Energy efficiency and advanced technologies in the iron and steel industry

The iron and steel industry is one of the largest energy-consuming and energy-intensive industrial sectors in the world. In the US it consumes approximately 8% of total manufacturing energy consumption. The development of energy efficiency and penetration rate of various technologies, e.g., BOF steelmaking and continuous casting is discussed and compared. Between 1980 and 1991 energy intensity of the US steel industry has declined by 17%, of which 11 %-points are due to efficiency improvements. Considerable potential for energy efficiency improvement can be realized by applying currently best available technology (the so-called technical potential). For the US the technical potential is estimated to be 43{+-}8%, taking the current industrial structure (mix of raw materials used and products produced) into account and the best available technology. The economically profitable potential is estimated to be 10--15%-points lower. The potential for energy efficiency improvement in the US is higher than that in other OECD countries, despite the improvements since 1980. Advanced technologies, such as smelt reduction and near net shape casting, present major opportunities for further reduction in energy consumption at potentially lower costs, as well as environmental benefits. This slab casting has first been introduced in the US by mini-mills to competemore » on the steel sheet markets. Since the first commercial introduction in 1989 the technology has shown rapid development and capacity growth. Smelt reduction on the other hand does not yet show such a rapid development. The authors discuss the status of smelt reduction, as well as the potential opportunities for the US integrated steel industry.« less