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Mined iron ore is processed in an agglomeration factory to be converted for use in an industrial
context. It is then combined with steel coke (a product obtained from coal and made up of 96% of
carbon) inside a blast furnace. The smelting of the two compounds results in the constitution of iron,
from which the residues are then taken out (or « slag »1). It takes 1.7 tons of iron ore to obtain a
ton of cast iron and between 450 and 650 kg of coke. The cast iron is therefore an alloy of iron and
carbon. Chrome, nickel or tin based alloys can also be obtained. The cast iron that has been obtained
must then be passed through a converter to transform it into steel. The conversion is completed by
heating the iron to a high temperature and injecting air or pure dioxygen into it to make the
combustion of carbon and impurities possible. The conversion is a delicate stage that conditions the
quality of the steel that will be obtained. This implicates having a command of the Gildchrist or
Bessemer processes .
A particularly reliable supply of mining products is required due to the important quantities of ore
used. These industrial installations consume large amounts of energy in order to reach the necessary
temperatures; consequently they are kept permanently active in order to maintain the correct
temperature.
The steel companies are able to acquire mining products from the principal general mining
companies (BHP Billiton, Rio Tinto, Xstrata) that are situated in various geographical locations. These
companies have important « multi mineral » resources available as well as large scale logistical
capacities that correspond to the steel sector’s demands: important volumes, worldwide
implantations, the need for various different metal ores, and coke. It is also possible to call upon
various mining companies, such as CVRD or Falconbridge, that are more specialized in certain
resources. The relations with these suppliers are governed by long-term procurement contracts that
enable them to secure necessary quantities and obtain more advantageous tariffs. As production
levels are not always guaranteed, the steel manufacturers can also procure the missing quantities on
the iron and coke spot markets (LME, NYMEX), whose prices have spiralled significantly since 2005,
following the trend of the other commodities.
1
Slag : calcium silicate and aluminium silicate
Businesses
Anglo Platinum,
England-
American 29 400 3 7,8% - - Diamonds,
South Africa
Copper
CVRD Molybdenum,
Brazil 12 800 nc nc 1 32,0%
Manganese
Xstrata 4,5%
Switzerland / 3 500 + 2
Falconbridge* 4 (avant - - Chromium
Canada 400
fusion)
The steel producing companies also have the possibility of integrating mining activities by buying out
operational mines or by equipping themselves with a mining exploration permit (see Appendix 2 :
Internal cover rate of mineral supplies of the principal steel manufacturers). However access to these
resources remains difficult, costly and risky. Thus the aim of this is more to guarantee supplies,
monitor the resource‘s evolution or to withstand price increases on the spot markets. This however,
is not the core business of steel manufacturers and the synergies of skills between mining and steel
production remain limited.
The other fundamental raw material in the steelmaking industry is energy. In France it is estimated
that steelmaking alone (which has strongly declined since the eighties) consumes 20 to 25% of the
total energy consumed by the industrial sectors as a whole. This energy consumption is mainly in the
form of electricity, supplied in Europe by powerful companies such as EDF, British Energy, Eon,
Endesa or Enel. In order to limit their energy costs and to guarantee their supplies in case of a peak
in consumption, the steel manufacturers generally conclude long term contracts.
In % of the total production in the region Basic Oxygen Furnace Electric Arc Furnace
Flat 51,2%
Long 41,4%
Pipe 7,4%
Total 100,0%
B. The clients
The versatility of steel and its alloys means that it is used in many areas and applications. The
majority of this consumption is concentrated around several large clients; however the volumes and
the quality of steel they require are not uniform. They often have very specific requests which force
the steel producers to work closely with their clients.
Mechanical
Contruction 43% Industries 22%
Automotive 19%
Others 2%
Rails 2%
Oil & Gas 5%
Ship Yards 3%
Packaging 4%
2. Mechanical construction
Steel (and its diverse alloys) satisfies the demand in this sector particularly well. More often than
not, clients need specific products, especially for precision parts, developed jointly with their R&D
departments. Steel is used in all forms: flat products, long products but also ingots intended for
moulded parts. The characteristics of steel and its reasonable price puts it in a favourable position
when compared to other metals that are generally more expensive (bronze, cobalt, manganese). The
mechanical construction sector is less cyclic than the construction and public works’ sector as it is
linked to a multitude of downstream markets. The mechanical construction sector is fragmented
(large number of companies) and the companies in this sector are extremely specialized. Hence, the
steel producers must collaborate closely with their their clients in the mechanical construction sector.
6. The shipyards
Steel is the main raw material used in shipbuilding. A ship’s structure (frame, bodywork of the hull
and the deck…) is constructed from semi-finished materials and products transformed into steel.
Therefore the quantities used by this industry are considerable, both in long products (girders) and
in flat products (strong sheets). Being highly shock resistant and low priced, steel is particularly
appreciated in this sector. The steels used for the majority of ships are essentially carbon steels with
a low value added. However, certain very specific activities (construction of gas carriers) require
special steels (with chrome and with nickel). The escalation in shipping traffic and the boom in
container transport (made from steel) have increased this sector’s demand for steel. The industry
has undergone major restructurations over the last few years and only the more stable shipyards
have survived, mostly in Asia (Hyundai, Daewoo) and a few in Europe, notably Aker Kvaerner.
EU 113 97 97 93 -17,6%
Japan 76 68 73 73 -4,0%
As a result of the decline in the demand, there was a surplus in the production and the steel
factories’ utilization rate fell strongly. This was accentuated by the inactivity of numerous investment
projects: they had been developed before the crisis but came into operation at the height of the
overproduction period. In the short term, price naturally became the adjustment variable which quite
collapsed.
However, the amplitude of the crisis was not simply due to the vicious circle of under-consumption /
overproduction, as eliminating the capacities of production in this case would have been sufficient to
stop the crisis in the steel industry. The steel industry suffered from other problems that were in fact
amplified by the crisis .
EU 6% 9% 20% 44%
Importation 21 14 14 21 30 +42,8%
The victors of the crisis were undeniably the Asian steel producers, whose technological and
managerial advance made it possible for them to impose themselves as extremely aggressive and
profitable actors, despite the difficult market conditions on a worldwide scale. In spite of increased
steel consumption and the stabilization in world development at the end of the Eighties, this did not
lead to a rise in production capacities.
1200
Steel Production in mt
1000
800
600
400
200
0
50
70
90
96
98
99
01
03
05
60
80
95
97
00
02
04
19
19
19
19
19
19
20
20
20
19
19
19
19
20
20
20
World Steel Production in mt
The modernisation efforts carried out in Europe and the US during the Eighties meant that the
pressure on prices was reduced with an increase in the range of products. The rationalization of the
continuous casting process, the oxygen converters and the development of the electric arc process
(mini mills) both improved the steel producers’ productivity. As a result of these two levers, the
profits of the companies in the sector were undeniably restored. However this balance remained
fragile right throughout the Nineties due to tough competition in the sector, all the more so due to
the appearance of new actors with low costs (labour force and raw materials) from countries whose
markets had been closed up until then (Russia: NLMK, Severstal, Evraz; and China: Baosteel). In
addition, for the traditional actors in the sector, the essential sources of productivity gains had been
exploited. The steel producers therefore had to find other alternatives in order to align themselves
with these newcomers and reduce their costs; this resulted in a merger wave in the sector.
2
Usinor also took over Sollac in 1990 and Ugine’s steel activities in 1991 following the elimination of the industrial conglomerate PUK
(Péchiney-Ugine-Kuhlman).
This first merger wave did not happen by chance and took place mainly in Europe. Face d with
competition from the Asian, Russian and Chinese steel producers, the principal companies
unquestionably sought to capitalize on the size effect and synergies to limit costs in order to remain
competitive. There is however another explanation. The fragile balance of prices depended mainly on
a rigorous management of production capacities. Bearing this in mind, the only way for the steel
producers to grow and increase their profitability was to absorb the production capacities of a
competitor. As a result steel producers were pushed to overgrow to increase their market power and
marginalise their competitors.
The favourable conditions within the sector and in the financial markets since 2003/2004 relaunched
another round of mergers and acquisitions within the steel industry (see Appendix 4: Main mergers
and acquisitions in the steel industry since 2004). Thus in 2005, Arcelor launched a takeover bid for
the Canadian company Dofasco, who specialised in flat products and was extremely well positioned
on the American automotive market. In spite of the German company ThyssenKrupp’s counter offer,
it was finally Arcelor who carried it off, before becoming itself the target of a takeover bid by Mittal
Steel in January 2006 (see Appendix 5: Profile of the main global steel-producing companies).
E. Market tendecies
1400
1200
1000
Rest of the World
In mt
800
600 China
400
200
0
2004 2005 2006e 2007e
China NAFTA
31% 14%
Japan
8%
Australia & New
Zealand
1%
CIS
4%
New EU Countries
2% Africa Other Europe
South & Central Middle East
2% 3%
America 3%
3%
2. Price increases
The tendency towards price increases in steel products persisted and it was not only Asia (south East
Asia and Japan) that was concerned. In all the major consumption zones, prices spiralled as never
before (between 100 and 200%), compared to 2001. Yet, this phenomenon of price increases did not
result in tensions between the offer and demand on a worldwide scale. Two major elements became
apparent; firstly the steel producers adopted a stocking policy to take advantage of the best prices,
800
700
600
500
In USD / Tonne
400
300
200
100
0
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
3. Escalation in exchanges
Up until now the steel market had resulted from the addition of regional markets that were relatively
« isolated », with differences in demand and high prices. The majority of the exports were limited to
inter-zone/inter-regional exchanges. This was explained by the protectionist policies that aimed to
stabilise prices in each region. However, since the end of the Nineties, despite the existence of a
pronounced American protectionist policy, the increase in China's needs led to a noticeable growth in
exchanges of steel products.
1000
900
800
700
600
In mt
500
400
300
200
100
0
75
81
87
97
03
77
79
83
85
89
91
93
95
99
01
19
19
19
19
20
19
19
19
19
19
19
19
19
19
20
Production Exports
. Nevertheless, this increase of exchanges did not have an impact on all types of steel products.
Globally it was long products that were exchanged the most.
India 89 20%
Russia 38 9%
Others 47 11%
These new capacities will progressively inundate a market that is fragile and extremely dependent on
world growth. Faced with an increase in production capacities, prices (which had been corrected and
lowered during the second semester of 2006 due to the effect of destocking) should be less
favourable for the steel producers in the years to come. The sector should therefore experience new
perturbations, whose effects will be felt progressively, with the risk of causing a decline in the
demand and over-capacities of production.
Steel Scraps
ContinuousCasting
Rolling Mill
Rolled Products
Source : Usinor
Appendix 2 : Internal cover rate of mineral supplies of the principal steel manufacturers in 2005
In % of the Arcelor Mittal Corus Acerinox Us Nucor Dofasco Nippon JFE Posco Evraz Severstal NLMK
consumption Steel Steel Steel Holding
Iron 6% 69% 0% nd 96% 0% 273% 19% 18% 17% 128% 61% 95%
Coal 85% 89% 90% nd 140% 0% 100% 92% 96% 100% 115% 100% 218%
Source : Brokers, Rapports annuels
Production mt 46,7 49,2 18,2 2,7 19,3 18,4 4,2 32 29,9 30,5 13,9 13,6 8,5
Revenue 40 764 28 132 18 556 5 267 14 039 12 701 3 802 31 561 26 108 26 041 6 508 7 973 4 469
Depreciation 1 618 829 562 140 366 375 195 1 682 1 674 1 597 243 256 284
Non Recurring Items 36 0 -73 0 -21 0 0 -461 1 652 0 -32 17 -12
5 470 4 746 1 244 322 1 439 2 053 252 3 561 3 018 6 023 1 584 1 873 1 822
EBIT (declared)
EBIT (Current) 5 434 4 746 1 318 322 1 460 2 053 252 4 022 4 670 6 023 1 617 1 856 1 834
Financial Result -318 -43 -183 -37 -127 -37 -27 -102 -191 -589 -65 -146 84
5 513 4 703 1 061 285 1 312 2 016 225 3 459 2 828 5 434 1 519 1 727 1 906
Profit Before Tax
Tax 201 818 236 94 365 706 79 1 278 1 319 1 468 476 436 496
Tax Rate (declared) 3,7% 17,2% 19,0% 29,2% 27,8% 35,0% 35,0% 36,9% 46,6% 27,0% 31,4% 25,2% 26,0%
Minorities 540 520 2 0 37 0 4 109 19 -6 137 3 29
Net Profit 4 771 3 365 824 191 910 1 310 146 2 181 1 509 3 972 905 1 289 1 382
Net Profit (Current) 4 375 3 365 897 191 931 1 310 143 2 534 3 142 3 972 938 1 271 1 393
Number of Shares
Diluted 649,532 687 889 261,4 113,47 157,1 77,2 6734,7 587,2 87,2 112,7 551,9 5993,2
Ordinary 688,493 687 963 261,4 129,97 158,6 77,6 6734,7 587,2 87,2 112,9 551,9 5993,2
EPS (declared)
Diluted 7,35 4,90 0,93 0,73 8,02 8,34 1,90 0,32 2,57 45,56 8,03 2,34 0,23
Ordinary 6,93 4,90 0,85 0,73 7,00 8,26 1,89 0,32 2,57 45,56 8,02 2,34 0,23
Source: Annual reports 2005
ASSETS
Actif circulant
Inventories 9 475 6 036 3 576 1 615 1 466 945 1 165 5 270 4 745 3 755 964 993 27
Debtors 4 645 2 287 2 767 650 1 598 1 001 537 4 261 4 827 3 015 375 460 660
Other Current Assets 2 224 1 392 199 61 288 288 67 988 1 142 4 109 665 624 718
Cash & Equivalents 5 806 2 035 1 594 102 1 479 1 838 102 1 188 560 647 641 1 819 1 897
Total Current Assets 22 150 11 750 8 136 2 428 4 831 4 072 1 871 11 707 11 274 11 525 2 644 3 897 3 302
Fixed Assets
Tangible Assets 17 209 15 539 5 161 1 984 4 015 2 856 1 849 15 591 17 191 12 150 2 960 5 985 2 394
Other Fixed Assets 5 536 3 901 1 237 147 976 212 137 8 758 5 583 3 560 1 047 867 355
Total Non Current Assets 22 745 19 440 6 398 2 131 4 991 3 067 1 987 24 350 22 774 15 710 4 007 6 853 2 749
TOTAL ASSET 44 895 31 190 14 534 4 559 9 822 7 139 3 857 36 057 34 048 27 235 6 651 10 749 6 051
Liabilities
LT Financial Debt 5 426 8 056 2 394 330 1363 922 487 7640 9429 1251 1545 1418 0
Other LT Debt 4 923 5 579 1 444 307 2354 487 727 2951 2732 491 325 1114 356
Creditors 6 535 2 504 3 375 428 1256 502 452 4487 4083 1327 398 318 508
ST Financial Debt 2 029 252 703 808 249 1 225 4299 4043 1898 835 556 0
Other ST Debt 3 941 2 815 437 121 1244 753 59 4761 4391 2598 663 253 41
Total Liabilities 22 854 19 206 8 352 1 994 6466 2665 1951 24138 24678 7565 3766 3659 904
Equity
Shareholder's Equity 18 886 10 150 6 134 2 431 3324 4280 1871 11066 9020 19287 2695 7004 5054
incl. Reserves nd 7 887 2 194 1 752 1605 4709 1184 4734 1833 15998 1738 2801 4749
Total Equity 18 886 10 150 6 134 2 431 3324 4280 1871 11066 9020 19287 2695 7004 5054
Minority Interest 3 155 1 834 48 133 32 194 36 852 350 383 190 85 93
TOTAL LIAB. & EQUITY 44 895 31 190 14 534 4 559 9822 7139 3857 36057 34048 27235 6651 10749 6051
Employees 96 256 227 000 48 200 6 695 46 000 11 300 7 200 20 432 52 503 19 004 110 000 52 919 52 461
Source: Annual reports 2005