Home > About Us > Corporate Social Responsibility > Sustainability Report > Environmental Sustainability Report 2005

Environmental Management
Environmental Sustainability Report 2005

Contribution to Environmental Protection through Products, Technologies and Services (1)

Kobe Steel has integrated its manufacturing and engineering technologies, systems and know-how to provide eco-friendly materials and products. We also provide equipment and plant services in the fields of environmental restoration, effective energy utilization, utilization of unused resources, and waste recycling. Kobe Steel will continue its efforts in R&D and the advancement of technologies to further contribute to environmental conservation.


Eco-Materials
Kobe Steel to stop production of chromate-treated hot dip galvanized steel sheet
First Japanese steelmaker to go completely chromate-free
As a company with social responsibilities, we consider environmental issues to be one of our top priorities. The manufacturing sector, Kobe Steel's base, demands the meeting of strict environmental standards and offers products responding to the expanding green market.

Kobe Steel has completed development of hot dip galvanized (CG) steel sheet with no chromate layer and has begun commercial production of this material. CG steel sheet is used in construction, home appliances, and office equipment. The new steel sheet will replace the current chromate-treated CG steel sheet products. Kobe Steel ceased production of chromate-treated electrogalvanized (EG) steel sheet at the end of March 2005. When production of chromate-treated CG sheet ends in March 2006, Kobe Steel will be the first Japanese steelmaker whose coated sheet products will be entirely chromate free.

Chromate treatment has been widely used for CG and EG steel sheet for over 50 years as it improves the corrosion resistance and paintability of coated steel sheet. However, the EU's RoHS* (Restriction of Hazardous Substances in Electrical and Electronic Equipment) Directive bans the use of certain substances, including hexavalent chromium, from July 2006. Numerous industries have been undertaking measures to reduce the environmental burden, and an important issue has been to make coated steel sheet with no chromate layer.

In 1998, Kobe Steel became the first Japanese steelmaker to commercialize a chromate-free EG steel sheet called Zinkobella GX-COTE, noted for its high anti-fingerprint resistance, and has completely switched over to this material.

In hot dip galvanized products, the new CG sheet uses GX-GC treatment, which coats an inorganic composite film on the galvanized layer of the steel. The coating contains no hexavalent chromium. Called Galva-Ace GX-GC, the steel sheet is noted for its corrosion resistance, paintability and weldability, and has the same or higher properties than conventional chromate-treated steel. This responds to users' needs to deal with environmentally hazardous substances at a more advanced level, and also improves Kobe Steel's working environment at its steelworks.


* The RoHS Directive aims at minimizing hazard to human health and the environment through the restricted use of certain hazardous substances in electrical and electronic equipment. Restricted substances are mercury, cadmium, lead, hexavalent chromium, polybrominated biphenyls or polybrominated diphenyl ethers. From July 1, 2006, designated substances will be banned from use in new electrical and electronic equipments on the EU market.

Galva-Ace GX-GC (hot dip galvanized with GX-GC Treatment)



Development of High Strength Steel Plate for Bridges with High Welding Efficiency
Kobe Steel has developed high strength steel plate for bridges, which enables high heat-input welding.

The new steel plate was added to the lineup of Kobe Super Toughness, which contained products for construction and shipbuilding. The product doubles the high heat-input welding capacity and triples the toughness of parts affected by welding heat. Welding man-hours can be cut down because the one-pass welding enables a reduction in working costs. Also, weld cracking, emerging from low-heat-input welding such as tack welding, can be reduced and thereby improves structure safety.

Wire rod for engine valve springs wins the 51st Okochi Memorial Technology Prize in 2004

The Okochi Memorial Prize is presented each year to commemorate the achievements of Dr. Masatoshi Okochi. The technology prize is awarded to distinctive industrial accomplishments based on the inventiveness and ideas attained by research on production engineering and technology.
The developed steel is ranked the highest among Kobe Steel's high strength wire rod for springs. It was evaluated on its superior fatigue resistance and sag resistance characteristics, which are required for wire rods to be used in engine valve springs.



Development of Aluminum Hood for Improved Pedestrian Safety and Lighter Automobiles
Kobe Steel and Toyota Motor Corporation have developed an aluminum hood in consideration of reducing injury to pedestrians. The hood was introduced in the latest model sedans, contributing to weight reduction and improved safety.
Two aluminum sheets comprise the outer panel and inner panel of the hood. The inner panel has a wavy structure, instead of a beam-like construction generally used. If a pedestrian comes into contact with the hood in an accident, the impact is absorbed by the hood.
From fiscal 2005, it will be compulsory for new cars to offer head protection to pedestrians. Automakers are conducting research and development on the impact absorbance of hoods.



Kobe Steel develops automotive aluminum products in respond to user needs

A solution for lighter automobiles is to use more aluminum. As a leading company of rolled and forged aluminum, Kobe Steel, with comprehensive capabilities including process technologies, offers automakers the optimum materials.
For example, we were the first to commercialize such products as panel materials for car bodies, forged parts for automobile suspension systems, and extrusions for bumper beams and door beams. Kobe Steel developed these products based on forming analysis, making full use of data that we accumulated independently.
A case in point are shock absorbing and reinforcing beams installed inside doors to protect passengers from side crashes. Aluminum beams are 2.5 kilograms lighter for each four-door car than steel beams. A total of 1.7 million units are sold so far.





Development of Aluminum Bottle Can Stock
Aluminum cans are widely used for containers of beer and other beverages. Aluminum bottle cans are increasingly seen these days. The bottle cans are narrow at the top and have screw caps just like PET bottles. They can be carried around and protect the contents from ultraviolet rays. Beverages can be kept for a long time, and the containers are easily recycled.

Kobe Steel accounts for over 30% of the Japanese aluminum can stock market and 70% of the aluminum bottle can stock. To make good use of the high recyclability of aluminum, we will continue to develop aluminum can stock production technology for advanced processing and forming.



Production Process of Bottle Can Stock and Bottle Cans



Cold Forged Steel for Extended Tool Life
Kobe Steel has developed a new steel for cold forging. Although the material does not undergo heat treatment, it has the same deformation capacity and mold life as the spheroidized annealed carbon steel for machine structural use. This is achieved by the optimized addition of age suppression elements. The environmental load from heat treatment was reduced, as soft annealing and other processes were omitted.







Development of lead-free, soft magnetic steel
Kobe Steel has developed a lead-free, free-cutting steel. The steel has improved machinability without lead which is hazardous to the environment, utilizing our special steel production technology.

The new steel enables electromagnetic parts to be made smaller and lighter with improved control and lowerpower consumption. The lead-free soft magnetic steel has been introduced in the electromagnetic clutch of a four-wheel-drive vehicle.

A part made of lead-free free-cutting steel



Non-copper-coated solid welding wire (SE wire)
Solid welding wires used to be copper-coated for smooth feeding. "SE Wire," non-copper-coated welding wire Kobe Steel has developed, has the same level of wire feeding as conventional welding wires and superior arc stability, due to a newly developed surface treatment technology. The environmental burden is reduced, as the copper-coating process is no longer necessary. Also, the reduction of generated fume and spatter during welding work improves the welding work environment.

SE Wire has won numerous awards including a prize from the Japan Welding Society.

SE Wire