Peter Cunningham
Analyst · JPMorgan
Thank you, Jakob, and good morning, and good evening, everyone.
Let's start by taking a look at the numbers. We've announced a solid set of results following robust demand for all our major commodities. And of course, this is set against the context of record prices and results last year. The 10% decline in revenues was driven by prices, primarily iron ore. This was offset in part by aluminum, where we saw strong pricing for the first 5 months of the year until markets changed in June. While the business remained resilient, cyclical cost inflation accelerated during the half. This led to some margin compression with $15.6 billion in underlying EBITDA and $10.5 billion of cash flow from operations. Free cash flow of $7.1 billion was after $3.1 billion of capital expenditure and a modest outflow in working capital, reflecting elevated prices for raw materials in aluminum inventory. Underlying earnings of $8.6 billion gave rise to a return on capital of 34% and led to us declaring an interim dividend of $4.3 billion, a 50% payout. Higher rates of inflation, increased closure liabilities, resulting in a $400 million pretax noncash charge to underlying earnings. We expect a similar impact in the second half under our existing policy if current rates of inflation persist.
We were very glad to reach a settlement with the Australian Tax Office on all tax issues stretching back over the last 12 years. The settlement had a limited impact on our half year results, but we will pay just over AUD 600 million in the second half of the year. Importantly, the settlement gives us certainty on our transfer pricing arrangements between Australia and Singapore for the next 5 years. There were no material unusual items in the first half, so net earnings were very similar to underlying earnings.
Let's now look at our key markets. Iron ore prices dropped 24% from the record highs we enjoyed in 2021 first half. In a context of continued softness in the Chinese property market and COVID restrictions, steel demand remained relatively robust. Prices were supported by weaker supply with flat production from the majors and disruption to some other sources of supply, in particular, from Russia and Ukraine. There was also disruption in the aluminum market, mainly from high energy prices which impacted supply from late 2021 and resulted in very low physical stocks. This pushed prices up 37% on average, although new capacity in China coupled with lower consumer sentiment elsewhere have reduced prices in the second quarter. The copper price has also been quite volatile. After a record first quarter, uncertainty in global -- in the global economy has weighed on prospects. A long position of just over 1 million tonnes in the copper market fully unwound in the second quarter.
Let's now take a closer look at the key drivers of EBITDA. As ever, commodity prices were the biggest movement, lowering EBITDA by $3.4 billion in aggregate. Iron ore was $5.7 billion negative, partly offset by higher realized pricing for aluminum to the tune of $1.9 billion. As you would expect, we are not immune to inflation, reflected on the left of this chart, with PPI, rising energy costs largely attributed to diesel and higher market-linked prices for raw materials in aluminum all having an impact. In aggregate, these factors lowered EBITDA by $1.5 billion.
If we look to the right of this chart, you can see the other impacts were relatively well contained, demonstrating the resilience of our operations. Sales volumes were reasonably flat overall, even though Kitimat was only operating at 25% of capacity. And we expect it to gradually recover over the second half. Higher iron ore sales from our portside operations in China were an important contributor with inventory reduced by just under 5 million tonnes this half. We did incur additional costs at Kitimat and Boyne as we recovered from disruption. And we also increased our resourcing in our iron ore business to support the ramp-up of Gudai-Darri and investment in the pit and health and system reliability. The impact of other cost increases overall was relatively muted, reflecting disciplined cost control across the business. Looking forward, a stronger U.S. dollar represents a decent tailwind to help offset further cost inflation in the second half.
Now on to our productivity drive, which is gathering momentum. We continue to successfully roll out the Rio Tinto Safe Production System and have 15 deployments at 11 sites compared to 5 sites at the start of the year. Each deployment addresses a different bottleneck. For example, at IOC and Kennecott, we focused on the concentrator. And at West Angelas, on the drill fleet. We are seeing Rio sustainable improvements in operating performance as well as in safety and employee engagement.
To give you an indication, in the half, there has been a 9% year-on-year improvement in average operating times across processing plants and drills at deployment sites versus the same period of 2021. Our focus is to scale it up to a multiyear program covering all assets across the group. And we are on track to meet our 2022 target of 30 deployments at 15 sites, and we'll build on that in 2023.
Let's now look at each division, starting with iron ore. Shipments were 2% lower due to COVID-19 disruptions and much higher-than-average rainfall in late May. However, we saw a notable reduction -- a notable recovery in second quarter production supported by our focus on mine pit health and Gudai-Darri's commissioning in June. We did have higher levels of SP10 following delays in mine development sequence, which fed through to average price realization. Our unit cost for the half, at $21.20 per tonne before COVID-related costs of $0.60 per tonne were just above full year guidance driven by the lower volumes and higher input prices.
The team continued to progress new ways of working with Traditional Owner groups. In May, the PKKP Aboriginal Corporation entered into a co-management heads of agreement with us. This is an important step towards rebuilding our relationship with the PKKP people and sets out how we will work in partnership on a co-management approach to mining activities in PKKP country. And following an agreement with the Yinhawangka people Aboriginal Corporation on a new co-design management plan earlier this year, we have received WA Environmental Protection Authority support for the development of Western range, a significant milestone for the project.
Overall, financials were strong with operating cash flow of $8.5 billion and free cash flow of $7 billion. We are advancing the studies on the new replacement mines that we first mentioned at our investor seminar last year. Sustaining CapEx remains an important focus, unchanged at around $1.5 billion per year. Meanwhile, our energy transition program is gathering momentum with a proposed 100-megawatt solar farm near Karratha, forming part of our 1 gigawatt renewable energy plan to replace gas. Planning is ongoing, and we continue to engage with the WA government, Traditional Owners and other stakeholders.
Moving on to aluminum, where we beat financial records with EBITDA of $2.9 billion. We benefited from higher market and product premiums in addition to the strong pricing environment for primary metal and alumina at least for the first 5 months of the year. This was partly offset by higher input costs for key materials such as caustic soda, coke, pitch and anodes, leading to an increase in cash costs. We generated $2.1 billion in operating cash flow, reflective of the higher EBITDA net of a $500 million working capital build. Free cash flow increased by 65% to $1.5 billion.
Now we did have some operational challenges in the half. Kitimat ran at less than 1/4 of capacity following strike action last year. A controlled restart took place at the end of the second quarter with ramp-up progressing over the year subject to plant stability. We also had some disruption of Boyne, where we have now stabilized production. And the sales that were taken offline will be ramped up over the next 12 months.
Given this cost inflation, we have provided additional sensitivities for aluminum raw materials. Now I'm not going to run through all the detail, but I would point out the time lags for the various price rises, in particular, for caustic, where we are now experiencing the full impact of our refineries.
Energy prices are clearly an important component of our aluminum cost base. We do have some exposure to spot thermal coal prices. For the Boyne smelter, it is 50%. And for the Yarwun refinery, it is around 1/3. However, all our Canadian smelters are hydro-powered at very competitive rates, and this remains a key source of competitive advantage for us.
On to copper. At $1.5 billion, underlying EBITDA was down 27% due to lower sales volumes with COVID-19 and other labor constraints impacting performance of the Kennecott smelter. Lower byproduct sales volumes, particularly gold at Oyu Tolgoi, as anticipated, also contributed. C1 unit costs were significantly higher at $1.48 per pound driven by lower by-product credits and cost inflation.
The team at Oyu Tolgoi reached some really important milestones this half. Of course, there was the agreement in January, which meant underground mining could commence, leading to the first and second draw bells being fired at Hugo North in June. This excellent progress means that the undercut progression remains on track to achieve sustainable production from Panel 0 in the first half of 2023. We also completed a reforecast in the total project estimate to $7.06 billion. The $300 million increase against the 2020 definitive estimate is largely due to COVID-19, quite an achievement given the disruptions over the past 2 years.
Turning to minerals. We benefited from strong market conditions for titanium dioxide, borates and diamonds partially offset by the weaker iron ore market. Underlying EBITDA of $1.3 billion was 10% lower primarily due to higher cash costs and energy price rises. Production performance was generally better than the first half of 2021, but there is certainly room for improvement. Importantly, we're moving ahead with our growth agenda, completing the acquisition of Rincon Lithium in March. And just yesterday, the Board approved $190 million for funding of a small start-up plant, an early works infrastructure to support a full-scale operation.
On to capital allocation. Now we've been showing this slide for nearly a decade now, and it's important to stress that our disciplined approach is unchanged and that we intend to maintain it throughout the cycle. We still expect a disciplined increase in our capital expenditure over the coming years, but we have slightly reduced our 2022 guidance from $8 billion to around $7.5 billion due to a stronger U.S. dollar and rephasing of decarbonization and development projects. Our best estimate for 2023 and 2024 remains between $9 billion and $10 billion, which includes the ambition to invest up to $3 billion each year in growth. But this is highly dependent on the timing of commitments as we prove up the value of investment opportunities. If we cannot develop value-accretive options, we will follow our capital allocation framework.
And it is to be noted that Simandou is included in our capital guidance and if we reach agreement to commit to the project with our JV partners, the Government of Guinea and WCS on the infrastructure pathway. Our best estimate of investment to decarbonize the business remains at $7.5 billion until 2030, including around $1.5 billion over the next 3 years which will be back-end dated. Sustaining capital remains at $3.5 billion a year, subject to inflationary pressures, while annual replacement capital is also unchanged at $2 billion to $3 billion.
Let's now take a look at the balance sheet. We maintained our net cash position just at the end of June. This is impressive given that we paid $7.6 billion in dividends and acquired Rincon for $825 million. As I've said before, it is just a snapshot in time. We would expect to move into a modest net debt position for the second half of the year based on current prices as capital expenditure gathers momentum. We will maintain our financial strength. It is essential as it allows us to reinvest for growth, accelerate our own decarbonization and continue to pay attractive dividends.
Finally, on to the dividend. We have declared a 50% payout for the interim, and this equates to $4.3 billion. This is in line with our policy and is our second largest interim payment in history. As ever, the balance of the dividend will be weighted towards the final at our full year results in February, when the Board will take full account of the outlook for major commodities and the long-term growth prospects of the business. It goes without saying that we remain firmly committed to capital discipline and our shareholder returns policy.
With that, let me pass back to Jakob.