Roy Harvey
Analyst · Morgan Stanley. Please go ahead
Thanks, Bill. I’d like to start my comments by focusing on the long-term fundamentals of our markets. While the world is currently in a period of heightened uncertainty, the outlook for our industry remains very positive and this view isn’t merely supported by the fact that year-over-year demand is consistently increasing. That’s been the case for more than a decade. Rather, I’d like to highlight the structural changes driven by evolving energy markets on both the demand and supply sides of our industry. Both the source and cost of energy supplies help determine whether a facility can compete economically. Renewable energy provides a further differentiation through lower carbon emissions. Still, decarbonization is not just a facet of energy sourcing, and therefore, Aluminum production, but it is also embedded in the choices of our customers, and ultimately, for their final consumers. For example, one tactic to reduce carbon emissions is to reduce vehicle weight by replacing heavier metals with lightweight Aluminum, especially during the transition from internal combustion engines to electric vehicles. On the left-hand side of the slide, you will see that the amount of Aluminum in passenger vehicles in North America, as one example, is expected to increase by nearly 25% by 2030 using 2020 at the baseline. This change is primarily driven by the transition to electric vehicles, which on average, contained 40% more Aluminum than vehicles powered by internal combustion engines. Another important end-use market for Aluminum is packaging. Demand in that sector is expected to increase steadily and consistently. Aluminum is a sustainable choice for packaging due to its recyclability, its low weight and the format that makes it easier to ship, all of which helps reduce emissions. Next, both the generation and transmission of solar and wind power will require more Aluminum than other forms of energy, such as thermal, hydro or nuclear. Solar generation, for example, requires approximately 13 metric tons of Aluminum per megawatt of generating capacity compared to coal that only requires about 1 metric ton. While these examples are meant to illustrate my point, they demonstrate that demand for our commodities should continue to grow long into the future and is positively supported by decarbonization and the trend toward renewable energy. Now moving to the right-hand side of the slide, to reduce their carbon footprints, we are continuing to see Aluminum producers move to renewable power and away from coal, which is still the predominant source of energy in the global Aluminum industry today. Renewable energy sources, as we know, are constrained by availability, posing a limit for capacity to grow in the future. Of the 15 million metric tons of new primary smelting capacity that we believe is required by 2030, only 6 million metric tons are currently expected to be sourced with renewable energy. This is one area where Alcoa is already a standout. 81% of our global smelting portfolio is powered by renewables, mostly hydro and some wind and we are continuing to work on boosting that percentage in the years ahead. Finally, energy is also affecting the amount of Aluminum produced. Today’s Aluminum market has been significantly impacted by the European energy crisis, which is rooted in Russia’s invasion of Ukraine. Due to the increased power costs in Europe, it has been reported that more than 1 million metric tons of Aluminum production have been taken offline, with another 1 million metric tons under threat. The combination of increased uncertainty, weakening European demand and the global energy market distortions created by the ongoing Russian aggression in Ukraine demonstrate how quickly our energy markets, and therefore, the Aluminum industry can be impacted. In March of this year, our company made the proactive decision to cease buying raw materials from or selling our products to Russian businesses. That had an adverse financial impact on our business, but it was the right decision to make and now we are seeing an increasing number of customers implement this same policy. We believe governments should consider sanctions on Russian metal as the distortions in the energy market can be directly linked to the invasion of Ukraine. And in the meantime, Russian companies continue to produce and sell their metal, while North American and European producers are curtailing smelters amidst declining Aluminum prices, skyrocketing energy costs and supply chain issues, and thus, we believe urgent action is necessary by the U.S. and its allies. Now let us take a closer look at what is happening in our industry today where, again, energy is the key driver. The fundamental difference in this downturn is that it is being driven by an energy crisis centered in Europe, and thus, its first impact has been to electricity intensive industries such as Aluminum smelters. And thus, what we see today is an industry with significant supply challenges, followed by impacts to Aluminum demand as downstream costs continue to inflate and significant uncertainty weighs on economic growth. The chart shows data on historical trends for Aluminum supply and demand, including days of consumption for inventories held in LME warehouses. The data illustrate the uniqueness of this energy driven downturn. During the global financial crisis in 2008 and the COVID-19 pandemic in 2020, sharp downturns in global demand drove significant increases in inventories and sharp declines in the price of Aluminum products. I would note here that we have seen significant delivery of metal to LME warehouses over these last few days. We believe that this metal represents material that was already held in global inventories and is thus more representative of a shuffle between inventories rather than simple overproduction. Anecdotally, we continue to see strength in demand for most of our value-add products in North America and Europe, while noting uncertainty in demand for some products, particularly for billet in Europe. These facts help to explain the environment where we find ourselves. Raw material and energy prices are at historic highs, while prices have notched downwards based on continuing uncertainty. We can further illustrate this situation by examining global cost positions. For Chinese smelting capacity that is operating, we believe that between 20% to 30% is operating on a cash negative basis, in the rest of the world, between 45% to 55% of Aluminum production is currently operating under water. In Alumina, the percentage of refineries operating on a cash-negative basis is less than what we are seeing in metal but still significant. In China, approximately 25% to 35% of refineries are operating at a loss, and the rest of the world is lower, ranging from 10% to 20% operating on a cash negative basis. Now let’s talk about our specific impacts focused on two locations and what we are doing to address the challenges. In 2021, energy comprised approximately 27% of our company’s total Alumina refining costs. In Aluminum smelting, electricity costs were approximately 31% of the total cost of production. Company-wide, our two greatest areas of exposure to spot energy prices are the Lista smelter and the San Ciprián refinery, both in Europe. Let’s start first with our smelter in Southern Norway. While our company overall only has about 5% of its smelting portfolio exposed to spot energy prices, this smelter represented approximately 65% of this spot exposure in the third quarter. In fact, we had some periods when we were paying as much as $600 per megawatt hour and the site lost $47 million in EBITDA in the third quarter. In August, we made the decision to curtail one of the sites, three potlines, to mitigate the high cost of energy. Importantly, we also negotiated an agreement with our power utility to provide more predictable energy costs throughout the remainder of the year and into 2023. We expect the site to see significant improvements in the fourth quarter as a result and we are continuing to monitor the situation. Next, let’s turn to the San Ciprián refinery. In January of this year, one of San Ciprián’s two natural gas suppliers terminated its contract that supplied approximately 50% of the refinery’s natural gas demand until June 2022 and 25% from July to December of this year. While we have been negotiating new contracts, we have been exposed to spot rates since February. The cost of natural gas in Spain have been exorbitant. In the third quarter, we began to cut our production at this facility so we would use less gas and avoid these high costs. At the end of the quarter, we had adjusted production to approximately 50% of the site’s 1.6 million metric tons of annual capacity. However, gas prices continue to escalate eroding to savings from reduced production. In the third quarter, the San Ciprián refinery lost $69 million in EBITDA due to these conditions. The high volatility for gas cost in Spain makes future estimates difficult to predict. We are actively reviewing the location’s operating levels and commercial options, including tittering further adjustments to production, as well as evaluating options for support. We will continue to look at ways to improve the cost structure at both facilities. Let me now discuss some other items that we are working to improve. In our global smelting portfolio, we are continuing to address our overall capacity, including progressing with restarting previously idle capacity at two sites. In Brazil, we continued to add new operations at the Alumar joint venture where the restart continues to progress. Alcoa’s fully owned subsidiary in Brazil owns 60% of the Alumar smelter or 268,000 metric tons, with the remaining percentage belonging to South32. We expect most of the smelter’s capacity to be operational by the end of the first quarter of 2023. Separately, in the United States, on July 1st, we safely curtailed one of the three operating smelting lines at our Warrick facility. We experienced staffing shortages to the smelter and the decision to curtail one line allowed us to focus on stability for the two remaining operating lines. In Spain, we have now reached two agreements for wind power that would support 75% of the energy needs for the restart of the San Ciprián smelter. We reached an agreement in 2021 to curtail the smelter until early 2024 to work on a plan to develop an energy solution, which will depend on a viable Spanish energy framework and a permitting process for wind farms. It’s good to see continued progress on this solution, but there is still much work to be done. Next, turning to the right-hand of this slide. In Australia, we are now implementing plans to improve the performance in our refinery system so we can recover from lower volumes that were due to unplanned outages and maintenance. We are bringing a renewed focus on system-wide performance, including our people, processes and equipment. From a people perspective, we are actively working to effectively manage the impacts of accelerated employee turnover due to higher than historical levels of attrition and retirement. In our processes, we are working to redeploy maintenance and operating strategies for all equipment and make our reliability excellence program even more friendly to users. So it can support a system that includes visible and relevant metrics, which are tracked with clear trigger levels for escalation. Also, we are working to address the challenges from lower grade Bauxite delivered from our colocated mines. Variability in Bauxite grades requires processing higher mud and sand loads, and removing higher levels of impurities, resulting in lower production volumes and higher costs. While we have a focused effort and a clear understanding of the drivers for improvement, it will take some time to restore stable operating performance at full system capability. Moving on to the next item, in July, we announced a return-seeking capital project to increase casting capabilities at our Deschambault smelter in Canada. That new ingot production line will meet needs for value-add products such as foundry alloys and is expected to be complete in the first quarter of 2023. Looking towards the future, we have numerous initiatives that support our strategic priority to advance sustainably and our vision to reinvent the Aluminum industry. We have now added all of our locations in Brazil to the rigorous certification process from the Aluminum Stewardship Initiative, which is the most comprehensive in the industry. Last month, we also introduced our new ExtruStrong alloy that is intended for the lightweight and high-strength applications that use billet. We also received recognition last month for an existing alloy that is gaining traction in one piece casting known as mega or gigacastings for the automotive market. Most of the world’s Aluminum alloys were first developed by Alcoa and we have decades of metallurgy and engineering leadership to help our customers solve challenges, including developing light weighting solutions for electric vehicles. In closing today, I want to quickly reiterate a few important items. Our balance sheet is solid, our proportional net debt is low and we finished the quarter with $1.4 billion of cash on hand. This quarter, we also continued to provide capital returns to our stockholders in the form of a quarterly dividend and completed stock purchases. As we move forward, our three segments remain well positioned on a cost basis and we are addressing operational improvements across our system, including in our Australia refining system. We are working to deliver today as we prepare for tomorrow, including realizing our vision to reinvent the Aluminum industry for a sustainable future. We have a robust technology roadmap of breakthrough R&D projects that have the potential to decarbonize the Aluminum industry and differentiate Alcoa. We are proud of the existing innovation and problem solving that we bring every day to our customers, including the industry’s most comprehensive portfolio of low carbon products in our Sustana line. Now Bill and I look forward to taking your questions. Operator, who do we have on the line?