MINEX Metallurgical Co. Ltd.

“Market Survey of Minex Range of Treatment Alloys in Steel Sector in India,

till 2017, Analyzing the value creating platform in this sector and strategy to be

followed. ”

You are what your deep, driving desire is.

As your desire is, so is your will.As your will is, so is your deed.

As your deed is, so is your destiny.

Presence of Minex in Steel Industry

Raw Material

Processes = Hot Metal

SMS = Crude Steel

Continuous Casting and

Finished Goods

Minex Treatment

Alloys

Metallurgical Process Involved

Understanding of Metallurgical Processes

Integrated Steel Plant • Blast Furnace Basic

Oxygen Furnace Ladle Treatment Continuous Casting Rolling Flat or Long Products

• Through BOF, broad steel specifications can be achieved.

• Secondary Steel Refining is done through Ladle Treatment and Various other furnaces like Degassers and Decarburizes.

Mini Steel Plants• Electric Arc Furnace

Ladle Treatment Continuous Casting Rolling Mostly Long Products

• EAF is basically a metal melting furnace, with no substantial refining required.

• Crude Steel obtained from EAF is used for producing special steels.

Effect of Impurity Elements

• S : Segregates during solidification; Hot shortness due to formation of FeS during solidification; Sulphide inclusions lower weldability and corrosion resistance; Development of tears and cracks while reheating.

• P : Segregates during solidification; impairs plastic properties.

• Si and Mn : Si reduces drawing capacity of steel. Mn increases strength without affecting ductility and reduces hot shortness.

• Gases : N impairs plastic properties; Increases embrittlement at lower temperatures. H causes defects such as flakes, fish-scale fracture. Excess O2 causes formation of blowholes and oxide inclusions.

• Inclusions : Inclusions present at grain boundaries weakens intra-granular bonds; Stress Concentrators.

• Tramp Elements : (Cu, Zn, Sb etc.) Create problem during reheating of steels as their melting points are much lower than that of steel reheat temperature.

Note: Whether Carbon or Alloyed ones, all steels contain impurities and these impurities are to be controlled during Steel-making.

Secondary Steel Refining

• Important for Continuous Casting which requires stringent Quality Control.

• Harmful Impurities in Steel: S,P,O,N & H. • O and S forms inclusion. • Treatment of liquid steel is done in special

units, LF (ladle furnace), VAD (Vacuum Arc Degasser), CAS-OB unit etc.

.

• LF (Ladle Furnace) Deoxidation and Composition Adjustments Temperature Adjustments by Arc Heating (graphite electrodes) Bath Stirring by Argon purging from bottom/top lancing For improved utilization of Aluminum, it’s wires are used• CAS-OB (Composition Adjustment by Sealed Ar Bubbling) Temperature can be raised by exothermic heat supplied by

aluminum oxidation. Dissolution is faster because of high turbulence and stirring

• VD: Vacuum Degassing • VOD: Vacuum-Oxygen

Decarburization • IGP: Inert Gas Purging • IM: Injection Metallurgy • AOD: Argon-Oxygen

Decarburization

• Degassing• Decarburization • Desulphurization• Reheating • Alloying Additions

• Inert Gas (Ar) Degassing Stirring = Homogenization of Temperature and Composition Faster Oxidation and Floatation of Inclusions• Deoxidation Addition of strong oxide formers (Mn, Si, Al, Ca as

ferromanganese, ferrosilicon, silico-manganese, aluminum, calcium silicide) in the ladle.

Ca > Al > Si > Mn (Decreasing strength of deoxidizers)• Decarburization Carbon content below 20ppm• Desulphurization Levels below 0.01% required during secondary steelmaking It is done by addition of a synthetic slag. Deep desulphurization

can be done by the injection of powders like Calcium Silicide. • Vacuum-oxygen Decarburization Developed for stainless steel refining Used for the production of ultra-low carbon steels (RH-OB also

used)

• Vacuum Degassing Desulphurization Heating Alloying Melt Homogenization Ar Injection – good homogenization, fast processing, inclusion

removal• RH Degasser (Melt Circulation)• Vacuum Arc Degassing Heating done by the arc with graphite electrodes. Heating, degassing, slag treatment and alloy adjustments are

done without interrupting the vacuum. • Argon-oxygen Decarburization Dilution of Oxygen with Argon lowers the partial pressure of CO,

which helps in preferential removal of CO without oxidizing Chromium Bath.

C content less than 0.03% required in all SS grades

Primary Steelmaking BOF/EAF

Ladle Treatment

Vacuum Degassing Ladle Furnace

Ladle Holding

Tundish

Continuous Casting

Argon Stirring+ of Al wire feedings

• Additions• Ar Purging• Arc Heating

• Additions• Arc/Chemical

Heating• Ar Injection

Ca Treatment

Alloying Elements and their Effect

Elements EffectsAluminum Deoxidizer, Grain refiner and occasionally alloying

agent in steel Boron Increases hardenability Carbon Increases hardenability and strength Chromium Increases corrosion and wear resistance , Also mild

hardening agent, Oxidation resistance Lead Increases machinability Manganese Counteracts bitterness of Sulphur, Acts as

deoxidizer, combines with Sulphur – improves hot-working properties

Molybdenum Deep hardening, Raises creep strength and hot hardness, Enhances corrosion resistance and increases wear resistance

Nickel Increases strength and toughness

Phosphorous Increases Strength and Machinability and atmospheric Corrosion Resistance

Silicon Deoxidizer, Helps electrical and magnetic properties, improves hardness and oxidation resistance

Sulphur Increases machinability but damages hot-forming characteristics

Titanium Forms carbides, Reduces hardness in stainless steelTungsten Increases wear resistance and raises hot strength

and hot hardnessVanadium Increases hardenability

Calcium (CaSi) Potent deoxidizer and desulphurizer, Controls the shape, size and distribution of oxide and sulphide inclusions

Steel Industry : Parameters, Growth and Prospects

Steel Industry : Some facts

• India stands fifth in the world with the production of 66.80 million tons of crude steel.

• Per capita consumption of steel in India is 49 kg against the world average of 182 kg.

• India aspires to produce 276 million tonne of steel and become the second largest producer of steel by 2015-2016.

• The steel demand drivers in India are manufacturing, construction and auto sector.

• % Production share of secondary steel producers has increased.

• % share of Alloy Steel Production has increased.

• 38 EAFs with the installed capacity of 18.04mtpa.

• 1114 units of Induction furnaces with capacity of 24.40mtpa.

• Observed and Expected CAGR is around 8%.

General Strategies

Business Tools • Acquisition of natural resources• Technology buying and process

innovation• Production of new and improved

grades of steel • Equipment Modification and Plant

Expansion • Mergers and Acquisitions

Technology Innovations • Low Ash Cokes• Futuristic Technology for alternate

reductants like Hydrogen• Process Simulators

Production & Capacity

Producers Capacity Main Producers 28.9mtpaMajor Producers 26.6mtpaOther Producers 25mtpa

Process CapacityBOF 38.06mtpaEAF 18.04mtpaIF 24.40mtpa

Plant Size- wise

Process-wise

Main Producers Installed Capacity SAIL 15.81mtpaTata Steel 6.8mtpaVIZAG Steel 6.3mtpa

Major producers Installed CapacityEssar Steel Limited 8.6mtpaJSPL 3mtpaJSW 10mtpaIspat Industries Ltd. 3mtpaBhushan Power & Steel Ltd. 2mtpaBhushan Steel Ltd. -

Other Producers 25mtpa

Other Producers

• Producers with less than 0.5mtpa installed capacity

• Production units are widely distributed

• Stainless and Special Steel Producers majorly come in this category

• Their share of production and products are not mapped properly.

Categorization of Steel Products

Steel

CompositionForm/Shape/Size

End Use

Semi-finished : Ingots/blooms/Billets/Slabs/Thin Slabs

Finished : Long and Flat products

Non-Alloyed Steel: Mild(<0.3%), Medium(0.3-0.6%) and High(>0.6%) C Steel Alloyed Steel : Stainless Steel, Silicon-Electrical Steel and High Speed Steel

Structural SteelConstruction SteelDeep Drawing Steel Forging QualityRail Steel

New and Improved Grades of Steel

Construction Manufacturing AutoFire resistant Steel Dual phase SteelVibration Damping Sheets

TRIP Steel

Weather resistant Steels

AHSS Grade

Special type of wide flanged beams

Nano Steel

Seismic resistant Ultra fine grain Steel

New Grades of Steel : Examples Quenched Tempered Plate for Gun Carriage DMR 249 Grade “B” Q&T for Aircraft Carrier Roof / rock bolt Fe 600 TMT Rebars for Mines and Tunnel

Thin Gauge High Strength HR Coil for high strength LPG Customized CR products for electrolytic precipitator Nitrovan Steel Plates for ATM Chest Cr – V 110 UTA Rails for high speed rails API X 80 / 100 Grade HR Coil and Pipes for Oil & Gas Sector CRGO Silicon Steel for Electric Transformers

VARIOUS SHAPES Wide Flange & Parallel Flange Sections Cold Formed Structural Sections Hollow Structural Tubes High Tensile Wire Ropes

Growth Parameters of Steel Industry

• Production • Product Range and Quality • Raw Material Improvement and its’

Cost • Business Tools and Market Demand • Global Scenario and Industrial Policy

Prospects of the Industry

• Increase in Production Capacity • Business and Technology Innovation• Product Up gradation and Quality

Improvement • Cost Reduction • Reducing Raw Material Requirement

and Improving it’s Quality

Process Feasibility Factors

• Cost of Installation and Operation • Production Capacity and Quality • Energy Requirements • Environmental and labor

Legislations • Sustainability and Compatibility with

other units• Raw Material Requirement

Minex Metallurgical Co. Ltd.

Factors affecting Minex

• Processes Adopted• Production Capacity• Product Quality • Product Specifications

Modifications and Expansions

Market Demand and Cost Improvement

Minex and Steel Industry

• Proportionate rise in demand of Minex products as steel industry grows.

• Capacity expansion, simultaneously with customer and market identification.

• Product innovation is needed to cater to the new and improved grades of steel.

• Process innovation in steel plants necessitates the product up gradation.

• Tata Steel is coming up with a new Thin Slab Caster which would increase their requirement of Calcium.

• By modifying existing on-line purging system at RSP, the consumption of deoxidizers (Al and Si-Mn) is observed to be decreased by 14% and 23%.

Categorization of Minex Products for Steel Industry

• Broadly: Alloying Products and Refining Products

Alloying Products: Micro Alloys and Alloying Elements

Refining Products: Deoxidizers/Desulphurizers /Inclusion Modifiers

• Minex Cored Wire, a type of product in the above categories

Product Analysis

• Ferro Chrome Cr – 50-70 % Steel Industry : Largest Consumer; Stainless Steel (10-20% Cr) Chrome below 56% = Charge Chrome, produced from an ore with

lower chrome content HC Ferro-Chrome Produced from higher grade ore Used in Engineering Steel with high Cr to Fe ratio and minimum

levels of other elements such as S, P and Ti LC Ferro Chrome Used during steel production to correct chrome % without causing

undesirable variations in C and trace element percentages Low cost alternative to metallic chrome for uses in super alloys

and other special melting applications

• Ferro Manganese Desulphurizing agent and a Deoxidizer Make the slag more fluid; Component of the alloy All steels contain Mn : 0.05-2%, reaching to 12% in some cases

• Ferro Niobium World’s largest deposit of Niobium is in Brazil Mineral : Pyrochlore. Processed: Output is Ferro-Niobium with

65% niobium oxide. End Uses: Carbon Steel(30%); HSLA(22%); Alloy Steel(14%);

Stainless and Heat resisting steel(13%) Effects Impacts doubling strength and toughness Weight reduction due to grain refining in carbon and HSLA steel First use in carbon pipelines, construction and automobiles Added to stainless steel to stop embrittlement after welding

• Ferro Silico Manganese Deoxidizer and alloying element Standard grade : 14-16% Si; 65-68% Mn and 2% C Special grade : Si up to 30%, used in manufacture of stainless

steel Deoxidation with SiMn results in cleaner steel Liquid Manganese Silicate formed coagulates and separates

easier from the melt Adds less P, C and N to steel

• Ferro Silicon Remove oxygen from steel and alloying element Basis for manufacture of pre-alloys like Magnesium Ferro Silicon Special grades (low Al, high purity and low C) Used in production special steels Keep both the content of inclusions and C content into the final

steels at very low level

• Ferro Titanium Titanium content 70% Low residual, low melting point titanium alloy Cleansing Agent Highly reactive with S, C, O and N, forming insoluble compounds

and sequestering them in slag Grain Refiner Promotes grain structure with steel matrix Improves malleability of carbon steel thereby increasing its’

versatility

• Nickel High melting point, high resistance to corrosion and oxidation,

excellent heat resistant properties and a good alloying ability with many other metals

Applications : Aerospace, military construction and consumer products

Stainless steel production consumes around 65% of the Nickel produced.

Forecast for Minex Products Product Steel

Production %Steel Treated Consumption

per year CaSi/CaFe (0.5/0.35 kg/t) = Ca(0.15kg/t)

80.5mtpa 30% = 24.15mtpa

3622.5 tons (2011-2012)

124mtpa 30% = 37.2mtpa

5580 tons (2015-2016)

276mtpa 30% = 82.8 12420 tons (2015-2016)

Aluminum wires (0.4kg/t)

80.5mtpa 100% 32200 tons (2011-2012)

124mtpa 100% 49600 tons (2015-2016)

276mtpa 100% 110400 tons (2015-2016)

Strategy Ahead

• Almost all major players are customers of Minex but with increasing share of secondary producers in production, some strategy is required to cover the small-scale and low-end producers.

• There is a growth in share of alloy steel production due to development of new and improved grades of steel. Minex should come up with some solution for such producers.

• Even major producers are not completely relying on Minex products because of the availability of product in domestic market and low-cost imports. This necessitates the technology improvement in production.

• Market Intelligence should certainly be increased with adopting better policies to reach the market.

• Technological roadmapping and a mechanism for periodic surveying of new markets and technology should be done

Peer Review: Products, Technology and Market Strategies • There seems no big competitor for Minex in it’s

range of products but other sellers are existing and their mapping is essential.

• Certain parameters like technology being used outside India, cost determination, market strategies and product range can be salient.

• Online and Physical marketing can be one of the factor in terms of reaching the markets.