Tuesday, 22 March 2016

Recycling of Steel


Steel like most other metals is recyclable. From time immemorial people have recycled Steel. In a world that is becoming increasingly  aware to environment protection; recycling of steel saves the entire range of raw materials that goes into production of steel; like 1.5 tons of iron ore, 0.6 tonnes of coal, 0.5 ton of lime stones and 250 liters of oil to name a few. This apart it also saves CO2 emission.
At this time, when steel prices are going through squeezing margins, scrap prices that influence the steel markets is an important factor to be consider.  Scrap represents 70% of production costs in steel manufactured through EAF (Electric Arc Furnace) route. This process is used to manufacture 26% of global steel output. Even in the normal blast furnace based production process, scrap constitutes as an important additive. 60% of USA production is based on scrap. USA is a major exporter of scrap while Turkey is a major importer of scrap with approximately 20 million tonnes. HMS #1 & 2 are the grades of scrap that is frequently traded and is appropriate for steel production. Its specification is defined by Institute of Steel Recycling Industries. (ISRI)
During a recent conference on metal recycling in India, Steel Secretary announced the Governments resolve to frame a policy on metal recycling. It was announced that there would be a set of policies on end-of-life-cycle of commodities and a new institutional mechanism framed as per the industry's requirements, the best that will suit the country's requirements.

While steel makers are livid with the havoc caused by Chinese exporters, India remains a bright spot, where the consumption is expected to grow at 7-8% yoy, for several years to come! Looking in this context recycled steel holds lot of promise.  Many everyday products, such as cars, cans and washing machines, refrigerators are made of steel. Once these products reach the end of their useful lives, the steel is recycled. Recycling reduces the consumption of raw materials and energy and is therefore is good for the environment. With recycling supplies will remain abundant for generations to come. Recycling reduces waste and produces alternate economics and employment potential. With global recovery rate of more than 70% steel is the most recycled material in the world. What is a railway wagon or container today can be a surgical blade tomorrow!

This also leads to one envisioning a future ready infrastructure which is completely focused on steel with minimal use of concrete, cement, tar and other materials which are non-recyclable. Already, in USA and other developed markets one will see that the ratio of steel to cement has increased as builders have started to use fabricated steel beams and reduced cement usage. This is not only a sustainable practice but also, increases the saleable square feet area. Indeed a perfect example of socially economical business! This is what the world needs to focus on.

Wednesday, 13 January 2016

MAKING OF STEEL



Steel is the most used metal today, because of its high quality and features such as durability, high strength, corrosion resistance, long lifespan, cost effectiveness and high efficiency. From small scale to large scale production all use steel of different grades in various quantities. Almost, 50% of the world steel production goes into construction. This means we are surrounded by steel. Most of our daily use products such as kitchen ware to transport to machinery everything is made up of steel. Steel has become such an indispensable metal that we just can’t imagine our life without steel. Steel has become synonymous to growth and development.

Yet, have we ever wondered how steel is made? Which processes produces steel with effective features and qualities.

1 . Extraction of Iron Ore
Steel is the most refined metal that is made from iron ore. Iron when mined from the earth is in its raw form. It is heated to remove the impurities to get purified iron ore extract. This process of getting pure iron is known as smelting. Once the impurities are removed, it forms into a stronger metal ready to be used, which can then be formed into steel.

2. Making of Steel

The steel can be obtained, mainly through two processes: Blast furnace/Oxygen furnace and/or Electric arc furnace (EAF)

Blast Furnace/Oxygen Furnace
This process basically uses iron ore, limestone, coke and scrap as its basic raw materials.
Iron ore and coke added to the blast furnace are heated to make pig iron. This pig iron is poured into torpedo car and then unloaded into a ladle. Here the chemical compositions are made suitable for the kind of steel in requirement.

Then, sulfur levels are reduced as it makes the steel brittle and impacts the final strength of the steel. Further, the pig iron is mixed with a lance of oxygen to reduce the carbon content. It is at this point scrap steel is added to the liquid. This results in production of steel which is very close to the chemical qualities of the final grade required. Majority of the steel produced in the world uses oxygen furnace method due to its reliability on the quality of steel produced.

Electric Arc Furnace
This method mainly uses scrap as its raw material. Scrap steel is put into electric arc to re-melt. Fluxes are added to it to get the desired end product of steel. Thus this method is short, easier and faster for making steel. This uses furnaces of around 100 tonnes capacity which can produce steel within 40 to 50 minutes. 

The gases emitted in making of steel by these processes can further be used for generating electricity through the use of reciprocating gas engines.

3. Continuous Casting
After the desired composition of liquid steel is obtained, it is poured into three different huge casters to produce various thickness and form of steel.
One caster creates steel slabs, which are used to produce steel plates and used in hot strip mills and cold roll mills to produce hot rolled coils and cold rolled coils respectively through steel rolling process.
Along with it, steel is poured in continuous billets casters to create billets, through which wire rods and steel wires are produced in wire mills.
Other than this is the bloom caster, which forms thick blooms which are used for making structural shapes and rails (railway tracks).

4. Making Of Plate

The first step includes removing of oxide coating. This requires heating a slab up to 12000C to obtain a top quality steel plate. These slabs are passed continuously through rolling stands to reduce the thickness of the slab to get the suitable thickness for the plates. It is easier to make thin plates compared to thick plates as only the thickness of the slab has to be reduced to an appropriate level.

5. Quality Testing & Delivery
Quality test such as leveling which checks the evenness off the plates, heat treatment, cooling for tempering, and a range of certifications and testings are carried out to match quality standards. After quality check and stamping the steel is cut into various size as per demand and then delivered to the customer.

V.K Industries being a major steel supplier in the market, prefers to deal in the best quality steel at best prices. By leveraging its 30 years of experience in the industry, it imports high quality steel from the best and renowned mills from all over the world. It is known for efficiently delivering any amount of quantity of steel material in short duration. It specializes in wire rods, steel plates and coils.
Feel free to send in your queries or send us your purchasing inquiries here. We would be glad to serve you.

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Monday, 7 December 2015

INDIAN STEEL SECTOR OUTLOOK 2015




Steel Industry is more than 125 years old. The 110 million ton a year Industry in India is poised to grow to 300 million ton by 2025. That is around 10-11% growth..! Despite short term dip in demand following global price slip that pushed prices down to 47% following Chinese recession; the industry is going through a consolidation phase. Indian GDP is expected to grow between 7 to 9 percent over the next decade, a fact that has been accepted by most analysts. Growth in infrastructure, real estate, and automobile sectors is likely to increase the demand for steel in India.

Rural India: Hub for Steel Demand
The rural demand is currently estimated at 9 to 11 kgs per capita. This is estimated to grow to 20 to 23 kgs in next decade as per JPC rural market study based on alternate economic growth scenarios. The rural demand can be improved by improving logistics and supply chain. There is a requirement of quality pucca houses, community centers, health clinics and other infrastructure. Today, Kerala has the highest level of rural demand at 18.6 kg per capita. Smaller lots sizes and small finished steel producers can spike rural demands. Increasing consumption of white good, automobiles and infrastructure in rural areas too may spur rural demand for steel.
Steel Demand by Product Mix
It is important to know the pattern of market demand by products as production of flat products take a different equipment route in the manufacturing process than the long products. Economics of scale and logistics of production and shipment of flat products are different from long products. It is observed that as the economy matures and steel consumption improves share of total consumption in flat products rises.

Product wise share of steel demand forecast
(as percentage of total consumption of finished carbon/mildsteel)





Year/Category
2010-11
2016-17
2020-21
2025-26





Bars and Rods
39.3
39.9
40.2
40.2
Structural
9.0
7.6
6.8
5.8
Raillway.Materials
1.8
1.3
1.0
0.8
Total Long Products
50.1
48.8
47.9
46.8
Plates
7.7
7.0
6.5
5.9
HR Coils/Skelp/Sheet
21.0
20.9
20.7
20.4
(Excluding double accounting)




CR Coils/Sheet
9.7
11.4
12.7
14.5
(Excluding double accounting)




GP/GC Sheets
7.6
7.8
7.9
7.9
Electrical Sheets
0.8
0.8
0.8
0.8
Tin Plate/TFS
0.6
0.7
0.7
0.7
Pipes
2.5
2.7
2.8
3.0
Total Flat Products
49.9
51.2
52.1
53.2


This articles looks to explore the long term and strategic issues which the steel industry is likely to confront. There are positive factors to support the view that if the economy continues to grow and the GDP chalks the achievable target rate of 7 to 9% YoY; the steel consumption is likely to touch the levels of 300 million tonnes by 2025-26.


-Mr. Balasubramanium Ramachandran

Monday, 21 September 2015

Is the Safeguard Duty on Steel Imports Really that Safe?



Today in India, to boost and encourage the domestic manufacturing sector and achieve the “Make in India” dream, the Indian government provides the domestic sector with constant support through numerous and various grants, subsidies, and duties. The primary motive of implementing these policies is to demotivate imports and boost exports, generate inflows of foreign currency, reduce unemployment and in turn improve and grow the Indian economy. A very apt example of this is the Steel Industry of India!

Today the government of India has already provided too many incentives to the domestic steel manufacturers in terms of heavy subsidies and grants, huge financial loans at low interest rate to compete globally, reduced competition by restricting cheap imports through imposition of heavy duties and quality standards, and by increasing demand by making the use of steel compulsory in many huge projects. Additionally, recently the government also announced a steep increase in the custom duty for selected steel products to 12.5% from 10% to curb the inflows of cheap imports and prevent the prices of steel from falling in the domestic market.

All these factors have resulted in the domestic steel manufacturing companies dominating the market by capturing 90% market share of total steel consumption in India. Whereas; the market share of imported steel is restricted to 10% of the total consumption of steel in India. The imported steel exists to satisfy the unmet needs in the steel industry, avoid unfavorable price appreciation and increase efficiency of domestic firms by exposing them to global competition.

Nevertheless, the increase in volume of cheap steel imports in the FY 2014-2015 attracted too much attention and was termed by many as harmful and disastrous. This even resulted in government increasing the custom duty for selected steel products to 12.5% from 10%. However, no one investigated the reason for this steep fall in steel prices globally or reviewed if these increased imports had any effect on the market share of domestic firms!

Coal and iron ore, two of the most important raw materials required for the production of steel, have become extremely cheap over the last year. Prices of iron ore fell from USD 140 pmt to USD 40 pmt over the past one year; almost 70% dip. Also, the prices of coal decreased to USD 47 pmt from USD 62 pmt, decrease by 25%. Due to the steep decrease in the cost of raw materials the steel imports became cheaper; the prices did not fall due to global mills dumping their while incurring losses. Thus, if global mills are able to reduce their prices then so should the domestic mills without complaining about any injuries in terms of profit loss or sales loss, as both the parties use the same priced coal and iron ore. In addition, if statistics are reviewed, it can be proved that the huge inflow of cheap steel has not taken any market share away from the domestic steel mills; instead it has only helped in satisfying the increased demand for steel as the capacity of domestic mills is limited.

Another very important point that needs to be brought to light is that there has not been even a slight effect on the export volumes of domestic mill in the last year, irrespective of decreased prices. On the contrary, they have always exported steel at lower prices compared to price of steel in domestic market. This proves that domestic mills are able to supply steel globally while competing with other cheap steel exports and maintain profits; however they are unable to supply the same steel in Indian market at the same global prices! Why should only the Indian consumers of steel face the brunt of high raw materials cost, while all global consumers are able to consume low cost steel?

Thus, the imposition of safeguard duty will only create demarcation as the government is favoring three-four domestic steel firms over the whole Indian economy. This will only be a gateway to ever increasing problems for the government and citizen of India as the long-term effects of the same are outlined below:

1. Today India's economy is said to be growing at the fastest rate in the world. This is only possible due to our efficiency in terms of competitive pricing and before time delivery. By curbing imports the government will only be hampering this whole growth cycle. Small engineering and consumers firms will not be able to compete globally due to their high raw materials cost compared to other countries. This will lead to industries shutting down or moving to other countries thus, resulting to unemployment and job losses. This will only have a direct negative impact on the growth of the Indian economy.

2. Domestic mills should continuously work towards becoming more efficient and globally competitive. Nevertheless, the imposition of duties will result in increased dependency of domestic mills on government for duties and grants!

3. Importers, who are also Indian citizens and have employees working under them and are paying huge taxes, will suffer heavy losses and some may not even be able to recover from this burden of loss. This means the government is ready to throw other businesses under the bus while fending for three to four firms.

4. Lastly, limiting imports from other countries wrongly, will only lead to retaliation by other countries in terms of increased duties on Indian exports. This will only cause more loss for the Indian economy as a whole.

Lastly, today India is at threshold of building its infrastructure, and it shall consume far more volumes of steel that what the Indian companies are geared to produce. And, if there are very less low priced imports available, it will only dampen the growth targets the government and Niti Aayog have set for the country. Typically, in a growing economy like India, steel consumption growth should be 2 percentage points above the GDP growth and considering that we shall grow the consumption to 9% and soon achieve double digit consumption, we will need the support of imports. In addition, India is very advantageously placed today to take advantage of fall in base metal and steel prices. Rather than decrease the supply of imports the government should take up this opportunity to build the same infrastructure at much lower cost. This will not only solve the problem of domestic mills as their sales volume will increase but will also not hamper the effective
imports.

Thus, instead of emanating a negative cycle of economic growth, the government should reconsider their preposterous decision of imposing duty on imports and wisely strategize to undertake measures, taking into consideration all the stakeholders and not only three to four firms of the country. For this, the government shall impart trust and confidence in the Indian manufacturers and discourage the concept of grants, subsidies only to elevate the stature of domestic mills in the market. Most importantly, the government should not jump to critical circumstances so soon and like other countries (e.g. USA), it should provide a 90 days window for material in transit as otherwise; importers will get buried under the burden of heavy losses.

-Kairavi Mehta,
 Director