Thermodynamic models for iron and steel manufacturing system are established to analyze the equilibriums of mass and energy and the characteristics of energy consumption. Based on the analysis of theoretical and practical energy consumptions, energy-saving potentials of the processes are obtained. Thermo-analysis software for iron-making process is developed and used to investigate the theoretical mechanisms and practical effects of some focused energy-saving technologies. For steel-making section, thermodynamic models of hot metal pretreatment, converter steel-making, secondary refining, and ladle transporting are established to simulate temperature and composition of liquid metal. Energy-saving measures are summarized by analyzing the effects of the operating parameters on energy-consuming process in the section. An integrated scheduling model of slab hot rolling section is established, which concerns the processes of slab transmitting, slab heating, and hot rolling. Production scheduling software and furnace control system are developed. As a result of practical application, the number of rolling units and energy consumption of reheating furnaces are minimized through the systematic optimization. Based on the physical model of dynamic ordered production, simulation platform of production and network model of energy flow are developed for iron and steel manufacturing system. The optimal operating parameters and energy distribution scheme of the main processes are obtained by using the platform and the model. Copyright (c) 2013 John Wiley & Sons, Ltd.