Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
AT
SUBMITTED BY
CHINMAY JOSHI
MBA (MARKETING)
IIMP-MBA
Title: “Survey of steel industries in India to study the potential for waste heat recovery
boilers for electric arc furnace”
JFE Engineering India Pvt. Ltd. is the 100% subsidiary of JFE Engineering Corporation
Japan.JFE Engineering Corporation is the part of JFE Holdings. JFE Holding has beenranked
316thin the 2014 Fortune 500 list. It operates in 14 countries across the globe having its
head offices at Tokyo and Yokohama in Japan overseas offices at Hong Kong, Myanmar,
Vietnam, Saudi Arabia and overseas subsidiaries at China, Philippines, Malaysia, Singapore,
Indonesia, Germany, Italy and India.
Corporate Office: 603, A Wing, 215 Atrium, Andheri- Kurla Road, Andheri (East),
Mumbai - 400093
Branch in Pune: Pune Engineering Centr, WestendCente III, 169/1, 2 nd floor, North
Wing, Sector II, Aundh, Pune – 411007
Objectives:
Primary Objectives:
To identify the potential market for waste heat recovery boilers for EAF in
Indian steel industry.
Secondary Objectives:
JFE being a new venture in India, to promote the company as a brand.
Create awareness amongst the customers regarding heat recovery on Electric
Arc Furnaces.
To check whether there is a technical feasibility for the product.
Also to check are there enough energy savings so that the project is also
commercially viable and has a shorter return on investment period.
The study involved identifying the potential customers in Indian market and
understanding their needs.
It involved meeting the person concerned in the steel plant and collecting the
technical data as per the questionnaire.
Creating a database of information received from all the steel plants and
analyze it.
To provide the client with a best possible solution as in where the generated
steam can be used in the plant processes.
Research Methodology:
Particulars Description
Research Approach Quantitative
Sampling Universe Steel Plants in India
Sampling Unit Steel Plants having Electric Arc Furnaces
Data Collection Tool Questionnaire
Personal survey method through
Survey Method
Preparation of questionnaire
Learning from the project:
The customer will only consider buying a product if he thinks it will add value
proposition in their business.
Meeting with the purchaser & user is very important and we must be ready to tackle
some very awkward questions.
Educating the potential customer is the sure way to guarantee an audience for the
product.
How to take an appointment of the highest authority in the organization.
How to give corporate level presentations.
What is the current market situation of steel industries in India.
Conclusion:
CHAPTER I
INTRODUCTION AND
RATIONALE OF THE STUDY
TITLE:
Survey of steel industries in India to study the potential for waste heat recovery boilers for
electric arc furnace
This project was carried out across Indian steel plants having electric arc furnaces.
CHAPTER II
INDUSTRY/ SECTOR
PROFILE
INDUSTRY PROFILE
The Indian steel industry, one of the core industries in India, is more than a century old
when the first integrated steel plant was established by Tata Iron & Steel (popularly
known as Tata Steel) in 1907. India is currently the world's fourth largest producer of
crude steel and is expected to become the second largest producer by 2015.
Steel industry derives its demand from other important sectors like infrastructure,
aviation, engineering, construction, automobile, pipes and tubes etc. Thus its intense
integration with other important industries makes it a strategic sector.
The Indian steel sector enjoys advantages of domestic availability of raw materials and
cheap labour. Iron ore is also available in abundant quantities, though the recent mining
restrictions have put a strain on its availability. This abundance has been providing a
major cost advantage to the domestic steel industry.
Steel plays a vital role in the development of any modern and emerging economy. The per
capita consumption of steel is generally accepted as a yardstick to measure the level of
socio-economic development and living standards of its countrymen. As such, no
developing country can afford to ignore the steel industry.
GLOBAL SCENARIO
In 2014, the world crude steel production reached 1661.5 million tonnes (mt) and showed
a growth of 1.2% over 2013. (Source: World Steel Association or WSA, prov)
China remained the world’s largest crude steel producer in 2014 (823 mt) followed by
Japan (110.7 mt), the USA (88.3 mt) and India (83.2 mt) at the 4th position.
WSA has projected that global apparent steel use will increase by 2% to 1,562 mt in 2014
following growth of 3.8% in 2013 while in 2015, world steel demand will grow by another
2% and will reach 1,594 mt. As per their forecast, India’s outlook is improving and in
2014, India’s steel demand is expected to grow by 3.4% to 76.2 mt, following growth of
1.8% in 2013. In 2015 structural reforms and improving confidence will support a further
6% growth in Indian steel demand but elevated inflation and fiscal consolidation remain
key downside risks to the outlook.
Per capita finished steel consumption in 2013 is estimated at 219 kg for world and 545 kg
for China by WSA. (note: 2014 data has not yet been released by WSA).
Production
1800
1600
1400
1200
1000
800 Production
600
400
200
0
1970
1990
1998
1975
1980
1985
1995
1996
1997
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Fig.World Crude Steel production from 1970 to 2013 in million tons
Others
33%
China
50%
Japan
India 7%
5%
United States
5%
The steel industry globally has faced a number of unsettling global events that have
reduced long-term viability of the current trends in the industry. There are a number of
crosscurrents due to exogenous factors that are making charting a steady course difficult.
Although there are many research organizations devoted to the study of the steelindustry
worldwide and there are as many forecasts, it may be worthwhile to focus on those ofan
authoritative agency such as the World Steel Dynamics (WSD), an US based research
organization of global reputation. Their forecasts are based on a few very important
strategic perspectives like annual growth of the country as shown in the table below.
If one examines the competitive scenario drawn by World Steel Dynamics of two major
Indian companies, SAIL and Tata Steel, relative to four other competitive steel producers in
the world, it will be clear that the Indian steel producers considered stand way behind in
most of the technical and financial parameters considered as shown in Annexure-2.
However, when it comes to the overall strength of the company from the point of view of
their intrinsic strength, performance, management’s vision, etc.., JSW Steel stands fairly
high in comparison. These are not exhaustive and definitive comparison, but, point to the
fact that there is still some distance to cover for the best Indian mills to reach the top. India
has a history of steel making and the industry has reached sufficient levels of maturity in
terms of technology absorption, product development and productivity gains. However,
capacity additions to the industry and the market growth both have been fairly slow,
especially when compared to countries such as China.
India’s market is growing but the domestic producers are yet to be fully competitive and
there is a strong demand routinely coming from the industry to raise tariff protection. It is
a different matter that much of the inefficiency is derived from external surroundings such
as poor infrastructure, etc.. While most other industries are also similarly placed, steel
being a high capital intensive and infrastructure dependent industry, it faces a greater
degree of disadvantage on account of this.
While large producers are partially or fully dependent on the electricity they generate
themselves in their captive power plants using purchased fuels such as coal or capturing
waste energy. The smaller plants or stand alone rolling mills are largely dependent on
purchased power. Apart from pure shortages, what seems to have hurt the small and
medium plants especially is the rising costs of the same. While one can realistically expect
the power situation to improve with the currently idle coal based capacities due to coal
shortages and the power projects which are either under construction or in advanced
stages of planning with the hope that coal shortages will be overcome, the costs of delivery
of power remains a big concern for the steel plants dependent on purchased power.
The costs of capital in India are much higher than those for the producers in the developed
or in some of the developing nations. Further, with the depreciating rupee and high
domestic inflation, the costs of setting up steel plants have also gone up substantially and if
the current trends persists, the same will increase further. The actual capital costs incurred
at the end of the day also gets jacked up due to time overruns which in turn leads to cost
overruns. In fact, weakness in implementing large projects in India has been experienced
widely and the steel industry has seen more of this. Whether it is a managerial inefficiency
due to lack of planning or externality, the fact remains that the project costs rise due to
poor handling of the same.
While large producers are partially or fully dependent on the electricity they generate
themselves in their captive power plants using purchased fuels such as coal or capturing
waste energy. The smaller plants or stand alone rolling mills are largely dependent on
purchased power. Apart from pure shortages, what seems to have hurt the small and
medium plants especially is the rising costs of the same. While one can realistically expect
the power situation to improve with the currently idle coal based capacities due to coal
shortages and the power projects which are either under construction or in advanced
stages of planning with the hope that coal shortages will be overcome, the costs of delivery
of power remains a big concern for the steel plants dependent on purchased power.
The costs of capital in India are much higher than those for the producers in the
developedor in some of the developing nations. Further, with the depreciating rupee and
high domestic inflation, the costs of setting up steel plants have also gone up substantially
and if the current trends persists, the same will increase further. The actual capital costs
incurred at the end of the day also gets jacked up due to time overruns which in turn leads
to cost overruns. In fact, weakness in implementing large projects in India has been
experienced widely and the steel industry has seen more of this. Whether it is a managerial
inefficiency due to lack of planning or externality, the fact remains that the project costs
rise due to poor handling of the same.
CHAPTER III
ORGANIZATIONAL PROFILE
AND BUSINESS OVERVIEW
Organizational profile
As long as the people in the world seek a more comfortable and better life, at JFE
Engineering we will keep providing society with the optimal solution as a company that
creates the foundation for life”.
The JFE Group - contributing to society with the world's most innovative technology
Corporate Office: 603, A Wing, 215 Atrium, Andheri- Kurla Road, Andheri (East),
Mumbai - 400093
Branch in Pune: Pune Engineering Centr, WestendCente III, 169/1, 2 nd floor, North
Wing, Sector II, Aundh, Pune – 411007
Company Profile:
To identify the potential market for waste heat recovery boilers for EAF in
Indian steel industry.
To promote the company as a brand, being a new venture in India.
To create awareness amongst the customers regarding heat recovery on
Electric Arc Furnaces or to introduce the product concept in the steel
industry of Indian market.
To check whether there is a technical feasibility for the product.
Also to check are there enough energy savings so that the project is also
commercially viable and has a shorter return on investment period.
To meet the person concerned in the steel plant and collect the technical data
as per the questionnaire.
To create a database of information received from all the steel plants and
analyze it.
CHAPTER V
LITERATURE REVIEW
Waste heat recovery Boiler for Electric Arc furnace (EAF-WHR Boiler):
One of the main cost factors within the EAF steelmaking process is energy costs. As this
process is very energy intensive, the recovery of energy is notably important. From the
total amount of energy used for the steel melting about 40% are leaving with the off-gas.
Globally it is very common to recover this energy by using EAF- WHR Boiler system to
generate steam for power or process use.
Like every steam boiler, an WHR Boiler behind an EAF has to match the contradictory
demand of maximum efficiency and cost-effectiveness, so it is essential to know the
emissions of the furnace in advance, even if it is not yet operational. It is required to use
the optimum heat recovery method for each EAF, considering the following points-
a) Energy balance of furnace
b) Heat generation pattern on processing time
c) Off gas components
d) How to use recovered energy
e) Construction time for changing the system
The other challenges involved in design of EAF-WHR Boiler are fluctuating temperatures
and gas flow due to batch operations, steady output despite of these fluctuations, high and
corrosive dust content and space constraints in the existing plant.
Above diagram is only for general understanding, depending upon other various
parameters as mentioned earlier, EAF-WHR Boiler position may change as these are tailor
made heat recovery steam generators.
Considering the large amount of energy in EAF off-gas, energy recovery solutions have by
far the biggest potential for improving overall energy balance. The recovered energy can be
used for:
a) Power Generation (Steam Rankine Cycle / Organic Rankine Cycle)
b) Steam for Vacuum Degasification or Process heating.
c) Steam for Chilling plant or Refrigeration plant.
Payback period shall be calculated by important factors such as Power Generation or saved
fuel consumption. Thus this technology has gained much attention for reducing greenhouse
gas emissions and improving energy consumption.
CHAPTER VI
OBJECTIVE AND SCOPE OF
PROJECT
Business Objectives:
Primary Objectives:
To identify the potential market for waste heat recovery boilers for EAF in
Indian steel industry.
Secondary Objectives:
JFE being a new venture in India, to promote the company as a brand.
Create awareness amongst the customers regarding heat recovery on Electric
Arc Furnaces.
To check whether there is a technical feasibility for the product.
Also to check are there enough energy savings so that the project is also
commercially viable and has a shorter return on investment period.
The study involved identifying the potential customers in Indian market and
understanding their needs.
It involved meeting the person concerned in the steel plant and collecting the
technical data as per the questionnaire.
Creating a database of information received from all the steel plants and
analyze it.
To provide the client with a best possible solution as in where the generated
steam can be used in the plant processes.
SCOPE
a. Geographical Scope:
The Geographical spread was Pan India. Most of the Steel Industries were concentrated
in the states of Maharashtra, Gujrat, Karnataka, Odisha, West Bengal, Jharkhand were
covered under this Market Study.
b. Temporal Scope:
The duration of the project was two months. The research was conducted from 15th of
May till 25th of July, 2015. The time spent on the research was 9 hours/day while
working for 5 days in a week. Respondents – Plant Managers, Energy Managers,
Maintenance Engineers, Energy Auditors and Purchase officers, were interviewed
mainly by direct visits to the plant.
c. Operational Scope:
Plant Managers, Maintenance Engineers, Energy Auditors and Purchase officers were
posed the questions to understand the Awareness level about the WHRB, JFE as a
Company / Brand, and various technical elements taken into consideration before
implementing the WHRB on Electric Arc Furnaces.
d. Conceptual Scope:
It is necessary for any organization to know the potential demand for their product in
market. This will help company to find the right customer for their product. It will be
helpful to create the awareness of non users and find out the expectation of users. The
study was of utmost importance to the company considering the fact the product is
relatively new.
CHAPTER VII
RESEARCH METHODOLOGY
The research methodology applied for this project is as follows:
Research Instruments
Management researchers have a choice of many research instruments in collecting primary
data. The descriptive function of research is heavily dependent on instrumentation for
measurement and observation.
Questionnaire
A Questionnaire is set of questions presented to respondent because of its flexibility; a
questionnaire is by far the most common instruments used to collect the primary data.
a. Close ended questions: Close ended questions specified all the possible answer and
provide answers that are easier to interpret and tabulate.
b. Open ended questions: Open ended questions allow respondents to answer in their
own word and often reveal more about how people think.
Sampling Design
A sampling design is a definite plan for obtaining a sample from a given sample limit. It
refers to the techniques or procedures the researcher would adopt in selecting items for
the sample, sample design is determined before data allotted.
Sample Units
Here the placement heads of various consultancies are the sample unit for interviewing
regarding the software. Sampling unit is the group or cluster of people from which the
information is collected.
Sampling procedure
Data Collection
In this study primary data and secondary data both are collected. Primary data is collected
through survey method. And the secondary data is collected through magazine, journals,
internet and reference books.
Primary Data
Primary data is collected by asking questionnaire to respective respondents. Primary data
is the data gathered by the researcher for first time. All respondents are asked to fill a given
set of questionnaire and the data collected is called as primary data. This can be collected
through survey method.
Secondary Data
Secondary data is collected for another purpose and already exists somewhere. Researcher
usually starts with the secondary data to see whether the problem can be partially or
totally solved. Secondary data provide a starting point of the research and after the
advantage of low cost and ready availability. Secondary data can be collected through
internal sources as well as external sources.
Internal sources: Company website, periodical records, etc.
External sources: Internet, company brochures, Questionnaire etc.
Data analysis to
check the
feasibility for
Appointment for WHR boiler
plant Visit and
collection of data
regarding the
Identifying exisiting EAF
potential market facility.
and calling to
understand the
steel making
process
The survey being carried out gives a very larger perspective regarding the potential
for WHR BOILER in the Indian market.
It will also help the management to formulate the strategies for further expansion in
the country.
The findings and suggestions would help the organization to take an appropriate
decision in better way to understand in detail the needs of the customer as it is
going be a customized product for each customer
PROCESS FLOW CHART DEPICTING ACTIVITIES CONDUCTED
Suggestion &
Recommendations
CHAPTER VIII
KEY LEARNINGS &
CONTRIBUTION TO HOST
ORGANIZATION
KEY LEARNINGS
The customer will only consider buying a product if he thinks it will add value
proposition in their business.
If the potential customer is going to invest in a highly priced product like Waste heat
Recovery Boiler, then Quality has be assured also the return on investment period plays
a very important role.
Meeting with the purchaser & user is very important and we must be ready to tackle
some very awkward questions.
It is difficult to get meetings with the decision makers directly, so the person who can
get that meeting should be totally convinced that they require our product.
Though the need for WHRB is necessitate by the management and earns a high amount
of savings in coming future still the Purchaser (Purchasing Officer) takes into
consideration the tender process. Also this being a separate project it needs to be
approved by the top management of the firm.
Personal visit is far more beneficial than the telephonic and online questionnaire.
Educating the potential customer is the sure way to guarantee an audience for the
product.
In case of Steel plants if telephonic appointment is not possible then direct walk in can’t
help to get an appointment.
Creating a win-win situation with the customer helps in creating long term relationship.
And in B2B selling customer always tries to maintain a long term relationship with the
vendor.
CONTRIBUTION TO THE HOST ORGANIZATION:
There are hundreds of markets in the B2B space, each with their own profile and
unique set of requirements. To ensure the sales team targets the right prospects a
B2B sales strategy must be built on a well-researched segmentation of the market.
The way you break down the market will depend on the product or service and its
value proposition to customers. Once you have identified your market segments
your sales team has the confidence to deliver the right solution to the right
customer.
Size matters
The way a product or service is used will differ between SMEs and large business.
Depending on who you're talking to you need to ensure your value proposition is
appropriately targeted to the specific customer. Thereof the organization provides
a good indicator in deciding what and what to sell to the business customer.
In B2B selling a tailored solution for each client is the key. A sales training
program should focus on understanding the client's business instead of just a
product range. To create a sales pitch with an impact it is important to understand
the customer and their strategic direction.
Business clients expect sales executives to have the business literacy and
commercial acumen to engage in strategic dialogue with them. This will often
require a larger investment in training than would usually be the case in a B2C
context as a big part of the business' unique value proposition rests in the sales
executive's commercial expertise.
The essence of building a value proposition around what you sell is discovering
how your solution can help the client achieve their strategic vision. Ultimately, you
want to create a true partnership with the client which goes beyond a traditional
customer-supplier relationship.
One mistake to avoid is taking a one- fits all approach. The temptation for many
sales executives is to communicate the full range of product options to potential
clients in the hope of making a sale. A tailored one-on-one approach will be a lot
more successful in the B2B space. Identify one or two products that are most likely
to be useful and focus on them. Also use research and your anecdotal experience to
identify solutions that will be valuable for your client.
Direct marketing works in B2B
Direct marketing and telemarketing can serve as a cost-effective lead generator in
the B2B space. To be effective the depth and breadth of your customer data is of
paramount importance. Customer data should be updated regularly and tested for
accuracy. This will ensure your marketing efforts are maximized and that your
message reaches the customer the first time.
Before engaging in direct marketing activity it is important to do the research.
Make sure you understand the clients' needs and the outcomes they are trying to
achieve
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