S T R AT E G Y

FOCUSAchieving a Carbon-neutral Society
with the Power of WEBTi Materials

Technologies thatContribute to Sustainability

p.23

R&D Case Studies

CASE 1

Reductionof CO2emissions

Establishing a new smelting technology with low energy and high efficiency
New titanium smelting method

R&D Enhancing the Value of Titanium, the Metal of the Future
The Toho Titanium Group have expanded its business areas
by readily responding to the emerging needs of our customers,
and steadily accumulating technological development that
increases the value of titanium, which has various properties
such as it being lightweight, strong, and gentle to the humanbody. Furthermore, we are now promoting the development of
new products that contribute to resource utilization, the spreadof clean energy, and reduction of environmental impact, thereby
contributing to the development of a sustainable society.

Advantages of Titanium

Titanium Challenges

Low thermalexpansion
coefficient

StrongAround twice
the specificstrength of iron(ordinary steel)

Designpotential
Various color
tones are obtainedby changing thethickness of theoxide film

Safe forhumans

mechanical engineering, and electrical engineering to solve highly

more diversified year by year. Titanium feedstock is widely available

challenging technical issues of high-temperature smelting reactions

around the world, but the smelting process currently being used

and molten salt electrolysis, and to design processes and facilities

to convert it into titanium metal is a complex technique based on asuitable for actual implementation. We aim to implement the newparticular method called the Kroll method.

smelting technology by the end of FY2025 by making full use of ouradvanced technologies and putting all our efforts into development.

derived from electricity emits approximately 9 tons of CO 2 to produce

technology, the Group as a whole aims to reduce CO2 emissions by

The current titanium smelting technique (Kroll method) uses batch

1 ton of titanium. Various alternatives to the Kroll smelting method

40% from 2018 levels by 2030, and to achieve carbon neutrality (netproduction, a complex process that consumes large amounts ofhave been studied, but none has yet been put into use. In order tozero CO2 emissions) by 2050.

electricity, resulting in high production costs. In addition, the burningbuild a low-carbon society, there is an urgent need to reduce CO2of coke produces large amounts of CO2.

emissions from the smelting process.

Anticipated Results

The new smelting technology that Toho Titanium is developing

Difficult to process

in collaboration with Universal Achemetal Titanium, LLC (UAT, LLC.)

Rustproof

Titanium has high strength, which makes it difficult to cut, press,of the United States is a smelting process that has the potential

Excellentcorrosion
resistance,
in seawaterand weld. In addition, because its thermal conductivity is low, heatto reduce CO2 emissions virtually to zero. We also aim at reducing

does not escape during machining, causing cutting heat to build up,

electric power consumption by approximately 75%.

thus making tools more prone to wear, and metal fires more likely toExcellent
biocompatibility

Furthermore, through measures centered on the new smelting

electricity, combining the CO2 emitted from the process and the CO2- We will reduce direct CO2 emissions from the titanium smelting process tozero.
- A major energy conservation effect is anticipated, as the introduction ofthis new smelting method has the potential to reduce the domestic power
consumption required for the production of metallic titanium by up to 75%.
- Titanium products manufactured with this newly developed technology canhelp create products with low environmental impact in both name and reality,
including the materials used.

In this development, it is necessary to utilize knowledge

occur. Processing methods and advanced technologies suited to thecharacteristics of the material are therefore required.

Technical details of the new processThis process is expected to be an excellent smelting
method since it is a simpler process than the current
method, uses almost no hazardous materials,consumes about a fourth of the electricity, andproduces no CO2.

Toho Titanium Takes Pride in Sustainable Technology
Reductionof CO2emissions

New energy-saving titanium production process enabled by
Reduce CO2 emissions in our customers' value chains byproviding titanium and products using related technologies●Reduction of material loss throughimprovement of existing processes andEffectiveresource
utilization

products, and development of newprocesses and products●

converted into an electrically conductive material, andR&D Organization

introducing new technology●

Promote reuse of titanium scrap

in the second process, it is electrolytically purified.

We conduct our research and development work undera policy of strengthening and building a managementfoundation through the pursuit of quality. In collaboration
with engineers from each Business Division, the Technology
Strategy Headquarters leads the development of newtechnologies and products in line with business strategies.

25

such as renewable energy andhydrogen energy

I N T E G R AT E D R E P O R T 2 0 2 3

Use of hazardous
substances
CO2 generation➡

Yes(Cl2 gas, molten Mg, TiCl4, etc.)
Yes➡

No➡

Zero

1 As an example, by first mixing granular titanium

High-grade titanium feedstockHigh-grade titanium feedstock

Finally, residual salt is removed to finish the product.

Coke (C)Cl2ore, calcium fluoride (fluorite), and metallic

Chlorination

CO2generation

aluminum and reacting at high temperatures, aHigh-purity TiCl4

Electrolysis

ReductionMg

easily recovered in isolation.
MgCl2

Low-carbon Al /Carbon-free AlExtraction

CO2Conservation
generation:of electric
Zeropower

Metallic titanium withHigh O, Al content
Electrolytic refining

Salt bath

Bath separation

Vacuum separation

2 We use a proprietary electro-refining process, inwhich titanium ions are mainly dissolved from theFluorite
CaF2
Al2O3

Crude TiCl4

Distillation/Refining

aluminum is produced. Slag consisting of theseparated by flotation, so the titanium alloy can be

Pure titanium (sponge)

Titanium containing Al,
Pure titanium (Grain)titanium alloy into the salt bath, and deposited asSupport the creation of nextgeneration energy sources

High4
1/5 to 1/4 of the current process(Note: electric power used toproduce ore, aluminum, salt baths
and other substances is not taken
into account.)

byproducts aluminum oxide and calcium fluoride isTechnology Strategy
Headquarters

TechnicalDevelopment Center●New process➡

Electricity
consumption

conductive titanium alloy containing oxygen andPresident and Representative Director

Corporate Planning
Department

Newenergycreation➡

6

Number of steps

This technology consists of two major
processes: In the first process, titanium feedstock is●Current process basedon Kroll methodElectric power consumption

Specific gravityof 4.51, around
60% that of iron(ordinary steel)of basis sciences such as thermodynamics, electrochemistry,strength, and high corrosion resistance, is expanding and getting

However, since this method consumes a large amount ofHigh manufacturing costs and environmental impact

Lightweight

Use of titanium, a metal characterized by its light weight, highdendritic solid metal titanium on the cathode. After
Each Business
Division

Pure titanium obtained by the new method

vacuum separation or rinsing, we obtain metallic
titanium with few impurities, equivalent to current
commercially pure titanium sponge.

Melting

Melting

Melting

Melting

Titanium Alloy IG
containing Al

Pure titanium IGTitanium Alloy IG
containing Al

Pure titanium IG

I N T E G R AT E D R E P O R T 2 0 2 326

R&D Case Studies

INTELLECTUAL
PROPERTY
STRATEGY

CASE 2

Reductionof CO2emissions

Effective
resource
utilization

IP Strategy

Greatly Simplified Titanium Foil Manufacturing Process
Direct Titanium Foil Production with Smooth Electrodeposition

We aim to be aggressive with ourintellectual property, which is the core ofour competitive strength.
For our company, whose core competency is advanced titanium-related technology, securing andutilizing intellectual property is an important initiative that can be called the core of our competitiveness.

In general, titanium foil is manufactured by melting and forging

to resource conservation.

raw materials such as titanium sponge, followed by a number of

The Intellectual Property Department continuously files strategic patent applications, provides IP

We have established the technology for manufacturing titanium

processing steps such as hot and cold rolling.

education for engineers, and steadily performs invention discovery activities.

foil of A4 paper size and approximately 100 μm thickness using this

There are two main roles that the Intellectual Property Department plays. The first is establishing an

The smooth electrodeposition method that we are currently

process, and will continue to develop the technology with the aim

appropriate patent network for the inventions we have developed to ensure our business dominance.

developing is a manufacturing process that can significantly eliminateof commercializing it. Taking advantage of titanium's high corrosion

The second is making full use of the IP landscape to contribute to the exploration and planning of new

steps of fabrication by electrodepositing the raw material in foilresistance, it is expected to be used in bipolar plates for PEM waterbusinesses from promising business areas. In these cases, it is also extremely important to consider

form through molten salt electrolysis. As a result, reduction in CO2electrolysis hydrogen production equipment and anti-corrosion films

sustainable materials and their manufacturing methods that contribute to reducing environmental

emissions can be expected through energy-saving manufacturing

for steel structural buildings, thereby contributing to the maintenanceprocess. Furthermore, since the electrodeposition also has a refining

and preservation of social infrastructure.

General Manager,
Intellectual Property Department,
Technology Strategy Headquarters

effect, low-cost titanium scrap can be used as raw material, leading
Smooth Electrodeposition Significantly Simplifies Titanium Foil Manufacturing Process
Titanium sponge,
etc.

Hot
rolling

Forging

MeltingColdrolling

Ti2+
Ti2+Ti2+

Molten salt

Ti2+Ti2+Ti2+

CathodeAnodePower source

Electro-deposited
titanium foil

Foil

Titanium ions areleached from thesoluble titanium
anode, and titanium
is deposited on thecathode in the formof a smooth foil.

impact. In order to turn the results of research and development into a competitive advantage for ourcompany, we will lead the strategic use of intellectual property, with an emphasis on medium- to longterm business growth.

Electro-deposited titanium foil with A4 dimensions

Smoothelectrodeposition Significant Simplification
Titanium sponge
Low-cost scrap, etc.

Masakatsu Ikisawa

230mm

Setting quantitative and qualitative goals

IP education

With regard to patent applications, we set annual targets for theIn FY2022, we conducted four IP training sessions for engineers.

number of applications and for acquisition of know-how based onUntil now, the only people eligible for in-house IP training were

the progress of our business strategy and development themes.

engineers who could become inventors. However, starting in

In FY2022, we acquired 42 patents in Japan. When determining

FY2023, we will begin providing IP training to sales personnel.

whether or not to obtain patents internationally, we use a checklist
300mm

In addition to basic knowledge of patent law and copyrightto check whether competitors have manufacturing and sales bases

law, the training content is related to situations that frequently

in a particular country, as well as the level of competition, and makeoccur in sales activities,

comprehensive decisions from the perspective of cost performance.

such as during sample
shipping, sales promotion

CASE 3

Reductionof CO2emissions

All-Solid-State Batteries Promote Clean Energy

For existing products, we use the IP landscape to compare theintellectual property capabilities of our competitors and to specify
We also share information about the current status of ourStructure of an all-solid-state battery with LLTO™
Cathode active material

enthusiasm to "create business with intellectual property", we willcontribute to management by proactively making proposals to ourand Clean Energy." The lithium-ion batteries that have been widelyused in the past have used liquid as the electrolyte, which has

Solid-state electrolyte: LLTO™

presented challenges in terms of capacity and safety. All-solid-statebatteries using solid electrolyte are attracting the most attention as

Anode active material

the next-generation battery.
We have focused our development work on lanthanum

Plate LLTO™ (LLTO™ in plate form)

is chemically very stable, and is expected to be used in multilayer(chip-type) all-solid-state batteries and large batteries for automotive
use in the future.
LLTO™, currently achieves ionic conductivity of 5×10-4Scm-1
at 27°C in plate form, demonstrating the characteristics of high ionic
conductivity among oxide-based solid electrolytes. We will continue
to develop all-solid-state batteries for practical use.

also provide explanations ofrelated knowledge along withhypothetical examples.
IP education materials for sales staff

monthly reporting meetings of the Technology Strategy Headquarters
as well as in the reporting meetings with management. With ourrenewable energy sources, as called for in SDG No. 7: "Affordable

guarantee contracts. We

IP capabilities and changes in our IP capabilities over time during

expanding the deployment of clean energy, electricity generated fromlithium titanate (LLTO™), an oxide-based solid-state electrolyte. It

operations, and signing patent

Leveraging the IP landscapethe content of patents that should be obtained in the future.

LLTO™ Technology Improves Performance of Lithium-ion Batteries
High-capacity, high-performance, safe batteries are essential inNew
energycreationbusiness divisions regarding patent acquisition and the explorationand narrowing down of new businesses.

Digital utilization in research and development
We aim to speed up R&D and improve the quality of R&D results
by introducing appropriate digital tools that match the content andstages of our R&D. Specifically, we are actively introducing varioussimulation software, through which we have achieved results such as
narrowing down the appropriate experimental conditions and clarifying

Promoting open innovation

the causal relationship between conditions and characteristics.

When it comes to technology development, we place the highest

We are working to further achieve labor saving, speed

priority on promoting development and early commercialization

improvement, and functionality enhancement in intellectual propertyof the results. To this end, we are proactively considering andwork. For example, when searching for past papers and documents,

introducing external technologies that we lack, rather than relying

it used to take time and effort to check a huge amount of documents,

on in-house development. For example, we not only exchange

one by one. Therefore, by introducing an AI tool that collects andtechnology with our parent company, JX Metals, through technology

displays articles in the order of their relevance to the target keyword

presentations, but also conduct joint research on multiple individual

being searched, we are now able to obtain the necessary documents

themes. In addition, we are collaborating with an overseas start-

extremely quickly, significantly reducing work time, and improving theup company to develop metallic materials, and joint research withquality of our staff's work.

several universities is underway.

27

I N T E G R AT E D R E P O R T 2 0 2 3

I N T E G R AT E D R E P O R T 2 0 2 328