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Abstract: Ferrous metal production is thought to be a major mercury emission source because it uses large amounts of coal and iron ore, which contain trace amounts of mercury impurities. However, there is limited information about mercury emissions during the production process. In this study, we focused on the coke-oven process, sintering furnace process, and blast furnace process. We measured the mercury concentration in the raw materials, products, and byproducts to estimate the amount of mercury emitted and to investigate the behavior of mercury during the processes. Average mercury concentrations were 30.8 μg kg−1 in 54 samples of iron ore and 59.9 μg kg−1 in 33 samples of coal. The total mercury used for ferrous metal production in Japan was estimated to be 8.45 tons in 2005, with 4.07 tons from iron ore, 3.76 tons from coal, and 0.478 tons from limestone. Emissions from the sintering process accounted for more than 90% of the total emissions, and mercury in the exhaust gas was reduced using an activated coke tower and desulfurization equipment installed downstream of an electrostatic precipitator. When byproduct gas generated from coke-oven and blast furnace processes were included, mercury emissions estimates based on actual measurements were 4.08 tons y−1 (in 2005). Thus, about 50% of the mercury input in ferrous metal production was emitted to the atmosphere. The emission factor was calculated as 0.0488 g Hg ton−1 for crude steel production. The introduction of activated coke tower or desulfurization equipment in sintering furnace facilities would reduce mercury emissions. [Copyright &y& Elsevier]