2016年日本钢铁科技进展
日本近代钢铁技术何以迅速跻身一流?
日本近代钢铁技术何以迅速跻身一流?如果说东北帝国大学钢铁研究所是物理学者通过基础科学的手段来研究钢铁材料的话,那么八幡制铁所技术研究所和日本其他民间钢铁企业研发机构则是企业研发人员为解决钢铁生产的实际问题而进行研发。
这两种研发行为虽然出发点不同,但从两个方向共同推动了日本近代钢铁技术的飞速发展。
提到日本的钢铁工业,新日铁、JFE、住友金属、神户制钢等世界顶级企业的名字马上就会涌入脑海。
作为钢铁强国,日本钢铁工业较高的产业集中度、良好的战略布局、重大的前沿工艺技术、高质量高档次的产品等得以使其在国际竞争中遥遥领先于其他国家。
而日本钢铁工业对先进技术矢志不渝的追求、科学的技术研发体系以及强大的消化吸收再创新能力更令人称道。
从技术发展的角度来看,日本钢铁工业的技术理念并非短时期内形成的,而是历经百年传承的结果。
19世纪末,一场自上而下、全面彻底的资产阶级改革在日本启幕,史称明治维新。
这次改革一举将日本推入一个前所未有的新时代,其国力与财富由此开始加速积聚。
为满足军事的需要,19世纪末至20世纪初,日本从国外引进了众多先进的工业技术,建立并逐步完善了现代高等教育制度,派遣大量留学生前往德国、美国、英国和法国学习深造。
在这样的大背景下,日本近代最早的一批钢铁技术研发组织应运而生。
本多光太郎与日本钢铁研发的“科学化”第一次世界大战以后,日本国内以自主技术研发振兴钢铁工业的思潮日渐浓厚。
1915年~1919年,一批重要的钢铁技术研发机构在日本相继诞生,标志着日本近代钢铁技术已经进入科学研究的新阶段,而钢铁研发的“科学化”带动了具有国际领先水平新材料的发明。
其中,1916年4月成立的东北帝国大学钢铁研究所(1922年更名为东北帝国大学金属材料研究所)是其中的典型代表。
该研究所首任所长本多光太郎在推动日本钢铁技术研究迈向“科学化”阶段发挥了核心作用。
本多光太郎(1870年~1954年),1894年~1897年就读于东京帝国大学物理学科,毕业后赴德国哥廷根大学深造,进行合金的物理冶金学研究。
2016年日本钢铁行业去产能研究报告
2016年日本钢铁行业去产能研究报告2016年2月目录一、1970s钢铁行业产能过剩的直接原因在于外部冲击 (4)1、倾斜式生产使日本钢铁行业在战后从瘫痪中迅速恢复 (4)2、经济高速发展使日本钢铁行业迅速扩张至巅峰 (7)3、连续的外部冲击导致日本钢铁行业产能严重过剩 (10)二、行政命令去产能,过程漫长且反复,政策效果有限 (11)1、行业协会最早着手研究去产能,仅提出方案无实质动作 (12)2、官方对过剩更为悲观,政策操作性强,企业配合,短期效果明显 (13)3、企业积极探索合并,抱团求生存 (16)4、去产能出现反复,政策效果大打折扣,安定基本计划被迫延长 (16)三、去产能期间,行业表现较差;去产能尾声,受益于需求扩张,行业表现较好 (18)1、钢铁行业扩张至巅峰,行业相对收益最为明显 (19)2、去产能过程中,行业持续弱势 (19)3、去产能阶段尾声,行业走强,相对收益明显但弱于行业巅峰时期 (19)4、去产能反复,行业再度走弱,且弱势程度加深 (20)5、去产能尾声,行业再次走强,但相对收益不明显 (20)日本钢铁行业在其战后恢复及后来的工业化进程中均起到了非常重要的推进作用,时至今日,其在世界钢铁业中依旧占据了重要地位。
纵观半个多世纪的发展,日本钢铁产业在粗钢产量1973年达到巅峰后随即就面临着产能过剩的调整需求,究其原因,较为复杂,本质上均可归结为经济增长变迁所致,但具体还与日本经济追赶战略、产业结构、国际环境等因素密切相关,这与当前中国所面临的情况极为相似。
就化解过剩产能所经历时间而言,相对漫长。
日本1970s的去产能前后持续近十年,直至1983年前后,之后在房地产行业的带动下日本经济快速增长,钢铁行业随即恢复生机,产能过剩问题一扫而光。
而且这期间集结了政府、行业协会、企业、银行等多方的智慧,任何政策的出台都需要经过充分的论证与利益协调,绝非一蹴而就。
就政策效果而言,不尽如人意。
日本国家钢铁行业发展史
日本国家钢铁行业发展史日本钢铁企业重组情况2000年前雄称日本六大钢铁公司的新日本钢铁(新日铁)、川崎制铁(川铁)、住友金属工业(住金)、日本钢管(NKK)、神户制钢所(神钢)和日新制钢(日新),随着日本经济的衰退,他们经过认真研究和探索,寻求了一条新的生存发展之路---合并重组资源共享。
日本的六大钢铁公司重组成两个集团统一组织经营和生产。
具体的组织构成如下:(1)NKK与川铁的合并NKK与川铁的合并事宜于2001年5月宣布,2001年12月21日公布了合资经营的计划,合并后的公司名称为JFE(J-Japan,F-Fe,E-Engineering)集团,于2002年10月成立持股公司。
JFE集团公司由现川崎制铁董事长江本宽治担任董事长职务,日本钢管总经理下坦内洋一就任总经理。
2003年4月成立下属钢铁、工程技术、城市开发、半导体、研究开发等5个股份分公司。
重组后的钢铁主业公司---JFE钢公司由现川崎制铁总经理数土文夫担任总经理职务,现日本钢管副总经理半明正之出任董事长,现日本钢管副总经理土手重治就任JFE工程技术公司总经理。
生产经营计划合并后年粗钢生产能力为2500万吨,规模与新日铁持平。
通过设备重组调整后,将减少产量200万吨。
通过统一经营,到2005年降低成本800亿日元。
其中自然减员6000~7000人,减少费用300亿,降低生产、维护、运输成本和设备集中减少费用200亿。
到2006年3月销售额与现在持平的话,可获利润2000亿日元(2002年3月单纯预计利润为零)。
合并后共分3个生产基地。
一个是以京浜(NKK)和千叶(川铁)为主的东日本钢铁厂;另一个是以水岛(川铁)和福山(NKK)为主的西日本钢铁厂;第三是知多制造所钢管生产基地。
(2)新日铁阵营日本铁老大新日铁在经济不景气的持续下,为了维持老大地位,不得不考虑新时期的适应对策。
在NKK与川铁将于2002年10月正式成立合营公司前,新日铁也加紧了与其它公司的联合事宜商谈。
日本钢铁技术现状及二氧化碳减排发展
日本钢铁技术现状及二氧化碳减排发展来源:王小天 文章发表时间:2010-04-06全球变暖是世界各国面临的一个严峻问题。
气候变暖影响着人类的生存和发展,应对这一难题是世界各国共同的责任,因此必须站在新的高度强调国际间的技术合作,以及向发展中国家转让技术。
在二氧化碳减排方面,不能低估炼铁工艺在整个钢铁工序中的作用。
可以毫不夸张地讲,钢铁工业未来的发展依赖于未来炼铁技术的进步。
因此,既要从短期着手又要从长远角度出发,针对局部区域和全球范围研究开发炼铁工艺技术。
在日本,钢铁工业面临降低能耗的任务是到2010年能源消耗在1990年的基础上下降10%。
为实现这一目标,日本钢铁业者一直致力于炼铁新工艺、新技术的开发。
1日本炼铁技术现状自1983年开始应用煤粉喷吹技术直至2000年,日本高炉喷煤比在不断增加。
在此期间,主要的经营目标之一就是大量使用廉价原料,例如从澳大利亚进口了大约50%的铁矿石,渣量大,大量劣质煤的使用虽然降低了生产成本,但导致还原剂消耗普遍超过500kg/t。
然而,由于全球气候变暖问题的日益加剧和产能提高的需要,自2000年起至2007年,高炉操作目标已经转为降低还原剂消耗。
降低还原剂消耗的工作主要集中在大型高炉上,特别是由于原燃料的变化,高炉操作需要做出相应调整。
2007年日本喷煤比接近130kg/t,低于其它国家。
主要原因是日本所用焦炭质量发生了变化。
如果盲目提高喷煤比,可能会影响高炉较高的利用系数。
但是从2008年下半年开始,由于全球经济危机的爆发,高炉操作条件彻底改变,高炉利用系数也大幅度降低。
未来经济复苏的前景仍不明朗,一些高炉已经关停。
所以近期钢铁行业的二氧化碳排放量显著降低。
尽管如此,降低高炉还原剂消耗仍然被视作重要操作目标之一。
2 针对二氧化碳减排的研究1996年,日本铁钢联盟JISF根据《京都议定书》制定了环境保护行动计划,把减少温室气体排放作为应对全球变暖的措施之一。
因此,该计划主要应用了以下温室气体减排措施:1) 在1990年的基础上,到2010年实现钢铁行业能耗下降10%;2) 通过政府建立回收机构,实现高炉回收利用100万t废塑料。
2015日本钢铁产量及技术
© 2016 ISIJ905* Corresponding author: E-mail: oshima@isij.or.jp DOI: /10.2355/isijinternational.56.905Production and Technology of Iron and Steel in Japan during 2015The Technical Society, The Iron and Steel Institute of Japan1. Overview of the Japanese Iron and Steel Industry Last year, the Iron and Steel Institute of Japan (ISIJ)celebrated its 100th anniversary. The first issue of Tetsu-to-Hagané was also published in 1915, the same year as the ISIJ was established. In that publication, before techni-cal reports, articles on business conditions and statistics, etc., several distinguished gentlemen whose efforts led to the creation of the ISIJ contributed commentaries on the steel industries of Japan and other countries. Those articles included “The Past and Future of the Iron and Steel Industry in Japan” by Dr. Kageyoshi Noro (Professor, Tokyo Impe-rial University, Faculty of Engineering, 1st Chairman of the ISIJ), “The Iron and Steel Industries of the Great Pow-ers” by Dr. Tsuruo Noda (General Manager, Steelmaking Dept., Kure Naval Arsenal, 10th Chairman of the ISIJ) and “Concerning the Business of Yawata Steel Works” by Dr. Susumu Hattori (Assistant Superintendent, Yawata Steel Works and concurrently engineer, 7th Chairman of the ISIJ). The origin of today’s Technical Society was five research committees (Pig Iron, Steelmaking, Steel Products, Castings and Iron and Steel Science) which were established in 1925, about 10 years after the establishment of ISIJ itself. Fol-lowing the Second World War, those committees continued their activities as the Iron and Steel Technology Research Liaison Council (later called the Steel Technology Joint Research Society), which was cosponsored by the ISIJ, the Iron & Steel Bureau of the Ministry of Commerce and Industry (later, the Heavy Industries Bureau of the Ministry of International Trade and Industry (MITI)) and the Japan Steel Association (later the Japan Iron and Steel Federation). Subsequently, jurisdiction for these activities was transferred to the ISIJ and it became the Joint Research Society. As a result of a sweeping reorganization of the ISIJ in 1995, the Technical Society and Academic Society were established, and the committees which were established in the Technical Society later became the current 19 Technical Committees. Tracing the history of this “Production and Technology of Iron and Steel in Japan,” the first predecessor of this annual review was published in 1957 under the title “Perspective of Production and Technique of Iron and Steel in Japan” by Dr. Takeshi Yamaoka, who was the Secretary-General of the Joint Research Society. In 1960, the title was changed to the present version, and in 1996, publication was changed from the ISIJ technical journal Tetsu-to-Hagané to Ferrum (Bulletin of the Iron and Steel Institute of Japan). With this year’s edition of “Production and Technology of Iron and Steel in Japan,” we celebrate the 60th article in this series.As in previous years, this year’s review of the production and technology of iron and steel in 2015 begins with an overview of the important political and economic situations which affected Japan during the year. First, looking at the political conditions surrounding Japan, key developments included the enactment in September of national security-related laws which approve the use of the right of collective self-defense, basic agreement in October by the 12 countries participating in negotiations on the Trans-Pacific Partner -ship (TPP), agreement by the ruling party in December to introduce a reduced tax rate when the consumption tax will be raised to 10% in April 2017, and preparations for the introduction of the “My Number” system, which began in January 2016. Next, regarding economic conditions in Japan, in comparison with 2014, when the economy was adversely affected by an increase in the consumption tax, government economic reports, etc . showed improvement in the employment and income environment in 2015. This pos-itive turn was driven by an economic and fiscal policy built on the pillars of bold monetary policy, flexible fiscal policy and a growth strategy to encourage private investment. In view of this improvement, as well as more favorable terms of trade thanks to lower crude oil prices, a continuing mod-erate recovery has been assumed. However, the recovery stalled in the second half of 2015 due to a slowdown in the emerging economies, and particularly China, a further drop in the price of crude oil, and other negative factors. As a result, the real GDP growth rate is expected to be around 1.2% for fiscal year 2015, and a nominal GDP growth rate of about 2.7% is foreseen.1,2)Under these economic circumstances, Japan’s crude steel production for calendar year 2015 decreased by 5.0% from the previous year, to 105.15 million tons (Fig. 1)3,4) According to the Japan Iron and Steel Federation (JISF), domestic iron and steel demand was generally stagnant in FY 2015, as there was no upsurge in capital investment in nonresidential building, industrial machinery, electrical machinery, etc., and the recovery of domestic auto sales was also delayed. Foreign demand was also weak due to the high level of Chinese steel exports, which caused a further relaxation of global supply and demand, and trade problems occurred frequently in many areas. As a result, in spite of various management measures by Japan’s steel companies, a downward correction in profitability predictions for the March 2016 period became inevitable. In particular, in response to the economic slowdown in China from summer, companies became increasingly cautious about investments, and exports were also sluggish. As has been pointed out for many years, excess production capacity in China is a fundamental problem. Moreover, in response to declining domestic steel consumption, China’s steel exports exceeded100 million tons for the first time. Thus, economic condi-tions in China clearly have a very large impact on Japanese iron and steel industry.On the raw material side, major producers of raw materi-als for iron and steel, and particularly iron ore and metal-lurgical coal, continued to produce at historically high levels in spite of the relaxation in steel supply and demand worldwide. Although the prices of those raw materials rose to very high levels at one time, prices have tended to decline since peaking in 2011, and that trend also continued in 2015 (Fig. 2). Overseas investment and offshoring of production continued in various product fields, in line with the overseas strategy of each steel company. In particular, there were many examples of offshoring of production of automotive materials. Overseas development in the form of capital participation in the construction of integrated steel works in Southeast Asia could also be seen. The following sections present an overview of the conditions affecting the Japanese iron and steel industry in 2015, focusing on trends in raw materials for iron and steel, trends in steel-consuming industries, crude steel production in Japan and worldwide, globalization efforts of Japanese steel companies, and recent conditions in China.1.1. Trends in Raw Materials for Iron and Steel Oligopolization of the iron ore market by three major ore producers (Vale, Rio Tinto and BHP Billiton) and a basic tone of increased production continued in 2015. Production by all of these companies was on historically high levels. According to the Metal Resources Report5) published by JOGMEC, these companies are engaged in an intense, ongoing struggle for share, taking advantage of price com-petitiveness gained by exhaustive cost-cutting efforts. While world crude steel production decreased from the previous year for the first time in 6 years, and pig iron production has basically been flat since around 2012, production of iron ore has remained high, creating an over-supply situa-tion. As a result, the price of iron ore continued a downward trend from its peak in 2011. In particular, the decline in the spot price of iron ore landed in China, which is an index of the quarterly price of iron ore, has been accelerated by continuing purchases of iron ore, which is comparatively economical due to the loose supply-and-demand conditions in Asian steel markets and the accompanying softening of steel prices. Moreover, supply-and-demand conditions for metallurgical coal are similar to those affecting iron ore. Although suppliers of metallurgical coal have continued toFig. 1.Transition of crude steel production in Japan (calendar year).3,4)Fig. 2.Transition of world pig iron production and unit price of imported iron ore & metallurgical coal (calendar year).6)(Source: World Steel Association, Trade Statistics of Japan, etc.)©2016 ISIJ906increase production, stagnant coal prices have resulted in deteriorating profitability. Given this situation, there have been reports that moves to reduce coal production may be easier than in the case of iron ore. Figure 2 shows the transition of world pig iron production and the unit price of imported iron ore and metallurgical coal according to the World Steel Association and customs statistics of Japan’s Ministry of Finance.6)These figures show that the high-est prices of iron ore and metallurgical coal in 2011 were $167/ton and $229/ton, respectively, but in 2015, prices fell to $71/ton for iron ore and $94/ton for metallurgical coal, or roughly the same levels as 10 years ago.1.2. Trends in Steel-consuming IndustriesThis section presents an overview of trends in steel-consuming industries in 2015 based on the quarterly steel supply-and-demand report of the Japan Iron and Steel Federation (JISF)7) and the websites of the Japan Auto-mobile Manufacturers Association, Inc., the Shipbuilders’ Association of Japan, the Japan Electrical Manufacturers’ Association, etc. For details, please refer to the original text or to the websites of the JISF, the Ministry of Land, Infrastructure, Transport and Tourism (MLIT) and manu-facturers’ associations.[Civil engineering] Due to a decrease in budgets for public works projects in FY 2015 (total of supplementary budget for FY 2014 and original budget for FY 2015) and the reactionary decrease associated with the Tokyo-Gaikan Expressway project, which was a large order issued in April 2014, public works civil engineering projects declined in the first half of FY 2015. No signs of recovery could be seen in the second half, and the contract amount of public works projects, which is a leading indicator, continued to be weak, falling below the level of the same period last year. In private-sector civil engineering, a favorable tone is expected for the year as a whole, as a domestic return could be seen in some industries and capital investment was firm. [Construction] In FY 2015, dwelling buildings construc-tion tended to recover from the negative reaction to the consumption tax increase in 2014. Although new construc-tion starts of dwellings had fallen to 800 000 from 2010, this index returned to the 900 000 level last year. By owner-occupant relation, construction of houses for rent showed a favorable trend, and there was also a recovering tendency in construction of owned house, buoyed by government housing support, while the tone in starts of construction of ready-built dwellings for sale were also firm. In non-dwelling construction (such as offices, stores, and factories, etc.), an expansion in building starts was expected due to the recovery of corporate profits, but overall, the feeling in this area remained bearish due to the chill in investor sentiment caused by stagnation in the Chinese economy, etc. [Shipbuilding] The volume of new shipbuilding starts continued to decline from the peak around 2010. Although the market for new ships has been extremely difficult recently, many shipyards secured backlogs extending to around 2018 due to stricter ship hull structure regulations from July 2015 and strengthening of NOx emission regula-tions on ships started in and after January 2016. By ship type, the shares of orders for oil tankers, LNG ships and container ships increased. While there was some feeling of stagnation in the volume of shipbuilding starts and in the amount of consumption of steels in FY 2015, roughly the same levels as in the previous year are foreseen for the year as a whole.[Motor vehicles] In new domestic motor vehicle sales for 2015, unit sales of large and small passenger cars other than midget passenger cars gradually improved, but unit sales of midget passenger cars decreased due to an increase in the light vehicle tax, and there was also a decrease in comparison with the previous year (for the year as a whole). Although exports of completed vehicles increased, centering on a strong North American market, domestic production of completed vehicles decreased overall. According to the Japan Automobile Manufacturers Association, production of four-wheeled vehicles in 2015 was 9 278 238 units, which was a decrease of 496 427 (5.1%) from 2014, and as a result, steel consumption also declined.8)[Industrial machinery] In shipments of construction machinery, implementation of stricter exhaust gas regula-tions was completed, and the downturn following the buy-ing-rush demand ahead of those regulations became appar-ent. Capital investment-related fields such as boilers/motors and metal processing and fabricating machinery were also weak, as companies postponed spending in response to increasing uncertainties about external demand. On the other hand, the tone in transportation machinery was strong, sup-ported by increased construction of distribution warehouses. Among orders received for industrial machinery in 2015, private sector demand increased, but both public demand and external demand decreased, resulting in a decrease of 2.9% from the previous year in this sector as a whole. The price of crude oil, which fluctuated widely during 2014, also continued to show a downward trend in 2015. The price was on the $50/barrel level at the start of the year, but had fallen to the $30 level by year-end. As a result, the recovery of demand for energy-related steel products was also delayed. [Electrical machinery] With the exception of certain replacement demand by domestic electric power compa-nies, the order environment for heavy electrical machinery was difficult due to weak external demand, particularly in the emerging countries, together with a declining trend in orders as companies postponed capital investment. The trend in the telecommunications field was also weak fol-lowing the completion of a series of investment related to LTE (Long-Term Evolution: high speed communication). In home electrical appliances, the reaction to the consumption tax increase had run its course. Production of some types of flat-panel televisions increased, and conditions suggested that consumer electronics had also bottomed-out.In 2015, the sustaining member companies of the ISIJ also developed new products responding to these trends in steel-consuming industries, centering mainly on civil engi-neering, construction and automobiles.1.3. Crude Steel ProductionDuring calendar year 2015, crude steel production in Japan was 105.15 million tons, representing a decrease of 5.0% from the 110.67 million tons in 2014. Thus, crude steel production fell below the 110 million ton level for the first time in 3 years, after exceeding 110 million tons for two consecutive years (2013, 2014). By furnace type, converter©2016 ISIJ907© 2016 ISIJ 908steel production was 81.04 million tons (decrease of 4.6% from 2014) and electric furnace steel production was 24.11 million tons (6.1% decrease). The share of electric furnace steel was 22.9%, which was a decrease of 0.3 points from the previous year (Fig. 1).World crude steel production in calendar year 2015 was 1 622 million tons, or a 2.9% decrease from the 1 670 million tons of the previous year.9) Following the global financial crisis triggered by Lehman Brothers’ bankruptcy, world crude steel production declined from the previous year in 2008 and 2009, but increased thereafter. However, in 2015, world production decreased from the previous year for the first time in 6 years as production decreased from the previous year in China, where production had grown con-tinuously until then. Among the top 10 countries in world crude steel production, production declined from the previ-ous year in all countries except India (Table 1). According to the World Steel Association (WSA), the average operat-ing rate of the main 66 steel-producing countries in 2015 was 69.7%,9) which was a decrease of 3.7 points from the 73.4% in 2014.The forecast for steel demand in FY 2016 published by the Japan Iron and Steel Federation predicts an overall increase in domestic demand due to the buying rush before the consumption tax increase planned in April 2017, the start of urban redevelopment projects, beginning with proj-ects related to the 2020 Tokyo Olympics, etc. However, in foreign demand, the JISF foresees a decline in Japan’s iron and steel exports due to the continuing relaxation of world supply and demand due to increased exports by China. As a result, crude steel production in FY 2016 is expected to be on the same level as in FY 2015, but the risk of a downturn in foreign demand cannot be ignored.10)1.4. Globalization of the Japanese Steel IndustryDuring 2015, as in previous years, there were reports of globalization efforts in the form of investment in overseas projects, etc. by Japanese steel makers.11) This section sum-marizes the moves by the main sustaining member compa-nies of the ISIJ.In February, Nippon Steel & Sumitomo Metal reachedagreement with Africa’s largest general can manufacturer on a stable, long-term supply of tinplate for food cans, and in May, and announced the construction of a production system for high formability, ultra-high strength steels for automotive use by a joint venture in North America. In other moves involving subsidiaries and joint ventures of the same company, a new hot dip Zn-coated steel strip production plant began operation at Baosteel-NSC Automotive Steel Sheets Co., Ltd. (BNA) in China in September, VAM ® BRN SDN BHD held the groundbreaking ceremony for a steel tube joints processing company in Brunei in October, its crankshaft manufacture and sales subsidiary in the US, International Crankshaft, Inc. (ICI), began commercial production at No. 4 forging press line of in November and Nippon Steel & Sumikin Cold Heading Wire (Suzhou) Co., Ltd. began operation in China in December.JFE Steel reached agreement with the United Arab Emir-ates for a joint venture large-diameter welded steel pipe plant in March, participated in the planning of an integrated steel works project in Vietnam of the Formosa Plastics Group in July and concluded an agreement in connection with the same project in September and held the Opening Ceremony for a joint venture, Jiaxing JFE Precision Steel Pipe Co., Ltd., in China in October. In December, a new company was established by a merger of the iron ore mining business of a steel company in Brazil with a company which will produce and sell iron ore in Brazil with investment by JFE Steel, domestic steel makers and a trading company, and steel makers in Korea and Taiwan.Kobe Steel began a joint study of the establishment of a joint venture for the production and sale of wire rod material in Thailand in June, and its wire rod secondary processing subsidiary in China increased its capacity in November.Among special steel makers, Daido Steel constructed a new base for its die and mold forging business in Thailand in May, and Sanyo Special Steel established and began operation of a machine parts and tooling company in Mexico in December.1.5. Recent Situation in ChinaIn 2015, world crude steel production decreased for theTable 1. Top 10 crude steel production countries (Source: WSA; Unit: Mt).9)Top 10 201520122013Growth rate from previous year 2013/2012 (%)2014Growth rate from previous year 2014/2013 (%)2015Growth rate from previous year 2015/2014 (%)1China 731.0815.411.5822.80.9803.8▲2.3 2Japan 107.2110.6 3.2110.70.1105.2▲5.0 3India 77.381.3 5.287.37.489.6 2.6 4US 88.786.9▲2.088.2 1.578.9▲10.5 5Russia 70.468.9▲2.171.5 3.871.1▲0.5 6Korea 69.166.1▲4.371.58.269.7▲2.6 7Germany 42.742.6▲0.242.90.742.7▲0.6 8Brazil 34.534.2▲0.933.9▲0.933.2▲1.9 9Turkey 35.934.7▲3.334.0▲2.031.5▲7.410Ukraine33.032.8▲0.627.2▲17.122.9▲15.6© 2016 ISIJ909Fig. 4. Transition of apparent consumption of steel of major coun-tries (calendar year).9)Fig. 5. Transition of crude steel production of major countries(calendar year).9)first time in 6 years. The effect of the downturn in Chinese production, which had increased until then, was particularly large. China has also increased exports of steel products in response to sluggish domestic demand. Chinese steel exports reached a historically high level, exceeding 100 million tons/year, which contributed to the global relaxation of supply and demand. Considering the importance of these and other developments in China, the following will review the recent economic situation and condition of steel supply and demand in China.Looking first at the economic situation in China, although the business slowdown due to stagnant domestic demand continued, China’s GDP is still rising, which indicates that economic growth is continuing. Comparing the nominal GDPs of the major countries, China overtook Japan in 2009 and became the world’s second largest economy after the United States, and its economy continued to grow thereafter at an annual rate of more than 10% (Fig. 3).12) However, China’s real GDP growth rate has decreased gradually since peaking at 14.7% in 2007, and there was also a slowing tendency in the activities of manufacturing industries as a whole beginning in the second half of 2015. As a result, China’s economic growth rate was 6.9% in 2015, and thus fell below 7%.Until recently, apparent consumption of steel had tended to increase annually. However, under the economic condi-tions outlined above, apparent steel consumption declined to 711 million tons two years ago (2014) after peaking at 735 million tons in 2013, and also decreased from previ-ous year for the first time (Fig. 4).9) Because crude steel production lag one year behind apparent steel consumption, crude steel production peaked at 823 million tons in 2014 and then fell to 804 million tons in 2015, for a decrease of 19 million tons or approximately 2.3% (Fig. 5).9) During this period, export of steel from China increased annually, exceeding 100 million tons for the first time and reached 112 million tons in 2015 (Fig. 6).3) Furthermore, the price of steel products has decreased as a result of looser supply and demand due to this increase in steel exports, causing a remarkable deterioration in the profitability of companies in other steel exporting countries, beginning with Japan. The rapid increase in steel consumption and crude steel production in China, which began in the 2 000 s, had been attributed to robust demand in the coastal areas of China, where more than 40% of the nation’s total population is concentrated. In particular, the construction sector accounts for more than 50% of steel consumption. If related fields are also included, construction substantially accounts for around 60–70% of Chinese steel demand. Although it is thought that this strong demand has roughly reached its peak, a stable, high trend in steel demand is seen after this peak in the future. Regionally, this will be supported by rising demand in inland China. Moreover, growth is also expected in new steel-consuming industries; these include non-construction sectors such as automobiles, household electrical appliances, machinery, etc. On the other hand, it is generally thought that China has excess production capacity of approximately 400 million tons in comparison with nec-essary steel demand. With sweeping improvement needed in the structure of steel production in China, it appeared that the government was implementing various measures, going beyond those taken to date, from the second half of 2015 with the aim of promoting concentration and reorganization (integration and abolition) of production facilities.13)Fig. 6. Transition of export of steel of major countries (calendaryear).3)Fig. 3. Transition of nominal GDPs of major countries (calendaryear).12)2. Technology and Equipment2.1. Technical Environment of the Japanese Iron andSteel IndustryDuring 2015, the Japanese economy as a whole contin-ued to mark time, and recovery of domestic demand was delayed. Exports were also sluggish due to the economic slowdown in the developing countries, and with the high level of steel exports from China, the global relaxation of supply and demand became increasingly serious. Under these conditions, Japan’s crude steel production in calendar year 2015 was 105.15 million tons, or a decrease of 5.0% from the previous year. From the second half of 2015, the stagnation of the Chinese economy also became apparent. Because excess production capacity again became a prob-lem, the Chinese government laid out policies calling for elimination of excess capacity, acceleration of corporate M&A, etc. There were also moves toward concentration of production facilities by Japanese steel companies. In the mid-term management plan announced in March, Nippon Steel & Sumitomo Metal presented plans to construct the optimum iron source system, which included idling Kokura No. 2 blast furnace at Yawata Works (Kokura Area) in addi-tion to the changeover to a 2-blast furnace system at Kimitsu Works announced earlier. In August, Kobe Steel announced that it would invest in a second dephosphorization furnace at its new hot-metal pretreatment plant at Kakogawa Works, in line with the previously-announced plan to concentrate the upstream process at Kobe Works to Kakogawa. Moves toward concentration of production also continued in the electric furnace industry, as Osaka Steel shut down the steel-making shop at Okajima Works and Kyoei Steel decided to idle the steelmaking shop at Osaka Works, among other developments.11)Japan’s Ministry of Economy, Trade and Industry (METI) formulated “Plans on Competitiveness Improve-ment for Metallic Materials” as a policy for enhancing the competitiveness of the metallic materials industry, which is a “key export industry” of Japan that “supports local econo-mies and job creation.” This policy comprises three strate-gies, (1) Strategy for technology development, (2) Strategy for strengthening domestic manufacturing infrastructure and (3) Global strategy.14) Because equipment-related acci-dents occurred at several steel works during 2014, METI also carried out an investigation to verify the condition of government-private sector efforts to prevent industrial acci-dents in the steel industry in the past 10 years, and compiled “Countermeasures for Prevention of Industrial Accidents in the Steel Industry: 13 Desirable Efforts.”15)Next, notable developments in National Projects related to research and development of iron and steel technology will be summarized. In “CO2 Ultimate Reduction in Steelmak-ing Process by Innovative Technology for Cool Earth 50 (COURSE50), which is a project of METI and the National Research and Development Agency New Energy and Industrial Technology Development Organization (NEDO), the test blast furnace with an inner volume of 10 m3 under construction at Kimitsu Works of Nippon Steel & Sumi-tomo Metal was completed in September and trial operation began. The purpose of this facility is to conduct combined tests of hydrogen reduction and CO2 separation and recov-ery, which are the key issues in Step 2 of COURSE50.22) Another METI National Project, “New Structural Systems Using Innovative New Structural Materials,” which involves technology development by the Innovative Structural Mate-rials Association (ISMA), was launched in 2013 and com-pleted its second year in 2015. As part of the development of ultra-high strength steel sheets in the field of iron and steel materials, the results of control of the carbon concen-tration distribution in the residual γ phase were reported.16) Next, the Cross-ministerial Strategic Innovation Promotion Program (abbreviation: SIP) of the Council for Science, Technology and Innovation of the Cabinet Office, Japan took up “Innovative Structural Materials,” which is one of 10 themes of the SIP program, and undertook basic research and development of iron and steel materials in the sub-theme Structural Materials for Innovation (SM4I) region.17) In the Industry-Academic Collaborative R&D Programs sponsored by the Ministry of Education, Culture, Sports, Science & Technology (MEXT) and the National Research and Development Agency Japan Science and Technology Agency (JST), “Heterogeneous Structural Control: Towards Innovative Development of Metallic Structural Materials” was in its 6th year. In addition to 9 new themes in the first year, 2010, 3 in 2011, and 3 in 2014, the program also selected 3 new themes in 2015.18) This long-range, 10-year R&D project is expected to create guiding principles for the development of new structural materials.The ISIJ began extraction of issues for the civil engineer-ing and construction markets by establishing a Working Group for Study of the Use of Steel Materials for Construc-tion in the Technical Society with the aim of identifying new issues for research at the scientific society level. In cooperation with the Japanese Society of Steel Construc-tion, this WG is studying proposals for new steel structural systems for the construction market. The existing WG for Study of Slag Technology is studying the development of uses for steel slag and is expected to propose plans for new themes.As described above, the iron and steel industry of Japan is striving to improve the level of technology through coopera-tion among industry, academia and the government in order to overcome increasingly intense international competition. The following introduces the main technological trends by field of iron and steel technology and technology topics of sustaining member companies of the ISIJ.2.2. Iron-makingPig iron production in calendar year 2015 was 81.01 million tons, which was a decrease in comparison with the 83.87 million tons in 2014.19) Average blast furnace productivity was 1.86 ton/m3-day; this was also a decrease from the 1.93 ton/m3-day of 2014. At the end of 2015, 27 blast furnaces were in operation, which was the same as the previous year, and the number of blast furnaces with inner volumes of more than 5 000 m3 was also unchanged at 14. Nippon Steel & Sumitomo Metal began recycling of container and packaging plastics (waste plastics) in 2000. These waste plastics are charged into coke ovens and are recycled as oil (40%) for use as a chemical feedstock, coke (20%) and gas (40%). In March 2015, a waste plastics addition facility was introduced at Wakayama Works. With©2016 ISIJ910。
日本钢企近年节能技术发展调研
日本钢企近年节能技术发展调研炼铁的重要原材料铁矿石为氧与铁的结合物,为此,将铁矿石中的氧高效分离是钢铁行业节能重要的研究改进方向。
目前,铁矿石还原用焦炭作为主要的还原剂,但在生产焦炭的过程中产生了大量的氢,如焦炉煤气中含有50%的氢和30%的甲烷。
若将这些氢提取则可供燃料电池汽车所用,不仅可大量节约燃油,而且改善环境和减排二氧化碳的效果十分显著。
为此,日本钢铁企业参与了很多开发项目,积极建设节能社会。
钢铁行业不仅以煤炭为热源,而且还以碳为还原剂,日本钢铁企业十分重视碳燃烧生成二氧化碳对地球气候变暖的影响,即开发二氧化碳分离技术。
近年来,日本钢铁企业已实用化的节能技术主要有以下几个方面:副产煤气方面:焦炉煤气、高炉煤气和转炉煤气等除用于本厂工业炉和锅炉燃料外,多余部分用于发电自用,基本没有放散。
炼焦工序方面:干熄焦普及率达到83%;煤调湿、煤预热和煤成型已经得到部分应用;全部实现焦炉燃烧自动化控制;炼焦中掺入2%废塑料,能量利用率达到94%。
此外,由日本政府组织开发的下一代新型焦炉Scope21已工试成功,可节能20%,生产效率为目前焦炉的2.4倍~3倍,非黏煤配比达到60%。
炼铁工序方面:炉顶余压发电已全部普及;热风炉余热利用和喷吹煤粉全部普及;喷吹废塑料率先在JFE的京滨、福山两厂应用,能量利用率达到75%~80%,神户制钢加古川厂也开始应用喷吹废塑料技术;对高炉鼓风系统普遍采取了防止漏风、降低压损和热风管保温等节能措施;神户制钢开发的非高炉炼铁法Fastmelt(法斯特梅铁)技术已用于回收含铁粉尘中的锌和制造球团供高炉利用,节能效果较好。
烧结工序方面:冷却矿余热回收、烧结均压气回收、分级布料、烧结机局部除尘、主风机高效化和防止漏风以及电机转数控制等节能措施已基本普及。
转炉炼钢工序方面:OG-IDF转数控制,制氧机、除尘器和冷却泵等设备高效化,近终形连铸和铸坯热送等节能措施已经普及。
突出的是新日铁广畑厂高炉停产后,全部以废钢为原料吹氧喷煤化铁后炼钢,并每年利用废轮胎12万吨,充分利用轮胎可燃部分和其中的子午线钢丝,节能效果更好。
日本高炉炼铁的新发展
传动齿轮箱上方有两个料仓轮换装卸炉料。每个料仓的上下口各有
一个密封阀、上密封阀3和下密封阀10。每个下密封阀上面设有节流 阀9(也称料流调节阀或料流调节闸门),以保护密封阀不与炉料接触,
同时可通过调节节流阀的开口度来控制料流量。为了交替往两个料
仓内装料,受料漏斗是可移动的。两个料仓均放置在电子秤8上,且 设有料仓空、满检测显示讯号,以便及时发现卡堵料现象。
2 煤和铁矿石资源环境利用价值变化及预加工技术
2.1 铁矿石资源环境变化
降低烧结矿中Al2O3含量,满足高炉生产的需求,铁矿石的 Al2O3 含量由1.52%上升到2.47%,粒度-0.15mm由4.58%升至28.8%。
7 COURSE 50技术
7.1 COURSE 50的基本内容:
COURSE 50是由JIFS会同日本六大钢铁公司提出的,是 指“美丽星球50”倡议,用技术创新从根本上减少CO2排放。
低碳炼铁工艺分两部分:
H 2 还原实用技术开发 1 廉价H 2 生产技术开发
高炉煤气中CO2 分离和收集技术 2 用技术 余热余能在CO2 分离及收集6.1减少CO2排放 日本提出了2020年与1990年相比减少温室气体排放25% 目标,已投入大量人力和物力实现目标。 6.2 炼铁工艺革新 2008年12月启动,是技术创新项目(为降低CO2排放), 其核心是复合铁矿石(铁氧化物与C和金属铁软化)的还原性和 生产工艺,目标是提高高炉炉身功效和热储备区的温度,由 1000℃降低到800℃,将炼铁能耗降低10%,该革新技术还有 相关炼铁过程数字模拟系统开发、高温和荷重软化实验数据。 根据这些数据使铁矿石还原更佳,使高炉内透气性得到明显 改善。
四十年前的那场去产能——来自日本钢铁行业萧条期的经验
四十年前的那场去产能——来自日本钢铁行业萧条期的经验下文作者为华泰证券宏观分析师李超、侯劲羽,来源于“ 华泰宏观研究”摘要(有删节):日本在钢铁行业的调整阶段也走过一些“弯路”。
在60年代,政府试图控制钢铁企业的过度扩产、过度投资的努力失败了。
以“特安法”公布为分界点,钢铁产业政策变得更注重间接引导行业发展,在去化产能过程中尊重市场规律,并非“一刀切”。
此后政府主要通过促进钢铁企业的兼并重组,形成行业的“萧条卡特尔”,来协助行业渡过难关。
在78年钢铁成为萧条行业以来,PPI和CPI确实出现了明显上升的趋势。
但钢铁行业价格上涨并非PPI指数大幅上扬的首要因素。
貌似“去产能”引起的通胀,实际上是外部冲击、经济转型、和行业发展变化三者合力的结果。
日本的产能去化较慢,在去产能政策推出初期到产能真正拐点之前,钢铁行业股价迎来三波上涨行情,且涨幅明显优于大盘。
但当临近产能拐点,钢铁股曾迅速下跌,随后表现显著弱于大盘。
正文:一、从经济支柱到萧条产业:日本钢铁行业产业政策变迁战后日本从废墟之上重建,在50年代大力推动重工业和化学工业,在60年代着重发展外向型经济,在70年代中后期转而注重内需、并逐渐在尖端技术上进入世界前列。
纵观日本经济发展史,可谓是追赶型经济体的典范。
虽然民营企业一直是战后日本经济的主体,但在经济高速增长的前20年内,政府对经济的直接干预是比较强的。
到了六十年代中后期,政府干预逐渐让步于市场经济,产业政策转为以间接干预为主。
在日本产业政策制定和执行过程中,所谓“主管部门”起到核心的作用。
每个产业都有各自的主管部门,制造业的主管部门通常是通产省及其下属部门。
此外,农林省主管农业和食品工业、厚生省主管医药工业、运输省主管造船业、大藏省主管金融业。
除了主管部门,参与产业政策制定的还有负责产业之间协调的协调部门、民间发起的各种行业团体、介于政府与民间之间的审议会和调查会等。
战后日本的钢铁产业支持政策日本钢铁产业的迅速发展,与产业政策的支持是分不开的。
脱碳化关乎日本钢材行业的生死存亡:日本钢铁制造商的脱碳化努力
脱碳化关乎日本钢材行业的生死存亡:日本钢铁制造商的脱碳化努力本文3479字,阅读约需9分钟摘要:炼钢过程只要缺少一种材料,便无法得到成品。
全球脱碳竞争愈发激烈,如果能够领先世界制造零碳钢铁,日本钢铁行业将能够重返世界第一。
事实上,在北欧正式推出特殊零碳钢的日本制铁集团山阳特殊制钢的股价在这一年半内翻了一番。
相反,如果在脱碳竞争中失败,钢铁行业或将从日本消失。
若广泛用于汽车、家电、建筑等领域的钢铁产业消失,将极大地动摇日本制造的根基。
本文将介绍日本钢铁行业面向脱碳的现状。
关键字:零碳钢铁、高炉氢还原、大型电炉、高级钢制造、100%氢直接还原工艺、钢铁脱碳目录•钢铁行业的生存挑战•高炉法作为最优的炼铁法,唯一的缺点是排放二氧化碳•高炉制造商致力于三项技术创新•2万亿日元脱碳基金完全不够•脱碳关系到日本制造业的复兴钢铁行业的生存挑战日本的钢铁需求在1990年达到9400万吨的峰值,现在已经下降到三分之二以下。
在内需减少的情况下,日本高炉制造商——日本制铁、JFE钢铁、神户制钢所三家公司,通过以汽车工业为中心,将钢铁直接出口增至3500万吨,成功维持了日本7500万吨的粗钢产量。
日本制铁的出口比例为45%,而世界平均值低于10%,日本制铁成为世界最大的独立出口制造商。
而中国的粗钢产量已超过10亿吨,成为世界最大的钢铁生产国。
日本在规模上已无法匹敌。
预计未来随着工业化和城市化进程发展,印度产钢量也将大幅增长。
日本钢铁行业的经常项目项下的利润(经常利润)在2006年达到1.9万亿日元(约1014亿元)的峰值,而到2020年下降到了十分之一。
与之相对,日本国内的设备投资却趋于增加。
自2012年以来,日本制铁已向国内钢铁厂的老旧设备更新和战略商品投入了约6万亿日元(约3203亿元)。
为什么会这样?钢铁行业竞争力的源泉在于一体化生产体制的核心技术力。
对于汽车制造商而言,每种车型和产品都有生产线和工厂,通过建立与日本类似的生产和销售体系,海外国产化率已提高到70%左右。
日本钢铁产业的发展历程借鉴意义巨大
中国钢铁业粗放型发展、求量不求质、打价格战的现象由来已久。
早在2000年,国家经贸委要求使用落后工艺与生产设备的小钢厂依法关停。
彼时,钢铁产能、结构亟待优化已初现端倪。
其后,钢铁产业也历经数轮产能调控政策,但效果并不理想。
在始于2006~2007年的一轮淘汰落后产能中,发改委要求各地按期完成淘汰300立方米及以下高炉产能和20吨及以下转炉、电炉产能。
但截至2008年年底,被列入“十一五”期间淘汰落后产能名单的13个产业中,电解铝、造纸等行业基本完成目标,而钢铁产业(包括炼铁、炼钢产能)却愈减愈多。
各地淘汰落后产能效果不理想的原因主要包括如下几点:国营钢企通常对地方税收贡献大、提供就业机会多等,地方直接关停其的积极性不高。
而部分民营钢企因效率相对较高,吨钢成本较低,能够在激烈的市场竞争中占据优势,这部分产能也很难去掉。
历次调控聚焦产能总量控制,在严格项目审批手续着手控制新上项目;而相当长的一段时间内,大量企业为了进入看似赢利美好的钢铁行业,很多项目并没有经过审批便上马投产。
历次调控中以高炉、转炉等关键生产设备的规模大小为标准来划分鼓励、限制、淘汰类产能。
相当数量的中小企业为避免被淘汰,对现有生产设备进行扩容改造、拆小上大,如将原属淘汰范畴的高炉改扩建成300立方米以上的。
产能自然而然不断得到扩大。
B兼并重组效果未显通过市场竞争自然淘汰、关停落后产能以达到去产能目的的效果也不理想,而由地方主导的兼并重组很难取得实质性进展。
21世纪以来国内钢铁产业的兼并重组主要可以分为两个阶段。
第一个阶段为2000~2005年,此阶段制造业、基建、房地产等下游用钢需求快速增长,钢铁产能过剩不突出;相反,黑色金属冶炼固定资产投资旺盛,包括中小规模企业在内的钢企数量迅速增长,产业集中度不断下降。
第二个阶段始自2005年,《钢铁产业发展政策》出台,支持和鼓励有条件的大型企业集团进行跨地区的联合重组。
自此,钢铁产业兼并重组进程加速。
近10年日本钢管制造技术进展
近10年日本钢管制造技术进展1 钢铁制造技术的变迁从20世纪60年代至70年代,日本的钢铁产量有大幅度的提高,这是由于日本引进和开发了大量高生产率技术所致。
LD转炉、连铸、高炉的大型化、板坯连续冷轧技术、高速轧制和芯棒式无缝管轧制等技术的开发为大幅度提高产量和生产率起了巨大的作用。
这些技术的发展离不开设备、材料和计算机等相关技术的发展。
在轧制和轧制理论发展的同时,如果没有计算机和计算机控制技术的发展,就没有连续轧制技术。
日本的钢铁业在高效、大量生产方面以先进的制造技术为武器,确立了其在国际上的钢铁技术的主导地位。
但是,在国际上对钢铁需求变化的同时,技术的发展方向也开始向重质轻量方向转变,并追求质量的稳定,进一步降低生产成本。
尤其是,随着汽车的迅速普及,对板材挤压成形性和耐蚀性提出了越来越高的要求,为此日本加强技术的主导地位,在IF钢和表面处理材料的开发方面取得了很大的进展。
在降低生产成本方面,开发了大幅度节能、提高产品合格率和提高生产率的技术。
在建筑建设领域,近年来随着超高层建筑和特大型桥梁的建设,开发了高强度、焊接性好的钢板。
在汽车制造业方面,为确保汽车碰撞时的安全性和环保的要求,开发了高强度、轻量化钢材生产技术。
在钢管制造方面,为确保轻量化和碰撞安全及降低生产成本,钢管的高强度化和管材液压成形技术引入关注,汽车生产厂和钢铁企业合作进行了钢管生产技术开发。
另外,在油井管和干线用管方面,进行了高耐蚀性和高强度材料的开发。
日本钢铁技术能够领先世界是由于日本始终以需求为先、认真实施技术开发的结果。
日本所具有的优势就是技术和需求的超前性。
在上述产品和生产技术开发中,一个非常重要的关键词就是技术的融合。
制造技术在吸收相关技术并与上游技术融合的同时不断发展。
另外,支撑加工技术发展的是加工模拟技术。
今后,日本应将制造、加工技术的经验和计算模拟取得的经验技术进行融合,在以需求为先的同时,创造出领先一步的制造技术,如高强度钢的加工技术、高精度稳定的加工技术和钢构功能开发技术等。
日本钢企开展超耐热合金开发等研究
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日本钢铁工业节能环保技术发展简介
日本钢铁工业节能环保技术发展简介日本钢铁工业节能环保技术发展简介日本钢铁工业节能环保技术发展简介工控论坛>《机械自动化》日本钢铁工业节能环保技术发展简介jiang_0514建议删除该贴!!|收藏|回复|202*-03-2312:52:23楼主日本钢铁工业节能环保技术发展简介日本的钢产量在1996年虽然被我国超过后退居世界第二位,但其钢铁产品的国际市场竞争力仍居世界首位,其中,先进的节能环保技术对此起了重大的支撑作用。
为有利于我国钢铁工业在由大变强中很好的学习和借鉴国际先进经验,现将促进日本节能环保技术发展的主要原动力分为三个阶段简介如下。
石油危机后依靠节能技术求生存的阶段1973年第一次世界石油危机后,由于石油价格暴涨带动了各种能源和矿产品的价格上涨,这对能源和原料基本依靠进口的日本钢铁工业是个很大的冲击,加上石油危机一度使世界经济发展停滞,对于钢材30%左右需要出口的日本钢铁工业也十分不利,以致钢产量由1973年的1.2亿t回落至1亿t以下,之后虽通过加大石油储备等措施来维持生产,但紧接着来的第二次、第三次石油危机,迫使日本钢铁业为保持竞争力以求生存而采取了技术节能和淘汰落后产能并举的节能措施,终于使吨钢能耗快速下降(以1973年为100,1975年为98,1980为89,1985年为80,1990年由于产量上升仍维持80)。
具体措施如下:1技术节能方面:(a)通过提高加热炉空气预热温度和强化炉体绝热以降低油耗的同时,充分回收利用厂内高炉煤气和转炉煤气以取代重油;(b)引进干熄焦、高炉顶压发电、热风炉余热利用和烧结机余热利用及电炉废钢预热等重大节能技术并在改进后加以推广;(c)实施工艺简化以节能,如通过提高连铸比以取消初轧、开坯工序以大幅节能;(d)改善能源结构和提高能源转换效率以节能,如高炉通过喷煤代喷油后不断扩大喷煤比来节焦,提高自发电和制氧机效率以节能,电炉通过UHP电源操作、吹氧喷燃和DC炉等节电,节能效果均很明显。
王丽文库之近10年日本轧钢技术的进步简况
近10年日本轧钢技术的进步简况一、轧钢技术的最近进展和今后展看日本最近10年轧钢生产虽受钢产量起伏的影响而波动,但技术仍在不断进步。
随着计算机的小型化、高速化和有限元法(FEM)的登场,材料三次元的解析得以应用,对以板材为首的各种钢材的加工压力、荷重、扭矩和金属活动等均可计算出。
变形阻抗作为高精度计算荷重和扭矩的物性值,现已进进数据收集和模式化阶段,热变形阻抗已在细晶粒钢开发中广为应用,冷变形阻抗也在高强度钢的开发方面实用化。
现结合由“大生产大消费时代”向资源循环型社会的转变,今后轧钢技术发展的主要方向如下:(1)从主要变形向大幅进步材料性能、且以最小能耗生产易再循环利用产品的新加工技术转变,如复合加工、多轴加工、超精密加工、工具自由化加工等和材质控制技术。
(2)研究开发方面,由利用模拟技术使试验时间和用度大幅下降的追求型向重视手工装置和发挥人才作用的方式转变。
(3)基础技术应重视工具特性的奔腾改进和与环境和谐技术的开发。
二、轧钢基础技术的开发1.变形的理论解析轧钢方面的理论数值解析已在各种钢材生产上应用。
如对产品尺寸精度和外形的猜测,对被轧材的材料活动、荷重、形变、温度分布等的解析,对轧钢变形和对产品影响的说明,产品材质、组织、残留应力等的猜测以及轧制条件的最佳化和轧钢设备的公道设计等方面的应用。
由于三次元FEM应用的快速发展,日本在轧钢技术理论方面已居世界领先地位。
上世纪80年代后期,在轧板解析方面以三次元FEM为主,结合轧辊弹性变形解析,可测出钢板宽边变形的具体情况后加以控制,对板材控制的高度化和轧机设备的高效设计作出了多方贡献,迄今已经基本实用化。
对串列轧机、非对称轧制也在试用中。
在钢板变形解析中,还建议采用计算时间短、更易理解的模拟三次元解析法。
在热轧方面,材质、猜测控制均十分重要,最近正在开发利用三次元FEM对其的轧制加工进行的解析模式,拟在超微细粒钢的开发中应用。
影响轧钢产品质量和操纵效率的表面缺陷很早即受到人们的重视。
日本炼钢技术十年进步概况
日本炼钢技术十年进步概况一、日本近十年钢产量及主要指标的变化从1994年到2003年的10年是钢产量波动较大的时期。
由于泡沫经济的破灭,钢产量由1995年的1.016亿t跌到1998年的9355万t的低谷,后又转为上升,进入21世纪后连续4年超过1亿t。
特别是近年由于高炉大钢的合并和东亚经济快速发展带动钢铁需求兴旺,2004年又超过1.1亿t大关而直追1973年1.1932亿t的历史最高纪录。
其中,电炉钢年产量亦由期初的2842万t上升到3425万t,特殊钢比例基本保持在18.4%~20%的水平。
而铁水预处理比则由44.9%猛升到67.6%。
至于二次精炼比,电炉钢由85%上升到95%,转炉钢由80%上升到86%。
连铸比则由96.9%上升到98.6%,其中特殊钢连铸比由87.2%上升到93.5%,而普碳钢则保持在99.8%的极限状态。
二、十年间有代表性的技术开发成果1.铁水预处理工艺的重组为取代过去在铁水罐车和铁水包内进行的预处理,各厂开发成功各种用转炉的预处理法(H炉法、SRP法、NRP法、MuRc法、LD-ORP 法),大幅提高了脱磷效率,减少了对外排渣。
个别工厂已实现全部铁水预处理。
2.环境友好型精炼工艺由于环保意识的提高,十分重视减少钢渣外排技术的开发,使钢渣外排总量达原来的1/2,突出的如彻底脱硅的零排渣工艺。
还开发成功含碳渣用于烧结矿和铁水脱硫,钢渣制砼用于护岸材,用含铁粉尘制球团矿等再生利用技术。
有的厂已作到了炼钢固体废物为零。
3.电磁力应用技术的革新从初期的电磁搅拌和局部作用的电磁制动发展到后期的可适应钢水的加减速而切换的电磁设备、在铸坯宽度方向均匀磁场的静磁场制动以及结晶器内钢水流动的模拟计算软件。
4.高质量技术不断进行提高产品质量的技术开发,坚持了洁净钢技术开发。
在硬件方面,二次精炼中增加燃烧器后使RH多功能化,开发成功连铸坯防止裂纹缺陷的技术。
在软件方面亦开发成功预测产品质量的技术,使轴承钢中的含氧量由1994年的5ppm降到2001年的4.7ppm,最好时达3ppm左右。
日本炼铁技术发展回顾与展望
日本炼铁技术发展回顾与展望1、炼铁技术发展趋势在二次世界大战后,日本钢铁工业积极引进了西方国家先进的钢铁生产技术,并加以改进,因而成为世界钢铁生产技术最先进的国家。
日本在沿海地区建设了许多钢厂,使之可以从世界各地大量进口高质量的生产原料。
在60年代和70年代,日本钢铁企业在降低还原剂(RAR)方面相互间开展了激烈竞争。
到了1980年11月,新日铁公司君津厂4号高炉取得了高炉还原剂最低的纪录,为406kg/t铁,而到了1981年11月,NKK公司福山厂(现JFE钢铁公司)3号高炉又创造了396kg/t铁的新纪录。
达到上述接近极限数值成绩所采取的措施包括加大高炉尺寸、提高炉顶压力和炉温,强化对炉料尺寸的控制,改善烧结矿质量,加强炉料分布控制和喷吹重油或其它燃料。
在1973年和1979年石油危机后,由于失去使用重油等成本上的优势,到1982年8月,日本所有42座高炉全部停止喷油。
为了使钢铁厂能源成本最小化,当时高炉操作上的发展趋势是采用较高的还原剂比例以提高高炉煤气的产生。
当时另一个发展趋势是开发高炉操作技术以增加低价原料的使用量来降低生铁的原料成本,并引入了煤粉喷吹技术(PCI)。
1981年,新日铁公司大分厂1号高炉成为日本首座引入喷煤技术的高炉牞并迅速在日本其它高炉上得到推广和应用。
到1998年,日本所有运转中的高炉都配备了喷煤装置,且平均喷煤比达到130kg/t 铁。
最高的喷煤比是神户制钢公司加古川厂1号高炉创造的254kg/t铁以及1998年JFE公司福山厂3号高炉达到266kg/t铁。
上世纪90年代,由于日本经济遇到困难,日本钢铁工业也同时面临困境,因此,采取了许多措施来应对,包括合理化和开发降低生产成本的技术并应用到工业生产中:(1)对炼铁工艺引入控制系统,并实施自动化控制;(2)大规模采用喷煤技术(改进煤粉的燃烧性能、炉料分布控制、改进烧结矿和焦炭的质量控制,如降低SiO2含量的烧结方法和高炉评估技术);(3)利用塑料作为高炉和焦炉的替代能源;(4)利用更加经济的原料;(5)节约劳动力成本(烧结机和干熄焦设备操作最佳化,采用连续卸料设备,焦炉操作自动化和缩短高炉换衬时间等);(6)延长设备服务周期(高炉和焦炉);(7)加大环保力度(利用回转窑处理炉尘,循环利用烧结尾气);(8)开发创新工艺(开发替代铁源生产技术、熔融还原工艺和新一代焦炉技术SCOPE21);(9)开发高炉内运转情况可视系统(开发高炉可视评估与数字分析系统,改进高炉预测模型的精度)。
新日铁住金在世界上率先开发出新型高效耐蚀钢板NSGP
新日铁住金在世界上率先开发出新型高效耐蚀钢板NSGP-1(环保1号),质量等级AH32,该钢板主要用于原油运输船和巨型油船。
与传统钢板相比,该钢板的耐蚀性能约为原钢板的5倍,可以省却为了防止腐蚀而进行的涂装工序,既提高船舶安全性又环保,且该钢板的焊接、加工等应用方式与传统钢材完全相同,建造时无需进行特别的施工管理。
为验证该新型钢板的耐腐蚀性能,原新日铁与日本邮船合作将该耐蚀钢板用在了2004年三菱重工建造的大型油船(MLCC)“Takamine”号的底板上,通过2.5年实船试验,结果显示新钢板能够有效防腐蚀。
NSGP-1钢板的最大腐蚀坑仅为2.8mm,而传统钢板的腐蚀坑深度达6.3mm。
根据国际惯例,腐蚀坑超过4mm需要重新涂装船体,超过7mm 则需要焊接维修。
此外,NYK使用15艘油船做了测试试验,其中6艘使用了NSGP-1钢板,测试结果表明NSGP-1的腐蚀率仅为传统钢板的1/5。
NSGP-1从2007年开始在日本国内正式接受订货,到2011年,已经应用于6艘油船的建造,就航最长的已经过6年时间,没有发现需要修理的腐蚀,确认NSGP-1钢板具有良好的耐蚀性能。
新日铁住金的SMICORE。
住友金属开发的油轮原油罐上甲板和底板部位用高耐腐蚀性厚板SMICORE,强韧级别为DH32级,厚度规格为16.5mm。
该钢板的机械特性、焊接性和焊接接头特性与传统的原油罐用厚板相当,而耐腐蚀性则更佳。
2005年8月,SMICORE在SANKOBLOSSOM号油轮的2号和3号原油罐上试用。
经过2年零9个月的航行,SANKO BLOSSOM号油轮进行了首次船坞检查。
检查结果显示,在原油罐上甲板部位,钢板厚度的减少量为传统钢板厚度减少量的60%左右;在底板部位,没有发生深度超过2mm的孔蚀,2号原油罐底板钢板的孔蚀深度为传统钢板孔蚀深度的1/4左右,3号原油罐底板钢板的孔蚀深度为传统钢板孔蚀深度的60%左右。
SMICORE应用于原油罐上甲板和底板部位时的耐蚀性得到了确认。
日本JFE钢铁公司产品研发战略及发展方向
日本JFE钢铁公司产品研发战略及发展方向当前,世界钢铁工业发展面临着新的巨大挑战。
在这种形势下,世界第三大钢铁联合企业——日本J FE钢铁公司的产品发展战略定位成努力研发创新技术,开发“独创”和“领先”产品,占领高端产品市场。
近年,随着创新技术的不断开发成功,各种高端新产品也应运而生。
一、研发机构及体制1.研发机构JFE集团的研发机构包括JFE钢铁研究所、工程技术研究所和技术研究所,其中隶属于JFE钢铁公司的钢铁研究所负责钢铁技术的研发,下设研究企划部和18个专业研究部,具体构成如图1所示。
JFE钢铁研究所有400多名职工,目前约40%的人员从事生产工艺技术的开发,60%从事新产品的开发。
JFE注重生产工艺技术的开发是因为该公司已经认识到新产品的开发首先要有相应的工艺技术做支持.在加大开发力度的基础上,JFE将集中力量加强JFE“独创”和“领先”产品的开发,同时研发费用也将向生产工艺领域倾斜。
2.研发体制为了促进各产品区域重点技术课题的制定和各工序间技术开发的横向推进,JFE钢铁公司采用横跨生产、研究和经营部门的研发体制——产品区域、SBU(战略经营单元)体制(见图2)。
产品区域由薄板、厚板等8部分组成,在经营计划的基础上制定技术开发战略,并制定重点技术课题,横向推进技术研发。
SBU由通用技术领域的炼铁、炼钢、炉渣、设备、环境和能源5个部门组成,各SBU要制定部门战略,横向推进技术开发。
产品区域、SBU中的各部门由专业技术会议联系在一起,专业技术会议以产品区域、SBU 提出的技术战略为基础推进课题、预测中长期技术动向、强化公司的技术创造力。
二、产品研发战略1.创新技术开发战略JFE集团的开发理念是以用户需求为第一,进行自主创新产品的开发;高效率生产优质产品技术的开发;环保型产品与技术的开发。
同时,通过充分发挥集团整体的协同作用,拓展新领域,灵活应对环境的变化,确保高收益率,获得市场和社会的信赖。
日本研究开发超级钢铁材料
日本研究开发超级钢铁材料
张唯敏
【期刊名称】《现代科技译丛(哈尔滨)》
【年(卷),期】1999(000)003
【总页数】4页(P5-7,11)
【作者】张唯敏
【作者单位】无
【正文语种】中文
【中图分类】TG14
【相关文献】
1.新一代钢铁材料的研究开发现状和发展趋势 [J], 王国栋;刘相华;朱伏先;刘振宇;杜林秀;刘彦春
2.21世纪的土木建筑结构物和超级钢材料:钢结构物的高强度化和钢铁材料的有效 [J], 丰田政男
3.日本开发超级钢铁材料目标及其动向 [J], 彭涛
4.新一代钢铁材料的研究开发现状和发展趋势 [J], 张永德
5.新一代钢铁材料的研究开发现状和发展趋势 [J], 张永德
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in both the advanced nations and the emerging economies. Reflecting these situations, crude steel production in Japan in 2016 (calendar year) was 104.77 million tons, which was roughly the same level (0.3% decrease) as the 105.13 million tons of the previous year (Fig. 1).3,4) As trends in the domestic steel industry, Nippon Steel & Sumitomo Metal Corporation (NSSMC) began a study of making Nisshin Steel Co. Ltd. a subsidiary, and equipment shutdowns and equipment consolidation advanced at both integrated steel makers and electric furnace steel makers. In response to the problem of excess iron and steel production capacity, beginning with China, the G20 member countries and others formally launched the Global Forum on Steel Excess Capacity in December. The prices of iron ore and metallurgical coal, which are the main raw materials for iron and steel, have shown a downward trend since peaking in 2011, and that trend continued in 2016 (Fig. 2).5) However, from the second half of 2016, the price of metallurgical coal spiked to more than 3 times its previous price due to operational problems at a leading coal mine in Australia, regulations on coal mine operation in China and other factors, raising concerns about the trend in and after 2017 as a factor in higher costs. As in past years, in 2016, steel makers invested or established operations overseas in Southeast Asia, Brazil, Mexico, etc. in various product fields in line with the overseas strategies of each company. On the other hand, in a
120
Crude steel Converter steel Electric furnace steel
104.77 Mt ↓
Crude steel produc 81.51 Mt.
40
20
↑ 23.26 Mt.
1996 1998 2000 2002 2004 2006 2008 2010 2012 2014 2016
national referendum in the United Kingdom in June 2016, the UK voted to leave the European Union (EU), and a new administration was born in the United States in November as a result the Presidential election in that country. These developments gave rise to concerns about future protectionist tendencies in the US and European countries among steel makers and others. The year 2016 also saw new developments in global warming countermeasures. Internationally, the Paris Agreement was ratified by the 21st Conference of the Parties to the United Nations Framework Convention on Climate Change (COP21) in December 2015. Based on that development, the Japanese Cabinet approved the Plan for Global Warming Countermeasures in May 2016. Subsequently, the Paris Agreement took effect in November 2016. The Japanese steel industry reaffirmed that it will steadily implement the Commitment to a Low Carbon Society, and is already engaged in efforts, centering on the JISF. As conditions surrounding the Japanese iron and steel industry in 2016, the following presents an overview of trends in raw materials for iron and steel, trends in steelconsuming industries, the condition of crude steel production in Japan and worldwide, etc. 1.1. Trends in Raw Materials for Iron and Steel As trends in iron ore, the basic conditions of increased production and oligopolization by the three major iron ore producers (Vale, Rio Tinto and BHP Billiton) also continued in 2016, and production was at record high levels at all companies. According to the Metal Resources Report6) of the Japan Oil, Gas and Metals National Corporation (JOGMEC), seemingly a continuation of fierce share competition using cost-competitiveness achieved by thoroughgoing cost reduction measures is seen at all companies. On the other hand, world crude steel production was flat from the previous year, and the basic tone of pig iron production has also been flat since around 2012. Because ore producers have maintained a high level of production, resulting in excess supply, the downward tendency in iron ore prices has continued since peaking in 2011. The supplyand-demand equation was also similar for metallurgical
0
Calendar year
Fig. 1.
Transition of crude steel production in Japan (calendar year). 3,4)
* Corresponding author: E-mail: oshima@isij.or.jp DOI: /10.2355/isijinternational.57.957
The Technical Society, The Iron and Steel Institute of Japan.
1.
Overview of the Japanese Iron and Steel Industry
Reviewing the economic condition of Japan during 2016, according to government economic reports and other sources, the employment and income environment improved, and a basic tone of gradual recovery continued, but weakness could be seen in overseas economies during the first half of the year. In addition, in the Japanese economy, individual consumption and private-sector capital investment lacked strength in comparison with the growth of incomes and profits. As a result, a real GDP growth rate of approximately 1.3% and a nominal GDP growth rate of approximately 1.5% are forecast for FY 2016.1,2) According to the Japan Iron and Steel Federation (JISF), domestic iron and steel demand was largely stagnant during FY 2015, but in FY 2016, there was on a track to recovery in public- and private-sector civil construction and residential construction in the construction market. On the other hand, industrial machinery and electrical machinery, which are related to capital investment, etc. in manufacturing industries, generally lacked strength. Although automotive demand was sluggish until mid-year due to the effect of the Kumamoto Earthquakes, improvement could be seen in the second half due to recovery production, and the effect of new models. Where external demand was concerned, world iron and steel demand slightly exceeded that of the previous year as a result of a turn to a gradual recovering tendency