EMECR2017
conditions of material recycling
andmaterial LCA reflecting closed-loop recycling

Steel as an eco-friendly
materialOct. 12, 2017

Toru Ono
Nippon Steel & Sumitomo Metal Corporation© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR20171

Table of Contents
1. Importance of life cycle thinking
2. Advantages of steel
in material recycling

3. worldsteel LCA methodology
for steel products
reflecting scrap recycling© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR20172

1. Importance ofLife Cycle Thinking© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR20173

What are eco-friendly materials?
 natural materials?
 recycled materials?
 carbon free materials?

Eco-friendly paper car…?

“Life Cycle Thinking” is important !

very

A Case Study on Automobile© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR20174

Tailpipe Emission Regulation
How to get it?

Weight reduction
is one of solutions.

© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR2017

5

Challenging weight reduction with HSS‘60 Tailpipe‘70‘68‘90 Regulation‘00‘10Emission
soft steel

Super HSS>1180MPa,
hot-stamping

HSS<590MPa

regular HSS<440MPaHSS - Super HSS
780-980MPa

Theoretical strength of iron is 12GPa.
We have commercially reached 1-1.5GPa in flat products and 4-4.5GPa in wire products.
Required Performance

Parts
outer

door outer

inner

floor

structure

Tensile stiffness

Anti-dent

StiffnessEndurance
strength

Dynamic crush
strength

Young'smodulus

Yield strength

Young'smodulus

Strength

Strengthfront rail
rear pillar
front side member
side sill
door guard coverunder floor

suspension arm
wheel disk

dominant factor except for thickness© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR20176CO2 emission frommaterial production stage
kg-CO25000

4000
Per 100kg Normal steel 100kg eq.
HSS:75kg
Aluminum:67kg
Magnesium:50kg
CFRP:45kg
Reference :World Auto Steel

3000

2000

1000

0
Normal steel

HSS

aluminummagnesium© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

CFRP
EMECR20177Life Cycle Thinking
Environmental burden
Highlighted stage

Hidden stage

Hidden stageburden in
production stage

burden inuse stage

burden for
waste treatment,
recycling effects

Evaluating only a partial stage (e.g. use stage) of theentire life cycle may lead us to a misleading result

total burden
throughout
the entire life cycle

Importance ofLife Cycle Thinking© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR20178Life Cycle CO2 Emission Comparison
among types of vehicle
Material selection becomes more important

Material selection is dominant ←Fuel economy is dominantDriving stage

Fuel
preparation

Material, body and parts productionwaste treating/recycling
ConventionalDiesel

EEA Signals 2017

EVFuture trend© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR20179

2. Advantages of steel
in material recycling

STEEL© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201710

Automobile Production in the World
automobile production (million)
areaEUJapan
USA
China
worldarea

2014
17.1
9.8
11.7
23.7
89.8
2014

2015
18.6
9.3
12.1
24.6
90.8
2015

JAMA2016
18.8
9.2
12.2
28.1
95.0
2016

Over 90 million cars are produced
disposed in the world
every year
What are the conditions for eco-material for mass
production products?
mass productivity, economy and technical performances areessential, in addition to those, “recyclability” is the key© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201711

Types of Material Recycling
ProductEnd of Life

Naturalresources

Material
Material
production
process

Final productprocess
production

Direct disposal

Thermal recycling
Cascade recycling

Use in society

Material

EoL

Closed-loop recycling
substitution

Thermal Recycling (Open-loop Recycling)
EoL products are incinerated and the heat is recovered as thermal energy to produce
electricity or steam. The recovery has no effect on the reduction of natural resource
consumption for virgin materials, but it is a low cost and energy saving way for recycling of
flammable materials.

Cascade Recycling (Open-loop Recycling)
The material is used as a secondary material in another product. The recycle may continue
cascadely in several steps. In each step, the material quality drops or changes and finallythe material comes to the EoL.

Closed-loop Recycling
The material is recycled to the original material without or with very little loss of its
characteristics or quality so that the number of recycling can be infinite. Closed-loop
recycling reduces consumption of natural resources of the material, accompanying
environmental impacts, and generation of wastes. Closed-loop recycling is superior toopen-loop recycling in terms of sustainability.
© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

STEEL

EMECR201712

Life Cycle of Steel Products
Steel keeps its metalic state even after the EoL of products
Fe2O3FeSteelNaturalresources

Steel

Steelproduction
process

Steelproducts

Final productproductionprocess

Steel is still Steel!

Finalproducts

SteelScrap

End of life offinal productSteelsubstitute

Steel can be recycled however many times
into whatever steel product you want…

Sustainable & Flexible Life Cycle© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201713

%Characteristics
ofSteel:Characteristics
ofAluminum:
Conditions
forQuality drop by recycling
Microstructure
Alloying Control
Autonomous/Sustainable

Al20
not
removable
HeatingFinishing elements)
Roughing (Tramp
Online cooling process
Hot revelercastingprocessVfurnacemillmill
18
B
16
Aluminum has a lotZrof
14 removable by gasification
tramp elements; Ti
12hence it is very CrTemp.
10berollingchangeZn
Strengthening by combination difficultof coolingto
and8
recycled
Steel has a limitedMg
finishingroughing
6 number of tramp heating
while keeping
cooling
Mn4 elements; hence
original quality.
Cu
2
steel
canbeeasily
Microstructure
Fe0changerecycled whileSi1080 original
2014
3004
4043
5086
6101
7N01
keeping
Intermediate coolingRapid cooling
Slow cooling
Graingrowthcontrol
Re-crystallization
elongation
Pure
AlAl-Cu
Al-Mn
Al-Si
Al-Mg
Al-Mg-Si
Al-Zn-Mg
quality.
600-800MPa
Over 800MPa
500-600MPa

Material Recyclinga) Separation and collection is easyb) Environmental impact of recycling is smaller
compared to production using natural resourcesc) Recycling system is economically sustainable

Additional conditions for “Closed-loop Recycling”
aluminum foiltankscrew, gear,
can body
piston, cylinder
automotive,
rivet,
head, panel
wheel,
shaping moldcan end
マルテンサイト：硬い組織 オーステナイト鋼を利用したTRIP鋼

car body,appliance, sash,
axle

airplane,railway card) No/small quality degradation through recycling

Variety of characteristics of steel products are realized by microstructure control
removable
by slaging
throughrolling andcooling in the process.

DP鋼の複合組織

Aluminum realizes its functions by alloying. Each alloy series must be recycled in the same alloy
system (same product like Can to Can). Mixture of several kinds of aluminum scrap can be used
Hiraki et al.
only
casted aluminumor die-cast
Theformicrostructure
is resetby melting and reconstructed for new product.
10μme) Can be recycled into various products
20μm

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14

LCI for steel products

3. worldsteel LCA methodology
for steel products
reflecting scrap recycling© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201718

Lifelong Environmental Burden of Steelwith eternal recyclingr ：scrap recovery rate×yield
Xpr ：burden for primary production
Lifelong burden ＝Xpr + ｒXre + ｒ 2Xre + ・・・ + ｒ n-1Xre Xre ：burden for recycling
Lifelong production ＝１ + ｒ + ｒ 2 + ｒ 3 + ・・・ + ｒ n-1

2Lifelong+ ｒ 3Xre + ・・・ + ｒ n-1Xre ＝(Xpr – Xre) (1-r) + Xre＝Xpr + ｒXre + ｒ Xre
１ + ｒ + ｒ 2 + ｒ 3 + ・・・ + ｒ n-1
unit burden(1-r n)When infinite recycling ( n → ∞ ), then r n → 0、 1 – r n → 1

Natural resources＝Xpr + r (Xre – Xpr）

Xpr

Substitute r ＝ 0.9×0.9, Xpr = 100, Xre = 25
＝39.25
Environmental burden

Average lifetime of steel(2005 stock base)* *Ichiro Daigo, Materials Science and Technology of Japan,
Vol.54(2), 15-18 (2017)

60use

r2r2Xre100

userrXre

A Amato, L Brimacombe, N Howard. (1996) Ironmaking and Steelmaking, Vol23, No. 3, 235-241

80

1use

r3r3Xre

use

40

20
0
12

3

4

5678910111213

1415

1617181920

Number of life cycle (= 1+recycled number)© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201719LCA methodology reflecting scrap recycling- worldsteel-LCA methodology -Cradle to “No” grave…

 It evaluates both BF-BOF and EAF as one whole steel cycle system.
 Through scrap recycling, the natural resource consumption and related
environmental impacts can be avoided (environmental value of scrap) Same as the economic value of scrap, the environmental value of scrap iscredited for its recovery and burdened for its use
A: Steel
production
processnatural resource
BF
substitution
BOF
B1: Burden for
EAF

Scrap recycling
effectEnd of lifeof products

scrap use

Scrap
Environmental value

B2: Credit for
scrap recovery

B2: Creditfor
scrap
recovery
A: Process B1: Burden
burdenfor
scrap use

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EMECR2017

Total
burden20

Evaluation of Scrap Recycling Effectassuming
the burden to produce a unit of steel product only from natural
resources is 100 (Xpr),
the burden to produce a unit of steel product only from scrap is 25 (Xre),and yield of steel product from scrap is 0.9,
thenenvironmental value of scrap = (100-25) x 0.9 = 67.5

The environmental value of scrap is credited when it is recovered andburdened when it is used.
for example,
when the recovery rate of scrap is 0.9, thencredit for scrap recovery equals to 67.5 x 0.9 = 60.75
And when the yield is 0.9, thenburden for scrap use equals to 67.5/0.9 = 75

Scrap recyclingeffects© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201721

A case study
100% virgin route100

Scrap recycling effect75
39.25 39.25

100% scrap route
25
Xpr

Xre

process burden

credit for scrap recovery
0burden for scrap use

Process burden of 100% virgin root: Xpr = 100
Process burden of 100% scrap root : Xre = 25
Scrap environmental value = (100-25) x 0.9 = 67.5
where yield of steel product from scrap =0.9
-60.75 -60.75
Burden for scrap use in 100% virgin root: 0Burden for scrap use in 100% scrap root : 67.5/0.9 = 75
where yield of steel products from scrap = 0.9
Credit for scrap recovery = 67.5x0.9 = 60.75
where scrap recovery rate = 0.9

total burden
There is no difference
between 100% natural
resource route and100% scrap route ifscrap recycling effects
are correctly reflected.

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EMECR201722

ISO Development ofworldsteel-LCA Methodology

ISO 20915: LCI calculation methodology for steel products2017 NIPPONSTEEL& SUMITOMO METALCORPORATIONAllEMECR2017Rights Reserved.
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Reserved.

23

worldsteel-LCI data collection
Access the most comprehensive and reliable
steel life cycle inventory data today:© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201724Conclusions
1. Life Cycle Thinking is the key to keep rightdirection in global environmental issues
2. Steel has great advantages in terms ofmaterial recycling
3. worldsteel LCA methodology gives a clear
answer for steel LCA reflecting closed-loop
scrap recycling© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201725

Thank you for your attention© 2017 NIPPON STEEL & SUMITOMO METAL CORPORATION All Rights Reserved.

EMECR201726