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(Exact name of Registrant as
specified in its charter)
Federative Republic of Brazil
(Jurisdiction of incorporation
or organization)
Avenida Graça Aranha, No. 26
20030-900
Rio de Janeiro, RJ, Brazil
(Address of principal executive
offices)
Securities registered or to be registered pursuant to
Section 12(b) of the Act:
Title of Each Class
Name of Each Exchange on Which Registered
Preferred class A shares of
CVRD, no par value per share
New York Stock Exchange*
American Depositary Shares
(evidenced by American depositary receipts) each representing
one preferred
class A share of CVRD
New York Stock Exchange
Common shares of CVRD, no par
value per share
New York Stock Exchange*
American Depositary Shares
(evidenced by American
depositary receipts) each representing one common share of CVRD
New York Stock Exchange
6.875% Guaranteed Notes due 2036,
issued by Vale Overseas
New York Stock Exchange
8.250% Guaranteed Notes due 2034,
issued by Vale Overseas
New York Stock Exchange
6.250% Guaranteed Notes due 2017,
issued by Vale Overseas
New York Stock Exchange
6.250% Guaranteed Notes due 2016,
issued by Vale Overseas
New York Stock Exchange
*
Shares are not listed for trading, but only in connection with
the registration of American Depositary Shares pursuant to the
requirements of the New York Stock Exchange.
Securities registered or to be registered pursuant to
Section 12(g) of the Act: None
Securities for which there is a reporting obligation pursuant
to Section 15(d) of the Act: None
The number of outstanding shares of each class of stock of
CVRD as of December 31, 2006 was:
1,471,607,838 common shares, no par value per share
944,585,684 preferred class A shares, no par value per share
6 golden shares, no par value per share
Indicate by check mark if the registrant is a well-known
seasoned issuer, as defined in Rule 405 of the Securities
Act. Yes þ No o
If this report is an annual or transition report, indicate by
check mark if the registrant is not required to file reports
pursuant to Section 13 or 15(d) of the Securities Exchange
Act of
1934. Yes o No þ
Indicate by check mark whether the registrant (1) has filed
all reports required to be filed by Section 13 or 15(d) of
the Securities Exchange Act of 1934 during the preceding
12 months (or for such shorter period that the registrant
was required to file such reports) and (2) has been subject
to such filing requirements for the past
90 days. Yes þ No o
Indicate by check mark whether the registrant is a large
accelerated filer, an accelerated filer, or a non-accelerated
filer. See definition of “accelerated filer and large
accelerated filer” in
Rule 12b-2
of the Exchange Act. (Check one):
Large accelerated
filer þ Accelerated
filer o Non-accelerated
filer o
Indicate by check mark which financial statement item the
registrant has elected to
follow. Item 17 o Item 18 þ
If this is an annual report, indicate by check mark whether the
registrant is a shell company (as defined in
Rule 12b-2
of the Exchange
Act). Yes o No þ
Aluminum oxide. It is the main component of bauxite, and
extracted from bauxite ore in a chemical refining process. It is
the principal raw material in the electro-chemical process from
which aluminum is produced.
Anthracite
The hardest coal type which contains a high percentage of fixed
carbon and a low percentage of volatile matter. Anthracite is
the highest rank coal and it contains approximately 90% fixed
carbon, more than any other form of coal. Anthracite has a
semi-metallic luster and is capable of burning with little
smoke. Mainly used for metallurgical purposes.
Austenitic stainless steel
Steel that contains significant amount of chromium and
sufficient nickel to stabilize the austenite microstructure,
giving to the steel good formability and ductibility and
improving its high temperature resistance. On average,
austenitic stainless steels usually contain approximately 8-10%
nickel. They are used in a wide variety of applications, ranging
from consumer products to industrial process equipment, as well
as for power generation and transportation equipment, kitchen
appliances and many other applications where strength, corrosion
and high temperature resistance are required. Nickel use in
nickel-bearing or austenitic stainless steels accounts for
60%-65% of annual global primary nickel consumption.
Austenitic stainless steel ratio
The ratio of nickel-based stainless steels (austenitic steels)
relative to all stainless steels produced.
Bauxite
A rock composed primarily of hydrated aluminum oxides. It is the
principal ore of alumina, the raw material from which aluminum
is made.
Beneficiation
A variety of processes whereby extracted ore from mining is
reduced to particles that can be separated into mineral and
waste, the former suitable for further processing or direct use.
Coal
Coal is a black or brownish-black solid combustible substance
formed by the decomposition of vegetable matter without access
to air. The rank of coal, which includes anthracite, bituminous
coal (both are called hard coal), subbituminous coal, and
lignite, is based on fixed carbon, volatile matter, and heating
value.
Cobalt
Cobalt is a hard, lustrous, silver-gray metal found in ores, and
used in the preparation of magnetic, wear-resistant, and
high-strength alloys (particularly for jet engines and
turbines). Its compounds are also used in the production of
inks, paints, and varnishes.
Coke
Coal that has been processed in a coke oven, for use as a
reduction agent in blast furnaces and in foundries for the
purposes of transforming iron ore into pig iron.
Coking coal
A bituminous hard coal with a quality that allows the production
of coke. Normally used in coke ovens for metallurgical purposes.
Concentration
Physical, chemical or biological process to increase the grade
of the metal or mineral of interest.
A reddish brown metallic element. Copper is highly conductive,
both thermally and electrically. It is highly malleable and
ductile and is easily rolled into sheet and drawn into wire.
Copper concentrate
Material produced by concentration of copper minerals contained
in the copper ore. It is the raw material used in smelters to
produce copper metal.
DR
Direct Reduction. Process that removes oxygen from iron ore by
using natural gas or coal. The resulting product has an iron
content of
90-92%.
DRI
Direct Reduced Iron. Iron ore (lump or pellets) converted by the
Direct Reduction process, used mainly as a scrap substitute in
electric arc furnace steel making.
DWT
Deadweight ton. The measurement unit of a vessel’s capacity
for cargo, fuel oil, stores and crew, measured in metric tons of
1,000 kg. A vessel’s total deadweight is the total weight
the vessel can carry when loaded to a particular load line.
Fe unit
A measure of the iron content in the iron ore that is equivalent
to 1% iron content in one metric ton of iron ore.
Ferritic steel
Steel that contains significant amount of chromium, but does not
contain nickel to stabilize the austenite microstructure.
Ferroalloys
Ferroalloys are alloys of iron that contain one or more other
chemical elements. These alloys are used to add these other
elements into molten metal, usually in steel making. The
principal ferroalloys are those of manganese, silicon and
chromium.
FOB
Free on Board. It indicates that the purchaser pays for
shipping, insurance and all the other costs associated with
transportation of the goods to their destination.
Gold
A precious metal sometimes found free in nature, but usually
found in conjunction with silver, quartz, calcite, lead,
tellurium, zinc or copper. It is the most malleable and ductile
metal, a good conductor of heat and electricity and unaffected
by air and most reagents.
Grade
The proportion of metal or mineral present in ore or any other
host material.
HBI
Hot Briquetted Iron. Direct reduced iron that has been processed
into briquettes. Because DRI (direct reduced iron) may
spontaneously combust during transportation, HBI is preferred
when the metallic material must be stored or moved.
Iridium
A dense, hard, brittle, silvery-white transition metal of the
platinum family that occurs in natural alloys with platinum or
osmium. Iridium is used in high-strength alloys that can
withstand high temperatures, primarily in high-temperature
apparatus, electrical contacts, and as a hardening agent for
platinum.
Kaolin
A fine white aluminum silicate clay used as a coating agent,
filler, extender and absorbent in the paper, ceramics and
pharmaceutical industries.
Iron ore or manganese ore with the coarsest particle size in the
range of 6.35 mm to 50 mm diameter, but varying slightly between
different mines and ores.
Manganese (Mn)
A hard brittle metallic element found primarily in the minerals
pyrolusite, hausmannite and manganate. Manganese is essential to
the production of virtually all steels and is important in the
production of cast iron.
Methanol
An alcohol fuel largely used in the production of chemical and
plastic compounds.
Mineral deposit(s) or mineralized material(s)
A mineralized body that has been intersected by a sufficient
number of closely spaced drill holes
and/or
underground/surface samples to support sufficient tonnage and
grade of metal(s) or mineral(s) of interest to warrant further
exploration-development work.
Mineral resource
A concentration or occurrence of minerals of economic interest
in such form and quantity that could justify an eventual
economic extraction. The location, quantity, grade, geological
characteristics and continuity of a Mineral Resource are known,
estimated or interpreted from specific geological evidence
through drill holes, trenches
and/or
outcrops. Mineral Resources are
sub-divided,
in order of increasing geological confidence, into Inferred,
Indicated and Measured Resources.
Nickel
A silvery white metal that takes on a high polish. It is hard,
malleable, ductile, somewhat ferromagnetic, and a fair conductor
of heat and electricity. It belongs to the iron-cobalt group of
metals and is chiefly valuable for the alloys it forms, such as
stainless steel and other corrosion-resistant alloys.
Nickel-in-matte
An intermediate smelter product that must be further refined to
obtain pure metal.
Ntk
Net ton (the weight of the goods being transported excluding the
weight of the wagon) kilometer.
Open-pit mining
Method of extracting rock or minerals from the earth by their
removal from an open pit. Open-pit mines for extraction of ore
are used when deposits of commercially useful minerals or rock
are found near the surface; that is, where the overburden
(surface material covering the valuable deposit) is relatively
thin or the material of interest is structurally unsuitable for
underground mining.
Oxides
Compounds of oxygen with another element. For example, magnetite
is an oxide mineral formed by the chemical union of iron with
oxygen.
Palladium
A silver-white metal that is ductile and malleable, used
primarily in automobile-emissions control devices, jewelry,
electrical and chemical applications.
Pellet feed fines or PFF (Ultra-fine)
Ultra-fine iron ore (less than 0.15 mm) generated by mining
and grinding. This material is aggregated into pellets through
an agglomeration process.
Agglomerated ultra-fine iron ore particles of a size and quality
suitable for particular iron making processes. Our pellets range
in size from 8 mm to 18 mm.
Pig iron
Product of smelting iron ore usually with coke and limestone in
a blast furnace.
Platinum
A dense, precious, grey-white transition metal that is ductile
and malleable and occurs in some nickel and copper ores.
Platinum is resistant to corrosion and is used in jewelry,
laboratory equipment, electrical contacts, dentistry,
automobile-emissions control devices, flat panel TVs and hard
disk drives.
Platinum-group metals (PGMs)
Consist of platinum, palladium, rhodium, ruthenium, osmium and
iridium, of which osmium has no industrial application (no
economic interest), while platinum and palladium have the
greatest economic interest.
Potash
A potassium chloride compound, chiefly KCl, used as simple
fertilizer and in the production of mixture fertilizer.
Precious metals
Metals valued for their color, malleability, and rarity, with a
high economic value driven not only by their practical
industrial use, but also by their role as investments and a
store of value. The widely-traded precious metals are gold,
silver, platinum and palladium.
Primary aluminum
White metal that is obtained in the electro-chemical process of
reduction of the aluminum oxide.
Probable ore reserves
The economically mineable part of an Indicated, and in some
circumstances, Measured Mineral Resource. It implies that
appropriate assessments have been carried out, with
consideration of mining, beneficiation process, economic,
marketing, legal, environmental, social and governmental
factors. These assessments demonstrate at the time of reporting
that extraction could be justified.
Proven ore reserves
The economically mineable part of a Measured Mineral Resource.
It implies that appropriate assessments have been carried out,
with consideration of mining, beneficiation process, economic,
marketing, legal, environmental, social and governmental
factors. These assessments demonstrate at the time of reporting
that extraction could be justified.
Reserve or ore reserve
The part of a mineral resource that could be economically and
legally extracted or produced at the time of the reserve
determination. Ore Reserves are
sub-divided
in order of increasing confidence into Probable Ore Reserves and
Proven Ore Reserves.
Rhodium
A hard, silvery-white, durable metal that has a high reflectance
and is primarily used in combination with platinum for
automobile-emission control devices and as an alloying agent for
hardening platinum.
Run-of-mine
(ROM)
Ore in its natural (unprocessed) state, as mined, without having
been crushed.
A hard, white metal that can harden platinum and palladium used
to make severe wear-resistant electrical contacts and in other
applications in the electronics industry.
Secondary, or scrap, nickel
Stainless steel scrap containing small quantities of nickel.
Seaborne market
Comprises the total ore trade (exports) between countries using
ocean bulk vessels.
Silver
A ductile and malleable metal used in photography, coins and
medal fabrication, and in industrial applications.
Sinter feed (Fines)
Iron ore with particles in the range of 0.15 mm to 6.35 mm
diameter. Suitable for sintering.
Sintering
The agglomeration of sinter feed, binder and other materials,
into a coherent mass by heating without melting, to be used as
metallic charge into a blast furnace.
Slabs
The most common type of semi-finished steel. Traditional slabs
measure 10 inches thick and
30-85 inches
wide (and average approximately 20 feet long), while the
output of the recently developed “thin slab” casters
is approximately two inches thick. Subsequent to casting, slabs
are sent to the hot-strip mill to be rolled into coiled sheet
and plate products.
Stainless steel
Alloy steel containing at least 10% chromium and with superior
corrosion resistance. It may also contain other elements such as
nickel, manganese, niobium, titanium, molybdenum, copper, in
order to improve mechanical, thermal properties and service
life. It is primarily classified as austenitic (200 and 300
series), ferritic (400 series), martensitic, duplex or
precipitation hardening grades.
Stainless steel scrap ratio
The ratio of secondary nickel units (either in the form of
nickel-bearing, stainless steel scrap, or in alloy steel,
foundry and nickel-based alloy scrap) relative to all nickel
units consumed in the manufacture of new stainless steel.
Thermal coal
Refers to the type of coal that is suitable to energy generation
after its steaming properties (for use in thermal power
stations).
Troy ounce
One troy ounce equals 31.103 grams.
Underground mining
Mineral exploitation in which extraction is carried out beneath
the earth’s surface.
We have prepared our financial statements appearing in this
annual report in accordance with generally accepted accounting
principles in the United States (U.S. GAAP), which differ
in certain respects from accounting practices adopted in Brazil
(Brazilian GAAP). Brazilian GAAP is determined by the
requirements of Law No. 6,404, dated December 15,
1976, as amended, which we refer to as the Brazilian corporation
law, and the rules and regulations of the Brazilian Securities
Commission (Comissão de Valores Mobiliários),
or CVM. We also publish Brazilian GAAP financial statements in
Brazil, which we refer to as our Brazilian corporation law
financial statements. We use our Brazilian corporation law
financial statements for:
•
reports to Brazilian shareholders;
•
filings with the CVM;
•
determination of dividend payments; and
•
determination of tax liability.
Our financial statements and the other financial information
appearing in this annual report have been translated from
Brazilian reais into U.S. dollars on the basis
explained in Note 3 to our financial statements, unless we
indicate otherwise.
References to “real,”“reais”or
“R$” are to Brazilian reais (plural) and to the
Brazilian real (singular), the official currency of
Brazil. References to “U.S. dollars” or
“US$” are to United States dollars.
Unless otherwise specified, we use metric units.
References to “CVRD” are to Companhia Vale do Rio
Doce. References to “Vale Overseas” are to our
subsidiary Vale Overseas Limited. References to “CVRD
Inco” are to our subsidiary, CVRD Inco Limited. References
to “Inco” are to Inco Limited, which we acquired and
subsequently renamed “CVRD Inco Limited.” References
to “us” or “we” are to CVRD and, except
where the context otherwise requires, its consolidated
subsidiaries.
References to our “ADSs” or “American Depositary
Shares” include both our common American Depositary Shares
(our common ADSs), each of which represents one common share of
CVRD, and our preferred American Depositary Shares (our
preferred ADSs), each of which represents one preferred
class A share of CVRD. American Depositary Shares are
represented by American depositary receipts (ADRs) issued by
JPMorgan Chase Bank, as depositary.
The estimates of proven and probable ore reserves at our mines
and projects and the estimates of mine life, as of
December 31, 2005 and 2006, included in this annual report
have been calculated according to the technical definitions
required by the U.S. Securities and Exchange Commission, or
the SEC. Our staff of experienced geologists and engineers
prepares our reserve estimates. We derived estimates of mine
life described in this annual report from such reserve
estimates. For manganese ore and bauxite deposits, we have
adjusted ore reserve estimates for extraction losses and
metallurgical recoveries during extraction. For iron ore,
kaolin, copper, potash, nickel, PGMs and cobalt, our reserve
estimates are of in-place material after adjustments for mining
depletion and mining losses (or screening and drying in the
cases of PT International Nickel Indonesia Tbk, or PT Inco, and
Goro) and recoveries, with no adjustments made for metal losses
due to processing. See Item 3. Key
information — Risk factors — Risks relating
to our business for a description of risks relating to
reserves and reserve estimates.
As part of our mineral reserves reporting strategy, we
periodically engage independent mining and geological
consultants to review estimates of our mineral reserves for all
operations and new projects. Mineral reserves are subjected to
outside review when significant changes in the reserve model
occur due to the inclusion of new geological information,
changes in production schedules, or changes in economic
assumptions such as costs or product prices.
This annual report contains statements that may constitute
forward-looking statements within the meaning of the safe harbor
provisions of the U.S. Private Securities Litigation Reform
Act of 1995. Many of those forward-looking statements can be
identified by the use of forward-looking words such as
“anticipate,”“believe,”“could,”“expect,”“should,”“plan,”“intend,”“estimate” and
“potential,” among others. Those statements appear in
a number of places and include statements regarding our intent,
belief or current expectations with respect to:
•
our direction and future operation;
•
the implementation of our principal operating strategies,
including our potential participation in privatization,
acquisition or joint venture transactions or other investment
opportunities;
•
our acquisition or divestiture plans;
•
the implementation of our financing strategy and capital
expenditure plans;
•
the exploration of mineral reserves and development of mining
facilities;
•
the depletion and exhaustion of mines and mineral reserves;
•
the future impact of competition and regulation;
•
the declaration or payment of dividends;
•
industry trends, including the direction of prices and expected
levels of supply and demand;
•
other factors or trends affecting our financial condition or
results of operations; and
•
the factors discussed under Item 3. Key
information — Risk factors.
We caution you that forward-looking statements are not
guarantees of future performance and involve risks and
uncertainties. Actual results may differ materially from those
in the forward-looking statements as a result of various
factors. These risks and uncertainties include factors relating
to the Brazilian and Canadian economies and securities markets,
factors relating to the iron ore and nickel businesses and their
dependence on the global steel industry, which is cyclical in
nature, and factors relating to the highly competitive
industries in which we operate. For additional information on
factors that could cause our actual results to differ from
expectations reflected in forward-looking statements, see
Item 3. Key information — Risk factors.
Forward-looking statements speak only as of the date they are
made, and we do not undertake any obligation to update them in
light of new information or future developments. All
forward-looking statements attributed to us or a person acting
on our behalf are expressly qualified in their entirety by this
cautionary statement, and you should not place undue reliance on
any forward-looking statement.
The table below presents selected consolidated financial
information as of and for the periods indicated. You should read
this information together with our consolidated financial
statements appearing in this annual report.
(US$, except recorded dividends and interest on
shareholders’
equity per share in reais and share numbers)
Basic earnings per Common and
Preferred Class A Share(2)
US$
0.30
US$
0.67
US$
1.12
US$
2.10
US$
2.69
Diluted Earnings per Common and
Preferred Class A Share(2)
0.30
0.67
1.12
2.10
2.69
Distributions to shareholders per
share in US$(3)
0.28
0.30
0.34
0.57
0.54
Distributions to shareholders per
share in reais(3)
R$
0.83
R$
0.84
R$
0.98
R$
1.34
R$
1.15
Weighted average number of shares
outstanding (in thousands):
Common shares(2)
1,499,184
1,471,608
1,471,608
1,471,608
1,471,608
Preferred class A shares(2)
810,252
831,428
831,432
831,432
954,426
Total
2,309,436
2,303,036
2,303,040
2,303,040
2,426,034
(1)
We carried out a
two-for-one
stock split in May 2006 and a
three-for-one
stock split in August 2004. Share and per-share amounts for all
periods give effect to the stock splits.
(2)
Each common American depositary
share represents one common share and each preferred American
depositary share represents one preferred class A share.
(3)
Our distributions to shareholders
may take the form of dividends or of interest on
shareholders’ equity. From 1997 to 2003, all distributions
were in the form of interest on shareholders’ equity. In
2004, 2005 and 2006, part of the distribution was made in the
form of interest on shareholders’ equity and part as
dividends. The amount shown represents distributions paid during
the year.
Due to
our dependence on the global steel industry, fluctuations in
demand for steel could adversely affect our
business.
Sales prices and volumes in the global iron ore market depend on
the prevailing and expected levels of demand and supply for iron
ore, and global iron ore demand depends on the global steel
industry. In addition, the stainless steel sector is the largest
global consumer of primary nickel. Primary nickel use in
stainless steel production accounts for over 60% of total
primary nickel demand. Global demand for steel is cyclical. A
number of factors, the most significant of which is the
prevailing level of global demand for steel products, influence
the performance of the global steel industry. During periods of
sluggish or declining regional or world economic growth, demand
for steel products generally decreases, which usually leads to
corresponding reductions in demand for iron ore and nickel.
Driven primarily by strong demand from Chinese steelmakers,
together with a modest expansion in other markets, the global
iron ore market experienced high demand and rising iron ore and
pellet prices from 2003 to 2005. In 2006, the price of iron ore
increased further, due to a continued imbalance between global
demand and supply that was driven by a significant expansion in
demand. However, in 2006 there was a reduction in the price of
blast furnace and direct reduction pellets. For 2007, iron ore
prices increased by 9.5%, while blast furnace and direct
reduction pellet prices increased by 5.28%. Since 2001, global
demand for iron ore has grown at an average annual rate of 9.8%.
We cannot guarantee that iron ore demand will remain at its
current high level or the direction of future prices. Sustained
declines in world contract prices or sales volumes for iron ore
could have a material adverse effect on our revenues.
Consolidation in the steelmaking industry may also lead to
backward integration, which might reduce global demand for iron
ore.
Driven by strong global economic activity and customers’
need to replenish inventories, global stainless steel production
grew 15.8% in 2006, with a significant portion of the increased
production coming from China, which led the way in stainless
steel capacity expansion in 2006. This expansion has driven an
increase in global demand for nickel, which exceeds supply and
has led to higher prices for nickel. We cannot guarantee that
demand for nickel will remain at its current high level or the
direction of future prices for nickel. Sustained declines in
stainless steel production could have a material adverse effect
on our revenues from nickel.
Increased
substitution for nickel applications could adversely affect our
nickel business.
Nickel prices and demand may be negatively impacted by an
increase in scrap nickel usage and by the substitution of
materials other than nickel in current applications. Scrap
nickel competes directly with primary nickel as a source of
nickel for use in the production of stainless steel, and the
choice between them is largely driven by their relative prices
and availability. In 2006, the stainless steel scrap ratio was
48%, compared to 49% in 2005. Recently, Chinese steelmakers have
developed a pig-iron product containing low grades of nickel
that competes with both primary and scrap nickel in the
production of stainless steel.
A
reduction of global demand for Brazilian steel
and/or
agriculture products could reduce the demand for our logistics
services.
The Brazilian agriculture and steel industries are currently the
primary drivers of demand for our logistics services to
customers. The percentage of our logistics revenues attributable
to these industries was approximately 78.6% in 2005, and 71.9%
in 2006. A reduction in world demand for Brazilian steel
and/or
agriculture products could reduce demand for our logistics
services and harm the profitability of our logistics business.
Adverse
economic developments in our principal markets, especially
China, could reduce demand for our products, leading to lower
revenues and profitability.
The global economy is the primary driver of demand in the global
market for iron ore and pellets. In recent years, China has been
the main driver of our sales increases. The percentage of our
total gross revenues attributable to sales to customers in China
was 15.0% in 2005 and 16.7% in 2006 (including CVRD Inco sales
as though we had acquired Inco on January 1, 2006). The
percentage of our gross revenues attributable to sales to
customers from Asian countries other than China was 14.9% in
2005 and 22.7% in 2006 (on the same basis). The percentage of
our gross revenues attributable to sales to European customers
was 28.5% in 2005 and 23.0% in 2006 (on the same basis). A
weakened global economy or a weakened economy in specific
markets where we sell our products, such as China, could reduce
demand for our products, leading to lower revenues and
profitability.
Nickel,
aluminum and copper are actively traded on world commodity
exchanges and their prices are subject to significant
fluctuations.
Nickel, aluminum and copper are sold in an active global market
and traded on commodity exchanges, such as the London Metal
Exchange (LME) and the New York Mercantile Exchange (NYMEX).
Prices for these metals are subject to wide fluctuations and are
affected by many factors, including actual and expected global
economic and political conditions, levels of supply and demand,
the availability and cost of substitutes, inventory, investments
by commodity funds and others and actions of participants in the
commodity markets. Prices for these metals are more volatile
than iron ore and pellet prices because they respond more
quickly to actual and expected changes in market conditions.
The
mining industry is an intensely competitive industry, and we may
have difficulty effectively competing with other mining
companies in the future.
Intense competition characterizes the global iron ore and nickel
industries. We compete with a number of large mining companies.
Some of these competitors possess substantial iron ore and
nickel deposits at locations closer to our principal Asian and
European customers. Competition from iron ore and nickel
producers may result in our loss of market share and revenues.
Our aluminum, ferroalloys, copper and other businesses are also
subject to intense competition and to similar risks.
Demand
for our products in peak periods may outstrip our production
capacity, rendering us unable to satisfy customer
demand.
Our ability to rapidly increase production capacity to satisfy
increases in demand for our products is limited. In periods when
customer demand exceeds our production capacity, we generally
meet excess customer demand by reselling iron ore, iron ore
pellets or nickel purchased from joint ventures or third
parties. If we are unable to satisfy excess customer demand by
purchasing from joint ventures or third parties, we may lose
customers. Similarly, because it takes time to increase
production capacity, we may fail to complete expansion projects
and greenfield projects in time to take advantage of the current
high levels of worldwide demand for iron ore and nickel. In
addition, operating at or above full capacity may expose us to
higher costs, including demurrage fees due to capacity
restraints in our mines, railroads and ports.
Political,
economic, regulatory and social conditions in the countries in
which we operate or have projects could adversely impact our
business and the market price of our securities.
Our financial performance may be negatively affected by general
economic, political, regulatory and social conditions in
countries in which we have significant operations or projects,
particularly Brazil, Canada, New Caledonia and Indonesia. Actual
or potential political changes and changes in economic policy
may undermine investor confidence, result in economic slowdowns
and otherwise adversely affect the economic and other conditions
under which we operate in ways that could have a material
adverse effect on our business. Governments in emerging
economies such as Brazil, New Caledonia and Indonesia frequently
intervene in the economy and occasionally make substantial
changes in policy that could adversely affect
exchange rates, inflation, interest rates, rates of taxes or
royalties and the economic and regulatory environment in which
we operate. In New Caledonia, a planned referendum in 2014 may
result in New Caledonia becoming fully independent from France,
which could result in significant political and economic changes
in New Caledonia and may adversely affect our Goro project. In
addition, actions by non-governmental organizations or community
activist groups may disrupt our operations or projects.
Acts
by protestors may hamper our mining and logistics operations and
projects.
Protestors, including protestors from indigenous communities
living near areas where we operate, have taken actions to
disrupt our operations and projects, and they may continue to do
so in the future. Although we vigorously defend ourselves
against illegal acts, while continuing to support the
communities living near our operations, future attempts by
protestors to harm our operations could adversely affect our
business. For more information, see Item 4. Information
on the company — Regulatory matters —
Environmental matters — Brazil.
Our PT
Inco operations are subject to significant risks.
In addition to political, economic and other risks described
separately, our PT Inco nickel operations in Indonesia are
subject to significant risks. In particular:
•
Groundwork on PT Inco’s new hydroelectric power project on
the Larona River near the village of Karebbe has been suspended
since January 2006 pending the amendment of a required permit
issued by the Minister of Forestry on terms acceptable to PT
Inco. Delays in obtaining the required permits may adversely
affect the timing and cost of the Karebbe project, impair PT
Inco’s ability to achieve planned increases in
nickel-in-matte
production and raise PT Inco’s production costs.
•
Under PT Inco’s Contract of Work with the Indonesian
government, PT Inco is required, subject to economic and
technical feasibility, to construct production plants at Pomalaa
in Southeast Sulawesi and Bahodopi in Central Sulawesi. The
obligation to build a commercial plant at Pomalaa is deemed
satisfied through the later of 2008 or the termination of PT
Inco’s Cooperative Resources Agreement with PT Antam Tbk
(an agreement providing for the supply by PT Inco of saprolite
ore to PT Antam), after which PT Inco must deliver a report
evaluating the technical and economic feasibility of
constructing a commercial plant at Pomalaa. Subject to technical
and economic feasibility, the Contract of Work requires PT Inco
to build the Bahodopi facility by about 2010. Failure to meet
these commitments under the Contract of Work would entitle the
Indonesian government, after a cure period of 180 days
following the date of a notice of default, to close and require
PT Inco to relinquish the mining areas related to the expansion
project.
•
Regulations issued by the Indonesian Minister of Forestry
relating to mining activities have imposed new restrictions on
mining in protected forests. If these regulations restrict PT
Inco’s ability to mine in certain areas included in its
Contract of Work, they could result in a reduction of PT
Inco’s estimated ore reserves and adversely affect PT
Inco’s long-term mining plans.
•
PT Inco’s Contract of Work may not be extended beyond its
scheduled expiration in 2025. For more information about the
Contract of Work, see Item 4. Information on the
company — Regulatory matters —
Mining — Indonesia.
The
requirement to build a nickel processing facility in the
Canadian Province of Newfoundland and Labrador by the end of
2011 involves risks.
Under definitive agreements with the Canadian Province of
Newfoundland and Labrador, we have agreed to build a commercial
nickel processing facility in this Province by the end of 2011
to treat all nickel ores or
intermediate products from our Voisey’s Bay operations for
the production of finished nickel and cobalt products. This
project involves several risks and challenges, including the
following:
•
Failure to complete the facility on the timetable agreed with
the Province of Newfoundland and Labrador could subject us to
sanctions under our agreements with the Province, including the
potential forfeiture of the lease to conduct our Voisey’s
Bay operations.
•
As currently proposed, the new processing facility will rely on
new hydrometallurgical processing and other technologies, and
there can be no assurance that these technologies will be
successful on a commercial basis. Unforeseen challenges in
implementing these new technologies could lead to delays in the
start-up of
commercial production or lead to higher than expected capital or
operating costs that could adversely affect the project’s
profitability.
•
We currently rely on the availability of Voisey’s Bay
nickel concentrates to maintain production levels at our
facility in the Canadian Province of Manitoba, but such
shipments must eventually cease under the agreement with the
Province of Newfoundland and Labrador. If we are unable to
develop sufficient low-cost sources of nickel concentrate to
supply our Manitoba operations in the future, we may be unable
to maintain nickel production levels at our Manitoba facility
without purchasing third-party nickel intermediates, which could
increase our overall unit production costs for nickel.
Our
development projects are subject to risks that may result in
increased costs, or delay or prevent their successful
implementation.
We are investing heavily to further increase our production
capacity, logistics capabilities and to expand the scope of
minerals we produce. Our expansion and mining projects are
subject to a number of risks that may cause them to be less
successful than anticipated, including the following:
•
We may encounter delays or higher than expected costs in
obtaining the necessary equipment or services to build and
operate our projects.
•
We may fail to obtain, or experience delays or higher than
expected costs in obtaining, the required permits to build our
projects. We have not yet obtained certain construction,
environmental and operating permits for the Goro project, the
most significant of which is an amended operating permit. Our
ability to obtain the amended operating permit, given the
expiration and cancellation of the prior permit, is crucial for
the completion of the Goro project. While we currently
anticipate that we will be able to obtain all necessary permits
on a timely basis, including the amended operating permit, any
failure to obtain, or any delay in the issuance of, such permits
could adversely affect our ability to develop the Goro project.
•
Changes in market conditions may make our projects less
profitable than expected at the time we initiated work on the
project.
•
Adverse mining conditions may delay and hamper our ability to
produce the expected quantities of minerals.
•
Some of our development projects are located in regions where
tropical diseases, AIDS, malaria and other contagious diseases
are a major public health issue and pose health and safety risks
to our employees. If we are unable to ensure the health and
safety of our employees, our business may be adversely affected.
If we are unable to successfully manage these risks, our growth
prospects and profitability may suffer.
Our
principal shareholder could have significant influence over our
company.
At December 31, 2006, Valepar S.A., or Valepar, owned 53.3%
of our outstanding common stock and 32.5% of our total
outstanding capital. For a description of our ownership
structure, see Item 7. Major shareholders and related
party transactions — Major shareholders —
Principal shareholder. As a result of its share ownership,
Valepar can control the outcome of any action requiring
shareholder approval, except for
the appointment of certain directors and certain members of our
fiscal council. Moreover, the Brazilian government owns six CVRD
golden shares that give it limited veto power over certain
actions that we could otherwise take. For a detailed description
of the Brazilian government’s veto power by virtue of its
ownership of these golden shares, see Item 10.
Additional information — Common shares and preferred
shares — General.
Many
of our operations depend on joint ventures or consortia, and our
business could be adversely affected if our partners fail to
observe their commitments.
We currently operate important parts of our pelletizing, nickel,
bauxite, coal and steel businesses through joint ventures with
other companies. Important parts of our electricity business are
operated through consortia. Our forecasts and plans for these
joint ventures and consortia assume that our partners will
observe their obligations to make capital contributions,
purchase products and, in some cases, provide managerial
personnel. If any of our partners fails to observe its
commitments, the affected joint venture or consortium may not be
able to operate in accordance with its business plans, or we may
have to increase the level of our investment to effectuate these
plans. For more information on our joint ventures, see
Item 4. Information on the company — Lines of
business.
Our
mining and logistics activities depend on authorizations from
regulatory agencies, and changes in regulations could adversely
affect our business.
Our mining and logistics activities depend on authorizations
from and concessions by governmental regulatory agencies of the
countries in which we operate. Our exploration, mining, mineral
processing and logistics activities are also subject to laws and
regulations that can change at any time. If these laws and
regulations change in the future, modifications to our
technologies and operations could be required, and we could be
required to make unexpected capital expenditures. For example,
in Indonesia, the pending new mining legislation could have a
material adverse effect on our PT Inco operations. For a more
detailed description of the authorizations and concessions upon
which our mining and logistics activities depend, see
Item 4. Information on the company —
Regulatory matters.
Our
mining and energy businesses may be adversely affected by
environmental regulation.
Our operations often involve using, handling, disposing and
discharging hazardous materials into the environment or the use
of natural resources, and nearly all aspects of our operations
and development projects around the world are subject to
environmental regulation. Such regulation requires us to obtain
operating licenses, permits and other approvals and to conduct
environmental assessments prior to initiating projects or
undertaking significant changes to existing operations.
Difficulties in obtaining licenses may lead to construction
delays or cost increases, and in some cases may lead us to
abandon a project. Environmental regulation also imposes
standards and controls on activities relating to mining,
exploration, development, production, reclamation, closure, and
the refining, distribution and marketing of our products. Such
regulation may give rise to significant costs and liabilities.
Environmental regulation in many countries in which we operate
has become stricter in recent years, and it is possible that
more regulation or more aggressive enforcement of existing
regulations will adversely affect us by imposing restrictions on
our activities, creating new requirements for the issuance or
renewal of environmental licenses, raising our costs or
requiring us to engage in expensive reclamation efforts. Some of
the significant environmental risks that could affect our
business are summarized below. For more information on
environmental regulation applicable to our operations, see
Item 4. Information on the company —
Regulatory matters — Environmental matters and
Item 8. Financial information — Legal
proceedings.
•
Brazilian laws restricting development in the Amazon region may
limit our ability to expand certain of our operations and to
fully exploit our mineral rights in those regions.
•
We are subject to Brazilian environmental legislation requiring
companies that undertake projects with a significant
environmental impact to pay an “environmental
compensation” fee in the amount of at least 0.5% of the
total investment in the venture. There are numerous
uncertainties regarding the
application of this law. An increase in the level of the fees
charged above 0.5% would significantly increase our costs and,
depending on the magnitude of the fees involved, could have a
material adverse effect on our liquidity and return on
investments. Uncertainties regarding calculation and payment of
these fees may strain our relations with the Brazilian
environmental authorities or lead to delays in obtaining
necessary environmental permits.
•
Several Brazilian states in which we operate are currently
considering implementing water usage fees under the National
Hydrological Resources Policy. This may require us to pay usage
fees in the future for water rights that we currently use for
free, which could considerably increase our costs in areas where
water resources are scarce.
•
We are subject to limits on sulfur dioxide and nickel emissions,
as a result of which we will be required to make significant
investments. We may be subject to additional emission limits in
the future, including potential limits on the emission of
greenhouse gases under the Clean Air Act in both Canada and the
United States. Complying with these or other future emission
limits could require significant capital expenditures or the
development of new technologies. Complying with such limits
could also have an adverse impact on production levels, to the
extent we are required to operate our facilities at reduced
levels to comply with emission limits or are unable to bank or
trade sufficient emission allowances in emissions trading
markets (where available).
•
We have been working with regulatory authorities and other
interested parties to evaluate elevated levels of nickel and
other metals in soils in the vicinity of our processing
facilities in Ontario, Canada that may have been affected by the
historical emission of windblown metal-containing particulates.
Any efforts we are required to undertake to remediate or
investigate these matters may involve significant expenditures.
We are also subject to related litigation in connection with
soils near our Port Colborne, Ontario facilities, and
environmental health studies and risk assessments are underway
to evaluate risks from chemicals of concern found in soils near
our smelters in Port Colborne and Sudbury. Given the existence
of various legal appeals and scientific and medical studies
currently underway, it is not possible to predict the effect
these actions and studies could have on our business, results of
operation or financial condition.
•
PT Inco’s facilities are subject to environmental
regulations and permits issued by the Government of Indonesia.
PT Inco has in the past exceeded regulatory limits on dust
emission levels from its facilities and could be subject to
regulatory actions by governmental authorities for any
non-compliance.
•
Asset retirement obligations for our Canadian facilities and
projects could differ materially from amounts currently
estimated by us.
•
The European Commission has adopted draft legislation for a new
policy (known as REACH) establishing an all-encompassing system
for the management of both new and existing chemicals that are
manufactured in or imported into the EU. The draft legislation
contains a broad definition of “chemicals” that
includes metals, alloys and all metal-containing compounds and
establishes a complex authorization process that may apply to
nickel and cobalt substances.
We are
involved in ongoing antitrust proceedings that could result in
divestitures, fines or other restrictions that could harm our
business.
Nearly all of our acquisitions and joint ventures are subject to
post-transaction review by the Brazilian antitrust regulator
(the Conselho Administrativo de Defesa Econômica),
or CADE. We are currently involved in five proceedings before
CADE, three of which involve post-transaction review of
acquisitions (including the acquisition of Inco) or joint
venture transactions. The other two are administrative
proceedings involving claims that we have violated antitrust
laws in connection with our logistics business. If CADE were to
rule against us, it could order us to cease the conduct in
question
and/or to
pay fines. We intend to defend these claims vigorously, but we
cannot predict their outcome.
We are appealing a CADE decision from August 2005 regarding
various transactions completed by us. The CADE decision
conditions approval of these transactions on our acceptance of
one of the following
alternatives: we must either (i) waive certain rights
obtained from CSN (Companhia Siderúrgica Nacional)
with respect to a particular iron ore mine (Casa de
Pedra) and restructure our equity stake in the railway
company MRS Logística S.A., or (ii) sell all the
assets we obtained through our 2001 acquisition of Ferteco
Mineração S.A. We are in the process of requesting an
injunction to suspend the implementation of the CADE decision,
but if we were ultimately required to comply with this decision
our iron ore and logistics operations could be adversely
affected. For more information, see Item 8. Financial
information — Legal proceedings.
Our
reserve estimates may materially differ from mineral quantities
that we may be able to actually recover; our estimates of mine
life may prove inaccurate; and market price fluctuations and
changes in operating and capital costs may render certain ore
reserves or mineral deposits uneconomical to mine.
Our reported ore reserves and mineral deposits are estimated
quantities of ore and minerals that have the potential to be
economically mined and processed under present and anticipated
conditions to extract their mineral content. There are numerous
uncertainties inherent in estimating quantities of reserves and
in projecting potential future rates of mineral production,
including many factors beyond our control. Reserve engineering
is a subjective process of estimating underground deposits of
minerals that cannot be measured in an exact manner, and the
accuracy of any reserve estimate is a function of the quality of
available data and engineering and geological interpretation and
judgment. As a result, no assurance can be given that the
indicated amount of ore will be recovered or that it will be
recovered at the rates we anticipate. Estimates of different
engineers may vary, and results of our mining and production
subsequent to the date of an estimate may lead to revision of
estimates. Reserve estimates and estimates of mine life may
require revision based on actual production experience and other
factors. For example, fluctuations in the market prices of ores
and metals, reduced recovery rates or increased operating and
capital costs due to inflation, exchange rates or other factors
may render proven and probable reserves uneconomic to exploit
and may ultimately result in a restatement of reserves.
We may
not be able to replenish our reserves, which could adversely
affect our mining prospects.
We engage in mineral exploration, which is highly speculative in
nature, involves many risks and frequently is nonproductive. Our
exploration programs, which involve significant capital
expenditures, may fail to result in the expansion or replacement
of reserves depleted by current production. If we do not develop
new reserves, we will not be able to sustain our current level
of production beyond the remaining lives of our existing mines.
Even
if we discover mineral deposits, we remain subject to drilling
and production risks, which could adversely affect the mining
process.
Once mineral deposits are discovered, it can take a number of
years from the initial phases of drilling until production is
possible, during which the economic feasibility of production
may change. Substantial time and expenditures are required to:
•
establish mineral resources through drilling;
•
determine appropriate mining and metallurgical processes for
optimizing the recovery of metal contained in ore;
•
obtain environmental and other licenses;
•
construct mining, processing facilities and infrastructure
required for greenfield properties; and
•
obtain the ore or extract the metals from the ore.
If a project proves not to be economically feasible by the time
we are able to exploit it, we may incur substantial write-offs.
In addition, potential changes or complications involving
metallurgical and other technological processes arising during
the life of a project may result in cost overruns that may
render the project not economically feasible.
We
face rising extraction costs over time as reserves
deplete.
Reserves are gradually depleted in the ordinary course of a
given mining operation. As mining progresses, distances to the
primary crusher and to waste deposits become longer, pits become
steeper and underground operations become deeper. As a result,
over time, we usually experience rising unit extraction costs
with respect to each mine. Several of our mines have been
operating for long periods, and we will likely experience rising
extraction costs per unit in the future at these operations.
We may
face a shortage in our supply of mining equipment due to
increased consumption by mining companies that exceeds
suppliers’ capacity.
Since early 2004, the global mining industry has experienced
shortages of
off-the-road
(“OTR”) tires, and we do not expect an improvement in
this situation in the short term. There are only five radial
tire factories worldwide, and each is working at maximum
capacity. Although the three major suppliers have announced
investments to increase capacity over the next three years,
these capacity increases are not expected to meaningfully reduce
the risk of shortages before 2009. In response to the risk of
shortages, mining industry participants are exploring
alternatives, such as bias ply tires, which have lower
performance ratings than radial tires. If we are unable to
secure sufficient OTR tires or alternative tires to maintain our
operations, we may suffer temporary reductions in our production
capacity.
We
have experienced labor disputes that have disrupted operations,
and such disputes could recur.
A substantial number of our employees and some of the employees
of our subcontractors are represented by labor unions and are
covered by collective bargaining or other labor agreements,
which are subject to periodic renegotiation. Strikes or work
stoppages have occurred recently in Canada and could reoccur in
connection with negotiations of new labor agreements or during
other periods for other reasons. Moreover, we could be adversely
affected by labor disruptions involving third parties who may
provide us with goods or services. Strikes and other labor
disruptions at any of our operations could adversely affect the
operation of facilities, or the timing of completion and the
cost of our capital projects.
An
increase in fuel costs may adversely affect our
business.
Our operations rely in part on oil by-products and gas, which
represented 9.0% of our cost of goods sold in 2006. Fuel costs
are a major component of our total costs in our logistics,
pellets and nickel businesses and indirectly affect numerous
other areas of our business, including our mining and aluminum
businesses. An increase in oil and gas prices adversely affects
margins in our logistics, mining, pellets, nickel and aluminum
businesses.
If we
are unable to maintain reliable access to electricity at
acceptable prices, our operations may be adversely
affected.
Electricity costs are a significant component of the cost of our
production, representing 6.1% of our total cost of goods sold in
2006. If we are unable to secure reliable access to electric
energy at acceptable prices, we may be forced to curtail
production or may experience higher production costs, either of
which would adversely affect our results of operations.
Electricity shortages have occurred in Brazil in the past and
could reoccur in the future, and there can be no assurance that
Brazilian government policies will succeed in encouraging growth
in generation capacity. Future shortages and government policies
to respond to or prevent shortages may adversely impact the cost
or supply of electricity for our Brazilian aluminum and
ferroalloy operations. Changes in the laws, regulations or
governmental policies regarding the power sector or concession
requirements could reduce our expected returns from our
investments in power generation.
Through our subsidiary PT Inco in Indonesia, we process
lateritic nickel ores, which is energy-intensive. Although PT
Inco currently generates a majority of the electricity for its
operations from its own hydroelectric facilities, certain
hydrological factors, such as low rainfalls or ineffective water
management practices, could
adversely affect electricity production at PT Inco’s plants
in the future, which could significantly increase PT Inco’s
costs or result in lower production. For more information on the
regulations governing energy production, see Item 4.
Information on the company — Regulatory matters.
Price
volatility of the currencies in which we conduct operations
relative to the U.S. dollar could adversely affect our
financial condition and results of operations
We are affected by fluctuations in the prices of the currencies
in which we conduct operations relative to the U.S. dollar.
A substantial portion of our revenues and debt is denominated in
U.S. dollars, and changes in exchange rates may result in
losses or gains on our net U.S. dollar-denominated
indebtedness and accounts payable. In 2006, 2005 and 2004,
changes in exchange rates led us to report foreign exchange
gains of US$452 million, US$227 million and
US$79 million, respectively. In addition, currency
fluctuations between the Brazilian real,
U.S. dollar, Canadian dollar, Indonesian rupiah and other
currencies of our subsidiaries affect our results. Currency
fluctuations are expected to continue to affect our financial
income, expense and cash flow generation.
Major volatility of any such currencies may also result in
disruption of the foreign exchange markets and may limit our
ability to transfer or to convert such currencies into
U.S. dollars and other currencies for the purpose of making
timely payments of interest and principal on our indebtedness.
The governments of countries in which we operate could institute
restrictive exchange rate policies in the future.
Investor
perceptions of risk in Brazil and other emerging economies may
undermine our ability to finance our operations at an acceptable
cost or reduce the trading price of our
securities.
Although our acquisition of Inco has significantly expanded the
proportion of our non-Brazilian operations, our largest
operations, corporate headquarters and senior management
continue to be located in Brazil. Investors generally consider
Brazil to be an emerging market. As a result, economic and
market conditions in other emerging market countries, especially
those in Latin America, influence the market for securities
issued by Brazilian companies. Economic crises in one or more
emerging market countries may reduce overall investor appetite
for securities of emerging market issuers. Past economic crises
in emerging markets, such as in Southeast Asia, Russia and
Argentina, have resulted in significant outflows of
U.S. dollars from Brazil and caused Brazilian companies to
face higher costs for raising funds, both domestically and
abroad, and have effectively impeded access to international
capital markets for extended periods. We cannot assure you that
global capital markets will remain open to Brazilian companies
or that prevailing interest rates in these markets will be
advantageous to us. In addition, future financial crises in
emerging market countries may have a negative impact on the
Brazilian markets, which could adversely affect the trading
price of our securities.
Our
market risk management strategy may not be
effective.
We are exposed to traditional market risks such as fluctuations
in interest rates, exchange rates and commodity prices. We earn
most of our revenues in U.S. dollars, but incur a
substantial portion of our costs and expenses in currencies
other than the U.S. dollar. The exchange rates for
converting such currencies into U.S. dollars have varied
substantially during the last three years. In order to protect
ourselves against market volatility, our Board of Directors has
approved a risk management policy. See Item 11.
Quantitative and qualitative disclosures about market risk.
Our strategy may not be successful in minimizing our exposure to
these fluctuations, and we may fail to identify correlations
between the various market risks to which we are subject. In
addition, to the extent we partially hedge our commodity price
exposure, we may limit the upside benefits that we would
otherwise experience if commodities prices were to increase.
We may
not have adequate, if any, insurance coverage for some business
risks.
Our businesses are generally subject to a number of risks and
hazards, including:
slope or pit-wall failures, cave-ins or rock falls;
•
environmental hazards;
•
electricity stoppages;
•
equipment or vessel failures;
•
severe weather and other natural phenomena such as seismic
events;
•
unavailability or late delivery of materials, supplies or
equipment;
•
unexpected ground, grade or water conditions; and
•
unusual or unexpected geological formations or pressures.
These occurrences could result in damage to, or destruction of,
mineral properties, production facilities, transportation
facilities, equipment or vessels. They could also result in
personal injury or death, environmental damage, waste of
resources or intermediate products, delays or interruption in
mining, production or transportation activities, monetary losses
and possible legal liability. The insurance we maintain against
risks that are typical in our business may not provide adequate
coverage. Insurance against some risks (including liabilities
for environmental pollution or certain hazards or interruption
of certain business activities) may not be available at a
reasonable cost, or at all. As a result, accidents or other
negative developments involving our mining, production or
transportation facilities could have a material adverse effect
on our operations.
Risks
relating to our acquisition of Inco
We may
experience difficulties integrating CVRD Inco and may fail to
achieve the expected benefits from the
acquisition.
Integrating CVRD Inco with our operations will be a complex,
costly and time-consuming process, and may be made more
difficult due to the unsolicited, cross-border nature of the
acquisition. Risks and challenges that may impair our ability to
achieve the benefits of the acquisition include the following:
•
Although we have experience integrating acquired companies into
our operations, we lack experience integrating operations as
substantial and geographically diverse as those of CVRD Inco.
The acquisition of CVRD Inco is significantly larger than any
other acquisition we have completed.
•
Integrating CVRD Inco and gaining familiarity with its
operations and challenges will require significant management
time and resources and may divert management’s attention
from our
day-to-day
business.
•
Although we have two nickel projects under development, we have
no significant prior experience producing or marketing nickel,
cobalt or PGMs or operating businesses in Canada, Indonesia,
New Caledonia, the United Kingdom, Japan, and China.
•
The successful integration of CVRD Inco will require us to
assimilate personnel with diverse backgrounds, languages and
cultures. We may have difficulty retaining and integrating key
employees and may be required to make substantial payments to
departing executives. The performance of CVRD Inco’s
operations could be adversely affected if we cannot retain key
employees to assist in the integration of CVRD and CVRD Inco and
operation of CVRD Inco.
•
We may encounter difficulties or delays in implementing common
information systems, operating procedures and financial controls.
If we are unable to successfully respond to these risks and
challenges, we may experience higher than expected operating
costs or fail to achieve the anticipated benefits of the
acquisition.
If
CVRD Inco’s business does not perform well or we do not
integrate it successfully, we may incur significant charges to
net income to write down the goodwill recognized as a result of
the acquisition.
As a result of the acquisition, we recognized, on a preliminary
basis, goodwill of US$3,876 million. Under Statement of
Financial Accounting Standards No. 142, “Goodwill and
Other Intangible Assets,” we must test our goodwill
annually for impairment and, if we determine that the goodwill
has been impaired, we must write down the goodwill by the amount
of the impairment, with a corresponding charge to net income. If
CVRD Inco’s business does not perform well or if we are
unable to successfully integrate it with our operations, we may
incur significant charges to net income to write down the
goodwill, which could have a material adverse effect on our
results of operations and financial condition.
We
have incurred a substantial amount of indebtedness in connection
with the acquisition of CVRD Inco, which could limit our
operating flexibility and make it more difficult for us to
maintain our investment grade rating.
As of December 31, 2006, as a result of the consolidation
of CVRD Inco’s indebtedness and the incurrence by CVRD of
indebtedness of US$14,600 million to fund the purchase
price for 100% of CVRD Inco’s shares, we had
US$22,556 million of debt outstanding, compared to
US$4,947 million outstanding at December 31, 2005. The
substantial increase in our outstanding debt and related
covenants could limit our operating flexibility. In particular:
•
A substantial portion of our cash flow from operations must be
dedicated to the payment of principal and interest on our
indebtedness, reducing the funds available to us for other
purposes.
•
Our higher levels of indebtedness and the need to comply with
financial covenants may impair our ability to adjust to changing
market conditions or withstand competitive pressures.
•
Our higher level of outstanding debt may make it more difficult
to maintain the financial ratios the rating agencies require in
order to maintain our investment grade credit rating.
Commitments
made to Canadian government authorities in connection with the
acquisition of CVRD Inco may limit our flexibility in managing
CVRD Inco’s operations.
In connection with the approval under the Investment Canada Act
of our acquisition of Inco, we made a series of commitments to
the Canadian Minister of Industry, in the form of undertakings,
including commitments to manage our global nickel business from
Canada, to refrain from making layoffs at our Canadian operating
facilities for three years and to maintain aggregate employment
at these facilities at a specified level for an agreed period.
We also committed to increase certain expenditures by specified
amounts over previously existing levels and expressed our wish
to accelerate the development of our Voisey’s Bay project.
See Item 4. Information on the company —
Regulatory matters — Investment Canada Act
undertakings. These commitments could limit our flexibility
in managing our business and responding to changing market
conditions, which could adversely affect our results of
operations.
Risks
relating to the American Depositary Shares
Restrictions
on the movement of capital out of Brazil may hinder your ability
to receive dividends and distributions on American Depositary
Shares and the proceeds from any sale of American Depositary
Shares.
The Brazilian government may impose restrictions on capital
outflows whenever there is a serious imbalance in Brazil’s
balance of payments or reason to foresee a serious imbalance.
This would hinder or prevent the custodian who acts on behalf of
the depositary for the American Depositary Shares from
converting proceeds from the shares underlying the American
Depositary Shares into U.S. dollars and remitting those
proceeds abroad.
The Brazilian government imposed remittance restrictions for
approximately six months in 1989 and early 1990. If enacted
in the future, similar restrictions would hinder or prevent the
conversion of dividends, distributions or the proceeds from any
sale of shares from reais into U.S. dollars and the
remittance of the U.S. dollars abroad. In that event, the
custodian, acting on behalf of the depositary, will hold the
reais it cannot convert for the account of the holders of
American depositary receipts who have not been paid. The
depositary will not invest the reais and will not be
liable for interest on those amounts. Furthermore, any reais
so held will be subject to devaluation risk.
If you
exchange American Depositary Shares for the underlying shares,
you risk losing the ability to remit foreign currency abroad and
Brazilian tax advantages.
The Brazilian custodian for the shares underlying our American
Depositary Shares will obtain an electronic registration from
the Central Bank to entitle it to remit U.S. dollars abroad
for payments of dividends and other distributions relating to
the shares underlying our American Depositary Shares or upon the
disposition of the underlying shares. If you decide to exchange
your American Depositary Shares for the underlying shares, you
will be entitled to continue to rely, for five business days
from the date of exchange, on the custodian’s electronic
registration. Thereafter, you may not be able to obtain and
remit U.S. dollars abroad upon the disposition of, or
distributions relating to, the underlying shares unless you
obtain your own electronic registration by registering your
investment in the underlying shares under Resolution
No. 2,689 of the National Monetary Council, which entitles
foreign investors to buy and sell securities on the São
Paulo stock exchange, or BOVESPA. For more information regarding
these exchange controls, see Item 10. Additional
information — Exchange controls and other limitations
affecting security holders. If you attempt to obtain your
own electronic registration, you may incur expenses or suffer
delays in the application process, which could delay your
ability to receive dividends or distributions relating to the
underlying shares or the return of your capital in a timely
manner. We cannot assure you that the custodian’s
electronic registration or any certificate of foreign capital
registration obtained by you will not be affected by future
legislative changes, or that additional restrictions applicable
to you, the disposition of the underlying shares or the
repatriation of the proceeds from disposition will not be
imposed in the future.
Because
we are not obligated to file a registration statement with
respect to preemptive rights relating to our shares, you may be
unable to exercise those preemptive rights.
Holders of American depositary receipts that are residents of
the United States may not be able to exercise preemptive rights,
or exercise other types of rights, with respect to the
underlying shares. Your ability to exercise preemptive rights is
not assured unless a registration statement is effective with
respect to those rights or an exemption from the registration
requirements of the Securities Act is available. We are not
obligated to file a registration statement relating to
preemptive rights with respect to the underlying shares or to
undertake steps that may be needed to make exemptions from
registration available, and we cannot assure you that we will
file any registration statement or take such steps. If a
registration statement is not filed and an exemption from
registration does not exist, JPMorgan Chase Bank, as depositary
for our American Depositary Shares, will attempt to sell the
preemptive rights, and you will be entitled to receive the
proceeds of the sale. However, the preemptive rights will expire
if the depositary cannot sell them. For a more complete
description of preemptive rights with respect to the underlying
shares, see Item 10. Additional information —
Common shares and preferred shares — Preemptive
rights.
Holders
of our American Depositary Shares may encounter difficulties in
the exercise of voting rights.
Holders of our common and preferred class A shares are
entitled to vote on shareholder matters. You may encounter
difficulties in the exercise of some of your rights as a
shareholder if you hold our American Depositary Shares rather
than the underlying shares. For example, if we fail to provide
the depositary with voting materials on a timely basis, you may
not be able to vote by giving instructions to the depositary on
how to vote for you.
Our corporate affairs are governed by our bylaws and Brazilian
corporation law, which differ from the legal principles that
would apply if we were incorporated in a jurisdiction in the
United States or elsewhere
outside Brazil. Under Brazilian corporation law, holders of our
common and preferred class A shares may have fewer and less
well-defined rights to protect their interests relative to
actions taken by our Board of Directors or by Valepar than under
the laws of some jurisdictions outside Brazil.
Although Brazilian law imposes restrictions on insider trading
and price manipulation, the Brazilian securities markets are not
as highly regulated and supervised as the U.S. securities
markets or markets in certain other jurisdictions. In addition,
rules and policies against self-dealing and regarding the
preservation of minority shareholder interests may be less
well-developed and enforced in Brazil than in the United States,
which could potentially disadvantage you as a holder of the
underlying shares and American Depositary Shares. For example,
when compared to Delaware general corporation law, Brazilian
corporate law and practice has less detailed and
well-established rules and judicial precedents relating to the
review of management decisions against duty of care and duty of
loyalty standards in the context of corporate restructurings,
transactions with related parties, and
sale-of-
business transactions. In addition, shareholders in Brazilian
companies ordinarily do not have standing to bring a class
action.
In addition, as a foreign private issuer, we are not required to
follow many of the corporate governance rules that apply to
U.S. domestic issuers with securities listed on the New
York Stock Exchange, or the NYSE. For more information
concerning our corporate governance policies, see
Item 6. Directors, senior management and employees.
Depreciation
of the Brazilian real against the U.S. dollar reduces the
U.S. dollar value of dividends paid to holders of our
American Depositary Shares.
Depreciation of the Brazilian real against the
U.S. dollar reduces the U.S. dollar value of dividends
paid to holders of our American Depositary Shares. We attempt to
mitigate this risk by setting our dividends in
U.S. dollars. However, shareholders are still exposed to
currency volatility risk for a period of at least two weeks, as
the U.S. dollar value of dividends is converted into
reais at least two weeks prior to its distribution, due
to operational requirements to process dividend payments.
We are the second-largest diversified metals and mining company
in the world, the largest metals and mining company in the
Americas, and one of the largest private-sector companies in
Latin America by market capitalization. We are the world’s
largest producer and exporter of iron ore and pellets and one of
the world’s largest producers of nickel. We also produce
copper, manganese, ferroalloys, bauxite, precious metals,
cobalt, kaolin, potash and other products. To support our growth
strategy, we are actively engaged in mineral exploration efforts
in 19 countries around the globe. We operate large logistics
systems in Brazil, including railroads, maritime terminals and
ports that are integrated with our mining operations. Directly
and through affiliates and joint ventures, we have major
investments in the aluminum, coal, energy and steel businesses.
The table below presents the breakdown of our total gross
revenues attributable to each of our main lines of business,
each of which is described following the table.
Percentages determined by adding
CVRD Inco 2006 pre-acquisition gross revenues to 2006 historical
gross revenues.
(2)
Figures included in the nickel
product segment in our consolidated financial statements.
•
Iron ore, pellets, manganese and
ferroalloys. We operate two fully integrated
systems in Brazil for producing and distributing iron ore (the
Northern System and the Southeastern System), consisting of
mines, railroads and port facilities. We operate a third system
(the Southern System), consisting of the MBR and Oeste mines and
the Guaíba Island and Itaguaí maritime terminals. We
also operate nine pellet-producing facilities, five of which are
joint ventures. We have a 50% stake in a joint venture that owns
and operates two pelletizing plants. We are one of the
world’s largest producers of manganese ore and ferroalloys.
•
Nickel. We are one of the world’s largest
producers of nickel. Our principal nickel mines and processing
operations are located in Canada, specifically in the Sudbury
area of Ontario, the Thompson area of Manitoba and at
Voisey’s Bay in Newfoundland and Labrador, and in Indonesia
through our 61%-owned subsidiary, PT International Nickel
Indonesia Tbk (“PT Inco”), on the Island of Sulawesi,
Indonesia. We also operate a nickel refinery in the United
Kingdom, own 67% of Inco TNC Limited, which operates a nickel
refinery in Japan, and have interests in nickel refining
operations in Taiwan and South Korea.
•
Copper. We have copper mining operations in
Brazil and Canada. We are Brazil’s largest copper
concentrate producer due to our operations at the Sossego copper
mine in Carajás. We also produce copper in conjunction with
our Canadian nickel mining operations at our Manitoba, Ontario
and Voisey’s Bay operations.
•
PGMs. We produce platinum-group metals
(platinum, palladium, rhodium, ruthenium and iridium) as
by-products of our nickel mining and processing operations in
Canada. The PGMs are concentrated at our facilities in Port
Colborne, Ontario and refined at our precious metals refinery in
Acton, England.
Other precious metals. We produce gold and
silver as by-products of our nickel mining and processing
operations in Canada. Some of these precious metals are upgraded
at our facilities in Port Colborne, Ontario, and all are refined
by third parties in Canada.
•
Other non-ferrous minerals. We are the
world’s second-largest producer of kaolin in the paper
industry and Brazil’s sole producer of potash. We produce
and sell cobalt, sulphuric acid, liquid sulphur dioxide, and
modest quantities of selenium and tellurium as by-products of
our processing operations.
•
Aluminum operations. We conduct bauxite
mining, alumina refining, and aluminum metal smelting.
•
Logistics. We are a leading provider of
logistics services in Brazil, with railroad, coastal shipping
and port handling operations. Two of our three iron ore
complexes incorporate an integrated railroad network linked to
automated port and terminal facilities, which provide rail
transportation for our mining products, general cargo and
passengers, bulk terminal storage, and ship loading services for
our mining operations and for third parties.
•
Other investments. We currently have
investments in three steel companies and two joint ventures to
produce steel slab in Brazil. We have also invested in
hydroelectric power generation projects.
CVRD’s legal and commercial name is Companhia Vale do Rio
Doce. CVRD is a stock corporation, or sociedade por
ações, duly organized on January 11, 1943,
and existing under the laws of the Federative Republic of
Brazil. CVRD was privatized in three stages between 1997 and
2002, beginning with the sale by the Brazilian government of a
controlling stake in CVRD to Valepar in 1997. The last stage of
the privatization took place in 2002, when the Brazilian
government sold a remaining minority stake of common shares
through a global equity offering. CVRD is organized for an
unlimited period of time. Its head offices are located at
Avenida Graça Aranha, No. 26,
20030-900
Rio de Janeiro, RJ, Brazil, and its telephone number is
55-21-3814-4477.
Business
strategy
Our goal is to strengthen our position as one of the
world’s leading diversified metals and mining companies by
building on our strengths in iron ore and nickel and increasing
our geographical and product diversification and logistics
capabilities. Over the past several years, we have developed a
robust long-term strategic planning process. Although we may
pursue strategic acquisitions, following the Inco acquisition we
are focused on organic growth in our core businesses. We are
pursuing disciplined capital management in order to maximize
return on invested capital and total return to shareholders.
Below we highlight our major strategies.
Maintaining
our leadership position in the global iron ore
market
We continue to consolidate our leadership in the global iron ore
market, having an estimated market share of 33% of the total
volume traded in the seaborne market in 2006. We are committed
to maintaining our position in the global iron ore market by
strengthening relationships with clients, focusing our product
line to capture industry trends, increasing our production
capacity in line with demand growth and controlling costs. We
believe that our strong relationships with major customers,
reinforced through long-term contracts, high quality products
and a strong technical marketing strategy, will help us achieve
this goal. We are also taking steps to encourage several steel
makers to develop steel slab plants in Brazil in order to create
additional demand for our iron ore.
Achieving
leadership in the nickel business
Following the acquisition of Inco in October 2006, we have
become one of the world’s largest nickel producers, with
large-scale, long-life, low-cost operations, a substantial
resource base, and a robust growth profile. We believe our
greenfield projects at Vermelho and Onça Puma in Brazil and
Goro in New Caledonia will further support our leadership
position in the nickel market.
We are developing and increasing production capacity in our
aluminum operations, focusing on the upstream portion of the
production chain and developing low-cost bauxite and alumina
projects. We have large, undeveloped high-quality bauxite
reserves and opportunities for low-cost expansions in our
alumina refinery. We are working on the development of these
opportunities. We are also investing in mineral exploration to
increase our bauxite resources.
Improvements
in our manganese ore and ferroalloys operations
We have been taking steps to improve our competitive position
and reduce operating costs at our manganese ore and ferroalloys
operations through divestments, reduction of personnel, and
streamlining of the management structure.
Developing
our copper resources
We believe that our Brazilian copper projects, which are all
situated in the Carajás region, in the Brazilian state of
Pará, could be among the most competitive in the world in
terms of investment cost per metric ton of ore. We expect these
copper mines to benefit from our infrastructure facilities
serving the Northern System.
Investing
in coal
We are pursuing various opportunities to become a large global
player in coal businesses. In April 2007, we acquired AMCI
Holdings Australia Pty (AMCI HA), which has coal operating
assets and reserves in Australia. In the past several years, we
have invested in two joint ventures in China, and we intend to
continue pursuing organic growth in the coal business through
development of the Moatize project in Mozambique and the
Belvedere coal deposit in Australia.
Enhancing
our logistics capacity
We believe that the quality of our railway assets and our many
years of experience as a railroad and port operator, together
with the lack of efficient transportation for general cargo in
Brazil, position us as a leader in the logistics business in
Brazil. We are expanding the capacity of our railroads through
the purchase of additional locomotives and wagons to serve the
increasing needs of our own businesses and those of our
customers.
Global
exploration efforts
We are engaged in an active mineral exploration program, with
efforts in 19 countries around the globe. We are mainly seeking
new deposits of copper, manganese ore, iron ore, nickel, kaolin,
bauxite, phosphate, potash, coal, uranium and platinum group
metals. Mineral exploration is an important part of our organic
growth strategy.
Developing
power generation projects
Energy management and efficient supply have become a priority
for us. As a large consumer of electricity, we believe that
investing in power projects to support our operations will help
protect us against volatility in the price of energy, regulatory
uncertainties and the risk of energy shortages. Accordingly, we
have developed hydroelectric power generation plants in Brazil
and in Indonesia, and we are using the electricity from these
projects to supply our internal needs.
Recent
acquisitions and significant changes
We describe below significant acquisitions and other changes in
our business in 2006 and 2007 to date.
In October 2006, we acquired 75.66% of the outstanding common
shares of Inco, then the world’s second-largest producer of
nickel, in an unsolicited cash tender offer. Following a
subsequent offering period and additional purchases, we
increased our stake to 87.73% by December 31, 2006. In
January 2007, the amalgamation of Inco with our subsidiary
Itabira Canada Inc. resulted in our acquisition of 100% of the
shares of Inco, and we formally changed Inco’s name to
“CVRD Inco Limited” (“CVRD Inco”). CVRD Inco
subsequently ceased to be a reporting issuer under both U.S. and
Canadian securities laws. The total acquisition cost for Inco
was US$18,931 million, which represents the purchase price
of US$17,744 million plus net debt of
US$1,187 million. US$15,691 million was paid to Inco
shareholders due to stock acquisitions in 2006, and
US$2,053 million was disbursed in 2007. Of the
US$17,744 million paid, US$593 million is attributable
to convertible debt and US$17,151 million to the
acquisition of outstanding shares.
Stock
merger with Caemi
In May 2006, we completed a stock merger with our controlled
company CAEMI. Pursuant to the stock merger, all preferred
shares of CAEMI owned by its public shareholders were exchanged
for new preferred shares issued by us, and CAEMI became our
wholly owned subsidiary. The exchange ratio was one CAEMI share
per 0.04115 CVRD preferred class A share. In December 2006,
we merged CAEMI into CVRD.
Iron
ore and pellets
Acquisition and usufruct agreement for MBR
shares. In May 2007, we entered into a
transaction by which we have effectively obtained 100% control
of MBR during the next thirty years, allowing us to maximize our
exposure to MBR, which we consider one of the best iron ore
assets in the world and to exploit synergies between the
companies. Prior to this transaction, we owned 89.9% of MBR,
directly and through our 80% stake in Empreendimentos
Brasileiros de Mineração S.A. (EBM), whose main asset
is a 51% stake in MBR. We acquired a further 6.25% of EBM for
US$231 million, and we simultaneously entered into a
usufruct agreement with respect to the 13.75% of EBM’s
total capital that we do not own. This agreement grants us
during the next 30 years all rights and obligations with
respect to these EBM shares, including the right to dividends.
In exchange, CVRD will pay a total of US$61 million and an
annual fee of US$48 million.
Development of a dedicated Brazil-China shuttle
service. In May 2007, CVRD entered into long-term
freight contracts to develop dedicated shuttle service from
Brazil to China. We expect this service to enhance in the future
our ability to offer our products in the Chinese market at
competitive prices and to increase our market share in China and
the global seaborne market.
Start-up
of Brucutu mine. Our new Brucutu mine started
operations in September 2006. When Brucutu reaches full capacity
in 2008, it is expected to produce 30 million metric tons
of iron ore. In 2007, we expect production to amount to
23 million metric tons.
Carajás expansion. In January 2007, we
completed the expansion of iron ore production capacity at
Carajás to 100 million metric tons per year, after
completing an expansion to 85 million metric tons per year
in the third quarter of 2006. We are conducting studies for a
possible further expansion to 130 million metric tons of
iron ore per year by 2009.
Reclassification of operations in the Southern
System. In the third quarter of 2006, in order to
maximize existing synergies and to continue to achieve
efficiency gains, we divided the management of our former
Southern System for producing and distributing iron ore into two
departments: the Southeastern System and the Southern System,
and we have begun reporting production separately for each
system.
the Guaíba Island and Itaguaí maritime
terminals, and
•
the MRS railroad.
Samarco expansion. We are increasing pellet
production capacity at Samarco, our 50% joint venture with BHP
Billiton, located in the Brazilian state of Espírito Santo.
The expansion at Samarco is expected to add 7.6 million
metric tons per year of capacity. In 2006, the engineering and
ground-leveling projects were completed. In 2007, construction
works and the assembly of electrical and mechanical components
will be undertaken, with operational
start-up
planned for the first half of 2008. Samarco obtained its own
financing for the project.
Itabiritos project. We are building a pellet
plant, located in the Brazilian state of Minas Gerais, with a
capacity of 7 million metric tons per year, an iron ore
concentration plant, and a short iron ore slurry pipeline. The
development of Itabiritos began in 2006, with the basic
engineering project and the commencement of civil engineering
works. Itabiritos’ operations are scheduled to begin in the
second half of 2008.
Joint venture in China. In September 2006, our
subsidiary MBR acquired a 25% stake in a joint venture, Zhuhai
YPM, to build a new pelletizing plant in Zhuhai, Guandong,
China. Our expected investment in this project will be
US$4 million and we will supply at least 70% of the iron
ore used to feed the plant, pursuant to a
30-year
contract. The plant is expected to become operational in 2008.
The other partners in this joint venture are Zhuhai Yueyufeng
Iron and Steel Co. Ltd. (with a 40% stake) and Pioneer
Iron & Steel Group Co. Ltd. (with a 35% stake).
Acquisition of Rio Verde Mineração
assets. In January 2006, we acquired certain
mineral resources, land and mining equipment of Rio Verde
Mineração for US$47 million. Rio Verde
Mineração is located in the Iron Quadrangle region of
the Brazilian state of Minas Gerais, near the operations of MBR
in the municipality of Nova Lima.
Nickel
Onça Puma. In the third quarter of 2006,
our Board of Directors approved our investment in the Onça
Puma nickel project, in the Brazilian state of Pará, which
is expected to have a nominal capacity of 58,000 metric tons per
year of nickel in the form of ferro-nickel, its final product.
Construction at the project site began in July 2006. We
currently estimate that the total investment in the project will
amount to US$1,437 million, and are targeting
start-up of
operations for the fourth quarter of 2008.
Goro. Following the acquisition of Inco, we
reviewed the Goro project and planned the implementation of
measures to reduce environmental, operational and technology
risks. The total cost of Goro is estimated to be
US$3,212 million, of which US$1,435 million was spent
from 2001 to 2006. The commissioning of Goro is scheduled for
the end of 2008.
Aluminum
Acquisition of remaining interest in
Valesul. In July 2006, we exercised our right of
first refusal under the Valesul Aluminio S.A.
(“Valesul”) shareholders’ agreement and acquired
BHP Billiton Metais S.A.’s 45.5% indirect interest in
Valesul for US$28 million, as a result of which we now own
100% of Valesul’s shares. We began consolidating Valesul in
our financial statements in the third quarter of 2006.
Paragominas project. We are developing a
bauxite mine in Paragominas, in the Brazilian state of
Pará, which was commissioned in the first quarter 2007,
with an initial capacity of 5.4 million metric tons per
year.
We have completed the first bauxite pipeline in the world, for
the transport of bauxite slurry from the Paragominas mine to the
alumina refinery in Barcarena, state of Pará. By 2008,
Paragominas’ capacity is expected to reach 9.9 million
metric tons per year, which will require further investment of
US$196 million. The bauxite produced at Paragominas will be
used to supply Alunorte’s expansion needs.
Alunorte expansion. In 2006 we completed our
alumina production capacity expansion at our Alunorte refinery
to 4.4 million metric tons per year, and we expect to
increase capacity further to 6.26 million metric tons per
year, at an estimated investment of US$846 million.
Expected startup for this project is in 2008.
New refinery project. We are studying a
potential investment in a greenfield alumina refinery in the
Brazilian state of Pará, near the existing facilities of
Alunorte in Brazil, expected to have an initial capacity of
1.8 million metric tons per year. Bauxite for the project
would be supplied from our Paragominas bauxite mine. If the
terms of the project are agreed, the first stage of the refinery
is expected to be completed and operational within three years.
The project is subject to the approval from our Board of
Directors.
Copper
Salobo. The Salobo project is located in
Brazil, in the Carajás region of the Brazilian state of
Pará. The environmental license was obtained in December
2006 and our Board of Directors approved the development of this
project in January 2007. However, the
start-up of
the development of the project is contingent on an appropriate
tax structure, which is currently being discussed with
government authorities. In its first stage, Salobo is expected
to produce 100,000 metric tons of copper in concentrate per year.
Project 118. The 118 copper project is
scheduled to begin operations in the first half of 2009, but we
are still awaiting the grant of a license without which
construction cannot begin. Therefore, the timing of
start-up
could be revised. A preliminary license was obtained in April
2006, and key equipment was ordered at the end of 2006. Basic
engineering for the project has been concluded.
Coal
and coke
We are pursuing several efforts to become a large global player
in the coal business.
•
Mozambique coal mine feasibility study. In
November 2004, a consortium controlled by CVRD won an
international auction to explore coal deposits in the Moatize
region, in the north of Mozambique for US$122.8 million. In
April 2005, Rio Doce Moçambique Limitada was incorporated
by CVRD under the laws of Mozambique, as the local entity to
hold the rights and obligations as developer of the Moatize
project. The project’s financial and technical feasibility
studies were completed in November 2006 and delivered to the
government of Mozambique. In March 2007 we delivered the
development plan to the government of Mozambique. Additional
studies and reports are still being conducted to support the
final decision expected to be made in 2007 regarding investment
in the project. If the project proceeds, the total investment
will include mine development costs, the construction of a
maritime terminal for ship loading, related investments and
social projects.
•
Belvedere Coal Underground Project. In July
2005, we signed an agreement with two Australian mining
companies for an exploration study of the Belvedere Coal
Underground Project, or Belvedere, located in the state of
Queensland, Australia. At the conclusion of the pre-feasibility
study this year, we have the option to acquire a 51% interest in
Belvedere at a price of US$90 million. We have further
options to increase our stake in the project to 100% by
acquiring our partners’ interests at a fair market value
determined at the time of our exercise of each option. We have
also obtained exploration rights for related areas near
Belvedere (referred to as Belvedere West and Belvedere South).
•
AMCI Holdings Australia. In April 2007, we
paid US$656 million for the acquisition of 100% of AMCI
Holdings Australia Pty (AMCI HA). AMCI HA controls and operates
coal assets through unincorporated joint ventures, with nominal
production capacity of 8.0 million metric tons of coal
(predominantly coaking coal) and reserves of 103 million
metric tons. AMCI HA had net debt of US$129 million as of
April 30, 2007.
We are taking steps to encourage steel makers to develop steel
slab plants in Brazil, in order to create value and additional
demand for our iron ore.
•
Ceará Steel. In November 2005, we agreed
to acquire a minority stake in Ceará Steel, an
export-oriented steel slab project in the Brazilian state of
Ceará, with a nominal capacity of 1.5 million metric
tons of slabs per year. The main shareholders are Dongkuk Steel,
a Korean steel maker, and Danieli S.P.A., an Italian equipment
supplier. We expect to invest US$25 million in the project,
which has an estimated total cost of US$750 million, and we
have put options to divest our stake in the future. We will be
the exclusive supplier of pellets for Ceará Steel. The
plant is expected to start production in 2009.
•
ThyssenKrupp — Companhia Siderúrgica do
Atlântico (“CSA”). In December
2004, we signed a memorandum of understanding with ThyssenKrupp
Stahl A.G., one of the largest European steel makers, for the
construction of a 5 million metric ton integrated steel
slab plant in the Brazilian state of Rio de Janeiro. The project
has been formally approved by both ThyssenKrupp Stahl A.G. and
CVRD, and is now being implemented. Commissioning of the plant
is foreseen for 2009, and our Board of Directors has approved an
investment of US$200 million for a minority stake in CSA.
We have a put option to divest our stake in the future.
•
Entry into Usiminas control group. In November
2006, we announced the restructuring of our equity interest in
Usinas Siderúrgicas de Minas Gerais S.A. —
USIMINAS (“Usiminas”). In connection with this
restructuring (i) we entered into a
15-year
shareholders’ agreement with the other members of
Usiminas’ control group, under which we will retain
6,608,608 common shares, and (ii) the Usiminas controlling
shareholders have agreed to carry out a feasibility study
regarding a potential investment by Usiminas in the construction
of a new steel slab plant.
•
Acquisition of remaining interest in Ferro Gusa Carajás
S.A. (“Ferro-Gusa”). In March 2007, we
acquired the 18% interest in Ferro-Gusa held by Nucor do Brasil
S.A. for US$20 million, as a result of which we now own
100% of Ferro-Gusa’s shares. Ferro-Gusa started operations
in October 2005 and produces 300,000 metric tons of pig iron per
year.
Divestitures
and asset sales
In line with our strategy, we have continued to reduce our
holdings of non-strategic assets. We summarize below our key
dispositions and asset sales since the beginning of 2006.
•
Foz do Chapecó and Santa Isabel hydroelectric power
projects. In February 2006, we sold to Furnas
Centrais Elétricas for US$4 million our 40% stake in
the consortium to build and operate the Foz do Chapecó
hydroelectric power plant. This transaction has been approved by
the Brazilian electricity regulatory agency (Agência
Nacional de Energia Elétrica), or ANEEL, and is
expected to close in 2007. We are also continuing our efforts to
return the concessions for the Santa Isabel hydroelectric power
project to ANEEL due to difficulties related to environmental
issues.
•
Nova Era Silicon. In February 2006, we sold to
our partner JFE Steel Corporation our 49% stake in Nova Era
Silicon, a ferrosilicon producer with operations in the
Brazilian state of Minas Gerais for US$14 million.
•
Sale of Interest in Gulf Industrial Investment
Company. In May 2006, we sold our 50% interest in
Gulf Industrial Investment Company (“GIIC”), a pellet
producer based in Bahrain, to our joint venture partner, Gulf
Investment Corporation, for US$418 million, due to
conflicting views about how GIIC’s business should be
managed. Although we have sold our interest in GIIC, we intend
to continue our strategy of pursuing the consolidation of our
global leadership position in the global market for pellets in
order to maximize the benefits arising from the significant
long-term growth potential we expect in pellet demand.
Usiminas. On November 13, 2006, we sold a
total of 5,362,928 common shares of Usiminas to Nippon Steel,
Votorantim Participações S.A. and Camargo Correa S.A.
for approximately US$176 million. We will keep 6,608,608
common shares of Usiminas pursuant to the Usiminas
shareholders’ agreement, which we signed in November 2006.
In May 2007, we sold in a public offering registered with the
CVM 13,802,499 Usiminas shares not subject to the
shareholders’ agreement and received total proceeds of
US$728 million. In connection with the offering, we entered
into a lockup agreement for a period of 90 days from
April 25, 2007. After the lockup period expires or is
waived, we intend to sell 36,691 additional shares that were not
sold pursuant to the offering’s overallotment option.
•
Siderar. In December 2006, we sold to Ternium
S.A. our entire 4.85% stake in Siderar-S.A.I.C. (Siderar), a
steel company located in Argentina, for US$108 million.
•
Gerdau. In the second half of 2006, we sold
all of our shares of Gerdau S.A. for US$67 million.
Our principal lines of business consist of mining and logistics.
We also invest in energy to supply part of our consumption. The
following map shows the locations of our current operations
worldwide.
We conduct our iron ore business primarily at the parent company
level and through our subsidiaries MBR and Urucum
Mineração S.A., or Urucum. Our iron ore mining and
related operations are concentrated in three systems in Brazil,
the Southeastern System, the Southern System and the Northern
System, further described below. The operation of these separate
systems, each with its own transportation capability, enhances
the reliability of the service we provide our customers.
Southeastern
System
The Southeastern System, carved out of our former Southern
System, recently became a separately managed department. Located
in the southeastern Brazilian state of Minas Gerais, in a region
known as the Iron Quadrangle, the iron ore mines of the
Southeastern System are divided into three mining areas:
Itabira, Centrais Mines, and Mariana. Our railroad, the
Vitória a Minas railroad, connects the mines in these areas
to the Tubarão port in Vitória, in the Brazilian state
of Espírito Santo.
Iron ore in the Southeastern System is mined by open-pit
methods. These ore reserves have high ratios of itabirite ore
relative to hematite ore. Itabirite is a quartz-hematite rock
with an average iron content ranging from
35-60%,
requiring concentration to achieve shipping grade, which is
above a 64% average iron content. Hematite is a high-grade ore
with an average iron content of approximately 66%.
Mines in the Southeastern System generally process their
run-of-mine
by means of standard crushing, classification and concentration
steps, producing sinter feed, lump ore and pellet feed in the
beneficiation plants located at the mining sites.
In 2006, we produced 100% of the electric energy consumed in the
Southeastern System at our Igarapava, Porto Estrela, Funil,
Candonga, Aimorés and Capim Branco I hydroelectric power
plants. The Southeastern System is accessible by road or by spur
tracks of the Vitória a Minas railroad.
Southern
System
The new Southern System, located in the Brazilian states of
Minas Gerais and Rio de Janeiro, consists of the Oeste mines and
the mines of MBR. MBR presently operates three major mining
complexes:
•
the Pico complex, comprised of the Pico, Sapecado and Galinheiro
mines, with one major plant and three secondary plants;
•
the Vargem Grande complex, comprised of the Tamanduá,
Capitão do Mato and Abóboras mines, and one major
beneficiation plant; and
•
the Paraopeba complex, comprised of the Jangada mine (with a
beneficiation plant), the Capão Xavier mine (with the
Mutuca beneficiation plant) and the Mar Azul mine (with a
beneficiation plant).
Wet beneficiation processes are used to convert
run-of-mine
obtained from open-pit mining operations into lump ore, sinter
feed fines and pellet feed fines, in addition to
hematitinha, a product used primarily by Brazilian
pig-iron producers.
The iron ore produced in our Southern System is transported by
MRS Logística S.A. (“MRS”), a railway company in
which we hold, directly and indirectly, 37.2% of the voting
capital and 40.5% of the total capital,
to the Guaíba Island and Itaguaí maritime terminals,
both located in the Brazilian state of Rio de Janeiro. In 2006,
we produced 22% of the electric energy consumed in the Southern
System at our Igarapava, Porto Estrela, Funil, Candonga,
Aimorés and Capim Branco I hydroelectric power plants.
Northern
System
The Northern System is comprised of open-pit iron ore mines and
an ore-processing complex in the Carajás region of the
Brazilian state of Pará. The mines are located in the north
of Brazil on public lands for which we hold mining concessions.
The Northern System’s reserves are among the largest iron
ore deposits in the world. These reserves are divided into two
main ranges (north and south), situated approximately
35 kilometers apart. Iron ore mining activities in the
Northern System are currently being conducted in the northern
range, which is divided into five main mining bodies (N4E, N4W,
N5W, N5E and N5EN).
Because of the high iron content (66.8% on average) in the
Northern System deposits, we do not have to operate a
concentration plant at Carajás. The beneficiation process
consists simply of sizing operations, including screening,
hydrocycloning, crushing and filtration. This allows us to
produce marketable iron ore in the Northern System at a lower
cost than in the Southern and Southeastern Systems. Output from
the beneficiation process consists of sinter feed, pellet feed,
special fines for direct reduction processes and lump ore. After
completion of the beneficiation process, our Carajás
railroad transports Northern System iron ore to the Ponta da
Madeira maritime terminal in the Brazilian state of
Maranhão.
Our complex in Carajás is accessible by road, air and rail.
It obtains electrical power at market rates from regional
utilities. To support our Carajás operations, we have
housing and other facilities in a nearby township.
Casa de
Pedra
In March 2001, we acquired certain rights of first refusal with
respect to the Casa de Pedra iron ore mine of CSN (Companhia
Siderúrgica Nacional): the right, for thirty years, to
purchase at market prices any excess iron ore as defined in the
agreement; the right, for thirty years, to purchase or lease the
mine if CSN decides to sell or lease it; and the right, for
thirty years, to become a joint venture partner if CSN decides
to form a pelletizing joint venture with a third party using
iron ore produced by the mine. On August 10, 2005, CADE
issued a decision approving certain of our acquisitions, which
imposed certain conditions on us, including a full waiver of our
preemptive rights relating to the Casa de Pedra iron ore mine.
See Item 3. Key information — Risk
factors — We are involved in ongoing antitrust
proceedings that could result in divestitures, fines or other
restrictions that could harm our business.
Iron
ore projects
We are developing the following iron ore projects in Brazil:
•
Carajás expansion to 130 Mtpa. This
expansion is a brownfield project to increase production
capacity in the northern part of the Carajás mineral
province. Investment in this project is estimated at
US$1.8 billion, covering costs of mine expansion, a primary
crushing plant, processing and classification units, locomotives
and wagons. In 2007 the detailed engineering project is to be
drawn up and completion is scheduled for 2009.
•
Fazendão. This project is expected to
produce 15.8 million metric tons of
run-of-mine
(unprocessed ore) iron ore per year and will allow the
commencement of operations at Samarco’s third pellet plant.
Construction began in the second half of 2006, and operations
are scheduled to begin in the first quarter of 2008.
The table on the next page sets forth information regarding our
proven and probable iron ore reserves and projected exhaustion
dates for the periods indicated. The projected exhaustion dates
are estimated based on our estimates of future production levels.
Open pit mines. CVRD’s equity
interest in mines is 100% unless otherwise noted.
(2)
Reserves are in wet,
run-of-mine
(ROM) ore metric tons unless otherwise noted.
(3)
Reserves were not reported for 2005
due to the mine’s depleted state. The Cauê plant
beneficiates iron ore from Minas do Meio mines.
(4)
Average product recovery after
beneficiation at the Conceição plant was 77.7%. The
Conceição plant beneficiates iron ore from the
Conceição mine and Minas do Meio mines.
(5)
Average product recovery after
beneficiation at the Cauê plant was 70.5%. The
run-of-mine
from Minas do Meio is sent to the Cauê concentration plant
and the Conceição concentration plant. The production
is declared in Cauê and Conceição.
(6)
Average product recovery after
beneficiation was 48.1%. Água Limpa is owned by Baovale, in
which CVRD owns 100% of the voting shares and 50% of the total
shares.
(7)
Average product recovery after
beneficiation was 81.4%.
Average product recovery after
beneficiation was 97%.
(9)
New project with audited reserves
under feasibility review.
(10)
New project with audited reserves
under feasibility review.
(11)
Reserves were not reported for 2006
due to the mine’s depleted state.
(12)
Average product recovery after
beneficiation was 69.7%. The Alegria plant processes ore from
the Alegria and Fabrica Nova mines.
(13)
Fabrica Nova ore is sent to the
Alegria and Timbopeba plants for processing.
(14)
Average product recovery after
beneficiation was 100% (direct shipping).
(15)
Average product recovery after
beneficiation was 78.9%.
(16)
Average product recovery after
beneficiation was 86.2%.
(17)
Average product recovery after
beneficiation was 66%. The
run-of-mine
is sent to the Fábrica concentration plant.
(18)
Average product recovery after
beneficiation was 90.1%.
(19)
Average product recovery after
beneficiation was 100% (direct shipping). In 2004, we entered
into an agreement to lease the Andrade iron ore mine, but we
only started to run this mine in January 2005.
(20)
Average product recovery after
beneficiation was 81.5%.
(21)
Average product recovery after
beneficiation was 78.6%. Tamanduá ore and Capitão do
Mato ore are processed at the Vargem Grande plant.
(22)
Average product recovery after
beneficiation was 100% (direct shipping).
(23)
Average product recovery after
beneficiation was 79.9%.
(24)
Average product recovery after
beneficiation was 78.6%.
(25)
Acquired in the first quarter of
2006. Average product recovery after beneficiation was 87.1%.
Changes
in iron ore reserves: 2005 versus 2006
Our 2006 iron ore reserve estimates reflect mining depletion in
2006 and the
build-up of
intermediate and buffer ore stocks, which are composed of ore
that has been mined out of “in situ” reserves but has
not been fed to the plants. These stocks may be partially
reclaimed during operations. Our 2006 reserve estimates also
reflect revisions to estimates in light of differences
identified in reconciliation testing between estimated ore
tonnages predicted by our reserves model and actual
run-of-mine.
We describe changes in reserves at our individual mines below.
•
Reserves at our Conceição mine decreased from 395.6 to
367.7 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, a reduction in our
reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model.
•
Reserves at our Minas do Meio mine decreased from 635.7 to
592.4 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, a reduction in our
reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model.
•
Reserves at our Água Limpa mine decreased from 63.8 to
57.0 million metric tons, primarily reflecting mining
depletion in 2006, which was partially offset by an upward
adjustment to our reserves estimates to reflect differences
between actual recoveries and amounts predicted by our reserves
model and by reclaimed stockpiles.
•
Reserves at our Gongo Soco mine decreased from 96.2 to
86.7 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, the
build-up of
buffer stockpiles and a reduction in our reserves estimates to
reflect differences between actual recoveries and amounts
predicted by our reserves model.
•
Reserves at our Brucutu mine decreased from 736.6 to
722.2 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, the
build-up of
buffer
run-of-mine
stockpiles and a reduction in our reserves estimates to reflect
differences between actual recoveries and amounts predicted by
our reserves model.
•
Reserves at our Andrade mine decreased from 129.2 to
127.0 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, a reduction in our
reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model.
•
Reserves at our Alegria mine decreased from 281.8 to
258.0 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, and a reduction in
our reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model.
Reserves at our Fabrica Nova mine decreased from 946.3 to
920.5 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, a net upward
adjustment to our reserves estimates to reflect differences
between actual recoveries and amounts predicted by our reserves
model.
•
Reserves at our Fazendão mine decreased from 351.3 to
349.5 million metric tons, primarily reflecting a reduction
in our reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model and, to a
lesser extent, mining depletion in 2006.
•
Reserves at our Timbopeba mine decreased from 81.7 to
75.1 million metric tons, primarily reflecting a reduction
in our reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model and, to a
lesser extent, mining depletion in 2006.
•
Reserves at our Córrego do Feijão mine decreased from
51.3 to 45.3 million metric tons, primarily reflecting
mining depletion in 2006 and, to a lesser extent, a reduction in
our reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model, which
decreases were partially offset by reclaimed stockpiles.
•
Reserves at our Segredo/João Pereira mine decreased from
501.5 to 485.8 million metric tons, primarily reflecting
mining depletion in 2006, which was partially offset by an
upward adjustment to our reserves estimates to reflect
differences between actual recoveries and amounts predicted by
our reserves model.
•
Reserves at our Pico/Sapecado/Galinheiro mine decreased from
662.0 to 633.2 million metric tons, primarily reflecting
mining depletion in 2006 and, to a lesser extent, the
build-up of
buffer
run-of-mine
stockpiles and a reduction in our reserves estimates to reflect
differences between actual recoveries and amounts predicted by
our reserves model.
•
Reserves at our Tamanduá mine decreased from 99.3 to
86.1 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, a reduction in our
reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model.
•
Reserves at our Abóboras mine decreased from 32.2 to
30.1 million metric tons, primarily reflecting mining
depletion in 2006, which was partially offset by an upward
adjustment to our reserves estimates to reflect differences
between actual recoveries and amounts predicted by our reserves
model.
•
Reserves at our Jangada mine decreased from 92.8 to
87.6 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, a reduction in our
reserves estimates to reflect differences between actual
recoveries and amounts predicted by our reserves model.
•
Reserves at our Capão Xavier mine decreased from 179.8 to
163.9 million metric tons, primarily reflecting mining
depletion in 2006, which was partially offset by a net upward
adjustment to our reserves estimates to reflect differences
between actual recoveries and amounts predicted by our reserves
model.
•
Reserves at our Serra Norte mine decreased from 2,056.3 to
1,960.2 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, the
build-up of
buffer
run-of-mine
stockpiles and a reduction in our reserves estimates to reflect
differences between actual recoveries and amounts predicted by
our reserves model.
•
Reserves at our Urucum mine decreased from 64.3 to
61.7 million metric tons, primarily reflecting mining
depletion in 2006 and a reduction in our reserves estimates to
reflect differences between actual recoveries and amounts
predicted by our reserves model.
We produce iron ore pellets in our own plants and through joint
ventures. The table below sets forth information regarding our
iron ore pellet business as of April 30, 2007.
We suspended operations at our São Luís pelletizing
plant from March to July 2006 due to a decrease in the global
demand for pellets, which is more concentrated in North America
and Europe.
We sell pellet feed to our pelletizing joint ventures at
market-based prices. Historically, we have supplied all of the
iron ore requirements of our wholly owned pelletizing plants and
our joint ventures, except for Samarco and GIIC, to which we
supply a portion of their needs. Of 2006 total pellet
production, 69% was attributable to blast furnace pellets, and
the remaining 31% to direct reduction pellets, which are used in
steel mills that use the direct reduction process rather than
blast furnace technology.
We are the operator of pelletizing joint ventures located in the
Tubarão Port area. In 2006, we received US$72 million
in fees for operating the plants of these joint ventures.
The table below sets forth information regarding our iron ore
sales to our pelletizing joint ventures for the periods
indicated.
In 2004 we sold 2.0 million
metric tons of concentrate and 2.6 million metric tons of
run-of-mine;
in 2005 we sold 2.0 million metric tons of concentrate and
4.2 million metric tons of
run-of-mine;
and in 2006 we sold 1.9 million metric tons of concentrate
and 5.6 million metric tons of
run-of-mine.
We are developing the following iron ore pellets projects in
Brazil and in China:
Samarco expansion. We are increasing pellet
production capacity at Samarco, our 50% joint venture with BHP
Billiton, which pellet plant is located in the Brazilian state
of Espírito Santo. The expansion at Samarco is expected to
add 7.6 million metric tons per year of capacity. In 2006,
the engineering and ground-leveling projects were completed. In
2007, construction works and the assembly of electrical and
mechanical components will be undertaken, with operational
start-up
planned for the first half of 2008. Samarco obtained its own
financing for the project.
Itabiritos project. We are building a pellet
plant, located in the Brazilian state of Minas Gerais, with a
capacity of 7 million metric tons per year, an iron ore
concentration plant, and a short iron-ore slurry pipeline. The
development of Itabiritos began in 2006, with the basic
engineering project and the commencement of civil engineering
works. Itabiritos’ operations are scheduled to begin in the
first half of 2008.
Joint venture in China. In September 2006 our
subsidiary MBR acquired a 25% stake in a joint venture, called
Zhuhai YPM, to build a new pelletizing plant in Zhuhai,
Guandong, China. We expect to invest US$4 million in this
project, and we will supply at least 70% of the iron ore used to
feed the plant, pursuant to a
30-year
contract. The plant is expected to become operational in 2008.
The other partners in this joint venture are Zhuhai Yueyufeng
Iron and Steel Co. Ltd. (with a 40% stake) and Pioneer
Iron & Steel Group Co. Ltd. (with a 35% stake).
Customers,
sales and marketing — iron ore and
pellets
We use all of our iron ore and pellets (including our share of
joint-venture pellet production) to supply the steel-making
industry. Prevailing and expected levels of demand for steel
products affect demand for our iron ore and pellets. Demand for
steel products is influenced by many factors, such as expected
rates of economic growth.
In 2006, China accounted for 27.4% of our iron ore and pellets
shipments, Europe accounted for 24.8% and Brazil accounted for
21.3%. Sales to the Tubarão pelletizing joint ventures, at
which most iron ore is transformed into pellets and then sent
abroad, accounted for 8.1% of total shipments in 2006. Our 10
largest customers collectively purchased 145.2 million
metric tons of iron ore and pellets from us, representing 52.6%
of our 2006 iron ore and pellet shipments and 51.9% of our total
iron ore and pellets revenues. With the exception of Arcelor
Mittal, which accounted for 17.9% of our shipments of iron ore
and pellets in 2006, no individual customer accounted for more
than 10% of our shipments of iron ore and pellets for any of the
three years ended December 31, 2006.
We strongly emphasize customer service in order to improve our
competitiveness. We work with our customers to understand their
principal objectives and to provide them with iron ore solutions
to meet specific customer needs. Using our expertise in mining,
agglomeration and iron-making processes, we search for technical
solutions that will balance the best use of our world-class
mining assets and the satisfaction of our clients. We believe
that our ability to provide our customers with a total iron ore
solution and the quality of our products are very important
advantages helping us to improve our competitiveness in relation
to competitors who may be more conveniently located
geographically. In addition to offering technical assistance to
our customers, CVRD operates sales support offices in Tokyo,
Japan; Seoul, South Korea and Shanghai, China, which support the
sales made by our international sales subsidiary located in
Saint Prex, Switzerland. These offices also allow us to stay in
close contact with our customers, monitor their requirements and
our contract performance, and ensure that our customers receive
timely deliveries.
Distribution —
iron ore and pellets
Our ownership and operation of transportation systems designed
for the efficient transportation of iron ore products complement
our iron ore mining business in the Northern and Southeastern
Systems where we operate an integrated railroad and terminal
network in each of them. These networks transport our iron ore
products from interior mining locations to maritime terminals
and Brazilian customers. For a more detailed description of the
networks, see — Logistics, below.
We do not own or operate an integrated transportation system for
our Southern System. Instead, we enter into freight contracts
with our affiliated company, MRS, to transport our iron ore
products at market rates from MBR’s mines and Oeste mines
to our Guaíba Island and Itaguaí maritime terminals.
Competition —
iron ore and pellets
The global iron ore market is highly competitive. Several large
producers operate in this market. The main factors affecting
competition are price, quality, range of products offered,
reliability, operating costs and shipping costs. In 2006, the
Asian market (primarily China, Japan and South Korea) and the
European market were the primary markets for our iron ore.
Our biggest competitors in the Asian market are located in
Australia and include subsidiaries and affiliates of BHP
Billiton PLC and Rio Tinto Ltd. Although the transportation
costs of delivering iron ore from Australia to Asian customers
are generally lower than ours as a result of Australia’s
geographical proximity, we believe we are able to remain
competitive in the Asian market for two main reasons. First,
steel companies generally seek to obtain the types (or blends)
of iron ore and pellets that can produce the intended final
product in the most economic and efficient manner. Our iron ore
has low impurity levels and other properties that generally lead
to lower processing costs. For example, the alumina content of
our iron ore is very low compared to Australian ore and has high
iron content, improving productivity in blast furnaces, which is
important especially during periods of high demand. Second,
steel companies often develop sales relationships based on a
reliable supply of a specific mix of iron ore and pellets. We
have a customer-oriented marketing policy and place specialized
personnel in direct contact with our clients to help determine
the blend that best suits each particular customer. In general,
in the Northern and Southeastern Systems, our ownership of the
process of transporting iron ore to our ports makes it easier
for us to ensure that our products get to our ports on schedule
and at competitive costs.
We are competitive in the European market for the reasons we
described above, as well as the proximity of the Ponta da
Madeira and Tubarão port facilities to European customers.
Our principal competitors in Europe are:
•
Kumba Resources (South Africa);
•
Luossavaara Kiirunavaara AB — LKAB (Sweden);
•
Société Nationale Industrielle et
Minière — SNIM (Mauritania);
•
Rio Tinto PLC (UK), Rio Tinto Ltd (Australia) and their
subsidiaries and affiliates; and
•
BHP Billiton (Australia) and its subsidiaries and affiliates.
The Brazilian iron ore market is competitive, with a wide range
of smaller iron ore producers and integrated steel companies
such as CSN and Mannesmann. Although pricing is relevant,
quality and reliability are important competitive factors as
well. We believe that our integrated transportation systems,
high-quality ore and technical services make us a strong
competitor in Brazilian sales. Prices to Brazilian customers are
based on global reference prices decreased by the transportation
costs to their facilities.
Manganese
ore and ferroalloys
In 2006, we were one of the largest producers in the global
seaborne market, with total shipments of 779 thousand
metric tons of manganese ore and 522 thousand metric tons of
ferroalloys.
We conduct our manganese ore and ferroalloy businesses through
four subsidiaries:
We produce manganese ore products from the Azul mine in the
Carajás region of the Brazilian state of Pará, and
from the Urucum mine of the Pantanal region of the Brazilian
state of Mato Grosso do Sul. We operate
on-site
beneficiation plants at both the Azul and Urucum mines. Both
mines are accessible by road, and the mines obtain electrical
power at market rates from regional electric utilities. We also
operate minor mines in the Brazilian states of Minas Gerais and
Bahia. Our Azul and Urucum mines have high-grade ores, and our
smaller mines in Minas Gerais and Bahia have low-grade ores.
Our manganese ore mines produce three types of manganese ore
products:
•
metallurgical ore used primarily for the production of
ferroalloys;
•
natural manganese dioxide suitable for the manufacture of
electrolytic batteries; and
•
chemical ore used in several industries for the production of
fertilizer, pesticides and animal food, and used as a pigment in
the ceramics industry.
The table below sets forth information regarding our manganese
ore production and reserves. We own 100% of all mines.
Proven and Probable Reserves as of December 31,
Projected
2005
2006
Began
Exhaustion
Production for the Year Ended December 31,
Ore
Ore
Operations
Date
2004
2005
2006
Type
Tonnage(1)
Grade(2)
Tonnage(1)
Grade(2)
(Million metric tons)
Azul(3)
1985
2017
2.0
2.2
1.7
Open Pit
45.7
35.7
42.9
35.2
Urucum(4)
1976
2020
0.4
0.4
0.4
Underground
8.2
45.3
7.7
45.3
Morro da Mina(5)
1902
2030
0.2
0.3
0.2
Open Pit
9.6
23.0
9.4
22.8
Bahia mines(6)
1972
N/A
0.1
0.1
0.0
Open Pit
N/A
N/A
N/A
N/A
Total
2.7
3.0
2.3
63.5
35.0
60.0
34.5
(1)
Reserves reported as
run-of-mine
wet metric tons, in millions of metric tons.
(2)
Reported as
run-of-mine
Mn% grade.
(3)
Average product recovery after
beneficiation was 69% of ROM metric tons.
(4)
Average product recovery after
beneficiation was 75% of ROM metric tons.
(5)
Average product recovery after
beneficiation was 88% of ROM metric tons.
(6)
There are no proven and probable
manganese reserves at the mines located in the Brazilian state
of Bahia.
Changes
in manganese ore reserves: 2005 versus 2006
•
Reserves at our Azul mine decreased from 45.7 to
42.9 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, the
build-up of
buffer
run-of-mine
stockpiles, which are mined out of “in situ” reserves
but have not been fed to the plants. These stocks may be
partially reclaimed during operations.
•
Reserves at our Urucum mine decreased from 8.2 to
7.7 million metric tons, primarily reflecting mining
depletion in 2006.
•
Reserves at our Morro da Mina mine decreased from 9.6 to
9.4 million metric tons, primarily reflecting mining
depletion in 2006.
CVRD produces several types of ferroalloys, such as manganese
ferro-silicon alloys (SiMnFe), ferro-manganese high-carbon
alloys (HCFeMn), and ferro-manganese mediumcarbon alloys
(MCFeMn). We currently operate eight plants that produce
ferroalloys and special alloys:
•
the plants of Santa Rita, Barbacena, Ouro Preto and São
João del Rey (all in the Brazilian state of Minas Gerais),
•
Simões Filho (in the Brazilian state of Bahia),
•
Corumbá (in the Brazilian state of Mato Grosso do Sul),
•
RDME (in Dunkerque, France), and
•
RDMN (in Mo I Rana, Norway).
The production of ferroalloys consumes significant amounts of
electricity, representing 13.2% of our total consumption in
2006. For information on the risks associated with potential
energy shortages, see Item 3. Key
Information — Risk Factors. The table below sets
forth information regarding our production in 2006.
Annual Production
Production
Capacity
in 2006
(Thousand metric tons)
RDME (Rio Doce Manganèse
Europe)
136
146
RDMN (Rio Doce Manganese Norway )
110
107
RDM (Rio Doce Manganês S.A.)
368
260
Urucum (Urucum Mineração
S.A.)
20
21
NES (Nova Era Silicon S.A.)(1)
45
6
Total
651
540
(1)
We sold our interest in NES in
February 2006.
Given the global excess supply that resulted in inventory
accumulation and falling ferroalloy prices, we decided to shut
down our ferroalloy plant in Norway between August and November
2005. We also decided to operate our ferroalloy plant in France
below its nominal capacity. As ferroalloy inventories were
consumed and prices stabilized, we resumed full capacity
operation at our Norwegian and French plants in December 2005.
On the other hand, given the weakness in Brazilian demand for
ferroalloys, we have shut down three furnaces at our Simões
Filho plant since January 2006.
Competition —
manganese ore and ferroalloys
The markets for manganese ore and ferroalloys are highly
competitive. Competition in the manganese ore market takes place
in two segments. High-grade (40% Mn or more) manganese ore
competes on a global seaborne basis, while low grade ore
competes on a regional basis. For some ferroalloys, high-grade
ore is mandatory, while for others high- and low-grade ores are
complementary. Besides manganese ore content, cost and
physical-chemical features play an important role in competition
(e.g. moisture, impurities). The main suppliers of
high-grade ores are located in South Africa, Gabon and
Australia. The main producers of low-grade ores are located in
Ukraine, China, Ghana, Kazakhstan, India and Mexico.
The ferroalloy market is characterized by a large number of
market players who compete primarily on the basis of price
(which is a function of the producer’s operating costs).
The principal competitive factors in this market are costs of
manganese ore, electricity, logistics and carbon. We compete
both with standalone producers and integrated producers that
also mine their own ore. Our competitors are located principally
in manganese-ore or steel producing countries.
We are taking steps to improve our competitive position and
reduce operating costs at our manganese ore and ferroalloys
operations through divestments, reduction of personnel, and
streamlining of the management structure.
We conduct our nickel business through our wholly owned
subsidiary CVRD Inco and its 61%-owned subsidiary PT Inco. CVRD
Inco operates two nickel production systems, one in North
America and Europe, and another in Asia.
Our principal nickel operations in North America and Europe are
set forth in the table below.
Location
Operations
Canada:
Ontario
Sudbury, Ontario
Fully integrated mines, mill,
smelter and refinery (producing finished nickel)
Manitoba
Thompson, Manitoba
Fully integrated mines, mill,
smelter and refinery (producing finished nickel)
Voisey’s Bay
Voisey’s Bay,
Newfoundland & Labrador
Mine and mill (producing an
intermediate product: nickel concentrates)
At our Ontario, Manitoba and Voisey’s Bay operations, we
mine nickel sulfide ore bodies. Sulfide deposits, which
currently account for about 28% of the world’s estimated
nickel resources, are generally found in bedrock, deep below the
earth’s surface. They can contain significant co-deposits
of copper, cobalt, platinum-group metals, and other precious
metals. Our long-established mines in Ontario and Manitoba are
primarily underground operations. Our newest mine, Voisey’s
Bay, which commenced commercial production in late 2005, is an
open-pit operation with the potential for underground operations
at a later stage.
In Ontario and Manitoba, we produce finished nickel at our
integrated mining, milling, smelting and refining operations. A
nickel intermediate product from our Ontario operations (nickel
oxide) is also shipped to our stand-alone nickel refinery in
Clydach, Wales for processing into finished nickel. Our
Voisey’s Bay ore is milled on site in Labrador and then
shipped as an intermediate product (nickel concentrates)
primarily to our Ontario and Manitoba operations for final
processing. A portion of our Voisey’s Bay nickel
concentrate is also toll-smelted and toll-refined by third
parties in Europe. Under our agreement with the Government of
Newfoundland & Labrador, we are committed to
constructing a nickel refinery in that Province by the end of
2011.
Our principal nickel operations in Asia are set forth in the
table below.
Location
Operations
PT Inco (61%)
Sulawesi, Indonesia
Mining and processing operation
(producing an intermediate product:
nickel-in-matte)
Our 61%-owned subsidiary, PT Inco, operates an open-pit mine and
related processing facility on the Island of Sulawesi,
Indonesia. PT Inco mines nickel laterite ore. Laterite deposits,
which currently account for around 72% of the world’s
estimated nickel resources, are generally located at or near the
surface and are amenable to open-pit production methods. PT Inco
produces an intermediate product
(nickel-in-matte),
which is shipped primarily to nickel refineries in Japan. PT
Inco is a public company whose shares are traded on the Jakarta
Stock Exchange. 20% of PT Inco’s shares are held by
Sumitomo Metal Mining Co., Ltd. (“Sumitomo”) of Japan,
with the remaining shares (18%) being widely held. PT Inco sells
80% of its production to CVRD Inco and 20% of its production to
Sumitomo, pursuant to
life-of-mine
off-take agreements.
Our 67%-owned subsidiary, Inco TNC Limited (“Inco
TNC”), operates a refinery near Tokyo, Japan, which
produces intermediate and finished nickel products primarily
using
nickel-in-matte
sourced from PT Inco. Inco TNC is a private company. Thirteen
percent (13%) of Inco TNC’s shares are held by Sumitomo, 7%
are held by Mitsui & Co., Ltd. (“Mitsui”) of
Japan, and the remaining shares (13%) are held by a number of
Japanese investors.
We also have investment interests in nickel refining operations
in Taiwan and South Korea, through Taiwan Nickel Refining
Corporation (“TNRC”) (49.9%) and Korea Nickel
Corporation (“KNC”) (25%). TNRC and KNC produce
finished nickel for the local stainless steel industry in Taiwan
and Korea, primarily using intermediate products from Inco TNC
and a product containing about 75% nickel from our Ontario
operations.
Through our Inco Special Products business unit, we develop,
manufacture and sell value-added specialty nickel products,
including powders, foams, flakes, oxides and nickel-coated
graphite. These products, which are generally sold at premium
prices, are used for such applications as consumer electronics,
rechargeable batteries for consumer and hybrid vehicle use, fuel
cells, powder metallurgy, automotive parts, electromagnetic
interference shielding for computers and cellular telephones,
catalysts and salts, metal injection molding, and hard metal
binders. Our nickel specialty products offices and operations
are located in Canada, in China, through our 76.7%-owned
subsidiary Inco Advanced Technology Materials (Dalian) Co.,
Ltd., our 77%-owned subsidiary Inco Advanced Technology
Materials (Shenyang) Co. Ltd. and our 65%-owned subsidiary Jinco
Nonferrous Metals Co. Ltd.; in Japan, in the United Kingdom, in
Germany, through our wholly-owned subsidiary Inco GmbH and our
50%-owned subsidiary Alantum GmbH & Co. KG; and in the
United States, through our wholly-owned subsidiary Novamet
Specialty Products Corporation.
Through our wholly-owned subsidiary The International Metals
Reclamation Company, Inc. (“INMETCO”), we process
stainless steel wastes,
end-of-life
batteries and other waste products primarily containing nickel,
chromium, iron and cadmium and sell the resulting recovered
metals as a remelt alloy ingot to the stainless steel industry.
INMETCO’s facilities are located in the state of
Pennsylvania in the United States.
Nickel
projects
We are developing the following nickel projects in Brazil and
New Caledonia:
•
Onça Puma. Construction at the project
site, in the Brazilian state of Pará, began in the third
quarter of 2006. Operations at Onça Puma are expected to
begin in the fourth quarter of 2008. Onça Puma is expected
to have a nominal capacity of 58,000 metric tons per year of
nickel in the form of ferro-nickel, its final product. We
currently estimate that the total investment in the project will
amount to US$1,437 million.
•
Vermelho. The process of obtaining the
necessary licenses for the development of this project, in the
Brazilian Province of Carajás, is still ongoing. Vermelho
has an estimated production capacity of 46,000 metric tons of
nickel per year and 2,800 metric tons of cobalt per year, and
has proven and probable reserves of 290 million metric
tons. Its lateritic (limonitic) ores have an estimated nickel
content of 0.8%. The technology to be used to extract the nickel
from the ore is high-pressure acid leaching (HPAL), with a
hydrometallurgical process. The project has an estimated cost of
US$1,452 million.
•
Goro. As a result of our acquisition of Inco,
we now hold a 74% interest in the Goro nickel-cobalt project in
New Caledonia through the project company Goro Nickel S.A.S. The
other investors are Sumic Nickel Netherlands, a joint venture
between Sumitomo and Mitsui (with a 21% stake), and SPMSC
(Société de Participation Minière du Sud
Calédonien) (with a 5% stake). Goro is a major
greenfield project consisting of an open-pit mine and processing
facility, which is expected to have an annual production
capacity of 60,000 metric tons of nickel upon completion. As a
result of a recent review of the project, we have planned the
implementation of measures to reduce environmental, operational
and technology risks. The total cost of Goro is estimated to be
US$3,212 million, of which
US$1,435 million was spent from 2001 to 2006. The
commissioning of operations at Goro is scheduled for the end of
2008.
Nickel
production and reserves
The table below sets forth information regarding production and
reserve data for finished nickel.
Proven and Probable Reserves as of December 31,(1)
Projected
Production for the Year Ended
2005
2006
Operating
Exhaustion
December 31,
Ore
Ore
Since
Date
2004
2005
2006
Type
Tonnage
Grade
Tonnage
Grade
(Thousand
(Million
(%)
(Million
(%)
metric tons)
metric tons)
metric tons)
Ontario(2)
1885
2042
109.1
96.5
93.8
Underground
163
1.22
175
1.18
Manitoba(2)
1960
2017
52.4
48.6
34.9
Underground
25
1.90
24
1.88
Voisey’s Bay(3)
2005
2019
—
—
35.5
Open pit
32
2.75
31
2.67
PT Inco(4)(5)
1977
2039
75.1
73.9
70.0
Open pit
147
1.80
177
1.77
External(6)
N/A
N/A
0.2
0.7
0.7
N/A
N/A
N/A
N/A
N/A
Goro Project(5)(7)
N/A
2036
N/A
N/A
N/A
Open pit
120
1.48
120
1.48
Vermelho Project(8)
N/A
2050
N/A
N/A
N/A
Open pit
N/A
N/A
245
0.81
Onça Puma Project(9)
N/A
2039
N/A
N/A
N/A
Open pit
N/A
N/A
78
1.80
Total(6)
236.8
219.8
234.9
487
1.59
850
1.37
(1)
Ore reserves listed are totals for
the operation and projects indicated and assume that we own, or
have all of the necessary rights to mine, extract and process,
all of such ore reserves and, accordingly, are not based upon
our ownership interest in the operation or project or properties.
(2)
Includes some finished nickel
produced by CVRD Inco from third-party purchased feeds. Primary
nickel production only (does not include secondary nickel from
INMETCO).
(3)
Includes finished nickel produced
at CVRD Inco’s Ontario and Manitoba operations, as well as
some finished nickel produced by third parties under
toll-smelting and toll-refining arrangements.
(4)
We have a 61% interest in PT Inco
(Indonesia) and these figures include the minority interests.
(5)
We have rights to other properties
in Indonesia, New Caledonia and in other locations, which have
not yet been fully explored.
(6)
Excludes finished nickel produced
under toll-smelting and refining arrangements covering purchased
intermediates with third parties. Third-party tolling of
purchased intermediates was 1.0 thousand metric tons in 2005 and
16.1 thousand metric tons in 2006. There was no third-party
tolling of purchased intermediates in 2004.
(7)
CVRD has a 74% interest in the Goro
project through CVRD Inco. Completion of comprehensive project
reviews, governmental or regulatory permitting and other
approvals
and/or
significant capital expenditures would be required before
operations could commence at this project.
(8)
New project. Reserve estimates are
reported for “in situ” metric tons and grades, without
adjustment.
(9)
New project.
Changes
in nickel reserves: 2005 versus 2006
•
Reserves at our Ontario operations increased 7%, from 163 to
175 million metric tons, after mining depletion, as a
result of exploration additions and mine plan re-evaluation due
to increased metal values. Nickel grades declined by
approximately 3% due to additions of lower grade material in the
mine plan, which were previously considered marginal.
•
Reserves at our Manitoba operations decreased from 25 to
24 million metric tons, primarily due to mining depletion,
which was partially offset by ore reserve additions resulting
from exploration and mine plan re-evaluation. The estimated
average nickel grade declined by 1%.
•
Reserves at our Voisey’s Bay operations decreased from 32
to 31 million metric tons, primarily due to mining
depletion, which was partially offset by a reduction in the
cut-off grade. The reduction in the cut-off grade has also
contributed to a 3% decline in the estimated average nickel
grade.
•
Reserves at PT Inco increased 29%, from 147 to 177 million
metric tons, after adjustments for mining depletion of
5 million metric tons and a reclassification of ore reserve
to mineral resource categories of 7 million metric tons due
to an increase in the minimum distance required between mining
activities and Lake Matano. The increase in reserves includes
12 million metric tons from recent detailed core drilling
to meet processing feed plant chemistry, 10 million metric
tons of estimated limonite reserves required for blending
purposes, 9 million metric tons of added open pit contact
dilution material and an
estimated 11 million metric tons of reserves from the Petea
deposit due to confirmation of a higher recovery factor
established through reconciliation studies.
Customers,
sales and marketing — nickel
Nickel is an exchange-traded commodity, listed on the London
Metal Exchange, or the LME. Although only about 5% of global
nickel consumption is physically delivered through the LME, the
LME nickel price is used as a reference price in supply
contracts for nickel products between nickel suppliers and their
customers. Most nickel products are priced according to a
discount or premium to the LME price, depending on the nickel
product’s physical and technical characteristics.
CVRD Inco’s finished nickel products represent what is
known in the industry as “primary” nickel, meaning
nickel produced principally from nickel ores. Finished primary
nickel products may be essentially distinguished in terms of
purity level, shape and size. As regards purity, historically
three broad categories of products have been identified:
(i) ferronickel
(20-40%
nickel), (ii) standard LME grade nickel (minimum 99.8%
nickel) and (iii) high purity nickel (99.9% nickel). In
addition to nickel content, the presence or absence of specific
elemental impurities (such as carbon, nitrogen, etc.) also play
an important role in defining “high purity” nickel.
The shape and size of a nickel product may affect its
suitability for various end use applications. In 2006, a new
primary nickel product entered the market, known as
nickel-chromium pig iron. This is a low-grade nickel product
made in China from imported lateritic ores (primarily from the
Philippines, Indonesia and New Caledonia), suitable primarily
for use in stainless steel production. The other type of nickel
used in industrial applications is known as “secondary
nickel,” also referred to as “recycled” or
“scrap nickel.” Secondary nickel units are largely
recovered from austenitic stainless steel manufacturing
operations or other recycled nickel-containing material.
The principal end-use applications for nickel are the following:
•
Stainless steel
(60-65%
of global nickel consumption). Stainless steel is the
main application of nickel. Approximately 75% of global
stainless steel consumption consists of nickel-bearing or
austenitic, grades of stainless steel, with an average of 8%
nickel content. Austenitic stainless steel is used in consumer
products, industrial processing equipment, power generation,
transportation equipment and kitchen appliances, in addition to
many other applications where strength, corrosion resistance and
aesthetics are required. While austenitic stainless steel
production drives global nickel demand, stainless steel is
generally the least demanding end use application for nickel in
terms of its technical requirements. Stainless steel producers
can use a variety of nickel products, including secondary nickel
and ferronickel as well as higher purity nickel products.
•
Melting applications (other than stainless steel)
(15-20%
of global nickel consumption). Nickel is used in a
number of other melting applications, including low alloy
steels, non-ferrous alloys and foundry industry castings.
Low-alloy steels are used primarily in construction. Non-ferrous
alloys, which contain no iron, are used typically in energy,
oil, gas, aerospace and electronic applications. They offer
superior strength, corrosion resistance and the ability to
withstand high temperatures. Primary nickel and reverted scrap
are the main source of nickel for these melting applications.
•
Plating and electroforming (10% of global nickel
consumption). Electroplating is used to coat objects
with nickel to achieve decorative and functional finishes. For
these applications, malleability of the nickel is important as
the materials must be adapted to customer equipment. Secondary
nickel is not used in these applications.
•
Specialty applications (5-10% of global nickel
consumption). Intermediate and finished nickel
products may be processed to obtain a variety of specialty
nickel products, such as powders, foams and oxides, which are
used in a wide range of products, such as batteries, fuel cells,
powder metallurgy and automotive parts. These specialty products
generally do not use secondary nickel.
CVRD Inco has a well-established global marketing network for
finished nickel, based at its head office in Toronto, Canada,
with sales offices in Saddle Brook, New Jersey and
San Antonio, Texas in the United States, in London,
England, in Tokyo, Japan, in Hong Kong and Shanghai, China, in
Kaohsiung,
Taiwan, in Bangkok, Thailand and in Bridgetown, Barbados. Over
the years, we have built strong customer relationships and a
brand name recognized for quality in the nickel market. We
believe that our global market reach is one of our key strengths
in the highly competitive global nickel industry. Our customers
are broadly distributed on a global basis and our global
marketing network works to direct our products to the regions
with the most attractive market dynamics. In 2006, CVRD Inco
made 26.0% of its total nickel deliveries to customers in the
United States and Canada, 61.3% to customers in Asia, 9.8% to
customers in Europe, and 2.9% to customers in other destinations.
In addition, we sell an above-average share of our products into
higher value-added, differentiated applications (such as alloys,
plating and specialty products). In 2006, approximately 61% of
CVRD Inco’s sales were made into non-stainless steel
applications, as compared to primary nickel producers’
industry average of approximately 37%. By virtue of our focus on
higher-value segments, our average realized nickel prices have
consistently exceeded LME cash nickel prices.
We have fixed-volume contracts with customers for a substantial
portion of our expected annual nickel sales. These contracts,
together with our sales of proprietary nickel products, provide
stable demand for a significant portion of our annual production.
Competition —
nickel
The global nickel market is highly competitive. In 2006, CVRD
Inco’s nickel deliveries, including intermediates and
purchased nickel, represented an estimated 20% of global demand
for primary nickel.
In addition to us, the largest suppliers in the nickel industry,
each with its own integrated facilities, including nickel
mining, processing, refining and marketing operations, are:
•
MMC Norilsk Nickel (with operations in Russia),
•
BHP Billiton plc (with operations in Australia and Colombia),
•
Xstrata plc (with operations in Canada, Norway and the Dominican
Republic), and
•
Jinchuan Nonferrous Metals Corporation (with operations in
China).
Including us, these companies accounted for about 59% of global
primary nickel production in 2006. In addition to these five
industry participants, about 25 other producers in various
countries also participate in the nickel industry.
The stainless steel and alloy sectors can satisfy their nickel
requirements by choosing secondary nickel instead of primary
nickel. The choice between primary and secondary nickel is
largely based on their relative prices and availability. In
recent years, secondary nickel has accounted for about
44-49% of
total nickel used for austenitic stainless steels, and primary
nickel has accounted for about
51-56%.
We believe that our key competitive strengths include our
long-life mines, which are supported by an industry leading
nickel ore reserve base; our low cash costs of production
relative to other nickel producers; and technological leadership
in nickel exploration, processing technology and specialty
products research and development; and our global marketing
reach, which directs our products to the applications and
geographic regions which offer the highest margins for our
products. We also offer sales and technical support to our
customers on a global basis.
Copper
Copper
operations
We conduct our copper operations in Brazil at the parent company
level and in Canada through CVRD Inco.
Our Sossego copper mine is in Carajás, in the Brazilian
state of Pará. The Sossego mine has two main copper ore
bodies, Sossego and Sequeirinho. The copper ore is mined by
open-pit method and the
run-of-mine
ore is processed by means of standard primary crushing and
conveying, SAG milling (a semi-autogenous mill which uses a
large rotating drum filled with ore, water and steel grinding
balls which transforms the ore into a fine slurry), ball
milling, copper concentrate flotation, tailings disposal,
concentrate thickening, filtration and load out.
Projected annual operating capacity is 15 million metric
tons of
run-of-mine
ore, to produce an average of 140,000 metric tons of copper
contained in concentrate (30% grade). The
ramp-up
process was completed in 2006. The concentrate is trucked to a
storage terminal in Parauapebas and then transported via the
Carajás railroad to the Ponta da Madeira maritime terminal
in São Luís, in the Brazilian state of Maranhão.
We have constructed an
85-kilometer
road to link Sossego to the Carajás air and rail facilities
and a power line that allows us to purchase electrical power at
market rates. We have a long-term energy supply contract with
Eletronorte, which sells us energy from the Tucuruí
hydroelectric power plant located on the Tocantins River.
We are constructing a semi-industrial scale plant for copper
processing, Usina Hidrometalúrgica de
Carajás — UHC, that is designed to produce copper
cathode using the hydro-metallurgical technology process route.
We will use Sossego copper concentrate to feed this plant, which
is located at our Sossego mine in Carajás. Operations are
scheduled to begin in the third quarter of 2007, with an annual
production capacity of 10,000 metric tons of copper. If proven
to be efficient, we believe this technology could be used to
process the sulphide ore produced by the mines of Carajás
region at a very competitive cost.
Canadian
copper operations
In Canada, we recover copper in conjunction with our nickel
operations, principally in Ontario and Voisey’s Bay. At our
Ontario operations, we produce two intermediate copper products:
copper concentrate and copper anodes. We expect to increase our
production of copper concentrate (and proportionately decrease
our production of copper anodes) over time as we streamline our
Ontario operations to separate nickel and copper production
streams. We also produce a lower-purity refined copper
(electrowon copper) in Ontario as by-product of our nickel
refining operations. At our Voisey’s Bay operations, we
produce copper concentrate. CVRD Inco commenced commercial
production of copper concentrate at Voisey’s Bay in
September 2005 and sold its first shipment in January 2006.
Copper
projects
We are developing the following copper projects in Brazil:
•
Salobo. We own a 100% stake in the Salobo
project in Brazil, for which feasibility study was concluded in
January 2007. Our Board of Directors has approved an investment
in Salobo of US$855 million. However, the
start-up of
the development of the project is contingent to an appropriate
tax structure, which is being currently discussed with
government authorities.
•
Project 118. We are developing the 118 copper
project, which has an average production capacity of
approximately 36,000 metric tons of copper per year, and its
estimated total cost is US$232 million. A preliminary
license was obtained in April 2006, and key equipment was
ordered at the end of 2006. Basic engineering for the project
has been concluded. Project 118 is scheduled to begin operations
in the first half of 2009, but we are still awaiting the grant
of a license without which construction cannot begin. Therefore,
the timing of
start-up
could be revised. In 2005, in accordance with the Mineral Risk
Contract, we entered into a specific agreement with the
Brazilian Development Bank (Banco Nacional de Desenvolvimento
Econômico e Social), or BNDES, which establishes that
CVRD shall pay to BNDES a specified percentage of Project
118’s net revenues that will vary in accordance with copper
market prices.
For 2004 and 2005, Ontario-source
production includes copper produced from third-party-purchased
feeds. For 2006, such “External-source” production is
stated as a separate line item.
Changes
in Copper Reserves: 2005 versus 2006
•
Reserves at the Sossego complex decreased 4.6%, from 225.1 to
214.8 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, the
build-up of
buffer
run-of-mine
stockpiles and a reduction in our reserves estimates to reflect
differences between actual recoveries and amounts predicted by
our reserves model, which were partially offset by reclaimed
stockpiles.
•
Reserves at our Ontario operations increased 7%, from 163 to
175 million metric tons, after mining depletion in 2006, as
a result of exploration additions and mine plan re-evaluation
due to increased metal values. Copper grades declined by
approximately 3%, reflecting additions of lower grade material
in the mine plan that had previously been considered marginal.
•
Reserves at our Manitoba operations decreased 5%, from 25.0 to
24.0 million metric tons, primarily reflecting mining
depletion in 2006, which was partially offset by ore reserve
additions due to exploration and mine plan re-evaluation. Copper
grade declined by less than 1%.
•
Reserves at our Voisey’s Bay operations decreased from 32
to 31 million metric tons, primarily reflecting mining
depletion in 2006, which was partially offset by a reduction in
the cut-off grade. The reduction in the cut-off grade also
contributed to a 3% decline in copper grade.
Customers
and sales — copper
In June 2005, Inco (now CVRD Inco) entered into a long-term
agreement with Noranda Inc. (now Xstrata Copper Canada, or
“Xstrata”) under which Inco agreed to sell to Xstrata
about 115,000 metric tons of copper in anode form each year for
a period of 10 years beginning January 1, 2006 (the
“Anode Agreement”). In addition, in August 2006, Inco
entered into an interim agreement with Falconbridge Limited (now
Xstrata) for the sale to Xstrata of approximately 150,000 metric
tons of copper concentrate (containing about 46,500 metric tons
of copper) each year for a term ending on the same date as the
Anode Agreement. The parties are currently working towards
replacing this interim agreement with a formal agreement. The
sale of copper concentrate to Xstrata under this agreement
reduces the quantity of copper anodes sold to Xstrata under the
Anode Agreement by about 30%, with the total annual quantity of
contained copper sold to Xstrata remaining fixed at
approximately 115,000 metric tons per year for the term of these
two agreements. Copper in
concentrate from Voisey’s Bay is sold under long-term
contracts to customers in Europe. Electrowon copper from Ontario
is sold to a single customer in the United States.
PGMs and
other precious metals
We recover significant quantities of platinum-group metals, as
well as small quantities of gold and silver, as by-products of
our Canadian nickel operations. We operate a precious metals
upgrading facility at Port Colborne, Ontario, Canada, which
produces PGMs, gold and silver intermediate products.
We refine our PGM intermediate products, as well as
third-party-purchased and toll-refined materials, at our
refinery in Acton, England. In 2006, about 29% of our PGM
production was supplied by concentrates from our Canadian
operations, while about 71% was supplied by third-party feeds
(including purchased and toll-refined materials). CVRD
Inco’s global marketing department sells our own PGMs and
other precious metals, as well as third-party toll-refined
products on a sales agency basis.
PGMs
and precious metal production and reserves
The table below shows production and reserve data for PGMs and
other precious metals produced at our Canadian operations.
Production for
Proven and Probable Reserves as of December 31,
Projected
the Year Ended
2005
2006
Operating
Exhaustion
December 31,
Ore
Ore
Since(1)
Date
2004
2005
2006
Type
Tonnage
Grade
Tonnage
Grade
(Thousand troy ounces)
(Million
(Grams per
(Million metric
(Grams per
metric tons)
metric ton)
tons)
metric ton)
Platinum
1885
2042
184
174
153
Underground
163
0.8
175
0.8
Palladium
1885
2042
223
222
209
Underground
163
0.8
175
0.8
Gold
1885
2042
81
81
78
Underground
163
0.3
175
0.3
(1)
Source of ore is Ontario operations
and excludes third-party purchased or toll-refined materials.
Changes
in PGM reserves: 2005 versus 2006
Our reserve estimates of platinum, palladium and gold are based
on estimated amounts of these metals contained in extracted
nickel ore. For a description of changes in nickel reserves
between 2005 and 2006, see — Nickel —
Nickel production and reserves — Changes in Nickel
Reserves: 2005 versus 2006. We do not have the drill hole
assays data required to update our estimate of their grades. As
a result, no change has occurred in the reserve grade for these
metals.
Other
products
Kaolin
We conduct our kaolin business through our subsidiaries, CADAM
S.A. (“CADAM”) and Pará Pigmentos S.A.
(“PPSA”). We hold 82.04% of PPSA total capital and
61.48% of CADAM’s total capital. These companies produce
kaolin for paper coating and conduct research and development in
other uses for kaolin products to create a more diversified
portfolio.
PPSA’s open-pit Rio Capim mine and beneficiation plant are
located in Ipixuna, in the Brazilian state of Pará. These
operations are linked to the land and port facilities in
Barcarena, also in the Brazilian state of Pará, via a
180-km
pipeline. The beneficiated kaolin is pumped through a slurry
pipeline. PPSA produces the following products: Century, Century
S, Paraprint, Paraplate and Paralux. They are sold mainly in the
European, Asian and North American markets.
CADAM is located on the border of the Brazilian states of
Pará and Amapá, in the Amazon area in northern Brazil.
CADAM’s reserves are principally concentrated in the
open-pit Morro do Felipe mine, in Mazagão, in the Brazilian
state of Amapá. The beneficiation plant and private port
are situated on the west bank of the Jari River, in Munguba, in
the Brazilian state of Pará.
The table below sets forth information regarding our kaolin ore
mines and kaolin ore production for the periods indicated.
Production for
Proven and Probable Reserves as of December 31,(1)
Projected
the Year Ended
2005
2006
Began
Exhaustion
December 31,
Ore
Ore
Operations
Date
2005
2006
Type
Tonnage
Grade
Tonnage
Grade
(Thousand
(Million
Brightness
(Million
Brightness
metric tons)
metric tons)
(%)
metric tons)
(%)
Morro do Felipe(2)
1976
2013
701.0
755.0
Open Pit
36.7
86.7
35.4
86.7
Rio Capim(3)
1996
2008
517.0
597.0
Open Pit
33.5
82.8
31.6
82.8
Total
1,218
1,352
70.2
—
67.0
—
(1)
Expressed as dry “in
situ” ore metric tons.
(2)
Owned by CADAM.
(3)
Owned by PPSA. Average recovery of
Century product is 55% of the ore metric tons.
Changes
in kaolin reserves: 2005 versus 2006
•
Reserves at the Morro do Felipe mine decreased from 36.7 to
35.4 million metric tons, primarily reflecting mining
depletion in 2006 and, to a lesser extent, a reduction in
estimates to reflect differences between actual recoveries and
amounts predicted by our reserves model.
Reserves at the Rio Capim mine decreased from 33.5 to
31.6 million metric tons, primarily reflecting mining
depletion in 2006, the
build-up of
buffer
run-of-mine
stockpiles and a reduction in our reserves estimates to reflect
differences between actual recoveries and amounts predicted by
our reserves model.
Potash
We conduct our potash operations at the parent company level. We
lease a potash mine (the Taquari-Vassouras mine) in Rosario do
Catete, in the Brazilian state of Sergipe, from
Petrobras — Petróleo Brasileiro S.A. (Petrobras),
a Brazilian state-owned oil company. The lease was signed in
1991, but was effective from 1992 for a period of 25 years,
and is renewable for another 25 years. The mine is the only
potash mine in Brazil and has a current nominal capacity of
850,000 metric tons per year. Taquari-Vassouras is an
underground mine. All sales from the Taquari-Vassouras mine are
to the Brazilian market.
The table below sets forth information regarding reserves and
production at the Taquari-Vassouras mine for the periods
indicated.
Production for
Proven and Probable Reserves as of December 31,
Projected
the Year Ended
2005
2006
Leased
Exhaustion
December 31,
Ore
Ore
Since
Date
2004
2005
2006
Type
Tonnage
Grade
Tonnage
Grade
(Thousand
(Million
(%)
(Million
(%)
metric tons)
metric tons)
metric tons)
Taquari-Vassouras(1)
1992
(2)
2012
638.0
641.0
731.0
Underground
19.2
31.0
16.6
31.0
(1)
Average mining extraction was 46%
of the “in situ” ore and average mass recovery was
87.5%.
(2)
The mine began operations in 1986.
Potash reserves at our Taquari-Vassouras mine decreased from
19.2 to 16.6 million metric tons, primarily reflecting
mining depletion in 2006.
Cobalt
We recover significant quantities of cobalt as a by-product of
our Canadian nickel operations and our reserve figures are based
on estimated amounts of cobalt contained in extracted nickel ore.
In 2006, we produced 1,245 metric tons of refined cobalt metal
at our cobalt refinery in Port Colborne, Ontario, Canada and 465
metric tons of cobalt hydrate at our nickel operations in
Thompson, in the Canadian Province of Manitoba. Our remaining
cobalt production consisted of 357 metric tons of cobalt
contained in intermediate products (such as nickel concentrates).
Cobalt metal is used in the production of various alloys,
particularly for aerospace applications, as well as the
manufacture of cobalt-based chemicals. We sell our cobalt metal
on a global basis. Our cobalt metal is of a very high purity
(99.8%), which commands a premium in the market.
Cobalt hydrate is used by chemical producers to make
cobalt-based chemicals. Our cobalt metal production is sold to a
single customer, for use at its facilities in Europe and the
United States. We expect to increase our production of cobalt
when we complete our Goro and Vermelho nickel development
projects, as the nickel laterite ore in these locations contains
significant co-deposits of cobalt.
The table below sets forth information on our cobalt production
and reserves.
Production for
Proven and Probable Reserves as of December 31,(1)
Projected
the Year Ended
2005
2006
Operating
Exhaustion
December 31
Ore
Ore
Since
Date
2004
2005
2006
Type
Tonnage
Grade
Tonnage
Grade
(Thousand
(Million
(%)
(Million
(%)
metric tons)
metric tons)
metric tons)
Ontario(2)
1885
2042
1,368
1,378
665
Underground
163
0.04
175
0.04
Manitoba
1960
2019
213
282
411
Underground
N/A
N/A
N/A
N/A
Voisey’s Bay
2005
2019
N/A
N/A
680
Open pit
32
0.14
31
0.13
External(2)
N/A
N/A
—
—
221
N/A
N/A
N/A
N/A
N/A
Goro Project(3)(4)(5)
N/A
2036
N/A
N/A
N/A
Open pit
120
0.11
120
0.11
Vermelho Project(6)
N/A
2050
N/A
N/A
N/A
Open pit
N/A
N/A
245
0.04
Total
1,581
1,660
1,977
315
0.08
572
0.06
(1)
Ore reserves listed are totals for
the operation and projects indicated and assume that we own, or
have all of the necessary rights to mine, extract and process,
all of such ore reserves and, accordingly, are not based upon
our ownership interest in the operation or project or
properties. Ore reserves are of in-place material after
adjustment for mining dilution and mining (or screening in the
case of PT Inco) recoveries. However, no adjustments have been
made for metal losses due to processing.
(2)
For 2004 and 2005, Ontario-sourced
production includes cobalt produced from third-party purchased
feeds. For 2006, such “External-source” production is
stated as a separate line item and does not include third-party
tolling of third-party purchased feeds.
(3)
We have rights to other properties
in New Caledonia and in certain other locations, which have not
yet been fully explored.
(4)
We have a 74% interest in the Goro
Project through CVRD Inco.
(5)
Completion of comprehensive project
reviews, governmental or regulatory permitting and other
approvals
and/or
significant capital expenditures would be required before
operations could commence at this project.
(6)
New project. Reserve estimates are
reported for “in situ” metric tons and grades, without
adjustment.
Changes
in cobalt ore reserves: 2005 versus 2006
•
Reserves at our Ontario operations increased 7%, from 163 to
175 million metric tons, after mining depletion, as a
result of exploration additions and mine plan re-evaluation due
to increased metal values.
•
Reserves at our Voisey’s Bay operations decreased by
1.3 million metric tons from 32 to 31 million metric
tons due to mining depletion in 2006, which was partially offset
by a reduction in the cut-off grade. The reduction in the
cut-off grade contributed to a less than 1% decline in cobalt
grade.
Coal
In April 2007, we paid US$656 million for the acquisition
of 100% of AMCI Holdings Australia Pty (AMCI HA). AMCI HA
controls and operates coal assets through unincorporated joint
ventures. Its stake is equivalent to nominal production capacity
of 8.0 million metric tons of coal (predominantly coking
coal) and reserves of 103 million metric tons. AMCI HA had
net debt of US$129 million as of April 30, 2007.
We have a 25% equity interest in Henan Longyu Energy Resources
Co., Ltd. (Longyu), a joint venture with Yongcheng
Coal & Electricity Co., Ltd., one of the largest
anthracite producers in China, and Baosteel
International, a subsidiary of the largest steel producer in
China. Longyu is located in the Henan Province, China. We
invested US$86.3 million for our participation in Longyu,
and we have the right to purchase 25% of coal produced by the
joint venture.
We have a 25% equity interest in Shandong Yankuang International
Coking Company Ltd. (Yankuang), a joint venture with Yankuang
Group Co., one of the main Chinese coal producers, and Itochu
Corp., one of the leading Japanese trading companies. The
Yankuang metallurgical coke plant, which has production capacity
of 2 million metric tons of coke per year and 200,000
metric tons of methanol per year, began production in June 2006.
Mineral
exploration
Our current mineral exploration efforts focus on copper, nickel,
iron ore, manganese, bauxite, coal, uranium, platinum-group
metals, potash and phosphates. We are actively exploring in 19
countries, with a large variety of projects. The costs of
exploration and feasibility studies are recorded as expenses
until the economic viability of mining activities is established
(see Note 3 to our financial statements). For 2007, the
capital expenditures budget for mineral exploration (included in
the research and development budget) is US$120 million. The
total research and development budget for 2007 is
US$452 million.
We and the Brazilian government development bank, BNDES, entered
into a contract in March 1997 relating to authorizations for
mining exploration. This contract, which we refer to as the
Mineral Risk Contract, provides for the joint development of
certain unexplored mineral deposits in approximately
2.5 million hectares of land in the Carajás region
(which is part of our Northern System), as well as proportional
participation in any profits earned from the development of such
resources. Iron ore and manganese ore deposits already
identified at the time we entered into the Mineral Risk Contract
were specifically excluded from the contract. An investment of
US$410 million was contemplated in the Mineral Risk
Contract, which amount had been invested by July 2006. We are
currently negotiating an extension of the Mineral Risk Contract.
Under the Mineral Risk Contract, BNDES has agreed to compensate
us for the contribution of some of our existing development and
ownership rights in the Carajás region by paying us a
royalty on mineral resources that are discovered and placed into
production. This royalty is equal to 3.5% of revenues from gold,
silver and platinum-group metals and 1.5% of revenues from other
minerals for extraction outside the Serra Leste region, and a
royalty of 6.5% of revenues from products originating from the
Serra Leste region.
Aluminum
operations
As of April 30, 2007, we operate our aluminum products
businesses through the subsidiaries and joint ventures in the
following table:
Our Direct or Indirect
Share of Capital
Business
Voting
Total
Partners
(%)
Albras-Alumínio Brasileiro
S.A. (Albras)
Aluminum
51.00
51.00
Nippon Amazon Aluminum Co.,
Ltd. — NAAC
Alunorte-Alumina do Norte do Brasil
S.A. (Alunorte)(1)
Alumina
61.74
57.03
Companhia Brasileira de
Alumínio — CBA JAIC Mitsui Mitsubishi Nippon
Amazon Norsk Hydro
Mineração Rio do Norte
S.A. (MRN)
Bauxite
40.00
40.00
Abalco Alcoa Alcan Alcoa World
Alumina LLC — AWA BHP Billiton Metais Companhia
Brasileira de Alumínio — CBA Norsk Hydro
Valesul Aluminio S.A. (Valesul)(2)
Aluminum
100.00
100.00
—
(1)
The percentages reflecting our
direct or indirect share of capital for Alunorte refer to
paid-in capital.
(2)
In July 2006, we exercised our
right of first refusal under the Valesul shareholders’
agreement and acquired BHP Billiton Metais S.A.’s 45.5%
interest in Valesul for US$28 million, as a result of which
we now own 100% of Valesul’s shares. We began consolidating
Valesul in our financial statements in the third quarter of 2006.
smelting alumina to produce primary aluminum and aluminum alloys.
Bauxite
MRN. Mineração Rio do Norte S.A.
(“MRN”), one of the largest bauxite operations in the
world, produces bauxite for sale to our joint venture partners
and us. Excess production may be sold to customers. MRN’s
production totaled 16.7 million metric tons in 2004,
17.2 million metric tons in 2005, and 17.8 million
metric tons in 2006.
MRN operates five open-pit bauxite mines, which produce high
quality bauxite. In addition, MRN controls substantial
additional high quality bauxite resources that it believes can
be produced economically in the future. MRN’s mines are
located in the northern region of the Brazilian state of
Pará.
MRN operates ore beneficiation facilities at its mines, which
are connected by rail to a loading terminal and port facilities
on the Trombetas River. The Trombetas River is a tributary of
the Amazon River and MRN’s port facilities can handle
vessels of up to 60,000 DWT. MRN owns and operates the rail and
the port facilities serving its mines. The MRN bauxite mines are
accessible by road from the port area and obtain electricity
from their own thermoelectric power plant. Our MRN bauxite joint
venture produces bauxite for sale on a
take-or-pay
basis to us and our joint venture partners at a price that is
determined by a formula linked to the price of aluminum for
three-month contracts in the London Metal Exchange and to the
price of alumina sold from Australia. In 2006, our Alunorte
alumina subsidiary purchased all of its bauxite requirements
from MRN.
The table below sets forth information regarding MRN’s
bauxite reserves as of December 31, 2005 and 2006.
Proven and Probable Reserves as of December 31,(1)
Projected
2005
2006
MRN
Exhaustion Date
Type
Ore Tonnage
Grade
Ore Tonnage
Grade
(Million metric tons)
(%
Al203)
(Million metric tons)
(%
Al203)
Almeidas
2009
Open pit
11.7
51.2
6.7
50.7
Aviso
2012
Open pit
48.2
51.1
40.2
51.1
Bacaba
2009
Open pit
6.2
53.1
6.2
53.1
Saracá V
2010
Open pit
5.7
47.2
4.8
48.1
Saracá W
2015
Open pit
17.1
50.3
15.7
49.3
Total
88.9
50.8
(2)
73.6
50.7
(1)
CVRD’s ownership of MRN’s
bauxite reserves is 40%.
(2)
Expressed as dry product metric
tons. Recovery of dry product from dry ROM bauxite ranges from
69-82%,
depending on the deposit, with a weighted average of 74%.
MRN’s bauxite reserve decreased from 11.7 to
6.7 million metric tons, primarily reflecting mining
depletion in 2006.
Paragominas mine. We hold active mining rights
in the Paragominas region of the Brazilian state of Pará,
where a new wholly-owned bauxite mine was commissioned in the
first quarter of 2007 to supply Alunorte’s new expansion
with 5.4 million metric tons per year of wet 12% moisture
bauxite. The bauxite quality will be similar to MRN’s, and
the project will use the strip mining method of extraction, and
have a beneficiation plant including milling and a
244-kilometer
long slurry pipeline. Total capital expenditures on this project
was US$352 million. Our Board of Directors has approved a
further expansion at Paragominas, which will require an
additional investment of US$196 million to produce an
additional 4.5 million metric tons. After the conclusion of
the expansion, we expect the Paragominas mine to achieve a
nominal production capacity of 9.9 million metric tons by
2008.
The table below sets forth information regarding
Paragominas’ bauxite reserves as of December 31, 2005
and 2006.
Proven and Probable Reserves as of December 31,(1)
2005
2006
Ore Tonnage
Grade
Ore Tonnage
Grade
(Million metric tons)
(%
Al203)
(Million metric tons)
(%
Al203)
Miltonia 3
204.9
49.4
204.8
49.4
Miltonia 5
98.6
47.3
98.6
47.3
Total
303.5
48.7
303.6
48.7
(1)
Expressed as dry product metric
tons. Planned product recovery is an average of 70% of the dry
ROM metric tons.
There was no production at Paragominas mines in 2006.
Consequently 2005 reserve estimates were not adjusted and
remained the same for 2006.
Alumina
Alunorte produces alumina by refining bauxite supplied by MRN.
The Alunorte plant concluded its first expansion of capacity
(stage 3) in 2003 and its second expansion
(stages 4 and 5) in the first quarter of 2006,
reaching a nominal production capacity of 4.4 million
metric tons of alumina per year and becoming the largest alumina
refinery in the world. Alunorte sells alumina to Albras, Valesul
and unaffiliated customers. The Alunorte plant is located in the
city of Barcarena, in the Brazilian state of Pará, next to
Albras’ aluminum production facilities. This allows
Alunorte and its principal customer, Albras, to share
infrastructure and other resources. This refinery has one of the
lowest conversion costs in the world (US$98.85 per metric
ton in 2006).
Each Alunorte partner must purchase on a
take-or-pay
basis all alumina produced by Alunorte in proportion to its
respective interest. The partners each pay the same price, which
is determined by a formula based on the price of aluminum for
three-month contracts on the London Metal Exchange. Alunorte
produced 3.939 million metric tons in 2006,
2.570 million metric tons in 2005 and 2.548 million
metric tons in 2004.
A US$846 million expansion at Alunorte is in progress,
which will increase refinery production capacity to
6.26 million metric tons of alumina per year, and is
expected to be completed in mid-2008.
Aluminum
Albras and Valesul each produce aluminum using alumina provided
by Alunorte. Alunorte supplied 100% of Albras’ alumina
requirements and 50% of Valesul’s alumina requirements in
2006. Albras produces pure metal ingots and Valesul produces
foundry alloy ingots and billets. Aluminum is produced from
alumina by means of a continuous electro-chemical process, which
requires substantial amounts of electricity.
Albras. The Albras plant, located at
Barcarena, in the Brazilian state of Pará, started
operations in 1985 and is one of the largest aluminum plants in
the Americas, with a nominal capacity of 445,000 metric tons per
year. Albras produced 456, 446 and 435 thousand metric tons of
aluminum ingots in 2006, 2005, 2004, respectively.
The Albras partners must purchase on a
take-or-pay
basis all aluminum produced by Albras in proportion to their
ownership interests. We generally market our aluminum in the
global markets to clients in the aluminum industry.
Albras purchases electric power from Eletronorte, a state-owned
electric power utility. Eletronorte generates electricity at the
Tucuruí hydroelectric power plant located on the Tocantins
River. This plant is the sole source of electrical power in the
region in the quantities required for Albras’ operations.
Albras consumes approximately one-quarter of the non-peak period
output of the Tucuruí plant.
In May 2004, Albras successfully executed an auction to purchase
electricity for a
20-year
period. This agreement became effective beginning June 2004. The
basic purchase price is R$53.00 per MWh, indexed to the
general market price index, IGP-M, as calculated by
Fundação Getúlio Vargas, a Brazilian
economic
research institute. In addition to the basic price, a premium is
paid that is linked to the amount by which the price of primary
aluminum exceeds US$1,450.00 per metric ton on the London
Metal Exchange. See Item 4. Information on the
company — Regulatory matters — Energy.
Valesul. Valesul operates a plant located in
the Brazilian state of Rio de Janeiro with a nominal capacity of
95,000 metric tons per year. Valesul produces primary aluminum
and aluminum alloys in the form of ingots and billets.
Valesul’s aluminum products are sold primarily in the
Brazilian market on a spot basis. Valesul produced 95, 93 and 96
thousand metric tons of aluminum and aluminum alloys and
recycled 13, 11 and 14 thousand metric tons of third-party
aluminum scrap in 2006, 2005, 2004, respectively.
Valesul currently obtains a portion of its electrical energy
requirements from four wholly-owned small hydroelectric power
plants located in the Brazilian state of Minas Gerais, a portion
from the Machadinho hydroelectric power plant, in the Brazilian
state of Santa Catarina, in which Valesul has a share of 7.28%,
and the remainder from a third-party power company at market
rates. Valesul is able to supply 40% of its own energy
requirements. Valesul is engaged in litigation regarding the
prices charged by the electricity company of the State of Rio de
Janeiro (Light — Serviços de Eletricidade S.A.)
for the transmission of electricity. See Item 8.
Financial information — Legal proceedings.
Competition —
bauxite, alumina and aluminum
The global aluminum market is highly competitive. The
world’s largest producers are Alcoa, Rusal, Alcan, Norsk
Hydro, BHP Billiton and Chalco. The alumina and bauxite markets
are also competitive, but are much smaller, because many of the
major aluminum-producing companies have integrated bauxite,
alumina and aluminum operations.
Bauxite. Most of global bauxite production is
not traded, as it is dedicated to integrated alumina refineries.
Competition in the bauxite market is based primarily on two key
factors: quality of bauxite and reliability of supply. We
believe that MRN remains competitive in this market because of
the high quality of Brazilian bauxite, and our aluminum
production system, which ensures internal use of our bauxite
production. We use a major part of our take of MRN’s
bauxite production to supply Alunorte.
Alumina. Competition in the alumina market is
based primarily on quality, reliability of supply and price,
which is directly related to lower costs. We believe that
Alunorte is competitive in the alumina market because of the
high quality of its alumina, its advantages in scale and
technology, low conversion cost, its efficient port facilities,
and the ongoing commitment of its shareholders to purchase a
substantial portion of its annual production. We use a portion
of our share of Alunorte’s alumina production to supply the
Brazilian market (Albras and Valesul), and sell the remainder to
customers in other countries, such as Canada, Argentina, Norway
and China.
Aluminum. As primary aluminum is a commodity,
competition in the aluminum market is based primarily on the
economics of transportation and the costs of production. We
believe that Albras is competitive in the aluminum market
because of its relatively efficient and accessible port
facilities, and its generally prevailing lower costs of
production. We generally sell aluminum to customers in Asia and
Europe.
Logistics
Our logistics business comprises the transportation of
customers’ products and passengers. We conduct this
business at the parent-company level, through subsidiaries and
through joint ventures.
We have the following logistics businesses at the parent-company
level:
•
Railroads: Vitória a Minas and Carajás;
•
A port complex: Tubarão;
•
Maritime terminals: Inácio Barbosa and Ponta da Madeira.
Our subsidiaries conduct the following logistics activities:
•
Operation of railroads (Ferrovia Centro-Atlântica S.A., or
FCA);
•
Operation of ports and maritime terminals (Cia. Portuária
Baía de Sepetiba, or CPBS, and Terminal de Vila Velha S.A.,
or TVV);
•
Shipping activities (Log-In Logística Intermodal S.A., or
Log-In, previously Navegação Vale do Rio Doce, or
Docenave, and DCNDB Overseas S.A., or DCNDB).
We also hold, directly and indirectly, 37.2% of the voting
capital and 40.5% of the total capital in MRS Logística
S.A., a railroad joint venture with Brazilian steel
manufacturers.
Railroads
Vitória a Minas railroad. The
Vitória a Minas railroad links our Southeastern System
mines in the Iron Quadrangle region in the Brazilian state of
Minas Gerais with the Tubarão Port, in Vitória, in the
Brazilian state of Espírito Santo. We operate this
905-kilometer
railroad under a
30-year
renewable concession, which expires in 2027. The Vitória a
Minas railroad consists of two lines of track extending for a
distance of 601 kilometers to permit continuous railroad travel
in opposite directions, and single-track branches of 304
kilometers. Industrial manufacturers are located in this area
and major agricultural regions are also accessible to it. The
Vitória a Minas railroad has a daily capacity of 312,000
metric tons of iron ore. In 2006, the Vitória a Minas
railroad carried a total of 71.7 billion ntk of iron ore
and other cargo, of which 17.7 billion ntk, or 25%,
consisted of cargo transported for customers, including iron ore
for Brazilian customers. The Vitória a Minas railroad also
carried approximately 1.1 million passengers in 2006.
The principal cargo of the Vitória a Minas railroad
consists of:
•
iron ore and pellets, carried for us and customers;
•
steel, coal, pig iron, limestone and other raw material carried
for customers with steel mills located along the railroad;
•
agricultural products, such as soybean, soybean meal and
fertilizers; and
•
other general cargo, such as building materials, pulp, fuel and
chemical products.
We charge market rates for customer freight, including pellets
originating from joint ventures and other enterprises in which
we do not have a 100% equity interest. Market rates vary based
on the distance traveled, the type of product transported and
the weight of the freight in question, and are regulated by the
Brazilian transportation regulatory agency (Agência
Nacional de Transportes Terrestres, or ANTT).
Carajás railroad. We operate the
Carajás railroad under a
30-year
renewable concession, which expires in 2027. This railroad,
located in the Northern System, starts at our Carajás iron
ore mine in the Brazilian state of Pará, and extends 892
kilometers to our Ponta da Madeira maritime terminal complex
facilities located near the São Luís Port in the
Brazilian state of Maranhão. The Carajás railroad
consists of one line of track, with spur tracks and turnouts to
permit the passage of trains in opposite directions. The
Carajás railroad has a daily capacity of 255,000 metric
tons of iron ore. In 2006, the Carajás railroad carried a
total of 78.0 billion ntk of iron ore and other cargo (of
which 7.0 billion ntk, or 9% consisted of cargo transported
for customers, including iron ore for Brazilian customers). The
Carajás railroad also carried approximately 372 thousand
passengers in 2006. The main cargo of the Carajás railroad
consists of iron ore, principally carried for us. In 2007, we
also intend to begin operations of the largest capacity train in
Latin America. This train will have 340 cars, measure 3.2
kilometers and weigh 37,900 gross metric tons when loaded.
Ferrovia Centro-Atlântica. Our subsidiary
FCA operates the central-east regional railway network of the
Brazilian national railway system under a
30-year
renewable concession, which expires in 2026. The central east
network contains approximately 7,000 kilometers of track
extending into the states of Sergipe, Bahia, Espírito
Santo, Minas Gerais, Rio de Janeiro and Goiás and
Brasília, the Federal District, Brazil. It connects with
our Vitória a Minas railroad near the cities of Belo
Horizonte, in the Brazilian state of Minas Gerais and
Vitória, in the Brazilian state of Espírito Santo. FCA
operates on the same track gauge as our Vitória a Minas
railroad and provides access to the Santos Port in the Brazilian
state of São Paulo. In 2006, the FCA railroad transported a
total of 10.8 billion ntk of cargo for clients.
MRS railroad. We own, directly and indirectly,
37.2% of the voting capital and 40.5% of the total capital of
the company that operates the MRS railroad. MRS, which
transported 113 million metric tons in 2006, is
1,674-kilometers long and links the Brazilian states of Rio de
Janeiro, São Paulo and Minas Gerais. It is operated under a
30-year
renewable concession granted in 1996.
As a result of our acquisitions of CAEMI and Ferteco, our
current participation in the voting capital of MRS is higher
than the limit of 20% imposed at the time of the bid for the MRS
railroad concession. We are currently challenging a decision by
the Brazilian antitrust authority requiring us to restructure
our equity stake in MRS as a condition to its approval of other
transactions we have completed. See Item 3. Risk
factors — Risks related to our nusiness — We
are involved in ongoing antitrust proceedings that could result
in divestitures, fines or other restrictions that could harm our
business and Item 8. Financial
information — Legal proceedings.
In April 2006, the Brazilian agency that regulates ground
transportation, or ANTT (Agência Nacional de Transportes
Terrestres), published a resolution requiring us to:
(i) sell those common shares we hold in MRS as a result of
our acquisition and consolidation of Ferteco which are covered
by the MRS Shareholders’ Agreement; or
(ii) (a) cause the shareholders of MRS to approve
certain changes in the capital structure of MRS, or
(b) waive our voting and veto rights specifically in
connection with the MRS shares we hold as a result of our
acquisition and consolidation of Ferteco. In May 2006, we
informed ANTT of our decision to waive our voting and veto
rights with respect to such MRS shares, which represent 10.9% of
the total capital stock and 19.3% of voting capital stock of MRS
and ANTT approved our election and suspended its recommendation
to consolidate our MRS shareholdings pending the outcome of the
CADE proceeding. See Item 4. Information on the
company — Regulatory matters — Railroads
and Item 8. Financial information — Legal
proceedings.
Ports
and maritime terminals
We operate ports and terminals principally as a means to
complete the distribution of our iron ore and pellets to
seaborne vessels serving the export seaborne market. See
Item 4. Information on the Company — Lines of
business — Mining — Ferrous
minerals — Pellets —
Distribution — iron ore and pellets. We also use
our ports and terminals to handle third-party cargo. In 2006,
15% of the cargo handled by our ports and terminals represented
cargo handled for third parties.
Tubarão Port. The Tubarão Port,
which covers an estimated area of 18 square kilometers, is
located near the Vitória Port in the Brazilian state of
Espírito Santo. The iron ore maritime terminal located in
this area has two piers. Pier I can accommodate two vessels at a
time, one of up to 170,000 DWT on the southern side and one of
up to 200,000 DWT on the northern side. Pier II can accommodate
one vessel of up to 365,000 DWT at a time, limited at 20 meters
draft plus tide. In Pier I there are two ship loaders, which can
load up to a combined total of 14,000 metric tons per hour. In
Pier II there are two ship loaders that work alternately
and can each load up to 16,000 metric tons per hour. In 2006,
88.1 million metric tons of iron ore and pellets were
shipped through the terminal for us. Praia Mole Terminal, also
located in the Tubarão Port, is principally a coal terminal
and handled 10.9 million metric tons in 2006. We operate a
grain terminal called Terminal de Produtos Diversos, in the
Tubarão area, which handled 4.8 million metric tons of
grains and fertilizers in 2006. We also operate a bulk liquid
terminal that handled 1.2 million metric tons in 2006.
Vitória Port. CVRD operated the Paul
Terminal, located near the Vitória Port in the Brazilian
state of Espírito Santo, which specializes in the handling
of pig iron. This terminal has one pier that can accommodate one
vessel up to 75,000 DWT, which can load up to 900 tons per hour.
The Paul Terminal handled 1.7 million metric tons of pig
iron in 2006.
The lease for the terminal expired in February 2007, and the
lessor, CODESA (Companhia Docas do Espírito Santos,
a state-owned company), has postponed for over two years the
bidding process for the right to
operate the terminal. At the request of the labor union SINDIFER
(Sindicato dos Ferroviários do Espírito Santo/Minas
Gerais), the Federal Courts in the state of Espírito
Santo granted an order under which CVRD operated the terminal
from February 2007 until April 2007, and CVRD no longer operates
it. CVRD subsequently entered into equipment leasing contracts
with SINDIFER for a period of 180 days, with the
possibility of sale to SINDIFER, CODESA or the new port operator.
Ponta da Madeira maritime terminal. The Ponta
da Madeira maritime terminal is located near the Itaqui Port in
the Brazilian state of Maranhão. The terminal facilities
can accommodate three vessels. Pier I can accommodate vessels
displacing up to 420,000 DWT. Pier II can accommodate
vessels of up to 155,000 DWT. The two berths have a maximum
loading rate of 16,000 tons per hour at Pier I and 8,000 tons
per hour at Pier II. In February 2004, Pier III began
operations. Pier III has two berths, can accommodate
vessels of up to 220,000 DWT and has a maximum loading rate of
8,000 metric tons per hour in each berth.
Cargo shipped through our Ponta da Madeira maritime terminal
consists principally of our own iron ore production. Other cargo
includes manganese ore and copper concentrate produced by us and
pig iron and soybeans for third parties. In 2006,
77.0 million metric tons were handled through the terminal
for us and 4.7 million metric tons for customers.
Inácio Barbosa maritime terminal
(TMIB). Since November 1994, CVRD has operated
the Inácio Barbosa maritime terminal located in the
Brazilian state of Sergipe. This terminal was built by
Petrobras — Petróleo Brasileiro S.A. and
transferred to Sergiportos, a state-owned company. In December
2002, Petrobras took over control of the Inácio Barbosa
maritime terminal in exchange for the cancellation of a
liability of the Brazilian state of Sergipe. CVRD and Petrobras
entered into an agreement in December 2002, which allows CVRD to
run this terminal for a period of 10 years ending in
December 2012. In 2006, 1,000 metric tons of fuel and
agricultural and steel products were shipped through the
Inácio Barbosa maritime terminal.
Terminal de Vila Velha S.A. (TVV). In May
1998, we entered into a
25-year
lease for the Capuaba maritime terminal in Vitória, in the
Brazilian state of Espírito Santo. To run this terminal
CVRD established Terminal de Vila Velha S.A. (TVV). TVV is a
terminal for loading and unloading of containers, in addition to
being an alternative for general cargo and automobile operations
in Southeast and Midwest Brazil. It is connected to the
Vitória a Minas railroad and with easy access to the BR101
and BR262 highways. The terminal is formed by berths 203 and 204
at the Capuaba Quay and has a 450-meter berth area and
retro-area measuring nearly 100,000 square meters. It has a
covered storage area measuring 13,300 square meters and a
yard with capacity for 3,300 containers. TVV is equipped with
two quays cranes, two portainers and four transtainers. In 2006,
184.9 thousand containers and 500 metric tons of general cargo
were shipped through TVV. CVRD has transferred its shares in TVV
to Log-In, which holds assets related to container-based
logistics services businesses.
Cia. Portuária Baía de Sepetiba (CPBS) —
Itaguaí maritime terminal, CPBS is a wholly-owned
subsidiary that operates the Itaguaí terminal, in the
Sepetiba Port, in the Brazilian state of Rio de Janeiro.
Itaguaí’s maritime terminal has a pier that allows the
loading of ships up to 18.1 meters and up to 230,000 DWT. In
2006, the terminal uploaded approximately 21.8 million
metric tons of iron ore.
Guaíba Island maritime terminal. MBR has
its own maritime terminal on Guaíba Island in the Sepetiba
Bay, in the Brazilian state of Rio de Janeiro. The iron ore
terminal has a pier that allows the loading of ships of up to
300,000 DWT. In 2006, the terminal uploaded approximately
45.7 million metric tons of iron ore.
Shipping
In December 2006, we reorganized our container-based logistics
services business. TVV, Mineração Andirá and the
intermodal terminal TERCAM were transferred to Docenave, which
later became Log-In. In February 2007, CVRD and Log-In filed
with the CVM a request for the registration of a primary and
secondary offering to be listed in the Novo Mercado of the
São Paulo Stock Exchange (Bovespa).
We operate in three distinct shipping areas: seaborne dry bulk
transportation services, coastal shipping liner service and tug
boat services. The table below sets forth information on the
volume of cargo that our seaborne dry bulk shipping service
carried for the periods indicated.
For the transportation of the cargo shown above for 2006, we
operated a fleet of bulk vessels, which is comprised of three
capesize vessels owned by us and a few other capesize and
panamax vessels chartered on a spot basis. Our own capesize
vessels have been trading worldwide carrying primarily iron ore.
The chartered vessels (two capesize and eight panamax) have been
contracted for the transportation of iron ore from Ponta da
Madeira maritime terminal, in the Brazilian state of
Maranhão, to Praia Mole Terminal, in the Tubarão Port,
in the Brazilian state of Espírito Santo.
The coastal shipping liner service is operated by five vessels,
chartered on a bare boat basis, which cover the South American
east coast from Buenos Aires, in Argentina to Fortaleza, in the
Brazilian state of Ceará, in the northeast of Brazil,
providing weekly service. This service transported 90,370
twenty-foot equivalent units (teus) in 2006.
We also operate a fleet of 19 tug boats (seven owned and 12
chartered) in the ports of Vitória in the Brazilian state
of Espírito Santo, Trombetas in the Brazilian state of
Pará, São Luís in the Brazilian state of
Maranhão and Aracaju in the Brazilian state of Sergipe.
Competition in the logistics industry. Our
railroads compete with road transport, including trucks, with
the main factors being cost, safety and shipping time. We also
have many competitors in the coastal shipping liner service.
Investments
in steelmaking
We have investments in the following joint ventures in the steel
business, as of May 7, 2007.
Hot-rolled, cold-rolled, hot dip
galvanized, sheet products
Ferro Gusa Carajás (Brazil)(2)
100
100
—
55
Pig iron
Usiminas (Brazil)(3)
6
3
Nippon Usiminas Previ Caixa dos
Empregados da Usiminas Others
5,703
Hot-rolled steel; cold-rolled
steel; heavy steel plates; electro galvanized steel
(1)
We sold our 4.85% interest in
Siderar in December 2006.
(2)
In March 2007, we acquired
Nucor’s 18% interest in Ferro Gusa Carajás for
US$20 million, as a result of which we now own 100% of
Ferro Gusa.
(3)
In November, we sold 5% of our
voting shares and 2% of our total shares. As of December 2006,
we had 18% of the voting capital and 9% of the total capital. In
May, we sold 12% of our voting shares and 6% of our total
shares, and we plan to sell a further 36,691 shares that
were not sold pursuant to the overallotment option in the
registered public offering of Usiminas shares concluded in May
2007.
We owned 4,740,925 shares of
Gerdau S.A. until the end of the first half of 2006. Since our
holdings represented only 0.7% of its total capital stock,
Gerdau was not included in our financial results. We sold all of
our shares of Gerdau S.A. in the second half of 2006.
The market value of our investments in Usiminas, which is a
publicly traded company, was US$844 million at
December 31, 2006. The net book value of this investment
was US$744 million at December 31, 2006. We earned
US$48 million in dividends from this investment in 2006. In
November 2006, we sold a total of 5,362,928 common shares of
Usiminas to Nippon Steel, Votorantim Participações
S.A. and Camargo Correa S.A. for US$176 million. We applied
the net proceeds from the sale of our Usiminas shares to reduce
principal amounts payable under our senior acquisition facility.
We entered into a shareholders’ agreement with the other
members of Usiminas’ control group, under which (i) we
will retain 6,608,608 common shares, and (ii) the Usiminas
controlling shareholders will conduct a feasibility study
regarding a potential investment by Usiminas in the construction
of a steel slab plant. In March 2007, we filed with the CVM an
application for the registration of a public offering of our
Usiminas’ shares not subject to the shareholders’
agreement. In May 2007, we sold in a public offering registered
with the CVM 13,802,499 Usiminas shares and received total
proceeds of US$728 million. In connection with the
offering, we entered into a lockup agreement for a period of
90 days from April 25, 2007. After the lockup period
expires or is waived, we intend to sell 36,691 additional shares
that were not sold pursuant to the offering’s overallotment
option.
We also operate an environmentally-friendly pig iron project in
northern Brazil, through our subsidiary, Ferro Gusa Carajás
S.A. (“Ferro-Gusa”). Ferro-Gusa was operated as a
joint venture with Nucor Corporation (“Nucor”) until
March 27, 2007, when we acquired Nucor’s entire
interest (18%) in Ferro-Gusa for US$20 million. Ferro-Gusa
utilizes two conventional mini-blast furnaces to produce
approximately 400,000 metric tons of pig iron per year, using
iron ore from our Carajás mines in Northern Brazil. The
charcoal source is exclusively from eucalyptus trees grown in a
cultivated forest of 82,000 acres, with the total project
encompassing approximately 200,000 acres.
Energy
Brazil
Energy management and efficient supply in Brazil are priorities
for us, driven by the uncertainties associated with changes in
the regulatory framework, and the risk of rising electricity
prices and electrical energy shortages, such as the one Brazil
experienced in the second half of 2001. We perceived favorable
investment opportunities in the Brazilian electricity sector and
took advantage of them by investing in eight hydroelectric power
generation projects in Brazil. See Note 12 to the
consolidated financial statements. We plan to use the
electricity produced by these projects for our internal needs.
We may experience construction delays in certain generation
projects due to environmental and regulatory issues, which may
lead to higher costs. As a large consumer of electricity, we
expect that investing in power projects will help to reduce
costs and protect us against energy price volatility.
We currently have seven hydroelectric power plants in operation
and one under construction in Brazil. We also hold 43.85% of a
consortium that has a concession to build the Santa Isabel
hydroelectric power plant at the Araguaia River, Brazil. In
2006, we continued our efforts to return the concessions for the
Santa Isabel hydroelectric project to the Brazilian electricity
regulatory agency (ANEEL) due to difficulties in obtaining the
necessary environmental license to begin its construction. In
addition, some of our affiliates generate part of their own
electric energy.
The Capim Branco I began commercial operations in February 2006.
Capim Branco II began operations in the first quarter of
2007, contributing to supply a portion of our electricity
consumption needs in southeastern Brazil.
Valesul currently obtains a portion of its electrical energy
requirements from four wholly-owned small hydroelectric power
plants located in the Brazilian state of Minas Gerais, a portion
from the Machadinho hydroelectric power plant, in the Brazilian
state of Santa Catarina, in which Valesul has a share of 7.28%,
and the remainder from a third-party power company at market
rates. Valesul is able to supply 40% of its own
energy requirements. Valesul is engaged in litigation regarding
the rates that Light — Serviços de Eletricidade
S.A., or Light, charges Valesul for the transmission of
electricity. See Item 8. Financial
information — Legal proceedings.
Canada
Energy requirements for production from our Canadian sulphide
ores are generally only about one-fifth of the energy required
to process lateritic ores. In addition, low-cost energy is
available from our hydroelectric facilities in Ontario and from
purchased hydroelectric power at our Manitoba operations. In
2006, our hydroelectric facilities in Ontario generated
approximately 19% of our Ontario operations’ electricity
requirements.
Indonesia
Nickel production is energy-intensive, and energy costs are a
significant component of our nickel production costs, especially
for the processing of lateritic ores at our PT Inco operations
in Indonesia.
Virtually all of PT Inco’s electric furnace power
requirements are supplied at low-cost by its hydroelectric
generating facilities on the upper Larona River, generating an
average of 165 megawatts, and its facilities near the village of
Balambano which began operation in 2000, generating an average
of 110 megawatts.
PT Inco announced plans in 2004 to construct a third dam on the
Larona River near the village of Karebbe. The new dam is the
first stage of a multi-year capital program aimed at raising PT
Inco’s annual production by 25% to about 90 thousand metric
tons of
nickel-in-matte
by 2010. The new dam is expected to increase PT Inco’s
hydroelectric generating capacity by an average of 90 megawatts
annually. In January 2006, PT Inco temporarily suspended
groundwork at the new dam site, pending the receipt of a
required permit issued by the Minister of Forestry on terms
acceptable to PT Inco. While we are optimistic that we will
receive the necessary approvals to continue the groundwork, any
delay will affect the overall project timing and PT Inco’s
ability to reach the annual 90 thousand metric tons of
nickel-in-matte
production by 2010 and increase PT Inco’s production costs.
Under the Brazilian Constitution, all mineral resources in
Brazil belong to the Brazilian government. The Brazilian
Constitution requires that mining companies incorporate in
accordance with Brazilian law.
The Brazilian Constitution and Mining Code impose on mining
companies various regulatory restrictions relating to, among
other things:
•
the manner in which mineral deposits are exploited,
•
the health and safety of workers and the safety of residential
areas located near mining operations,
•
the protection and restoration of the environment,
•
the prevention of pollution, and
•
the promotion of local communities where mines are located.
Mining companies in Brazil can only prospect and mine for
mineral resources pursuant to prospecting authorizations or
mining concessions granted by the National Mineral Production
Department (Departamento Nacional de Produção
Mineral), or DNPM, an agency of the Ministry of Mines and
Energy of the Brazilian government. DNPM grants prospecting
authorizations to a requesting party for an initial period of
three years. These authorizations are renewable at DNPM’s
discretion for another period of one to three years, provided
that the requesting party is able to show that the renewal is
necessary for proper conclusion of prospecting
activities.
On-site
prospecting activities must start within 60 days of
official publication of the issuance of a prospecting
authorization. Upon completion of prospecting activities and
geological exploration at the site, the grantee must submit a
final report to DNPM. If the geological exploration reveals the
existence of a mineral deposit that is economically exploitable,
the grantee will have one year (which DNPM may extend) from
approval of the report by DNPM to apply for a mining concession
or to transfer its right to apply for a mining concession to a
third party. When a mining concession is granted, the holder of
the concession must begin
on-site
mining activities within six months. DNPM grants mining
concessions for an indeterminate period of time lasting until
the exhaustion of the mineral deposit. Extracted minerals that
are specified in the concession belong to the holder of the
concession. With the prior approval of DNPM, the holder of a
mining concession can transfer it to a third party that is
qualified to own concessions. In some cases, mining concessions
are challenged by third parties.
The Brazilian government charges us a royalty known as the CFEM
(Compensação Financeira pela Exploração
de Recursos Minerais) on the revenues from the sale of
minerals we extract, net of taxes, insurance costs and costs of
transportation. The current annual rates we pay on our products
are listed below.
•
bauxite, potash and manganese ore: 3%;
•
iron ore, kaolin, copper, nickel, fertilizers and other
minerals: 2%; and
•
gold: 1%.
The Mining Code and ancillary mining laws and regulations also
impose other financial obligations. For example, mining
companies must compensate landowners for the damages and loss of
income caused by the use and occupation of the land (either for
exploitation or exploration) and must also share with the
landowners the results of the exploration based on 50% of the
CFEM. Mining companies must also compensate the government for
damages caused to public lands. A substantial majority of our
mines and mining concessions are on lands owned by us or on
public lands for which we hold mining concessions.
We are currently engaged in a series of administrative and other
legal proceedings alleging that we have failed to collect the
proper amount of CFEM. In addition, we are discussing with DNPM
the applicable rate for potash. Because potash is used as a
fertilizer, we believe the applicable rate is the 2% rate that
applies to fertilizers, but DNPM has asserted that CFEM should
be levied on all potash products, regardless of how they are
used, at the higher rate of 3% that generally applies to potash
products. See Item 8. Financial information —
Legal proceedings.
Canada
Licenses and permits. The following discussion
reflects a summary of the property rights, mining rights,
licenses, leases or other concessionary rights to mine for or
extract metals and other associated minerals from the areas that
we currently mine or expect to mine as part of our long-term
mine plans in Canada. With respect to those properties which are
not currently owned but are subject to leases or licenses with
finite terms that are not perpetual or cannot be automatically
renewed or extended and on which estimated ore reserves are
located
and/or are
covered by our current long-term mine plans, we currently
believe that we will be able to obtain renewals or extensions of
such leases or licenses, if required as part of our long-term
mine plans on a timely basis.
Ontario operations. All operating mines,
non-operating mines and undeveloped properties which contain
estimated proven and probable ore reserves for our Ontario
operations are on lands owned by us, with the exception of a
portion of Copper Cliff South Mine (known as Kelly Lake) and a
portion of the Victor non-operating mine. These portions of the
Copper Cliff South and Victor mines are located on lands under
21-year
leases.
In the Canadian Province of Ontario, we also hold mining rights,
surface rights, licenses of occupation and mining claims granted
to us by the Province. Mining rights are rights to exploit and
extract minerals on, in or under the land, and surface rights
are rights to use the surface of the land. These rights remain
in effect so long as we own the land to which these rights
apply. We also own a combination of mining and surface
rights covering land leased from the Province of Ontario. These
leased lands, which include a combination of mining and surface
rights, are leased for either 10 or 21 years. Annual
rentals are paid to the Province of Ontario to keep the leases
in good standing. These leases are renewed for further 10- or
21-year
terms as they come up for renewal. CVRD Inco currently holds 165
licenses of occupation for mining, hydroelectric installations
and various other industrial purposes in Ontario. These licenses
of occupation allow CVRD Inco to use the land in the manner
specified in each license, including the right to dig, excavate
and remove ores and minerals from and under the land. CVRD Inco
currently also has a number of mining claims in Ontario. Mining
claims represent rights to explore the land covered by the claim.
The permission of the government of the Province of Ontario is
required for CVRD Inco to export from Canada intermediate
products derived from its Ontario ores. In December 2005, the
Ontario government granted us permission to continue to export
intermediate nickel products to our nickel refinery in Clydach,
Wales until December 31, 2015. In December 2005, the
Ontario government also granted us permission to continue to
export semi-refined PGMs concentrate to our precious metals
refinery in Acton, England until December 31, 2015. We are
not aware of any information or other factors at this time that
would prevent us from reaching an agreement with the Province of
Ontario to extend these permits for additional periods upon
their expiration.
Manitoba operations. CVRD Inco’s
landholdings or mining rights in Manitoba consist of
order-in-council
leases (“OIC Leases”), mineral leases and mining
claims. OIC Leases were negotiated as part of an agreement
entered into in 1956 between Inco and the Province of Manitoba
covering the development of the Thompson, Manitoba nickel
deposits. OIC Leases entitle the lessee to explore for, and
mine, all minerals in the subsurface (except hydrocarbons,
industrial minerals and superficial deposits that are not
incidental to the mining, milling, smelting and refining
processes). OIC Leases provide for an initial
21-year term
and two subsequent guaranteed renewals of 21 years each,
for a total guaranteed lease period of 63 years. Subsequent
lease renewals beyond the three guaranteed
21-year
terms, can be granted at the discretion of the Province of
Manitoba. All of our current OIC Leases have now been renewed
twice (each is in its third guaranteed
21-year
term) and remain in effect through the
2020-2025
period. Mineral leases are
21-year
leases that are renewable at the discretion of the Province of
Manitoba. CVRD Inco holds seven mineral leases in the Thompson,
Manitoba nickel belt. CVRD Inco also holds mining claims, a
right issued by the Province of Manitoba under provincial
legislation which conveys to the holder exclusive rights to the
minerals (other than quarry minerals) that occur on or under the
land covered by the claim and access rights to explore for and
develop minerals owned by the Province. A mining claim does not,
however, entitle the holder to extract minerals from the land
covered by the claim. In order to extract minerals from the land
covered by a mining claim, the holder must obtain a mineral
lease from the Province of Manitoba.
Voisey’s Bay project. Our wholly-owned
subsidiary Voisey’s Bay Nickel Company Limited
(“VBNC”), holds mineral claims (which have been
grouped into mineral licenses), a mining lease and surface
rights in the Province of Newfoundland and Labrador. All of the
Voisey’s Bay project’s current estimated proven and
probable ore reserves are located on lands covered by a
25-year
mining lease. Since September 30, 2002, VBNC has had the
exclusive right to extract minerals and carry out mineral
exploration, mining operations or mining processing and
development in, on or under the lands, or part of the lands,
covered by the lease so long as it and CVRD Inco continue to
meet the terms and conditions of the development agreement
entered into in October 2002 between VBNC, Inco and Her Majesty
the Queen in right of Newfoundland and Labrador. This mining
lease can be renewed for further
10-year
terms so long as VBNC has been in compliance with the terms of
the lease and has applied for such renewal at least three months
prior to the expiration of the then current lease. Under the
terms of the mining lease, production cannot exceed on
average 2.2 million metric tons of ore annually for
the first 10 years of mining operations and on
average 5.5 million metric tons of ore annually
thereafter. We are not aware of any information at this time
that would prevent us from reaching an agreement with the
Province on a new mining lease or an extension when the current
mining lease expires in September 2027. In conjunction with the
mining lease, VBNC received a surface lease entitling it to use
certain lands necessary for its mining operations. Like the
mining lease, the surface lease came into effect
September 30, 2002 for a period of 25 years, and may
be renewed for further
10-year
terms.
Pursuant to the terms of an option agreement originally entered
into in 1993, a royalty is payable to a third party on a
quarterly basis on the proceeds received by VBNC on the sale of
its production, equal to 3% of net smelter returns from mining
production from VBNC’s Labrador properties, including the
Voisey’s Bay deposit, and a 3% gross royalty (also payable
quarterly) is assessed on the gross value of raw diamonds
and/or
gemstones recovered from these properties.
There are also restrictions relating to the export of
intermediate products from the Province of Newfoundland and
Labrador. The mining lease for our Voisey’s Bay project is
subject to an order issued by the provincial government
requiring us to complete primary production (smelting,
processing or refining) in the Province of all minerals
extracted under the lease. However, as part of our agreement
with the government for the development of the Voisey’s Bay
project, the government has also issued an order allowing us to
export from the Province nickel concentrates containing up to
355,000 metric tons of nickel until we have completed the
construction of a processing plant in the Province.
Indonesia
PT Inco’s operations in Indonesia are conducted pursuant to
a Contract of Work with the Indonesian government. The Contract
of Work grants PT Inco all necessary licenses and permits to
conduct its operations and gives PT Inco the exclusive right to
mine certain areas on the Island of Sulawesi and to process and
sell the nickel and associated minerals recovered from those
areas. The original Contract of Work was signed in 1968 for a
40-year term
ending in 2008. In January 1996, it was modified and extended by
the parties and now continues until 2025.
Under the modified Contract of Work, PT Inco agreed to several
undertakings with regard to future expansions of its operations,
including an undertaking, subject to economic and technical
feasibility, to construct production plants at Pomalaa in
Southeast Sulawesi and Bahodopi in Central Sulawesi. One of
these plants was to be in operation by 2005 and the second by
2010. PT Inco’s obligations with respect to the
construction of a plant at Pomalaa has been deemed to be
satisfied through 2008 under certain ore supply arrangements
entered into with PT Antam Tbk, a government-controlled
diversified Indonesian mining company. PT Inco’s obligation
with respect to the construction of a commercial plant at
Bahodopi by 2010, subject to economic and technical feasibility,
remains in effect.
New
Caledonia
New Caledonia is an overseas territorial community
(collectivité territoriale) of France having special
legal status under the French constitution with significant
autonomy except in the areas of foreign relations, defense,
judicial, currency and certain other related areas. In a move
toward independence, the French government and two New
Caledonian political movements (one of them representing the
native population) entered into the Noumea Accord, setting forth
a process and timetable for increasing the autonomy of
New Caledonia over the coming years, culminating in a first
referendum to be held by 2014 on whether New Caledonia will
become fully independent from France. There is a possibility of
a second referendum to be held in 2018 if the outcome of the
first referendum is not in favor of independence. The initial
phase of this accord could include the enactment of a new mining
law. Although we do not believe that these developments will
have an adverse effect on the Goro project, there can be no
assurances in this regard.
Our 74%-owned subsidiary, Goro Nickel, currently holds 69 mining
concessions in the Massif du Sud (part of the south Province of
New Caledonia) covering 20,600 hectares and authorizing the
mining of nickel, cobalt, chrome, iron ore and manganese, and
approximately 26 surface rights. An additional 10 mining
concessions are held by a subsidiary of CVRD Inco, outside the
Goro project area, in a mining domain called Tiebaghi. Of the 69
concessions held by Goro Nickel, the Goro project covers 6,042
hectares within seven mining concessions, of which four are
perpetual in term, two are renewable prior to their expiry dates
in 2016 and one is renewable prior to its expiry date in 2051.
Concessions generally represent long-term permits (usually
75-year
terms, with some having longer or perpetual terms) granted for
mining large deposits which entitle the holder the exclusive
right to exploit, extract and mine. A concession applies to one
or several minerals defined by the granting decision along with
its geographical location. The granting of a concession is
based on the delineation of an exploitable orebody made during
exploration activities conducted pursuant to exploration
permits. Surface rights can be granted independently of mineral
rights. Goro Nickel holds surface rights, which are rights to
use surfaces on or outside mining permits for mining-related
activities, including surfaces of other owners.
With respect to exploration in New Caledonia, Goro was granted
an exploration permit for an area next to the Goro deposit known
as Prony West. Subsequently, following applications by nine
different third parties, the exploration permits were annulled.
Goro has appealed the decision to the Administrative Court of
Appeal in Paris, but a hearing date has not yet been set. If the
tribunal’s decision to annul the permit is upheld on
appeal, we expect that the Prony West exploration rights would
then be subject to the submission of a new application by Goro
Nickel for an exploration permit.
In order to mine the concessions it currently holds (once the
construction of the facilities are complete), Goro Nickel must
hold an operating permit. Goro Nickel was granted an operating
permit in October 2004 with an expiry of two years. Following
lengthy proceedings based on claims of alleged adverse
environmental impacts of the project brought by a New Caledonian
indigenous group called Comité Rheebu Nuu, the
New Caledonian Administrative Court cancelled Goro’s
operating permit. Although we are appealing the decision to
reinstate the operating permit, Goro Nickel had already begun an
application for an amended operating permit because of the
impending expiration of the original operating permit (October
2006) and the project’s revised configuration. We
believe the process for obtaining a new operating permit is on
track. The fact that the Goro project does not currently have an
operating permit does not currently impact development because
the operating permit does not cover construction. The
Comité Rheebu Nuu and other individuals, however, have
filed an action to obtain an injunction against construction at
Goro based on the cancellation of the operating permit. Although
we succeeded in challenging this action upon appeal, the
plaintiffs have further appealed the decision.
Railroads
Brazil
The Brazilian Ministry of Transportation and the transportation
regulatory agency (ANTT) regulate and supervise the policies for
the railroad transportation sector. The federal government may
grant private companies concessions for the construction,
operation or commercial exploitation of railroads. Railroad
concession contracts granted by the Federal government impose
certain shareholder ownership limitations. For FCA, the
concession contract provides that each shareholder can only own
up to 20% of the voting capital of the concessionaire, unless
otherwise permitted by ANTT. The 20% ownership limitation does
not apply to our Vitória a Minas and Carajás
railroads. We are in compliance with the requirements imposed by
the concession contracts for our FCA railroad operations, for
which we have received an authorization from ANTT for our
current 99.99% ownership stake. ANTT also sets different tariff
limits for railroad services for each of the concessionaires and
each of the different products transported. So long as these
limits are respected, the actual prices charged can be
negotiated directly with the users of such services.
The MRS concession contract provides that each shareholder can
only own up to 20% of the voting capital of the concessionaire,
unless otherwise permitted by ANTT. As a result of our
acquisitions of CAEMI and Ferteco in 2003, we increased our
stake in MRS beyond the 20% threshold, to 37.2% of its voting
capital and 40.5% of its total capital. In April 2006, ANTT
published a resolution requiring us to (i) sell the MRS
shares we hold as a result of our acquisition and consolidation
of Ferteco which are covered by the MRS Shareholders’
Agreement; or (ii) either (a) cause the shareholders
of MRS to approve certain changes in the capital structure of
MRS, or (b) waive our voting and veto rights with respect
to the MRS shares we hold as a result of our acquisitions and
consolidation of Ferteco. The ANTT resolution also recommends
that we comply with a CADE decision requirement to consolidate
our MRS shareholding into a single block. In May 2006, we
informed ANTT of our election to waive our voting and veto
rights with respect to the such MRS shares, representing 10.9%
of the total capital stock and 19.3% of voting capital stock of
MRS. ANTT approved our election and suspended their
recommendation to consolidate our MRS shareholdings pending the
outcome of
the CADE proceeding. See Item 4. Information on the
company — Lines of business — Logistics
and Item 8. Financial information — Legal
proceedings.
Electric
energy
Brazil
The power industry in Brazil is regulated by the Ministry of
Mines and Energy and the regulatory agency ANEEL. The role of
ANEEL is to implement and enforce policies and regulations
designated by the Ministry of Mines and Energy and aimed at
organizing and regulating the electricity sector and power
companies. ANEEL is responsible for ensuring an efficient and
economical energy market through regulation, enforcement, as
well as monitoring prices and the operational efficiency of
power companies.
Under the law governing the electricity sector, concessions
grant exclusive rights to generate and transmit or to distribute
electricity in a particular area for a period of time that
should be sufficient for the concessionaire to recover its
investment. The concessions for power generation before
December 11, 2003 were granted for up to 35 years and
may be renewed at the Federal Government’s discretion for
an additional period of up to 20 years. Concessions granted
after December 11, 2003 are granted for up to
35 years, without the possibility of renewal.
Concessionaires (distributors) are required to supply
electricity for public services, on a continuing basis, in
sufficient quantity and within approved standards of quality.
Given the hydrologic and integrated nature of the Brazilian
electricity generation matrix, Decree No. 2655/1998 created
the Mecanismo de Realocação de Energia (Energy
Reallocation Mechanism), known as MRE, a mechanism for sharing
hydrological risk, and consequently reducing generation
volatility among all generators. In order to implement the MRE,
ANEEL designates a level of energy production, known as Assured
Energy, for each generator that may be reviewed every five
years. Assured Energy is calculated in accordance with a
statistical model based on average rainfalls in the relevant
region, water flows of rivers and water levels in each
plant’s reservoir over a multi-year time frame. Each
generator is allowed to enter into contracts to sell up to 100%
of its Assured Energy. To the extent a generator has signed
contracts for the sale of its Assured Energy, and as long as MRE
members, as a whole, are able to meet MRE Assured Energy levels,
it receives payments based on these contractual terms,
regardless of its level of actual generation. If all MRE members
meet their contracted energy and there is a surplus of energy
remaining, the net regional surplus generation is allocated
among generators in different regions and this energy surplus
may be sold in the wholesale market.
All contracts for wholesale energy purchases and sales are
currently recorded in the wholesale market, the Câmara
de Comercialização de Energia Elétrica, known
as the CCEE. The CCEE is a nonprofit private entity subject to
the authorization, regulation and supervision of ANEEL, and is
responsible for operating the wholesale energy market and for
ensuring that energy transactions in the short-term market are
settled and cleared in an efficient manner. The CCEE is
primarily designed to effect the settlement of differences
between the amount of energy contracted under bilateral
contracts of the several market agents (generators,
distributors, traders and large consumers), and the amount of
energy actually consumed and produced. The settlement is done in
accordance with the CCEE spot prices, which are expressed in
R$/MWh and are calculated for each settlement period for each
sub-market.
In March 2004, the Brazilian government heightened regulation of
the electricity sector, especially in the generation segment,
with the approval of Law No. 10,848/2004 and the
regulations promulgated pursuant to it. The new law transfers
jurisdiction of some regulatory areas from ANEEL to the Ministry
of Mines and Energy. Under this new law, all consumers of
electricity, including large consumers, such as CVRD, must
contract the totality of their energy needs through contracts.
This law created two parallel markets for energy: a regulated
market, in which distributors enter into supply contracts with
regulated customers, subject to regulated prices, and an
unregulated market, in which a consumidores livres, or
“free consumers,” enter into contracts with
independent power producers at prevailing market prices.
Regulated consumers may migrate to the unregulated market, but
only after the termination of their long-term contracts.
The new law created an energy trading commission, or the CCEE,
to replace the Mercado Atacadista de Energia (the
“MAE”). Apart from the replacement of the MAE by the
CCEE as the wholesale energy market, we do not expect
significant changes in the settlement procedures for short-term
transactions. Self-generators of energy, such as CVRD, are
required to provide a pre-determined percentage of their
generated energy from new concessions acquired after 2004 to the
regulated market for distributors’ acquisition.
Because the regulation for the sector is subject to change, we
cannot be certain of the material impact that this new law could
have on our energy business. Changes in the regulatory
environment could adversely impact our energy investments.
Valesul is currently engaged in litigation regarding the rates
that Light charges Valesul for the transmission of electricity.
See Item 8. Financial information — Legal
proceedings.
Indonesia
PT Inco’s existing hydroelectric facilities were
constructed and are operated pursuant to a 1975 decree of the
Indonesian government. These facilities generate virtually all
of PT Inco’s electricity requirements. The 1975 decree
gives the government the right to acquire PT Inco’s
hydroelectric facilities upon two years’ notice to PT Inco.
No such notice has been given by the government. If this right
were to be exercised, the decree provides that the hydroelectric
facilities would be acquired by the government at their
depreciated value, subject to the government providing PT Inco
with sufficient electricity to meet its operating requirements,
at a rate based on cost plus a normal profit margin, for the
remaining term of PT Inco’s Contract of Work. The new
hydroelectric dam that is to be constructed as part of PT
Inco’s latest expansion program is also expected to be
subject to this decree.
Environmental
matters
Environmental legislation is becoming stricter worldwide, which
could lead to greater costs for environmental compliance, for
instance if we are required to modify installations, develop new
procedures or purchase new equipment.
Brazil
Federal, state and municipal legislation contain provisions for
the control and protection of the environment in Brazil. These
laws govern the use of natural resources, the reclamation and
restoration of mined areas, the control of atmospheric
emissions, the treatment of industrial effluents, as well as the
use, handling and final disposal of hazardous materials and the
control of water resources.
In order to conduct our mining, energy generation and industrial
activities, we must prepare environmental impact assessments and
submit them to authorities that oversee the granting of
environmental permits. We seek to comply with all legal
requirements and to achieve good relationships with interested
parties, especially communities located near our operations. Our
environmental management system is designed to provide a
systematic approach to environmental issues.
Under Brazilian Federal Law
No. 9,605/1998,
non-compliance with environmental laws and regulations can
result in criminal penalties, such as imprisonment and other
restrictions for individuals (including directors, officers and
managers of companies), and fines and the mandatory rendering of
public services by companies. Administrative penalties range
from warnings and fines to the suspension of corporate
activities, and may also include the loss or reduction of
incentives, or the cancellation or interruption of credit
facilities granted by governmental institutions.
Issuance of environmental licenses. We must
obtain environmental licenses in order to build, develop, expand
and operate facilities that use natural resources or may pollute
the environment. License validities can vary from one to ten
years, and have to be renewed for the life of the undertaking.
We seek to obtain the legally required licenses for each of our
facilities and activities. In some cases, this process requires
a significant amount of time for the preparation of
comprehensive environmental reports and their evaluation, as
well as for the establishment of appropriate programs for
environmental education of communities residing in areas
affected by the proposed projects. We enter into agreements with
the appropriate federal and state
governmental environmental authorities with respect to
facilities whenever environmental non-compliance is detected in
order to make these facilities compliant.
Environmental compensation. Environmental Law
No. 9,985/2000 requires us to pay “environmental
compensation” to state and federal authorities, in order to
create and maintain protected sites, in the amount of at least
0.5% of the total investment of each venture with a material
environmental impact. There are a number of uncertainties
regarding the scope and application of this law, including what
rate will be applied by the federal or state governments’
environmental agencies, how such a rate will be applied and
under what basis an investment will be valued. We are therefore
currently contesting this compensation payment requirement.
Amazônia Legal reserve. Economic
development in the Amazon basin is regulated under the Brazilian
Forest Code. In order to develop projects in the Amazon basin, a
certain threshold (80%) of each rural property must be allocated
for the purpose of forestry preservation. With respect to mining
operation projects under development, we are able to allocate
the land where there are no exploration activities for
preservation purposes, and we expect to be able to acquire
additional undeveloped land if needed to comply with the Code.
We have a number of projects in the Amazônia Legal reserve,
such as the mining sites of CVRD, MRN, PPSA and CADAM. We are
currently below the exploitation threshold in all of these
projects. Some of our mines may approach this threshold as we
expand our operations. There are a number of uncertainties
regarding the scope and application of the Brazilian Forest Code.
Prevention and environmental control
measures. Our environmental policies also aim to
prevent, control and reduce the environmental impact caused by
our business operations. To that end, we have made significant
environment-related investments in our facilities (approximately
US$86 million in 2006). We are also investing to develop
environmental projects directed at the communities located near
our facilities (approximately US$2 million in 2006).
Water use. We are intensive water users in
11 states with hydrological resources that vary from very
high water availability in the Amazon region to the scarcity in
the northeast of Brazil. The Hydrological Resources Management
System implemented throughout CVRD includes evaluation of the
availability of water in the areas where we operate and programs
to rationalize and control water use. We continually monitor new
water legislation and regulations and take particular interest
in requirements adopted under the National Policy of
Hydrological Resources, which defines the conditions for
obtaining water use grants and the fees applicable to that use
and for effluents disposal.
Environmental control systems. As a mining
company, air emissions control is one of our main objectives,
including in our pelletizing plants. Control equipment and
systems, such as stockpiles and road water aspersion and use of
chemical dust suppressants or installation of filters and
electrostatic precipitators at our facilities are complemented
by comprehensive monitoring systems and control software.
Besides achievement of legal compliance, air quality in the
installations and its effects in the neighboring communities are
continuously evaluated and we make necessary investments for air
quality improvement.
With respect to improvements in water quality, we strive to
treat and control the pollutants disposed into the sea and local
rivers or other water sources and also use extensive water
recycling in our operations. We are researching new processes
and technologies for the improvement of water use and recycling
and treatment. Through our comprehensive waste management
system, we aim to achieve greater control of the generation and
disposal of our waste, to develop opportunities to reuse,
recycle and to reduce waste.
In 2003, our mine decommissioning manual was developed, which
described a complete set of directives, including technical
practices and procedures to be followed during mine closures.
The manual outlines procedures for the rehabilitation and
monitoring of degraded areas, the main steps and sequence to be
followed during closure, and any liabilities that may result
after mine closure. The manual also provides standardized basic
criteria and procedures, based on the directives of the CVM and
the SEC (FAS 143), for cost evaluation, the establishment
of current budgets, future decommissioning and reclamation (see
Note 3 to our consolidated financial statements).
The mines water and tailings storage dams and sterile deposits
are classified according to a risk matrix involving all the
parameters related to construction, operation and safety
monitoring. A comprehensive audit
program has been established, which evaluates the stability of
all those structures and provides the inputs for the development
of corrective or preventative action plans when necessary.
Our environmental program also includes reforestation projects,
which are intended to protect the soil against erosion and to
create buffers between our activities and communities in the
surrounding areas. We partner with universities and governmental
research entities to conduct extensive research to develop
procedures for reforestation, soil protection using native
species of the managed regions and for the improvement of the
growth and growth rate of seedlings. Comprehensive fauna and
flora investigations are performed as an ongoing activity,
mainly in the Carajás region, to comprehend and avoid the
environmental risks involved in investing in potentially
sensitive areas.
We also participate in the maintenance and preservation of
approximately 1.3 million hectares of Brazilian forests,
including the federal Conservation Units and Xikrin Indigenous
Land located in the Carajás area in the Amazon, and we own
and preserve the Vale do Rio Doce Natural Reserve in the Mata
Atlântica forest in the Brazilian state of Espírito
Santo. In the last 25 years we have provided support to the
indigenous communities in the areas of education, health,
infrastructure development and technical assistance with the aim
of enhancing life quality and self-sustainability of these
communities. Expenditures on these programs amounted to
US$9 million in 2006.
In the first quarter of 2006, members of the indigenous Xikrin
community blocked the Carajás railroad, disrupting our
shipments of iron ore. In October 2006, protestors invaded our
installations in Carajás, halting operations at this site
for two days. On October 31, 2006, we announced the
suspension of a voluntary financial aid package for the Xikrin
community. In accordance with a judicial order, we have since
deposited specified amounts with the court to establish a
court-administered fund for the benefit of the Xikrin, and we
are exploring with the Brazilian Indian Foundation other
potential aid programs.
Mata Atlântica. The Mata Atlântica
forest is protected under the Brazilian constitution and other
laws aimed at ensuring its sustainable development. Certain laws
regulate activities that could interfere with the forest’s
vegetation, which is classified in terms of “primary”
and “secondary” stages of growth. The cutting of or
other interference with primary vegetation by companies
classified by law as “public utilities” (such as
railroad and power companies) is permitted subject to certain
conditions, and the law provides that mining activities are not
conducted by “public utilities.” However, this law
does permit interference with the forest’s secondary
vegetation in order to enable mining activities. The law’s
compensatory provisions require us to set aside land in the Mata
Atlântica for preservation that is equivalent in area and
ecological characteristics to any land that we use for mining
activities in the forest. Our operations in the Brazilian states
of São Paulo, Minas Gerais and Espírito Santo could be
affected by such regulations
Canada
CVRD Inco’s operations in Canada are subject to numerous
environmental laws and regulations relating to air emissions,
water discharges, soils, recycling and waste management,
decommissioning and reclamation, and employee health and safety,
among other areas.
SO2
and CEPA metals emissions reduction. Our Ontario
smelting operations are subject to legislation of the Ontario
government requiring CVRD Inco to significantly reduce its
emissions of sulphur dioxide
(“SO2”).
In 2006,
SO2
emissions from our Ontario operations were 183,000 metric tons,
meeting the required limits. In 2007, we are required to comply
with a reduced emissions limit of 175,000 metric tons
(previously 265,000 metric tons) and to reduce
SO2
ground level concentrations from the previous limit of
0.50 ppm to 0.34 ppm. From 2008 to 2014, emissions
limits could be reduced below 175,000 metric tons depending on
actual production rates over a three-year rolling period. In
2015, the limit will fall to 66,000 metric tons for
SO2.
Based on our “life of business” plan, our production
in Ontario can be maintained well beyond the 2015 timeline. We
expect that our Sudbury operations will achieve the 2007 limits
as a result of the installation in 2006 of fluid bed roaster
off-gas scrubbing technology at our Ontario smelter. We believe
that this technology, together with our ability to bank and
purchase emission allowances as permitted by the 2005
legislation, should allow us to meet the limits in effect until
2014 without seriously affecting production rates at our
Ontario operations or requiring significant additional capital
expenditures. Compliance with the 2015 limit will require
significant capital expenditures, estimates of which are
included in our five-year capital plan. We are currently
investigating various technologies in order to meet the 2015
limit.
Emissions from our Manitoba smelting operations are also
regulated under Manitoba legislation limiting
SO2
emissions to 23,000 metric tons per month and 220,000 metric
tons per calendar year. In 2006, emissions from our Manitoba
operations were within these limits, at 191,000 metric tons for
the year.
We also expect that the Canadian federal government will
legislate emissions limits before 2015. In April 2006, the
federal government, through the Environment Canada department,
encouraged base metal smelters and refineries to voluntarily
prepare “Pollution Prevention Plans,” addressing
“limit targets” for
SO2,
particulate and other toxic metals. Following discussions with
Environment Canada, the target limits for 2015 for our Ontario
operations were set at 66,000 metric tons for
SO2,
matching the Ontario government requirements, 864 metric tons
for particulate and a 90% reduction of the CEPA toxic metals
(nickel, lead, arsenic and cadmium) from the 1988 baseline. For
Manitoba, the limit targets for 2015 are 22,800 metric tons for
SO2,
198 metric tons for particulate and a 90% reduction of the CEPA
toxic metals from the 1988 baseline. These target levels are
lower than the current emission limits and we will not be able
to meet these targets without making significant capital
expenditures, and compliance with these targets could adversely
affect our production levels, financial results and cash flow
particularly for our Manitoba operations.
Sudbury and Port Colborne soils. CVRD Inco has
been working with regulatory authorities and other interested
parties to evaluate elevated levels of nickel and other metals
in soils in the vicinity of our processing facilities in Sudbury
and Port Colborne, Ontario that may be related to the historical
emission of windblown metal-containing particulates. CVRD Inco
voluntarily agreed to conduct detailed risk assessments and to
remediate soils as necessary to reduce risks to negligible
levels in both the Sudbury and Port Colborne areas. Any efforts
we are required to undertake to remediate or investigate these
matters may involve significant expenditures. Given the
existence of various legal appeals and scientific and medical
studies currently underway, it is not possible to predict the
effect these actions and studies could have on our business,
results of operation or financial condition.
Smelter emissions. In 2010, a regulation
promulgated by the Ontario government (called “Air
Pollution Regulation — Local Air Quality”) will
take effect with respect to base metal smelters. This regulation
incorporates existing air quality standards, but the Ontario
Ministry of the Environment plans to revise many of these
standards on an ongoing basis for priority contaminants, which
include nickel, lead, cadmium, arsenic and others. A proposed
new standard for lead and cadmium was issued in 2006. If the
proposed standard becomes law, compliance could require process
modifications. Our five-year capital plan includes estimates for
these changes. We expect the Ministry of the Environment to
release its proposed new standard for nickel in 2007.
Clean Air Act and greenhouse gases. The
Canadian government is in the process of amending provisions of
the Clean Air Act (“CAA”) related to control of
emissions of greenhouse gases,
SO2
and particulate matter, and metals. Some of the key proposals
affecting our business include (i) substitution for
carcinogenic substances (nickel and cobalt could be affected),
(ii) mandatory emissions targets (gradually reducing
targets every 15 years, reaching a reduction, based on 1990
levels, of an amount yet to be defined that will range from 60%
to 80% by 2050), (iii) carbon trading for non-compliance
and (iv) a proposal to regulate contaminants by sector and
region. At this stage in the legislative process, we do not know
what additional operating or capital expenditures will be
required to comply with enacted amendments or what effect they
would have on our business, financial results or cash flow from
operations.
Canadian Environmental Protection Act
(“CEPA”). Pursuant to the Canadian
Environmental Protection Act, in 2006 the government categorized
approximately 23,000 chemical substances in terms of two
criteria: (a) persistence, bioaccumulation, and inherent
toxicity to the environment; and (b) high hazard to humans
with a high likelihood of exposure to individuals in Canada. For
substances that meet either or both criteria for categorization,
screening or detailed assessments must be undertaken, and if
deemed necessary, risk management measures may be required. In
late 2006, the government began a study of 200 high-priority
chemical substances. Cobalt and cobalt chloride are among these
chemicals and specific studies with respect to them
could begin in late 2007 or early 2008. We cannot predict what
impact the CEPA data challenge will have on our business,
financial results of cash flow from operations.
Silica (Canada and United States). In 2006,
the American Conference of Governmental Industrial Hygienists
(“ACGIH”) adopted new exposure limits for silica, with
TWA (time-weighted average) values of 0.025 µg/m3 for both
crystalline crystobalite silica and crystalline α-quartz.
These TWA values are half the value of the previous limits and
represent a significant challenge for compliance. Meeting the
proposed TWA values via engineering controls will require
significant operational resources. In some jurisdictions, the
ACGIH exposure limits become legal regulatory limits when they
are published. Consequently, at Thompson, Manitoba and
Voisey’s Bay, Newfoundland, the ACGIH values are legally
binding. It is not clear at this time what impact, including in
terms of compensation claims, the ACGIH Silica TWA values will
have on our financial results.
Indonesia
PT Inco’s operations are subject to environmental
regulations and permits issued by the Indonesian government. PT
Inco is in compliance with these regulations and permits, except
dust emission levels from its facilities. For several years, PT
Inco has had a program in place with the Indonesian government
to explore the most effective ways to further reduce PT
Inco’s dust emissions. This program has included the
installation of electrostatic precipitators, wet and dry
scrubbers and other equipment to capture and reduce emissions of
dust and particulates, from PT Inco’s dryers, reduction
kilns and converters. In 2005, PT Inco installed dust control
equipment on one of its four furnaces, which has reduced dust
emissions to below the Indonesian emission limits and has also
addressed workplace air quality concerns with respect to dust
emissions. As a result of the success of this equipment on the
first furnace, similar equipment was installed on another
furnace in early 2007, and we plan to install such equipment on
the other two furnaces by the end of 2007. While PT Inco has not
received any indication from Indonesian governmental authorities
that it would be subject to any penalties or sanctions for
exceeding certain emissions limits as it works to correct these
problems, PT Inco may still be subject to regulatory actions for
non-compliance with these limits.
New
Caledonia
Our Goro project is subject to environmental regulations in New
Caledonia and in France. In preparation for the operation phase,
a new tree nursery capable of producing over 500,000 seedlings
was constructed and will begin operations in 2007. Environmental
baseline monitoring, particularly for the marine environment,
continued in 2006. Goro has also been subject to environmental
protests by certain groups in New Caledonia. Comité Rheebu
Nuu, a local environmental association opposed to the
development of the Goro project, has been making applications to
the governmental authorities in New Caledonia and in France,
based on various environmental claims. One of the applications
pertained to our operating permit. See —
Mining — New Caledonia.
United
States
Clean Air Act. Nickel compounds are among the
chemicals or chemical groups regulated as hazardous air
pollutants (“HAPs”) under the U.S. Clean Air Act.
Pursuant to this legislation, the EPA has been promulgating
stringent technology-based standards for controlling emissions
of HAPs from designated “major source” categories.
This process will continue in the future and ultimately may
include the promulgation of additional risk-based standards.
Some of these standards may limit emissions of nickel and its
compounds, most likely through limits on overall emissions of
particulate matter. While it does not appear that the
“major source” HAP control program will target
emissions at nickel producing or using industries, it is
possible that some nickel-emitting sources may ultimately be
covered by such standards. We are unable to predict what capital
expenditures or increases in operating costs CVRD Inco or its
customers may incur if that proves to be the case.
European
Union
REACH. In October 2003, the European
Commission adopted draft legislation intended to consolidate and
streamline 30 different EU laws. The new European Chemicals
Policy, better known as REACH (the
acronym for “Registration, Evaluation, and Authorisation of
Chemicals”), which takes effect on June 1, 2007, is
designed to protect human health and the environment from risks
posed by chemicals. Towards that end, it establishes an
all-encompassing system for the management of both new and
existing chemicals that are manufactured in or imported into the
EU. The definition of chemicals is very broad and includes
metals, alloys and all metal-containing compounds.
Under REACH, importers will be required to register certain
chemicals prior to their entry into the European market. Certain
substances, possibly including nickel and cobalt substances,
will be subject to an authorization process prior to import. The
authorization application must include an analysis of possible
substitutes and, if suitable substitutes are deemed available, a
substitution plan. If suitable substitutes are not available,
information on relevant research and development activities must
be provided, as appropriate. How this analysis of substitutes
and the development of a substitution plan will work in practice
remains to be seen. CVRD Inco and other companies that produce
and sell nickel and cobalt products have created a number of
consortia to manage the registration of similar products.
Comprehensive legislative review and risk
assessment. EU Regulation 793/93(EEC), a
regulation covering the evaluation of the risks of and controls
for existing substances, includes five nickel substances (nickel
sulphate, nickel chloride, nickel nitrate, nickel carbonate and
nickel metal) as targets. The Danish Environmental Protection
Agency (the “Danish EPA”) has been appointed the
principal agency for conducting risk assessments on these
substances. The Human Health risk assessment was completed in
early 2006 and the Danish EPA release a draft risk reduction
strategy in late 2006. The main recommendation is a review of
the occupational exposure limits for various nickel species. The
environmental risk assessment for nickel is expected to be
released in 2007.
International
ISO and OHSAS certifications. Our
environmental management system is based on the International
Organization for Standardization (ISO) standard 14001 and under
the Occupational Health and Safety Standards (OHSAS) 18001. We
have obtained ISO 14001 certificates covering iron ore and
pelletizing operations (Alegria, Timbopeba, Água Limpa,
Fábrica Nova, Fazendão, Cauê,
Conceição, Córrego do Feijão, Brucutu, Morro
da Mina, Gongo Soco, Fábrica, Mutuca, Tamanduá,
Capitão do Mato, Pico, Capão Xavier, Jangada and
Carajás complex), manganese and ferroalloys plants (Azul
mine, RDME and RDMN), nickel operations (Clydach Refinery, Acton
Refinery, Inco TNC Limited, Jinco Nonferrous Metal, IATM
Dalian & Shenyang), port operations (Tubarão
complex and CPBS), our research center, aluminum operations
(Alunorte, Albrás and Valesul) and kaolin production
facilities (PPSA and CADAM). Samarco and MRN are also certified
under this standard. We also have obtained OHSAS 18001
certificates for the MBR system, our Clydach refinery, Acton
refinery, as well as the operations of our IATM
Dalian & Shenyang and Jinco Nonferrous Metals Co.
subsidiaries.
Harmonization of classification and labeling of
chemicals. In 1990, the International Labour
Organization initiated a project to harmonize existing systems
for the classification and labeling of chemicals. This
ultimately led to the promulgation of a globally harmonized
hazard classification and compatible labeling system called the
Globally Harmonized System (“GHS”). Although adoption
of the GHS by individual countries is voluntary, the goal of the
Intergovernmental Forum on Chemical Safety is to promote
widespread adoption of the GHS by 2008. Japan has recently
implemented the GHS, while the United States will be enforcing
the GHS for transportation purposes in January 2008. Other
countries will implement the GHS over the next several years. We
do not believe that the adoption of the GHS will have a material
impact on our results of operations or financial condition.
Investment
Canada Act undertakings
On October 20, 2006, we obtained approval under the
Investment Canada Act, in the form of a “net benefit to
Canada” ruling from the Canadian Minister of Industry, in
connection with our offer to acquire the
outstanding common shares of Inco Limited. In connection with
that approval, we made a number of undertakings in furtherance
of which we intend to take certain steps, including the
following:
Creation of a Canadian-based global nickel
business. We have committed to base our global
nickel business in Toronto, Ontario, with responsibility for the
global nickel business and related activities of CVRD and a
mandate to expand its business as a global leader in the nickel
industry. In furtherance of this mandate, we will transfer
management responsibility for our interest in existing and
future nickel projects to CVRD Inco, including our interest in
the Onça Puma and Vermelho projects in Brazil. CVRD
Inco’s global activities will be managed from its Toronto,
Ontario head office, which will continue to exercise head office
functions and activities with significant Canadian
participation. We have undertaken that there will be no layoffs
at Canadian operating facilities for at least three years, and
that, for an agreed period, aggregate employment at such
facilities will not fall below 85% of the aggregate employment
level as at the date on which the acquisition of CVRD Inco
occurred.
Acceleration of Voisey’s Bay development
project. We have indicated that we fully support
the Voisey’s Bay development project, and expressed our
wish to accelerate its implementation. We also indicated our
intention, upon completion of the acquisition of Inco Limited,
to approach the Government of Newfoundland and Labrador to
initiate discussions with respect to our desire to accelerate
the Voisey’s Bay development project by a period of 12 to
18 months.
Enhanced investments in CVRD Inco’s long-term
future. To help strengthen CVRD Inco’s
position as a leader in the global nickel mining business and
contribute to ensuring the long-term viability of CVRD
Inco’s operations in Sudbury, Ontario, and Thompson,
Manitoba, Canadian expenditures will be increased in a number of
areas, including exploration and research and development, for a
three-year period.
Corporate social responsibility. We will
increase spending on apprenticeship programs for First Nations,
student employment programs and employee recruitment, education,
apprenticeship and training programs in Canada for a three-year
period. We will increase spending on environmental compliance
programs in Canada over that same period.
Continuing contributions to communities. We
will maintain our involvement and commitment to the growth of
Ontario’s mining cluster, including its membership in the
Mineral Industry Cluster Council. We will respect all agreements
entered into by CVRD Inco with provincial governments, local
governments, labor unions and aboriginal groups, including the
Labrador Inuit Association and the Innu Nation, in Canada. We
will also honor all commitments made by CVRD Inco with regard to
the funding of educational institutions, including commitments
made with respect to the Centre for Excellence in Mining
Innovation at Laurentian University in Sudbury, Ontario.
Each of the undertakings made by us to the Canadian Minister of
Industry is subject to the “Investment Canada Act,
Guidelines — Administrative Procedures, Monitoring of
Investments.” Among other things, these guidelines state
that performance is judged in the context of overall results and
that an investor who is unable to fulfill a commitment will not
be held accountable where such inability is clearly beyond its
control.
The table below sets forth our historical capital expenditures
by business area for the periods indicated. See Item 5.
Overview — Key Factors Affecting Revenues and Results
of Operations — Divestitures and Asset Sales, for
a description of our divestitures.
2006
capital expenditures and budgeted capital expenditures for
2007
During 2006, CVRD made capital expenditures and other
investments of US$20,628 million, of which
US$3,464 million was on organic growth, composed of
US$2,988 million on projects and US$476 million on
research and development, while US$1,360 million was
invested in maintaining existing business, and
US$15,804 million in acquisitions. Total capital
expenditures in 2006, excluding spending on acquisitions and
other investments and including US$324 million arising from
two-months of consolidation of CVRD Inco, were
US$4,824 million. This information on capital expenditures
includes research and development expenditures, which are
treated as a current expense for accounting purposes.
In 2006, we acquired two companies: Inco
(US$18,931 million) and Valesul (US$28 million). We
also acquired certain assets of Rio Verde Mineração
for US$47 million. See Item 4. Acquisitions, Asset
Sales and Significant Changes in 2005 and 2006. The
US$18,931 million invested in the acquisition of Inco
reflects the purchase price of US$17,744 million plus
Inco’s net debt of US$1,187 million.
US$15,691 million was paid to Inco shareholders in 2006,
and US$2,053 million was paid to Inco shareholders in 2007.
The purchase of the 39.8% minority stake in Caemi belonging to
minority shareholders, equivalent to US$2,552 million,
involved a share exchange, so there was no financial
disbursement.
In our financial planning for 2007, we have budgeted
US$7,351 million for capital expenditures in 2007. Of this
total, 72.9%, or US$5,356 million, will be allocated to
growth capital expenditures — US$4,904 million on
projects and US$452 million on research and
development — and the remaining US$1,995 million
will be allocated to capital expenditures for maintaining
existing operations
(“stay-in-business
capital expenditures”). The acquisition of AMCI Holdings
Australia Pty (announced in February 2007) for
US$656 million, excluding net debt, was not included in the
2007 capital expenditure-budget figure.
The 2007 capital expenditure budget consolidates planned capital
expenditure of CVRD Inco, which accounts for
US$1,950 million of the investments programmed for this
year. The
stay-in-business
capital expenditure budget for nickel operations in Ontario and
Manitoba, Canada has been set at US$477 million, due to the
age of these operations and the low level of investment in the
period
2003-2005
(an annual average of US$208 million). These investments
are important for the conservation of these operations and the
extension of their useful lives.
Global economic growth, the resumption in investment by the
mining and metals industry, rising raw material prices and the
appreciation of mineral-exporting countries’ currencies
against the U.S. dollar — such as the Brazilian
real and the Canadian dollar — have contributed
to a sharp increase in the cost of mining projects. The price of
equipment and engineering services has risen substantially since
2003, which has
contributed to a major increase in the unit cost of mining
projects around the world. We have been making efforts to
minimize the impact of this increase in investment costs.
Investment of US$1,869 million, or 25.4% of the total 2007
budget, has been earmarked for our ferrous minerals business.
Investment of US$885 million is allocated to the aluminum
division, while US$784 million is allocated to our
logistics business. Investment of US$3,125 million is
planned for our non-ferrous minerals businesses.
The following table describes our expenditures for our main
investment projects in 2006 and our budgeted expenditures for
projects in 2007, together with estimated total expenditures for
each project.
Actual
Budgeted
Area
Project
2006
2007
Total
Status
(US$ million)
Ferrous minerals
Expansion to iron ore production
capacity at Carajás to 85 Mtpa (Northern system)
87
—
296
This project has added
15 million metric tons per year of iron ore production
capacity. It was completed in the third quarter of 2006.
Expansion to iron ore production
capacity at Carajás to 100 Mtpa (Northern System)
258
87
366
This project has added
15 million metric tons per year of production capacity. It
was completed in January 2007.
Expansion to iron ore production
capacity at Carajás to 130 Mtpa (Northern System)
—
66
1,828
This project, which is subject to
approval by our Board of Directors, is expected to add
30 million metric tons per year of production capacity,
with the construction of a new plant, consisting of primary
crushing, and processing and classification units. Completion is
scheduled for 2009.
Brucutu iron ore mine (Southeastern
System)
415
43
856
This project has added
30 million metric tons per year of production capacity. It
was completed in the third quarter of 2006.
Expansion of Fazendão iron ore
mine (Southeastern System)
23
111
129
Project for the production of
15.8 million metric tons per year of
run-of-mine
(ROM), or unprocessed, iron ore. This project will enable
Samarco’s third pellet plant to begin operations. Work
began in the second half of 2006 and is expected to be completed
in the first quarter of 2008.
Itabiritos pelletizing plant
(Southern System)
98
417
759
This project involves construction
of a pelletizing plant in the Brazilian state of Minas Gerais,
with a nominal production capacity of 7 million metric tons
per year, as well as construction of an iron ore concentration
plant. Start-up is targeted for the second half of 2008.
Non-ferrous minerals
Salobo copper mine
—
78
855
This project is expected to have
production capacity of 100,000 metric tons per year of copper in
concentrate. Development
start-up is
contingent on obtaining an appropriate tax structure, which is
currently being discussed with government authorities.
Onça Puma nickel mine
64
658
1,437
Onça Puma is expected to have
a nominal annual nickel production capacity of 58,000 metric
tons. Construction began in July 2006 and the main equipment has
already been contracted.
Start-up is
planned for the second half of 2008.
Vermelho has an estimated
production capacity of 46,000 metric tons per year of finished
nickel, and 2,800 metric tons per year of cobalt. Work on
obtaining required environmental license is still in progress.
Goro nickel mine
N/A
938
3,212
Goro has an estimated production
capacity of 60,000 metric tons per year of finished nickel and
4,600 metric tons of cobalt. Commissioning is scheduled for the
end of 2008.
Aluminum
Expansion of Alunorte:
stages 4 and 5 — alumina
219
—
583
Stages 4 and 5 began
operations in the first half of 2006, expanding the alumina
refinery’s capacity to 4.3 million metric tons per
year from 2.4 million metric tons per year in 2005.
Paragominas I bauxite mine
219
35
352
The mine’s first module has a
nominal production capacity of 5.4 million metric tons per
year of bauxite. Operations began in January 2007.
Expansion of Alunorte:
stages 6 and 7 — alumina
226
520
846
Stages 6 and 7 will increase
alumina refinery capacity to 6.26 million metric tons per
year. Completion of this project is scheduled for mid-2008.
Paragominas II
bauxite mine
16
115
196
The second phase of Paragominas
will add 4.5 million metric tons per year of bauxite to the
production capacity of 5.4 million metric tons per year
achieved on the first phase. Completion is scheduled for the
second quarter of 2008.
All figures reported in the table above are presented on a cash
basis, according to our financial planning for 2006 and 2007.
In addition to these projects, CVRD has budgeted
US$452 million for research and development. Of the total
budgeted, 72% is expected to be spent in Brazil and 28% in South
America, North America, Africa, Australasia and Europe.
In the fourth quarter of 2006, we acquired 87.73% of Inco, the
world’s second largest nickel producer. The acquisition has
led us to become one of the world’s largest nickel
producers, with more diversified revenues in terms of products,
markets and geographical asset base, and the second largest
mining and minerals company in the world by market value.
The year 2006 was our fourth consecutive year of record growth
in revenues, operating income and net income. In spite of
increasing cost pressures — due primarily to higher
prices for equipment and raw materials reflecting the high
production levels in the mining industry, higher costs for fuel
and energy, and the appreciation of the real against the
U.S. dollar — we generated net income of
US$6,528 million in 2006, a
34.8% increase over 2005. Our results were driven primarily by a
40.6% increase in operating income, reflecting a 53.6% increase
in net revenues that was partially offset by a decline in
overall operating margins, from 42.5% of net revenues in 2005 to
38.9% in 2006.
The increase in revenues reflected strong demand and rising
prices for our principal products driven principally by
continued strong demand from China and expanded demand from our
other markets in Asia and Europe, as well as high production
levels supported by new projects coming on stream, operation at
full capacity at most of our units, productivity gains and the
acquisition of Inco in the fourth quarter of 2006. The decrease
in overall operating income margins primarily reflects the
impact of purchase accounting adjustments to inventory values in
connection with the acquisition of Inco.
Demand
Demand
for iron ore and pellets
Demand for our iron ore products is a function of global demand
for steel, which is, in turn, heavily influenced by worldwide
economic activity. In recent years, we have experienced a
significant increase in demand, particularly from China. Global
demand for steel has been growing since 2002, and global demand
for iron ore grew at a rate of approximately 8.3% in 2006. In
China, where we became the largest supplier of iron ore in 2006,
we expect that although steel production will tend to grow at a
more moderate rate in the near term than it has over the last
ten years, demand for imported iron ore will continue to require
additional quantities through the end of this decade, thus
maintaining pressure on global supply.
Demand for iron ore exceeded our production capacity throughout
2006, and we expect that this situation will also prevail in
2007. We continue to invest to increase capacity and our
programmed iron ore production for 2007 is higher than in 2006,
but we continue to face excess demand. We expect to continue
purchasing and reselling iron ore from third parties to meet the
shortfall. In 2006, we purchased 10.2 million metric tons
of iron ore and 8.9 million metric tons of pellets from
third parties.
In early 2006, global demand for pellets, which is more
concentrated in North America and the European Union, softened.
In order to adjust to the new demand level, we decided to
temporarily shut down our São Luís plant in late
March and accelerate planned maintenance, and to reallocate the
volume of iron ore fines. São Luís resumed
operations in July. We believe there is significant long-term
growth potential for pellet demand and are therefore expanding
our pellet production through two projects —
Itabiritos, in the Brazilian state of Minas Gerais, which
involves the construction of a pellet plant with an expected
production capacity of 7 million metric tons per year, and
the third pellet plant of Samarco, with an expected production
capacity of 7.6 million metric tons per year. Both of these
projects are targeted for
start-up in
2008.
Demand
for nickel
Demand for primary nickel is driven primarily by world economic
conditions and associated industrial production. World primary
nickel demand increased by approximately 8% to an estimated
1.384 million metric tons in 2006. The main drivers of
nickel demand in 2006 included strong global economic activity,
a robust rebound in global stainless steel production, and solid
nickel demand for non-stainless steel applications. Nickel
demand was strong in all global regions in 2006, but
particularly strong in China, which accounted for approximately
half of world demand growth.
Primary nickel use in stainless steel production accounts for
over 60% of total primary nickel demand. Global stainless steel
production grew 15.8% to an estimated 28 million metric
tons in 2006. We believe stainless steel production was aided by
rising demand due to strong global economic activity as well as
the need by consumers to replenish low stainless steel
inventories. China led the way in new stainless steel capacity
expansions in 2006, and we anticipate it will continue to lead
the way in coming years. Chinese stainless steel production in
2006 is estimated to have grown by over 2 million metric
tons to 5.3 million metric tons.
In 2006, the non-stainless steel sector contributed to strong
demand for alloys with high nickel content in the United States
and Europe, driven by the energy and aerospace sectors. The
growth in the energy sector included strength in applications in
the oil, liquid natural gas, and nuclear industries.
The global nickel market continues to face the effects of
structural constraints on the supply side. The source of current
global nickel production is mainly nickel sulphides, and as
these traditional sources are depleted, future production growth
will depend on laterite deposits. Development of greenfield
laterite projects has continued to face major delays resulting
from cost and technical and political challenges. The majority
of new supply projects are forecast to
ramp-up no
sooner than 2009. In 2006, primary nickel supply grew by
approximately 5% to 1.354 million metric tons. The increase
in supply from traditional sources was limited to below 3%, as
disruptions occurred at a number of producers. Traditional
supply was augmented by a new source of primary nickel
introduced during the year, known as NiCr pig iron.
Robust nickel demand, coupled with limited increases in nickel
supply, resulted in an estimated worldwide supply deficit of
about 30,000 metric tons in 2006. London Metal Exchange (LME)
inventories declined to just 6,594 metric tons by the end of
2006 — a drop of 29,448 metric tons, or
82% — representing less than two days of world nickel
consumption.
In 2007, we anticipate continued solid nickel demand from both
stainless and non-stainless steel applications, with China
continuing to drive nickel demand as its production of stainless
steel increases to meet expected strong economic growth and
domestic demand. We believe underlying nickel demand will
continue to be constrained by available supply.
Demand
for aluminum
Demand for aluminum products is driven primarily by world
economic conditions. In recent years, China has been the primary
driver of demand in the aluminum sector. Chinese producers have
announced plans for significant growth in alumina production in
the next few years. Growth in Chinese alumina production is
supported by a sharp increase in bauxite imports, which could
lead to upward pressure on the price of bauxite in the short
term.
Demand
for copper
Global demand for copper is driven primarily by world economic
conditions. In recent years, growth in copper demand has been
driven primarily by Chinese imports. The behavior of the copper
market in 2006 was characterized by shortages of concentrates
and refined metal. As in the nickel market, there are few shock
absorbers on the supply side — inventories are
relatively low, producers already operate at full capacity and
significant increases in global capacity are not expected in the
short term.
Demand
for transportation services
Demand for our transportation services in Brazil is primarily
driven by growth in the Brazilian economy, mainly in the
agricultural and steel sectors. Demand for rail transportation
grew more slowly in the last two years, due to lower Brazilian
agricultural exports and lower Brazilian steel production. These
two industries are the main users of our railroads. Each of
these markets has begun to recover in 2007.
Production
capacity
Capacity expansions are a key factor influencing our revenues.
We continue to invest in expanding capacity at a large number of
facilities. Completed expansions that had a significant effect
on 2006 results included the following:
•
The expansion project at Carajás to 85 million metric
tons per year was completed in the third quarter of 2006. In
2006 we produced 81.8 million metric tons of iron ore in
Carajás.
•
Our greenfield iron ore project at Fábrica Nova, which has
a capacity of 15 million metric tons per year, began
operations in the second quarter of 2005 and produced
13.2 million metric tons in 2006.
Operations at our Brucutu iron ore mine began in September 2006.
Production amounted to 7.7 million metric tons in 2006, and
is expected to reach 23 million metric tons in 2007 and
30 million metric tons in 2008.
•
The expansion of our Tubarão Port in the Southeastern
System was completed in December 2006.
•
Stages 4 and 5 of the expansion of Alunorte, designed to
increase its nominal capacity to 4.4 million metric tons
per year from the previous 2.4 million metric tons per
year, were completed in the first quarter of 2006. Production
amounted to 3.9 million metric tons in 2006 and is expected
to reach full capacity in 2007.
•
We purchased 26 locomotives (all for iron ore transportation)
and 1,416 wagons (primarily for iron ore transportation) in 2006.
•
We completed our capacity expansion project at the
Taquari-Vassouras potash mine in September 2005, increasing its
capacity from 600,000 metric tons per year to 850,000 metric
tons per year. In 2006 we produced 731 thousand metric tons of
potash.
•
Our Yankuang metallurgical coke plant, with an estimated
production capacity of 2 million metric tons of coke per
year and 200,000 metric tons per year of methanol, began trial
production in June 2006. Total production in 2006 was 268,000
metric tons of coke and we expect to produce 1.2 million
metric tons in 2007.
In addition to the above projects, the following major projects
will affect our results in 2007:
•
The expansion of Carajás to 100 million metric tons
per year was completed in January 2007.
•
The Paragominas mine, with an estimated production capacity of
5.4 million metric tons of bauxite per year, was
commissioned in the first quarter of 2007. The bauxite from
Paragominas will be used to supply Alunorte’s alumina
refinery.
See Item 4. Information on the company —
Capital expenditures for more details concerning our 2007
capital expenditure budget.
Prices
The following table sets forth our average realized prices for
our principal products for each of the years indicated.
Iron ore. Our iron ore sales are made pursuant
to long-term supply contracts, which provide for annual price
adjustments. Cyclical changes in the global demand for steel
products affect sales prices and volumes in
the world iron ore market. Different factors influence price
differences in US-dollar per metric ton terms between the
various types of iron ore, such as the iron content of specific
ore deposits, the various beneficiation and purifying processes
required to produce the desired final product, particle size,
moisture content and the type and concentration of contaminants
(such as phosphorus, alumina and manganese ore) in the ore.
Fines, lump ore and pellets typically command different prices.
We generally conduct annual price negotiations beginning in
November of each year. Due to the wide variety of iron ore and
pellet quality and physical characteristics, iron ore and
pellets are not considered commodities. This factor combined
with the structure of the market has prevented the development
of an iron ore futures market. We do not hedge our exposure to
iron ore price volatility.
Driven by continued high levels of demand in the global iron ore
market, customer demand for iron ore continued to exceed our
production capacity in 2006. Reflecting this excess demand, we
reached agreements with major steelmakers in May 2006 under
which our reference prices for iron ore increased by an average
of 19.0% and prices for pellets decreased by 3.0%. These price
agreements had a significant positive effect on our gross
revenues in 2006. Our reference prices per Fe unit for iron ore
fines increased
across-the-board
in 2006 by 19.0%, after increasing by 71.5% in 2005 from 2004
levels. In December 2006, we reached agreements with major
steelmakers under which our 2007 reference prices for
Carajás (SFCJ) and Southern System (SSF) iron ore fines
increased by 9.5% relative to 2006. Blast furnace and direct
reduction pellet prices, both from the Tubarão and São
Luís plants, will increase by 5.28% relative to 2006.
Nickel. Prices for our nickel and other
primary metals products generally reflect prices at the LME, the
principal terminal market for primary nickel in the world, or
prices at other metal markets. Nickel prices depend principally
on the balance between demand for nickel products in the
marketplace relative to the supply available from us and our
competitors, including the supply of similar primary metals
materials in various producer, merchant and consumer
inventories, inventories of secondary or scrap materials
containing nickel and other metals in usable or recyclable form,
and supplies of other materials which may be substituted for
nickel. Over the long term, a particularly important determinant
of price will be the costs associated with bringing additional
nickel supply to market to meet overall nickel demand.
Our nickel price realizations tend to lag LME cash nickel price
movements, due primarily to the terms of our contractual sales
arrangements with certain customers. We realize a premium over
prevailing LME cash prices for our finished nickel products.
Aluminum products operations. Aluminum is sold
in an active world market where prices are determined by
reference to prices prevailing on terminal markets, such as the
London Metal Exchange and the New York Mercantile Exchange or
NYMEX, at the time of delivery.
We are engaged in the production and sale of bauxite, alumina
and aluminum primarily through several joint ventures. Some of
them are consolidated subsidiaries and others are accounted for
on the equity method. The basic arrangements are as follows:
•
MRN (an unconsolidated joint venture in which we own 40%)
produces bauxite. It sells on a
take-or-pay
basis to us and the other joint venture partners, at a price
that is determined by a formula linked to the price of aluminum
for three-month contracts on the London Metal Exchange and to
the price of alumina exported from Australia. We sell part of
the bauxite we purchase from MRN to Alunorte and part to
unaffiliated customers.
•
Alunorte (a consolidated subsidiary in which we own 57%)
produces alumina. In 2006, it purchased substantially all of its
bauxite requirements from MRN, and its annual purchase
commitment for 2006 was approximately US$221 million. In
2007, Alunorte will also buy bauxite from the Paragominas mine.
It sells alumina on a
take-or-pay
basis to us and the other joint-venture partners in proportion
to their respective interests, at a price which is determined by
a formula based on the price of aluminum for three-month
contracts on the London Metal Exchange. In 2006, 23.3% of
Alunorte’s alumina production was sold to unaffiliated
customers.
Albras (a consolidated subsidiary in which we own 51%) produces
primary aluminum. It sells on a
take-or-pay
basis to us and the other joint-venture partners, in proportion
to their respective interests. We sell the aluminum we purchase
from Albras directly to customers.
•
Valesul (a former unconsolidated joint venture which became a
consolidated wholly-owned subsidiary in July 2006) also
produces aluminum and sells aluminum products directly to its
customers.
Manganese ore and ferroalloys. Manganese ore
and ferroalloy prices are influenced by trends in the steel
market. Manganese ore prices are generally negotiated on an
annual basis using a benchmark established in the Japanese
market based on the reference price for the related ferroalloys.
Ferroalloy prices are negotiated in open bids, quarterly
contracts (particularly in Europe) or on a spot basis. They are
influenced by a number of factors and are more volatile than
prices for manganese ore. Among the principal factors are the
price of manganese ore, the inventories held by producers or
traders, occasional interruptions in production and anti-dumping
tariffs in the main markets (U.S., Europe, Japan and South
Korea). Average realized manganese ore prices decreased 16.8% in
2006. Average realized ferroalloy prices increased 4.7% in 2006.
In response to continued global excess supply that resulted in
inventory accumulation and falling ferroalloy prices, we managed
our manganese and ferroalloys business in 2006 with the aim of
cutting costs and maximizing efficiency. In this context, we
reduced production, in part by shutting down inefficient
furnaces and some small manganese mines, and we also began
combining ore from our Azul mine with that acquired from other
producers, producing a blend capable of improving productivity
in the alloy manufacturing process.
Copper. We sell our copper concentrate in an
active world market where prices are determined on the basis of
(i) prices on terminal markets, such as the LME and the
COMEX, at the time of delivery and (ii) treatment and
refining charges negotiated with each customer. World copper
prices on the LME increased 42.8% in 2006 relative to 2005.
These high prices reflect increased global demand, primarily
from China, and the historically low level of inventories.
Logistics. We earn our logistics revenues
primarily from fees charged to customers for the transportation
of cargo via our railroads, ports and ships. Most of these
revenues are earned by our railways, and nearly all of our
logistics revenues are denominated in reais. Prices in
the Brazilian railroad market are subject to maximum levels set
by the Brazilian regulatory authorities, but they primarily
reflect competition with the trucking industry.
Acquisitions
and divestitures
We have made a number of significant acquisitions and
divestitures in recent years. For more information, see
Item 4. Information on the Company — Business
overview — Recent acquisitions and significant changes
and Divestitures and asset sales. During 2006 and
2007, the following transactions had a significant impact on our
performance:
Acquisitions
•
In October 2006, we acquired 75.66% of Inco in an unsolicited
cash tender offer. Following a subsequent offer period and
additional purchases, we held 87.73% of the shares at
December 31, 2006, and in January 2007 the amalgamation of
Inco with our subsidiary resulted in our owning 100% of the
shares. We paid a total purchase price of
US$17,151 million, of which US$15,098 million was
disbursed in 2006 and US$2,053 million in 2007.
•
In April 2007, we paid US$656 million for the acquisition
of 100% of AMCI Holdings Australia Pty — AMCI HA, an
Australian company that operates and controls coal assets
through joint ventures.
In May 2007, we entered into a transaction by which we have
effectively obtained control of 100% of MBR’s total capital
during the next 30 years. Prior to this transaction, we
owned 89.9% of MBR, directly and through our 80% stake in
Empreendimentos Brasileiros de Mineração S.A. (EBM),
whose main asset is a 51% stake in MBR. We acquired a further
6.25% of EBM for US$231 million, and we simultaneously
entered into a usufruct agreement with respect to the 13.75% of
EBM’s total capital that we do not own. This agreement
grants us during the next 30 years all rights and
obligations with respect to these EBM shares, including the
right to dividends. In exchange, CVRD will pay a total of
US$61 million and an annual fee of US$48 million.
Because we already consolidate MBR, this transaction will not
have a significant impact on our consolidated results of
operations.
•
In July 2006 we acquired the remaining 45.5% of Valesul
Alumínio S.A., which had previously been a joint venture
with equal voting rights, for US$28 million. Upon the
acquisition, we began consolidating Valesul. Valesul accounted
for US$153 million of our sales of primary aluminum in 2006.
•
In March 2006, we acquired the outstanding minority interest in
Caemi through a stock merger. In December 2006, Caemi was merged
with and into CVRD.
Divestitures
•
In December 2006, we sold our 4.85% interest in
Siderar — S.A.I.C, a steel plant located in Argentina,
to Ternium S.A. for US$108 million.
•
In the second half of 2006, we sold all of our shares of Gerdau
S.A. for US$67 million.
•
In November 2006, we announced our entry into the control group
of Usiminas and the concurrent sale of a portion of the shares
not subject to the controlling shareholders’ agreement for
US$176 million. In May 2007, we sold in a public offering
registered with the CVM 13,802,499 Usiminas shares and received
total proceeds of US$728 million. In connection with the
offering, we entered into a lockup agreement for a period of
90 days from April 25, 2007. After the lockup period
expires or is waived, we intend to sell 36,691 additional shares
that were not sold pursuant to the offering’s overallotment
option.
•
In May 2006, we sold our 50% interest in Gulf Industrial
Investment Company (GIIC), a pellet producer based in Bahrain,
to our joint venture partner, Gulf Investment Corporation, for
US$418 million.
•
In February 2006, we sold our 49% stake in Nova Era Silicon, a
ferrosilicon producer with operations in the Brazilian state of
Minas Gerais, to our partner JFE Steel Corporation for
US$14 million.
•
In February 2006, we sold our 40% stake in the consortium to
build and operate the Foz do Chapecó hydroelectric power
plant to Furnas Centrais Elétricas for US$4 million.
Impact
of Inco acquisition
Our 2006 results reflect just over two months of CVRD
Inco’s operations, as shown in the table below.
Of the cost of goods sold attributable to CVRD Inco,
US$953 million was generated by purchase accounting
adjustments in accordance with SFAS 141 and 142. Under
these standards, an acquired company’s assets, including
inventories, must be adjusted to fair value upon acquisition.
When the related inventories are sold, the difference between
fair value and production cost is included in cost of goods
sold. Applying these principles, the market value of Inco’s
inventories at the time of acquisition was adjusted upward by
US$1,686 million at December 31, 2006, when we had
acquired 87.73% of the shares. US$946 million of the market
value difference was recognized in the fourth quarter of 2006
upon sale of a portion of the inventories. We booked
US$984 million for the first quarter of 2007 and an
adjustment of US$78 million will be made in the second
quarter of 2007, due to the completion of the acquisition of
Inco in January 2007 and a significant increase in nickel prices
since October 2006.
As a result of the acquisition of Inco, we recognized, on a
preliminary basis, US$3,876 million of goodwill at
December 31, 2006, which increased in the first quarter of
2007 when we paid the balance of the purchase price. We also
substantially increased our indebtedness to finance the
acquisition, as discussed in more detail below.
Currency
exchange rates
Most of our revenues are U.S. dollar-denominated, while
most of our costs (other than debt service expenses) have
historically been denominated in Brazilian reais. As a
result, the strength of the real in recent years has had
a negative effect on our reported financial results from
operations. On the other hand, because most of our debt is
dollar-denominated, appreciation of the real causes us to
record foreign exchange gains.
The acquisition of Inco has significantly changed the
composition of our non-debt service costs. As a result of the
acquisition, a significant portion of our costs are now
denominated in Canadian dollars and Indonesian rupiahs. The
diversification of our cost base should reduce the impact of the
appreciation of the real on our reported financial
results from operations in future periods.
Changes in exchange rates had a negative effect on our operating
income in 2006. The average R$/US$ exchange rate was R$2.4341
during 2005 and R$2.1771 during 2006, representing an 11.8%
appreciation of the real. Although the U.S. dollar
depreciated by 8.7% from year-end 2005 to year-end 2006,
compared to depreciation of 11.0% from year-end 2004 to year-end
2005, our overall foreign exchange gains were higher in 2006 due
primarily to the significant increase in debt incurred in
connection with the Inco acquisition.
Inflation
in Brazil
As measured by the IGP-M Index, the Brazilian inflation rate was
approximately 12.4% in 2004, 1.2% in 2005, and 3.8% in 2006. In
the first four months of 2007, the Brazilian inflation rate was
1.15%. Most of our costs are incurred in Brazil in reais,
while most of our revenues are earned outside of Brazil in
U.S. dollars. Brazilian inflation has a negative impact on
our operating margins.
Operating
expenses
Our principal operating expenses consist of cost of goods sold,
selling, general and administrative expenses and research and
development expenses.
•
Cost of goods sold. Our cost of goods sold
consists principally of costs for raw materials (especially
bauxite purchased under
take-or-pay
arrangements from MRN, and iron ore, pellets and nickel
purchased from third parties), services (especially mine waste
removal and freight), materials and supplies, labor, fuel,
energy and depreciation and depletion. As described above, our
cost of goods sold also reflect the non-cash effect of purchase
accounting adjustments in connection with our acquisition of
Inco.
•
Selling, general and administrative
expenses. Our selling, general and administrative
expenses consist principally of personnel expense, sales expense
and depreciation.
•
Research and development expenses. Our
research and development expenses consist primarily of
investments related to mineral exploration and studies for the
development of projects.
Our gross operating revenues rose to US$20,363 million in
2006, a 51.9% increase over 2005. Our net operating revenues
increased 53.6% to US$19,651 million in 2006. The following
table summarizes our gross revenues by product and our net
operating revenues for the periods indicated.
Includes copper, precious metals,
cobalt and other by-products produced by CVRD Inco.
(2)
Does not include copper produced by
CVRD Inco.
Iron ore. Gross revenues from iron ore
increased by 35.6%, driven primarily by a 22.7% increase in
average selling prices and a 10.6% increase in shipments of iron
ore. The price increases resulted from agreements with major
steelmakers in May 2006 under which our reference prices for
iron ore increased by an average of 19%. This price increase,
which was retroactive to January for most clients in Europe and
to April for most clients in Asia, began to favorably affect our
gross revenues in the latter half of the second quarter of 2006.
The increase in shipments was made possible by higher production
at our existing mines, the expansion of our Carajás mine,
the startup of our Fábrica Nova mine in April 2005 and
production from MBR’s Mar Azul mine, which we acquired in
the first quarter of 2006. Our Brucutu mine began operations in
the third quarter of 2006, further increasing our production
capacity.
Pellets. Gross revenues from pellets decreased
by 5.0%. Total shipments in 2006 of 25,354 million metric
tons were 11.0% lower than in 2005, primarily reflecting our
decision to temporarily shut down our São Luís pellet
plant from March until July 2006 in response to lower demand
resulting from steel production cuts in Europe and North
America. Reflecting the lower demand for pellets, we agreed to a
3% cut in the reference price for blast furnace and direct
reduction pellets in our negotiations with major steelmakers in
May 2006, which began to have an impact on gross revenues in the
latter part of the second quarter of 2006. Despite this
reduction in reference prices, average selling prices for 2006
were 6.8% higher in 2006 than in 2005. As described above, we
reached agreements with major steelmakers under which prices for
blast furnace and direct reduction pellets from our Tubarão
and São Luís plants will increase by 5.28% relative to
2006.
Nickel and other products. We acquired Inco in
the second half of October 2006, and our 2006 results include
two months of its operations. Nickel and other products sold by
CVRD Inco accounted for revenues of US$2,802 million in
2006.
Manganese ore and ferroalloys. Gross revenues
from sales of manganese ore and ferroalloys decreased by 1.4%.
Because of lower market prices for ferroalloys, we have reduced
production since 2005. See Item 5. Operating and
financial review and prospects — Overview —
Prices — Manganese ore and ferroalloys.
•
Gross revenues from ferroalloys increased by 2.8%, from
US$494 million in 2005 to US$508 million in 2006, due
to a 4.7% increase in average selling prices partially offset by
an 1.3% decrease in volume.
•
Gross revenues from manganese ore decreased by 28.6%, from
US$77 million in 2005 to US$55 million in 2006,
reflecting a 16.8% decrease in average selling prices and a
14.1% decrease in volume.
Potash. Gross revenues from sales of potash
decreased by 4.0%, from US$149 million in 2005 to
US$143 million in 2006. The decrease was driven by a 16.2%
decrease in average selling prices. Sales volume increased by
14.5%, reflecting a full year of operation at higher capacity of
the Taquari-Vassouras mine.
Kaolin. Gross revenues from sales of kaolin
increased by 23.2%, from US$177 million in 2005 to
US$218 million in 2006 due principally to a 13.4% increase
in average selling prices. Volume increased by 8.6%.
Logistics services. Gross revenues from
logistics services increased by 13.2%. The increase reflects the
appreciation of the real, since our prices are generally
denominated in reais, as well as price increases in
reais. In particular:
•
Revenues from railroad transportation increased by 14.8%, from
US$881 million in 2005 to US$1,011 million in 2006.
Average prices increased by 14.2%. Volume shipped remained
stable.
•
Revenues from port operations increased by 13.5%, from
US$230 million in 2005 to US$261 million in 2006.
Average prices increased by 17.1%. Volume decreased by 3.1%.
•
Revenues from shipping remained stable, at US$105 million
in 2005 and US$104 million in 2006.
Aluminum products. Gross revenues from
aluminum products increased by 69.1%. The main drivers were:
•
A 51.2% increase in gross revenues from sales of aluminum, from
US$823 million in 2005 to US$1,244 million in 2006.
This increase was mainly driven by a 39.0% rise in average
selling prices, reflecting strong worldwide demand for aluminum.
Volume increased by 8.5%, primarily due to the consolidation of
Valesul beginning in July 2006.
•
A 108.7% increase in gross revenues from sales of alumina, from
US$531 million in 2005 to US$1,108 million in 2006.
The increase in alumina gross revenues resulted from a 76.2%
increase in sales volume, reflecting the startup of
Stages 4 and 5 of Alunorte’s Barcarena refinery in the
first quarter of 2006. These expansion projects increased our
annual production capacity from 2.5 million metric tons to
4.4 million metric tons. The growth in alumina production
more than offset the accounting impact of eliminating sales of
alumina by Alunorte to Valesul upon its consolidation beginning
in July 2006. Higher LME prices for aluminum, the reference
price for our alumina sales, drove an 18.4% increase in average
selling prices.
•
Gross revenues from sales of bauxite decreased by 46.3%, from
US$54 million in 2005 to US$29 million in 2006. Volume
decreased by 50.0%, reflecting higher consumption of bauxite by
our Alunorte subsidiary, which reduced the amount of bauxite
available for sale to customers. This was partly offset by a
7.4% increase in average selling prices due to higher LME prices
for aluminum, the reference price for our bauxite sales.
Copper. Gross revenues from sales of copper
almost doubled, due to an 85.7% increase in average selling
prices and a 7.3% increase in sales volume. This reflects sales
of copper concentrate from our Brazilian operations but not
sales of copper from our CVRD Inco operations, which are
included in nickel and other products.
Other products and services. Gross revenues
from other products and services increased from
US$14 million in 2005 to US$95 million in 2006,
primarily reflecting a coal shipment realized in the first
quarter of 2006 and sales of pig iron.
Like other mining and metals companies, we are currently
experiencing high prices for equipment, replacement parts,
energy, raw materials and services. The appreciation of the
real against the U.S. dollar has increased these
pressures, because of our costs denominated in reais. The
following table summarizes our operating costs and expenses for
the periods indicated.
The following table summarizes the components of our cost of
goods sold for the periods indicated.
Year Ended December,
2006
Attributable to
Total
CVRD Inco
2005
% Change
(US$ million)
Outsourced services
US$
2,056
132
US$
1,483
38.6
Materials costs
1,584
128
1,126
40.7
Energy
Fuel
912
91
630
44.8
Electric energy
623
31
456
36.6
Subtotal
1,535
122
1,086
41.3
Acquisition of iron ore and pellets
758
—
761
(0.4
)
Acquisition of other products
Nickel
482
482
—
—
Aluminum products
336
—
299
12.4
Other
97
32
33
193.9
Subtotal
915
514
332
175.6
Personnel
917
210
514
78.4
Depreciation and depletion
899
124
585
53.7
Inventory adjustment
946
946
—
—
Others
537
54
342
57.0
Total
US$
10,147
US$
2,230
US$
6,229
62.9
%
Our total cost of goods sold increased by 62.9%. This increase
resulted primarily from the following factors:
•
Impact of Inco acquisition. CVRD Inco
operations in the fourth quarter of 2006 contributed total cost
of goods sold of US$2,230 million. As described above,
US$946 million of this amount relates to purchase
accounting adjustments under SFAS 141/142 that required us
to mark to market the inventories of Inco upon acquisition. The
excess of the market price over the production cost of these
inventories is included in cost of goods sold when the
inventories are sold. We expect to incur a further
US$1,062 million in increased cost of goods sold in 2007
related to the remaining inventories.
Impact of appreciation of the real. The
average value of the real increased 11.8% against the
U.S. dollar in 2006 compared to 2005. Because the majority
of our costs and expenses are denominated in reais, this
led to increased
U.S.-dollar
costs.
•
Outsourced services. Outsourced services costs
increased by 38.6% in 2006. Of the US$573 million increase,
US$132 million was attributable to CVRD Inco. The remaining
US$441 million increase was driven primarily by the
appreciation of the real and higher rail freight costs
due to higher iron ore production at our MBR subsidiary, which
uses the MRS railway to transport its iron ore to the port. The
higher outsourced services costs also reflect increased waste
material removal at our mines and higher costs for maintenance
services.
•
Material costs. Material costs increased by
40.7% in 2006. Of the US$573 million increase, CVRD Inco
contributed US$128 million. The remaining
US$330 million increase primarily reflected higher volumes
and the appreciation of the real against the
U.S. dollar.
•
Acquisition of iron ore and pellets. Cost of
iron ore and pellets purchased from other mining companies
remained stable, as price increases more than offset declines in
metric tons purchased. Iron ore purchased from third-party
suppliers in 2006 decreased by 33.8% to 10.2 million metric
tons in 2006 compared to 15.4 million metric tons purchased
in 2005. We purchased 8.9 million metric tons of pellets
from third parties in 2006, a decrease of 7.1% compared to
9.7 million metric tons purchased in 2005.
•
Acquisition of other products. Acquisition of
other products increased by US$583 million in 2006, of
which US$514 million was attributable to CVRD Inco. The
remaining US$69 million was driven primarily by higher
purchases of bauxite from third parties by Alunorte to supply
the expanded operation of Alunorte’s Barcarena alumina
refinery. We expect third-party bauxite purchases to decline
following the
start-up of
the Paragominas mine in 2007.
•
Energy costs. Energy costs increased by 41.3%
in 2006. Of the US$449 million increase,
US$122 million was attributable to CVRD Inco. Electricity
costs increased by US$167 million, of which
US$31 million was attributable to CVRD Inco. The remaining
increase in electricity costs primarily reflects 31.1% higher
electricity prices for aluminum production, driven by the Albras
electricity contract, under which a portion of the price is
indexed to the LME price for aluminum, and by the consolidation
of Valesul, which pays higher prices for its supply of
electricity. The volume of electricity consumed also increased
by 17.6%. Fuel costs increased by US$282 million, of which
CVRD Inco accounted for US$91 million. The remaining
US$191 million increase was driven by higher production,
the appreciation of the real and higher prices.
•
Personnel costs. Personnel costs increased by
78.4%. Of the US$403 million increase, US$210 million
was attributable to CVRD Inco. The remainder of the increase
reflects the impact in 2006 of salary increases agreed in July
2005, an increase in the number of our employees as a result of
our expansion projects and our consolidation of Valesul, the
appreciation of the real against the U.S. dollar,
and the payment of a special bonus to employees in August 2006.
In July 2006, we agreed on a 3% wage increase that took effect
in January 2007.
Selling,
general and administrative expenses
Selling, general and administrative expenses increased by 40.0%.
Of the US$233 million increase, US$62 million was
attributable to CVRD Inco. The remainder of the increase
resulted primarily from higher selling expenses due to the
increase in sales volume, an annual increase in the salary of
administrative employees and the appreciation of the real
against the U.S. dollar.
Research
and development expenses
Research and development expenses increased by 73.6%. Of the
US$204 million increase, US$39 million was
attributable to CVRD Inco. The remainder of the increase
primarily reflects an increase in mineral exploration and
project studies in several regions, including South America,
Asia, Africa and Australia. The
increase also includes US$25 million of expenses relating
to the construction of a hydrometallurgical plant for processing
copper.
Other
costs and expenses
Other costs and expenses more than doubled. The
US$299 million increase was primarily attributable to a
US$171 million provision for mine closure and other
environmental remediation matters, resulting from a
comprehensive review.
Operating
income by segment
The following table provides information concerning our
operating income by segment and as a percentage of revenues for
the periods indicated.
Our operating income decreased as a percentage of net operating
revenues from 42.5% in 2005 to 38.9% in 2006.
•
This decrease was driven primarily by decreases in the margins
on our iron ore, manganese, ferroalloys and potash businesses,
which, together with the impact of consolidating Inco and its
operating margin of 14.6%, more than offset higher margins in
our copper, alumina and aluminum businesses.
•
The decrease in margins in our iron ore business primarily
reflects the impact of the appreciation of the real
against the U.S. dollar, higher research and
development expenditures, higher depreciation charges due to the
expansion of our asset base and higher freight and other
outsourced services costs. Together, these factors more than
offset the impact of higher average selling prices.
•
Revenues and operating margins increased in our copper, alumina
and aluminum businesses. In each of these segments, higher
prices more than offset the production cost increases described
above.
•
The significant margin declines in the manganese and ferroalloys
segments are due to lower market prices for these products and
the higher production costs described above.
The margin decline in the potash segment is due to the lower
potash prices noted above and higher production costs due
primarily to the appreciation of the real against the
U.S. dollar.
•
The operating margin for nickel and other products reflects in
part the impact of the purchase accounting adjustments relating
to inventories described above.
Non-operating
income (expenses)
The following table details our net non-operating income
(expenses) for the periods indicated.
We had net non-operating revenues of US$192 million in
2006, compared to net non-operating expenses of
US$12 million in 2005. This change primarily reflects:
•
Higher exchange rate gains on our net
U.S. dollar-denominated liabilities caused by the exchange
rate variation of CVRD Inco’s debt.
•
An increase in financial income, due mainly to higher interest
rates and higher average cash balances.
•
An increase in financial expenses, principally due to a
significant increase in average debt incurred in connection with
the Inco acquisition.
•
A US$674 million gain on sales of investments in 2006, from
the sale of our interest in Siderar (US$96 million gain),
Usiminas (US$175 million gain), GIIC (US$338 million
gain), Nova Era Silicon (US$9 million gain) and Gerdau
(US$56 million gain), compared to gains in 2005 related to
the sale of the Quebec-Cartier Mining Company
(US$126 million gain).
Income
taxes
In 2006, we recorded a net income tax expense of
US$1,432 million, compared to US$880 million in 2005.
The effective tax rate on our pretax income was 18.3% in 2006
and 16.2% in 2005. Our effective tax rate is lower than the
statutory rate because (i) income of some non-Brazilian
subsidiaries is subject to lower rates of tax, (ii) we are
entitled to deduct the amount of our distributions that we
characterize as interest on shareholders’ equity and
(iii) we benefit from tax incentives applicable to our
earnings on production in particular regions of Brazil.
Our equity in the results of affiliates and joint ventures and
provisions for losses on equity investments resulted in a gain
of US$710 million in 2006, compared to a gain of
US$760 million in 2005. The following table summarizes the
composition of our equity in results of affiliates and joint
ventures for the periods indicated.
Equity in results of affiliates
and joint ventures
Ferrous
US$
312
US$
435
Logistics
95
54
Aluminum products
76
65
Steel
201
197
Coal
26
9
Total equity in results of
affiliates and joint ventures and provisions for losses
US$
710
US$
760
The change from 2005 to 2006 primarily reflected lower results
in ferrous minerals because of the sale of GIIC and higher
results in logistics because of better performance at MRS
Logistica.
Our gross operating revenues rose to US$13,405 million in
2005, a 58.1% increase over 2004. Our net operating revenues
increased 58.6% to US$12,792 million in 2005. The following
table summarizes our gross revenues by product and our net
operating revenues for the periods indicated:
Iron ore. Gross revenues from iron ore
increased 85.1%, from US$3,995 million in 2004 to
US$7,396 million in 2005, driven primarily by a 66.3%
increase in average selling prices and a 11.4% increase in
shipments of iron ore. The price increases resulted mainly from
the 71.5% rise in iron ore prices agreed with major steelmakers
in February 2005, which was retroactive to January for most
clients in Europe and to April for most clients in Asia. We also
increased our shipments of iron ore by 23.1 million metric
tons, or 11.4%, compared to 2004. The increase in shipments was
made possible by higher production at our existing mines,
initial production increases under capacity expansion projects
at Capão Xavier and Fábrica
Nova, and an increase in iron ore purchases from third parties,
from 15.9 million metric tons to 16.4 million metric
tons, in response to strong demand growth.
Pellets. Gross revenues from pellets increased
by 81.4%, from US$1,148 million in 2004 to
US$2,083 million in 2005. The increase was driven primarily
by a 77.8% rise in average selling prices. The price increases
reflect the 86.67% rise in pellet prices we established with
major steelmakers in February 2005, which was retroactive to
January for most clients in Europe and to April for most clients
in Asia. Total shipments in 2005 of 28.5 million metric
tons were 3.6% higher than the 27.5 million metric tons in
the same period in 2004, primarily reflecting higher production
at our pelletizing plants in response to demand.
Manganese ore and ferroalloys. Gross revenues
from sales of manganese ore and ferroalloys decreased 18.5%,
from US$701 million in 2004 to US$571 million in 2005.
Because of lower market prices for ferroalloys, we reduced
production during 2005. See Item 5. Operating and
financial review and prospects — Overview —
Prices — Manganese ore and ferroalloys. As a
result:
•
Gross revenues from ferroalloys decreased 21.0%, from
US$625 million in 2004 to US$494 million in 2005, due
to a 14.1% decrease in sales volume and an 11.5% decrease in
average selling prices.
•
Gross revenues from manganese ore remained stable, at
US$76 million in 2004 and US$77 million in 2005,
reflecting an 11.2% increase in average selling prices and a
9.5% decrease in volume.
Potash. Gross revenues from sales of potash
increased 20.2%, from US$124 million in 2004 to
US$149 million in 2005. The increase was driven by an 18.3%
rise in average selling prices, reflecting strong demand. Sales
volume increased by 1.6%.
Kaolin. Gross revenues from sales of kaolin
increased 7.9%, from US$164 million in 2004 to
US$177 million in 2005, due principally to a 6.1% increase
in average selling prices. Volume remained relatively stable.
Logistics services. Gross revenues from
logistics services increased 38.7%, from US$877 million in
2004 to US$1,216 million in 2005. The increase reflects the
appreciation of the real, since our prices are generally
denominated in reais, as well as price increases in
reais. In particular:
•
Revenues from railroad transportation increased 44.0%, from
US$612 million in 2004 to US$881 million in 2005.
Average prices increased 50.0%. Volume shipped remained stable.
•
Revenues from port operations increased 32.9%, from
US$173 million in 2004 to US$230 million in 2005.
Average prices increased 25.7%. Volume increased 6.7%.
•
Revenues from shipping increased 14.1%, from US$92 million
in 2004 to US$105 million in 2005. Average selling prices
increased 25.0%. Volume decreased 5.0% due to operational
problems with one of our ships.
Aluminum products. Gross revenues from
aluminum products increased 12.6%, from US$1,250 million in
2004 to US$1,408 million in 2005. The main drivers were:
•
An 11.4% increase in gross revenues from sales of aluminum, from
US$739 million in 2004 to US$823 million in 2005. This
increase was mainly driven by an 8.9% rise in average selling
prices, reflecting strong worldwide demand for aluminum. Volume
increased 4.0% due to production increases.
•
A 15.9% increase in gross revenues from sales of alumina, from
US$458 million in 2004 to US$531 million in 2005. The
increase in alumina gross revenues resulted from a 2.2% increase
in sales volume and an increase in worldwide demand for alumina
that drove a 13.5% increase in average selling prices.
•
Gross revenues from sales of bauxite remained stable, at
US$54 million in 2005, compared to US$53 million in
2004. An 11.3% increase in average selling prices due to a
general rise in worldwide bauxite prices was partially offset by
an 8.3% decrease in volume, reflecting higher consumption of
bauxite by our Alunorte subsidiary, which reduced the amount of
bauxite available for sale to clients.
Copper. Copper production at CVRD started in
June 2004. Gross revenues from sales of copper nearly doubled to
US$391 million in 2005 from US$201 million in 2004,
when we had only seven months of copper production. The output
from our Sossego copper mine in 2005 was lower than initially
expected due to the need to replace equipment because of harder
than expected rock conditions. The new equipment started to
operate in the fourth quarter of 2005. Problems with the ball
mill caused significant production decreases in the first
quarter of 2006. We did not reach full capacity in 2006. Gross
revenues in 2005 were also positively impacted by copper prices,
which continue to post record levels, reflecting strong Chinese
demand, disruptions in production worldwide and lower levels of
reported inventories.
Other products and services. Gross revenues
from other products and services decreased 26.3%, from
US$19 million in 2004 to US$14 million in 2005.
Operating
costs and expenses
Like other mining and metals companies, we experienced high
prices for equipment, replacement parts, energy, raw materials
and services. The appreciation of the real against the
U.S. dollar increased these pressures for us, because
approximately 70% of our costs are denominated in
reais. The following table summarizes our
operating costs and expenses for the periods indicated.
General. Total cost of goods sold increased
52.6%, from US$4,081 million in 2004 to
US$6,229 million in 2005. This increase resulted primarily
from the following factors:
•
The average value of the real increased 16.8% against the
U.S. dollar in 2005 compared to the 2004. Because
approximately 70% of our costs and expenses are denominated in
reais, this led to increased U.S. dollar costs.
•
Material costs increased by US$646 million, or 58.3%, in
2005, driven primarily by the rise in the price of raw materials
and fuel, as well as expanded production and an increase in
prices for spare parts.
•
Outsourced services costs increased by US$670 million, or
82.4%, in 2005, driven primarily by higher sales volumes,
increases in rail freight charges, increased waste material
removal in the mines and higher prices for maintenance services.
•
Cost of iron ore and pellets purchased from other mining
companies increased by 60.5%, reflecting price increases in 2005
as well as higher volumes purchased. Iron ore purchased from
third party suppliers in 2005 increased to 16.4 million
metric tons, 3.2% more than the 15.9 million metric tons
purchased in 2004.
•
Energy costs increased by US$141 million, or 44.8%, in 2005
driven primarily by higher electricity prices under the Albras
long-term energy supply contract. In addition to the basic
price, the seller participates in earnings from our sale of
primary aluminum when the price exceeds US$1,450.00 per
metric ton, as registered at the London Metal Exchange (LME).
The LME price has exceeded the threshold during the entire
contract to date.
Cost of ores and metals. Cost of ores and
metals sold increased by 60.4% to US$4,620 million in 2005
from US$2,881 million in 2004, primarily due to higher
input prices, the appreciation of real against the
U.S. dollar and the increased production. The cost of ores
and metals during 2005 also reflected a US$130 million
increase in costs related to our Sossego copper mine, which
began operations in June 2004.
Cost of logistics services. Cost of logistics
services increased by 37.4%, from US$513 million in 2004 to
US$705 million in 2005 due to higher cargo volumes, higher
fuel costs, higher freight costs charged by MRS and the
appreciation of the real against the U.S. dollar.
Cost of aluminum products. Cost of aluminum
products increased by 32.5%, from US$674 million in 2004 to
US$893 million in 2005, primarily reflecting higher prices
for the bauxite Alunorte acquires from MRN, higher fuel prices,
and higher prices under the Albras long-term energy supply
contract.
Cost of other products and services. Cost of
other products and services decreased from US$13 million
2004 to US$11 million in 2005.
Selling,
general and administrative expenses
Selling, general and administrative expenses increased 28.9%,
from US$452 million in 2004 to US$583 million in 2005.
The increase resulted primarily from higher selling expenses due
to the increase in sales volume, an annual increase in the
salary of administrative employees and the appreciation of the
real against the U.S. dollar.
Research
and development expenses
Research and development expenses increased by 81.0%, from
US$153 million in 2004 to US$277 million in 2005, due
to increase in mineral exploration and project studies in
several regions, including South America, Asia, Africa and
Australia.
Other
costs and expenses
Other costs and expenses increased from US$257 million in
2004 to US$271 million in 2005.
Our operating income increased as a percentage of net operating
revenues from 38.7% in 2004 to 42.5% in 2005. This increase was
driven primarily by higher revenues and operating margins in the
iron ore and pellets businesses. In each of these segments,
higher prices more than offset the production cost increases
described above.
The improvement in the iron ore and pellet segments was
partially offset by a decline in the operating margins of most
of our other segments:
•
The decline in aluminum segment margins primarily reflects the
appreciation of the real and higher energy and other raw
material prices, which more than offset the impact of higher
aluminum prices.
•
The decline in kaolin operating margins is due to higher storage
and packaging costs and port expenses in Europe and higher fuel
costs.
•
The decline in copper operating margins resulted primarily from
higher unit operating costs and lower than expected volumes due
to the adverse drilling conditions described above.
•
The decline in the railroad segment operating margins primarily
reflects higher fuel prices, which were only partially offset by
higher average selling prices.
We had net non-operating expenses of US$12 million in 2005,
compared to net non-operating expenses of US$120 million in
2004. This change primarily reflects:
•
The positive impact of exchange rate movements on our net
U.S. dollar-denominated liabilities caused by the
appreciation of the real, which was 11.0% in 2005 and
8.1% in 2004.
•
An increase in financial income from US$82 million in 2004
to US$123 million in 2005 due mainly to an increase in
treasury funds invested.
•
A decrease in financial expenses from US$671 million in
2004 to US$560 million in 2005, principally due to a
reduction in average debt.
•
A gain on sale of investments in 2005 of US$126 million due
to the sale of the Quebec Cartier Mining Company in July 2005,
compared to a gain of US$404 million in 2004, due to the
sale of CST.
Income
taxes
In 2005, we recorded a net income tax expense of
US$880 million, compared to US$749 million in 2004.
The effective tax rate on our pretax income was 16.2% in 2005
and 24.9% in 2004. Our effective tax rate is lower than the
statutory rate because (i) income of some non-Brazilian
subsidiaries is subject to lower rates of tax, (ii) we are
entitled to deduct the amount of our distributions that we
characterize as interest on shareholders’ equity and
(iii) we benefit from tax incentives applicable to our
earnings on production in particular regions of Brazil. The
effective tax rate decreased in 2005 because a higher proportion
of our income was generated by non-Brazilian subsidiaries or was
eligible for tax incentives.
Affiliates
and joint ventures
Our equity in the results of affiliates and joint ventures and
provisions for losses on equity investments resulted in a gain
of US$760 million in 2005, compared to a gain of
US$542 million in 2004. The following table summarizes the
composition of our equity in results of affiliates and joint
ventures and provisions for losses on equity investments for the
periods indicated.
Ferrous Minerals. Our equity in the results of
iron ore and pellet affiliates and joint ventures and provisions
for losses on equity investments amounted to a gain of
US$435 million in 2005, compared to a gain of
US$170 million in 2004. The improvements at each of these
affiliates were due to strong demand in the market for iron ore
and pellets and higher prices.
Logistics. In 2005, our equity in the results
of logistics affiliates and joint ventures and provisions for
losses on equity investments amounted to a gain of
US$54 million, compared with a gain of US$33 million
in 2004, reflecting improved results at MRS Logística S.A.
Aluminum products. Our equity in the results
of our aluminum affiliates and joint ventures and provisions for
losses on equity investments was US$65 million in 2005,
compared to US$71 million in 2004. This decrease resulted
primarily from lower results at Valesul due to higher fuel and
energy costs, which more than offset improved results at MRN.
Steel. In 2005, we recorded a net gain of
US$197 million with respect to our equity in the results of
steel affiliates and joint ventures, compared to a net gain of
US$271 million in 2004. The decrease primarily reflects the
impact of the sale of CST in 2004 and declining results at CSI
in 2005, both of which were partially offset by improved 2005
performance at Usiminas resulting primarily from higher average
selling prices.
Coal. In 2005, we recorded equity in the
results of our Longyu coal joint venture of US$9 million.
In January 2006, CVRD received its first trial shipment of coal,
approximately 40,000 metric tons, from China to Brazil.
In the ordinary course of business, our principal uses of funds
are: capital expenditures, dividend payments and repayment of
debt. We have historically met these requirements by using cash
generated from operating activities and through short-term and
long-term debt. We believe these sources of funds, together with
our cash and cash equivalents on hand, will continue to be
adequate to meet our anticipated capital requirements.
In addition, from time to time, we review acquisition and
investment opportunities and will, if a suitable opportunity
arises, make selected acquisitions and investments to implement
our business strategy. We generally make investments directly or
through subsidiaries, joint ventures or affiliated companies,
and fund these investments through internally generated funds,
the issuance of debt or a combination of these methods.
Borrowings under our senior acquisition facility in connection
with the acquisition of Inco and refinancing of those
borrowings, together with debt of CVRD Inco, have led to a
significant increase in the amount of our consolidated
outstanding indebtedness and related debt service requirements.
At December 31, 2006, we had US$21,833 million of
long-term debt outstanding, compared with US$4,932 million
of long-term debt outstanding at the end of 2005. Our financial
expenses have increased as a result of these borrowings.
We financed the purchase price for Inco and related transaction
expenses using drawings of US$14,600 million under our
acquisition facility (all in 2006) and cash on hand. We
began refinancing the acquisition facility in November 2006, and
by December 31, 2006 we had arranged the refinancing of 84%
of the amount originally drawn. We paid off the acquisition
facility in full at the end of April 2007. The principal sources
of funds were the following:
•
A US$3,750 million issuance of
10-year and
30-year
guaranteed notes by our finance subsidiary Vale Overseas Limited
that closed in November 2006;
•
A US$2,544 million issuance of four-year and seven-year
real-denominated non-convertible debentures that closed
in December 2006; and
A US$6,000 million issuance of five-year and seven-year
pre-export finance transaction that closed in December 2006.
In 2007, in addition to the refinancing of the remaining balance
of our acquisition facility, we expect our major cash needs to
include repayment of long-term debt maturing during 2007,
budgeted capital expenditures of US$7,351 million,
announced minimum dividend payments for 2007 of
US$1,650 million and the US$656 million purchase price
for the acquisition of AMCI described below. We expect to meet
these cash needs primarily through a combination of operating
cash flow and cash and cash equivalents on hand.
Sources
of funds
Our principal sources of liquidity are cash and cash equivalents
on hand and cash flow from operating activities. At
December 31, 2006, we had cash and cash equivalents of
US$4,448 million. Our operating activities generated
positive cash flows of US$7,232 million in 2006.
In addition, CVRD has committed credit facilities for the
purpose of improving the efficiency of its cash management and
reducing debt refinancing risks during moments of instability in
financial markets. We currently have a committed credit facility
of US$650 million that is available through May 2007, with
an amortization period if drawn down of two years, and a
US$500 million revolving credit line that is available
through 2011. In May 2007, we concluded an agreement for a new
revolving credit line in the amount of US$650 million. We
have not used any of the funds available under either our
committed or revolving credit facilities. CVRD Inco also has a
revolving credit facility of US$750 million that is
available through 2011. Currently, US$642 million is
available under this credit facility, as the remaining portion
has been used. Subject to the lender’s approval, certain
commitments under the facility may be extended for an additional
one-year period on each anniversary date. At December 31,2006 there were no amounts drawn under the revolving credit
facility. However, two letters of credit totaling
US$108 million were issued and outstanding under this
facility. We generated a total of US$837 million in cash
through disposals of investments in 2006. On May 7, 2007,
we closed a transaction for the sale of Usiminas shares for
US$728 million.
We believe we are well positioned to raise additional capital,
given our access to global capital markets and our investment
grade rating. Following our acquisition of Inco, Moody’s
confirmed our Baa3 foreign currency rating, Dominion Bond Rating
Services confirmed our BBB (high) rating, Fitch Ratings
confirmed our BBB- rating, and Standard & Poor’s
downgraded our rating from BBB+ to BBB and placed us on credit
watch with negative implications. In February 2007,
Standard & Poor’s removed us from credit watch
and affirmed our BBB rating.
Uses of
funds
Acquisitions
In 2006, we used cash of US$13,201 million, net of cash
acquired, to acquire subsidiaries. This amount includes cash
used to acquire Inco in October 2006 as well as cash used to
acquire the remaining 45.5% stake in Valesul for
US$28 million in July 2006. In April 2007, we acquired AMCI
Holdings Australia Pty-AMCI HA for US$656 million,
excluding net debt. In May 2007, we increased our stake in EBM
to 86.25% for US$231 million. EBM’s main asset is a
51% stake in our subsidiary MBR, in which we already had an
89.9% interest. We simultaneously entered into a usufruct
agreement with respect to the 13.75% of EBM’s total capital
that we do not own, which grants us all rights and obligations
with respect to these shares during the next 30 years and
consequently entitles us to 100% control of MBR. In exchange, we
will pay US$61 million plus an annual fee of
US$48 million to the owners of the shares.
Capital
expenditures
Capital expenditures amounted to US$4,538 million in 2006.
In 2007, we have budgeted US$7,351 million for capital
expenditures. This amount includes expenditures on projects as
well as expenditures for maintenance and exploration. For more
information about the specific projects for which we have
budgeted funds, see Item 4. Information on the
company — Capital expenditures.
We paid total dividends and interest on shareholders’
equity of US$1,300 million in 2006. The announced minimum
dividend amount for 2007 is US$1,650 million. The first
installment of this dividend was approved by our Board of
Directors in the amount of US$825 million and was paid on
April 30, 2007. See Item 8. Financial
information — Dividends and interest on
shareholders’ equity.
Share
buyback
We repurchased our preferred shares in the open market from June
through August 2006, pursuant to an announced repurchase program
limited to 5% of our preferred shares. We repurchased a total of
15,149,600 shares under this program at a cost of
US$301 million.
Debt
At December 31, 2006, we had an aggregate outstanding debt
of US$22,581 million, consisting of short-term debt of
US$1,459 million (including US$711 million in current
portion of long-term debt and US$25 million of loans from
related parties), and long-term debt (excluding current portion)
of US$21,122 million. At December 31, 2006,
approximately US$909 million of our debt was secured by
liens on some of our assets.
Our short-term debt consists primarily of
U.S. dollar-denominated trade financing, mainly in the form
of export prepayments and export sales advances with foreign and
Brazilian financial institutions.
Our major categories of long-term indebtedness (including the
current portion of long-term debt and excluding accrued charges)
are as follows:
•
U.S. dollar-denominated loans and financing
(US$10,814 million at December 31,2006). These loans include export financing
lines, import finance from export credit agencies, and loans
from commercial banks and multilateral organizations. They also
included our acquisition facility for CVRD Inco, which was
repaid in April 2007. The loans generally bear floating rate
interest at spreads over LIBOR. The amount outstanding at
December 31, 2006 does not include US$6,000 million
drawn under a pre-export finance transaction in January 2007,
proceeds of which were used to repay part of the drawings under
our senior acquisition facility.
•
U.S. dollar-denominated fixed rate notes
(US$6,897 million at December 31,2006). We have issued several series of
fixed-rate bonds through our finance subsidiary Vale Overseas
Limited with a CVRD guarantee. These include the
US$3,750 million of fixed-rate bonds issued in November
2006 to refinance a portion of the drawings under the senior
acquisition facility.
•
U.S. dollar-denominated loans secured by future export
receivables (US$345 million at December 31,2006). We have a US$550 million
securitization program based on existing and future receivables
generated by our subsidiary CVRD Overseas Ltd from exports of
iron ore and pellets to six of our customers in Europe, Asia and
the United States. The securitization transaction is divided
into three fixed-rate tranches and one floating-rate tranche.
•
Brazilian reais-denominated non-convertible debentures
(US$2,774 million at December 31,2006). In November 2006, we issued
non-convertible debentures in the amount of approximately
US$2,500 million, in two series, with four- and seven-year
maturities. The first series, approximately US$700 million,
matures in 2010 and bears interest at 101.75% of the accumulated
variation of the Brazilian CDI (interbank certificate of
deposit) interest rate. The second series, approximately
US$1,800 million, matures in 2013 and bears interest at the
Brazilian CDI interest rate plus 0.25% per year. Proceeds
from these issuances were used to repay part of the drawings
under our senior acquisition facility.
•
Perpetual notes (US$86 million at December 31,2006). We have issued perpetual notes that are
exchangeable for 48,000 million preferred shares of MRN.
Interest is payable on the notes in an amount equal to dividends
paid on the underlying preferred shares.
•
Other domestic debt. (US$728 million at
December 31, 2006). We have several
Brazilian loans, principally from BNDES and commercial banks,
most of which are linked to floating rates in Brazil, with the
balance mainly linked to U.S. dollars.
Some of our long-term debt instruments contain financial
covenants. Our principal covenants require us to maintain
certain ratios, such as debt to equity, net debt to EBITDA and
interest coverage. We were in full compliance with our financial
covenants as of December 31, 2006, and we believe that our
existing covenants will not significantly restrict our ability
to borrow additional funds as needed to meet our capital
requirements. We believe we will be able to operate within the
terms of our financial covenants for the foreseeable future.
None of these covenants directly restricts our ability to pay
dividends on equity securities at the parent company level.
At the time of the first stage of our privatization in 1997, we
issued shareholder revenue interests known in Brazil as
“debentures” to our then-existing shareholders. The
terms of the debentures were established to ensure that our
pre-privatization shareholders, including the Brazilian
government, would participate alongside us in potential future
financial benefits that we derive from exploiting certain
mineral resources that were not taken into account in
determining the minimum purchase price of our shares in the
privatization. In accordance with the debentures deed, holders
have the right to receive semiannual payments equal to an agreed
percentage of our net revenues (revenues less value-added tax,
transport fee and insurance expenses related to the trading of
the products) from certain identified mineral resources that we
owned at the time of the privatization, to the extent that we
exceed defined thresholds of sales volume relating to certain
mineral resources, and from the sale of mineral rights that we
owned at that time. Our obligation to make payments to the
holders will cease when the relevant mineral resources are
exhausted. Based on current production levels and estimates for
new projects, we began payments relating to copper resources in
2004 and expect to start payments relating to iron ore resources
beginning in approximately 2016 for the Northern System and
approximately 2028 for the Southeastern System, and payments
related to other mineral resources at the end of the current
decade.
The total payments made under the shareholder debentures
amounted to US$2 million in 2004, relating to 2003 results.
The total payments made under the shareholder debentures
amounted to US$5 million in 2005, relating to 2004 results.
In 2006, we made total payments under the shareholder debentures
in the amount of US$6 million. We also made a payment of
US$6 million in March 30, 2007, relating to the second
half of 2006 results. See Note 18 to our consolidated
financial statements for a description of the terms of the
debentures.
The following table summarizes our long-term debt, short-term
debt, operating lease obligations, purchase obligations and
Alunorte
take-or-pay
obligations at December 31, 2006. This table excludes other
obligations that we may have, including pension obligations
(discussed in Note 17 to our consolidated financial
statements).