Presentation made on the manganese ferro alloy industry in India and dwells on the opportunities for the industry and key success factors for the industry.
In June 2010, the European Commission (EC) published a report which identified 14 raw mineral materials as critical to European industry. In this paper they explore te supply risks facing producers and consumers of these technology minerals, and assess the European mining and metals sector's ability to respond to the supply chain challenge.
This lecture reviews briefly the commercially available superplastic aluminium alloys and gives their processing and service properties. General background in production engineering and material science is assumed.
Briquetting of Ferro Manganese Fines & Use in Steel MakingPRABHASH GOKARN
Ferro Manganese(FeMn) is used for alloying & refining of steel. During manufacture of FeMn fines are generated which are not useable (except in small induction furnaces). This paper describes a process for agglomeration of FeMn fines and its use in steel making.
Paper submitted for NMD 2012.
Brazil's Mining Tragedy : Lessons for the Mining IndustryPRABHASH GOKARN
The Brazilian mining tragedy was an eye-opener for the mining fraternity to introspect on the existing tailing management processes, identify gaps, complete hazard identification and risk assessments, and modify or develop safe operating procedures and emergency preparedness plans in line with the guidelines issued by Statutory Authorities from time to time. This is necessary to avert the occurrence of similar incidents in the future.
In June 2010, the European Commission (EC) published a report which identified 14 raw mineral materials as critical to European industry. In this paper they explore te supply risks facing producers and consumers of these technology minerals, and assess the European mining and metals sector's ability to respond to the supply chain challenge.
This lecture reviews briefly the commercially available superplastic aluminium alloys and gives their processing and service properties. General background in production engineering and material science is assumed.
Briquetting of Ferro Manganese Fines & Use in Steel MakingPRABHASH GOKARN
Ferro Manganese(FeMn) is used for alloying & refining of steel. During manufacture of FeMn fines are generated which are not useable (except in small induction furnaces). This paper describes a process for agglomeration of FeMn fines and its use in steel making.
Paper submitted for NMD 2012.
Brazil's Mining Tragedy : Lessons for the Mining IndustryPRABHASH GOKARN
The Brazilian mining tragedy was an eye-opener for the mining fraternity to introspect on the existing tailing management processes, identify gaps, complete hazard identification and risk assessments, and modify or develop safe operating procedures and emergency preparedness plans in line with the guidelines issued by Statutory Authorities from time to time. This is necessary to avert the occurrence of similar incidents in the future.
InterfaceIndian Ferro Alloy Industry –An Outlook
Steel Industry Snap Shot
Ferro Alloy Industry
Demand Drivers
Industry Structure
Capacity, Production, Exports & Imports
Raw Materials and Inputs
Manganese
Chrome
Power
Demand of Steel
Ferro Alloy Capacity Utilisation
Capacity Addition
Infrastructure
India’s Competitiveness
Conclusions
Ferrochrome &
Stainless Steel : Brightening
India’s future
Tata Steel Ferro Alloys & Minerals participated in India’s first international Stainless Steel fair held at Ahmedabad between Jan 16 – Jan 19, 2009.
FAMD’s stall at the fair (titled “Making Steel Stainless”) showcased Tata Steel as being among the top 6 global chrome players and the largest manganese alloy player in India.
Amongst the visitors to Tata Steel’s stall, were the steel minister, Shri Virbhadra Singh and Chairman, SAIL, Mr S K Roongta; apart from the who’s who of the Stainless Steel industry of India, and international delegates (from China, EU, Bhutan, Japan, US, UK, Bangladesh, Pakistani, Sri Lanka).
FAMD also participated in the B2B session with Stainless Steel producers and presented this paper
Presentation made at INDINOX 2010 - World's first Stainless Steel fair at the B2B Meeting & Conference.
Presentation makes a point that
- Rapid increase in Ferro chrome demand in China and India will boost Ferro Chrome production in India in a big way.
- An opportunity exists for India to grow like China did in the global Stainless Steel arena, and emerge as a big global producer, consumer and exporter of stainless steel
Permanent Magnets is Manufacturer of various permanent Magnetic products including Alnico Magnets and NdFeB Magnet.Find information about Permanent Magnets Manufacturer, NdFeB Magnet and Alnico magnets from www.pmlindia.com.
Exploratory Data Analysis Example - Credit Risk Analysis (Second Attempt)PRABHASH GOKARN
An attempt to analyze Bank Data on loans and find patterns in the data that are predictors of loan defaults. This will ensure that future loan decisions are made more logically and reduce possible defaults. The analysis has been done using Python.
Magnetic Separation of Metallics from Ferrochrome SlagPRABHASH GOKARN
At a Ferroalloy Plant producing High Carbon Ferro Chrome, the slag co-produced is granulated. The separation between slag and metal is not perfect and the granulated slag contains ~1% to 3% of entrapped ferrochrome. Apart from being a loss of valuable Ferro Chrome, local miscreants climb the unstable slag heaps to manually recover and steal the carry over Ferro Chrome granules, which is both a security and safety risk. We have successfully implemented a magnetic separation method for the recovery of metallics from the slag.
60 not out - sixty successful years of continuous ferro alloy making at jodaPRABHASH GOKARN
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The Ferro Alloy sector globally, and especially in India, is notoriously short-lived for reasons detailed in the paper. It also elaborates the reasons for the longetivity of FAP Joda.
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The plant was set up as a wholly owned subsidiary(Joda Ferro Alloy Pvt Ltd). It was the first assignment of M/s M N Dastur and completed eight months ahead of schedule. This is a booklet published by M/s MN Dastur on the occasion.
SEWAGE AND ITS TREATMENT - Experience from setting up Sewage Treatment Plants PRABHASH GOKARN
Growing population has resulted in a steep increase in demand for freshwater coupled with increased contamination from untreated wastewater. Along with steps taken to clean our polluted rivers and streams, laws for disposal of wastewater are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper discusses the major technologies for sewage treatment.
Sewage and its treatment - experience from setting up STPs PRABHASH GOKARN
Growing population has resulted in a steep increase in demand for fresh water coupled with increased contamination from untreated waste water. Along with steps taken to clean our polluted rivers and streams, laws for disposal of waste water are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper describes most of the popular technologies adopted for sewage treatment and the possible reasons for their selection.
InterfaceIndian Ferro Alloy Industry –An Outlook
Steel Industry Snap Shot
Ferro Alloy Industry
Demand Drivers
Industry Structure
Capacity, Production, Exports & Imports
Raw Materials and Inputs
Manganese
Chrome
Power
Demand of Steel
Ferro Alloy Capacity Utilisation
Capacity Addition
Infrastructure
India’s Competitiveness
Conclusions
Ferrochrome &
Stainless Steel : Brightening
India’s future
Tata Steel Ferro Alloys & Minerals participated in India’s first international Stainless Steel fair held at Ahmedabad between Jan 16 – Jan 19, 2009.
FAMD’s stall at the fair (titled “Making Steel Stainless”) showcased Tata Steel as being among the top 6 global chrome players and the largest manganese alloy player in India.
Amongst the visitors to Tata Steel’s stall, were the steel minister, Shri Virbhadra Singh and Chairman, SAIL, Mr S K Roongta; apart from the who’s who of the Stainless Steel industry of India, and international delegates (from China, EU, Bhutan, Japan, US, UK, Bangladesh, Pakistani, Sri Lanka).
FAMD also participated in the B2B session with Stainless Steel producers and presented this paper
Presentation made at INDINOX 2010 - World's first Stainless Steel fair at the B2B Meeting & Conference.
Presentation makes a point that
- Rapid increase in Ferro chrome demand in China and India will boost Ferro Chrome production in India in a big way.
- An opportunity exists for India to grow like China did in the global Stainless Steel arena, and emerge as a big global producer, consumer and exporter of stainless steel
Permanent Magnets is Manufacturer of various permanent Magnetic products including Alnico Magnets and NdFeB Magnet.Find information about Permanent Magnets Manufacturer, NdFeB Magnet and Alnico magnets from www.pmlindia.com.
Similar to Fimi Paper Manganese Alloy Industry In India Gokarn (10)
Exploratory Data Analysis Example - Credit Risk Analysis (Second Attempt)PRABHASH GOKARN
An attempt to analyze Bank Data on loans and find patterns in the data that are predictors of loan defaults. This will ensure that future loan decisions are made more logically and reduce possible defaults. The analysis has been done using Python.
Magnetic Separation of Metallics from Ferrochrome SlagPRABHASH GOKARN
At a Ferroalloy Plant producing High Carbon Ferro Chrome, the slag co-produced is granulated. The separation between slag and metal is not perfect and the granulated slag contains ~1% to 3% of entrapped ferrochrome. Apart from being a loss of valuable Ferro Chrome, local miscreants climb the unstable slag heaps to manually recover and steal the carry over Ferro Chrome granules, which is both a security and safety risk. We have successfully implemented a magnetic separation method for the recovery of metallics from the slag.
60 not out - sixty successful years of continuous ferro alloy making at jodaPRABHASH GOKARN
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The Ferro Alloy sector globally, and especially in India, is notoriously short-lived for reasons detailed in the paper. It also elaborates the reasons for the longetivity of FAP Joda.
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The plant was set up as a wholly owned subsidiary(Joda Ferro Alloy Pvt Ltd). It was the first assignment of M/s M N Dastur and completed eight months ahead of schedule. This is a booklet published by M/s MN Dastur on the occasion.
SEWAGE AND ITS TREATMENT - Experience from setting up Sewage Treatment Plants PRABHASH GOKARN
Growing population has resulted in a steep increase in demand for freshwater coupled with increased contamination from untreated wastewater. Along with steps taken to clean our polluted rivers and streams, laws for disposal of wastewater are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper discusses the major technologies for sewage treatment.
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Growing population has resulted in a steep increase in demand for fresh water coupled with increased contamination from untreated waste water. Along with steps taken to clean our polluted rivers and streams, laws for disposal of waste water are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper describes most of the popular technologies adopted for sewage treatment and the possible reasons for their selection.
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Pre-fabricated buildings (or simply, pre-fabs), are buildings that are manufactured off-site in advance, usually in standard sections that can be easily shipped, and are assembled at site. There are many advantages of Pre-Fabricated buildings which make it especially suited to Mining Locations. With the improvement in the materials used in making pre-fab buildings, the rising cost of labour, safety & quality concerns, and environmental concerns of construction waste disposal; pre-fab buildings are poised to increase in popularity. This article discusses the experience in making a pre-fabricated office building at a mining location.
Safety Challenges in the Construction of a Large Water Recovery PlantPRABHASH GOKARN
The Ferro Alloy Plant at Joda was commissioned in 1958 and is in continuous operation since. It currently produces 50,000 MTPA of HC Ferro Manganese in two Submerged Arc Furnaces.
Gas Cleaning Plant (GCP) slurry generated in wet venture scrubbers is collected in slurry pits inside the plant for drying and subsequent disposal. Because of space constraints, and in order to recycle the water used in the wet venture scrubbers, Tata Steel is upgrading its GCP slurry handling process by the installation of a GCP slurry dewatering plant.
Construction of large structures within an operating plant, without affecting operations is always a challenge. The job is even more challenging, since the plant is 58 years old, with many unmarked structures, pipes, and cables lying underneath.
This paper discusses how new and unexpected challenges are tackled during the construction of the Slurry Dewatering Plant without compromising on safe working.
Constructing on of India's largest single location Effluent Treatment PlantsPRABHASH GOKARN
Tata Steel operates one of the largest chromite mines in India at the Sukinda Valley in Odisha. The chrome ore produced is subsequently converted it to Ferro Chrome and sold to customers across the world, making Tata Steel one of the top ten Chrome players in the world. A large quantity of water, generated during mining and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent chromium oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.05 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel has set up an Effluent Treatment Plant at Sukinda with a capacity of ~108 million litres/day, the largest in the region, and possibly one of the largest single location ETPs in India. This paper discusses how the challenges faced during construction of this Effluent Treatment Plant were successfully tackled.
Presentation at the 9th WORLD AQUA CONGRESS on 26th-27th Nov 15PRABHASH GOKARN
Tata Steel operates chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, pumped out from the mining pit and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an additional state of art effluent treatment plant at Sukinda with a capacity of 108 million litres/day; one of the largest in the region; which will be completed by Sept 2015. This paper discusses how the technology for the Effluent Treatment Plant was chosen amongst various alternatives, how the capacity of the plant was decided, the challenges during construction of the said Effluent Treatment Plant that were faced, and how these were successfully tackled. The paper also describes how, because the outlet water is of a better quality than the water from the local water body, the outlet water will be used as the input to the Water Treatment Plant, aiding water consumption and lowering operating cost.
Improving Water Quality by Constructing an Effluent Treatment PlantPRABHASH GOKARN
Tata Steel operates chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, pumped out from the mining pit and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an additional state of art effluent treatment plant at Sukinda with a capacity of 108 million litres/day; one of the largest in the region; which will be completed by Sept 2015. This paper discusses how the technology for the Effluent Treatment Plant was chosen amongst various alternatives, how the capacity of the plant was decided, the challenges during construction of the said Effluent Treatment Plant that were faced, and how these were successfully tackled. The paper also describes how, because the outlet water is of a better quality than the water from the local water body, the outlet water will be used as the input to the Water Treatment Plant, aiding water consumption and lowering operating cost.
Project Management Challenges in an Effluent Treatment Plant Construction PRABHASH GOKARN
Tata Steel operates India’s largest chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, generated during mining and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an effluent plant at Sukinda with a capacity of 108 million litres/day; perhaps one of the largest in the region; which will be complete by end June 2015.
Sustainable Development in the Mining Industry - presentation at QCFI BhilaiPRABHASH GOKARN
Mining is the primary method of extraction of minerals needed by man.
The main constraint to sustainability in mining stems from the increasing pollution generated by the extraction process and the large consumption of resources (mostly energy and water) needed in refining of the minerals.
Mining operations are associated with a range of environmental and social impacts, as well as the non-renewable nature of many mined resources. Thus the sustainability of this industry and the efficient use of its resources for development remain crucial.
There is a growing realization globally of the importance of strong and effective legal and regulatory frameworks, policies and practices for the mining sector that deliver economic and social benefits.
It is possible for mining to contribute to sustainable development through:
• Enhancing the benefits while mitigating the negative impacts both when mining is taking place and subsequently as well (by scientific mine closure)
• Improving stakeholder participation in the management of the resources including local and indigenous communities
• Addressing the environmental, economic, health and social impacts and benefits of mining throughout their life cycle, including workers' health and safety.
There must be a balance between contrasting claims of sustainability for the future versus current economic benefit from mining. We must :
• Stay within the capacity of ecosystems to absorb change.
• Provide an adequate standard of living for those in the area of influence.
• Create wealth for development of society & provide for the development of advanced technology.
• Develop systems of governance which promote and sustain these goals.
Sustainable Development in the Mining Industry - presentation at QCFI Bhilai
Fimi Paper Manganese Alloy Industry In India Gokarn
1. Manganese Alloy Industry in India
- Opportunities and Challenges
Prabhash Gokarn
Tata Steel, Kolkata
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
2. Disclaimer
The presentation is an amalgamation of author’s own
views and thoughts.
Tata Steel does not necessarily subscribe to the views
and thoughts expressed in the presentation and
should not be held responsible for the same.
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
3. Presentation Outline
A. Manganese Market Flow
B. Demand Drivers
C. Manganese Alloy Industry
D. Decreasing Global Presence of China
E. Opportunity For Indian Manganese Alloy Industry
F. Key Success Factors for the Indian Manganese Alloy Industry
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
4. A. Manganese Market Flow
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
6. 2. Manganese Uses
Steelmaking
Strong sulphide former
Reduces undesirable amount of sulphur and oxygen in steel
Deoxidant
Improves the response of steel to quenching
Weak carbide former
Enhances mechanical properties of steel by increasing hardenability rate
Alloying element 90%
Carbon Construction Stainless Steel High Strength Stainless Steel Hadfield
Mn content Steel Steel (other series) Low Alloy Steel (series 200) Steel
0.5% 1.0% 1.0% 1.5% 12% 13%
Non-
Non-ferrous alloys
Deoxidant Enhances corrosion resistance of Al alloys
Alloying element Improves copper alloys castability and strength
Can replace part of the Nickel in Ni-Al alloys
Ni-
Other uses 10%
Depolarizer Used in dry-cell batteries in the manganese dioxide form
dry-
Bactericidal Used in purifying drinking water, treating waste water and odour control
Fungicidal Used for controlling crop and cereal diseases
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
7. 3. Manganese Ferro Alloys In Steel Making
Ferroalloys are produced by reducing metal
Coke
Flux
Ore
oxides with a reductant such as coke or coal,
coal,
ususlly in an Electric Arc Furnace.
Furnace
Low ash metallurgical coke is the preferred
FeMn,
FeMn, SiMn Production Process
reductant.
reductant. Electric power is used in the
smelting process and is another important
element of cost.
Crusher
Alloy casting Unit consumption per
HC FeMn SiMn
tonne of alloy
HC FeMn Ref FeMn SiMn
3.34 kg 0.93 kg 5.44 kg Energy (kWhrs)
(kWhrs) 2,600 4,200
FeMn & Refined FeMn SiMn used as a
deoxidizer & Ore1 (tonne)
tonne) 2.3 2.2
used as an alloying
additive to Carbon & Cr-
Cr- alloying additive Slag
Mn Stainless Steel to Carbon Steel Coke1 (tonne)
tonne) 0.6 0.5
High MnO Slag 1 Manganese ore of 44% Mn,
Mn,
produced in
Avg 9.71 kg of Manganese making FeMn
Alloys used per MT Steel used in making
SiMn
Source : Roskill
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
8. B. Manganese Demand Drivers
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
9. 4. Demand Driver – Steel Production (1)
Global Steel Production
Index : Peak Scaled to 100
Global Manganese Alloy Production closely related to Steel Production
In the long run, Mn alloy demand should grow higher than Steel demand
due to higher growth of “Mn intensive steels” (e.g. HSLA, 200S SS, alloy steel)
(e. 200S
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
10. 4. Demand Driver – Steel Production (2)
Apparent steel demand 2009 – 2010 in mill MT, (Y/Y % chg) Effective crude
CIS steel capacity in
-31% 8% 2008
NAFTA EU - 27
-33% 12%
-36% 17% China +19% +5%
181 137
122
145
2008 2009 e 2010 f
China
250
158 12% -5%
India +8%
677
C & S America Rest of Asia
Rest of Asia
10% -24% 14%
-24%
70
62 268
Apparent Steel Demand in 2010 : growth in all regions after slowdown
High Growth in China & India : significant Mn Alloy market opportunity
Source: WSA, SRO_Oct09
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
11. 4. Demand Driver – Steel Production (3)
India
China , at “j” curve around 2000, likely to show tapering growth (2012-15).
(2012-
India has reached the “j” curve, a will grow at double digits (2012-15).
(2012-
India & China will remain high growth markets for Mn Alloys
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
12. C. Manganese Alloy Industry
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
13. 4. Global Manganese Alloy Industry
World’s largest manganese alloys producers
Share in the
Capacity,
Company Country world
`000 mt
market
USA, Romania, Poland, Georgia,
Privat Group 2,556 20%
Ukraine, Russia
Eramet USA, France, Italy, China, Norway 1,130 9%
BHP Billiton Australia, South Africa 900 7%
Vale (CVRD) Brazil, Norway, France 620 5%
Nippon
Japan, China 483 4%
Denko
Tinfos Norway 420 3%
Highly consolidated, with 6 players controlling almost 50% of total production
Source: Metal Expert, CY 2009
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
14. 5. Indian Manganese Alloy Industry
NBFA, 77 Shyam, 70
MEL, 68
Hira, 65
Srinivasa,
62
Others,
792 Sharda,
60
Tata, 22
Highly fragmented, top 7 players contribute to just ~30% of total production.
~ 70 players in Mn alloy business : large swing capacities.
150 Furnace with size range from 4 MVA to 33 MVA
Almost 15-20% of the idle capacity unlikely to revive.
15-
Price dependent on local demand-supply but a strong correlation with world trends
demand-
Source: Metal Expert
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
15. 6. Indian Manganese Alloy Production
1,200 In ‘000 MT
995
845*
859
1,000
738
800
565
467
600
405
380
378
371
281
256
400
251
232
200
0
2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2010-10
* Global recession
HC Ferro Manganese Silico Manganese
Production of Ferro Manganese has grown @ CAGR of 10%
Production of Silico Manganese has grown @ CAGR of 17%
Around 25% -30% is exported – is there a potential to increase this ?
Source : IFAPA
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
16. D. Decreasing Chinese Presence
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
17. 7. Chinese Manganese Alloy Industry
China is the world’s largest Mn Ore producer by volume and by Mn
Content producing 35% of the world’s total production.
China has traditionally been a large exporter of Mn Alloys.
The Change In 2009 :
Mn Alloy Supply (World, without China)
China became a net importer of Mn alloys for
the first time in August 2009.
China has become a net importer of SiMn,
SiMn,
ironically, in past years SiMn was the Mn
alloy commodity that China
exported the highest volume of.
China continued to export more FeMn than it
imported, (both Ref FeMn and HC FeMn).
FeMn).
CY 2008
Source : ERAMET, Metals Expert
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
18. 7. Decreasing Competitiveness of China
Power Tariff Increases
Apart from the increased
(6.25-7.5 c/kWh)
6.25- c/kWh)
internal demand for Mn Alloys
Regional & Seasonal Increased due to the rapid increase in
Power Shortages Environmental steel production, which is
North in Winter, Decreased Costs limiting Chinese exports,
East/South in Summer Competitiveness Decreased Chinese
of China in Mn
Competitiveness has resulted
Alloys
in sharp reduction in bulk Mn
Cost Increases : Freight, Increased Proportion of alloy exports from China
Labour & Regulatory Imported Mn Ore (specially SiMn)
SiMn)
Costs
Source : ERAMET, Metals Expert
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
19. 8. Chinese Manganese Alloy Exports
China has practically retreated from the export market due to high
internal demand & decreased competitiveness in alloy making.
making.
93%
drop
This presents an opportunity for India to consolidate its
position as a Ferro Alloy exporter.
Source : ERAMET,
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
20. E. Opportunity for India
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
21. 9. Opportunity For India ?
Mn Alloy Supply (World, without China) Mn Alloy Supply (World, without China)
2008 2010
Opportunity for India to :
a) Replace China in the international Silico Manganese trade.
b) Explore market opportunities in Manganese Alloys in China.
This is apart from the opportunity presented by the steel growth in India
Source : ERAMET,
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
22. 10.
10. Advantage India
* Large Capacity for Ferro Alloys
Ability to
* Industry currently operating at 60% of rated capacity
immediately
* New capacities coming up. Capacities coming up near ports
scale up
(Vizag, Haldia).
Location near •Freight advantage in markets such as China, Korea & Japan
high growth compared to Ukraine or South Africa
regions • No seasonal effects
•Short sailing time, freight advantage
* Domestically sourced LG & MG Mn Ore available for
blending with imported HG Mn Ore. Higher indigenous ore
Cost Advantage
availability compared to Chinese producers.
over China
* Comparable power, labour & inland freight costs to
China.
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
23. F. Key Success Factors
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
24. 10.
10. Key Success Factors For Indian Ferro Alloy Industry(1)
Action Required / Changes Taking
Key Issues Description
Place
* India has limited availability of * Continue to allow free import of
Availability of Medium to Low Grade Mn Ores HG Manganese Ore
High Grade Mn * Indigenous Manganese Ore * Indian Ore, sweetened with HG
Ore grade & quantity better than Mn Ore suitable for SiMn
with China production.
* Import of low ash coking coal for
Coking Coal & Ferro Alloy & BF Coke making in
* Indian coal has high ash
LAM Coke India
* Exposure to availability &
availability & * Blending indigenous cokes with
price of LAM coke from China
cost imported LAM coke for economic
considerations
* Indian average power tariff at
* Power Sector reforms in place -
Power similar level to China.
allowing for Captive Power Plants &
Availability & * Power shortages in summer in
Power Wheeling.
Power Cost Eastern India (hub of Ferro Alloy
* Increase grid power generation.
production)
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
25. 10.
10. Key Success Factors For Indian Ferro Alloy Industry(2)
Action Required / Changes Taking
Key Issues Description
Place
* Consolidation taking place with
•Furnaces sizes start from 4MVA
significant capacity expansion by
Small capacities, * Almost 15%-20% capacity
key players.
inefficient unlikely to revive.
* Increasingly, capacities with
operations •Global furnaces moving to
Captive Power Plants, Coal and ore
higher sizes.
linkages.
* Inadequate roads, railway * Encourage FDI for rapid
Infrastructural network capacity & ports for infrastructure development; Special
Bottlenecks handling large scale ore imports Economic Zones
& ferro alloy exports * Special Freight Corridors
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
26. Can We Do It ?
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
29. Vol.42, No. 9964 THE TEX REPORT Wednesday,
Wednesday, May 12, 2010
Cost To Produce Silico-Manganese In China Moves To Rise By US$100 / Ton =
Silico-
Owing To A Rise Of 10% For Price Of Manganese Ore To Be Imported By China
In consequence of that major manganese mines have risen their price of
manganese ore for shipment to China in June of 2010 by 10% compared to that
for shipment in May, the cost to produce manganese ferro-alloys in China is
ferro-
thought to be inevitable to increase. It seems to be certain that the cost to produce
silico-
silico-manganese in China will rise by more than US$100 per ton. This increase of
the production cost is anticipated to put an actual impact on negotiations to
export Chinese silico-manganese for shipments in July - August.
silico-
The price of manganese ore for China has already risen by 4.7% for May shipment
and, by adding a further rise for June shipment, the ore price for China has risen
by more than 15% in total for shipments in the two months of May and June. The
June.
direct cost to produce silico-manganese at plants in China is presumed to total to
silico-
US$1,407 per metric ton, comprising three main factors of manganese ore as raw
ton,
material, coke as a reducing agent and electricity fee.
The price of coke in domestic market of China is CNY1,950 - 1,980 per ton, having
remained unchanged without a substantial movement.
movement.
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
30. Also, electricity fee in China has risen by 5% from November of 2009 ( having
resulted in new fee of CNY0.52 ( = 7.6 US-Cents ) per 1 KWH on average as the
CNY0 US-
whole country of China ) and, accordingly, this rise of electricity fee has put an
impact on the cost for production of silico-manganese in China.
silico- China.
Incidentally, preferential fees of electricity applied to west-south and west-north
west- west-
districts of China were abolished from the beginning of 2010 and this
abolishment has caused to increase the production cost in these districts.
districts.
While price of Chinese silico-manganese for export has risen from April, in view
silico-
of an instability of the foreign exchange caused by a crisis of the financial market
in Greece, the price of Chinese silico-manganese to import into Japan has had a
silico-
hesitation.
hesitation.
Because of high prices of raw materials, a possibility to reduce price of Chinese
silico-
silico-manganese for Japan is unlikely to arise but an atmosphere to rise price of
Chinese product for export has been not felt.felt.
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
31. The negotiations with electric furnace mills in Japan on Yen price of silico- silico-
manganese for shipments in July – September quarter will be taken place in due
course of time and, therefore, the trading companies concerned have taken an
attitude to watch carefully about further movements of the market.
market.
By taking into account of the clear factors to raise the production cost, Chinese
shippers have targeted to export silico-manganese at a high price of US$1,700
silico- US$
per metric ton CIF Japan but Indian silico-manganese is now being offered at
silico-
US$
US$1,580 - 1,630 per metric ton CIF Japan on a center of US$1,600 CIF and,
US$
accordingly, a high price of Chinese silico-manganese as mentioned above is
silico-
thought to be difficult to work on the market in Japan.
Japan.
It was informed that major manganese mines have aimed to rise price of medium
grade lumpy manganese ore (with Mn 44% ) for China to a level of US$10 per Mn
44% US$
1% CIF in the course of 2010. Therefore, there is a view in themarket that prices
2010.
of manganese ores in the second half of 2010 will still maintain a firm tone.
tone.
Mn-
Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010