Roy Harvey
Analyst · Cowen and Company
Thanks, Bill. To start, I'd like to provide additional details on the rationale behind our decision to restart aluminum production at our Warrick smelter in Indiana and explain why this was the right decision for our business. To recap the details, the restart is expected to be complete in the second quarter of 2018 and includes 3 of 5 pump lines. Restart expenses are estimated between $30 million and $35 million in second half of this year. And lastly, we plan to record an after-tax benefit in the third quarter to reverse our accruals from the previous decision to halt production at the smelter.
To be clear, the decision to restart production at our Warrick smelter was not about adding more capacity to the aluminum market, rather we based our decision on 3 things.
First, our ability to more fully utilize the assets at the integrated site, which includes the smelter, a rolling mill and power supply. Initially, as you may recall, the assets of Warrick operations would've been divided as part of the company's separation. The rolling mill would've gone to our former parent company. Meanwhile, the power plant and the idle smelter would be with Alcoa Corporation. Now as one integrated location, we can increase the efficiencies at the site. The demolition of the smelter had not yet started and our environmental operating permits remained effective.
Second, we evaluated the ability to restart the site with minimal capital expense while directly supplying the mill with molten metal. Essentially, the chosen solution was the optimal use of capital to ensure our Warrick mill was fully supplied with high-quality metal at the lowest possible cost.
Third, we also considered that this restart would make our rolling mill more competitive in the canned sheet market through operational efficiencies as the rolling mill prepares to meet expected growth in production volume. Importantly, the decision is also aligned with our strategic priorities. We can reduce complexity by more fully utilizing the assets at an integrated site and will drive returns due to cost synergies and the expected volume growth for our rolling business at Warrick.
Turning now to our fundamental outlook for bauxite, alumina and aluminum. We continue to expect our markets to remain stable in 2017. For bauxite, we continue to see the market in relative balance. Our view anticipates that the Chinese will continue to stockpile bauxite strategically throughout this year while in search of new sources of high-quality, consistently delivered material. To maintain our view that China is likely to grow a strategic bauxite stockpile due to refining, we maintain our view that China is likely to grow its strategic bauxite stockpile due to refining expansions in China, offset by production growth in Guinea and the potential export of the remaining port stocks in Malaysia.
For alumina, our forecast has somewhat improved with a slight deficit compared to what we anticipated last quarter. We continue to expect that China will curtail refining capacity during the winter heating season for environmental reasons, and we are forecasting slightly stronger global alumina demand driven by additional Chinese smelting production.
In aluminum, we continue to see strong demand, and we are increasing our global aluminum demand growth outlook from a range of 4.5% to 5% last quarter to a range of 4.75% to 5.25% this quarter. This revision includes a slightly higher 2.75% to 3.25% demand growth forecast outside of China, driven by strong European demand where we see improved forecast for Rolled Products and extrusion and production.
In China, we are maintaining our demand growth figure at 6.5% to 7% on expected strong growth in electrical and machinery applications and in the transportation and construction markets, which are the 2 largest aluminum-consuming sectors. However, this increased demand is offset by higher expected supply in China, so we maintain our general view of a modest aluminum surplus this year.
With our aluminum supply forecast still projecting a modest surplus, I'd like to spend a few minutes describing policy activities in China. The Chinese government has made 2 significant announcements about potential supply reforms in aluminum through 2 different government agencies.
First, the Chinese Ministry of Environmental Protection announced the reduction of metal production in select cities to improve air quality during the winter heating season. Second, the Chinese National Development and Reform Commission announced that aluminum smelters operating without proper licenses will be curtailed. These actions could potentially impact about 6 million metric tons of capacity per annum. If all of that occurs, we could see a reduction in China's 2017 aluminum surplus. However, only about 800,000 tons per year have been curtailed so far, and our 2017 outlook assumes that these initiatives will have only a moderate impact this year. It is clear, though, that the effects of these policies could be significant, creating risk to both the upside and the downside relative to our forecasts. The potential for meaningful positive change remains, but at present, we maintain our 2017 outlook for a continued surplus of aluminum in China.
As we continue to see strength in both aluminum demand and, more importantly, aluminum supply, we have also been experiencing raw material cost inflation over these last critical months. In our aluminum and alumina markets, particularly, we have seen steep increases from last year in the prices for caustic, calcined coke and pitch. As you can see on the right side of this chart, caustic prices have increased by more than 50% compared to the year-ago quarter, pitch prices by more than 25%, and coke prices by more than 10%. We expect these increases to continue, and they are the principal basis for our net performance guidance change. However, this inflationary environment also represents an opportunity for operators, like Alcoa, who are more efficient and with access to high-quality raw materials.
Let me illustrate how this helps with a deeper dive into caustic soda's impact. In the last year, we have seen average caustic prices, a key input in alumina production, climb 54% from the second quarter 2016's average of $295 per metric ton to this quarter's average of $455. Alcoa is an efficient consumer of caustic per ton of alumina produced, using less than other ex China refineries, and essentially half as much as Chinese refineries. This difference is created by 2 things: the characteristics of the bauxite supplied by our mines and our process control systems that optimize our refineries. As a result, our refineries see less of a cost increase than most of the market. Higher caustic consumers on the right of the cost curve experience cost inflation faster than those in the left, steepening the cost curve and supporting Alcoa's cost position.
On this slide, we quantify the approximate impact from the $160 per metric ton increase in caustic prices experienced over the last year, showing Alcoa refineries cost improving $12 per ton relative to those of Chinese producers and $3 per ton versus the rest of the world average.
Increases in input costs are an unfortunate characteristic of a stronger market. However, we believe Alcoa Corporation can create 3 advantages in these situations: number one, strong procurement processes in the advantage of the scale of our purchases blunts the impact versus the general market; number two, the efficiency of our operations strengthens our competitive position; and number three, the attractiveness of our low caustic consumption bauxite is enhanced in our own refineries but also as part of our third-party sales portfolio.
As we enter the second half of the year, we remain focused on our 3 strategic priorities which we factor into each of our decisions. We seek to reduce complexity, drive returns and strengthen the balance sheet. To reduce complexity and improve the operational efficiency of the Warrick integrated site, we are restarting some aluminum capacity at the Warrick smelter. It will provide a direct supply of molten metal to the site's rolling mill as it prepares for production growth, which optimizes our use of capital in this business and will also serve to drive returns. We will continue to pursue opportunities to further streamline our business as the year progresses. We delivered solid profitability in the second quarter and generated $1 billion in profits for the first half of the year.
As we get a better view of the second half, we have tightened our outlook for 2017. We expect our business to remain strong and to generate $2.1 billion to $2.2 billion in adjusted EBITDA this year, excluding special items. The strength in our markets is creating an increase in input costs, and we've adjusted our net performance outlook for 2017 to negative $50 million. And lastly, we increased our cash position to $954 million last quarter and improved our working capital, both serving to strengthen our balance sheet.
Our 3 strategic priorities have guided our actions so far in 2017, and we are making a concerted effort to drive these priorities deep into the organization at every plant and every resource unit by encouraging our employees to pursue all opportunities that can further strengthen Alcoa.
With that, I'd like to invite any questions that you might have either for Bill or for me.