In an effort to pave a path to sustainable industry future, SteelKorea 2019 dedicated a session to the industry’s up-and-coming concept, Life Cycle Assessment (LCA). Toshio Isohara, an LCA specialist from the Japan Iron and Steel Federation (JISF), presented his research on the topic. What insights does his work provide for POSCO who has been making a sizable investment towards clean steel initiative since its establishment? POSCO’s Newsroom reports.

l Throughout Life Cycle, Steel Is Environmentally Friendly

How sustainable is steel? Demonstrating the sustainability of steel in comparison to other materials involves applying the LCA approach.

LCA refers to Life Cycle Assessment, which is a technique to evaluate environmental impacts associated with all the stages of a product’s life from raw material extraction, through manufacture, to disposal and recycling.

When applying the LCA approach, the environmental impact of steel becomes much less compared to other materials. In other words, steel is more sustainable.

Just how sustainable is steel, really?

(1) Steel equals high carbon emission? Per-kilo emission is low!
Steel is often blamed for high carbon emission, but that can be attributed to the high volume of steel production, not steel itself. When it comes to per-kilogram CO2 emission, the CO2 output is significantly less than other materials.

The CO2 emission from the steel manufacturing process is less than other major lightweight materials. However, since steel production is overwhelmingly massive compared to other materials, the total amount becomes much higher. The chart below demonstrates when producing automotive parts of the identical function, the amount of CO2 emission of steel is much less.

▲ Presented by Toshio Isohara at SteelKorea 2019

Let’s compare aluminum with advanced high-strength steel (AHSS). Assuming the production of same auto parts with identical function, 75 kg of AHSS will be required – for aluminum, only 67 kg will be needed. In this scenario alone, aluminum is the clear winner. However, the CO2 emission of AHSS at the production stage is 2.3 kg per kilogram – however, aluminum emits 11.3 kg of CO2 per kilogram. The CO2 generated by AHSS is about 20% of CO2 emission by aluminum.

(2) High-strength steel – sustainable and lightweight
Per same strength, the weight of steel is getting even lighter than aluminum. Applying lightweight steel to vehicles improves fuel efficiency while contributing to reducing greenhouse gas (GHG) emission.

▲ Presented by Toshio Isohara at SteelKorea 2019

The strength of steel exceeds almost every material presented above save for the carbon fiber. The range of strength is also widespread, so it can be applied to automobiles, strand wires, tire cords, etc. Furthermore, with the theoretical strength at 10,400MPa, steel exceeds that of aluminum (3,500MPa) or concrete (6,400MPa), which means steel has even more potential for lightweighting. As technology advances, when building vehicles of identical strength, the required thickness for steel gets lower and lower, bringing down the overall car weights – all in all reducing total environmental impacts.

(3) The more, the better: multiple recyclability of steel
The magnetic nature of steel makes it easy to separate from other materials boosting its recyclability. Once scrap steel is separated, it doesn’t get used straight away but any residue of chemical impurities must be separated so only pure steel can be extracted and recycled. Any impurities in steel scrap can be easily removed through oxidation process through which whole new steel is born.

How do we quantify and calculate the recycling effect of steel? The premise behind such calculation is that steel follows ‘closed-loop’ system and can be recycled infinitely. Most materials are ‘open-loop’ in which case downcycling occurs. Downcycling deteriorates the value of original material whereas steel retains its original value even when recycled. The following graph describes the steel recycling rate in construction, which is much higher than concrete or wood.

▲ Presented by Toshio Isohara at SteelKorea 2019

Now, let’s calculate the recycling effects of steel. In the past, the calculation only considered the first cycle of recycling. However, when taking steel’s multi-recyclability into consideration, the amount of CO2 generated in the entire process should be divided by the total amount of steel production.

Source: JSIF – Presented by Toshio Isohara at SteelKorea 2019

The above calculation takes a product’s whole life cycle into consideration. A is the amount of steel production, and B is the amount of CO2 in the same stage. Both A and B in the primary production stage are set at 1.00. At the second production stage, using steel scrap – the total amount of steel becomes 1.81 (1.00+0.81), and the total CO2 at the same stage becomes 1.20 (1.00 + 0.20).

The amount of CO2 generated per steel production (B divided by A) reduces to 0.67 at the second stage (1st stage 1.00). Using the same calculation, the amount of CO2 per steel production at the third stage becomes 0.55 – almost halved when compared to the first stage of 1.00. From such LCA perspective, it can be surmised that the rate of CO2 emission gradually reduces because of the infinite recyclability of steel in a closed-loop system.

l l Promoting steel sustainability

Steel sustainability is of little use if it doesn’t become common knowledge. That’s why JISF is taking meticulous steps to promote the eco-friendliness of steel by recycling water and steel byproducts like slags while striving to improve energy efficiency.

▲ Environment-related activities of the Japan Steel Federation reported to the UN SDGs (Sustainable Development Goals)

More specifically, under the three pillars of Eco Process, Eco Product, and Eco Solution, JISF strives to reduce environmental impacts in the entire life cycle of steel. Japan’s spirit of Monozukuri plays a particularly important role here.

* Monozukuri refers to the spirit of Japan’s manufacturing practices. It includes a sincere attitude towards production with pride, skill, dedication and the pursuit of innovation and perfection.

▲ Source: JISF – Presented by Toshio Isohara at SteelKorea 2019

Currently, JISF is developing COURSE50, a blast furnace technology utilizing hydrogen. What lies at the heart of this technology is the reduction of CO2 by transforming iron ore into hydrogen, which can reduce CO2 emissions by approximately 30%. Research and development are underway to commercialize it by 2050.

There is also an effort to develop Japanese industry standard (JIS Q 20915) in parallel with the international standard, ISO 20915. This standard requires recycling effects to be included in the calculation of LCI. The early draft version of the JIS Q 20915 has been adopted last March, and the full transfer just completed on June 20.

**LCI refers to Life Cycle Inventory. LCI involves the compilation and quantification of inputs and outputs for a product throughout its life cycle. Inventory flows include inputs of water, energy, and raw materials, and releases to air, land, and water.

In addition, JISF’s LCA-focused exhibition, Eco Pro, was favorably received both by visitors and the industry in the eco-friendly product exhibition held in Tokyo in 2017 and 2018 – visitors had the opportunities to appreciate the value of steel from an LCA perspective.

▲ LCA promotion clip from NSC: Nippon Steel Corporation:  Click to watch

JISF’s endeavor to promote steel sustainability from LCA perspective bore fruit in the form of Grand Prize at the Japan LCA Forum Awards, sponsored by the Japan LCA Association. JISF also produced promotional video clips on steel recyclability. It can be streamed online but will also be promoted on public transportation like trains, in the hope to raise public and industry awareness on the sustainability of steel.

l Persistence is the key for disseminating LCA perspective

In the world we live in, where environment issue is a matter of global concern, steel is undeniably a competitive material. From the LCA perspective, JISF will seek constant communication with our consumers as well as with end users in order to publicize the sustainability of steel. Along with industry stakeholders, we will do our part, and more, to help improve the global environment by advancing steel sustainability and developing quality products.

※ This article is based on Mr. Toshio Isohara’s presentation at SteelKorea 2019 and the article published in ‘Japan Steel Daily Report Vol.20’ in December 2017.

On April 22, POSCO kicked off #SteelSaveEarth campaign in commemoration of the Earth Day. Earth Day was founded in 1970 by a U.S Senator, and it has since spread across the globe, being celebrated in more than 193 countries through various coordinated events.

In the recycling value chain, recycling plastic is economically, as well as environmentally, unviable as the value of scrap plastic is constantly fluctuating. The sustainability of steel, however, is drawing attention, especially when considered from the perspective of Life Cycle Assessment (LCA) which examines the environmental impacts of materials throughout their full life cycle, from raw material procurement to distribution and recycling.

#SteelSaveEarth campaign aims to raise awareness on the sustainability of steel. Through various online and offline events, POSCO also demonstrated the company’s commitment to curbing single-use plastics.

For the Instagram campaign, followers can post photos of their plastic-free lifestyle with the following hashtags: #SteelSaveEarth. To commemorate the April 22 Earth Day, POSCO will select 422 people who will receive travel mugs. These travel mugs were made of POSCO’s stainless steel and designed in collaborating with the trending Instatoon artist @inoo.ari.duri. The campaign will continue until May 15.

▲ Click on the picture to visit #SteelSaveEarth Instagram campaign

On May 11, POSCO is also holding a concert for children by incorporating with #SteelSaveEarth campaign. Children can make their own travel mugs utilizing @inoo.ari.duri‘s designs and take a photo in front of the campaign wall. POSCO will also participate in the annual sustainability-themed music festival, Beautiful Mint Life festival from May 11 to 12. On this two-day music festival, POSCO will set up a #SteelSaveEarth campaign booth where POSCO University Student Brand Ambassador will carry out various events to promote steel sustainability.

▲ POSCO is planning a concert for children in collaboration with a trending Instatoon artist. The company will also participate in the annual sustainability-themed music festival, Beautiful Mint Festival.

Meanwhile, POSCO is producing various informational materials to make the concepts of LCA and steel sustainability more accessible to the public. Recently, POSCO enlisted specific YouTubers to create informational and educational contents on steel sustainability from an LCA perspective. So far, these videos are logging more 130,000 views on the channel.

▲ POSCO produced an informational YouTube video to raise public awareness on steel sustainability.

The #SteelSaveEarth is not a one-off event – POSCO will continue the initiative to spread steel sustainability awareness and eco-friendly practices. The company will also continue the endeavor to obtain official certifications like EPD (Environmental Product Declaration) to ensure environmental sustainability for their products and roll out plans to keep their steel mills more sustainable.

More and more automakers are adding EVs to their fleet. (Source: Engineering and Technology)

While all this sounds promising for the environment, EVs don’t automatically translate into lower GHG emissions. According to World Auto Steel (WAS), the emissions from vehicle production will be greater than the amount of emissions from driving. As such, it is becoming increasingly important for manufacturers, policymakers and consumers alike to view material options by considering its life cycle assessment (LCA).

World Auto Steel Case Study

WAS conducted a case study in which they compared two popular lightweight materials for EVS; aluminum and Advanced High-Strength Steel (AHSS). The study followed the University of California Santa Barbara Automotive Energy & GHG Model (UCSB Model) for a comprehensive analysis of each material’s total energy use throughout its entire life cycle, from production to end of life recycling. For the study, WAS examined 1,000,000 BEVs of equal range that were made up of either entirely aluminum or AHSS.

BEVs made of AHSS require over 15 percent less energy than aluminum cars. (Source: World Auto Steel)

The study found that automakers can make over 17 percent more BEVs made of AHSS than aluminum BEVs with the same amount of energy. In other words, with the energy it takes to make 1 million aluminum BEVs, automakers can make 1.17 million AHSS BEVs.

Why is AHSS More Energy Efficient?

Aluminum production requires 8 times more energy per kilogram than steel production because the production process of aluminum is much more complicated and involves more steps than steel production. The aluminum BEVs in the study used up 30 percent more energy than those made from AHSS throughout its entire life cycle. Plus steel is 100 percent recyclable and can be reused almost indefinitely.

There are many sources of emissions output involved in the entire life cycle of a vehicle. (Source: World Auto Steel)

This poses a serious need to reexamine existing policies and regulations that only seek to reduce tailpipe emissions. By also taking into account emissions from the production of materials all the way to how a car is disposed at the end of its life cycle, automakers can grasp a better picture of the real impact of their choices on the environment.

A Sustainable Choice

As a solution-providing partner for automakers, steelmaker POSCO designed the perfect AHSS for cars that is lightweight, extremely strong, highly formable and environmentally friendly. POSCO GIGA STEEL belongs to the highest category for tensile strength of greater than 1GPa (Gigapascal). It can withstand more than 100 kg of force per square millimeter, making it 3 times stronger than aluminum. It is also 3.5 times cheaper than aluminum and 2.1 times cheaper to manufacture.

SEE ALSO: Infographic: Driving the Future with POSCO GIGA STEEL

POSCO GIGA STEEL is three times stronger than aluminum.

In 2016, POSCO sold 9 million tons of steel sheets for cars, making up 10 percent of the entire global automotive market for steel sheets. POSCO GIGA STEEL was designed to further improve the performance and efficiency of POSCO’s auto partners around the world. As the auto industry heads towards a future where environmentally-friendly EVs become the norm, POSCO will strive to equip its auto partners with the materials and tools necessary to stay ahead and competitive.

Contrary to popular belief, mass reduction does not automatically equal fuel savings, especially when it comes to urban driving. There are other factors that determine the fuel efficiency of a vehicle such as driving cycle, vehicle size and its powertrain. Until recently, there was a  lack of variety in engine types and powertrains, so even though automakers reduced the weight of car frames, they could not apply a complementary engine or powertrain to the lighter parts.

So, have automakers been lightweighting for nothing?

Of course not, in the past decade alone, engines and powertrains have also become extremely efficient through advancements in start-stop-systems and downsizing, and newer options including hybrids, electric batteries and range extenders that now allow automakers to capitalize on their lightweight materials.

Although there are several lightweight materials, below are 5 reasons why AHSS continues to be the lightweight material of choice for automakers:

1. Decision Makers Care About the Environment

Well, not everyone, but many countries around the world have started the process to phase out gasoline and diesel-fueled cars, including India and China, the two largest automotive markets in the world. Governments are taking serious action against climate change and it will reflect in their policies. Automakers are choosing to lightweight their vehicles for lower emission rates with AHSS, because not only is AHSS lightweight, there are no trade-offs with other vital features such as safety and cost-effectiveness.

2. Everyone’s Going Electric

Globally, automakers are investing in electric vehicles (EVs) in line with national and international environmental policies. However, EVs still have a ways to go before they become the norm. EVs will face the same safety requirements as regular cars, but with the added responsibility of protecting the battery and its flammable components during a crash.

In 2016 there were several car accidents involving the Tesla Model S, where leaked battery fluids caused fires. Automakers need to find a solution to make EVs as safe, and eventually, safer than traditional cars. As an innovative automotive material, AHSS was built for safety.

3. Safety is Always First

Safety is and should always be the number one priority for automakers, material providers and policymakers alike. Even with all the hype about autonomous driving and sensors, there is very little chance that policymakers will reverse the stringent safety regulations in place today. People want to feel safe, no matter what type of car they are getting into.  

2016 Smart Fortwo and the Mercedes S Class take part in a crash test (Source: Green Car Reports)

One possible material solution is Complex Phase (CP) steel, a type of POSCO GIGA STEEL for the vehicle’s side panels, bumper rails and door impact bars- the parts that determine the safety ratings of the vehicle. It has superior strength and shock-absorbing qualities, without the added weight of traditional high-strength materials, and that’s why carmakers such as GM Korea, Ssangyong Motors and Renault Samsung Motors all use POSCO GIGA STEEL.

4. Cost is Always Second

This goes for automakers as well as drivers on the consuming end. Drivers want lower costs without compromising safety and performance ratings, and desire fuel efficiency- a major reason why automakers are lightweighting.

Some automakers choose alternative materials such as aluminum and carbon fiber to meet lightweight requirements to find that not only are the materials more costly over steel, factories need an equipment overhaul to work with them. Moreover, there are additional costs related to training employees to work with new materials, whereas all auto manufacturers are familiar with welding and forming steel.  

Take a look at this infographic and see how AHSS stacks up against other lightweight materials in terms of cost and performance.  

5. It’s Not Over Till It’s Over

No two lightweight materials are the same when observed under the life-cycle approach, a comprehensive life cycle assessment of a material’s automotive carbon emissions from production to disposal. Often times, the process of manufacturing lightweight materials and improved powertrains result in more carbon emissions than they are saving.

The life cycle assessment can be used to determine the carbon output of a vehicle. (Source: World Auto Steel)

At the end of the day, steel has the lowest production-related emissions and can be recycled at the end of its lifecycle. Steel remains the most recycled material because it can be reapplied in different forms almost infinitely.

Automakers are increasingly incorporating lightweight materials to their new models. Although competition for the greatest market share of lightweight materials is fierce, AHSS is by far the leading material when it comes to lightweight solutions. According to McKinsey & Company’s Lightweight, Heavy Impact report, the percentage of high-strength materials used for cars will increase to 38 percent by 2030, compared to 15 percent in 2010. Steel continues to evolve according to the changing demands of the auto market, and for now, there is no other multi-solution material that can compete.

Cover photo courtesy of Hyundai.

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