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Products, Technologies and Services to Benefit the Environment

The Kobe Steel Group has long experience in the materials field, covering iron and steel and aluminum, and the machinery and engineering field. The Group has developed production technologies, engineering technologies and know-how that are now being used in products, technologies and services to help conserve the environment.

Materials Field

The Kobe Steel Group, as a comprehensive producer of materials, uses its advanced technologies developed over many years, balanced by its comprehensive strength in manufacturing, processing and product development, to create and supply "Only One" upper-end products such as high strength steel sheet, wire rod for engine valve springs and aluminum parts. In this way we contribute to lighter, safer, more environment-friendly vehicles. We also supply other products that reduce the environmental impact, such as chromate-free steel sheet and aluminum soundproofing materials.

Steel products that help reduce vehicle weight

To meet the need for lightweight materials that help improve fuel consumption in automobiles, Kobe Steel took an early lead in developing and mass producing high strength steel. In the fields of wire rod and bar, Kobe Steel developed the world's highest strength steels for springs and bolts. Now in mass production, these products contribute to the environment.


Examples of steel products used in vehicle parts

Examples of steel products used in vehicle parts


	High Strength Steel Sheet

High strength steel sheet is a continuously evolving material utilizing know-how on chemical composition and heat treatment texture control acquired from our long familiarity with specialty steels for wire rod and bar. Featuring high tensile strength combined with high formability, this steel is used widely in the auto industry, in vehicle bodies, functional components such as bumpers and door impact beams, and seat parts that require complex processing.

For shipbuilding we have developed high strength steel plate with a yield point of 47 kg, without using nickel or any other special high-value elements. The steel plate has characteristic features of high strength and high fatigue-resistance. In May 2007 we received approval from the Japanese Shipowners' Association to manufacture the plate up to a thickness of 60 mm. This steel was used for a largecontainer vessel in October 2008 and for a large automobile carrier in February 2009. This was the first time that steel plate with a yield point of 47 kg was used in shipbuilding for a vessel other than a container ship.

Growth in Orders for High Strength Steel Sheet for the Auto Industry

Growth in Orders for High Strength Steel Sheet for the Auto Industry


	Wire rod for engine valve springs

Kobe Steel has developed an ultra-high strength steel for next-generation engine valve springs, KHV12N, by furthering the technology to reduce inclusions that cause springs to fracture with increased quantities of alloy element additives such as vanadium. These springs are critical parts that control the action of the air intake and emission valves in engines and must be of high strength and high durability so as not to fracture under repeated loads of several thousand times per minute, in cars traveling distances of over 100,000 km over a 10-year period. This newly developed material has a fatigue strength 50% higher than standard steel, and valve springs can be made 50% lighter. Cases have confirmed that when used in automobiles it is possible to improve fuel economy by 2%.

Since mass production commenced, KHV12N has been adopted by a growing number of car and motorcycle manufacturers both in Japan and overseas.

Wire rod for engine valve springs

	Topics

Special Award from Toyota for Weight Reduction

Kobe Steel has received a "Special Award for Lightweighting" from Toyota for the development of center pillars using 980MPa-class ultra high strength steel sheet to boost side impact performance. The award was made at the 2008 Toyota Global Suppliers Convention held on 29 February. Awards for technical developments have been received five times in the past, but this was the first time we received this particular award.

Amid tightening controls on auto CO₂ emissions and regulations covering collision safety, there is a growing need for high tensile steel that combines light weight with high strength. In light of this award, Kobe Steel will proceed with further research and development on auto-part applications for high strength steel.


	Chromate-free steel sheet

In 1998, Kobe Steel was first in the steel industry to put on the market a chromate-free steel sheet, Zinkobella GX-COTE, as a substitute for chromate-coated electrogalvanized steel sheet. Since then, chromate-free products have been consistently upgraded so now all galvanized steel sheet is chromate-free.

It's now possible to offer customers a higher grade product to help reduce their environmental impact, and the working environment at steelworks has also benefited.

Chromate-free steel sheet


	Titanium welded tube used in electric bicycle

Titanium welded tube manufactured and marketed jointly by Kobe Steel and Kobe Special Tube Co., Ltd. was selected for the frame of an electric power-assisted bicycle made by Panasonic Cycle Technology Co., Ltd., achieving a weight reduction from 20 kg to 16.7 kg. Vibration absorption is also improved, lessening fatigue for the rider. Titanium's outstanding resistance to corrosion and durability mean that the bicycle can be used for many more years than models made of conventional materials.

Titanium Light EB:
light-weight premium electric bicycle with titanium welded tube frame

	Topics

Titanium alloy used in JAXA's space transport

Kobe Steel's titanium alloy is used in the fuel tank of the H-IIB Launch Vehicle developed by the Japan Aerospace Exploration Agency (JAXA) to transport cargo to the International Space Station. From our considerable experience in forged products for aerospace use made of titanium alloy, as well as forging technology, Kobe Steel can supply titanium alloys that are lightweight, high-strength and highly corrosion-resistant, meeting the highest levels of quality and reliability to withstand the punishing conditions of use in space.

Aluminum products that help reduce vehicle weight

To help cut CO₂ emissions by reducing vehicle weight, Kobe Steel is exploring the use of aluminum for more and more auto parts. Aluminum is particularly effective as panel sheet used for hoods and doors; for extruded parts such as bumpers; and for forged underbody components such as suspensions, helping to make vehicles more fuel-efficient.

Materials and forming technology have been developed in line with the wider use of panel sheet. For bumpers and suspensions, analysis technology offers structural proposals for further advances in lightweight. Amid the current downturn in vehicle production, auto industry products are expected to account for 20% of the Aluminum & Copper Company's sales turnover in 2009, which is about the same level as 2005 to 2008.


Examples of aluminum products used in vehicle parts

Examples of aluminum products used in vehicle parts


	Design change: automotive suspension arms switching to aluminum forged parts

Aluminum forged parts have higher strength than parts made by other processes such as casting and are 35% to 40% lighter in weight than forged steel parts, so they can have a significant effect in reducing product weight in a range of manufacturing processes. Being consistent in internal quality and highly reliable, they are well suited for suspensions, in which the underbody is targeted for weight reduction.

Production of aluminum forged parts for Japan's auto industry has been growing year by year since 2000.

Upper arm

Knuckle


Ratio of automotive product sales to total sales in the Aluminum & Copper Company: Results & Forecast

Ratio of automotive product sales to total sales in the Aluminum & Copper Company: Results & Forecast

Kobelco & Materials Copper, Ltd.
Two-layer copper tube cuprotherm CTX launched

Kobelco & Materials Copper Tube, Ltd. has launched a new product cuprotherm CTX, for use with the EcoCute* natural refrigerant heat pump electric water heater, to connect the heat pump unit to the tank. cuprotherm CTX is a copper tube with a firm adherent coating of heat-resistant polyethylene (PE-RT), which cuts the quantity of copper used by about half compared with conventional copper hot water pipe, reducing its weight. The tube is easy to work, and its copper inner surface maintains the same excellent hygienic qualities as conventional copper tube, being reliable and resistant to bacteria in cold or hot water.

Besides conventional coated copper tube, increasingly either crosslinked polyethylene tube or aluminum three-layer tube is used for EcoCute connecting pipe, but there is a growing need in the market for products reliable to high temperatures of 95°C. Cuprotherm CTX is a new product that meets these specific market requirements.

*EcoCute is a registered trademark of Kansai Electric Power Co, Inc.

cuprotherm CTX connecting tube for EcoCute water heaters

Taseto Co., Ltd.
Ecopack-Shot
Environment-friendly low cost rechargeable spray system

Taseto Co., Ltd. markets a color contrast dye penetrant called Color Check that reveals minute surface defects in materials and parts. It has the dominant share of the Japanese market.

An aerosol propellant is used to ensure that the penetrant fluid thoroughly coats the surface to be inspected, but aerosols present a number of environmental problems such as disposal of empty cans and leakage of the propellant gas into the atmosphere. Taseto has therefore adopted a new rechargeable aerosol system called Ecopack-Shot that uses compressed air instead of LPG, DME or CFC gas. It's now possible to use an environment-friendly color contrast dye penetrant.

Ecopack-Shot rechargeable aerosol system that uses compressed air

High-grade anti-bacterial KENIFINE coating used in bathroom heater/dryer

High-grade anti-bacterial KENIFINE coating used in bathroom heater/dryer
The high-grade anti-bacterial KENIFINE coating technology developed by Kobe Steel has been adopted by Noritsu, a manufacturer of bathroom fittings, for use in its wall-mounted bathroom heater/laundry dryer, to control mold. After two hours' use, only 5% of the mold fungus normally found on non-coated equipment was found on the filter.

KENIFINE is an electro-plated nickel-alloy coating for metal products, and has excellent anti-bacterial and anti-fungal properties. It has applications in many different fields where cleanliness is critical, including medical and welfare services, and the food processing, electrical equipment, air purification and fishing industries.

Bathroom heater/laundry dryer with KENIFINE coating

Machinery and Engineering Field

Utilizing a wealth of experience built up in the industrial machinery field, as well as strengths in technologies and engineering and the general know-how to respond to customers' needs, the Kobe Steel Group contributes to environmental conservation by supplying compressors and construction machinery with improved energy-saving performance, and new ironmaking technologies with energy-saving potential. Furthermore, we have considerable experience in the fields of water purification, waste processing and recycling. We supply many types of environment-friendly equipment for water purification and waste treatment.

Kobelion Standard Compressors

Developed under the concept of reliability, innovation, optimal performance and environment-friendliness, Kobelion standard compressors supplied by Kobe Steel achieve significant reductions in energy loss. Fitted with the world's first IPM high-speed motor, the volume of airflow is increased by up to 32% over conventional compressors. Combined with an inverter, this provides users with maximum airflow at an optimal pressure. A compressor one rank lower than usual can be used, saving up to 21% of running costs. The market share of these energy-saving models is growing year by year.

Kobelion Standard Compressors


Annual sales of Kobelion Energy-Saving Compressor Models

Annual sales of Kobelion Energy-Saving Compressor Models

Emeraude-Aqua next-generation inverter oil-free compressor,
for outstanding environmental performance

Emeraude-Aqua developed by Kobe Steel is a high-performance water-injection oil-free screw compressor. With excellent cooling and sealing characteristics, Emeraude-Aqua is equipped with a Kobe Steel-designed non-contact screw unit directly coupled to an inverter-drive IPM high-speed motor, giving excellent performance covering a wide range of air volume.

Emeraude-Aqua water-injection oil-free screw compressor

New SteamStar model launched

The Machinery & Engineering Company and Technical Development Group of Kobe Steel and Group companies Shinsho Corporation and Shinko Engineering Co., Ltd. have jointly developed with TLV Co., Ltd. a high-output model in the SteamStar range of compact screw-type steam generators.

StreamStar generators use excess steam created at industrial plants and low-pressure steam energy before manufacturing processes for high-efficiency power generation. They have been very well received by users, who have been waiting for high output models of 100 kW and above. To meet this demand, the line-up has been expanded with the launch of a new model with output increased about 30% to 132 kW. A further 160 kW model will also be launched.

SteamStar compact screw-type steam generator

High Efficiency Mini II: The Industry's Most Energy-Efficient Water-Cooled Screw Chiller

Kobe Steel and the Chubu, Tokyo and Kansai electric power companies have jointly developed a water-cooled screw chiller, the High Efficiency Mini II, which was released in December 2008 to widespread interest in the air-conditioning industry. At COP6.0 it has the highest ranked energy efficiency for this type of equipment. Running costs are far lower than for gas-fired absorption chillers and CO₂ emissions are cut by 70% over the year, making a significant contribution to environmental protection.

High F Mini II Ultra high efficiency water-cooled screw chiller

High Efficiency Mini II ultra high efficiency water-cooled screw chiller

An index of mid summer season energy efficiency, the higher the COP figure the greater the energy saving. COP6.0 means six times the heat energy is output per unit of input energy (electricity consumed).

Jointly developed steam-driven air compressor system saves energy and cuts CO₂ emissions

Kobe Steel and Miura Co., Ltd. have jointly developed a steam-driven air compressor system comprising an air compressor unit with a screw-type steam-driven motor, and a heat recycling unit that redirects compression heat to the water supply for the boiler. Compared with electricity, steam is a low-cost power source that is also low in CO₂ emissions, and this together with recycling the previously un-recovered compression heat to warm the cold water supplied to the boiler, gives the ultimate in energy-saving equipment, with CO₂ emissions cut by up to 90% and running costs by up to 85% compared with electrically driven air compressors.

Steam-driven air compressor

LNG cold heat power generation

The LNG cold heat power generation system developed by Kobe Steel generates electricity through the temperature difference between a cold heat source, which is the LNG vaporization heat that was formerly discarded in seawater, and a warm heat source, which is the seawater itself. The system has an established record of many years' running at gas and power companies that hold stocks of LNG. As it involves no combustion, this system releases no CO₂, and it generates electric power from LNG cold heat, which has been earmarked as an unexploited form of energy. Compact, reliable and with excellent operability, these power generation facilities can make a big contribution to reducing global warming.

Cold heat power generating facilities (Osaka Gas Senboku Plant)

Kobelco Eco-Solutions Co., Ltd.
Gasification and Melting Furnace

By utilizing the energy contained in wastes for combustion at higher temperatures than conventional incineration systems, the gasification and melting furnace limits emissions of hazardous substances and reduces output volumes by turning ash into molten slag, thereby lightening the environmental impact.

Kobelco Eco-Solutions has created the world's first practical application of a fluidized bed-type gasification and melting system to handle city garbage. The company is an industry leader, receiving a total of 12 orders since the plant was first launched commercially in 1999. Four of the 12 plants are under construction. To add further to the merits of this technology, technical refinements have focused on energy-saving. By utilizing sensor technology that can measure and control the temperature inside the furnace to keep it stable even in a high temperature environment, we have developed for practical application the technology to maintain the furnace environment at optimum conditions. Also, more of the plant operation has been automated to cut the electricity needed. In this way, the energy consumed for urban waste disposal is greatly reduced, contributing not only to making a pleasant environment but also moving closer to a low carbon society.

Fluidized bed-type gasification and melting system

Kobelco Eco-Solutions Co., Ltd.
Efficient Recovery of Rare Metals from Liquid Industrial Wastes

The rare metals in waste liquids conventionally disposed through drainage systems as industrial waste can now be easily and efficiently extracted for recycling. Kobelco Eco-Solutions has developed a technology whereby aluminum pellets of 2 to3 mm in diameter are mixed into the liquid waste. The differences in ionization cause copper to be deposited on the surface of the pellets, which is then separated using ultra sound.

The metal in liquid waste from metal processing or plating plants is usually in the form of a high-volume sludge. This new technology efficiently separates out the metal, and can reduce the volume to just one twentieth or one thirtieth of what it was before.

Minute granules of copper separated using ultra sound. (magnified)

Kobelco Eco-Solutions Co., Ltd.
DT Module System Leachate Treatment Equipment

The DT Module System used at landfill sites for industrial waste excels at removing dioxins and salts, and sales have increased steadily over recent years. The straightforward system uses simple pre-processing followed by a unique reverse osmosis membrane to make the leachate as clean as natural water. It takes little space and is easy to maintain.

Concerns are heightened at landfill sites for both local residents and the environment in general, but costs must also be held down due to the financial constraints of local government authorities. This system meets all these requirements, and with ongoing upgrading of the technology we will continue to help harmonize environmental conservation with local communities.

DT Module System

Kobelco Construction Machinery Co., Ltd
New hybrid hydraulic excavator reduces fuel consumption by average 50%

In October 2009 Kobelco Construction Machinery Co., Ltd. is launching the SK70 Hybrid, a 7 ton-class hybrid hydraulic excavator that uses a battery system to cut fuel consumption by an average of 50% compared with conventional models.

Part of the energy the engine generates while the machine is not being operated or when the brake is engaged is stored in batteries and used as supplementary energy for the engine. The stored electrical energy is less likely to suffer loss of voltage than in a hybrid system that utilizes a capacitor, and the highly efficient energy use means a smaller sized engine can be used and less fuel is consumed. Also, by electrifying the swing action, energy from swing braking can be recovered and recycled, further helping to save on fuel.

SK70 Hybrid hydraulic excavator

Kobelco Systems Corporation
Green IT Solutions contribute to global environmental protection

Kobelco Systems Corporation is promoting Green IT Solutions. Green IT refers to IT-related measures to protect the global environment in two different ways: by lowering the environmental impact of IT itself, and by using IT to reduce the consumption of energy resources.

In the former area we offer the following solutions:
1) Sales of IT equipment that consumes less electricity, and transition support
Sales of energy saving server equipment that boosts processing capacity while holding power consumption at former levels or below, and transition support.
2) Server integration
Saving energy, space and labor by combining several separate systems on a small number of servers.
3) Virtualization technology
As servers are said to be in use on average 20% of the time, using free server resources for other applications to make more efficient use of them.

Our solutions for using IT to save energy include an electronic reference system for print data, measures to reduce paper use, such as an electronic approval system, and teleconferencing systems that cut travel time and save energy.


Saving energy and space through server integration

Numbers of servers (upper figures = integrated servers; lower figures = separate servers

Source: IBM Japan Inc.