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Contributing to the Environment through R&D

The Kobe Steel Group is actively promoting the commercial development of environment-friendly materials and machinery to create more and sell more "Only One" Kobelco products. Here we introduce the technical developments underlying these environment-friendly products.

Materials

Developing technology to balance lightweighting and higher safety in transportation

We are using environment-friendly materials technology to develop new materials such as high strength steel, high crack arrest steel plate, ultra high strength aluminum, and highly formable aluminum panels, that will lighten the weight of vehicles, ships and other transport means, thereby reducing fuel consumption and CO₂ emissions.

In recent years, parts and materials for vehicles are required not only to be lower in weight to improve fuel efficiency, but also to better protect passengers in vehicles and pedestrians who might be struck in an accident. Aluminum alloy is lighter than steel but not as strong, and in an impact deformation is concentrated in one area. We are therefore using an aluminum-magnesium-silicon alloy (6000 class) that offers increased material strength while absorbing impacts over a wider area. Working with client companies, we are using structural analysis technology to develop structural parts to reduce damage to a pedestrian's head. Thus, we have established and developed for commercial use technologies that can balance weight reduction against safety issues.

Fig. 1 Vehicle hood made of aluminum alloy that balances light weight against safety

Fig. 1 Vehicle hood made of aluminum alloy that balances light weight against safety

For shipping, to save energy through larger bodied, lighter weight vessels, with improved weldability, there is a growing trend to use high strength heavy steel plate that provides improved safety of the vessel structure. (Fig. 2) We have developed new shape-control technology for steel materials that combines low carbon fine bainite technology with uniform strength cooling TMCP (Thermo-Mechanical Control Process) technology. We also produce a high strength, high toughness, high weldability heavy plate with a 47 kg class yield point, without using special elements such as nickel. (Fig 3)


Fig. 2 Uses of high strength heavy steel plate in ultra-large container ships


Fig. 3 Technology to improve toughness of high heat input welded parts

Fig. 3 Technology to improve toughness of high heat input welded parts

Using Alloys for Greater Energy-Saving

We are developing copper alloy tube that can contribute to the improved performance of a natural refrigerant heat pump-type electric water heater called EcoCute. The temperature of the hot water output is about 90°C for this type of equipment, because the water has to be stored in a tank, and as this is higher than the 60°C usual in a combustion type water heater, deposits largely of calcium carbonate more easily attach to the inside of the copper pipe used in the heat exchanger, and this may over time lead to a loss of performance. By developing an experimental method to accelerate the speed of deposition we found an alloy that cut by half the amount of deposit. This is a copper alloy Cu-Sn-Zr-P called PICOLESS. Currently its performance with actual equipment is being studied with a view to commercial application.

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

Fig. 4 Calcium carbonate deposits on inner surface of conventional tube and PICOLESS tube (magnified)

Fig. 4 Calcium carbonate deposits on inner surface of conventional tube and PICOLESS tube (magnified)

Source: R&D Kobe Steel Engineering Reports Vol.58, No.3 / Dec. 2008

Machinery and Engineering

The Kobe Steel Group's main lines of business are machinery and engineering (which includes compressors, plastic mixers and tire machinery) and construction machinery (excavators and cranes). We are pursuing technical development so that these products can contribute to energy savings, reduction of CO₂ emissions and other forms of environmental protection. Recent R&D results for increasing the efficiency and saving energy in our machinery products are introduced below.

Reducing CO₂ and Noise with Water

The Emeraude-Aqua water injection inverter-driven screw-type air compressor is an oil-free type of compressor in which water injected into the compression process provides for simultaneous cooling and sealing. By using water injection and an inverter-driven IPM high-speed motor we have achieved an enormous output in air quantity that tops the class (non-contact body therefore no loss in performance). (Fig. 5) We have also reviewed the shape of the water cooler and inverter cooling fan in the cooling system and achieved energy savings and reduced CO₂. Also, by using low noise technology we have reduced noise and improved noise quality, thereby benefiting the environment surrounding the equipment.


Fig. 5 Structural design of Emeraude-Aqua and energy-saving performance comparisons

Fig. 5 Structural design of EmerauDe-Aqua and energy-saving performance comparisons

Improvements in Heat Exchanger for Highest Level Energy-Savings Performance

Water-cooled screw chiller High Efficiency Mini II was jointly developed by Kobe Steel and Chubu, Tokyo and Kansai Power companies and by upgrading with two heat exchangers (evaporating and condensing) the COP value that shows energy-saving performance reached a record level of 6.0 in this equipment.

All High Efficiency Mini series models have been fitted with a plate-type heat exchanger in which high temperature and low temperature fluids (water, refrigerant) flow back and forth between stacks of heat exchange plates with a wave-pattern for heat exchange. Three modifications have been made to these plates in the High Efficiency Mini II series. (Fig. 6)

1	Heat transfer performance enhanced through improved wave pattern
2	Heat transfer performance enhanced through improved flow speed of heat medium flowing through plates
3	Improved shape around the holes for better distribution of fluid to the plates, and effective area of heat exchanger increased.

With the optimal design of the plate pattern, the heat flow is improved for greater efficiency.

Fig. 7 shows performance characteristics when the temperature of the cooling water changes. With the cooling water entering at 30°C as per the JIS standard, an excellent COP 6 is achieved, and as the outside air temperature falls the COP value increases so that at the cooling water lower limit temperature of 13°C performance is 16% better than previous models, and up to 74% higher than the chiller we marketed in 1997, with a COP value that is almost double.


Fig. 6 Plate-type heat exchanger


Fig. 7 Effect on performance of temperature changes to cooling water

Fig. 7 Effect on performance of temperature changes to cooling water