The development of Japan's steel industry has many similarities with that of China, and Japan's scrap industry is very mature. An in-depth analysis of the generation, consumption and management mode of Japanese scrap steel will provide beneficial enlightenment and reference for the development of China scrap steel industry.
On May 6th, the latest data from Japan's Ministry of Finance showed that in the first three months of this year, Japan imported 226,000 tons of scrap steel, up nearly 400% year-on-year. The total amount of exported scrap steel was 6.5438+0.5 million tons, down 3.865438+0% year-on-year. In addition, Japanese companies are also actively investing in scrap steel overseas. At the end of April this year, Toyota Tsusho of Japan has invested in Scholz, a German scrap recycler of ferrous and nonferrous metals, and the former will acquire 39.9% of the latter's shares.
Generally speaking, the production of scrap steel is in direct proportion to the accumulation of steel. In Europe and America, where steel consumption has a long history, scrap steel is also produced due to a large amount of steel saving. Japan used a lot of steel more than 50 years later than Europe and America. Since the end of 1950s, steel widely used in Japan has become scrap after entering the old scrap forming cycle. Around the 1990s, the average recovery rate of scrap steel in Japan was 2.5%-3%. In recent 20 years, the growth rate of scrap steel in Japan has slowed down, and the recovery rate is 2%-2.3%. However, the total amount of scrap steel in Japan is still increasing.
Development Model of Scrap Steel Industry: Legislation, Management and Ways
In order to solve the contradiction between population, resources and environment and maintain sustainable development, it has become Japan's national policy to build a circular economy society of resources-products-renewable resources. Waste recycling is an important part of developing circular economy in Japan. Since the mid-1950s, Japan began to attach importance to the recycling of scrap steel. After 1970s, Japan not only realized an efficient scrap management system, dredged the circulation channels of scrap steel, but also used modern technology to treat scrap steel, making the management of its scrap steel industry reach the advanced level in the world.
Perfecting the legal system of circular economy
Since the 1970s, the Japanese government has formulated a multi-level and multi-directional circular economy legal system, which has made specific provisions on waste treatment and resource reuse in different industries, and has vigorously promoted it. The Japanese government's legal system for circular economy can be roughly divided into three aspects, as shown in figure 1.
Establish an efficient management system
In order to strengthen the macro management of scrap steel industry, Japan has established an efficient management system. Set up specialized agencies in the Bureau of Basic Industries of the Ministry of Trade and Industry, formulate relevant policies and decrees, and coordinate and comprehensively manage the scrap industry and enterprises. The specific macro-management shall be undertaken by non-governmental organizations.
From 65438 to 0975, Japan unified and merged the original scrap civil organizations, and on this basis, Japan Scrap Industry Association, Scrap Reserve Association and Renewable Iron Source Utilization Promotion Association were established. 1982, the Japanese government set up an agreement meeting to promote the modernization of scrap steel circulation in the Bureau of Basic Industries of the Ministry of International Trade and Industry. 1In August, 988, Japan Scrap Reserve Association was renamed as Japan Iron Source Association, and its functions were also adjusted, mainly to provide exchanges and cooperation for raw material suppliers, investigate, provide and study raw material information, with the goal of stabilizing the supply and demand of raw materials and improving the quality of raw materials.
Neither the Japanese government nor the above-mentioned non-governmental organizations directly interfere with the circulation, production and management of scrap steel, so that enterprises have full autonomy and give full play to their vitality in mutual competition.
Straighten out the circulation channels of scrap steel
Whether scrap steel can be fully developed as a renewable resource depends on whether the circulation channels are reasonable and smooth. At the beginning, the management of scrap steel circulation in Japan was rather chaotic. Enterprises and families that produce scrap steel, commercial enterprises of scrap steel, local governments and steel mills are all directly involved in the circulation of scrap steel, which leads to many chaotic circulation links, slow speed and high cost. However, since the mid-1960s, Japan's steel scrap circulation channels have been gradually rationalized and highly efficient.
Specifically, the circulation process of scrap steel in Japan is as follows: the scrap steel produced by the family flows to the designated point and then to the waste station, and then screened; Scrap steel produced by public institutions is sent to the scrap steel concentration station, and scrap steel that is difficult to dismantle such as ships and bridges is sent to dismantling enterprises. These three types of scrap steel resources should be transported to processing enterprises and then sent to retailers; The scrap resources of non-steel enterprises and steel enterprises are divided into scrap that needs to be processed and scrap that does not need to be processed, and some of them are sent to retailers after processing.
In order to speed up the circulation of scrap steel, the Japanese government has not only established the above-mentioned circulation channels, but also taken the following measures: (1) The Environmental Protection Law stipulates that no enterprise or individual may place wastes at will; Incorporate the sale of scrap steel into the circulation of social materials, stipulate its proper circulation behavior, and its transaction must comply with the government's policies and decrees to curb black market transactions; Formulate unified specifications and standards for scrap steel, so that buyers and sellers can't make a deal because of different specifications and standards; Implement a unified national scrap inspection, acceptance and recycling system.
In scrap processing, Japan has continuously adopted advanced and applicable technology and equipment, which has improved the labor productivity of scrap processing enterprises. In order to stabilize the supply of raw materials, Japan has continuously improved the pricing mechanism of the scrap steel market. Japan Central Commodity Exchange launched the world's first scrap futures contract in June 5438 +2005 10, and selected the highest specification (grade) scrap (heavy waste) as the standard of futures varieties.
"Tailor-made" Development of Electric Furnace Steelmaking
The sources of scrap steel in Japan include steel mills' self-produced scrap steel and social scrap steel, and social scrap steel is divided into waste scrap steel and processing scrap steel. Scrap steel includes recycled products of automobiles, steel, instruments, rails and ships, while processing scrap is the scrap produced by various industrial departments that use steel when processing steel.
The output rate of processing scrap steel in automobile, industrial machinery, shipbuilding and other departments is higher than that in construction industry. Therefore, although the steel consumption of Japanese construction industry is relatively large, the average productivity of processing scrap steel is lower than that of European and American countries. Relevant data show that in recent years, 68% of processed scrap steel in Japan comes from automobile industry, followed by industrial machinery, accounting for 10%, and processed scrap steel from motor and shipbuilding industries accounts for 7% and 6% respectively.
With the continuous production of scrap steel resources, Japanese iron and steel industry began to pay attention to the selection of steelmaking process according to domestic scrap steel resources.
Judging from the history of Japanese steelmaking development, Japan was in the first half of the period of rapid economic growth after World War II, and its demand for steel increased rapidly, so it vigorously developed the steel industry. During this period, the consumption of scrap steel in Japan was controlled by the output of crude steel and influenced by the output ratio of electric furnace, open hearth furnace and converter with scrap steel as the main raw material.
During the period of 1950-1965, the increase of Japanese crude steel output was mainly realized by a large number of scrap steel used in open hearth steelmaking. However, due to the domestic production of scrap steel is not enough to meet the demand, it is necessary to import a large number of scrap steel, and the supply is unstable. Therefore, the Japanese iron and steel industry began to turn to the pig iron production structure with converter production as the main mode, and the open hearth steelmaking method was abolished in 1977. Japan controlled the proportion of electric furnace steel during the period of developing converter and reducing the production ratio of open hearth furnace, so the proportion of electric furnace steel in Japan was less than 20% in the 1960s and 1970s.
After 1975, Japan's dependence on imported scrap steel decreased, and at the same time, Japan Electric Furnace Factory rationalized its product structure and equipment during the 1973 oil crisis. Since then, EAF steelmaking has entered a stage of rapid development, and the output ratio has increased year by year, from 17% in 1975 to the peak of 33% in 1996. After 1996, the proportion of electric furnace steel in Japan began to decline continuously, mainly because of the stagnation of Japanese economy and the downturn of construction industry after the 1990 s, which made the demand for electric furnace steel products begin to decline. However, after a period of decline in the early 1990s, Japan's transportation output maintained a steady upward trend, which means that Japan's overall steel demand remained stable. Therefore, while the output of crude steel is increasing steadily, the proportion of electric furnace steel is decreasing due to the decline of electric furnace steel output, and it dropped to 265,438+0% in 2009.
In other words, the proportion of electric furnace steel in Japan is only about 33% at the peak, while that in the United States is 50%-60% and that in the European Union is about 40%. At present, there are about 40 electric furnace enterprises in Japan, with an annual production capacity of 40 million tons, while the actual output is only over 20 million tons, with a serious overcapacity.
Due to the shortage of scrap steel in China and the high production cost of electric furnace steel, the development of electric furnace steel is slow, and the output rate of electric furnace steel is declining, which has been maintained at the level of 10% in recent years.
At present, China's scrap steel supply mainly comes from self-produced scrap steel, social scrap steel and imported scrap steel. With the advancement of industrialization and the increase of steel savings, China's scrap production has increased year by year, from 5410.5 million tons in 2005 to about 65438 million tons in 20 12. However, the domestic supply of scrap steel is not enough to meet the demand, and it is still necessary to import scrap steel. According to relevant analysis in the industry, around 2020, China will begin to enter the peak consumption of scrap steel, and the proportion of electric furnace steel production will begin to rise. The development of Japanese scrap steel industry has the following enlightenment to China:
First, improve and strengthen the legislation in the field of scrap steel. The good operation of Japan's scrap steel industry can not be separated from the relevant national laws and regulations, and from the perspective of establishing a circular economy legal system in Japan, it is very perfect from the basic level to the specific laws and regulations. Therefore, China should learn from its experience and formulate relevant legislation to ensure and promote the healthy development of scrap industry.
Second, increase the recovery of scrapped cars and scrap steel in automobile enterprises. With China entering the peak period of automobile scrapping around 20 17, the recycling and dismantling industry of scrapped automobiles will also usher in a period of rapid development, but the supporting recycling and dismantling system has not yet been established, and the state should speed up the improvement of policies related to scrapped automobiles.
Third, improve the circulation channels of scrap steel. In the case that scrap resources have not yet entered the high-yield period, improving the circulation efficiency of scrap and reducing the circulation cost will play a certain role in increasing the supply of scrap. We can learn from Japan's way of setting up waste stations and concentrating waste stations, speed up the construction of waste processing and distribution system, and improve the circulation channels of waste products in various fields. In addition, we should also establish the mutual trust and cooperation relationship between scrap processing enterprises and steel enterprises, build processing and distribution bases, and change from market-oriented mode to service-oriented mode.
Fourth, increase the management and support for waste disposal enterprises. Scrap processing enterprises play a key role in scrap utilization, and the state should strengthen the management of these enterprises. In addition, the scrap steel industry is a low-profit industry with large investment and low profit. It is necessary to appropriately increase support for scrap processing enterprises and reduce the cost of scrap mining, separation and processing. In China, the steel market is booming, the steel industry continues to accelerate its development, and the demand for scrap steel resources is greatly increased. In 2008, China accumulated 502 million tons of crude steel, most of which were produced in recent years, and accumulated scrap 1 ton. In 2007, the total consumption of steel scrap actually used in steelmaking in China was 68.5 million tons, including 27 million tons of steel scrap produced by iron and steel enterprises, 4,365,438+million tons of steel scrap purchased by the society, 0.2 million tons of steel scrap imported for steelmaking, and 2.8 million tons of scrap exported and increased in inventory.
With the progress of world civilization, electric furnace will gradually replace converter, scrap steel will gradually replace iron ore, and a small amount of iron ore will be used as a supplement to natural consumption of resources, truly becoming an ecological industry in harmony with nature. Due to the rising iron ore market price in the international market, the domestic power supply capacity is enhanced, and the domestic scrap production is increased, it is expected that the electric furnace production capacity in China will increase rapidly in the future, and the market demand will also increase. Compared with the traditional process, the construction benefit of the new EAF steelmaking capacity will greatly narrow the gap. Therefore, it can be expected that the demand for scrap steel in the steel industry will also grow rapidly.
In addition, with the construction of national key projects and the implementation of urbanization, the demand for steel products has increased rapidly. However, China is short of iron ore resources, and the world iron ore resources are limited, so iron and steel enterprises tend to develop circular economy. Therefore, the demand for scrap steel will increase rapidly and the development prospect will be broad.
Technical requirements of metallurgical industry for scrap steel (1)
Scrap steel is an important resource for the sustainable development of iron and steel industry, especially an important and essential raw material for electric furnace steelmaking, and also the best coolant in converter steel. In order not to affect the normal progress of steelmaking and ensure the quality of finished steel parts, high-quality scrap raw materials must be selected and added to the steelmaking furnace; That is, scrap steel must meet certain technical requirements before it can be used as raw materials. This is because in the process of collecting scrap steel, some impurities, such as non-ferrous metal coatings such as zinc, aluminum, nickel and copper, are often entrained or polluted. These metals will cause the molten steel to boil due to the high temperature generated by arc and oxygen blowing during EAF steelmaking, and make a large number of toxic elements such as zinc, lead and cadmium in the molten steel volatilize. For another example, scrap iron collected by people often contains some organic substances, such as plastics, grease and so on. In addition to their own impurity rings, the surface of scrap iron and automobile waste often has a thick paint coating. These organic substances will form toxic substances such as sulfur monoxide, nitrogen oxides and carbon monoxide at the high temperature above 1000 degrees Celsius, which will not only cause environmental pollution, but also greatly increase the hole defects of steel. Therefore, scrap steel must be thoroughly sorted and cleaned before entering the furnace, so that it can meet the technical standards of scrap raw materials with different uses.
Technical Requirements of Metallurgical Industry for Scrap Steel (2)
In the process of steelmaking, it is mainly to realize "five degassing and one integration", that is, decarbonization, dephosphorization, desulfurization, deoxidation, gas inclusion removal and alloying. Metallurgical industry has put forward more detailed technical requirements for scrap steel.
A the sulfur and phosphorus contents of scrap steel shall not be greater than 0.08% respectively.
B. Ferroalloy, nonferrous metals and other impurities shall not be mixed in the scrap steel; Non-alloy steel and low-alloy steel can be mixed, but alloy waste and pig iron can not be mixed; Alloy steel waste shall not be mixed with non-alloy steel, low-alloy steel and scrap iron; Scrap iron shall not be mixed with scrap steel.
There should be no dirt, cement, sand, rubber, etc. On the surface of scrap steel.
D. the oil stain on the surface of scrap steel should be removed.
E closed-end pipes, closed containers, inflammable and explosive articles, radioactive and toxic articles are not allowed in scrap steel.
F scrap iron is not allowed in complete sets of machinery, equipment and structural parts.
G. abandoned weapons must be technically inspected and disposed of.
It should be pointed out that the cleanliness and overall dimensions of scrap steel are generally inspected by visual inspection, while chemical analysis can be carried out by sampling during batch delivery. When scrap iron is delivered in batches, it should be classified according to its category and steel group. In particular, alloy scrap steel should be classified according to GB/T4223- 1996 as far as possible, which is not only beneficial to the smelting of Jintai scrap steel, but also can recover the alloy elements in it.
Technical requirements of waste pig iron: the phosphorus content is not allowed to be greater than 0.85%; The surface should be clean. If slag and sand particles are attached to the surface, they should be removed, but lime and graphite are allowed.
The requirements for pig iron blocks are as follows:
(1) There are two kinds of steel-making pig iron: small pieces of pig iron, each weighing 2-7 kg; Bulk pig iron, the mass of each pig iron shall not exceed 40 kg, and there are two gaps, the thickness of which shall not exceed 45 mm.
(2) Cast iron shall be cast into small pieces of 2 ~ 7kg, and the sum of iron pieces larger than 7kg and smaller than 2kg shall not exceed 10% of the total mass of each batch, and the length of iron pieces shall not exceed 200mm. ..