The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry, discusses energy efficiency practices and technologies that can be implemented in iron and steel manufacturing plants. This guide provides current real world examples of iron and steel plants saving energy and reducing cost and carbon dioxide emissions.
Shaft Furnace Scrap Preheating
The shaft furnace technology has been the outcome of the efforts to overcome the shortfalls of the bucket preheating techniques. It uses the energy obtained by the post-combustion to heat the scrap. This technology has evolved in stages. With a single shaft furnace at least 50% of the scrap can be preheated whereas a finger shaft furnace (involving a shaft with a scrap retaining system) allows preheating of the total scrap amount. A further modification is the double shaft furnace which consists of two identical shaft furnaces positioned next to one another and which are serviced by a single set of electrode arms (Worrell et al., 2010. p. 94).
The exact energy savings depend on the scrap used, and the degree of post-combustion (oxygen levels). For the finger shaft furnace tap-to-tap times of about 35 minutes are achieved, which is about 10-15 minutes less compared to EAF without efficient scrap preheating. The process may reduce electrode consumption, improve yield by 0.25 to 2 percent, increase productivity by 20 percent, and decrease flue gas dust emissions by 25 percent. (US EPA, 2010. p.36)
These technologies require close control of carbon monoxide and oxygen concentrations in order to reduce the risk of explosions.
Development Status | Products |
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Commercial
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Shaft Furnace Scrap PreheatingCosts & Benefits
Parent Process: Electric Arc Furnace | |
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Energy Savings Potential |
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). |
CO2 Emission Reduction Potential |
Emissions are reduced by 35 kg CO2/t-steel. |
Costs |
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) |
Shaft Furnace Scrap Preheating Publications
Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry
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Available and Emerging Technologies for Reducing Greenhouse Gas Emissions from the Iron and Steel Industry
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Global Warming Countermeasures: Japanese Technologies for Energy Savings / GHG Emissions Reduction
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This revised 2008 version of the publication from New Energy and Industrial Technology Development of Japan includes information on innovative Japanese technologies for energy efficiency and for the reduction of CO2 emissions.