuring the integrating heavy oil flowmeter equipped to LPF
Reference production of billet
Monitored data.- Counting the number of the produced billets divided into eachbillet size.- Having data of the weight per a billet of each billet size by directmesuaring or by calculating using billet size and dencity.- Calculating "Pbillet,ref" from the number of the produced billetsand the weight per a billet of each billet size
Reference consumption of elecricity for LPFMonitored data,- Measuring the Watt-hour meter equipped to LPF
Reference consumption of coal for CGF
Reference consumption of elecricity for CGF
Reference consumption of natural gas for LPF
Based on the amount of transaction which is measured directly using measuring equipments (Data used: commercial evidence such as invoices)Based on the actual measurement using measuring equipments (Data used: measured values)
Based on public data which is measured by entities other than the project participants (Data used: publicly recognized data such as statistical data and specifications)
CO2 emission factor of coalThe data is sourced from "CO2 EMISSIONS DATA COLLECTION,User Guide, Version 6"(worldsteel) unless instructed by the JointCommittee.
Monitored data,- Measuring the weight of the charged coal
CO2 emission reductions
Monitored data,- Measuring the Watt-hour meter equipped to CGF
1,502
Reference consumption of heavy oil for LPF
(b)
Description of data
(e)
Source of data
(f)
Other comments
The combined margin(CM) emission factor in Viet Nam from"IGES CDM project database"(http://www.iges.or.jp/en/cdm/report.html)The data is sourced from "CO2 EMISSIONS DATA COLLECTION,User Guide, Version 6"(worldsteel) unless instructed by the JointCommittee.The data is sourced from "CO2 EMISSIONS DATA COLLECTION,User Guide, Version 6"(worldsteel) unless instructed by the JointCommittee.The data is sourced from "CO2 EMISSIONS DATA COLLECTION,User Guide, Version 6"(worldsteel) unless instructed by the JointCommittee.
89
Figure 4.2-2 An example of JCM spreadsheet “PMS(calc_process)”
1. Calculations for emission reductions Fuel type Value Units Parameter
Emission reductions during the period of year y 1,502 t-CO2/y ERy
2. Selected default values, etc.
CO2 emission factor of coal ----- 3.257 t-CO2/dry t-coal EFcoal
CO2 emission factor of electricity ----- 0.564 t-CO2/MWh EFelec
CO2 emission factor of oxygen ----- 0.355 t-CO2/km3N-o2 EFo2
CO2 emission factor of natural gas ----- 2.014 t-CO2/km3N EFng
CO2 emission factor of heavy oil ----- 2.907 t-CO2/m3 EFoil
CO2 emission factor of steam ----- 0.195 t-CO2/t-steam EFsteamElectricity equivalent value of oxygen ----- 0.629 MWh/km3N-o2 UOP
3. Calculations for reference emissions
Reference emissions during the period of year y 5,170 t-CO2/y REy
CO2 emissions by reheating ladle fossil fuel 5,537 t-CO2 REcoal
CO2 emissions from coal 5,537 t-CO2 REcoal
CO2 emissions from natural gas 0.0 t-CO2 REng
CO2 emissions from heavy oil 0.0 t-CO2 REoil
CO2 emissions by electricity consumption electricity 338 t-CO2 REelec
4. Calculations of the project emissions
Project emissions during the period of year y 3,668 t-CO2/y PEy
CO2 emissions by reheating ladle fossil fuel 3,322 t-CO2/y PEcoal
CO2 emissions from coal 3,322 t-CO2/y PEcoal
CO2 emissions from natural gas 0 t-CO2/y PEng
CO2 emissions from heavy oil 0 t-CO2/y PEoil
CO2 emissions by electricity consumption electricity 338 t-CO2/y PEelec
59 MWh/y EPld o2,y
CO2 emissions by steam consumption steam 7 t-CO2/y PEsteam
38 t-steam/y WPsteam.ySteam consumption for production ofoxygen used at ladle preheating
Electricity consumption for oxygen used atladle preheating
90
4.3 JOINT CREDITING MECHANISM METHODOLOGY OF “INTRODUCTION OF
REGENERATIVE BURNER TO THE REHEATING FURNACE FOR SEMI-PROCESSED
STEEL”
The old burners, which are attached to the reheating furnace are replaced to the regenerative burners
in the process of producing steel bars by rolling the heated billets. The burner combustion exhaust gas
is discharged to the outside of the system at high temperatures until introduction of the project.
However, after introduction of the project, heat loss to the outside of the system is significantly
reduced. Therefore, the consumption of fossil fuel for the burners and relating CO2 emission are
reduced.
JCM Proposed Methodology Form
Cover sheet of the Proposed Methodology Form
Form for submitting the proposed methodology
Host Country Socialist Republic of Vietnam
Name of the methodology proponents
submitting this form
JFE Steel
JFE Techno-Research
Sectoral scope(s) to which the Proposed
Methodology applies
4. Manufacturing industries
Title of the proposed methodology, and
version number
Introduction of Regenerative Burner to the
Reheating furnace for Semi-processed Steel
Version number: 1.0
List of documents to be attached to this form
(please check):
The attached draft JCM-PDD:
Additional information
Date of completion
History of the proposed methodology
Version Date Contents revised
91
A. Title of the methodology
Introduction of Regenerative Burner to the Reheating Furnace for Semi-processed Steel
Version number: 1.0
B. Terms and definitions
Terms Definitions
Billet Semi-processed steel which have square or circle cross
section. The products are manufactured by continuous
casting.
Reheating furnace (RHF) The furnace which reheats the semi-processed steel like
billets. The fossil fuel such as natural gas, coal gas and heavy
oil is used for the burner of the RHF.
Semi-processed steel Billet slab etc. These are rolled into sheets, steel bars etc.
C. Summary of the methodology
Items Summary
GHG emission reduction
measures
The old burners, which are attached to the reheating furnace are
replaced to the regenerative burners in the process of producing
steel bars by rolling the heated billets. The energy efficiency of
the burner fuel is improved. Therefore, the consumption of
fossil fuel for the burners and relating CO2 emission are
reduced.
Billet
Electricity
Coal
Natural Gas
Heavy Oil
Reheating Furnace(RHF)
Heated Billet
Coal Gasification
PlantElectricity
Coal gas
92
Calculation of reference
emissions
The reference data measurement period should be provided
before the project. The reference emissions are calculated from
the quantities of electricity, fossil fuel etc. at the RHF or at the
coal gasification plant during the reference period and their CO2
emission factors.
Calculation of project
emissions
The project emissions are calculated from electricity, fossil fuel
etc. at the RHF, coal gasification plant and CO2 emission
factors during the project period.
Monitoring parameters 1) Supply of billets
2) Consumption of natural gas at the RHF
3) Consumption of heavy oil at the RHF
4) Consumption of electricity at the RHF
5) Consumption of coal at the coal gasification plant
6) Consumption of electricity at the coal gasification plant
D. Eligibility criteria
This methodology is applicable to projects that satisfy all of the following criteria.
Criterion 1 The project of reducing consumption of fossil fuel by improving the energy
efficiency at RHF for billet.
Criterion 2 The burners of the RHF are not regenerative type before the project.
Criterion 3 The burners of introducing to the RHF are regenerative type.
Criterion 4 The burner fuel is natural gas, heavy oil, or coal gas.
E. Emission Sources and GHG types
Reference emissions
Emission sources GHG types
Natural gas, which is consumed at the RHF CO2
Heavy oil, which is consumed at the RHF CO2
Electricity, which is consumed at the RHF CO2
Coal, which is consumed at the coal gasification plant CO2
Electricity, which is consumed at the coal gasification plant CO2
Project emissions
Emission sources GHG types
Natural gas, which is consumed at the RHF CO2
93
Heavy oil, which is consumed at the RHF CO2
Electricity, which is consumed at the RHF CO2
Coal, which is consumed at the coal gasification plant CO2
Electricity, which is consumed at the coal gasification plant CO2
F. Establishment and calculation of reference emissions
F.1. Establishment of reference emissions
The reference data measurement period should be provided before the project. The
consumption of electricity and fossil fuels (coal, natural gas, heavy oil) at the RHF and the coal
gasification plant, also the supply of billets to the RHF are measured. The CO2 emission factors
are of the project period. The yearly supply of billets to the RHF during the project is used
when the reference values are converted to the yearly amounts.
REng : CO2 emission from natural gas, which is consumed at the RHF during the
reference period [t-CO2]
REoil : CO2 emission from heavy oil, which is consumed at the RHF during the
reference period [t-CO2]
REelec : CO2 emission from electricity, which is consumed at the RHF during the
reference period [t-CO2]
REcoal : CO2 emission from coal, which is consumed at the coal gasification plant
during the reference period [t-CO2]
REelec2 : CO2 emission from electricity, which is consumed at the coal gasification plant
during the reference period [t-CO2]
WRSbillet : Supply of billets to the RHF during the reference period [t-billet]
WRSbillet,y : Yearly supply of billets to the RHF during the project [t-billet/y]
REng = QRng × EFng
Where,
QRng : Consumption of natural gas at the RHF during the reference period [km3N]
94
EFng : CO2 emission factor for the natural gas [t-CO2/km3N]
REoil = QRoil × EFoil
Where,
QRoil : Consumption of heavy oil at the RHF during the reference period [m3]
EFoil : CO2 emission factor for the heavy oil [t-CO2/ m3]
REelec = ERrhf × EFelec
Where,
ERrhf : Consumption of electricity at the RHF during the reference period [MWh]
EFelec : CO2 emission factor for the Viet Nam grid system [t-CO2/MWh]
REcoal = WRc × EFcoal
Where,
WRc : Consumption of coal at the coal gasification plant during the reference period
[t]
EFcoal : CO2 emission factor for the coal[tCO2/t]
REelec2 = ERcgp × EFelec
Where,
ERcgp : Consumption of electricity at the coal gasification plant during the reference
period [MWh]
EFelec : CO2 emission factor for the Viet Nam grid system [t-CO2/MWh]
G. Calculation of project emissions
PEy = (PEng + PEoil + PEelec + PEcoal + PEelec2)
Where,
PEy : Project emissions in year y [t-CO2/y]
PEng : CO2 emission from natural gas, which is consumed at the RHF during the
project [t-CO2/ y]
PEoil : CO2 emission from heavy oil, which is consumed at the RHF during the
project [t-CO2/ y]
PEelec : CO2 emission from electricity, which is consumed at the RHF during the
project [t-CO2/ y]
PEcoal : CO2 emission from coal, which is consumed at the coal gasification plant
95
during the project [t-CO2/ y]
PEelec2 : CO2 emission from electricity, which is consumed at the coal gasification plant
during the project [t-CO2/ y]
PEng = QPng, y × EFng
Where,
QPng, y : Consumption of natural gas at the RHF during the project [km3N/ y]
EFng : CO2 emission factor for the natural gas [t-CO2/km3N]
PEoil = QPoil, y × EFoil
Where,
QPoil, y : Consumption of heavy oil at the RHF during the project [m3/ y]
EFoil : CO2 emission factor for the heavy oil [t-CO2/ m3]
PEelec = EPrhf, y × EFelec
Where,
EPrhf, y : Consumption of electricity at the RHF during the project [MWh/ y]
EFelec : CO2 emission factor for the Viet Nam grid system [t-CO2/MWh]
PEcoal = WPcoal, y × EFcoal
Where,
WPcoal, y : Consumption of Coal at the coal gasification plant during the project [t/ y]
EFcoal : CO2 emission factor for the coal [t-CO2/t]
PEelec2 = EPcgf, y × EFelec
Where,
EPcgf, y :Consumption of electricity at the coal gasification plant during the project
[MWh/ y]
EFelec : CO2 emission factor for the Viet Nam grid system [t-CO2/MWh]
H. Calculation of emissions reductions
Emission reductions are calculated as the difference between the reference emissions and
project emissions, as follows.
96
DPRy = REy - PEy
Where,
DPRy :GHG emission reductions in year [t-CO2/y]
I. Data and parameters fixed ex ante
The source of each data and parameter fixed ex ante is listed as below.
Parameter Description of data Source
EFng CO2 emission factor for the
natural gas
1) The data is calculated from the carbon content of
the natural gas, which is measured by chemical
analysis.
2) The data is sourced from "CO2 EMISSIONS
DATA COLLECTION, User Guide, Version 6"
(worldsteel).
(unless instructed by the Joint Committee)
EFoil CO2 emission factor for the
heavy oil
1) The data is calculated from the carbon content of
the heavy oil, which is measured by chemical
analysis.
2) The data is sourced from "CO2 EMISSIONS
DATA COLLECTION, User Guide, Version 6"
(worldsteel).
(unless instructed by the Joint Committee)
EFelec CO2 emission factor for the
Viet Nam grid system
The combined margin(CM) emission factor in Viet
Nam from "IGES CDM project data base"
(http://www.iges.or.jp/en/cdm/report.html)
EFcoal CO2 emission factor for the
coal
1) The data is calculated from the carbon content of
the coal, which is measured by chemical analysis.
2) The data is sourced from "CO2 EMISSIONS
DATA COLLECTION, User Guide, Version 6"
(worldsteel). The factor of steam coal is the first
choice in the 2nd case.
(unless instructed by the Joint Committee)
As an example, JCM Methodology Spreadsheets (Input sheet, Calculation process sheet) are shown in
Figure 4.3-1 and Figure 4.3-2.
97
Figure 4.3-1 Input sheet
JCM_VN_F_PMS_ver01.0
Joint Crediting Mechanism Proposed Methodology Spreadsheet Form (input sheet) [Attachment to Proposed Methodology Form]
Table 1: Parameters to be monitored ex post(a) (b) (c) (d) (e) (f) (g) (h) (i) (j)
Monitoringpoint No.
Parameters Description of dataEstimated
ValuesUnits
Monitoringoption
Source of data Measurement methods and proceduresMonitoringfrequency
Othercomments
(1) WPSbillet, y Supply of billets to the RHFper a year ex post
250,000 t-billet/ y C Monitored data
- Counting the number of the supplied billets divided intoeach billet size.- Having data of the weight per a billet of each billet sizeby direct mesuaring or by calculating using billet size anddencity.- Calculating "Sbillet, y" from the number of the suppliedbillets and the weight per a billet of each billet size
once at theend of theyearlymonitoring
(2) QPng, y Consumption of natural gasat the RHF
0 km3N/ y C Monitored data- Measuring the integrating flowmeter equipped to theRHF
at the startand the endof the period
(3) QPoil, y Consumption of heavy oil atthe RHF
2,250 m3/ y C Monitored data- Reading the delivery amount of the oil described in theinvoice
at everydelivery
(4) EPrhf, y Consumption of electricity atthe RHF
2,500 MWh/ y C Monitored data - Measuring the Watt-hour meter equipped to the RHFat the startand the endof the period
(5) WPcoal, y Consumption of coal at thecoal gasification plant
0 t/ y C Monitored data- Reading the delivery amount of the coal described in theinvoice
at everydelivery
(6) EPcgf, y Consumption of electricity atthe coal gasification plant
0 MWh/ y C Monitored data- Measuring the Watt-hour meter equipped to the coalgasification plant
at the startand the endof the period
Table 2: Project-specific parameters to be fixed ex ante(a) (c) (d)
ParametersEstimated
ValuesUnits
EFng 2.014 t-CO2/km3N
EFoil 2.907 t-CO2/m3
EFelec 0.564 t-CO2/MWh
EFcoal 2.461 t-CO2/t
WRSbillet 50,000 t-billet
QRng 0 km3N
QRoil 500 m3
ERrhf 500 MWh
WRc 0 t
ERcgf 0 MWh
Table3: Ex-ante estimation of CO2 emission reductionsUnits
tCO2/y
[Monitoring option]Option AOption BOption C
(f)
Other comments
(e)
Source of data
1) The data is calculated from the carbon content of the natural gas, which is measuredby chemical analysis.2) The data is sourced from "CO2 EMISSIONS DATA COLLECTION, User Guide,Version 6"(worldsteel).(unless instructed by the Joint Committee)
Based on the actual measurement using measuring equipments (Data used: measured values)
(b)
Description of data
CO2 emission reductions
726
CO2 emission factor for the natural gas
Based on public data which is measured by entities other than the project participants (Data used: publicly recognized data such as statistical data and specifications)
CO2 emission factor for the coal
1) The data is calculated from the carbon content of the steam coal, which is measuredby chemical analysis.2) The data is sourced from "CO2 EMISSIONS DATA COLLECTION, User Guide,Version 6"(worldsteel). The factor of steam coal is the first choice in the 2nd case.(unless instructed by the Joint Committee)
Consumption of heavy oil at the RHF duringthe reference period
Based on the amount of transaction which is measured directly using measuring equipments (Data used: commercial evidence such as invoices)
CO2 emission factor for the heavy oil
1) The data is calculated from the carbon content of the heavy oil, which is measured bychemical analysis.2) The data is sourced from "CO2 EMISSIONS DATA COLLECTION, User Guide,Version 6"(worldsteel).(unless instructed by the Joint Committee)
CO2 emission factor for the Viet Nam gridsystem
The combined margin(CM) emission factor in Viet Nam from "IGES CDM project database"(http://www.iges.or.jp/en/cdm/report.html)
Consumption of natural gas at the RHFduring the reference period
Monitored data.- Measuring the integrating flowmeter equipped to the RHF
Monitored data.- Reading the delivery amount of the oil described in the invoice
Consumption of electricity at the RHF duringthe reference period
Monitored data.- Measuring the Watt-hour meter equipped to the RHF
Supply of billets to the RHF during thereference period
Monitored data.- Counting the number of the supplied billets divided into each billet size.- Having data of the weight per a billet of each billet size by direct mesuaring or bycalculating using billet size and dencity.- Calculating "Sbillet, ref" from the number of the supplied billets and the weight per abillet of each billet size
Consumption of coal at the coal gasificationplant during the reference period
Monitored data.- Reading the delivery amount of the coal described in the invoice
Consumption of electricity at the coalgasification plant during the reference period
Monitored data.- Measuring the Watt-hour meter equipped to the coal gasification plant
98
Figure 4.3-2 Calculation process sheet
JCM_VN_F_PMS_ver01.0
1. Calculations for emission reductions Fuel type Value Units Parameter
Emission reductions during the period of year y 727 tCO2/y DPRy
2. Selected default values, etc.
CO2 emission factor for the natural gas ----- 2.014 t-CO2/km3N EFng
CO2 emission factor for the heavy oil ----- 2.907 t-CO2/m3 EFoil
CO2 emission factor for the Viet Nam grid system ----- 0.564 t-CO2/MWh EFelec
CO2 emission factor for the coal ----- 2.461 t-CO2/t EFcoal
3. Calculations for reference emissions
Reference emissions during the period of year y 8,678 tCO2/y REy
Supply of billets to the RHF during the reference period ----- 50,000 t-billet WRSbillet
Consumption of natural gas at the RHF during the reference peri Fossil Fuel 0 km3N QRng
Consumption of heavy oil at the RHF during the reference period Fossil Fuel 500 m3 QRoil
Consumption of electricity at the RHF during the reference perio Electricity 500 MWh ERrhf
Consumption of coal at the coal gasification plant during the refe Fossil Fuel 0 t WRc
Consumption of electricity at the coal gasification plant during th Electricity 0 MWh ERcgf
4. Calculations of the project emissions
Project emissions during the period of year y 7,951 tCO2/y PEy
Supply of billets to the RHF per a year ex post ----- 250,000 t-billet/ y WPSbillet, y
Consumption of natural gas at the RHF Fossil Fuel 0 km3N/ y QPng, y
Consumption of heavy oil at the RHF Fossil Fuel 2,250 m3/ y QPoil, y
Consumption of electricity at the RHF Electricity 2,500 MWh/ y EPrhf, y
Consumption of coal at the coal gasification plant Fossil Fuel 0 t/ y WPcoal, y
Consumption of electricity at the coal gasification plant Electricity 0 MWh/ y EPcgf, y
Joint Crediting Mechanism Proposed Methodology Spreadsheet Form (Calculation Process Sheet)
[Attachment to Proposed Methodology Form]
99
5. REPORTING OF ENERGY SAVING TECHNOLOGIES TO
VIETNAM
Seminar in Hanoi was held in January 2015, in order to widely dissement JCM scheme and to report
the study results of this project, to government officials related to JCM and concerned personnel in
steel industry in Vietnam.
At the same time, during 1st or 2nd visit to Vietnam, we visited government departments related to
JCM and explained JCM scheme and activities of this project
This chapter shows the meeting with government departments, and Seminar in Hanoi.
5.1 PRIOR EXPLANATION TO THE GOVERNMENT OFFICIALS
During 1st or 2nd visit to Vietnam, JFE group visited government officials related to JCM, and
explained JCM scheme and activities of this project. The followings show the departments which JFE
group visited, and attendance at the meeting
(1) MOIT(Ministry Of Industry and Trade)General Directorate of Energy
Date: Sep. 15th ,2014
Attendance:
Mr. Pham Thanh Tung: Director of International Cooperation Department
Mr. Nguyen Van Long: Deputy Director General Science Technology and Energy Efficiency
Figure Annex1-3 No.4: Aluminum Alloy Conductor Arm for Supporting Electrode
(From NIKKO Industry CO.,LTD)
<DC furnace>Graphite hearth
electrode
Hearth Electrode
Electric room
DC reactor(DCL)
trans
VCBThyristor
Transformerstation
High-frequencyfilter
<DC furnace>Graphite hearth
electrode
Hearth Electrode
Electric room
DC reactor(DCL)
trans
VCBThyristor
Transformerstation
High-frequencyfilter
Figure Annex1-4 No.5: DC Electro Arc Furnace
(From NEDO Handbook)
114
Figure Annex1-5 No.6: Oxy-fuel Burners/Lancing (or Super Sonic Burner )
(From NIKKO Industry CO.,LTD)
HeatExchanger
Cooling waterCirculation
pump Boiling feedWater pump
Deaerator
Condensatepomp
From applicationsystemWHRB steam drum
Accumulator
To applicationsystem
Steam drum
Super heater
BoilerCirculation
pump
Make-upwater
HeatExchanger
Cooling waterCirculation
pump Boiling feedWater pump
Deaerator
Condensatepomp
From applicationsystemWHRB steam drum
Accumulator
To applicationsystem
Steam drum
Super heater
BoilerCirculation
pump
Make-upwater
Figure Annex1-6 No.8: Waste Heat Recovery from EAF
(From JASE-World)
115
Horizontal Type Vertical Type
Waste gas 170deg.CWaste gas
COG920 Mcal/h
Air 20deg.C
1000deg.C
Waste gas 4-way selector Valve
Heat Storage material(ceramic honeycomb)
Air
1000deg.CCOG
600 Mcal/h
Regenerative burnerConventional burnerFig Non heat recovery type burner ladle
Drying deviceRegenerative burner-type ladle
Drying device
from brochure of Chugai Ro
Making it possible to preheat a number of ladles in a single installation.Furthermore, the high-temperature heating of the ladles is possible with the ladles attached closely together. The preheating of a number of ladles in a single installation is enabled by sliding movement. Furthermore, opening and closing movement back and forth enables the high temperature heating of the ladles with lids attached closely together.
Horizontal Type Vertical Type
Waste gas 170deg.CWaste gas
COG920 Mcal/h
Air 20deg.C
1000deg.C
Waste gas 4-way selector Valve
Heat Storage material(ceramic honeycomb)
Air
1000deg.CCOG
600 Mcal/h
Regenerative burnerConventional burnerFig Non heat recovery type burner ladle
Drying deviceRegenerative burner-type ladle
Drying device
from brochure of Chugai Ro
Making it possible to preheat a number of ladles in a single installation.Furthermore, the high-temperature heating of the ladles is possible with the ladles attached closely together. The preheating of a number of ladles in a single installation is enabled by sliding movement. Furthermore, opening and closing movement back and forth enables the high temperature heating of the ladles with lids attached closely together.
Figure Annex1-7 No.9.1: Regenerative Burner Total System for Ladle Preheating
(From NEDO Handbook、Photo. from CHUGAI RO CO.,LTD)
Figure Annex1-8 No.9.2: Oxygen Burner Total System for Ladle Preheating
(From CHUGAI RO CO.,LTD)
116
EAF Process Optimization by Off-gas Analysis
Power Input Control
・Off Gas Analysis
・Temp, O2, CO, CO2, H2, N2 H2O
Carbon & Oxygen Injection
Natural Gas & Lime Injection
EAF Process Optimization by Off-gas Analysis
Power Input Control
・Off Gas Analysis
・Temp, O2, CO, CO2, H2, N2 H2O
Carbon & Oxygen Injection
Natural Gas & Lime Injection
Figure Annex1-9 No.11.2: Control and Automation for EAF Optimization
(From SOACT)
EAF
Voltage inverter
Control Panel
Scrap data presetting
Automatic Scrap Meltdown Timing Judgment System by Acoustic Spectrum Analysis for AC EAF
Meltdown signal
Data collection
Current transformer
Signals from EAF
Touch panel
Sound signal
Current
Microphone
EAF
Voltage inverter
Control Panel
Scrap data presetting
Automatic Scrap Meltdown Timing Judgment System by Acoustic Spectrum Analysis for AC EAF
Meltdown signal
Data collection
Current transformer
Signals from EAF
Touch panel
Sound signal
Current
Microphone
Figure Annex1-10 No.11.3: Control and Automation for EAF Optimization
(From Home page of DAIDO STEEL)
117
molten steel
② O2 Covering Frame
① Focused O2 Frame (Mach = 2)
Carbon Electrode HYBRIDJet Burner
Carbon injectionlance1500 kg/h
Cooling copper box with fins
D: Temperature homogenizationby bath stirring on tapping
Figure Annex1-11 No.12: Carbon and Oxygen Injection System for foamy slag practice
(From NIKKO Industry CO.,LTD)
base condition
High temperature heat exchanger
Regenerative burner
Δ30%
Δ45%
Application of Regenerative burner can achieve (45%) energy saving (45%-20%=25% better than conventional Recuperator).Further information is required for accurate estimation.
Application of Regenerative burner can achieve (45%) energy saving (45%-20%=25% better than conventional Recuperator).Further information is required for accurate estimation.
Figure Annex1-12 No.13: Comparison of fuel usage quantities versus pre-heating air
temperature
(From SOACT)
118
Preheating temperature >1000℃ by Regenerative Burner Total System
FuelFuel
Burner ABurner B
CeramicRegenerator B Ceramic
Regenerator A
Exhaust gas 200 deg.C Switch valve
Air
Regenerative burners, using temperature resistant ceramic heat media, can recover approximately 85% of waste heat from high temperature exhaust gas from reheating furnaces or ladle preheating by directly introducing high temperature exhaust gas into heat media and alternate switching between heat storage and preheating of combustion air. This high performance burner technology achieves superior fuel gas saving and compact reheating furnace equipment. It is desirable to install this system when new furnace is introduced, because the cost will be saved compared to modification of furnaces.
Preheating temperature >1000℃ by Regenerative Burner Total System
FuelFuel
Burner ABurner B
CeramicRegenerator B Ceramic
Regenerator A
Exhaust gas 200 deg.C Switch valve
Air
Regenerative burners, using temperature resistant ceramic heat media, can recover approximately 85% of waste heat from high temperature exhaust gas from reheating furnaces or ladle preheating by directly introducing high temperature exhaust gas into heat media and alternate switching between heat storage and preheating of combustion air. This high performance burner technology achieves superior fuel gas saving and compact reheating furnace equipment. It is desirable to install this system when new furnace is introduced, because the cost will be saved compared to modification of furnaces.
Figure Annex1-13 No.13.1: Combustion Air Preheating for reheating furnace
Actual results shows approximately 30% reduction of fuelIn case of Reheating furnace, the average is 10-20% reduction compared to the furnace with conventional Recuperator.(These results are mainly from Japanese industries, and the energy saving effectFor Reheating furnace depends on the range of revamping)
Actual results shows approximately 30% reduction of fuelIn case of Reheating furnace, the average is 10-20% reduction compared to the furnace with conventional Recuperator.(These results are mainly from Japanese industries, and the energy saving effectFor Reheating furnace depends on the range of revamping)
In case of ReheatingFurnace
10 -20% Reduction
Field test project167 furnaces
Figure Annex1-14 No.13.1: Actual Results of application of Regenerative burner
(From SOACT)
119
Temperature and pressure Control in furnace, ,O2 Control in Fuel gas and Change to ceramic fiber inner wall
O2 meter Furnace manometer
(Heating Furnace) Preheating Area Heating Area SoakingArea To Rolling Line
Billet
CombustionAir Fan
Flue gas
Damper
Cooling water
High efficiency recuperator
Combustion control system (DCS)
Fuel
FurnacethermometerNo.14 Thermal insulation by
Ceramic Fiber on inner wall
High-performance combustion control system- Furnace temperature control- Flue gas O2 control- Furnace pressure control
Temperature and pressure Control in furnace, ,O2 Control in Fuel gas and Change to ceramic fiber inner wall
O2 meter Furnace manometer
(Heating Furnace) Preheating Area Heating Area SoakingArea To Rolling Line
Billet
CombustionAir Fan
Flue gas
Damper
Cooling water
High efficiency recuperator
Combustion control system (DCS)
Fuel
FurnacethermometerNo.14 Thermal insulation by
Ceramic Fiber on inner wall
High-performance combustion control system- Furnace temperature control- Flue gas O2 control- Furnace pressure control
Figure Annex1-15 No.15: Process Control for Reheating Furnace + No.14 Thermal
insulation by Ceramic Fiber on inner wall
(From NEDO Handbook)
Figure Annex1-16 No.16: Air Conditioning by Hot Water Absorption Chiller utilizing Waste
Heat
(From revised figure supplied by EBARA Refri. Equip. & Systems Co., Ltd.)
120
(1) Delivery side damper control
Intake side damper control
Ideal control
(2) Inverter control
Variable control of transmitted power(eddy current coupling with fluid gear box)
Source: electrical Installation TechnologyP27. February 2001
Airflow (%)
Req
uire
d el
ectr
ic p
ower
(%
)
(1) Delivery side damper control
Intake side damper control
Ideal control
(2) Inverter control
Variable control of transmitted power(eddy current coupling with fluid gear box)
Source: electrical Installation TechnologyP27. February 2001
Airflow (%)
Req
uire
d el
ectr
ic p
ower
(%
)
Figure Annex1-17 No.17: Inverter (VVVF; Variable Voltage Variable Frequency) Drive for
Motors
(From NEDO Handbook)
Data Acquisition & Monitoring System
Management System
Electric Arc Furnace&
Ladle furnace
Reheating furnace&
Rolling Mill
Production Scheduling
Power, Carbon, Oxygen, etc. Fuel, Temperature , etc.
Do
Check
Action
Plan
Data Acquisition & Monitoring System
Management System
Electric Arc Furnace&
Ladle furnace
Reheating furnace&
Rolling Mill
Production Scheduling
Power, Carbon, Oxygen, etc. Fuel, Temperature , etc.
Do
Check
Action
Plan
Figure Annex1-18 No.18: Energy Monitoring and Management Systems for Steel Plant with