Annual Business Plan FY 14

Annual Business Plan 2014-15

March, 2014

MTI, Ranchi

Highlights: 2013-14Battery # 5 commissioned in Sept13 after hot complex repair, 25 days ahead of schedule.Battery # 4 commissioned on 31st January14 after cold repair.Common facilities of COB#3&4 were successfully revamped.New DE#16 & 17 fabricated in-house, introduced in COB#5 & 4 respectively.Modification in hammer crusher to reduce micro-fines in Coal blend.Revival of Tar Unloading Facility to reduce consumption of Furnace oil (4600 Tons unloaded)

Strategy & Key Assumptions : 2014-15

Hot Complex Repair of COB#6 within 6 months.Composite Contract for Heating Control, Anchorage regulation, Condition Based Battery Monitoring system (COMIT) in COB#1&2COB#3 under Cold repair Commissioning by May 2015.Ceramic welding of Joints after Hot repair of COB#5Complete Battery Maintenance & End vertical repair in COB#8 by M/S Fosbel.

Production Potential : 2014-15UNIT / ITEMBest Achieved (000 Ts)2013- 142014-15ABP (000 Ts)Likely (000 Ts)Proposed Plan (000 Ts)Growth Planned over Likely FY 14 (in %)Oven Pushing (Nos.)531.3938336942510.9%SinterHot MetalCrude SteelMill Wise Production:Tot. Saleable Steel% Value Added Products

4

Break-up of Production from existing and new facilitiesITEMEXISTINGNEW(Cap Utilsn)TOTALOven Pushing/Day4250425Gross Coke Sinter Hot MetalPig IronCrude SteelFinished SteelProduct 1.Semi FinishedProduct 1.Total Saleable Steel

000 T

High Impact Initiatives Planned for 2014-15ParticularCurrent StatusPlanned Improvement1.Hot repair of COB#6Work to start from 1st week of April.From 40 unhealthy ovens we shall gain 60 healthy ovensPhysical contract to be awarded by 15/03/14, Refractory bricks available, Mechanical spares under procurement.

2.Introduction of new Door extractor for COB#6 & Comprehensive revamping of all machines of COB#6Presently machines of COB#6 are unhealthyAll machines will be reliable improving pushing consistency.Order for new DE ram for new door extractor (being made in house,) placed on HEC. Spares & Contract for comprehensive repairs are being finalised.

Coke oven7

Oven Availability : ABP vs Actual : 2013-14BattAprMayJuneJulyAugSepOctNovDecJanFebMar1ABP696969696969696969696969Actual69696969696969696969692ABP696969696969696969696969Actual69696969696969696969693ABP37373738383840400000Actual35.4035.3938.3735.9036.6810.4027.4828.5710.39004ABP00000000006969Actual0000000000685ABP00003030454560606969Actual3.430000.0044.0767.74686868686ABP495454545656565656566060Actual47.6344.1640.8039.773839.7040.7444.0344.8144.8742.397ABP000000000000Actuall000000000008ABP545760606464646464646464Actual53.5355.6155.3754.1660.8762.2362.9461.4762.616464OverallABP278286289290326326343343318318400400Actual277.99273.16272.54267.8273.55294.40336.90340.07323.81314.87380.50

Unit : Nos./day

Oven Pushing : ABP Vs Actual : 2013-14BattAprMayJuneJulyAugSepOctNovDecJanFebMar1ABP898989909090909084849090Actual91.9392.2692.9792.9793.2993.2092.4892.6087.8781.3284.862ABP898989909090909084849090Actual92.5790.4591.4792.0391.6592.2390.1491.3087.0380.8485.323ABP37373738383840400000Actual34.6033.9437.5034.0334.528.1326.4826.9010.390.000.004ABP00000000006972Actual0000000000705ABP00003032484864647679Actual3.27000043.8069.4872.8074.0676.1075.326ABP545959596161616161616566Actual53.7749.0043.2045.1342.3542.6340.3243.7044.8144.2342.367ABP000000000000Actual000000000008ABP636669697373737373737373Actual64.3768.6569.0768.4272.0374.8774.1071.5771.1976.0674.93OverallABP332340343346382384402402366366463470Actual340.50334.29334.20332.58333.84354.87393.00398.87375.35358.55432.89

9Unit : Nos./day

Likely pushing for 2013-14BattQ1Q2Q3Q42013-14APPActAPPActAPPActAPPLikelyAPPLikely1899290938891888589902899190928889888589893373538252721002521400000047471212501211553727375374165749604361436444614570000000000866687272737373757172Total338336371340390389433412383369%99.4191.8499.7695.1596.45

Unit Nos./Day

10CO&BPP

Battery wise Repair Plan vs. Actual Repair 2013-14Bat #Repair PlanActual Repair1None2None3Stopped for Cold repair & Common facilities job on 12/12/13 commissioning by May 2015.4Re-commissioned after Cold Repair on 31st January 2014.5Stopped for a 6 month Hot repairCommissioned 25 days ahead of schedule.6None7Under rebuilding, stage 2 obtained in Oct13, contract finalized in Dec13, Work started on 10/02/2014, commissioning by 1st June 20168End vertical repair in 15 HWs11 nos completed.

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Oven Availability vs Pushing Potential : 2014-15BattAprMayJuneJulyAugSepOctNovDecJanFebMarAvg1Availability69696969696969696969696969Potential84848484848484848484848484.02Availability69696969696969696969696969Potential84848484848484848484848484.03Availability0000000000000Potential00000000000004Availability69696969696969696969696969.0Potential75788284858585858585858583.25Availability69696969696969696969696969.0Potential74747474747474747474747474.06Availability00000060606060606030.0Potential00000060606060606030.07Availability0000000000000Potential00000000000008Availability63626262626251515166666660.3Potential72727273737358585876767669.8OverallAvailability339338338338338338387387387402402402366.3Potential389392396399400400445445445463463463425.0

12Unit : Nos./day

Strategy for COB#1&213All 69 ovens are in healthy condition. New Hydraulic PLC driven battery machines. Pushing is consistent. To sustain coefficient of pushing, Enablers areA Composite contract has been started for Operational Cleaning, Heating, Anchorage regulation and Condition based monitoring of Battery Health (COMIT).AMC for Door Maintenance, Compressor Maintenance.2013-14 (till Feb)Oven AvailabilityOven PushingCoking PeriodCoefficient of PushingABPActualABPActual16969.008990.5218:230.9726969.008989.5518:380.97

Strategy for COB#314Battery is under Cold repair (Job started in Feb14) Commissioning by May 2015.2013-14 (till Feb)Oven AvailabilityOven PushingCoking PeriodCoefficient of PushingABPActualABPActual2823.512822.4125:480.85

Strategy for COB#415Battery was commissioned after Cold repair on 31st January 2014, as per schedule.Oven pushing will increase after due regulation as indicated in Pushing plan.2013-14 (till Feb)Oven AvailabilityOven PushingCoking PeriodCoefficient of PushingABPActualABPActual46666.3723:000.95

Strategy for COB#5Battery was commissioned after Hot Complex repair on 10th September 2013, 25 days ahead of schedule.Oven pushing has been stabilized.Ceramic welding of joints and Cleaning of regenerator ports is being done to reduce cross leakage between Old New brick joints and to improve the temperature profile of the Battery.2013-14 (till Feb)Oven AvailabilityOven PushingCoking PeriodCoefficient of PushingABPActualABPActual53435.203337.7122:150.90

Strategy for COB#617It is a 31 year old battery. Presently 41 ovens are in operation. Most ovens are damaged and require constant Ceramic welding / Dry Gunniting for operation.A 6 month long Hot complex repair including changing Coke side service platform and Gas collecting mains is planned.After repair at least 60 healthy ovens will be in operation.2013-14 (till Feb)Oven AvailabilityOven PushingCoking PeriodCoefficient of PushingABPActualABPActual5542.456044.6820:440.85

Status for COB#7Stage 1 approval for rebuilding obtained in Oct12. Divided into 4 packagesStage 2 approval obtained in Oct13Dismantling started on 11.12.12 and expected to be completed.LOA issued to Mecon on 05/11/2013.Final contract signed on 16/12/2013.Work started 10/02/2014.Commissioning COB#7 by 01/06/2016.

Strategy for COB#81964 ovens are in operation. Remaining ovens have hole and need to be repaired.A package of Complete Battery Maintenance is being executed by M/S Fosbel, including All activities except Pushing / Charging.M/S Fosbel is carrying out End vertical repair and full wall repair will be carried out in selected ovens as per plan. 2013-14 (till Feb)Oven AvailabilityOven PushingCoking PeriodCoefficient of PushingABPActualABPActual6259.717171.3919:500.95

REPAIR PLAN: 2014-15BatAprMayJunJulAugSepOctNovDecJanFebMar12345678

COLD REPAIREND FLUE REPAIRREBUILDING20HOT COMPLEX REPAIR

20

Repair/Rebuilding Plans for Next 5 YearsYear2013-142014-152015-162016-172017-18COB#123456 789

Feb14 to May15Dec13 to May16Jun16 to Mar19Apr15 to Dec17Oct14 to Mar18Jan12 to Jan14Apr13 to Sep13Apr14 to Sep14COLD REPAIRREBUILDINGHOT COMPLEX REPAIRNEW CONSTRUCTION

21CO&BPP

Availability of Indian Prime Coking coal in 2013-14SlMonthReceiptAllocation% Pro rataBlend1April 208713500059.639.242May176342700065.3110.003June220653100071.1810.004July250743100080.8811.855August155453100050.158.616September194322700071.9710.337October153672400064.036.198November142492200064.776.749December1583415000105.537.1610January177982300077.388.0011February172602800061.647.45

Blend usage as per APP: 14%

Availability of Indian Medium Coking coal in 2013-14SlMonthReceiptAllocation% Pro rataBlend1April 94685000189.367.432May131351900069.137.003June182682700067.667.004July70291900036.995.215August70291900036.994.896September120443000040.154.267October169951700099.976.098November83371500055.585.539December101921500067.955.4910January78281200065.235.0011February153801900080.956.34

Blend usage as per APP: 04%