Unleashing the Potential of By-Products

Transcription

1 Unleashing the Potential of By-Products 10 th January 2018

2 Mr. T V Narendran, CEO & MD, TATA STEEL 2

3 Waste Management Summit 2017 The key idea 1 Prevention 2 Minimisation 3 Reuse November Recycle 5 Recover & Co-processing 6 Safe Disposal Food for thought Disposal is equivalent to throwing away potential resource. Generation of waste is not charged currently i.e., possible concept of Solid Waste Tax. Waste Yard should be termed as Resource Yard and the Plant Manager should visit the waste management site. Source Segregation is the key to success in waste management.

4 Steel By-Products Coal By-Products Key By-Products Products End Usage Customers Middlings Power External Internal Captive Power Plant Tailings Rejects Brick Kilns Cokeries Power Captive Power Plant BF Slag Pooled Iron/ MRP Scrap Cement Ingot/Billets Road making / Mine stowing LD Shops Steel Scrap Sec Steel Products LD Shops Coal Tar LD Slag CTP/ Naptha/ Creosote Oil Various Applications Pellet Plant Blast Furnace Sinter Plant Blast Furnaces LD Shops

5 Other solid waste Other By-Products Products End usage Customer Flue dust GCP sludge Agglomeration through Sinter Making Sinter Plant LD sludge Mill scale & sludge ESP/DE dust Lime fines BOD sludge Kiln dust 90% of other solid wastes recycled. Sinter charged in blast furnace as raw material

6 By-Products Workshop 2018 A key agenda Communication, Perception and Marketing Choice of terminology Branding A Tata Steel, Kalinganagar Story..

7 By-Product : Perception and Value Proposition By-Product Generator Raw material with specification Product (Prime) By-Product Raw material with specification Product (Prime) By-Product By-Product Consumer

8 Pooled Iron : Crude Process, Commodity Product Mines Iron Ore Sinter Plant Long Products Coal Coke Plant Blast Furnace LDs Caster Flat Products Pooled Iron Chunks Pooling of Hot Metal (Excess + Off-Chem.) Processing of Pooled Iron ( Breaking, Balling and Lancing) Prime Pooled Iron

9 Challenges : Environmental and Safety Pooling Mixed Pooled Iron Pooled Iron Chunks Unsafe Workplace Fumes & Emissions Energy Intensive Air Pollution PROCESS Environmental Concerns Safety Concerns Huge Thermal Energy Loss Energy Intensive Processing Fumes & Dust Emissions Heavy Equiment Requirement Land Requirement High Processing Time PRODUCT Large chunks upto 500 Kgs to 1 Ton. Handling & transportation challenges Inconsistent Dimensions & Specs Inconsistent chemical properties Further processing required at Customer s end. Low yield of Pooled Iron ~ 88% Viz 94% of Pig Iron Wastage of Fines 9

10 Pooled Iron : The Power Within! Iron Making Pooling Pooled Iron Steel Making (IF/EAF) End Products ~ % Fe, ~ 4 % Carbon, ~ 0.8 % Silicon ~ 88 % to 90 % Yield A mixture of Good and Off Chemistry Established Market and Customer Base Great Intrinsic Value! Is there a way to Leverage the Inherent Potential?

11 Focus on the Weak Link! Iron Making Pooling Pooled Iron Steel Making (IF/EAF) End Products Iron Making Granulation Tata Ferroshots Steel Making(IF/EAF) End Products Granulated Pig Iron : Environment Friendly, Safe, State of the Art Technology 11

12 A New Kid on the Block! Societal Benefits Tata Ferroshots : Weak Link No More!

13 Value Proposition Societal Benefits Green Product Energy Saving Business Ethics Co-Creation Emotional Trust of Tata Consistent Supplies Improved Yield Low Power Consumption Easy Handling Functional Homogeneous Composition High Bulk Density No Off Chemistry Attributes 13

14 Customer Segmentation Induction Furnace Electric Arc Furnace Cupola Furnace Volume Share: 76% Volume Share: 14% Volume Share: 10% Customer Profile Industry Profile Typical F/c Size: 5-25 T Production: T/M Pig Iron Req: T/M Steel Grade Pig Iron End Product: Structural/Rebar Lot Size: Small to Medium Quality Reqmnt: Low/Medium Credit days Channel: Traders/Direct Typical F/c Size: 40T Production: ~20000 T/M Pig Iron Req: ~2000 T/M Steel Grade Pig Iron End Product: Alloy Steel-Auto Lot Size: Medium to Large Quality Reqmnt: Medium/High Cash Buying Channel: Direct Typical F/c Size: 3-10T Production: ~ T/M Pig Iron Req: ~250 T/M Foundry Grade Pig Iron End Product: Castings Lot Size: Small Lots Quality Reqmnt: Medium/High Prefers Credit Days Channel: Traders/Direct 30 + PAG Trials to establish Usage Norms & Charge Patterns across Segments.

15 Logistics Solution Rake Despatch Containerised Containerised Despatch Despatch Export 15

16 Leveraging Digital Mobile / Web Booking 16

17 Service Offerings Customized Offering 50 Kgs 500 Kgs 100 Kgs Foundry Steel Knowledge Workforce Go...to Market!

18 By-Product Management Journey.. Customer Focus TDCs & TCs Customer Relationship Customer Segmentation Customer Satisfaction Survey IT based Order Generation & Fulfilment Process Downstream Value Channel Sales Retail Value Management Customer Service Team Voice of Customer Customer Complaint Management Online Price Approval System Yard Management System IBMD Information Portal GPS Tracking Vendor Feedback Fume Extraction System LD Slag Stabilization Digitization LD Slag : Dephosphorization LD Slag : Steam ageing Oxy-torch for Scrap cutting Vehicle Tracking System Wagon Loading System Process Focus

19 Tata Ferroshots Grand Prix If You think You can, or You can t, You are Right! Thank You...