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Issue 11, 3rd Quarter 1999
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NEWS FROM THE "ENERGY/ALUMINUM
INTERFACE"
The ENAL Newsletter is free of charge to panelists. However, in return
for the free newsletter, we ask for a contribution from our panelists
in the shape of comments, criticisms, and information, which we will take
into account.
Note: Text in bold font constitutes information received since last issue.
Current projects are identified by region. Upcoming projects are grouped
by year, then by country. The resulting capacity changes are tabulated
and inputted to adjust the World Capacity Matrix
Forecast.
Contents
Major Projects Currently In Progress (return
to Contents)
Africa:
- Nag Hammadi (Egypt) - Commissioning of a 55ktpy
expansion was completed by January 1999. (EnalPanel) Revamping of Söderberg
lines is in progress, to be completed by 2003, with an increase in capacity
of 64 ktpy. Then, a 7th line of 55 ktpy in 2005. The 2nd
potroom (55 ktpy) has already been transformed from 160kA VSS to point
feeder prebake pots (PFPB) with 200 kA current intensity, but not yet
started up. (EnalPanel) VAW provided assistance to develop the experimental
pilot prebake potlines. (MetalBulletin) (According to one panelist,
it seems quite doubtful that VAW provided assistance to develop the
experimental pots, as these were developed from VAMI from Russia and
the Egyptians themselves. (EnalPanel)) Start-up of the new anode production
plant is heavily delayed. (EnalPanel) 100% of anodes are bought through
Alusuisse (ex-Aluchemie and ex-Lauralco) (EnalPanel) Egyptalum has chosen
the French consortium of Cegelec and Aluminium Pechiney to modernize
the process control system for the three existing potlines, along with
the installation of the control system for the new line (for a total
of 552 cells). (Aluminium)
- Maputo (Mozambique) - Phase I is under construction:
245 ktpy to start up over 2000-2001. Equipment for anode rodding
was being shipped from France at the end of May '99. (EnalPanel)
- Ikot Abasi (Nigeria) - In mid-June, Alscon suspended
production due to a lack of funding from the Nigerian government. (MetalBulletin)
Nigeria may lose $200m per year in foreign exchange earnings following
the closure of Alscon, according to Nigeria's Assn of Primary Aluminium
Producers (APAP). The APAP and regional political leaders have been
putting pressure on the government for its promised assistance to Alscon.
(MetalBulletin) The APAP - representing the country's downstream aluminum
companies - has also called for the lifting of the 10% import duty on
aluminum ingots and billet since Alscon remains closed. (MetalBulletin)
The military government, which handed over power to civilians in
May, had promised $78-mil to be used to complete the dredging of the
Imo River and the anode plant. Alscon had hoped to reach 75% capacity
by mid-'99. (MetalBulletin) Metal Bulletin has concluded that the
Nigerian government may not have supplied the promised $78m because
of what it considers to be a "high ratio of expatriate staff", which
it claims are costing the company "a fortune". (MetalBulletin) Production
could resume within the next three months, according to Nigeria's Minister
of Mines & Power - although more than $235m will be needed to bring
the smelter to full capacity, while at least $45m is required for operational
costs. Market sources remain extremely skeptical that the necessary
funding will be available. (MetalBulletin) In addition to these funds,
the previous military government had also pledged to privatize the smelter.
(MetalBulletin) As of early August, the government has resolved to go
ahead with plans to divest its 70% shareholding in Ikot Abasi. Industry
sources believe that Reynolds may increase its equity in Alscon. The
Minister of Mines & Power is reported to be insisting that before
Alscon opens up for bids, both Reynolds and Ferrostaal must pay for
their outstanding shares and also contribute to increase the share capital.
(MetalBulletin) Reynolds and Ferrostaal refuse to pay what the government
wants. Alcoa will now determine what is going to happen. (EnalPanel)
Americas: (return
to Contents)
- Aluar (Argentina) - Production
from the 72ktpy expansion was scheduled to begin in mid-May. Full production
is expected in the autumn of '99. (Reuters) Work for revamping of the
pot control system of lines 1 and 2 started in ’98. (EnalPanel)
- Alma (Canada) - 375 ktpy over 2000-2002. (EnalPanel)
This greenfield project, which is under construction, will replace the
existing obsolete lines at the nearby (2.5km away) Isle Maligne site
and other obsolete lines in Quebec. (EnalPanel) Earlier this year, Alcan
decided to completely shut down the old Isle Maligne smelter by the
end of '99, rather than September 2000 as was planned. (Platt'sMtlWk)
The first potroom was definitely closed in April '99. Potrooms 2 and
3 were to follow in August and September this year. (EnalPanel) The
Alma project, with 432 Péchiney AP30.pots in 1½ lines, has an
estimated cost of $1.6bn and a startup date of late 2000. (AMM, Financial
Times, MetalBulletin, EnalPanel) According to one panelist, Alcan
has never said that they will shut down more capacity in Quebec than
only this smelter. They count on 300 ktpy plus capacity once the Alma
smelter has started up. (EnalPanel)
- Alouette - Sept-Iles (Canada) - The smelter underwent
a revamping during which amperage was increased from 300 to 328 kA,
resulting in DC power consumption of 13.0 kWh/kg Al and a capacity increase
to 235 ktpy. The project was completed in 1998. (EnalPanel)
- Hawesville (USA) - First metal was produced from
Hawesville's fifth potline in April. 100 new employees were hired
for the new line. (MetalBulletin, Platt'sMtlWk) As of mid-June, 46
of the 112 new pots were operational. The line is on schedule to be
fully operational by September 20. (MetalBulletin) (See Other Items
of Interest for news regarding NSA strike and sale.)
- Massena Reynolds (USA) - This smelter is undergoing
a revamping which will add 10ktpy in 1999. (EnalPanel)
- New Madrid (USA) - 33 ktpy capacity increase due to
anode size increase in 1999. (Aluminium Today) Noranda is on track
to complete its expansion at New Madrid by the end of this year. (MetalBulletin)
- Warrick (USA) - Alcoa, Fluor Daniel and SNC Lavalin
have awarded $30-million in contracts to ABB Environmental for emissions-reduction
and alumina handling equipment at Alcoa's Warrick and Wenatchee plants.
The new systems should be operating by mid-2000. (AMM)
- Wenatchee (USA) - See Warrick (above).
- Alcasa (Venezuela) - 50ktpy of capacity was idled
in 1998 in order to undertake a revamping. The project is to be
completed in 1999. (EnalPanel) No work has started on revamping the
idled capacity of 50 ktpy. (EnalPanel)
Asia: (return
to Contents)
Note regarding CNNC references: The China Aluminium
Corp. (Chalco) was to begin operation in June '99 and was to take over the
management of the former-CNNC smelters, refineries and downstream facilities.
(MetalBulletin) For an update of the status of Chalco, see "Other Items
of Interest". Smelters referred to as CNNC can be considered as "formerly
CNNC".
- Baotou (China) - Adding more pots for an additional
capacity of 30ktpy. (Aluminium Today) 90 prebake pots (135kA) are
being added for 30 ktpy. (EnalPanel)
- Chongqing (China) - 55 ktpy expansion to be completed
in 1999-2000. Addition of 1 prebake potline of 124 pots, 50 ktpy,
is now under construction. The existing Söderberg potline is 55kA,
corresponding to 86 pots. (EnalPanel) We expect that the Söderberg
line will be shut down as the prebake expansion starts up.
- Danjiang (China) - A 30ktpy expansion to reach 53ktpy.
This 30ktpy expansion involves the relocation of the remaining Toging
potline. The line is composed of 100 VAW pots, running at 115kA. (Aluminium
Today) VAW only had 92 end-to-end pots at Toging, so some pots have
been added. The VAW pots were not relocated, only parts have been
shipped. What has been used from the Toging smelter is: the pot
superstructures, operation panels, anode stems, alumina conveying system
and some generators. The new electrolysis pots have been designed by
Guiyang Aluminium Magnesium Design Institute. The new pots use VAW-ELAS
pot control. (EnalPanel) According to another panelist,
the new electrolysis pots design are entirely VAW design. The Guiyang
Al Mg Design Institute has carried out the detailed engineering. (EnalPanel)
- Fushun (China) - Fushun is made up of two parts:
three obsolete (60-65kA) HSS lines with a capacity of 65 ktpy and an
energy consumption of about 16kWh/kg Al; and a newer SWPB line with
a current of 140kA and a capacity of 30ktpy. The obsolete pots are being
replaced by a new PFPB line with a capacity of 85 ktpy and a current
of 180 kA. The new pots are based on Japanese technology (center-worked
prebake) but have been modified by the Chinese to include point feeders
instead of bar breakers, long-side risers to improve magnetic conditions,
and better process control equipment. The pots could eventually be run
at 200 kA. The investment of US$118.2 mil (which covers the potrooms,
busbar, cranes…) means an investment of approximately US$1400 per installed
ton. Whereas the obsolete lines demand about 1050GWh of energy, the
new line (with 30% more capacity) will demand about 1150GWh (only about
10% more). (EnalPanel)
- Hanzhong (China) - 40ktpy expansion to be completed
in 1999. This smelter started up in 1996 with a capacity of 40ktpy.
After negotiating better power rates, the smelter is now doubling capacity
with a PFPB, 160kA potline, using China's Shenyang technology (used
at Guizhou). The expansion is almost complete. (Aluminium, EnalPanel)
- Luoyang (China) - An expansion of 50 ktpy to be completed
in ‘99. (MBR) The smelter is owned by Luoyang Xin’an Electricity
Corp. (Henan government, not central government). Existing capacity
is 25 ktpy, expanding using same prebake technology as Pingguo, with
a current of 180kA. (MBM)
- Pingguo (China) - Pingguo is planning to boost smelter
capacity to 127ktpy following the installation of new technology at
the site. According to one source, 32 320kA prebaked cells were being
installed in June with a total capacity of 27ktpy, to come on stream
on July 1. (MetalBulletin)
- Pingyin (China) - Pingyin will raise its ingot output
by 23% in 1999 to reach maximum capacity of 32ktpy compared to the 26kt
achieved in 1998. Electricity costs were high in 1998, but power charges
have been cut. 150 pots have been running since January. All 170 pots
should be in operation by the end of the third quarter. (Platt'sMtlWk)
- Qingtongxia (China) - 100 ktpy expansion to be completed
in 2002-2004. The smelter is currently being expanded by 100 ktpy,
using 185 kA prebake pots (Guiyang technology). (AlumVerlag) The work
is expected to be completed in 2001. (Platt’sMtlWk) The firm orders
for anode production equipment from France and Switzerland were placed
by the end of ’98. (EnalPanel) Upgrading of the two existing Söderberg
lines to prebake technology is planned and should take place as soon
as the new line 3 is in operation. (EnalPanel) According to one panelist,
a smaller expansion of 14ktpy is planned in 2000-2002. (EnalPanel)
- Xiezhou (China) - Completion of 67 ktpy expansion
by end of 2002. The Xiezhou Aluminium Plant said its smelter
expansion is running "very smoothly" and should be completed as scheduled
in April 2000, raising capacity to 65ktpy from the current 30ktpy. Work
on phase one started March 1, 1999, and their final aim is to reach
100ktpy. Phase two construction should start by end-2000, after phase
one is complete. An estimated Yuan 760-mil ($91.8mil) will be invested
in the expansion project. Xiezhou has targeted output of 33ktpy in 1999.
(Platt'sMtlWk) Capacity is to rise from 33 to 100 ktpy in 2002. (ABA)
- Yunnan (China) - Expansion of 80 ktpy over 1998-1999.
(AlumVerlag) All of pots for the 80ktpy expansion should be completely
installed by third-quarter '99 (118 out of 192 running in April). Yunnan
then has plans for another 80ktpy expansion in the next two years. (Platt'sMtlWk)
- Madras (India) - 6 ktpy capacity increase from revamping
(EnalPanel) Madras has expanded the capacity of its smelter from
25 ktpy to 32 ktpy and has also boosted the capacity at its alumina
refinery. (MetalBulletin)
Australia/New Zealand: (return
to Contents)
- Portland (Australia) - Increase in amperage to 312kA
has increased rated capacity to 345ktpy. (EnalPanel)
- Tomago (Australia) - Expansion of 40 ktpy (addition
of 40 pots each to potlines 1 and 2) was in operation at the
end of ’98 with an upgrade adding another 20ktpy. Graphitized cathode
blocks are now being used in the pots and the amperage at the pots has
been raised to 195-200kA, increasing capacity to 450ktpy. (AlumVerlag)
The rectifiers have the capacity for a current load of the potlines
of 210kA. (EnalPanel)
Europe: (return
to Contents)
- Mostar (Bosnia Herzegovina) - Restart of smelter
is in progress. Aluminij Mostar managed to produce 50kt of aluminum
and alloys and 120kt of baked anodes in total during the last two years.
All production is intended exclusively for export. By the end of this
year the last phase of electrolysis will start. The production will
rise by 20kt of aluminum and 50kt of baked anodes. (EnalPanel) There
appears to be significant disagreement between the smelter's management
and the government about the status of Aluminij Mostar's privatization.
The general manager claims that privatization was completed "a long
time ago" and that ownership is clear. The government disagrees. (EnalPanel)
- Essen (Germany) - Reconstruction of line 3 (55 ktpy)
was completed in July ‘98. (EnalPanel) Line 3 is running at 160kA
(+14%) due to the introduction of Alusuisse magnetic optimization at
94-95% CE. The other two lines will be optimized in the near future.
(EnalPanel)
- Stade (Germany) - This 70 ktpy continuous SWPB smelter
is undergoing a revamping that includes the insulation of the cell sides
(like VSS) and gluing of long PB blocks. The revamping will add 4
ktpy. (EnalPanel)
- Straumsvik (Iceland) - A complete revamping of this
smelter is to take place over 1999-2000, adding 15 ktpy. The project
has already begun. (EnalPanel)
- Ardal (Norway) - Conversion of Söderberg (presently
50 ktpy) to prebake with added capacity of 40 ktpy in 1999. The
Söderberg line is 110 kA and was built in ‘58 (later converted
to Sumitomo). Question: What is the status of this project?
- Slatina (Romania) – Revamping of the cells of potroom
10 and a new control system were commissioned in ’97. Work for revamping
of cells of room 9 started in ’98 and will be commissioned during the
first half of ’99. (EnalPanel) Alro is to invest $14.4 million
in its operations this year. The company is negotiating for further
investments of $10 million. (MetalBulletin) The proposed merger between
Alro and Alprom has been approved by the State Ownership Fund. (MetalBulletin)
In June, the tender for an adviser for the privatization of Alro and
Alprom was suspended after the World Bank stepped in to iron out problems
in the sales process. (MetalBulletin)
- Sayanogorsk (Russia) – An expansion in capacity of
58 ktpy in 1998. Earlier in 1999, twenty 255kA pots that were formerly
300kA test pots (dismantled in 1998) were under construction to start
up this year with a capacity of 12 ktpy. (EnalPanel)
Middle-East: (return
to Contents)
- Bandar Abbas - Almahdi (Iran) - This smelter is being
built as a technology transfer from Dubai Aluminium: PFPB, 200kA, 220ktpy,
2 potlines. Construction of this smelter is progressing and will continue
to progress very slowly, may not reach 220 ktpy until 2004. New financing
has been arranged through Gaspeks, a Swiss company with a Uzbekistani
background, using a bartering arrangement of gas supplies from Iran
against steel supplies from the Ukrainian steel giant SUMY. Yuri Matveev,
chief engineer designing VAMI aluminum smelters, is supervising construction.
(EnalPanel) The infrastructure allows for future expansions of up to
330 ktpy. Lack of funds still limits the start-up of 40 nearly finished
pots (20 ktpy). (EnalPanel)
- Jebel Ali (United Arab Emirates) - Dubal started
up the first cell of its 6th line expansion in June. The
new pots will expand production by year-end to 530kt, 36% above the
current production capacity of 390ktpy. (AMM)
Upcoming Projects in Chronological
Order (return to Contents)
Projects are no longer listed by region, but rather are listed
chronologically (and in order by country under each year). The subheadings
are an indication of our opinion of the projects' beginning date. Underlined
text in the following sections highlights our own projections, which may
disagree with other published data.
1999:
- Bell Bay (Australia) - 16 ktpy capacity increase
in 1999.
- Becancour (Canada) - Revamping to increase productivity
by up to 10%, work to start in 1999. Reynolds intends to change
over to graphitized cathode blocks thus having the possibility to increase
the current load by 5-10% and increase productivity by up to 10% (of
its share). (EnalPanel) Pechiney, the technical manager, is introducing
the upgrading of AP18 to AP20, a technology learned from the conversion
of AP30 pots from amorphous cathode to graphitic cathodes. This will
result in an increase of capacity of 10%-12% for all shareholders including
Reynolds 50% share. (EnalPanel)
- Grande-Baie (Canada) - Revamping of 183ktpy to take
place over 1999-2000. This revamping will increase anode size, increase
amperage, and add 18ktpy capacity. (EnalPanel)
- Taiyuan (China) - A 50ktpy expansion. Taiyuan
was to add a new prebake line of 50ktpy, to be running partially in
1997. (Shanxi website 1997) The new prebake line was still not running
as of the end of ’98. (EnalPanel)
- Tongchuan (China) - 5 ktpy increase in capacity
from modernization in 1999-2000 of this small, 175kA prebake.
Nissho Iwai and Nippon Light Metals agreed to provide help for the project,
which include a bauxite mine and an alumina refinery. (AlumVerlag)
- Yongcheng (China) - 30 ktpy expansion in 1999.
Wonson Metals & Minerals, a Hong Kong based privately owned trading
company, acquired 51% of the 30 ktpy Yongcheng smelter for $18m, the
49% left being held by Yongcheng Aluminium, itself owned by the employees
or local government. The new capacity (doubling present capacity of
30 ktpy) is a greenfield smelter, prebake, using the Guiyang technology.
Probably 104 pots and 113kA, which is half of Guizhou. (EnalPanel) Wonson
is in the process of installing a power plant for the smelter (2 units,
50 MW each). (MetalBulletin) The construction of Shangqiu Yonghe's
power plant has been delayed due to the recent flooding in China. Senior
engineers involved in the power plant's construction and commissioning
have been deployed to the affected regions to assist in the emergency.
(Investor Relations Asia Website)
- Alupuram (India) - Shutdown of 7 ktpy (25 kA) in
1999. Modernization of remaining 21 ktpy to follow. Indal is planning
substantial investment to modernize 21ktpy Alupuram. (Platt'sMtlWk)
The 25kA line will be shutdown. The company will run only its 50kA line
to produce about 13ktpy of metal. (MetalBulletin)
- Belgaum (India) - Indal has decided to completely shutdown
the smelter and related plants at Belgaum due to inconsistent power
supply and high cost of power. (MetalBulletin, Platt'sMtlWk)
- Lista (Norway) - A revamping of 80ktpy (with additional
10ktpy) in 1999-2001. Expansion of 100 ktpy in 2006.
According to Elkem, NOK100m will be used to convert side worked Söderberg
pots to point feeder Söderberg pots, the remaining NOK160m will
be used for environmental reasons. The conversion will be completed
by 2001. (EnalPanel) A 40ktpy expansion is possible if Elkem gets extra
energy by adding gas-fired power to existing hydroelectric supply.
- Paranam (Surinam) - Complete shutdown in 1999 (30ktpy)
was partially due to market conditions and partially due to technical
problems with the 160-170kA VSS lines. If Alcoa can solve the mainly
magnetic problems, the smelter might survive at the low power price
there. (EnalPanel)
- Sundsvall (Sweden) - The Soderberg pots will be transformed
to process controlled point feeding (PFVSS) during the years 1999-2001.
The Swedish government will support this project with SKR33.6m. (AlVerlag)
- Mead (USA) - Revamping of 200 ktpy with capacity
increase of 40 kpty in 1999-2000. Kaiser announced in '96 that Mead
has been experimenting for about 2 years in liaison with Reynolds' R&D
the new technology for cathode blocks developed jointly by Reynolds,
Kaiser, SGL Carbon, and the US Dep't of Energy's Office of Industrial
Technologies (OIT). It is a new cathode material made of Titanium Diboride
plus Graphite (TiB2-G). Higher wettability means that the
anode can be closer to the cathode, thus saving 20% in voltage and 10%
savings in energy: decrease energy consumption by 1.5kWh/kg. Planned
cost of retrofitting: 2.4 cents/lb of capacity. (AlumVerlag) Only
experimental pots will be equipped and run with these aluminum wettable
"mushrooms". Earnings through retrofit with this technique would be
5 cts/kg of aluminum produced. (EnalPanel)
2000: (return
to Contents)
- Kurri Kurri (Australia) - Conversion from SWPB
to PFPB in 2000. The smelter is working on a feasibility study
for the introduction of point feeders to the first SWPB potline in 1999.
(AlumVerlag)
- Belem (Brazil) - Expansion of 43 ktpy in 2000.
(EnalPanel) Expansion of 90 ktpy over 2007-2008. In September
'97 Albras' CEO announced a plan to expand capacity by 37 ktpy by adding
36 pots to potlines 2, 3, and 4, thus giving them the same number of
pots as potline 1. The project is to be completed by 2000. Magnetic
compensation is being introduced with Alcoa's (formerly Alumax’s) technical
assistance in '95-'99 (as agreed in ‘96), which would bring total capacity
to 351 ktpy. This is on a trial scale on 14 pots. A 5th potline is seriously
considered later, if uncertainties are cleared regarding energy contract
to be renewed in 2004. Belem, same as all Brazilian smelters, suffered
from the country's general energy shortage. Rates have fluctuated for
Belem between 10 and 17 mils. (EnalPanel)
- Arvida (Canada) - Horizontal Söderberg lines
to shutdown (now 15 ktpy) to zero when the Alma smelter (AP30) starts
in 2000-2002 as part of Alcan’s replacement of Söderbergs by new
capacity. Prebake lines (150 ktpy) are to be revamped only if the Alma
smelter is not expanded from 1½ to 2 AP30 lines, which will not be before
2005. (EnalPanel) After Alma and Kitimat, the replacement of the
HSS pots and modernization of the SWPB pots at Arvida is priority 3.
(EnalPanel)
- Jiaozuo (China) - 50 ktpy expansion in 2000-2001.
Construction of a new 50ktpy line is under way and will be completed
by late 2000. An estimated Yuan 1.2-bil ($145mil) has been injected
into the project. Jiaozuo plans to operate at full capacity in 1999
at 53kt, up 3kt from 1998. Meanwhile, Jiaozuo's output in the year 2000
might be 13ktpy less than 1999 due to new national environmental restrictions
set by the government. If Jiaozuo is unable to meet these standards
within this year, their 13ktpy production line will be forced to shut
down by year end. (Platt'sMtlWk)
- Qinghai (China) - 100 ktpy expansion to 300ktpy in
2000. Another 100 ktpy expansion after 2006. Alcoa is said to
be close to securing a deal to acquire a majority stake in Qinghai.
It is extremely likely that if Alcoa takes a majority stake in Qinghai,
its alumina will be sent to one place only, the Qinghai smelter. (MetalBulletin)
- Sanmenxia (China) - 50 ktpy expansion in 2000.
Project to expand 33ktpy smelter by 50kpty has been delayed. Originally
the expansion was to be completed by the end of 1999, but now that has
been delayed. (Platt'sMtlWk)
- Yangquan (China) - 30 ktpy expansion in 2000-2001.
Planned to begin construction in 1998, but was still seeking funding.
(Platt’sMtlWk)
- Grundartangi (Iceland) - Expansion to 90 ktpy in
2000-2001 and possibly to 180 ktpy three to five years later. There
are plans to expand the existing line by 60 pots in the second phase
of the project, scheduled for completion by 2000, bringing capacity
to 90 ktpy. A panelist believes that the expansion cannot take place
that soon, possibly in 2001. (EnalPanel) CVC is permitted to expand
to reach 180 ktpy and plans to put the infrastructure in place to at
least double capacity. (MetalBulletin) The date for the expansion to
180ktpy has not been determined, but it might begin within three or
four years. (MBM) Nordural is still in talks with Landsvirkjun over
increased electricity supplies for Grundartangi, but could sign a contract
in July. (MetalBulletin)
- Qeshm Island (Iran) - 33 ktpy in 2000. This
is the transfer of one of the ZSNP (Slovakia) lines. This project is
very unlikely as the Elkem technology is obsolete and dirty and a site
of 35ktpy is not economical. (EnalPanel)
- Tiwai Point/Bluff (New Zealand) - 5ktpy capacity
increase from modernization in 2000 (MB conference)
- Krasnoyarsk (Russia) - A complete revamping over
2000-2005 is planned. It will add 80ktpy of capacity.
(EnalPanel) Krasnoyarsk has not decided yet how to increase capacity
by approximately 10% (80 ktpy). It will definitely not convert to prebake
technology. Once decided it will take a minimum of four years to reach
that goal, starting from the year 2000. (EnalPanel)
- Sayanogorsk (Russia) - Planned expansion of 104ktpy
(line 5) in 2000-2001. Another expansion of 104ktpy (line 6) in 2002-2003.
255kA technology to be used. A conversion of SWPB to PFPB is planned
over 2000-2004 (EnalPanel) Ownership is Sibirsky Aluminy (69.16%),
TWG (14.14%), Gavrohe Investments (12.61%) A panelist estimates the
ownership as Sibirsky Aluminy (75%), TWG (15%), Banks (10%), with the
regional Khakassia government being involved through the banks' share.
(EnalPanel) Sibirsky Aluminy said it is planning to increase capacity
at SaAZ to 620ktpy by 2003, with construction of additional facilities
starting in mid-2000. Current capacity, including the recently completed
expansion, is 380ktpy. The expansion would rely on investment of $480m,
and the company is currently in negotiations to find a partner for the
project, as well as to secure syndicated project finance. (MetalBulletin)
- Kinlochleven (United Kingdom) - Complete shutdown
in 2000 linked to expansion at Lochaber.
2001: (return
to Contents)
- Jiamusi (China) - 50ktpy smelter in Heilongjiang
province around 2001. Jiamusi Aluminium has plans to build a 50ktpy
plant in northeastern Heilongjiang province. Construction is expected
to start by 1999 or 2000, but falling prices and insufficient funds
make a completion date uncertain. (Platt’sMtlWk)
- Zhongzhou (China) - 200 ktpy around 2001.
New greenfield capacity to reach 200 ktpy by 2000. (ABA)
- Inota (Hungary) - Power plant by 2001. Inota
is currently paying 3.75 cents per kWh to local electricity utility
Edasz. As of Oct. ’98, Magyar Aluminium was still planning to build
its own 100MW power plant (76MW for Inota, 14 by Ajka refinery, rest
sold to national grid). A final decision on the power plant was expected
by the end of ’98. Magyar Al. is also lobbying the government to supply
power to industrial users at a preferential rate. (MetalBulletin) As
of May '99, Magyar Aluminium had not given up its plan to construct
its own dedicated gas-fired power station, in spite of improvements
in the cost of electricity at Inota. (MetalBulletin)
- Renukoot (India) - 15 ktpy capacity increase from
modernization in 2001. (MB conference) 60 ktpy expansion in
2001-2002, another in 2003-2004. Instead of pursuing the Orissa
greenfield project, Hindalco will upgrade the Renukoot facility. (AMM)
Instead of building a greenfield smelter using VAW Toging's 180kA side-by-side
technology, Hindalco decided to add a brownfield line (using the same
technology) of 60 ktpy (first stage) and 120 ktpy (second stage). Time
frame: 2001-2002. (EnalPanel) Another panelist states that Hindalco
will add only 60 ktpy in 2 potlines (EnalPanel) (we assume using the
technology of the other lines.)
- Sunndalsora (Norway) - We foresee a revamping of
obsolete capacity (66 ktpy) with a 15 ktpy capacity increase in 2001
and a further expansion of 80 ktpy in 2004. Sunndalsora combines
an 85 kA Söderberg with a 150 kA prebake. Two approaches to expansion
have been discussed. According to LMA, Sunndal is considering a 200ktpy
expansion using Hydro 230kA technology. The Söderberg potrooms
would be leveled to make room for the new potrooms. (LMA) According
to one of our panelists, a dual project is highly probable for the years
2003-2004: the conversion of old VSS pots to PFPB and a one line expansion
(184 pots, PFPB, 160kA, 80ktpy). Although this expansion would create
more jobs and take advantage of available energy, the environmental
commission opposes it. (EnalPanel) Anthony Bird forecasts capacity
to rise from 138 to 204 ktpy in 2000. (ABA)
- Konin (Poland) - Revamping of 65 ktpy with a capacity
increase of 13 ktpy and expansion of 17 ktpy in 2001-02. This depends
on Impexmetal, present owner, finding a foreign partner, which is possible.
In 1998, Impexmetal considered several plans (all in very early stages)
to increase primary production. According to Konin, the electrolysis
computer control system has started and a new alumina pot-feeding system
has been implemented. (Huta Aluminium Konin website)
- Slovalco (Slovakia) - 35 ktpy expansion between
2001 - 2003. A decision is to be made in 1999, construction to start
in 2000. Startup to be between 2001 and 2002. (Reuters, MetalBulletin)
- Lochaber (United Kingdom) - Increase amperage from
180 to 200kA, adding 8ktpy to capacity in 2001-2002. (EnalPanel,
AlVerlag)
- Goldendale (USA) - Installation of point feeders
to VSS pots. Increase in capacity from 167ktpy to around 200ktpy in
2001-2003. Norsk Hydro is funding a $55m project to install point
feeding technology and increase casthouse capacity. (Platt’sMtlWk, AlumVerlag)
At present there are only test pots using Hydro's pointfeeder and
magnetic compensation technology. The results will be known late in
2000. Therefore the expansion of 30-33 ktpy will take at least until
2003. (EnalPanel)
2002: (return
to Contents)
- Sumgait (Azerbaijan) - Small probability of a conversion
to prebake of this 60ktpy HSS plant over 2002-2006. There has been
talk of such a conversion for several years and it has been studied
by Kaiser Engineers. The smelter plans to become a joint stock company
in order to encourage financing for the upgrade. (AlVerlag) The smelter
is currently idled. (LMA)
- Alba (Bahrain) - 250 ktpy expansion
over 2002-2004. Alba may increase its primary aluminum
capacity by 250ktpy following its decision to complete a feasibility
study into the plant's expansion. The study will be completed in one
to one-and-a-half years, after which a decision would be taken on the
proposal. The expansion would most likely take the form of a new potline.
(MetalBulletin) The expansion, once decided, will take not more than
3 years. Therefore 250 ktpy expansion till 2005 is more likely than
2007-2008 given the situation that Alba wants to remain the largest
smelter in the region and not Dubal. (EnalPanel)
- Beauharnois (Canada) - Complete shutdown in 2002
to coincide with start up of Alma.
- Lanzhou (China) - 100 ktpy prebake expansion to
replace existing Soderberg capacity around 2002. Lanzhou plans to
build a new 100ktpy smelter equipped with 200kA prebaked cells in the
Lianghai Development Zone at an estimated cost of around 1.5bn yuan.
Lanzhou has already submitted an application to the State Economic &
Trade Commission for approval. If everything goes smoothly, the project
will take up to two years to complete. Lanzhou will raise capital for
the project by listing its 97%-owned Lanzhou Aluminium Holdings Co either
on the Shanghai or Shenzhen stock exchanges. Once completed, the new
plant will replace the company's existing 60kA Soderberg smelter. Lanzhou
is also keen to team up with a foreign partner. (MetalBulletin)
- Pingguo (China) - 80 ktpy expansion
in 2002, 100 ktpy in 2005. This smelter has the
lowest production cost in China. (AluminiumToday) Expansion plans,
if endorsed, will double current output of both alumina and aluminum
ingots to 600 ktpy and 200 ktpy respectively. The long-term target is
for the plant to produce 1Mtpy of alumina and 300 ktpy of aluminum.
(MetalBulletin) Capacity is to rise from 132 to 212 ktpy in 2002.
Probability of further expansion to 312 ktpy with a completion date
of 2004 is 20%. (ABA)
- Pingyin (China) - 70 ktpy expansion over 2002-2003.
Pingyin plans to construct a new 70ktpy ingot line by early 2000. An
estimated Yuan 1-bil ($121-mil) will be injected into the expansion
project. Negotiations with the State Economic and Trade Commission are
under way. Once the project has been approved, they can start construction
next year. The expansion is to be completed by 2003. Pingyin's capacity
will then be increased to 100ktpy. (Platt'sMtlWk )
- Yanji (China) - 150 ktpy expansion over 2002-2007.
Company plans a flotation in ‘99 to obtain funding for the expansion.
(Platt’sMtlWk)
- Lannemezan (France) - Complete shutdown in 2002-2004.
The smelter is scheduled to be shut down definitely between 2000
and 2005. (AlVerlag)
- Angul Orissa (India) - 115 ktpy expansion over 2002-2003.
The third potline (to bring capacity to 345 ktpy) has been planned for
a long time but was not approved until Feb 3, 1998. (MetalBulletin)
The expansion program includes plans to expand power plant capacity
from 720 to 840MW. The cost of the smelter and power plant expansion
is estimated at $490m. (Reuters) The tenders for the new brownfield
anode production line have been sent out. Accepted bidders are KHD (Germany)
and FCB (France). (EnalPanel) Nalco has now resumed normal operations
following repair work to pots damaged at the smelter and is targeted
to produce 218kt of metal this year. The company will add a new potline
of 240 pots at its smelter to boost output to around 345kt. (MetalBulletin)
- Hirakud (India) - 30 ktpy expansion in 2002.
In May, Indal decided to move 200 pots from Belgaum to Hirakud. (40
pots were transferred from Belgaum to Hirakud in 1998.) (AMM) Indal
was to decide by the end of June or middle of July whether to build
a brownfield prebake line, 150kA, 60 ktpy, or to double the existing
horizontal Söderberg line. (EnalPanel)
- Korba (India) - Conversion to VSSPF in 2002-2003
adding 15ktpy. (EnalPanel) Indal is launching an expansion program
that includes bidding for 51% of Balco. (AMM) India's government is
likely to sell a stake of up to 51% in Balco by year-end. A change in
the company's management is likely to be decided by the new investor.
(MetalBulletin)
- Bratsk (Russia) - Revamping of 860 ktpy with
a projected capacity increase of 85 ktpy planned for 2002-2005.
(EnalPanel) Twelve lines were built between 1966 and 1976
using 160 kA VSS pots, which now have a capacity of 860 ktpy. Earlier
in 1999, a new 110 kA VSS line was started up with a capacity of 45
ktpy. Total capacity is 905 ktpy. Algroup is in the process of optimizing
busbar design and cathode lining for the 160 kA lines, which could increase
the capacity of these lines by at least 10%. (EnalPanel) According
to Metal Bulletin Monthly, reconstruction of the electrolysis facility
is complete. (MBM)
- Shelekhovo (Russia) - Revamping of full capacity
in 2002-2004. South Urals Aluminium Co (Sual) has approved a five-year
expansion plan based on upgrading and refurbishing its two core assets,
the Irkutsk aluminum smelter (IrkAZ) and the Uralsk refinery and smelting
complex (UAZ). Sual plans to maintain its primary aluminum output at
337ktpy this year. It aims to install new electrolytic technology using
a dry gas purification system in its existing electrolytic potlines,
which it hopes will both reduce dangerous emissions and enable the plant
to increase output of primary aluminum. The company also plans to equip
one of the electrolytic lines with an automatic alumina feed system.
Sual said it plans to modernize paste production at IrkAZ and to equip
the plant to process its by-product tailings. (MetalBulletin)
- Kamensk-Uralsk (Russia) - see Shelekhovo above.
- Volgograd (Russia) - Complete revamping with conversion
from Söderberg to prebake and capacity increase of 45 ktpy over
2002-2008. This Russian Söderberg suffers from high operating
costs. Meanwhile privatization Russian style has transferred ownership
49% to Raznoimport, Russian metal trader, and 51% to employees. As with
all Russian smelters, privatization is delayed because of uncertainties
on alumina and energy availability and cost. Two Söderberg lines
are closed down for good. Therefore, the capacity is down to 130 ktpy.
They got a new power contract in 1998 which brought power costs down
to 15 mils. (EnalPanel) Engineers from the All-Russian Aluminium and
Magnesium Institute of St. Petersburg were to complete a plan for a
$500-mil modernization by the end of ‘98. The main equipment suppliers
for the upgrades could be French or Swiss firms. The smelter will start
talks with potential investors after the plan is completed by designers.
The plan focuses on converting two Söderberg lines to prebake technology
and the introduction of new computerized process control systems. Targets
are to save electricity and raise output by 14% to 149ktpy. The smelter
does not plan to increase actual capacity because it would entail an
increase in use of electricity. (Platt’sMtlWk)
- San Ciprian (Spain) - We foresee a complete revamping
(adding 10ktpy) in 2002-2004 with a 200 ktpy expansion eventually.
(EnalPanel) The expansion would allow this site to replace Aviles and
La Coruna (old Söderbergs). This is the most modern Inespal smelter,
with Péchiney prebake 143kA technology, which is the same as
Mostar’s (Pechiney P-140). (EnalPanel) As part of Alcoa's acquisition,
Inespal will benefit from the gradual deregulation of electricity distribution
and is planing to build its own generating facilities. (Platt’sMtlWk,
LesEchos)
- Trinidad and Tobago (Trinidad and Tobago) - 237 ktpy
project over 2002-2004. 237 ktpy expansion after 2006. Attracted
by abundant gas supplies and the chance to import aluminum duty-free
from this former Dutch colony into the European Union, Hydro chose Trinidad
over Qatar in 1998 for the site of a greenfield smelter and signed an
agreement with the Trinidad government to build a 474ktpy, $1.5-2.0b
plant in Point Lisas, Trinidad, to be built in two equal 237ktpy phases.
Construction was expected to begin in 2000, with first aluminum expected
in 2002. (AMM, MetalBulletin, Platt’sMtlWk) The first phase is highly
probable before 2005. The second phase is more probable after 2008 in
order to give Hydro time to evaluate potlife. (EnalPanel) An environmental
impact study is currently under way in Trinidad for Hydro's project.
(MetalBulletin) The feasibility studies into possible primary aluminum
smelters in Iceland and in Trinidad are still continuing and "one or
the other" will eventually be selected. Hydro regards a sustained price
of $1,600 per tonne as necessary before proceeding with either the Iceland
or Trinidad smelter projects. (MetalBulletin) Supported by tax breaks
and pre-sold supply contracts in the United States and Spain, a partnership
was formed a few years ago by Amoco Trinidad, British Gas Trinidad,
Repsol of Spain, Cabot LNG of Boston and Trinidad's state gas company
to build a $1 billion liquid natural gas (LNG) processing plant. The
Atlantic LNG plant was built in record time and under budget and made
its first shipment this April to the USA. Among the encouraged industrial
development tied to Trinidad's gas supplies: Norsk Hydro's plans to
build a $1.6billion smelter that will eclipse Atlantic LNG as the largest
investment in the Caribbean. (AP)
- Seydisehir (Turkey) - 60 ktpy revamping with a capacity
increase of 40 ktpy over 2002-2004. In 1993, the banking arm
of Etibank was restructured and transferred to the privatization administration
under the name Etibank Banking. This was privatized in March 1998, while
at the same time the industrial conglomerate became a holding company
- named Eti Holding - with seven main subsidiaries including aluminum.
Eti Aluminium is the second largest revenue generator for Eti Holding
and the government is of the opinion that it is not suitable for privatization
in its present condition and would rather invest in it first. The plan
is to both modernize and increase smelter capacity to 100ktpy, for which
the company says it can produce sufficient alumina, and a feasibility
study is currently being carried out by VAW of Germany which is expected
to be complete next month. The modernization includes converting the
smelter from Soderberg to prebaked anode technology, and if the plan
were approved, construction would probably start next year. (MBM)
One of our panelists thinks that a conversion to VSSPF is more likely
than a conversion to prebake. (EnalPanel)
- Turkmenistan (Turkmenistan) - 162 ktpy greenfield
in 2002-2004. The Ministry of Energy and Industry of Turkmenistan
has been interested in the possibility of a greenfield primary aluminum
smelter within the country's borders for at least the past few years.
Now, the US government and Bechtel are sponsoring a feasibility study
for a 162ktpy smelter in the southeastern region. Initially, the Ministry
expressed interest in a smaller project (50ktpy). The feasibility study,
to be undertaken by Bechtel and Reynolds Metals, is expected to cost
US$752,000. The project should take advantage of alunit ore deposits
in the country. Natural gas power will be used. (EnalPanel, Platt'sMtlWk,
AlumVerlag)
2003: (return
to Contents)
- Tomago (Australia) - An expansion of 235 ktpy (if
AP30 is used) or 150 ktpy (if AP20 is used) over 2003-2005. (EnalPanel)
A decision on whether to build a fourth line, which would require new
energy contracts, is to be made by the end of '99. (Reuters) Probability
of an expansion using AP20 is high before 2005 because of power availability,
performance is best in the "AP18 club", and the infrastructure exists.
Probability of using AP30 for expansion is low because the AP30 is less
fool-proof, needs different (wider) cranes, increases capacity by 240ktpy
and therefore needs 60% more investment. (EnalPanel) The planned
fourth potline (planned for 2002-2003) at Tomago is in doubt after management
raised fears over safety, emission control and labor costs. These were
subsequently confirmed by company and union spokesmen. (CRU) A feasibility
study for a fourth potline is being undertaken. (EnalPanel)
- Sao Luis (Brazil) - Expansion of 115 ktpy over 2003-2004.
A major expansion of this 360 ktpy, Alcoa technology smelter is planned,
but would depend on the go-ahead of a $1.2bn hydroelectric plant doubling
the capacity of the Tucurui plant on the Amazon. (AlumVerlag) Probability
of 120ktpy (1 line) expansion is high before 2004. This is because low
priced alumina is nearby, power price is around 15 mills, infrastructure
exists, and freight costs are low. (EnalPanel)
- Baie Comeau (Canada) - Expansion of 115 ktpy over
2003-2005 with shutdown of Söderberg capacity in 2003-2005.
In ‘96 Reynolds reached an agreement allowing completion of the modernization
and environmental upgrading of the plant. Reynolds intends to increase
production by changing over to graphitized cathode blocks, thus having
the possibility to increase the current load by 5-10% (189-195kA). (EnalPanel)
We expect this expansion after the current modernization and environmental
upgrading of the plant.
- Shawinigan Falls (Canada) - Complete shutdown in
2003.
- Aba (China) 100ktpy in 2003-2004. In Oct. '98,
Aba (Sichuan province) was discussing a possible joint venture with
Alcoa to expand its capacity by 100-200 ktpy from the current 14 ktpy.
An Aba official claims Alcoa is interested because electricity costs
are comparatively lower in the Sichuan province since hydro power is
used. The project is expected to take two years once construction begins.
(Platt'sMtlWk)
- Baiyin (China) - 45 ktpy expansion to 100 ktpy around
2003. Chinese and US investors withdrew from the Baiyin expansion
projects after the provincial government lowered electricity costs.
Xincheng Electric (Hong Kong) and AES (US) were mainly interested in
building a new power plant for the smelter, but insisted on charging
a higher price. The expansion will be 50ktpy, but there is no timeframe
for its completion. (Platt'sMtlWk)
- Shanxi (China) - 240 ktpy spread over 2003-2006.
This old project is progressing slowly. Alcan is moving ahead with the
feasibility study for the integrated 240 ktpy smelter and dedicated
power facility. The study will cost about $5m and is scheduled for completion
some time in 1999. (AMM) Alcan is to provide technical and management
know-how as well as financial investments. (Aluminium)
- Xianning (China) - Complete shutdown in 2003.
- Zunyi (China) - A 70ktpy expansion to 100ktpy in
2003-04. Due to market conditions, Zunyi may delay its expansion
until 2001 (from 2000). (Platt’sMtlWk) Anthony Bird gives this project
a low probability and a completion date of 2003. (ABA)
- Madras (India) - Expansion of 112 ktpy over 2003-2004
using Pechiney AP30. The area is already being leveled for the expansion.
Phase 2 (112ktpy) of the expansion is to follow a few years later. (EnalPanel)
Sterlite will either pursue this two-phase expansion or the Jharsuguda
greenfield. (See Jharsuguda - 2005) We think the expansion is more likely.
(Enal) Sterlite is now (’99) setting up a captive coal-based power
plant (75MW) for the Madras smelter and alumina refinery. It should
be completed by March ’99. (Platt’sMtlWk) A delay in commissioning
of a new 75MW captive power plant at Madras has forced production to
be cut to just 20% of capacity. Full production is expected to resume
in June once full power is available from the captive power plant. (CRU)
- Karmoy (Norway) - We project a 165 ktpy expansion
(Péchiney AP21) over 2003-2005 (probably with an integrated carbon
plant.) Probability of an expansion using Pechiney, 210 kA, 165ktpy
is high before 2009 because power is still cheap (Scandinavian exchange
of power), space still available, infrastructure is there. (EnalPanel)
- Kidricevo Talum (Slovenia) - An expansion of 40ktpy
(80 PFPB pots) is probable once the smelter is privatized in 2003-2004.
SWPB pots would be shut down at the same time. (EnalPanel)
- Hillside (South Africa) - 25 ktpy increase in capacity
in 2003. (MetalBulletin)
- Ravenswood (USA) - 50ktpy expansion in 2003-2005.
Century Aluminum is considering the addition of a potline at Ravenswood.
(MetalBulletin) Century Aluminum and the USW reached a tentative
agreement for a new labor contract at Ravenswood on June 30. (MetalBulletin)
On July 2, the USW ratified a four-year labor contract at Ravenswood.
(MetalBulletin)
- Sebree (USA) - 75 ktpy expansion in
2003-2006. An expansion using PFPB Alcoa 205kA (Alumar tech.), 140
pots, 75ktpy is highly probable before 2009 because power deregulation
will provide a better power price. New technology would require an investment
of less than $2,500/tpy. (EnalPanel) Alcan and the USW union are
not expected to begin bargaining until mid-October. (Platt'sMtlWk)
2004: (return
to Contents)
- Lithgow (Australia) - 450 ktpy in
2004 - 2005. The bankable feasibility study for the proposed
smelter at Lithgow is expected to be completed by December and construction
is scheduled to start in May next year with first production in January
2002. Full production at the rate of 450ktpy is planned for June 2003.
(MetalBulletin) The project is being sponsored by Aust-Pac and the
study is being carried out by Babcock & Brown, with the support
of SNC-Lavalin. (Platt'sMtlWk) Only two issues could derail
the project: getting a suitable power agreement and the state's acceptance
of the environmental impact statement. Getting financing for the A$1bn
plus project is the least of its problems. The government is expected
to give the project the green light as the smelter is to be built on
an industrial estate set aside for this type of development. The smelter
will require 850MW to be sourced from three separate suppliers; and
although Aust-Pac is prevented from talking to the three generating
companies as a consortium, good progress is being made. Discussions
with potential suppliers of alumina (in Australia) and potential customers
are also well-advanced. Aust-Pac plans to bring in a majority partner,
likely a supplier of technology. Discussions with a potential investor
are well-advanced. Aluminum production will be targeted for the Asian
markets. Lithgow is 200km by rail from Port Kembla and was chosen because
of the existing infrastructure and availability of a skilled workforce.
(MetalBulletin) This project was originally intended for Southeast
Asia, but the site was changed due to unstable conditions there. (MetalBulletin)
- Alouette - Sept-Iles (Canada) - Possible expansion
of 265 ktpy over 2004-2007. (EnalPanel) Using AP30 technology. (EnalPanel)
Alouette is in a standoff with Hydro-Quebec over a power deal for its
planned expansion. (AMM) A decision by the Quebec Energy Board on a
possible rate reduction was expected by the end of Jan. ’99. (AMM) Anthony
Bird's expansion forecast: 281 ktpy (expanding to 510ktpy); completion
date - 2003; probability - 0.3. (ABA)
- Becancour (Canada) - An expansion of existing lines
by 40 pots each (total 60ktpy) in 2004-2005 with addition of
4th potline (140 ktpy) over 2006-2008. (EnalPanel)
- Auzat (France) - Complete shutdown in 2004-2005.
Pechiney has decided to shut down the smelter in the year 2005. (AlVerlag)
- Hydro Iceland (Iceland) - 200 ktpy possible in 2004.
Hydro will decide by June 2000 whether to proceed with a planned
120ktpy smelter in Reyoarfjorour, Iceland. Hydro, along with Iceland's
national power company Landvirkjun and the country's Ministry of Industry
& Commerce, signed a declaration on June 29 concerning the undertakings
of each party in the project, including further feasibility studies
and a time scale for the next eleven months. The project will depend
on Landvirkjun starting construction of the Fljotsdalur hydroelectric
power plant in the eastern region of the country by June next year.
If this goes ahead, the smelter will be commissioned before the end
of 2003. An environmental impact report on the power plant is due to
be published this autumn, part of the extensive feasibility studies
that the three parties involved will complete before making a final
decision. Hydro will jointly own a majority share in the project. The
project will have the potential to expand to a capacity of 480ktpy.
Carbon for anodes will be imported. (MetalBulletin) (Also see Trinidad
- 2002) Columbia Ventures recently made a formal approach to the Icelandic
government stating its interest in building a smelter in the same area
as the proposed Hydro plant. If this project succeeds and construction
starts as early as possible, the new smelter could be in production
by the end of 2003. It is proposed that the smelter would have a first-phase
capacity of 90ktpy. Power would not be available until 2003. Start-up
would be timed to coincide with new electricity supplies which are expected
to come on stream in the area. (MetalBulletin)
- Indal Orissa (India) 250 ktpy in 2004-2008 (2 phases).
VAW or Dubal technology is much more likely to be used than Pechiney.
(EnalPanel) The 20% stake previously owned by Tata Iron & Steel
Co in the Utkal greenfield alumina project has been reallocated following
its withdrawal from the 1m tpy project. The financial adviser to the
group is ready to put in draft financing proposals for the project.
(MetalBulletin)
- Mosjoen (Norway) - Probable scenario: Expansion of
100 ktpy combined with a shutdown of obsolete pots (50 ktpy) in 2004-05.
Alternate possible scenario: Conversion of Söderberg to PFPB with
an increase in capacity of 20 ktpy (estimated cost of NOK500-550m).
As with most Norwegian smelters, expansion depends on Government energy
policy which was paralyzed by environmentalists in the early ‘90s.
- Oman (Oman) - 130-140 ktpy (phase I) over 2004-2008.
The technology supplier is most likely to be Dubal. (EnalPanel)
- Bayside (South Africa) - Upgrade of Söderberg
lines adding 20ktpy in 2004.
- Steg (Switzerland) - Complete shutdown in 2004-2005.
2005: (return
to Contents)
- Kurri Kurri (Australia) - Expansion by 60ktpy in
2005-2006. If power contracts are favorable, the company will most
likely commit itself to the construction of a fourth potline. (AlumVerlag)
The future of Kurri Kurri is uncertain after electricity price negotiations
stalled. (CRU)
- Valesul (Brazil) - Expansion to 229ktpy in 2005.
Valesul is in the early stage of studying a possible expansion to 229
ktpy. Before such a project is possible, a power supply must be found.
Construction of the Machadinho hydropower plant, of which Valesul has
a 7% share, is on target for start-up in 2002. (Platt'sMtlWk)
- Kitimat (Canada) - Either a 250 ktpy expansion
or greenfield nearby in 2005-2007. According to one panelist,
Alcan is still considering a greenfield prebake smelter using either
Pechiney AP30 or Alcoa 696 technology (215kA). (EnalPanel) AMM reported
that Alcan is still considering a brownfield expansion (of 100 to 250
ktpy, depending on market demand) at Kitimat but is in no hurry. A decision
would be made in 2003 or 2004 and the project would have a two-year
time period to start-up. (AMM)
- Aisen (Chile) - 230 ktpy over 2005-2007. Noranda
is near to having talks with prospective partners in this project. Forming
a consortium to spread the cost of the smelter is the major task facing
Noranda, which is currently undertaking an environmental impact study.
In spite of protests by salmon fisheries last year, Noranda does not
foresee any major problems. They are still waiting for a permit for
water rights at Rio Blanco, necessary for the integrated hydro power
project. The smelter is expected to cost $1.6bil and have a capacity
of up to 440ktpy. The hydro project is expected to cost another $1bil.
Noranda has stated that the earliest start-up date would be sometime
in 2005. (AMM, MetalBulletin) A power plant and a new harbor have to
be built before the project can start. A hydroelectric power plant with
a huge dam will take 5 years at least once financing is undertaken.
Therefore the smelter is not likely to come on stream before 2005-6.
(EnalPanel)
- Jharsuguda (India) - 250 ktpy in 2005-2009. Sterlite
had plans to build a 250 ktpy capacity smelter, a 1m tpy alumina refinery
and a 720MW captive power plant. The total project cost is estimated
at Rs85bn. (MetalBulletin) The expansion at Madras is more likely to
be used to increase Sterlite's capacity. (See Madras - 2003)
However, Sterlite is scouting for a partner to build its proposed
1-mil mt/year alumina venture in Orissa. The company has already received
"in principle" clearance for a $350-mil loan from Merrill Lynch and
has approached Indian financial institutions as well. Pechiney is to
provide the technology (an MoU has been signed). (Platt'sMtlWk) Malco
is currently conducting a feasibility study into a 125 ktpy greenfield
aluminum smelter in Orissa, along with a captive power plant, for an
estimated cost of Rs36bn. It has acquired the land for the project and
will soon make a decision on whether to go ahead. (MetalBulletin)
- Asahan - Kuala Tanjung (Indonesia) - We foresee a
150 ktpy expansion over 2005-2006. The site would deserve
an expansion if an energy source, other than hydroelectric, were found,
which is possible. A qualified source close to management says that
a future expansion depends on the energy policy negotiated directly
between the parent company in Japan and the local utility, and agrees
that, in the present structure, power availability limits any future
expansion which otherwise would be justified if only by market prospects
in Indonesia. (MetalBulletin) Kuala Tanjung saw another sharp fall
in output in the January-May period this year as a result of continuing
low water levels in Lake Toba. Only 206 of 510 pots are currently in
operation. The company's target is to have 285 pots working by the end
of the current fiscal year in March 2000. The company plans to produce
around 105kt this year. (MetalBulletin)
- Pavlodar (Kazakhstan) - 160-170 ktpy after 2005
using VAMI technology. (EnalPanel) The Kazakhstan ministry for ecology
and natural resources has rejected applications from Aluminium of Kazakhstan
to build a new smelter at Pavlodar. The company may be asked to consider
alternative locations. (Platt’sMtlWk) According to the latest studies,
a greenfield smelter using VAMI technology appears very unlikely. (EnalPanel)
- Beira (Mozambique) - 240 ktpy greenfield after 2005.
An MoU was signed in Dec. ’98 by Fluor Daniel and the Government of
Mozambique to study the feasibility of a second greenfield in Mozambique.
Fluor Daniel has begun work on the feasibility study for the 250ktpy
smelter. (Reuters) The study is sponsored by the U.S. Trade and Development
Agency, with technical assistance from Fluor Daniel, and from Kaiser
Aluminum and ABB as Fluor’s subcontractors. The U.S. Government is to
put up half of the cost of the study, which is expected to be completed
by the end of ’99. This project in Beira would be 500 miles closer to
the Cahora Bassa Dam than the Maputo project. (AMM, Platt’sMtlWk, BusinessWire)
- Kandalaksha (Russia) - Modest revamping of 70 ktpy
with capacity increase of 15 ktpy starting in 2005 while keeping
the Söderberg technology with a Reynolds type modernization.
2006: (return
to Contents)
- Maputo (Mozambique) - Second line of 245 ktpy over
2006-2007. Billiton is already working on an expansion plan. (MetalBulletin)
- Alcasa (Venezuela) - 250 ktpy expansion (5th line)
in 2006-2010. An expansion using Reynolds technology is very
unlikely. An expansion using Alcoa 205kA PFPB (like Alumar, Brazil)
or Pechiney 205kA PBPF (Puerto Madryn, Argentina) is much more likely.
Probability of this expansion before 2009 is fairly high because hydro
power is available at low cost, space is still available, and the environmental
situation will improve after privatization. (EnalPanel) Earlier this
year, it was decided that Alcasa is to be sold in parts under joint-venture
schemes in the fourth attempt at the privatization of Venezuela's aluminum
assets. The operations of Alcasa that are to be sold separately include
the Puerto Ordaz rolling mill, lines 1 and 2, lines 3 and 4, the plant's
laboratory, and the port. It is as yet undecided whether anodes producer
Carbonorca will be sold alone, or as a part of a joint venture with
line 5 of Alcasa. The CVG president has proposed issuing $200m worth
of bonds to help Alcasa raise cash. (MetalBulletin) Venezuela has again
put off the starting date for another effort to sell a controlling interest
in its aluminum industry, possibly until some time in 2001. (AMM)
- Bell Bay (Australia) - Expansion of 170 ktpy over
2006-2008. Probably will use Bluff technology. A 4th potline
at a cost of A$650m to prolong smelter life until 2025 depends on securing
extra power. This was secured in January ‘96 at level of 19 MW only.
In any case, Comalco will insist on controlling the power supply, as
is now their strategy. Power prices have been secured and guarantee
Bell Bay's future until 2014 at the earliest. (MetalBulletin) One of
our panelists considers an expansion of 170 ktpy unlikely due to energy
problems. (EnalPanel)
- Zaporozhye (CIS Ukraine) - Complete shutdown in 2006-2007.
Two 16% share blocks in the smelter will be sold sometime this year.
(AMM)
2007: (return
to Contents)
- Guinea (Guinea) - 240 ktpy in 2007-2009. Site
unknown. We consider Guinea a good site for a greenfield smelter, primarily
due to the proximity of the Friguia refinery. A lot depends on the situation
at the refinery. Reynolds has signed a MoU with the Guinean government
for the sale of the government's 100% stake in Friguia. Originally,
Reynolds planned to use the alumina from Friguia to supply Alscon (Ikot
Abasi), but until problems in Nigeria are straightened out, Reynolds
may direct its alumina to the Volta smelter in Ghana. (MetalBulletin)
- Jajarm (Iran) - 220 ktpy after 2007. Iran
is studying preliminary plans for a new 220ktpy, US$500-600m aluminum
smelter, which could be built near to the alumina refinery in Jajarm
(expected to open in September). The area is said to have the potential
of becoming a self-contained aluminum production center. The smelter
would be allowed to have up to 49% foreign ownership. Jajarm has good
road, rail and air links, and sufficient gas and electricity supplies.
(CRU, MiningJournal)
- AISA (Malaysia) - 240 ktpy in 2007-2008. AISA
is concentrating on an integrated gas-power plant scenario with a site
on the mainland. (EnalPanel) AISA has decided to build its own gas plant
with a capacity of 660MW for the price of US$350 million on a turnkey
basis as quoted by Alsthom. (EnalPanel)
- Umm-Said (Qatar) - 530 ktpy after 2007 (Hydro or
other producer). Umm-Said is a old project that has been studied
and reviewed by all aluminum producers interested in the Middle East.
It is a very serious project on an excellent site, but the project competes
with others in the Emirates and Arabia. Norsk Hydro and the government
of Qatar put talks for a greenfield smelter in Qatar on hold indefinitely.
Both cited the weak aluminum market as a reason for the decision. (Platt’sMtlWk)
This project is reasonably probable before 2009 because the gas price
is low (less than 0.5USD/mioBTU), infrastructure is subsidized, freight
cost for alumina is low, and calcined coke would be available from Alba
nearby. (EnalPanel)
- Novokuznetsk (Russia) - Revamping of 100 ktpy with
capacity increase of 20 ktpy postponed to after 2007. In the past,
VAW completed a detailed feasibility study based on conversion to prebake
at minimal costs. (EnalPanel) VAW has given up plans to modernize Novokuznetsk.
The financial situation and higher than normal Russia power price will
delay a revamping. (EnalPanel) NkAZ is discussing the financial aspects
of upgrading its 275 ktpy smelter with the help of Alcoa. NkAZ plans
to upgrade its pot lines from HSS to prebake anode technology with support
from Alcoa. The new technology is expected to almost double output,
so the plant now plans to close one of its two potlines when the potlines
are upgraded. The upgrade will take four to five years and costs are
expected to reach a total of US$500m. (Aluminium) In late ’98, NkAZ
signed a 5-year agreement with their power supplier, KuzbassEnergo,
ensuring uninterrupted power supplies to the plant at set tariffs. A
condition of the agreement is that all electricity bills will be paid
in cash. (MetalBulletin)
- Tadaz (Tadjikistan) - Revamping of entire capacity
over 2007-2008, enabling plant to produce at full capacity.
A IFC-World Bank study, which is to make recommendations on the future
structure of Tadaz, was scheduled for completion by the summer of '99.
(MetalBulletin) The Tajik president has instructed managers of the
republic's sole aluminum plant to raise output to 300ktpy as of the
year 2000. The smelter produced only 195kt in 1998 and plans to raise
output to 220kt in 1999. The plant has obsolete equipment and needs
much more electricity than the republic can supply. The government plans
to submit the smelter to an international audit, believing this would
attract investment. (Reuters)
- Vietnam (Vietnam) - Greenfield could start up in
2007-2008. In ’97, Daewoo of South Korea signed a letter of intent
with the state-owned Vietnam Minerals Corp (VMC) to survey bauxite reserves
in Vietnam. The project would investigate the possibility of setting
up bauxite mining, alumina refining and possibly aluminum smelting.
(Platt’sMtlWk, MBR) In Sept. ’98, the VMC and Pechiney completed a prefeasibility
study for an aluminum exploration and production project. The feasibility
study should be complete in ’99 and the project could start production
by 2005. (SaigonTimes) Vietnam Mineral Corp (Vimico) and Pechiney
have signed an agreement to undertake a prefeasibility study to develop
a 1m tpy alumina refinery in Landong province near Ho Chi Minh City.
The site has around 300m tonnes of proven bauxite reserves and prefeasibility
studies are expected to last for two years. There are no plans for a
smelter due to a lack of electricity. (MetalBulletin) A lack of power
in the area could make this a candidate for an integrated aluminum smelter
and power plant.
2008: (return
to Contents)
- Orissa Hindalco (India) - 150 ktpy after 2008.
Hindalco has decided to shelve plans to set up a greenfield aluminum
project in eastern Orissa state. This decision was based on findings
from the detailed techno-economic feasibility study conducted jointly
by ICF Kaiser Asia and Bechtel Australia. (Platt'sMtlWk, AMM)
- Kuwait (Kuwait) - 120-180 ktpy after 2008. Kuwait
Industries and Raytheon apparently are both competing for this project.
Kuwait's government approved a "conceptual study" in November ‘96 that
envisioned a 230 ktpy, $1.2bn smelter in the Shuaiba industrial zone
and the participation of Raytheon. The project is still delayed (AMM)
due to the issues of power availability and energy rates that would
be set by a state-owned power company. The government is hesitating
to sign a long-term contract at the undisclosed rate originally agreed
upon, even though a source says that the rate was higher than either
the industrial (3.3 mil/kWh) or residential (6.6 mil/kWh) rates. (Platt’sMtlWk,
AMM) Raytheon would use a Reynolds technology. (Platt’sMtlWk) Meanwhile
Kuwait Industries’ project has been progressing. Kuwait Industries seems
to be in the best position to obtain government license to build and
operate a smelter. The power rate should be in line with other greenfields
in the Persian Gulf, somewhat more than 10 mils. (EnalPanel)
- Aviles (Spain) - Complete shutdown in 2008
(upon expansion of San Ciprian).
- Alisa (Venezuela) - 80-90 ktpy in 2008-2009 (initial
phase). Alisa is a Reynolds project with Reynolds technology. Reynolds
confirmed in March ’98 that this project is still considered to be very
much alive. Interest may center on having a nearby aluminum source for
its Venezuelan automotive wheel venture. (AMM) According to one panelist,
the probability of this project is less than 5% because of a bad choice
of technology and the size of the smelter is unrealistic for a greenfield
nowadays. (EnalPanel)
2009 and later (or still very uncertain): (return
to Contents)
- Angola (Angola) - According to the Angolan Ministry
of Industry, Angola is investigating the possibility of building a greenfield
smelter with Prodev International of Switzerland. Foreign participation
will be limited to a maximum of 49%. A feasibility study has yet to
be performed. (Aluminium)
- Bahia Banca (Argentina) - Aluar has mentioned the possibility
of a 250 ktpy greenfield smelter at this port 300 miles north of Puerto
Madryn. (AMM)
- Aratu (Brazil) - Partial shutdown (28 ktpy) in 2009-2010.
- British Columbia (Canada) - Alcan, Alcoa, Columbia Ventures
Corp., Pechiney and Kaiser Aluminum have all looked into British Columbia
as a possible site for a greenfield smelter. (Aluminium Today) Alcoa
put the possibility of a project in BC on hold. (BusinessWire, AP, AMM,
Platt’sMtlWk) In addition to British Columbia, Columbia Ventures has
been considering possible sites in Oregon and Washington for a 90-180ktpy
smelter. (Platt’sMtlWk) In Jan. ’99, CVC announced that it would concentrate
on its Grundartangi expansion, rather than these greenfields, until
the market improves. (Platt’sMtlWk)
- Deschambault - Lauralco (Canada) - Expansion of 227
ktpy to double capacity is possible after 2010. In ‘97, the use
of graphitized cathodes permitted an amperage increase from 295 to 325
kA (capacity increase to 235 ktpy). (AlumVerlag, EnalPanel)
- Yangxin (China) - In 1998, there were reports that this
small smelter was considering an expansion of 50ktpy in two phases of
25ktpy each. (Platt'sMtlWk)
- Kumera (Finland) - There was talk of Kumera considering
the construction of a greenfield smelter in Finland. (MetalBulletin)
This project is dead for good as no cheap power was available
from Sweden, Finland, or Russia. (EnalPanel)
- Dunkerque (France) - For the long-term, we foresee
a possible doubling of capacity. Doubling capacity could justify
negotiating a more favorable energy contract and a debt restructuring
in a context of job creation in and around the smelter, while reducing
total capital intensity of the site. We bet that Péchiney, needing
to transfer jobs from other sites, and the present French government,
desperate to reduce unemployment, will not miss such an opportunity...
A second potline could be envisaged as soon as debt is lighter and Pechiney
decides to shutdown obsolete, French smelters. (EnalPanel) An increase
of potline current to 320 kA is in progress which would increase the
capacity without expansion. (EnalPanel) Usinor's decision to integrate
a power plant to be built by Air Liquide next to the smelter is a major
breakthrough in France. It is the first major investment in the energy
industry totally escaping the influence of EDF. (EnalPanel)
- Atlantal - Keilisnes (Iceland) - 200 ktpy after 2008.
Once sponsored by Hoogovens, Granges Aluminium and Alumax. Granges has
since sold its Sundsvall smelter in a management buy-out and Alcoa bought
Alumax. (EnalPanel) What will be the effect of the acquisition of Alumax
by Alcoa? According to one panelist, Alcoa is not continuing talks with
Statskraft SF at this time. (EnalPanel)
- Iceland X - A German company supposedly has expressed
interest in an aluminum project in eastern Iceland. (MetalBulletin)
- Vlissingen (Netherlands) - Pechiney is planning to integrate
a gas-fired power plant. (EnalPanel)
- Bratsk Irkutsk (Russia) - There have been plans for
a 200-250ktpy, $1.5b, greenfield smelter in Irkutsk, probably close
to the existing Bratsk smelter. The primary investor is to be the Bratsk
smelter itself (MetalBulletin, Platt’sMtlWk) At this point, we consider
this project to be very uncertain and only for the long term. The
plan for a greenfield smelter near Irkutsk has been shelved despite
available hydroelectric energy. (EnalPanel)
- Krasnoyarsk 2 (Russia) - The governor of the Krasnoyarsk
territory proposed plans to build a 200 ktpy smelter in order to win
the ’98 re-election. Since he was not re-elected, it is unlikely
that the project will get off the ground. ( Platt’sMtlWk, MetalBulletin,
EnalPanel)
- Nadvoitsy (Russia) - Revamping to add 15ktpy over
2009-2011.
- Shelekhovo (Russia) - Expansion of 70 ktpy 2009
or later. This VAMI Söderberg, 130kA (2 lines) and 160kA
(2 lines), is rated at 260ktpy capacity. Shelekhovo is to undergo
reconstruction costing $180-mil to expand production by 70 ktpy, this
includes commissioning of a fifth line. (Platt’sMtlWk) The planned
expansion of 2 potrooms (1 potline) would involve VSS 160kA. (EnalPanel)
- La Coruna (Spain) - Complete shutdown in 2010 (upon
expansion of San Ciprian).
- Sweden - In autumn '98, a Japanese company was considering
Sweden for the site for a new aluminum smelter.
- Mount Holly (USA) - Possibility of a new line
being added using Alcoa technology.
Other Items of Interest (return
to Contents)
Mergers & Acquisitions
- Alcan / Pechiney / Alusuisse and Alcoa / Reynolds - On Tuesday,
August 10, an announcement was made that negotiations were under way
for a possible merger of Alcan, Pechiney, and Alusuisse. Alcan shareholders
would own 44% of the new group, provisionally named APA, with Jacques
Bougie as the head and Jean-Pierre Rodier as COO. Pechiney would hold
29% of shares and Alusuisse 27%. The initial merger agreement is to
be limited to Alcan and Alusuisse because Pechiney must consult with
its workers council before entering the deal. Alusuisse would be expected
to sell its chemicals business, possibly as part of a similar merger.
On the following day, August 11, Alcoa offered to buy Reynolds Metal
Co. for $5.6 billion in cash and stock. Alcoa does not anticipate antitrust
issues. On Thursday of that week, Pechiney's Rodier did not rule out
a counterbid for Reynolds by APA. By Friday, VAW was in the mix, announcing
that it was considering a large acquisition (though not on the scale
of the APA merger or the Reynolds acquisition) within the next year
or two. No specific candidates were discussed. On Friday, Michigan Avenue
Partners made an all-cash offer for Reynolds that they claimed was higher
than Alcoa's bid. Initially, Alcoa's bid was rejected, which spurred
them on to take steps toward a hostile takeover. The aluminum giant
was going to take the bid to the Reynolds shareholders. In the meantime,
Alcan stated that they might consider a purchase of certain portions
of Reynolds, but not of the entire business. By August 18, a week after
announcing their intentions to acquire Reynolds, they had accomplished
just that. The speedy decision and the lack of effort put forth by the
Reynolds board to solicit other bids resulted in a letter being sent
to the Reynolds Board of Directors by Highfields Capital Management
(a Reynolds shareholder), harshly criticizing the Board's lack of consideration
of the company's shareholders throughout the entire process. They strongly
encouraged the Board to solicit bids from other potential investors
in the 30 days following Reynolds' acceptance of Alcoa's offer. (Reuters,
AP)
PANELISTS / SUBSCRIBERS: What is your opinion on the above
item? Will the APA merger take place? What about the Reynolds acquisition?
How would this affect the primary aluminum market? How would this affect
equipment suppliers to the industry? Would some projects become more or
less likely to take place? What companies should VAW consider as potential
acquisitions? We would be interested to hear what you think.
PANELIST FEEDBACK (from Panelist 1): The Alcan/Alusuisse merger will most
likely take place because both are 100% private companies. In the case
of Pechiney, the government of France and the unions (not the workers)
will have a say in the merger and there is a good chance that they will
veto it.
In the case of Alcan/Alusuisse there are a lot of obsolete smelters especially
in the case of Alcan in Quebec. In exchange for a good power contract
from Hydro Quebec, Alcan has agreed to maintain the present number of
working places until 2003. Therefore some difficulties will have to be
solved.
In any case, an expansion of the 1½ AP30 line at Isle Maligne will be
made sooner and the new greenfield or brownfield smelter in Kitimat is
more likely to be realized.
As Alusuisse has a good technology in increasing the amperage of pots,
the prebake smelters in the UK and in Arvida can be expected to be upgraded
by 10-15% more capacity.
If Pechiney joins the club, the overstaffed fabrication plants in Germany
and Switzerland are likely to get "reengineered" with a substantial cost
reduction (20-30%). There will be a battle between French and Swiss/German
technical staff which the superbly trained Pechiney people are likely
to win.
The main benefit of the merger will be that the Alcan organization which
paid only "lip-service" to CEO Bougie's profitability drive will be severely
shaken up and awaken to today's realities.
As the Alcoa/Reynolds merger has already been accepted by Reynolds' board
of directors, we foresee:
- Shutdown of all the obsolete facilities of Reynolds in the Northwest
of the USA
- Absolute dominance of Alcoa in the alumina market with dire consequences
for the Russian aluminum industry (part of cost advantage will disappear)
- Venezuelan smelters, including Alcasa where Reynolds has a small interest,
will fall to Alcoa.
PANELIST FEEDBACK (from Panelist 2): Re: Alcan/Pechiney/algroup merger:
In any case, Alcan and algroup officers have signed a two-way agreement
for a takeover by Alcan, even if Pechiney does not have the possibility
to join due to difficulties with local unions. The new merger is said
to control 27 smelters worldwide representing a capacity of more than
3.3m tpy of installed capacity (the Alma project under construction included).
The joined forces will also control more than 7m tpy of metallurgical
grade alumina. This is the status quo with no obsolete capacities shut
down. This means that the new company will control more than 13% of the
global installed capacity. If Alcoa buys Reynolds Metals, then these two
companies will control more than 4m tpy of primary aluminum installed
and more than 16m tpy of metallurgical grade alumina. Both new merged
companies will control more than 23m tpy of metallurgical alumina (more
than 40% worldwide) and more than 7m tpy of primary aluminum capacity
installed (about 30% of the worldwide primary aluminum capacity). Alcoa
will buy Reynolds if the US Justice Department approves the merger.
OUR COMMENT: We repeatedly exposed that, since 1973, aluminum prices
increased against steel and copper, thus making the industry artificially
attractive and inviting newcomers. The aluminum industry has de-concentrated
since then, while attempting several maneuvers to beef up prices (MoU,
6% customs duty in Europe, etc.) The industry is now again market-driven.
Two major forces are behind this trend: the automobile industry wants
stable, predictable metal prices with international suppliers and the
energy industry is deregulating, bringing energy costs down. We expect
the aluminum industry to catch up with delayed concentration until two
leaders together control 50% of world production. We also expect a radical
technology change, probably to electrolysis of aluminum chloride, to be
operational by 2015. The debate is open.
- Pechiney to acquire Century's fabricated aluminum businesses
- Century Aluminum has decided to sell its fabricating assets and to
concentrate on its primary aluminum business. It is looking at acquiring
primary aluminum facilities in North America, Europe and Australia.
Among those perceived as possible targets for Century would be Xstrata's
23% stake in the Mount Holly smelter in the USA, in which Century already
holds a 26.7% stake, and Alcoa holds the controlling interest. (MetalBulletin)
A definitive agreement has been signed for Pechiney's acquisition of
Century's two fabricated aluminum businesses (rolling mill in Ravenswood,
West Virginia, and a cast plate unit in Vernon, California) for US$248
million. (BusinessWire, MetalBulletin, AMM)
- Pechiney considers expanding Tomago share - Pechiney has expressed
interest in buying CSR's 36% stake in Tomago. Pechiney has a pre-emptive
right to CSR's share when it decides to sell. (MetalBulletin)
- Hoogovens mergers - On June 7, the merger between Koninklijke-Hoogovens
and British Steel was announced, officially forming British-Steel-Koninklijke-Hoogovens
(BSKH). The new group will retain Hoogovens smelters, extrusion plants
and rolling mills alongside a merged steel production. Not only will
Hoogovens Aluminium be retained by the group, there is the possibility
that it could be expanded. There has been speculation that the Hoogovens
aluminum operations may be acquired by Pechiney, Glencore or Alusuisse-Lonza.
(MetalBulletin) The European Commission approved the merger in mid-July.
(MetalBulletin) Hoogovens' central works council stated that it is in
favor of the proposed merger with British Steel. It also stated that
aluminum operations should be expanded. (AMM) Both companies expect
the merger to be completed in October. (MetalBulletin) Hoogovens has
also announced plans to form a 50:50 joint venture between Hoogovens
Technical Services and Danieli, forming Danieli-HTS. The jv would offer
a variety of engineering and contracting services to the steel and aluminum
industries. (MetalBulletin) Former British Steel chairman Sir Bob Scholey
has indicated his approval of the proposed BS-Hoogovens merger. (MetalBulletin)
- Norway looks to increase stake in Norsk Hydro - Uncomfortable
with the idea of the government's majority stake in Norsk Hydro being
diluted after Norsk Hydro's planned share offer for Saga Petroleum,
the Norwegian Oil and Energy Minister said that the government may consider
buying shares in Hydro. (AMM)
- Hydro buys stake in Alunorte - Hydro Aluminium has agreed to
pay $200m for a 25.3% stake in the Alunorte alumina refinery in Brazil.
An MoU between the two companies could lead to an increase of refinery
capacity by 800ktpy to 2.3 million tpy. The expansion would require
an added investment of $300m, of which Hydro agreed to pay half, and
is scheduled to take place within the next 24 months. The extra production
will be taken up entirely by Norsk Hydro. (AMM, MetalBulletin)
- VA Tech signs letter of intent to buy Kvaerner - VA
Tech has signed a preliminary letter of intent to buy Kvaerner's Metals
Equipment design and supply business. The deal does not include Kvaerner's
UK manufacturing facilities, which will be sold separately. In Stockton,
VA Tech is buying the iron and steel division. Danieli and Techint could
still be interested in the remaining companies. (MetalBulletin)
- Columbia Falls Aluminum – Glencore announced the
agreement to purchase Columbia Falls May 21 without disclosing the terms.
Final closing was expected to take place in early June, pending the
transfer of necessary permits and regulatory approvals. Glencore is
expected to honor the existing Pechiney tolling contract but not to
renew it. (Platt'sMtlWk) (A panelist pointed out that there is no tolling
contract with Pechiney but with Hydro Aluminium. (EnalPanel))
- IDC stake in Billiton - IDC has reduced its stake in Billiton
to 8.96%. (MetalBulletin)
Labor Issues (return
to Contents)
- Strike at Kaiser Aluminum Smelters - The strike that began
on September 30, 1998, at five Kaiser Aluminum USA locations (including
the Tacoma and Mead smelters) continued into August ’99. (MetalBulletin,
AMM) On July 15, Kaiser indicated that the National Labor Relations
Board (NLRB) intended to recommend dismissal of all charges of unfair
labor practices brought against the company by the USW. On July 19,
Kaiser submitted a proposal to the USW and the Federal Mediation &
Conciliation Service which included a proposal for a two-week negotiating
session beginning August 9. (BusinessWire) Three rounds of talks are
scheduled between Kaiser and USW during the month of August. (BusinessWire,
AP)
- Southwire versus strikers - Southwire fired 17 USW members
who went on strike against NSA more than a year ago. Southwire said
the strikers were fired because of "threats and other acts of violence
against NSA employees and their families." (Platt'sMtlWk)
- Kitimat strike - After the expiration of a labor contract on
July 24, members of the Canadian Autoworkers union went on strike for
about four hours. About half the smelter was shut down, but was back
in full operation by the next morning. A new three-year contract was
agreed upon within a week of the short-lived strike. (MetalBulletin)
China (return
to Contents)
- Chinese Aluminum - According to China Metals, 39 new primary
aluminum smelters have been built in the past two years. There are now
106 smelters in China, mostly under 30ktpy. 13 smelters were forced
to shut down in late ’98 with a total capacity of 260ktpy. (MBM) Twenty-one
Chinese aluminum plants are expected to be consolidated into a large
aluminum group in the near term. The plants account for 1.1-mil mtpy
of aluminum capacity. Small aluminum plants with a capacity of below
10ktpy are expected to shut down gradually, but this process will take
some time due to regional protectionism. The Chinese government has
plans to restrict new aluminum expansion projects of below 100ktpy in
a bid to eliminate the pollution problems associated with small plants.
(Platt'sMtlWk)
- Chalco plans face local opposition - Current plans are to consolidate
China's largest refineries and smelters into the China Aluminium Co.
(Chalco). A policy of shutting down smaller, inefficient smelters (announced
in January) has been linked to this plan in the central government's
overall aluminum strategy. More than 80% of China's aluminum smelters
(111 at last count) have capacities of less than 50 ktpy. In 1998, 12
plants with capacities of less than 30 ktpy were built. (Platt'sMtlWk)
Another aspect of the Chalco plan is that smelter development projects,
other than those using prebake technology, will be prohibited for three
years. (MetalBulletin)
- Guizhou working on casthouse - Guizhou is purchasing equipment
for the casthouse from ODT Engineering (Australian licensee of Maerz-Gautschi)
and VAW. (AlumToday)
CIS (return
to Contents)
- Where is KrAZ general director? - The general director
of KrAZ resurfaced four weeks after disappearing amid charges of corruption.
Bykov was in an Austrian clinic recovering from a spinal operation.
(AMM) He has been reappointed chairman of Krasnoyarsk. The meeting of
shareholders approved the issue of 15m additional shares, aimed at raising
$80m worth of investment. (MetalBulletin)
- Sayanogorsk wins appeal - An appeal court in Moscow ruled in
favor of SaAZ on June 1, dismissing an earlier ruling in April which
declared illegal the issue of shares carried out by SaAZ in 1998 and
subsequent government tenders for SaAZ shares. Ownership is now: TWG
(14.14%), Sibirsky Aluminy (69.16%), Gavrohe Investments (12.61%). (MetalBulletin)
- Who controls Nikolaev? - Nikolaev general director Vitaly Meshin
was replaced by Trans-World Group-linked Nikolay Naboka. Meshin is appealing
this decision, but the summer recess of the Ukrainian parliament has
delayed a hearing. In the meantime, Naboka has reportedly dismissed
the plant's previous management and has halted shipments to Bratsk,
Tadaz and Sayanogorsk. (MetalBulletin, Platt'sMtlWk)
Other (return
to Contents)
- Comalco’s Gladstone Refinery Project - Comalco has given
the go-ahead for the final feasibility study for its proposed alumina
refinery based at Gladstone. The Queensland government has reached agreement
with the Papua New Guinea Pipeline Joint Venture for the supply of gas
to a number of Queensland companies, including Comalco. According to
Comalco's managing director, it would take at least twelve months before
the sponsors of the PNG gas project make firm commitments for the supply
of gas. In contrast, copious quantities of gas are already onshore for
a possible Malaysia alumina refinery. Comalco is close to finalizing
terms for the supply of natural gas and electricity in the short and
longer term with Malaysia's national oil company, Petronas, in a joint
venture with Shell Malaysia and with the Sarawak Electricity Supply
Corp. (MetalBulletin)
- Tiwai Point production is up - The plant produced a record
79kt in the first quarter of 1999, up from 77kt in the final quarter
of 1998. Improvements included better quality carbon anodes, a new scrubber
to recycle carbon and clean the air, and energy efficiency projects.
(Southland Times)
- UK energy tax - The UK energy tax, or "climate change levy",
to be introduced by the government in April 2001, could put the country's
primary aluminum smelters out of business, according to Tom Campbell,
md of Anglesey Aluminium Metal Ltd. He stated that the levy would account
for an increase in costs at the Holyhead smelter of 12% of the selling
price. (MetalBulletin)
- NSA Sale- Southwire announced in April that it intends
to sell Copper Division Southwire (CDS) and NSA, its primary aluminum
smelter in Hawesville, Kentucky, although a sale is not expected to
go through if Southwire does not get the right price. Michigan Avenue
Partners has expressed interest in the sale. Lazard Freres & Co.
has been hired as financial advisor. (Platt'sMtlWk, Business Wire) Southwire
has entered into confidentiality agreements with prospective buyers,
yet to be publicly disclosed, of its copper refinery, copper rod plant
and NSA. (Platt'sMtlWk) A source close to Southwire said that the company
is hoping to secure supplier agreements with whomever acquires the assets.
Assistant VP Eddie Adams and gm Jeff Herrin have been reassigned from
NSA to other parts of Southwire's business. (MetalBulletin) Southwire
has split the top executive duties and eliminated 258 positions in an
effort to streamline management and lower overhead costs. The majority
of the eliminated jobs are in sales, general and administrative positions.
(AMM)
- BPA Sued - Aluminum producers in the US Pacific Northwest have
asked the US Circuit Court of Appeals to review BPA's sales strategy.
They anticipate not having access to enough electricity and want to
begin negotiations now for contracts to take effect in 2001. (Platt'sMtlWk)
The companies filing suit feel that the BPA is not doing enough to ensure
that power will be available. (EnalPanel) As of mid-June, the BPA
had not reached an agreement with smelters in the Northwestern USA regarding
power contracts covering 2001 to 2006. The BPA final offer was 1,500
MW at an average price of US$23.50/MWh. The US Energy Secretary has
supported the smelters' efforts to receive a significant allotment of
low-cost power from the BPA as a result of lobbying by the USW union.
The union has warned that efforts to charge market rates to smelters
in the region could have the same effect that such efforts had in the
Tennessee Valley a decade ago. In that case, nine aluminum plants closed.
Regional utilities which buy power from the BPA for the residential
and small-business markets say that their customers would be charged
higher rates, especially during times of lower aluminum prices. (EnalPanel)
Most of the aluminum producers in the US northwest have signed letters
of agreement to purchase a total of 1,170MW of firm power at 23.5 mils/kWh,
or at a variable rate tied to aluminum prices, in five-year contracts
that start Oct. 1, 2001. Remaining energy requirements will be purchased
from the market. The new fixed-price contracts will be take-or-pay.
(Platt'sMtlWk) Environmental groups do not favor the agreement, believing
funding for protection of fish and wildlife will be cut. Other regional
utilities believe residential customers will not have less access to
low-cost power. (EnalPanel) The Oregonian (a newspaper out of Portland,
Oregon) has estimated that annual costs for efforts to save fish in
the northwest are approaching $1 billion, without much success. (Oregonian
06/28/99)
- CVG privatization - After extensive talk of new privatization
plans, including the decision to split up CVG's aluminum plants and
deal with them separately, Venezuela has again put off the starting
date for another effort to sell a controlling interest in its aluminum
industry, possibly until some time in 2001. (AMM) CVG has reduced its
operating costs in the past ten months. Venalum is producing an average
profit of $151/mt of raw aluminum produced. Alcasa has reduced its operating
deficit from around $700/mt during most of 1997 and 1998 to a present
loss of $151/mt of aluminum produced. The CVG complex has reduced its
payroll, dropping 839 persons in 1998 and 140 workers in the first quarter
of 1999. (Platt'sMtlWk) The closure of the Pivensa aluminum mini-mill
at Puerto Ordaz leaves Venalum without a sizable convenient customer,
as well as cash-pinched. Pivensa's debt to Venalum is said to be about
$25million. (AMM)
- Podgorica (ex-Titograd) - Podgorica is operating
at its target capacity despite a brief interruption to raw materials
deliveries. The smelter's production is expected to reach 95kt to 100kt
this year. (Platt'sMtlWk)
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