first integrated steel manufacturing facility in gcc · steel making process flow 1978: started two...
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First Integrated Steel Manufacturing Facility in GCC
Steel Melting By Electric Power
(Electric Arc Furnace)
The Rolling Mill Epitomises Quality & Productivity
Well Equipped Jetty in close
proximity to production facility
World Class Direct
Reduction Facility The Billets Are Cut Automatically By Gas
Cutting Equipment (Continuous Casting)
3
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Production Capacities - Qatar & Dubai
Plants Products Capacity
mtpa
QA
TAR
Direct Reduction Plants DR-1 DRI 0.80
DR-2 DRI/HBI 1.50
Steel Melt Shops
EF/CC-1&2
Billets
0.60
EF/CC-3 0.70
EF/CC-4 0.75
EF/CC-5 1.10
Rolling Mill Plants RM-1
Re-bars 0.70
RM-2 0.80
DU
BA
I
Rolling Mill Plants
RM-3 Re-bars 0.30
WRM Wire Rod/ Coiled Rebar
0.24
DR: Direct Reduction, EF: Electric Arc Furnace, CC: Continuous Casting, RM: Rolling Mill, WRM: Wire Rod Mill
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Direct Reduction Process 1978: Start-up of 1st Midrex module (400 Series Module with designed capacity 400,000 t/y)
2007: Commissioning of 2nd Midrex Mega Mod Combo (DRI/HBI) module (designed capacity1,500,000 t/y)
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82
,63
3
2,3
85
,49
3
0
300,000
600,000
900,000
1,200,000
1,500,000
1,800,000
2,100,000
2,400,000
1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2013
Year
Direct Reduction Plant Production (1978 – 2013)
tons
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Steel Making Process Flow
1978: Started two 80t EAF’s, 50 MVA each) and two straight mould billet
casters ,150mm square, (Kobe Steel)
1999: Commissioned SMS-Demag, 80t EAF and Mitsubishi billet caster
(EF3)
2006: Commissioned LF for EF3-line (Danieli)
2007: Commissioned 80t EAF4, LF4 and CC4 (Danieli) along with gunning
robot
2014: Commissioned 110t EF-5 in Q1-14
DRI
HBI
Scrap
Electric Arc Furnace
Ladle furnace
Billets
Continuous Casting
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Steel Making Production (1978 – 2013)
127,4
43
2,2
63,6
38
0
300,000
600,000
900,000
1,200,000
1,500,000
1,800,000
1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2001 2002 2004 2006 2008 2010 2013
YEAR
ton
s
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Rolling Mill Process 1978: Started tandem type mill (RM1) consisting of
Re-heating furnace, Roughing, inter, and
finishing strands
1996: Commissioned High Speed Finishing Bar
Mill
2003: Implemented the PLC control system in the
Re-heating Furnace, mill motors, and the
auto counting machine
2005: straightening machine installed for
deformed coils of 8-12 mm
2007: commissioned a ultra-modern Rolling Mill
(RM2) from VAI POMINI
Billets
Reheating
Furnace
Roughing Stands
Intermediate Stands Finishing Stands
Cooling bed Re-bars for distribution
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Rebar Production (1978 – 2013) 113,9
94
1,6
95,8
09
0
300,000
600,000
900,000
1,200,000
1,500,000
1,800,000
1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2013
YEAR
ton
s
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Product Portfolio & Markets
• Feedstock for steel plants.
• Excess production exported
• GCC • International
• From Yr 2014 onwards, Qatar Steel will have shortages of DRI/ HBI. There will be no quantities available for sale
• Used exclusively for Rebar production
•Captive Consumption •Supply to QS FZE •Supply to Open market
• Used primarily in the construction sector
• Qatar • Other GCC
• Predominantly operates in GCC, focused on Qatar (+95% market share)
• UAE market catered through our Qatar & Dubai operations
• End user product • Wide applications,
including usage in the construction industry
• GCC • Others
• Sales on monthly basis • Supplies to Asian countries (India,
Pakistan, & Bangladesh)
DRI/ HBI
Billet
Re-bar
Wire Rod &
Re-bar in
coils
Product Primary use Markets Remarks
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QSC’s Direct Reduction Modules
DR-2
DR-1
QSC’s Direct
Reduction Modules
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13
QSC - DR Modules
Direct Reduction Modules – Qatar Steel
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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
• SAMARCO, Brazil
• VALE, Oman
• IOC, Canada
• QCM, Canada
• GIIC, Bahrain
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Salient Features of the DR Modules
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DR1 Module (1978~2013)
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CDRI Quality from 1994~2013
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DR2 Module Production (2007~2013) 112%
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CDRI Quality from 2007~2013
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DR Module Performance
Scheduled Hrs, 1042.82
UnSchedule Hrs, 245.53
Net Operating Hrs, 7471.65
Scheduled Hrs, 491.52 UnSchedule
Hrs, 183.57
Net Operating Hrs, 8084.91
DR-1 Module
Year Reliability Availability Operating hours
2011 97.66 93.92 8227
2012 99.67 92.64 8132
2013 96.82 85.29 7472
DR-2 Module
Year Reliability Availability Operating hours
2011 96.22 86.86 7610
2012 99.42 92.45 8121
2013 97.80 92.29 8085
DR-1 DR-2
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1st Quarter Production results
439,916
462,227
193,668
221,155
100,000
150,000
200,000
250,000
300,000
350,000
400,000
450,000
500,000
Yr 2013 Yr 2014 Yr 2013 Yr 2014
DR2 DR1
Cummilative Production Q1 (Yr 2013 vs Yr 2014)
DR2 Yr 2013 DR2 Yr 2014 DR1 Yr 2013 DR1 Yr 2014
49,798 tons more production in Q1 2014 vs Q1 2013
DR2 Module consistently producing 5600 TPD against
designed capacity of 4500 TPD
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200,000 tons more production expected
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Operating cost Model for 1.7 MTPA DRI plant
Natural gas cost 1 US$/MMBTU Natural gas cost 3 US$/MMBTU