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Developments in Steel Minimills Thomas A. Danjczek Steel Manufacturers Association October 3, 2006 SMA Meetings – Indianapolis Plant Operations Division Associate Members Environment Committee Human Resources Committee Safety Committee
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Developments in Steel Minimills I.SMA II.2006 Developments World Steel Production/Operating Rate China (Growth, Questions, Concerns, Challenges) Raw Material Pricing 2006 U.S. Market Outlook Consolidations III.Impact of Mercury in Scrap IV.Conclusion SMA Meetings – Indianapolis
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The Steel Manufacturers Association (SMA) –38 North American companies: 32 U.S., 3 Canadian, and 3 Mexican –118 Associate members: Suppliers of goods and services to the steel industry SMA member companies –Operate 120 Steel plants in North America –Employ about 40,000 people –Minimill Electric Arc Furnace (EAF) producers
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SMA Meetings – Indianapolis Production capability –SMA represents approximately 70% of U.S. steel production Recycling –SMA members are the largest recyclers in the U.S. –Last year, the U.S. recycled over 70 million tons of ferrous scrap Growth of SMA members –Efficiency and quality due to low cost –Flexible organizations –EAF growth surpassed 53% in 2004, 56% in 2005, and anticipated to be 58% in 2006
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Projected Worldwide Crude Steel Capacity vs. Demand (2006 – 2010) Million Metric Tons *Demand growth estimated at 6%/yr
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Worldwide Announced Steel Capacity Additions By Region Million Metric Tons 110 106 139 51 120 45 44
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SMA Meetings – IndianapolisChina’s Impact After 5 Trips in the Past Two Years… Key Questions: - When will Chinese steel production significantly exceed its own domestic consumption – i.e. 50/60 MMT? - Will the Chinese government shut down inefficient, excess capacity? (has not done so with polluting facilities, despite strong policy) - How can North American steel industry compete against Chinese government - - IT CAN’T!
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SMA Meetings – Indianapolis China’s Subsidies -Export subsidies -Import substitution subsidies -Grants (land, cash, energy, raw materials -Tax incentives & reductions -Debt to equity conversion -Debt forgiveness -Environmental non-enforcement & weak regulation -Non-performing loans at state banks -Preferential loans -RMB manipulation -Barriers to foreign investment WHO IN THE ROOM IS RECEIVING ANY OF THE ABOVE???
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CHINA’S CHALLENGES Area Comment EnvironmentTrade policy and laws are not enforced regarding emissions and effluents; Province versus Beijing; employment rules, not environment; 20% of particulate matter in Los Angeles can be traced to China ConsolidationsState-owned facilities; only non-controlling foreign ownership allowed; antiquated facilities; policy is 20 large producers, push small producers out Technology/QualityQuality in flat rolled will affect export capabilities. Switch from long to flat not easy InventoriesRun full out. Not always market-oriented CapitalWill not always be free; could lose state credit PersonnelSome “unrest” expressed toward elite class. Internet is politically uncontrollable
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RAW MATERIALS I n the four years from Q1-2002 to Q1-2006, raw material and energy input costs for U.S. steelmakers have increased dramatically. January 2002 = 100 Courtesy of Chris Plummer, Metal Strategies
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2006 U.S. MARKET OUTLOOK We project apparent consumption growth in the 7-10% range for 2006, driven by the energy, construction and industrial capital equipment sectors. Courtesy of Chris Plummer, Metal Strategies
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Individual Domestic Demand Sectors - Automotive is high, but dipping slightly - Residential construction is falling, but still high - Industrial machinery production rising - Non-residential growing, but not back to 2000 level - Heavy machinery is strong - Energy is the best sector Plate, pipe, and specialty SMA Meetings – Indianapolis
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TOP-THREE MARKET SHARES 2000 compared to 2005 Flat Rolled Weighted Average 2005:65% 2000:47% Long Products Weighted Average 2005:68% 2000:51% Courtesy of Chris Plummer, Metal Strategies
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History: 2001 –Partnership for Mercury-Free Vehicles (PMFV) is formed Members:Automotive Recyclers Association (ARA); Clean Car Campaign; Clean Product Network; Ecology Center; Environmental Defense; Great Lakes United; Institute of Scrap Recycling Industries (ISRI); Mercury Policy Project; Steel Manufacturers Association (SMA); Steel Recycling Institute/American Iron & Steel Institute (SRI/AISI) PMFV, through memberships, lobbies several state legislatures to pass a measure to institute a state vehicle mercury switch removal program, with costs associated to be paid by US automotive companies. States with legislatively enacted switch removal programs: Maine; Arkansas; Rhode Island; North Carolina; South Carolina;Texas; and New Jersey Mid-2005 – US EPA calls stakeholders meeting to bring all major actors to negotiation table March 2006 – Compromise reached in negotiations to form a fund (paid for by US auto co.s and US steel industry) to create a national switch removal program. August 2006 – Signing Ceremony planned for enactment of National Vehicle Mercury Switch Removal Program MOU
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Signatories: Vehicle Manufacturers; iron & steel industry trade associations on behalf of member companies (SMA; ISRI; ARA; SRI/AISI); Environmental Defense, on behalf of the environmentalist community; Environmental Council of the States (ECOS) Elements – 1. Education and outreach 2. Removal, collection and management of switches 3. Recordkeeping and accountability of mercury recovery 4. Scrap Selection and corroboration 5. Review and improvement of program performance goal (80% target), with expectation of removing about 12-16 tons of mercury in first three years (2007-2010) Responsibilities (of all signatories): 1.The obligation to carry out responsibilities under the agreement in good faith, and work continuously to improve the performance of the NVMSRP; 2. Help formulate and implement an outreach strategy 3. To forego the initiation of new State legislative activities 4. To support existing state programs, and to implement the NVMSRP in states without existing programs. Responsibilities of steel companies: 1) Issue a public statement; 2) Develop a plan; 3) Document communications to appropriate company staff of requirements to suppliers; 4) Strongly encourage suppliers to participate, and communicated to suppliers the need to further promote the program; 5) Utilize the ELVS database to verify supplier participation on a routine basis; 6) Conduct periodic site visits, spot checks, or other means to verify supplier participation; 7) Cooperate with ELVS in the development of education, training materials and outreach
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SMA Meetings – Indianapolis Conclusions - 2006 Hell, it’s still a cyclical business, but enjoy today! Fundamental shift in both demand and supply due to China & its appetite for raw materials – China is still the “wild card”. Risk near term is auto’s; long term is China… “China is the story, the rest is embellishment” Continued North American steel industry resiliency; North American mills, for the most part, are technologically advanced, highly competitive, and environmentally acceptable Consolidations and discipline have had an impact to reduce volatility Role of inventories affecting pricing and production Demand still healthy and growing Unknowns (oil, interest rates, auto sector, energy, freight rates, federal spending, China, China, China) Significant changes ahead in trade, metallics, energy, and consolidation Still reasons for meaningful optimism; positive outlook, despite China, energy costs, and interest rates
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