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Improved Process Control (Neural Networks)
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Electricity savings of 30 kWh/t-steel are estimated, and values may change based on scrap and furnace characteristics. (APP, 2010. p. 79)
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Emissions reduction potential of the technology is 17.6 kg CO2/t-steel (US EPA, 2010. p.11).
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Commercial |
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EAF Controls
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This technology results in 14% reduction in electricity consumption. Additionally a 6% reduction in natural gas consumption were achieved all together.
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Direct and indirect CO2 emissions reduction potential of the technology is 34 Kton/year.
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An Investment of €3.8 Million over two years aimed at energy savings was made.
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Commercial |
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Oxyfuel Burners/Lancing
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2–3 kWh/t-steel of energy can be saved for every minute of heating time reduced;
Electricity savings 0.14GJ/t-steel, with typical oxygen injection rates of 18 Nm3/t-steel.(APP, 2010. p. 80).
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 Emissions can be reduced by 23.5 kg CO2/t-steel.
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Retrofit capital cost for a 110t capacity EAF is $4.8/t.
Due to reduced tap-to-tap time of around 6%, annual savings of $4/t have been realized (APP, 2010. p.80).
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Commercial |
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Flue Gas Monitoring and Control
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Electricity savings of 0.05GJ/t-steel are estimated by using this technology (US EPA, 2010. p. 11) .
Chemical energy recovery rate from exhaust gases can be increased by 50% by adjusting oxygen injection levels for post-combustion based on real time CO and CO2 readings in flue gases, instead of using preset values (Worrell, et al., 2010. p. 90).
A specific post combustion control system installed in two plants in Mexico and the US lead to reductions of 2% and 4% in electricity consumption, 8% and 16% in natural gas consumption, 5% and 16% in oxygen use, 18% and 18% in carbon charged and injected (Worrell, et al., 2010. p. 90).
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Emissions reduction potential of the technology is estimated to be 8.8 kgCO2/t-steel (US EPA, 2010. p. 11).
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Retrofit capital cost are estimated at $3.1/t-steel (US EPA, 2010. p. 11).
The monitoring system installed in Mexico and the US resulted in yield improvements between 1% and 2%, decreased electrode consumption between 3.5% and 16%, increased productivityby 8%.
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Commercial |
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Post Combustion Optimization in Steelmaking
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Energy requirement for BOF reduces by 30%. 50 to 100 kWh/tonne of steel electricity reduction in EAF is estimated.
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CO is combusted to produce CO2 and the energy.
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Commercial |
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Hot DRI/HBI Charging to EAF
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Charging hot DRI at temperatures up to 600 °C rather than cold DRI results in a melting energy reduction of 150 kWh/t-steel (>0.5 GJ/ton).
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Environmental emissions are lower due to energy savings.
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Commercial |
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Foamy Slag Practices
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The net energy savings are estimated at 6-8 kWh/t-steel (Worrell et al., 2010. p. 93).
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Emissions reduction of 10.6 Kg CO2/t-steel is estimated (US EPA, 2010).
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Retrofit capital cost is estimated at $15.6/t-steel (US EPA, 2010).
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Commercial |
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Scrap Preheating
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Scrap preheating can save 0.016 to 0.2 GJ/t-steel.
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Commercial |
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Bottom Stirring/Stirring Gas Injection
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Electricity savings can vary between 12 to 24 kWh, or 0.07 GJ, per ton of steel.
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Emissions saving potential of the technology is 11.7 kg CO2/t-steel.
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Retroftit capital cost is $0.94/t-steel.
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Commercial |
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Shaft Furnace Scrap Preheating
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With single shaft furnace upto 77kWh/t-steel of electric energy can be saved. Finger shaft furnace allows savings up to 110 kWh/t-steel, which is approximately 25% of the electricity input (Worrell et al., 2010. p. 95).
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Emissions are reduced by 35 kg CO2/t-steel.
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Retrofit costs were estimated to be $9.4/t-capacity for an existing 100 tonfurnace. Production cost savings may amount $6.7/t-steel. The payback time is estimated as one year. (US EPA, 2010. p.36)
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Commercial |
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Tunnel Furnace Preheating – CONSTEEL Process
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Electricity savings are estimated to be 60 kWh/t for retrofits or 0.22GJ/t-steel.
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Emissions reduction of 35.5Kg CO2/tonne steel is achievable.
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Investment costs were estimated to be $3.2 million 500,000 t/y, or $7.8/t-steel. Annual costs savings were estimated to be $3.0/t-steel. The payback time is estimated as 1.3 years. (US EPA, 2010. p. 36)
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Commercial |
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Direct Current (DC) Arc Furnace
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Net energy savings over older AC furnaces are estimated to be 0.32GJ/t-steel. Compared to new AC furnaces, the savings are limited to 0.036-0.072 GJ/t-steel (US EPA, 2010. p.35).
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Emissions reduction potential of the technology is 52.9 Kg CO2/t-steel (US EPA, 2010. p.11).
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The additional investment costs over that of an AC furnace are approximately $6.1/t capacity. The payback time is estimated as 0.7 years (US EPA, 2010. p.35).
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Commercial |
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Waste Heat Recovery for EAF
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Approximately 130 kWh/t-s of energy can be recovered (efficiency 30%).
If recovered energy is used for power generation with saturated steam 2.8 MWh/y of electricity can be generated.
If the recovered energy is used for power generation with superheated steam, 15.1 MWh/y of energy can be generated. (For an EAF melting 150 t/charge of DRI with tap-to-tap time of 49 mins, and power on time of 40 mins) (JASE-W, 2012)
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If recovered energy is used for power generation with saturated steam, corresponding CO2 emission reduction will be 12,600 t/y;
If recovered energy is used for power generation with superheated steam, corresponding CO2 emission reduction will be 73,400 t/y. (For an EAF melting 150 t/charge of DRI with tap-to-tap time of 49 mins, and power on time of 40 mins) (JASE-W, 2012)
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Research |
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Airtight EAF Process
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Energy savings are estimated to be around 110 kWh/t-steel (Worrell et al., 2010. p. 95)
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Significant emissions reduction can be expected due to reduction in energy consumption.
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Commercial |
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Adjustable Speed Drives (ASDs)
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Total fan energy consumption can be decreased by 67%. Electricity savings are estimated to be 16.5 kWh or 0.06 GJ per ton of steel.
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Decreased energy consumption will lower emissions.
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Retrofit capital costs are $2/tonne steel. The payback time is estimated as 2 to 3 years.
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Commercial |
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Comelt
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Reduction of energy consumption of approximately 100 kWh/tonne is expected compared to the conventional EAF.
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Reduced energy consumption will eventually result in reduced emissions.
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Maintenance costs would decrease due to a simpler plant design.
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Commercial |
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Contiarc Furnace
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Energy losses are reduced by 220 kWh/t-steel as compared conventional furnace systems. Also electric power consumption reduces by 25 kWh/t-steel (0.091 GJ/t) due to reduced flue gas amount requiring cleaning.
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Waste gas and dust volumes are considerably reduced by the technology.
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Commercial |
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Twin-Shell DC Arc Furnace
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Electricity savings are 0.068GJ/t-steel.
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Emissions reduction potential of the technology is 11.1KgCO2/t-steel.
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Retrofit capital cost is $9.4/t-steel over that of a single-shell furnace. The payback time is estimated as 3.5 years..
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Commercial |
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Post Combustion of EAF Flue Gas
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For a particular post-combustion system, electricity savings ranged from 6 to 11% depending on the operating conditions (Worrell et al., 2010. p. 93).
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Energy savings will result in reduced emissions.
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In a particular application tap-to-tap times were decreased by 3 to 11% depending on operating conditions (Worrell et al., 2010. p. 93).
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Commercial |
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Engineered Refractories
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Savings of 11kWh/-steel are expected by applying this technology.
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Energy savings will result in reduced emissions.
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Commercial |
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Eccentric Bottom Tapping
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Electricity savings of 0.05GJ/t-steel are estimated by using this technology.
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Emissions reduction of 8.8 Kg CO2/t-steel are expected.
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Retrofit capital costs are $5.0/t-steel.
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Commercial |
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ECOARC
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This furnace consumes 200 kWh/ton power at oxygen injection rate of 40Nm3/ton.
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Flexibility of scrap mixing reduces the costs for the process. Electrode consumption is as low as 0.8-1.0 kg/ton.
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Demonstration |
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Ultra High Power (UHP) Transformers
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Electricity savings are estimated to be 1.1 kWh/t-steel for every MW power increase.
Power consumption dropped by 11 and 22kWh/t respectively for 2 furnace lines when operating voltage increased from 600V to 660V in one furnace and from 400V to 538V in another (Worrell et al, 2010. p. 91).
.
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Emission reductions are estimated to be in the range of 10 kg/t-steel (US EPA, 2010. p. 11)..
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To increase the operating voltage from 600V to 660V in one furnace and from 400V to 538V in another a $1.1 million investment was made (Worrell et al, 2010. p. 91).
.Capital costs were estimated to be $3.9/ton ($4.3/tonne). The payback time is estimated as 5.2 years (US EPA, 2010. p. 33).
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Commercial |
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Used Tires for Insulation in EAF
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Electrical energy consumption to produce one tonne of billet was reduced from 424 kWh to 412 kWh.
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CO2 savings were equivalent to the removal of approximately 4,000 cars from the road.
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Using rubber tyres, steelmaking costs are 80% of what they were when using coking coal.
|
Demonstration |
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New-Scrap Based Steelmaking Process using Primary Energy
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About 32% reduction of primary energy Intensity for liquid steel production compared to the conventional EAF is expected by this technology.
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Depending on the CO2 emission of the electricity grid, the significant amount of CO2 emission will also be reduced.
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There will about 19% reduction in the energy cost per tonne of liquid steel produced.
|
Demonstration |
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Injection of Aluminium instead of Ferrosilicon for Stainless Steel Making in EAF
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Electrical energy demand was significantly decreased by approximately 10%.
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Reduction in emissions because CO is not let to oxidize rather it foams the slag.
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Cost decreases due to savings in alloying agents such as Cromium.
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Research |
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Model Based Steel Temperature Measurement
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Energy savings are achieveable by the implementation of this technology.
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There will be related CO2 emission reduction.
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Evaluation of attainable savings will be performed on the basis of energy balance of whole process.
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Research |
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Optimal Charge Calculation in EAF
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Energy-Optimal charging of scrap by using this technology.
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This technology is expected to bring savings of 5 – 10 % in scrap costs.
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Commercial |
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Holistic Quality Driven Production Control
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The technology reveals significant saving potential in terms of energy.
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|
Cost savings are obtained due to on-line monitoring of the amount of alloying agent.
|
Demonstration |
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Dynamic Asymmetrical Control of AC EAF
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The melting rate was Improved by as much as 8 % by increasing the mean electric power Input and by shortening the power-off times.
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|
The economical mode of operation reduces the consumption of refractory gunning mixes by around 10 %.
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Commercial |
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Hydrogen and Nitrogen Control in Ladle and Casting Operations
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Better control results in energy savings by an estimated 400 million kilowatt hours (kWh) per year.
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CO2 emissions decreases.
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Estimated annual savings are $20 million when technology is in widespread commercial use.
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Research |
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Modification of Side Wall Water Cooled Panels and Water Header
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This technique increases furnace capacity by 18-20 tonnes. Power consumption was reduced from 800 kWh to 620 kWh/t-steel.
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Annual savings of Rs. 864 000 000 were obtained.
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Commercial |
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Development of a process to continuously melt, refine and cast high quality steel
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A total of 10% energy savings will occur by reducing the energy needed for auxiliary operations. Savings of 20 kWhr/t in auxiliary energy are reported.
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Capital cost for the equipment is $35 million for a 1,000,000 tpy facility.
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Demonstration |
