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Financial review | Business operations review | Overview of group operating results |
Chief executive officer's review
Exxaro’s performance in its second full year of operating
as a listed, empowered mineral resources group
reflects
the benefits of diversification in a volatile global market,
with record financial results from our coal business and
a significant profit contribution from our mineral sands
operations. We recorded several major milestones during
the period, particularly in our coal business. These included
a 40-year coal-supply agreement for Eskom’s Medupi power
station, the full ramp-up of Mafube mine, and our new
Inyanda mine exceeding capacity to reach 1,8Mtpa. We also
completed the Namakwa Sands acquisition to strengthen
our mineral sands portfolio and made good progress on
conversion and new mining rights applications.
Business environment
The global economic slowdown accelerated markedly in
the second half of the year, impacting on the South African
economy as well. Local gross domestic product growth of
3,2% was well below the 5,1% achieved in the prior year and
the outlook for 2009 is for further contraction to around
1,9%. The macro-economic review on page 18 details global
economic performance during the year and the outlook
for 2009.
In some commodity markets it was decidedly a year of two
halves, characterised by volatile supply and demand levels.
Oil and bulk commodities reached record levels in the first
half, but prices collapsed in the second half. Base metals and
industrial minerals followed suit. The cycle of rising iron ore
and coal prices is expected to reverse in 2009, while zinc
prices have come down substantially from high 2007 levels.
However, some perhaps unexpected benefits emerged from
this gloomy picture: firstly the upward spiral in mining costs
and project capital costs was arrested and, secondly, the
worldwide shortage of skills and equipment was alleviated
by the plethora of announced cutbacks and project deferrals.
We expect this trend will continue for much of 2009.
Powering possibility
Individual performances during the year have further
entrenched the hallmark of this group to power possibility:
• Exxaro’s North Block Complex was named best-performing
coal mine in South Africa by the South African Colliery
Managers’ Association in recognition of 26 years of
fatality-free shifts.
• Following the successful rebuild of the no 4 roaster in
2007, Zincor simultaneously rebuilt roasters no 1 and 2 at
a cost of some R28 million during the year as part of the
drive to ensure plant efficiency, availability and increased
output.
• We concluded the empowerment transaction in which
Namibian shareholders acquired a further 43% of Rosh
Pinah lead-zinc mine. As part of this landmark transaction,
the mine’s employees now hold 3% of the share capital
and will share in its growth and prosperity.
• Through strategic focus and innovative thinking, Rosh
Pinah has extended its life of mine until 2018, a far cry
from four years ago when the mine had a life of less than
five years and faced closure.
• A groupwide business improvement programme has
already identified savings of R190 million as part of our
process of continuous improvement.
• Exxaro has sponsored a research chair at the Unisa
Centre for Corporate Citizenship to develop a core body
of knowledge on climate change in South Africa.
• We opened a new international office in Switzerland to
service the European steam coal market. Market demand,
strong prices and Exxaro’s focus on value-in-use marketing
are expected to underpin an increase in international coal
exports to at least 10Mtpa over the next eight years.
• An Exxaro employee made history in July 2008 when he
became one of 21 000 torch bearers – and the only South
African – to carry the Olympic flame on its four-month
journey around the world to the host city of Beijing.
The review period however presented some considerable
challenges:
• Regrettably, five employees lost their lives, despite
ongoing and company-wide initiatives to enhance safety
awareness. Disappointingly, we also fell far short of our
target for lost-time injuries.
• Our base metals division recorded an operating loss for
the year, through a combination of production disruptions,
lower revenue, increased operating costs and higher
provisions for environmental rehabilitation.
• Limited power supply and a total plant blackout following
a transformer failure at Zincor caused major delays
and plant instability in the second half of the year. Rosh
Pinah was similarly affected by equipment failures, plant
availability and the impact of an unstable power supply.
Safety
The group again recorded a poor safety performance, with
five fatalities in the review period, while the average lost time
injury frequency rate (LTIFR) per 200 000 man-hours
worked was 0,39 which is well above the target for 2008 of
0,21 (page 82). We deeply regret the loss of our colleagues
and extend our sincere condolences to their families, friends
and colleagues.
We are determined to meet our target of zero harm in all
our operations and have begun implementing revised safety
policy and corporate management standards across the
group – detailed on page 82
The South African mining industry as a whole is trying to be
more consistent in how it applies safety standards, and one
of the behaviours it encourages is zero tolerance for safety
violations. Among other things, this means that safety
behaviour needs to be as much part of performance reviews
and recognition as it is an individual responsibility.
In November 2007, the former president of South Africa,
Thabo Mbeki, announced the implementation of health
and safety audits. All Exxaro mining operations have now
been audited, and results indicate the extent to which our
operations comply with health and safety requirements.
We were particularly pleased with results from our
coal operations which, at 73%, exceeded the average
Department of Minerals and Energy scores of 70% for coal
and 66% for all mines. The outcomes from these audits and
our own investigations will form the framework to refine
and improve our practices.
Externally facilitated, our first CEO’s Safety Summit was
convened in March 2009. A second summit is planned for
October 2009 at which progress against targets will be
mapped and agreement reached on further improvements.
At Exxaro, safety is our foremost priority. Our North Block
Complex is a prime example of what can be achieved through
diligent application of safety standards. We plan to drive our
safety initiatives and programmes aggressively throughout
the organisation.
Operational overview
Exxaro’s coal business units recorded good operating
performances complemented by additional production from
Inyanda and North Block Complex. Total production volumes
neared the 45Mt mark.
Coal markets continued to benefit from strong local and
international demand which translated into favourable coal
pricing despite significant softening in international prices
as the global economic meltdown in the second half of 2008
took effect. Expansion of Grootegeluk mine to supply power
station coal to Eskom’s Medupi power station is underway
following the conclusion of a long-term supply agreement
on the back of unabated local demand. Discussions continue
with Transnet on rail capacity to use Exxaro’s export
entitlement of 6,3Mtpa by end 2009.
The mineral sands business was complemented by the
acquisition of Namakwa Sands from Anglo Operations
Limited with effect from 1 October 2008. Feedstock
supply levels continued to affect markets while the global
economic crisis is expected to compound the negative
impact on pigment demand. Exxaro’s 2008 financial
results were again negatively influenced by the strength
of the Australian currency against the US dollar, despite
the weakening of the former in the last quarter of 2008.
Zircon enjoyed good global demand and pricing in 2008, resulting in record operating results from Namakwa Sands.
Higher production from all operations should benefit this
business in 2009.
In base metals, the record high price environment in 2006
and 2007 has been followed by significantly lower local and
international demand and resultant unfavourable pricing.
The oversupply of concentrate has only partially been offset
by higher treatment charges. The business is expected
to remain under pressure in 2009 given depressed zinc
markets and poor zinc metal prices.
Operational performance
Despite challenges during the year, most notably the extent
of the global economic meltdown and unavailability of plant
capacity in the mineral sands and base metals businesses,
there were a number of notable achievements:
• Record annual production and sale of power station coal
to Eskom.
• Increased production of coal from Inyanda (above design
capacity) and North Block Complex, combined with new
reserves and capacity at the latter mine.
• Record synthetic rutile production at Australia Sands
following the successful kiln shut in 2007.
• Annual records for zircon, titanium slag and pig iron
production at the newly acquired Namakwa Sands.
• Efficiency improvements at Namakwa Sands translating
into a record chlorinatable slag ratio of 84,5% and iron
recovery rate of 91,3%.
• Zincor completed its roaster rebuild programme in the
acid plant to position itself for improved efficiencies.
New operations
Commissioning and ramp-up to full capacity of the Mafube
expansion project has been completed. The mine will produce
3Mtpa of export steam coal and 2Mtpa of power station coal.
Exxaro’s 50% joint venture participation with Anglo Coal,
although still awaiting fulfilment of all conditions precedent,
added 733kt to overall export volumes allowing the group to
benefit from higher average export prices during the year.
The Inyanda mine was also successfully commissioned and
ramped up to design capacity of 1,5Mpta.
Energy
In South Africa, coal has attracted much media attention
during the year, with coal-fired power stations contributing
some 92% of South Africa’s energy-generating capability.
While energy is an immediate focus area for Exxaro, as
detailed on page 87, several issues are worth noting here,
given their importance to our long-term growth.
Although Eskom is planning to shift to a 30% nuclear
mix within the next 15 years, coal will continue to play a
significant role in power generation. Given that South Africa
needs to double its generating capacity by 2025 to support
current growth rates while keeping costs down means a
continued reliance on coal, which is still the cheapest source
of power generation.
Currently the fourth-largest coal producer in the country,
Exxaro is one of the largest suppliers to Eskom, accounting
for more than 30% of total power station demand. With
the Waterberg expansions, Exxaro could become one of the
largest coal producers in South Africa.
The coal supply agreement for Eskom’s new base-load
power station, Medupi, was signed in September 2008,
underscoring the valued and long-standing business
relationship Exxaro has built with the power utility. In
terms of the agreement, Grootegeluk will supply an
average of 14,6Mtpa of power station-grade coal for the
next 40 years through a R9-billion brownfields expansion
of the mine. The mine will increase production through
a seven-day continuous operations programme to supply
additional coal to the adjacent Matimba power station.
Two new beneficiation plants will be constructed at the
mine to process new production for Medupi. Grootegeluk
has the largest washing and beneficiation complex in the
world. Production from the new section of Grootegeluk is
planned for the end of 2011, with ramp-up to full production
by 2014.
These investments by Exxaro and Eskom will have a
significant benefit for the local, provincial and ultimately
national economy. Direct jobs created during construction
will peak at about 9 500 (8 000 from Eskom’s investment,
and 1 500 from Exxaro’s) and thousands of indirect jobs will
be created. Some 550 permanent jobs will be created at
Grootegeluk mine alone.
As a key role player in the mining industry, it is our
responsibility to become more energy efficient, to promote
the use of clean technologies, and to fast-track coal mining
projects. In turn, it is government’s responsibility to ensure
approval of mining rights and to provide a context in which
private investors can – and are encouraged to – invest in
independent power producers.
Mineral sands acquisition
Effective 1 October 2008, we began the formal process of
integrating Namakwa Sands into Exxaro. Namakwa Sands’ products are sold mainly on international
markets, and for an entity that operates in one of South
Africa’s most beautiful but challenging environments on
South Africa’s west coast, it boasts significant market share.
In 2007, Namakwa Sands produced 10% of the world’s zircon,
8% of its titanium dioxide slag, and 5% each of its rutile and
high-purity pig iron. Namakwa Sands has a well-established
customer base across the world, and its incorporation into
Exxaro will more than double the group’s production of
zircon, and effectively double its pig iron capacity.
Namakwa Sands’ products are sold mainly on international
markets, and for an entity that operates in one of South
Africa’s most beautiful but challenging environments on
South Africa’s west coast, it boasts significant market share.
In 2007, Namakwa Sands produced 10% of the world’s zircon,
8% of its titanium dioxide slag, and 5% each of its rutile and
high-purity pig iron. Namakwa Sands has a well-established
customer base across the world, and its incorporation into
Exxaro will more than double the group’s production of
zircon, and effectively double its pig iron capacity.
With Namakwa Sands in our stable, Exxaro is now the third largest
integrated titanium dioxide feedstock group in the
world. The benefits are considerable – ranging from a single
marketing team for the mineral sands business, to shared
infrastructure, furnace technology and mineral separation
technology.
This makes Exxaro unique in that various mineral sands
technologies representing the entire value chain, from mine
to pigment, are housed in one group.
The strategy behind our continued presence in the mineral
sands market is now unfolding. We have always believed we
need to offer our stakeholders a balanced portfolio and, from
the outset, we have chosen to protect the group’s interests
by spreading the risk to deliver value to our stakeholders,
including our employees, over the longer term. This
underpins our strategy of a moderately diversified portfolio
with the building blocks of our sands business remaining
sound as it is a dollar-denominated market where prices
are contracted annually and often for three- to five-year
terms. Together with our leading position as a long-term
power station coal supplier to Eskom, this should provide
considerable protection against market fluctuations and
times of economic uncertainty. With demand for titanium
dioxide feedstocks growing internationally, accompanied
by supply constraints, we remain optimistic about this
strategy.
Integration
In just two years, Exxaro has proved its ability to integrate
acquisitions and mould these into a cohesive group. The
process of integrating Namakwa Sands is currently well
under way.
An integral element in creating value in the current
economic environment has been to develop a focused group
by integrating our people, attitudes, processes and systems
to function as a single entity. During the year, this meant consolidating the strategies and best practices of all the
different teams in our group. With the integration of people
under way early in the year, and succession planning bedded
down, the focus shifted to processes and systems.
A project to optimise enterprise resource planning was
initiated in the first quarter. This included migrating
various business units on to Exxaro’s enterprise-wide
resource planning system. By mid-2009, this will ensure
more effective groupwide governance, decision-making,
recording of business activities, risk management and
greater ability to identify opportunities for continuous
improvement.
Strategy
Our strategy is to consolidate in the short term, optimise
growth plans over the medium term and innovate in the
longer term. In light of global challenges, I believe it is
more pertinent to review our immediate strategy (the year
ahead) in this report. In our current consolidation phase our
short-term goals are to focus on operational excellence, to
optimise cash flow and implement the new organisational
structure. Given the credit crisis and worldwide economic
meltdown in the second half of 2008, the group is reviewing
its capital expenditure programmes, including sustaining
capital, as well as the project pipeline. We will focus on
successfully implementing committed expansions while
reprioritising other identified growth opportunities. These
projects are detailed on page 43.
A continuous business improvement programme is under
way to preserve the group’s cash flow and ensure availability
of sustaining capital.
Exxaro is well positioned to weather this economic storm:
• We are a major (and proven) supplier to Eskom
• We have a growing role as a steam coal exporter
• Production has been sustainably increased in our
mineral sands operations and the marketing strategy
consolidated
• An asset management and plant efficiency programme
is under way in our zinc business. We are exploring
alternative markets and reviewing strategic options.
Legislation
In recent years, the legislative environment for South Africa’s
mining industry has changed significantly. We welcome the
deferment of the draft royalty bill – this is a valuable respite
in the current economic climate.
Calendar 2009 also marks the end of the first cycle of the
mining charter and its attendant scorecard. The process of
reviewing the charter against progress and developments
in the past five years begins in April and is expected to
take some time to finalise. Exxaro has made good progress
against scorecard targets (page 107), but our ultimate aim
is closely aligned to the intention and spirit of the charter – equitable participation in the country’s natural resources,
with fair and representative workplaces.
During the year, Exxaro’s applications to convert the mining
rights associated with former Kumba Resources operations
were granted. The process for executing these conversions
should be completed in the current year. Applications to
convert former Eyesizwe Coal mining rights were submitted
in June 2008.
Sustainable development
This year, I have separated my review for the convenience
of stakeholders. Our comprehensive sustainability report
begins on page 74 with a message that outlines our strategy,
progress and targets. This is supported by illustrative case
studies available in a dedicated section in our electronic
annual report, on www.exxaro.com/case_studies
Transformation
The genesis of today’s Exxaro Resources has been a case
study in transformation. On unbundling from Iscor in 2001,
the groundwork was done under the Kumba Resources
banner to create a group that offered equal opportunity to all
stakeholders. This ethos permeated the 2006 transactions
to create Exxaro, South Africa’s flagship empowerment
group in the mining industry. Among Exxaro’s shareholders
are over 9 000 of our own employees and communities that
enable us to trade.
At a time when many black economic empowerment
groups are struggling with onerous debt burdens,
Exxaro’s black shareholders are seeing the fruits of
their investment. To date, shareholders in BEE Holdco
(page 109), which owns some 53% of Exxaro, have
received dividends totalling R994 million. Our own
people, through the MPOWER trust, have benefited from
over R28 million in dividends.
We have achieved the targets set by the mining charter for
transformation (page 96 and 107), but we will not be satisfied
until transformation is truly widespread and our workforce
a fully representative demographic slice of South Africa.
Directorate and governance
Best-practice governance remains the standard at Exxaro,
facilitated by the skills and experience of a dedicated board
of directors.
In August 2008, Mike Kilbride retired after more than
30 years in the mining industry, predominantly with our
group and most recently as chief operating officer. Mike
played an invaluable role in shaping today’s Exxaro and
we wish him well in this new phase of his life. There is
now a direct reporting line between the heads of Exxaro’s
commodity businesses and the chief executive officer.
Subsequent to the year end, Dirk van Staden retired
as financial director of Exxaro after 12 years with the
group and its predecessors, during which he played an
instrumental role in almost every corporate transaction.
His career spanned 34 years in the corporate environment
and we thank him for an exceptional contribution and
extend our very best wishes for a healthy and rewarding
retirement. Dirk is succeeded by Wim de Klerk, a chartered
accountant by profession, miner by experience, and long
part of the Exxaro team who will head the competent
Exxaro finance team.
During the year, Ms Nonkululeko Nyembezi-Heita and
Ms Pinkie Ncetezo resigned from the board. We thank these
directors for their contributions while in office.
Ms Simangele Mngomezulu and Mr Jeffrey van Rooyen were
appointed as non-executive directors in August 2008. Both
directors add to the expertise and diversity of the Exxaro
board.
We thank Dr Len Konar for continuing to serve as Exxaro’s
acting chairman during the period. While the process
of appointing an independent chairman has been more
protracted than we envisaged, progress is being made.
Appreciation
It has been a year of highlights and challenges, at times
formidable challenges. The spirit and dedication our people
brought to dealing with the challenges was inspiring, as
was their delight in celebrating the milestones. Exxaro is
fortunate to have exceptional people at every level and
I thank each of you for the valuable role you play in our
success.
We also continue to enjoy a mutually beneficial relationship
with our empowerment partners and we will concentrate on
entrenching this partnership as we grow.
Prospects
After two years, Exxaro is proving its mettle in the
commodities market – having grown admirably through
good times and bad.
The group is expected to continue benefiting from strong
demand for local power station coal. However, coking coal
sales could be lower at reduced prices. Steam coal sales
volumes should increase but at lower international prices.
Increased production volumes at all mineral sands
operations, a full 12 months’ contribution from Namakwa
Sands together with the local and Australian currencies
remaining at their present weaker levels, should improve
prospects for this business in 2009 if market demand and
prices remain at current stable levels.
The base metals business is expected to remain under
pressure in 2009 as a result of continued depressed market
conditions and zinc prices.
The equity accounted contribution from Sishen Iron Ore
Company will be affected by market demand and the level
of iron ore price adjustments effective from 1 April 2009.
Accordingly, the group will concentrate on capital
prioritisation and working capital management together
with continuous business improvement initiatives and cost
control to offset lower demand and price challenges.
Consolidated results for 2009 will largely be driven by the
extent to which global recessionary conditions impact on
demand and prices for the group’s commodities as well as
the trading levels of the local and Australian currencies.
However, the uncertain market outlook remains a key factor
to the group’s results for 2009.
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