tata steel : commitment to excellence
DESCRIPTION
Tata Steel : Commitment to Excellence. 1 MTPA expansion. New SP # 3 : 2 mtpa ‘G’ BF Upgradation from 1.24 to 1.8 mtpa, increase coal injection Fourth stove at ‘G’ BF Augmentation of pulverized coal injection for ‘F’ & ‘D’ BF. Iron making. Steel making. Casting. Rolling. - PowerPoint PPT PresentationTRANSCRIPT
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Tata Steel : Commitment to Excellence
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Iron makingSteel makingCastingRollingNew SP # 3 : 2 mtpa G BF Upgradation from 1.24 to 1.8 mtpa, increase coal injectionFourth stove at G BFAugmentation of pulverized coal injection for F & D BF 1 MTPA expansion
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Iron makingSteel makingCastingRollingLD#1, Two Billet castersCapacity from 1.5 to 1.8 mtpa One caster to cast larger sections LD#2, Three slab castersCapacity from 2.7 to 3.2 mtpaHSM capacity from 2.6 to 3.1 mtpa New Rebar mill of 0.6 mtpa1 MTPA expansion
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1 mtpa expansion : Balancing facilities & utilities Bedding & blending yard capacity from 4 to 7.75 mtpa 6th Lime kiln : 425 tpd New PH#5, Conversion of 7 boilers from coal fired to gas firedNew oxygen plant : 720 tpd
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1 mtpa expansion : Quality improvement 100% Desulphurization 2nd ladle furnace in LD1One vertical bending caster Auto slab scarfing machine Auto surface inspection system at HSM On line pinch roll polisher
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G Blast Furnace
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5 MT crude steelReduce cost Reduce specific consumptionImprove productivityImprove raw material qualityImprove product mix Tata Steel FY06 Plan
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FY06 : Daily crude steel production 103 tpd5 mtpy = 13700 tpd1st April31st Aug'G' Fce. Blown in HSM ShutdownLD#2 : Caster # 3 shutdown
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G Fce. Production ( kt / month )Blown out for upgradation : 3rd Dec041.8 mtpa = 150 kt/monthMayJul
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Cost comparison F , G vs. A to E 100135110Period Aug05Indexed (Rs/t)
RMIM_AUG05 (2)
Report Run Date:05.09.2005Page #:1
Selection Criteria
Material(s) :
Material Group(s) :423,429,430,440,443,455,
Product Heirarchy :
Valuation Type(s) :
Plant(s) :077,
Posting Period(s) :005 -005,
Fiscal Year :2006
Show Arising Quantity
PrimeTotalTarget Cost-Single Level-Single Level-Multi-LevelMulti-LevelGross Actual
Material GroupProduction QuantityArising QuantityProductionRs/TnVar. Rs/TnCost Rs/TnVar. Rs/TnCost Rs/TnCost Rs/Tn
423-FUEL
000000000140000015-"CRUDE CO GAS-SC 5,6,7(CO-PRODUCT)"141,322.110141,322.11531.3319.79551.1235.47586.59586.59
000000000140000016-"CRUDE CO GAS-SC 8,9(CO-PRODUCT)"157,862.790157,862.79523.0742.18565.25-10.68554.57554.57
000000000140000017-CRUDE CO GAS-TC(CO-PRODUCT)48,570.20048,570.20674.56128.24802.8-25.64777.16777.16
347,755.100347,755.10547.5945.1592.695.99598.68598.67
429-Hot Metal A to F Fce
000000000100000180-HOT METAL PRODUCTION FROM BF-A45,585.40045,585.406,236.47-206.726,029.75-329.535,700.225,700.22
000000000100000182-HOT METAL PRODUCTION FROM BF-B33,599.20033,599.204,923.09455.725,378.81-609.464,769.354,769.35
000000000100000183-HOT METAL PRODUCTION FROM BF-C31,885.60031,885.605,234.051,409.226,643.27-872.265,771.015,771.01
000000000100000184-HOT METAL PRODUCTION FROM BF-D51,452.20051,452.206,348.20206.556,554.75-759.35,795.455,795.45
000000000100000185-HOT METAL PRODUCTION FROM BF-E33,492.80033,492.808,581.69798.439,380.12-3,232.726,147.406,147.40
000000000100000186-HOT METAL PRODUCTION FROM BF-F105,920.500105,920.505,638.62-1,531.564,107.06100.964,208.024,208.02
301,935.700301,935.706,053.92-245.195,808.73-662.255,146.485,146.471827894572.9441753862958.6611553906041.336
430-Hot Metal G Fce
000000000100000187-HOT METAL PRODUCTION FROM BF-G157,131.600157,131.604,373.41296.724,670.1386.874,757.004,757.00
157,131.600157,131.604,373.41296.724,670.1386.874,757.004,757.00687200910.756733824999.108747475021.2
HOT METAL (A-G BF)459,067.305,478.715,419.005,013.172515095483.72487687957.7692301381062.536
440-Sinter
000000000100000188-NET SINTER 1130,151.000130,151.001,137.16-59.761,077.4098.731,176.131,176.13
000000000100000189-NET SINTER 2173,015.000173,015.001,056.29-40.871,015.4283.371,098.791,098.79
000000000100003355-NET SINTER 3:175,115.000175,115.001,128.09272.991,401.08-58.241,342.841,342.84
SINTER478,281.000478,281.001,104.5868.91,173.4835.71,209.181,209.19
443-Base Mix and Flux
000000000100000172-BASE MIX350,738.000350,738.00635.07-10.79624.28-26.62597.66597.66
000000000100000173-CRUSHED COKE BREEZE19,747.04019,747.042,665.92-1,193.631,472.29994.612,466.902,466.90
000000000100000174-CRUSHED LIME FLUX1,681.0001,681.001,407.38-289.471,117.91570.341,688.251,688.25
000000000100002404-CRUSHED LIME FINES7,055.0007,055.001,352.0201,352.0217.071,369.091,369.09
000000000100003351-SP#3: CRUSHED COKE BREEZE13,336.00013,336.002,290.37-840.421,449.95977.872,427.822,427.82
000000000100003352-SP# 3:CRUSHED LIME FLUX :46,810.00046,810.001,352.2534.391,386.64-44.771,341.871,341.87
000000000100003354-SP#3: BASE MIX336,058.000336,058.00643.19-20.87622.32-44.21578.11578.11
775,425.040775,425.04770.27-57.33712.949.63722.57722.57
455-Coke
000000000120000091-BF COKE-SC 5,6,770,813.00070,813.003,414.36250.113,664.47263.313,927.783,927.78241781074.68259492114.11278137885.14
000000000120000092-BF COKE-SC 8,979,375.00079,375.003,353.54392.083,745.62-793,666.623,666.62266187237.5297308587.5291037962.5
000000000120000093-BF COKE-TC26,122.00026,122.004,468.79666.395,135.18-177.384,957.804,957.80116733732.38134141171.96129507651.6
OWN BF COKE176,310.003,543.203,918.903,962.81624702044.56690941873.57698683499.24
000000000120000094-NUT COKE- TC(CO-PRODUCT)3,358.0003,358.003,587.85-581.113,006.74-103.862,902.882,902.8812048000.310096632.929747871.04
000000000120000096-NUT COKE-SC 5,6,7(CO-PRODUCT)8,564.0008,564.002,741.28-460.612,280.67163.882,444.552,444.5523476321.9219531657.8820935126.2
000000000120000097-NUT COKE-SC 8,9(CO-PRODUCT)8,909.0008,909.002,692.45-180.62,511.85-52.982,458.872,458.8723987037.0522378071.6521906072.83
OWN NUT COKE20,831.002,856.872,496.592,524.5659511359.2752006362.4552589070.07
000000000120000283-BF Coke(Converted by outside agent)20,670.40020,670.402,692.45-77.842,614.61-22.832,591.782,591.78
000000000120000400-Low Ash Converted Coke3,500.0003,500.002,692.45-459.712,232.74-134.852,097.892,097.89
000000000120000410-High CSR coke4,000.0004,000.002,692.45-402.242,290.21-117.992,172.222,172.22
000000000120000953-HCC-40/WBC-30/JDB-3015,019.64015,019.642,692.45-107.122,585.33-31.422,553.912,553.91
240,331.040240,331.043,330.82217.613,548.4326.783,575.213,575.22
Grand Total2,300,859.4802,300,859.482,012.9912.642,025.63-66.61,959.031,959.02
Chart1
5654
4208
4757
Chart2
134.3631178707
100
113.0465779468
Sheet1
A TO E1345654
F1004208
G1134757
RMIM_AUG05
Report Run Date:05.09.2005Page #:1
Selection Criteria
Material(s) :
Material Group(s) :423,429,430,440,443,455,
Product Heirarchy :
Valuation Type(s) :
Plant(s) :077,
Posting Period(s) :005 -005,
Fiscal Year :2006
Show Arising Quantity
PrimeTotalTarget Cost-Single Level-Single Level-Multi-LevelMulti-LevelGross Actual
Material GroupProduction QuantityArising QuantityProductionRs/TnVar. Rs/TnCost Rs/TnVar. Rs/TnCost Rs/TnCost Rs/Tn
423-FUEL
000000000140000015-"CRUDE CO GAS-SC 5,6,7(CO-PRODUCT)"141,322.110141,322.11531.3319.79551.1235.47586.59586.59
000000000140000016-"CRUDE CO GAS-SC 8,9(CO-PRODUCT)"157,862.790157,862.79523.0742.18565.25-10.68554.57554.57
000000000140000017-CRUDE CO GAS-TC(CO-PRODUCT)48,570.20048,570.20674.56128.24802.8-25.64777.16777.16
347,755.100347,755.10547.5945.1592.695.99598.68598.67
429-Hot Metal A to F Fce
000000000100000180-HOT METAL PRODUCTION FROM BF-A45,585.40045,585.406,236.47-206.726,029.75-329.535,700.225,700.22284291979.538274868565.65259846808.788
000000000100000182-HOT METAL PRODUCTION FROM BF-B33,599.20033,599.204,923.09455.725,378.81-609.464,769.354,769.35165411885.528180723712.952160246344.52
000000000100000183-HOT METAL PRODUCTION FROM BF-C31,885.60031,885.605,234.051,409.226,643.27-872.265,771.015,771.01166890824.68211824649.912184012116.456
000000000100000184-HOT METAL PRODUCTION FROM BF-D51,452.20051,452.206,348.20206.556,554.75-759.35,795.455,795.45326628856.04337256307.95298188652.49
000000000100000185-HOT METAL PRODUCTION FROM BF-E33,492.80033,492.808,581.69798.439,380.12-3,232.726,147.406,147.40287424826.832314166483.136205893638.72
196,015.206,278.336,728.255,653.581230648372.6181318839719.61108187560.974
000000000100000186-HOT METAL PRODUCTION FROM BF-F105,920.500105,920.505,638.62-1,531.564,107.06100.964,208.024,208.02597245449.71435021848.73445715582.41
301,935.700301,935.706,053.92-245.195,808.73-662.255,146.485,146.471827894572.9441753862958.6611553906041.336
301,935.706,053.925,808.735,146.471827893822.3281753861568.331553903143.384
430-Hot Metal G Fce
000000000100000187-HOT METAL PRODUCTION FROM BF-G157,131.600157,131.604,373.41296.724,670.1386.874,757.004,757.00
157,131.600157,131.604,373.41296.724,670.1386.874,757.004,757.00687200910.756733824999.108747475021.2
HOT METAL (A-G BF)459,067.305,478.715,419.005,013.172515095483.72487687957.7692301381062.536
440-Sinter
000000000100000188-NET SINTER 1130,151.000130,151.001,137.16-59.761,077.4098.731,176.131,176.13
000000000100000189-NET SINTER 2173,015.000173,015.001,056.29-40.871,015.4283.371,098.791,098.79
000000000100003355-NET SINTER 3:175,115.000175,115.001,128.09272.991,401.08-58.241,342.841,342.84
SINTER478,281.000478,281.001,104.5868.91,173.4835.71,209.181,209.19
443-Base Mix and Flux
000000000100000172-BASE MIX350,738.000350,738.00635.07-10.79624.28-26.62597.66597.66
000000000100000173-CRUSHED COKE BREEZE19,747.04019,747.042,665.92-1,193.631,472.29994.612,466.902,466.90
000000000100000174-CRUSHED LIME FLUX1,681.0001,681.001,407.38-289.471,117.91570.341,688.251,688.25
000000000100002404-CRUSHED LIME FINES7,055.0007,055.001,352.0201,352.0217.071,369.091,369.09
000000000100003351-SP#3: CRUSHED COKE BREEZE13,336.00013,336.002,290.37-840.421,449.95977.872,427.822,427.82
000000000100003352-SP# 3:CRUSHED LIME FLUX :46,810.00046,810.001,352.2534.391,386.64-44.771,341.871,341.87
000000000100003354-SP#3: BASE MIX336,058.000336,058.00643.19-20.87622.32-44.21578.11578.11
775,425.040775,425.04770.27-57.33712.949.63722.57722.57
455-Coke
000000000120000091-BF COKE-SC 5,6,770,813.00070,813.003,414.36250.113,664.47263.313,927.783,927.78241781074.68259492114.11278137885.14
000000000120000092-BF COKE-SC 8,979,375.00079,375.003,353.54392.083,745.62-793,666.623,666.62266187237.5297308587.5291037962.5
000000000120000093-BF COKE-TC26,122.00026,122.004,468.79666.395,135.18-177.384,957.804,957.80116733732.38134141171.96129507651.6
OWN BF COKE176,310.003,543.203,918.903,962.81624702044.56690941873.57698683499.24
000000000120000094-NUT COKE- TC(CO-PRODUCT)3,358.0003,358.003,587.85-581.113,006.74-103.862,902.882,902.8812048000.310096632.929747871.04
000000000120000096-NUT COKE-SC 5,6,7(CO-PRODUCT)8,564.0008,564.002,741.28-460.612,280.67163.882,444.552,444.5523476321.9219531657.8820935126.2
000000000120000097-NUT COKE-SC 8,9(CO-PRODUCT)8,909.0008,909.002,692.45-180.62,511.85-52.982,458.872,458.8723987037.0522378071.6521906072.83
OWN NUT COKE20,831.002,856.872,496.592,524.5659511359.2752006362.4552589070.07
000000000120000283-BF Coke(Converted by outside agent)20,670.40020,670.402,692.45-77.842,614.61-22.832,591.782,591.78
000000000120000400-Low Ash Converted Coke3,500.0003,500.002,692.45-459.712,232.74-134.852,097.892,097.89
000000000120000410-High CSR coke4,000.0004,000.002,692.45-402.242,290.21-117.992,172.222,172.22
000000000120000953-HCC-40/WBC-30/JDB-3015,019.64015,019.642,692.45-107.122,585.33-31.422,553.912,553.91
240,331.040240,331.043,330.82217.613,548.4326.783,575.213,575.22
Grand Total2,300,859.4802,300,859.482,012.9912.642,025.63-66.61,959.031,959.02
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Bigger furnace : Cost advantage Higher % SinterLower/no Sponge IronCoke rate Coal injectionPurchased metallic consumption
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Coal injection rate ( kg/thm )G Fce. blown in 6th Apr05
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Sponge & Pig iron consumption trend
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COST RESEARCH & STANDARD COSTING SCRAPHM+SCRAP (KG/TCS)HM (KG/TCS)Maximising hot metal ratio
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Specific energy consumption (Gcal / CS )G Fce. blown in 6th Apr051 GCal/CS = Rs 274 Cr
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FY02=100Saleable steel cost ( Rs / t indexed )G Fce. blown in 6th Apr05
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Cumulative inflation
Cost
Real Cost
Saleable steel cost ($/t)
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Production & manpower productivity264
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5 MT crude steelReduce cost Reduce specific consumptionImprove productivityImprove raw material Improve product mix Tata Steel FY06 Plan
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Sinter production (mt)
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Ash Clean Coal ( Lakh t )Yield Loss 2%Yield Loss 3.5%Clean Coal Production at West BokaroFY-88
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1 t of ash needs1 t of coke 1 t of DRI 0.9 t of flux$ 350 per t of ashClean Coal : Low ash advantage *Exchange Rate: Rs 45/USD
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COST RESEARCH & STANDARD COSTING Higher usage of own coal (64%) planned in FY06 (P) against FY05 (54%) to reduce the coal billCoke plant : Change in coal blend ( FY06) *Exchange Rate: Rs 45/USD
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5 MT crude steelReduce cost Reduce specific consumptionImprove productivityImprove raw material productivityImprove product mix Tata Steel FY06 Plan
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FP market share in domestic marketCold Rolled ProductGalvanized ProductOverall Flat Product DomesticFY06 : 0.4 mtpa capacity addition, domestic HR sales Hot Rolled Product* (Incl. Free Market)
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Automotive sales trend Domestic + Export(In 000 MT)FY-05 FY-06 (P)FY-04510648933
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Long products product mix improvement
Chart1
0.38718849910.09569368510.21916007820.2979577376
0.33808887310.07149648220.19173965920.3986749854
0.12968470140.06323148780.34746901940.4596147914
0.09509143710.00305781830.28005358650.6217971581
0.03113333060.00000838260.30170297060.6671553162
0.0200.240.74
Semis
FQ/Structurals
Wire rods
Rebars
Sheet1
PERFORMANCE ALL INDIA
Apr - Mar
PRODUCT CATEGORYFY01FY02FY03FY04FY05
QtyNRQtyNRQtyNRQtyNRQtyNR
FQ Cr C/Mn230031641731560151312297815369101013436
FQ C/Cr, C/Cr//Mo298711869335634185883767318644142420207
FQ Cr/Ni/Mo7530208145948182404582206483314043
FQ STEEL6040318091731421706865233176312467173526.7546.754
CHQ WIRE ROD454421886831200283020145696837195109460.3655492649460.3724899796
HC WIRE ROD458881365571582135951745941366111829316971120541.291179392120541.379616019
LC WIRE ROD77435131058430413094108559135539595416571115105.657854658115105.742303364
SPECIAL STEEL SEMIS45448972744489103903777510847430721338016573.366716893562.7416573.3788761513
LONG SPECIALITY23371914015274349138673891821403026415616306261681261680.873285514
MS WIRE ROD958141226843887124157469212850111401558421296.408496253721296.4241206302
STRUCTURAL3726410430166013638436181936810323
TISCON CRS292851226918655123382531413392213131688218904.50166344818904.5155329722
TISCON27481911702398451118804520211225349428815158570193.642509685570194.060839384
SECONDS LONG369909253206409458196829873116891269310917.364206883610917.3722165444
DEFECTIVES000000
LONG COMMODITY47417311560483293118495721461230453849915181621312621312.372709531
TOTAL LONG PRODUCT70789112371757642125809613281300380265515551882993882993.245995045
TESTED SEMIS312738914628859093127722810299240901280800
CC SLABS00000000
TOTAL SEMIS312738914628859093127722810299240901280800
TOTAL10206291138310462321167810385551280282921215477882999883000883000
0
Product gradetonnageFy'01%tonnageFY'02%tonnageFy'03%tonnageFy'04%tonnageFy'05%tonnageFy'06%
Wire rods22368122%20060419%36086635%23222428%26640430%25664924%
Rebars30410430%41710640%47733546%51560262%58909867%79499974%
FQ/Structurals9766810%748027%656696%25360%70%00%
Semis39517639%35371934%13468513%7885110%274913%250002%
total domestic1020629100%1046232100%1038555100%829212100%882999100%1076648100%
00000
Wire rodsRebarsFQ/StructuralsSemis
Fy'0122%30%10%39%
Fy'0219%40%7%34%
Fy'0335%46%6%13%
Fy'0428%62%0%10%
Fy'0530%67%0%3%
Fy'0624%74%0%2%
Sheet1
0000
0000
0000
0000
0000
0000
Semis
FQ/Structurals
Wire rods
Rebars
Sheet2
2001MarginNRMargin % NR
HCWR40161365529%
LCWR43361310533%
Tiscon Proj31501171327%
Tiscon Retail41501193135%
FQ164180911%
Structurals28001043027%
MSWR41681226834%
1021 KT
1046 KT
1039 KT
829 KT
883 KT
Sheet3
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Global leader & World class Maintain low cost advantageTata Steel Future Plan
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NatSteel integration 1 mtpa + 2 mtpa expansion at Jamshedpur6 mtpa green field project in Kalinganagar, Orissa12 mt greenfiled project in Jharkhand5 mtpa green field project in Chhattisgarh Iran : Iron ore, pellets & steel Green field project in BangladeshPort infrastructure in Dhamra, OrissaCoke Project in Haldia Ferro Chrome project in South AfricaTitania project in Tamil NaduMedium term growth plans
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Strong base in India De-integrated dispersal of facilities in select geographiesPrimary steel making in countries rich in Iron ore and / or coal / gas (low cost regions)Finishing facilities in growing marketsOwnership and development of raw material sources Access to captive ports and other dedicated logistics facilitiesSize of 20 - 25 mtpa by 2015More from Steel via branding and presence in high entry barrier segmentsTata Steel future strategy
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Thank You !