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.
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
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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.
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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
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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4. A. Manganese Market Flow
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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
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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
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8. B. Manganese Demand Drivers
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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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
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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
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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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
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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12. C. Manganese Alloy Industry
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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
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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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
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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
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16. D. Decreasing Chinese Presence
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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
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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,
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
Puducherry, 13-14 May 2010
20. E. Opportunity for India
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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,
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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.
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23. F. Key Success Factors
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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)
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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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
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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26. Can We Do It ?
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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.
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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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.
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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.
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Mn-Cr Ores & Ferroalloys Buyer/Seller Interface Puducherry, 13-
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