Professional Documents
Culture Documents
The ppurpose
p of this studyy is to determine the strategic
g importance
p of the Malaysian
y iron and steel
industry and to define the direction and policy recommendations to ensure industry success
• Current context, achievements and challenges affecting the end-to-end industry
• Economic contribution to-date
• Potential
P t ti l opportunities
t iti tot develop
d l andd grow th
the iindustry
d t
• Government priorities and policies to support industry success
This study will address three key questions for the industry
• What is the strategic importance of the steel industry to Malaysia?
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 1
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7 Stakeholder engagement
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Project SCM #1 SCM #2 SCM #3 SCM #4
kick-off (3 April 2012) (17 April 2012) (7 May 2012) (29 May 2012)
(19 March 2012) Inception Draft Final
Interim Report Final Report
Source: BCG Report Report
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 2
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Executive Summary
Today Malaysian steel industry contributes ~4% to the economy and has a significant opportunity at ASEAN level
• There is a ~22.4 MTA opportunity in ASEAN, of which 18.3 MTA for flat products
• Malaysia should have the ambition to retain and develop a comprehensive end-to-end steel industry
• A fully developed steel industry could contribute up to ~6.5% to the Malaysian economy by 2020
Malaysian long industry is already liberalised and competitive, whereas flat industry is facing challenges
• Sole flat upstream producer (Megasteel) uncompetitive, unprofitable, with negative repercussions on mid/downstream players
The window of opportunity is short for flat industry to become competitive and seize regional opportunity
• Regional players ramping up investments in Indonesia and Vietnam to reduce ASEAN gap
Aside from Lion Group, there are 4 projects to build flat upstream capacity in Malaysia
• Only
O l 1 meeting
ti mostt off long
l term
t success factors
f t
Malaysia steel industry could be structurally competitive: 3 Government initiatives to support the entire steel industry
• Provide advantaged access to select inputs: Primarily iron oreore, to a lesser extent gas
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• Enhance capabilities of the Steel Industry (e.g. Steel Institute set-up)
• Enforce trade defenses and trade barriers to guarantee a fair level playing field
Steel mill
Iron &
Steel-
making Crude steel
Steel
Casting core
Long (Bloom, Billets)
activities
Flat (Slabs)
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C
Commercial,i l corporate,
t
residential, ship-building, agricultural etc. etc. appliances, etc.
public transport, etc.
etc. equipment etc.
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1. Kuwait and Bahrain have no upstream long steel, Denmark has no downstream long capacity, among the 97 countries represented in Metal Bulletin;
Note. 31 high income defined as GDP per capita above $20k in world PPP dollars from the World Bank's 2010 GDP per capita data.
Source: Metal Bulletin Capacity Q3 2011; Worldsteel Steel Statistical Yearbook 2011; WSD, SEAISI, BCG Model; EU DG Trade statistics; BCG Analysis
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Flat steel industry similarly present in almost all high income
economies
No flat steel
Only operate very far
downstream4
Only downstream flat
Both
B th upstream
t and
d downstream
d t
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1. Norway is an exception; 2. Portugal is an exception; 3. Defined as <100% of GDP. Luxembourg, UAE and Estonia are exceptions; 4. 75% of them operate in tinmills and further downstream where only
40% of Malaysia's downstream capacity is.; Note. 31 high income defined as GDP per capita above $20k in world PPP dollars from the World Bank's 2010 GDP per capita data
Source: Metal Bulletin Capacity Q3 2011; World Bank; BCG Analysis; CIA World Factbook: EU DG Trade statistics; WTO statistics; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 7
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49
5.3%
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1. ASEAN-6: Indonesia, Thailand, Malaysia, Vietnam, Philippines, Singapore; Source: IISI / WSA Steel Statistical Yearbooks 1990 to 2004, SEAISI 2005 to 2010, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 8
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Regional finished product gap of ~22.4 MTA, including ~18.3
MTA for flat products
Long steel is primarily domestic market Flat demand met largely by imports
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1. Hot rolled steel products (rails and accessories, steel sheet piles, sections, bars, wire rods, round for tubes, plates, hot rolled sheet and strips and tyres and wheels), cold rolled steel products (cold
rolled sheets and strips, cold rolled electrical sheets), coated sheets and strips (galvanized sheets, tinplates, etc.), pipes and tubes (seamless and welded)
Source: SEAISI, BCG analysis
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Today, Malaysian steel industry contributes ~4% to GDP,
employing ~150,000
150,000 people
Steel industry contribution to Malaysian GDP Steel industry contribution to Malaysian employment
(in thousands)
4.3% 4.3% 152 152
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1. Key assumptions: 10 MTA new Malaysian capacity. 6% CAGR real increase in GDP, 1.6% CAGR in iron& steel productivity; 2. Assumes Malaysia serves 10 MTA production in flat steel, supplied by 2
upstream players; Note: Upstream considered from iron to hot-rolling, midstream is cold-rolling to galvanizing, downstream is further down the value chain. Current estimates of Value Added to GDP are
shown for 2009, using data obtained directly from the Department of Statistics for MSIC codes 241, 243, 251 and 259; Current industry multiplier of 1.7 calibrated by benchmarking. Distribution among
flat/long and upstream/midstream/downstream explained on backup slide.
Source: Malaysia Department of Statistics; Bekhet (2011) on "Output, Income and Employment Multipliers in Malaysian Economy:Input-Output Approach"; BCG analysis
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Breakdown of Malaysian Malaysian vs international Avg profit margin of main long steel
imports of long products1 prices for long products manufacturers (2007 – 2011)
(%) (USD/MT)
84% 100%
100 900
Malaysia2
75 800
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1. HS codes 7213 to 7217 2. Mild Steel Round Bars - R25, MS146, 3. Long Products / BOCE Rebar / China West Cash bid/settlement; 4. Long Products / Rebar / Japan domestic (Tokyo Steel) CIF,
5. 2008-09 industry average; Note: Quarterly exchange rate applied; S; Note: Ann Joo and Lion Group: Includes limited non-steel activities , Lion Group: Excludes DRI activities, Southern Steel:
Includes pipe and tube activities;
Source: Bloomberg, company websites, annual reports 2007-2011, China Metallurgical Industry Planning and Research Institute, DOS, CIDB, SBB Steel Prices, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 11
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...with negative
Low profits/losses at Still high HRC import duty repercussions on
Megasteel in Malaysia... mid/downstream players
Megasteel's profitability 2008-2011 Import duty1 applied for Current duties impacting
HRC in ASEAN countries mid/downstream players
• Import d
duties
ties 5% or belo
below for
Positive results due (%) coated / galvanised products
to accounting
200 150 adjustments – 40 and further downstream
100 inventory write-off • Domestic raw materials price
20% ~10-20% higher than
100 20
international prices
4% 5%
A rights reserved.
0% 0%
0 -6x 0
Issues raised on product quality
-500 • Multiple players reporting that
-500
500 Megasteel products lead to 10-
10
Megasteel
g needs restructuring
g of its lending
g facilities
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by June 2012
1. Based on Product HS code7208 – Flat-rolled products of iron or non-alloy steel, of a width of 600 mm or more, hot-rolled, not clad, plated or coated; 2. Duty exemption mechanism recently revised
in 2009; Note: 2012 results are from Megasteel's own projections for profitability; Source: Megasteel's audited accounts for 2008-2011 and own projections for 2012; interviews and confidential inputs
received from other industry players; Press Search, Macmap; Customs data, Government websites, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 12
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Flat industry: Short window of opportunity to become
competitive and seize regional opportunity
ASEAN: Announced capacity for hot rolled flat and supply-demand gap evolution
Capacity extension in MTA ASEAN supply-Demand Gap in MTA
20 20
18.3 18.6
17.2
15.0
15 15
10.6
10 10
NA 0.4
0 0
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of 3-4MTA based in Malaysia
Note: Only officially announced and documented projects are included; All projects unlikely to come online in time – Formosa project with 3 years delay already, Lion Group and MIG lack financing;
Source: Plantfacts, Metal Bulletin, Press Search, SEAISI Steel Statistical Yearbook 2011, BCG Analysis
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Thailand and Indonesia with lower import tariffs, but tighter
non-trade
non trade barriers and defenses
Thailand Indonesia Vietnam Malaysia
(MTA)
Imports as % of flat
61%4 56%5 100% 67%
consumption
Non-ASEAN FTAs 6 2 2 5
Required Required
Import license Required Required
(annual renewal) (monitoring purpose)
"Indonesia's President Susilo said the construction of a steel factory Krakatau-Posco would be an
essential support to accelerate Indonesia’s
Indonesia s economic growth in the next 15 years"
years
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1. Range for flat HRC and CRC products; 2. The data represents cumulative trade defenses employed for base metals and articles, which includes, but is not limited to steel products; 3. Data taken
from the WTO database of cases from 1995-2011. Zero assumed due to no reports received by the WTO from reporting country (as required by the WTO regulations);
4. 3 key upstream producers with multiple mid-stream players; 5. Krakatau key upstream player with multiple mid-stream players
Source: MITI, SIRIM, CIDB, DOSM, ISIT, BSN – SISNI, MIDA, Tariff Finder, UNCOMTRADE , Macmap, OECD, Standards, Regulatory Reforms & Development in APEC, Press Search , SEAISI,
WTO (1995-2011); industry interviews, BCG Analysis
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Another four local projects underway... ...only one able to meet most KSFs
1 5MTA BF
1.5MTA BOF Kemaman,
BF-BOF, K T
Terengganu
• Financing completed, contracts
3-10MTA
3 10MTA BF-BOF
BF BOF (location TBD)
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operations in Malaysia to serve regional demand
Source: Press searches, Interviews, BCG experience Does not meet criteria Fully meets the criteria
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 15
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Megasteel: Urgent need to resolve challenges in flat industry
especially, related to sole up
up-stream
stream player
Continuum of solutions
Sudden exit Controlled exit Free market Shared Protection
success responsibility
p y
A rights reserved.
Steel Steel Very low likelihood Steel Steel
Banks Banks Banks Banks
Ind. Ind. given current Ind. Ind.
industry situation
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economy benefits
1. Except for re-export, automotive, shipbuilding and 50-50 for re-rollers
Note: For each stakeholder, the higher the score the better the outcome
Source:: SEAISI; MIDA; Megasteel documents; Megasteel P&L, manufacturing accounts; Megasteel balance sheets; WSD; elasticity estimates by NSC USA; Department of Statistics; Platts SBB
Steel; steelonthenet; Annual Reports of various players; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 16
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H Controlled
Laissez-faire exit Shared
L Take-over by M responsibility
Government Government
M
supportt
L
Sh d
Shared
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Free market
L success
L : Low probability
Written-off loans
▬ ~0.8
~0 86 ▬ ~0.8
~0 86
(RM Bn)
Rescheduled loans ▬ ~0.67 ▬ ~0.67
RM Bn)
el
1. Average change in price index for HRCs, CRCs, coated steel, pipes & tubes, driven by elimination of duties on imported HRCs because no longer produced locally (Sudden exit and Controlled
exit), driven by requisite clampdown in import volumes across value-chain and lower Megasteel prices (Shared responsibility), driven by clampdown in import volumes across value-chain (Protection);
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2. Megasteel's employment is 1700 (4600 including supporting companies); 3. Assuming projected 20 to 40% decline in flat mid/downstream due to prohibitively high raw material prices; 4. From
elimination of duties (no local production means full duty exemption); 5. From 15% duty paid on remaining imports; 6.Banks' exposure to Megasteel (unless provisioned); 7. Syndicated loan amount
outstanding; 8. Share capital; 9. Profitability derived from estimated Megasteel's cost curve at target production levels; 10. Conservative estimates does not include further gains by mid/downstream.
Source: SEAISI; MIDA; Megasteel documents; Megasteel P&L, manufacturing accounts; Megasteel balance sheets; WSD; elasticity estimates by NSC USA; Department of Statistics; Platts SBB
Steel; steelonthenet; customs data; Annual Reports of various players; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 18
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Megasteel: ...and would open the way to become competitive
in the long run
Three key projects can provide 13% ... improving its competitive position
cost savings to Megasteel... in the region
Blast Furnace Project Cash cost production curve for Hot rolled coils (USD/t)
Construction of a Blast
Furnace (1.6MTA)
(1 6MTA)1 , sinter Landed cost in M
M'sia
sia index
plant and coke oven plant 150 Import duty
• Objective to enable CFR
Megasteel to produce higher 120
grade steel quality and -13% 112 114
105 105
reduce costs 100 100
100 92 95
TAI BOF
JAP BOF
KOR EAF
INDO BOF
CHI BOF
VIE BOF
EAF (Future)
KOR BOF
JAP EAF
INDO EAF
THA EAF
CHI EAF
energy fuel with natural gas
Megasteel
Megasteel
w t/around)2
• Diesel used as input for
reheating
EAF (w
BF-E
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1. Includes 2.1MTA for liquid steel 2. Refers to optimised Megasteel production from short-term turnaraound; current Megasteel at ~ 119
Note: BF/BOF state of the art plant is compared to average BOF and EAF cost bases in Asia-Pacific countries; Megasteel EAF Future based on 100% utilisation rate of 3.2MTA capacity;
Megasteel numbers include $60 margin from Lion BF; Source: BCG Model, WSD March 2012 database, Megasteel, EIU, TNB
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Megasteel: Any potential Government support should hinge
on Megasteel meeting strict conditions
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to 'Sudden Exit' outcome
1. Corporate Debt Restructuring Committee under BNM 2. Estimated reduction of ~25% of current imports required Source: BCG
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Megasteel: "Shared responsibility option" would be
challenging to execute
Maintain domestic prices
within 5-10% range of Tighten duty exemptions Stricter enforcement of
benchmark import prices across the value chain duty exemptions
Transparent mechanism to Target import volumes servicing Improved training for custom
define import benchmark steel value chain officers
Megasteel
M t l
• Weighted average of top-3 additional
• Knowledge of steel
countries of origin for Imports volumes products and common
reference product Total 2.3 0.8
falsification tactics
• Public data sources
• Actual or forward prices HRCs 70% 30% Increased frequency of
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1. ~40% of current HRC imports are in grades Megasteel does not produce. Reducing imports to 70% will allow the continued import of HRCs in these categories, but reducing to 37% will require
substituting Megasteel grades for some materials in place of grades that Megasteel does not produce.
Note: Volume estimates constructed from multiple sources as below, based on 2011 data. Conversion yields from HRC to CRC, etc. taken from WSD.
Source: Megasteel documents; WSD; MIDA 2011 imports of flat steel by category; Customs data; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 21
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Overall steel industry: Government should focus efforts on
three key initiatives
Provide advantaged Enforce trade remedies Enhance capabilities of
access to select inputs & standards the overall industry
Exploit Malaysian potential Implement trade remedies Steel institute as mechanism
for iron ore1 • Provide support for anti- to close critical gaps within
• Support renewed dumping, countervailing & the steel industry
exploration to unlock safeguards • Most urgently to help put in
Malaysia's full potential place stricter importation
• However, with specific Strengthen safety nets & processes to meet quality
prerequisites: standards standards
– favor domestic use of • Duty exemptions: Simpler • Help recommend trade
iron ore; but tighter process, better remedies based on robust
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1. Landed cost is highly sensitive to iron ore – 20% variation of iron ore cost changes landed cost by 8%
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In summary, two main recommendations to enhance
competitiveness of the overall steel industry in Malaysia
Main initiatives Details
1.0 Proceed with Megasteel
g exit No change
g to industry
yppolicy
y
olutioning1
Megasteel
Change in government policy on flat steel Tighten duty exemptions granted by JPC3
to be implemented for 24 – 36 months only Stricter enforcement of duty exemptions process
1.1
M
so
Implement conditions on Megasteel to Lower domestic HRC price: Keep Megasteel prices within an agreed
demand turnaround within 24 – 36 months range (5-10% of benchmark imports)
1
• Gas price monitoring Be aware and avoid significant gas price gap with regional neighbors
Enhance capabilities of the overall industry Mechanism to close critical gaps within the industry: especially
especially,
ndustry sup
24
2.4 Implement trade remedies Joint Private sector/Government effort to leverage best practices from
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other industries in Malaysia
1. Recommendation 1.0 corresponds to "Sudden exit" and "Controlled exit" options. Recommendation 1.1 corresponds to "Shared responsibility option"
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 23
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Set up
to Megasteel Positive
exemption EBITDA
Remove
exemption
restrictions restrictions
1.1
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 24
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Communication p
plan including g implementation
p approach
pp
• Announcement to key stakeholders (Megasteel, MISIF, MSA, Financial sector, etc.)
• Announcement to the press and other stakeholders
Agenda
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 26
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This study
y is to determine the strategic g importance
p of the domestic iron and steel industry y and to define
the appropriate direction and policy recommendations for the industry to achieve its full potential
• Current context, achievements as well as key challenges affecting the industry (across the value chain)
• Economic contribution to-date from the industry
• Potential opportunities to further develop and grow the industry to contribute to the economy
• Strategic priorities and policies for the Government to ensure the success of the industry
This study will address three key questions for the industry
• What is the strategic importance of the steel industry to Malaysia?
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 27
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The study
y was conducted over 9 weeks and split
p into 3 sections
• 19 Mar-15 Apr: "Where we are today." Assessment of the current steel industry
• 16 Apr-06 May: "Where we want to be." Synthesize baseline findings into a coherent end-state vision
• 07 May- 28 May: "How do we get there." Translate requirements into recommendations and implementation
plans
l
The recommendations were derived from an independent and robust fact base
• Comprehensive industry analysis through desktop and market research
• Insights from discussions with ~30 key stakeholders (40+ approached) in the industry
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 28
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7 Stakeholder engagement
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Project SCM #1 SCM #2 SCM #3 SCM #4
kick-off (3 April 2012) (17 April 2012) (7 May 2012) (29 May 2012)
(19 March 2012) Inception Draft Final
Interim Report Final Report
Source: BCG Report Report
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 29
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Formosa Vietnam Mr Chi-Hsing Tu Senior administrator No response
Dongkuk / Union Steel Mr Kwangyong Kwon Manager of corporate strategy dev
Hyundai Steel Mr Hyukje Cha Manager of corporate planning
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx Completed Scheduled 30
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Director.
Ministry of Domestic Trade & En Mohd Nasir Noryakin Director of Domestic Trade sector Declined
Consumer Affairs participation
C y Development
Construction Industry p En Razuki Ibrahim S g of Assessment &
Senior Manager
Gove
Board Accreditation
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Completed Scheduled
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 31
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Agenda
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 33
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There are two main products of steel-making – long products (typically used in Construction) and flat
products (typically used for Automotive and Electrical appliances)
• Steel is made using two major technology routes– Blast Furnace (BF) or Electric Arc Furnace (EAF)
– New technologies are available (e.g. Corex, Finex), however market penetration is still low
Today,
T d the
h steell industry
i d contributes
ib ~4%
4% to the
h M Malaysian
l i GDP,
GDP and d most off the
h GDP contribution
ib i is i
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– e.g. Symbiotic effects of strategic related industries – construction, automotive
Malaysia should have the ambition to retain and develop a comprehensive, end to end steel industry
• Malaysian steel industry should cover long and flat products across upstream, mid stream and downstream
A fully developed steel industry could contribute up to ~6.5% to the Malaysian economy with 225,000
employees by the year 2020
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 35
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Steel mill
Iron &
Steel-
making Crude steel
Steel
Casting core
Long (Bloom, Billets)
activities
Flat (Slabs)
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C
Commercial,i l corporate,
t
residential, ship-building, agricultural etc. etc. appliances, etc.
public transport, etc.
etc. equipment etc.
Direct
Limestone reduction
Converter Electric
(P i
(Primary Scrap
Coal Coke Blast arc furncace
steelmaking) (Primary
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Tyre wire – wire,
Cars – white goods Welded pipes – ships Rebars nuts and bolts Pipeline Structural profiles Train rails
Natural gas
High pressure (pre-converted)
Natural gas Ambient pressure
Feeder shaft furnace shaft furnace
Rotary kiln
Rotary DRI,
cooler HBI DRI, HBI, hot liquid iron DRI, HBI
• Rotary kiln based process • Shaft furnace based process • Shaft furnace based process
• Coal as reducing agent • Gas is converted to reducing agent in furnace • Gas is prepared for reduction in separate process
system
Offgas Shaft
furnace
Iron ore Smelt reduction Coal DRI Coal DRI Natural gas
((fines)) vessel (SRV) Natural g
gas (from coal)
Smeltin
S lt
Smelter
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fluidized bed reactors used as a reducing agent in shaft furnace
Note: Smelting reduction: Coal directly used as reducing agent, process as substitute of BF; Direct reduction: Gas as reducing agent, even gasification of coal, product used as input in EAF
Source: Lockwood Greene; IEA Clean Coal Center; Rio Tinto Hismelt website; Siemens VAI website; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 38
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Upstream Midstream
"Integrated route"
Continuous Plate mill Surface finished sheet:
casting
Hot dip aluminizing
Blast furnace Slabs - Aluminized strip
Secondary thin slabs Hot dip galvanizing
Scrap
metallurgy
gy - Galvanized strip
Basic oxygen Ladle Electrogalvanizing
furnace treatment (Vacuum Plastic coating - Plastic coated strip
treatment)
Electrolytic tinning
Hot strip mill Cold rolling - Tinplate strip
Iron ore: mill Electrolytic chromating
beneficiated Sheet metal
pelletized
sintered Hot rolled strip
Tube welding
Straight bead & spiral
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Liquid hot metal Cold formed steel
Liquid crude steel Coated/surface finished steel
Source: VDEh
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Today, steel industry contributes ~4% to Malaysian GDP,
employing ~150,000
150,000 people
payments/remuneration by the
of employees) establishments to all employees steel industry
~2.5% of GDP1
2 ~ 150,000 jobs2
Steel players' profit margins Players in steel
Profits
industry
3 Spill-over effects from the domestic steel
alue added
industry
Spill-over
4
eyond currrent
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transfer possible, hence higher contribution
1. Calculations on Value Added to GDP are shown for 2008 and 2009, using data obtained directly from the Department of Statistics for MSIC codes 241, 243, 251 and 259; 2. Employment numbers are
shown for 2009, taken from the 2010 Report on the Annual Survey of Manufacturing Statistics for MSIC codes 241, 243, 251 and 259; 3. Industry multiplier of 1.7 calibrated by benchmarking.
Source: Malaysia Department of Statistics; Malaysia Labour Force Statistics; Bekhet (2011) on "Output, Income and Employment Multipliers in Malaysian Economy:Input-Output Approach"; BCG analysis
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Most of the GDP contribution is attributed to the long industry
and midstream, downstream activities
Steel industry contribution to Malaysian GDP Steel industry contribution to Malaysian employment
(in thousands)
4.3% 4.3% 152 152
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Note: Upstream considered from iron to hot-rolling, midstream is cold-rolling to galvanizing, downstream is further down the value chain. Current estimates of Value Added to GDP are shown for 2009,
using data obtained directly from the Department of Statistics for MSIC codes 241, 243, 251 and 259; Current industry multiplier of 1.7 calibrated by benchmarking. Distribution among flat/long and
upstream/midstream/downstream explained on backup slide.
Source: Malaysia Department of Statistics; Bekhet (2011) on "Output, Income and Employment Multipliers in Malaysian Economy:Input-Output Approach"; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 41
Confidential Backup
Upstream:
Flat Employment:
Firm-level data on employment 5
+
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steel industry obtained from Bekhet's 2011 paper, which compares favorably with BCG's benchmark multiplier data; 5. Firm-level employment data obtained for Megasteel (and its supporting
companies) and Southern Steel, firm-level data for remaining upstream players estimated from production volume and best practices; 6. 2009 Steel Industry Employment data obtained from the
Annual Survey of Manufacturing Industries (2010) from the Department of Statistics for MSIC codes 241, 243, 251 and 259.
Source: SEAISI Steel Statistical Yearbook 2010; steelonthenet.com; Department of Statistics; Bekhet (2011): "Output, Income and Employment Multipliers in Malaysian Economy: Input-Output
Approach", International Business Research Vol 4(1); Annual Reports; company interviews and publications; BCG analysis
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No high-income country (other Rapidly industrializing countries have Less than 5% of the world's steel
than Estonia) exists without a high demand for construction consumption in final goods is met by
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1. Kuwait and Bahrain have no upstream long steel, Denmark has no downstream long capacity, among the 97 countries represented in Metal Bulletin; 2. World comprises all the countries
represented in Worldsteel's Steel Statistical Yearbook
Note. 31 high income defined as GDP per capita above $20k in world PPP dollars from the World Bank's 2010 GDP per capita data.
Source: Metal Bulletin Capapcity Q3 2011; Worldsteel Steel Statistical Yearbook 2011; WSD, SEAISI, BCG Model; EU DG Trade statistics; BCG Analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 43
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Flat steel industry similarly present in almost all high income
economies
Countries without upstream
>90% high-income industry are fundamentally
economies produce flat steel different from Malaysia
No flat steel
Only operate very far
downstream4
Only downstream flat
Both
B th upstream
t and
d downstream
d t
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1. Norway is an exception; 2. Portugal is an exception; 3. Defined as <100% of GDP. Luxembourg, UAE and Estonia are exceptions; 4. 75% of them operate in tinmills and further downstream where only
40% of Malaysia's downstream capacity is; Note. 31 high income defined as GDP per capita above $20k in world PPP dollars from the World Bank's 2010 GDP per capita data
Source: Metal Bulletin Capacity Q3 2011; World Bank; BCG Analysis; CIA World Factbook: EU DG Trade statistics; WTO statistics; BCG analysis
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A fully developed steel industry could contribute up to ~6.5%
to the Malaysian economy by 2020
Today
y steel industry
y is smaller contributor to Capacity-building
p y g and required
q optimization
p
GDP than Palm oil and Construction can be completed by 2020
% 2009 GDP contribution for selected industries From inception to fully operational, a BF+BOF
6
Direct contribution project typically takes ~ 4
4-5
5 years:
4
2 4.1
only • Formosa's estimates are ~ 4 years per BF
3.3 3.1 2.5
0 0.8 • Krakatau's estimates are ~ 2+ years
Palm Construction Refined Iron and Rubber • Ann Joo's estimates for BOF are ~ 2+ years
Oil Petroleum Steel • Delays have plagued projects in the region, by
about 2 years on average
2009 2020
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1. Current estimates of Value Added to GDP are shown for 2009, using data obtained directly from the Department of Statistics for MSIC codes 241, 243, 251 and 259; 2. Current industry multiplier of 1.7
calibrated by benchmarking. Projections to 2020 assume 6% CAGR real increase in Malaysian GDP and 1.6% CAGR in iron& steel productivity, and that new Malaysian capacity comes online to
produce 10 MTA of hot-rolled products by 2015.
Source: Malaysia Department of Statistics; Bekhet (2011) on "Output, Income and Employment Multipliers in Malaysian Economy:Input-Output Approach"; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 45
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Agenda
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 46
Confidential
Executive summary
Overview of steel market in Malaysia and ASEAN
The global steel industry is currently facing two major trends – volatility in the environment and the
growing opportunity in Asia
Currently, high fluctuations in raw material prices and end product demand is creating fierce competition
• Steel players are worse positioned than miners to take advantage of market evolutions
• Structural drivers of competitiveness for steel players: critical size, technology and site location
Steel consumption is moving to Asia, creating an greater opportunity for the steel industry in ASEAN
• Within Asia, ASEAN-6 demand growing at a solid 5% p.a. across the past 20 years and is expected to
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– There is still room for growth, though Malaysia is the most mature market in the region
• ~70% of Malaysian demand for flat is met with imports rather than domestic production
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Raw-material spot prices very volatile, contract prices Shift of steel consumption towards China ...
steadily increasing—example IO spot and contract prices 1,386
$/ton 1 203
1,203
1,131
600
200 China
565 (43%)
853 32%
(47%) India
150 20% 4% 5%
4% Other
30% 5%
100 31% 28% North America
27%
50 18% 14% 9% Japan
9% 7% 8% 5%
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1975 1980 1985 1990 1995 2000 2005 2010 2001 2005 2009 2010
Real GDP PPP growth Finished-steel consumption growth
1. Adjusted to $/t using 6% moisture and normalized to 63% Fe dry to compare it to China import from India (63%) 2. CFR prices used adjusted for freight Capesize voyage rate Goa/Beilun 140,000t
Source: SBB December 2011; Clarkson; EIU; World Steel Association
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1 Confidential
Steel players worse positioned than miners to take advantage
of market evolutions
18
20 20 15
Steel players
15 13
0 0
1975 1990 2005 2002 2003 2004 2005 2006 2007 2008 2009
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1. Top 15 steel producers: By market cap – Arcelormittal, Posco, CSN, Nippon Steel, JFE, SAIL, Gerdau, Baoshan, TK, Usinas Sider, Jindal, Evraz, Nucor, China Steel Corp, Sumitomo; Top 3 miner:
RioTinto, BHP, Vale
Source: BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 49
1
Castiing produc
ction Casting production n
cap
pacities 20
012 capaciities 2008
0
500
1000
0
500
1,000
0
0
Other SA
Brazil
Other NA – LC South Afric
ca
East. Eur. – LC
Oceania
Brazil
uth Africa
Sou USA – LC
China – LC
C
500
500
China – LC France
UK
Taiwan
Eur. – LC
Other W. E
Other Africa
a
South Koreea
Japan
Fran
nce
UK
Taiw
wan
Confidential
Germany
Other W. Eur. – LC
1000 East. Eur. – HiC
1000
Other NA – HCt
Other Africa Other W. EEurope – HC
Other Asia
Sou
uth Korea India – HC
CIS – HC
Jap
pan USA – HC
Key drivers of competitiveness:
Gerrmany
critical size, technology and site location
Easst. Eur. – HC
C
China – HC
Other NA – HCt
C
Other W. Europe – HC
Other Asia
India – HC
1500
1500
CIS
S – HC
USA
A – HC
facilities are structurally better positioned than others
China – HC
In this challenging environment, select steel production
50
Production capacity (mio t p.a.)
2000
2000
Copyright © 2
2012 by The Boston Co
onsulting Group, Inc. A
All rights reserved.
2 Confidential
Consumption in MTA
60
50 49
5.3%
46
8.3%
44
42
39 14 Thailand 4.4% 3.6% 11.3%
40 37 38 13
13 11
34 33 33 33
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1. ASEAN-6: Indonesia, Thailand, Malaysia, Vietnam, Philippines, Singapore
Source: IISI / WSA Steel Statistical Yearbooks 1990 to 2004, SEAISI 2005 to 2010, BCG analysis
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Different key industries drive demand for long, flat and
tubular finished steel products
Share ASEAN Malaysia
of steel Type of expected expected Examples of steel
Key end-industries demand demand growth1 growth1 products
T b
Tube Fl t
Flat L
Long
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1. 2010-2020 CAGR based on BCG model 2. ASEAN forecasts have been used for Malaysia
Source: BCG Model, WSD, SEAISI Steel Statistical Yearbook 2011, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 52
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Solid growth in long finished products Yet stronger growth in flat finished products1
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xx% : CAGR 1998-2010
1. Including pipes and tubes
Source: IISI / WSA Steel Statistical Yearbooks 1998 to 2004, SEAISI Steel Statistical Yearbook from 2005 to 2010, BCG analysis
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Regional growth driven by Expected regional consumption by country and by product type
Thailand and Vietnam in 2020
Consumption in MTA
150 Share of total consumption in %
36 38 5
100
+5% 5%
100 17%
31 79
8
9 80 40% 29%
49
50
32%
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0
2010 Delta 2020 Thailand Vietnam Indonesia Malaysia Philippines Singapore
1. Share of flat products including pipes and tubes
Source: BCG Model, SEAISI Steel Statistical Yearbook 2011, IHS Global Insights, Rystad, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 54
2 Confidential
Today, net imports fulfill ~60% of ASEAN steel demand,
indicating substitution opportunity for local steel makers
22.4
22
2.2
6.6
Current supply
4.9 14.1
40 gap of ~32 Mt
3.7
(>60% of 3.3
9.2 1.9
consumption) 2.0 10.6
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1. Ingots, nillets, blooms and slabs 2. Hot rolled steel products (rails and accessories, steel sheet piles, sections, bars, wire rods, round for tubes, plates, hot rolled sheet and strips and tyres and
wheels), cold rolled steel products (cold rolled sheets and strips, cold rolled electrical sheets), coated sheets and strips (galvanized sheets, tinplates, etc.), pipes and tubes (seamless and welded)
Source: SEAISI Steel Statistical Yearbook 2011
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2 Confidential
SEA has minimal intra regional trade and imports from Japan,
China, Korea and Taiwan
Net imports of semi-finished and finished products1 in MTA (2010)
From
Indonesia Malaysia Thailand Vietnam Japan China Korea Taiwan CIS Others2
To
Indonesia - 0.2 0.1 0.0 1.7 1.3 0.6 0.5 1.7 0.2
Malaysia -0.2 - -0.0 -0.6 1.5 0.6 0.5 0.8 0.1 0.1
Thailand -0.1 0.1 - -0.2 4.8 1.6 1.0 0.5 2.6 1.6
Philippines 0.0 0.0 0.0 0.0 0.5 0.8 0.2 0.4 0.9 0.1
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Low volume of SEA intra regional trade ~32 Mt of net imports from outside SEA
1. Hot rolled steel products (rails and accessories, steel sheet piles, sections, bars, wire rods, round for tubes, plates, hot rolled sheet and strips and tyres and wheels), cold rolled steel products (cold
rolled sheets and strips, cold rolled electrical sheets), coated sheets and strips (galvanized sheets, tinplates, etc.), pipes and tubes (seamless and welded) 2. Includes USA, EU, India, Australia and
any other trade partners
Source: SEAISI Steel Statistical Yearbook 2011
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2 Confidential
~80% of ASEAN net imports are flat steel, while long steel is
mostly a local market
Long steel is primarily domestic market Flat steel demand met largely by imports
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1. Hot rolled steel products (rails and accessories, steel sheet piles, sections, bars, wire rods, round for tubes, plates, hot rolled sheet and strips and tyres and wheels), cold rolled steel products (cold
rolled sheets and strips, cold rolled electrical sheets), coated sheets and strips (galvanized sheets, tinplates, etc.), pipes and tubes (seamless and welded)
Source: SEAISI, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 57
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Malaysia
y only
y reached 1997 consumption
p ... as a result,, its share of ASEAN consumption
p
levels in 2008... fell from 25% in '97 to 16% in '10
8.5 23 21 27 25 25
8.1 8.3 30 33 34 29 29 26 29
8 7.7 80 36 34
7.4
7.1 7.1 5 11
6.8 6.8 6.6 10 10 13
62
6.2 62
6.2
14
6 5.6 60 21 15 14 15 21 18 26 22
14 18 14 16
Copyright © 2
become the 4th behind Thailand, Vietnam and Indonesia
Source: IISI / WSA Steel Statistical Yearbooks 2008 to 2004, SEAISI 2005 to 2010, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 58
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27 2%
27.2% 32 0%
32.0%
e of apparentt consumption
80
34.1%
39.7%
49.3% 68.5%
60
40
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Pipes and tubes2 Flat carbon Long carbon
1. Production (hot-rolled steel products) – Imports + Exports 2. Pipes and tubes are derived from welded flat products (produced and imported), with the exception of limited imports of seamless
pipes and tubes
Source: SEAISI Steel Statistical Yearbook 2011, EIU (2010 data), BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 59
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Still room for growth, though Malaysia is the most mature
market in the region
x 3.8
1,131
1,000
,
516 507
312 293
293
215
120
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Source: SEAISI Steel Statistical Yearbook 2011, EIU, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 60
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Expected
p consumption
p growth
g in Malaysia
y Resulting
g evolution in consumption
p split
p
0 0
2010 Const
Const. Auto Machinery Oil &
Auto. Others 2020 2010 2020
BCG Model p
projections
j in line with consensus steel analyst
y
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views (e.g. Business Monitor International)
Source: BCG Model, SEAISI Steel Statistical Yearbook 2011, IHS Global Insights, Rystad, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 61
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Most long
g consumption
p met with local While most flat p
products consumed are
production imported
6 6
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1. Hot rolled steel products (rails and accessories, steel sheet piles, sections, bars, wire rods, round for tubes, plates, hot rolled sheet and strips and tyres and wheels) 2. Apparent consumption is
based on production of hot rolled steel products + all steel product imports – all steel product exports
Source: SEA ISI Steel Statistical Yearbook 2011
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Agenda
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 63
Confidential
The Malaysian
y flat steel industry
y only
y has a small window to become competitive
p and to seize on the
regional opportunity
• In 2020, there will be an additional ~7MTA addressable market opportunity at ASEAN level
– Assuming efficient use of existing capacities and ~29 MTA new capacity coming online in the region
– Addressable market for Malaysian players will be around 6 6-7
7 MTA in 2020
• Current trade policy already putting regional competitive pressure across the entire value-chain
– Signed FTAs will further increase competitive pressure over the next 4-5 years
Moving forward, the Malaysian flat steel industry could be structurally competitive to address the regional
However, today
H d theh Malaysian
M l i flat
fl upstream industry
i d is
i currently l uncompetitive
i i andd unprofitable
fi bl
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 65
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Upstream:
p Longgpproduction fairly
y stable;; Midstream: Longgpproduction fairly
y stable;;
Flat production reducing across past 5 years Flat production affected from 2009
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1. Including pipes and tubes
Source: SEAISI Steel Statistical Yearbook 2011, BCG analysis
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Southern Steel EAF (1.5 MTA) Billet (1.5 MTA) Long (1.5 MTA), Pipe (0.2 MTA)
BF (0.5 MTA)
Ann Joo Billet (0.9 MTA) Long (0.7 MTA)
EAF (0.8 MTA)
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Others Long (0.2 MTA), Flat (1.1 MTA), Pipes (0.8 MTA)
1. Lion Group plant under construction; 2. Melewar MIG plant plans for construction; Note: Eastern Steel recently commenced construction of 2.2 MTA BF plant in Kemaman;
Note: in additon, ~5000 SMEs are active in metal manufacturing (<RM 25 mil or <150 employees)
Source: Metal Bulletin Capacity Q3 2011, Company website, Press search
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 67
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Perlis
Kedah
Sabah
Kinsteel
Southern steel Pinang
Sarawak
Ann Joo (BF plant) Terengganu
Kelantan
Eastern Steel
Ann Joo Perak (BF project Kemaman,
Melewar Melaka
Flat
Johor
Long CSC
Copyright © 2
Upcoming capacity
700
JSW Steel, Mumbai
• Capacity:
Capacit 7.8MTA
7 8MTA
600 • ~3,700 acres
500
Copyright © 2
• ~18,900 employees
1.Cash cost based on 2008 Malaysia production cost curves, import tariffs, inbound and outbound freight. Production cost curve for Malaysia BOF estimated based on Asian BOF cost curve adjusted
for labour productivity, inbound freight and energy costs.
Source: World steel dynamics, Simpson Spence Young, Steel Business Briefing (SBB), EIU, Metal Bulletin Capacity 2011, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 69
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Long products
20 20 20 20
0 0 0 0
Production
Capacity
Copyright © 2
Note: Production based on SEAISI figures for 2010, Capacity figures based on Q3 2011 figures from MBR; Utilisation rate measured as production divided by capacity;
Source: Metal Bulletin Capacity Q3 2011, SEAISI Steel Statistical Yearbook 2011
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 71
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Trade barriers almost non-existent today for long products,
and with no major complaints from market participants
Domestic prices 5-10%
All long
g products
p with less higher
g than international No major
j complaints
p from
than 5% of import duty benchmarks market participants
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1. HS codes 7213 to 7217 2. Mild Steel Round Bars - R25, MS146 3. Long Products / BOCE Rebar / China West Cash bid/settlement 4. Long Products / Rebar / Japan domestic (Tokyo Steel) CIF
Note: Quarterly exchange rate applied
Source: DOS, CIDB, SBB Steel Prices, BCG analysis
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Average profit margin of main long steel manufacturers Upstream: operation of iron ore mine and
(2007 – 2011) construction of concentration plant
(%) • Kinsteel applied to operate iron-ore
iron ore mining
concession in Bukit Besi, Terengganu
10
• Construction of new concentration plant and
pelletizing plant in Terengganu, completed by 2013
8 – RM 570 Mln annual cost savings estimated
– Kinsteel has the ambition to become lowest cost
Copyright © 2
reduce price volatility"
- RBS
1. Includes limited non-steel activities 2. Excludes DRI activities 3. Includes pipe and tube activities 4. 2008-09 industry average
Source: Bloomberg, company websites, annual reports 2007-2011, China Metallurgical Industry Planning and Research Institute, BCG analysis
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2007-2010 import price for top-5 long products: delta to average (USD/ton)
200
Import volumes
Bars and rods 0 -58 14 54 16
-94 -134
(diam. <14 mm)
-200
200
200
H sections 76 106
0 -55 -39 -83
-101
-200
200
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China Korea Japan Thailand Taiwan Indonesia
Flat products
Crude steel making Hot rolled sheets and Cold rolled sheets and Coating
• BOF or EAF strips
p making g strips
p making g • Hot dip
pggalvanizing,
g,
High-level
High level
Slab casting • Hot roll mill • Pickling line etc.
description Plates making • Cold roll mill Welding of tubes and
• Plate mill pipes
Etc.
22.4
22 4
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1. Assuming net imports can be replaced by local production that can match downstream needs in terms of specifications / quality and cost competitiveness 2. Indirect gap assumes that additions to
upstream capacity is matched with similar downstream capacity increases (e.g. increasing slab production beyond 4.1 MTA requires additional HRC capacity, etc.)
Source: SEAISI Steel Statistical Yearbook 2011, BCG Analysis
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But gap for hot rolled products in ASEAN could reduce to
5-7
5 7 MTA by 2015 if all capacity extensions come online
ASEAN: Announced capacity for hot rolled flat and supply-demand gap evolution
Capacity extension in MTA ASEAN supply-Demand Gap in MTA
20 20
18.3 18.6
17.2
15.0
15 15
10.6
10 10
NA 0.4
0 0
Copyright © 2
of 3-4MTA based in Malaysia
Note: Only officially announced and documented projects are included; All projects unlikely to come online in time – Formosa project with 3 years delay already, Lion Group and MIG lack financing;
Source: Plantfacts, Metal Bulletin, Press Search, SEAISI Steel Statistical Yearbook 2011, BCG Analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 77
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Formosa p
plans to build the largest
g steel mill in
ASEAN The project timeline is ambitious
Finishing
Copyright © 2
over >2,000 ha of land of China Steel (5% stake)
1. Both long and flat products
Source: Formosa documentation, press search
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Regional players are ramping up investments to produce flat
steel at all steps of the value chain
Flat steel upstream Flat steel midstream Not all investments validated
Coating and
H t rolling
Hot lli 1 C ld rolling
Cold lli
finishing
Krakatau 0.4MTA 2011 Krakatau NA 2013 Bluescope (galv.) 0.3MTA 2011
Krakatau-Posco 3.0MTA 2013 Bajatama 0.1MTA 2012
• Plate mill 1.0MTA
• HRM 2.0MTA
Krakatau2 (HRM) 2.0MTA 2015
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1. Only impact on flat hot-rolling capacity shown, higher upstream projects including steel making and casting not shown 2. Additionally, 1.25MTA BF and 0.3MTA DRI to feed existing EAF 3. JV
between Hiap Teck – Shougang 4. Additionally 0.25MTA came online in December 2011 (stainless steel)
Note: Only officially announced and documented projects are included, confidential plans not included, some small capacity additions (<0.1MTA) may not appear, only flat steel products are shown
Source: Plantfacts, Metal Bulletin, Press Search, BCG Analysis
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If all announced capacity comes online, the ASEAN gap for
hot rolled products will be ~7
7 MTA in 2020
Conservative scenario assuming all announced capacity goes online
SEA expected supply-demand gap for hot rolled flat steel products in 2020
Volumes in MTA
50
Vietnam expected to become a major steel
16.9 42.8 14.1
exporter if all announced capacity comes
40 5.7 online
9.0
3.8 15.5
3.1
3 1
30 4.5 21.7
2.0
2010 2010 2010 2010-2020 2020 Efficient use Efficient use Net Net
Production Gap Consumption growth Consumption of current of new exports imports
capacity1 capacity1
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Thailand Vietnam Indonesia Malaysia Philippines Singapore
1. Using average downstream capacity utilization per country as starting point and assuming 75% utilization rate of existing and new capacity in 2020 (Arcelor Mittal benchmark)
Note: Only officially announced and documented projects are included
Source: SEAISI Steel Statistical Yearbook 2011, BCG model, Plantfact, Metal Bulletin, Press search, BCG analysis
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The addressable market for Malaysian players will be around
6-7
6 7 MTA in 2020
Flat Addressability for local BF/BOFs
demand
share Local JV (e
(e.g.
g Japanese) Rationale for addressability
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Addressable gap 4-5 MTA 6-7MTA
1. Several project with Government Special Projects status allowing for different customs duty conditions
Source: BCG model, SEAISI Statistical Yearbook, expert interviews, BCG analysis
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Confidential Backup
Access to ASEAN markets without tariffs, however strict non-
tariff barriers can present a challenge
Thailand Indonesia Vietnam Malaysia
(MTA)
Imports as % of flat
61%4 56%5 100% 67%
consumption
Non-ASEAN FTAs 6 2 2 5
Required Required
Import license Required Required
(annual renewal) (monitoring purpose)
"Indonesia's President Susilo said the construction of a steel factory Krakatau-Posco would be an
essential support to accelerate Indonesia’s
Indonesia s economic growth in the next 15 years"
years
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1. Range for flat HRC and CRC products; 2. The data represents cumulative trade defenses employed for base metals and articles, which includes, but is not limited to steel products; 3. Data taken
from the WTO database of cases from 1995-2011. Zero assumed due to no reports received by the WTO from reporting country (as required by the WTO regulations);
4. 3 key upstream producers with multiple mid-stream players; 5. Krakatau key upstream player with multiple mid-stream players
Source: MITI, SIRIM, CIDB, DOSM, ISIT, BSN – SISNI, MIDA, Tariff Finder, UNCOMTRADE , Macmap, OECD, Standards, Regulatory Reforms & Development in APEC, Press Search , SEAISI,
WTO (1995-2011); industry interviews, BCG Analysis
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Thailand imports accounted for ~60% of Indonesia imports accounted for ~55%
flat consumption of flat consumption
Thailand production and trade of flat Indonesia production and trade of flat
finished products (2010) finished products (2010)
I MTA
In I MTA
In
12 60% 12
10 0.5 0.5 10
0.5
0.6
6 4.8 6
10
1.0 0.6
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Source: Tariff Finder, UN COMTRADE, SEAISI Steel Statistical Yearbook 2011, BCG Analysis
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In addition, signed FTAs will further increase competitive
pressure over the next 4-5
4 5 years
Agreed 2012 import rates for Malaysia
ASEAN FTA 0% 0% 0% 0%
(ASEAN ATIGA) (2008) (2008) (2008) (2008)
ASEAN – China 0%
20% 15% 20% 15% 20%1 15%
(ACFTA) (2005)
(2012) (2015) (2012) (2015) (2012) (2015)
Copyright © 2
1. 7210.50 & 72010.69 are already at 0% import duty 2. Includes 7208.10, 7208.27, 7208.39, 7208.51; 3. Only includes 7209.18 ; 4. Does not include 7210.41, 7210.50, 7210.70, 7210.90;
Note: Based on 2012 numbers from the original agreement; Slabs based on code 7207.12.10, HRC-7208, CRC-7209, Coated / Galvanised – 7210;
Source: Tariff Finder
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Confidential Backup
Many FTA agreements agreed and already in place at regional
(ASEAN) and bilateral (Malaysian) level
ASEAN Malaysia
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1. Investment and Services only – Goods already approved; 2. Involving 9 countries – Australia, Brunei, Chile, Malaysia, New Zealand, Peru, Singapore, US, Vietnaml; Source: MITI, MITI website
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 85
Confidential Backup
Singapore and Thailand lead the way for FTA adoption and
many discussions currently underway for other countries
Copyright © 2
Thailand-Pakistan
Singapore-Sri Lanka Indonesia-Chile
Indonesia-NZ
1. Palm oil only, 2. Limited FTA, Agriculture only; Note: Based on press search from 2009-2012; Source: Bilaterals.org, press search, Government websites
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 86
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51% of HRC imports from 76% of CRC imports from 74% of galv./ coated imports
countries under FTAs countries under FTAs from countries under FTAs
Sources of Malaysian Sources of Malaysian Sources of Malaysian galv./
HRC imports (2011) CRC imports (2011) coated imports (2011)
% % %
41% 100% 13% 100% 19% 100%
100 100 100
12% 11%
18%
6%
80 38% 80 76% 80 74%
9%
10%
8% 9%
60 60 60
51% 19%
0 0 0
FTA CEPT MFN 100% FTA CEPT MFN 100% FTA CEPT MFN 100%
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rate for CRC and potentially for HRC (40% local content)
Japan
South
Anshan Integrated
g Steel Complex
p Korea
Focus on high-end flat steel products
16 MTA capacity
Yawata Steel Complex
HRC FOB cost: 490 USD/MT
5 MTA capacity
China HRC FOB cost: 657 USD/MT
Taiwan
A rights reserved.
onsulting Group, Inc. All
Dangjin
8 MTA capacity
HRC FOB cost: 603 USD/MT
Malaysia
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10 MTA capacity
Major exporters to SEA HRC FOB cost: 638 USD/MT
1. Not exhaustive, examples of largest coastal integrated steel mills in North Asia with low cash cost
Source: Plantfacts 2011, press search, BCG analsysis
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Further integrated steel mills with BF/BOF technologies are
expected to come online in the coming years
Major projects announced in Asia-Pacific (2012-2020)
Japan
South
Korea
Dangjin Integrated Steel Mill 3rd line
4 MTA capacity – 2015
BF/BOF, slab, HRC
Asansol Integrated Steel Mill
6 MTA capacity – 2015 China
BF/BOF slab,
BF/BOF, slab HRC
Taiwan
A rights reserved.
onsulting Group, Inc. All
Zhanjiang
Zh ji Integrated
I t t d Steel
St l Mill
15 MTA capacity – 2018
BF/BOF, slab, HRC, CRC, HDG
Malaysia
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10 MTA capacity – 2012
Major exporters to SEA
BF/BOF, slab, HRC, CRC, plates
1. POSCO plant project postponed by Environmental Court
Source: Plantfacts 2011, press search, BCG analsysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 89
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In current conditions, Malaysia flat steel industry could be
structurally competitive to address this market opportunity
Applying current market conditions
0 0
IND MAL CHI MAL IND CHI TAI KOR JAP JAP KOR IND CHI IND CHI MAL TAI KOR MAL JAP JAP KOR
BOF BOF BOF EAF EAF EAF BOF BOF EAF BOF EAF BOF BOF EAF EAF BOF BOF BOF EAF EAF BOF EAF
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1. Cash cost excluding overheads, interest, depreciation;
Note: Antidumping measures targeting Malaysia assumed not applicable to new players, BF/BOF state of the art plant is compared to average BOF and EAF cost bases in Asi-Pacific countries
Source: BCG Model, WSD March 2012 database, EIU, TNB
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 90
Confidential Backup
HRC CRC
Gross
G USD/ MT (2011) Gross
G USD/ MT (2011)
imports imports
(2010) Dom. Export ∆ (2010) Dom. Export ∆
03
0.3
800 609 191 02
0.2
1,069
, 789 280
A rights reserved.
0.1
643 593 50 0.1
805 706 99
00
0.0 05
0.5 10
1.0 1 5 MTA
1.5 00
0.0 05
0.5 1 0 MTA
1.0
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Note: Trade volumes uses data from 2010 to highlight major trading countries, price data is representative of Nov. 2011.
Source: SEASI, Steel Statistics Yearbook 2011, UN Comtrade, Metal Bulletin Research
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However, sole upstream producer is facing structural
problems, with negative impact on mid/downstream players
...with negative
Low profits/losses at Still high HRC import duty repercussions on
Megasteel in Malaysia... mid/downstream players
Megasteel's profitability 2008-2011 Import duty1 applied for Current duties impacting
HRC in ASEAN countries mid/downstream players
• Import d
duties
ties 5% or belo
below for
Positive results due (%) coated / galvanised products
to accounting
200 150 adjustments – 40 and further downstream
100 inventory write-off • Domestic raw materials price
20% ~10-20% higher than
100 20
international prices
4% 5%
A rights reserved.
0% 0%
0 -6x 0
Issues raised on product quality
-500 • Multiple players reporting that
-500
500 Megasteel products lead to 10-
10
Megasteel
g needs restructuring
g of its lending
g facilities
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by June 2012
1. Based on Product HS code7208 – Flat-rolled products of iron or non-alloy steel, of a width of 600 mm or more, hot-rolled, not clad, plated or coated; 2. Duty exemption mechanism recently revised
in 2009; Note: 2012 results are from Megasteel's own projections for profitability; Source: Megasteel's audited accounts for 2008-2011 and own projections for 2012; interviews and confidential inputs
received from other industry players; Press Search, Macmap; Customs data, Government websites, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 92
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...and current trade policy already putting regional
competitive pressure across the entire value-chain
value chain
Duty structure not providing price wall Duty exemptions putting indirect
to coaters and galvanizers pressure on upstream players
Consumption 51%
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1. Selected the tariff rate where majority of the imports for this product category comes in. 2. Taiwan is the largest exporter of HRC to M'sia under MFN rates of 20% 3. Japan is the largest exporter of
CRC to M'sia under MJEPA tariffs of 18% 4. Japan is the largest exporter of Galvanised/ coated steel to M'sia under MJEPA tariffs of 18% 5. Majority of finished steel products have 0% (CEPT, MFN
& FTA) 6. Price differences are obtained from industry interviews 7. Calculated as = Import Duty Applied – Average Price Difference
Source: Tariff Finder, BCG Analysis, Interviews with Industry Players
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Agenda
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 94
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We can leverageg learning g from other countries, and have conducted a benchmarking g exercise on four
countries: China, Korea, Turkey and Mexico
• Selection criteria: Steel plays an integral role in the economy, country's steel player(s) are significant in the
global steel market, country is a net exporter of steel, country is a developing economy
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 95
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other interventions • Provided tax breaks assistance to failing steel
companies
Sources: World Steel Association; POSCO Steel: KIET, Korea Steel Association, ISSB, World Bank, BCG Analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 97
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South Korea: ... resulting in a boost of steel industry
performance
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1. 1989 2. 2009 # employees
Sources: World Steel Association; POSCO Steel: KIET, Korea Steel Association, ISSB, World Bank, BCG Analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 98
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trading partners • Anti dumping investigations on Japan imports
Sources: World Steel Association; POSCO Steel: KIET, Korea Steel Association, ISSB, World Bank, BCG Analysis
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Mexico: After poor results of nationalization, privatization
and opening of the economy have been preferred policies
1970 1986 1994 2012
• Crisis of steel industry in the • Change of government brought • Mexico joined GATT (now
beginning of 70's, driven by: a policy of "structural changes", WTO) in 1986, reducing
– Global steel demand shock based on privatization and significantly import barriers
– Energy crisis of 1973 opening of the economy (from up to 40% to 10%)
– US import barriers
– Devaluation of peso in • The decision to privatize • Imports increased dramatically
1976 after 24 years of
1976, generated a restructuring when Mexico joined NAFTA in
stability process (technology, 1994, a FTA with the US and
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1998) commercial agreements with
~40 countries, including Japan
Source: Acerotek, Universidad Nacional Autonoma de Mexico, Canacero
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Mexico: Privatization and FTAs significantly improved
performance
M
Measures off P
Performance
f 1990 2010
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1. Current prices 2. 1989 3. Direct employees 4. 2011 employees
Source: Ministry of Economy of Mexico, Canacero, Instituto Nacional de Estadistica
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 101
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Increase competitiveness and long term Privatization of government owned steel players
sustainability of the industry • Restructuring process to increase
Promote exports to drive growth and Signature of FTAs and dramatic reduction of
encourage competition and efficiency trade barriers
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continues until today (current average 1.4%)
Source: Acerotek, Universidad Nacional Autonoma de Mexico, Canacero, Ministry of Economy
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Subsidiary
Arcelor Mittal 3.8 100% 2001
(A l )
(Arcelor)
Subsidiaryy 2002
TAMSA 10
1.0 100%
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Source: company websites
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• Liberalization included promotion of growth • Turkey joined the Customs Union treaty with
through exports, based on: the EU in 1996, which involved the abolition of
– Wage supression customs duties and quotas on bilateral steel
– Generous export subsidies trade
– Gradual domestic currency depreciation
• Facilitation of trade with Europe and other
• Liberalization of the economy initiated a period regions (Middle East
East, Gulf)
Gulf)... has contributed to
of progress for the iron and steel industry, boost steel output and to encourage the
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– Third fastest growing producer globally
Source: Steelworld, Turkish Ministry of Industry and Trade, Turkish Iron and Steel Producers Association, Istanbul Technical University
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 104
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Turkey: Output multiplied by three, thanks to trade
agreements
M
Measures off P
Performance
f 1990 2010
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1. Direct employees
Source: TISPA, WSA,
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Source: Steelworld, Turkish Ministry of Industry and Trade, Turkish Iron and Steel Producers Association, Istanbul Technical University
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 106
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Turkey: Industry is mostly local but foreign players have
started to be attracted and form JVs/subsidiaries
Production
Foreign Year
Company name 2009 (base Ownership
stake established
sales, Mn TRY)
Ereğli Demir Çelik 3,576 Turkish 0% 1960
Habas Sinai ve Tibbi Gazlar Istihsal
2,520 Turkish 0% 1964
Endustrisi
İçdaş Çelik Enerji Tersane ve
2,450 Turkish 0% 1880
Ul
Ulaşım S
San. AS
A.S.
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Atakaş Metalurji N.A. 50% 2007
co. MMK
Source: company websites
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China: Initial focus on rapid growth led to a fragmented
industry that required consolidation
1990 2005 2012
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– Research funding • Construction of facilities (i.e. technology parks) to support
interventions – Debt forgiveness the steel industry
Sources: World Steel Association; International Iron and Steel Institute; Organisation for Economic Co-operation and Development (OECD); JP Morgan, ISSB, BCG Analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 108
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China: Dramatic growth in 20 years, becoming #1 world
producer
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1. 2009; Sources: World Steel Association; International Iron and Steel Institute; Organisation for Economic Co-operation and Development (OECD); JP Morgan, ISSB, BCG Analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 109
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• Put greater emphasis on high-end products
Sources: World Steel Association; International Iron and Steel Institute; Organisation for Economic Co-operation and Development (OECD); JP Morgan, ISSB, BCG Analysis
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Agenda
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 111
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Target industry structure for flat steel industry in Malaysia for 1-2 players operating integrated steel mills
• The addressable market for Malaysian players will be around 6-7 MTA in 2020
• Minimum efficient scale of flat steel production via an integrated mill is ~ 3-4 MTA
– Around USD 2-4Bn of investment for 4MTA capacity will be required
Reaching competitive levels will require bringing in an international player with the relevant know-how
• All high grade projects involve large international steel makers
• Large integrated players dominate the market of high-value added flat steel products
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Confidential
There have also been multiple marks of interest from international players for an investment in Malaysia
flat upstream
• Shougang recent investment in Eastern Steel, CSC binding offer for Lion Group assets and ongoing
discussions with several international players (details protected for confidentiality reasons)
• International investors anticipate the end of protection in Malaysia and are looking for opportunities with
genuine competitive advantage
– Requirements: location, investment flexibility, access to inputs, select form of government support
Today, Malaysia's current sole upstream flat producer, Megasteel is in urgent need of a turnaround
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Shared responsibility
p y outcome has the least cost of resolution for all p
parties involved, however is fairly
y
complex to execute
• Steel industry, Government & the economy and Megasteel expected to benefit from the shared responsibility
outcome, with limited cost for banks
• Strong coordination and support required from the Government over period of 2-3 years to ensure execution
success
The shared responsibility outcome would open the way for Megasteel to be competitive in the long-term
• In addition to benefits from increased production in the shared responsibility outcome, three projects will
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Confidential
Target industry structure with room for more than one player
based in Malaysia
Flat steel industry has high economies ...but addressable domestic and
of scale... regional demand can serve >1 player
Average cost curve of a flat steel producer
• Minimum efficient scale of flat steel production
Average
g cost / RM p
per MT
Key:
K via
i an iintegrated
t t d mill
ill iis ~ 3
3-4
4 MTA
Inefficient producer
Efficient producer • Addressable market size in 2020, potentially by
Minimum Addressable demand
Malaysian player(s) : ~ 10 MTA
High efficient scale prod ction gap2
– SEA region's addressable production
cost
~6-7 MTA
Inefficient player
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1. Average cost benchmarked for a Japanese notional steel producer, cost shown for production of an MT of liquid steel via the BOF route; 2. Gap and consumption figures shown for hot-rolled
products; gap includes direct hot-rolled products gap and indirect derived hot-rolled products gap; 3 Announced pipeline projects include Lion Group, Eastern Steel and MIG-Melewar's announced
capacity-building, all assumed to run at 75% capacity.
Source: "Industry Studies" by Deutsch; IISI / WSA Steel Statistical Yearbook 2011; steelonthenet.com; BCG model; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 115
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Initial investment expected to be ~USD 2-4 Bn, given
minimum efficient scale of 3
3-44 MTA
Capex per metric ton of capacity for announced new steel mills
Budget estimates k$/t
1.5
1 3 1.3
1.3
Low budgets – 1.3
unclear if all CAPEX included 1.2
1.1
1.1 1.1
1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
1.0
Ø 0.90
0 8 0.8
0 8 0.8 08
0.7 0.8
0 8 0.8
0 8 0.8
0.7
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Source: SBB 2011, BCG analysis
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High-value added flat steel requires know-how transfer from
leading international players
All high
g grade
g projects
p j involve large
g Large
g international steel makers bring
g access
international steel makers to technologies and know-how
Shougang with 40% stake "We need
"W d th
the JV ((...)) tto b
be able
bl tto b
build
ild a world-class
ld l
Eastern Steel • Leading state-owned steel industry (...) so that we can feed our downstream
(Project) Chinese integrated industries with Indonesian steel"
Malaysia
Currently seeking a
Posco with 70% stake
Indo.
Posco the blast furnace plant. Shougang group also has the
• Leading Korean financial muscle to lead the project"
(Under integrated player
construction) g Malaysia,
- The Edge y , 12 December 2012
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International player involved Seeking international partner
Source: Company websites, press search, BCG experience
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handymax vessels
60
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1. High value added products categorized here as cold-rolled and processed steel 2. Large integrated players refers to the following 20 players her: ArcelorMittal, BaoSteel, Nippon Steel, Posco , US
Steel, Anben, TATA Steel, ThyssenKrup JFE, Severstal, Wuhan, China Steel, Magnitogorsk, Hebei, Essar, Chougang, Hyundai, Sistema Usiminas, Techint, Riva 3, HRC data using Metal Bulletin
2011 while other data using Platfact 2008
Source: Plantfact database 2008; WSA, Metall Bulletin 2011, BCG analysis
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Status: Currently on hold due to
uncertainty of Megasteel's future
Source:SEAISI, Company websites, Interviews, BCG Analysis
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Confidential
Existing projects assessed based on 9 key requirements to
ensure Malaysia's
Malaysia s competitiveness in the flat steel market
Production facilities Management capabilities
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7MTA by 2015 • Financing agreed, contracts
finalised, land developed, level of
construction, securing of inputs)
Source: BCG analysis
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Critical size
(3-4 MTA)
duction facilities
Technology ? ?
(BF BOF HRM)
(BF-BOF,
Location
(Land, port
access)
Prod
Global
Timing
Know-how
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Status
Source: BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx Does not meet criteria Fully meets the criteria 122
1 Confidential
Maegma project: Melewar Group plans to build
a DRI
DRI-EAF
EAF plant in Tanjung Hantu, Perak
Production facilities Management capabilities
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(Online by 2015) • Preparation of the land milestone status) most major suppliers
expected to start end • Currently negotiating
2012 gas agreement
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Confidential
DRI-EAF gas technology not mainstream, but can achieve
competitive levels when in close proximity to cheap resources
~5% of total using DRI-EAF ...of which >40% is in ... driven by good
t h l
technology... ME & NN. A
America...
i supplyl off gas
Middle East:~70% of ME steel
% total iron-making capacity
100%
% DRI-EAF capacity production
100 2% Others 100 • Local supply of gas & low gas
5% Direct Reduction prices
Coal-based
31
DRI-EAF
– ~40% of global gas reserves
80 80
• Marginal use of BF technology in
1 3 the region2
5
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1. Includes EAF by smelting reduction, 2. One BOF plant in Iran – IMIDRO Esfahan steel company 2.2MTA;
Source: Metal Bulletin Capacity 2011, BP Statistical Review of World Energy June 2011, US Energy Information Administration 2011 report, Company websites, press search, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 124
2 Confidential
New technology project: Plans to build an integrated steel
mill using new technology in Penang
Production facilities Management capabilities
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(Online by 2015)
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3 Confidential
Lion BF: Lion Group plans to build BF steel mill
in Banting Selangor
Production facilities Management capabilities
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months after funding is milestone status) • Building contracts &
(Online by 2015)
in place MOU with iron ore and
coal supply
Source: Interviews, press searches, company website
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4 Confidential
Eastern Steel: Plans to build steel mill in Kemaman as part of
JV with China Shougang
Production facilities Management capabilities
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Phase 1 Stage 2 by 2015 milestone status) • Inputs – in-progress
(Online by 2015)
• Construction – May /
June 2012
Source: Interviews, BCG analysis
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5 Confidential
Integrated Steel Project: Plans to build an integrated BF-BOF
steel mill either on the East or West coast of Malaysia
Production facilities Management capabilities
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(Online by 2015)
Most international p
players
y seeking
g genuine
g competitive
p advantage;
g ;
Copyright © 2
they anticipate the end of protection for flat upstream in Malaysia
1. China Shougang is the 5th largest steel producer in China; Source: Press searches, Interviews, BCG experience
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 129
Confidential
Leading international players assessed along 6 key
dimensions for suitability as a potential JV partner
No current p
presence
O
Openness to
t JV investments
i t t
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to partner with
1. Based on World Steel Dynamics rankings
Source: World Steel Dynamics, BCG experience
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 130
Confidential
ArcerlorMittal
Baosteel
POSCO
Nippon
pp Steel
Jiangsu
TataSteel
Ansteel
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Gerdau
Source: World Steel Association; Press search, Company website, BCG analysis
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Confidential
Nucor
Severstal
Wuhan
ThyssenKrupp
y pp
Shougang
SAIL
Hyundai
y
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;
Source: World Steel Association; Press search, Company website, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx Does not meet criteria Fully meets the criteria 132
Confidential
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Plate, Electrolytic Tin Plate and
Tin Coated Sheet, Galvanised Sheet,
1. Based on crude steel production over 3mmt in 2010, 2. Measured as EBITDA / revenue;
Source: World Steel Association, Bloomberg, Company websites
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 133
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goods, Oil & Gas, Ship-building, Machinery
1. Based on crude steel production over 3mmt in 2010, 2. Measured as EBITDA / revenue;
Source: World Steel Association, Bloomberg, Company websites
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 134
Confidential
Megasteel
g will have to increase p production volume and
Copyright © 2
utilisation ratio to break even
1. Unrealistic from a production perspective 2. By assuming order sizes increase without volumes increasing, for example.
Source: Megasteel costs and audited final accounts; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 136
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H Controlled
Laissez-faire exit Shared
L Take-over by M responsibility
Government Government
M
supportt
L
Sh d
Shared
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Free market
L success
L : Low probability
A rights reserved.
Steel Steel Very low likelihood Steel Steel
Banks Banks Banks Banks
Ind. Ind. given current Ind. Ind.
industry situation
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economy benefits
1. Except for re-export, automotive, shipbuilding and 50-50 for re-rollers
Note: For each stakeholder, the higher the score the better the outcome
Source:: SEAISI; MIDA; Megasteel documents; Megasteel P&L, manufacturing accounts; Megasteel balance sheets; WSD; elasticity estimates by NSC USA; Department of Statistics; Platts SBB
Steel; steelonthenet; Annual Reports of various players; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 138
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Shared responsibility outcome with least cost of resolution
for all parties
Written-off loans
▬ ~0.8
~0 86 ▬ ~0.8
~0 86
(RM Bn)
Rescheduled loans ▬ ~0.67 ▬ ~0.67
RM Bn)
el
1. Average change in price index for HRCs, CRCs, coated steel, pipes & tubes, driven by elimination of duties on imported HRCs because no longer produced locally (Sudden exit and Controlled
exit), driven by requisite clampdown in import volumes across value-chain and lower Megasteel prices (Shared responsibility), driven by clampdown in import volumes across value-chain (Protection);
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2. Megasteel's employment is 1700 (4600 including supporting companies); 3. Assuming projected 20 to 40% decline in flat mid/downstream due to prohibitively high raw material prices; 4. From
elimination of duties (no local production means full duty exemption); 5. From 15% duty paid on remaining imports; 6.Banks' exposure to Megasteel (unless provisioned); 7. Syndicated loan amount
outstanding; 8. Share capital; 9. Profitability derived from estimated Megasteel's cost curve at target production levels; 10. Conservative estimates does not include further gains by mid/downstream.
Source: SEAISI; MIDA; Megasteel documents; Megasteel P&L, manufacturing accounts; Megasteel balance sheets; WSD; elasticity estimates by NSC USA; Department of Statistics; Platts SBB
Steel; steelonthenet; customs data; Annual Reports of various players; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 139
Confidential Backup
Behind the numbers: Impacts on GDP contribution,
employment, tariff revenues (I)
Option Element Calculation steps and key assumptions
Controlled exit
• No domestic flat upstream means retrenchment of flat upstream workforce in the short
Impact on
employment run3
• Fall in raw material prices along the value chain means increased margins across the
Copyright © 2
and midstream players by ~1.4 percentage points (raw materials are ~70% of costs). Conservative estimates of average profit margins across value chain are ~4%, so increase in profits from the flat
steel industry is by ~35%. Profits comprise ~60% of direct GDP contribution so increase in GDP contribution across value chain is by 0.6*0.35*(0.1+0.3)%=0.084%; 8. Via the multiplier detailed in
footnote 1, indirect contribution increase is 0.7*0.084%= 0.06%;
Source: SEAISI; Department of Statistics; TEX Report; Bekhet (2011): "Output, Income and Employment Multipliers in Malaysian Economy: Input-Output Approach", International Business Research
Vol 4(1); Annual Reports; company interviews and publications; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 140
Confidential Backup
Behind the numbers: Impacts on GDP contribution,
employment, tariff revenues (II)
Option Element Calculation steps and key assumptions
• Ri
Rise in
i raw material
t i l prices
i along
l the
th value
l chain
h i means d depressedd margins
i across
Protection Impact on GDP the flat value chain of ~2.8 percentage points and decreased direct contribution to
contribution GDP of ~0.336%1. This feeds into indirect contribution to GDP of ~0.235%2 via the
multiplier effect3
• Prohibitively high raw material prices means some downstream players may have to
Impact on
shut down/relocate to outside Malaysia. With 20%-40% shutdowns, employment falls
employment
by 10,000-20,000 people4
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40% assumed shutdowns, loss in employment is given by 0.2*(47700), which is ~10% of employment; 5. Target tariff rate under Protection option is 15%; 6. MIDA duty exemption data used, in
conjunction with SEAISI data; 7. 2011 average import prices used; 8. current MFN duty rate used;9. Target volumesof HRC imports obtained by reducing HRC imports by 63% as detailed in
accompanying slide.
Source: SEAISI; Department of Statistics; TEX Report; Bekhet (2011): "Output, Income and Employment Multipliers in Malaysian Economy: Input-Output Approach", International Business Research
Vol 4(1); Annual Reports; company interviews and publications; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 141
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Steel industry: Stands to benefit over status quo from all
options except Protection
Steel Steel Steel Steel
Industry Industry Industry Industry
Coated
Coated
Coated
HRC
CRC
Pipes
HRC
CRC
Pipes
HRC
CRC
Pipes
HRC
CRC
Pipes
Impact on flat -10 -10 -10 -10
midstream,
downstream ▬ Increased exposure ▬ Downstream players
IIncreasedd exposure
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1. Numbers shown assume import gduties for HRC eliminated, and cost-drops are passed-through at 50-50 with customers down the value-chain; 2. numbers shown assume only HRC exemptions
gets patched and cost-drops passed-through at 50-50 with customers down the value-chain; 3. Numbers shown assume clampdowns on exemptions at all levels as explained in backup slide.
Source: SEAISI, MIDA exemptions data; Megasteel documents; customs data; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 142
Confidential Backup
Steel industry: Shared responsibility and Protection options
only feasible with limits on imports coming into Malaysia
* Volumes shown for all products are in equivalent required HRC volumes
Current Shared Protection
production responsibility
C
Current
t iimportt volumes
l servicing
i i T
Target
t import
i t volumes
l servicing
i i T
Target
t import
i t volumes
l servicing
i i
steel value chain steel value chain steel value chain
Imports Imports Megasteel Imports Megasteel
0 1.0 2.0 3.0 MTA* 0 1.0 2.0 3.0 MTA* 0 1.0 2.0 3.0 MTA*
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1. ~40% of current HRC imports are in grades Megasteel does not produce. Reducing imports to 70% will allow the continued import of HRCs in these categories, but reducing to 37% will require
substituting Megasteel grades for some materials in place of grades that Megasteel does not produce.
Note: Volume estimates constructed from multiple sources as below, based on 2011 data. Conversion yields from HRC to CRC, etc. taken from WSD.
Source: Megasteel documents; WSD; MIDA 2011 imports of flat steel by category; Customs data; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 143
Confidential
Steel industry: Shared responsibility option additionally
requires temporary control of domestic HRC prices
Simple, transparent mechanism proposed to control prices But regular attention needed
Simple, transparent mechanism to calculate controlled price index Regularly monitoring Megasteel's
• weighted by volume of 3 largest HRC exporters to Malaysia to be representative actual prices for compliance
• Invoices from domestic HRC
Volume of CIF cost of customers
Volume of HRC ( imports from A1 x imports from A2 ) – e.g., Mycron, CSC
1 imports into Malaysia +
(by country/region) 1 Volume of CIF cost of Regularly recalibrating index to
( imports from B1 x imports from B2 ) reflect current reality
• e.g., monthly
2 Volume of CIF cost of
+
CIF cost of HRC imports ( x )
1. Moving average basis from Department of Statistics data 2. Cost, insurance and frieght cost, per ton 3. Metal Bulletin, TEX Report and Platts SBB are just 3 possible sources. Prices should be
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current, or preferably forward-looking where available, referring a specific grade of HRC from a specific origin. 4. Simpson, Spence and Young is one possible source, 5. Average cost per ton
Malaysia 6. 5-10% markup will decrease average cost of HRCs in Malaysia (from current average price), benefiting mid/downstream and end-users. 5-10% will also allow Megasteel to make profits
7. Controlled price index will need to be decomposed and scaled appropriately to apply to each international grade of HRC made by Megasteel (e.g., JIS G 3132 SPHT2); one way is to look at
historical price differentials among the grades and apply those
Source: BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 144
Confidential Backup
Megasteel price1 x
IImportt price
i 1x (Importt price
(I i 1 + 20%3) x
Megasteel share of HRC price
domestic HRC + Duty-exempted import share of + Duty-paid import share of = index
domestic HRC consumption2 domestic HRC consumption2
consumption2
• Similarly, CRC price index, Coated price index, Pipes price index4
• Average price is the weighted average of the price indices, weighted by volume:
HRC price index x HRC price index x HRC price index x HRC price index x
HRC share of HRC share of HRC share of HRC share of Average price
domestic flat steel
+ domestic flat steel + domestic flat steel
+ domestic flat steel = index
consumption5 consumption5 consumption5 consumption5
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1. 2011 averages used for Megasteel and import prices; 2. Shares at 2011 calculated from SEAISI and MIDA numbers; 3. current MFN tariff rate for HRCs; 4. Proportion of exempted versus full-duty
paid products assumed at same ratio as for HRCs (due to unavailability of detailed data); 5. Considered as sum of HRC consumption, CRC imports, Coated steel imports and imports of pipes & tubes
Source: SEAISI Steel Statistical Yearbook 2010; steelonthenet.com; MIDA; interviews with domestic steel players; Megasteel documents; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 145
Confidential
Government and the Malaysian economy: Shared
responsibility option least costly
Govt & Govt & Govt & Govt &
Economy Economy Economy Economy
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Source: Department of Statistics Manufacturing publication 2010; Platts SBB Steel; steelonthenet; Annual Reports of various players; Megasteel documents; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 146
Confidential
Financial system: Pain in all options, but less so for Shared
responsibility and Protection options
Banks Banks Banks Banks
▬ Banks need to absorb ▬ Banks need to absorb ▬ Banks need to ▬ Banks need to
Megasteel's Megasteel's restructure restructure
bankruptcy bankruptcy Megasteel's loans, Megasteel's loans,
• Sell
S ll / liliquidate
id t • Receive
R i partt off debt
d bt andd makek allowances
ll andd make
k allowances
ll
Megasteel's assets (at haircut) from for more credit for more credit
• Write-off rest of Megasteel • Restructure ~RM • Restructure ~RM
Impact on Megasteel's bad bankruptcy 0.6bn2 syndicated 0.6bn2 syndicated
financial debt (if not • Write-off rest of loan by June 2012 by June 2012
institutions / provisioned ) Megasteel's bad – forgone earnings – forgone earnings
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Financial a whole can contain a whole can contain Megasteel future Megasteel future
system potential damage potential damage investment credit investment credit
1. Banks' exposure to Megasteel (unless provisioned); 2, Syndicated loan amount outstanding; Source: Megasteel accounts; Megasteel interviews and documents; Discussions with Bank Negara
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 147
Confidential Backup
Financial system: Impacts from Sudden exit and Controlled
exit options seem containable
Megasteel's
g exit would hurt bank p
profits,, banks Impact
p on trade creditors seem likely
y to be
may seek compensation from Government contained
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1. Includes other companies that directly support Megasteel, e.g., Lion DRI Sdn Bhd, Secomex Manufacturing Sdn Bhd, Lion Waterway Logistic Sdn Bhd, Compact Energy Sdn Bhd
Note: Megasteel does not have significant bondholdings.
Source: Megasteel audited Balance Sheet; Megasteel-provided documentation; BNM interview with the Director of the Financial Surveillance Department on 25 April 2012; Tenaga Annual Report
2011; Lion Corporation Berhad Annual Report 2010; BCG analysis
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Confidential
Megasteel: Shared responsibility and Protection are the only
two favourable options
Megasteel Megasteel Megasteel Megasteel
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Further Further
mitigates impacts
investments investments
1. Share capital; 2. Import reductions of this volume detailed in accompanying slide, directly translates to increase in Megasteel's production from 2011 numbers; 3.. Profitability derived from estimated
Megasteel's cost curve at target production levels; Source: Megasteel accounts; Megasteel interviews and documents; BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 149
Confidential Backup
Megasteel: Profitability from Shared responsibility option
(and Protection option) driven by increased volumes
Shared Increased volume and lower prices affords Megasteel
responsibility benchmark profitability under Shared responsibility
Leaner operations
lowers average Lowering prices
costs absorbs increased
100
demand
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1. Depends on assumptions made on landed price of imports. With higher landed price of imports, indexed quantity closer to 190; 2. Depends on assumptions made on import prices. With lower landed
price of imports, number closer to 92; 3. Depends on assumptions made on import prices. With lower landed price of imports, number closer to 86; Note: Megasteel's audited P&L accounts and
manufacturing accounts used as basis for constructing cost curves. Demand, volume and price estimates constructed from multiple sources. Source: Megasteel P&L accounts, Megasteel manufacturing
accounts, steelonthenet.com estimates, WSD, MIDA, 2011 imports of flat steel by category; elasticity estimates by NSC USA; BCG analysis
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Confidential
Building on shared responsibility, Megasteel plans to
complete 3 long-term
long term projects reducing its landed cost...
and coke oven plant • Iron ore is a key input in the • Diesel used as input for
• Objective to enable DRI process reheating
Descrip
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Note: Based on assumption Megasteel will be operation at 100% utilisation rate of 3.2MTA; Source: Megasteel, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 151
Confidential
60
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Note: BF/BOF state of the art plant is compared to average BOF and EAF cost bases in Asia-Pacific countries; Megasteel BF-EAF Future based on 100% utilisation rate of 3.2MTA capacity;
Megasteel numbers include $60 margin from Lion BF; Source: BCG Model, WSD March 2012 database, Megasteel, EIU, TNB
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 152
Confidential
To be competitive in ASEAN Megasteel needs to keep
utilization ratio above 75%
115
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100% Hot 55% Hot
metal1 metal
1. Assumes BF running at minimum limit of 70% capacity 1.4MTA;
Source: Megasteel savings estimates, BCG analysis
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Confidential
Megasteel: Any potential Government support should hinge
on Megasteel meeting strict conditions
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to 'Sudden Exit' outcome
1. Corporate Debt Restructuring Committee under BNM 2. Estimated reduction of ~25% of current imports required Source: BCG
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 154
Confidential
Agenda
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240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 155
Confidential
Access to key inputs is critical to the competitiveness of the Malaysian steel industry
80% of the total cost base is attributed to cost of raw materials and energy
• ~80%
• Iron ore is the key cost driver – 20% price increase will increase total cost by ~8%
Currently, many critical capability gaps with the MalaysianSteel industry need to be addressed
Currently
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• Potential Gov policy: Set-up Steel institute to enhance steel industry capabilities and close gaps
– Initial phase requires RM4-5Mn seed money from the Government
Enforcement of trade barriers, trade defenses and control of import process is required to guarantee a fair
level playing field
• Tariff and non-tariff barriers
– Import duties: Proceed with progressive reduction (as planned)
– Duty exemptions: Simplified application process,
process refined governance and transparency
– Mandatory standards: Selectively fine-tune breadth and depth of testing
• Trade defenses
– Joint p
private-Government effort to implement
p anti-dumping
p g measures for steel
– Leverage best practices from other industries – e.g. Paper, plastics
Cash cost of HRC with Malaysian BOF in USD/t1 Cash cost of HRC with Malaysian BOF in USD/t
800 680 8%
4 670
42 6 9 631 5%
660
600 76 42 3%
23 650
498 15
38
640 2%
0 580
Customs Other cost Gas Coal & coke Gas Scrap Coal Iron ore
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Freight Other fuels Labour cost Iron ore
Credits Electricity Scrap x% : Impact of 20% variation on total HRC cost base
1. Cash cost example is for Thailand market
Source: WSD March 2012, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 159
1 Iron ore Confidential
25,000
140 250
3,500
63% 56%
6,300
170
65%
6,000 75 125
3,000
30% 40%
6,900 23,000
128
30% 2,500 83 19
56% 33%
7,000
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1. Production assumed at ~4 Mt based on JMG data and interviews
Source: BMI 2011 Mining Malaysia, USGS 2011, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 160
1 Iron ore Confidential
Existing mines with limited reserves, renewed exploration
necessary to unlock Malaysia's
Malaysia s full potential
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Major iron ore basins
1. Current production boom primarily from old mines reopening to mine remaining low grade iron ore
Source: Iron Ore Deposits of West Malaysia – Minerals and Geoscience Department Malaysia, published in 1969
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 161
1 Iron ore Confidential
Current domestic production is sufficient, but using it needs
compliance with several pre
pre-requisites
requisites
MTA
8 A Processing required prior to
Iron ore feeding BF / DRI to get
6.31 processing • Pellets / sinter
Production CAGR: 55.2% capabilities • Blended lumps and fines of
6
Consumption CAGR: 6.1% different quality
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Exported Imported
Sold domestically Produced domestically
1. Export numbers both from mining and de-stocking 2. Local consumption of domestic iron ore is considered similar to 2010 (data not available)
Sources: Mineral Yearbook 2010 (Malaysia), Department of Statistics, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 162
1 Iron ore Confidential
Significant
g savings
g from local iron ore Prices expected
p to remain high
g ,
sourcing1 unless Chinese steel demand falls significantly
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1. Assumption: Local iron ore can be supplied at market price, 50% of local iron ore is used with the rest from Australia, margins on iron ore processing about 10%
Source: WSD, BCG model, Steel Index, Brokers' reports, SSY, BCG analsysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 163
1 Iron ore Confidential
Potential key government policies to match pre-requisites for
iron ore import substitution
Cost
Potential policy Pros Cons est.
A
Support beneficiation and pelletization • Focused policy • Does not address Limited
plant development with significant matching of iron cost
I
Iron ore processing
i • Access to financing impact on local ore supply and Incl. in
capabilities • Equipment duty waivers value added demand current
• Infrastructure support pioneer
• Technical support status
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• Technical support industry
1. For example, at currently assumed mining rate (~4 MTA), 50% domestic sourcing of iron ore by steelmakers will result in 40% of mining output or ~1.5 MTA consumed locally and 60% generating
export duties (~USD 5-10M) Such revenues would then be redistributed to finance sales to local processing plants
Source: BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 164
2 Coal Confidential
Malaysia has coal reserves: location and quality make it
unattractive for steel making
Production ramping up, but exclusively Limited exploitable coking coal reserves
thermal coal (<100 Mt), unlikely to be economical
Production in MTA
3 Most of 1.9 Bnt deposits are located in interior
areas, which lack infrastructure, therefore they
2.5 are uneconomical
2.4
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Major thermal coal reserves Major coking coal reserves
Source: IEA, Malaysia Mineral yearbook 2010, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 165
2 Coal Confidential
But Malaysia is strategically located nearby key met coal
sources: China, Australia and India
Malaysia strategically located: 72% of global Distance disadvantage vs. Indonesia can be
met coal produced in the region offset with efficient coastal setup
249
Row #1
450
51
China
Malaysia
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217 Reserves / production 2011 217 Other landed cost
Australia
Source: IEA Coal information 2011 edition and IEA 2003 report on reserves, SSY, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 166
3 Scrap Confidential
High
g scrap
p prices
p compared
p with other Asia- Malaysian
y exports
p of scrap
p remain limited
Pacific markets while imports are already significant
Scrap price in USD/MT2 Volumes in MTA Malaysia already applies 10% export
600 5 duties to limit export of scrap
+16%
Steel players claim that significant volumes
486 are exported under other HS codes
473 473 478
450 4
425 3.6
419 3.5
400
3
Export
p duties on scrap
p are unlikely
y to impact
p export
p
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volumes, if most exports are under other HS codes
1. Volume derived from total import and export values 2. Price as of March 2012
Source: UN Com Trade via Department of Statistics as of March 2012, WSD database as of March 2012, MISIF-MSA interview, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 167
4 Gas Confidential
Industrial g
gas price
p fixed by
y the state and Current industrial p
prices still competitive
p
set to increase by 3 RM every 6 months within the region
45.0
22 8
22.8
0 0
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1. Assuming 1038 liter per metric ton in fuel oil with high sulphur, 4.546 liters per imperial gallon and 177,000.00 Btu per imperial gallon, using yearly average RM/USD exchange rate 2. Using PTT
natural gas price as of Q4 2011
Source: Bloomberg, Energy Commission Malaysia, PGN, PVD, PTT, Oanda, BCG analysis
A B
All countries expected
p to Downward ppressure on
move towards market price market price expected
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Indonesia is the only country likely to • Petronas pursuing intense
sustain subsidies in the medium run capex as price goes up
Source: Bloomberg, Energy Commission Malaysia, PGN, PVD, PTT, Oanda, Brokers's reports, Press search, Expert interviews, BCG analysis
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 169
4 Gas Confidential
Not all industries are equal when facing energy price hikes
Key criteria for industry selection: Energy intensiveness
intensiveness, commoditized products
products, regionalized market
mod-
Regional-
sive
Energy
ed
ized
d
intens
Comm
itize
Key consuming Subsidy
sectors Impact of gas and electricity tariff hikes needed
Power
• Gas concessions with fixed price till 2015
• Gas price increase expected to be fully passed on to Tenaga
−
• Majority of Petronas Chem's electricity supply generated in-house
Petrochemical • Expected to be able to pass some of the hike +
: St
Strongly
o gy
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Malaysia should attempt to mitigate Indonesian subsidies
: Moderately
100% local iron ore use 50% local iron ore use Unchanged inbound freight cost
Iron ore • No inbound freight cost, in- • Fall in inbound freight cost and • Sourced from Western
house processing of pellets pellet processing cost Australia
Subsidies match other ASEAN Moderate hike relative to others Cost hike as announced
countries for steel makers • 30 RM/mmBtu in Malaysia • 45 RM/mmBtu in Malaysia
Gas1 • Unchanged
U h d relative
l ti costt off • No
N hik
hike assumed d iin other
th • No
N hik
hike assumedd iin other
th
gas vs. other players countries: 10 RM/mmBtu gap countries: 25 RM/mmBtu gap
Landed cost to
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Note: Assuming existing export incentives remain in India and China, taking into account only changes in the cost base that have a relative impact on Malaysian cost base versus other players' cost
bases (e.g. evolution of iron ore global prices are ignored as they are assumed to equally impact all players for the purpose of this analysis)
1. Gas prices in other countries are assumed to remain at current levels (e.g. at 45 RM/mmBtu in Japan) 2. Assuming key FTAs are renegotiated to (but not below) 10% or MFN rate falls to 10%
Source: BCG Model, WSD March 2012 database, EIU, TNB
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 171
Confidential
S tti up a St
Setting Steell IInstitute
tit t could
ld h
help
l close
l capability
bilit gap
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1. Mechanism/ service provided to the steel industry, however by another institution (e.g. association)
Source: Research Institute of Industrial Science and Technology (RIST), Australian Steel Institute, Iron and Steel Institute of Thailand, China Iron & Steel Research Institute Group, China Steel
Association
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 173
Confidential
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M'sian steel
Support & promotion Human capital development
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 174
Confidential
South
Australia China Thailand Malaysian Malaysian
Korea
Key Characteristics Palm Oil Rubber Iclif
Board Board
Financial
Industry Steel Steel Steel Steel Palm Oil Rubber
Services
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1. Figure based on 2010 data; 2. Figure based upon 2007 data; 3. Total disposable income 2010; 4. Funding allocated for FY2011 5. Amount available in trust 2010 6. South Korea was able to run a
privately funded institute as it is able to successfully commercialise its research (supported by POSCO)
Source: Research Institute of Industrial Science and Technology (RIST), Australian Steel Institute, Iron&Steel Institute of Thailand, China Iron&Steel Research Institute Group, China Steel Association
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 175
Confidential
Ph
Phase 3
3: P t T
Promote Tech.h IInnovation
ti
(5 years)
Phase 2: Create Industry Expertise
(3 years)
Phase 1: Build Internal Capability
(2 years) • Conduct own R&D
• None • Issue research grants • Provide R&D outsourcing services - pilot
Techno.
• Facilitate technology exchange plant for int'l players to test new tech.
Research
• Commercialise tech developed
Industry • Conduct competitive benchmarking • Provide detailed analytics for all segments • Provide detailed demand analysis for
Human • Train steel generalist (basic skills) • Train specialists • Train industry experts
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Req.
1.Requirements represent seed funding req. for proposed services; 2. Total human capital requirement – full time equivalents; 3. Financial support approved for Steel Institute; 4. Based upon function
requirements Mgt (4), Ind Analytics (3) Human Capital Dev. (8) Alliance Mgt (5); 5. Assumes double of workforce and RM5 mn for research grants; 6. 0.1mt pilot plant built (RM50 mn), land is given,
R&D lab (RM5 mn), org. growth (25%) Researchers is 30% of desired size (20), research grants (RM10 mn) – benefits to be realised from R&D outsourcing services (financial and tech transfer)
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 176
Confidential
Tariff barriers
• Import duties
• Duty exemptions
Non-tariff barriers
• Mandatory
M d t standards
t d d Trade barriers
• Import licenses
• Quotas1
Australia 5.0% 5.0% 0.1% 5.0% 5.0% 0.1% 0.1% 0.0% 0.0% 5.0% 5.0%
Brazil 11.6% 11.6% 11.6% 11.6% 11.6% 11.6% 11.6% 11.6% 11.6% 11.6% 11.6%
China 5.2% 5.2% 5.2% 5.2% 5.2% 5.2% 0.0% 0.0% 0.0% 0.0% 0.0%
Taiwan 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
ntries
India 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0%
porting coun
Korea 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
Imp
Singapore 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
Thailand 5.0% 5.0% 5.0% 5.0% 5.0% 5.0% 5.0% 0.0% 0.0% 0.0% 0.0%
Indonesia 5.0% 5.0% 0.0% 5.0% 5.0% 5.0% 5.0% 0.0% 0.0% 0.0% 0.0%
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current lack of production capacity
1. Based on Product HS code7208 – Flat-rolled products of iron or non-alloy steel, of a width of 600 mm or more, hot-rolled, not clad, plated or coated
Note: Ad valorem tariff: calculated as a % of the value of goods cleared through customs. For example, 15% ad valorem tariff means; Includes FTA information for ASEAN countries 15% of the value
of the entered merchandise; Source: WTO, Tariff Finder, Press Search, Macmap; Government websites, BCG Analysis (Note: selected non ASEAN countries are using 2007 data)
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 179
Confidential
Australia 5.0% 5.0% 5.0% 5.0% 5.0% 5.0% 0.0% 0.0% 0.0% 5.0% 5.0%
Brazil 12.0% 12.0% 12.0% 12.0% 12.0% 12.0% 12.0% 12.0% 12.0% 12.0% 12.0%
China 4.8% 4.8% 4.0% 3.5% 4.8% 3.5% 0.0% 0.0% 0.0% 0.0% 0.0%
Taiwan 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
porting countries
India 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0% 5 0%
5.0%
Korea 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
Malaysia 20.0% 20.0% 20.0% 20.0% 20.0% 18.2-20.0% 20.0% 0.0% 0.0% 0.0% 0.0%
Singapore 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
Thailand 5.0% 5.0% 5.0% 5.0% 5.0% 5.0% 5.0% 0.0% 0.0% 0.0% 0.0%
Indonesia 7.5-10.0% 7.5-10.0% 7.3% 7.5-10.0% 7.0% 7.5-10.0% 7.5-10.0% 0.0% 0.0% 0.0% 0.0%
Volumes for CRC from other ASEAN
countries
t i are nott significant
i ifi tddue tto
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current lack of production capacity
1. Based on Product HS code7209 – Flat-rolled products of iron or non-alloy steel, of a width of 600 mm or more, hot-rolled, not clad, plated or coated
Note: Ad valorem tariff: calculated as a % of the value of goods cleared through customs. For example, 15% ad valorem tariff means; Includes FTA information for ASEAN countries 15% of the value
of the entered merchandise; Source: WTO, Tariff Finder, Press Search, Macmap; Government websites, BCG Analysis (Note: selected non ASEAN countries are using 2007 data)
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 180
Confidential
Tariff barriers: Malaysia is the only ASEAN country with
significant variation of import duty along the value chain
Average import duty weighted by import volumes for top-3 countries (MFN & FTA rates)1
Downstream
HRC CRC Coated Steel Non-Coated Steel
(e.g. Containers)
Malaysia
19.7% 16.0% 16.3% 11.2% 0.0%
Indonesia
5 0%
5.0% 7 1%
7.1% 11 6%
11.6% 9 1%
9.1% 0 0%
0.0%
A rights reserved.
Thailand
2.6% 4.6% 5.7% 6.7% 8.2%
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1. Not taking into account duty exemptions
Note: HS Code definitions: HRC – 7208, CRC – 7209, Coated Steel – 7210, Non-coated Steel 7211 & 7212, Downstream 7308, 7309, 7310, 7311.
Source: MIDA, Tariff Finder, UNCOMTRADE, DOSM, Macmap
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Confidential
Tariff barriers: Duty exemption process is cumbersome and
requires refinement in governance and transparency
Only manufacturers and SSCs5 are eligible Users are not represented in Technical Committee
• Traders are not eligible • Current composition: MITI, MIDA, Customs, HRC
• Import
I t licenses
li are automatically
t ti ll granted
t d and
d producer
d
used for monitoring purposes only
Selected duty exemptions can be granted outside
Qualification assessed by a Technical Committee of JPC3 committee
(provide recommendation only) based on 3 • E.g.
E g MOF has authority to grant duty exemptions
criteria on its own
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10% increase2
1. Domestic availability in Sabah & Sarawak should be understood as local manufacturing in Sabah & Sarawak 2. Subject to maximum capacity 3. Quantity consumed/Period in monthsx12 4.
Quantity consumed/Period in monthsx12 5. Steel Service Centres
Source: MITI, MIDA, Industry interviews
240682-86-Iron and Steel industry-Final report-29May12-vf.pptx 182
Confidential
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locations
1. E.g. K2 form, packing list, bill of lading
Source: Guidelines for traders for inward processing (Revenue)
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B
Duty exemption: Governance and transparency
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Non-tariff barriers: Breadth and depth of mandatory
standards could be selectively fine-tuned
fine tuned
Mandatory standards cover imports but Moreover, testing for mandatory standards
not domestic production could be enhanced
Chemical
alysis
141 1,012 794 649 33
% 100 5% 4% 4% None content for classification
Oth componentt
Other
ana
content for environment
other ttests
Corrosion resistance 5
Domestic production currently not covered by
Yield strength
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1. The list displays key dimensions assessed by the European Union for iron and steel products, testing methods vary depending on the iron and steel products being evaluated, moreover, not all
dimensions are assessed for all products 2. Standards are mandatory for commercial steel only, where local production is considered competitive, advanced standards for high value added steel are
voluntary as of now 3. Auditors to check producer's quality management system, production capabilities and perform visual check of products 4. Visual check of 10% sample, no external analysis
beyond visual control 5. Visual check only
Source: MITI, SIRIM, CIDB, DOSM, CEN=ECISS (EU), ISIT (Thailand), BSN – SISNI (Indonesia), Expert Interviews, BCG Analysis
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Trade defences: Need for a joint private-Government effort
to implement anti
anti-dumping
dumping measures for steel
Malaysia has yet to employ trade Need for a joint effort between private
defenses to protect its steel industry sector and government agencies
Countervailing measures2 for steel products1 Currently steel players complaining about lack of
Nb government support...
60 "Th anti-dumping
"The ti d i process iis complex
l with
ith ttemplates
l t and d
Measures
lack government assistance" / "Thailand and Vietnam
40
have already taken measures in response to Chinese
56
20
boron steel exports... Malaysia has yet to do something"
17
– Industryy p
players
y
0 5 3 0
Thailand Indonesia Philippines Singapore Malaysia Paper Plastics, Chemicals Vehicles Stones,
rubber glass
Government could support by establishing the Steel Institute
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(industry analytics) and providing legal trade assistance
1. The data represents cumulative trade defenses employed for basic metals which includes, but not limited to steel products 2. Currently no ASEAN country has yet implemented countervailing
measures, but investigations have been initiated by Indonesia and Thailand on boron steel coming from China
Source: WTO (1995-2011); industry interviews
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Trade defences: Anti-dumping measures implemented by
Malaysia
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Note: The paper and plastics industry contributes 2.2% & 4.2% respectively to the Malaysian economy
Source: DOSM, MITI
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Importation process: ~90% of HRC and CRC imports
entering Malaysia with duty exemption or through LMWs
(kTA)
HRC1 and CRC2 imports entering Malaysia (K1 forms)
1500
1047
1000 961
13%
848 860 11% 849
8%
8% 11%
10% 681 5%
500 Other
79%
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1. HS code 7208 2. HS code 7209
Source: Customs data
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Importation process: Industry players identify several
opportunities to improve control
• Consignment checks are not thorough in terms of
container coverage and product inspection
2 Consignment Check • Samples
p are not p
picked up
p at p
ports or are not checked
&OObtain SSamples against the load imported
• Imports enter M'sia for Testing
without inspection
• Falsified Tariff Payment
y
documentation - 0% 5
& Consignment
tariff when duties
should be applied Enters M'sia
A rights reserved.
1 Consignment Arrives at Royal Malaysian
Port & Document Check Customs • Consignments enter Malaysia
even without a COA
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Testing & Verify
Report
1. Licensed manufacturing warehouse
Source: SIRIM QAS, Industry Interviews
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Q i k wins
Quick i L
Long-term
t actions
ti
Improved training for custom officers Current/ future enhancement of Customs IT
• Knowledge of steel products2 and common systems
falsification tactics • Data-mining
Data mining of custom
c stom data
(kTA)
Movements from Sabah & Sarawak to Peninsula
20
10
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1. HS code 7208 2. HS code 7209
Source: Customs data
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Agenda
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Executive summary
Implementation plan
The report
p recommendations are translated into an implementation
p plan
p made of two main sections and
five initiatives
• Section 1: Megasteel solutioning, focuses on the "Shared responsibility" option, the most complex to
implement
– If another option is decided by the Economic Council
Council, Section 1 is not applicable
• Section 2: Support to the wider steel industry, which is split in four distinct initiatives
– Provide advantaged access to select inputs
– Enhance capabilities of the steel industry - e.g. Steel Institute
– Enforce trade barriers and importation processes
Effective
Eff i governance will ill require
i clear
l lleadership
d hi and d allocation
ll i off resources to coordinate di the
h project
j
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• Immediate next steps to be taken by PMO staff following the EC approval to comply with project objectives
• Charters and roadmaps for each initiative will provide guidance to project members
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In summary, two main recommendations to enhance
competitiveness of the overall steel industry in Malaysia
Main initiatives Details
1.0 Proceed with Megasteel
g exit No change
g to industry
yppolicy
y
olutioning1
Megasteel
Change in government policy on flat steel Tighten duty exemptions granted by JPC3
to be implemented for 24 – 36 months only Stricter enforcement of duty exemptions process
1.1
M
so
Implement conditions on Megasteel to Lower domestic HRC price: Keep Megasteel prices within an agreed
demand turnaround within 24 – 36 months range (5-10% of benchmark imports)
1
• Gas price monitoring Be aware and avoid significant gas price gap with regional neighbors
Enhance capabilities of the overall industry Mechanism to close critical gaps within the industry: especially
especially,
ndustry sup
24
2.4 Implement trade remedies Joint Private sector/Government effort to leverage best practices from
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other industries in Malaysia
1. Recommendation 1.0 corresponds to "Sudden exit" and "Controlled exit" options. Recommendation 1.1 corresponds to "Shared responsibility option"
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Recommendations translate into 2 sections and 5 initiatives
with clear views on objectives and deliverables
Note: Recommendation 1.0 corresponding to "Sudden exit" and
"Controlled exit" options not detailed in the implementation plan
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level playing field Section
Members' Meeting
g
Organization chart Role profile frequency
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Customs,
SIRIM)
Source: BCG experience
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Temporary roles required to drive and coordinate the
implementation project
Director / Assistant Director level (Sector Assistant Director to head PMO team
head or deputy) • Manager role required
Profile • Significant experience at MITI or other At least one other team member with prior
federal agencies steel experience
• Some experience with the steel industry
20% of a full
full-time
time workload initially Initially 3 full
full-time
time equivalent resources
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• One person in 2014-2015
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Source: BCG experience
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Implementation milestones are spread over time with
Megasteel in H22012 and other initiatives in 2013
Note: Recommendation 1.0 corresponding to "Sudden exit" and
"Controlled exit" options not detailed in the implementation plan 2012 2013 2014 2015
Set up
exemption
solutioning
1.1
• Provide government support MITI
eel
restrictions
Megaste
Positive Remove
EBITDA exemption
restrictions
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Communication p
plan including g implementation
p approach
pp
• Announcement to key stakeholders (Megasteel, MISIF, MSA, Financial sector, etc.)
• Announcement to the press and other stakeholders
Megasteel Agree/Com-
mit on p
plan Restrict duty
y exemptions
p Follow-up
p on implementation
p
Remove
policy
solutioning changes
Setup
(Megasteel exit options price Price revisions
ready
Revised Megasteel prices Finalize all
projects
revisions Positive EBITDA
not detailed in the Turnaround
planning Restructuring operations, corporate restructuring Monitoring
implementation plan) Turnaround
Turnaround pplan ready
y
Quick wins plan ready
(quality,
Draft final
2 2.1 Com. survey report
Access to key
24
2.4
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Extend mandatory standards/testing
Com.
Trade defenses EC option Identify roadblocks and KSF
selection
Drive roll-out
Source: BCG project and analysis
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1 Confidential Note: Recommendation 1.0 corresponding to "Sudden exit" and
"Controlled exit" options not detailed in the implementation plan
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exemption customs process improvement and Key Inputs for – Utilization rate • HRC price, quality and
the pelletizing plant and Steel Ind. Capabilities on expertise – Cost per tonne delivery time
A ti it
Activity 2012 2013 2014 2015
Launch initiative
Agree on plan Follow-up on stakeholders commitments
and obtain
commitment
Provide government support
Restrict duty Follow-up on implementation Remove
exemptions exemption restrictions
Key milestones
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Source: BCG analysis
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2.1 Confidential
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• Impact on Megasteel solutioning as pelletizing plant comes • Share of local iron ore usage in domestic steel production
online
A ti it
Activity 2012 2013 2014 2015
Key milestones
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Source: BCG analysis
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2.2 Confidential
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Defenses and Trade Barriers and import process • Steel institute launched • # workers trained
• Share private funding • Width and usage of data
• Potential overlaps with MISIF-MSA initiatives • # of key activities launched
Source: BCG project, MITI interviews
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2.2 Confidential
A ti it
Activity 2012 2013 2014 2015
Team build-up
Setup Appoint Appoint Develop local and Team build-up
Committee CEO N-1/N-2 international partnerships
Industry analytics
Build business Publish Gradually expand data and
information database initial reports analyses coverage
Human capital development
Prepare trainings Launch key Gradually increase sophistication of trainings
Identify contributors services
Industry support and development
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Source: BCG analysis
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2.3 Confidential
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• Exemption and customs processes support implementation • Exemption volumes vs. peers
of Megasteel turnaround
Source: BCG project, MITI interviews
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2.3 Confidential
A ti it
Activity 2012 2013 2014 2015
Duty exemptions
Simplify duty exemption Follow-up and fine-tune
process / Improve
I governance duty
d t exemption
ti processes
Customs processes
Identification of Detailed Oversee Follow-up and fine-tune
detailed weaknesses recommendations implementation process
M d t
Mandatory standards
t d d
Update mandatory standards policy
Key milestones
EC Commence trade Implement Approve customs Finalize mandatory
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Source: BCG analysis
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2.4 Confidential
Trade defenses
Initiative charter
Organization Position Role • Trade defenses including • Tariff barriers and non-tariff
TBD Initiative leader anti-dumping, barriers incl. import duties,
MITI-Trade Practice
TBD Initiati e member
Initiative co nter ailing and
countervailing duty exemptions
exemptions,
MITI trade mandatory standards,
agreements- TBD safeguards
import licenses and quotas
MISIF TBD Initiative member • Importation processes
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• Potential support to Megasteel solutioning (e.g. countervailing • Share of imports due to unfair practices
duties on Boron steel from China)
Source: BCG project, MITI interviews
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2.4 Confidential
Trade defenses
Detailed roadmap
A ti it
Activity 2012 2013 2014 2015
Best practices
Identify best practices Prepare report
Drive roll-out
Align
g with stakeholders Drive roll-out of recommendations Follow-up
p on
on recommendations implementation
Key milestones
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Source: BCG analysis
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