Adversity to Opportunity: The Tata Nirman Story

Fly Ash Utilization Conference 2018, Goa28th February, 2019Presented By: Aparajita Mridha Manager, New Business DevelopmentTata Steel India

Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

Opportunity: Infrastructure Growth in India

LD Slag Application in Fly Ash Bricks and Cement Industry: Tata Nirman

Miles to Go

Content Flow

US $18.11 bnTurnover in FY 17

A GLOBALCONGLOMERATE

2ndmost geographically diversified

steel producer in the world

23.88 milliontonnes of annual crude steel production

50 Countries with commercial presence

(Source: Integrated Report and Annual Accounts 2016-17, TSL IndiaAs of March 31, 2017)

Tata Steel Group Overview

3

Enabling Raw Material Self Sufficiency

• Presence of captive mines enableun-interrupted supply of rawmaterials, and help to maintaincost competitiveness andefficiencies

• Reduction in the consumption ofiron ore, coal and fluxes and theenergy required for reducing eachtonne of hot metal is at the core oftechnological research in ironmaking

TATA STEEL VALUE CHAIN

RAWMATERIALS

IRON MAKING

STEELMANUFACTURING

DOWNSTREAM PROCESSING

MARKETING& SALES

CUSTOMERS

Ensuring Sustainability

• Tata Steel over theyears, has undertakenextensive research inmaking the process ofsteelenergy

making moreefficient,

economically viableand environmentallysustainable

Driving Profitability

• Value-added downstream products such as hot rolled, cold rolled and coated steel, rebars, wirerods,wiresprofits

tubes andmake for centres at

TataSteel

Developing Solutions

• Tata Steel has embarked ona mission to providededicated distribution networkand innovative productsolutions. Based on marketrequirements, Tata Steel hasinnovated several solutionsthat have resonated with itsgrowing customer base

Enabling Sustainability – Staying Green

4

Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks Industry: Tata Nirman

Miles to Go

No Structured Organizational Setup

Secondary Products

Industrial By-Products Management Division

Waste Management

Sales Through Auction

Value Creation &

Value Selling

Sustainable Eco-system

Tata Steel’s Journey in By-Products Management

2014

2008Emergence of Profit Centre, By-Product Sales

By-Products Commercialization, Value Enhancement through Downstream Forays

Disposal Mode

6

Industrial By-products Management Division, with its myriad products and customer segments, open up opportunity for innovation and value enrichment..

Industrial By-products Management Division (IBMD)handles all by-products across the steel value chain.

Purpose of the Business

Recover & Process metallics from Steel Slag

Recycle and reuse waste & scrap

Value enhancement of By-Products

Converting into marketable products

Moving downstream in the Value Chain

Volume Handled : ~ 13 MnTPA

Net Revenue : ~ $ 500 Million

Vision : To be recognised as one of the most Innovative &Enterprising By-Products Divisions of the World !

Approach : Recover, Recycle, Re-Use

Product PortfolioIBMD handles more than 20+ product categories spanning over 250+ SKU’s serving 1500+ Customers

4.7

2.5

4

1

0.5 0

Major Products Gen (Vol in Major Products Gen (Vol in MnTMnT))Total Gen: ~13 Total Gen: ~13 MnTMnT AnnuallyAnnually

BF Slag

LD Slag

Coal by-products

Scrap and Others

Pooled Iron

Ferroshots Coal Tar GGBS

Iron OxideZincSulphur

Some other significant products include:

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Sinter PlantBlast FurnacesLD Shops

ProductsProducts End UsageEnd Usage CustomersCustomers

Middlings Power

Tailings Brick Kilns Cokeries

Rejects Power Coa

l By-

Prod

ucts

Stee

l By-

Prod

ucts

BF Slag Cement

LD SlagVarious Applications

Pooled Iron/

MRP ScrapIngot/Billets

Steel Scrap Sec Steel Products

LD Shops

Coal Tar CTP/ Naptha/ Creosote Oil

Pellet Plant Blast Furnace

Captive Power Plant

External Internal

Captive Power Plant

LD Shops

Road making / Mine stowing

… and address a multitude of industries and segments from infrastructure to automotive

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Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks Industry: Tata Nirman

Miles to Go

1622.8

2000

95255

2015 2030

Crude Steel Production

892.54

1100

64.8184

2015 2030

Solid By-Products GenerationWORLD

INDIA

Mill

ion

Tonn

es

Solid By-Products Generation in Tons per Ton of Crude Steel

@ 0.55 across World @ ~0.72 in India

References :-1) International Journal on Solid Waste Management in Steel Industry – Challenges & Opportunities by World Academy of Science – Engineering & Technology (Pg 1); 2) Long Term Perspective – Ministry of Steel (Pg 12); 3) Annual Technical Volume of Metallurgy & Material Engg Board (Pg 30). 4)National Steel Policy 20175) Steel Demand Beyond 2030. Accenture Strategy. OECD 2017 10

World

India

Significant generation of Solid By-Products – Worldwide and in India will continue to be a challenge to deal with

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Varied type of Solid By-Products Generation in Steel Industry will require different approaches for utilisation

Slag is a by-product generated during manufacturing of pig iron and steel. It is produced by action of various fluxes upon gangue materials within the iron ore during the process of pig

iron manufacturing in blast furnace and steel manufacturing in steel melting shopBF Slag LD Slag

Application in manufacturing of Portlandcement, Glass, mineral wool insulation,

replacement of sand, etc.

Application in Steel Industry, Cement and various civil engineering application

Contains SiO2, CaO, MnO, Al2O3, S, TiO2 & Glass Contains Metallic Fe, CaO, SiO2, P, MgO, Al2O3, TiO2, &Cr2O3

3700 KT 1860 KT 1000 KT

99 % 59 % 98 %

BF Slag LD Slag(LD, HSI & LF Slag)

Other SolidBy-products

Gen

erat

ion

Util

izatio

n

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The BOTTLENECK

FY18

Adversity or Opportunity ?At Jamshedpur Works

Amongst the solid by-products LD Slag Remains the Major Concern in terms of its utilisation!

Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks and Cement Industry: Tata Nirman

Miles to Go

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Production of LD Slag in Steel Works

Metal Recovery Plant

Transport to Stockyard

Screening Plant

Dry & Wet Aging Process

QC for Weathered Slag

QC for LD slag fines

Weathered LD Slag 6-65mm

LD Slag Fines 0-6mm

In Tata Steel LD Slag Processing undergoes various screening and weathering processes to be made fit for use

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Recover Recycle Re-use

Recover Metallics from LD Slag

Recycle for In-house consumption

Developing new Markets/applications of LD

slag

Plant modificationsBenchmarking

Trials with BFs, LD shops

Maximize Utilization at Sinter Plant,De-phosphorization

Product developmentStatutory approvals

Initiatives

Enablers

LD Slag Utilization – The 3R approach in Tata Steel

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Recover Recycle Re-use

Initiatives

Nearing its Maximum Capacity Potential Lever

Recover Metallics from LD Slag

Recycle for In-house consumption

Developing new Markets/applications of LD

slag

LD Slag Utilization – The Limiting Agent and The Lever

Cement

Physical Properties• Highly angular in

shape • Rough surface texture• High bulk specific

gravity

Mechanical Properties• Good abrasion

resistance • Good soundness • High bearing strength

Chemical Properties• Alkaline• Soluble silicate

content

Potential usage of LD slag

Road

Clinker

Rail ballast

Agriculture

Hardstand

Fly ash bricks

Under Development

Commercialized

Re-Use: Favourable properties of LD Slag opens up Usage and Commercialization in different applications

Properties of LD Slag

Commercialized

Under Development

Commercialized

Under Development

Possible application areas

Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks

Miles to Go

Indian Real Estate Story : Opportunity for LD Slag in Fly Ash Bricks

Source: Union Budget FY’18, Bloomberg, Economic Times, IBEF

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Fly ash brick is composed of Filler and Binder material in varying proportion

Source: Market vists

Fly AshBricks

Filler

Fly Ash

Crusher Dust

Bad Dust

Sand

Binder

Gypsum

Lime

OPC/PSC

GGBS

Mixer Control Unit

Press ShopFinal Bricks

Fly ash bricks manufacturing process

Depletion of natural resources (sand) and expensive raw material (lime)

Tata Nirman : Branded Fine Aggregates made from LD Slag

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• Superior Quality Bricks

• Conservation of Natural Resources

• Cost Savings

• Ready Availability

• Consistent Size (0-6mm)

• Superior Quality

• Assured Delivery

• Ease of Ordering

Properties of LD Slag enables us to replace sand & lime in the brick manufacturing process….suggested Process – Fly ash (50-60 %), LD( upto 30%) and Lime & gypsum/cement (upto 10 %)

Stronger bricks

Lower production cost

Zero environmental impact

Water sprinkling on Tata Nirman for 10 days

SandTata Nirman

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Summary of Results obtained on testing of brick samples made using LD slag

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We tested different raw-mix compositions viz-a-viz a refence brick of the manufacturer

The optimum compressive strength was attained with a combination of 30% LD slag

30 % slag and 6% binder gave the best results in terms of water absorption

LD +

Lim

e +

gyps

umLD

+ C

emen

t

Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

Opportunity: Infrastructure Growth in India

Miles to Go

25

In view of its various initiatives to improve LD Slag Utilization, TSL plans to achieve ~ 100%

Utilization by FY20 which is substantially above other steel players in India.

2644 43

53 59

98 100

FY14 FY15 FY16 FY17 FY 18FY 19 EFY22 E

% Utilization for LD Slag by Tata Steel (at Jamshedpur Plant)

LD Slag utilization for major steel producing companies across world ranges from 53%

to 72%.Source: survey by LD Slag Association.

Average LD Slag Utilization in India ranges from 15% to 35%

Various initiatives has enabled Tata Steel to utilize LD Slag upto 98%...however we have Miles to Go!

As on date, ~ 1 Billion Tonnes of Solid By-products is generated worldwide which is expected to rise substantially in view of the increasing Steel Production.

It is very important to find suitable ways to utilize this by aligning ourPolicy Frame Work, Funds, Infrastructure, Technology and R&D with Sustainability

240 KT of Tata Nirman sold is one of the initiatives that has helped us achieve 98% Utilization in FY 19

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Tata Steel Launched India’s First Branded LD Slag Product for fly-ash bricks and Clinker making

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In Pictures

Our LD slag Puja EF Bricks Purulia RK Gupta Jamshedpur

Customer meet FY 18 Customer meet FY 19 Gandhari and Sons Ranchi

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Questions Please

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Back Up Pages

Source:CRRI: Central Road Research Institute of India

Properties TestedTest Results

MoRTH SpecificationsSteel Slag Aggregate Natural Aggregate

Aggregate Impact Value 11.75% 15.64% Max 27 %

Los Angles Abrasion Value 11.26% 15.23% Max 30%

Water Absorption Value 1.08% 0.80% Max 2%

Specific Gravity 3.25 2.75 -

Combined(EI + FI) Index 8.09% 24.2% Max 30%

Stripping 99% 98.5% Minimum retained coating 95%

Our Steel Slag Test Results by CRRI:

Comparison of TSL’s Processed LD Slag with Natural Aggregates

Steel Slag found suitable for replacement of natural aggregates

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Tata Aggreto : Branded Road Aggregates made from LD Slag

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Tata Nirman : Branded Fine Aggregates made from LD Slag

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