KHOUZESTAN STEEL CO. 2 nd Word DRI&Pellet Congress. Khouzestan Steel Co. In The Name Of God April 2014 Abu Dhabi U.A.E

Transcription

1 In The Name Of God KHOUZESTAN STEEL CO. 2 nd Word DRI&Pellet Congress April 2014 Abu Dhabi U.A.E

2 Natural Resources Proved Crude OIL Reserves(157.3 billion bbl 13% OPEC MEMBERS) Proved Natural gas Reserves (33.8 trillion cu m ) Iron ore Coal Copper Lead & Zinc and. KSC Source : OPEC Annual Report 2013

3 World Crude Production Country %2013/ Rank Tonnage (MMT) Rank Tonnage (MMT) Rank Tonnage (MMT) China Japan United State India Russia South Korea Germany Turkey Brazil Ukraine Italy Taiwan, China Mexico France Iran Spain Canada World 1,607 1, Source: World Association

4 Crude Production in Iran (m. tons) World Association, Statistical Yearbook 2013

5 Technology Production Portfolio Iran Industry Global Industry 17% 30% 83% 70% Electric Arc Furnace Blast Furnace World Association, Statistical Yearbook 2013

6 Word DRI Production , 42% 20.0, 27% 12.0, 16% INDIA IR-IRAN SAUDI ARABIA UAE QATAR Rest -W 2.4, 3% 2.7, 4% 5.6, 8% Source : 2012 Word Direct Reduction Statistic 3 rd Quarter 2013

7 Apparent Use in Iran & Middle East (crude steel equivalent) Iran Middle East 60,000 50,000 44,678 48,528 44,414 50,906 53,823 54,299 40,000 35,031 37,291 37% 30,000 20,000 14,681 14,142 20,589 16,517 19,097 21,720 23,268 20,199 10, World Association, Statistical Yearbook 2013

8 KHOUZESTAN STEEL CO. Crude Index Iran 2013 :15.4(MMTon) Ranking 15 th (WSA) Domestic Demand :~ 20MMT/Y Caspian Sea Islamic Republic of KSC IRAN Apparent use PerCapita (2012): Kg/P KSC Production : 3.5(MMTon) Employee:7411 Owner :Private Sector Products: Slab&Billet&Bloom Technology : DIR+EAF Production Plan:3.7 (MMTon) Capacity Plan: (MMTon)

9 History As a consequence of the existence of rich sources of energy ( GAS, ELECTRICITY AND WATER ) in khouzestan province and its proximity to the sea,using rail and road connections, steel- making project based on Direct Reduction and EAF With capacity of 1.55 Mt/y Were initiated in Ahwaz. Production started in The Capacity increased to 2.4 Mt/y by 2005 and now it has reached 3.7 Mt/y. Vision One of the largest steel Producer of Finished and semi-finished products in the region. Excellent in profit-making in the steel industry throughout the country. A knowledge-based Organization with the ability to supply steel production technology to other companies. Values Islamic values and work perseverance. Human dignity. Value creation for customers and other stakeholders. Social responsiveness, law and regulation. Team working, innovation, creativity and continues improvement.

10 Special Features Customer orientation, flexibility towards customer requirements Experience of products Export (Europe Persian Golf Countries- Asia ) On time delivery of products Specialized and experienced human resources (providing technical knowledge and engineering and consulting services to Mobarakeh steel Co, Hormozgan Azarbayejan ) Easy access to energy sources (water, gas, electricity). Localization of technology and technical knowledge of ladle furnace and Midrex ( Zam Zam Project) and grass roots projects like Oxin wide plate rolling Mill, BOT projects (Oxygen Plant no.3), The first producer of sponge iron using direct reduction technology in Iran Producing Clean steel with variety of grades with high level of Quality. Connection with railway transportation network & Accessibility to international waters Infrastructures for investment and Expansion projects Management standards and systems : ISO-9001:2008 ISO-14001:2004 OHSAS : 2007 ISO-10015:1999 ISO-27001:2005

11 Learning & Growth Processes Customer Financial KSC Strategy Map Productivity-cost reduction Sustainable Growth & Increase Profitability F01 Grow Revenue F04 Manage Strategic Costs F03 increase productivity optimum sale in foreign and domestic markets F02 C01 To increase the customer satisfaction C02 Competitive price C03 offering Products with expected quality timely delivery C04 Increasing diversity of products C05 P01 P02 P03 Operational Excellence Sustainable & Economic Supply Effective management of market Development and Technology Management P04 P07 P09 Development of products with higher added value Increasing products with higher value added Increase production and Products quality promotion Optimize consumption rate of materials, Energy and water P05 P06 sustainable and economic supply Sustainability in the supply of electrical energy development of spare parts Localization & domestic production support P08 Development Of Customer relation Marketing and sales for training services, engineering and technology P10 P11 P12 Presence in the value chain downstream Increase Capacity with development projects Technology localization P13 P14 P15 Social responsibility change the work environment & safety conditions Environmental Protection And improved waste management promotion of interactions with officials and community representatives L01 Human Capital Management L02 Improve satisfaction, motivation and loyalty of employees Human capital Development Improve safety culture organizational capital Management Organizational Leadership Development Improve the effectiveness and integrity of the management system Information Capital Management L03 L04 L05 L06 L07 integration the communicatio n infrastructures Development of information systems and integrated automation throughout the value chain Financial Resources Management L08 supply Optimum Finance resources

12 KSC Main Plants Pelletizing Plant Direct Reduction Plant making Plant

13 Pelletizing Plant This section is consist of two Units : Material handling Two pelletizing plants (Nominal Capacity 5 MT extend to 6 Mt will Reich to 7.2 MT)

14 Direct Reduction Plant This section is consist of three Units : - 3 Midrex modules 1.2 Mt/y Mt/y - 2 zam zam modules 1.8 Mt/y Project - 1 Zam Zam Mega Modules 1.7 Mt/y

15 Increasing Capacity of Midrex Modules nominal first improvement second Impr. Each M.Capacity : 0.4 Mt/y 0.55 Mty 0.8 Mty Production Rate : 50 T/h 75T/h ~ 100 T/h First Improvement: Extending 1 more Bay - Reformer Changing the Process Gas Compressor Changing the Air Bundle Tubes Changing the Stuck Fan Second Step : Installation Desulfurization Increasing Operation Experience Modification on Cooling Scrubber

16 Making Plant This unit Produces Slab and Billet s using Sponge iron (~% 90) and Scrap (~%10) in EAF s ( Electric Arc Furnaces ) The main melting and casting facilities are : Six Electric Arc Furnaces. Four Ladle Furnaces ( LF). TWO Slab Casting machines. Three Billet & bloom casting machines

17 000 tone Year Crude % Growth Y.O.Y KSC - CRUDE STEEL PRODUCTION Plan Plan Incrsing more than 1.37 Million Tone Crode

18 Y-O-Y Growth Rate 20.0% 15.0% 14.0% 16.2% 15.6% 15.3% 10.0% 5.0% 0.0% -5.0% -10.0% 9.0% 10.1% 10.0% 9.8% 6.2% 0.9% 4.0% -1.0% 0.7% -0.4% % WSA Iran KSC Source : World Association

19 KSC Pellet & DRI Production Plan Pellet - Production DRI - Production

20 Production Share( ) Iranian Calendar Hormozgan INSIG Khorasan Source : IMIDRO Annual Report Yazd Alloy Saba Esfehan KSC Mobarakeh

21 DRI Production Share( ) SABA Ghadir Iron and Kaveh Source : IMIDRO Annual Report Khorasan Hormoz gan KSC Mobarakeh

22 Production Midrex HYL Zamzam1 Zamzam2 Total Billet Bloom Slab Total Title Pellet Zamzam1 Crude

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25 Processes Cap. Mt/y Plan Mt/y Processes Mt/y Pellet DRI Slabs-Billets DRI Billets o.8-1 1

26 MMT Trend of Production & Capacity Capacity Production Expansion Project Increasing Capacity 1.8 MMt/y

27 KHOUZESTAN STEEL CO. Increasing 1.8 Mt/y Capacity

28 PELLETIZING CASTING STACKING &RECLAIMING STEEL MAKING DIRECT REDUCTION FUME 6 FUME 5 FUME 4 FUME 3 FUME 2 FUME 1 SVC E LF3 Bilet 3 1,000,000,000 t/y Car Tippler 3 SVC D Bilet 2 550,000 t/y Car Tippler SVC C LF1 LIMESTONE YARD LF2 5,220,000 t/y Bloom 550,000 t/y 5,000,000 t/y Slab 2 775,000 t/y LIMEPlant ORE & BLENDING YARD 7,500,000 t/y SVC B. SVC A EAF6 EAF 5 EAF 4 EAF 3 EAF 2 EAF 1 LF5 Bilet 1 550,000 t/y SVC F LF2 VOD/RH LF4 Slab 1 775,000 t/y Wide Slab 1,200,000t/y Oxygen 4 Oxygen Nm3 Oxygen 2 Oxygen 1 WTP2 WTP1 New Semi Revamp Full Revamp Exist Plants Capacity in Phase#3 5,000,000 ton/year )0.85 million ton scrap per year(15% scrap 5,208,000 t/y 3 DRI MODULES 3 x 650,000 t/y ZAM/ZAM 1 910,000 t/y ZAM/ZAM 2 960,000 t/y ZAM/ZAM 3 1,760,000 t/y Coating Project 7,500,000 t/y

29 Outline of Expansion Project Increase in semi-finished products capacity from 3.2 mt/y to 5 mt/y by implementing: Iron ore handling system capacity enhancement Pelletizing plant capacity enhancement New 1.76 mt/y direct reduction plant (ZamZam 3) EAF capacity enhancement New billet caster New wide slab caster New oxygen plant New ladle furnace New water treatment plant Utilities revamp or capacity enhancement

30 Our Strategy Sustainable Environmental sustainability Social sustainability Economic sustainability

31 Ton KSC Incidents Vs Production Curve Number

32 KSC Lake KSC Swimming Pool KSC Hospital

33 KSC Exhibition KSC Bridge KSC Football Stadium

34 Save The Earth For The Posterity Green Space : 492 Hectare Unser construction

35 Establishment Title Standard No. (1996/6/27) Quality Systems. Model for quality assurance in design, development, production, installation and servicing (QS) ISO9001:1994 (2003/12/8) Quality Management Systems (QMS) ISO 9001:2000 (2009/12/22) Quality Management Systems (QMS) ISO 9001:2008 ( 2002/11/18) Environmental Management Systems (EMS) ISO : 1996 ( 2005/11/13) Environmental Management System (EMS) ISO 14001:2004 (2005/5/16) Occupational Health and Safety Management System (OHSAS) (2008/7/13) Occupational Health and Safety Management Systems ( OHSAS) OHSAS 18001:1999 OHSAS 18001:2007 (2009/10/2) Information Security Management Systems (ISMS) ISO 27001:2005 (2010/02/17) Quality management guidelines for training ISO :1999

36 Thank YOU