Direct Reduction Modules Performance in Qatar Steel

Transcription

1 We Make Steel Matter Direct Reduction Modules Performance in Qatar Steel Ali Saleh Al-Marri Manager Direct Reduction Department Durgesh R. Gupta Assistant Manager Direct Reduction Department

2 Qatar Steel: Geographical Location Mesaieed City 45 kilometers south of Qatar s capital city, Doha 2

3 Qatar Steel is one of the four entities of IQ with Several Strategic Investments and Alliances Industries Qatar 75% 80% 50% 100% QAFCO 25% Yara Netherlands QAPCO 20% Total Petrochemicals QAFAC 20% OPIC Middle East 15% LCY Middle East C 15% International Octane Qatar Steel 1 Key QS Products DRI (Sponge Iron) HBI (Hot Briquetted Iron) Steel Billets Deformed bars Wire rod and rebar in coils 100% 50% 31% 25% Qatar Steel FZE Q-Coat South Steel GUC (Foulath) 8% 50% Sphere Investments Qatar Steel International 3

4 Qatar Steel Company An Introduction 1974 Established in Industries Qatar Acquired QS FZE from Steel Makers Fully-owned by Industries Qatar (IQ) First integrated steel plant in GCC as a joint venture between KOBE Steel, Tokyo Boeki and the Government of Qatar Became fully owned by Government of Qatar in 1997 Qatar Steel has two operating units - integrated facility in Qatar and Rerolling facility in UAE Employing around 2000 people from 12 different nationalities Revenue Expansions & Investments Several investments in the steel & non steel business Increased capacities of DR, SMS and RM Company developed its new brand identity in 2007; QASCO became Qatar Steel. Recorded revenue of QAR 6.2 billion in 2012 with significant economic contribution to IQ which recorded revenue of QR 18.7 billion in the same year New SMS EF5 Commissioning planned in H

5 Development of Qatar Steel Production Facilities in Last 30 Years 1978 : Start-up with one Midrex module (400,000 t/y) : Two 80t EAF s (50 MVA each) and two straight mould billet casters (150mm square) (Kobe Steel)- Re-bar Mill : Commissioning of SMS-Demag, 80t EAF and Mitsubishi billet caster (EF3) : Commissioning of LF for EF3-line (Danieli) : Commissioning of ultra modern Rolling mill from Siemens VAI - Pomini, Italy : Commissioning of 4 th 80t EAF2R, LF2R and CC2R (Danieli) :Commissioning of 2 nd Midrex Mega Mod Combo module (1,500,000 t/y) 2013 : Commissioning of SMS EF5 Planned in H

6 Qatar Steel Production Flow DR Iron Ore Pellets HBI Product for Sale DRI EAF RM Re-bars Billets CC LF Product for Sale 6

7 Qatar Steel: Product Portfolio Product Primary Use Markets Feedstock for steel making plant. HBI Production is exported Feedstock for Rebar production 7

8 Qatar Steel: Product Portfolio Product Primary Use Markets 8

9 Organization with many certifications, accreditations and awards Qatar Steel has been recognized by many accreditations, certification and awards from quality, environment, HESQ and continuous improvement in line with the aspirations to become the standard for quality enterprise and to exude a winning attitude in order to make a difference in their environment. Management System Product Certification Certificate Number ISO Certificate Number

10 First Qatari Company and Steel Producer in the Region to be Inducted into Palladium s HoF for Strategy Execution The Hall of Fame is an annual award which honors those organizations that have achieved an Execution Premium extraordinary performance results through the use of the Kaplan-Norton Balanced Scorecard, the world s preeminent strategy management framework. Winners are inducted at the annual Palladium summit organized around the world, announced in Harvard Business Review, and profiled as exemplars of good management. 10

11 tons DRI Production ( ) 2,423,449 T 2,400,000 2,100,000 Recession 1,800,000 1,500,000 2 nd DRI-Plant 1,200, , ,000 1 st DRI-Plant 300, Year 11

12 tons Steel Making Production ( ) 2,400,000 2, T 2,100,000 1,800,000 Recession 1,500,000 4 th EAF 1,200,000 3 rd EAF 900, ,000 1 st & 2 nd EAF 300, YEAR 12

13 tons Rebar Production ( ) 1,800,000 1,642,651 T 1,500,000 1,200,000 New Rolling Mill (RM2) in , , , YEAR 13

14 QSC s Direct Reduction Modules QSC s Direct Reduction Modules DR-1 DR-2

15 Direct Reduction Modules Qatar Steel QSC - DR Modules 15

16 Selective premium DR grade pellets with low acidic gangue & very low content of undesirable chemical elements are sourced to produce consistently high quality CDRI/HBI product. Major Suppliers for Iron ore pellets to Qatar Steel LKAB, Sweden GIIC, Bahrain SAMARCO, Brazil VALE, Brazil/Oman QCM, Canada

17 Salient Features of the DR Modules

18 DR-1 Module (1978~2012)

19 DR-1 PRODUCTION MILESTONES DURING 1978 ~ 2012

20 Days between Milestones (DR-1 Module)

21 CDRI Quality from 1994~2012 (DR-1 Module)

22 DR-1 Module Performance for Yr 2012

23 DR-2 Module (2007~2012)

24 CDRI Quality from 2007~2012 (DR-2 Module)

25 DR-2 Module Performance for Yr 2012

26 DR-2 MODULE PERFORMANCE DURING Q1-2013

27 DR (DR-1 + DR-2) Production balance for Yr 2012

28 HBI/CDRI Export quantities from Year 2007~2012

29 HBI Specifications & its advantages: Less porosities and surface area, hence less susceptible to Re-oxidation Higher bulk density ( t/m3,while cold DRI t/m3) Less associated risk during transport Minimum risk of overheating and hydrogen generation during transport and handling/storage (e.g. IMO allows open storage prior to loading ) Only minimal loss of metallization even after long time storage Open air storage both at the producers and users site does not cause problems Easily handled by conventional loading and discharge equipment.

30 Steps taken for loading CDRI in Ship

31 Steps taken for loading CDRI in Ship

32 HSE Excellence:Both DR Modules has excellent safety performance

33 THANK YOU FOR YOUR ATTENTION