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UNNATI
SECTOR
REPORT
METALS, CEMENT & PAPER SECTOR
2017-18
Table of Contents
3.0 STEEL......................................................................................................................................21
3.1 Introduction .......................................................................................................................21
3.2 Manufacturing Process ......................................................................................................21
3.3 Global Scenario .................................................................................................................23
3.4 Indian Steel Industry .........................................................................................................25
3.5 Structure of Indian Steel Industry .....................................................................................26
3.6 Key Drivers of Steel Industry............................................................................................29
3.7 Impact of Union Budget ....................................................................................................31
1.1 Introduction
Mining is a backbone sector for the Indian economy, providing inputs to many manufacturing
industries. The sector’s GVA accounted for some 3.8% of GDP in FY2016, as against 4.5% in the
previous year. Coal, Iron Ore, Manganese, Bauxite, and Chromite are the key minerals produced
in the country. Total value of minerals produced in the country is estimated to be INR 2,830 Bn in
the fiscal year 2017. Fuel minerals form the largest segment, accounting for 68% of total value of
minerals produced in the country while metallic minerals accounted for ~12% and non-metallic &
minor minerals together accounted for rest 20%.
India is endowed with huge resources of many metallic and non-metallic minerals. These include
4 fuel minerals, 23 non-metallic minerals, 10 metallic minerals, 3 atomic minerals, and 55 minor
minerals. Coal and lignite mines form 16% of total operating mines; metallic mineral mines form
18% while non-metallic minerals form rest 66%
The total value of minerals produced in the country is estimated to be INR 2,830 Bn in the fiscal
year 2017.India is self-sufficient in case of 36 minerals and deficient in respect of a number of
minerals. The table below shows the rank of India in world production in some of the major
minerals.
Bauxite 4th
Zinc 4th
Lead 6th
In India, 80 % of mining is in coal and the balance 20 % is in various metals and other raw materials
such as Iron, Copper, Bauxite, Zinc, Lead, Gold and uranium.
Minerals and mining sector plays an indispensable role in accelerating growth and development
of a nation. Most of the basic manufacturing industries depend on the availability and exploration
of mineral resources. For example, coal and iron are the basic minerals needed for the growth of
iron and steel, power and cement industries. Similarly, minerals like mica, manganese, copper,
lead and zinc are of economic importance with varying degree.
The Indian mining sector grew at a CAGR of 7.3 % in the last decade compared to 22 % in China
for the same period. Despite this scenario, India is in a good starting position to transform its
mining sector. This is due to India’s large reserve base of coal, iron ore, bauxite manganese, etc.,
0and also the push towards progressive policy measures initiated by the Ministry, such as the
MMDR Act, and IBM/GSI reforms. With the new government initiatives the revival of the sector
are already visible. Mining output expanded by 4.2% over the last year to achieve total production
of 639.2 MT.
Mining and metals sectors can play a critical role in the economic development, attracting
investment and employment generation in the country. The demand for various metals and
minerals will grow 4-5 times over the next 15 years (9-11% growth per annum – Source: Ministry
of Mines, Strategic Plan 2013) against a backdrop of globally dwindling and increasingly scarce
resources. India’s per-capita consumption is almost four times less than global levels and there
will be huge demand for the metals in view of the rapid urbanization and growth in the
manufacturing sector in India.
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Regulatory Scenario
Indian mining sector is regulated by central as well as state government with the later having a
higher say. State government has the authority to regulate and develop mines within their
boundaries for minor as well as major minerals, except fuel minerals and atomic minerals. In the
case of fuel minerals and atomic minerals prior approval from central government is required
before state grants mining concessions. Major reform measures in mining sector were initiated
after the passage of National Mineral Policy in 1993. This policy was aimed at attracting private
investments both from Indian and foreign investors so as to improve the state of technology used
in mining. Post 1993 several regulations were introduced at periodic intervals all meant to improve
private sector participation. Currently there is no upper limit on foreign equity holding on
companies engaged in mining in the country
Regulatory framework governing mining sector saw disruptive changes in the past few years
culminating in the passage of Mines and Minerals (Development and Regulation) Amendment Bill
2015. This bill sought to address the concerns regarding allotment of mining licenses,
compensation, and rehabilitation of population affected by mining, granting of licenses and
clearances and investment climate.
Indian mining sector was besieged by instances of illegal mining and regulatory uncertainties. Iron
ore and coal mining – two the largest segment – was the most impacted leading to drastic reduction
in output of these two minerals. Iron ore mining in several states was banned as rampant practice
of illegal mining came into light. Key iron ore rich states of Karnataka, Goa, and Odisha were
among the most affected. Iron ore mining was banned in Karnataka in 2011 and in Goa in 2012.
Consequently, iron ore production in India dropped from 208 Mn tonnes in FY 2012 to 137 Mn
tonnes in FY 2014. In Odisha, partial ban on iron ore mining was imposed in 2014 when Supreme
Court issued orders ban on mining in 26 iron ore mines in the state. Although mining ban on
several of mines across all three states was relaxed by 2014 the sector is yet to recover fully. Coal
mining segment was faced with an uncertainty as Supreme Court in 2014 canceled 214 out of 218
coal blocks licenses allocated by the government during the period 1993-2010. Bulk of these
cancelled coal blocks were allotted to private players for captive mining to meet their end use
requirements. Cancellation impacted the mining operations as well as dented the confidence of
private sector to invest in mining sector.
Extension of mining leases acquired through competitive bidding from 30 years to 50 years.
Automatic renewal of mining licenses at the end of lease period done away with and replaced
by competitive bidding process.
Setting up of National Mineral Exploration Trust to promote exploration. The trust found would
be created out of contribution from existing mining lease holders.
Simplifying mining operations by removing multiple approvals, including prior approval from
central government for granting mining licenses.
To check illegal mining, The Mineral Conservation and Development Rules, 1988 was
strengthened which mandates mining companies to provide periodic reports on production of
mineral production. Amendment in this rule also makes it mandatory for reporting production and
trade of minerals at every level of mining operations, from pit head to traders to stockists to end
users.
The National Mineral Policy was revised in 1994 and as a result, private investment (both domestic
and foreign), has been permitted for the exploration & exploitation of 13 minerals. In 1994, the
MMDR Act, 1957, had accordingly been amended.
The government has also amended MMDR Act, 1957 for allocation of coal and lignite blocks
through competitive bidding and has also put its foot forward by instructing Coal India to adopt a
PPP (Public Private Partnership) model to enhance coal production in India. This step will further
enhance the production of coal reduce dependence on the imported coal.
In 1999, the foreign investment policy has been further liberalized to promote Foreign Direct
Investment (FDI) in the mining sector. In a significant relaxation of the general policy governing
process of automatic approval for FDI for the mining sector, the automatic route for FDI and/ or
technology collaboration is also available to those who have or had any previous joint venture or
technology transfer agreement, subject to a declaration being filed that they have no existing joint
venture for the same area and/ or the mineral concerned. As on date, 100% FDI is allowed in:
• Mining and Exploration of metal and non-metal ores, excluding titanium bearing minerals
and its ores
• Coal and Lignite mining though only for captive consumption by power projects, iron &
steel and cement units
Investment Incentives
The government offers a wide range of concessions to investors who are engaged in mining activity
in India. The main concessions offered are:
Direct Taxes:
• Mining in specified backward districts is eligible for a complete tax holiday for a period of
5 years from commencement of production and a 30 % tax holiday for 5 years thereafter.
• Environment protection equipment, pollution control equipment, energy saving equipment
and certain other equipment eligible for 100% depreciation.
• One fifth of the expenditure on prospecting or extracting or production of certain minerals
during five years ending with the first year of commercial production is allowed as a
deduction from the total income.
• Export profits from specified minerals and ores are eligible for certain concessions under
the Income tax Act.
Indirect Taxes:
To boost exploration and detailed prospecting of high value and scarce minerals, the area for
prospecting has been increased from 25 sq.km to 5,000 sq.km for a single licence, and 10,000
sq.km for aerial prospecting.
Aluminium Industry
2.1 Introduction
Aluminium is the most abundant metal in the earth’s crust. It is the second most widely used metal
in the world after steel. Aluminium has multiple applications across industries owing to its
favorable physical, chemical and mechanical properties, which include light weight, high strength,
moderate melting point, ductility, conductivity, resistance to corrosion and the ability to be recycled
without any loss of original properties.
Construction
Automobile
Packaging
Electrical & Electronics equipments
Machinery equipments
Household Items
Power
Domestic aluminium demand grew at 5-6% in 2016-17, driven largely by demand from the
power sector.
Since China is one of the one of the major consumer and producer of the metal, the economic
conditions of the nation, the smelter capacity production projections and any ramp up or shut down
of plants have a direct bearing on aluminium prices. LME daily publishes inventory levels of
aluminium which has a direct impact on the prices of aluminium and on the stock prices of
aluminium producing companies.
Global aluminium prices had taken fallen sharply in FY 2015-16 (USD 1592/tonne) falling 16%
y-o-y from the prices in FY 2014-15(USD 1889/tonne). Prices of aluminium have shown some
recovery in FY 2016-17. In FY 2016-17 global aluminium prices recovered by 6% (USD
1688/tonne).
The Chinese economy experienced a slowdown due to the change from an investment driven
economy to a consumer driven economy during the years 2013 to 2015. Oversupply of Chinese
aluminium due to overcapacity had caused the prices to fall sharply in FY 2015-16, Q3FY16 the
prices of aluminium globally was the lowest (USD 1494/tonne). The LME prices continued to
remain depressed till the end of 2015.
FY2016-17 there was a pickup in Chinese demand due to stimulus measures, adopted by the
Chinese economy. Post the U.S elections, LME prices in aluminium witnessed a rally due to
expected boost on infrastructure development by the new President.
Globally, the automobile and construction sectors account for about 25% each, of the total
aluminium consumed. The automobile manufacturers globally opt for aluminium as it improves
fuel efficiency, reduces emission and enhances the vehicle's performance. Aluminium is used in
the real estate sector for window panes and door frames. The power sector accounts for
only 11% of total
aluminium consumed
globally. This is because,
in most developed
economies, power is
transmitted through
underground cables that
largely use copper. Copper
is mainly used in
underground cables
(operating at
higher voltages of 400
kV) because of its higher
thermal and electrical
conductivity which helps
to conserve space,
minimize power loss and
maintain lower cable
temperatures.
2. India
Power sector, major aluminium
consumer in India
In contrast to the global
trend, in India, the
power sector accounts for about 56% of
total aluminium consumption, as the
metal is a cheaper substitute for copper
and also has lower weight. In India,
power is supplied through grids that
comprise transmission towers, in which
the overhead conductors are mainly
made of aluminium. Aluminium is used
It is projected that primary aluminium demand will post a healthy 7-8% compound annual growth
rate (CAGR) during 2016-17 to 2021-22, compared with 5.4% during 2011-12 to 2016-17.
Demand is estimated to have grown by 5-6% in 2016-17, largely driven by higher power sector
and consumer durables demand.
The key sectors of power, construction, automobile and consumer-durable sectors, together
accounting for over 80% of domestic aluminium demand, will aid growth:
The power sector is set to witness steady growth on the back of investments in distribution
and transmission by Power Grid Corporation of India Limited (PGCIL) and state
transmission companies. Government initiatives such as the Ujwal Discom Assurance
Yojna (UDAY) scheme are further expected to support sectoral growth.
Construction sector demand is set to pick up pace following rising urbanisation coupled
with an acute housing shortage in urban areas.
Automotive sector demand will continue to rise, as domestic sales of cars and two-wheelers
are expected to increase at a steady pace, led by an improvement in consumer sentiment
amid expectations of faster economic growth. Further, with the Make in India policy,
manufacturers are targeting India as an export hub for automobiles. Commercial vehicle
sales are also expected to improve as a result of a revival in industrial and commercial
activity.
Consumer durable demand too will see strong growth due to upbeat consumer sentiment.
In the aftermath of demonetization, a 100-200 basis point impact on demand growth for
Automotive, Building & Construction, and Consumer Durables sectors was observed in 2016-17.
As demand arising from power cables and conductors largely emanates from orders by PGCIL or
other govt. bodies (as opposed to retail buyers) this section of demand remained insulated from
the impact of demonetization.
During 2011-12 to 2016-17, primary aluminium demand posted a CAGR of 5.4%, in line with the
aggregate growth recorded by power, construction, and automobile sectors. In 2016-17,
aluminium demand rose ~5-6% to 2.4 million tonnes, after slowing from the 11.6% growth seen
in 2015-16. The slowdown in demand was largely attributed to a decline in demand growth from
the power sector resulting from lower off-take.
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As of 2016-17, the consumption of primary aluminium was dominated by power (56%),
construction (15%) and automotive (9%) sectors.
Looking forward
Electricity
Power sector demand to remain healthy. Higher demand from PGCIL and steady addition of
transmission lines by state companies resulted in a significant improvement of aluminium
demand from the sector (via power conductors and cables) in 2015-16. However, delayed
installations have had a cascading effect on demand in 2016-17, which resulted in a slowdown in
demand growth for the year (relative to last year). Going forward, growth in power conductors
will be led by state discoms’ investments in infrastructure, which is expected to drive demand.
Investments under the centrally-sponsored schemes- Deen Dayal Upadhyay Gram Jyoti Yojana
and Ujwal Discom Assurance Yojana - will drive incremental demand. These schemes are likely
to further boost investments in transmission and distribution over the long term.
Over the next five years, investments totaling Rs ~4 trillion are being planned to expand India's
transmission and distribution network.
Construction
Construction sector demand to maintain mediocre pace. Aluminium is widely used in the
construction sector to make doors, window frames, false ceilings and industry roofing. Increasing
urbanisation coupled with an acute housing shortage in urban areas is expected to drive housing
construction.
While primary aluminium off take from this sector continued to grow at a steady pace in 2015-16,
demonetization had a detrimental impact on demand during 2016-17, slowing growth to 2-3%.
Though the sector’s recovery is expected to be slow in the near term, a slight improvement for
aluminium demand is expected in the subsequent years, driven by increase in intensity of usage
within the sector. As a result, overall aluminium demand from the construction industry is
projected to record a moderate 4-5% CAGR over the next five years.
What are the key inputs that affect an aluminium manufacturer's cost
structure and profitability?
Alumina and Power
Alumina (refined from bauxite) and power are the major inputs for an aluminium manufacturer
and form about 30% and 40% of total cost structure of aluminium manufacturers. About 4 tonnes
of bauxite are required to produce 2 tonnes of alumina. About 2 tonnes of alumina are then
electrolytically reduced to produce 1 tonne of aluminium. Electrolysis consumes about 15,000
kWh of power.
Over the past decade, access to captive bauxite and coal (fuel for captive power plants) mines
enabled Indian aluminium manufacturers to control cost and protect operating margin. This
Indian bauxite production has risen to 25 million tonnes in 2016, an increase of 4% CAGR over
the past decade
Globally, about two-thirds of aluminium smelters purchase power through long-term contracts at fixed
prices, or source it through short-term arrangements from the state grid (like China). In India, aluminium
manufacturers have traditionally had cheaper, captive power plants that ensure uninterrupted supply to
smelters. Most of these plants generate power by using thermal coal. Prior to 2010, the operating
margin of aluminium producers was as high as 28-35%, as their access to captive raw material
protected their margins. However, in 2009-10, the favourable cost structure shifted. While some
Indian aluminium manufacturers had acquired mines for upcoming capacity, a Supreme Court
order de-allocated the mines.
After the de-allocation, the coal ministry identified 101 coal blocks for re-auction. The first two
batches of 23 coal blocks, auctioned during February and March 2015, included operational and
ready-to-produce blocks. Aluminium players won five coal blocks - Hindalco four and Balco one.
Their bids appeared to be steep at the e-auction and coal import price levels. With the cost of
procuring captive coal 20-25% higher than that of imported coal, we believe aggregate profitability
will significantly decline over the next 2-3 years since market fundamentals are unlikely to let
aluminium prices see much upward movement.
Investment in rural electrification through Deen Dayal Upadhyaya Gram Jyoti Yojna to
jump 44% on-year to Rs 48 billion in FY18.
30% export duty on previously exempted ‘other aluminium ores and concentrates,’ and
15% on ‘other aluminium ores, including laterite’.
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Possible Implications
Higher budget allocation for rural electrification to boost demand for aluminium cables
and conductors, which comprise 56% of primary aluminium consumption.
Imposition of export duties on ‘other aluminium ores and concentrates’ and ‘other
aluminium ores, including laterite’ to slow down the unprecedented surge in export
volumes and conserve domestic resources. Exports surged from one kilo tonne (KT) in
FY14 to 158 KT in FY16, and further to 177 KT in first half of FY17.
*Aluminium products exclude foils, doors, windows (and their frames) and sanitary-ware and parts
thereof
^Includes Excise duty of 12.5%, VAT of 5.5% and other levies wherever applicable etc.
^^Includes Excise Duty of 6.18%, VAT of 5%, Entry Tax of 0.5% and other levies wherever
applicable, etc.
Aluminium sector already attracts levies which add up to ~18%, which is equivalent to the GST
rate fixed for most products in this sector. Further, a lower tax on coal will likely help improve
industry profitability given that power and fuel costs account for 30-40% of production costs.
Domestic aluminium demand grew at 5-6% in 2016-17, driven largely by demand from the power
sector. Demand growth during the year was far slower than the previous year (11.6% in 2015-16),
largely on account of a slowdown in ordering by the power sector, while demand from
other sectors such as building and construction, automotive, and consumer durables is expected to
moderate by 100-200 basis points in the aftermath of demonetization.
India has a high growth potential for the aluminium industry. The forecast for domestic demand is
that it will grow at a 7-8% CAGR from 2016-17 through 2021-22, with demand touching ~3.6
million tonnes in the terminal year of our forecast. Higher ordering by the Power Grid Corporation
of India Limited and steady additions to transmission lines by state transmission companies,
coupled with a rise in state distribution companies' investments in distribution infrastructure of
conductors, will drive demand. Domestic aluminium demand is forecasted to post healthy growth
till 2021-22.
. Key sectors power, construction, automobile and consumer-durable sectors, together accounting
for over 80% of domestic aluminium demand, will aid growth:
The power sector is set to witness steady growth on the back of investments in distribution
and transmission by Power Grid Corporation of India Limited (PGCIL) and state
transmission companies. Government initiatives such as the Ujwal Discom Assurance
Yojna (UDAY) scheme are further expected to support sectoral growth.
Construction sector demand is set to pick up pace following rising urbanization coupled
with an acute housing shortage in urban areas
Automotive sector demand will continue to rise, as sales of cars and two-wheelers are
expected increase at a steady pace, led by an improvement in consumer sentiment amid
expectations for faster economic growth. Commercial vehicle sales are also expected to
improve as a result of a revival in industrial and commercial activity.
Consumer durable demand too will see strong growth due to upbeat consumer sentiment.
The uptick in prices during H2 2016 was supported by rise in China’s construction demand coupled
with rising coal cost. Additionally, elevated price levels in H2 2016 prompted 2-3 MT of closed
capacities in China to resume production. Consequently, robust alumina demand from China sent
alumina prices soaring, with prices rising ~30% q-o-q in Q4 2016 and remaining at similar levels
in Q1 2017. This rise in alumina prices further supported the elevated aluminium price levels.
Alumina prices have seen a partial pull-back in Q2 2017.
Aluminium prices (including premiums) saw further upward movement in H1 2017 on the back of
environmental impact driven supply disruptions and production cuts in key aluminium smelting
districts in China. The impact of the same is expected to be seen throughout 2017, with premiums
also remaining elevated owing to the partial alleviation of the regional supply-demand surplus.
Through 2018, aluminium prices (including premiums) are expected to hover around the 1,800 –
2,000 $/tonne levels as the global demand-supply balance gradually stabilizes. Any surge in prices
however, would be capped by the existing capacity overhang.
Globally, we foresee demand growth moderating for aluminium over 2016 to 2021 because of
cooling Chinese economy and extended Eurozone crisis. On the other hand domestic demand is
expected to post robust growth on back of investments in the power sector. As the global demand-
supply balance begins to ease, realisations are expected to improve, while reducing input costs are
expected to support an improvement in profitability for domestic producers in the near term.
STEEL INDUSTRY
3.1 Introduction
Steel is the most common metal alloy in the world. In its simplest form, it consists of iron and
carbon varying between 0.02 % - 1.7 % (by weight). Steel is characterized by high strength, low
weight, durability, flexibility and corrosive resistance. It is widely used in construction, automobile
and consumer durables industries. Steel forms the backbone of all industries, and is one of the
basic ingredients of growth and development of a country. Traditionally, the fortunes of the steel
industry have been linked to the economic cycle of a country. Steel is also the most commonly
traded commodity across the globe.
India will continue to remain a net importer in the near term due to surge in imports and heightened
competition in export market, but in the long term, India is expected to turn into a net exporter of
steel as Indian steelmakers are focusing on producing value-added products, which will ultimately
help substitute imports and increase exports.
In a bid to maintain the optimum utilization levels, Indian steelmakers are diversifying into the
export market and enhancing competencies in niche areas such as automobiles. Besides, cost
competitiveness (India lies in the second quartile of the global steel cost curve) and a weak rupee
would continue to favour export-focused players. The share of Indian steelmakers in the global
export market is expected to inch up to 3 % from 2 %, over the next five years.
According to International Iron & Steel Institute (IISI), for statistical purpose, crude steel also
includes liquid steel which goes into production of steel castings.
There are three popular processes to produce crude steel from raw materials:
•In BF/BOF, iron ore and coking coal are fed into a BF to produce hot metal. The BOF
converts the hot metal into crude steel.
•It is the most common process for producing steel
•Steel scrap, pig iron or sponge iron is used as raw material in an EAF. The raw
material is melted using heat generated with the aid of an electric arc. The EAF
process generally follows the following pattern Charging, Melting, Oxidising,
Deoxidising or refining
Corex BOF
Finished Steel
Products obtained on hot rolling/forging of semi-finished steel (blooms/billets/slabs). These
cover two broad categories of products - long products and flat products:
CTDand TMT
Wire Rod
LongProducts AnglesShapesand
Sections
Rails
Wires
FinishedSteel
Bright Bars
Plates
NarrowStrips
■ Over 2016 and early 2017, steel prices rallied due to a combination of high demand from Chinese
steel users restocking the metal, government stimulus measures implemented in the housing
market and positive investor sentiment. Government led consolidation is expected to take place
over 2017, which will gather pace from 2018 onwards, as increasing trade tensions within the
global market due to accusations of Chinese steel dumping, will pressure the Chinese government
to scale back domestic steel production and exports over the coming years. For instance, in August
2016, the European Commission imposed a five-year import duty of 19.7%-22.1% on cold rolled
steel products from China. These products are primarily used in the construction and automotive
sector. Global steel consumption growth will average 0.7% annual growth during 2017-2021,
significantly slower than the 1.2% y-o-y growth during 2012-2017. The decline in Chinese steel
consumption will weigh heavily on global steel consumption, as China will account for 44.3% of
global consumption in 2017. Nevertheless, the slowing consumption growth will still result in
greater consumption than production in absolute terms, resulting in growing deficits over the years.
We expect global consumption to increase from 1,621mnt in 2017 to 1,665mnt by 2021.
Going forward, we expect utilization rates in the industry to continue to remain at low levels as
the demand-supply imbalance persists amidst subdued demand growth. China, the largest producer
of steel is expected to cut down production to bring about discipline its supply. In the long run
however we expect utilization rates to pick up moderately with shut down in excess capacities,
muted new capacity additions and demand pick-up.
Domestic iron ore miners have resorted to selective mining keeping the cut-off grade as high as
58-60%. The resources and reserves of will almost double if cutoff grade lowered to 45%.
Steel Production
Steel Production in India increased to 8362 Thousand Tonnes in July from 7950 Thousand Tonnes
in June of 2017. Steel Production in India averaged 3036.45 Thousand Tonnes from 1980 until
2017, reaching an all time high of 9000 Thousand Tonnes in March of 2017 and a record low of
713 Thousand Tonnes in September of 1980.
The crude steel capacity utilisation ratio of the 67 countries in June 2017 was 73 per cent. This is
1.4 percentage points higher than June 2016. Compared to May 2017, it is 1.3 percentage points
higher, it said.
It is seen from the official data that capital goods that comprise of heavy machineries and
equipment have gone down by a whopping 14% during the period.
A major sub-sector, ship-building and repairs have curtailed its activities by nearly 50% in
February 2017 itself.
The electrical machinery and apparatus segment has experienced a high negative growth
of around 36% in the total period in spite of growing by more than 17% in February.
Construction
• The average per capita consumption of finished steel in rural India has been assessed at 10
kg in to 2010, which is estimated to rapidly increase to further due to increased rural
penetration.
• There has been a perceptible rise in steel consumption in the rural and retail sector. Projects
like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas Yojana
have led to increasing demand for constructional steel items like TMT Bars, Light and
medium structurals, GP & GC sheets.
• The trend towards higher rates of urbanization will lead to increase in intensity of steel as
per capita consumption of steel of urban India is many times more than in rural India. It is
estimated that India’s urban population will increase to 600 million by 2030 from the
current level of 400 million.
Automobiles
• The Indian automobile sector is the second fastest growing market after China and has
emerged as a prime demand driver for alloy steel.
• The rising middle class population of India, with higher income levels will generate
additional demand for automobiles
Apart from laying cross-country pipelines, exploration and production activities are also
experiencing strong growth in both international as well as domestic markets
A) Import Duty on HRC Used for Tube & Pipe making Reduced: Basic customs duty on MgO
coated cold rolled steel coils [72251990] for use in the manufacturing of CRGO steel, subject to
actual user condition reduced from 10% to 5%; provisional anti-dumping duty exists on this grade.
Also, basic customs duty on HRC (7208) for use in the manufacturing of welded tubes and pipes
falling under heading 7305 or 7306, subject to actual user condition reduced from 12.5% to 10%.
It depicts government’s bid to boost Make in India movement.
B) Indirect Boost to Steel Sector: Flexibility would be given to Railways to implement end to
end integrated transport solutions for select commodities through partnership with 18 logistics
players, who would provide both front and back end connectivity. Also, to improve the Operating
ratio of the Railways, its tariffs would be fixed taking into consideration costs, quality of service,
social obligations and competition from other forms of transport. Thereby, it is expected to help in
lowering the rates for steel and other commodities.
C) The infrastructure push, especially as expenditure for transport sector, is raised to INR 0.64
trillion, taking it up to a total of INR 2.4 trillion. Around INR 1.31 trillion of capital expenditure
is assigned towards Railways. Railway lines of 3,500 kms will be commissioned in 2017-18, as
against 2,800 kms in 2016-17. This will clearly have a large effect on the demand for steel and the
metals. The budget also focuses on housing, which is expected to revive domestic steel demand as
it will push up demand for construction grade steel particularly those for roofing purposes.
The hope for the steel industry in the budget is the infrastructure allocation, which will anchor a
growth trajectory for the industry.Overall, this year’s budget continues to build on the promise of
delivering and a drive for long-term impact on the economy and its citizens, helping India for the
next wave of growth and development, just as the Finance Minister concluded the budget saying,
“Transform, Energize and Cleanse India”.
Impact of GST
GST rate to bring no change to Steel Products; however, reduction in coal tax to benefit
steelmakers
Includes Excise duty of 12.5%, VAT of 5.5% and other levies wherever applicable
^^ Includes Excise Duty of 6.18%, VAT of 5%, Entry Tax of 0.5% and other levies wherever
applicable, etc.
Credits: CRISIL
LEAD INDUSTRY
4.1 Introduction
Lead is one of man's most valuable commodities. The metal is mined and processed in some 60
countries. While it has a high economic value, lead is relatively economical to produce. As with
all metals, there are two main production routes. Primary production from mined lead ore is of
course the original source of all lead, but secondary production, where it is recovered from
recycled products or from residues arising from the production process is of enormous importance.
Secondary lead production now accounts for more than half of all lead produced throughout the
world. In the US more than 80% of lead comes from secondary production with Europe reporting
over 60%. These impressive figures are made possible by the fact that most lead is used in readily
recyclable applications. And unlike many recycled materials, the value of lead means that
recycling is economically viable and hence self-sustainable.
Lead is a very corrosion-resistant, dense, ductile, and malleable blue-gray metal which has a
wide range of applications. The largest single use of lead today is in the manufacture of lead acid
storage batteries. Lead is also used in radiation protection, underwater power and
communication cables, vehicle batteries, electric vehicle batteries and in batteries operating
emergency power supplies
Consumption Pattern of
4.3 Consumption Pattern Lead- India
2% 3% 4%
The consumption pattern of lead is almost similar
globally as well as in India. Globally and in India 10% Batteries
World Mine Production and Reserves: Reserves estimates for China, Peru, and Russia were revised and
estimates for Iran, Kazakhstan, and Macedonia were added based on information from Government and
industry sources.
Source: https://minerals.usgs.gov/minerals/pubs/commodity/lead/mcs-2017-lead.pdf
Like Copper and Zinc, Lead is also 100% recyclable, if treated properly. About 50% of the lead
production globally comes from recycled material. The high recycling rate for lead is driven
principally by lead-based batteries, more than 95% of which are recycled at the end of life.
Recycling: In 2016, about 1.07 million tons of secondary lead was produced, an amount equivalent
to 69% of apparent domestic consumption. Nearly all secondary lead was recovered from old scrap,
mostly lead-acid batteries.
During the first 9 months of 2016, the average London Metal Exchange (LME) cash price for lead
was $0.81 per pound, slightly less than that in the same period of 2015. The average monthly LME
price ranged between $0.75 and $0.82 per pound during the first half of 2016 and increased through
the third quarter of the year to $0.88 per pound in September. Global LME lead warehouse stocks
were 190,250 tons at the end of September, slightly less than those at yearend 2015.
Substitutes: Substitution of plastics has reduced the use of lead in cable covering and cans. Tin has
replaced lead in solder for potable water systems. The electronics industry has moved toward lead-
free solders and flat-panel displays that do not require lead shielding. Steel and zinc are common
substitutes for lead in wheel weights.
Lead production in India is largely dependent on the zinc production rate as mining of lead is
carried out as a co-product with the mining of zinc so, both of them generally follow a similar
trend. Thus, its lead production rate is quite fluctuating as per the scenario. The total resources of
lead and zinc ores as on 1.4.2010 as per UNFC system, are estimated at 685.59 million tonnes. Of
these, 130 million tonnes fall under 'reserves' category while balance 555.69 million tonnes are
classified as 'remaining resources'. With regard to lead resource, significant addition of zinc-lead
resources occurred as a result of the government initiative; the reserve base of lead metal in India
increased from 7.0 million tonnes in 2005 to 11.55 million tonnes in 2011. In terms of reserves,
2.20 million tonnes of lead metal have been estimated.
Industry Structure
All the primary lead produced in India comes from the state of Rajasthan. The domestic industry
is characterized by the presence of only a few players in the primary segment. Binani Industries
Limited and Hindustan Zinc Ltd. (HZL) are the major players in the domestic lead industry. HZL
is one is one of the top ten lead mining companies by production volume worldwide. HZL is the
only producer of primary lead in the country and has a smelting capacity of 1.85 lakh TPA. HZL
is the only integrated lead and zinc producer in the country. Its operation can be classified into
mining and smelting. It has seven mining operations and three smelting operations. All operations
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are located in Rajasthan. One new mining operation at Kayad in Ajmer district, Rajasthan is in
development stage. For producing secondary lead, Indian Lead Ltd (ILL), a private sector company
has two units, one at Kolkata and other at Thane (Maharashtra), each having 12,000 TPA capacity.
Both the units are based on imported concentrates/scrap. However, no production was reported by
ILL. Indian Lead Limited (ILL) is yet to start production.
Government of India has enacted Battery Management and Handling Rules (BMHR), 2002 to
organize the recycling of lead acid batteries and to make available raw material to the lead
reproducers. This has led to increase in collection of used lead batteries and caused a substantial
increase in secondary lead production from recycling. Enactment of this act has also led to focus
on protecting the environment by collection of used lead batteries and using them for recycling
rather than disposing them.
Exchange Rate
India imports some part of its total demand for lead. The weakening currency would increase the
raw material cost for the lead refiners.
Similar to Zinc and Copper, the LME Official lead price is used as the global reference for physical
contracts of Lead. Another factor which influences LME prices is the LME warehouse stock levels.
The official 3 month price and cash settlement price based on the warehouse stock levels for July
2017 as forecasted by LME exchange is forecasted as follows
Traditionally, the automotive sector has been the major consumer of lead/lead acid batteries in
India, in tune with the global practices. About 70% of lead consumed in India goes to the lead
battery sector. As mentioned before, automotive sector in India is expected to see ~ 9% growth till
2038 across all segments which will increase demand for lead.
For a long time, India has been having a perennial shortage of power in different parts of India and
lead-acid battery powered inverter is very common in offices, banks, schools, hospitals, hotels etc.,
The inverter sector witnesses huge growths in summer months especially.
In the telecom sector, with the advent of the mobile phones and the expansion of 3G and 4G
network, there is always a bank of lead acid batteries, at the base of the telecom towers, to provide
a continuous supply of power so that the mobile phones have the signal, non-stop. The mobile
companies are now focusing on smaller cities and rural areas for a greater penetration which will
increase demand for lead. Same is the case for the computer, where there is a lead acid battery –
driven UPS (Uninterrupted Power Supply) source.
Electric vehicles and renewable energy are high thrust areas of the government and once these
areas expand, lead acid battery sector will make significant inroads and accordingly the demand
for lead would increase.
Provisional data reported to the ILZSG indicate that world refined lead metal demand
exceeded supply by 86kt during the first half of 2017. Over the same period total reported
stock levels decreased by 18kt.
• An 11.7% rise in global lead mine production compared to the first half of 2016 was
primarily due to higher output in China, India and Kazakhstan that more than offset a
reduction in Australia.
Increases in China, India, the Republic of Korea and the United States were the main
influences on a rise in world refined lead metal production of 7.8%.
A 10% increase in global lead demand for refined lead metal was principally a
consequence of sharp rises in apparent demand in China and the United States of 13.3%
and 22.8% respectively. Usage in Europe rose by a more modest 2%.
Imports to China of lead contained in lead concentrates fell by 6.1% to 341kt. Chinese
net imports of refined lead metal totalled 52kt compared to net exports of 12kt during the
first half of 2016.
NMDC Ltd. is engaged in the exploration of minerals and production of primarily iron ore and
other minerals like copper, rock phosphate, lime stone, dolomite, gypsum, bentonite, magnesite,
diamond, tin, tungsten, graphite, and beach sands, among others. NMDC is a Navratna
company, which is under the administrative control of the Ministry of Steel, Government of
India. It was incorporated in 1958 as a Government of India fully owned public enterprise. NMDC
generates revenues through two business segments: iron ore and other minerals and services.
NMDC is India’s single largest iron ore producer, presently producing about 30
million tonnes of iron ore from three fully mechanized mines viz Bailadila Deposit-14/11C,
Bailadila Deposit-5, 10/11A (Dantewada, Chhattisgarh), and Donimalai iron ore mines
(Karnataka). It also has a mechanized diamond mine with a capacity of 31,533.39 carats per annum
at Panna, Madhya Pradesh.
NMDC is gearing itself to meet the expected increase in demand by enhancing production
capabilities of existing mines and opening up new mines - Deposit -11B in Bailadila sector and
Kumaraswamy in Donimalai sector. The production capability would increase to around 50 million
tonnes per year in coming years.
Tata Steel generates revenues through two segments: steel, and others. The steel segment of the
company comprises of the subsidiaries, Tata Steel India, Tata Steel Europe, NatSteel Holdings, and
Tata Steel (Thailand) Public Company.
Tata Steel India produces hot metal, crude steel, and saleable steel. In FY2013, it produced 8.86
Mt of hot metal, 8.13 Mt of crude steel, and 7.94 Mt of saleable steel. Tata Metaliks (TML), a
subsidiary of Tata Steel India, is engaged in the business of manufacture and sale of pig iron. It
operates two plants and has an annual total capacity of 650,000 tons. Tata Metaliks' plants are
located at Kharagpur (West Bengal, India) and Redi (Maharashtra, India). Tata Metaliks also has
a joint venture called Tata Metaliks Kubota Pipes (TMKPL) with Kubota Corporation of Japan
for producing ductile iron pipes with an annual capacity of 110,000 tons. In April 2013, Tata
Steel India announced the merger of TML and TMKPL with itself through a composite scheme
of amalgamation which is to be sanctioned through a court approval process.
Tata Steel Europe (formerly Corus), a subsidiary of Tata Steel, is Europe's second largest steel
producer with a crude steel production of 18 MTPA. NatSteel Holdings, a 100% subsidiary of
Tata Steel, has presence in Singapore, China, Vietnam, Australia, Indonesia, Malaysia, the
Philippines, and Thailand. It produces products used in the construction of residential, industrial,
and commercial buildings, as well as infrastructural works.
Tata Steel has 67.9% equity in Tata Steel (Thailand) Public Company, headquartered in
Bangkok, has three main subsidiaries: Siam Iron and Steel Company (SISCO); NTS Steel Group
(NTS); and The Siam Construction Steel Company (SCSC). TSTH manufactures rebar sales, the
wire rods product line, and Seismic rebars; and sells these products in Thailand under the brand
Tata Tiscon.
In 2008, Tata Steel India became the first integrated steel plant in the world, outside Japan, to be
awarded the Deming Application Prize 2008 for excellence in Total Quality Management. In 2012,
Tata Steel became the first integrated steel company in the world, outside Japan, to win the Deming
Grand Prize 2012 instituted by the Japanese Union of Scientists and Engineers
Company Profile
Vedanta Limited, formerly known as Sesa Sterlite/Sesa Goa Limited, a Vedanta Group company is
one of the world's largest global diversified natural resource majors, with operations across zinc-
lead-silver, oil & gas, iron ore, copper, aluminium and commercial power. The company was
founded in 1954, as Scambi Economici SA Goa. It has grown to be one among the top low-cost
producers of iron ore in the world since then. During 1991-1995, it diversified into the manufacture
of pig iron and metallurgical coke. It has also developed indigenous and environment-friendly
technology for producing high quality metallurgical coke.
It became a majority-owned subsidiary of Vedanta Resources Plc, listed on the London Stock
Exchange in 2007, when Vedanta acquired 51% controlling stake from Mitsui & Co., Ltd. In June
2009, Sesa Goa Limited acquired VS Dempo & Co. Private Limited (now Sesa Resources Limited)
along with its fully owned subsidiary Dempo Mining Corporation (now Vedanta Limited) and 50%
equity in Goa Maritime Private Limited. Sesa acquired 51% stake in Western Cluster Limited,
Liberia in 2011.
The company operates its business through five segments: copper, iron ore, aluminum, power and
other business. Vedanta‘s copper segment consists of the manufacturing of copper cathode,
continuous cast copper rod, anode slime including from purchased concentrate and manufacturing
of precious metal from anode slime, sulfuric acid, phosphoric acid. The company’s iron ore segment
is engaged in the production and exportation of iron ore, and operates mining and processing
facilities in Goa and Karnataka, India. The company’s iron ore mines include Codli Group of Mines,
Sonshi mines, Sesa Resources mines, Narrain mine and other mines. The aluminum segment
consists of manufacturing of alumina and various aluminum products. The company’s power
segment consists of power excluding captive power and including power facilities engaged in
generation and sale of commercial power. SSL‘s other business segment comprises of pig iron and
metallurgical coke.
The company’s operations are located predominantly in Goa and Karnataka, with offices in various
locations across India. Its head office in India in Panaji, Goa, while its Liberia office is
in Monrovia and China office is in Shanghai. The company operates in India, Australia, the
Netherlands, the US, the UAE, Mauritius, Namibia, South Africa, Ireland, the UK, the British
Virgin Islands and Sri Lanka.
NICKEL INDUSTRY
5.1 Introduction
Nickel is a naturally occurring, lustrous, silvery-white metal. It is the fifth most common element
on earth and occurs extensively in the earth's crust. However, most of the nickel is inaccessible in
the core of the earth. Some of the key characteristics of nickel are its high melting point, resistance
against corrosion and oxidation, ductility and catalytical properties, ease of deposit by
electroplating and formation of alloys readily. Nickel plays an important role in our daily lives,
making its way in myriad objects around us like food preparation equipment, mobile phones,
medical equipment, transport, buildings, and power generation—the list is almost endless. There
are about 3000 nickel-containing alloys in everyday use. About 65% of the nickel produced is used
to manufacture stainless steel. Another 20% is used in other steel and non-ferrous alloys, often for
highly specialized industrial, aerospace, and military applications. About 9% is used in plating and
6% for other uses, including coins, electronics, batteries for portable equipment, and hybrid cars.
In many of these applications there is no substitute for nickel without impairing performance or
increasing cost. Nickel gets precedence over other metals because it offers better corrosion
resistance, better toughness, and better strength at high and low temperatures; it also provides a
range of special magnetic and electronic properties
Supply
Nickel market supply/demand has performed better than other base metals over the past 3 years
Nickel market will need another 400-500kt to meet trend nickel demand by 2021 (and
significantly more if forecasts for batteries come anywhere close to expectations!)
Equivalent to doubling Chinese NPI industry at its peak
Very little visibility into future supply - extended period of low prices has resulted in very few
opportunities for new supply and more dependence on future growth from higher political risk
areas
Underinvestment led to flat to declining production at most large nickel operations
Old, deep operations take several years and hundreds of millions of dollars to ramp-up
Nickel supply becoming highly dependent on higher political risk countries (Indonesia,
Philippines)
Remaining ramp-up from new large HPAL projects uncertain
Indonesian developments create massive uncertainty for the most active source of new supply
Project cupboard outside Indonesia largely empty
Relaxation of Indonesian ban has hurt nickel market in near-term but setting stage for very
robust long-term nickel market outlook
Demand
Usage of nickel has increased over time and is correlated with economic development. World
nickel demand increased from 907 thousand tonnes in 1990 to 1.465 million tonnes in 2010, an
annual average growth rate of 2.3%. Since then the strong growth recorded by the Chinese
economy has further accelerated the increase in nickel demand that recorded in only six years,
from 2010 up to 2015, an annual growth rate of 5.0%. Asia is now by far the largest regional
market for nickel currently representing 71% of total world demand. China alone now accounts
for close to 52% of world nickel demand compared with18% ten years earlier.
Source: Insg.org
The price of nickel has shown considerable volatility over the last forty years. The chart below
shows the historic LME price for nickel in nominal values from 1991 to 2016. In the late 1980s
there was a peak in the price of nickel. In the first half of the 1990s the economic collapse of the
former "Eastern Bloc" countries resulted in a surge of nickel exports that drove nickel prices lower
than the cash costs of production resulting in reduced nickel production in the "West". Until 2003
the nickel cash price remained below US$10,000 per tonne. The price breached
$14,000 per tonne in 2005 and then escalated dramatically through 2006 before peaking at $52,179
per tonne in May 2007. Nickel prices then declined until the end of 2008, when the average cash
price in December hit a low of $9,678. In early 2009, nickel prices began to once again climb and
reached $24,103 by the end of 2010. In 2011 the price continued up and reached the peak in
February, with an average price of $28,247, and has declined since then until the end of 2013 when
it stayed below $14,000. The initial reaction to the implementation of the export ban of
unprocessed ores in Indonesia in January 2014, nickel price climbed to just below $20,000 in July
2014, but since then it has declined almost every month until March 2016 to be traded at around
$8,700. LME stocks of nickel were relatively stable during the period 2001 to 2005 at around
20,000 tonnes. In 2005 stocks increased somewhat and again declined in 2006. During the period
2007 to 2009 stocks rapidly increased to over 158,000 tonnes at the end of the period. In 2010 and
2011 destocking took place with stocks at the end of December 2011 at 91,000 tonnes. Since the
beginning of 2012 to March 2016 a long period of stocking took place, reaching over 470,000
tonnes in June 2015.
Source: Focus-economics.com
Domestic nickel prices are linked to the international spot prices and are also affected by the
exchange rate in the market. Another factor which influences LME prices is the LME
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warehouse stock levels. Thus, these factors, in addition with others, determine the nickel
prices.
The stainless-steel industry, which is the major contributor to nickel consumption in India, has
a direct correlation with the nickel prices. If the demand for stainless steel is high, the nickel
prices will also rise. Conversely, a low demand for stainless steel will translate into a lower
demand and consequently, lower price of nickel.
Since, India’s nickel needs are met through imports, the policies, regulations and tariffs set by
the government play a major role in driving up or down the nickel prices.
The nickel prices are also directly linked with the economic growth of the company. The
economic growth of the country has a direct bearing on its industrial growth. As a consequence,
the demand for nickel can be significantly boosted with a higher level of economic and
industrial growth.
Closure of nickel processing plants, identification of nickel ore mines or any changes
pertaining to the related industries will directly impact the nickel prices.
In India, demand for nickel stands boosted following deregulation of its imports. After growing 16
per cent in 2012, demand slowed slightly in the following years but the demand is expected to
increase on account of improved outlook for the Indian economy. A higher consumer demand in
segments such as kitchenware, infrastructure, consumer durables and automobile is anticipated.
This will lead to an increased consumption of stainless steel, which will directly translate into a
higher demand for nickel in the country. Also, a continued uptick in demand from alloy
manufacturers will lead to higher nickel imports. As Nickel prices in India are fixed on the basis
of the rates that rule on the international spot market, and Indian Rupee and US Dollar exchange
rates, fluctuations in the currency rates will also impact nickel prices in the country.
The global nickel market has witnessed strong growth in production as well as consumption
patterns, in the recent years. Although consumption levels increased across the world, China
exhibited one of the largest growth rates. This phenomenal growth has made China, the world's
largest consumer of nickel, and the country is anticipated to account for a larger share in the coming
years as well.
The growing demand from stainless steel producers, a trend that is likely to continue in the near
future as well, will drive the buoyant global nickel market. Our report reveals that global refined
nickel consumption is continuously increasing as it is used in more industrialized products.
Copper industry
6.1 Introduction
Copper is the third most widely used metal in the world after iron ore and aluminium. One of the
earliest metals to be discovered, most of the copper is mined from open pits that contain nearly
0.4% to 1% of copper. On an average continental crust contains about 0.0058 % of copper or 58
parts per million. A typical characteristic of the copper deposits are that they are available in low
concentrations. This thus makes most of the copper mines less economically viable to be
commercially extracted.
Copper is one of the most efficiently recycled materials in the world such that it is 100% recyclable.
Historically, copper has found immense usage in the production of utensils and coins. Of late,
copper has found varied applications across various industries. Known as one of the best
conductors of heat and electricity, copper is largely used in the electrical and instrumentation
industry. It is also widely preferred for wiring in industries and in telecommunications. Also,
copper is heavily used in the plumbing industry and since it is highly biostatic (which means
bacteria will not grow upon it), the metal is hugely used to line ships in order to protect it against
barnacles and mussels. To a lesser extent, copper is also used in the jewellery industry. Some of
the major properties of copper are figuratively described below:
Excellent Physical
conductor of Machinable &
electricity & Properties Formable
non-magnetic of Copper
Copper is extracted from mines and then broken down into smaller pieces
The copper pieces are then concentrated to increase the copper content as the ore
contains other minerals as well
Smelting of the copper ore- decomposing the ore and driving out various gases to
leave behind the base metal
The smelted copper is then subjcted to the process of refining which removes the
various impurities that get formed in due course of the refinement process
The refined copper is finally casted into ingots, casks, billets, rods and wires
World mine production increased strongly in 2016 benefitting from new and expanded
capacity brought on stream mainly in Mexico and Peru and the low frequency of supply
disruptions due to strikes, accidents or adverse weather conditions.
Lack of significant output from new projects or expansions, contrary to what happened in 2016,
and reduced output from some SX-EW mines will impact world mine production growth rates
in 2017 and 2018.
Furthermore, 2017 production growth is also impacted by the significant supply disruptions
that occurred in the 1st quarter of the year notably in Chile, Indonesia and Peru.
While world concentrate production is expected to remain essentially unchanged in 2017, an
anticipated decline of around 5% in SX-EW output will lead to an overall decline in world
mine production of around 1%.
Production in Chile and Peru, the world’s biggest copper mine producers, is only expected to
present higher growth in 2018.
India is among top 20 major producers copper globally. But falling prices of copper in international
markets would also benefit India, as it is one of the world’s biggest importers of the metal,
alongside China, Japan, South Korea and Germany. As a consequence, volatility in prices of the
metal on the LME has a significant bearing on Indian copper trading. Typically, over 30 per cent
of India’s copper demand comes from the telecom sector and 26 per cent from the electrical sector
in India. In addition, the building and construction, engineering, transport and consumer durables
sectors are major consumers of copper in India. These sectors stand to benefit the most from lower
prices of copper.
The Indian copper industry grew by nearly 50% in 2011. India has become a net exporter of copper
after being a net importer during the last decade, even as the country is not a major producer of
copper ore, but produces the refined forms of copper. About a decade ago, the Indian copper
industry consisted of a single state-owned company and now the copper industry in India takes up
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about 3% of the global market for copper. In 2011, India’s copper demand is estimated to grow by
at least 7% - following a similar forecast in 2010, fed by the power sector. According to India’s
11th five year plan (2007-2012), the country’s power generation sector is likely to make a huge
investment with 150 power projects for the various stages of installation.
Mines are generally located in the north western region of the country and go on to exist as far as
the central India. During the last few years, India’s switch from net importer to exporter is due to
a rise in production by three companies: Sterlite Industries, Hindalco, and Hindustan Copper. The
state-owned Hindustan Copper is a vertically integrated producer, whereas Hindalco and Sterlite
Industries are mainly custom smelters. Hindalco and Sterlite industries account for more than 80%
of India’s total copper production. Growing trend in the building construction and automobile
sector is expected to keep demand of copper high.
Exchange Rate
Though India accounts for 2% of world reserves, the total production capacity is not self sufficient
to meet the domestic demands. As such a major share in the copper industry of India is imported
to fill this gap. Thus, the copper industry of India is highly dependent on the volatile exchange
price of the Indian currency. With a recent government devaluation of Chinese Yuan, the Indian
Rupee had come under further pressure and had weakened against the dollar. This had increased
the overall cost of imports.
LME Prices
World over the prices of copper are referenced by the London Metal Exchange (LME) Official
copper price. The weakening demand owing to a weakening Chinese economy has pressured the
worldwide copper prices and they currently stood at $4622/tonne as of 5st September, 2016.
Another factor which influences LME prices is the LME warehouse stock levels. Higher stock
levels reduce prices and reducing stock levels generally lead to increase in prices.
Zinc Industry
7.1 Introduction
A bluish, white lustrous metal, Zinc is the most widely used metal after iron ore, aluminium and
copper. Normally, it is covered with a white coating on exposure to the atmosphere in the Earth’s
crust. Zinc finds majority of its applications in galvanizing steel, alloys, batteries, rubber, paint,
electroplating metal spraying and several other sectors. Because of its resistance to non-acidic
atmospheric corrosion zinc is instrumental in extending the life of buildings, vehicles, ships and
steel goods and structures of every kind.
Zinc oxide is widely used as a white pigment in paints, and as a catalyst in the manufacture of
rubber. It is also used as a heat disperser for the rubber and acts to protect its polymers from
ultraviolet radiation. Also, it is an ideal material for die casting and is extensively used in making
builders hardware, automotive, electrical and electronic components. Zinc compounds and
powders are used in cosmetics, plastics, ointments, sun screen creams, soaps, paints, inks and
fertilizers. The metal zinc is also an important trace element found in our bodies. The importance
of zinc can be ascertained from the fact that its concentration is second only to iron in the body.
Ore Mining
Roasting and Sintering
Extraction and Refining
As of today, 80% of the zinc mines are of underground type. The metal once extracted is primarily
manufactured by two ways either through Hydrometallurgical Process wherein the metal is
purified by electrolysis or through Pyrometallurgical Process wherein the metal is smelted in a
specialised chamber with carbon. However, the Pyrometallurgical process is quite costly and hence
the hydrometallurgical process for the production of zinc has taken over. A schematic flowchart
for the production of zinc is as given below:
The zinc ore is first crushed, ball-milled and then concentrated through the
froth floation process. This removes unwanted impurities such as lead
components
The concentrated iron ore is then roasted with oxygen, i.e., oxidised. This
converts the naturally occuring zinc sulphide into zinc oxide
The zinc oxide is then converted to its sulphate form and finally the compound
is subjected to electrolysis to purify the metal and to obtain it in its purest form
Global mined zinc production will return to growth in 2017, as increasing zinc prices encourage
ramp ups. Major miners Glencore and Nyrstar's output cuts and the closure of MMG's Century
mine in Australia and VedantaZinc's Linsheen mine in Ireland drove the decline in zinc output in
2016. Glencore, which suspended 500 thousand tonnes (kt) across three countries, reported a 25%
y-o-y decline in zinc output in 2016, to 1.0 million tonnes (mnt). While the exact schedule and
pace of restarts remains a risk to our forecast, we expect Glencore to steadily restart production in
CEMENT INDUSTRY
9.1 Introduction
One of the most widely known substances, Cement is a binding agent which is extensively used in
building and construction activities. The latter spans the breadth of nearly the entire human
civilization, thus making cement a quintessential product affecting lives of all and sundry. Widely
used in key segments such as housing, real estate and infrastructure development, the growth of
the cement industry is directly linked with the economic growth of the country.
India has a lot of potential for development in the infrastructure and construction sector and the
cement sector is expected to largely benefit from it. Some of the recent major government
initiatives such as development of 98 smart cities are expected to provide a major boost to the
sector.
With the growth of the cement industry directly proportional to the growth of the economy in
general, the sector started to see structural reforms since 1982. It was during this phase when the
government started to decontrol the sector in essence- although partially. Further liberalization of
the sector realized in due course when the government imposed quota of 66% on existing units
and 50% on new and sick units for sales to the government was removed. This was the year of
1989; two years shy from the historical liberalization era of India. Subsequent happenings shaped
the sector to greater heights.
After showing a strong growth between FY09 and FY13, Indian cement industry witnessed
demand disruption in FY14 due to a slowdown in the infrastructure and construction sector. During
that period, consumption growth was in mid-single digit trajectory, while a massive one- fourth of
the overall capacities were lying unutilized. Besides, the 6.5 percent hike in freights by the Indian
Railways in June 2014 and the country's sluggish economy growth also weighed on cement
demand. India's cement demand remained sluggish for most of FY16, particularly on account of
low demand from the housing segment. There was a slight rise of 2% in the prices of 50kg cement
bags. The average prices across India were about Rs. 333.
The domestic manufacturers can broadly be bucketed into pan-India, regional and standalone
players. Pan-India players are large players like Holcim Group companies - ACC and Ambuja, and
Aditya Birla Group company - UltraTech Cement (including Samruddhi Cement). Players whose
presence is restricted to one or two regions are categorized as regional players. Key players
included in this segment are Jaiprakash Associates (North and Central), Lafarge (concentrated in
the East and North), India Cement (South, West), Shree Cements (North and East), Binani Cement
(North), Kesoram Industries (South), Chettinad Cement (South), Dalmia Cement (South) and
Ramco Cements (South). Players like Panyam Cement, Penna Cement, etc. are operational in few
states within a region. Owing to their largely local reach, these players are classified as standalone
players.
To obtain a deeper understanding and to get an insight of the industry, the cement sector of India
can be analyzed for its attractiveness and competition level through Porter’s Five Forces model.
The latter hinges upon five key instruments viz. Bargaining Power of Suppliers, Bargaining
Power of Buyers, Threat of new entrants, Threat of Substitutes and Industry Rival. The lesser the
competition after analyzing these five forces, the more attractive the industry is. Since a major
segment of the Indian cement industry is under control by a few players, there exists a sort of
cartelization in the cement sector. The latter is highly responsible for barring the entry of new
players into the industry. Although the cement industry is highly dependent on the railways for
The capacity of 420 million tonnes is produced from 575 operational plants fragmented across
India, and is scattered throughout. 210 large cement plants account for a cumulative installed
capacity of over 350 million tonnes, while over 350 mini cement plants have an estimated
production capacity of nearly 11.10 million tonnes, as of 2016. Of the total 210 large cement
plants in India, 77 are situated in the states of Andhra Pradesh, Rajasthan and Tamil Nadu.
M&A’s that took place throughout 2016: -
9.6 Demand
In 2016-17, demand remained flattish, growing at 0-1%, lower than 4.2% growth recorded in the
previous year. While the infrastructure segment growth remained healthy on account of higher
construction of NH's, railways, PMGSY roads etc., weakness in housing especially rural dragged
the overall demand growth.
Source: CRISIL
Rural housing demand, badly hit by demonetization in FY18 is expected to witness a revival on
CRISIL
Further in long term cement demand is expected to grow at 6-7% compound annual growth rate
(CAGR) over 2016-17 to 2021-22,as against 3.2% CAGR during 2011-12 to 2016-17.
Infrastructure segment, which accounts for 15-20% of cement demand is expected to grow at a
fast pace of 10-12% CAGR, as both central and state government increase their focus on
infrastructure projects. As a result, share of infra demand will increase to 20-25% from current
levels of 15-20%.
Source: CRISIL
The share of housing sector has dropped over the past five years on back of housing sector being
caught in a quagmire of slow economic growth, weak demand, high finance cost and buyer-
unaffordability. Further increased government induced spending in infrastructure sector has
pushed its share upwards. As per the 12th Five Year Plan, production is expected to reach 407
million tonnes by FY17.
CRISIL
Other Expenses
Other expenses include employee cost, administration expenses, repair and maintenance charges,
etc. These account for around 15-20% of the cost of sales.
Price
The prices of the cement industry have recently come under a lot of pressure owing to a low
demand and excess capacity. Broadly speaking, the prices are chiefly governed by the following
factors:
Region Dependent
Although most of these factors continue to pull down the prices of cement, the industry is hugely
oligopolistic in nature. This has thus led to a subdued cartelization of the major players and a
tacit collusion exists which controls the price of the industry.
9.10 Profitability
Operating margins for cement companies is estimated to have expanded healthily by ~220 bps
in 2016-17 aided by lower power and fuel costs ( especially in H1FY17 ) which is primarily
attributable to increased share of pet coke, as players substituted coal requirements by pet coke,
it being more economical on calorific value especially during H1FY17.
Apart from the power and fuel costs , the improvement was also supported by lower raw
material costs and stable freight costs ( attributed to exemption from busy season surcharge in
Q1FY17 , which offset the higher costs on account of increase in road freight costs ).
We expect the margins to further widen , though by a lesser quantum in FY18 and FY19 largely
on the back of anticipated increase in realizations, with healthy demand growth in
FY18. However, increase in power and fuel costs (on account of higher pet coke prices) and
freight costs is expected to limit the margin expansion.
Power and fuel costs are expected to be higher on a y-o-y basis as pet coke prices are likely to
Source: CRISIL
CRISIL Research has classified cement players into large [>8 million tonnes per annum (mtpa)],
mid (2-8 mtpa) and small (<2 mtpa) as per their installed capacity. Over the years, cement
players' profitability has varied in relation to their size, with large players typically earning
higher operating and net margins compared to small players.
During FY17, while large and medium size players are estimated to have improved margins
by 200-250 bps, aided by lower power and fuel costs, small players in contrast were most hit
amid weak demand and witnessed a decline of 350 bps.
With the cement industry of India poised to grow at a rate of 9.7% CAGR from FY11 to FY20,
reaching a capacity of 550 MTPA looks highly encouraging. The cement industry's medium to
long term outlook looks optimistic as demand for cement is likely to get boost from industrial and
commercial segments as well as from mass housing and mid-income housing schemes across the
country. In order to achieve the Government's vision of 'Housing for All' by 2022, where 11 crore
houses have to be constructed at an investment of $ 2 trillion (Rs 13,600 billion), is going to drive
cement consumption in coming year. Progress in infrastructure activities is likely to fuel cement
consumption in short-run on account of massive investment in infra projects like freight corridors
(Western and Eastern), railways, smart cities, metro railways, roads and highways, among others.
The government under its current fiscal year's budget has allocated Rs 3.96 lakh crore for
infrastructure sector, a crucial move to revive investments in the sector with the participation of
the private players. Moreover, the government plans to expand the capacity of the railways and the
facilities for handling and storage to ease the transportation of cement and reduce transportation
costs.
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Metals, Cement & Paper
Sector
Going forward, incremental capacity addition is expected to be limited as many cement players
have already commenced their new units, while cement demand is likely to improve, resulting in
higher capacity utilization. Demand from rural market is also expected to rise as better than
expected monsoon as well as strong government push for the rural sector will improve rural
income. The government has also increased its budget allocation for the IAY (Indira Aawas
Yojana), PMGSY (Pradhan Mantri Gram Sadak Yojana) and MNREGA (Mahatma Gandhi
National Rural Employment Guarantee Act) that have the potential to further improve cement
demand.
In terms of pricing, despite healthy growth, Pan-India cement prices are expected to witness
decline as year-end prices were significantly lower in FY16 and only a moderate increase in prices
on sequential basis wouldn’t be enough to pull Pan-India FY17 prices higher than FY16. With
most infrastructural projects expected to pick-up pace in FY18, the prices are expected to see an
improvement of 5-6% in FY18.
Margin Ratios
Performance Ratios
Efficiency Ratios
Growth Ratios
The company is among the first companies in the cement industry to have entered the power
business. It has evolved from a mere captive power producer to a major merchant power player
Unnati Sector Report 2017-18 | 74
Metals, Cement & Paper
Sector
and is also a Category I power trading licensee. The company has increased its capacity from
560 MW in FY12 to 612 MW in FY16. The power business contributes more than 10% to total
revenues of the company. Moreover, it is also one of the most efficient users of fuel in the
industry. Captive capacity along with better efficiency results in lower P&F cost per tonne for
the company. It is the first company in the world to utilize 100% pet coke in all its operations for
both cement and power plants.
Shree Cements has created the world record for completing its 1mtpa clinkerisation plant in 330
days against an industry average of 630 days. Its subsidiaries include Katni Industries Pvt. Ltd
and Shree Global Pvt. Ltd.
Financial Ratios
Margin Ratios
Performance Ratios
Efficiency Ratios
Growth Ratios
It is the first Indian cement manufacturer to build a captive port with four terminals along the
country’s western coastline to facilitate timely, cost effective and environmentally cleaner
shipments of bulk cement to its customers. Ambuja Cements subsidiaries include Chemical
Limes Mundwa Private Limited, M.G.T. Cements Private Limited, Kakinada Cements Limited,
Dang Cements Industries Private Limited, Nepal and Dirk India Private Limited. The proposed
acquisition of ACC by Ambuja is expected to reduce cost through consolidation of shared
services (like finance, HR and marketing) vendor consolidation and swapping of plants (to
reduce lead distance).
Financial Ratios
Margin Ratios
Performance Ratios
Efficiency Ratios
Growth Ratios
Paper Industry
10.1 Introduction
Paper is a thin material produced by pressing together moist fibers of cellulose pulp derived from
wood, rags or grasses, and drying them into flexible sheets. It finds usage across various industries in
different capacities and touches he human civilization quite closely. Some of the applications include
writing and printing (W&P), newsprint, packaging and cleaning besides being used as input for
various chemical, industrial and construction processes.
•Calculated by dividing grammage by caliper and expressed in grams per cubic centimeter
•Typical values are in the range of 0.75 (for loosely formed papers) to 1.20 (for bond sheets)
Apparent
denisty
• Paper surface made of hills and valleys- thus varying degrees of smoothness and reference is
made such as smooth or rough texture
• Smoother the paper, stiffer it is and better is the print reproduction
•High levels of smoothness is achived by a process called calendering which might lead to lesser
Smoothness brightness
Paper pulp can be manufactured via three routes: mechanical, chemical and a combination of the two.
Generally, these three processes use wood as raw material for manufacturing paper. Even for
manufacturing paper with other raw materials, the basic processes remain the same with a few minor
modifications. In nearly all of these processes the wood as a raw material is first chipped, pulped,
bleached, added with additives, removed from water and finally dried to manufacture paper. The
following flow chart gives a more comprehensive idea of the entire manufacturing process of paper.
Paper making
•Beating of pulp to make it
flexible
•Consists of forming pressing
and drying paper
•Power intensive
Demand to grow at a subdued pace between 2016 and 2021. The rate of growth will be marginally
higher than posted between 2011 and 2016. Paperboard is the only segment that is forecasted to rise
during the period.
Over the next 5 year period, overall demand for paper and board is expected to grow only marginally
by 0.5-1% CAGR, primarily on the back of rising demand from paperboard segment, with demand
for W&P and newsprint segment will continuing to head south.
Source: CRISIL
Source: CRISIL
Global pulp consumption is estimated to have witnessed a marginal growth of 0.8% y-o-y to around
174.4 million tonnes in 2016 with the marginal growth being attributed to steady growth in paperboard
segment coupled with rise in demand from specialty grade segments (majorly tissue paper).
During 2011-2016 period, pulp consumption grew marginally by 0.5% CAGR, largely supported by 1.7%
rise in demand from the paperboard segment. Global pulp consumption will continue to be driven by
Asia which contributes ~50% of global imports, where demand for both paperboard and W&P paper is
relatively higher.
Going ahead global pulp consumption is expected to continue to witness a marginal improvement
despite decline from W&P segment, as incremental rise in paperboard segment and higher growth from
FBB/SBB segment (which requires up to 100% pulp) will keep the demand afloat. The paperboard
segment is expected to witness a steady growth of ~1.5% CAGR during 2016-2021 period. Moreover, the
incremental pulp consumption will also be supported by capacity addition in the specialty-tissue paper
segment.
We expect paper & board demand to grow at 6-7% to touch ~20 million tonnes in 2021-22:
Demand for paperboard is expected to grow at a healthy 7-8% CAGR over the next 5 years, driven
by packaging of fast-moving consumer goods (FMCG) products, readymade garments,
pharmaceuticals, e-commerce, and household appliances.
Writing and printing demand is expected to grow at 5-6% CAGR (against 3.4% between FY12-
FY17) on account of a likely pick-up from the corporate and education sector.
Specialty paper (majorly tissue paper and thermal paper) is expected to continue growing at a
robust 9-10% CAGR
Domestic paper demand posted a 4.5% compound annual growth rate (CAGR) over FY12-FY17,
reaching 14.3 million tonnes. The expansion was on the back of increased industrial activity and
corporate spending on office stationery and advertisements following improving economic growth.
During FY12 and FY17, demand in the W&P segment grew at 3.4% CAGR, rising to 4.3 million tonnes
on back of increased government and corporate spending. Copier was the fastest-growing sub-
segment in the uncoated category at ~9% CAGR, while Creamwove and Maplitho grew 1.3% and
2.1% respectively. Creamwove grew at a slower pace on account of a shift towards better quality
paper requirements from state textbook societies, resulting in cannibalisation for Maplitho papers.
Paperboard
Kraft paper, recycled board and virgin board come under this category. This paper is used for
various industrial purposes and its consumption is closely linked to:
Speciality Paper
Paper with specific applications such as tissue paper, decor paper, electrical grade paper, fine
printing paper, business card paper, photo paper and greeting card paper is called speciality paper.
It contributes to a very small percentage of total paper demand. Consumption of speciality papers is
linked to the general standard of living in the country.
Newsprint
Newsprint is mainly used in printing of newspapers and magazines. Although used for printing
purposes, newsprint is considered a separate end-use category because of the difference in its usage
as compared to other W&P varieties. Besides, newsprint is consumed in very large volumes vis-a-vis
other varieties.
Drivers
Source: CRISIL
The company operates through three segments: paper, paper products and office supplies, and
pulp.
The company manufactures a wide range of papers such as coated wood free, uncoated wood
free, copy paper, packaging, business stationery, industrial grades and speciality and fine paper.
Financial Ratios
Margin Ratios
Performance Ratios
Efficiency Ratios
Growth Ratios
JK Paper has been constantly creating value in a highly capital intensive and cyclical business,
where volume is traditionally considered as Key profit driver. JK Paper was also among the
earliest to invest in state-of-the-art A4 cutting lines for mass production of these products. JK
Paper is synonymous with premium quality paper, which is reflected in customer’s trust in its
products enjoying the ‘Brand’ status among its competitors.
Financial Ratios
Margin Ratios
Performance Ratios
Efficiency Ratios
Growth Ratios