Essar Steel (I) Ltd. Hazira Presentation on : Technological conjunction of Iron & Steel Making at Essar Steel India Ltd. By : Mr. Hitesh Sheth (Hitesh.Sheth@essar.com) Ms. Neeru Singh (Neeru.Singh@essar.com)
Indian Steel Industry : Long Term Outlook GDP projections indicate steel industry to reach 155-170 MTPA by 2025 Benchmarking India's position in the steel growth curve, followed by other countries indicates potential to go up to 250 MTPA by 2025 Manufacturing vision laid down by government also translates into higher steel intensity, indicating potential to go up to 250-300 MTPA by 2025 Increasing finished steel consumption lead to multiple secondary benefits like creation of additional jobs, development of supply chain industry and allied industries. Pros : availability of plenty of iron ore reserves comparatively low wages growing market human resources and strategic location for exports act as supporting factors. Cons : ore & coal availability fluctuating NG prices land availability full capacity utilization because of varying parameters. 2
Indian Steel Industry : Long Term Outlook Demand : India's inherent advantage is going to make it a natural choice / place / economy to become a 300 MT player by 2025 owing to following facts: Being globally 5 th highest in iron ore reserves. Having lowest labor cost in the world Steel industry having a good mix of public & private firms with considerable experience. Rising steel consumption in the sectors of : Construction Infrastructure Steel Intensive Industries Export 3
Indian Steel Industry : Long Term Outlook Cost of Bulk Raw Materials : With current global scenario the prices of the commodities are dynamic in nature. The viability of steel plant is highly dependent on the cost of following key critical raw materials: 1. Iron ore; 2. Coal / Coke; 3. Natural Gas; 4. Electrical Power. This needs promotion of flexibility in the process route wherein, cheaper raw material utilization without affecting the productivity becomes the key towards making steel business sustainable. 4
Essar Steel India : Current Facilities Bahadurgarh 5 Material Movement and Supply Chain Hazira facility Bhuj 5 Hazira 3 5 4 5 Mahan Indore 5 Pune Kirandul Dabuna 1 Iron Ore Iron Ore 1 Deposits 2 Vizag Kolkata 5 2 Paradeep Vizag Pellet Plant Essar Port Limited Essar Power Limited Essar Shipping Limited 5 Chennai 1 2 3 4 5 Beneficiation Plant Slurry Pipeline Pellet Plant Hazira Steel Facility Pune Downstream Facility Service Center Kirandul Beneficiation Plant Strategically located manufacturing & distribution facilities bringing Essar close to raw materials & customer 5
Essar Steel Hazira : Current Facilities Unique Facility State of the Art, Most Modern Integrated Steel Plant Complex 10 MTPA Capacity Encompassing all fundamental technologies All Weather Captive Port with Jetty 1.5 KM. Iron Making : BF, Corex & Midrex DRI Route Steel Making : DC EAF & Conarc Route Rolling CSP, HSM, Plate Mill & CRM Complex Pipe Mill. Well Connected through Sea, Road and Rail. Product Range : Capital, White & Yellow Goods, Shipbuilding, Sweet & Sour Gas Pipeline, Electrical Steel, Dual Phase Steel and prestigious Automobile Sector. Strategic location makes it an ideal gateway for meeting the global demand for steel 6
Current Facilities : Hazira Complex Hazira Projects 7
Essar Steel Hazira : Current Facilities 8
Essar Steel Hazira : Current Facilities All the stated plants have developed in-built flexibilities and process stabilization by using varieties of input materials Iron Bearing Material Ore / Pellets / Lump Ore with Fe content ranging from 62.5 to 66 %, Wide ranging types of coal for Corex, Innovative sources of Coke for BF and Operating Midrex at varying levels as per NG availability. Steel Making with Hot Metal, Pig Iron, DRI (Cold, Hot and Briquettes), Scrap (internal / external), Pot Skull (BF / Corex / Steel Plant returns), Oxides, fines etc. Casting need base through conventional, vertical or strip caster. 9
Iron Making - Midrex DRI Modules 1-6 : 7 MTPA In-house design engineering & modification to achieve the rated capacity from 57 tph to 100 tph. To name the few as : Enhanced reforming capacity. Increased the reaction temperature in furnaces O2 Injection. Improving CCS of pellets along with lime spraying to withstand higher reaction temperature. Introduction of Corex gas into Midrex modules for full utilization of Corex gas from Corex modules. 10
Iron Making - Blast Furnace : 1.73 MTPA Day production : 6066 T Monthly production : 170058 T Day productivity : 3.17 thm/m 3 /day Month Prod. : 2.88 t/m 3 /day Month O2 enrichment : 4.52% TRT power generation : 6.93 MWh 18.5 MWh power generation utilizing surplus capacity of BF boiler 11
Iron Making - Corex 1-2 : 1.74 MTPA Production of 116070 Tons. Lowest specific oxygen consumption rate of 503 Nm3/thm. Operated at lowest coke rate of 102 Kg/thm. Achieved lowest fuel Rate of 900Kg/thm. Usage of thermal steam coal such as South African coal usage initiated within a week of COREX 2 commissioning. The usage of South African Coal in Coal mix is maximized up to 85% - plant trial. 12
Steel Making - DC Electric Arc Furnace : 4.6 MTPA 13
Steel Making - Conarc Furnace : 5 MTPA 14
Steel Making - DC EAF + Conarc Furnace : 9.6 MTPA SMPs Achievements : 1. Flexibility of iron bearing material usage with varied quality and proportion HBI / Hot DRI / Cold DRI, Hot Metal / Pig Iron, Scrap Internal, Skull from Blast Furnace / Corex / Furnace / Ladle Return, Oxides. Operating profiles developed to manage dynamics iron bearing material on heat to heat basis. 2. Heats made with 100 % Scrap or DRI or with 90 % of Hot Metal. 3. Zero Power Heat Making Furnaces used as Convertor. 4. Redesign and master steel refining process for managing S, P, N2 arising due to varied quality of Hot Metal. 5. As high quality steel maker, serving and meeting the need of all valued segments; be it White & Yellow Goods, Capital Goods, Shipbuilding, Pipeline for Sweet & Sour Gas, Electrical Steel, Dual Phase Steel and prestigious Automobile Sector. It has taken a long stride in serving Defence Sector as well. 15
Other Facilities at Hazira : Essar makes pipes and extra wide plates as well as hot rolled, cold rolled, galvanized and color coated steel through Conventional or Compact Strip Caster. All stated plants are backed-up by robust in-house developed Process Monitoring and Controlling Automation System, Central Command Centre, Planning Software s like IMPS, Factory Link, i2 etc., SAP, RCM and many more, facilitating to manage dynamics from varieties of input to quality outputs at an optimum cost. Esteemed organisational objectives are achieved through highly talented, enthusiastic, open minded and valuable team members, who are always striving for achieving greater heights. Hazira facility of Essar steel is a world class facility and a jewel in the crown for Indian steel industry. 16
Steel Industry Way Forward : Challenge for the steel companies : Adopt technologies which use non coking coal as against coking coal for steel making. Secure raw material availability globally. Partner with professional and technical institutions to develop the necessary skill sets and competencies. Consolidate and enhance capacities to achieve economies of scale. Adopt cleaner and greener technologies. Need to create a strong infrastructure in terms of railways, roads and ports. Innovation to improve sustainability. 17
Steel Industry Way Forward : Long and promising road ahead for the steel sector. Steel is the foundation of our future it is the pillar that supports industry, infrastructure and country s economic growth. 18
THANK YOU 19