Indian Steel Industry
INDIAN Perspective
BHARAT HEAVY ELECTRICALS LTD.
Industrial Systems Group, Bangalore
CONTENTS
1
Indian Steel Industry – An Overview
2
Iron & Steel Making Process
3
Raw Material for Iron Making
4
Iron Ore: Techno-economical Issues
5
Agglomeration of Iron Ore Fines
6
Ore Beneficiation, Pellet Plants and Sinter Plant
7
Assessment Of Situation
8
Initiation By ISG
9
Conclusion
2
Indian Steel Industry – An Overview
3RD largest steel producer in the world
Largest producer of Sponge Iron in the world – 26.3 mT in 2010
Per capita steel consumption in the country, currently estimated at 52 kg
(2010). World Average 203 kg
Production of Finished steel in 2010-11, 66.01 mT (Prov.) a growth of 5.8%
Apparent Consumption of Finished Steel in 2010-11 – 65.61 mT, growth of
8.8%.
India’s exports of Finished Steel in 2010-11, 3.46 mT, Imports 6.8 mT
Huge Iron Ore resources & reserves – Approx. 26 bn. Tonnes
Indian Steel Producers are increasingly looking for overseas acquisitions in
steel as well as raw materials.
Capacity Planned till 2020
300
256
250
191
200
150
100
73
78
89
2009-10
2010-11
2011-12
mT
50
0
2016-17
2017-20
Source: Report of the working group on steel industry 12TH plan and SAIL Vision 2020
4
Indian Steel Industry – Major Players
Crude Capacity (P)
2011-12
Company
11-12
(MT)
16-17
(MT)
Additi
on
0
30
30
12.49
28.99
16.5
Tata Steel
6.8
24.3
17.5
JSPL
2.4
13.4
11
0
12
12
RINL
2.9
7
4.1
JSW
6.6
6.6
0
ESSAR
4.6
6.3
1.7
NMDC
0
6
6
1.5
5.2
3.7
51.71
51.71
0
89
191.5
102.5
SAIL
14%
Tata Steel
8%
RINL
3%
5 Yr
CAGR
15.4%
Others
58%
BSL
2%
2016-17
JSW
7%
JSPL Essar
3% 5%
Arcelor
Mittal
16%
Others
27%
BSL
3%
NMDC
3%
Essar JSW RINL
3% 3% 4%
SAIL
15%
Arcelor Mittal
SAIL
POSCO
Bhushan SL
OTHERS
POSCO
6%
JSPL
7%
Tata Steel
13%
Total
RINL (4.1MTPA), Essar (1.7MTPA), Bhushan (3.7MTPA)NMDC(3MTPA) are under execution
Source: Report of the working group on steel industry 12TH plan SAIL Vision 2020
5
Indian Steel Industry – Pellet Plant/ Ore
Beneficiation
Capacity Planned up to 2017
50 MTPA Pellet Plant
50 MTPA Ore Beneficiation
Source: Report of the working group on steel industry 12TH plan
Existing Plants
Sl. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Customer
Plant Capacity
(MTPA)
Jindal Steel & Power Ltd., Barbil
Global Supply Ltd. (Essar group Company), Dabuna
Brahmani River pellets Ltd., Barbil
Shri Bajrang Power & Ispat Ltd., Raipur
Sree Metalliks Ltd., Keonjhar
Bhushan Power and Steel Limited, Jharsuguda
Indrani Pattnaik, Barbil
KJS Ahluwalia, Barbil
Janki Corporation, Bellary
Korp Resources, Keonjhar
SSAB Energy & Minerals Ltd., Barbil
Sriram Mineral, Barajamda
Madras Cements Ltd., Alathiyur
Ankit Metal & Power Ltd., Bankura
11
8
4
1.8
1.2
8
1.2
1.2
1.2
0.5
0.5
0.5
2.6
1.1
Source: Web / Company
6
Raw Material for Iron Making
1. Iron Ore
•Hematite (Fe203) – 58% of Total Reserve
•Magnetite (Fe304) – 42% of Total Reserve
2. Limestone or Dolomite
3. Coke
4. Coal
Input Materials for Blast Furnace
Iron Ore (10/40 mm)
Sinter and Pellet
Limestone (Flux)
Metallurgical Coke (Fuel)
OUTPUT
Pig Iron
Molten Iron taped
from the BF
Fe 90-95%
PROCESS
Total metallic yield Fe for pig iron will typically be in the range of 90 – 95 % which is comparable to #1 prompt scrap
Input Materials for Direct-reduced iron (DRI)
Iron Ore (5/40 mm)
Pellet
Limestone or Dolomite (Flux)
Natural Gas or Non Coking Coal
Input Materials for Smelting Reduction (SR)
Iron Ore (-6/30 mm)
Pellet
Limestone or Dolomite (Flux)
Oxygen and Non Coking Coal
OUTPUT
OUTPUT
Sponge Iron
Iron produced as a solid
by reduction of Iron
Oxide
Fe 90-92%
Liquid Iron
Which utilize Oxygen
and Non Coking Coal
Fe 97%
Iron Ore: Techno-economical Issues
The country’s iron ore requirement is going to increase substantially
(almost 340 Mt/yr by 2020)
The ration of Lump to Fines produced is 2:3
The percentage of Fines to lumps is generally rising as mining goes deeper
Fines generated as such cannot be used for Iron Making (BF/DRI)
Large portion of the Fines are being exported
Limited reserves of high grade iron ore (+62% Fe) pose a great challenge in
long term sustainability of Indian iron & steel industry
There is a pressing need to utilize existing low grade iron ores including
slimes and dump fines which are stockpiled in millions of tonnes in different
mine heads
The availability of large quantities of subgrade fines and slimes in the
mines has necessitated beneficiation of the same followed by
pelletisation.
Beneficiation of low grade ores, mostly at micro-fines level, provides
concentrate which can be used in iron making in the form of pellets
8
Agglomeration of Iron Ore Fines
Agglomeration of Iron Ore Fines basically involves two main methods
1. Sintering
2. Pelletising
Sintering is the agglomeration technique of Iron Ore Fines in the size rage of 10+0.15 mm to produce clusters by incipient fusion at high temperature.
Pelletisation is the other mode of agglomeration applicable for fines below 325
mesh size.
1% replacement of calibrated lump by Sinter or Pellet reduces the Coke rate by
1.5Kg/T of hot metal produced
20 to 70% Sinter can be used successfully in Blast Furnace
Use of Pellet gives rise to improved permeability compared to Lump Ore or Sinter
15 to 20% of pellets are used in many furnaces along with lump ore & sinter
9
Ore Beneficiation, Pellet Plants
and Sinter Plant
Ore Beneficiation & Pellet Plants
Ore Beneficiation
Very low grade Iron ore cannot be used in metallurgical plants
Needs to be upgraded to increase the iron content and reduce the gangue
content
.
.
A process adopted to upgrade ore is called Beneficiation
Each source of Iron ore has its own peculiar mineralogical characteristics
Specific beneficiation and metallurgical treatment to get the best product
out of it
Several techniques such as washing, jigging, magnetic separation, advanced
gravity separation and flotation are being employed to enhance the quality of
the Iron ore
Major Equipment
Ball mills for primary grinding and
regrinding
Concentrate, tails & hydro-cyclone overflow Thickeners
Hydro-cyclones for classification and desliming
Slime Tanks with agitators & Sumps
Wet high intensity magnetic separator
Agglomeration (Sintering & Pelletising)
•
•
Common methods of burden preparation related to the performance
improvements of iron making (blast furnaces & direct reduction process)
Growth of steel industry with depleting resources of high grade ores have led to a
very strong demand for both pelletising and sintering of iron ores.
Pellet Plant
The process of Pelletisation helps converting Iron Ore Fines into
“Uniform Size Iron Ore Pallets” that can be fed in the blast furnaces
or in the DRI kiln (DRI).
Pelletisation was invented to make use of ultra fine concentrate
generated in the Iron ore beneficiation plants
There are two main processes for producing iron ore pellets:
(1).The Grate-Kiln System
(2).The straight grate system
Major Equipment
Pulverizing mill for lime stone, bentonite
and coal
Travelling grate complete with burners,
lubricating system and accessories
Intensive Mixer with accessories
Rotary kiln with accessories
Swing Belt Conveyor & wide belt conveyor
Annular Cooler
Roller screen for screening green pellets
Pellet Plant-Grate-Kiln System
Process adopts three equipment viz. grate, rotary kiln and annular
cooler
Green balls are first dried and preheated on the straight grate followed
by hardening in a counter flow manner in rotary kiln and air cooling in an
annular cooler
Pellet Plant-Straight Grate System
In the straight grate system, a continuous parade of grate cars moves at
the same speed though the drying, induration and cooling zones.
Sinter Plant
Sinter making is a method of fusing iron ore fines into larger particles
suitable for charging into the blast furnace.
Major Equipment – Sinter Plant
Proportioning
Mixing & Nodulizing
Sintering
Sinter Cooler
Cold Sinter crushing
Cold Sinter screening
Waste Gas & Plant de-dusting
Indian Steel Industry – 12TH Plan
2012-2017
• Steel production of the country will go up by 90 MTPA
in 2016-17 from 89 MTPA likely in FY11-12.
• It is estimated with feasibility factor that 21 MTPA
shall be installed
• 50 MTPA Ore Beneficiation
• 50 MTPA Pellet Plant
• As per SAIL Vision 2020 (60 MTPA)
Source: Report of the working group on steel industry 12TH plan
19
20
THANKS
Need for Pelletisation Contd.
ADVANTAGES OF PELLETS:
• Good Reducibility:
Because of their high porosity that is (25-30%), pellets are usually reduced
considerably faster than hard burden sinter or hard natural ores/lump ores.
• Good Bed Permeability:
Their spherical shapes and containing open pores, gives them good bed
permeability. Low angle of repose however is a drawback for pellet and creates
uneven binder distribution.
• High uniform Porosity (25-30%):
Because of high uniform porosity of pellets, faster reduction and high metallization
takes place.
• Less heat consumption than sintering.
Approx. 35-40% less heat required than sintering.
• Uniform chemical composition & very low LOI:
The chemical analysis is to a degree controllable in the concentration processing
within limits dictated by economics. In reality no LOI makes them cost effective.
• Easy handling and transportation.
Unlike Sinter, pellets have high strength and can be transported to long distances
without fine generation. It has also good resistance to disintegration.
21
ORE BENEFICIATION AND PELLET PLANT UPCOMMING PROJECTS - 2020
SL. NO.
PROJECT/PROMOTER
1
Iron Ore Pellets (Jamtara) Project
Maa Chandi Durga Ispat Private Ltd.
Iron Ore Pellets (Haridaspur) Project
Rashmi Metaliks Pvt. Ltd.
Iron Ore Beneficiation & Pelletisation
(Motuda) Project
Indo Pellets Pvt. Ltd.
Iron Ore Benefication & Pelletisation
(Jilling) Project
Essel mining & Industries Ltd.
Iron Ore Beneficiation & Pelletisation
(Raipur) Project
Bagadiya Brothers Pvt. Ltd.
Iron ore Pelletisation (Sundargarh)
Project
Shyam Steel Industries Ltd.
Iron Oxide Pellets (Bommanahalli)
Project
Iron Ore Pellets (Kotgarh) Project
Shree Sai Shraddha Metallics Pvt. Ltd.
Iron Ore Pellets (Hospet Vada)
Project
Ishitha Mining Company Pvt. Ltd.
Iron Ore Pellets (Hospet Vada)
Project
Arun Metallurgicals Pvt. Ltd.
Iron Ore Beneficiation & Pelletisation
(Tilda) Project
Gopal Sponge & Power Pvt. Ltd.
Iron Ore Pellets (Yerabanahally)
Project
Kmmi Steel Pvt. Ltd.
Iron Ore Pellets (Dharsiwa) Project
Real Ispat & Power Ltd.
Iron Oxide Pellets (Bagalkot) Project
Doddanavar Najinzhaw Mining &
Metallurgy Pvt. Ltd.
2
3
4
5
6
7
8
9
10
11
12
13
14
Source: Projects Today/ Web
Approx. COST
(Crore)
MTPA
Rs. 1,500
1
SL. NO.
15
Rs. 800
3
16
Rs. 800
Rs. 600*
6
2.4
Rs. 750
3.4
2
Rs. 350
17
18
1.25
19
Rs. 325
20 Lakh TPA
20 Lakh TPA
Rs. 284
Rs. 260
6 Lakh TPA
6 Lakh TPA
Rs. 250
3 Lakh TPA
Rs. 250
3 Lakh TPA
Rs. 150
6 Lakh TPA
Rs. 150
6 Lakh TPA
Rs. 50
6 Lakh TPA
Rs. 49
0.6
20
21
22
23
24
PROJECT/PROMOTER
Iron Ore Pellets (Badtumkela)
Project
Singhal Sponge Pvt. Ltd.
Iron Ore Beneficiation &
Pelletisation (Byree) Project [Phase I]
Pro Minerals Pvt. Ltd.
Iron Ore Pelletisation (Jagdalpur)
Project
Baldev Alloys Pvt. Ltd.
Iron Ore Pelletisation (Ethora
Salanpur) Project
Sangeeta Ispat Pvt. Ltd.
Iron Ore Pelletisation (Paschimi
Singhbhum) Project
Steel Authority of India Ltd.
Iron Ore Pelletisation Plant (Bonai)
Project
Patwari Forgings Pvt. Ltd.
Iron Ore Pelletisation (Horomoto)
Project - Phase I
Shyam Steel Industries Ltd.
Iron Ore Pelletisation (Thakurani)
Project
Orissa Minerals Devp. Co. Ltd.
Iron Ore Beneficiation & Pelletisation
(Dharsinwa) Project
Vandana Global Ltd.
Iron Ore Pelletisation (Bagalkot)
Project
Shree Renuka Energy Ltd.
TOTAL
* Estimated
Approx. COST
(Crore)
MTPA
8
600*
300*
2.1
1.2
3 Lakh TPA
200*
5 Lakh TPA
900*
4
2 Lakh TPA
100*
0.6
600*
2
300*
15 Lakh TPA
250*
1.2
Rs. 5,968
48.75
SINTER PLANT UPCOMMING PROJECTS-12TH PLAN
Sl. Project / Promoter
Approx. Cost Rs. MTPA
No.
Crores
1 Sinter Plant at Bastar, Chhattisgarh
750
3
NMDC Ltd
2 Sinter Plant at Kalingnagar, Odisha
1500
6
TATA Steel Ltd
3 Sinter Plant at Bastar, Chhattisgarh
1500
5.5
TATA Steel Ltd
4 Sinter Plant at Seraikela, Jharkhand
2250
12
TATA Steel Ltd
5 Sinter Plant at Paradeep, Odisha
1500
6
ESSAR Steel Ltd
6 Sinter Plant at Bastar, Chhattisgarh
750
3.2
ESSAR Steel Ltd
7 Sinter Plant at Chaibasa, Jharkand
750
3
ESSAR Steel Ltd
8 Sinter Plant at Bellary, Karnataka
1500
6
ESSAR Steel Ltd
9 Sinter Plant at Patratu, Jharkand
1500
6
JINDAL Steel
10 Sinter Plant, Asanboni, Jharkand
1500
5
JINDAL Steel
11 Sinter Plant at Jagatsingpur, Odisha
2250
12
POSCO India
12 Sinter Plant at Keonjhar, Odisha
750
3
Arcelor Mittal India
13 Sinter Plant at Bokaro, Jharkhand
2250
12
Arcelor Mittal India
14 Sinter Plant at Bellary, Karnataka
1500
6
Arcelor Mittal India
15 Sinter Plant at Jharkhand
750
2.8
ISPAT Industries
16 Sinter Plant at Jharkhand
750
2.8
ISPAT Industries
Total
21,750
94.3
Source: Answers Given By Minister of Steel in Rajya Sabha on 24/11/2011
Projects Details Up to 2020
SL. No. Company / Place
12 TH PLAN
STEEL PLANT
NMDC -Bastar
3.0 MTPA
1 Chattisgarh
SAIL
FCI SINDRI
5.6 MTPPA
2
POSCO -BSL
1.5 MTPPA
3
Vision 2020 9.0 MTPPA
4
Private Investors
Tata Steel
Bastar
Chattisgarh
MTPA
3
6
1.5
9
5.5 MTPA
5.5
12 MTPA
12
12 MTPA
12
Project implemented stage – 2016
12 MTPA
12
6 MTPA
6
Project implemented stage – 2015 (3
MTPA)
Project implemented stage – 2015 (3
MTPA)
12 MTPA
12
Phase i: 3.0 MTPA
6
completion of 3 MTPA (Phase 1)
capacity will be 2013.
First phase would be completed by
2015
5
Seraikela
Jharkhand
6
7
Arcelor Mittal
Keonjhar
Chattisgarh
Bokaro
8
9
10
11
12
Bellary
Karnataka
POSCO
Jagatsinghpur
Orissa
SL.
No. Company / Place
Status
Jindal Steel & Power Ltd.
Patratu
6 MTPA
Jharkhand
Asanboni
5 MTPA
Jharkhand
Sub-Total
Existing Capacity
RINL Ongoing Project
NMDC, Nagarnar
Others
Total Capacity up to 2017
5
90
89
3
3
6.5
191.5
DPR Completed.
Capacity of 5.5 mtpa likely to be
achieved by FY’2015
DPR Completed. Capacity of 12.0
mtpa likely to be achieved by
FY’2016.
MTPA Status
1 SAIL Vision 2020 (60 MTPA)
31.01
Tata Steel Ltd. Orissa Greenfield project at
2 Kalingnagar
6
Essar Steel Orissa Ltd. Orissa Greenfield plant
3 at Paradeep
6
Essar Steel Chhattisgarh Ltd. Chhattisgarh
4 Greenfield plant at Bastar
3.2
Essar Steel Jharkhand Ltd Jharkhand
5 Greenfield plant at Chaibasa
3
Essar Steel Karnataka Ltd., Karnataka
6 Greenfield plant at Bellary
6
Ispat Industries Ltd, Jharkhand Greenfield
7 project
2.8
Ispat Industries Ltd. Karnataka Greenfield
8 project
2.8
Visa Steel Ltd Chhattisgarh Greenfield plant
9 at Raigarh
2.5
Visa Steel Ltd. Orissa Greenfield plant at
10 Jajpur
1.5
64.81
Total Capacity up to 2020
256.3
SAIL up to 2017
SAIL
Existing
Capacity Addition
SAIL
24MT (2013) * #
16MT (2017)**
Total
5.6 MT at sindri,
Dhanbad
Rs. 22,960 Cr ***
1.5MT at BSL with
POSCO
Rs. 6,150 Cr ***
9MT (Estimated)
Rs. 36,900 Cr ***
Rs 66,110 Cr
Source: Report of the working group on steel industry for the 12TH five year plan
*SAIL total projected 20.75 for terminal year
# As per SAIL Web Site
** Proportionally changed for 2017 (26MT for 2020) SAIL Vision 2020 (60 MT)
*** Estimated
Indian Steel Industry
SWOT Analysis
STRENGTHS
WEAKNESSES
•Abundant resources of iron ore
•High cost of energy
•Low cost and efficient labour
force
•Higher duties and taxes
•Strong managerial capability
•Infrastructure
•Quality of coking coal
•Strongly globalised industry and
emerging global competitiveness
•Labour laws
•Modern new plants & modernised
old plants
•Dependence on imports for
steel manufacturing equipments
& technology
•Strong DRI production base
•Regionally dispersed merchant
rolling mills
•Slow statutory clearances for
development of mines
26
Indian Steel Industry
SWOT Analysis
OPPORTUNITIES
THREATS
• Huge Infrastructure demand
• Slow growth in infrastructure
development
• Rapid urbanisation
• Increasing demand for
consumer durables
• Untapped rural demand
• Market fluctuations and
China’s export possibilities
• Global economic slow down
• Increasing interest of foreign
steel producers in India
27
Growing Indian Economy
28
Indian Steel Industry – A Bright Future
RESOURCES
Abundant Iron Ore reserves
Strong Managerial skills in Iron and Steel making
Large pool of skilled Man-power
Established steel players with strong skills in steel making
OPPORTUNITIES
High economic growth driven increasingly by industry
Faster Urbanisation
Increased Fixed Asset Building
Automobiles and component industry growth
POLICY
Pro-active stance of Govt.
Encouragement for overseas investments
29
Iron Making Process
The three different methods that can be used for production of iron
from Iron ore are:
• Coke-Ovens -Sinter-Blast Furnace (BF) Route
• Direct Reduction Technique (DRI)
• Smelting Reduction Technologies.
For producing Crude Steel, two types of techniques are adopted;
• Basic Oxygen Furnace (BOF) type
• Electric arc furnace (EAF) type
Sinter Plant
Sinter Plant
Sinter
Sinter
30