Roy Harvey
Analyst · Citi. Please go ahead
Thanks, Molly. Next, I'd like to provide some updates from our operations across the globe, beginning with Western Australia. As I said last quarter, we're continuing to work with a host of government agencies on the approvals process for our annual mine plan. Our Mine Management Programs or MMPs are normally approved annually on a five-year basis. Separately, the Western Australian Environmental Protection Authority or EPA is considering whether to conduct additional environmental review on these MMPs. The resolution of our mine approvals does not have a fixed timetable, but we are working to constructively address stakeholder needs and expectations in a timely fashion. This is a key priority for our Company and we're focused on doing what is necessary to secure approvals. We are increasing controls to protect drinking water sources, further stepping up mine site rehabilitation, and enhancing the management of social impacts. This requires discussion and action with various government agencies. So to give this complex regulatory process appropriate time, we are now mining lower-grade bauxite in previously approved areas. As Molly just pointed out, using lower-grade bauxite has a cost. It means using more raw materials and producing less alumina per ton of bauxite. In the second quarter, this unfavorably impacted Alumina segment adjusted EBITDA by $45 million. This is better than we originally expected due to slightly higher bauxite grades and good operational practices. As we look to future quarters, bauxite grades will continue to vary. We expect that it could take nine months to 12 months to transition to new mine areas once approved and improve the bauxite quality sent to our refineries. Thus, the expected impact of these lower bauxite grades will stretch into at least mid-2024. Next, let me provide some more detail on what we're awaiting from the EPA. The authority has indicated it could decide by the end of this month whether to proceed to the next stage in its consideration process, which would be a public comment period. If that occurs, the EPA would then decide whether to conduct additional environmental reviews on all or part of our MMPs, and if so, at what level. We support the authorities process for future major mine extensions, but we believe the current statutory process for our MMPs provide appropriate environmental and social protections in existing mine regions as part of a transition period. As an example, we've already proactively initiated assessment by the EPA for two future regions, Myara North and Holyoake. Finally, on this issue, I want to stress that I'm very proud of how our team has been operating through different and difficult conditions. We have some of the world's most highly-skilled people and we have strong operating processes. We are working together to operate safely, stably and efficiently, and we are pooling our collective knowledge to secure our approvals and we will strive to reduce the impact of lower-grade bauxite in the coming quarters. Now, let's turn to some key operational items across our two segments. First, in Alumina, some may recall that we had a failure in the first quarter on a ship-to-shore conveyance system that unloads bauxite for the Alumar refinery in Brazil. Our teams worked to successfully make repairs and restore bauxite flows. I was impressed by how our team quickly and safely recovered. Then in June, we proactively began a project to replace a large bearing on the alumina ship loader at the same location. This four-meter bearing supported the 820 metric ton structure. With much planning and coordination, the teams safely executed this major repair in eight days working with a specialized contractor. This well-coordinated effort enabled the loading of alumina ships to quickly resume. We didn't miss any customer shipments because of this work, and it demonstrates our push to move to proactive rather than reactive measures to keep our facilities at peak capacity. Meanwhile, in Spain, we continued to work to find the optimum production levels at the San Ciprián refinery. Considering market conditions, it is currently operating at about 50% of its capacity. In the second quarter, a modest increase in production at this facility partially offset some reduced production at Alumar and in Western Australia where our Kwinana refinery is operating four of its five digesters and where we finished a major maintenance project at Wagerup. In our Aluminum segment, six of our smelters are operating at full capacity with high production levels. Meanwhile, the smelters that have reduced production volume due to partial curtailments, Lista in Norway, Portland in Eastern Australia and Warrick in the United States, are all running stably at those levels. Meanwhile, the ongoing restart of the Alumar smelter is progressing with an intentional and deliberate process to ensure that every part of that restart is stable and operating well. We now have greater than 60% of that site's total capacity operating and we're also continuing to invest per our agreements to support the phased restart of the San Ciprián smelter beginning next year. As I said earlier, we are enabling our operational leaders to spend more time in the field. This will bring an increased focus on safety, more fruitful dialogue and interactions with our employees, and a renewed drive to find productivity and efficiency improvements. Now, let me provide our current view of the overall market for aluminum and discuss Alcoa's position as a producer of choice, both today and in the future. The global aluminum market is currently showing some mixed signals, with limited supply growth in divergent demand trends, depending on specific end markets. In China, some previously curtailed capacity is restarting in Yunnan province, but there are questions about hydroelectric power availability and stability for both the Yunnan and Sichuan provinces where China's low-carbon aluminum suppliers concentrated. In the rest of the world, conditions are still not favorable for restarts and there is very little new capacity ramping up. On the demand side, China is expected to see growth this year for aluminum used in electrical grid investments and vehicle production. The country's weaker real estate market, however, has slowed demand for aluminum in the construction sector. In the rest of the world, we see strong year-on-year growth in the automotive market, particularly in Europe and North America. The same is true for electrical applications, although construction and packaging have slowed this year as a knock-on impact from higher interest rates, inflation and destocking trends. The long-term outlook remains positive as the world will need more aluminum from both primary and recycled sources for existing users as well as global decarbonization efforts, including the transition to renewable energy, more electric vehicles and recyclable packaging. Recovery is expected in the construction market long term as developing markets see interest rates stabilize with continued urbanization trend. While more aluminum will be needed, China is still expected to continue to enforce its 45 million metric ton per year capacity cap, which it will approach in the next year or two. Also, China's existing low-carbon capacity is likely to face ongoing challenges related to hydroelectric power reliability. In the rest of the world, we also see limited supply growth, especially in the production of aluminum made with lower carbon emissions. The announced projects in the pipeline are not expected to be enough to meet demand of our critical metal. Market conditions are expected to be favorable for aluminum in the future and Alcoa will also remain well-positioned as a low-carbon primary aluminum producer of choice in key regions. We are a domestic producer in North America and Europe, which are both deficit regions where customers prefer domestically and responsibly produced metal. Now, I'd like to return to an issue that we discussed in prior quarterly earnings calls, the continued risk for the London Metal Exchange or LME related to Russian origin aluminum. In the past two years, we've seen customers move away from Russian metal, particularly in Europe and North America. Also in Asia, many banks that traders use are not financing Russian metal. Many of these customers in this region are served by these small local traders. The dynamic regarding Russian origin aluminum should raise alarm as we've previously stressed at our last earnings call in April. The situation has since worsened. Russian stocks in LME warehouses recently reached an all-time high concentration, representing 80% of total LME aluminum stocks as of the end of June. The physical stocks in LME warehouses are the basis of the published LME aluminum price, which is widely used as a price reference in global aluminum contracts. Because those stocks are now predominantly Russian origin metal, which is unwanted by much of the world, it is difficult to have confidence that the LME exchange price matches the true physical price for non-Russian aluminum that customers largely require. We have continued to reiterate our position to the LME that should take immediate action to delist Russian origin metal. There is a real risk here that if the LME delays acting, a stockpile of metal that is under extremely punitive tariffs and/or self-sanctioned will continue to build up. That would then cause this unwanted metal to inappropriately influence the global benchmark on pricing, damaging the integrity and relevance of the LME's aluminum contract. Returning to Alcoa. We continue to see growing sales in our Sustana product portfolio as customers seek metal made with lower carbon emissions to reach their own sustainability goals. This year, we expect to see our sales of EcoLum brand to reach 40% of our total European production, which would be a 60% annual increase. We also offer a wide range of value-add aluminum products that serve a diverse end market, and we have seen the same demand trends that I discussed earlier play out in our order book. Our participation in a variety of end markets allows us to benefit from diverging trends as we can flex our value-add production to adapt to different market conditions across the various end markets. Now, let me discuss opportunities for our business. While we are currently working through challenging market conditions, we look forward to recovery and the expectation of growth in the long-term aluminum demand. And as we look toward this future, I'd like to stress not only the value of our current products such as our Sustana offerings in alumina and aluminum, but the value that is embedded in Alcoa as a pure-play innovations-focused aluminum company. We are well-positioned as the world moves to a decarbonized economy. The future requires more aluminum, which is a material of choice due to its lightweight, recyclability, durability and strength. And with customers increasingly focused on the need for responsible production, Alcoa is the company to deliver due to our environmental, social and governance practices. We know all metal is not created equally, and our focus on sustainability is what will differentiate us from other global competitors. That's why we're working so diligently to adapt to increased expectations in Western Australia, which will allow us to optimize our bauxite mines and return to higher-grade ore as soon as possible. And this focus on community engagement and responsible practices can also be applied globally across our mines, refineries, smelters and casthouses. Developing these systems not only helps us to surmount these immediate challenges, but it will also provide the roadmap to operating responsibly long into the future. Meanwhile, we're focused on finishing some key projects, including returning to Alumar refinery to normal production after the repair and maintenance projects I discussed earlier. And our focus on driving simple yet effective and proactive maintenance programs will ensure we are operating stably across our portfolio. We are also continuing to increase production by our operational improvements that allow us to creep our capacity, and we're investing in next-generation casthouse technology to grow our value-add product capabilities and capacity. Two recent examples of this include a new casting line at Deschambault to cast smaller ingots that will allow the smelter to produce alloys from Alcoa's award-winning EZCast family. And at our Bécancour smelter in Canada, we're working to install technology that will improve the surface quality of slabs, helping customers improve their recovery of finished products. It will also help us attract new customers, specifically in the packaging and automotive markets. For our production levels, I noted earlier that we're progressing with the Alumar restart and we're investing for the phased restart of the San Ciprián smelter in Europe and its 228,000 metric tons of aluminum capacity currently idled. We also have some other curtailed capacity both in refining and smelting, and we have options that will continue to evaluate should market factors and overall economics improve. Finally, we continue to work on next-generation technologies that have the potential to further differentiate our products from our competitors. These three projects, ELYSIS, our Refinery of the Future initiative and the ASTRAEA scrap purification process, are all part of our technology roadmap. These remain under development and will help us on our journey to decarbonize and achieve our net zero 2050 ambition. As you recall, ELYSIS is a partnership company based on process innovations that Alcoa first developed at the Alcoa Technical Center outside of Pittsburgh. The process eliminates all direct greenhouse gas emissions, replacing those with pure oxygen. ELYSIS is currently working to ramp-up this technology to commercial scale, including the development of larger smelting cells that would operate at 450 kiloamperes at the end of an existing potline in Quebec. Also, unlike some competing technologies, the ELYSIS process has already produced commercial-grade aluminum at research scale and has been used in end products from such brands as Audi and Apple. We also know that the final carbon footprint of aluminum is not only determined by the electrolysis process itself, but also by the energy source in the alumina that is used to feed those smelting pots. That's why we're also working on the Refinery of the Future which will help to improve a refinery's carbon footprint, reduce water usage and reduce bauxite residue. This includes electric calcination, mechanical vapor recompression and other developing technologies. Meanwhile, we're also continuing our R&D work in our ASTRAEA technology, our proprietary scrap purification process that can economically separate aluminum from other non-ferrous metals and impurities. It could provide metal of a purity level that would far exceed the quality of what most commercial smelters can produce. In closing, we continue to work to optimize our portfolio so we can succeed regardless of market cycles. We are focused on continued improvement and we have a strong balance sheet with $1 billion of cash, allowing us to drive improvements during a challenging market and to focus on operational excellence. Our priorities are clear, securing our mine approvals in Western Australia, driving stability across our operations, adapting to a volatile aluminum market and ensuring we operate the right portfolio for today and tomorrow. Also, we remain a supplier of choice and we're proud that customers come to us for solutions, including our recently announced contract with Emirates Global Aluminium. We not only sell low-carbon metal through our Sustana mine, but we are the only producer in the aluminum industry that also markets and sells a low-carbon alumina brand. These products, which include EcoLum, EcoDura and EcoSource, can help producers lower their carbon footprint by switching to our material. EcoLum is our low-carbon aluminum. EcoDura contains recycled content. And EcoSource is our low-carbon aluminum. We are encouraged to see demand and sales growth in this brand family. Albeit still a small percentage of our overall sales, still the growth demonstrates the rising demand for low-carbon technologies. This shows the strong potential and value in the work we're doing to bring forward our research and development programs and reinvent the industry we created. Molly and I are now ready to take your questions. Operator, who do we have on the line with our first question today?