POSCO Group does its best to develop technologies that contribute to safety and carbon neutrality. We introduce POSCO Group’s excellent new technologies to create a better world! In this edition, we spotlight POSCO’s revolutionary One-Touch Converter Operation Automation Technology. With a single press of a button, this cutting-edge innovation fully automates converter operations to ensure operator safety while maintaining consistently superior operating quality.

▲ After successfully completing one-touch operation of the No. 2 steelmaking furnace at Gwangyang works on October 24, Head, Gwangyang Works Dong-ryeol Lee and employees are taking a commemorative photo.

Have you heard of the term Intelligent Factory? An Intelligent Factory actively introduces core technologies of the Fourth Industrial Revolution, such as IoT, AI, and big data, to redefine efficiency and innovation. Unlike traditional “lighthouse factories,” Intelligent Factories take things further by autonomously collecting, integrating, and analyzing data in all processes for smart, data-driven decision making. In October, POSCO made a significant stride toward realizing the Intelligent Factory vision by developing One-Touch Converter Operation Automation Technology. This innovation automates the entire steelmaking process, removing impurities from molten iron from the blast furnace to produce clean steel with just a single press of a button.

POSCO’s one-touch technology applies AI to complete all converter operations without human intervention. The system also automates post-conversion processes such as tapping, slag separation, and coating, by integrating IoT-enabled vision measurement systems that collect and analyze visual data, which is then processed through AI. With this technology development, operators can monitor and manage operations remotely anytime, anywhere without manual control for safety, efficiency, and convenience.

The Need for Digital Transformation in Operating Environments

At Gwangyang works, which produces 22 million tons of crude steel annually, the converter operations in the steelmaking plant demand meticulous control by skilled operators. Each set of three converters required the involvement of 11 operators to manage the processes effectively. Molten steel reaches temperatures exceeding 1600°C and weighs up to 300 tons, which puts immense pressure on operators who must perform their tasks with the utmost care in very demanding conditions. This raised concerns about workplace safety and the need for automation technologies to ensure worker safety. Moreover, digital transformation of traditional operating methods was needed to adapt to the evolving steel industry paradigm. In 2018, POSCO’s Gwangyang works Steelmaking Division teamed up with POSCO’s Research Institute of Technology to develop intelligent, autonomous manufacturing processes that prioritize cost efficiency, quality, and safety.

Gwangyang works’ steelmaking plant had confidence in its ability to develop automation technologies due to the large number of experienced operators and vast operational data accumulated over years of production. After seven years of relentless effort, the team achieved the remarkable milestone of automating the process and reducing the 25 existing manual operations to just a single touch of a button. Let’s take a look at the three key pillars of One-Touch Converter Operation Automation Technology.

IoT-Powered Vision Measurement and Control System Automates Tapping Operations

In converter operations, where 1.5 tons of molten steel are tapped every second, the extreme heat and weight required operators to visually monitor and manually control equipment. To solve this problem, POSCO focused on automating the tapping process, one of the most complex stages in converter operations. IoT-based cameras and vision measurement devices were installed around the converter to collect years of data. This data was processed using computer vision technology, and control logic incorporated the extensive expertise of experienced operators. As a result, POSCO achieved full automation of tapping operations. Additionally, a system was established to monitor blind spots and high-risk areas to replace manual observation and prevent hazardous situations.

POSCO’s Signature AI Converter Model Hits 97% Accuracy in Temperature and Composition

Converter heat matching involves calculating the total thermal energy of molten iron, scrap, and auxiliary materials introduced into the converter. POSCO has improved this critical task by harnessing three years of accumulated operational big data and seamlessly integrating it with AI to develop a sophisticated algorithm. This innovation made it possible to produce consistent, high-quality steel, even in dynamic and variable operating environments. The developed model achieved a remarkable 97% accuracy in temperature and composition prediction, a level comparable to the expertise of top-grade operators.

Digital Twin-Enabled One-Touch Automation Integrates and Remotely Controls Processes

The digital twin system digitally replicates physical objects for real-time synchronization and interaction between virtual and physical environments. By implementing a virtual converter synchronized with real-time operations, POSCO achieved integrated management and monitoring capabilities. This advancement also enabled the creation of a system where operators can remotely control the converter process with a single touch anytime, anywhere.

▲A demonstration of the one-touch automation system held at the POSCO Center in Seoul on October 24.

▲(left) After the system demonstration, POSCO President Si-woo Lee is taking a photo with Gwangyang works Steel Department General Technical Manager Deung-mo Choi. (right) galvanized steel sheet (EG 1500Mart steel) produced through remote Converter one-touch operation.

On October 24, a demonstration of the One-Touch Automation System was held at POSCO Center in Seoul. POSCO President Si-woo Lee successfully initiated the remote operation of Gwangyang works’ No. 2 converter to produce top-grade automotive steel.

▲ The Gwangyang works Steelmaking Department team won the grand prize, the ‘Innovation Award’, at the ‘2024 POSCO Technology Awards’ (Fifth from the left, In-hwa Chang, Chairman of POSCO Group)

One-Touch Converter Operation Automation Technology is a cornerstone of POSCO’s transformation into an Intelligent Factory. It was recognized for its innovative capabilities by winning the Innovation Award at the ‘2024 POSCO Group Tech Forum’ held in POSTECH’s main auditorium on November 6.

The introduction of this technology has transformed the work environment for operators by alleviating their workload and reducing concerns about safety risks. Beyond these benefits, the accuracy of the temperature and composition of molten steel was improved from 94% to 97%, while the error rate in steelmaking decreased to maintain consistent product quality. These advancements are projected to yield annual economic benefits of approximately KRW 33.8 billion.

POSCO has also unveiled a roadmap to expand the use of One-Touch Converter Operation Automation Technology from Gwangyang works to Pohang works and its Indonesian works in the near future. Get ready to witness POSCO redefine the future by spearheading groundbreaking innovation and making a bold leap into the era of Intelligent Factories!

POSCO introduced its advanced solution marketing campaign ranging from energy steel products to end products at OTC held in Houston, Texas, on April 30th.

POSCO decorated various technologies and solutions in the Main hall

The main purpose for the convention was maximizing promotion activity by POSCO’s unique solution program. Therefore, from the last year, POSCO set up the booth in the main hall (NRG Center) with the global major companies including Exxon, Siemens and GE. POSCO is the first domestic company that set the booth at NRG center.

Technologies from the fundamental materials to final products

POSCO has got huge attentions from by participants by presenting various unique solutions ranging from materials and end products, including 9% Ni steel LNG storage tanks and LNG fueled ship equipped with storage tanks made of high-manganese steel, large diameter thick wall welded steel pipe that POSCO’s high-strength panels applied and the Fitting, the joint between the pipe, the world’s leading wire rope that is made of ultra-high-strength for offshore construction, membrane for fuel storage of LNG carrier and tubes for energy mining.

Strengthen the relationship with global partners

In addition, POSCO and marine equipment manufacturers held a technical meeting with EPC (Engineering, Procurement and Construction) companies to discuss and encourage new projects. POSCO also engaged in consultations with a range of companies, including potential clients located near Houston in order to penetrate a new market for World Premium steel products.

POSCO has been participated the OTC every year since 2008 and established strong network with major oil companies and global ETC companies and promote POSCO’s finest high manganese steel.

Technology isn’t just securing the safety. Also boosts athlete’s motivation

Pride of the Korean-Made

The passion of the athletes seen at The PyeongChang 2018 Paralympic Winter Games is unforgettable. It is to this end that POSCO has devoted itself to supporting athletes with disabilities.

When it comes to sports, even small improvements in technology or changes to the gear may bring about huge differences. Having supported the national para ice hockey team since 2016, POSCO developed lightweight sledges with improved tolerance shock absorption for the Korean para ice hockey team so that the athletes could focus more on the game. This made POSCO the first company in Korea to manufacture athletic gear for national Paralympic teams. Equipped with motivation and new gear, the Korean para ice hockey team achieved an amazing Bronze medal in The PyeongChang 2018 Paralympic Winter Games.

SEE ALSO: Parallel: Shining a Spotlight on the Korean National Para Ice Hockey Team

With memories of The PyeongChang 2018 Paralympic Winter Games still fresh, South Korea recently observed the National Day of Persons with Disabilities on April 20. In recognition of this day, POSCO interviewed Jin-Owan Jung, head officer at the Korea Paralympic Committee Icheon Training Center and manager of the Korean Paralympic team the man who led the Korean team at The PyeongChang 2018 Paralympic Winter Games and one who both understands and represents the interests of people with disabilities in Korea.

“It’s Not Just About Overcoming Your Disability But Accepting It.- Jin Owan, Jung”

He emphasized the recognition and acceptance rather than struggling

Accept who you really are

Jin-Owan Jung was 22 years old when a car accident left him paralyzed from the waist down in 1987. Undeterred by the accident, Jung set his eyes on becoming an athlete for the Paralympics when he saw the Seoul Paralympic Games in 1998. He won 2 medals – a gold and a bronze – in Shooting in the 2000 Sydney Paralympics Games. After retiring as an athlete, his passion for sports drove him to take on a new role in administration. The experiences gained as a Para sport athlete and also by interacting with others with disabilities, gave him a perception that acceptance of one’s disability is more important than struggling to overcome it.

He agrees that the situation is getting better but still needs more support such as financial aspects

You are not alone

The PyeongChang 2018 Paralympic Winter Games was a huge success in that the athletes’ passion inspired positive change in the society’s views toward people with disabilities. Jung noted that the infrastructure for people with disabilities in The PyeongChang 2018 Paralympic Winter Games was much improved in comparison to past games. However, he believes there is still room for improvement. Additional and sustainable social support is necessary to ensure those with disabilities can enjoy living conditions equal to those of other citizens and have an equal share in the development of their societies.

POSCO supports not only their technology but also financial aid

How to support?

Jung explains, “Financial support is not everything but it is important in certain circumstances.” POSCO has been a proud sponsor of athletes with disabilities and has provided roughly $2.6 million in support of Para sport since 2011. This year, POSCO donated $370,000 to the Korean Paralympic team in honor of their effort and passion.

‘Harmony’ is the element that POSCO will promise for better society

Jung believes that sports might be the key to resolving discrimination against people with disabilities. However, this can only be accomplished with active contribution from supporters. POSCO will continue to support Jin-Owan Jung’s dream of achieving social harmony and creating a society where having a disability does not impede one’s quality of life.

‘Future Vision Declaration Ceremony’was held on April 1, the 50th anniversary of POSCO, POSCO CEO Ohjoon Kwon shared his philosophies of the centennial enterprises and the new mission and vision

On April 1st, the 50th anniversary of POSCO, named ‘Future Vision Ceremony’ was successfully held. The main topic of the anniversary was not only celebrating 50th years POSCO’s efforts both industrial and social fields but also suggestion of future directions of POSCO, ‘Missions and Visions’ 

‘Unlimit the limt: Steel and Beyond’

POSCO is dreaming of KRW 500 trillion in consolidated sales in 2068, the 100th anniversary of the company.

On the occasion of its 50th anniversary, POSCO held the ceremony to declare its future vision, and announced the mission and vision as a global centennial enterprise at the POSTECH gymnasium at the 50th anniversary of POSCO on April 1, and announced its mission and vision of being one of the true global centennial enterprises.

The new mission of the global centennial enterprise POSCO, which POSCO CEO Ohjoon Kwon detailed in the form of his TED Talk, is ‘Unlimit the Limit: Steel and Beyond.’ This mission, which was finalized after a few months of intensive debate among executives, means that POSCO will capitalize on its past 50-year history of challenges to become a power in the future not only in steel, but also in non-steel areas.

To this end, POSCO is seeking to change its current revenue streams, in which about 80% of the group’s profits come from steel and steel-related areas, in which profits will come evenly from the top three core business groups, i.e. steel, infrastructure and new growth engines, at a ratio of 4:4:2. POSCO aims to see its consolidated sales reach KRW 500 trillion and its operating profits reach KRW 70 trillion in 2068, its 100th anniversary.

In addition to its primary business, i.e. steel, POSCO will concentrate on such infrastructure areas as trading, construction, energy and ICT were included, and such new-growth areas as energy storage materials and light-weight materials.

The vision, which was declared along with the mission, is ‘POSCO the Great.’ ‘POSCO the Great’ was the slogan that CEO Kwon used when he was first inaugurated as CEO in 2014 to revive POSCO which faced a crisis at the time. Now the slogan has become more systematic: Great Business, Great Technology and Great Culture. It means pushing the business structure, technology and organizational culture to the highest level.

As POSCO has contributed to the country and society through steel and educational patriotism, at a time when the company is celebrating its 50th anniversary and starting its march forward toward a centennial enterprise, it decided to conduct business that will repay the country in addition to declaring its mission and vision.

POSCO supports Youth

In return for the country’s unsparing support and the citizens’ enthusiastic support which made POSCO what it is today, POSCO opted to construct the ‘Youth Creativity Center’ (tentative), which features various contents, including the Science and Experience Center in Seoul Forest, located in the center of the capital city of Korea, and donate it to the nation.

The ‘Youth Creativity Center’ will become a learning center where youths, who will lead the country into the future, can easily understand the principles of technology and science through experience, and translate their creative ideas into reality.

Also, the center will have various concert halls and exhibition halls so that anyone can easily enjoy culture and art in everyday life.

If the international design competition for world-renowned architects is held this year, it will reveal its splendor as being the best science and culture complex in Korea.

The POSCO Center in Seoul, which was erected more than 20 years ago, now features a new product exhibition hall that will familiarize citizens with steel, and show customers the future vision of steel, and added a 30-seat PR video center. The product exhibition hall displays various industries demanding steel in the future, and state-of-the-art steel products, and allows visitors to experience the various uses of steel used in our everyday lives using the cartoon and touch technique in a fun way. At the PR video center, visitors can watch POSCO PR videos, and view a steel mill in 3D imagery.

Close to people 

On its 50th anniversary, POSCO, which has contributed to the growth of the country with steel, will air a TV ad, which reflects its will to transcend beyond steel, ‘50-Year Challenge and 100-Years New Dream’ until June 10, and the POSCO Art Museum in the first lower level of the POSCO Center will host the ‘Homage to POSCO’ exhibition until May 8. The artworks embodying the growth and rebirth of POSCO will be on display. Also, the POSCO Museum in Pohang will host the ‘Half-Century Video Records of POSCO,’ which introduces various images and historical materials which recorded its 50-year history of growth, until June 30.

In addition, until the end of May, POSCO will prepare an opportunity for the CEO and employees to communicate and harmonize with one another in Seoul, Pohang and Gwangyang with the aim of strengthening the solidarity among employees marching toward a centennial enterprise.

POSCO always stands with country 

POSCO’s 50-year history is in true sync with the history of the growth of the Korean economy. POSCO has never stopped growing for half a century since its foundation, and continued to turn profits without ever running into the red and still contributes to the economic development of the country.

POSCO was established in 1968, and molten metal was first produced in 1973. Its sales amounted to KRW 41.6 billion in that year, and increased 686 times last year to KRW 28,553.8 billion. Korea’s per capita GDP was merely US$ 198 in 1968, but it increased about 140 times in 2016 to US$ 27,539.

As POSCO grew and its steel production increased, domestic industries such as automobiles and shipbuilding continuously grew as well. In 1973, when POSCO started to produce molten metal for the first time, POSCO’s steel production amounted to 449,000 tons, but in 2017, it rose to 37.2 million tons. Likewise, Korea’s shipbuilding tonnage increased from 12,000 tons in 1973 to 23.5 million tons, and automobile production rose from 25,000 cars to 4.11 million cars.

POSCO has also grown remarkably in terms of technology. The FINEX technology, which replaces the modern blast furnace with more than 100 years of history, is an environmentally-friendly and economical innovative technology. POSCO independently developed and commercialized this. Also, in 2013, the company completed the construction of Southeast Asia’s first integrated steel mill in Indonesia. Just 40 years after POSCO owned the first integrated steel mill with the help of Japanese steelmakers in 1970, it grew so big as to build an integrated steel mill in a foreign country on its own, and transformed itself from a technological follower to a technological leader.

Also, POSCO sold 9 million-odd tons of automotive steel last year, which accounts for about 25% of its total sales, the largest proportion among major global automotive steelmakers and sellers. One out of every 10 cars sold in the world is made of POSCO’s automotive steel.

Smarter POSCO 

Recently, the company built its own smart factory platform called PosFrame, leading the smartization of the global steel industry.

In recognition of its excellent business performance, competitiveness and sustainability management, POSCO has been selected by WSD as one of the ‘world’s most competitive steelmakers’ for the past 8 consecutive years since 2010, and in the global sustainability management evaluation, it has been selected as an excellent company in sustainability and as the best company in the steel industry for the past 13 consecutive years, dating back to 2005. It has remained in this honorable position for the longest time in Korea.

Existing airports are facing a growing capacity crunch in the midst of a growing global economy. (Source: Skift)

The Asia Pacific region’s Available Seat Kilometers (ASK) has increased 7.9 percent YoY, as China leads the way with numerous airport construction projects. Current and anticipated expenditure on airport infrastructure is USD 391 billion for the entire region.  European airports experienced a 30 percent increase in passenger volume from 2012 to 2017. Currently, there are 450 airports facing a capacity crunch in Europe, and the region is currently expecting to spend USD 123 billion on airport infrastructure. North America saw a 4.9 percent YoY growth in its ASK and is currently and expected to spend about USD 123 billion in upgrading its existing airport infrastructure.

There’s no set formula to deal with the growing capacity crunch, and airports in different regions are finding their own solutions from high tech to high-quality materials.

SEE ALSO: Clear Landing into 2018: What’s Ahead for the Aviation Industry

Speeding up passenger flow

Developing countries rich in land and capital, such as China, will deal with the growing number of passengers by building more airports. In other places such as North America, the focus will be on upgrading existing infrastructure and improving passenger flow with the help of technology.

One example of software that is being applied to speed up the flyer’s journey and minimize errors is biometric technology. In Changi Airport Terminal 4, a system called Fast and Seamless Travel (FAST) with biometric technology and self-service features is already in place and will begin operations at the end of October.

Changi Airport’s new terminal will have numerous self-service stops with biometric technology for identification. (Source: Today Online)

Passengers will be able to check-in, check baggage and board the plane, all through a series of self-service stops equipped with fingerprint scanners and facial recognition for identification instead of passports and boarding passes. Sydney Airport will also have a similar system running by the second half of 2018, and many major airports are looking to expand biometric technology applications to other areas such as flight information display systems and on-flight payments.

This is great news for crowded airports. Besides bad weather, the biggest reason for delayed flights is delayed passenger information. As of now, airlines and airports do not share data regarding passengers. Even though airports are aware of passenger check-ins hours before departure, airlines are only notified at boarding gates. Thus, airlines are rushed last minute to verify passenger and flight crew information, causing delays. Reducing the redundant check-in process alone will speed up the flow of passengers through airports.

AI and robotics to lead airport services

In line with the trend toward self-service and passenger interactions with technology, airports and airlines are implementing AI and robotics to improve the passenger flight experience and make it more personalized.

Last year, Incheon International Airport (ICN) in Korea added LG’s robots to its service team – the Airport Guide Robot and the Airport Cleaning Robot. The Guide Robot roams the terminals, ready to help out a passenger in need with airport and flight information in English, Korean, Chinese and Japanese. The bot even personally escorts travelers to the right terminal or boarding gate when passengers scan their boarding passes. The Cleaning Robot cleans nonstop, and can even detect dirty areas, analyze cleaning patterns and calculate the most efficient cleaning routes.   

The Airport Guide Robot and the Airport Cleaning Robot roam the terminals of ICN as part of the airport’s customer service and cleaning crew. (Source: Android Central)

Haneda Airport in Japan is also testing 7 different types of robots equipped with AI software to cover security, translation and baggage transportation. Investment in robotics is crucial for a country like Japan where there is a severe labor shortage due to low birth rates, and the airport is planning to have their bots up and running by 2020, in time for the Olympic Games in Tokyo.

Passengers will also be greeted by a robot named Josie Pepper at Munich Airport’s Terminal 2. Josie Pepper functions on IBM Watson’s IoT and AI technologies. Her high-performance processor with a WLAN internet access connects to a cloud service that is also linked to airport data to deliver information to passengers in real-time. Moreover, machine learning allows Josie Petter to collect and analyze data and improve her responses over time instead of repeating inputted text.  

The bigger the better

The use of technology will greatly improve the passenger flow through airports and increase passenger capacity. However, the new software systems will work best when accompanied by upgraded airport infrastructure. That’s why airports all over the world are undergoing expansion projects including Heathrow Airport (USD 17.3 billion), Sharjah International Airport (USD 400 million) and Auckland Airport (USD 160-180 million).

ICN recently finished and opened its new Passenger Terminal 2, expanding the airport’s capacity to 72 million passengers and 5.8Mt of cargo every year. The terminal was built using 380 tons of POSCO’s 446M stainless steel that contains high amounts of chromium (26%) and molybdenum (2%) for maximum corrosion resistance against the airport’s coastal climate. Moreover, an innovative Bead Blast process was used to process the stainless steel to create a rough texture to decrease sunlight reflectivity for aircraft pilots during take-offs and landings.

ICN’s new passenger terminal is outfitted with high-quality stainless steel. (Source: Airport Technology)

As with ICN, ongoing and future airport expansion projects are projected to consume vast amounts of high-quality steel that is superior in strength, corrosion-resistant and boosts the safety of passengers and flight crew. The renovated infrastructure will further be enhanced by new software upgrades, and future airports will be vastly more efficient and passenger-friendly.

Cover photo courtesy of Dubai Airports.

The U.S. is headed towards a major shortage of truck drivers. (Source: The New York Times)

However, the U.S. is short of about 30,000 to 35,000 drivers for every 750,000 trucks, and the number of driver shortages may reach up to 245,000 by 2022. That’s because right now, the average age of truck drivers in the U.S. is 55, and potential new recruits are choosing to sign up for construction or manufacturing jobs instead.

All this leads to climbing prices for freight transportation. Last December, at the peak of holiday deliveries, U.S. companies saw the highest monthly average rate for freight transportation since 2010. The high operation costs and lower profit margins are putting a heavy strain on industries. Heading into 2018, companies have to compete for carriers as there is just one truck available for every 12 loads.

As a result, Major automakers are heavily invested in autonomous electric freight trucks such as Tesla, Volvo and Daimler, and there are many proponents of an eco-friendly, safe and driverless future for freight transportation. However, autonomous freight trucks are not a realistic option for companies just yet. At a time of transition between the old and the new, there is a serious lack of capacity in freight transportation, and companies are left to deal with the higher costs for delivery.  

But good news right around the corner

Although the driver shortage is a major concern, it is a natural phenomenon in the transition towards a safer, more sustainable and more efficient freight transportation industry.

Uber’s autonomous freight trucks are in operation with a human safety driver on the highways of Arizona. (Source: Future Car)

Already, Uber has its autonomous trucks on the highways of Arizona. Every truck does have a human driver present to take over anytime, and the company uses transfer hubs to transfer goods between highways and local roads. Autonomous trucks are the safest and most efficient for use on highways, so human drivers transport goods from highways to the final destination. The company is working to operate without human backup drivers in the near future.

Waymo’s autonomous freight trucks have gone through almost a decade of testing and is now delivering supplies for Google in Atlanta. (Source: Wired)

Waymo is another company with autonomous trucks already in operation. Just this month, the company’s autonomous freight trucks started transferring equipment for Google data centers in Atlanta.

Embark was the first company to complete a successful coast to coast run with an autonomous truck. (Source: Micro Power Grids)

Embark also has its autonomous trucks in operation. Earlier this year, the company made a successful 2,400-mile trip from California to Florida with a human safety driver on board. The company has plans to commercialize its services in the coming years.

SEE ALSO: 6 Cities On the Road to a Driverless Future

Speeding up delivery

Numerous other automotive and tech companies besides those mentioned above are getting ready for autonomous freight transportation. The faster autonomous freight trucks are able to operate commercially, the faster industries can cut costs, improve delivery times and reduce their carbon footprint.

This means software technology, high-capacity batteries as well as the right automotive materials will play a crucial role in the future of the freight transportation industry, as well as in related industries. This transformation will open up new business opportunities for automakers, software companies as well as steel manufacturers like POSCO.

For autonomous truck manufacturers looking for ultra-lightweight yet super strong materials for optimal fuel efficiency, POSCO developed POSCO GIGA STEEL. The advanced high-strength steel (AHSS) material is 3 times stronger and 3.5 times cheaper than aluminum. Steel is also 100 percent recyclable and an electric vehicle made of AHSS requires 30 percent less energy than aluminum throughout its entire lifecycle. POSCO also developed a premium non-oriented electrical steel called Hyper NO for the most advanced and sustainable electric motors.

SEE ALSO: Why Electrical Steel Can Make All The Difference In EV Motors

POSCO also works with its auto partners to research and provide customized technology and materials solutions for their autonomous EVs. In the midst of a critical shortage of truck drivers, POSCO hopes to speed up autonomous EV adoption both for personal and commercial transportation and aid the transition into a more efficient and environmentally sustainable economy.

Cover photo courtesy of Time.

As a result, new innovations in battery technology are beginning to open up new possibilities for not just the automotive industry, but for consumer electronics, wearables, drones and much more. Such industries are positioned for growth in the Fourth Industrial Revolution, and supplying enough lithium to meet the growing demand through sustainable practices is posing a challenge.  

SEE ALSO: The Fuel of Tomorrow: Mining Lithium for Tomorrow’s Cars

New Developments in Lithium Batteries

Today, almost every automaker is invested in EVs, and it will be batteries and software, not brakes and engines, that will play a decisive role in the success of future fleets. The biggest challenge for battery manufacturers is to make a high-capacity battery that can charge in a short period of time, but still be lightweight and compact at the same time.

Solid-state lithium-ion batteries are lighter, more compact and safer than liquid-state batteries. (Source: UPS Battery Center)

Solid-state lithium-ion batteries are a feasible solution. These super-capacity batteries replace traditional semi-liquid electrolytes with solid electrolytes that allow for faster charging times (about 7 minutes) and are not susceptible to explosion on impact as liquid-state electrolytes are. Solid-state batteries can also operate in dynamic temperatures between -30 degrees Celsius and 100 degrees Celsius. Plus, they are far lighter and take up less space in an EV. Toyota has announced they will use solid-state lithium-ion batteries in their EVs starting from 2020.

Professor Yang’s flexible lithium-ion batteries are composed of stiff and flexible parts to resemble the human spine. (Source: eeNewsAnalog)

Besides cars, lithium-ion batteries are great for portable electronic devices, and a new invention looks to widen the applicability of the batteries. Assistant Professor Yuan Yang of Material Science and Engineering at Columbia University recently came up with a flexible type of lithium-ion battery that resembles the human spine. He first got the idea for the design while doing sit-ups at the gym when he noticed how his flexible spine allowed his body to move in various ways. Yang applied the idea to lithium-ion batteries by rearranging the traditional battery in a vertical structure made of stiff and flexible parts, just like the human spine. The end result was a flexible battery with more than 85 percent of the energy density found in a standard battery. The flexible and energy-dense batteries are expected to open up new possibilities for consumer technology designs and further accelerate the growing wearables market.

SolidEnergy Systems lithium-metal batteries are energy-dense and one of the smallest batteries available. (Source: Digital Trends)

There’s another up-and-coming invention that makes use of solid-state lithium batteries. SolidEnergy Systems recently received USD 34 million in funding to commercialize their lithium-metal batteries, bringing total funding to USD 50 million. The batteries have twice as much energy density as lithium-ion batteries, making them perfect for devices that have battery size limitations. By replacing graphite with lithium metal foil for the negative electrodes, the company was able to pack more energy into a smaller space. The resulting energy density is 450 watt hours per kilogram and 1200 watt hours per liter. For now, it is being sold to drone companies and the makers are working on lithium-metal batteries for wearables and EVs.

Sustainable Lithium Extraction

In the midst of development and advances in lithium batteries, the question to ask is where is all the lithium coming from, and is there enough to feed growing demand? The answer is yes, there is more than enough lithium in different parts of the world, but the problem is that there are not enough mines to extract all the lithium in demand.

Lithium is a growing source for jobs in South America due to the high demand. (Source: Twitter/@BrianDColwell)

More than half of the world’s lithium reserves are in South America, more specifically in Chile and Argentina, but Australia is the biggest producer. Even with new mines opening up at a frequent pace, lithium extraction isn’t easy. Political, social and environmental hurdles have led to unstable output. Coupled with the exponential growth of the EV market, the price of lithium carbonate has more than doubled from 2011 to 2016.

Another concern is the environmental impact of lithium extraction and production. Critics have pointed out that raw materials, such as lithium, used to produce eco-friendly batteries have a large carbon footprint on their own.

POSCO CEO Ohjoon Kwon holding lithium during his visit to PosLX, POSCO’s battery production factory in Korea.

That’s why earlier this year, steelmaker POSCO opened up PosLX, Korea’s first lithium plant, as part of the move to expand its non-steel businesses and make headways into the batteries market. The new plant has an annual production capacity of 2,500 tons and will use POSCO’s innovative technology, developed in-house. POSCO’s eco-friendly extraction technology entails extracting lithium from water, and takes anywhere between 8 hours up to a month to complete. Traditional evaporation methods take 12 to 18 months to produce the same amount. Moreover, POSCO’s technology can obtain a purity rate of 99.9 percent, as well as a recovery rate of over 80 percent.

In addition, POSCO has developed a way to extract lithium phosphate, a raw material of lithium carbonate, from used rechargeable batteries. The lithium carbonate produced from recycled secondary batteries are equal in purity, charge, discharge efficiency and capacity as existing lithium carbonate, but at a lower cost to the environment.  

SEE ALSO: POSCO’s Innovation Shapes the Ever-Growing Lithium Market

Going forward, POSCO plans to increase its lithium production capacity to 40,000 tons per year to supply the increasing demand from new-growth industries and ensure a sustainable future of renewable energy.

Cover photo courtesy of Cleantechnica.

POSCO started supporting the team last year after CEO Ohjoon Kwon watched the team take the bronze medal at the 2017 World Championships. As shown in the documentary, the athletes were playing on insufficient sledges that would often break down and cause injuries. Some players were fixing their own sledges between matches, others made do with what they had. CEO Kwon knew POSCO had the solutions for the team and started a project with sledge-maker Massive Blade to revamp the sledges for the team. Now, ahead of the 2018 PyeongChang Winter Paralympics, the team is equipped and ready with the world’s leading technology.

SEE ALSO: How POSCO’s Advanced Technology Gives Speed to Korea’s Para Ice Hockey Team

Parallel: A Documentary

Parallel was directed by Kyungman Kim in 2012. He wanted to make the movie to document the para ice hockey players’ endurance and grit in overcoming their physical limitations through the sport. “However, as I started editing the footage and putting it all together, I noticed how happy the players looked on the ice. That’s when I decided the documentary was going to be about happiness – what it really means to be happy. That’s what I want to share with viewers,” said director Kim.

Director Kim couldn’t help but notice the smile on the players’ faces. (Source: Taehung Pictures Naver Post)

That’s exactly what the movie delivers. Of course, the players face challenges every day due to their injuries and physical conditions, but the interviews in the documentary reveal the players to be genuinely happy and grateful for their sport. Seunghwan Jung, one of the players, says, “I used to wish I had legs all the time, but when I started playing hockey, the thought just never crossed my mind. In a way, the sport has allowed me to accept myself… understand myself.”

One of the players take break from intense training. (Source: Taehung Pictures Naver Post)

For many of the players, playing para ice hockey has been a healing process, but it doesn’t end there. The team is as competitive as any other Olympic team, and even with a lack of spectators and interest in the sport, the national team has produced impressive results. In the 2010 Vancouver Winter Paralympics, the team placed 6th, and then 7th in Sochi in 2014. This is even more remarkable given the poor equipment, especially the sledges, they were using at the time.

POSCO Gives Ice Sledges a Technological Makeover

In order to qualify as a para ice hockey player, a person must have a physical impairment in the lower part of their body, but this can come in many different forms. As a result, one of the biggest challenges teams face is finding sledges that fit, protect and enhance each player. Before POSCO signed on as a sponsor, the Korean National Team relied on expensive imported sledges from Canada that were heavy and susceptible to structural damage from harsh contact. On average, 5 to 7 sledges required repair work during a single game. In an attempt to produce the first domestic sledge, POSCO’s researchers jumped on board to provide sledge-producer Massive Blade the materials for a lightweight, strong and corrosion resistant sledge.

Researchers at POSCO’s Research Institute of Industrial Science & Technology (RIST), came up with a way to use magnesium as the main material for the sledge frame. Magnesium is one of the lightest materials available as it is one third lighter than aluminum, but it is extremely hard to treat and bend into shape. RIST not only developed the technology to treat magnesium, but also applied it to sledges for the first time in history. POSCO also provided its advanced high-manganese anti-vibration steel and stainless steel to finish off the new sledges, fit for a national team.

RIST researchers developed a processing technology to increase the moldability of magnesium.

Outfitted with the new sledges, the team beat out strong European teams in the 2017 World Championships to place 3rd, and just last month, they won a four-nation friendly tournament in Japan. Now, they have their eyes on an Olympic medal in PyeongChang.

Regardless of the results, POSCO will continue to support the Korean National Para Ice Hockey Team so they can continue doing what makes them and others around them happy.

Cover photo courtesy of Hello PyeongChang.

Watch hundreds of steel cans being produced at a Soudronic canning factory.

Advantages of Steel Packaging

Steel is one of the most commonly used packaging materials by manufacturers, because it is widely available, cost-effective and easy to work with. Steel packages can be customized to just about any shape and size depending on the needs of the business, and the continuously improving quality of steel lets manufacturers use less material without losing rigidity.

Steel as a packaging material is tamper-resistant, durable and has an extremely long shelf life, hence the reason why canned food seems to last forever. At the end of its life cycle, steel is 100 percent recyclable and does not lose any of its properties or qualities in the process. Plus, at least 25 percent of every steel can must be made of recycled steel, and its magnetic properties make it even easier to recover for recycling.

Steel is 100 percent recyclable and the most-recycled material in the world. (Source: Causeway Coast and Glens)

According to the Association of European Producers of Steel for Packaging (APEAL), steel packages are the most recycled packages out of all packaging materials, and its recycling rates keep climbing. In Europe, over 77 percent of steel packages are recycled and in countries such as the Netherlands, Belgium and Germany, rates exceed 90 percent.

New Innovations

Today, there are numerous new technologies taking steel packaging to a whole new level. Higher-quality alloys of steel and innovative new methods for processing steel are making everyday products safer, more convenient and efficient. Here’s some examples to show the advances being made in steel packaging.

Bacteria-free stainless steel surfaces

Researchers at Georgia Institute of Technology recently invented a new way to fight harmful bacteria such as E. coli on steel surfaces. Instead of the traditional antibiotics that are temporary and can aid bacteria in developing resistance, this new process uses an electrochemical etching chemical process to create thousands of tiny nano spikes on stainless steel surfaces. By switching up the levels of voltage and current flow in the electrochemical process, the researchers ended up with a rougher, “spiked” surface.

The spikes are about 25 nanometers long, and will kill both gram-positive and gram-negative bacteria on contact, without damaging human cells. The human eye cannot tell the difference between nanotextured steel and regular steel, and the technology increases corrosion resistance as well.

Nanotextured steel can kill bacterial upon contact without harming human cells. (Source: The Engineer)

Though the technology is new and is awaiting additional tests, it could be a permanent solution to treating bacteria and potentially change the medical and food industries completely. Nanotextured stainless steel can be used not only for packaging, but the manufacturing equipment that come in to contact with food. Researchers are also working to apply the technology to spine implants and other implants that come in direct contact with the body.

The world’s lightest 3-piece aerosol can

German company Henkel and packaging manufacturer Ardagh Group developed a new, sustainable aerosol spray can for Henkel’s beauty products using high-quality steel. The can is a mere 0.13mm thick, using up 15 percent less materials than its counterparts, but is also more rigid. The world’s lightest aerosol can also reduce C02 output by 3500 metric tons and water consumption by 900,000 cubic meters per year.

High-quality steel makes this aerosol eco-friendly. (Source: Pack World)

The development is in line with Henkel’s efforts to contribute to a circular economy. Thus the company aimed to design a packaging material that is not only effective and sustainable to produce, but is also 100 percent recyclable.

As the most recycled packaging material in the world, steel will continue to package food, beauty products, paints, chemicals and more manufactured goods. Especially with advances in the quality of steel alloys and innovative ways to process steel, manufacturers can be assured their products will be safe and sound in effective, cost-efficient, sustainable and safe packages.