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ABSTRACT STRUCTURE OF THE INDIAN STEEL INDUSTY DEMAND & SUPPLY PRODUCTION
September 2010
INDEX
INFRASTRUCTURAL & LOGISTICS CHALLENGES IN INDIA FOR EXISTING, BROWNFIELD AND GREENFIELD STEEL PROJECTS IN INDIA SWOT ANALYSIS
STRENGTHS WEAKNESSES OPPORTUNITIES THREATS
CHALLENGES OF LOGISTICS IN THE INDIAN STEEL INDUSTRY PERFORMANCE OF LOGISTICS CHALLENGES OF OCEAN LOGISTICS
MITIGATION PLAN FOR PORT LOGISTICS MITIGATION PLAN FOR ROAD LOGISTICS
ABSTRACT Logistics and supply chain management is the most challenging responsibility in the Indian Steel Industry. There has been tremendous pressure on the Industry vis-a-vis stringent competitive resources, performance, productivity, quality control and price reduction. The Steel sector requires 4MT of bulk cargo to produce 1MT steel output.
Availability of iron ore is a major challenge for the domestic steel industry. The total production of iron ore is 70%-72% as fines and 25%-30% as lumps / CLO.
STRUCTURE / MARKET SIZE The steel industry in India has been moving from strength to strength and, according to the Annual Report 2009-10 compiled by our Ministry of Steel, India has emerged as the fifth largest producer of steel in the world, and is likely to become the second largest producer of crude steel by 2015-16, more than doubling its capacity to 124 million tonnes.
Coking Coal
Million Tonne
Non-coking Coal Million Tonne Coal Dust Injection Iron Ore Scrap Steel Limestone Dolomite Natural Gas Ferro Alloys Power Million Tonne
In Million Tonnes
2011-12 Supply
Non-Flat
29
36.1
Production
Steel production rose by 4.2 per cent to reach 60 MT in 2009-2010, according to the Ministry of Steel. Moreover, according to the ministry, the crude steel production capacity in the country by 2011-12 will be nearly 124 MT. According to the Ministry of Steel, 222 memorandums of understanding (MoUs) have been signed with various states for a planned capacity of around 276 MT. Major investment is planned in the states of Orissa, Jharkhand, Chattisgarh, West Bengal, Karnataka, Gujarat and Maharashtra. According to the Annual Report 2009-10 of the Ministry of Steel, domestic crude steel production grew at a compounded annual growth rate of 8.6 per cent during 2004-05 and 2008-09.
2007-08
2008-09 2009-10*
53.86
58.44 64.88
5.98
8.50 11.02
Inves tor
G reenfield 2012
S AIL R INL T ata S teel E s s ar S teel J S W S teel JS PL Is pat Indus tries B hus han P ower & S teel B hus han S teel O thers & S econdary Total
S ourc e: F inmin
12.84 2.90 6.80 4.60 6.60 2.40 3.60 1.20 0.80 31.00 72.74
8.56 3.40 3.20 3.90 4.40 4.80 0.60 1.60 2.20 3.20 35.86
12.25
Total c apac ity likely by Dec ember 2012 21.40 6.30 13.00 * 14.50* 11.00 10.45 4.20 2.80 3.00 34.20 120.87
With additional capacity expansion, as shown above, surging imports from China are a matter of great concern for the Indian Steel Industry. Chinese imports may pose a major hurdle to Indian expansion projects, in addition to logistics and infrastructural challenges.
In the period Apr-Jun10 , the Indian Steel Industry reported a loss of US $ 1458 million (excluding erosion in market capitalisation). In July10, prices were further down by US $ 21.6 per MT ,eroding an additional million US $ 41.0 on sales volume of 1.8 MT of HRC. In the same period ,China gained million US$ 1047 on cheaper imports of iron ore from India.
Note: US$ Rupee parity has been taken Average of Apr-Jun10 at 46.35
For the period Apr-Jun10 due to low price of Iron Ore China has gained million US$ 1047.
SAIL, Bokaro
Essar,Sur at ISPAT
ArcelorMittal Orissa
Tata Steel CSP Essar Manoharpu r POSCO
JVSL
JSW
Major steel plants (brown & green fields) in India would be clustered mostly around the red circle passing through three states rich in coal and iron ore, putting severe pressure on logistics infrastructure.
Investments
A host of steel companies have lined up major investment proposals. Furthermore, with an expanding consumer market, the Indian steel industry is likely to receive huge domestic and foreign investments. The domestic steel sector has attracted a staggering investment of about US $ 238 billion, according to the Minister of State for Steel, A. Sai Prathap. This consists of nearly 222 MoUs signed between the investors and various state governments, mostly in the states of Orissa, Jharkhand, Chhattisgarh and West Bengal. SAIL is planning to set up a 12-million tonne plant in Jharkhand. In December, Indias largest engineering conglomerate -- Larsen & Toubro (L&T) -- and state-owned Nuclear Power Corporation of India Limited (NPCIL) formed a US$ 373.2 million joint venture for specialised steel and forging products. Stainless steel manufacturer and exporter Varun Industries is setting up a US $ 171.8 million stainless steel-cum-alloy steel plant at Rohat, Jodhpur. Tata Steel has entered into a joint venture with Japans Nippon Steel for the production and sales of automotive cold-rolled flat products at Jamshedpur. This jv is expected to invest US $ 400 million to set up an automobile venture in India. Steel major JSW Steel has earmarked a capex of US $ 1.6 billion for 2010-11, and plans to increase thecapacity of its Bellary plant in Karnataka from 7 MT to 10 MT by the end of 2010-11.
SWOT ANALYSIS
Strengths
Abundant supply of iron ore Low cost and reasonable efficient labour force Strong man ower capability and improving productivity History in steel making and acquired skill Strongly globalised industry and emerging global competitiveness Increases in productivity through the adoption of more efficient and cleaner technologies in the manufacturing sector will be effective in merging economic, environmental, and social development objectives Strong steel production base and achieved productivity levels High degree of entrepreneurship Availability of investments and capital backup Support from government , which helped in growth of the steel industry The biggest boost to efficiency in the steel industry has come from the increased use of continuous casting an indicator of the modernity of the production process. Availability of a good railway network for domestic shipping
Weaknesses
Limited availability of coking coal High transportation and handling costs Mining costs are also high Implementing the latest technology has become a concern for the Indian steel industry The steel industry in India did not attain self sufficiency in constructing and efficiently maintaining steel plants. It still relies on countries like Russia, Ukraine and Kazakhstan, etc, for installing new steel plants in the country.
Although India has modernized its steel making considerably over the past decades, nearly 6% of its crude steel is still produced using the outdated open hearth process.
Quality is also one of the drawbacks India needs to address. Quality of flat steel or long steel is an issue for reaching international quality standards.
Weaknesses
Logistics is one of the constraints for Indias steel industrys competing in global markets. Our domestic steel industry has to concentrate on the supply of raw materials and meeting the customers delivery time. The loading and unloading rates at ports, container handling, and in plant logistics also hamper the global success of the Indian steel industry. A tonne of finished steel requires handling and transportation of around 4 tonnes of bulk material, so the anticipated expansion of steel capacity, even accounting for delays, would exert tremendous pressure on Indias logistics infrastructure post the commissioning of projects. The problem would get aggravated if future capacities show regional concentration, which is likely.
Opportunities
Huge increase in steel consumption will result in the tremendous growth of the steel industry in the coming years India has all the resources and capabilities to become a global supplier of quality steel Low steel prices make imports from Russia, Ukraine and Kazakhstan attractive. The geographical proximity of Japan, South Korea and China makes them important suppliers as well. With the decreased potential for steel in developed countries, India has opportunities for becoming the world leader in the production and supply of steel and iron ore Concurrently, industries like automobiles and urban infrastructure are also growing..
Threats
Infrastructure is a major problem for the steel industry in India. Insufficient infrastructure, in terms of transportation and logistics, is becoming a growing concern for the Indian steel industry. The government is also planning to increase its share in infrastructure as part of the GDP, from 2.5% currently. Huge competition in the global markets. In the Indian market, too, with the entry of foreign players, domestic steel producers are facing tough market competition. Increasing concern for global climate change is becoming a threat to the industry. Countries are focusing on the reduction in carbon emissions, particularly with respect to energy intense industries like steel, cement, etc. The steel industry accounts for between 5%-6% of total man-ade CO2 emissions. This is less than that accounted for by transport or power use by the general public, showing the steel industry is at the frontline in fighting global warming. Future energy use and carbon emissions depend on the level of production and the technologies employed. Moreover, different economic and policy settings affect structures and efficiencies within the sector. Issues with the dumping of low priced steel products from China and other countries is also another hurdle in the growth of the Indian steel industry. Infrastructure, with respect to steel plants and logistics of the steel industry, is also one of the key challenges for the Indian steel industries.
Lack of connectivity to the ports, with sufficient rail and road networks, is also one of the causes for high transportation costs.
Proximity and access to raw materials. Infrastructure requires to be developed to transport raw materials for steel production, for achieving the production goal of 75 million tonnes of additional capacity by 2019-20. There will an additional movement of 300 million tonnes of raw material.
The efficiency of Indian ports is affected by shallow draught, low productivity, high costs, long vessel turnaround times, poor governance, and lengthy Customs delays. Shipping costs are consequently high a shipment from India to the United States can cost 20% more than it would cost from Thailand and 35% more than China.
Unlike international ports like Singapore and Rotterdam, the shortage of storage space in the major Indian ports has further compounded the problem of speedy cargo evacuation from port premises.
Customer/Processi ng Agencies/Hubs LP
LP
Road
Rail
Ports
Total raw material movement plan at 110 MTPA steel capacity will be 405MT besides the movement of 110MT of finished steel.
No rail connectivity to ports like Belikeri, Karwar, Krishnapatnam. Thus movement by trucks is inevitable.
Poor infrastructure at ports leads to high throughput time, high turnaround time for ships, slower loading rates, delays due to break-downs, thus resulting in port congestions, higher incidence of demurrage costs and high costs. Higher costs erode competitive advantage vis--vis exporters from other countries.
India is unable to derive full benefit of geographical advantage to export markets due to poor infrastructure and high costs
Future developments of railway networks related to the steel industry should be given utmost importance in the annual Railway Budget
Separate guidelines with equal participation are required from the Railways for electrification/modifications of existing sidings having large volume of traffic
Roadways - Network
Indian Roads
National Hihways State Highways Major District Roads Rural and Other Roads Total Highways Length North South Corridor East West Corridor Total Corridor Length Golden Quadilateral Length
Length (Kms)
66,790 128,000 470,000 2,650,000 3,314,790 4,000 3,300 7,300 5,846
Source: -NAHAI
Roadways - Solutions
More Expressways and Highways should be constructed More Highways should be made four- and six-lane More Road Connectivity with remote areas for goods distribution Road Maintenance should be done regularly, especially for heavy traffic roads Use of an intelligent transport system, system of green channel, and rationalization of discretionary powers is required
Conclusion
Infrastructure will be a major challenge by 2020 at 180 MTPA of steel production.
Indian ports should immediately go for capacity enhancement as well as modernization of the existing system, including the development of deep draft for accommodating the capsize /super capsize vessels. Railway infrastructure will become a bottle neck. More PPP projects to be initiated to expedite pending projects. Latest technology to be deployed and implemented. Pipeline infrastructure to be the most common mode of transportation for Iron Ore fines and concentrates. Railway infrastructure shall be developed inline with the freight corridor from mines head to major ports to avoid congestion. Infrastructure is a major challenge for the Indian steel industries . We need to form an apex body for financing the infrastructure and ogistics required for the total movement of raw material and finished steel by the year 2020.