Activities of Japanese Steel Industry
to Combat Global Warming
Report of “JISF’s Commitment to a Low Carbon Society”
February 2018
The Japan Iron and Steel Federation

0.
1.
2.
3.
4.
5.

Index
FY2020 Targets (reexamined in FY 2016)
Eco Process
Eco Solution
Eco ProductPromotion of Environmentally Harmonized Steelmaking Process
Technology Development (COURSE50)
Reference1

On February 20, 2014, JISF became the first industry association in theworld to receive ISO50001 certification (energy management system).
This certification recognizes measures to combat global warming in the
Voluntary Action Plan/Commitment to a Low Carbon Society as well asactivities for conserving energy.

No. N001-ISO 50001
Initial registration:
Extension:

February 20, 2014
February 2, 20172

0. FY2020 Targets (reexamined in FY 2016)3

0. FY2020 Targets

Reexamination of Stance for Targets Established in FY2017
In FY2017, the following reexamination took place concerning the eco process target in the JISF’s
Commitment to a Low Carbon Society. An explanation of this reexamination was given at the steel working
group and the Keidanren third-party evaluation committee.

Eco Process Before reexamination
The target is a CO2 emission reduction of 5 million tons by FY2020 vs.
expected emissions for each production volume (BAU) by fully implementing
state-of-the-art technologies.
Interim- Review
1.

Properly determine BAU by reflecting changes in steel production mix

2.

Include actual emission reductions resulting from the use of waste plastics
and other recycled materials

Eco Process After reexamination
The target is a CO2 emission reduction of 5 million tons by FY2020 vs.
expected emissions for each production volume (BAU) by fully implementing
state-of-the-art technologies. Of this reduction, JISF prioritizes 3 million tonsof reduction arising from energy conservation and other voluntary actions bysteelmakers. For waste plastics and other recycled materials, the emission
reduction includes only a decrease resulting from the increase in the volumeof these materials collected vs. the FY2005 level.

40. FY2020 Targets

Reexamination of BAU by reflecting changes in steel production mix (1) Up to FY2014, the JISF’s Commitment to a Low Carbon Society used evaluations with a BAU line (left graph) incorporating theassumption that the FY2005 production mix will not change.
 Currently, changes are taking place in the production mix. For example, as Japanese steelmakers move production to Southeast
Asia and other overseas locations, the shift of some final production processes has raised the percentage of intermediate
products (such as hot-rolled sheets). Also, the percentages of some finished products (such as galvanized sheets) aredecreasing. Pig iron production has increased in proportion to these changes and CO 2 emissions are rising as a result.
 Incorporating these changes was not possible with the previous BAU line. Consequently, the change in CO2 associated with the
production mix change was calculated by using the production mix index produced by RITE (the RITE index). Starting in FY2015,
emissions have been evaluated by using the adjusted BAU line, which incorporates the BAU line.
When production mix change increases CO2
emissions

Used for FY2016

Assumes no change in production
mix from FY2005 level
2.2
Emissions target
目達後排出量2.0

Since FY2015
Adjusted to reflect production mix
change since FY2005

1.9

Emissions target
目達後排出量

粗鋼生産量
Crude steel production(100 million tons)

When production mix change reduces CO2
emissions

1.8

BAU排出量BAU emissions

1.6
0.90

0.95

1.00

1.05

1.10

1.15

1.20

1.25

1.30

1.35

Crude steel production(100 million tons)
粗鋼生産量（億ﾄﾝ）* This target assumes that Japan’s crude steel output will be 120 million tons,
with a variance of no more than 10 million tons.
* The colored sections of the graphs on this page show the range of production
at companies participating in the Commitment to a Low Carbon Society when
Japan’s crude steel output is between 110 million and 130 million tons.

Emissions target
目達後排出量

CO2排出量1.7

CO2 Emissions (100 million tons)

CO2排出量（億ﾄﾝ）

CO2 Emissions (100 million tons)

BAU排出量BAU emissions

2.1

BAU emissions
BAU排出量

CO2排出量BAU and Target Lines (before production mix index adjustment)

CO2 Emissions (100 million tons)

Until FY2014

粗鋼生産量(100 million tons)
Crude steel production

5

0. FY2020 Targets

Reexamination of BAU by reflecting changes in steel production mix (2)When determining the RITE index, the total change in CO2 emissions caused by a production mix change is evaluated by adding thechanges in emissions associated with a change in the pig iron ratio for upstream processes and a change in the product mix fordownstream processes.
The BAU line uses a production mix that remains the same as in FY2005. As a result, it is possible to perform a proper evaluation with
the BAU line in which the changes in the production mix are incorporated by shifting the line according to the changes.
Share of Long and Flat Products (Downstream processes)

Share of Pig Iron (Upstream processes)
2005

Crude steel (1000t)

2015

2016

16/05
(%)

16-05

83,64528,59582,937

BF-BOF (%)
EAF (%)
Pig Iron (%)

74.2
25.4
73.6

80,647 81,294 -2,352
23,263 23,545 -5,051
80,535 79,829 -3,107
77.4
22.3
77.3

77.3
22.4
75.9

16/15
(%)

937

0.9 Long Shape

-2.8
-17.7
-3.7

646
282
-705

Bar
0.8
total
1.2
-0.9 Flat Plate
HRS

-

-0
0
-1

112,718 104,229 105,166 -7,551

BF-BOF (1000t)
EAF(1000t)
Pig Iron (1000t)

16-15

-6.7

3.1
-3.0
2.3

-

2005

2015

2016

ratio (%)

ratio (%)

ratio (%)

7.5
12.3
23.5
11.3
11.3
8.6

6.8
9.9
20.0
10.4
19.7
7.8

6.8
9.8
19.8
10.2
19.3
7.9

-0.9
-2.5
-3.6
-1.1
8.0
-0.8

-0.2
-0.1
-0.2
-0.1
-0.3
0.1

14.6
46.3

12.3
50.7

12.5
50.5

-2.1
4.2

0.2
-0.2

Cold-rolled
flat products
Galvanized
sheet

total

16-05

15-15

 Between FY2005 and FY2016 the share of long products
decreased and the share of flat products increased.

 An increase of 2.3 percentage point in
pig iron’s share from FY2005 to
FY2016

 In flat products, HRS (hot-rolled strips) increased and coldrolled flat products and galvanized sheets decreased.

CO2 conversions using the RITE index toincorporate the above changes

Upstream:+3.370 mmtCO2

Downstream: -1.944 mmt-CO2

Total: +1.426 mmt-CO2

6

0. FY2020 Targets

Summary of the Upstream Process Index

Crude steel is made by reducing natural resources to make pig iron or by using steel scrap that has already been reduced. The
pig iron ratio is the amount of pig iron produced in relation to the production of crude steel (pig iron output divided by crude steel
output). Variations in this ratio also affect unit CO2 emissions.
To evaluate this effect properly, a primary coefficient is established that includes (1) comprehensive energy statistics, (2) IEA
energy balance table, (3) environmental reports of steelmakers, (4) international peer-reviewed papers and other items.
The number obtained by using this primary coefficient is the upstream process index. The formula is: y (Upstream index) = 1.419
x (Pig iron ratio) +0.70.
Changes in CO2 emissions caused by changes in the pig iron ratio are calculated multiplying the difference between the
upstream process index for FY2005 and each subsequent year by crude steel output.

Relationship between Pig Iron Ratioand Upstream Process Index
Upstream process index (tCO2/t crude steel)

Upstream process index=1.419*Pig iron ratio+0.70*※

Actual data (FY2005 and FY2016)

Actual data from
FY2005 to FY2016

0.70

Pig iron ratio

Upstreamprocess index

FY2005

0.736

1.743

・
・
・

・
・
・

・
・
・

FY2016

0.759

1.776

2.12

Pig iron ratio (t pig iron/t crude steel)* This equation incorporates (1) comprehensive
energy statistics, (2) IEA energy balance table, (3)environmental reports of steelmakers, (4)international peer-review papers and other items.

FY2005: 1.419×0.736+0.70=1.743
FY2016: 1.419×0.759+0.70=1.776
Change in CO2 emissions due to change in pig iron ratio(FY2016)(1.776-1.743)×101.95mnt = 3.37mnt⇒Assessed as a 3.37 million ton increase in CO2emissions70. FY2020 Targets

Summary of the Downstream Process Index

Unit CO2 emissions per ton of production* have been established for different shapes of ordinary steel and types of specialty steel, a total of 35 productcategories, for which general statistics are accessible. Using FY2005 as the reference year, the change in CO2 emissions caused by the change in the
production mix in each year is then calculated. This calculation is performed as follows.
A. The product mix ratio for each steel product in each year (Table 1) and unit CO 2 emissions (Table 2) are multiplied (Table 3).
B. All the numbers obtained from the step A are added (which yields a composite unit emission value weighted for the production mix): 0.846 in FY2005 and0.827 in FY2016 in the table below
C. Multiply the difference between the composite unit emission value for the year being evaluated and the reference year (FY2005), which is the composite
unit emission difference) and crude steel output (convert the unit difference into a total volume).
For FY2016: (0.827-0.846) x 101.95mnt = -1.94mnt*Unit CO2 emissions for each steel product category for all years are based on the worldsteel LCI data collection. Averages for Japan calculated by using actual FY2014 data
are used when available for these products. For products where there is no Japan average, unit emissions are estimated by using the relationship between unit emissions forsteel for which Japan averages exist and selling prices (FY2010 export prices using trade statistics).

Hot-rolled
stripsSteel bars

FY2005
Product mix
ratio (1)・・・FY2016

Unit CO2 emissions per ton of
production (2) (common figures)

FY2005(3) = (1) x (2)・・・FY2016

Cold-rolledsheetsGalvanizedsheets・・・・・・

Total

12.3%

9.9%

6.6%

12.0%

・
・
・

・
・
・

・
・
・

・
・
・

9.8%

16.9%

6.4%

9.8%

100%

0.73

0.67

0.71

0.96

－

0.09

0.07

0.05

0.11

0.846

・
・
・

・
・
・

・
・
・

・
・
・

0.07

0.11

0.05

0.09

A composite unit emission figure that reflects the product mix in each year

100%
・
・
・

・
・
・

・
・
・

・
・
・
0.827

8

0. FY2020 Targets

Include actual emission reductions resulting from the use of waste
plastics and other recycled materials• Assuming that the government establishes collection systems, JISF was aiming for a CO 2 emission reduction of 2 million tons
by increasing the use of chemical recycling (waste plastics, etc.) to 1 million tons at steel mills.
• The May 2016 Report on the Assessment and Study of Implementation of a Container and Packaging Recycling Systemestablished the policy of maintaining the 50% material recycling priority and the review resulted the goal of reaching this target
in five years.
• Due to the current level of recycling, achieving the FY2020 goal of increasing the use of used plastics and other recycledmaterials to 1 million tons will be almost impossible. Consequently, only the amount of the increase in the collection of waste
plastics and other recycled materials in relation to the FY2005 level is included in the reduction in CO 2 emissions.

(10,000t)

Use of Waste Plastics and Waste Tires

Unchanged from 2005

(FY)
Source: The Japan Iron and Steel Federation

90. FY2020 Targets

JISF’s Commitment to a Low Carbon Society - Phase I
Japanese steel industry is supporting the Commitment to a Low Carbon Society by fighting global warmingwith the “three ecos” created during the Voluntary Action Plan along with COURSE50.

2020←2013

Eco Process
The target is a CO2 emission reduction of 5 million tons by FY2020 vs. expected emissions for each production
volume (BAU) by fully implementing state-of-the-art technologies. Of this reduction, JISF prioritizes 3 million
tons of reduction arising from energy conservation and other voluntary actions by steelmakers. For waste
plastics and other recycled materials, the emission reduction includes only a decrease resulting from theincrease in the volume of these materials collected vs. the FY2005 level.

Eco Solution
Contribute worldwide by transferring the world’s most advanced energy-saving technologies toother countries (especially to developing countries)and increasing the use of these technologies.
(Estimated emission reduction contribution of about 70 million tons in FY2020)

Eco ProductBy supplying the high-performance steel that is essential to create a low-carbon society,contribute to lowering emissions when finished products using this steel are used
(Estimated emission reduction contribution of about 34 million tons in FY2020)

2050←

Development of revolutionary steelmaking processes (COURSE50)
Cut CO2 emissions from production processes about 30% by using hydrogen for iron ore
reduction and collecting CO2 from blast furnace gas. The first production unit is to begin
operations by about 2030*. Goal is widespread use of these processes by about 2050 in linewith timing of updates of existing blast furnace facilities.
* Assumes establishment of economic basis for CO2 storage infrastructure and creation of a practical unit using theseprocesses.

101. Eco Process111. Eco Process

FY2016 Results of JISF’s Commitment to a Low Carbon Society

Progress toward targets *Totals for companies participating in the Commitment to a Low Carbon Society•

Crude steel production: 101.95 million tons (down 5.7% from FY05)•

BAU emissions for FY16 crude steel production: 182.06 million tons of CO2 - (1)•CO2 emissions (using FY05 electricity coefficient): 179.60 million tons (down 4.7% from FY05) - (2)•Reduction vs. BAU ((1) – (2)): 2.46 million tons of CO2 (540,000 tons above the target)

FY2016 Energy Consumption and CO2 Emissions••

Energy consumption: 2,172PJ (down 5.1% from FY05)
CO2 emissions (using electricity coefficient with FY16 credit): 182.57 million tons (down 3.1%
from FY05)

Reference: Japanese steel industry total•••

Crude steel production: 105.17 million tons (down 4.7% from FY05)
Energy consumption: 2,241PJ (down 5.1% from FY05)
CO2 emissions (using electricity coefficient with FY16 credit): 186.75 million tons (down 3.0%
from FY05)* Energy consumption and CO2 emissions for the Japanese steel industry are estimates based on statistics for the use of
petroleum and other energy sources.

121. Eco Process

Annual Trend of Energy Consumption and CO2 Emissions
Unit Energy Consumption
エネルギー原単位（1990年度基点）(FY1990 level=100)

Total エネルギー消費量
Energy Consumption(FY)
Crude steel(million ton)

(FY)

Unit CO2 Emissions
CO2原単位（1990年度基点）(FY1990 level=100)（毎年度のクレジット反映後の電力係数を反映）

CO2 Emissions
from Fuel
Combustion
エネルギー起源CO
2排出量(Incorporate
improvement by emission credit)（毎年度のクレジット反映後の電力係数を反映）(Incorporate improvement by emission credit)

Mt-CO2(FY)(FY)
Crude steel(million ton)
*PJ is a petajoule (1015 joules). One joule is 0.23889 calories. 1PJ is equivalent to about 2.58 million kiloliters of crude oil.

13

1. Eco Process

Components of Changes in FY2016 CO2 Emissions••

In FY2016, CO2 emissions were 2.46 million tons below the BAU level. Energy and CO2
conservation measures cut emissions by 2.44 million tons, aging bricks in coke ovens raisedemissions by 1.11 million tons, and other measures cut emissions by 1.13 million tons.
0.54 million tons below the target.

(Mt-CO2)190

VS. BAU emissions-2.46Mt-CO2

185

VS. Target+0.54Mt-CO2
1.11
1.43*1

2.44
1.13

180

182.06175

170

179.60 *2

BAUemissionsAgingcoke ovenbricksEnergy/ CO2
conservation

OthersFY16
emissions*1 182.06 Mt-CO2 BAU emissions have been adjusted by 1.43 Mt-CO2 using RITE index.
*2 FY2016 CO2 emissions use the FY2005 electricity coefficient.

179.06

Target based on FY15
production volume

14

1. Eco Process

Evaluation of FY2016 Performance Despite a number of factors unforeseen when targets were established, the emissions
continued to decrease steadily in FY2016 as numerous voluntary actions took effect.
1. Progress with measures incorporated in the target(1) Reductions from energy
saving actions

Expectedtarget

FY2016-3.00Mt-2.44Mt• Progress of about 80% toward the target between FY05-FY16 (12 years)－

0.00Mt• Reported as zero since the volume collected in 2016 remained unchanged
compared to 2005.

 Higher coke oven efficiency
 More efficient power
generation
 More energy conservation(2) Increase use of waste
plastics and other recycledmaterials

2. Factors affecting emissions that were unforeseen when targets were established
Expectedtarget

FY2016

Aging coke oven bricks－+1.11Mt• Aging coke oven bricks caused unit energy consumption to climb. Probablecauses are the aging of bricks (especially significant in ovens above acertain age) and the impact of the Tohoku earthquake and tsunami of 2011.
• JISF member companies have started replacing coke oven bricks.

Other issues－-1.13Mt• Difficult to analyze causes, but one probable cause is efforts by operational
improvement in steel mills.

Not included-0.02Mt

Total

VS. adjusted BAU emissions: 2.46 Mt (0.54Mt below the target)15

1. Eco Process

Coke Oven Updates•

JISF member companies have started replacing aging bricks in coke ovens, which is one
cause of the increase in CO2 emissions. Improvements at six coke ovens were alreadycompleted during Phase I of the Commitment to a Low Carbon Society.

•As shown below, although work has started, it will not be possible to update all coke ovens
quickly because of the limited availability of workers (coke oven construction specialists)
and the high cost of updates (tens of billions of yen for each oven).

JISF Member Company Coke Oven Update Plans (Company and newspaper announcements as of February 2018)(1) Completed Updating Projects (6 ovens as of Feb. ’18)

(2) Planned Updating Projects (6 ovens as of Feb. ’18)

Year

Steel works

Cost

Year

Steel works

Cost

FY2013

JFE Steel, West Japan Works,
Kurashiki

About ¥15
billion

FY2018

Nippon Steel & Sumitomo Metal,
Kashima Works

About ¥31
billion

FY2015

JFE Steel, West Japan Works,
Kurashiki

About ¥20
billionNippon Steel & Sumitomo Metal,
Kimitsu Works

About ¥33
billion

FY2016

Nippon Steel & Sumitomo Metal,
Kashima Works

About ¥18
billionJFE Steel, East Japan Works,
Chiba

JFE Steel, East Japan Works,
Chiba

FY2017FY2019Nippon Steel & Sumitomo Metal,
Kimitsu Works

About ¥29
billionJFE Steel, West Japan Works,
Kurashiki

About ¥18.4
billionNippon Steel & Sumitomo Metal,
Muroran WorksJFE Steel, West Japan Works,
Fukuyama

FY2021JFE Steel, West Japan Works,
Fukuyama

About ¥13
billion
About ¥27
billion16

1. Eco Process

Major Initiatives implemented or planned since FY2005
1. Next-generation coke oven (SCOPE21)

2. More efficient power

Nippon Steel & Sumitomo Metal Oita Works(2008)

Kobe Steel Kakogawa Station No. 1
Gas turbine combined cycle unit (2011)

Nippon Steel & Sumitomo Metal Nagoya Works(2013)

Kimitsu Joint Thermal Station No. 6
Advanced combined cycle unit (2012)
Kashima Joint Thermal Station No. 5
Advanced combined cycle unit (2013)
Wakayama Joint Thermal Station No. 1
Advanced combined cycle unit (2014)

Advanced Combined Cycle
Power Generation

Oita Joint Thermal Station No. 3
Advanced combined cycle unit (2015)
Kobe Steel Kakogawa Station No. 2
Gas turbine combined cycle unit (2015)
JFE Steel Chiba Station West-No. 4
Gas turbine combined cycle unit (2015)
Nisshin Steel Kure Power Station No. 6
Boiler, turbine and generator (planned for 2017)
JFE Steel Ohgishima Thermal Station No. 1
Gas turbine combined cycle (planned for 2019)
Fukuyama Joint Thermal Station No. 2
Gas turbine combined cycle (planned for 2020,
assessment under way)

Source: Kimitsu Cooperative Thermal Power Company, Inc.

17

1. Eco Process

Energy Conservation in Electric Arc Furnace (EAF) As part of measures to streamline steel production, Daido Steel constructed and began operating in November 2013 a large
EAF at its Chita Plant with technologies to achieve the highest possible uniformity of scrap melting. The new furnace raised
capacity from 70 to 150 tons.
 Three-phase AC EAFs normally require three electrodes. Melting can be uneven due to differences in how far each electrodeis from the furnace wall. To solve this problem, most companies place an auxiliary burner in locations far from electrodes(cold spots).
 Although burners improve melting performance, unit energy consumption is higher and flame rebound damages the furnace,
which boosts maintenance expenses. Daido developed a rotating EAF that uses the spinning motion to move cold spots
closer to the electrodes. This dramatically improves melting uniformity and cuts the amount of energy required.

EAF Problems

Rotating Furnace Technology• Triangular configuration of three electrodes ina round furnace results in different electrodewall distances• Materials near electrodes (hot spots) melt
before materials farther from electrodes (coldspots). This causes a big energy loss in hot
spots if the furnace continues to operate.

• Maximum furnace rotating angle is 50°

Melting time in conventional 70-ton
EAF
Hot spot
Cold spot (materials
ホットスポット
コールドスポット(exposed to
not yet melted))(原料溶け残り)(炉壁の露出)furnace wall)

With scrap
materials inside

A typical rotating EAF
Meltingｺｰﾙﾄﾞｽﾎﾟｯﾄ
Cold spot

Benefits of the Rotating EAF

After furnace
rotation• Lower EAF unit energy consumption (including
benefit of the larger furnace volume)• In addition to EAF improvements, Daido Steel’s
improvements shortened processing time bycreating a separate ladle transport line, greatly
reduced variations in steel quality, and lowered thetemperature required by the ladle refining furnace.
• Overall, Daido Steel cut unit energy consumption by
about 15%.
Energy Saving Due to Streamlined
Continuous Casting Line*
100 = Energy used byconventional CC line

A rotating electric arc furnace

Ladle refining
furnace andother steps

Electrode
電極位置

EAF

Before improvements

Source: Daido SteelAfter improvements* Continuous casting covers all steps from the EAF
through casting.

18

1. Eco Process

Use of Waste Plastics and Other Recycled Materials
 JISF’s commitment to a Low Carbon Society has the goal of raising the use of waste plastics and otherrecycled materials to 1 million tons, assuming the government establishes the necessary collection
infrastructure. However, collections totaled 450,000 tons in FY2016, unchanged from FY2005 collections ofrecycled materials.
 A great amount of CO2 emission reduction is possible by reexamining associated policies for the use of waste
plastics and other materials. At government councils and other opportunities, JISF constantly ask for reviewsof the current recycling system and revisions as soon as possible.

(10,000t)

Use of Waste Plastics and Waste Tires

Unchanged from 2005

(FY)
Source: The Japan Iron and Steel Federation

19

1. Eco Process

Japan’s steel industry (BF-BOF) maintains the world’s highest energy efficiency
 The Research Institute of Innovative Technology for the Earth (RITE) issued an report in January
2018 on international comparison of energy efficiency level in steel industry (BF-BOF*). The report
revealed that Japan maintains the world’s highest energy efficiency in 2015, as in 2005 and 2010.
*A RITE survey is now under way for the energy efficiency of EAF steelmakers in 2015. Japan was first in 2005 and 2010.

Estimate of Steel Industry (BF-BOF) Energy Efficiency(2015, Japan=100)
Japan has the world’s highest
energy efficiency.

Why is Japan’s steel
industry the mostefficient?
• The penetration rate ofenergy-saving
technologies is very highin Japan’s steel industry.
• All steelmakers areworking on achieving thegoals of the JISF’s
Commitment to Low
Carbon Society andsharing best-practiceknowledge among
themselves.

In addition to actions in Japan, increasing the use of energy-saving measures and technologies
worldwide will be an effective way to further lower CO2 emissions in the steel industry.
20

2. Eco Solution21

2. Eco Solution

Eco Solution: CO2 Emission Reduction from Increasing Use of Technologies••

There is much potential for increasing the use of major energy conservation technologies in China, which
accounts for almost half of global crude steel production, and India, where steel production is expected tocontinue to grow.
Major energy conservation technologies developed and used in the Japanese steel industry are alreadylowering CO2 emissions overseas as Japanese companies provide these technologies to other countries.
CDQ, TRT and other major types of equipment alone are already lowering annual aggregate CO2 emissionsin China, Korea, India, Russia, Ukraine, Brazil and other countries by approximately 6.0 million tons.

Utilization Rates of Major Energy Conservation Equipment
by Blast Furnace Steelmakers
Japan

China (only large andmidsize companies)

India

Emission Reductions in Other Countries from Japanese
Energy-conserving Equipment (FY2016)(Mt/year)No. of units

Continuous
casting

Coke oven gas
recoveryLD convertergas recovery

Top pressure
Coke dryrecovery turbine
quenching (CDQ)(TRT)

Reduction

Coke dry quenching (CDQ)

96

18.16

Top-pressure recovery turbines (TRT)

62

11.02

Byproduct gas combustion (GTCC)

52

21.18

Basic oxygen furnace OG gas recovery

21

7.92

Basic oxygen furnace sensible heat recovery

7

0.85

Sintering exhaust heat recovery

6

0.88

Total emission reduction

60.01Mt

CDQ：Coke Dry Quenching
TRT：Top Pressure Recovery Turbines
GTCC：Gas Turbine Combined Cycle system

Ref: Total emission reduction in FY2015 was 54.58Mt - CO2/year

Note: Continuous casting figures for all three countries include blast furnace and EAF steelmakers (Total continuous casting production/Total crude steel
production in 2013). For other equipment, figures are for FY2014 in Japan, 20134for coke oven gas recovery and LD converter gas recovery and 2010
for CDQ and TRT in China, and 2000 for all other categories in India.
Sources
Japan: JISF
China: Coke oven/LD converter gas recovery = China Iron and Steel Association; CDQ = Metallurgy report (Nov. 27, 2012); TRT = Wang Wei Xing (China
Metallurgy Association, Information on Major Steel Companies in 2010, World Metals Report (March 8, 2011)
India: Steel edition of Diffusion of energy efficient technologies and CO2 emission reductions in iron and steel sector (Oda etal. Energy Economics, Vol. 29,
No. 4, pp 868-888, 2007)22

1-2. 低炭素社会実行計画フェーズⅠ(2013~2020年)

2. Eco Solution

International cooperation to support Eco Solution
2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

Japan-China Steel Industry Environmental Protection
and Energy Conservation Technology Conference (2005~)
The Public and private collaborative meeting between Indian andJapanese Iron and Steel Industry (2011~)

Bilateral
Activities

ASEAN-Japan
Steel Initiative (2014~)

Multilateral
Activities

APP Steel TF(2006~2010)

GSEP Steel WG(2010~2015)

APP: Asia Pacific Partnership

GSEP: Global Superior Energy Performance
Partnership

ENCO (~2009)

EPCO (2010~2013)

ECO (2014~)

Environment Committee

Environmental Policy Committee

Environment Committee“CO2 Breakthrough Program”：Participating with COURSE50 (2003~)

CO2 data collection (2007~)Development of ISO14404* (2009~)

worldsteel etc.

Versions for integrated steel plants and EAF issued in 2013, version for DRI-EAF in 2017
*International standard for the calculation of CO2 emission from steel plants23

3. Eco Product24

3. Eco ProductEco Product: Japanese Industrial Products that Conserve Energy and Cut CO2 Emissions•

Japanese manufacturers have taken the lead in developing and commercializing many highly efficient industrial
products. Examples include fuel-efficient automobiles and highly efficient power generation equipment andtransformers. These products have made a big contribution to conserving energy and cutting CO2 emissions inJapan and worldwide.

•

The Japanese steel industry has established a close relationship with these manufacturers by developing andsupplying steel that has a variety of characteristics. This high-performance steel is a vital to achieving theoutstanding functions of advanced products and has earned a reputation for reliability among manufacturers.
Airplane components
Strong and durable jet engine shafts further
boost maximum thrust = Longer range, better
fuel efficiency

Motors for hybrid/electric cars
High-efficiency non-oriented electrical
sheets for higher fuel efficiency, more
power, smaller size and lower weightAutomotive and industrial machinery
parts
Strong gear steel increases gears and reduces
size and weight – higher fuel efficiency

Boiler tubes
Steel tubes that resist high temperatures andcorrosion make power generation more efficientSuspension springs
Higher strength steel forvalve and suspension
springs used in punishing
applications makes
vehicles lighter and lowers
fuel consumption

Generator parts
Steel for high-efficiency power plantturbines can withstand hightemperatures and high rotation speeds

253. Eco ProductEco Product Contribution: Quantitative Evaluations – Contributions of Major High-performance Steel Products••

To establish a method to determine the quantitative contribution of high-performance steel, JISF establishedin FY2001 a committee with the participation of associations of steel-consuming industries, The Institute ofEnergy Economics, Japan and the Japanese government. The committee has been monitoring contributions
every year since then.
Statistics are for the five major types of high-performance steel for which quantitative data are available(FY2016 production of 7.36 million tons, 6.9% of Japan’s total crude steel output). The use of finishedproducts made of high-performance steel cut FY2016 CO2 emissions by 9.83 million tons for steel used inJapan and 18.64 million tons for exported steel, a total of 28.47 million tons of CO2.

CO2 Emission Reductions by the five major types of high-performance steel (FY2016)
1. Domestic

2. Export

Transformers

Transformers
CO2 reduction

Trains9.83 Mt-CO2

CO2 reduction

Ships

Automobiles

Ships

18.64 Mt-CO2

Automobiles

Power generation
boilers

CO2 Emission Reductions: 28.47 million tons CO2 in total(7.36 million tons of high-performance steel)Power generation
boilers
Ref:
CO2 Emission Reductions: 27.51 million tons
CO2 by the end of FY2015(7.24 million tons of high-performance steel)Source: The Institute of Energy Economics, Japan*The five categories are automotive sheets, oriented electrical sheets, heavy plates for shipbuilding, boiler tubes and stainless steel sheets. In FY2016, use of the five categories of steel products in Japan was 3.79 million tons andexports were 3.57 million tons for a total of 7.36 million tons.
*Assessments in Japan started in FY1990 and for exports assessments started in FY2003 for automobiles and shipbuilding, in FY1998 for boiler tubes, and in FY1996 for electrical sheets.

26

4. Promotion of Environmentally
Harmonized Steelmaking
Process Technology
Development (COURSE50)

27

4. COURSE50

Development of Environmentally Responsible Steelmaking Processes (COURSE50)

Less coke is needed

Coke

Absorption
tower

Coke ovenBlast
furnace
Strong and highly reactive coke

Hydrogen

Iron orepreliminary
reductiontechnology(a separate
project)• Chemical absorption method• Physical adsorption method

Blastfurnace gas

Hydrogen production (COG modification)technology for hydrogen reduction

Hydrogen

Blast furnace hydrogen
reduction technology

Cool air2010(2008～12）

Kalina cycle
power generation,
etc.

2020

Comprehensive
Basic technology
technology development
development
Phase 1,Step2
Step 2Phase
1, Step1
ﾌｪｰｽﾞ1
Step1
ﾌｪｰｽﾞ1(2013～17）

SteamElectricity
Pig iron

Technology for effective use ofunused exhaust heat

Development schedule

Developmentof practical
実用化開発
use
ﾌｪｰｽﾞ2Phase 22030

Reboiler

CO2 separation andstorage technology

Slag sensible heat recovery technology (one example) Exhaust heat recovery boiler
Hot air
Slag

Regeneration
tower

Hydrogen reduction cokeproduction technology

Hydrogenamplification
COG
modification unit

Shaft oven, etc.

Iron ore

CO2 storage technology

Project summary
Work is under way on developing a technology for using hydrogen for the reduction of iron ore (method for lowering
blast furnace CO2 emissions). Hydrogen in the very hot coke oven gas (COG) generated during coke production is
amplified and then used to replace some of the coke. Furthermore, for the separation of CO2 from blast furnace gas(BFG), a revolutionary CO2 separation and collection technology (technology for separating and collecting CO2 fromblast furnaces) will be developed that utilizes unused heat at steel mills. The goal is to use these technologies for lowcarbon steelmaking that cuts CO2 emissions by about 30%. (a project for NEDO)

2040

2050年

Actualuse* and increase in use
実用化※・普及
All blast furnaces are to be switched to this technology by 2050 as
blast furnace facilities are updated and replaced.

* assumptions are that an international equal footing isestablished and the necessary social infrastructure is created,
including the site selection and establishment of a storage
facility for government-led carbon capture and sequestration
programs. Targets will be reexamined if these conditions are
not fulfilled.

28

5. Reference29Eco Solution: ISO50001 Certification•••

5. Reference – Eco Solution

ISO50001 is an international standard for energy management systems that was issuedin June 2011.
On February 20, 2014, JISF became the first industrial association in the world to receive
ISO50001 certification, the result of global warming and energy conservation measuresassociated with the voluntary action plan and the Commitment to a Low Carbon Society.
This certification is proof that the voluntary actions of the steel industry are sufficiently
transparent, reliable and effective in relation to the requirements of international
standards.

JISF Energy Management
SystemJISF establishes the highest
possible goals based on available
technologies

Member companies take actions
for conserving energy and cutting
CO2 emissions based on JISF
targets

Suitability of the plan is confirmed by providing
explanations during the target establishment
process to the government advisory council andthe Keidanren third-party evaluation committee.

JISF checks progress by receiving reports fromcompany presidents at its Executive Board
Meeting

The plan is revised as needed
based on assessments andinstructions from the government
advisory council (steel working
group) and Keidanren third-party
evaluation committee

Performance is evaluated every
year by a government advisory
council (steel working group) and
Keidanren third-party evaluationcommittee

ISO50001 Certificate

30

5. Reference – Eco Process

Effective Use of Waste Plastics (Containers and Packaging Recycling)•

Due to priority on recycling materials, purchased 260,000 tons of waste plastics in FY2016 under thecontainer and packaging recycling system; current waste plastic processing capacity in the steel industry
is about 400,000 tons, leaving significant unused capacity (utilization rate is slightly over 60%)
A review of policies can produce a big drop in CO2 emissions through the effective use of waste plastics,
etc. JISF hopes to see a quick reexamination of recycling systems from the following standpoints.
(1)

From the standpoint of efficiently and effectively using waste materials (recycling waste materials that are highly effective at cutting CO2 emissions
and have a low social cost), the container and packaging recycling system should stop placing priority on recycling materials that produce only
small reductions in CO2 emissions.
A payment system should be considered to provide incentives to local governments that cut costs below a certain level or make big improvements;
this would lower the social cost of recycling by encouraging local governments to improve efficiency of collecting and storing waste materials inseparate categories
Collection of waste materials should not be restricted to items covered by the Container and Packaging Recycling Law; collecting product plastic
waste and other materials too could reduce the need for consumers to discard trash by category and reduce the trash classification expenses for
local governments. The government should thus consider enlarging recycling activities to include more types of materials.

(2)

(3)

Volume Purchased and Unit Price by Method for Recycling
Container and Packaging Plastics

Materials Received, Products Sold and Reuse Ratio by Method (FY2016)
400

100%

市町村からの引取量
再商品化製品販売量(1,000ｔ)

350

85%

300
250

200

80%

60%
49%
40%

150
100

(t)

引取量：ﾏﾃﾘｱﾙﾘｻｲｸﾙ＞ｹﾐｶﾙﾘｻｲｸﾙ

再資源化率

•

20%

50
0

0%
マテリアルリサイクル

ケミカルリサイクル（高炉･ｺｰｸｽ炉）

Source: The Japan Containers and Packaging Recycling Association

FY2000 01 02

03

04

05

06

07

08

09

10

11

12 13

14

15

FY16 unit purchase price for recycled materials
was ¥51,000/ton and ¥41,000/ton for chemicals

1631

5. Reference – Eco Process

Investments for Environmental Protection and Energy Conservation••

Japanese steel industry made investments of about ¥3 trillion between FY1971 and FY1989
for environmental protection and energy conservation. These investments totaled about ¥1.8
trillion between FY1990 and FY2012.
Investments for rationalization and labor-saving totaled about ¥1.6 trillion between FY2005
and FY2016.
(¥100million)

Cut energy use by 20%¥3 trillion from FY1971 to FY1989

Fig.
Accumulative
investment forenvironmental
facilities since
FY1971

Cut energy use by 10%¥1.8 trillion from FY1990 to FY2012

Data available
until FY2012(FY)

Source: ~FY2011: METI Survey on Capital Investments of Major Industries, FY2002~: METI Survey on Corporate Finance (former Survey on Capital Investments)(¥100million)

Fig.
Accumulative
investment for
rationalizationand laborsaving since
FY1999

Data available
since FY1999(FY)

Source: Development Bank of Japan Inc

32

5. Reference – Eco Process

Energy Conservation Initiatives of the Steel Industry
’70s

’80s

1) Process innovations

Continuous casting,continuous annealing, etc.

Hot charge rolling, automatedcombustion control, etc.

2) Recovery and efficient use of
byproduct gases
3) Exhaust heat recovery

Blast furnace coal powder input, coalmoisture control, etc.

SCOPE-21

Artificial intelligence, supply chain network, etc.

Constant
improvements

Gas holder, high-efficiency gas turbine combined cycle generation, etc.

TRT, (CDQ), etc.

Regenerative burners, etc.

Waste plastics and tires,
biomass

Hydrogenamplification, CO2
recoveryRecovery of mid/lowtemp. exhaust heat

Gasification, etc.

Net consumption4) Use of waste materials

Process
innovations
Process
improvements

Recovered

Total energy consumption

’10s

’00s

COURSE-50
Ferro-coke

Process
improvements’90s

Byproduct gas
use
Exhaust heatrecovery

‘73

‘80

‘90

‘00

‘10

Waste materialuse

33

5. Reference – Eco Process

International Comparison of Energy Efficiency in the Steel Industry•

According to the IEA, Japan has world’s smallest potential for energy conservation per ton of
crude steel. According to RITE, Japan has the world’s most energy efficiency steel industry.
These figures demonstrate that virtually all steel mills in Japan use existing technologies andthat there is very little potential for further energy-conservation measures.

Energy Saving
Potential fromTransferring andPromoting Energy
Conservation
Technologies (2011)

Japan’s energy
conservation
potential per ton of
crude steel is thesmallest in the world.

1

Source: IEA “Energy Technology
Perspective 2014”

Estimate of Steel
Industry (BF-BOF)
Energy Efficiency

Japan has the world’s highest
energy efficiency.

(2015, Japan=100)
Source: RITE “Estimated Energy Unit
Consumption in 2015”34

5. Reference – Eco Process

Crude Steel Output and Total and Unit CO2 Emissions

Crude steel output (left scale)

Crude steel output (left scale)

BAU emissions before adjustment

BAU emissions before adjustment

BAU emissions after adjustment

BAU emissions after adjustment

Actual CO2 emissions

Actual CO2 emissions(FY)

Crude Steel Output and CO2 Emissions(constant FY2005 electric power emission coefficient)(FY)

Crude Steel Output and Unit CO2 Emissions(constant FY2005 electric power emission coefficient)35

5. Reference – Eco Solution

Eco Solution: Growth of Global Crude Steel Output
 As of end of 2015, the per capita steel stock in Japan was 10.7 tons compared with 4.0 tons worldwide.
 Steel stock per capita is an indicator of the penetration of social infrastructure and industrial products, which

are a measure of prosperity. The steel stock is expected to grow steadily in emerging countries as thesecountries become more prosperous and accomplish Sustainable Development Goals (SDGs).

Global crude steel output will increase for many more years
India’s steel industry plans to approximately triple crude steel output to 300 million tons by 2030.
Global Crude Steel Output(Million tons)

2017

1,800
1,600

1.69bn tons

World total
Japan
China
India

1,400
1,200
1,000

India: Goal is annual
crude steel
production capacityof 300 million tons by
2030-31

800
600
400
200
0
45

50

Source: worldsteel

55

60

65

70

75

80

85

90

95

00

05

10

15

20

25

30

(CY)

36

5. Reference – Eco Solution

The Japanese Steel Industry’s Overseas Contributions to Energy Conservation
1. China: Japan-China Steel Industry Environmental Protection and Energy
Conservation Technology Conference (2005~)• This conference has been held periodically since steel industry leaders of the two countries signed an MoU in
July 2005. Providing a forum for exchanges of information about steel technologies, this conference plays a
key role in international steel industry cooperation.
• The ninth conference took place in October 2017 in Zhanjiang, China. This event confirmed that majoradvances in the environmental protection and energy conservation measures have been made by Chinese
steel mills during the decade since these conferences started. Participants also recognized the contribution ofthese conferences to the actions for steel mills in China.

2. India: Public and Private Collaborative Meeting between the Indian and Japanese Steel industries (2011~)• Started in 2011, this meeting has been held eight times, bringing together public and private-sector
energy conservation experts in the two countries.
• The Japanese steel industry has provided assistance concerning the introduction of its energy
conservation technologies in India. Activities include steel plant diagnosis using ISO14404, theestablishment of a Technologies Customized List containing energy conservation technologies suitablefor India, and technology seminars held by Japanese manufacturers of energy conservationequipment.

3. ASEAN: ASEAN-Japan Steel Initiative (2014~)• Started in February 2014, this initiative brings together steel industry energy conservation professionals
from Japan and six ASEAN countries. Since the start of this initiative, workshops for specific themes havebeen held for the ASEAN region and individual countries to support energy conservation measures in the
ASEAN steel industry.
• There have been steel plant diagnosis at 13 ASEAN steel mills in order to provide advice for improving
operations and using new technologies.

375. Reference – Eco Solution

Technologies Customized List
The Technologies Customized List contains information about technologies involving energy conservationand protecting the environment that are recommended for specific countries and regions. These lists havebeen prepared for India and the ASEAN region.
35 recommended technologies(19 energy and 16 environmental
technologies)

The Technologies
Customized List for India

Energy conservation benefits, technology
suppliers and other information

Technology Explanation
SheetsThorough explanations of individual
technologies

India Technology Customized List: http://www.jisf.or.jp/business/ondanka/eco/documents/TechnologiesCustomizedListIndiav3.pdf
ASEAN Technology Customized List: http://www.jisf.or.jp/business/ondanka/eco/documents/ASEANTechnologiesCustomizedListv2.pdf

38

5. Reference – Eco Solution

Steel Plant Diagnosis
Objective
1. Evaluate energy efficiency level of the steel plant using ISO14404*.
2. Recommend energy saving technologies from Technologies Customized
List (TCL) based on the equipment diagnosis to encourage technology
transfer from JapanThe steel plant
diagnosis has been
performed at 23
locations.
*ISO14404 is an international standard for calculating CO2 emissions from a steel plant .

Day1~3Day4

1

Operation observation of BF-BOF, EAF,
reheating furnace and other facilities

2

Energy data collection by using
ISO14404

3

Reporting session
Based on ISO14404, Japanese experts
1. analyze energy consumption trend
2. recommend suitable energy saving
technologies mainly from TCL
3. provide advice for operational improvement

10 plants in India
13 plants in the ASEAN
region in 6 countries**Indonesia, Singapore, Thailand,
Philippines, Vietnam, Malaysia

39

5. Reference – Eco Product

The Importance of Increasing the Use of Eco Product•••High-performance steel generally has higher CO2 emissions than ordinary steel does during the
manufacturing stage. But high-performance steel is an eco product because it greatly lowers CO2
emissions when used by making finished products more energy efficient.
By supplying high-performance steel, the Japanese steel industry is making a big contribution to energy
conservation and cutting CO2 emissions in Japan and around the world. Furthermore, this steel
supports “green” economic growth in Japan and creates jobs as the steel is exported to users
worldwide.
Global demand for electricity and motor vehicles is certain to increase as economic growth continues,
chiefly in emerging countries. Demand for high-performance steel is expected to become even greater
as a result. Meeting the need for high-performance steel will therefore be critical from the standpoints ofsupporting Japan’s economic growth and protecting the global environment.
Asia/Global Energy Outlook 2015 by The Institute of Energy Economics, Japan
Global Electricity Output

Global Automobile Ownership
Million vehicles

World except Asia

World except Asia

Asia

Asia

Year

Source: The Institute of Energy Economics, Japan

Year
Year

40

5. Reference – Eco Product

Crude steel production trend per demand in Japan•

Steel exports from Japan have been increasing. The main reason is strong demand
overseas for high-performance steel backed by global economic growth, primarily in Asia.

•

In recent years, external demand (direct and indirect exports) has accounted for morethan half of Japan’s crude steel production.

Crude steel production trend per demand in Japan(Million ton)

Net export

IndirectexportComposition ratio (%)

Net domestic
demandNet export

Source: JISF

(FY)

IndirectexportNet
domestic
demand(FY)

41

5. Reference – Eco ProductEco Product: The global competitive edge of the Japanese steel industry, mainly for high-performance steel•

Steel from other countries cannot match Japan’s high-performance steel in terms of performance, quality,
supply and other attributes. High-performance steel is the core element of the international competitiveedge of the Japanese steel industry.

•

China, the world’s largest steel producer, became a net exporter of steel in 2006. Only Japan is the only
net exporter of steel to China now.

With Japan

Steel Trade of China (Total)(10,000 tons)

Japan’s share of
China’s steel imports

Excess import

2005
Japan

Export24%

OthersImportWith Korea

76%
Excess export from 2005

ExcessimportExportImportExcess export from 2006

Excess

Total

Japanese share grewalmost double in 11
years

importExportImportOthers
58%

Japan
42%

2016
Source: Customs statistics China

42

Quantitative Assessment of High-performance Steel Benefits

5. Reference– Eco Product5.参考（コプロダクト）(1) Background/Objectives
Study groups and activities(1) FY1996 Energy Evaluation Survey for Use of Steel Products from an LCA Perspective• Established a JISF committee headed by a university professor to study this issue.

(2) FY2001 Survey for Contribution of Steel Products to Energy Conservation in Society from an LCA
Perspective• Under the supervision of this JISF committee chairman, a study was conducted with the participation of associations ofsteel-consuming industries (construction, automobiles, machinery, shipbuilding, electrical equipment) and The Institute ofEnergy Economics, Japan. Results of this survey are in a paper posted on this institute’s website.
• Following up on the FY1996 study, methods were determined for the quantitative measurement of contributions of highperformance steel.

(3) Added exported steel to evaluations in FY2009• Up to 2008, the survey covered only steel used in Japan. Starting in FY2009, these evaluations have also included
emission-reduction benefits of the use of exported steel in finished products in other countries.

Objectives• Japan’s steel industry significantly cut energy use following the oil shocks of the 1970s. But in the 1990s, the paceof efficiency improvements slowed due to increase in processes and treatments for high-performance steel,smaller lots and upgrading of environmental equipment.
• But high-performance steel has a greater energy conservation benefit than ordinary steel does when used infinished products. Also, energy is conserved because producing high-performance steel requires a smaller amountof raw materials. Therefore, high-performance steel must be evaluated by using all characteristics to determine its
effect on energy consumption.
• Determining the energy conservation benefit of high-performance steel requires analysis and assessments using
an LCA perspective in order to encompass both the manufacturing and utilization stages.
• The LCA approach is critical with regard to viewing measures to fight global warming as rational initiatives forsociety as a whole. As a result, this method is used to perform a comprehensive analysis and evaluation.

43

Quantitative Assessment of High-performance Steel Benefits

5. Reference – Eco Product(2) Calculation Scope/Stages
Scope of calculations
Quantitative assessments cover the following high-performance steel products for which supplementary
figures, manufacturing energy use and other data are available.
(1) Automotive high-strength sheets(2) High tensile strength sheets for shipbuilding(3) Stainless steel sheets for railway cars
(4) Oriented electrical sheets for transformers(5) Heat-resistant high-strength pipes for boilers* High-strength H-beams for building construction were included in the FY2001 survey. But emission-reduction benefits do
not appear during a building’s use. Benefits are during the manufacture and transport due to using a smaller amount of raw
materials for production. Consequently, this steel was excluded from the evaluation of contributions during the use of steel.

Calculation stages• In most cases, evaluations need to cover the entire life cycle, extending from the mining of natural
resources to the discarding of end-of-life products. The FY2001 survey was centered on social benefits ofhigh-performance steel. The survey covered the analysis and assessment of steel production, steeltransport, finished product manufacture and finished product use.
• Reports produced by JISF every year place priority on emission reduction figures showing the quantitative
benefits to society when products with high-performance steel are used. Therefore, data are only for thefinished product use stage.
* The mining and transport of raw materials are only a negligible component of the life cycle of steel. In addition, there was adifficulty in data collection for these stages in the study at that time. Furthermore, the amount of steel used decreases whenhigh-performance steel lowers the weight of a product. As a result, the mining and transport portions fall below the baseline.
Regarding assessments other than lighter weight, high-performance transformer electrical sheets and boiler pipes do not reduce
the amount of steel used. As a result, the mining and transport portions are the same as the baseline. Excluding the mining andtransport portions from evaluations thus prevents an excessive evaluation of the total energy conservation benefit.
* Due to the difficulty of obtaining data concerning steel transport and finished product manufacturing, which are included in thescope of the evaluation, and for other reasons, there are instances where it was not possible to perform adequate analysis.

44Quantitative Assessment of High-performance Steel Benefits

5. Reference – Eco Product(3) Boundaries/Period/Baseline
Boundaries• Steel used in Japan and exported (exported steel was included starting in FY2009)• Steel manufactured in Japan and not steel manufactured overseas• (No Japanese steelmaker has an integrated plant in another country.)
Evaluation period• Stock (individual years) is evaluated from the standpoint of making comparisons with CO2 emissions frommanufacturing processes in each year.
Steel used for baseline comparisons• In principle, differences with high-performance steel are evaluated by using steel with no functions(ordinary steel) as the baseline.
In product categories that do not use ordinary steel, differences with high-grade products are evaluatedby using products assumed to be suitable for replacement as of FY2001.
Baseline

Steel used for comparison

Benefit evaluatedAutomobiles

Ordinary steel

High tensile strength sheets (YP340)

Energy saving due to lighter weight

Ships

Ordinary steel

High tensile strength sheets (YP315/YP355)

Energy saving due to lighter weight

Railway cars

Ordinary steel

Stainless steel sheets (SUS301L)

Energy saving due to lighter weightTransformers

Electrical sheets
used 30 years ago*

Electrical sheets used now

Energy saving due to lower eddy
current loss

Boilers

Boiler pipe for
566ºC steam
power plants

High-alloy steel pipes (modified 9Cr-5Mo
pipes/heat-resistant pipes)

Energy saving due to high heat
resistance and strength (higher
generating efficiency resulting fromhigher temperature of steam)*Assumes a 30-year life for transformers

45

5. Reference – Eco Product(Reference) Methodology Announcements
Overview
http://eneken.ieej.or.jp/data/pdf/462.pdf
1. H-beams for Buildings
http://eneken.ieej.or.jp/data/pdf/463.pdf
2. Power Plant Boilers (Heat-resistant pipes)
http://eneken.ieej.or.jp/data/pdf/464.pdf
3. Automobiles (High-strength sheets)
http://eneken.ieej.or.jp/data/pdf/465.pdf
4. Ships (High tensile strength sheets)
http://eneken.ieej.or.jp/data/pdf/466.pdf
5. Transformers (Oriented electrical sheets)
http://eneken.ieej.or.jp/data/pdf/467.pdf
6. Railway cars (Stainless steel sheets)
http://eneken.ieej.or.jp/data/pdf/468.pdf

46

5. Reference – Eco Product(Reference) Major Applications for High-performance Steel
High-strength sheets forautomobiles

High tensile strength
sheets for ships

Stainless steel sheets forrailway cars

Strong and heat-resistantboiler pipes

47

International Cooperation (1)5. Reference – Eco Product

Examples of international cooperation for improving products
worldsteel posts case studies of member companies on its website.

https://www.worldsteel.org/steel-by-topic/life-cycle-thinking/case-studies/48

5. Reference – Eco ProductInternational Cooperation (2)Establishment of steel LCI calculation method and ISO standard (worldsteel-LCA method) A method to calculate the environmental value of steel products (for example, the environmental impact per kilogram of hotrolled sheets) This can be used as the environmental impact of the steel portion of a product when a company using steel performs a life
cycle assessment of its own products.
 The worldsteel-LCA method has five key points:
 The blast furnace method and EAF method are both evaluated as a single steel cycle system.
 Scrap is given an environmental value to reflect the reduction in the use of natural resources, the lower environmental
impact and other benefits resulting from the use of scrap.
 When scrap is used to manufacture steel products, the scrap environmental value and volume of scrap used are
multiplied. The resulting number is reflected in the steel product’s LCI as the environmental impact associated with theuse of scrap.
 The value of the ability to recycle steel when a finished product reaches the end of its life must be evaluated. To do this,the steel product’s LCI incorporates a number obtained by multiplying the scrap environmental value and the recycling
ratio.
 This method conforms with ISO14040 and ISO14044, which are the basic international standards for LCA.
 Activities are under way to establish an international standard (ISO) based on Japan’s proposal. The goal is to issue thisstandard during FY2018. (ISO20915: LCI calculation methodology for steel products)
Portion evaluated as eco products
Natural Resources
Iron & Steel Process

Steel
Products

Industrial
manufacturers
e.g. car makers

Final
Products

Use in Societye.g. cars, ships

End of Life of
Final Products

substitutio

Steel Scrap

Internal Scrap Home Scrap

Manufacturing Scrap

End of Life Scrap

Scrap poolclosed loop recycling

Yellow shows the boundary of theworldsteel methodology

49

5. Reference – Eco Product

CO2 Emission Reduction from Blast Furnace Slag Used in Cement
Mixed cement (mainly slag cement) is one way to lower CO2 emissions related to energy
consumption. The use of this cement is growing and a further increase in the production ratioof mixed cement could significantly lower CO2 emissions.
Replacing conventional cement (Portland cement), which generates CO2 during the firing of raw materials, with slag cement,
which does not generate CO2 during production, reduced annual CO2 emissions by 10.40 million tons/year (FY16).
• Japan:Annual reduction of 3.48 mn tons of CO2• Exports: Annual reduction of 6.92 mn tons of CO2（万t-CO(10,000 tonsof CO22)）
1,200

Export
輸出

Domestic
国内

924 921 911

1,000

806
800

600

716
577 165
511 53746

774

191 283 271

847
381

886

441 464 472 465

928

1,100
1,088
1,072
1,068 1,040
966

842
454
569

686

672 706

717 692

611

47

400

200

464

525

550

555
523

503
465

483

456 439421

388 360

386
355

428

382

352

348

0
1990199520002001200220032004200520062007200820092010201120122013201420152016 (FY)
（年度）
Assumptions for emission reduction contribution Conversion to volume of
cement: 450kg of slag/ Ton of cement CO2 emission reduction: 312kg of CO2/Tonof cement

Source: Japan Cement Association, Nippon Slag Association50

Initiatives in the cargo transport sector

5. Reference – Commercial,residential and transport sector•

CO2 emissions per unit of cargo transport decreased to 41.8kg of CO2/k ton-km in FY16 from
44.0kg of CO2/k ton-km in FY06.

•

In FY16, the steel industry modal shift (ships + rail) was 77% for primary transportation and 97%
for cargo transported more than 500km. This is far higher than the average modal shift rate of
38.1% for all industries in Japan (Ministry of Land, Infrastructure and Transport FY05 data for
more than 500km).

•

Steelmakers are taking other actions too, such as improving cargo transport efficiency by using ahigher pct. of cargo space on ships, utilizing shore-based electric power supplies for ships andusing eco-tires on trucks and using eco-friendly driving methods.

(kg-CO2/千トン・km)(kg of CO2/k tons-km)

CO2 Emissions per Unit of Cargo Transport

Fuel saving by using electricity from shore-based sources

46
Cuts fuel oil use by 70% to 90% while ships
are docked

44.0
44
▲５．０％
-5.0%

No. of
units

42

41.8
40
2006

2016

(FY)
(年度)

(注)調査協力44社のガソリン、軽油、重油等の使用に伴うCO2排出
Note:
Total CO2 emissions from use of gasoline, light oil and heavy oil at 49 companies
surveyed
divided by total ton-kilometers of cargo transported量の合計を輸送トン・kmで除したもの。

Steel mills

218

Junction port

41

(Totals for 4 blast furnace and2 EAF steelmakers as of theend of FY16)

51

Initiatives in commercial/residential sector••

5. Reference – Commercial,residential and transport sector

In FY2005, Japan’s steelmakers started energy conservation programs using environmental
ledgers for residential sector. Steelmakers started education programs that included all
employees, including at group companies, promotion of use of household environmental
ledgers, and other actions. There are around 18,000 households participating in this programin FY2016.
Steel industry is taking actions to reduce energy consumption and CO2 emission from offices.
Unit energy consumption in offices in 2016 were down 23% compared to FY 2008-2012.
Unit energy consumption in offices

Household CO2 Emissions(CO2 emissions per individual: kg of CO2/person-year)

Unit energy consumption per floor area [MJ/m 3]-23%
Gasoline
Electricity
etc

Japan
Total
(FY2014)

Steel
Industry(FY2014)

Steel
Industry(FY2015)

Source: Estimates based on Greenhouse Gas Inventory Office materials
Notes:
1.Total for Japanese households includes households and household use of
automobiles.
2. Total for steel industry households is an estimate by JISF based on the inventoryin Japan

Avg. FY08-FY12FY15Data for 339 business sites of 68 companies in FY2016

52

5. Reference – Commercial,residential and transport sector

Example of use of unused energy in nearby locations
Supply of heat to sake companies by a steelmaker in the Kobe area
Equipment to supply heat to sake companies
Features of the heat source system
1. Supply of heat source
Steam from a power plant is used as the heat source.
2. Energy conservation
Energy use is down 30% from when each company had its own boiler. Part of steam
used for power generation is drawn off from between turbines and supplied in order toreduce energy lost to cooling water.
Equipment

Steam generators

3

Steam generation:
Heating capacity:
Thermal transmission area:
Primary steam pressure:
Secondary steam pressure:

40 tons/hour
29.5GJ
382m2
1.01MPa (saturation temperature)
0.837MPa (saturation temperature)

Water softener: 1 set
Water supply method: Two-pipe system with direct-buried steam (300-150A) and recirculated water (50A) (24-hour supply all year)

Steam generators

53

5. Reference – COURSE50

Phase 1, Step 2 (FY13-17) Initiatives

Development item (a): Technology for reducing blast furnace CO2 emissions
To develop this technology, a 10m3 blast furnace was constructed for testing. Comprehensive trials were
performed to verify the results of laboratory research conducted during Phase 1, Step 1. One goal is tocreate a reaction control technology that maximizes the effectiveness of hydrogen reduction. Another is toobtain data for increasing the scale for phase 2 tests using the demonstration test blast furnace.
Development item (b): Collection of CO2 from blast furnace gas
The goal is to develop a technology that makes it possible to collect CO2 at a cost of ¥2,000 per ton of CO2,
which is the cost that matches the requirements of the demonstration test blast furnace. This will requiredeveloping a high-performance chemical absorption liquid and other substances, creating a more efficientphysical adsorption method, performing applied research for technologies for utilizing exhaust heat, andcreating technologies for more cost reductions.

(a)for reducing 削減技術
blast furnace CO2 emissions(a)Technology
高炉からのCO
2

コ
Cokeー
ク
Ovenス
炉

ｺｰｸｽ炉ガス
Coke Oven Gas(COG)

Modified coke oven
ｺｰｸｽ炉ｶﾞｽ改質
gas (hydrogen（水素増幅）
amplification)(b)
for collecting CO2 fromblast furnace gas(b)Technology
高炉ガスからのCO
2分離回収技術
Blast furnace gas
CO2 separation/
高炉ガス

Blast 高炉
FurnaceHydrogen水素還元
reduction
Hydrogen
gas
水素ガス

Blast
高

炉
Furnace

CO2
gas
CO
2ガス

CO2collection
分離･回収

(BFG)

Unused sensible/

未利用顕熱･排熱
exhaust heatCO2storage*
貯留CO2(a)+(b)＝
CO2 reduction
target is about
30%* assumptions are that an international equal footing isestablished and the necessary social infrastructure is created,
including the site selection and establishment of a storage
facility for government-led carbon capture and sequestration
programs. Targets will be reexamined if these conditions are
not fulfilled.

54

5. Reference – COURSE50

Construction of Trial Blast Furnace
 In Phase 1, Step 2, a 10m3 blast furnace for testing was constructed at the Kimitsu Works,
which has a trial CO2 separation and collection system (CAT1, CAT30) that can be used fortests with this blast furnace.
 Trial operations were performed four times during FY2016 and FY2017.

Volume of
10m3

CAT1
（1t-CO2/d）

CAT30（30t-CO2/d）

Construction and operation of trial blast furnace

Kimitsu Works CO2 separation and collection system55

5. Reference – Towards 2030

Commitment to JISF’s Low Carbon Society Phase II
Eco Process
Aiming 9 million-tons CO2 reduction vs BAU emission in FY2030 by fully implementing state-ofthe-art energy technologies

Eco Solution

2030←2020

Contribute worldwide by transferring the world’s most advanced energy-saving technologies toother countries (especially to developing countries)and increasing the use of these technologies.
(Ca. 50 million ton of CO2 reduction contribution in FY2013. Ca. 80 million tons of estimated CO2
emission reduction contribution in FY2030)

Eco ProductBy supplying the high-performance steel that is essential to create a low-carbon society, contributeto lowering emissions when finished products using this steel are used.
(Ca. 26 million tons of CO2 emission reduction contribution in FY2013. Ca. 42 million tons ofestimated CO2 emission reduction contribution in FY2030.)

Development of revolutionary steelmaking processes (COURSE50)
Cut CO2 emissions from production processes about 30% by using hydrogen for iron ore reduction
and collecting CO2 from blast furnace gas. The first production unit is to begin operations by about
2030*. Goal is widespread use of these processes by about 2050 in line with timing of updates ofexisting blast furnace facilities.

Development of innovative ironmaking process (Ferro Coke)
Develop ferro-coke that can speed up and lower the temperature of the reduction reaction inside a
blast furnace and create the associated operating process. Develop revolutionary technologies
that can reduce energy consumption for pig iron production and permit the greater use of lowgrade raw materials.
56

5. Reference 5.参考（フェーズⅡ）– Towards 2030

Eco Process (Reduction targets in Japan for production processes)
The 2030 goal for steel production processes is to use advanced technologies as much as possible to lower
CO2 emissions by 9 million tons compared with the volume of these emissions (BAU emission volume)
expected from each production volume figure*1 (but excluding the improvement in the electricity coefficient).
BAU Emissions and Target
BAU比削減目標のイメージ

2.2

BAU排出量BAU emissions

CO2排出量（億ﾄﾝ）
volume (100mn tons)
CO2 emission

2.1

Actions

Phase II 2030

Phase I 2020

(1) Improve coke oven efficiency

About 1.3mn tonsof CO2

About 0.9mn tonsof CO2(2) More efficient electricity
generation

About 1.6mn tonsof CO2

About 1.1mn tonsof CO2(3) More energy conservation

About 1.5mn tonsof CO2

About 1.0mn tonsof CO2(4) Waste plastics*2

2.0mn tons of CO2－(5) Develop and use
revolutionary technologies*3

About 2.6mn tonsof CO2－Total

9mn tons of CO2

3mn tons of CO2 +Target
目達後排出量

2.0
1.9
1.8
1.7

Waste plastics*4
These reductions do not include the effect of changes in the electric power emissions coefficient.

1.6

0.90

0.95

1.00

1.05

1.10

1.15

1.20

1.25

1.30

参加会社粗鋼生産量（億ﾄﾝ）
Crude steel production (100mn tons)

1.35

Fiscal 2030 Assumption
Crude steel output inJapan (10,000 tons)

Participants’ Crude steel
output (10,000 tons)

BAU emissions (tons of
CO2)

Emissions after target isreached (tons of CO2)

12,00011,50819,733

18,833*1 These targets are based on total crude steel production of 120 million tons in Japan, plus or minus 10 million tons. Emission reductions may be more or less than the anticipatedrange if there is a significant change in production volume. If there is a significant change, the suitability of the BAU figure and emission reduction will be reexamined in accordancewith the actual production level.

*2 Points concerning increasing the use of waste plastics and other waste materials
a. Awaiting results of studies concerning a Japanese government review of the container, packaging and plastic recycling system and other related items; may be reviewed (target
reduced) if there is no outlook for growth in the waste materials handling capacity of the steel industry by FY2030 in relation to the actual FY2005 capacity.
b. In addition, for the reduction target incorporated in the FY2020 target, awaiting results of a Japanese government study of the recycling system; may be reviewed (target
reduced) if there is no outlook for growth in waste materials handling capacity by FY2020 in proportion to the above target.
*3 For the development and use of revolutionary technologies, assumptions are that (a) technologies will be in use in FY2030 and (b) the use of these technologies is economicallyfeasible. In addition, for COURSE50, assumptions are that an international equal footing is established and the necessary social infrastructure is created, including the site selectionand establishment of a storage facility for government-led carbon capture and sequestration programs. Targets will be reexamined if these conditions are not fulfilled.
*4 Within the target for the 5 million ton reduction in CO2 emissions in FY2020, the primary focus is on a 3 million ton reduction in CO2 emissions by steelmakers’ own initiatives for
efficient use of energy and other ways. Concerning collection of waste plastics and other ways, only an increase in the collected volume compared to FY2005 is counted as theamount of reduction in emissions57

5. Reference – Production Process

Steel Production Processes and Development
and Use of Energy Conservation Technologies
Fuel heavy oil

Coal moisture control equipment
Coke dry quenching equipment

Pulverized coal input

SCOPE21

Top pressure recovery turbine HS

Reuse of waste plastics

top pressure recovery turbine (TRT))

Automation of coke oven combustion control

Electric
power
plant

Byproductgas(Dry/low-pressure loss furnace
Exhaust heat recovery

OG boiler

Reuse of waste plastics

Kalina cycle power
generation

COG

Fuel

BFG

ACC USCLDG

OxygenCoking coalMore LDG recovery by expanding sources
Control of OG-IDF rotation speed

LD converter gas

Coke ovenBlast
furnace

Equalization gas recovery equipment
Suitable capacity for blowers

Pulverized
coal

Iron ore

More efficient main exhaust blowers

Cut electricity consumption by dust collectors
Suitable volume for cooling pumps

Localized dust collection for casting

Prevention of air leakage

Temperature retention on billet transport line

Recovery of latent heatand sensible heat

Input equipment for different granule sizes(smaller and lower lifting)○

LD converter

Pellet plantContinuous casting line

Recovery of main and cooler exhaust heat

Suitable size for dust collection blowers
Control of electric motor speed

BlowerBloom

Torpedo car

OxygenPrevention of air leakage
Prevention of pressure loss for
input/exhaust

Construction of high recovery rate plants

Input of hot slab
Direct rolling

SlabElectricity

More efficient raw material air compressors

Thermal insulation for blower pipes(For entire steel mill)

Exhaust heat recovery

CDCM

Continuous electroplating
equipment

High-efficiency power
generation

Slab yard temperature retention measures

Use less power for lights

More efficient recuperator(use sodium lamps, separate power supplies, etc.)

Modify ovens (increase length, use partitions to improve heattransmission, increase oven thermal insulation, better seals for
input/output doors)

Measures to reduce drain in steam piping

Cut use of power for auxiliary machinery(control no. of compressors, etc.)
Suitable volume for cooling pumps (smaller andlower lifting power)

More efficient cooling water system

Use plunger pumps, smaller and lower lifting power, control
speed of heating oven blowers and cooling water pumps, lesspower for auxiliary machinery (less power for wasted mill motor
operation, auto stop for table rolls, etc.)

Improve thermal insulation for skid pipes
Improve heat pattern
Measures for low-temperature billet output (temperature retention ontransport table, etc.)

Heating
furnace
Efficient continuous annealing

Cold rolling mill

Hot rolling millHeating furnace with regenerative
burner58

5. Reference – RITE analysis(Reference) Change in Product Mix for Downstream Evaluations
Appendix

31. Other specialty steel*

29. Piano wire
28. Free cutting steel
27. Bearing steel*
26. Spring steel
25. Structural alloy steel*
24. Structural carbon steel*
23. High-speed steel+other tool steel
22. Alloy tool steel
21. Carbon tool steel

Specialty steel (14 categories)

30. High-tensile-strength steel*

20. Stainless steel*
19. Seamless pipes, specialty steel
18. Seamless pipes, stainless

16. Seamless pipes, ordinary steel
15. Other metal coated sheets
14’. Galvanized sheets, export hightensile-strength steel
14. Galvanized sheets
13. Tin-free steel
12. Tinplate

11. Cold-rolled electrical sheets
10 Cold-rolled sheets
9’ Hot-rolled strips, export hightensile-strength steel
9 Hot-rolled strips
8 Steel sheets, medium/thin

Ordinary steel (20 categories)

Production volume ratio

17. Other pipes, ordinary steel

7’ Heavy plates, export high-tensilestrength steel
7 Heavy plates
6 Special steel wire rod

5 Ordinary wire rod, bar-in-coil
4 Bars3 Sections
2 Steel plates and piling
1 Rails, tires and rolled wheels
0. Net exports of semi-finishedproducts

59