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Tata Steel : Commitment to Excellence

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.

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Tata Steel : Commitment to Excellence

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  1. Tata Steel : Commitment to Excellence

  2. 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

  3. 1 MTPA expansion Iron making • LD#1, Two Billet casters • Capacity from 1.5 to 1.8 mtpa • One caster to cast larger sections • LD#2, Three slab casters • Capacity from 2.7 to 3.2 mtpa Steel making Casting • HSM capacity from 2.6 to 3.1 mtpa • New Rebar mill of 0.6 mtpa Rolling

  4. 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 fired • New oxygen plant : 720 tpd

  5. 1 mtpa expansion : Quality improvement • 100% Desulphurization • 2nd ladle furnace in LD1 • One vertical bending caster • Auto slab scarfing machine • Auto surface inspection system at HSM • On line pinch roll polisher

  6. “G” Blast Furnace

  7. Tata Steel FY06 Plan • 5 MT crude steel • Reduce cost • Reduce specific consumption • Improve productivity • Improve raw material quality • Improve product mix

  8. FY06 : Daily crude steel production 103 tpd 5 mtpy = 13700 tpd HSM Shutdown LD#2 : Caster # 3 shutdown 'G' Fce. Blown in 31st Aug 1st April

  9. 157 142 135 109 122 104 102 98 92 85 66 62 67 Jun 92-93 94-95 96-97 98-99 00-01 02-03 04-05 Apr'05 Aug'05 ‘G’ Fce. Production ( kt / month ) 1.8 mtpa = 150 kt/month Blown out for upgradation : 3rd Dec’04 Jul May

  10. Cost comparison F , G vs. A to E Period – Aug’05 Indexed (Rs/t) 135 110 100

  11. Bigger furnace : Cost advantage • Higher % Sinter • Lower/no Sponge Iron • Coke rate • Coal injection • Purchased metallic consumption

  12. Coal injection rate ( kg/thm ) ‘G’ Fce. blown in 6th Apr’05

  13. Sponge & Pig iron consumption trend

  14. Maximising hot metal ratio HM+SCRAP (KG/TCS) SCRAP HM (KG/TCS) COST RESEARCH & STANDARD COSTING

  15. Specific energy consumption (Gcal / CS ) 1 GCal/CS = Rs 274 Cr ‘G’ Fce. blown in 6th Apr’05

  16. Saleable steel cost ( Rs / t indexed ) FY’02=100 ‘G’ Fce. blown in 6th Apr’05

  17. Production & manpower productivity 264

  18. Tata Steel FY06 Plan • 5 MT crude steel • Reduce cost • Reduce specific consumption • Improve productivity • Improve raw material • Improve product mix

  19. Sinter production (mt)

  20. Clean Coal Production at West Bokaro Clean Coal ( Lakh t ) Ash Yield Loss 3.5% Yield Loss 2% FY-88

  21. Clean Coal : Low ash advantage • 1 t of ash needs • 1 t of coke • 1 t of DRI • 0.9 t of flux • $ 350 per t of ash *Exchange Rate: Rs 45/USD

  22. Coke plant : Change in coal blend ( FY06) • Higher usage of own coal (64%) planned in FY’06 (P) against FY’05 (54%) to reduce the coal bill COST RESEARCH & STANDARD COSTING *Exchange Rate: Rs 45/USD

  23. Tata Steel FY06 Plan • 5 MT crude steel • Reduce cost • Reduce specific consumption • Improve productivity • Improve raw material productivity • Improve product mix

  24. FP market share in domestic market Overall Flat Product Domestic Hot Rolled Product* (Incl. Free Market) Cold Rolled Product Galvanized Product FY06 : 0.4 mtpa capacity addition, domestic HR sales

  25. Automotive sales trend – Domestic + Export 933 (In 000 MT) 648 510 FY-05 FY-04 FY-06 (P)

  26. Long products product mix improvement

  27. Tata Steel Future Plan • Global leader & World class • Maintain low cost advantage

  28. Medium term growth plans • NatSteel integration • 1 mtpa + 2 mtpa expansion at Jamshedpur • 6 mtpa green field project in Kalinganagar, Orissa • 12 mt greenfiled project in Jharkhand • 5 mtpa green field project in Chhattisgarh • Iran : Iron ore, pellets & steel • Green field project in Bangladesh • Port infrastructure in Dhamra, Orissa • Coke Project in Haldia • Ferro Chrome project in South Africa • Titania project in Tamil Nadu

  29. Tata Steel future strategy • Strong base in India • De-integrated dispersal of facilities in select geographies • Primary steel making in countries rich in Iron ore and / or coal / gas (low cost regions) • Finishing facilities in growing markets • Ownership and development of raw material sources • Access to captive ports and other dedicated logistics facilities • Size of 20 - 25 mtpa by 2015 • ‘More from Steel’ via branding and presence in high entry barrier segments

  30. Thank You !

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