Uniform Reporting Format:
Activities Implemented Jointly Under the Pilot Phase
List of
Projects
A. Description of Project
1) Title of project:
The Model Project for Energy Conservation in Electric Furnace used for Ferro-Alloy Refining
2) Participants/actors:
Please fill in one table for each participant/actor. For individuals fill in as from item
"Function within activity".
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Error! Bookmark not defined.Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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New Energy and Industrial Technology Development Organization
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Department:
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International Cooperation Center
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Acronym:
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Acronym (English):
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NEDO
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Function within activity:
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Governmental Organization of Japan side in charge of
project evaluation, negotiation as well as implementation
of national AIJ program
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Street:
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1-1, 3-chome Higashi-Ikebukuro, Toshima-ku
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Post code:
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170-6028
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City:
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Tokyo
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Country:
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Japan
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Telephone:
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81-3-3987-9313
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Fax:
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81-3-5992-2290
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E-mail:
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WWW-URL:
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http://www.nedo.go.jp
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Contact person (for this activity):
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Surname:
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Kigasawa
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First name, middle name:
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Takaji
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Job title:
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Director
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Direct tel:
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81-3-3987-9466
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Direct fax:
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81-3-3987-5103
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Direct E-mail:
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kigasawatkj@nedo.go.jp
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Error! Bookmark not defined.Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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NKK Corporation
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Department:
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Engineering Division
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Acronym:
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Acronym (English):
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NKK
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Function within activity:
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Entrusted by NEDO to execute Japanese scope of this AIJ project in cooperation with Chinese
counterpart.
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Street:
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2-1, Suehiro-cho, Tsurumi-ku
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Post code:
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203-8611
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City:
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Yokohama
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Country:
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Japan
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Telephone:
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81-45-505-6568
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Fax:
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81-45-505-8929
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E-mail:
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WWW-URL:
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http://www.tsurumi.nkk.co.jp
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Contact person (for this activity):
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Surname:
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Ishii
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First name, middle name:
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Akira
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Job title:
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Deputy General Manager
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Direct tel:
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81-45-505-6568
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Direct fax:
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81-45-505-8929
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Direct E-mail:
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ishiia@eng.tsurumi.nkk.co.jp
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Error! Bookmark not defined.Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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The Ministry of Science and Technology, People's Republic of China
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Department:
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Department of Rural and Social Development
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Acronym:
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Acronym (English):
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MOST
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Function within activity:
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Governmental Authority of China side in charge of project evaluation, negotiation and approval as
well as implementation of national AIJ program
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Street:
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15B Fuxing Road
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Post code:
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100862
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City:
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Beijing
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Country:
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The People's Republic of China
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Telephone:
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Fax:
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E-mail:
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WWW-URL:
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Contact person (for this activity):
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Surname:
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Lu
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First name, middle name:
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Xuedu
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Job title:
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Direct Tel.:
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86 10 68514054
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Direct fax:
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86 10 68512163
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Direct E-mail:
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Lv Xuedu LVXD@MAIL.MOST.GOV.CN
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Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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The State Development Planning Commission, People's Republic of China
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Department:
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Department of Regional Economy
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Acronym:
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Acronym (English):
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SDPC
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Function within activity:
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Governmental Authority of China side in charge of national development plan and national project
evaluation and domestic approval for project financing and construction.
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Street:
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38,S. Yuetan Street
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Post code:
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100824
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City:
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Beijing
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Country:
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The People's Republic of China
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Telephone:
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Fax:
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E-mail:
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WWW-URL:
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Contact person (for this activity):
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Surname:
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First name, middle name:
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Job title:
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Direct tel:
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Direct fax:
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Direct E-mail:
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Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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The State Metallurgical Industry Bureau, People's Republic of China
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Department:
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Acronym:
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Acronym (English):
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SMIB
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Function within activity:
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Governmental Authority of China side in charge of sectoral management for state owned metallurgical
industry, including energy conservation renovation.
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Street:
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46 Dongsi Xidajie
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Post code:
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100711
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City:
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Beijing
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Country:
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The People's Republic of China
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Telephone:
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Fax:
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E-mail:
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WWW-URL:
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Contact person (for this activity):
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Surname:
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First name, middle name:
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Job title:
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Direct tel:
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Direct fax:
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Direct E-mail:
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Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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Planning Committee of Liaoning Province, People’s Republic of China
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Department:
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Acronym:
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Acronym (English):
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PCLP
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Function within activity:
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Provincial governmental authority of Liaoning Province of China side in charge of provincial
development plan and provincial project evaluation and domestic approval for project financing and
construction.
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Street:
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No.45 Beijing Street, Huanggu District
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Post code:
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110032
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City:
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Shenyang
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Country:
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The People's Republic of China
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Telephone:
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Fax:
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E-mail:
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WWW-URL:
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Contact person (for this activity):
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Surname:
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First name, middle name:
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Job title:
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Direct tel.:
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Direct fax:
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Direct E-mail:
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Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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Liaoyang Ferroalloy Group
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Department:
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Acronym:
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Acronym (English):
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LFG
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Function within activity:
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The owner and executive entity of the project.
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Street:
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No.21 Zhenxing Road
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Post code:
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111004
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City:
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Liaoyang, Liaoning Province
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Country:
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The People’s Republic of China
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Telephone:
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86 419 3306858
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Fax:
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86 419 3303264
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E-mail:
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Lythj@public2.lyptt.in.cn
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WWW-URL:
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Contact person (for this activity):
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Surname:
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CHEN
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First name, middle name:
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Tie Gang
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Job title:
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Director
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Direct tel.:
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86-419-3306858
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Direct fax:
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86-419-3303264
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Direct E-mail:
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Item
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Please fill in if applicable
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Name of organization(a):
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Name of organization (English):
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Tsinghua University
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Department:
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Institute for Techno-Economics & Energy Systems Analysis / Institute of Nuclear Energy
Technology
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Acronym:
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Acronym (English):
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ITEESA /INET
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Function within activity:
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Entrusted by MOST to execute Chinese scope of this AIJ project in cooperation with Japanese
counterpart. See A. 5) in detail.
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Street:
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Tsinghua Yuan Street, Haidian District
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Post code:
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100084
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City:
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Beijing
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Country:
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The People's Republic of China
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Telephone:
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86-10-6277-2752, 6278-3655
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Fax:
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86-10-6277-1150
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E-mail:
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Liuds@tsinghua.edu.cn
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WWW-URL:
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http://www.inet.tsinghua.edu.cn
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Contact person (for this activity):
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Surname:
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Liu
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First name, middle name:
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Deshun
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Job title:
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Professor, Deputy Director, Global Climate Change Institute (GCCI), INET/ITEESA Tsinghua University
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Direct Tel.:
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86-10-6277-2752, 6278-3655
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Direct fax:
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86-10-6277-1150
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Direct E-mail:
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Liuds@tsinghua.edu.cn
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a) Organization includes: institutions, ministries, companies, non-governmental organizations,
etc. involved in the activity, i.e. research institutes associated with the project, auditors, government
agency closely following the activity.
3) Activity:
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Item
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Please fill in if applicable
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General description :
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The objective of the Project is to contribute to efficient use of energy and consequently the
protection of the local environment in Liaoyang, P.R.China as well as the reduction of
CO2 emission, by installing furnace cover, CO gas recovery system, and a palletizing
plant into existing electric furnaces at Liaoyang Ferroalloy Works and disseminating the technology
in P.R.China.
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Type of project :
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Energy efficiency
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Location (exact, e.g. city, region, State):
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No.21 Zhenxing Road, Liaoyang Liaoning, 111004, P.R. China
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Activity starting date:
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September 1998
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Expected activity ending date:
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March 2021
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Stage of activity:
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Mutually agreed
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Lifetime of activity if different from ending date:
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20 Years
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Technical data:
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Annual production of ferro-chromium at Liaoyang Ferroalloy Works is around 38,300 ton/year.
After implementing the project:
- Unit electricity consumption of the furnace is expected to be reduced by 132 kWh/ton-FeCr.
- Unit coke consumption is expected to be reduced by 49kg/ton-FeCr.
- The waste CO will be recovered as fuel at the net rate of 471 Nm3-CO/ton-FeCr, which
will replace boiler fuel equivalent to 6,945 ton-coal/year.
- Calorific value of the gas is 2,700 kcal/ Nm3.
- CO2 emission is then expected to be reduced by 29,050 ton-CO2/year.
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4) Cost (to the extent possible): 1US$= 120 Japanese Yen; 1US$= 8.27Yuan RMB;
Base Year :1999
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Item
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1997
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1998
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1999
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2000
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Total
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Cost of the project in US$:
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3,750,000
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6,192,000
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3,330,000
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8,623,000*
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AIJ component in US$**:
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3,750,000
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6,192,000
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3,330,000
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8,623,000*
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US$ per avoided ton of CO2***
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22.64
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Cost of the project given above is based on the budget
*: of which cost invested by Japanese side is 1,333,000 US$, while 7,290,000 US$ by Chinese side,
**: For this AIJ project as energy conservation retrofitting, it is hard to distinguish which component is
AIJ specific one, since all components are necessary in contributing to the energy saving benefits
eventually.
***: It is defined here as life cycle averaged annual incremental cost for CO2 emission
reduction against the baseline, see Table 1 in detail in Attachment.
5) Mutually agreed assessment procedures:
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Describe the procedures, including name of organizations involved a):
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Basic Agreement concerning the execution of this project was concluded between NEDO and SDPC, SMIB
and PCLP on September 3, 1998.
NEDO concluded with NKK Co. to trust the execution of Japanese scope of this project in December 4,
1998.
NKK Co. and LFG concluded the Execution Document (ED) in which concrete specification, detail work
assignment, etc. concerning this project was clearly specified in September 16, 1998, and started
the design and engineering work of the project.
As determined in ED, LFG shall have responsibility to record and provide technical and economic
data, which will be necessary for calculation of the CO2 emission level both for
baseline and the AIJ project and for calculation of the emission reduction cost. Such data shall
cover, for example, unit electricity consumption, unit coke consumption and total amount of
recovery furnace gas, etc., as well as other investment and operation cost data for the subsequent
reporting period.
LFG and NKK shall submit the report on the data listed as above to MOST and NEDO before and after
completion of the test run for review.
Based on the data available, ITEESA, Tsinghua University shall make feasibility study on the
eligibility of the AIJ project and on assessment of the environmental benefits relating to the
CO2 emission reduction, as well as on the methodological issues in close co-operation
with LFG and NKK experts, with a view of preparing study report and draft report in uniform
reporting format, to be submitted to both governments.
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a) Please ensure that detailed contact information for all organizations mentioned is reported
under section A.2 above.
B. Governmental acceptance, approval or endorsement
Bearing in mind that all activities implemented jointly under this pilot phase require prior acceptance,
approval or endorsement by the Governments of the Parties participating in these activities, which shall be
shown as follows:
a. In the case of joint reporting, the report is submitted by the designated national authority of one
participating Party with the concurrence of all other participating Parties as evidenced by attached
letters issued by the relevant national authorities;
b. In the case of separate reporting, the reports are submitted separately by the designated national
authority of each and every participating Party. Information will only be compiled once reports have been
received from all participating Parties.
1) For the activity:
This report is the first report covering the activities at AIJ project feasibility study and AIJ project
design stage, and copies of letters of endorsement by each designated national authority of Parties are
attached.
Describe:
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MOST and NEDO concluded the "Memorandum of Understanding on Cooperation in the Model Project
for Energy Conservation in Electric Furnace Used for Ferro-Alloy Refining as a project of AIJ under
the pilot phase"on September 25, 1998.
The Ministry of International Trade and Industry of Japan (MITI) approved this project as Activity
Implemented Jointly - Japan Program on June 17, 1998.
(MITI) The Japanese government confirmed this project as Activity Implemented Jointly (AIJ) under
pilot phase on June 23,1999.
MOST authorized by Chinese government, confirmed this project as Activity Implemented Jointly (AIJ)
under pilot phase on July 9,1999.
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2) This report is a joint report:
- Yes, forward copy of agreement/endorsement by the designated national authorities involved
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No, this is a separate report. The reports are submitted separately by the designated national
authority of each and every participating party.
3) General short comment by the government(s) if applicable:
This is the first project report. The system boundary design and technical basic data were preliminary
checked among the Chinese and Japanese experts. The environmental benefits and methodological and technical
issues were addressed on the project specific basis. On the other hand, due to
insufficient data availability and lack of uniformed methodology
guide-lines the results reported here may be subject to modification. Hopefully with the further
progress of the project activities, more monitoring information on emissions and experiences in
methodologies will be built up, and therefore the subsequent reports could be updated later on.
C. Compatibility with and supportiveness of national economic development and socio-economic and
environment priorities and strategies
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Describe (to the extent possible) how the activity is compatible with and supportive of national
economic development and socio-economic and environment priorities and strategies
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As energy supply and demand issues and protection of the global environment have become the focus
of worldwide interest, NEDO is promoting energy conservation model projects in Asian countries
including China, to contribute to the effective use of energy and improvement of environmental
pollution.
In China, strong national policies for energy conservation and environmental protection have been
set, and relating regulations and laws have come into effect. The energy intensive metallurgical
industry in China has been listed as focused sector for energy conservation.
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As an AIJ cooperation between Japan and China, this project will contribute to efficient use of
energy and consequent protection of the local environment in China as well as CO2
emission mitigation by adopting advanced technology and equipment provided by Japan in the
Ferro-Alloy Refinery Works in the sector. Therefore the AIJ activity is compatible with and
supportive of national economic development and socio-economic environment priorities and
strategies.
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D. Benefits derived from the activities implemented jointly project
Whenever possible, quantitative information should be provided. Failing that, a qualitative description
should be given. If quantitative information becomes available, it could be submitted using the update(s).
(If the amount of quantitative information is too large, the source could be indicated.)
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Item
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Please fill in
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Describe environmental benefits in detail:
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Electric power and consumption of cokes and electrode consumption will be reduced and waste CO will
be recovered by implementing the project. Accordingly,
- CO2 emission associated with power generation, coke and CO combustion will be
reduced.
- SO2 emission associated with power generation and production of cokes will be
reduced.
- As recovery system equipped with series of Venturi scrubbers will be installed to remove most
of the dust contained in the gas, therefore, the dust emission will be dramatically reduced.
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Do quantitative data exist for evaluation of environmental benefits?
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Yes, CO2 emission reduction is estimated as 29,050 ton-CO2/year.
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Describe social/cultural benefits in detail:
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- Project management method
- Management of pelletizing plant operation including pellet size control
- Operating of CO gas recovery system
- Increase in job opportunity for pelletizing plant
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Do quantitative data exist for evaluation of social benefits?
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No
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Describe economic benefits in detail:
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- Cost in electric power consumption will be reduced.
- Cost in coke consumption will be reduced by less coke/Fe ratio, when pellets ore are used.
- Raw material cost can be reduced by utilizing pellets which is made from the cheaper fine
chromium ore, instead of expensive bulk ore.
- CO gas will be recovered from the electric furnace as fuel used in steam boiler to generate
heat replacing those for TiO production process and space heating in winter that are currently
purchased from thermal power utility.
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Do quantitative data exist for evaluation of economic benefits?
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Yes
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E. Calculation of the contribution of activities implemented jointly projects that bring about real,
measurable and long-term environmental benefits related to the mitigation of climate change that would not
have occurred in the absence of such activities.
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Estimated emissions without the activity (project baseline):
Description of the baseline or reference scenario, including methodologies applied:
System Boundary:
This AIJ project is a technical retrofit project. So the CO2 emission baseline is the current
emission level based on the existing operation condition in Liaoyang Ferroalloy Refinery Works Group in
absence of the AIJ project. According to the project specific baseline approach, the system boundary design
for the AIJ project will be illustrated as in the Fig. 1.
The direct emission levels from major processes both in baseline case and the AIJ project are covered
within the system boundary. The major processes relating to the energy conservation retrofitting in the AIJ
project are following:
- Installing a Fe-Cr ore-palletizing facility which will result in coke and electricity saving in the
refinery process;
- Installing a furnace cover system by which waste carbon monoxide (CO) gas emissions will be recovered
in the refinery process;
- Recovered CO will be used as fuel in an industrial boiler to generate steam for industrial heating,
which, otherwise, would be purchased from a local coal fired co-generation power plant;
- Meanwhile, additional electricity, steam and recovered CO will be used in the Fe-Cr ore-palletizing
process and in the CO recovery process, which will result in less net emission reduction somehow.
Therefore, the technical and economic parameters, including energy efficiency and CO2 emission
rate for both baseline case and the AIJ project could be identified as shown in the Fig.1 as following:
(obtained from the LFG and the project proposal – submitted by Anshan Metallurgical Design and
Research Institute, and NKK/Japan)
Figure 1: System boundary of the AIJ project in Liaoyang Ferroalloy Refinery Works Group
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The production capacity: 38,300 ton-FeCr/year (without change between baseline and AIJ),
- Unit electricity consumption: for baseline is 3676 kWh/ton-FeCr, for AIJ is
3384kWh/t-FeCr;
- Unit coke consumption: for baseline is 526 kg/ton-FeCr, which is in the form of bulk Fe
ore with higher price at 132.9 US$/ton-Fe ore, and
for AIJ is 477kg-Coke/ton-FeCr, which is in the form of powder Fe ore with lower price
at 100.4 US$/ton-Fe ore;
Comparing with AIJ project, more coke is wasted in baseline case at the emission rate of
526-477 = 49 kg/ton-FeCr;
- Fixed carbon rate in the coke: 83%
- Reaction gas emission rate: for baseline is 711 m3/ton-FeCr, and for AIJ is
635 m3/ton-FeCr in which the content of CO2 and CO are 7.57% and
84.48% respectively; Comparing with AIJ project, more gas is released in baseline case at the
emission rate of 711-635 = 76 m3/ton-FeCr which mainly consists of CO2
emitted by those waste coke that are not involved in the oxygenating reduction reaction with Fe ore
and eventually burnt into the air in the form of CO2;
- The effective thermal value of the recovered reaction gas emission in AIJ project is 2700
Kcal/Nm3 and converted into 0.385 kgce/Nm3;
- Energy efficiency for the coal fired co-generation boiler is 75 %,
150Kgce/ton-steam, and for the gas fired industrial boiler is 80%,
141Kgce/ton-steam;
- These part of steam purchased from cogeneration utility will be replaced by steam generated
from industrial boiler fueled with recovered CO;
- Energy intensity of electricity supply in local grid is 400gce/kWh ;
- Calorific value of steam in Liaoyang’s heat supply pipeline is 113 kgce/ton-steam;
BASELINE (Calculation)
The baseline emission could be calculated based on three processes in baseline case, i.e. the
Ferro-alloy refinery with bulk Fe ore, CO gas generation without recovery and steam generation from
local coal fired co-generation power plant;
1. The CO2 emission from the Ferroalloy refinery works with bulk Fe ore:
In this process, CO2 emission is accrued from energy consumption of the electricity used
in the electric furnace, from coke in its reaction with Fe-Cr ore and from the waste coke which
will be saved otherwise in the AIJ project. So the CO2 emission EF can be
calculated by the following formula:
EF = ? EFi = ? Di×F1i×F2i =
40067.94 ton-C/a +986.28 ton-C/a + 1557.66 ton-C/a = 42,611.88 ton-C/a = 156,243.56
t-CO2/a
where i: electricity, coke, and waste coke, respectively,
(1) CO2 emission from electricity, EFelec =
Di×F1i×F2i , i = electricity
Delec= Annual consumption of electricity = production capacity × Unit electricity
consumption
= 38300 ton-FeCr/a × 3676 kWh/ton-FeCr =1.4079 × 108kWh/a
F1elec = the energy efficiency of electricity generation = 0.400kgce/kWh;
F2elec = the emission factor of CO2 = 0.726´ 0.98=0.711kg-C/kgce-coal;
EFelec = 1.4079*108kWh/a ´ 0.400kgce/kWh ´ 0.711kg-C/kgce =
40067.94ton-C/a
(2) CO2 emission from coke in reaction with Fe ore, EFcoke =
Di×F1i×F2i , i = coke
Dcoke = Annual reaction gas emission from coke in reaction with Fe ore
= production capacity × Unit gas emission rate, which is the same as that in the AIJ project,
due to the same productive reaction process.= 38300t-CrFe/a × 635 gas Nm3/t-CrFe =
2432.05 × 104 gas Nm3/a
F1coke = the content of CO2 in the reaction gas = 7.57%
F2coke = the conversion factor for CO2 from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
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EFcoke = 2432.05 × 104 gas Nm3/a ´
7.57%/(22.4Nm3/kmol)) ×12kg/kmol = 986.28ton-C/a
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(3) CO2 emission from burning of waste coke without reaction with Fe ore,
EF wast coke = Di×F1i×F2i , i = waste coke
D wast coke = Annual waste coke consumption = production capacity × Unit waste
coke consumption = 38300t-CrFe/a × (0.526-0.477) t-coke/t-CrFe = 1876.7 t-C
F1waste coke = the content of fixed carbon in the coke = 83%
F2waste coke = the conversion rate from waste coke to CO2 = 100%,
EFwaste coke = 1876.7 t-C ´ 83% × 100% = 1557.66 ton-C/a
2. The CO2 emission from the CO generation and burning without recovery:
In this process, CO emission is firstly generated in coke-Fe oxygenating reduction reaction and
mixed with the reaction gas, and then burning without recovery. Similar to CO2 emission
in 1. (2), those reaction gas emission is the same as that in the AIJ project, due to the same
productive reaction process. So the CO2 emission ECO can be calculated as
following:
ECO = Di×F1i×F2i , i = CO
DCO = Annual reaction gas emission from coke in reaction with Fe ore
= production capacity × Unit gas emission rate.
= 38300t-CrFe/a × 635 gas Nm3/t-CrFe = 2432.05 × 104 gas
Nm3/a
F1CO = the content of CO in the reaction gas = 84.48%
F2CO = the conversion factor for CO from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
ECO = 2432.05 × 104 gas Nm3/a ´
84.48%/(22.4Nm3/kmol)) ×12kg/kmol = 11006.76 ton-C/a.
3. The CO2 emission from steam generation by local coal fired co-generation power
plant
It should be noted that this amount of CO2 emission is accrued from those steam
generation in the local co-generation utility, that will be replaced by net steam output to be
generated by recovered CO in industrial boiler in the AIJ project. Here the net steam output should
be less than gross steam output, due to the part of recovered CO will be used as fuel for heating
in palletizing process, at the rate of 146 m3gas/T-FeCr, and the part of
recovered steam will be used for CO recovery process, at the rate of 28.617
m3/ton FeCr .
(see AIJ project part for detail)
So the CO2 emission from steam generation equivalent to the net output from AIJ project,
Esteam can be calculated as following:
Esteam = Di×F1i×F2i = 4930.643 ton-C/a, i =
steam
Dsteam: Annual consumption of steam generation equivalent
= production capacity × (unit steam output by net recovered CO in AIJ project – unit
steam consumption for CO recovery process)
= 38300 t-CrFe/a × (635-164-28.617) m3gas/t-FeCr × 0.385 kgce/m3
× tce/1000kgce
× 80%/0.113 tce/ton-steam = 46181.34 ton-steam,
|
|
Here, we use the following parameters:
reaction gas CO emission rate = 635 m3/ton-FeCr,
recovered gas CO consumption rate for Fe-Cr ore-palletizing process = 164
m3/ton-FeCr,
equivalent CO consumption rate for heating in CO recovery process = 28.617
m3/ton- FeCr,
F1steam: the energy intensity of steam generation in cogeneration utility
=150kgce/ton-steam
F2 steam: the emission factor of CO2 = 0.711kg-C/kgce;
E steam = 46181.34 t-steam ×150kgce/ton-steam ×0.711kg-C/kgce =
4925.24ton-C/a,
4. The total CO2 emission in baseline is:
42611.88 ton-C/a +11006.76 ton-C/a + 4925.24ton-C/a
= 58543.88 ton-C/a = 214660.9 t-CO2/a
|
|
2) Estimated emissions with the activity:
|
|
Description of the scenario, including methodologies applied:
|
|
AIJ PROJECT (Calculation)
The technical and economic parameters, including energy efficiency and CO2 emission rate
for the AIJ project have been listed before. (obtained from the LFG, NKK and the project proposal
– submitted by Anshan Metallurgical Design and Research Institute)
-
The CO2 emission could be calculated based on three processes in the AIJ project, i.e.
the Fe-Cr ore-palletizing and Ferro-alloy refinery process with palletized Fe-Cr ore, CO gas
recovery and steam generation from recovered CO gas.
-
1.The CO2 emission from the palletizing process and Ferro-alloy refinery process
with palletized Fe ore
In this process, CO2 emission is accrued from energy consumption of the electricity used
in the electric furnace, from coke in its reaction with Fe-Cr ore and from additional electricity
and CO consumption for palletizing process in the AIJ project. So the CO2 emission
EF can be calculated by the following formula:
EF = ? EFi = ? Di×F1i×F2i =
36885.33 ton-C/a +986.28 ton-C/a + 4040.87 ton-C/a = 41912.48 ton-C/a ,
where i: electricity, coke, and pallet, respectively,
(1) CO2 emission from electricity, EFelec =
Di×F1i×F2i , i = electricity
Delec= Annual consumption of electricity = production capacity × Unit electricity
consumption
= 38300 ton-FeCr/a ×3384 kWh/ton-FeCr = 1.29607 × 108kWh/a
F1elec = the energy efficiency of electricity generation = 0.400kgce/kWh;
|
|
F2elec = the emission factor of CO2 = 0.726´ 0.98=0.711kg-C/kgce-coal;
EFelec = 1.29607 *108kWh/a ´ 0.400kgce/kWh ´ 0.711kg-C/kgce =
36885.33 ton-C/a
|
(2) CO2 emission from coke in reaction with Fe ore, EFcoke =
Di×F1i×F2i , i = coke
Dcoke = Annual reaction gas emission from coke in reaction with Fe ore
= production capacity × Unit gas emission rate.
= 38300t-CrFe/a × 635 gas Nm3/t-CrFe = 2432.05 × 104 gas Nm3/a
F1coke = the content of CO2 in the reaction gas = 7.57%
F2coke = the conversion factor for CO2 from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
EFcoke = 2432.05 × 104 gas Nm3/a ´
7.57%/(22.4Nm3/kmol)) ×12kg/kmol = 986.28ton-C/a
(3) CO2 emission from palletizing process,
EFpallet = ? Dj×F1j×F2j , j = electricity, CO,
respectively
Delec = Annual consumption of electricity in palletizing process
= Production capacity × Unit electricity consumption for palletizing.
= 38300 ton- FeCr /a × 110 kWh/ ton- FeCr = 0.04213×108kWh/a,
Delec×F1elec×F2elec = 0.03353*108kWh/a ´
0.400kgce/kWh ´ 0.711kg-C/kgce
= 1198.178 ton-C/a
DCO = Annual consumption of CO in palletizing process
= Production capacity × Unit CO consumption for palletizing process.
= 38300t-CrFe/a × 164 gas Nm3/t-CrFe = 628.12 × 104 gas Nm3/a
F1CO = the content of CO in the reaction gas = 84.48 %
F2CO = the conversion factor for CO2 from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
DCO×F1CO×F2CO = 628.12× 104 gas
Nm3/a ´ 84.48%/(22.4Nm3/kmol)) ×12kg/kmol= 2842.692 ton-C/a
EFpallet = 1198.178 ton-C/a + 2842.692 ton-C/a = 4040.87 ton-C/a
2. The CO2 emission from the CO gas recovery:
In this process, CO emission is firstly generated in coke-Fe oxygenating reduction reaction and mixed with
the reaction gas, and then recovered without burning. The CO2 emission will be accrued by
additional electricity and steam consumption for the CO recovery process. So we have
-
ECO = ? Dj×F1j×F2j = (544.626 + 496.03) ton-C/a =
1040.656 ton-C/a
-
j: the electricity and steam
-
Delec = Annual consumption of electricity = Production capacity × unit CO recovery
× electricity intensity of the CO recovery
= 38300t-CrFe/a × 50 kWh/ t-CrFe = 1915000 kWh/a
-
= 826897 kWh/a,
Delec×F1elec×F2elec=1915000
kWh/a×0.400kgce/kWh×0.711kg-C/kgce-coal
= 544.626 ton-C/a
Dsteam = Annual consumption of equivalent CO in CO recovery process
= Production capacity × Unit CO consumption for CO recovery process.
= 38300t-CrFe/a × 28.617 gas Nm3/t-CrFe = 109.603 × 104 gas
Nm3/a
F1steam = the content of CO in the reaction gas = 84.48 %
F2steam = the conversion factor for CO2 from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
Dsteam×F1steam×F2steam= 109.603× 104 gas
Nm3/a ´ 84.48%/(22.4Nm3/kmol)) ×12kg/kmol
= 496.03 ton-C/a
ECO = 544.626 ton-C/a +496.03 ton-C/a = 1040.656ton-C/a
3. The CO2 emission from steam generation by recovered CO as fuel
As mentioned in the baseline calculation, this amount of CO2 emission is accrued from net steam
output generated by net recovered CO gas in industrial boiler in the AIJ project. Here the net recovered CO
gas should be the gross recovered CO gas – that for heating in palletizing process, at the rate of
146 m3gas/T-FeCr – that steam equivalent for CO recovery process, at the rate of
28.617 m3/ton FeCr.
So the CO2 emission from the net output of steam generated by net recovered CO gas,
Esteam can be calculated as following:
-
Esteam = Di×F1i×F2i = 7667.99 ton-C/a, i = steam
Dsteam = Annual consumption of net CO recovered
= production capacity × (unit gross reaction gas recovery– unit reaction gas recovery used for
palletizing and CO recovery process)
= 38300 t-CrFe/a × (635-164-28.617) m3gas/t-FeCr = 1694.3154 104m3/a
F1steam = the content of CO in the reaction gas = 84.48%
F2steam = the conversion factor for CO from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
Esteam= 1694.3154×104 gas Nm3/a ´
84.48%/(22.4Nm3/kmol))×12kg/kmol=7667.99 ton-C/a
Note: from energy balance point of view, we use the following parameters:
Unit gross reaction gas recovery = 635 m3/ton-FeCr,
Unit reaction gas recovery used for palletizing process = 164 m3/ton-FeCr,
Unit reaction gas recovery used for CO recovery process = 28.617 m3/ton- FeCr,
which is resulted from the following calculation:
Considering that, for CO recovery process, 0.9 t-steam/hr of heating is required for 5 months in Winter
season, and production rate per furnace is 2.419 ton-FeCr/hr, then the unit steam consumption rate is 0.9
t-steam/ (2.419× 2) ton-FeCr = 0.078 t-steam/ ton-FeCr.
And considering 113 kgce/t-steam of steam’s thermal value, and 0.385 kgce/Nm3 of recovered
CO gas’s thermal value, and 80% efficiency of the CO gas fired boiler, the unit CO intensity for
steam generation is 113 kgce/t-steam / 0.385 kgce/Nm3 × 0.80 = 366.88 Nm3/
t-steam.
Therefore the unit reaction gas recovery used for CO recovery process = 366.88 ×0.078 = 28.617
m3/ton- FeCr.
4. The total CO2 emission in AIJ Project is:
-
41912.48 ton-C/a+1040.656ton-C/a +7667.99 ton-C/a
-
= 50621.126 ton-C/a = 185610.795 ton-CO2/a
-
-
The annual total CO2 emission reduction = 214.66 Kton-CO2/year–
185.611 Kton-CO2/year = 29.050 Kton-CO2/year
Fill in the following tables as applicable:
Summary table: Projected emission reductions (unit: 1,000 ton-CO2/year):
|
GHG
|
1998
|
1999
|
2000
|
2001
|
2002
|
2010
|
|
A) Project baseline scenario
|
CO2
|
214.66
|
214.66
|
214.66
|
214.66
|
214.66
|
214.66
|
|
CH4
|
|
|
|
|
|
|
|
N2O
|
|
|
|
|
|
|
|
Other
|
|
|
|
|
|
|
|
B) Project activity scenario
|
CO2
|
|
|
|
185.61
|
185.61
|
185.61
|
|
CH4
|
|
|
|
|
|
|
|
N2O
|
|
|
|
|
|
|
|
Other
|
|
|
|
|
|
|
|
C) Effect ( B-A )
|
CO2
|
|
|
|
-29.05
|
-29.05
|
-29.05
|
|
CH4
|
|
|
|
|
|
|
|
N2O
|
|
|
|
|
|
|
|
Other
|
|
|
|
|
|
|
|
D) Cumulative effect
|
CO2
|
|
|
|
-29.05
|
-58.10
|
-290.5
|
|
CH4
|
|
|
|
|
|
|
|
N2O
|
|
|
|
|
|
|
|
Other
|
|
|
|
|
|
|
F. Additionally to financial obligations of Parties included in Annex II to the Convention within the
framework of the financial mechanism as well as to current official development assistance flows
Please indicate all sources of project funding a) .
|
Category of funding
(For each source one line)
|
Amount
(US dollars)
|
|
Subsidy for improving international energy use (Japanese national budget, which is sponsored by
MITI). The funds are additional to Japanese GEF and current ODA budget.
|
9,942,000 US$ (1997FY-1998FY)
4,663,000US$ (1999FY-2000FY)
|
1US$ = 120 Japanese Yuan
a) Only refer to all those sources that were funded by MITI/Japan as Annex II country Party to the UNFCCC.
G. Contribution to capacity building, transfer of environmentally sound technologies and know-how to
other Parties, particularly developing country Parties, to enable them to implement the provisions of the
Convention. In this process, the developed country Parties shall support the development and enhancement of
endogenous capacities and technologies of developing country Parties
|
Transfer of environmentally sound technologies and know-how
|
Describe briefly
|
-
Transfer of energy efficient electric furnace equipment and pelletizing plant as well as their
know-how technology for Ferroalloy refinery in the Liaoyang Ferroalloy Works Group
|
By installing pelletizing plant, CO gas recovery system, and furnace cover at Liaoyang Ferroalloy
Works, this project demonstrates:
- Reduction in electric power consumption
- Reduction in coke consumption
- Recovery of CO gas as fuel
- Reduction in dust emission
|
-
Capacity Building
|
By implementing the project, following capacity building can be attained:
- Project management
- Operation of the pelletizing plant
- Operation of CO gas recovery system
|
-
-
H. Additional comments, if any, including any practical experience gained or technical difficulties,
effects, impacts or other obstacles encountered
Fill in as appropriate:
1) Any practical experience gained:
Since the Project is a Model Project, dissemination activity of the technology through demonstration
operation is planned in the final stage of overall project schedule. A large effect of energy conservation
and environmental improvement is expected through dissemination of the technology in the future
2) Technical difficulties:
Meanwhile the technical difficulties in determining the system boundary are encountered.
3) Negative impacts and/or effects encountered:
4) Other obstacles encountered:
5) Other:
|
Suggestion: Personnel training
(1) The key staff member of the plant will be educated to enhance their public awareness on the
CO2 emission mitigation, climate change and AIJ pilot phase under UNFCCC.
(2) The professional training will be done for the technical engineers and workers who will be
involved in the monitoring tasks.
The training course could be given three months in advance of the plant’s putting into
operation.
|
Attachment
Table 1. The cost-benefits analysis on CO2 emission reduction in AIJ Pilot Project :
Energy conservation of Liaoyang Ferroalloy Group
|
Item
|
Unit
|
Data
|
|
Project scale: Palletizing of Fe ore
|
Ton/year
|
70000
|
|
Project scale: Fe-Cr Production
|
Ton/year
|
38300
|
|
Waste gas recovered
|
MNm3/y
|
24
|
|
Total investment cost
|
MUS$
|
24.77
|
|
Discount rate
|
%
|
10
|
|
1. Heat supply in baseline: Steam from local CHP power plant
|
|
Energy efficiency of heat supply in baseline
|
%
|
75
|
- Energy efficiency of heat supply in AIJ
|
%
|
80
|
- Unit heat supply cost in baseline
|
US$/T-steam
|
9.19
|
|
|
Ton/year
|
46200
|
|
2. Electricity supply in baseline same as in AIJ
|
|
Liaoning Grid
|
|
Energy efficiency of electricity supply
|
gce/Kwh
|
400
|
|
Electricity price
|
US$/Kwh
|
0.0423
|
|
Electricity demand in baseline
|
Kwh/T-FeCr
|
3676
|
|
Electricity demand in AIJ
|
Kwh/T-FeCr
|
3384
|
|
3. Coke consumption in baseline
|
Ton/T-FeCr
|
0.526
|
|
Coke consumption in AIJ
|
Ton/T-FeCr
|
0.427
|
|
Coke price
|
US$/Ton
|
47.64
|
|
Incremental cost per unit
|
US$/T-C
|
83.1
|
|
CO2 emission reduction
|
US$/T-CO2
|
22.64
|
|
Annual CO2 emission reduction by the AIJ project
|
KT-C/year
|
7.92
|
|
KT-CO2/year
|
29.05
|
|
Annual incremental expense for CO2 emission reduction
|
MUS$/year
|
0.66
|
|
Present value of Incremental expense on CO2 emission reduction over AIJ project life
time
|
MUS$
|
5.62
|
|
Total CO2 emission reduction over AIJ project life time (discounted)
|
KT-C
|
67.5
|
|
KT-CO2
|
247.5
|
|
Emission reduction and its incremental cost calculated by equivalent static approach
|
|
Equivalent static incremental cost
|
US$/T-C
|
35.4
|
|
per unit CO2 reduction
|
US$/T-CO2
|
9.6
|
|
Total CO2 emission reduction over AIJ project life
|
KT-C
|
159
|
|
time, physical amount, no discount
|
KT-CO2
|
581
|
|
4. The total CO2 emission in baseline is:
42611.88 ton-C/a +11006.76 ton-C/a + 4925.24ton-C/a
= 58543.88 ton-C/a = 214660.9 t-CO2/a
AIJ PROJECT (Calculation)
The technical and economic parameters, including energy efficiency and CO2 emission rate
for the AIJ project have been listed before. (obtained from the LFG, NKK and the project proposal
– submitted by Anshan Metallurgical Design and Research Institute)
The CO2 emission could be calculated based on three processes in the AIJ project, i.e.
the Fe-Cr ore-palletizing and Ferro-alloy refinery process with palletized Fe-Cr ore, CO gas
recovery and steam generation from recovered CO gas.
1.The CO2 emission from the palletizing process and Ferro-alloy refinery process with
palletized Fe ore
In this process, CO2 emission is accrued from energy consumption of the electricity used
in the electric furnace, from coke in its reaction with Fe-Cr ore and from additional electricity
and CO consumption for palletizing process in the AIJ project. So the CO2 emission
EF can be calculated by the following formula:
EF = ? EFi = ? Di×F1i×F2i =
36885.33 +986.28 + 3796.28 (4040.87) ton-C/a = 41667.89 (41912.48) ton-C/a ,
where i: electricity, coke, and pallet, respectively,
(1) CO2 emission from electricity, EFelec =
Di×F1i×F2i , i = electricity
Delec= Annual consumption of electricity = production capacity × Unit electricity
consumption
= 38300 ton-FeCr/a ×3384 kWh/ton-FeCr = 1.29607 × 108kWh/a
F1elec = the energy efficiency of electricity generation = 0.400kgce/kWh;
F2elec = the emission factor of CO2 = 0.726´ 0.98=0.711kg-C/kgce-coal;
EFelec = 1.29607 *108kWh/a ´ 0.400kgce/kWh ´ 0.711kg-C/kgce =
36885.33 ton-C/a
|
(2) CO2 emission from coke in reaction with Fe ore, EFcoke =
Di×F1i×F2i , i = coke
Dcoke = Annual reaction gas emission from coke in reaction with Fe ore
= production capacity × Unit gas emission rate.
= 38300t-CrFe/a × 635 gas Nm3/t-CrFe = 2432.05 × 104 gas Nm3/a
F1coke = the content of CO2 in the reaction gas = 7.57%
F2coke = the conversion factor for CO2 from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
EFcoke = 2432.05 × 104 gas Nm3/a ´
7.57%/(22.4Nm3/kmol)) ×12kg/kmol = 986.28ton-C/a
(3) CO2 emission from palletizing process,
EFpallet = ? Dj×F1j×F2j , j = electricity, CO,
respectively
Delec = Annual consumption of electricity in palletizing process
= Palletizing capacity × Unit electricity consumption
(= Production capacity × Unit electricity consumption for palletizing.)
= 70000 ton-pallet Fe ore/a × 47.9 kWh/ton- pallet Fe ore = 0.03353×108kWh/a,
(= 38300 ton- FeCr /a × 110 kWh/ ton- FeCr = 0.04213×108kWh/a,)
Delec×F1elec×F2elec = 0.03353*108kWh/a ´
0.400kgce/kWh ´ 0.711kg-C/kgce
= 953.59 (1198.178) ton-C/a
DCO = Annual consumption of CO in palletizing process
= Production capacity × Unit CO consumption for palletizing process.
= 38300t-CrFe/a × 164 gas Nm3/t-CrFe = 628.12 × 104 gas Nm3/a
F1CO = the content of CO in the reaction gas = 84.48 %
F2CO = the conversion factor for CO2 from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
DCO×F1CO×F2CO = 628.12× 104 gas
Nm3/a ´ 84.48%/(22.4Nm3/kmol)) ×12kg/kmol
= 2842.692 ton-C/a
EFpallet = 953.59 (1198.178) + 2842.692 = 3796.28 (4040.87) ton-C/a
2. The CO2 emission from the CO gas recovery:
In this process, CO emission is firstly generated in coke-Fe oxygenating reduction reaction and mixed with
the reaction gas, and then recovered without burning. The CO2 emission will be accrued by
additional electricity and steam consumption for the CO recovery process. So we have
ECO = ? Dj×F1j×F2j = (235.169 (544.626 ) + 496.03)
ton-C/a = 731.20 (1040.656) ton-C/a
j: the electricity and steam
Delec = Annual consumption of electricity = Production capacity × unit CO recovery ×
electricity intensity of the CO recovery
= 38300t-CrFe/a × 635 CO gas Nm3/t-CrFe ×340kWh/104m3-CO gas
(= 38300t-CrFe/a × 50 kWh/ t-CrFe = 1915000 kWh/a)
= 826897 kWh/a,
Delec×F1elec×F2elec=826897
(1915000)kWh/a×0.400kgce/kWh×0.711kg-C/kgce-coal = 235.169 (544.626) ton-C/a
Dsteam = Annual consumption of equivalent CO in CO recovery process
= Production capacity × Unit CO consumption for CO recovery process.
= 38300t-CrFe/a × 28.617 gas Nm3/t-CrFe = 109.603 × 104 gas
Nm3/a
F1steam = the content of CO in the reaction gas = 84.48 %
F2steam = the conversion factor for CO2 from volume to weight (in kg-C)
= 12kg/kmol/(22.4Nm3/kmol))
Dsteam×F1steam×F2steam= 109.603× 104 gas
Nm3/a ´ 84.48%/(22.4Nm3/kmol)) ×12kg/kmol
= 496.03 ton-C/a
ECO = 235.169 (544.626) ton-C/a +496.03 ton-C/a = 731.20 (1040.656)ton-C