resource efficiency efforts in mhi group · 1/31/2018 · • since 2015, mhi has partnered with...
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© 2019 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.
Plenary Session 3
“Measuring our Progress on Using Materials Smarter, Less and Longer”
MHI Technical Senior Fellow
Dr. Eisaku Ito
Resource efficiency efforts in MHI group
World Materials Forum 2019
13 June 2019 Nancy, France
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© 2019 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2
Current list of 9 KPIs
The scope of KPIs:
Decoupling materials efficiency from economic growth while creating value for all
stakeholders involved.
KPIs Description
Use
Less
Buy-to-use Material value in the product / material value used in production
% of recycled materials Weight of recycled / total weight of materials in new product
End-of-life recycling Weight of materials effectively recycled / total weight of materials
Energy Total energy consumption to produce the product
Use
Longer
Product lifetime Total lifetime of the product, from completion to waste
Resale price Resale price after Y years / initial price(Y is industry specific)
Use
Smarter
% of innovative materials Weight of new of innovative materials / total weight of materials
Product performance vs. weight Performance measurement of the product key functions vs. weight
Overall product usage % of the time the product is used relatively to its full capacity
Source: WMF & Arthur D Little analysis
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MHI contribution to WMF
• Since 2015, MHI has partnered with WMF and KPIs were set in 2017.
• Since 2018, MHI has introduced activities related to KPIs.
• From 2019, MHI focuses on megatrends & CO2 KPI.
Problem
Definition KPIs definition KPIs in MHI plants
2015 2016 2017 2018 2019
Megatrendsin Steel Industry
&
CO2 KPI
KPIs in detail
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Some megatrends and their impact on the steel industry
Mass urbanization
Mobility (and electric vehicles)
Global climate action
(Paris 2015)
Fourth Industrial Revolution
(4IR)
A megatrend represents a long-term transformation process with a broad scope and significant
impact in reshaping the world we live in. By understanding, analyzing, and predicting megatrends,
companies can stay competitive by gaining insights into emerging growth areas in their respective
industries.
In addition, the following are also ongoing
megatrends which will continue to
influence the steel industry:
• Industrialization (of EMDEs1)
• Globalization (global trade and supply
chains) 1) EMDEs: Emerging Market and Developing Economies
Source: Posco Research Institute
ON
GO
ING
EM
ER
GIN
G
Urbanization Rate
Motorization Rate
https://www.pwc.co.uk/issues/megatrends.html#tab_5-0https://www.pwc.co.uk/issues/megatrends.html#tab_5-1
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Life-cycle of steel
Coal Iron Ore
Blast Furnace
Steel processing (casting,
rolling, annealing etc.)
Mass urbanization
mobility
EAFScrap recycling
CO/CO2
Fossil fuel
Less CO2
(Dragon steel Taiwan)
EAF: Electric Arc Furnace
(Usiminas; Cubatao; Brazil)
(Colakoglu; Turkey)
(Source; Alliance steel)
(Source; Bharat steels)
(Source;
Mining Journal)
(Source;
world coal association)
1,670 Million tons of steel were produced and 440 Million tons of scrap were recycled in 2017.
1,670M tons
440M tons
Hot metal
Steelmaking
Direct reduced iron
1,230M tons
Global climate action
(Dragon steel Taiwan)
https://www.pwc.co.uk/issues/megatrends.html#tab_5-0https://www.pwc.co.uk/issues/megatrends.html#tab_5-1
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Steel industry responses to megatrends
Megatrends
Steel Market
MobilityMass urbanization Global climate action
Solutions
(A)Digitalization (B)H2 DRI (C)High Efficiency EAF (D)Bio Carbon converting
Less CO2 emission
By MHI Group
Digitalization
Source: https://www.conservationinstitute.org
Source: Lanzatech
MHI group offers solutions to the steel industry related to megatrends.
4IR
Steel for Motor
Source: Mitsubishi Motors websiteSource: Volvo website
Mass production of AHSS1) & Electrical Steel 2)
1) Advanced High Strength Steel (light and strong steel) 2) Electrical steel (used for motor coil)
Light & strong steel
EAF: Electric Arc Furnace
https://www.pwc.co.uk/issues/megatrends.html#tab_5-1
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(A)Digitalization
Real-time analysis and control
• Digitalization allows steel plants to produce AHSS & Electrical Steel with greater efficiency.
• The reduction of steel weight in car will be ca.500kg CO2/car.
(Usiminas; Cubatao; Brazil)
Car weight
reduction(221kg steel/car)
(508kgCO2/car)
Digitalization
2300kg CO2/t crude steel 1) x 0.221ton = 508kg CO2
1) Nishino , ISIJ Ferrum vol.3(1998)No.1,
Material Economics, 2018, The Circular Economy
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(B) Direct Reduced Iron by Hydrogen
Source: K1-Met, Seminar: Steel Industry: The Wind of Change, Brussels, January 31, 2018
• Hydrogen can be used in existing Direct Reduction (DR) shafts without major modifications.
• H2 DRI will reduce ca.1000kg CO2/t crude steel compared with BF/BOF steelmaking.
1000kg CO2 /t crude steel reduced
1250
250
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Quantum EAF
• High efficiency EAF increasing with scrap availability and improving recycling rates
• Quantum EAF reuses exhaust heat from molten metal to preheat scrap.
• 30% energy saving in Quantum EAF is equivalent to ca.50kg CO2/t crude steel.
Preheating system
Preheating
Scrap
Molten metal
Preheated
Scrap
Electrodes
Exhausted
hot gas
Drop
(C) High Efficiency EAF
Ele
ctr
icity c
on
su
mptio
n(k
Wh/t
)
Conventional
EAF
Quantum EAF(New Method)
-50kgCO2(30% Energy
Reduction)
Overview of Quantum EAF
EAF (Recycle)
Now
BF
DRI
Source; World steel September 5th 2008 Japan
180kg
CO2 *)
130kg
CO2
*) kg /t crude steel
430
300
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(D) Bio Carbon Converting
Source: CCU-Now: fuels and chemicals from Waste Lanzatech 2018
Source: Virgin Atlantic
Source: Lanzatech
GHG: Green house gas
i.e. ArcelorMittal Belgium: Steelanol Project
80.000.000 l/y bio-fuel from 90.000 Nm³/h BF gas
* Base on life-cycle GHG calculation by Ecofys for the Gent plant
87%* GHG Reduction
vs. Petroleum based fuel
• CO generated in steel plant can be converted to ethanol (Bio fuel) by Bio Gas Fermentation.
• Bio fuel save ca.100kg CO2/1000km (car), 87% reduction from Petroleum base fuel.
Bio Gas Fermentation Process
Ethanol
Fleet emissions Europe avg. ~120 g CO2/km
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(A)Digitalization (B)H2 DRI (C)High Efficiency EAF (D) Bio Carbon converting
➢ 4 solutions satisfy “Use less, longer, smarter” KPIs.
➢ Reducing CO2 will remain a major KPI in steel industry.
Conclusion
✔ Bio-fuel
✔ Recycle
✔ Hydrogen use ✔ Pre-heating ✔Carbon converting
✔ Smart operation
✔ AHSS
Digitalization
CO2 KPI (ca.) - 500 kg/car - 1000 kg/t crude steel - 50 kg/t crude steel - 100 kg/1000km
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