Minerals to Metals Sep10

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Minerals to metals

H M NERURKAR

MD, Tata Steel

Kolkata ± Sept¶10

CII Eastern Region

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When nature finishes to produce its own

species, man begins using natural things in

harmony with this very nature to create an

infinity of species. Leonardo da Vinci

It is this propensity of man to use natural things which turns

minerals into metals. The harmony with nature part is sadly

missing now creating myriad problems.



3

From the womb to the tomb, minerals & metals

contribute extensively

Average consumption in a lifetime



And behind each metal is a mineral

Metals have dominated the human civilization

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5

Coal

Iron ore

Chromite

Bauxite

Manganese

Mica

Barite

Production of Major minerals position in

the world

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3

4

6

Indias Mineral Resources :

Out of 1100 minerals

- India produces : 89

- Self sufficient : 35



As metals dominate the ages, their demand grows

For example India steel demand to grow @ 7-8% over the

next decade. Expected to touch 90 million tons by FY15

6Source : JPC, Team Analysis



.. Leading to increased pressure on Raw Materials

1.5 billion tons

of steel p.a

2. 5 billion tonsof Iron Ore

950 million tons

of Coal

225 million tons

of Limestone

Chrome ore Manganese ore Refractory materials

Other materials

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This pressure on the

mineral resources

brings us faceto face with the

inevitable depletion

and eventual

end of resources



Innovation : The story of taconite

After the World War II, most of the high grade ores in US had

been consumed

Taconite with 25-30% iron ore was till then not used

With the development of the economic pelletizing process by

Edward W Davis, Taconite became the main raw material for

the US steel industry.

Today, over 80% of steel in the US is produced from Taconite

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From Minerals to Metals challenges

at each stage



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17

8

6

6

4

316

14

14

8

4 Coal

Metals &

Mining

Non coal power

Petroleum & Gas

Cement

Chemicals

Forestry

Transport

Agriculture

Construction

Waste

Metals & Mining : Among largest GHG emitters

McKinsey Report

% contribution



Reduce emissions

Remote location technology

Mining Deeper, hotter, lower grade,

highly stressed deposits

Multiple & thick seams¶ mining

Using advanced mining equipment

Automated haulage, traffic management.

Resource : Challenges to the Mining industry

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Conservation of resources

Scientific mining

Minimization of wastage



The industry has to innovate technologically

to sustain growth while conserving raw materials

a)- Green processes to reduce pollution

b)- Advanced and alternate materials

c)- Quality Coke from semi coking indigenous coal.

d)- Process improvement to reduce coke requirement-

e)- Minimize process wastage

f)- Production of recyclable material

13



Establishment of pollution norms

Minimum production levels for lease grant

Scientific Mining and Mineral Beneficiation

Lease grant solely on the basis of technical & financial

capability

FDI & private sector participation for infrastructure development

Time bound grant/renewal process

Focus on finished products as against raw materials

Active role by the Government

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. however, capacity utilization would be 65%

Global Crude steel capacity ~ 2 billion tons

by 2011-2012

16Source : WSA



a)- Thinner and lighter but stronger and safer.

For example, replacing the conventional steel of a typical

five-passenger vehicle with advanced high strength steel

(AHHS) results in a lifetime CO2 equivalents emission

reduction of 6%.

This saving in emission is more than the total CO2

emittedDuring the production of all the steels in the vehicle.

Use of high performance steel in bridges can reduce emissions

by 40% as against the same for conventional steels

Develop newer variety of steel green concern

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Crude Steel capacity increase led by the BRIC

BRIC share of the global capacity will increase from 26%

in 2000 to 52% in 201118

Source : WSA



Develop newer variety of steel green concern

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..Increasing advanced steels to protect the green



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Minerals the wealth of India

Mining of last 150 years resulted:

- Limited Quantity

- Low grade ; scattered

- Thin / abnormally thick- Deep seated

- Geologically disturbed

- Remotely located.

Indias Mineral Resources :

FACTS

Out of 1100 minerals

India produces : 89

-Self sufficient : 35

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Establish precise mineral inventory using advanced

techniques of remote sensing & locating

Accountability of reserves µGrade-Tonnage¶ curve for each

deposit

Challenges to the Mining industry

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From Minerals to Metals challenges

at each stage



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Coal

Chromite

Iron ore

Bauxite

Manganese

Mica

Barite

India : Major minerals



A look at the important material reserve situation

Iron Ore :

World Reserve 800 bmt

(Contains 230 bmt

Iron ore)

India 25 bmt

Coal:


India 24 bmt

Limestone:World Reserve Abundant

India 160 bmt

Chrome ore:


India 0.12 bmt

Manganese ore:

World Reserve 5 bmt

India 0.4 bmt

bmt : Billion Metric Tons

Source : Geological Survey of India, WSA25

Minerals to Metals Sep10

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