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World Best Practice Energy Intensity Values for Selected Industrial Sectors LBNL-62806
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EV
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World Best Practice Energy
Intensity Values for Selected
Industrial Sectors




Ernst Worrell, Lynn Price, Maarten Neelis,
Christina Galitsky, Zhou Nan


Environmental Energy
Technologies Division






February 2008








This work was supported by the China Sustainable Energy Program of the Energy
Foundation through the U.S. Department of Energy under Contract No. DE-AC02-
05CH11231.
E
RNEST
O
RLANDO
L
AWRENCE

B
ERKELEY
N
ATIONAL
L
ABORATORY




Disclaimer

This document was prepared as an account of work sponsored by the United States
Government. While this document is believed to contain correct information, neither
the United States Government nor any agency thereof, nor The Regents of the
University of California, nor any of their employees, makes any warranty, express or
implied, or assumes any legal responsibility for the accuracy, completeness, or
usefulness of any information, apparatus, product, or process disclosed, or represents
that its use would not infringe privately owned rights. Reference herein to any specific
commercial product, process, or service by its trade name, trademark, manufacturer, or
otherwise, does not necessarily constitute or imply its endorsement, recommendation,
or favoring by the United States Government or any agency thereof, or The Regents of
the University of California. The views and opinions of authors expressed herein do
not necessarily state or reflect those of the United States Government or any agency
thereof, or The Regents of the University of California.

Ernest Orlando Lawrence Berkeley National Laboratory is an equal
opportunity employer.


Abstract

World best practice energy intensity values, representing the most energy-efficient
processes that are in commercial use in at least one location worldwide, are provided for
the production of iron and steel, aluminium, cement, pulp and paper, ammonia, and
ethylene. Energy intensity is expressed in energy use per physical unit of output for each
of these commodities; most commonly these are expressed in metric tonnes (t). The
energy intensity values are provided by major energy-consuming processes for each
industrial sector to allow comparisons at the process level. Energy values are provided for
final energy, defined as the energy used at the production facility as well as for primary
energy, defined as the energy used at the production facility as well as the energy used to
produce the electricity consumed at the facility. The best practice figures for energy
consumption provided in this report should be considered as indicative, as these may
depend strongly on the material inputs.

Key words: energy intensity, industry, steel, aluminium, cement, paper, ammonia,
ethylene

Table of Contents

1. Introduction... 1

2. World Best Practice Energy Intensity Values.. 5
2.1 . Iron and Steel.. 5
2.1.1 Blast Furnace Basic Oxygen Furnace Route. 6
2.1.2 Smelt Reduction Basic Oxygen Furnace... 10
2.1.3 Direct Reduced Iron Electric Arc Furnace 13
2.1.4 Electric Arc Furnace. 15
2.1.5 Casting.. 16
2.1.6 Rolling and Finishing 17
2.2 . Aluminium18
2.2.1 Alumina Production.. 19
2.2.2 Anode Manufacture.. 19

2.2.3 Aluminium Smelting (Electrolysis).. 20
2.2.4 Ingot Casting. 20
2.2.5 Secondary Aluminium Production 21
2.3 . Cement. 22
2.3.1 Raw Materials and Fuel Preparation. 22
2.3.2 Clinker Production 29
2.3.3 Additive Preparation. 29
2.3.4 Cement grinding.

29
2.3.5 Other Production Energy.. 30
2.4 . Pulp and Paper. 31
2.4.1 Non-Wood Pulping32
2.4.2 Kraft Pulping 35
2.4.3 Sulfite Pulping.. 35
2.4.4 Mechanical Pulping.. 35
2.4.5 Fiber Recovery. 36
2.4.6 Papermaking. 36
2.4.7 Integrated Pulp and Paper Mills 36
2.5 . Ammonia..38
2.5.1 Natural Gas Steam Reforming.. 38
2.5.2 Coal... 39
2.6 . Ethylene... 40

2.6.1 Naphtha and Ethane . 40
2.6.2 Other Feedstocks and Emerging Technologies.43

3. Summary and Next Steps..... 44

4. Acknowledgments.44


1
1. Introduction

This report provides information on world best practice energy intensity values for
production of iron and steel, aluminium, cement, pulp and paper, ammonia, and ethylene.
World best practice values represent the most energy-efficient processes that are in
commercial use in at least one location worldwide.
1


These values are expressed in energy use per physical unit of output for each of these
commodities; most commonly these are expressed in metric tonnes (t). Energy values are
provided in both syst�me international (SI) units (joules) and in kilograms of coal
equivalent (kgce), a common unit in China.
2


Energy values are provided for final energy, defined as the energy used at the production
facility as well as for primary energy, defined as the energy used at the production facility
as well as the energy used to produce the electricity consumed at the facility. For primary
energy values, the losses associated with conversion of fuels into electricity along with
the losses associated with transmission and distribution of the electricity are included. It
is assumed that these losses are 67%. The energy values referenced in the text of this
document are provided for final energy only; primary energy values can be found in the
tables.

Table 1.1 provides a summary of the world best practice final energy intensity values for
the sectors covered in this report. Table 1.2 provides a summary of the world best
practice primary energy intensity values. Details regarding the calculation of these values
and references are provided in the following sections.

1

While this report describes best practices in energy efficiency for key processes, the integration of these
individual technologies is key to obtain the full benefits of these technologies. For example, combined heat
and power would increase the efficiency of steam supply for the described processes, while by-product
energy flows may also be used more efficiently by implementing more efficient technologies (e.g. use of
blast-furnace gas in a combined cycle instead of a boiler).

2

In April 2006, Chinas central government launched the Top-1000 Enterprises Energy-Efficiency
Program (Top-1000 program), the goal of which is to improve industrial energy efficiency by targeting
Chinas 1000 highest energy-consuming enterprises. These enterprises currently account for approximately
50% of total industrial sector energy consumption and 30% of total energy consumption in China. During
the summer of 2006, energy-saving agreements with targets for 2010 were signed with all Top-1000
enterprises. The Top-1000 enterprises are from the iron and steel, petroleum and petrochemical, chemical,
non-ferrous metal, building materials, pulp and paper, electricity production, coal mining, and textile
industries. Chinese government officials have expressed a desire to understand how Chinese industrial
enterprises compare to international best practice.

2
Table 1.1. Summary of World Best Practice Final Energy Intensity Values for Selected
Industrial Sectors


Unit
GJ/t
kgce/t
Iron and Steel





Blast Furnace Basic Oxygen Furnace Thin Slab Casting
t steel
14.8
504.5

Smelt Reduction Basic Oxygen Furnace Thin Slab Casting
t steel
17.8
606.4

Direct Reduced Iron Electric Arc Furnace Thin Slab Casting
t steel
16.9
576.2

Scrap - Electric Arc Furnace Thin Slab Casting
t steel
2.6
87.5
Aluminium





Primary Aluminium
t aluminium
70.6
2411

Secondary Aluminium
t aluminium
2.5
85
Cement





Portland Cement
t cement
2.9
100

Fly Ash Cement
t cement
2.0
70

Blast Furnace Slag Cement
t cement
1.7
57
Pulp





Non-wood Market Pulp
air dried t
7.7
264

Wood Kraft Pulp
air dried t
11.1
380

Wood Sulfite Pulp
air dried t
18.5
632

Wood Thermo-mechanical Pulp
air dried t
6.6
224

Recovered Paper Pulp
air dried t
1.5
51
Paper





Uncoated Fine Paper
air dried t
9.0
307

Coated Fine Paper
air dried t
10.4
355

Newsprint
air dried t
7.2
244

Board
air dried t
9.6
327

Kraftliner
air dried t
7.8
267

Tissue
air dried t
10.5
358
Pulp and Paper





Bleached Uncoated Fine
air dried t
18.3
625

Krafliner (unbleached)/Bag Paper
air dried t
17.6
601

Bleached Coated Fine
air dried t
22.4
765

Bleached Uncoated Fine
air dried t
22.3
762

Newsprint
air dried t
6.