National Academies Press: OpenBook
Suggested Citation:"Front Matter." National Research Council. 1987. Increasing Energy Efficiency in the Steel and Petrochemical Industries Through Waste Recycling and Reduction. Washington, DC: The National Academies Press. doi: 10.17226/19174.
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Suggested Citation:"Front Matter." National Research Council. 1987. Increasing Energy Efficiency in the Steel and Petrochemical Industries Through Waste Recycling and Reduction. Washington, DC: The National Academies Press. doi: 10.17226/19174.
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Suggested Citation:"Front Matter." National Research Council. 1987. Increasing Energy Efficiency in the Steel and Petrochemical Industries Through Waste Recycling and Reduction. Washington, DC: The National Academies Press. doi: 10.17226/19174.
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Suggested Citation:"Front Matter." National Research Council. 1987. Increasing Energy Efficiency in the Steel and Petrochemical Industries Through Waste Recycling and Reduction. Washington, DC: The National Academies Press. doi: 10.17226/19174.
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Suggested Citation:"Front Matter." National Research Council. 1987. Increasing Energy Efficiency in the Steel and Petrochemical Industries Through Waste Recycling and Reduction. Washington, DC: The National Academies Press. doi: 10.17226/19174.
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Suggested Citation:"Front Matter." National Research Council. 1987. Increasing Energy Efficiency in the Steel and Petrochemical Industries Through Waste Recycling and Reduction. Washington, DC: The National Academies Press. doi: 10.17226/19174.
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Suggested Citation:"Front Matter." National Research Council. 1987. Increasing Energy Efficiency in the Steel and Petrochemical Industries Through Waste Recycling and Reduction. Washington, DC: The National Academies Press. doi: 10.17226/19174.
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NATIONAL RESEARCH COUNCIL COMMISSION ON ENGINEERING AND TECHNICAL SYSTEMS NATIONAL MATERIALS ADVISORY BOARD The purpose of the National Materials Advisory Board is the a d v a n c e me nt of materials science ·and engineering in the national interest. CHAIRMAN PAST CHAIRMAN Dr. Bernard H. Kear Dr. Arden L. Bement, Jr. State of New Jersey Professor Vice President, Technical of Materials Science and Resourc es Technology Science and Technology Dept. Director. Center for Materials TRW, Inc . Synthe sis 1900 Richmond Road College of Engineering Cleveland, OH 44124 Rutgers University P.O. Box 909 Piscataway. N J 08854 MEMBERS Dr. Ri,hard C. Alkire Dr. James Economy Dr. Dennis W. Readey Profes�or ;,nd Head Manager, Organic Polymer Professor and Chairman, Department of Chem"al Engineering Re s earch Ceramic Engineering University uf lllinoi� IBM Almaden Research Center Department 120'J We st California Street Department K9180 Ohio State University Ur ba na . IL 61801 650 Harry Road 2041 College Road San Jose, CA 95120-6099 Columbus. OH 43210 Dr. Norbert S. Baer Professor. Conservation Center Dr. Menon C. Flemings Or. John P. Riggs of the Institute of Fine Ans Professor and Chairman Executive Director, New York Uni versity Department of Materials Techno logy 14 East 78th Stree t Science and Engineering Celanese Research Corporation New York. NY 10021 Massachusetts Institute of 86 Morris Avenue Tech nology Summit, NJ 07901 Dr. L. Eric Cross 77 Massachusetts Avenue Di r e ctor . M a t erial s Re se arch Cambridge, MA'il2139 Dr. William P. Stichter L<>borator y Executive Director, Research Evan Pugh Professor of Dr. Brian R. T. Frost Materials Science and Electrical Engineering Director, Technology Transfer Engineering Division Pennsylvania State University Center ATclT Bell Laboratories University Park, PA 16802 Argonne National Laboratory 600 Mountain Avenue 9700 South Cass Avenue Murray Hill, NJ 07974 Dr. Fr . mk W. Crossm an Argonne, IL 60439 Manager. Mechanics and Dr. John E. Tilton Materials Engineering Dr. Gordon S. Kino Coulter Professor Lockheed Palo Alto Research Professor, Electrical Depanme�t of Mineral Laboratory Engineering and Physics Economtcs 325 I Hanover Street Stanford University Colorado School of Mines Palo Alto. CA 94304 Stanford, CA 94305 Golden, CO 80401 Dr. Ray mond F. Decker Or. Alan Lawley Dr. JaJT.es C. Williams Pre sident and Professor, Materials Dean, Carnegie Institute of Chief Executive Officer Engineering Tech nolog y University Science Partners. Inc. Drexel University Carnegie Mellon University 321 Fisher Bldg. Depa � men ! of Materials Schenley Park Detroit. Ml 411202 Enganeenng Pittsburgh, PA 15213 Philadelphia, PA 19104 Mr. Edward J. Dulis President Dr. Adolph J. Lena NMAB STAFF Cru cib le Re s earch Center Executive Vice President Cruc ib le M ateria b Co rporation Chief Operating Officer K. M. Zwil sky. D i rector P.O. Box 88 Carpenter Technology Corp. S.M. Barkin. Assoc. Director Pittsburgh, PA 15230 P.O. Box 662 Mary W. Br ittain . Adm. Officer Reading, PA 19603 2101 Constitution Ave . . NW Washington. DC 20411\ Dr. David L. Morrison President liT Research Institute 10 West 35th Street ,-� 12186 Cbicqo, IL 60616 . ' ,__. , ) . -

REFERENCE COPY INCREASING ENERGY EFFICI ENCY IN THE STEEL AND PETROCHEMI CAL � INDUSTRI ES THROUGH WASTE RECYCLING AND REDUCTION Report of the Committee on Industr ial Energy Conservat ion PROPERTY OF NRC LIBF\AxY SEP 2 7 \988 National Materials Advis ory Board Comm i s s ion on Engineer ing and Technical Sys tems Nat ional Re se arch Counc i l Ordef trom NationJI T ecMicJI Pub l icat ion NMAB 429-2 lnform2ti�n s�;-.;lce. Nat ional Academy Pre s s Springfield. Va. Wash ington , D . C . 22161 Augus t 1987 Order No.---

NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competences and with regard for appropriate balance. This report has been reviewed by a group other than the authors according to procedures approved by a Report Review Committee consisting of members of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Frank Press is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Robert M. White is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an advisor to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Samuel 0. Thier is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy's purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Frank Press and Dr. Robert M. White are chairman and vice chairman, respectively, of the National Research Council. This study by the National Materials Advisory Board was conducted under Contract No. DE-AC01-84CE40625 with the U.S. Department of Energy. This report is for sale by the National Technical Information Service, U.S. Department of Commerce, 5285 Port Royal Road, Springfield, VA 22161. Printed in the United States of America.

ABSTRACT Thi s report addre s s e s energy cons e rvat ion opportuni t i e s in the U . S . s te e l and pe trochemical indus tries . The pr imary focus is on the potent ial for waste minimizat ion and waste ut i l izat ion to imp rove ene rgy e ff i c i ency . Areas e specially recommended for inc lus ion in s teel indus try re se arch and deve lopment programs are re finement and reuse o f s crap, inc luding phys ical s eparat ion, hydrome tal lurgical separat ion, and pyrome tal lurgical separation ; technique s for near-net-shape forming , such as e l ectromagnet ic casting , spray cas t ing , and twin ro l l cas t ing ; proce s s e s to produc e s te e l s low in ni trogen and carbon in an e lectric arc furnace to expand the us e of sc rap ; improved ins t rumentat ion and contro l procedure s to e l iminate de fects in cold-rolled and ho t-ro lled s l abs and shee t s ; cos t-e ffe c t ive techno logie s for the recove ry of energy in was te stre ams ; and low-c o s t , high-temperature me tal l ic and ce ramic mater ials for use in recuperators . The pe trochemical indus try already fol l ows ene rgy-cons erving prac t ic e s to a h i gh de gree ; however, a c r i t i cal problem o f the indus try invo lve s the treatment and disposal of hazardous was te s . S ince inc inerat ion i s the preferred me thod of dispos al, and s ince the disposal of hazardous was tes i s an impor tant prob lem fac ing the nat ion as a who le, fur ther re s earch on the s c ience base unde rly ing the inc inerat ion proce s s is recommended . iii

COMMITTEE ON INDUSTRIAL ENERGY CONSERVATION Cha i rman David L . Morr i s on , Pres ident , liT Re search Institute, Ch icago , I l l ino i s Members Har r i s M . Burte , Ch ief S c ient i st , Air Force Mate rials Laboratory , Wr ight­ Patterson Air Force Base , Ohio Richard Fruehan, Profe s s or, Department o f Me tal lurgical Engineer ing , Carnegie - Me l lon Univers ity , P i t tsburgh , Pennsylvania Noe l J arrett , Technical D irector , Alcoa Laborator ies, Alcoa Center , Pennsylvania Fr itz Kalhammer , Vice Pre s ident , Management and Ut i l izat ion D iv i s ion , Electr i c Powe r Res earch Institute , Palo Alto , Cal i fornia Allen M . Ko l e ff , D irector , Energy and Environmental Techno logy , S tone Conta iner Corporat ion , Atlanta , Georgia Ado lph J . Lena, Execut ive Vice Pre s i dent , Carp enter Techno logy , Reading , Pennsylvania Robert B . Ros enberg , Senior Vice Pre s i dent, Gas Res earch Institute , Ch icago, I l l ino i s David K . Snediker, Manager, Energy and Chemical Proce s s ing Depar tment , Batte l l e Co lumbus Laboratories , Co lumbus , Ohio Jul ian Szeke ly, Pro fe s s or, Materials Engineer ing , Mas s achus etts Inst i tute of Techno logy , Cambridge, Mas s achusetts Roger L . Wh i te ly , Emmaus, Pennsylvania v

Technical Advisor Byron Brown , Engineer ing Depar tment , E . I . Dupont deNemours and Company , W i lmington , Delaware Liaison Representat ive W i l l iam B . W i l l iams, Director , Office o f Industrial Programs, Cons e rvat ion and Renewab le Ene rgy , Department o f Energy, Wash ington, D . C . Donald G . Grove s, Staff Sc ient i st M . Cathryn Summ e rs, Senior Secre tary vi

EXECUTIVE SUMHARY The Office o f Indus trial Programs ( O I P ) in the U . S . Depar tment o f Energy i s charged with evaluat ing new and ex i s t ing techno logies, economic e l ements , and legis lated direc t ives that could enc ourage or enhance energy cons e rvat ion in the industrial sector o f the economy . To carry out thi s charge , O I P has funded a var iety o f projects and s tudie s . The Nat ional Re s e arch Counc i l ' s Commi ttee on Industr ial Ene rgy Conservat ion has, at the reque st o f the Depar tment, assessed var ious parts o f OI P ' s ac t ivi t ie s , including tho se for spec ific indus trial segments as we l l as the overall program . Th i s report i s directed at ene rgy conservat ion opportunit i e s in the s te e l and pe trochemical indus tr ies . Bo th o f the se industr ies consume large amounts of ene rgy, and the comm i ttee examined the potent ial of was te recyc l ing and was te reduc t ion in improving the i r ene rgy e ffic iency . The s te e l indus try i s an important s egment of the U . S . e conomy . It i s b e s e t b y a wide range o f s tre s s e s , from changing techno logies to reduc­ tions iri demand to fore ign compet i t ion . S avings in energy consumpt ion could be an important fac tor in revital iz ing the indus try, but better ut i l izat ion o f energy would not by its e l f be enough to increase its internat ional comp e t i t ivene s s . The comm i ttee reviewed industry trends and prac t ices and exp lored four areas that could lead to reduc ed energy consump t ion: recove ry of was te energy ; proc e s s improvements to increase yield and decrease me tal l ic waste s ; increased recyc l ing o f s crap ; and improved p o l luti on-abatement technique s . Revo lut ionary advance s in thes e areas are not ant i c ipated, but incremental advanc e s could s t i l l provide s igni ficant improvements in energy u t i l izat ion . A reduc t ion o f more than 0.3 quad o f energy is po s s ible ( out o f the present 1 . 7 quads consumed annual ly by the indus try) i f the techno logical imp rovements ident i fied here are pursued . The committee spe c i fical ly recommends that O I P cons ider the fo l l owing areas for inc lus i on in its research and deve lopment programs: refinement and reuse of scrap, inc luding research on phys ical separat ion, hydro­ me tal lurgical s eparat ion, pyrome tallurgical s eparat ion, and the e ffects 1

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