Breakthrough Technology Development to Decarbonize Steelmaking Processes

Nippon Steel has completed the installation of an experimental EAF (with a capacity of 10 tons/charge), aimed at developing and verifying the technologies required for the commercial-scale implementation of high-grade steel production technologies at large size EAFs, and has already started tests for high-efficiency dephosphorization and denitrification processes at this experimental EAF from 2025.

The COURSE50 is a technology development we undertook from 2008 to 2022 to realize steelmaking using hydrogen. At an experimental BF with a volume of 12m³ constructed in the East Japan Steel Works Kimitsu Area, we conducted operational tests on hydrogen injection into the BF using hydrogen-rich by-product gas (coke oven gas) generated within the steelworks, verified over a 10% reduction in CO₂ emissions. We also developed an energy-saving CO₂ separation and capture technology using a chemical absorption method, which led to its commercial-scale implementation in the industrial CO₂ field.

The Super COURSE50 is a Green Innovation Fundsubsidized project that aims for a further reduction of CO₂ emissions (50% or more). This is a technology for heating and using hydrogen purchased from external sources for maintaining the heat balance in the BF in anticipation of an era when social infrastructure for a sufficient hydrogen supply is available. Since the start of test in May 2022, we have steadily made progress, including the achievement of a 43% reduction in CO₂ emissions from the BF during operational tests conducted in November to December 2024. This achievement sets a new world record.

Nippon Steel Engineering Co. in the Nippon Steel Group has commercialized an energy-saving CO₂ chemical absorption process called ESCAP™(Energy Saving CO₂ Absorption Process), which uses chemical absorption, one of the methods for CO₂ separation and recovery. Two units are already in operation in Japan, including the one installed in the North Nippon Works Muroran Area.

The ESCAP™ is characterized by high energy efficiency with a more than 40% reduction in heat consumption compared to general-purpose technology. In addition, its proprietary impurity removal facility enables recovery of more than 99.9% of high-purity CO₂ from raw material gas with high impurities.

Nippon Steel, in collaboration with Oita University, Osaka University, Kyoto University, Chiba University, Nagoya University, Hokkaido University, and Resonac Corporation, started the full-scale development of separation/capture technology for low-concentration CO₂ contained in industrial emission gases.

To separate/capture CO₂ efficiently from low-pressure, low concentration emission gases (with a CO₂ concentration of 10% or less at the atmospheric pressure), we are working on the development and social implementation of a new CO₂ separating agent (structurally flexible PCP), which has higher CO₂ selectivity and enables CO₂ adsorption and desorption with minimal levels of pressure operation.

Nippon Steel participates in three CCS-related joint projects, the Tohoku Region West Coast CCS Project, the Metropolitan Area CCS Project, and the Oceania CCS Project, which the Japan Organization for Metals and Energy Security (JOGMEC) adopted in FY2024 as part of its publicly solicited project, the "Engineering Design Work for Advanced CCS Projects."

In these projects, we are conducting, jointly with other companies, the engineering design work for the entire CCS value chain and preparing the work for storage potential assessment as a follow-up phase to the post-feasibility study. At the same time, we are actively promoting the early social implementation of CCS by taking the lead in studies related to CO₂ separation, capture, and liquefaction, as well as shipping terminals.

In April 2023, Nippon Steel, Osaka Metropolitan University, Kyoto University, Tohoku University, Tokyo University, and UBE Corporation started research and development on the “development of one-step synthesis process for polycarbonate diol from CO₂.” Polycarbonate diol is a representative material for producing high value-added carbon compounds that do not require hydrogen. It is also a raw material for high-performance polyurethanes, widely used worldwide and whose demand is expected to grow further. However, the high environmental impact of its synthesis process has been a major issue. In contrast, this research and development aims to develop an innovative green process that effectively utilizes CO₂ instead of highly toxic gases such as CO and achieves high yields in one-step synthesis.

Develop and commercialize technology to create seaweed beds (blue carbon ecosystem) by using fertilizers made of steel slag, a by-product of steelmaking, in coastal areas.