Sterlite Industries (India) Limited
Delivering Gr ow t h Long-term value Su st ai n ab i l i t y
STERLITE INDUSTRIES (INDIA) LIMITED ANNUAL REPORT 2011 Our Values
Entrepreneurship We foster an entrepreneurial spirit throughout our businesses and value the ability to foresee business opportunities early in the cycle and act on them swiftly. Whether it be developing organic growth projects, making strategic acquisitions or creating entrepreneurs from within, we ensure an entrepreneurial spirit at the heart of our workplace.
Growth We continue to deliver growth and generate signi cant value for our shareholders. Moreover, Our Vision our organic growth pipeline is strong as we To create a world class, seek to continue to deliver signi cant growth for diversi ed resources company shareholders in the future. We have pursued with high quality assets, low cost growth across all our businesses and into new production, providing superior areas, always on the basis that value must be returns to our shareholders. delivered.
Excellence Achieving excellence in all that we do is our way of life. We strive to consistently deliver projects ahead of time at industry-leading costs of construction and within budget. We are constantly focused on achieving a top decile cost of production in each of our businesses. To achieve this, we follow a culture of best practice benchmarking.
Trust The trust that our stakeholders place in us is key to our success. We recognise that we must responsibly deliver on the promises we make to earn that trust. We constantly strive to meet stakeholder expectations of us and deliver ahead of expectations.
Sustainability We practise sustainability within the framework of well-de ned governance structures and policies and with the demonstrated commitment of our management and employees. We aim that our projects make a net positive impact on the environment, wherever we work. Sterlite Industries (India) Ltd. Annual Report 2011 1
Contents
02 Highlights Company Overview 04 Sterlite at a glance 06 Chairman’s Communiqué 08 Company Overview 14 Board of Director’s Pro le
18 Performance 20 – Copper Business 22 – Zinc and Lead Review 24 – Aluminium 27 – Energy 28 Operational Performance 32 Financial Performance 34 Risk and Uncertainties Development Sustainable
42 Sustainability Report 53 Corporate Social Responsibility (CSR) Governance Corporate
65 Directors’ Report 75 Corporate Governance Report
94 Auditors’ Report 138 Consolidated Balance Sheet 98 Balance Sheet 139 Consolidated Pro t and Loss Account 99 Pro t & Loss Account 141 Consolidated Cash Flow Statement
100 Cash Flow Statement 143 Schedules forming part of the Statements Financial 102 Schedules forming part of the Consolidated Balance Sheet Balance Sheet 151 Schedules forming part of the 114 Schedules forming part of the Consolidated Pro t and Loss Account Pro t & Loss Account 153 Notes forming part of the 116 Notes Forming Part of the Accounts Consolidated Accounts th 136 Balance Sheet Abstract and 174 Notice of the 36 Annual General Company’s General Business Pro le Meeting 137 Auditors’ Report on the 181 Information to shareholders on Consolidated Financial Statements dematerialisation of shares 2 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Highlights
Financials Zinc-Lead Indian Operations: — Highest ever production of Rods – — Consolidated turnover for the — Highest ever zinc and lead mined 1,60,665 MT and Rolled Products nancial year 2010-11 ` 30,248 metal production of 840,000 MT – 66,706 MT Crore up by 23% — Re ned zinc metal production of — Construction of 1,200 MW CPP — PBIDT of ` 10,522 Crore up 712,000 MT and 174,000 kg at BALCO is progressing well for by 32% of silver commissioning of First unit by Q2 — PAT of ` 7,322 Crore up by 35% — Accelerated ramp up at silver FY 2011-12 — Attributable Pro t of ` 5,043 Crore rich Sindesar Khurd mine - up by 35% successfully commissioned the Power — Consolidated EPS ` 15/- post 1.50 million tonne per annum — Record sales of 2,035 million share split and bonus issue concentrator units, up 44% from previous year — ` 1.1/- dividend per equity share — New 160 MW captive power plant — First 600 MW unit of the 2,400 of ` 1 each (110%) on increased commissioned at Dariba, India MW (600 MW x 4) Independent capital following 1:1 bonus issue Power Plant (IPP) at Jharsuguda for the nancial year 2010-11 Zinc-Lead International Acquisition commissioned and the Second & Operations: unit under trial Market Capitalisation — The acquisition of Skorpion Zinc, — Addition of 48 MW Wind Power — ` 58,283 Crore Sterlite’s market Namibia was completed in Plant at HZL making total green capitalisation as on 31 March 2011 December 2010 power to 171 MW — The acquisitions of Black Copper Mountain Mines in South Africa Port & Infrastructure Project — Cathode production 303,991 MT and Lisheen Mines in Ireland were — Successful entry into the growing — Highest ever domestic sales of completed in February 2011 port sector in India. 2,06,653 MT — Successful tender to construct — 160 MW captive power plant Aluminium a coal berth of ` 675 Crore construction work progressing — Highest ever hot metal production at Vizag for scheduled completion well of 2,55,298 MT by mid 2012 Sterlite Industries (India) Ltd. Annual Report 2011 3
Consolidated Performance
Sales & Services ` Crore Gross Pro t (PBDIT) ` Crore Cash Pro t (PBDT) ` Crore
35000 12000 12000 Company Overview 30000 10000 10000 25000 8000 8000 20000 6000 6000 15000 4000 4000 10000
5000 2000 2000 Business Review 0 FY-2011 FY-2010 FY-2009 FY-2008 FY-2007 0 FY-2011 FY-2010 FY-2009 FY-2008 FY-2007 0 FY-2011 FY-2010 FY-2009 FY-2008 FY-2007
Attribuitable Pro t ` Crore Gross Fixed Asset ` Crore Net Worth ` Crore 6000 50000 45000 40000 5000
40000 35000 Development Sustainable 4000 30000 30000 25000 3000 20000 20000 2000 15000
10000 10000 1000 5000
0 FY-2011 FY-2010 FY-2009 FY-2008 FY-2007 0 FY-2011 FY-2010 FY-2009 FY-2008 FY-2007 0 FY-2011 FY-2010 FY-2009 FY-2008 FY-2007 Governance Corporate
Segment Contribution
2005-06 (PBIT) 2010-11 (PBIT) Statements
Other Financial Zinc & Lead 1% 66% Power 3%
Copper 23% Zinc & Lead Copper 77% 12%
Aluminium 7%
Aluminium 11% 4 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Sterlite at a Glance
Our principal operations are located in India, where we have a substantial market share in each of our main metal: aluminium, copper, zinc and lead and also operate a copper mine in Australia. In the year 2010-11, we acquired zinc assets in Namibia, South Africa and Ireland, thus spreading our global presence.
Group Structure
Vedanta Resources (Listed on LSE)
70.5% 54.6% 94.8% 29.5%Sterlite 3.1% Vedanta Industries Madras Aluminium (Listed on BSE, Aluminium (VAL) NSE and NYSE (MALCO)
Bharat Zinc-India(HZL) Australian Aluminium (Listed on BSE Sterlite Energy Copper Mines (BALCO) and NSE)
51.0% 64.9% 100% 100%
KEY Skorpion Black Aluminium and Lisheen Mountain Copper Power Zinc-India Zinc-International 100% 74%
Percentage Shareholding as of March 31, 2011 Sterlite Industries (India) Ltd. Annual Report 2011 5 Company Overview Business Review
Aluminium Copper Zinc
Power Development Sustainable Projects under development India Captive Power Plant 01. Debari Smelter 02. Chanderiya Smelters 03. Rampura Agucha Mine 04. Rajpura Dariba and Sindesar Khurd Mine 05. Zawar Mine 06. Silvassa Re nery 07. Tutircorin Smelter and Re nery 08. Vizag Smelter 13 Governance
09. Lanjigarh Mine and Re nery (VAL) Corporate 10. Jharsuguda Aluminium (VAL) and Commercial Power project 11. Korba Smelter 12. Mt. Lyell Mine 3 13. Talwandi Sabo Power Limited 14. Skorpion Mine 1 4 15. Black Mountain Mine 2 5 16. Lisheen Mine 11 11
Australia Namibia Statements
10 10 Financial 6
9 14
8
12 Ireland South Africa
15 16
7
The maps are not to scale. 6 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Chairman’s Communiqué
Against a background of robust demand for commodities, we have delivered an exceptional nancial performance, achieving record levels of production and record sales of power. Our industry- leading organic growth programme, supplemented by strategic acquisitions, places Sterlite in a strong position to capitalise on the growing demand for commodities, and will underpin our objective to deliver growth and long-term value for our shareholders.
Dear Shareholders, delivered a robust nancial performance. smelter at Dariba commissioned at the end Strengthening prices, increased volumes of the nancial year 2009-10 ramped up. It gives me great pleasure to share the and a continued strong focus on We are also well on our way to becoming performance and highlights of the year operational ef ciency have contributed one of the world’s largest integrated silver 2010-11. It has been a ful lling year for to a substantial growth in Net Sales of producers, as we ramp up production at the Sterlite, with achieved record levels of ` 30,248 Crore, a 23.4% increase Sindesar Khurd (SK) mine. Once the SK production, record sales of power, and compared to last year and a record PBDIT mine reaches full capacity in FY 2012, we an impressive 32% increase in PBDIT, of ` 10,522 Crore. EPS increased by 28% will have a capacity of 16 million ounces of as we continue our focus on delivering during the year. We continue to deliver re ned silver per annum. growth and creating long-term value for our volume growth, with signi cant increases shareholders. achieved in zinc-lead and commercial We started two 600 MW units of the 2,400 energy businesses. MW power plant at Jharsuguda and also Our extensive investment in organic announced the addition of a fourth 660 MW growth projects continues, driving strong The balance sheet remained strong unit at the Talwandi Sabo Power Limited PBDIT and cash ow growth. During the with cash and liquid investments of (TSPL) project in Punjab, taking the total year we acquired the zinc assets of Anglo- ` 22,617 Crore. capacity of TSPL to 2640 MW. The power American Plc. there by expanding our zinc generated by this new unit will be largely business geographical footprint. Operational Performance sold in the merchant market, signi cantly The ramp up of our various expansion enhancing the overall return of this project. Financial Performance projects contributed to record production The rst phase of our 150 MW wind power Against a background of recovering volumes in the year. expansion project has been commissioned: economic conditions in the developed when complete, this project will make us world and a continued strong demand Zinc production at our operations in India one of the largest wind power producers in from emerging economies, we have rose signi cantly as the 210 kt per annum India with a capacity of 273 MW. Sterlite Industries (India) Ltd. Annual Report 2011 7
We remain committed to an integrated good governance, environmental footprint woman employees to join us and take aluminium strategy, and we continue reduction and creating value for all our leadership position.
to engage in discussions with the stakeholders. The international consulting Company Overview Government of Orissa regarding access rm, Scott Wilson, was engaged by our The Company’s dedicated and talented to alternative sources of bauxite for VAL. parent Vedanta Resources Plc. last year workforce of more than 15,000 people has to review our sustainability practices. assisted in driving our achievements and Acquisitions Some of its key recommendations were success. We remain committed to continuing We completed the acquisition of the zinc to deliver an improved Code of Conduct to provide a challenging and rewarding work assets of Anglo-American in the second and Practices, to widen the remit of environment to all our employees. half of the nancial year, increasing our the Health, Safety and Environment zinc-lead capacity to 1.5 million tonnes Committee and reconstitute it as the On behalf of the Board, I am thankful to Business per annum. This acquisition makes us the “Sustainability Committee” and to all of them for their continuing support Review largest producer in the world and extends enhance the scope of Environmental The Company continued to enjoy cordial our zinc footprint in Africa and Ireland. Impact Assessments (EIAs) for large industrial relations. new projects in line with international Reserves and Resources best practice. We are progressing well I would like to thank all my fellow directors Exploration continues to be a major focus, on implementing their recommendations for their invaluable contribution, support and this year too, we have successfully while retaining our focus on continuing and guidance. I take this opportunity Development added reserves and resources of 22.1 to improve our safety performance; to express my gratitude to all our stake Sustainable million tonnes in our Zinc-India business, contributing further to local communities; holders who have reposed trust in our increasing the life of our mines. The continuing to manage and minimise abilities and extended support to us. additional zinc reserves from the promising our impact on air, water and land; and Gamsberg project acquired from Anglo- maintaining a dialogue with stakeholders Outlook American Plc. Group further reinforce this on an ongoing basis. Looking forward, we anticipate continued rm foundation. growth in metal consumption lead by India Dividend and China, with tight supply in speci c Governance
Markets The Board of Directors has recommended markets – particularly for copper and zinc. Corporate Commodity prices began rising again a dividend @ ` 1.1/- per equity share on The nancial year 2011-12 is an important in the second half of the year, as euro - face value of ` 1/- each (i.e.110%) for the year for Sterlite, with signi cant growth in our zone debt fears receded and developed nancial year 2010-11 on increased capital production capacities as we ramp up many economies stabilised. Demand from base subsequent to 1:1 bonus issue. of our organic expansion projects. Higher the Asian economies remained robust, commodity prices are driving up input costs in although Chinese markets cooled, and the People our industry; we believe that our structurally on-going Indian growth story remains a We believe that the people are the low-cost assets, combined with our key contributor to our success. The long vital force of the organization. The HR continuous improvement culture, will enable Statements Financial term trend of urbanisation and accelerated philosophy is to recruit fresh, young us to mitigate the effects of this phenomenon. infrastructure development will continue to and talented people and nurture drive strong demand for our products. them to become the future leaders With our industry leading organic growth and entrepreneurs. Your Company programme and the successful integration Strong Financial position encourages employees to come up of our recent strategic acquisitions, Sterlite Over the years, we have consistently with innovative ideas and projects to is very well placed to capitalise on the generated strong free cash ow. The show case their entrepreneurial skills. positive outlook for commodities demand net cash as at 31 March 2011 was The Company encourages a culture of and to continue to deliver growth and long- ` 22,617 Crore. ownership in everything we do and same term value for our shareholders. is re ected the fact that many of our Sustainability employees have become shareholders. We remain committed to sustainable Your Company is an equal opportunity Anil Agarwal, development, focusing on the priorities of employer and encourages more and more Chairman 8 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Company Overview Sterlite Industries (India) Ltd. Annual Report 2011 9 Company Overview
We aim to create a globally respected, world-class metals and mining company that generates consistently strong nancial returns for its shareholders. Business Review
Sterlite is India’s largest Development non-ferrous metals and Sustainable mining company and is one of the fastest growing private sector companies. Governance Corporate
Sterlite strives to drive its business based on sustainability and safe
operations. Statements Financial 10 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Sterlite Industries (India) Limited Sterlite Copper Laboratories at Tuticorin Tasmania in Australia, which provides (Sterlite) is the principal subsidiary of and Silvassa have been recognized around 8% of our copper concentrate Vedanta Resources plc., a diversi ed with ISO 17025:2005 certi cation from requirements at Sterlite Copper In 2010- and integrated FTSE 100 metals and National Accreditation Board for Testing 11, we produced 304 kt of re ned copper. mining company, with principal operations and Calibration Laboratories (NABL). located in India, Australia, U.A.E, The company is LME approved copper Zinc and Lead Namibia, South Africa and Ireland tester. Our copper products meet the HZL was acquired by Sterlite in the year requirement of Restriction of Hazardous 2002 when the Government disinvested Sterlite’s principal operating companies Substances (RoHS complied) and certi ed the stake in HZL. Sterlite has a 64.9% comprise Hindustan Zinc Limited (HZL) for by Underwriters Laboratories Inc. Its ownership interest in HZL, with the its fully integrated zinc and lead operations; Central lab at Silvassa is a GoI approved remainder owned by the Government of Sterlite Copper - Tuticorin & Silvassa and R&D laboratory. The Company has also India (29.5%) and institutional and public Copper Mines of Tasmania Pty Limited won numerous awards for safety and shareholders (5.6%). (CMT) for its copper operations in India/ environment. Australia; and Bharat Aluminium Company Sterlite’s fully integrated zinc business (BALCO), for its aluminium and alumina Our Goal in India is owned and operated by HZL, operations and Sterlite Energy Limited To create a globally respected, world- India’s leading primary zinc producer with (SEL) for its commercial power generation class metals and mining company that a 82.1%. market share by sales volume business. During the year Sterlite through generates consistently strong nancial in India in scal 2011, according to the its wholly owned subsidiaries acquired Zinc returns for its shareholders. Indian Lead Zinc Development Association assets comprising 100% of Skorpion, which (ILZDA). In FY 2011, HZL was the world’s owns the Skorpion mine and re nery in Copper largest integrated producer of zinc based Namibia, a 74% stake in Black Mountain, Sterlite is one of the largest integrated on production volumes and in the lowest whose assets include the Black Mountain copper rod producer in Asia. Sterlite cost quartile in terms of all zinc mining mine and the Gamsberg project in South copper business comprises of two operations worldwide, according to Brook Africa, and 100%. of Lisheen, which owns operations, namely, Sterlite custom Hunt. The agency also stated that HZL’s the Lisheen mine in Ireland. smelting and re nery in India and CMT Rampura Agucha mine was the largest zinc mining operations in Australia. The mine in the world on a production basis. The Sterlite is India’s one of the largest primary products in this segment are Company’s Chanderiya hydro-metallurgical diversi ed non-ferrous metals and mining copper cathode and copper rods. The zinc smelter was the fourth largest smelter company. Sterlite is listed on BSE, NSE copper business comprises smelting, on a production basis worldwide. Mined and NYSE. It was the rst Indian Metals & processing of copper and its by-products. metal production of zinc and lead in the Mining Company to list on the New York Our operations include a smelter, re nery, nancial year 2010-11, up 9.0% to 840 kt. Stock Exchange. phosphoric acid plant, sulphuric acid plant and copper rod plant at Tuticorin in the HZL’s operations include four lead-zinc Sterlite has continually demonstrated state of Tamil Nadu in southern India; and mines, four hydro-metallurgical zinc its ability to deliver major value creating a re nery and two copper rod plants at smelters, one lead smelter, one lead- projects, offering unparalleled growth Silvassa in the Union territory of Dadra zinc smelter, ve sulphuric acid plants, at lowest costs and generating superior and Nagar Haveli in western India, The one silver re nery, ve captive power nancial returns for its shareholders. At Tuticorin Smelter has been operating for plants in Northwest India, one hydro- the same time, it strives that its expansion more than thirteen years in accordance metallurgical zinc smelter and a sulphuric projects meet high conservative with global standards. It employs the acid plant at its Vishakapatnam facility in nancial norms. ISA Smelt process which is considered southeast India. HZL has entered into a globally as an environmentally advanced consortium for developing the Madanpur A majority of Company’s operations are technology as well as a precious metal South Coal Block in Chhattisgarh for certi ed to the International Standards like re nery at Fujairah in the UAE. In addition, securing its coal requirements for captive ISO 9001, ISO 14001 and OHSAS 18001. we own the Mt. Lyell copper mine at power generation. Sterlite Industries (India) Ltd. Annual Report 2011 11 Company Overview Business Review
During the year, the Company completed a pre-baked smelter of capacity 245 kt of Understanding dated 8 August 2007 the acquisition of Anglo American Plc’s per annum has been established in the with the Government of Chhattisgarh for Development zinc assets (Anglo Zinc) for a total cash year 2004. The Company is playing a setting up of a new smelter with a 6.5 Sustainable consideration of $1,513 million. This crucial role in introducing aluminium as a lakh mt per annum capacity. Towards acquisition comprised the 100 %owned potential alternative to other metals like this, the Company has commenced the Skorpion mine in Namibia, the 100% owned Steel in construction, and Copper in power implementation process of the rst phase Lisheen mine in Ireland and the 74% owned transmission industry. The smelter plants of expansion for setting up 3.25 lakh mt per Black Mountain Mines, which includes the are being supported by uninterrupted annum pre-bake aluminium smelter at an Black Mountain mine and the Gamsberg power supply through Captive Power estimated project cost of ` 3,215 Crore for project in South Africa. Anglo Zinc is an Plants - 270 MW at Jamnipali, Korba and commissioning by Q2 of FY 2013. Governance
excellent operational and strategic t 540 MW at smelter site. Corporate with our existing business and will create The Company is in the process of setting signi cant long term value for shareholders. BALCO had a 36% primary market share up the 1200 MW power plant project at a This acquisition consolidate our position by production volume in India in scal cost of ` 4,912 Crore. The rst two units is as the world’s largest integrated zinc - lead 2011, according to Aluminium Association expected to be commissioned in FY 2011- producer with signi cant reserves and of India (AAI). 12. The foundation work of the chimney resources of 478 million tonnes. in place of the collapsed chimney for third BALCO’s partially integrated operations and fourth unit is under progress and
Aluminium include two bauxite mines, captive construction of the chimney is expected in Statements Financial BALCO was incorporated in the year power plants and re ning, smelting and the rst quarter of 2012-13. Consequently 1965 as a Public Sector Undertaking fabrication facilities at our Korba facility in the synchronisation of the third and fourth (PSU) and since then the Company Central India. unit is expected in second quarter of has been closely associated with the 2012-13. Subject to statutory consents, the Indian Aluminium Industry, in a pivotal During the year, the production of saleable approval process for BALCO’s 211 million role. Located in Korba in the state of metal was 2,55,298 MT from the 2.45 tonnes coal block is progressing well and Chhattisgarh in central India, our majority lakh mt per annum pre-baked smelter as is expected to commence coal mining by owned subsidiary, BALCO is one of the compared to 2,68,425 MT in the previous Q4 FY 2011-12. four primary producers of Aluminium in year which also included production from India. Government of India (GoI) divested the VSS smelter which was completely Vedanta Aluminium 51% equity in the year 2001 in favour of phased out in June 2009. Limited (VAL) Sterlite Industries (India) Limited. Balance The Company has commenced We are expanding our aluminium 49% is with GoI. After disinvestment, implementation of the Memorandum business through Vedanta Aluminium. 12 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
We hold a 29.5% minority interest in and an associated 75 MW captive power for progressive commissioning by Q3 Vedanta Aluminium, a 70.5%-owned plant at Lanjigarh in the state of Orissa. of FY 2014. The production of saleable subsidiary of Vedanta. This is in line with VAL’s strategy to metal for the nancial year 2010-11 was promote Lanjigarh as a self sustained 3,85,363 MT. Vedanta Aluminium Ltd (VAL) is a manufacturing unit in terms of cost subsidiary of Vedanta Resources Plc and advantage and resource availability. The The idea of sustainable development is an associate company of Sterlite. Originally alumina re nery at Lanjigarh continues to deeply ensconced in VAL’s business ethos. incorporated in 2001, VAL is a leading operate with bauxite sourced from BALCO VAL is committed to the socio-economic producer of metallurgical grade alumina and other third parties. transformation of local communities and other aluminium products, which cater residing around the plant sites and to a wide spectrum of industries. VAL is operating a 0.5 MT per annum undertakes several initiatives to promote aluminium smelter and 1,215 MW captive sustainable development. The rm has VAL has carved out a niche for itself in power plant supported by highly modern focused on developing modern health the aluminium industry with its superior infrastructure at Jharsuguda, Orissa. In amenities, educational facilities for children product quality based on state-of-the-art addition to this construction of 1.25 MT and skill development programmes for technology. The rm operates a 1.0 MT per annum aluminium smelter expansion adults. Several other programmes have per annum green eld alumina re nery project at Jharsuguda is processing well been undertaken to enhance health and Sterlite Industries (India) Ltd. Annual Report 2011 13
sanitation, promote livelihood generation state electricity boards in India. This has a seventy four percent interest in a
and improve infrastructure in the villages project is anticipated to be funded through consortium between Sterlite and Leighton Company Overview surrounding Jharsuguda and Lanjigarh. The internal resources and would provide tax Contractors India Pvt Ltd (Leighton). The rm believes that its development initiatives incentives under the Income Tax Act. Company has incorporated the SPV, will encourage a dedicated team of self Paradip Multi Cargo Berth Private Limited. motivated individuals to participate and Ports and Infrastructure drive the Company’s growth in the future. Business The new berth is expected to facilitate the Vishakapatnam Port movement of cargo such as aluminium Commercial Energy The Company was the successful ingots, steel and containers and to have Business. bidder for mechanisation of the coal a capacity to handle up to 5.0 million Business The Sterlite Group has set up and operating handling facilities at the outer harbour of tonnes per annum of cargo. Upon Review captive power plants since 1997. Sterlite Vishakapatnam port on the east coast of receipt of environmental approval by the is currently developing a commercial India, which is based on the Public Private port authority, Paradip Port Trust, the power generation business in India that Partnership (PPP) model. The Company consortium will enter an agreement with leverages its experience in setting up and has a seventy four percent equity interest Paradip Port Trust, to operate the berth operating captive power plants that support in VIZAG General Cargo Berth Pvt Limited on a build-operate-transfer basis for 30 its primary businesses. As at March 31, (VGCB), a special purpose vehicle formed years commencing on the date of award of Development 2011, the total surplus power generation as a joint venture between the Company concession. Paradip Port Trust will receive Sustainable capacity of its thermal power plants and and Leighton Contractors India (Private) a share of the revenue earned from wind power plants was 1,041 MW of which Limited. the berth. approximately 870 MW was from coal- based thermal captive power plants. The initial capacity of the upgraded berth The expected costs for the project is ` 392 will be 10.2 million tonnes per annum Crore and construction activity is yet to Our wholly-owned subsidiary Sterlite with exibility to upgrade to 12.5 million commence. Energy is setting up a 2,400 MW thermal tonnes per annum. VGCB entered into a Governance
coal-based power facility (comprising four concessionaire agreement on October 08, Infrastructure Corporate units of 600 MW each) in Jharsuguda in 2010 with Vishakapatnam Port Trust, for The Company actively considers on an the State of Orissa. mechanisation the coal handling facilities ongoing basis investment opportunities and upgrade the general cargo berth in port and infrastructure. Any future The 2400 MW Independent Power Plant on a build-operate-transfer basis for 30 transactions will be publicly announced Jharsuguda, Orissa at a cost of ` 8,484 years commencing on the date of award by the Company at the appropriate time in Crore is under progress and is expected of concession. Vishakapatnam Port Trust accordance with applicable law and stock to complete by end of FY 2012. First will receive a share of the revenue earned exchange rules and regulations. unit of 600 MW has been capitalized from the berth. Statements Financial in March, 2011. The expected costs for the project is ` 675 The Company’s commercial power Crore (US$ 150 million) and construction generation business also includes the has commenced with completion of the wind power plants. The establishment of berth expected by mid 2012. additional wind power plants of 150 MW was announced by HZL, of which 48 MW have Paradip Port already been commissioned during the year The Company was declared as the taking the wind generation capacity to 171 successful bidder for Paradip Port’s MW as on 31 March 2011. Multi Cargo Berth on build, own and operate basis which is situated in the The power generated from these wind Jagatsinghapur District of Orissa, on power plants is proposed to be sold to the east coast of India. The Company 14 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Board of Director’s Pro le
Mr. Anil Agarwal Mr. Navin Agarwal Mr. Gautam Bhailal Doshi Chairman Executive Vice-Chairman Director
Mr. Anil Agarwal, 58, who founded the Mr. Navin Agarwal, 50, is our Executive Mr. Gautam Bhailal Doshi, 58, is our Non- Group in 1976, is our Non-Executive Vice-Chairman and was appointed to our Executive Director and was appointed to Chairman and was appointed to our board Board of Directors in August 2003. His our Board of Directors in December 2001. of directors in 1978. He was earlier the responsibilities as Executive Vice-Chairman He is also the Group Managing Director Chairman and Managing Director and CEO include executing our business strategy of the Reliance ADA Group Limited. from 1980 till 2004. Mr. Agarwal was also and managing the overall performance and Prior to that, he was a partner of RSM the Chief Executive Of cer of Vedanta growth of the organisation. Mr. Agarwal & Co. in India from September 1997 to from December 2003 to March 2005. Mr. joined the Company at its inception. July 2005. Mr. Doshi has more than 30 Agarwal has over 35 years of experience as Mr. Agarwal has over 25 years of years of experience in the areas of audit, an industrialist and has been instrumental experience in general management nance and accounting. Mr. Doshi has a in the growth of the Company and its and commercial matters. Mr. Agarwal Bachelor of Commerce and a Master of development since inception. He is a has completed the Owner / President Commerce from the University of Mumbai Director of several companies including: Management Programme at Harvard and is a Fellow Member of the Institute of — Bharat Aluminium Company Ltd. University and has a Bachelor of Chartered Accountants of India. He is a — Sterlite Technologies Ltd. Commerce from Sydenham College, Director of several companies including: — Vedanta Aluminium Ltd. Mumbai, India. He is a Director of — Sonata Investments Ltd. — Vedanta Resources Plc., UK several companies including: — Reliance Communications Infrastructure Ltd. — Sterlite Energy Ltd. — Bharat Aluminium Company Ltd. — Reliance Life Insurance Co. Ltd. — Anil Agarwal Foundation- Under — Hindustan Zinc Ltd. Section 25 of the Companies — Reliance Media Works Ltd. Act, 1956 — The Madras Aluminium Co. Ltd. — Reliance Anil Dhirubhai Ambani — Sterlite Industries (India) Ltd. Group Ltd. — Sterlite Iron & Steel Company Ltd. — Reliance Big TV Ltd. — Sterlite Infrastructure Holdings — Reliance Telecom Ltd. Private Ltd. — Piramal Life Sciences Ltd. — Malco Power Company Ltd. — Digital Bridge Foundation — Malco Industries Ltd. (Sec. 25 Comp) — Vedanta Aluminium Ltd. — Reliance Broadcast Network Ltd. — Hare Krishna Packaging Private Ltd. — Konkola Copper Mines, Plc. — Vedanta Resources Plc., UK — Vedanta Resources Holdings Ltd. — Vedanta Resources Investment Ltd. Sterlite Industries (India) Ltd. Annual Report 2011 15 Company Overview Business Review
Mr. Berjis Minoo Desai Mr. Sandeep H. Junnarkar Mr. D. D. Jalan Director Director Whole Time Director & CFO
Mr. Berjis Minoo Desai, 54, is our Non- Mr. Sandeep H. Junnarkar, 59, is our Non- Mr. D.D. Jalan, 54, is presently Whole Executive Director and was appointed to Executive Director and was appointed to Time Director and CFO of the Company. Development our Board of Directors in January 2003. our Board of Directors in June 2001. He is also the CFO of Vedanta Resources Sustainable Mr. Desai is a solicitor and is the managing Mr. Junnarkar is a solicitor and a partner Plc. also. Mr. Jalan joined Sterlite in partner of Messrs J. Sagar & Associates of Messrs Junnarkar & Associates. Prior January 2001 as President of Australian since April 2003 specialising in mergers to that, he was a partner at Messrs operation responsible for its mining and acquisitions, securities, nancial Kanga & Co. from 1981 until 2002. operation and moved to the position of and international business laws and Mr. Junnarkar specialises in banking and CFO of SIIL and then to CFO of Vedanta international commercial arbitration. Prior corporate law and regularly advises on Resources Plc. Mr. Jalan is a Chartered to that, Mr. Desai was a partner at Messrs all aspects of exchange control under Accountant and has over 32 years of Governance
Udwadia, Udeshi & Desai from 1997 to the Foreign Exchange Management experience in leadership position of Corporate 2003. Mr. Desai has a Bachelor of Arts Act, 1999, (FEMA), and the Securities companies in engineering, mining and and a Bachelor of Law from the University Contracts (Regulation) Act, 1956 (SCRA). non-ferrous sector. He is a Director of of Mumbai and a Master of Law from Mr. Junnarkar is a Bachelor of Law from several companies including: the University of Cambridge, UK. He is a the University of Mumbai and is also a — Sterlite Opportunities & Ventures Ltd. Director of several companies including: member of the Bombay Incorporated — Vedanta Resources Finance Ltd. — The Great Eastern Shipping Law Society. He is a Director of several — Vedanta Resources Cyprus Ltd. Company Ltd. companies including: — Vedanta Resources Jersey Ltd.
— NOCIL Ltd. — Vedanta Resources Jersey II Ltd. Statements
— Everest Industries Ltd. Financial — Praj Industries Ltd. — Excel Crop Care Ltd. — Vedanta Investment Jersey Ltd. — Edelweiss Capital Ltd. — IL&FS Infrastructure Development — Sesa Resources Ltd. — Deepak Nitrite Ltd. Corpn, Ltd — Sesa Mining Corporation Ltd. — Himatsingka Seide Ltd. — Jai Corp. Ltd. — Thalanga Copper Mines Pty Ltd. — Greatship (India) Ltd. — Jai Realty Ventures Ltd. — Copper Mines of Tasmania Pty Ltd. — Emcure Pharmaceuticals Ltd. — Reliance Industrial — Talwandi Sabo Power Ltd. — JSA Law Ltd. Infrastructure Ltd. — Vizag General Cargo Berth Pvt. Ltd. — JSA Lex Holdings Ltd. — Reliance Industrial Investments & — Paradip Multi Cargo Berth Pvt. Ltd. Holdings Ltd. — Centurm Fiscal Pvt. Ltd. — Twinstar Energy Holdings Ltd. — Reliance Ports and Terminals Ltd. — Capricorn Studfarm Pvt. Ltd. — Twinstar Mauritius Holdings Ltd. — Sterlite Energy Ltd. — Capricorn Agrifarms & Developers — THL Zinc Ventures Ltd. Private Ltd. — Sterlite Industries (India) Ltd. — THL Zinc Ltd. — Capricorn Plaza Private Ltd. — Sunshield Chemicals Ltd. — Pecvest 17 (Pty) Ltd. – South Africa. — Equine Bloodstock Private Ltd. 16 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Business Review Sterlite Industries (India) Ltd. Annual Report 2011 17 Company Overview
Growth story in India continues to remain strong with increased demand for consumption of commodities. Business Review
We have made excellent Development progress during the year Sustainable in executing our industry leading organic growth programme. Governance Corporate
The Indian copper market continues to demonstrate a robust growth rate of 4% in
FY 2011. Statements Financial 18 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Performance
The Management Discussion and Analysis begins with an overview; then analyses each of the businesses; moves on to details on nancial performance, risks and internal control measures and concludes with sustainable development initiatives.
303,991 tonnes Copper production 934,053 tonnes Zinc and Lead production 255,298 tonnes Aluminium production Sterlite Industries (India) Ltd. Annual Report 2011 19
Overview and strong prices we delivered record During the year all our businesses delivered
Global economy growth exceeded most productions and a very strong set of results volume growth, with signi cant increase Company Overview expectations in the nancial year although across our businesses. in zinc and commercial power production. the global economy remained volatile. Our ongoing cost reduction measures have Commodity prices declined at the start of During the year 2010-11, we completed helped to contain the impact of higher input the year but recovered in the second half the acquisition of Zinc assets of Anglo- prices while higher volumes have also as European sovereign debt concerns American Plc. (Anglo Zinc) comprising bene ted unit operating costs. Stronger receded and developed economies its Skorpion mines in Namibia, Lisheen commodity prices for copper, aluminium started to stabilise. Demand from Asian mines in Ireland and 74% owned Black and zinc have also contributed to the economies remained robust and was the Mountain mines in South Africa, which increase in PBDIT during the year. Business key driver of growth. includes the Black Mountain mine and the Review Gamsberg project. Sterlite is the world’s We have made excellent progress during Growth story in India continues to remain largest integrated zinc-lead producer the year in executing our project led strong with increased consumption demand and has signi cant operating expertise organic growth programme. Our focus of commodities. We remain focused on with zinc. The acquired zinc assets is an on continued asset optimisation and delivering operational excellence and excellent operational and strategic t with reduction of controllable costs remains sustained volume growth. On the backdrop our existing business and is expected to key to delivery excellent results and long Development of this favourable increased demand create signi cant long term value. term value. Sustainable Governance Corporate Statements Financial 20 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Performance - Copper
Market Overview Global re ned copper production in 2010 was reported as 19.1 million tonnes, an increase of about 4%, over the 2009 gure of 18.4 million tonnes. Global re ned consumption exceeded supply by about 2,50,000 tonnes. Global mine production growth slowed to 0.8% in 2010, hampered by falling copper grades and labour disputes. Global copper consumption is estimated to increase by about 5% during 2011. Similar to last year, overall Indian copper consumption grew by 4% in the nancial year 2011, constrained by increased imports of nished electrical machinery. We sold 68% of production in our local market and the remaining 32% was exported to China, South East Asia and the Middle East. • Continue to retain and further sharpen Production Performance Growth in the power sector in India, and cost ef ciency Production of cathodes at our Copper— increased spending on infrastructure • Commission captive power plant India business was 304 kt in the nancial including housing, continued to drive the and continue to drive operational year 2011, lower by 9% year on year, growth of copper consumption. Over the excellence initiatives re ecting the impact of bi-annual shutdown medium to long term it is expected to of smelter undertaken and temporary grow at about 8-9% per annum. The performance of our Copper—India shutdown following the Hon’ble Madras / Australia business in the nancial year High Court order in end of September Strategic Priorities 2010-11 is set out below. 2010. The Company’s Special Leave • Double the copper smelting capacity to Petition (SLP) challenging the High Court meet growing regional demand order is being heard by the Hon’ble Supreme Court, and the unit is currently operational at its full capacity. Table 1: Performance of Copper
Particulars 2010-11 2009-10 % Change During the year we also stabilised the Production volumes (‘000 tonnes) precious metal re nery and rod plant — Mined metal content 23 24 (4) at Fujairah. — Cathodes 304 334 (9) — Rods 188 197 (5) Mined metal production at our Australian mines was 4.2% lower at 23 kt in the — Sulphuric acid 969 1,036 (6) nancial year 2010-11. — Phosphoric acid 154 206 (25) Cash Settlement Prices (US$ per tonne) 8,138 6,112 33 Unit Costs Unit costs (US cents per lb) (net) 4 10 (60) Bene ting from improved by-product sales Realised TC/Rc’s (US cents per lb) 11.9 13.6 (15) and improved operational performance, Revenue (` Crore) 15,655 13,063 20 Copper India performed well delivering a PBDIT (` Crore) 1,043 744 40 reduction in unit conversion cost from 10.4 PBDIT Margin (%) 6 5 17 US cents per lb in nancial year 2009-10 Sterlite Industries (India) Ltd. Annual Report 2011 21
to 4.0 US cents per lb in nancial year during the last nancial year. The Indian 12 and the TC/RC terms are expected
2010-11. Treatment and re ning charges import prices of Phosphoric acid saw an to turn more favourable. Sterlite has Company Overview (TC / RCs) received in the nancial year increase by about 7% during the year suf cient coverage and receives the 2010-11 were lower at 11.9 US cents per from $ 775 per MT CFR to $ 830 per MT copper concentrate under its long term lb as compared with 13.6 US cents per lb CFR. Despite a steep surge in input costs contracts and a small amount of the in the nancial year 2009-10 due to the company was able to control the cost spot requirement is covered as per the tighter copper concentrate market. of production of Phosphoric acid business smelter’s requirement. through optimal selection of raw material The unit cost of production at our blend (rock phosphate). Financial Performance Australian operations, including TC / RCs PBDIT for the nancial year 2010-11 was Business and freight, in nancial year 2010-11 was Gypsum Sales Last year surpassed the ` 1,043 Crore, 40% higher than the Review 190 US cents per lb up from 160 US cents Production by about 0.26 million tonnes, PBDIT of ` 744 Crore for the nancial per lb in nancial year 2009-10, mainly due thus depleting the stocks further .The year 2009-10. This was primarily due to to higher mining cost and strong Australian higher demand from cement industry due higher LME prices and lower unit costs at dollar. to their capacity augmentation created Copper India and with the improved by- a big demand for the material which in product realisation. Sales turn helped in fetching a better realisation Development Copper sales in the domestic market were compared to previous years. The unit Projects Sustainable 206 kt in the nancial year 2011. 76% has planned for several measures in the 400 kt per annum Copper Smelter of these were value added copper rods, nancial year ahead to make Superior Whilst MoEF clearance is in place for supplied largely to the rapidly growing Quality Gyspum to cater to its customers. the 400 kt per annum copper smelter power sector. The Indian copper market expansion project at Tuticorin, this project continues to demonstrate a robust growth Copper Slag sales was a breakthrough is being rescheduled awaiting consent rate of 4% growth in the nancial year achievement during the year. Slag sales to establish from the State Pollution 2010-11. The revenues increased by 20% of 700 kt was in excess of generation. Control Board. Governance
to ` 15,655 Crore. Copper slag was sold to various industry Corporate segments like abrasives, cement and 160 MW Captive Power By-Products road ll applications. The potential usage Plant The Sulphur market in the nancial year in other applications like concrete, etc. The construction of the captive power 2010-11 witnessed a year on year reduction are being explored. The usage of Copper plant at Tuticorin is in progress and in global supplier inventory level and slag is getting increased as construction the rst unit is now scheduled for improved demand in the fertilizer segment. as an alternate to sand. Assessing the commissioning in Q4 of the nancial This along with high demand in the metal demand and successful eld trials, copper year 2011-12. leaching segment due to rising copper and slag is expected to add further value to Statements Financial nickel prices, pushed the Sulphuric acid the Company’s by products chain. Outlook prices upwards. The Sulphur prices during The global market is expected to grow the year witnessed an increase by about Treatment Charges and at around 5% in current year with higher 23% from $170 per MT FOB ADNOC to Re ning Charges (TC/RC) demand from developing countries to $210 per MT FOB ADNOC (Abu Dhabi TC / RC realisation during the nancial support the infrastructure growth. We National Oil Corporation). The Company year 2011, was 11.9 USc/lb, when expect stable operating performance was able to capitalise on this surge and compared to 13.6 USc/lb in the at our smelter in India and our mines achieved better realisation compared to the previous year. Copper Mines continue in Australia. previous year. to underperform in production due to falling head grades leading to pressure The increased consumption of phosphate on TC / RC . However a signi cant fertilizers in India had lead to overall amount of copper mine production is increase in the Phosphoric acid prices expected to come on stream in FY 2011- 22 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Performance - Zinc and Lead
Market Overview Strategic Priorities 3. Deliver ramp-up of silver production. Global zinc demand rebounded strongly 1. Retain and further sharpen our relative 4. Develop Gamsberg project in South in 2010, growing by 14.8% following a fall cost competitiveness. Africa. of 9.4% in 2009, at 11.6 MT. Urbanisation 2. Continue to focus on adding reserves The performance of our Zinc and Lead and increased spending on infrastructure and resources in excess of mining business in the nancial year 2010-11 is in developing countries have continued depletion. set out in the table below. to be the key driver for demand. While Table 2: Performance of Zinc and Lead long-term global demand is expected Particulars 2010-11* 2009-10 % Change to grow at 3-4% per annum, the near Production volumes (‘000 tonnes) term demand growth in Asia (excluding Zinc China), our key export market, is poised — Mined metal content 782 683 10 — Re ned Metal 762 578 23 to grow at 7%. India, where our major zinc Lead facilities are located, continues to present — Mined metal content 102 86 2 a promising growth trajectory on the back — Saleable Metal 57 64 (11) of low per capita zinc consumption at 0.45 Average LME Zinc Cash settlement prices (US $ per tonne) 2,185 1,936 13 kg as compared to the global average zinc Average LME Lead Cash settlement prices (US $ per tonne) 2,244 1,990 13 Unit costs (US $ per tonne) consumption of 1.8 kg per capita zinc. – HZL 990 850 16 – Skorpion 1,180 — — Hindustan Zinc Limited (HZL), our Indian – Black Mountain Mines 1,309 — — zinc-lead-silver business, has been – Lisheen Mines 917 — — successful in maintaining around 82% Revenue (` Crore) 10,839 7,943 36 PBDIT (` Crore) 6,057 4,714 28 market share in the local zinc market, PBDIT Margin (%) 56 59 (3) registering a 7% year on year growth. * Figures for international zinc entities are taken from the date of acquisition to 31 March 2011 Sterlite Industries (India) Ltd. Annual Report 2011 23
Production Performance 66,000 dry metric tonnes of surplus to gross R&R, prior to 0.8 mt mined out in
zinc and 39,000 dry metric tonnes the nancial year 2010-11. Total R&R on Company Overview Zinc India Operations: of lead concentrate. March 31, 2011 was 34.7 million tonne of Improved operational performance contained zinc-lead metal and 885 million and ramp up of enhanced capacity at The revenue during the year increased oz of silver. our mines contributed to an increase by 24% to ` 9,844 Crore. This was in mined metal production of zinc and mainly due to volume growth, higher LME Zinc International lead in the nancial year 2010-11, up realisation and improved operational Operations 9.0% to 840 kt. The new mill at the mine ef ciencies. Post acquisition of zinc assets from Anglo achieved 84% capacity utilisation in America Plc. Group, we have produced Business March 2011. Financial Performance 44 kt of mined metal and 50 kt of re ned Review Increased production volumes, higher Zinc metal a total of 94 kt metal units. Re ned zinc production also rose prices and by-product credit contributed substantially to 712 kt, an increase to a strong increase in PBDIT for the Outlook of 23.2%, primarily due to additional nancial year 2010-11, up 18% to Zinc India continues to be on a volume volumes from the newly commissioned ` 5,556 Crore, compared with the growth path having recently reached its zinc smelter at Dariba. Lead production nancial year 2009-10. targeted mining capacity, equivalent to Development was 57 kt, a decrease of 7 kt over the 1 MT of re ned metal, and the ramp-up Sustainable previous year. Higher silver content in This increase was partially off-set by of the Sindesar Khurd mine is expected the Ore was the key factor behind the increased net operating costs and to increase silver content in concentrate. record silver production of 4.76 million royalties. Commissioning of the lead smelter ounces in the nancial year 2010-11, at Dariba will help conversion of lead 6.7% higher than the 4.46 million The positive impact of higher volumes, concentrate to lead metal. ounces produced in the nancial year rupee appreciation against US dollar 2009-10. and stable operating cost, contributed The outlook for demand remains Governance
signi cantly to company’s operating positive in our target markets and Corporate Unit Costs margins. globally and our new acquisition, The unit cost of zinc production in Zinc International, is expected to the nancial year 2010-11, excluding Projects deliver steady performance. royalties, rose 16.5% to US $808 per The Silver rich Sindesar Khurd mine tonne compared with US $698 per tonne expansion project was completed one in the nancial year 2009-10, primarily year ahead of schedule and the new due to higher coal costs, higher strip mill of 1.5 million tonnes capacity ratio at mines and one-off gratuity was commissioned in Q3 of the Statements Financial (retirement bene ts) costs. Royalties nancial year 2010-11. were also higher at US $30 per tonne linked with LME prices. At Dariba, both units of the 2 x 80 MW power plant were commissioned in the Sales nancial year 2010-11. The 100 kt per Our domestic sales of zinc metal annum lead smelter at Rajpura Dariba is at 412 kt were up 6.7% (the nancial expected to be completed by Q1 of the year 2009-10: 386 kt) maintaining 82% nancial year 2011-12. market share. The rest of the metal produced was exported to neighbouring Exploration markets like Taiwan, Indonesia, Ongoing exploration activities at HZL Malaysia and Middle East. Revenues have yielded signi cant success with were further augmented by the sale of 1.4 million tonne contained metal added 24 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Performance - Aluminium
Market Overview Table 3: The performance of our Aluminium Business in nancial year 2010-11 is set The global aluminium industry recorded out in the table below. a 12.8% growth in production and 16.7% Particulars 2010-11 2009-10 % Change growth in consumption during the year after Performances of Aluminium Business – BALCO a turbulent period. Globally the industry is Production volumes (‘000 tonnes) facing the challenge of rise in costs and other input costs. This is also re ected in – Aluminium 255 268 (5) the increase in aluminium LME prices. Average LME Cash settlement prices 2,257 1,868 21 (US per tonne) Our aluminium facilities are located in Unit costs India in the state of Orissa and Chattisgarh BALCO Plant 2 (Production costs) (US$ per tonne) 1,784 1,534 16 where there are abundant bauxite and BALCO Plant 2 (Smelting costs) (US$ per tonne) 1,007 862 16 coal deposits. This underscores India’s Revenue (` Crore) 3,024 2,837 7 unique advantage of being rich in natural PBDIT (` Crore) 616 599 3 resources required to produce aluminium PBDIT Margin (%) 20 21 (1) at a competitive cost. Performances of Aluminium Business – VAL Production volume – Aluminium (‘000 tonnes) 386 264 46 Sterlite emerged as the largest producer Unit cost (US$ per tonne) of aluminium in India and, within a short – Jharsuguda (Production costs) (US$ per tonne) 1,820 1,645 11 period, acquired industry leading market – Jharsuguda (Smelting costs) (US$ per tonne) 1,173 925 27 Sterlite Industries (India) Ltd. Annual Report 2011 25
share of 39% (including VAL production) by 8% as compared to the previous year. The approval process for BALCO’s 211
in the local Indian market. The Indian LME aluminium prices increased by 21% million tonnes coal block is progressing Company Overview aluminium market is dominated by growing to US$ 2,257 per tonne as compared to well, and we expect to commence coal demand from the power sector. Over US$ 1,868 per tonne in the previous year. mining by Q4 of the nancial year 2011-12, time, the relative share of aluminium subject to statutory approvals. The new applications in other segments is expected Financial Performance 325 kt aluminium smelter at Korba to pick up with rapid urbanisation and PBDIT for the nancial year 2010-11 was is making good progress. construction sector growth. ` 616 Crore, 3% higher than the nancial year 2009-10. This improved performance Vedanta Aluminium Limited Sterlite’s plants had focused on value was primarily driven by LME prices, Lanjigarh Alumina Re nery at Business added products like wire rods, rolled partially off-set by higher carbon and coal Lanjigarh Review product and billets to capitalise on market costs, which were further increased by Alumina hydrate production during the growth and optimise returns. around 30% by Coal India in March 2011 year was 696 kt was lower by 7.70% and a new green tax on coal. as compared to the previous year. The Strategic Priorities production of calcined alumina produced 1. Complete expansion projects. Projects during the year was 707 kt which is lower 2. Expedite development of coal block. BALCO Aluminium Smelter by 7.2% as compared to the previous Development The 1,200 MW (4 x 300 MW) captive year. The aluminium re nery at Lanjigarh Sustainable Production Performance thermal power plant at Korba, Chhattisgarh continue to operate at a capacity of 1 MT The saleable production during the year is progressing well, and we expect to per annum with bauxite supply from BALCO that ended on March 31, 2011 was 255 kt commence power generation from the rst and other third parties i.e. from eastern, as against 268 kt during the corresponding unit by Q2 the nancial year 2011-12. central and western India. period of the previous year. The reduction was mainly due to lower availability metal on account of phasing out of plant I Governance
smelter. However with the installation of the Corporate new rod mills and increased availability of rolling mills the product mix was enriched.
Unit Costs The unit cost of production at the BALCO Korba II smelter was US $1,784 per tonne for the nancial year 2010-11, 16% higher than last year primarily due to increase Statements Financial in alumina, coal and carbon costs and a one-off increase in gratuity (retirement bene ts) cost.
Sales During the year, the sales volume was 2,47,412 tonnes as against 2,67,802 tonnes of the last year. The revenues increased by 7% at ` 3,024 Crore. The lower sales quantity were due to lower availability of metal on account of closure of plant I smelter. However, the sales of value added products i.e. rods increased 26 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Jharsuguda Aluminium Financial Performance Company’s re nery. At present the re nery Smelter (VAL) PBDIT for the nancial year 2010-11 is in operation with outsourced Bauxite from Aluminium production in the nancial year was ` 715 Crore, 95% higher than the various states. Since there are nearly 800 2010-11 was at record 386 kt primarily due nancial year 2009-10. This improved million tonne of a bauxite reserve available to increase in production from the new performance was primarily driven by in the surrounding area of the plant, the 500 kt Jharsuguda aluminium smelter. rising volumes and LME prices, partially Company does not envisage problem in off-set by higher carbon and coal costs. availability of Bauxite. Operational Performance We had restabilised pots post the Bauxite Mining at Niyamgiri Hills, Projects power outage in Q1 the nancial year Lanjigarh (VAL) Post the MOEF direction in August 2010, 2010-11, the relining cost of the pots The Ministry of Environment & Forests further work on the re nery expansion has contributed to increase in cost of (MOEF) vide order dated 30 August 2010 project at Lanjigarh has been put on hold. Jharsuguda. rejected the forest clearance relating to The 1.25 mt per annum aluminium smelter Niyamgiri mining lease to Orissa Mining project in Jharsuguda is making good The unit cost of production at the VAL Corporation (OMC) for mining Bauxite.This progress for progressive completion by Jharsuguda smelter was US $1,820 per was despite the approval of forest diversion Q3 of FY 2014. tonne for the nancial year 2010-11, given by Honourable Supreme Court of higher than previous year mainly due India in 2008. OMC has subsequently Outlook to increase in alumina, coal and carbon led a Writ Petition in the Supreme Court We expect to increase volumes at our cost. The alumina cost of production challenging the MOEF decision and for alumina re nery in Lanjigarh and improve was US $326 per ton, marginally higher issuing direction to MOEF to grant the operating performance at the new compared with previous year, primarily forest clearance. In the meantime, Govt. Jharsuguda smelter post stabilisation. due to higher input prices for caustic of Orissa (GOO) is considering grant of We will continue to focus on value added soda and coal. alternate mines for supply of Bauxite to the products to optimise returns. Sterlite Industries (India) Ltd. Annual Report 2011 27
Performance - Energy
Indian power sector is best characterised the FY 2010-11 was ` 335 Crore as Outlook
by a historical gap between demand and against ` 418 Crore in the previous year. We plan to complete the ongoing projects Company Overview supply due to slow project development, PBDIT was lower primarily due to higher on schedule and to continue to focus on lagging behind the increase in consumption operating costs, primarily coal and lower improving coal logistics and expediting led by robust economic growth. This gap sales prices. coal block development at SEL. is expected to remain in near to medium term, creating an attractive market for the Unit Costs SIIL has a long history of developing supply of energy commercially. Average power generation cost in the and operating captive power plants at nancial year 2010-11 was ` 1.77 per benchmark capital expenditure cost and Strategic Priorities unit compared with ` 1.48 per unit in the industry leading operating ef ciency and Business • Complete 2,640 MW project at nancial year 2009-10, largely re ecting we plan to exploit this track record in the Review Talwandi Sabo, Punjab. higher coal costs which were increased by construction of the IPP at Talwandi Sabo • Complete 2,400 MW project at 30% in February 2011, in addition of new in the Punjab and the IPP at Jharsuguda, Jharsuguda, Orissa. green tax on coal. Orissa in addition to constructing a • Develope the Sterlite Energy Limited captive power plant at Korba. We will (SEL) coal block. Projects continue to sell surplus power in the • Participating in any new coal block Jharsuguda IPP commercial energy market, capitalising Development auctions / allotments. First 600 MW unit of the 2,400 MW on the accelerating demand for power Sustainable SEL Jharasuguda power plant was in our home market. Operational Performance successfully commissioned in March During the nancial year 2011, we sold 2011. Second unit is under trial run. Other Business 2,035 million units of power, compared The remaining two units are expected Vizag Coal Berth with 1,416 million units in the previous to be synchronised in Q3 and Q4 of the To support our entry into the growing port year. This growth in volume was mainly nancial year 2011-12, respectively. and infrastructure sector in India we have on account of surplus power sales Transmission lines are being set up to secured a tender from Government of Governance
from 270 MW power plant at BALCO enhance existing transmission capacity India’s Vishakapatnam Port Company. Corporate and commissioning of rst unit of 600 to meet the requirements for new units to We will be constructing a coal berth on a MW commencing power generation at be commissioned, and are expected to revenue sharing basis in a joint venture Jharsuguda, SEL. be completed by Q3 of the nancial year with Leighton Contractors (India) Pvt. Ltd. 2011-12. The estimated cost of the project is ` 675 Financial Performance Crore and it is scheduled for completion Revenue (net of inter-segment transfers) Talwandi Sabo IPP by mid 2012. for the nancial year 2011 was ` 728 Work at the 2,640 MW power project
Crore, compared with ` 657 Crore in at Talwandi Sabo is progressing as per Overall Business Outlook Statements Financial the previous year and PBDIT for the schedule. Seven shipments have been The medium and long term outlook for received, and construction of the rst boiler the resource sector remains positive. The performance of our Energy business structure is in progress. We have a strong growth pipeline and in nancial year 2010-11 is set out below. all our expansion projects are on track (in US$ millions, FY FY % Wind Energy to deliver industry leading organic except as stated) 2010 2009 Change 48 MW of the 150 MW expansion in wind growth. We remain confident that we -2011 -2010 power generation capacity announced in are on track to deliver superior results Power Sales (MU) 2,035 1,416 44 January 2011 was commissioned during going forward. Revenue (` Crore) 728 657 11 the fourth quarter, and the remaining 102 PBDIT (` Crore) 335 418 (20) MW is expected to be commissioned in the COP (` / Unit) 1.77 1.48 20 nancial year 2011-12. Post the expansion, the Company’s wind power generation NSR (` / Unit) 3.38 4.16 (19) capacity will increase to 273 MW. 28 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Operational Performance
Human Resources Incentive Plan’ (LTIP), under which, Safety Module and speci c training Our Philosophy meritorious employees are granted programme like Campus to Corporate At SIIL we believe in building an options of our parent Company Vedanta before being put on to their work. At organization having human resource Resources Plc. shares. the end of their induction they also with world class capabilities and high have an informal interaction with Senior performance culture. For achieving this Get Nurture and Grow Management through a get together in objective we recruit, develop and retain “Get, Nurture and Grow” is the mantra which the new joiners are also given a talented and motivated employees who for Human Resources practices at platform to exhibit their talent. The new share our Company’s vision and values. Sterlite. The Sterlite team is very young, employers are assigned mentors for We seek to create an environment of energetic and vibrant with the average the rst year which facilitates further in fairness, transparency and mutual respect age being 29 years. Keeping in line with entrenching into the work. wherein the aspirations of employees and the group philosophy of growth from the goals of the enterprise are aligned within, we recruit freshers at graduate, Skill and Development to achieve mutual bene t on a long term engineers and management level. We Sterlite focuses on learning and continual basis, thereby enabling us to be have introduced a 15 days ‘Structured development to enhance the knowledge the preferred employer of choice. A young, Induction Module’ for our new joiners and skill, preparing its people to face vibrant and dynamic workforce handling covering all departments and plant the challenges in the dynamic business critical roles and wide job responsibilities processes. The same is taken up by the scenario. SIIL has a structured learning is the USP of SIIL. The Company’s respective departmental heads. At the need identi cation process. During the philosophy of shared ownership is also end of the 15 day induction, they also year, we had organised various training re ected through the ‘The Long Term have to undergo a 3 day E-Learning programmes with an objective to achieve a Sterlite Industries (India) Ltd. Annual Report 2011 29
minimum of 2 man-days of training for every Development programmes like Leadership and employees holding critical positions.
employee. 982 out of 1,198 employees Excellence programme and Seven Senior management was sent for Company Overview at Sterlite Copper were covered under Habits of Highly Effective People were Management Development Programmes minimum of 2 man-days of training. Similar held to address the training needs of to premier institutes like IIM’s, ISB, etc. IIM training is provided in Zinc, Aluminium, potential leaders of our organisation. Indore conducted in-house management Power and all other businesses. It covered all the Stars of the business programme for the engineers to give them overview on the managerial qualities. Case Study 360 Degree Feedback We also initiated a 6 day training module IGNITE for line managers covering technical and behavioural skills. The work Leadership development has always occupied a crucial position among the HR practices at Sterlite. Business The 360 degree feedback was aimed towards the objective of developing holistic leaders by holding life balance programmes like APEX from Review to them a mirror to show them how they are perceived by others. Art of Living was well received. With a The 360 degree feedback covered all Managers and above employees. To facilitate the 360 view to equip the employees with tools degree feedback process and give a structured output, an external consultant Franklin Covey was for systematic problem-solving on a day engaged to conduct the assessment through a questionnaire which measured individual behaviours considered critical for performance. to day basis and to make continuous improvement, initiatives/programmes such as 5S, TPM, SPIDER, IDEAS at Sterlite Development continue to be in place. Sustainable
In the past one year, at Sterlite Copper employees’ productivity has increased from 99.1 to 111.3 metric tons per employee. This has been achieved mainly The questionnaire chosen for Senior Management focused on the following four points: by making the organisation leaner at the — Inspire Trust — Clarify purposes top. In achieving this, the manpower was — Align Systems Governance rationalized and many employees were Corporate — Unleash Talent transferred to the Group companies for The questionnaire chosen for Middle Management was the 7 Habits Questionnaire which focused better career prospects. on the 7 Habits: — Be Proactive — Begin with the end in mind Knowledge Management — Put rst things rst Taking into consideration the business — Think win-win — Seek rst to understand then to be understood expansion and new projects, employees — Synergize were nominated for visit to foreign smelters — Sharpen the saw / re neries and rod plants to get the Statements Financial The methodology used was a Multi-Rater Feedback System in which the candidate was assessed international exposure which would help by self and by a number of assessors including his/her superiors, direct reportees (subordinates), in increasing the workforce capability and colleagues, internal and external customers. All participants were administered an online survey and participants could choose their assessors and the survey was forwarded to them. Once all the process improvements. These employees responses were obtained a feedback report was generated by all the participants. on their return share their knowledge with The feedback workshop consisted of a common brie ng session on how to read the report and their fellow employees and also draw up an individual feedback session with the HR and the Departmental Heads where the report was an action plan for implementation. The analyzed in detail and the areas of strength and improvement were spelt out for each individual and a developmental plan was framed accordingly. The developmental needs arising out of the exercise learnings were implemented both in day have formed the basis for the training needs of Managers and above for the current nancial year. to day activities and also during annual maintenance shut down. The participants felt that the 360 degree feedback was a more objective system and helps in developing leadership competencies critical for carrying out leadership and managerial roles effectively. All participants have individual development plans framed for bridging the gaps. A Leadership Development second round of feedback is scheduled for July 2011 to measure the progress made against the developmental areas agreed upon. SIIL has strong Talent management processes in place like the STARs 30 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Case Study LNG to reduce the cost of copper rod production
The energy source used at our Sterlite Copper Rod plant at Silvassa (Union Territory of Dadra & Nagar Haveli) was Lique ed Petroleum Gas (LPG). With a continuous focus on cost reduction and asset optimization, we identi ed an economical and environment-friendly alternative in Lique ed Natural Gas (LNG). LNG is normally distributed in India through a nationwide pipeline network, but the pipeline did not cover Silvassa.
We overcame this challenge by setting up an LNG storage and regasi cation facility, which was commissioned in February 2011. This is the rst such facility in the metals and mining industry in India and only the third in India. The imported LNG is transported from ports through special cryogenic tankers and stored in our cold storage tanks at Silvassa. The liquid is fed into an ambient vaporiser which provides natural gas to the point of use.
Our Copper rod plant at Silvassa has been an early adopter of a technology that enables consumption of more environment friendly fuel and the switch from LPG to LNG is already yielding multiple bene ts. LNG is more economical in terms of market prices. It undergoes natural gasi cation i.e. it converts into vapors at room temperature, unlike LPG, which requires heating. Hence, usage of power has been reduced by around 5%. LNG has higher calori c value, and lower residue elements, resulting in about 5% higher fuel consumption ef ciency. LNG has lower sulphur content than LPG and has contributed towards reducing our environmental footprint. Overall, the switch to LNG resulted in a substantial reduction in the total conversion cost of copper rods by approximately 20%.
of Business Programme and Global Connect where the employees from accepted ISO 27001 standards and CoBIT Leadership Programme for developing different cross sections get to interact with frame-work. Deploying the Financial identi ed talents and ensuring the the senior management. To substantiate business controls as per SOX (Sarbanes Company a perennial source of good our Employer of choice status we have Oxley) was the prime focus of IT leadership and other talent to deliver value participated in the survey conducted by department which was again a milestone to the organisation and society. Accelerated Hewitt for achieving Best employer status. for Sterlite. Competency Tracking and Upgradation The Company is working on the feedbacks (ACT-UP) workshops were conducted in all received from the survey. The Company has taken many new the business and STARS were identi ed strategic IT initiatives during the year, in during the year. The identi ed STARS Information Technology line with the IT Roadmap of being Best-in- of Business are elevated and put on an Sterlite implemented SAP R/3 in the late Class amongst the Industry. Many critical accelerated growth path, given cross- 1990’s and has improvised year after projects have been kick started and will functional responsibilities or seconded to year. All our critical business transactions be completed in due course of time. More group companies in recognition of their across all the operations are now tracked emphasis was given on enhancing the potential to deliver value to the Group. through SAP R/3. Sterlite is now working utilisation of Shop Floor SAP modules The STARS either occupy critical positions on SAP Enterprise Central Component and implementation of SAP Blend or are groomed as second in line to critical version on a wide range of 9 modules Planning Module which has resulted in positions. To fuel our exponential growth, from Finance and Controlling , Materials increased Asset optimisation and system we have robust leadership pipeline to Management, Plant Maintenance, dependence. Benchmarking has always head various businesses. Critical positions Production planning, Quality been the effective tool for Sterlite for its are mapped and second line for all Management, Sales and Distribution, continuous improvement. these positions are maintained ensuring Human Capital Management, and successful and smooth transition in cases Supplier Relationship Management. The year proven to be very successful of change. with implementation of big projects like Sterlite has deployed a policy and Governance Risk and Compliance with Employer of Choice procedure based environment to ensure which management of employee roles We have introduced various employee security and con dentiality of information in business happens through SAP, XMII engagement initiatives like Employee system which is in line with internationally basically an interface of our control system Sterlite Industries (India) Ltd. Annual Report 2011 31
with ERP and brings manufacturing
Intelligence through online dashboards. Company Overview This also enables the knowledge transfer across locations.
Desktop Virtualisation, SAP BI / BO (Business Intelligence, Mobile Asset Management and e-learning are some of the other projects which are in the conceptualisation stage). Agreement Business with SAP for around 25 products will help Review Sterlite to have a complete ERP based organisation across the verticals. Similar agreement with Microsoft for the Microsoft Exchange and of ce related products has resulted in many strategic bene ts to Sterlite. Development Sustainable
As a value added service to the customers performance management and workforce Award and Consistency Award for Customer on Web (CoW) / e-Salesmate, analytics has been automated with Silvassa. The award acknowledges a web based system is provided to the minimum human intervention. The Annual excellence in our manufacturing customers to access their information performance appraisal of Sterlite for the process. on-line. Each customer is provided with year 2010-11 employees was completely individual user id and password. CoW automated, made paperless through HCM, — International Team Excellence Award serves as a portal to share the information was a signi cant achievement to add upon. 2010 : Finalist award for Tuticorin from Governance
with customers in a collaborative way. American Society for Quality (ASQ) Corporate This portal is interfaced with core business Awards and Recognition in recognition to the TQM Project application SAP R/3 in the back-end. Sterlite has won the following awards and Increasing the crane reliability from recognition during the year 2010-11. 56% to 94.54%. Special focus has been given to Sterlite IT Infrastructure to match it to world class. Business: — Sterlite Silvassa unit has bagged Virtualisation is one among the initiative — Indian Merchants Chambers (IMC) “Excellence in Energy Management spearheaded by Sterlite to strengthen Ramkrishna Bajaj National Quality 2010 “ award from CII – Godrej GBC our IT Infrastructure. Implementation Award (RBNQA) : Performance in recognition towards achieving Statements Financial of System Centre Con guration Excellence Trophy 2010 for both improvements in Energy Management. Management (SCCM) has been very Tuticorin and Silvassa units under instrumental for us to manage our day to manufacturing category. The award — ‘IMC Ramakrishna Bajaj National day IT Infra activities in a better way. was in recognition of the Company’s Quality Award – Performance excellence in senior leadership, Excellence Trophy’ (RBNQA 2010); Sterlite has reached yet another milestone strategic planning, customer and the ‘CII – National Water Management by implementing the Human Capital market focus, measurement analysis Award 2010’; the ‘CII - National Energy Management module in SAP. With the and knowledge management, human Management Award 2010’; and the successful implementation of Human resource focus, process management ‘FIMI-Gem Granites Environment Capital Management (HCM), the entire and business results. Award for the Year 2009-10 for our function of HR including leave & travel zinc mines and smelter. management, organisation management, — Frost & Sullivan, India Manufacturing recruitment, training and development, Excellence Award 2010 : Platinum 32 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Financial Performance
Crore in 2010-11 mainly due to increase in interest income on deposits and loans.
Raw materials In Copper business, the major portion of raw material cost is on account of Copper concentrate which is fully imported. Our fully owned copper mines (Mt. Lyell in Tasmania, Australia) supply approximately 8% of our concentrate requirement and the balance is sourced from other mines through a mix of long term contracts and spot purchases. The price of copper concentrate is linked to prevailing LME prices of re ned copper. Average LME prices for copper increased by 33% between scal 2010 and 2011. We also import rock phosphate for conversion into phosphoric acid. The total value of raw material consumed was ` 14,389 Crore in 2010-11, representing a 18.5% increase over the previous year.
Manufacturing, Employee HZL Consolidated Financials Table 4 lists the Net sales and services and other expenses performance of Sterlite as a consolidated entity Net Sales for the year increased by 23.5% from Personnel expenses increased by 33% to for the year ended March 31, 2011, compared ` 24,501 Crore to ` 30,248 Crore. Net sales ` 1,132 Crore in scal 2011, mainly on account with the previous year. Further details are increased primarily as a result of higher volumes wage revision and increase in gratuity cost. Other given in the balance sheet, pro t and loss in Zinc and higher LME prices in the scal 2011. expenses, comprising of power and fuel, stores account and the notes accompanying this and spares, repairs, administration, selling and annual report. Other income distribution etc. increased to ` 6,858 Crore as Other income increased by 57.2% to ` 2,653 compared to ` 5,214 Crore in the previous scal year. The rise in cost was mainly on account of Table 4 : Consolidated Financial Performance Sterlite, 2010-11 and 2009-10. increase in royalty, fuel, coal and other basic Particulars FY 2010-11 FY 2009-10 inputs. The man power costs, manufacturing Net Sales/ Income from operations 30,248 24,501 expenses and administrative costs of the Other Income 2,653 1,688 acquired international zinc entities has also Total Income 32,901 26,189 contributed to increase in the expenditure. Consumption of Raw materials including stock adjustment 14,389 12,140 Employee cost 1,132 854 Depreciation Power, Fuel & Water 2,380 1,953 Other Expenditure 4,478 3,261 Depreciation increased by ` 280 Crore to Total Expenditure 22,379 18,208 ` 1,030 Crore for 2010-11 as compared to Pro t Before Depreciation, Interest and Tax 10,522 7,981 ` 750 Crore in the previous year. This was Depreciation 1,030 750 primarily due to capitalisation of new facilities Interest & Finance Charge 301 292 at HZL and depreciation on assets of acquired Exceptional expenses 57 297 international zinc entities. Tax expenses 1,812 1,233 Pro t After Tax 7,322 5,409 Interest and nance charges Minority interest 1,994 1,724 Net interest costs for 2010-11 decreased by 3% Consolidated share in the Pro t/(Loss) of Associate (285) 59 Attributation PAT 5,043 3,744 i.e. from ` 301 Crore to ` 292 Crore. Sterlite Industries (India) Ltd. Annual Report 2011 33
Exceptional items reserves constituted the balance. Reserves and debt mutual funds which were partly offset
Exceptional items ` 57 Crore for the year and surplus during the year have increased by by proceeds from sale of current investments. Company Overview includes compensation paid under Voluntary ` 4,423 Crore, registering a growth of 12%. Net cash of ` 1,604 Crore provided by nancing Retirement Scheme at HZL & BALCO. activities primarily consist of proceeds from Debt commercial paper and repayment of long term Corporate Income tax The Company’s debt increased from ` 9,260 loans and payment of interest. We remain Corporate income tax provision for 2010-11, was Crore in the previous year to ` 11,729 Crore as focused on maintaining a strong balance sheet to greater at ` 1,812 Crore, compared to ` 1,233 on March 31, 2011 which was mainly due to the fund our future growth. Crore in the previous year mainly due to the issue of commercial paper and buyers credit increase in pro tability. availed during the year. Internal Control Systems and Business their adequacy Review Pro t after tax Gross block and investments Sterlite is committed to maintaining high standards Pro t after tax increased to ` 7,322 Crore in 2010- During the year, Company completed acquisition of internal control and risk management to provide 11 as against ` 5,409 Crore in the previous year. of Anglo Zinc assets and commissioned the appropriate assurances to all the stakeholders. signi cant capacity expansions in its zinc & power The Company believes it has a proper and Share of loss in associates business. This has mainly led to the increase in adequate system of internal controls commensurate Share of loss in VAL was at ` 285 Crore as gross block to ` 33,548 Crore as on March 31, with its size and business operations at its plants Development compared to the previous year share of pro t of 2011. The total investments decreased by and at the corporate headquarters. Sustainable ` 59 Crore. The losses in VAL was due to higher ` 7,349 Crore from ` 20,304 Crore as on March interest cost (including one time mark to market 31, 2010 to ` 12,955 Crore as on March 31, 2011 The strength of a business’s internal control gain in the previous year) and redemption for due to investment in xed assets and redemption environment also forms a component of senior acquisitions depreciation which could not be fully for funding acquisitions. managers’ performance appraisals. During the absorbed on account of initial production ramp up. year 2010-11, the Company has implemented Inventories and debtors effective internal control over nancial reporting Attributable pro t and Minority Inventories increased by ` 2,172 Crore from based on the criteria established in Internal Governance
interest ` 2,983 Crore as on March 31, 2010 to ` 5,155 Control-Integrated Framework issued by Corporate The attributable pro t increased by 34.7% to Crore as on March 31, 2011 primarily due to Committee of Sponsoring Organisation (COSO). ` 5,043 Crore in FY 2010-11 as compared to higher LME. Debtors increased by ` 1,024 Crore ` 3,744 Crore in the previous year. The minority to ` 1,595 Crore as March 31, 2011. We have appointed internationally reputed audit interest share of pro t was ` 1,994 Crore for the rms to conduct the internal audit of the Company year 2010-11 as against ` 1,724 Crore in the Cash ow at all its locations. The scope and direction of the previous year. The cash ow summary for the year is given in annual audit programme is guided by the Vedanta Table 5: Group’s Management Assurance Services
Capital structure Table 5: Net cash from/(used in) (MAS), which, in turn, operates under the overall Statements Financial Total shareholders funds as on March 31, 2011 ` in Crore guidance of Sterlite’s Audit Committee. aggregated ` 41,435 Crore, of which equity capital 2010-11 2009-10 was ` 336 Crore comprising 3,36,12,07,534 Operating Activities 5,855 4,182 The objective of the internal audit process is shares of Re. 1 each. Consequent to the Bonus & Investing Activities (7,540) (13,267) not only to report deviations but also to identify Share Split issue of June 2010, the paid up share Financing Activities 1,604 8,822 systemic risks, based on the risk pro le analysis capital of the Company increased by ` 168.04 conducted by the MAS and the auditors. Internal Crore post bonus and share split. Cash ows generated from operations have auditors regularly visit our operations at its various been utilised towards payment of dividend and locations to ensure that transactional and process Reserves and surplus taxes and partly for expansion activities etc. issues are addressed while conducting audit. As on March 31, 2011, reserves and surplus of We have used cash in the investing activities Every quarter, the Audit Committee is briefed the Company aggregated to ` 41,099 Crore. primarily towards Investment in Anglo Zinc about the internal control ndings, along with the Free reserves accounted for 54% of the reserves acquisition, purchases of xed assets, loan to remedial actions that have been suggested or and surplus, and share premium and other associate company, investment in xed deposit have been already implemented. 34 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Risks and Uncertainties
Our businesses and operations are subject to a variety of risks and uncertainties which are no different from any other company in general and our competitors in particular. Such risks are the result of both the business environment within which we operate and other factors over which we have little or no control. These risks can be categorised as operational, nancial, environmental, health and safety, political, market-related and strategic risks. We have well documented and practised risk management policies that act as an effective tool in minimising the various risks that our businesses are exposed to during the course of their day-to-day operations as well as in their strategic actions.
Risks are identi ed through a formal risk management programme with the active involvement of business managers and senior management personnel at both the subsidiary level as well as at are undertaken to ensure that the Risks and risk management the corporate level. Each signi cant risk Group’s standards of internal control practices has an ‘owner’ within the Group at a are maintained. The strength of a Commodity risks senior level, the impact to the Group if business’s internal control environment Our principal commodities are copper, a risk materialises, and its likelihood of forms a component of senior managers’ zinc, aluminium and lead. are priced occurrence. A risk register and matrix is performance appraisals. The audit with reference to LME prices. LME prices maintained, which is regularly updated in process and audit plan cover the key risks are in uenced by global demand and consultation with business managers. The identi ed through the ‘risk management supply for these metals which in turn is risk management process is coordinated programme’ and the existence and in uenced by global economic scenarios, by our management assurance function effectiveness of control measures against regional growth, infrastructure spending by and is reviewed by the Audit Committee. each risks are veri ed. Control measures governments and also by hedge Key business decisions are discussed at stated in the risk matrix are also veri ed by fund activities. the monthly meetings of the Executive the business managers. Further details on Committee and senior managers address the Group’s internal control environment While the Group aims to achieve risk management issues when presenting are provided in the annual Corporate average LME prices for a month or for initiatives to the Executive Committee. Governance Report. a year, average realised prices may The overall internal control environment not necessarily re ect the LME price and risk management programme is During the year, the Group risk matrix movements because of a variety of reviewed by our Audit Committee on was updated through a comprehensive reasons including uneven sales during the behalf of the Board. and holistic exercise carried out at each year. Any uctuation in the prices of the operating subsidiary level and at corporate metals that we produce and sell will have We have a strong internal control level. The updated risk matrix and risk an immediate and direct impact upon the culture throughout the Group. Regular registers were then reviewed in the light pro tability of our businesses. We follow management assurance visits to our of changes in nature and extent of risks, offset hedging model for copper custom operations and holding companies controls and actions required. smelting business in order to manage price Sterlite Industries (India) Ltd. Annual Report 2011 35
risk, emanating from our normal business and those which are sourced at long-term estimates and represent the quantities
operations and ensure 100% back to back contractual TC / RCs. of copper, zinc, lead and bauxite that Company Overview policy. The prices of input and output are we believe could be mined, processed, derived from the same benchmark and / or Political, legal, economic recovered and sold at prices suf cient are linked to each other through a de ned and regulatory risks to cover the estimated future total costs formula. The objective of risk management Our key mining and smelting operations of production, remaining investment and is to attempt to use hedging to balance are located in India, Ireland, Namibia, anticipated additional capital expenditures. out the price uctuations on the input and South Africa and Australia and our holding Our future pro tability and operating output side so as to pass through the and investment companies are located in margins depend upon our ability to access change in input cost to customers to make jurisdictions including the United Kingdom, mineral reserves that have geological Business the margins immune to the uctuations in Mauritius and Netherlands. characteristics enabling mining at Review prices of the input and output. competitive costs. Replacement reserves The political, legal, scal and other may not be available when required or, if As a general policy, we aim to sell our regulatory regimes in these countries may available, may not be of a quality capable products at prevailing market prices. result in higher operating cost or restrictions of being mined at costs comparable to the Hedging activity in commodities is such as the imposition or increase in existing or exhausting mines. undertaken on a strategic basis to a royalties, mining rights, taxation rates, Development limited degree and is subject to both strict legislation pertaining to repatriation of Moreover, these estimates are subject Sustainable limits laid down by our Board and strictly money and so on. Changes to government to numerous uncertainties inherent in de ned internal controls and monitoring policies such as changes in royalty rates, estimating quantities of reserves and mechanisms. Decisions relating to reduction in import tariffs in India, reduction could vary in the future as a result of hedging of commodities are taken at the in assistance given by Government of India actual exploration and production results, corporate level and with clearly laid down for exports and the reduction or curtailment depletion, new information on geology guidelines for their implementation by the of income tax bene ts available to some and uctuations in production, operating subsidiaries. of our operations in India, Australia, UAE, and other costs and economic parameters Governance
Namibia, South Africa and Ireland are some such as metal prices, smelter treatment Corporate Our custom smelting operations of copper of the examples of risks under this category. charges and exchange rates, are also at Tuticorin enjoy a natural hedge except factors that may in uence the estimating to the extent of a possible mismatch in The majority of our Group revenues and of reserves, many of which are beyond quotational periods between the purchase pro ts are derived from commodities sold our control. of copper concentrate and the sale of to customers in India. Any downturn in nished copper. The Group’s policy on overall health of the Indian economy, any We continue to access our mineable custom smelting is to generate its margins political or regional instability may impact reserves and resources using the latest mainly from TC / RCs, premiums and revenue margins arising out of import available techniques and also get them Statements Financial sale of by-products. Hence quotational tariffs prevailing in India. periodically veri ed by independent experts. period mismatches are actively managed Our technical team continuously keep to ensure that the gains or losses are We may also be affected by the political monitoring the mineralogy of our future minimised. TC / RCs are a major source of acts of governments in these countries mineable resources and back it up with income for the copper smelting operations over which we have no control. required technological inputs to address in India and therefore are susceptible to any adverse changes in mineralogy. uctuations which are in uenced by factors We perform thorough risk assessment on such as demand and supply conditions a country by country basis to review the Delivery of expansion prevailing in the market for mine output. risks and to ensure that risks have been projects on time and The copper smelting business actively properly identi ed and managed. within budget reviews its procurement strategy to strike We have a strong pipeline of green eld a judicious balance between copper Reserves and resources and brown eld expansions projects and we concentrate procured at spot TC / RCs The ore reserves stated in this report are have committed funds for these projects. 36 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
These projects have achieved various monitoring systems to track the projects decide on the optimal levels of insurance stages of completion. Our plans to generate progress and over time developed skills coverage typical of our industry in India suf cient cash ows from these projects to to overcome challenges. Ireland, Nambia, South Africa and Australia. repay our long-term debt and our ability to raise further debt are dependent upon the Assets use continuity and Safety, health and successful completion of these projects on insurance environment risks time and under budgeted cost and a faster Productive assets used in mining and We are engaged in mining activities which production ramp-up. smelting operations and the associated are inherently hazardous and any accident power plants may face breakdowns in or explosion may cause personal injury or Our current and future projects may the normal course of operations or due to death, property damage or environmental be signi cantly delayed by failures to abnormal events such as re, explosion, damage at or to our mines, smelters, receive regulatory approvals or renewal environmental hazards or other natural re neries or related facilities and also to of approvals in a timely manner, failure calamities. Our insurance policies may communities that live near the mines and to obtain suf cient funding, technical not cover all forms of risks due to certain plants. Such incidents may not only result dif culties, human resources constraints, exclusions and limitations. It may also not be in expensive litigation, damage claims and technological or other resource constraints commercially feasible to cover all such risks. penalties but also cause loss of reputation. or for other unforeseen reasons, events or circumstances. As a result, these projects It may also not be commercially feasible We accord very high priority to safety, may incur signi cant cost overruns and to cover all such risks. Consequently, health and environment matters and may not be completed on time, or at all. our insurance coverage may not cover these are regularly monitored and We continue to invest to ensure having all the claims including for environmental reviewed by the senior management team. best in class human resources to maintain or industrial accidents or pollution. We Simultaneously we continue to invest our track record of completing large regularly carry out extensive work on the on training our people on these matters projects on time and within the budgeted adequacy of our insurance coverage by besides time to time interventions for cost. We also have in place rigorous engaging consultants and specialists and improvements by the experts. Sterlite Industries (India) Ltd. Annual Report 2011 37
Operational risks Financial risks and The conservative nancial policies have Our operations are subject to conditions Sensitivities enabled us to protect our investments in
and events beyond our control that Within the areas of nancial risk, the the long run. Company Overview could, among other matters, increase Company has approved policies which our mining, transportation or production embrace liquidity, currency, interest rate, Liquidity costs, disrupt or halt operations at our counterparty and commodity risks, which We require funds both for short-term mines and production facilities for varying are strictly monitored at our Executive operational needs as well as for long-term lengths of time or even permanently. Committee meetings. investment programmes, mainly in growth These conditions and events include Our core philosophy in treasury projects. Banks and nancial institutions disruptions in mining and production management revolves around three main have tightened lending norms post the global due to equipment failures, unexpected pillars, namely: (a) capital protection; nancial crisis. If this situation continues, our Business maintenance problems and other (b) liquidity maintenance; and (c) yield ability to raise funds and at attractive rates Review interruptions, non-availability of raw maximisation. may be signi cantly impacted. materials of appropriate quantity and quality for our energy requirements, Treasury policies are approved by the We aim to minimise this risk by disruptions to or increased cost of Board and adherence to these policies generating suf cient cash ows from our transport services or strikes and industrial is strictly monitored at our Group’s current operations which in addition to actions or disputes. While many of these Executive Committee meetings. Day- available cash and cash equivalents, and Development risks are beyond our control, we have to-day treasury operations of our liquid nancial asset investments, and Sustainable adequate and competent experience Group subsidiaries are managed by the suf cient committed funding facilities, will in these areas and have consistently respective subsidiary nance teams provide liquidity both in the short term demonstrated our ability to actively within the framework of the overall Group as well as in the long term. Long-term manage these problems proactively. It is treasury policies. Long-term fund raising borrowings are supplemented by short our policy to realise market prices for our including strategic treasury initiatives are to medium term project nance wherever commodities and therefore the pro tability handled by a central team while short- required. Our Balance Sheet is strong and of our operations is dependent upon our term funding for routine working capital gives us suf cient headroom for raising Governance
ability to produce metals at a low cost requirements is delegated to subsidiary further debt as and when required. We Corporate which in turn is a factor of our commercial companies. Each of our subsidiaries has generally maintain a healthy debt-equity ef ciencies and higher volumes. Prices of a strong internal control system including ratio as well as retain the exibility in our many of our input materials are in uenced segregation of front of ce and back nancing structure to alter this ratio when by a variety of factors including demand of ce functions with a separate reporting the need arises. and supply as well as in ation. structure. We have a strong system of internal control which enables effective Currency Risks Increase in the cost of such input monitoring of adherence to Group Our receipts are in Indian rupees, but materials would adversely impact our policies. The internal control measures revenues are linked to LME commodity Statements Financial competitiveness. We have consistently are effectively supplemented by regular prices and the US dollar. Also, the cost of demonstrated our ability to manage our management assurance audits. imported materials is usually determined costs and some of our operations have in US dollars. Hence, any uctuation in costs situated in the lowest quartile of the We do not purchase or issue derivative the rupee-dollar exchange rate impacts cost curve. We have a strong commercial nancial instruments for trading or Company’s nancials. Additionally, it has function and we identify the best speculative purposes and neither do we currency exposures on account of capital opportunities for cost reduction and quickly enter into complex derivative transactions expenditure and services denominated in implement them. We are highly focused to manage our treasury and commodity foreign currencies. on costs and volumes and all operational risks. Derivative transactions in both ef ciencies and cost ef ciencies are treasury and commodities are normally in Our borrowings are predominantly discussed regularly at the business the form of forward contracts and interest denominated in US dollars while a large review meetings as well as at the Group rate swaps and currency swaps, which are portion of cash and liquid investments are Executive Committee meetings. subject to strict guidelines and policies. held in the Indian rupee. Some nancial 38 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Our deposits are in mutual funds with a mix of xed and oating interest rate and most of the oating rate deposits are in INR. With an increase in interest rates, the return on INR deposits has also increased during the year.
We have borrowings with a blend of xed and oating rates in US dollars.
Counterparty Risks We are exposed to counterparty credit risks on our investments and receivables.
We have clearly de ned policies to mitigate these risks. Cash and liquid investments are held primarily in debt mutual funds and banks with high credit ratings. Emphasis is given to the security of investments. Limits are de ned for exposure to individual counterparties in the case of mutual fund houses and banks. Most of the surplus cash is invested in banks and mutual funds in India where there is a well developed nancial market. We also review the underlying investment assets and liabilities are not held in the Interest Rate Risks portfolio of mutual fund houses to ensure functional currency of the respective We are exposed to the interest rate risk that indirect exposures or latent exposures subsidiary. We also hold some intra- on short-term and long-term oating rate are minimised. The investment portfolio Group balances in currencies which instruments and also on the re nancing of is monthly being reviewed by external are not the functional currency of the xed rate debt. Our policy is to maintain a agency i.e. CRISIL (subsidiary of respective subsidiary exposing the Group balance of xed and oating interest rate Standard & Poor). to movements in the functional currency of borrowings. The proportion of xed and those entities and the currencies in which oating rate debt is determined by current A large majority of receivables due from these balances are held. market interest rates. third parties are secured either as advance receipt of money or by use of trade Foreign currency exposures are managed Considering our net debt position on nancial instruments such as letters of through a Group-wide hedging policy. The March 31, 2011 any decrease in interest credit. Moreover, given the diverse nature policy is reviewed periodically to ensure rates would result in a net gain and any of our businesses, trade receivables that the risk from uctuating currency increase in interest rates would result in are spread over a number of customers exchange rates is appropriately managed. a net loss. with no signi cant concentration of credit Foreign exchange exposures on imports, risk. Our history of the collection of trade net of natural hedges in place, are hedged During the nancial year 2010-11, interest receivables shows a negligible provision based on their maturity. Short-term foreign rates, specially for debts denominated in for bad and doubtful debts. Therefore exchange exposures relating to capital INR have hardened re ecting tightening we do not expect any material risk on expenditure are hedged, whilst medium to monetary policy by the Government of account of non-performance by any of the long-term exposures are unhedged. India. counterparties. Sterlite Industries (India) Ltd. Annual Report 2011 39
Employees of the audit and compliance function is We have a well laid out growth pipeline
People are one of our key assets and ensured by direct reporting to the Audit and most of our expansion projects are on Company Overview we derive our ability to maintain our Committee of the Board. Details on the track to deliver an industry leading organic competitive position from them. Therefore, composition and functions of the Audit growth. We remain con dent to deliver people in general and key personnel in Committee can be found in the chapter superior results as we are progressing. particular leaving the organisation is a on Corporate Governance of the Annual risk. Additionally, our inability to recruit Report. Cautionary Statement and retain good talent would adversely In this Annual Report we have disclosed affect us. Critical Accounting forward-looking information to enable Judgements and investors to comprehend our prospects Business Our vision is to build a fast, exible Estimation Uncertainty and take informed investment decisions. Review and at organisation with world class In the course of applying accounting This report and other statements – written capabilities and a high performance policies outlined in the Notes to the and oral – that we periodically make culture across all of our businesses. We Consolidated Financial Statements, contain forward looking statements that believe in nurturing leaders from within and management necessarily makes set out anticipated results based on the providing opportunities for growth across estimations and assumptions that can management’s plans and assumptions. all levels and geographies. We have have impact on the nancial statements. We have tried wherever possible to Development robust processes and systems in place identify such statements by using words Sustainable for leadership development, training and Taxation such as “anticipate’, “estimate’, “expects’, growth to deliver value to the organisation Changes to tax legislation and regulation “projects’, “intends’, “plans’, “believes’, and society. or their interpretation may adversely and words of similar substance in affect the value of an investment in connection with any discussion of future We provide superior rewards for securities and may affect Shareholders performance. We cannot guarantee outstanding performance and have a differently. that these forward looking statements long-term incentive plan which covers a will be realised, although we believe, Governance large number of employees in the Group. Unforeseeable Risks we have been prudent in assumptions. Corporate A large proportion of our workforces are There are likely to be risks that the The achievement of results is subject to members of a trade union. We actively Directors and the Company and its risks, uncertainties and even inaccurate communicate and enter into dialogue with advisors are unaware of or do not fully assumptions. Should known or unknown our workforce and believe in maintaining appreciate at any point in time. Over risks or uncertainties materialise, or should a positive atmosphere by being proactive time or with the bene t of hindsight these underlying assumptions prove inaccurate, with respect to resolution of labour issues. sometimes become apparent. Such risks actual results could vary materially from We have long-term settlement with the may be related to legislation, regulation, those anticipated, estimated or projected. trade unions, where it is more frequent, business conditions, land access, con icts Readers should bear this in mind. We Statements Financial being concluded amicably. and disputes at a local or international undertake no obligation to publicly update level, data issues and a variety of other any forward-looking statements, whether Internal Controls unforeseen eventualities. as a result of new information, future We have effective and adequate internal events or otherwise. audit and control systems, commensurate Outlook with the size of our business. Regular The recovery in demand and commodity internal audit visits to the operations are prices backed by growth momentum undertaken to ensure high standards in China, Brazil and India appears well of internal control measures are founded. The medium and long-term maintained at each level. These consist outlook for the resource sector remains of comprehensive internal and statutory positive. We are well positioned to bene t audits which are conducted by audit rms from the upswing, bene ted by our of international repute. Independence structurally low cost position. 40 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Sustainable Development Sterlite Industries (India) Ltd. Annual Report 2011 41 Company Overview CSR activities spread in more than 200 villages, 5 lakhs people and more than 60,000 household in four district of Rajasthan, one district of Andhra Pradesh, Tamilnadu, Punjab, Orissa and Chhattisgarh Business Review Development Our strategy for community Sustainable engagement is intensive, comprehensive, long-term and sustainable. Governance Corporate
We are conscientious of the impact of our operations on the society and environment, and strive to carry out our
CSR activities / sustainability Statements Financial practices with high degree ef ciency and empathy. 42 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Sustainability Report
Health, Safety & Environment unit has devoted HSE teams including compared to 8.48 m3/MT of cathode in the (HSE) water and energy & CDM managers. As year 2009-10. The increase in consumption The HSE is an integral component of a regular practice, we engage reputed was mainly on the grounds of lower volume our philosophy of conducting business external consultants such as KPMG, of production. in a responsible manner. It is very well Chillworth Global, National Safety integrated in our routine operations and Council and Synergic Safety Engineers, Energy Management practices. We are committed towards for assessment of our performance, During the year, the speci c energy creating & maintaining sustainable growth identi cation of gaps and suggestions for consumption for producing one ton of for our stakeholders and accordingly improvement. Most of our operations have cathode was 9.97 GJ/MT when compared strive to maintain balance between social, formal HSE management systems aligned to 9.44 GJ/MT in the year 2009-10. environment and economic aspects of our to the international standards like OHSAS Overall speci c energy consumption business. ‘Zero harm’ to people, our host 18001 and ISO 14001 in place. including value added products was communities and the environment is our 12.31 GJ/MT in 2010-11 as compared to key focus areas. Copper 11.69 GJ/MT in the year 2009-10. Here Our HSE efforts are centered on the Environmental performance again higher consumption was mainly below pillars: Water Management due to lower volume of production, which • Safety: Provide a safe workplace. The Speci c water consumption of copper has offset the bene ts gained through • Environment: Minimise impact on business till cathode was 7.94 m3/MT several energy saving measure such as environment by conserving natural of cathode compared to 6.24 m3 /MT of reduced LPG consumption in smelter, resources through ef cient use. cathode in the year 2009-10. Overall plant air header replacement, modi cation • Health: Eliminate occupational illness. speci c water consumption including of oxygen plant compressor lters etc Our HSE focus is pervasive all across value added products the speci c water undertaken by the company during the group companies. Each company/ consumption was 10.78 m3/MT of cathode the year. Sterlite Industries (India) Ltd. Annual Report 2011 43
Climate Change Mitigation Bio-diversity training to 100% of the employees per year
At Sterlite, we acknowledge the threats/ As a part of recommendation by Forest and was successful in achieving 95.3%. Company Overview risks posed by global warming to the entire Research Institute (FRI), Dehradun, For contract staff, safety and health training humanity. Therefore, we are taking all we initiated a bio diversity conservation target of 16 man-hours per employee possible measures to reduce our impact project in nearby ve villages at Tuticorin per year was xed against which the Unit on climate change. We have gone forward (Melavittan, South veerapandiyapuram, achieved safety training of 17.9 man-hours with rigor in identifying CDM projects and pandarampatti, Saminatham, per employee per year. We have initiated implementation. One of our project, Waste Vadakusilikanpatti) to conserve the Web delivered interactive safety training for Heat Recovery Boiler installed at ISA endangered/rich medicinal plants. A our employees and contract staff. We have furnace was registered as CDM project NGO has been engaged to carry out this also introduced e-learning course in Tamil & Business with UNFCCC. It utilizes waste heat to project. Objectives of project is to conserve Hindi for contractors during the year. Review generate electricity, which displaces equal medicinal plants and create a livelihood amount of power import from grid, thereby opportunities for village to commercially Training on life saving techniques reducing greenhouse gas emissions from exploit this resource available. and re ghting the grid connected to fossil fuel-based A unique programme on life saving power plants. This project helps avoiding Occupational Health & Safety technique and re ghting was organised in release of 18,000 tons of CO2 per year to We believe we can be a business without which 92 employees and 158 contractors Development the atmosphere. injuries and rmly consider that every were trained. First aid training was Sustainable safety incident is preventable. The health organised through St. John Ambulance The same project was also registered in and safety of employees and contractors is co-ordinated by the Unit’s Chief Medical the Voluntary Carbon Standard (VCS) in the major focus area at Sterlite. We believe Of cer and 247 employees were trained. 2010 and we have accumulated 67,900 that continuous improvement on this CERs for the pre-registration period, which aspect is instrumental for the sustainable Zinc were sold in the voluntary carbon market. success of our organization. Occupational Health Three more CDM projects have been We follow the ‘Lost Time Injuries It is our paramount endeavor to eliminate Governance
identi ed in our expansion project and Frequency Rate (LTIFR)’ index system for occupational illness by providing a Corporate PDD preparations are in progress. These evaluating the safety performance. It is workplace that is free from occupational three projects will result in a reduction of the number of lost time injuries per million health risk & hygiene hazards; and
65,000 tons of CO2 in the atmosphere man-hours worked. proactively work with employees and per year. contractors to contribute towards healthier Safety statistics lifestyles. Apart from being our social Waste management During the year, we lost one responsibility, this also facilitates enhanced Our continuous efforts towards irreplaceable live at work who is driver of productivity and reduced absenteeism. improvement of environmental Sulphuric acid tanker. Table below gives Statements Financial performance have shown tremendous trend of Lost Time Injury Frequency Rate We have engaged occupational health results with reference to waste (LTIFR) for last 3 years. experts across all mines and smelters for management. During the period regular health examination of employees, we were able to dispose gypsum to LTIFR contract workmen and workplaces. tune of 1.33 times that of generated Speci c examination including blood lead FY-2 011 quantity. This resulted in net depletion test, audiometric tests, spriometry test, of stock and contributed towards FY-2 010 ECG and chest x-rays are done frequently. sustainable applications such as cement FY-2 009 0.0 0.2 0.4 0.6 0.8 1.0 manufacturing. Slag disposal of was also The health of our employees is monitored a big success story for us, we were able by our internal system that ensures dispose copper slag to the tune of 1.11 Training statistics regularity of medical examinations. During times of generated quantity in application During the year the Copper business xed the year more than 3,500 employees have such as cement, road, abrasive and lling. a target of providing safety and health gone under periodical medical examination. 44 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
several initiatives focused on improving safety systems and building & strengthening our ‘safety culture’.
Notable amongst those are: — Visible commitment by senior management towards safety improvement. — 45,623 man-days of safety training to employees (including contract employees). — Five fundamental safety cardinal rules have been prepared. These are under implementation across all locations. Violation of any rule will be subjected to disciplinary actions as per the rules (see box). — Safety management of contract workforce is also one of our key There was no case of occupational spaces, and using explosives and focus areas (see box). disease reported during the year. chemicals in pressurised systems. — Uniform near miss reporting reward Over the years, we have consistently policy was launched during the year improved our LTIFR at smelters, from 7.59 Due to our persistent efforts and approach to enhance the reporting of incidents. in the nancial year 2006 to 1.47 in the towards safety, LTIFR performance over ` 100 /- is rewarded for each near miss nancial year 2011, translating in reduction the last ve years at mines has improved reported along with reward of of 81% over last ve years. These from 15.08 in the nancial year 2006 to ` 1,000/- to 10% of near miss reported continuous improvements have made our 4.64 in the nancial year 2011, marking a in the month as per lottery. Due to this smelters comparable to other benchmark signi cant decrease of 69%. initiative, we have recorded 996 near global smelters in safety performance. misses across all the units during the year. All near misses reported are Mine - LTIFR Smelter - LTIFR promptly analysed and appropriate FY-2011 corrective actions are taken. FY-2011 FY-2010
FY-2010 FY-2009
FY-2009 FY-2008 Safety Cardinal Rules: FY-2008 FY-2007 — Do not override or interfere with FY-2007 FY-2006 any safety provision, nor let anyone 04812 16 FY-2006 else override or interfere regardless 0 2 4 6 8 of seniority. — Personal Protective Equipments Despite our relentless safety improvement (PPEs) applicable to the given task We have a very strong and resolute focus efforts, we unfortunately lost ve lives must be adhered to. on safety at mines, as mining activities at operations and projects. Disciplinary — Always follow isolation and lock out and minerals processing require the actions were taken against the responsible procedure. management of signi cant hazards, employees and contract supervisor to — No person will be allowed to work including controlling rock strata, operating bring the safety accountability. under the in uence of alcohol or high voltage equipment, heavy machinery drugs and large mobile equipment, working Strengthening of Safety Systems — Report all injuries and illness underground, at height or in con ned During the year, we have undertaken Sterlite Industries (India) Ltd. Annual Report 2011 45
— Safety theme of the month - Road and
traf c safety - was launched across all Company Overview units in July 2010. Road safety signs were increased and 250 persons were imparted external safety trainings on safe two-wheeler riding by ‘Honda’. — Safety awareness videos & audio systems are run at strategic locations at various operations for increasing safety awareness. Business Review
Contractor management We give equal importance to contract workmen safety, as in case of our own employees. Contractors are included in our safety data and must comply in full with our safety standards and procedures. Development Sustainable
During the year, we have reviewed on critical observations are taken of best available technology & resources, safety performance of major contractors immediately and others are complied recycle/reuse practices and conserving and communications were made to the senior management of the agency in time bound manner. bio-diversity in and around our operating deteriorating on safety aspects. Our — Focus on PPE compliances by locations. contractors also participate actively in enforcement. Safety Committee meetings to facilitate Our key focus area is to conserve further strengthening of safety systems. Environment the Lead-Zinc ore, judiciously use Governance
Wherever appropriate, we have We recognise that mining & smelting the other natural resources including Corporate minimised the number of contractor operations have the potential to unfavorably water, energy and land; and reduce air companies used, in order to improve effect the environment through emissions, emissions, to ensure sustainability of accountability and enable us to ensure waste generation, water consumption and our operations. consistent safety standards. We monitor land-use changes. We are persistently high risk activities closely, provide regular feedback on performance and promptly focused on minimizing the environmental Speci c water consumption at smelters act on any failures by contractors in impacts of our operations through adoption has improved from 17.33 m³/tonne of complying with our safety procedures. Statements Case Study Copper Slag Financial — Safety e-learning designed by DuPont Waste to Resource has been launched at Chanderiya. Copper slag, also known as Ferro sand, is generated during the pyro- metallurgical production This learning module is a self training of copper from copper concentrate and contains mainly iron, alumina, calcium oxide, silica, etc. programme implemented for training, For every ton of metal production, approximately 1.8 - 2.2 tonnes of slag are generated. Sterlite educating and creating awareness has carried out various studies through reputed CSIR (Council for Scienti c and Industrial Research) institutes on characteristics. The studies have concluded that copper slag is non- among the employees. leachable and non-toxic and possesses properties similar to natural aggregates. As a part of — Regular safety management system sustainable application of slag, we have used it in manufacturing interlock pavers. Padestrian audits are carried out across walkway covering an area of 2,500 sq meters was constructed. Approximately 268 tonnes of locations through inter-unit & inter- copper slag was used in this activity. These pavers can be claimed as the green building products which contain less embodied energy, optimised utilisation of natural resources, water in its group company audits. We also manufacturing process when compared to the common alternatives. Studies show that there is have external consultants for safety huge potential in using copper slag as a natural aggregate in building materials such as pavers. audits and recommendations. Actions 46 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
metal in the nancial year 2006 to 9.72 m³/ Initiatives • The tailing generated at mines tonne in the nancial year 2011 indicating a We have taken up several projects during bene ciation process is reduction of 44% over the last ve years. during the year to reduce our speci c transported to the tailing dam in water consumption. 126 projects were slurry form through pipe lines. The completed during the year with estimated water which gets stored in tailing Sp. Water consumption, Smelters potential saving of 19,167 cum/day. The dam is then reclaimed and is FY-2011 major initiatives undertaken include: recycled back in the processes. FY-2010
FY-2009 • Reduced evaporation losses by using This year we have increased the FY-2008 evaporation retardant chemicals at reuse of tailing dam reclaimed FY-2007 open water storage ponds, Tidi dam water at all the mines. FY-2006 0 510 15 20 and over tailing dam at all the mines • Existing water pressing lters at m³/tonne of metal and smelters. Rampura Agucha have been replaced • Use of dust suppression chemical on with air pressing lters. Speci c water consumption at mines haul roads at Rampura Agucha has • To further improve process water has improved from 7.77 m³/tonne of reduced water consumption as well as recovery, a paste thickener (deep concentrate in the nancial year 2006 improved working conditions due to cone thickener) has been constructed to 3.26 m³/tonne of concentrate in the reduction of dust load. at Rampura Agucha. nancial year 2011 demonstrating a reduction of 58% over the last ve years. Case Study Mobile RO (Reverse Osmosis) system for better excess water management
The Sterlite Tuticorin Copper Smelter is a zero discharge plant. Two RO plants were already in Sp. Water consumption, Mine operation at the unit to manage the utility waste water and ETP treated water. However during
FY-2011 monsoon / heavy rains, managing excess water was a big challenge. In order to manage the
FY-2010 excess water during heavy rain, it was decided to set up a mobile RO as per CPCB (Central Pollution Control Board) guidelines. FY-2009 FY-2008 Accordingly a new RO plant was set up with a state of art technology from GE water solutions. FY-2007 The rain water is collected in the rain water catchment ponds was completely treated and reused FY-2006 in sulphuric acid plant cooling tower. The mobile RO plant would help the plant to manage any 0 369 excess water during heavy rain fall in monsoon season and to maintain zero discharge. m³/tonne of concentrate Sterlite Industries (India) Ltd. Annual Report 2011 47
• To improve water availability at The speci c energy consumption in Initiatives Rampura Agucha, six bore wells smelters has reduced from 24.62 GJ/ We have undertaken several projects
have been drilled & one open well tonne of metal in the nancial year 2006 during the year to reduce our speci c Company Overview has been deepened. The fresh water to 16.29 GJ/tonne of metal in the nancial energy consumption. Of these, 82 system is now capable of supplying year 2011, signifying a reduction of 34% projects have been completed during the approved quantity even during a over the last ve years. year with signi cant savings in energy. draught year. Notable few include: • Grouting of dam body & porous areas Sp. Energy consumption, Smelters • Automation of atmospheric cooling
at Tidi dam at Zawar have prevented FY-2011 tower blowers and GR thickener cooler a loss of approximately 4,000 cum/ FY-2010 in Chanderiya Cell House. FY-2009 day. This has also improved structural • Substitution of all the halogen lights FY-2008 Business Review
safety of the dam. FY-2007 (500 &1000 W) from the elds with
• Installation of push cocks, ferules FY-2006 metal halide lights (125 & 250 W) 15 20 25 30 in quarters / public water points has Giga joule / tonne of metal at Dariba & Debari has facilitated reduced wastage of water. reduction of 7,500 units / annum. • A collection sump of 1.4 lakh cum At our mines, the speci c energy • Installation of 9 energy ef cient capacity has been constructed at consumption has reduced from 2.19 GJ/ motors for spent cooling pumps at Rampura Agucha for rain water tonne of concentrate in the nancial year Vishakapatnam. Development harvesting. The water collected in this 2006 to 2.0 GJ/tonne of concentrate in • Solenoid valve installation in oil lift Sustainable sump has helped us in running our the nancial year 2011, translating in a pumps and installation of solar water Rampura Agucha operations during reduction of 8% over the last ve years. heater at Debari. the summer of 2010 when there was Higher excavation at Rampura Agucha • Several rounds on internal energy acute water crisis. and the recently commissioned projects audits for exploring new energy have slightly increased the speci c energy consumption reduction opportunities at We have maintained zero-discharge at all consumption. This is however expected to Chanderiya. our smelters and mines. reduce in the coming years. • Installation of VFD in cooling tower Governance
fan, ISF slag venturi fan and copper Corporate Energy drossing ventilation fan at Chanderiya. Sp. Energy consumption, Mines We are focused on optimisation and • Replacement of Sinter Ignition burner FY-2011 ef cient use of energy, which is one of the system to reduce 20% oil consumption FY-2010 most critical resources today. Effective FY-2009 at Chanderiya. utilisation of energy helps in reducing FY-2008 the operating costs as well as the direct FY-2007 Managing Climate Change FY-2006 and indirect greenhouse gas emissions. 0 123Climate change is one of the biggest global Giga joule / tonne of concentrate As a part of our green energy initiatives, challenges of our times. We recognise Statements Financial we have also set up our wind power plants. We strive to ensure a secured and cost-effective supply of energy to all Case Study Replacing two ID fans with single ID fan in RHF- HVS our operations, which is crucial for the sustainability and growth of our operations. To maintain better hygiene in ISA and RHF area, two ID fans were running to collect the fugitive gas emissions. Though each fan was having a capacity of 105 KNm3, the scrubber can handle a maximum volume of 180 KNm3/hr. The excess capacity was unutilized and both fans were Through our continuous energy consuming more power. The motor capacity of each fan was 450 KW. So it was decided to conservation and captive power convert the system to the optimum capacity. generation efforts over the years, we Instead of two ID fans of each 450 KW, one single ID fan of 500 KW was installed. To have been successful in reducing the accommodate the ow rate, lines were modi ed during annual shut down -2010. This single ID speci c energy consumption (i.e. energy fan can handle the required ow rate in the scrubber. A net of 300 KW saving was achieved by implementing this project. consumed per tonne of metal produced) of our mines and smelters. 48 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
LCV boiler at Chanderiya Pyro smelter In line with our commitment towards environmental protection and preservation of natural resources, we have taken up an initiative to utilise the heat of LCV (low calori c value) gases generating from Pyro zinc operations, which were otherwise being ared in stack. In Imperial Smelting furnace of Pyro Zinc operation, sintered lumps of Zinc and Lead oxide are charged with the preheated coke. During burning process of coke around 65 to 70 KNM3/H (LCV) gas gets generated, of which approx. 42 KNM3/H is consumed for preheating the coke and blast air. Remaining 23 to 25 KNM3/H was being ared in stack. However, now we have installed a boiler to utilise this cleaned gas for generating steam. This project is presently under the signi cance of this colossal global Karnataka, Maharashtra and Tamilnadu. CDM registration, having a CER threat and strive to mitigate the socio- Of the total 150 MW, we have successfully potential of 33,000 tonne of equivalent
environmental impact of our operations. commissioned 48 MW in March 2011, CO2 / year the balance 102 MW is scheduled for India is one of the non-Annexure ‘1’ commissioning by Q2 of the nancial year countries as per the Kyoto Protocol, 2012. The additional 150 MW will also be Waste Management consequently Hindustan Zinc does not registered under the UNFCCC’s Kyoto Non-ferrous mining & metal industry, hold any carbon liabilities. However, being protocol for CDM. It has a CER potential of owing to the nature of operations, a responsible organisation, we endeavour approximately 2,70,000 per annum. generates a large quantity of hazardous to reduce our operational impacts on the as well as non-hazardous wastes. environment. We also generate power by utilising waste The wastes include mine overburden, heat at Smelters. Of the total waste heat bene ciation tailings, slag, jarosite, We have two Wind Power Plants having generation capacity, 9.4MW is UNFCCC y-ash and other process residues. combined capacity of 123.2 MW and CER registered CDM project. potential of 2,25,000 per annum, located We have a strong focus on recycling in the states of Gujarat and Karnataka. During the year, we have sold 1,34,138 our wastes back to the processes, Last year both of our Wind Power Plants CERs generating revenues of around which has the potential to replace virgin got registered as CDM projects under ` 9.76 Crore. This year we have received material, thereby conserving the natural United Nations Framework Convention the Host country approval for one waste resources. We are on constant look out for on Climate Change (UNFCCC). This heat recovery based boilers at Chanderiya. opportunities to prevent waste generation, year, we have reiterated our commitment Over the years, we have been voluntarily minimise the generation of waste and towards promoting green energy with the ling Carbon Disclosure Project (CDP) enhance waste re-use and waste recycling. announcement of 150 MW addition in responses as a proactive step towards The wastes which are not usable are the existing wind power capacity located reporting our carbon foot-printing. We have disposed in a scienti c manner as per the across four states, namely, Rajasthan, led CDP 8 response this year. best environmental practices. Sterlite Industries (India) Ltd. Annual Report 2011 49
Most of the mine overburden generated disposal yard, specially constructed for the ef cacy of construction. Hazardous
is utilised for secondary construction work the purpose. At Chanderiya smelter, wastes such as used oil and waste oil along Company Overview including rising of tailing dam heights and the jarosite is converted into an inert with few other process wastes are sold to mine back lling, with the remaining being material called Jaro x by adding lime authorised recyclers registered with the disposed in waste dump in a systematic and cement. Hindustan Zinc is the rst regulatory authorities. manner. Similarly some of the tailings company in Asia to employ this state-of-art are used for mine back lling and the technology of Jarosite stabilisation called We hold a clear focus on waste remaining is disposed in the tailing dams Jaro x technology (patented by Canadian minimisation and strive to utilise the constructed specially for the purpose. Environmental Zinc (CEZ)). This Jaro x is wastes in alternative gainful use. The slag These tailing dams (designed by Central then is disposed in lined Jaro x disposal generated from our Pyro operations of Business Water Commission and Indian Institute yard in a systematic manner. Jaro x Chanderiya is gainfully utilised for cement Review of Science, Bangalore) are made of disposal yard is lined with an impervious manufacturing. Likewise, y ash is used in rock ll with lining to avoid any seepage layer underneath to avoid any possibility of cement production, brick manufacturing and into groundwater. We have had Aquifer leaching. We have also constructed garland other secondary constructions. Vulnerability Study (AVI) done by NEERI drains all around the disposal yard to collect using DRASTIC model of USEPA, which run-off water during the monsoons. This year around 2,46,921 MT was done for the rst time in India. The (100% of generation) of Fly ash and Development study concluded that the aquifer is least The hazardous wastes generated are about 2,37,950 MT of ISF slag (more Sustainable vulnerable to any seepage from dam. being disposed in the secured land lls in than our generation) has been used for Safety of our tailing dam is ensured environment-friendly manner, designed cement manufacturing. This has helped through periodic examinations. with state-of-art technologies and approved us in reducing our waste inventories and by statutory bodies. Also, we have taken conserving natural resources by replacing At our Debari and Vizag smelters, the Construction Quality Assurance (CQA) at the virgin material at the other end where waste Jarosite is disposed in the Jarosite various stages of construction to ensure it is gainfully utilised. Governance Corporate Statements Financial 50 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Extensive R&D has been undertaken for Few if the initiatives in this direction, • Roaster dome top brick lining job done
gainful utilisation of Jarosite (a waste from undertaken during the year are: to arrest SO2 emissions in Hydro-1 at Hydro operations), in road construction • Reduced dust emission at Rampura Chanderiya. and cement manufacturing. We have Agucha by: • Vetiver plantations done on waste associated with premier research • Spraying water on mine haul roads. disposal heap to minimise dust y-over institutes and industries including National • Use of chemicals for dust in the area. Council for Cement and Building Materials suppression on haul roads. (NCCBM) and Cement industries & • High pressure jet water spray Biodiversity Tiles industries, for the same. We have nozzles provided at primary Biodiversity – the variety of life on earth obtained positive results and are hopeful crusher. – provides a range of goods and services on alternative gainful utilisation of jarosite. • Cleaning industrial roads by collectively termed as ecosystems mechanical road sweeper. services. As a business, we are reliant on Air quality • Revamping of de-dusting system to these services and have a responsibility to We strive to minimise the impact of air improve work environment in Melting & reduce the impact of our operations on the emissions from our operations through Casting section at Chanderiya. surrounding environment. We aim to avoid adaptation of cleaner technologies. We have installed cleaner tail gas treatment Case Study Nitrogen purging in anode furnace to reduce LPG consumption plants at all our smelting locations to prevent SO emissions. This technology 2 Anode furnace process involves oxidation and reduction of molten metal to convert the blister does not produce any wastes. All our new copper into anode copper to get the higher purity. Compressed air is used as oxidant to acid plants have adopted double conversion remove the sulphur content in molten copper and LPG is used as reductant to remove the double absorption (DCDA) technique. oxygen content in the metal. Oxygen present in liquid copper is enough for reacting with sulphur present in the molten metal. Dissolved Oxygen and dissolved Sulphur are to be mixed thoroughly for better oxidation. For mixing, additional agitation with inert gas like Nitrogen is Several technical up-gradations including required. The inert gas shall eliminate the oxygen content in the molten metal during oxidation improved bag lters, wet scrubbers and and reduce the oxygen concentration at the start of reduction.
electrostatic precipitators have helped in Hence nitrogen comes as by product from oxygen plant process passed through Anode minimising the impact from air emissions. Furnace tuyeres during oxidation and results in less oxygen content in molten copper. Due to We have a robust air monitoring system less oxygen content in the molten metal less LPG is required for the reduction process. This initiative has given a potential saving of 100 kg of LPG per re ning. through online stack monitors and ambient air quality monitoring stations. Sterlite Industries (India) Ltd. Annual Report 2011 51
losses or degradation of natural habitats, have been taken towards conservation We continue to develop green-belt in Company Overview biodiversity and landscape functions. and enhancement of biodiversity. However and around our operations with the help there are patches of noti ed reserve of expert botanists and horticulturists Biodiversity management is an integral forest in the buffer zone, surrounding engaged across our units. Green belt is part of our environmental management some of our smelters and mines. For assessed from time to time for ef cacy and plan, linked to initial site-level instance, Haridwar Zinc Plant (HZP) (a appropriateness of species diversity and environmental impact assessments as melting and casting unit) is installed in the remedial measures are initiated wherever well as within operational ISO 14001 industrial area at Haridwar (Uttrakhand) necessary. Responsible closure of mines management systems. All our Green eld near Rajaji National Park. However, since is embedded in the respective mine plans. Business projects and expansions undergo HZP operations only involve physical Review Environmental Impact Assessment (EIA) transformation of Zinc cathode sheets into The key objective is to rehabilitate studies to understand the status of the Zinc ingots, without chemical processes, it exhausted open pit mine areas and convert biodiversity value of the region in which we has negligible impact on the environment. them into usable lands through forestry operate. None of our operations qualify as We have taken all plausible measures for management programmes. Several units artisanal and / or small scale mining. effective control of pollution, to avoid any have undertaken plantation rallies involving adverse impact on Rajaji National Park. school children and local communities. Development We do not own any land in the protected We are also progressively developing Sustainable areas or in the areas with high biodiversity the greenbelt area surrounding our Over the years we have planted 1.10 value. There are no signi cant impacts of operational site. Inactive benches of million plants at all our operating our activities, products and services on waste dump are being systematically locations. We continue to further improve biodiversity rich areas. Several initiatives stabilised with green cover. the density and greenbelt coverage. Governance Corporate Statements Financial 52 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Aluminium
Safety Health & With a view to further improve safety lter has been installed in one of the unit Environment management systems, independent safety of its 540 MW CPP and upgradation The aluminium operations of BALCO are and compliances audits were carried out by has also been carried out for one of the certi ed by IRQS for OHSAS 18001:2007 renowned agencies like Du Pont, BVIL, etc. ESPs & Economisers of its 270 MW and ISO 14001. During the year 2010- CPP. These measures have resulted in 11, BALCO has taken many initiatives Various Safety Motivational Programmes bringing down the emissions level well in the area of Safety Management. viz. National Safety Day, Road Safety within the revised prescribed norms. Some of the major initiatives taken were Week, Fire Service Day and Safety During the year, a major Afforestation - implementation of Lock Out Tag Out Marathon were organised. Besides these drive was initiated and in all, 3.30 (LOTO) across all the units, thrust on safety events, the company also hosted lakhs saplings were planted in and behavioural safety and enhanced focus on “Annual Safety Celebration 2010 under around Korba Plant and Mines. Safety Training and awareness for regular the aegis of DGMS (Bilaspur & Raigarh In the area of Water Conservation, as well as for contractors’ employees. Regions) at Korba wherein 46 mining company has taken initiatives in In total, 6,296 man-days Safety Training organisations participated. bringing down the speci c water was imparted. As a consequence of consumption by arresting all the these initiatives in the area of Safety Environment Management leakages and seepages. Management, BALCO achieved lowest During the year BALCO took the following Speci c Energy consumption reduced ever LTIFR of 0.62. major initiatives were taken towards to 57 GJ/MT of metal during the year minimising pollution - from 60.5 GJ/MT during 2009-10. As a proactive approach, Structural This was mainly due to suspension of Stability & Lightening Protection studies To reduce air emissions and maintain Alumina Plant operations and partly were undertaken and thereafter, remedial the same as per the revised MOEF/ due to implementation of few energy measures have also been initiated CPCB norms. The Company has saving improvement projects in the wherever required for installations of plant undertaken major modi cations in its running smelter operations. at Korba. Power Plants. As part of this, Hybrid Bag The CDM project, titled “Emission Reduction Through Change in Smelter Technology at BALCO, India”, is in the process of being registered with UNFCCC, consequent to the ongoing replacement of 1.0 lakh MT per annum VSS aluminium smelter with 3.25 lakh MT per annum pre- bake technology smelter, which is being set up as approved by the Board at its 265th meeting held on July 25, 2008, has received the host country approval from Ministry of Environment & Forests. The project aims at achieving a reduction in
PFC and CO2 emission reductions through improved technology leading to reduction in AEF and AED and Speci c Energy consumption per tonne of Aluminium. This
would result in lower net CO2 load in the atmosphere, thereby helping in reduction of global warming. The project would also yield carbon credits to the tune of 0.71 million CERs per annum. Sterlite Industries (India) Ltd. Annual Report 2011 53
Corporate Social Responsibility (CSR)
Copper community participation and community All these centres organised science
Consolidation of intention contribution in all our activities. The exhibition and this has enabled the Company Overview As an evolved and concerned corporate company play the catalyst role in taking students to show case their talents and citizen, Sterlite believes that corporate the bene ts of government schemes to the create interest in science subject. Many social responsibility(CSR) initiatives are rural poor. The projects are driven as per of our employees also participated in the a way to re ect the respect and concern the needs of the poeple and are planned exhibition and motivated the rural students. for people and communities living around an executed in partnership with community Around nine centres conducted science us. We see CSR as an opportunity to and government. exhibition in their respective centres during make a positive change and all our CSR the reporting year. activities are determined by the concept Our programmes and performance Business of ‘Changing Lives’: where we constantly Education Scholastic Excellence Awards Review endeavour to improve the quality of life Sterlite awards ‘Scholastic Excellence of the communities where we operate. Objectives: Awards’ to the 11 District toppers in SSLC Our CSR activities are conceived to • To improve the school pass and HSC in the presence of parents bridge gaps in society and help transform percentage in our area of operations and Higher authorities from Education communities around our workplace and • To reduce school drop-outs in rural department every year to recognise are concentrated around 25 villages in and coastal communities. educational excellence in Tuticorin Development Tuticorin district and positively enhancing • To achieve 100% school enrolment. district and to motivate students for a Sustainable the quality of life of over two lakh people. • To offer career guidance to the school better performance. Cash awards also nal year students. extended to the rural students securing We pay our maximum attention to uplift the more than 80% in the public exams. This quality of life of women, children and youth Initiatives: was presented to 29 of our evening study in our focus areas. • Evening Study Centres centre students. • Scholastic Excellence Awards We began our CSR initiatives since • Educational scholarship Educational Scholarships Governance
inception. Over the time, we have • District level Environmental Awareness As part of Academia – Industry Corporate evolved a tripartite approach, where we, competitions to students partnership, Sterlite instituted ve as catalysts, bring together government • Career Orientation education scholarships in V.O.C. College, resources, eld expertise of NGOs and • Support for parentless children Tuticorin to support economically our vision of a growing community. We backward/meritorious students to believe that people know their problems Evening Study Centre continue their studies every year. Sterlite and solutions better than anybody else; Sterlite Copper’s education initiatives are has also extended nancial assistance to what they lack are the means and through focused on improving school nal year deserving students recommended every our efforts and by partnering with NGOs, results and to reduce school drop outs now and then. So far seven students with Statements Financial government departments, academic enabling rural children to compete with excellent academic records from poor institutions, nationalised banks and their counterparts in the schools. Sterlite socio-economic background identi ed hospitals, we catalyse the means. is running 25 evening study centres in the and help them to continue their studies. economically backward zones of Tuticorin All these students have enrolled in Approach and strategy town and in rural areas as part of the engineering colleges and they will be Sterlite believes in building partnership and education promotion initiatives. These sponsored for the complete four years thereby channelling the various resources centres serve 1,600 students on a daily of study. for community development activities. basis. A comparison of marks between Sterlite follows a bottom up process, where quarterly and half yearly exams prove that Free Note Books Distribution people are involved right from the planning the pass percentage is increased by 10% Note books supplied to the 1,600 evening to implementation of projects. We strongly (from 75% to 85%). ‘Parent -Teacher meets’ study centre students including the poor feel that community ownership is essential are periodically conducted to encourage students in and around Thoothukudi for the success of projects and encourages parent’s participation in promoting education. (Tuticorin). 54 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Besides, extending support to the PHCs, Sterlite also supports PHCs in Pulse Polio Immunisation camps in publicity initiatives and transportation for smooth conduct. The Sterlite CSR team had made house visits and identi ed 162 children, who would otherwise have failed to immunise. Sterlite aims at achieving ‘Polio Free Zone’ Status in its area of operations. More than 19,000 children were covered by these centres under pulse polio program. Advertisements were also released in local cable network and FM radio to communicate the message to to the people about pulse polio event.
Industrial Intervention on HIV –AIDS Sterlite observed World AIDS day on Dec 1, 2010 and all employees wore red ribbon and spread the awareness on the deadly disease.
Health: emphasis on preventive, curative and A public rally was held in Tuticorin town in Objectives: rehabilitative aspects of health. Sterlite partnership with Suryan FM and more than • To contribute towards Mother and is operating six rural health clinics in the 500 people participated in the event. Child Care. neighbourhood providing health access • To offer holistic health services to to two panchayats on a weekly basis Blood Donation Camp rural communities. covering a population of 6,270, bene ting Sterlite Industries Red Ribbon Club, in • To provide need based health camps. 1,250 - 1,500. These centres offer patients association with Government Blood Bank, • To support Government Health with free health screening, medicines and organised a Blood Donation Camp. The Initiatives. referral services as follow up. camp aims at creation of awareness on the • To bring behavioural change in importance of Blood Donation in the present the rural communities. General Health Camps Scenario. More than 40 employees donated • To initiate Awareness in HIV–AIDS / Besides rural health clinics, a full- edged blood in the camp held at Government Blood Donation. medical team also organises health camps hospital campus, Tuticorin. every month in the outskirts of Tuticorin Initiatives: and in coastal areas. These camps offer Project Clean Hand Support to Government hospital: patients with general screening, treatment The objective of this project was to bring — Donated bed material worth two lakhs with free medicines. Around two camps hand washing behaviour change among to Government Hospital,Tuticorin were conducted and it has bene ted the rural communities especially in the on Feb 19, 2011 in the presence of 568 people. target villages (Therkuveerapandiapuram, Hon’ble Minister for Social Welfare, Millavittan, Pandarampatty, Govt. of Tamil Nadu. Polio Eradication Project Vadakusilukanpatty, Nainarpuram, Rural Health Clinics Sterlite extended support to four Primary Saminattham, T.Kumaragiri), to Sterlite follows a holistic approach in health Health Centres (PHC) in three panchayats demonstrate hand washing done for all the care services to the rural communities to enhance the quality of health care schools on every month and to distribute in the neighbourhood. The strategy lays services of PHCs. bathing soaps to all children. More than Sterlite Industries (India) Ltd. Annual Report 2011 55
500 children are bene ting from of this
programme. An awareness programme Company Overview was conducted for the general public and women Self Help Groups (SHGs) were organised and pamphlets were distributed.
Model Village: Objectives: • Health : To provide better health services and to create polio free zone. Business • Education : To achieve 100% enrolment. Review • Livelihood : To create a supplementary income for the families • Agriculture : Transfer of latest production technologies to increase productivity and to provide health care for livestock. Development • Infrastructure : Access to portable This has resulted in no school drop • To encourage community participation Sustainable drinking water and to create a model outs in the village. Around 75 birthdays in village suf ciency. Sanitation Block. were celebrated during the year. Many of our employees participated in the Drinking water sump in Villages birthday celebrations at the village level Vadakusilukanpatty: Vadakkusilukkanpatty and all these birthday celebrations were Constructed underground drinking water Milavittan sponsored by our employees. sump in Vadakusilukanpatty village at a TherkuVeerapandiapuram cost of ` 2.10 lakhs under Namaku name Governance
With the objective of improving the Thittam with water holding capacity of Corporate Child Friendly Village nutritional security of the household, 30,000 litres. The Company contributed One of the major interventions in the vegetable seed kits were distributed to 2000 33% of the project cost. This was model village is the launch of child families covering six villages. The rural dedicated to the public in October 2010. friendly village’s concept. In addition families were motivated and encouraged to to that education, health and women raise backyard vegetable gardens. Around Drinking water sump in Milavittan: empowerment are also the key focus seven varieties of seeds were distributed to Construction of underground drinking areas and the work carried out in the the families. The community members were water sump with water holding capacity of model village is given below. given information about how to sow the 1,50,000 litres is in progress in Milavittan Statements Financial seeds and manure application. Each family village. This project was taken up under To ensure that - has harvested 600-750g of vegetables per Namaku name Thittam at a cost of ` 6.5 • All school age children are in school. day continuously for 60 days in a year. This lakhs and company contributed 50% of the • There is no child labour in the village. activity has improved the household food project cost. The project will be dedicated • All children are immunised. security, thereby improving the nutritional to the public in August 2011. • All children possess a valid birth status of the children. certi cate. Drinking water project in South • All households are nutritionally secure. Rural Infra Structure: Veerapandiapuram: Objectives: To overcome the drinking water crisis in Celebrated the rst birthday of all babies • To improve basic amenities in the south Veerapandiapuram, the Panchayat in the project villages and used that event villages. Company has initiated integrated drinking as a platform for creating awareness • To support Government rural water project at a cost of ` 34 lakhs under on the concept of child friendly villages. infrastructure development initiatives. Namaku name Thittam. The Company has 56 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
contributed 50% of the project cost. The understand customer perceptions to project work will commence in the month modify the products according to the of April 2011 and it will be dedicated to market demand. public in August 2011. Implementation: Sterlite Women Empowerment The Project was implemented in Project ( SWEP) partnership with six local NGOs. Around Objectives: 25 eld level group organisers are playing • To empower women socially and a key role in forming women groups at the economically. village level. Periodic training programmes • To generate supplementary income for were organised for the women groups women Self help Groups. which include training in book-keeping, • To provide training to upgrade the skills leadership qualities and decision making. of women and to create opportunities The women SHGs hold regular monthly for viable economic activities. meetings and repay regularly, and use • To create market linkages for trained bookkeepers for proper book- economic activities of women SHGs. for empowering rural and coastal women. keeping. The monthly meetings provide a • To act as a catalyst in linking resources It was launched on March 5, 2005. The platform for sharing and discussing broad from Government, NGOs, Banks and project has achieved formation of more social, legal, political and economic issues corporate for the success of SHGs. than 1,000 Self-Help Groups covering that affect their lives. Depending on the around 15,000 rural women from group’s interest, the income generation Details of the Project: marginalised sections of the society. More programmes are identi ed and they are The project design was evolved while than 250 groups have taken up pro table trained in basic skills. Exposure visits undertaking a need assessment study Income Generation Activities. Sterlite paid were organised for the group members in three villages. The basic information attention to micro- nance as a strategy and this has helped them to learn about the village like the number of capable of reaching women and involving from other peoples experiences. The households, infrastructure, agriculture them in the development process. The groups are recognised by the District pattern, employment, health facilities, micro- nance grass root institutions have Women Development Corporation of education were collected with the help of a made great strides toward identifying the Government of Tamil Nadu. The questionnaire by the project team of Sterlite barriers to women’s access to nancial institutional support is arranged by linking Industries. PRA methods were adopted services and developing ways to overcome the groups with recognised banking for collecting more information about the those barriers. Sterlite initiatives have institutions. The groups were exposed to villages. A number of interactions were held helped the women to have access to various markets and they were taught the with the community members for prioritising working capital and training. The micro- skills of marketing. The groups repay the the community needs. The interactions nance have helped to mobilise women’s bank loan in easy instalments. helped to understand the issues faced by productive capacity to alleviate poverty the women in rural areas. Women have and maximise economic output Results: limited or no access to formal credit. They The income generation programmes borrow money from money lenders for The income generation activities vary have enabled the women to increase domestic purposes and repay with a high from pickle processing to dry ower their family income and in an average, rate of interest. Women in rural areas are making, household provision supply, they earn ` 3,000 - 3,500 per month under paid and working in unorganised candle making, milk vending, rabbit as additional source of income. During informal sectors. Keeping this background in rearing, vessels rental and petty shops. the reporting period, the groups have mind, Sterlite is giving priority in increasing SHGs displayed their products in District availed loan, ranging from ` 50,000 to women’s access to nancial services. level Exhibitions held in Tuticorin and ` 2,00,000. The project has enabled the The Sterlite Women Empowerment they also put up stalls in our company women to have greater access to capital Project (SWEP) was initiated by Sterlite campus. This also exposed them to credit. As a result, women have taken Sterlite Industries (India) Ltd. Annual Report 2011 57
up income generation activities and this Introduction Activity
has substantially helped them to increase The Horticulture Department, Ottapidaram Demonstration trials have been initiated Company Overview their family income. block, in association with Sterlite, has in 110 farmer’s elds and trial is in good undertaken projects in the fourteen progress. Tissue cultured banana saplings International Women’s Day villages, for the bene t of farmers. are distributed free of cost to 80 farmers Celebrations and hybrid vegetable seeds to 30 farmers. Sterlite celebrated International Women’s Plan: day by organising a grand public function • Transfer of latest production Veterinary Camps of SHG women members under the technologies to increase productivity. Sterlite conducted periodic Veterinary Sterlite Women Empowerment Project on • Laying out of demonstration for the Camps in co-ordination with Tamil Nadu Business March 8 of every year, since 2006. The impact area under horticulture. Animal Husbandry Department to support Review programme served to create awareness • Support of input supply in farmers in cattle management to eradicate about International Women’s Day and appropriate time. “Blue Tongue Disease” in our area of to encourage and inspire more SHG • Information / Education / Communication operations. During the reporting year, six women under SWEP to undertake Income & Capacity building. camps have been conducted in six villages Generation Projects. The most interesting covering 1,284 cattle. part of this function was the parade and Approaches: Development drill performed by over 7000 SHGs, which • Improving knowledge base of farmers. Coastal Livelihood Project (CLP) Sustainable is the rst and largest of its kind in this • Exposure to modern and up-to-date Sterlite Industries Ltd. launched the part of the state. Awards for excellence cultivation technologies. ‘Coastal Livelihood Project’ to promote in Income Generation Projects, for the 32 • Increasing productivity through tissue technical skills among coastal youth in best SHGs, 20 Entrepreneurs, and also for culture varieties and hybrid varieties. Tuticorin. The 11 lakh project is to enable 6 respective NGOs were also distributed • Conducting demonstrations. them to get employment in different on the occasion. A variety of folk dances like Karagaatam, Oyilattam, Kolaattam, Governance OyilKummi, and Villupattu were performed Case Study Corporate by the SHGs. Various sports events were conducted and prizes distributed. Case Study No. : SWEP March 2010-11 Location : Tuticorin Tailoring Training Centre Subject (Social/Economic/Environment) : Economic To offer vocational training for livelihood Partner (GO / NGO / Others) : Chevalier Roche Society for women, six tailoring centres are Period of Project Implementation : 1 year functioning very successfully. The rst Title of your Project or Case Study : Packing of refreshments in small packets Purpose and Objective / Felt need : JeyaLakshmi / Geetha / Sathya belongs such institute which was started with Statements to the SHG of Muthu and Tamira Sangamam, residing at Anandnagar. They have started the Financial Sterlite’s help in 1999 and trainees have group in 2008. They are 15 members in the group in the age group of 25-30. All the members are taken up ready made garment units as married and have children. During every group meeting ,the SHG staff motivated the members to utilise the time, towards the generation of income and to be helpful to families. income generation activity supplement Brief Background / Description of your Project : The eatables are procured in bulky quantities with income for their families. Currently every week for ` 7,000/-. Every day, they start the work of packing at 10 a.m. and work till 3 p.m. 69 women are undergoing training. Results (Cost-bene t Analysis / Quantitative Indicators / Qualitative) : Investment = 3 members Investment + Loan Agriculture = ` 15,000 + ` 12,000 Objectives Pro t = ` 2,000 /- for each member To increase the income of farmers per Quotes from different stakeholders of the project : unit land / per unit of irrigation water. Sathya says, “The income which I am getting is being utilised for my children’s education. Increase horticulture area substantially JeyaLaksmi says, “My needs are met by my income. I am independent.” Geetha fondly remembers the day of starting up her business and thanks the PROJECT to utilise less water and realise more FOCUS - “Women to turn into Entrepreneurs.” prices. 58 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Our community development approach is based on Public-Private-Panchayat- Partnership (4P) model. Our strategy for community engagement is intensive, comprehensive, long term and sustainable. We have constructive partnerships with like-minded organisations including government agencies, Non Governmental Organizations, local communities and Panchayats, for functioning our community development initiatives. Our community development process involves comprehensive engagement / interactions with the local community. The data for need assessment and baseline studies is collected based on the “Participatory Rural Appraisal” interviews with village heads, elds, involving Non Government in various CSR activities during the Sarpanchs, Panchayat members, farmers, Organizations. In the year 2010-11, ` 11 nancial year 2010-11. Activities like tree SHG members and other stakeholders. lakh was spent on the project, offering plantation, health camps, sponsoring child Their feedback is used to develop new vocational education to more than 240 birthday are some of the events where programs and improve on the existing ones. people. Around 11 courses are offered employees have actively participated. We are signatories of the United under the initiative that include fashion No of Amount Nations Global Compact, TERI-BCSD, Employees contributed by designing, desktop publishing, shipping Year and National Population Stabilisation participated in employees for management, nurse assistant training, CSR activities CSR activities Fund and network with the national garment manufacturing and designing. 2009 - 2010 299 ` 1,62,580 bodies including the Federation of Sterlite has identi ed various areas of 2010 - 2011 297 ` 2,78,577 Indian Chambers of Commerce and skills development need to be offered to Total 596 ` 4,41,157 Industry (FICCI), Confederation of Indian the shing community members such as: Industries (CII) and the Federation of • Computer training Zinc Indian Mineral Industries. • Beautician We strongly believe in giving it back • Nursing assistant to the society and are resolute on With a strong team of 150 CSR • Embroidery enhancing the socio-economic well being professionals, specialists and grass root • Tailoring of the communities in the vicinity of our workers, we have a total outreach of • Shipping management operations. We are conscientious of the 180 villages, 5 lakh people and 54,000 • JCB and Crane operator impact of our operations on the society households, in four districts of Rajasthan and environment, and strive to manage (Rajsamand, Bhilwara, Chittorgarh and These trainings have given con dence the same with high degree ef ciency & Udaipur) and one district of Andhra Pradesh to the young men and women of coastal empathy. We have several high impact (Vishakapatnam). We have done intensive areas and helped them to nd a job in initiatives / projects in place to achieve interventions in 101 villages through the Tuticorin town. During the reporting year, sustainable socio-economic development of “Integrated Panchayat Development we have achieved an employability rate of communities. Our community development Programme”. In the rest of the identi ed 78%. On an average, they earn ` 3,000 to efforts are focused on fostering self-reliance villages, we adopt an extensive approach. ` 4,000 per month. through education, livelihood interventions, Internal reviews and audits of our vocational trainings, integrated village community interventions are periodically Employee volunteering development, empowerment of women and conducted to facilitate transfer of autonomy Around 297 employees have participated social mobilisation. to the villages and expand our reach. Sterlite Industries (India) Ltd. Annual Report 2011 59
Snapshots FY 2011: Education 7. Support to schools at Vishakapatnam
Health & Hygiene 1. Provided scholarship amounting to by distributing lab items bene ting Company Overview 1. Organised rural medical camps in ` 83,000/- to 23 talented students for 890 students. collaboration with HelpAge India higher education through SUMEDHA. 8. Distributed 150 sets of table chairs & ACE - bene ting around 1 Lakh 2. Sponsored 9 girls of Zawar and in Senior Secondary School (Narela) patients; and medical check-up camps Rampura Agucha for higher education bene ting 250 students at Chanderiya; at all Child Welfare Centers (CWC) at Vedanta PG Girls College (Ringus). distributed notebooks, bags and bene ting 544 children in 18 centres. 3. Bene ted 1,800 students in 20 schools stationery items for the school children at 2. Organised several need based at Rampura Agucha and Zawar, under Vishakapatnam bene ting 960 students; camps like Family Planning Camps, Siksha Sambal Project. and distributed uniforms to BPL students Business immunisation camps, Surgical Camp, 4. Organised remedial classes for poor in 185 schools, bene ting 1,350 students Review Gynaecology Camps, Anti-Tobacco performers bene ting 1,200 students at Rampura Agucha, in collaboration Camps, Eye Care Camps, Blood from grade VIII to XII. with Bharat Vikas Parishad. Donation camps etc., bene ting 5. Bene ted 1,250 SHG women through around 22,000 people. Adult Education Camps. Sustainable Livelihood 3. Eye care campaigns were conducted 6. Regular monitoring of existing 1. Tailoring training to 210 village in collaboration with Sankar 18 CWCs. Vedanta Bal Chetna women, hand loom training to 50 SHG Development Foundation - bene tting around 1,800 Anganwadi Project - bene ting more members and Meenakari training to Sustainable students at Vishakapatnam. than 50,000 children in the age 30 women at Rampura Agucha. 4. Free medical treatment to 86,878 group of 3-6 years through 1,500 2. Distributed 15 sewing machines to rural people through the Company-run centres ensuring their health care, trained women at Vishakapatnam. hospitals; and nancial help of around imparting non-formal education in 3. SHG women of Chanderiya participated ` 2 Lakh to 1,010 widows by providing play-way method to improve the in ‘Mewar Udyog Utsav, 2010’ for 6 free medicines through Swami attendance in recorded time at each days, wherein they had exhibited SHG Vivekanand Seva Nyas. centre. Regular monitoring of existing products and sold various domestic Governance
5. Installed 10 R.O. plants to provide safe computer education programmes in items amounting to ` 32,000. Corporate drinking water and reduce water borne 682 government schools bene ting 4. Distributed tool kits to 40 rural artisans diseases in 10 IPDP villages. 68,000 students. (including carpenter, cobblers, drummers, pipe tters, blacksmith and cycle repairing) at Chanderiya for enhancing family income levels by promoting traditional vocation in the villages. Statements Financial Agriculture & Animal Husbandry 1. Bene ted more than 45,000 cattle through various cattle camps, ensuring 100% cattle vaccination. 2. Organised farmers’ trainings in joint collaboration with Government Agriculture Department, bene ting 618 farmers. 3. Distributed hi-yield seeds and fertilizer kits to 1,000 farmers. 4. Wadi project started for 17 farmers at Chanderiya. Wadi structure developed consisting of Guava and lemon plants 60 Sterlite Industries (India) Ltd. Annual Report 2011 www.sterlite-industries.com
Case Study