100th Annual Report 2006-2007 - Tata Steel

The “G” Blast Furnace in Jamshedpur crossed 2 million tonnes
production of hot metal against its rated capacity of 1.8 million
tonnes.
The New Rebar Mill which was installed under the One million
tonnes expansion project also achieved its rated capacity of
50,000 tonne per month during the year. The total production
of rebars at the Jamshedpur Works almost reached the 1 million
tonne mark during the year.
The Hot Strip Mill produced 3.24 million tonnes as compared
to 3.08 million tonne in the previous year. The Cold Rolling Mill
crossed the milestone of 1.5 million tonnes against its rated
capacity of 1.2 million tonnes.
The all round increase in production came with improvements
in the manufacturing processes specially in the areas of specific
consumption of raw materials, energy, refractories, water and lime.
The Company successfully completed in-house up-gradation of
the “E” blast furnace in Jamshedpur. The “E” blast furnace which
used to produce 1,050 tonnes per day before up-gradation will
now be able to produce 1,350 tonnes per day. The coke and
fuel rate consumption of the “E” blast furnace will also reduce
due to the increase in the size of the furnace.
Raw Materials
The West Bokaro Collieries for the first time dispatched 1.9
million tonnes of clean coal at an average of 13% ash content.
The reduced ash level in captive coal contributed significantly
in substituting the more expensive imported low ash coal. In
order to reduce the alumina content in the iron ore, a modern
beneficiation plant for iron ore fines has been set up by
the Company.
Research & Development
• Commercial production of various grades of high strength
steel for automobiles was established for the first time.
• Super ductile rebars and galvanised wires with thin organic
coating were produced for the first time.
• Breakthrough was achieved in establishing a new grade of
cold rolled ultra low carbon electric grade steel which has
significant usage in electrical appliances.
G) Marketing & Sales
Finished steel sales increased by 11.3% to 4.51 million tonnes
as compared to 4.05 million tonnes in the previous year.
Flat Products sales to the automotive sector were the highest
ever at 0.86 million tonnes, an increase of 30% as compared
to sales of 0.67 million tonnes in the previous year. Sales of
specialty HR coils used for the long and cross members of chasis
of heavy vehicles, high end cold rolled and coated sheets were
also higher compared to last year.
Enhancing Operational Efficiency
Raw Material Consumption
Ton/ton of Saleable sheet
4
3.31
3.11
Coke and Fuel Rate Consumption
Fuel Rate (Coke rate + Injection)
Kg/thm
600 587 578
Power Consumption
Kwhr/tss
450
400
402
388
Specific Energy Consumption
Gcal/tss
8
7
6.96
6.72
3
76
6
500
511
91
350
5
2
487
300
4
400
250
3
1
2
200
1
0
FY 2005-06
FY 2006-07
300
FY 2005-06
FY 2006-07
150
FY 2005-06
FY 2006-07
0
FY 2005-06
FY 2006-07
Coke Rate
Coke Injection
99