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Iron and Steel Manufacturing Assumptions and calculations for waste heat losses in iron and steel manufacturing are included below. For coke oven waste gas and hot blast stove exhaust gas, calculations of waste heat losses were performed using methods described in Appendix A.1. For coke oven gas, blast furnace gas, basic oxygen furnace gas, and electric arc furnace gas, the chemical composition of exhaust gases could not be calculated by simply assuming complete combustion of fuel sources. Therefore, estimates of exhaust gas composition, flow rate, and waste heat losses were based on data reported in published literature. Table A2.5 - Assumptions for Calculating Energy Consumption and Waste Heat Losses in Iron and Steel Manufacturing Steel Integrated Steel Mills Coke Ovens Coke Oven Gas Waste Gas Blast Furnace Blast Furnace Gas Blast Stove Blast Stove Exhaust -No Recovery Blast Stove Exhaust - With Recovery Basic Oxygen Furnace Mini Mills Electric Arc Furnace No Scrap Preheat With Scrap Preheat Production (tons steel/year)a 104,579,800 56,473,092 56,473,092 56,473,092 56,473,092 56,473,092 56,473,092 56,473,092 28,236,546 28,236,546 56,473,092 38,485,366 48,106,708 38,485,366 9,621,342 Net Energy Consumption (10^6 Btu/ton)b 1.16c 11.31d 1.24e 0.82f 1.50g 1.39h Net Energy Consumption (TBtu/year) 66 642 70 50 58 13 Assumed Average Exhaust Temperaturei °F °C 1,800 980 392 200 200 430 482 250 266 130 3,100 1,700 2,200 1,200 400 204 a. Total steel production from USGS 2005 Minerals Yearbook: Iron and Steel. p. 38.5 2007. It was assumed that integrated steel mills are responsible for 54% of steel production, based on Energetics, 2000, Energy and Environmental Profile of the US Iron and Steel Industry. p. 3. Also assumed 50% of blast stoves include heat recovery. b. Values do not include electricity-related losses. Values include credit for recovered fuel. c. Freuhan, p. 16 d. Energetics, p. 6. Value initially reported per ton of pig iron. Converted to tons of steel assuming 1000 kg steel produced for every 940 kg pig iron. Based on data reported by PCC, Best Available Techniques Reference Document on the Production of Iron and Steel. p. 176. 2001. e. Energetics, p. 45. 10-12% of blast furnace energy consumption is in the hot blast stove. f. Energetics, p. 12. g. Energetics, p. 62. h. Energetics, p. 64. Scrap preheat saves from 5-10% of power input. i. See temperatures listed in Table A 8. A - 10PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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