Energy as a key factor for an energy intensive company. Lutz Bandusch, CEO of ArcelorMittal Hamburg GmbH
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1 Energy as a key factor for an energy intensive company Lutz Bandusch, CEO of ArcelorMittal Hamburg GmbH 15. June 2012
2 Agenda ArcelorMittal Hamburg Resources as a key factor Energy efficiency Efficient production route Optimized process Impact for energy-intensive industry Conclusions and outlook Confidential 1
3 ArcelorMittal ArcelorMittal: World s biggest steel producer 61 plants worldwide 110 Mio. t/a production capacity approx employees Future: focus on mining activities Main shareholder: Lakshmi Mittal Production figures of steel: China: 600 Mio t/a Germany: 43 Mio t/a Europe: 145 Mio t/a Confidential 2
4 ArcelorMittal Hamburg Scrap Billets Wire Rod DRI Iron ore pelltes MIDREX- Plant t/a Electric Arc Furnace Ladle Furnace Continuous Casting Machine Rolling Mill t/a t/a 573 Employees Founded in 1970 for production of Mesh and Rebar simple steel grades Today: Production of High Added Value steel grades Continuous Optimization concerning Quality and Energy Unique Feature in Europe: MIDREX plant Confidential 3
5 [Source: ArcelorMittal Hamburg Confidential 4
6 Resources as a key factor
7 Required Resources For the annual production of approx. 1 Mio tons of steel the following resources are needed: t iron ore pellets t scrap kwh el = 1 TWh el (incl. Luftzerleger) (equal to electricity consumption of households) kwh th = 2 TWh th (equal to natural gas consumption of households) Additioanal resource: Climate effected by CO 2 -release Confidential 6
8 Cost Structure Approx. 79% of production costs for resources like iron ore, scrap & alloys as well as energy Strong focus on efficiency since foundation of this plant Confidential 7
9 Resources as key factors Resources are key factors for economic situation of a company / of an industrial sector. Access to resources like iron ore, scrap and energy at world-market prices is essentiell Prices for iron ore and scrap are dominated by demand from China Energy prices are influenced by local government and EU Strong local influence on an essential resource with prices way above world-market level! Confidential 8
10 Resource-Efficiency
11 Resource-Efficiency Resource-Efficiency can be optained by two methods (Optimum: combination of both methods) resource-efficiency production route with low resource demand optimized process 1 2 Example: Car engine running with patrol or gas Mitsubishi Colt 1.1: 135 g/km Mitsubishi Colt 1.1 LPG: 116 g/km Example: Patrol comsumtion of a 100 kw car engine 2000: 10 l / 100 km 2011: 7 l / 100 km Confidential 10
12 Example: production of welding wire Standard production via blast furnace route: Coke as the reduction agent Iron ore as the main raw material Due to process restriction only limited usage of scrap possible Little utilisation of recyclability of steel / scrap approx kg CO 2 per ton of steel (mainly due to coke) Demand of kg iron ore per ton of steel Confidential 11
13 Example: production of welding wire Production route at ArcelorMittal Hamburg Usage of natural gas a reduction agent instead of coke much lower CO 2 -emissions Iron ore and scrap as raw materials utilization of recyclability of steel approx. 840 kg CO 2 per ton of steel (mainly due to electricity and gas) Demand of 400 kg scrap and kg iron ore per ton of steel Confidential 12
14 Comparison of CO 2 -Emissions Production route with low resource demand 1 Production route with high rescoure-efficiency due to usage of natural gas as reduction agent and scrap as recycled raw material Advantage compared to blast furnace process Highest flexibility on charging material possible 100% iron ore based or 100% scrap based possible Confidential 13
15 Projects 2012 at ArcelorMittal Hamburg Example for current energy-efficiency projects New de-dusting systems Optimization of coal injection Variable speed drives Control system for reheating furnace Temperatur control for cooling water > t CO 2 /a Optimized process Confidential 14
16 Resource-efficiency Significantly reduced CO 2 -emissions and low iron ore share compared to production route via blast furnace due to production route (1) and optimized process (2). Steady optimization and improvement of efficiency Effect decreases continuously Investments in other plants are more reasonable for ArcelorMittal Further enhencement projects in concept phase: Usage of regenerative energy Usage of Hydrogen in the MIDREX plant possible Economically not feasible today! Confidential 15
17 Impact for the energy-intensive industry Confidential 16
18 Impact for the industry Strong increase in prices for iron ore and scrap due to growth in China Scrap is nowadays a globally traded raw material and is sold for world-market prices No distortion of competition since goods are traded worldwide Additional costs can be transferred to customer Energy and CO 2 -emssions are becoming a significant threat Distortion of competion by artifical increase of prices Additional costs cannot be transferred to customer Energy is the major drawback for energy-intensive industry in Germany Confidential 17
19 Impact for the industry Example: Price increase of 1 Ct/kWh el Household with kwh el /a Additional costs of: 40 /a ArcelorMittal Hamburg with kwh el /a Additional costs of: /a EBITDA pre-crisis years: /a Costs of Energiewende are hard to predict Calculation from the Deutsche Energie Agentur (dena) in the range of 5 Ct/kWh el... Significant threat for company (2.5 times the EBITDA!) Very high uncertainty for investments Politics to decide, whether steel stays in Germany or not Confidential 18
20 Impact for the industry Since many years, increase of resource-efficiency is major topic for energy-intensive industries huge results achieved in the past years most efficient plants in Germany Already excellent values compared to plants in foreign countries due to high cost pressure Additional costs due to energy cannot be compensated by efficiency projects Further increase of efficiency (e.g. -20%), like demanded by politics, are not reasonable see ThyssenKrupp: Shifting of production capacity to Brasil and USA Confidential 19
21 Conclusion and Outlook Confidential 20
22 Conclusions and Outlook ArcelorMittal Hamburg is a good example for energy efficiency and a strong will to improve the processes KnowHow from Germany Results of increased energy-efficiency cannot be transferred into economic advantanges Costs are increasing faster than efficiency Efficiency can only deflate the cost increase Energiewende and European Trading System can mark a significant decision point for German industry Goal: Level Playing Field Confidential 21
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