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TABLE OF CONTENTS
Vale S.A. Financial Statements
As filed with the Securities and Exchange Commission on April 13, 2018
UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Form 20-F
ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d)
OF THE SECURITIES EXCHANGE ACT OF 1934
For the fiscal year ended: December 31, 2017
Commission file number: 001-15030
VALE S.A.
(Exact name of Registrant as specified in its charter)
Federative Republic of Brazil
(Jurisdiction of incorporation or organization)
Luciano Siani Pires, Chief Financial Officer
phone: +55 21 3485 5000
Praia de Botafogo 186 offices 701 1901 Botafogo
22250-145 Rio de Janeiro, RJ, Brazil
(Address of principal executive offices)
Securities registered or to be registered pursuant to Section 12(b) of the Act:
Title of Each Class | | Name of Each Exchange on Which Registered |
| |||
---|---|---|---|---|---|---|
Common shares of Vale, no par value per share |
| | New York Stock Exchange* | | | |
American Depositary Shares (evidenced by American Depositary Receipts), each representing one common share of Vale |
| | New York Stock Exchange | | | |
4.625% Guaranteed Notes due 2020, issued by Vale Overseas |
| | New York Stock Exchange | | | |
5.875% Guaranteed Notes due 2021, issued by Vale Overseas |
| | New York Stock Exchange | | | |
4.375% Guaranteed Notes due 2022, issued by Vale Overseas |
| | New York Stock Exchange | | | |
6.250% Guaranteed Notes due 2026, issued by Vale Overseas |
| | New York Stock Exchange | | | |
8.250% Guaranteed Notes due 2034, issued by Vale Overseas |
| | New York Stock Exchange | | | |
6.875% Guaranteed Notes due 2036, issued by Vale Overseas |
| | New York Stock Exchange | | | |
6.875% Guaranteed Notes due 2039, issued by Vale Overseas |
| | New York Stock Exchange | | | |
5.625% Notes due 2042, issued by Vale S.A. |
| | New York Stock Exchange | | |
Securities registered or to be registered pursuant to Section 12(g) of the Act: None Securities for which there is a reporting obligation pursuant to Section 15(d) of the Act: None The number of outstanding shares of each class of stock of Vale as of December 31, 2017 was: 5,197,432,081 common shares, no par value per share 12 golden shares, no par value per share |
Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act. |
Yes þ No o |
If this report is an annual or transition report, indicate by check mark if the registrant is not required to file reports pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934. |
Yes o No þ |
Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports) and (2) has been subject to such filing requirements for the past 90 days. |
Yes þ No o |
Indicate by check mark whether the registrant has submitted electronically and posted on its corporate website, if any, every Interactive Data File required to be submitted and posted pursuant to Rule 405 of Regulation S-T (§232.405 of this chapter) during the preceding 12 months (or for such shorter period that the registrant was required to submit and post such files). |
Yes þ No o |
Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, or a non-accelerated filer. See definition of "accelerated filer" and "large accelerated filer" in Rule 12b-2 of the Exchange Act. (Check one): |
Large accelerated filer þ Accelerated filer o Non-accelerated filer o Emerging growth company o |
If an emerging growth company that prepares its financial statements in accordance with U.S. GAAP, indicate by check mark if the registrant has elected not to use the extended transition period for complying with any new or revised financial accounting standards provided pursuant to Section 13(a) of the Exchange Act. o |
Indicate by check mark which basis of accounting the registrant has used to prepare the financial statements included in this filing: |
U.S. GAAP International Financial Reporting Standards as issued by the International Accounting Standards Board þOther |
If "Other" has been checked in response to the previous question, indicate by check mark which financial statement item the registrant has elected to follow. |
Item 17 o Item 18 o |
If this is an annual report, indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act). |
Yes o No þ |
Page
i
FORM 20-F CROSS-REFERENCE GUIDE
Item |
| Form 20-F caption |
| Location in this report |
| Page |
---|---|---|---|---|---|---|
| | | | | | |
1 |
| Identity of directors, senior management and advisers |
| Not applicable |
| |
| | | | | | |
2 |
| Offer statistics and expected timetable |
| Not applicable |
| |
| | | | | | |
3 |
| Key information |
| | ||
|
| 3A Selected financial data |
| Selected financial data |
| 12 |
|
| 3B Capitalization and indebtedness |
| Not applicable |
| |
|
| 3C Reasons for the offer and use of proceeds |
| Not applicable |
| |
|
| 3D Risk factors |
| Risk factors |
| 15 |
| | | | | | |
4 |
| Information on the Company |
| | ||
|
| 4A History and development of the company |
| Business overview, Capital expenditures |
| 1, 76 |
|
| 4B Business overview |
| Business overview, Lines of business, Reserves, Regulatory matters |
| 1, 30, 67, 77 |
|
| 4C Organizational structure |
| Exhibit 8 |
| |
|
| 4D Property, plant and equipment |
| Lines of business, Capital expenditures, Regulatory matters |
| 30, 76, 77 |
| | | | | | |
4A |
| Unresolved staff comments |
| None |
| |
| | | | | | |
5 |
| Operating and financial review and prospects |
| | ||
|
| 5A Operating results |
| Results of operations |
| 90 |
|
| 5B Liquidity and capital resources |
| Liquidity and capital resources |
| 106 |
|
| 5C Research and development, patents and licenses, etc. |
| Capital expenditures |
| 76 |
|
| 5D Trend information |
| Results of operations |
| 90 |
|
| 5E Off-balance sheet arrangements |
| Off-balance sheet arrangements |
| 111 |
|
| | Critical accounting policies and estimates |
| 112 | |
|
| 5F Tabular disclosure of contractual obligations |
| Contractual obligations |
| 110 |
|
| 5G Safe harbor |
| Forward-looking statements |
| 14 |
| | | | | | |
6 |
| Directors, senior management and employees |
| | | |
|
| 6A Directors and senior management |
| Management |
| 131 |
|
| 6B Compensation |
| Management compensation |
| 144 |
|
| 6C Board practices |
| ManagementBoard of directors |
| 145 |
|
| 6D Employees |
| Employees |
| 147 |
|
| 6E Share ownership |
| Major shareholders, EmployeesPerformance-based compensation |
| 118, 148 |
| | | | | | |
7 |
| Major shareholders and related party transactions |
| | ||
|
| 7A Major shareholders |
| Major shareholders |
| 118 |
|
| 7B Related party transactions |
| Related party transactions |
| 122 |
|
| 7C Interests of experts and counsel |
| Not applicable |
| |
| | | | | | |
8 |
| Financial information |
| | ||
|
| 8A Consolidated statements and other financial information |
| Financial statements |
| F-1 |
|
| | Distributions |
| 124 | |
|
| | Legal proceedings |
| 149 | |
|
| 8B Significant changes |
| Not applicable |
| |
| | | | | | |
9 |
| The offer and listing |
| | ||
|
| 9A Offer and listing details |
| Share price history |
| 127 |
|
| 9B Plan of distribution |
| Not applicable |
| |
|
| 9C Markets |
| Trading markets |
| 126 |
|
| 9D Selling shareholders |
| Not applicable |
| |
|
| 9E Dilution |
| Not applicable |
| |
|
| 9F Expenses of the issue |
| Not applicable |
| |
| | | | | | |
ii
Form 20-F cross-reference guide
Item |
| Form 20-F caption |
| Location in this report |
| Page |
---|---|---|---|---|---|---|
| | | | | | |
10 |
| Additional information |
| | ||
|
| 10A Share capital |
| Memorandum and articles of associationCommon shares and golden shares |
| 159 |
|
| 10B Memorandum and articles of association |
| Memorandum and articles of association |
| 159 |
|
| 10C Material contracts |
| Lines of business, Results of operations, Related party transactions |
| 30, 90, 122 |
|
| 10D Exchange controls |
| Exchange controls and other limitations affecting security holders |
| 167 |
|
| 10E Taxation |
| Taxation |
| 169 |
|
| 10F Dividends and paying agents |
| Not applicable |
| |
|
| 10G Statement by experts |
| Reserves |
| 67 |
|
| 10H Documents on display |
| Information filed with securities regulators |
| 185 |
|
| 10I Subsidiary information |
| Not applicable |
| |
| | | | | | |
11 |
| Quantitative and qualitative disclosures about market risk |
| Risk management |
| 116 |
| | | | | | |
12 |
| Description of securities other than equity securities |
| | ||
|
| 12A Debt securities |
| Not applicable |
| |
|
| 12B Warrants and rights |
| Not applicable |
| |
|
| 12C Other securities |
| Not applicable |
| |
|
| 12D American Depositary Shares |
| Depositary shares |
| 128 |
| | | | | | |
13 |
| Defaults, dividend arrearages and delinquencies |
| Not applicable |
| |
| | | | | | |
14 |
| Material modifications to the rights of security holders and use of proceeds |
| Not applicable |
| |
| | | | | | |
15 |
| Controls and procedures |
| Evaluation of disclosure controls and procedures |
| 177 |
|
| | Management's report on internal control over financial reporting |
| 178 | |
| | | | | | |
16A |
| Audit Committee financial expert |
| ManagementFiscal Council |
| 140 |
| | | | | | |
16B |
| Code of ethics |
| Code of ethics and conduct |
| 183 |
| | | | | | |
16C |
| Principal accountant fees and services |
| Principal accountant fees and services |
| 184 |
| | | | | | |
16D |
| Exemptions from the listing standards for audit committees |
| ManagementFiscal Council; Corporate governance |
| 140, 179 |
| | | | | | |
16E |
| Purchase of equity securities by the issuer and affiliated purchasers |
| Purchases of equity securities by the issuer and affiliated purchasers |
| 130 |
| | | | | | |
16F |
| Change in registrant's certifying accountant |
| Not applicable |
| |
| | | | | | |
16G |
| Corporate governance |
| Corporate governance |
| 179 |
| | | | | | |
16H |
| Mine safety disclosure |
| Not applicable |
| |
| | | | | | |
17 |
| Financial statements |
| Not applicable |
| |
| | | | | | |
18 |
| Financial statements |
| Financial statements |
| F-1 |
| | | | | | |
19 |
| Exhibits |
| Exhibits |
| 186 |
| | | | | | |
iii
Vale S.A. is a stock corporation, or sociedade por ações, that was organized on January 11, 1943 under the laws of the Federative Republic of Brazil for an unlimited period of time. Its head office is located at Praia de Botafogo 186 offices 701-1901 Botafogo, 22250-145 Rio de Janeiro, RJ, Brazil, and its telephone number is 55-21-3485-5000.
In this report, references to "Vale" are to Vale S.A. References to "we," "us" or the "Company" are to Vale and, except where the context otherwise requires, its consolidated subsidiaries. References to our "ADSs" or "American Depositary Shares" are to our common American Depositary Shares (our "common ADSs"), each of which represents one common share of Vale. American Depositary Shares are represented by American Depositary Receipts ("ADRs") issued by the depositary.
Unless otherwise specified, we use metric units.
References to "real," "reais" or "R$" are to the official currency of Brazil, the real (singular) or reais (plural). References to "U.S. dollars" or "US$" are to United States dollars. References to "€" are to Euros.
SUMMARY
We are one of the largest metals and mining companies in the world, based on market capitalization. We are the world's largest producer of iron ore and iron ore pellets and the world's largest producer of nickel. We also produce manganese ore, ferroalloys, metallurgical and thermal coal, copper, platinum group metals (PGMs), gold, silver and cobalt. We are presently engaged in greenfield mineral exploration in six countries. We operate large logistics systems in Brazil and other regions of the world, including railroads, maritime terminals and ports, which are integrated with our mining operations. In addition, we have a distribution center to support the delivery of iron ore worldwide. Directly and through affiliates and joint ventures, we also have investments in energy and steel businesses.
| 1 | |
Business Overview
The following table presents the breakdown of total net operating revenues attributable to each of our lines of business with continuing operations.
|
| Year ended December 31, | | ||||||||||||||||
|
| 2015 | | 2016 | | 2017 | | ||||||||||||
|
| (US$ million) | | (% of total) | | (US$ million) | | (% of total) | | (US$ million) | | (% of total) | | ||||||
Ferrous minerals: |
| | | | | | | | | | | | | ||||||
Iron ore |
| 12,330 | | | 52.7 | % | | 15,784 | | | 57.4 | % | | 18,524 | | | 54.5 | % | |
Pellets |
| 3,600 | | | 15.4 | | | 3,827 | | | 13.9 | | | 5,653 | | | 16.7 | | |
Ferroalloys and manganese |
| 162 | | | 0.7 | | | 302 | | | 1.1 | | | 469 | | | 1.4 | | |
Other ferrous products and services |
| 470 | | | 2.0 | | | 438 | | | 1.6 | | | 483 | | | 1.4 | | |
| | | | | | | | | | | | | | ||||||
Subtotal |
| 16,562 | | | 70.8 | | | 20,351 | | | 74.0 | | | 25,129 | | | 74.0 | | |
| | | | | | | | | | | | | | ||||||
Coal |
| 526 | | | 2.3 | | | 839 | | | 3.1 | | | 1,567 | | | 4.6 | | |
Base metals: |
| | | | | | | | | | | | | ||||||
Nickel and other products(1) |
| 4,693 | | | 20.1 | | | 4,472 | | | 16.3 | | | 4,667 | | | 13.7 | | |
Copper(2) |
| 1,470 | | | 6.3 | | | 1,667 | | | 6.0 | | | 2,204 | | | 6.5 | | |
| | | | | | | | | | | | | | ||||||
Subtotal |
| 6,163 | | | 26.4 | | | 6,139 | | | 22.3 | | | 6,871 | | | 20.2 | | |
| | | | | | | | | | | | | | ||||||
Other(3) |
| 133 | | | 0.5 | | | 159 | | | 0.6 | | | 400 | | | 1.2 | | |
| | | | | | | | | | | | | | ||||||
Total net operating revenues from continuing operations |
| 23,384 | | | 100.0 | % | | 27,488 | | | 100.0 | % | | 33,967 | | | 100.0 | % | |
| | | | | | | | | | | | | |
Ferrous minerals:
Base metals:
| 2 | |
Business Overview
copper cathodes in conjunction with our nickel mining operations at Sudbury and Voisey's Bay.
Coal:
Logistics infrastructure:
BUSINESS STRATEGY
Our mission is to transform natural resources into prosperity and sustainable development. With this purpose, we are committed to:
Below are the highlights of our major business strategies.
| 3 | |
Business Overview
Commitment to sustainability
We are committed to becoming a sustainability benchmark through a comprehensive approach based on systematic planning and execution, prioritizing risk and impact management (seeking to achieve zero harm to our employees and surrounding communities) and establishing a positive social, economic and environmental legacy in the places where we operate. Below is a list of measures illustrating our commitment to sustainability:
Improving our margins in the iron ore business
We are committed to improving our margins in the iron ore business by achieving better price realization, based on adjustments to our product portfolio according to market demand and supply chain optimization. We are focusing our product line to capture industry trends, improving quality and productivity, controlling costs, strengthening our logistics infrastructure of railroads, ports, shipping and distribution centers, and strengthening relationships with customers. Our diversified portfolio of high-quality products, strong technical marketing strategy, efficient logistics and long-standing relationships with major customers will help us achieve this goal.
In September 2017, Vale inaugurated the global Integrated Operations Center (IOC) at the Aguas Claras mine. The IOC brings together various functions in the iron ore supply chain to support improvements in the planning processes from mine to port, including optimization of ship distribution and response to client demands. These improvements to our operations and sales planning are expected to lead to better sales price realization and product quality management.
| 4 | |
Business Overview
We will continue to promote the Brazilian blend fines (BRBF), a product standard with silica (SiO2) content limited to 5%, offering strong performance in any kind of sintering operation. We produce BRBF by blending fines from Carajás, which contain a higher concentration of iron and a lower concentration of silica in the ore, with fines from the Southern and Southeastern Systems, which contain a lower concentration of iron in the ore. It is blended and sold in our Teluk Rubiah Maritime Terminal in Malaysia and in twelve distribution centers in China. This process reduces the time needed to reach Asian markets and increases our distribution capillarity by allowing the use of smaller vessels. The blending strategy also permits the use of iron ore with lower concentration, particularly from the Southern System, allowing more efficient mining plans and increasing the use of dry processing methods, which in turn reduce capital expenditures, extend the life of our mines and reduce the use of water in our operations.
Preserving optionality in our nickel business and increasing production of our copper assets
Our strategy for our nickel business is to preserve optionality. We are the world's largest nickel producer, with large-scale, long-life and low-cost operations, a substantial resource base and diversified mining operations that produce nickel from nickel sulfide and laterite sources using advanced technology. We are transitioning to a smaller footprint in our nickel business by calibrating investments and production to reflect current market conditions, such as the reduction of production volume at Voisey's Bay while a mine expansion project is being reassessed. In the long term, the battery segment shows important upside potential as electric vehicle production continues to attract significant investments, which could positively affect nickel price and our nickel premiums. We continue to optimize our operations and to review our asset utilization, aiming to increase productivity and improve returns.
A key aspect of our strategy for our copper assets in the Carajás region is to improve efficiency and asset utilization while we evaluate opportunities to extend our operations at Sossego and expand Salobo. These copper mines benefit from our infrastructure facilities serving the Northern System. The gold we produce at Sossego and Salobo increases the total aggregated value of those operations.
Leveraging our mine and logistics in the coal business
We have been increasing our coal production, mainly through the ramp-up of a new coal handling processing plant (CHPP) in the Moatize operations and the ramp-up of the Nacala Logistics Corridor (NLC) in Mozambique and Malawi, where we have entered into a strategic partnership with Mitsui. As we complete the ramp-up of our new CHPP in Moatize and the NLC, we expect our costs to diminish, enhancing the competitiveness of our coal operations.
Reducing net debt
Our goal is to reduce indebtedness to US$10 billion by the end of 2018, taking advantage of our cash flow generation. This level of net debt will enable us to withstand cycles in the mining business while maintaining a solid balance sheet and an investment-grade credit rating.
Enhancing corporate governance
Following the conversion of our class A preferred shares into common shares, in December 2017, we completed our listing on the Novo Mercado segment of the B3 exchange (formerly BM&FBovespa), the special listing segment of B3 for companies committed to the highest standards of corporate governance. Also in 2017, our shareholders elected two independent board members to the Board of Directors. We are committed to continuing to improve our corporate governance.
| 5 | |
Business Overview
REORGANIZATION OF OUR SHAREHOLDING STRUCTURE AND LISTING ON NOVO MERCADO
In 2017, we successfully completed a series of measures to simplify our shareholding structure and enhance our corporate governance. Below is a summary of these measures:
In August 2017, upon conclusion of the merger of Valepar into Vale, certain former shareholders of Valepar entered into a Shareholders' Agreement pursuant to which they undertake, among other things, to vote jointly on certain key matters. This Shareholders' Agreement is expected to expire in November 2020. See Share ownership and tradingMajor shareholders.
SIGNIFICANT CHANGES IN OUR BUSINESS
We summarize below major events related to our divestitures, acquisitions and other significant developments in our business since the beginning of 2017.
Dispositions and asset sales
We are always seeking to optimize the structure of our portfolio of businesses in order to achieve the most efficient allocation of capital. We summarize below our most significant dispositions since the beginning of 2017.
| 6 | |
Business Overview
Partnership in coal assets in Mozambique
We have a partnership with Mitsui in coal assets in Mozambique. In March 2017, we completed the equity transaction with Mitsui, which consisted of: (i) the sale of 15% of our 95% stake in the Moatize coal mine, (ii) the sale of 50% of Vale's stake in the NLC and (iii) a long-term facility by Mitsui to NLC. We received US$690 million upon completion of the equity transaction in March 2017, and US$87 million in the first quarter of 2018 upon closing of the project financing described below.
In November 2017, the NLC entities entered into agreements for a project financing in the total amount of US$2.730 billion, as follows:
| 7 | |
Business Overview
The transaction closed in February 2018 and we received the proceeds of the project financing in March 2018. Vale received US$2.6 billion in proceeds, in repayment of certain shareholders loans provided for construction of NLC, net of certain commissions paid by NLC. The project financing will be repaid in 14 years with the proceeds obtained from the tariff charged by NLC in connection with its provision of coal transportation services and general cargo services.
Optimizing our base metals operations in Canada
We are optimizing our nickel operations across Canada, as part of an overall strategy to prioritize value over volume, reduce our atmospheric emissions and comply with local regulations. In 2018, we will phase out our smelting and refining activities in Thompson, where we will focus on nickel concentrate production. As a result, we will concentrate more of our refining and smelting activities in Sudbury, where we will focus on the production of copper concentrate, copper matte and refined nickel. In Long Harbour, we produce nickel rounds, copper cathode and cobalt rounds.
| 8 | |
Business Overview
Resumption of operations of São Luis and Tubarão I and II pellet plants
In January 2018, we resumed the operations of our Tubarão II pellet plant. We expect to resume operations at the Tubarão I and São Luis pellet plants in the second and third quarters of 2018. The operations of these plants had been suspended since 2012 due to market conditions.
FAILURE OF SAMARCO'S TAILINGS DAM IN MINAS GERAIS
Samarco's dam failure
In November 2015, the Fundão tailings dams owned by Samarco S.A. failed, releasing tailings downstream, flooding certain communities and causing impacts on communities and the environment along the Doce river. The failure resulted in 19 fatalities and caused property and environmental damage to the affected areas. Samarco is a joint venture equally owned by Vale S.A. and BHP Billiton Brasil Ltda. ("BHPB"), a Brazilian subsidiary of BHP Billiton plc.
Emergency actions
Immediately after the dam failure, Samarco, together with the public authorities, provided first aid, food, water, housing, social assistance and financial aid to the affected families and individuals. As Samarco's shareholders, we were actively involved in supporting Samarco during this period. In addition to these emergency actions, Samarco has been monitoring the affected area, performing emergency work to contain any movement of tailings, reinforcing the structures of its dams and dikes to ensure the safety of the region and mitigating the environmental and social impacts of the event.
Fundação Renova and the remediation process
In August 2016, Samarco and its shareholders (Vale and BHPB) created the Fundação Renova, a not-for-profit private foundation, to develop and implement (i) social and economic remediation and compensation programs and (ii) environmental remediation and compensation programs in the region affected by the dam collapse.
The social and economic remediation and compensation programs conducted by Fundação Renova include, among others:
| 9 | |
Business Overview
The environmental remediation and compensation programs conducted by Fundação Renova include, among others:
The creation of Fundação Renova was provided for under the Agreement of Transaction and Conduct Adjustment (TTAC or Framework Agreement) signed in March 2016 by Vale, BHPB, Samarco, the Brazilian federal government, the two Brazilian states affected by the failure (Espírito Santo and Minas Gerais) and other governmental authorities. The Framework Agreement has a 15-year term, renewable for successive one-year periods until all the obligations under the Framework Agreement have been performed. The Framework Agreement does not provide for admission of civil, criminal or administrative liability for the Fundão dam failure. In January 2017, Samarco, Vale and BHPB entered into two preliminary agreements with the federal prosecution office (the "MPF") providing for, among other things, the appointment of experts selected by the MPF to review and monitor the remediation programs provided under the Framework Agreement. The preliminary agreements contemplate a potential revision in the remediation programs provided under the Framework Agreement, based on the findings of the experts selected by the MPF.
| 10 | |
Business Overview
Under the Framework Agreement, Fundação Renova must be funded by Samarco. As Samarco is currently unable to resume its activities, we and BHPB have been funding the foundation and also providing funds directly to Samarco, to preserve its operations and to support Samarco's funding obligations. Samarco's funding obligations to Fundação Renova, pursuant to the Framework Agreement, are summarized below:
Fundação Renova must allocate a minimum annual amount of R$240 million over 15 years to the implementation of compensation programs; these annual amounts are included in the annual contributions described above for the first six years.
Under the terms of the Framework Agreement, Fundação Renova must spend R$500 million on sewage collection and treatment and solid waste disposal through the end of 2018.
Fundação Renova and Samarco allocated R$1.7 billion to remediation and compensation programs in 2017, and have allocated R$3.2 billion to these programs since their creation.
Impact of dam failure on Samarco's operations
Following the dam failure, governmental authorities ordered the suspension of Samarco's operations. Samarco's management is working on a plan that would permit it to obtain the necessary licenses and approvals to resume operations and provide a long-term solution for the disposal of tailings. The feasibility, timing and scope of measures necessary to resume Samarco's operations remain uncertain. With the exception of the Fundão tailings dam and the Santarém water dam, which was impacted by the overflow of tailings from the Fundão dam, all other production assets owned by Samarco were undamaged.
Impact of the failure of Samarco's tailings dam in our financial statements
For a discussion of the impact of the failure of Samarco's tailings dam in our financial statements, see Operating and financial review and prospectsFailure of Samarco's tailing dams.
Legal proceedings
For a discussion of the legal proceedings resulting from the failure of Samarco's tailings dam, see Additional informationLegal proceedings.
| 11 | |
The tables below present selected consolidated financial information as of and for the periods indicated. You should read this information together with our consolidated financial statements in this annual report.
Consolidated statement of income data
|
| For the year ended December 31, | | ||||||||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| 2013 | | 2014 | | 2015 | | 2016 | | 2017 | | ||||||||||
|
| (US$ million) |
| ||||||||||||||||||
Net operating revenues | | 43,953 | | | 35,124 | | | 23,384 | | | 27,488 | | | 33,967 | | | |||||
Cost of goods sold and services rendered | | (21,668 | ) | | (22,790 | ) | | (18,751 | ) | | (17,650 | ) | | (21,039 | ) | | |||||
Selling, general, administrative and other operating expenses, net | | (1,101 | ) | | (2,059 | ) | | (819 | ) | | (774 | ) | | (951 | ) | | |||||
Research and evaluation expenses | | (748 | ) | | (662 | ) | | (395 | ) | | (319 | ) | | (340 | ) | | |||||
Pre-operating and operational stoppage | | (2,375 | ) | | (975 | ) | | (942 | ) | | (453 | ) | | (413 | ) | | |||||
Impairment and other results on non-current assets | | (397 | ) | | (266 | ) | | (8,708 | ) | | (1,240 | ) | | (294 | ) | | |||||
| | | | | | | | | | | | ||||||||||
Operating income (loss) | | 17,664 | | | 8,372 | | | (6,231 | ) | | 7,052 | | | 10,930 | | | |||||
Non-operating income (expenses): | | | | | | | | | | | | ||||||||||
Financial income (expenses), net | | (8,314 | ) | | (6,018 | ) | | (10,654 | ) | | 1,843 | | | (3,019 | ) | | |||||
Equity results in associates and joint ventures | | 469 | | | 501 | | | (445 | ) | | 309 | | | 98 | | | |||||
Impairment and other results in associates and joint ventures | | 14 | | | (61 | ) | | (349 | ) | | (1,220 | ) | | 180 | | | |||||
| | | | | | | | | | | | ||||||||||
Net income (loss) before income taxes | | 9,833 | | | 2,794 | | | (17,679 | ) | | 7,984 | | | 7,829 | | | |||||
Income taxes | | (6,889 | ) | | (1,603 | ) | | 5,249 | | | (2,781 | ) | | (1,495 | ) | | |||||
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Net income (loss) from continuing operations | | 2,944 | | | 1,191 | | | (12,430 | ) | | 5,203 | | | 6,334 | | | |||||
Net income (loss) attributable to non-controlling interests | | (191 | ) | | (308 | ) | | (501 | ) | | (8 | ) | | 21 | | | |||||
| | | | | | | | | | | | ||||||||||
Net income (loss) from continuing operations attributable to Vale's stockholders | | 3,135 | | | 1,499 | | | (11,929 | ) | | 5,211 | | | 6,313 | | | |||||
| | | | | | | | | | | | ||||||||||
Net income (loss) from discontinued operations attributable to Vale's stockholders | | (2,551 | ) | | (842 | ) | | (200 | ) | | (1,229 | ) | | (806 | ) | | |||||
Net income (loss) attributable to Vale's stockholders | | 584 | | | 657 | | | (12,129 | ) | | 3,982 | | | 5,507 | | | |||||
| | | | | | | | | | | | ||||||||||
Net income (loss) attributable to non-controlling interests | | (178 | ) | | (304 | ) | | (491 | ) | | (6 | ) | | 14 | | | |||||
| | | | | | | | | | | | ||||||||||
Net income (loss) | | 406 | | | 353 | | | (12,620 | ) | | 3,976 | | | 5,521 | | | |||||
| | | | | | | | | | | | ||||||||||
Total cash paid to stockholders(1) | | 4,500 | | | 4,200 | | | 1,500 | | | 250 | | | 1,456 | | |
Earnings (loss) per share
The table below shows our earnings (loss) per share. The earnings (loss) per share for 2013 to 2016 have been retrospectively adjusted to reflect the conversion of our Class A preferred shares into common shares, which was concluded in November 2017, as if the conversion had occurred at the beginning of the earliest year presented.
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| For the year ended December 31, | | ||||||||||||||||||
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|
| 2013 | | 2014 | | 2015 | | 2016 | | 2017 | | ||||||||||
|
| (US$, except as noted) |
| ||||||||||||||||||
Earnings (loss) per common share from continuing operations | | 0.60 | | | 0.29 | | | (2.30 | ) | | 1.00 | | | 1.21 | | | |||||
Earnings (loss) per common share from discontinued operations | | (0.49 | ) | | (0.16 | ) | | (0.03 | ) | | (0.23 | ) | | (0.16 | ) | | |||||
| | | | | | | | | | | | ||||||||||
Earnings (loss) per common share | | 0.11 | | | 0.13 | | | (2.33 | ) | | 0.77 | | | 1.05 | | | |||||
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| | | | | | | | | | | | | | | | | |||||
| | | | | | | | | | | | ||||||||||
Weighted average number of shares outstanding (in thousands)(1)(2) | | 5,197,432 | | | 5,197,432 | | | 5,197,432 | | | 5,197,432 | | | 5,197,432 | | | |||||
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| | | | | | | | | | | | | | | | | |||||
| | | | | | | | | | | | ||||||||||
Distributions to stockholders per share(2) | | | | | | | | | | | | ||||||||||
Expressed in US$ |
| 0.87 | | | 0.81 | | | 0.29 | | | 0.05 | | | 0.28 | | | |||||
Expressed in R$ |
| 1.81 | | | 1.89 | | | 0.98 | | | 0.17 | | | 0.90 | | |
| 12 | |
Selected Financial Data
Balance sheet data
|
| As of December 31, | | ||||||||||||||||||
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|
| 2013 | | 2014 | | 2015 | | 2016 | | 2017 | | ||||||||||
|
| (US$ million) |
| ||||||||||||||||||
Current assets | | 20,611 | | | 16,594 | | | 11,429 | | | 13,978 | | | 15,367 | | | |||||
Non-current assets held for sale | | 3,766 | | | 3,640 | | | 4,044 | | | 8,589 | | | 3,587 | | | |||||
Property, plant and equipment, net and intangible assets | | 88,536 | | | 84,942 | | | 59,426 | | | 62,290 | | | 63,371 | | | |||||
Investments in associated companies and joint ventures | | 3,584 | | | 4,133 | | | 2,940 | | | 3,696 | | | 3,568 | | | |||||
Non-current assets | | 8,100 | | | 7,180 | | | 10,653 | | | 10,461 | | | 13,291 | | | |||||
| | | | | | | | | | | | ||||||||||
Total assets | | 124,597 | | | 116,489 | | | 88,492 | | | 99,014 | | | 99,184 | | | |||||
| | | | | | | | | | | | ||||||||||
| | | | | | | | | | | | | | | | | |||||
| | | | | | | | | | | | ||||||||||
Current liabilities | | 9,164 | | | 10,626 | | | 10,438 | | | 10,142 | | | 11,935 | | | |||||
Liabilities associated with non-current assets held for sale | | 448 | | | 111 | | | 107 | | | 1,090 | | | 1,179 | | | |||||
Long-term liabilities(1) | | 22,379 | | | 22,043 | | | 15,896 | | | 19,096 | | | 20,512 | | | |||||
Long-term debt(2) | | 27,670 | | | 27,388 | | | 26,347 | | | 27,662 | | | 20,786 | | | |||||
| | | | | | | | | | | | ||||||||||
Total liabilities | | 59,661 | | | 60,168 | | | 52,788 | | | 57,990 | | | 54,412 | | | |||||
| | | | | | | | | | | | ||||||||||
| | | | | | | | | | | | | | | | | |||||
| | | | | | | | | | | | ||||||||||
Stockholders' equity: | | | | | | | | | | | | ||||||||||
Capital stock |
| 60,578 | | | 61,614 | | | 61,614 | | | 61,614 | | | 61,614 | | | |||||
Additional paid-in capital | | (552 | ) | | (601 | ) | | (854 | ) | | (851 | ) | | (1,106 | ) | | |||||
Retained earnings and revenue reserves | | 3,299 | | | (5,891 | ) | | (27,171 | ) | | (21,721 | ) | | (17,050 | ) | | |||||
| | | | | | | | | | | | ||||||||||
Total Vale shareholders' equity |
| 63,325 | | | 55,122 | | | 33,589 | | | 39,042 | | | 43,458 | | | |||||
| | | | | | | | | | | | ||||||||||
Non-controlling interests | | 1,611 | | | 1,199 | | | 2,115 | | | 1,982 | | | 1,314 | | | |||||
| | | | | | | | | | | | ||||||||||
Total stockholders' equity | | 64,936 | | | 56,321 | | | 35,704 | | | 41,024 | | | 44,772 | | | |||||
| | | | | | | | | | | | ||||||||||
Total liabilities and stockholders' equity | | 124,597 | | | 116,489 | | | 88,492 | | | 99,014 | | | 99,184 | | | |||||
| | | | | | | | | | | | ||||||||||
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| | | | | | | | | | | |
| 13 | |
This annual report contains statements that may constitute forward-looking statements within the meaning of the safe harbor provisions of the U.S. Private Securities Litigation Reform Act of 1995. Many of those forward-looking statements can be identified by the use of forward-looking words such as "anticipate," "believe," "could," "expect," "should," "plan," "intend," "estimate" and "potential," among others. Those statements appear in a number of places and include statements regarding our intent, belief or current expectations with respect to:
We caution you that forward-looking statements are not guarantees of future performance and involve risks and uncertainties. Actual results may differ materially from those in forward-looking statements as a result of various factors. These risks and uncertainties include factors relating to (a) economic, political and social issues in the countries in which we operate, (b) the global economy, (c) commodity prices, (d) financial and capital markets, (e) the mining and metals businesses, which are cyclical in nature, and their dependence upon global industrial production, which is also cyclical, (f) regulation and taxation, (g) operational incidents or accidents, and (h) the high degree of global competition in the markets in which we operate. For additional information on factors that could cause our actual results to differ from expectations reflected in forward-looking statements, see Risk factors. Forward-looking statements speak only as of the date they are made, and we do not undertake any obligation to update them in light of new information or future developments. All forward-looking statements attributed to us or a person acting on our behalf are expressly qualified in their entirety by this cautionary statement, and you should not place undue reliance on any forward-looking statement.
| 14 | |
EXTERNAL RISKS
Our business is exposed to the cyclicality of global economic activity and requires significant investments of capital.
As a mining company, we are a supplier of industrial raw materials. Industrial production tends to be the most cyclical and volatile component of global economic activity, which affects demand for minerals and metals. At the same time, investment in mining requires a substantial amount of funds in order to replenish reserves, expand and maintain production capacity, build infrastructure, preserve the environment and minimize social impacts. Sensitivity to industrial production, together with the need for significant long-term capital investments, are important sources of risk for our financial performance and growth prospects.
Also, we may not be able to adjust production volume in a timely or cost-efficient manner in response to changes in demand. Lower utilization of capacity during periods of weak demand may expose us to higher unit production costs since a significant portion of our cost structure is fixed in the short-term due to the capital intensity of mining operations. In addition, efforts to reduce costs during periods of weak demand could be limited by labor regulations or previous labor or government agreements. Conversely, during periods of high demand, our ability to rapidly increase production capacity is limited, which could prevent us from meeting demand for our products. Moreover, we may be unable to complete expansions and greenfield projects in time to take advantage of rising demand for iron ore, nickel or other products. When demand exceeds our production capacity, we may meet excess customer demand by purchasing iron ore, iron ore pellets or nickel from joint ventures or unrelated parties and reselling it, which would increase our costs and narrow our operating margins. If we are unable to satisfy excess customer demand in this way, we may lose customers. In addition, operating close to full capacity may expose us to higher costs, including demurrage fees due to capacity restraints in our logistics systems.
The prices for our products are subject to volatility, which may adversely affect our business.
Global prices for metals are subject to significant fluctuations and are affected by many factors, including actual and expected global macroeconomic and political conditions, regional and sectorial factors, levels of supply and demand, the availability and cost of substitutes, inventory levels, technological developments, regulatory and international trade matters, investments by commodity funds and others and actions of participants in the commodity markets. Sustained low market prices for the products we sell may result in the suspension of certain of our projects and operations, decrease in our mineral reserves, impairment of assets, and may adversely affect our cash flows, financial position and results of operations.
Demand for our iron ore, coal and nickel products depends on global demand for steel. Iron ore and iron ore pellets, which together accounted for 71.2% of our 2017 net operating revenues, are used to produce carbon steel. Nickel, which accounted for 13.7% of our 2017 net operating revenues, is used mainly to produce stainless and alloy steels. The prices of different steels and the performance of the global steel industry are highly cyclical and volatile, and these business cycles in the steel industry affect demand and prices for our products. In addition, vertical backward integration of the steel and stainless steel industries and the use of scrap could reduce the global seaborne trade of iron ore and primary nickel. The demand for copper is affected by the demand for copper wire, and a sustained decline in the construction industry could have a negative impact on our copper business.
We are mostly affected by movements in iron ore prices. For example, a price reduction of US$1 per dry metric ton unit ("dmt") in the average iron ore price would have reduced our operating income for the year ended December 31, 2017 by approximately US$300 million. Average iron ore prices significantly
| 15 | |
Risk Factors
changed in the last five years, from US$135 per dmt in 2013 to US$97 per dmt in 2014, US$55.5 per dmt in 2015, US$58.5 per dmt in 2016 and US$71.3 per dmt in 2017, according to the average Platts IODEX (62% Fe CFR China). On February 28, 2018, the year to date average Platts IODEX iron ore price was US$76.60 per dmt. See Operating and financial review and prospectsOverviewMajor factors affecting prices.
Adverse economic developments in China could have a negative impact on our revenues, cash flow and profitability.
China has been the main driver of global demand for minerals and metals over the last few years. In 2017, Chinese demand represented 74% of global demand for seaborne iron ore, 55% of global demand for nickel and 48% of global demand for copper. The percentage of our net operating revenues attributable to sales to customers in China was 41.3% in 2017. Therefore, any contraction of China's economic growth could result in lower demand for our products, leading to lower revenues, cash flow and profitability. Poor performance in the Chinese real estate sector, the largest consumer of carbon steel in China, would also negatively impact our results.
Changes in exchange rates for the currencies in which we conduct operations could adversely affect our financial condition and results of operations.
A substantial portion of our revenues, trade receivables and our debt is denominated in U.S. dollars, and given that our functional currency is the Brazilian real, changes in exchange rates may result in (i) losses or gains on our net U.S. dollar-denominated indebtedness and accounts receivable and (ii) fair value losses or gains on currency derivatives we use to stabilize our cash flow in U.S. dollars. In 2017, we had net foreign exchange losses of US$463 million, while we had net foreign exchange gains of US$3.252 billion in 2016 and net foreign exchange losses of US$7.044 billion in 2015. In addition, changing values of the Brazilian real, the Canadian dollar, the Australian dollar, the Euro, the Indonesian rupiah and other currencies against the U.S. dollar affects our results since most of our costs of goods sold is denominated in currencies other than the U.S. dollar, principally the real (52% in 2017) and the Canadian dollar (12% in 2017), while our revenues are mostly U.S. dollar-denominated. We expect currency fluctuations to continue to affect our financial income, expense and cash flow generation.
Significant volatility in currency prices may also result in disruption of foreign exchange markets, which could limit our ability to transfer or to convert certain currencies into U.S. dollars and other currencies for the purpose of making timely payments of interest and principal on our indebtedness. The central banks and governments of the countries in which we operate may institute restrictive exchange rate policies in the future and impose taxes on foreign exchange transactions.
FINANCIAL RISKS
Lower cash flows, resulting from decreased prices of our products, may adversely affect our credit ratings and the cost and availability of financing.
Lower prices of our products may adversely affect our future cash flows, credit ratings and our ability to secure financing at attractive rates. It may also negatively affect our ability to fund our capital investments, provide the financial assurances required to obtain licenses in certain jurisdictions, pay dividends and comply with the financial covenants in some of our long-term debt instruments. See Operating and financial review and prospectsLiquidity and capital resources.
| 16 | |
Risk Factors
We may not be able to implement our strategy with respect to divestments and strategic partnerships.
In the past few years, we have entered into agreements to dispose of assets and to make strategic partnerships, in order to optimize our business portfolio and implement our financing strategy and capital expenditure plans. We may continue to seek opportunities for divestments and strategic partnerships in the future. We are exposed to a number of risks in connection with these transactions, including imposition of regulatory conditions, inability to satisfy conditions for completion or for receipt of additional payments, and negative market reactions. If we are unable to complete our dispositions or strategic partnerships, we may have to revise our business and financing strategy and incur additional costs, which could in turn adversely affect our results of operations, financial conditions or reputation.
RISKS RELATING TO LEGAL PROCEEDINGS
We are involved in legal proceedings that could have a material adverse effect on our business in the event of unfavorable outcomes.
We are involved in legal proceedings in which adverse parties have sought injunctions to suspend certain of our operations or claimed substantial amounts, including several legal proceedings and investigations relating to the failure of Samarco's Fundão tailings dam. Although we are vigorously contesting them, the outcomes of these proceedings are uncertain and may materially and adversely affect our business, our liquidity and the value of the securities issued by us or our subsidiaries. See Additional informationLegal proceedings.
Our obligations and potential liabilities arising from the failure of a tailings dam owned by Samarco Mineração S.A. ("Samarco") in Minas Gerais could negatively impact our business, our financial conditions and our reputation.
In November 2015, the Fundão tailings dam owned by Samarco failed, causing environmental damage in the surrounding area. The failure of Samarco's tailings dam has adversely affected and will continue to affect our business, and the full impact is still uncertain and cannot be estimated. Below is a discussion of the main effects of the dam failure on our business.
| 17 | |
Risk Factors
agreements contemplate a potential revision in the remediation programs provided under the Framework Agreement, based on the findings of the experts selected by the MPF. As Samarco is currently unable to resume its activities, we and BHPB have been funding Fundação Renova and also providing funds directly to Samarco, to preserve its operations and to support certain remediation measures undertaken by Samarco. If Samarco is unable to resume operations or to generate sufficient cash flows to fund the remediation measures required under these agreements, we will be required to continue funding these remediation measures, which in turn may adversely affect our financial conditions and results of operations. See Business overviewFailure of Samarco's tailings dam in Minas Gerais.
POLITICAL, ECONOMIC, SOCIAL AND REGULATORY RISKS
Political, economic and social conditions in the countries in which we have operations or projects could adversely impact our business.
Our financial performance may be negatively affected by regulatory, political, economic and social conditions in countries in which we have significant operations or projects. In many of these jurisdictions, we are exposed to various risks such as political instability, bribery, extortion, corruption, robbery, sabotage, kidnapping, civil strife, acts of war, guerilla activities, piracy in international shipping routes and terrorism. These issues may adversely affect the economic and other conditions under which we operate in ways that could have a materially negative effect on our business.
Political and economic instability in Brazil could adversely impact our business and the market price of our securities.
The Brazilian federal government's economic policies may have important effects on Brazilian companies, including us, and on market conditions and prices of securities of Brazilian companies. Our financial condition and results of operations may be adversely affected by the following factors and the Brazilian federal government's response to these factors:
| 18 | |
Risk Factors
Historically, the country's political situation has influenced the performance of the Brazilian economy, and political crises have affected the confidence of investors and the general public, which resulted in economic deceleration, downgrading of credit ratings of the Brazilian government and Brazilian issuers, and heightened volatility in the securities issued abroad by Brazilian companies. In August 2016, the Brazilian Congress approved the impeachment of the Brazilian president. Also, ongoing corruption investigations have led to charges against former and current public officials, members of several major political parties and directors and officers of many Brazilian companies. In addition, Brazil's next presidential and federal legislative election will be in October 2018. We cannot predict the outcome of these elections or whether the elections will result in changes in Brazilian governmental and economic policies or in the Brazilian mining industry. Political instability and the upcoming elections may aggravate economic uncertainties in Brazil and increase volatility of securities of Brazilian issuers.
In the last years, Brazil faced an economic recession, adverse fiscal developments and political instability. Brazilian GDP grew by 1.0% in 2017, but declined by 3.6% in 2016 and by 3.85% in 2015. Unemployment rate was 12.7% in 2017, 11.5% in 2016 and 6.9% in 2015. Inflation, as reported by the consumer price index (IPCA), was 2.95% in 2017, 6.29% in 2016 and 10.67% in 2015. The Brazilian Central Bank's base interest rate (SELIC) was 7.00% on December 31, 2017, 13.75% on December 31, 2016 and 14.25% on December 31, 2015. Future economic, social and political developments in Brazil may impair our business, financial condition or results of operations, or cause the market value of our securities to decline.
Disagreements with local communities in which we operate could adversely impact our business and reputation.
Disputes with communities where we operate may arise from time to time. In some instances, our operations and mineral reserves are located on or near lands owned or used by indigenous people or other groups of stakeholders. Some of our mining and other operations are located in territories where title may be subject to disputes or uncertainties, or in areas claimed for agriculture or land reform purposes, which may lead to disagreements with landowners, organized social movements, local communities and the government. In some jurisdictions, we may be required to consult and negotiate with these groups as part of the process to obtain licenses required to operate, to mitigate impact on our operations or to obtain access to their lands.
Disagreements or disputes with local groups, including indigenous groups, organized social movements and local communities, could cause delays in obtaining licenses, increases in planned budget, delays or interruptions to our operations. These issues may adversely affect our reputation or otherwise hamper our ability to develop our reserves and conduct our operations. Protesters have taken actions to disrupt our operations and projects, and they may continue to do so in the future, which may harm our operations and could adversely affect our business. See Information on the CompanyRegulatory matters and Additional informationLegal proceedings.
| 19 | |
Risk Factors
We could be adversely affected by changes in government policies or by trends such as resource nationalism, including the imposition of new taxes or royalties on mining activities.
Mining is subject to government regulation, including taxes and royalties, which can have a significant financial impact on our operations. In the countries where we are present, we are subject to potential renegotiation, nullification or forced modification of existing contracts and licenses, expropriation or nationalization of property, foreign exchange controls, changes in local laws, regulations and policies and audits and reassessments. We are also subject to new taxes or raising of existing taxes and royalty rates, reduction of tax exemptions and benefits, renegotiation of tax stabilization agreements or changes on the basis on which taxes are calculated in a manner that is unfavorable to us. Governments that have committed to provide a stable taxation or regulatory environment may alter those commitments or shorten their duration. We also face the risk of having to submit to the jurisdiction of a foreign court or arbitration panel or having to enforce a judgment against a sovereign nation within its own territory. See Information on the CompanyRegulatory matters and Additional informationRoyalties and other taxes on mining activities.
We are also required to meet domestic beneficiation requirements in certain countries, such as local processing rules, export taxes or restrictions or charges on unprocessed ores. The imposition of or increase in such requirements, taxes or charges can significantly increase the risk profile and costs of operations in those jurisdictions. We and the mining industry are subject to rising trends of resource nationalism in certain countries in which we operate that can result in constraints on our operations, increased taxation or even expropriations and nationalizations.
As a supplier of iron ore, nickel and other raw materials to the global integrated steel industry, we are subject to additional risk from the imposition of duties, tariffs, import and export controls and other trade barriers impacting our products and the products our customers produce. Global trade is subject to a growing trend of increased trade barriers, which could exacerbate commodities' price volatility and in turn result in instability in the prices of our products.
Concessions, authorizations, licenses and permits are subject to expiration, limitation on renewal and various other risks and uncertainties.
Our operations depend on authorizations and concessions from governmental regulatory agencies in the countries in which we operate. We are subject to laws and regulations in many jurisdictions that can change at any time, and changes in laws and regulations may require modifications to our technologies and operations and result in unanticipated capital expenditures.
Some of our mining concessions are subject to fixed expiration dates and might only be renewed a limited number of times for a limited period of time. Apart from mining concessions, we may need to obtain various authorizations, licenses and permits from governmental or other regulatory bodies in connection with the planning, maintenance, operation and closure of our mines and related logistics infrastructure, which may be subject to fixed expiration dates or periodic review or renewal. There is no assurance that renewals will be granted as and when sought, and there is no assurance that new conditions will not be imposed in connection with renewal. Fees for mining concessions might increase substantially due to the passage of time from the original issuance of each individual exploration license. If so, the costs of holding or renewing our mining concessions may render our business objectives not viable. Accordingly, we need to continually assess the mineral potential of each mining concession, particularly at the time of renewal, to determine if the costs of maintaining the concession are justified by the results of operations to date, and we might elect to let some of our concessions lapse. There can be no assurance that concessions will be obtained on terms favorable to us, or at all, for our future intended mining or exploration targets.
| 20 | |
Risk Factors
In a number of jurisdictions where we have exploration projects, we may be required to retrocede to the state a certain portion of the area covered by the exploration license as a condition to renewing the license or obtaining a mining concession. This requirement can lead to a substantial loss of part of the mineral deposit originally identified in our feasibility studies. For more information on mining concessions and other similar rights, see Information on the CompanyRegulatory matters.
OPERATIONAL RISKS
Our projects are subject to risks that may result in increased costs or delay in their implementation.
We are investing to maintain and further increase our production capacity and logistics capabilities. We regularly review the economic viability of our projects. As a result of this review, we may decide to postpone, suspend or interrupt the implementation of certain projects. Our projects are also subject to a number of risks that may adversely affect our growth prospects and profitability, including the following:
Operational problems could materially and adversely affect our business and financial performance.
Ineffective project management and operational breakdowns might require us to suspend or curtail operations, which could generally reduce our productivity. Operational breakdowns could entail failure of critical plant and machinery. There can be no assurance that ineffective project management or other operational problems will not occur. Any damages to our projects or delays in our operations caused by ineffective project management or operational breakdowns could materially and adversely affect our business and results of operations. Our business is subject to a number of operational risks that may adversely affect our results of operations, such as:
| 21 | |
Risk Factors
Our business could be adversely affected by the failure of our counterparties, joint venture partners or joint ventures we do not control to perform their obligations.
Customers, suppliers, contractors, financial institutions, joint venture partners and other counterparties may fail to perform existing contracts and obligations, which may unfavorably impact our operations and financial results. The ability of suppliers and customers to perform their obligations may be adversely affected in times of financial stress and economic downturn.
Important parts of our iron ore, pelletizing, nickel, coal, copper, energy and other businesses are held through joint ventures. This may reduce our degree of control, as well as our ability to identify and manage risks. Our forecasts and plans for these joint ventures and consortia assume that our partners will observe their obligations to make capital contributions, purchase products and, in some cases, provide skilled and competent managerial personnel. If any of our partners fails to observe its commitments, the affected joint venture or consortium may not be able to operate in accordance with its business plans, or we may have to increase the level of our investment to implement these plans.
Some of our investments are controlled by partners or have separate and independent management. These investments may not fully comply with our standards, controls and procedures, including our health, safety, environment and community standards. Failure by any of our partners or joint ventures to adopt adequate standards, controls and procedures could lead to higher costs, reduced production or environmental, health and safety incidents or accidents, which could adversely affect our results and reputation.
| 22 | |
Risk Factors
We may not have adequate insurance coverage for some business risks.
Our businesses are generally subject to a number of risks and hazards, which could result in damage to, or destruction of, properties, facilities and equipment. The insurance we maintain against risks that are typical in our business may not provide adequate coverage. Insurance against some risks (including liabilities for environmental pollution or certain hazards or interruption of certain business activities) may not be available at a reasonable cost, or at all. Even when it is available, we may self-insure where we determine that is more cost-effective to do so. As a result, accidents or other negative developments involving our mining, production or transportation facilities could have a material adverse effect on our operations.
Labor disputes may disrupt our operations from time to time.
A substantial number of our employees, and some of the employees of our subcontractors, are represented by labor unions and are covered by collective bargaining or other labor agreements, which are subject to periodic negotiation. Strikes and other labor disruptions at any of our operations could adversely affect the operation of facilities and the timing of completion and cost of our capital projects. For more information about labor relations, see Management and employeesEmployees. Moreover, we could be adversely affected by labor disruptions involving unrelated parties that may provide us with goods or services.
Higher energy costs or energy shortages would adversely affect our business.
Costs of fuel oil, gas and electricity are a significant component of our cost of production, representing 10.8% of our total cost of goods sold in 2017. To fulfill our energy needs, we depend on the following sources: oil byproducts, which represented 32.0% of total energy needs in 2017, electricity (31.6%), natural gas (16.7%), coal (15.0%) and other energy sources (4.7%).
Electricity costs represented 4.6% of our total cost of goods sold in 2017. If we are unable to secure reliable access to electricity at acceptable prices, we may be forced to curtail production or may experience higher production costs, either of which would adversely affect our results of operations. We face the risk of energy shortages in the countries where we have operations and projects, especially Brazil, due to lack of infrastructure or weather conditions, such as floods or droughts. Future shortages, and government efforts to respond to or prevent shortages, may adversely impact the cost or supply of electricity for our operations.
Failures in our information technology, operational technology, cybersecurity and telecommunications systems may adversely affect our business and reputation.
We rely heavily on information technology, operational technology and telecommunications systems for the operation of many of our business processes. Failures in those systems, whether caused by obsolescence, technical failures, negligence, accident or malicious acts, may result in the disclosure or theft of sensitive information, misappropriation of funds and disruptions to or interruption in our business operations. We may be the target of attempts to gain unauthorized access to information technology and operational technology systems through the internet, including sophisticated and coordinated attempts often referred to as advanced persistent threats. Disruption of critical information technology, operational technology, cybersecurity or telecommunications systems, or breaches of information security, may harm our reputation and have a material adverse effect on our operational performance, earnings and financial condition.
| 23 | |
Risk Factors
HEALTH, SAFETY AND ENVIRONMENTAL RISKS
Our business is subject to environmental, health and safety incidents.
Our operations involve the use, handling, storage, discharge and disposal of hazardous substances into the environment and the use of natural resources, and the mining industry is generally subject to significant risks and hazards, including fire, explosion, toxic gas leaks, spilling of polluting substances or other hazardous materials, rockfalls, incidents involving dams, failure of other operational structures and incidents involving mobile equipment, vehicles or machinery. This could occur by accident or by breach of operating and maintenance standards, and could result in a significant environmental and social impacts, damage to or destruction of mineral properties or production facilities, personal injury, illness or death of employees, contractors or community members close to operations, environmental damage, delays in production, monetary losses and possible legal liability. Additionally, in remote localities, our employees may be exposed to tropical and contagious diseases that may affect their health and safety. Notwithstanding our standards, policies and controls, our operations remain subject to incidents or accidents that could adversely affect our business, stakeholders or reputation.
Our business may be adversely affected by social, environmental and health and safety regulation, including regulations pertaining to climate change.
Nearly all aspects of our activities, products, services and projects around the world are subject to social, environmental and health and safety regulations, which may expose us to increased liability or increased costs. These regulations require us to have environmental licenses, permits and authorizations for our operations and projects, and to conduct environmental and social impact assessments in order to get approval for our projects and permission for initiating construction. Significant changes to existing operations are also subject to these requirements. Difficulties in obtaining or renewing permits may lead to construction delays, cost increases, and may adversely impact our production volumes. Social, environmental and health and safety regulations also impose standards and controls on activities relating to mineral research, mining, pelletizing activities, railway and marine services, ports, decommissioning, refining, distribution and marketing of our products. Such regulation may give rise to significant costs and liabilities. Litigation relating to these or other related matters may adversely affect our financial condition or cause harm to our reputation.
Social, environmental and health and safety regulations in many countries in which we operate has become stricter in recent years, and it is possible that more regulation or more aggressive enforcement of existing regulations will adversely affect us by imposing restrictions on our activities and products, creating new requirements for the issuance or renewal of environmental licenses, resulting in operation delays, raising our costs or requiring us to engage in expensive reclamation efforts.
It is possible that in certain of our iron ore mining operations or projects, we may be required to limit or modify our mining plans or to incur additional costs to preserve caves or to compensate for the impact on them, with potential consequences for production volumes, costs or reserves in our iron ore business. For more information about Brazilian environmental regulations related to caves, see Information on the CompanyRegulatory mattersEnvironmental regulations.
In response to the failure of Samarco's tailings dam in Minas Gerais, additional environmental and health and safety laws and regulations may be forthcoming in Brazil and authorities may impose more stringent conditions in connection with the licensing process of our projects and operations. Also, we may encounter more stringent requirements for and delays in the receipt of environmental operating license for other tailings dams.
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Risk Factors
National policies and international regulations regarding climate change may affect a number of our businesses in various countries. The ratification of the Paris Agreement in 2016 increased international pressure for the establishment of a global carbon price, and on companies to adopt carbon pricing strategies. The pricing of greenhouse gas emissions may impact our operational costs, mainly through higher price for fossil fuels as mining is an energy intensive industry, and our cost of international freight. Consumption of coal, one of the products we sell, in particular, is facing pressure from international institutions due to its carbon intensity.
Regulatory initiatives at the national and international levels that affect our shipping practices could increase our costs or require us to make new capital expenditures.
Natural disasters may cause severe damage to our operations and projects in the countries where we operate and may have a negative impact on our sales to countries affected by such disasters.
Natural disasters, such as wind storms, droughts, floods, earthquakes and tsunamis may adversely affect our operations and projects in the countries where we operate, and may cause a contraction in sales to countries adversely affected due to, among other factors, power outages and the destruction of industrial facilities and infrastructure. The physical impact of climate change on our business remains uncertain, but we are likely to experience changes in rainfall patterns, increased temperatures, water shortages, rising sea levels, increased storm frequency and intensity as a result of climate change, which may adversely affect our operations. On some occasions in recent years, we have determined that force majeure events have occurred due to effect of severe weather on our mining and logistics activities.
RISKS RELATING TO OUR MINING RESERVES
Our reserve estimates may materially differ from mineral quantities that we are actually able to recover; our estimates of mine life may prove inaccurate; and market price fluctuations and changes in operating and capital costs may render certain ore reserves uneconomical to mine.
Our reported reserves are estimated quantities of ore and minerals that we have determined can be economically mined and processed under present and assumed future conditions. There are numerous uncertainties inherent in estimating quantities of reserves and in projecting potential future rates of mineral production, including factors beyond our control. Reserve reporting involves estimating deposits of minerals that cannot be measured in an exact manner, and the accuracy of any reserve estimate is a function of the quality of available data, engineering and geological interpretation and judgment. As a result, no assurance can be given that the indicated amount of ore will be recovered or that it will be recovered at the rates we anticipate. Reserve estimates and estimates of mine life may require revisions based on actual production experience, projects, updated exploration drilling data and other factors. Lower market prices of minerals and metals, reduced recovery rates or increased operating and capital costs due to inflation, exchange rates, changes in regulatory requirements or other factors may render proven and probable reserves uneconomic to exploit and may ultimately result in a reduction of reserves. Such a reduction could affect depreciation and amortization rates and have an adverse effect on our financial performance.
We may not be able to replenish our reserves, which could adversely affect our mining prospects.
We engage in mineral exploration, which is highly uncertain in nature, involves many risks and frequently is non-productive. Our exploration programs, which involve significant expenditures, may fail to result in
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Risk Factors
the expansion or replacement of reserves depleted by current production. If we do not develop new reserves, we will not be able to sustain our current level of production beyond the remaining lives of our existing mines.
The feasibility of new mineral projects may change over time.
Once mineral deposits are discovered, it can take a number of years from the initial phases of drilling until production is possible, during which the economic feasibility of production may change. Substantial time and expenditures are required to:
If a project proves not to be economically feasible by the time we are able to exploit it, we may incur substantial losses and be obliged to take write-downs. In addition, potential changes or complications involving metallurgical and other technological processes arising during the life of a project may result in delays and cost overruns that may render the project not economically feasible.
We face rising extraction costs and investment requirements over time as reserves deplete.
Reserves are gradually depleted in the ordinary course of a given open pit or underground mining operation. As mining progresses, distances to the primary crusher and to waste deposits become longer, pits become steeper, mines may move from being open pit to underground, and underground operations become deeper. In addition, for some types of reserves, mineralization grade decreases and hardness increases at greater depths. As a result, over time, we usually experience rising unit extraction costs with respect to each mine, or we may need to make additional investments, including adaptation or construction of processing plants and expansion or construction of tailings dams. Several of our mines have been operating for long periods, and we will likely experience rising extraction costs per unit in the future at these operations in particular.
RISKS RELATING TO OUR CORPORATE STRUCTURE
The shareholders that are party to our shareholders' agreement have significant power over Vale.
On August 14, 2017, Litel Participações S.A. ("Litel"), Bradespar S.A. ("Bradespar"), Mitsui & Co., Ltd. ("Mitsui") and BNDES Participações S.A. ("BNDESPAR") entered into a shareholders' agreement pursuant to which they undertake to vote jointly on certain key matters (the "Shareholders' Agreement"). The Shareholders' Agreement is expected to expire on November 9, 2020. See Share ownership and tradingMajor shareholders. On December 31, 2017, Litel, Bradespar, Mitsui and BNDESPAR together held 40.29% of our total capital stock. As long as no other shareholder or group of shareholders owns more shares than
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Risk Factors
the parties to the Shareholders' Agreement, these major shareholders may elect a majority of the members of the board of directors and control the outcome of certain actions requiring shareholder approval.
The Brazilian Government has certain veto rights.
The Brazilian government owns 12 golden shares of Vale, granting it limited veto power over certain company actions, such as changes to our name, the location of our headquarters and our corporate purpose as it relates to mining activities. For a detailed description of the Brazilian government's veto powers, see Additional informationMemorandum and articles of associationCommon shares and golden shares.
Our governance and compliance processes may fail to prevent regulatory penalties and reputational harm.
We operate in a global environment, and our activities extend over multiple jurisdictions and complex regulatory frameworks, with increasing enforcement activities worldwide. Our governance and compliance processes, which include the review of internal control over financial reporting, may not timely identify or prevent future breaches of legal, accounting or governance standards. We may be subject to breaches of our code of ethics and conduct, anti-corruption policies and business conduct protocols and to instances of fraudulent behavior, corrupt practices and dishonesty by our employees, contractors or other agents. Our failure to comply with applicable laws and other standards could subject us to investigations by authorities, litigation, fines, loss of operating licenses, disgorgement of profits, involuntary dissolution and reputational harm.
It could be difficult for investors to enforce any judgment obtained outside Brazil against us or any of our associates.
Our investors may be located in jurisdictions outside Brazil and could seek to bring actions against us or our directors or officers in the courts of their home jurisdictions. We are a Brazilian company, and the majority of our officers and directors are residents of Brazil. The vast majority of our assets and the assets of our officers and directors are likely to be located in jurisdictions other than the home jurisdictions of our foreign investors. It might not be possible for investors outside Brazil to effect service of process within their home jurisdictions on us or on our officers or directors who reside outside their home jurisdictions. In addition, a final conclusive foreign judgment will be enforceable in the courts of Brazil without a re-examination of the merits only if previously confirmed by the Brazilian Superior Court of Justice (STJSuperior Tribunal de Justiça), and confirmation will only be granted if the foreign judgment: (a) fulfills all formalities required for its enforceability under the laws of the country where it was issued; (b) was issued by a competent court after due service of process on the defendant, as required under applicable law; (c) is not subject to appeal; (d) does not conflict with a final and unappealable decision issued by a Brazilian court; (e) was authenticated by a Brazilian consulate in the country in which it was issued or is duly apostilled in accordance with the Convention for Abolishing the Requirement of Legalization for Foreign Public Documents and is accompanied by a sworn translation into Portuguese, unless this procedure was exempted by an international treaty entered into by Brazil; (f) it does not cover matters subject to the exclusive jurisdiction of the Brazilian courts; and (g) is not contrary to Brazilian national sovereignty, public policy or good morals. Therefore, investors might not be able to recover against us or our directors and officers on judgments of the courts of their home jurisdictions predicated upon the laws of such jurisdictions.
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Risk Factors
RISKS RELATING TO OUR DEPOSITARY SHARES
If ADR holders exchange ADSs for the underlying shares, they risk losing the ability to remit foreign currency abroad.
The custodian for the shares underlying our ADSs maintains a registration with the Central Bank of Brazil permitting qualifying institutional foreign investors to buy and sell securities on the B3 and entitling the custodian to remit U.S. dollars outside Brazil for payments of dividends and other distributions relating to the shares underlying our ADSs or upon the disposition of the underlying shares. If an ADR holder exchanges its ADSs for the underlying shares, it will be entitled to rely on the custodian's registration for only five business days from the date of exchange. Thereafter, an ADR holder may not be able to obtain and remit foreign currency abroad upon the disposition of, or distributions relating to, the underlying shares unless it obtains its own registration under applicable regulation. See Additional informationExchange controls and other limitations affecting security holders. If an ADR holder attempts to obtain its own registration, it may incur expenses or suffer delays in the application process, which could delay the receipt of dividends or other distributions relating to the underlying shares or the return of capital in a timely manner.
The custodian's registration or any registration obtained could be affected by future legislative changes, and additional restrictions applicable to ADR holders, the disposition of the underlying shares or the repatriation of the proceeds from disposition could be imposed in the future.
ADR holders may not have all the rights of our shareholders, and may be unable to exercise preemptive rights relating to the shares underlying their ADSs.
ADR holders may not have the same rights that are attributed to our shareholders by Brazilian law or our bylaws, and the rights of ADR holders may be subject to certain limitations provided in the deposit agreement or by the securities intermediaries through which ADR holders hold their securities. Also, the ability of ADR holders to exercise preemptive rights is not assured, particularly if the applicable law in the holder's jurisdiction (for example, the Securities Act in the United States) requires that either a registration statement be effective or an exemption from registration be available with respect to those rights, as is in the case in the United States. We are not obligated to extend the offer of preemptive rights to holders of ADRs, to file a registration statement in the United States, or to make any other similar filing in any other jurisdiction, relating to preemptive rights or to undertake steps that may be needed to make exemptions from registration available, and we cannot assure holders that we will file any registration statement or take such steps.
ADR holders may encounter difficulties in the exercise of voting rights.
ADR holders do not have the rights of shareholders. They have only the contractual rights set forth for their benefit under the deposit agreements. ADR holders are not permitted to attend shareholders' meetings, and they may only vote by providing instructions to the depositary. In practice, the ability of a holder of ADRs to instruct the depositary as to voting will depend on the timing and procedures for providing instructions to the depositary either directly or through the holder's custodian and clearing system. With respect to ADSs for which instructions are not received, the depositary may, subject to certain limitations, grant a proxy to a person designated by us.
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Risk Factors
The legal protections for holders of our securities differ from one jurisdiction to another and may be inconsistent, unfamiliar or less effective than investors anticipate.
We are a global company with securities traded in several different markets and investors located in many different countries. The legal regime for the protection of investors varies around the world, sometimes in important ways, and investors in our securities should recognize that the protections and remedies available to them may be different from those to which they are accustomed in their home markets. We are subject to securities legislation in several countries, which have different rules, supervision and enforcement practices. The only corporate law applicable to our parent company is the law of Brazil, with its specific substantive rules and judicial procedures. We are subject to corporate governance rules in several jurisdictions where our securities are listed, but as a foreign private issuer, we are not required to follow many of the corporate governance rules that apply to U.S. domestic issuers with securities listed on the New York Stock Exchange, and we are not subject to the U.S. proxy rules.
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II. INFORMATION ON THE COMPANY
Our principal lines of business consist of mining and related logistics. This section presents information about operations, production, sales and competition and is organized as follows.
1. Ferrous minerals 1.1 Iron ore and iron ore pellets 1.1.1 Iron ore operations 1.1.2 Iron ore production 1.1.3 Iron ore pellets operations 1.1.4 Iron ore pellets production 1.1.5 Customers, sales and marketing 1.1.6 Competition 1.2 Manganese ore and ferroalloys 1.2.1 Manganese ore operations and production 1.2.2 Ferroalloys operations and production 1.2.3 Manganese ore and ferroalloys: sales and competition 2. Base metals 2.1 Nickel 2.1.1 Operations 2.1.2 Production 2.1.3 Customers and sales 2.1.4 Competition 2.2 Copper 2.2.1 Operations 2.2.2 Production 2.2.3 Customers and sales 2.2.4 Competition 2.3 PGMs and other precious metals 2.4 Cobalt |
| 3. Coal 3.1 Operations 3.2 Production 3.3 Customers and sales 3.4 Competition 4. Infrastructure 4.1 Logistics 4.1.1 Railroads 4.1.2 Ports and maritime terminals 4.1.3 Shipping 4.2 Energy 5. Other investments |
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Our ferrous minerals business includes iron ore mining, iron ore pellet production, manganese ore mining and ferroalloy production. Each of these activities is described below.
1.1 Iron ore and iron ore pellets
1.1.1 Iron ore operations
We conduct our iron ore business in Brazil primarily at the parent-company level, and through our subsidiaries Mineração Corumbaense Reunida S.A. ("MCR") and Minerações Brasileiras Reunidas S.A.MBR ("MBR"). Our mines, all of which are open pit, and their related operations are mainly concentrated in three systems: the Southeastern, Southern and Northern Systems, each with its own transportation capabilities. We also conduct mining operations in the Midwestern System and we have a 50% stake in Samarco. Samarco's operations have been suspended following the failure of one of its tailings dams located in Minas Gerais in November 2015 (see Business overviewFailure of Samarco's tailings dam in Minas Gerais). We conduct each of our iron ore operations in Brazil under concessions from the federal government granted for an indefinite period, subject to the life of the mines.
Company/Mining System | Location | Description/History | Mineralization | Operations | Power source | Access/Transportation | ||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
Vale | ||||||||||||
Northern System | Carajás, state of Pará | Divided into Serra Norte, Serra Sul and Serra Leste (Northern, Southern and Eastern ranges). Since 1984, we have been conducting mining activities in the northern range, which is divided into three main mining areas (N4W, N4E and N5) and two major beneficiation plants. In 2014, we started a new mine and beneficiation plant in Serra Leste. Our operations in Serra Sul, where our S11D project is located, started in 2016. | High-grade hematite ore type (iron grade of more than 65% on average). | Open-pit mining operations. In Serra Norte, one of the major plants applies the natural moisture beneficiation process, consisting of crushing and screening, and the other applies both the natural moisture and the wet beneficiation process in distinct lines. The wet beneficiation process consists simply of sizing operations, including screening, hydrocycloning, crushing and filtration. Output from this site consists of sinter feed, pellet feed and lump ore. Serra Leste and Serra Sul natural moisture beneficiation process consists of crushing and screening. Serra Sul produces only sinter feed and Serra Leste produces lump and sinter feed. | Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. | Carajás railroad (EFC) transports the iron ore to the Ponta da Madeira maritime terminal in the Brazilian state of Maranhão. Serra Leste iron ore is transported by trucks from the mine site to EFC railroad. The Serra Sul ore is shipped via the new 101-kilometers long railroad branch. | ||||||
Southeastern System | Iron Quadrangle, state of Minas Gerais | Three mining complexes: Itabira (two mines, with three major beneficiation plants), Minas Centrais (two mines, with two major beneficiation plants and one secondary plant) and Mariana (three mines, with two major beneficiation plants). | Ore reserves with high ratios of itabirite ore relative to hematite ore type. Itabirite ore type has iron grade of 35-60%. Part of the ore is concentrated to achieve shipping grade and part is shipped and blended in Asia with the high-grade ore from our Northern System. | Open-pit mining operations. We generally process the run-of-mine by means of standard crushing, classification and concentration steps, producing sinter feed, lump ore and pellet feed in the beneficiation plants located at the mining complexes. | Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. | EFVM railroad connects these mines to the Tubarão port. |
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Company/Mining System | Location | Description/History | Mineralization | Operations | Power source | Access/Transportation | ||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
Southern System | Iron Quadrangle, state of Minas Gerais | Three major mining complexes: Minas Itabirito (four mines and three major beneficiation plants); Vargem Grande (three mines and two major beneficiation plants); and Paraopeba (five mines and two major beneficiation plants). | Ore reserves with high ratios of itabirite ore type relative to hematite ore type. Itabirite ore has iron grade of 35-60%. Part of the ore is concentrated to achieve shipping grade and part is shipped and blended in Asia with the high-grade ore from our Northern System. | Open-pit mining operations. We generally process the run-of-mine by means of standard crushing, classification and concentration steps, producing sinter feed, lump ore and pellet feed in the beneficiation plants located at the mining complexes. | Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. | MRS transports our iron ore products from the mines to our Guaíba Island and Itaguaí maritime terminals in the Brazilian state of Rio de Janeiro. EFVM railroad connects certain mines to the Tubarão port. | ||||||
Midwestern System | State of Mato Grosso do Sul | Two mines and two plants located in the city of Corumbá. | Hematite ore type, which generates lump ore predominantly. Iron grade of 62% on average. | Open-pit mining operations. The beneficiation process for the run-of-mine consists of standard crushing and classification steps, producing lump ore and sinter feed. | Supplied through the national electricity grid. Acquired from regional utility companies or acquired through power purchase agreements. | Transported through barges traveling along the Paraguay river to ports in Argentina, and on to European and Asian markets from there, or delivered to customers at Corumbá. | ||||||
Samarco | Iron Quadrangle, state of Minas Gerais | Integrated system comprised of two mines, three beneficiation plants, three pipelines, four pellet plants and a port. The mines and the beneficiation plants are located in the state of Minas Gerais and the pellet plants and port are located in the state of Espírito Santo. From Minas Gerais to Espírito Santo state production flows through the three pipelines which extend for approximately 400 Km. | Itabirite ore type. | Open-pit mining operations. The three beneficiation plants, located at the site, process the run-of-mine by means of standard crushing, milling and concentration steps, producing pellet feed and sinter feed. Samarco's mining operations have been suspended following the failure of one of its tailings dams located in Minas Gerais in November 2015 (see Business overviewFailure of Samarco's tailings dam in Minas Gerais). | Supplied through the national electricity grid. Acquired from regional utility companies or produced directly by Samarco. | Samarco's mines supply Samarco's pellet plants using three pipelines extending approximately 400 kilometers. These pipelines transport the iron ore from the beneficiation plants to the pelletizing plants. From the pelletizing plants to the Ubu port in the Brazilian state of Espírito Santo, pellets are transported by conveyor belts of approximately one kilometer. |
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Lines of Business
1.1.2 Iron ore production
The following table sets forth information about our iron ore production.
|
| |
| Production for the year ended December 31(2), |
| |
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|
| |
| 2017 process recovery(3) |
||||||
Mine/Plant | | Type | | 2015 | | 2016 | | 2017 | ||
|
| |
| (million metric tons) |
| (%) |
||||
Southeastern System |
| | | | | |||||
Itabira |
| Open pit | | 35.6 | | 33.4 | | 37.8 | | 50.9 |
Minas Centrais(1) |
| Open pit | | 41.3 | | 40.9 | | 37.6 | | 67.6 |
Mariana |
| Open pit | | 36.1 | | 28.4 | | 33.1 | | 85.4 |
| | | | | | | | | | |
Total Southeastern System |
| | 113.0 | | 102.7 | | 108.6 | | ||
| | | | | | | | | | |
Southern System |
| | | | | |||||
Minas Itabirito |
| Open pit | | 41.4 | | 40.1 | | 36.8 | | 82.1 |
Vargem Grande |
| Open pit | | 29.3 | | 29.2 | | 23.3 | | 63.2 |
Paraopeba |
| Open pit | | 28.1 | | 26.4 | | 26.3 | | 92.9 |
| | | | | | | | | | |
Total Southern System |
| | 98.8 | | 95.7 | | 86.4 | | ||
| | | | | | | | | | |
Northern System |
| | | | | |||||
Serra Norte |
| Open pit | | 127.6 | | 143.6 | | 142.7 | | 96.1 |
Serra Leste |
| Open pit | | 2.0 | | 4.2 | | 4.3 | | 99.2 |
Serra Sul |
| Open pit | | | | 0.4 | | 22.2 | | 100.0 |
| | | | | | | | | | |
Total Northern System |
| | 129.6 | | 148.1 | | 169.2 | | ||
| | | | | | | | | | |
Midwestern System |
| | | | | |||||
Corumbá |
| Open pit | | 2.8 | | 1.9 | | 2.4 | | 67.9 |
Urucum |
| Open pit | | 1.7 | | 0.4 | | 0.0 | | 0.0 |
| | | | | | | | | | |
Total Midwestern System |
| | 4.5 | | 2.3 | | 2.4 | | ||
| | | | | | | | | | |
Total Vale Systems |
| | 345.9 | | 348.8 | | 366.5 | | ||
| | | | | | | | | | |
Samarco(2)(3) |
| Open pit | | 12.7 | | 0.0 | | 0.0 | | |
| | | | | | | | | | |
Total |
| | 358.6 | | 348.8 | | 366.5 | | ||
| | | | | | | | | | |
| | | | | | | | | | |
| | | | | | | | | | |
1.1.3 Iron ore pellet operations
We produce iron ore pellets in Brazil and Oman, directly and through joint ventures, as set forth in the table below. We also have a 25% interest in two iron ore pelletizing plants in China, Zhuhai Yueyufeng Iron and Steel Co., Ltd ("Zhuhai YPM") and Anyang Iron & Steel Co., Ltd ("Anyang"). Our total estimated nominal capacity is 64.7 Mtpy, including the full capacity of our pelletizing plants in Oman, but not including our joint ventures Samarco, Zhuhai YPM and Anyang. We supply all of the iron ore requirements of our wholly owned pellet plants and part of the iron ore requirements for Samarco and Zhuhai YPM. In 2017, we sold 0.5 million metric tons of pellet feed to Zhuhai YPM. We suspended our sales of run-of-mine to Samarco following the failure of Samarco's tailings dam in November 2015.
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Company/Plant | Description/History | Nominal capacity (Mtpy) |
Power source | Other information | Vale's equity interest (%) |
Partners | ||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
Brazil: | ||||||||||||
Vale |
||||||||||||
Tubarão (state of Espírito Santo) | Three wholly owned pellet plants (Tubarão I, II and VIII) and five leased plants (Itabrasco, Hispanobras, Kobrasco and two Nibrasco plants). These plants receive iron ore primarily from our Southeastern System mines and use our logistics infrastructure for distribution. | 36.7(1) | Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. | Operations at the Tubarão II pellet plant started up in January 2018, Tubarão I pellet plant is expected to restart operations in the first half of 2018 in response to market conditions. Operations at these plants have been suspended since 2012. | 100.0 | | ||||||
Fábrica (state of Minas Gerais) |
Part of the Southern System. Receives iron ore from the Minas Itabirito mining complex, more specifically from João Pereira and Segredo mines. Production is mostly transported by MRS and EFVM. |
4.5 |
Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. |
|
100.0 |
|
||||||
Vargem Grande (state of Minas Gerais) |
Part of the Southern System. Receives iron ore from the Minas Itabirito and Vargem Grande mining complexes, more specifically from Sapecado, Galinheiro, Capitão do Mato and Tamanduá mines. Production is mostly transported by MRS. |
7.0 |
Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. |
|
100.0 |
|
||||||
São Luís (state of Maranhão) |
Part of the Northern System. Receives iron ore from the Carajás mines. Production is shipped to customers through our Ponta da Madeira maritime terminal. |
7.5 |
|
Operation at the São Luís plant are expected to restart operations in the second half of 2018 in response to market conditions. Operations at this plant have been suspended since 2012. |
100.0 |
|
||||||
Samarco |
Four pellet plants, with aggregate nominal capacity of 30.5 Mtpy, located in the Ponta Ubu unit, in Anchieta, state of Espírito Santo. |
30.5(2) |
Supplied through the national electricity grid. Acquired from regional utility companies or produced directly by Samarco. |
In January 2016, Samarco suspended its pelletizing operations as pelletizing feed became unavailable as a result of the suspension of its mining operations in November 2015. |
50.0 |
BHP Billiton Brasil Ltda. |
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Company/Plant | Description/History | Nominal capacity (Mtpy) |
Power source | Other information | Vale's equity interest (%) |
Partners | ||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
Oman: | ||||||||||||
Vale Oman Pelletizing Company LLC |
Vale's industrial complex. Two pellet plants with a total nominal capacity of 9.0 Mtpy. The pelletizing plants are integrated with our distribution center that has a nominal capacity of 40.0 Mtpy. |
9.0 |
Supplied through the national electricity grid. |
Oman plants are supplied by iron ore from the Iron Quadrangle state of Minas Gerais through the Tubarão Port (80%) and by iron ore from Carajás through the Ponta de Madeira maritime terminal (20%). |
70.0 |
Oman Oil Company S.A.O.C. |
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Lines of Business
1.1.4 Iron ore pellets production
The following table sets forth information about our main iron ore pellet production.
|
| Production for the year ended December 31, | ||||
---|---|---|---|---|---|---|
Company | | 2015 | | 2016 | | 2017 |
|
| (million metric tons) | ||||
Vale(1) |
| 46.2 | | 46.2 | | 50.3 |
Samarco(2) |
| 12.3 | | 0.0 | | 0.0 |
| | | | | | |
Total |
| 58.5 | | 46.2 | | 50.3 |
| | | | | | |
| | | | | | |
| | | | | | |
1.1.5 Customers, sales and marketing
We supply all of our iron ore and iron ore pellets to the steel industry. Prevailing and expected levels of demand for steel products affect demand for our iron ore and iron ore pellets. Demand for steel products is influenced by many factors, such as global manufacturing production, civil construction and infrastructure spending. For further information about demand and prices, see Operating and financial review and prospectsMajor factors affecting prices.
In 2017, China accounted for 57% of our iron ore and iron ore pellet shipments, and Asia as a whole accounted for 71%. Europe accounted for 13%, followed by Brazil with 9%. Our ten largest customers collectively purchased 134 million metric tons of iron ore and iron ore pellets from us, representing 39% of our 2017 iron ore and iron ore pellet sales volumes and 39% of our total iron ore and iron ore pellet revenues. In 2017, no individual customer accounted for more than 7% of our iron ore and iron ore pellet shipments.
Of our total 2017 pellet production, 59% was blast furnace pellets and 41% was direct reduction pellets. Blast furnace and direct reduction are different technologies employed by steel mills to produce steels, each using different types of pellets. In 2017, the Asian market (mainly Japan), the European market and the Brazilian market were the primary markets for our blast furnace pellets, while the Middle East and North America were the primary markets for our direct reduction pellets.
We invest in customer service in order to improve our competitiveness. We work with our customers to understand their objectives and to provide them with iron ore solutions to meet specific customer needs. Using our expertise in mining, agglomeration and iron-making processes, we search for technical solutions that will balance the best use of our world-class mining assets and the satisfaction of our customers. We believe that our ability to provide customers with a total iron ore solution and the quality of our products are both very important advantages helping us improve our competitiveness in relation to competitors that may be more conveniently located geographically. In addition to offering technical assistance to our customers, we have sales offices in St. Prex (Switzerland), Tokyo (Japan), Seoul (South Korea), Singapore, Dubai (UAE) and Shanghai (China), which support global sales by Vale International, and an office in Brazil, which supports sales to South America. These offices also allow us to stay in close
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contact with our customers, monitor their requirements and our contract performance, and ensure that our customers receive timely deliveries.
We sell iron ore and iron ore pellets under different arrangements, including long-term contracts with customers and on a spot basis through tenders and trading platforms. Our pricing is generally linked to market price indexes and uses a variety of mechanisms, including current spot prices and average prices over specified periods. In cases where the products are priced before the final price is determinable at delivery, we recognize the sale based on a provisional price with a subsequent adjustment reflecting the final price.
In 2017, we hedged part of our total exposure to bunker oil prices relating to our owned fleet and long-term contracts of affreightment connected to our FOB and CFR international and domestic sales. The 2017 hedge program was settled in 2017.
1.1.6 Competition
The global iron ore and iron ore pellet markets are highly competitive. The main factors affecting competition are price, quality and range of products offered, reliability, operating costs and shipping costs.
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competitive in the European market for the same reasons as in Asia, but also due to the proximity of our port facilities to European customers.
With respect to pellets, our major competitors are LKAB, Iron Ore Company of Canada, Ferrexpo Plc, Arcelor Mittal Mines Canada (former Quebec Cartier Mining Co.) and Bahrain Steel (former Gulf Industrial Investment Co.).
1.2 Manganese ore and ferroalloys
1.2.1 Manganese ore operations and production
We conduct our manganese mining operations in Brazil through Vale S.A. and our wholly owned subsidiaries Vale Manganês S.A. ("Vale Manganês") and MCR. Our mining operations are carried out under concessions from the federal government granted for an indefinite period. Our mines produce metallurgical ore, used primarily for the production of manganese ferroalloys, a raw material used to produce carbon and stainless steel.
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Mining complex |
Company | Location | Description/History | Mineralization | Operations | Power source | Access/ Transportation |
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Azul |
Vale S.A. | State of Pará | Open-pit mining operations and on-site beneficiation plant. | High- and medium-grade oxide-ores (24-46% manganese grade). | Crushing, scrubbing and classification steps, producing lumps and fines. | Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. | Manganese ore is transported by truck and EFC railroad to the Ponta da Madeira maritime terminal. | |||||||
Morro da Mina |
Vale Manganês | State of Minas Gerais | Open-pit mining operations and concentration plant. | Medium- and low-grade silicocarbonate ores (an average content of 30% manganese grade). | Crushing, screening and dense-heavy medium separation DMS / HMS process producing lumps to the Barbacena and Ouro Preto ferroalloy plants. | Supplied through the national electricity grid. Acquired from regional utility companies. | Manganese ore is transported by truck to the Barbacena and Ouro Preto ferroalloy plants. | |||||||
Urucum |
MCR | State of Mato Grosso do Sul | Underground mining operations and on-site beneficiation plant. | High-and medium-grade oxide ores (an average content of 46% manganese grade). | Crushing, scrubbing and classification steps, producing lumps and fines. | Supplied through the national electricity grid. Acquired from regional utility companies or acquired through power purchase agreements. | Manganese ore is transported by barge traveling along the Paraguay and Paraná rivers to transhippers at the Nueva Palmira port in Uruguay. |
The following table sets forth information about our manganese ore production, obtained after beneficiation process, and mass recovery.
|
|
Production for the year ended December 31, | |
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|
|
2017 process recovery |
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Mine | Type | 2015 | 2016 | 2017 | ||||||
|
(million metric tons) | (%) | ||||||||
Azul |
Open pit | 1.7 | 1.7 | 1.4 | 41.5 | |||||
Morro da Mina(1) |
Open pit | | 0.0 | 0.1 | 60.0 | |||||
Urucum |
Underground | 0.7 | 0.7 | 0.7 | 82.7 | |||||
| | | | | | | | | | |
Total |
2.4 | 2.4 | 2.2 | |||||||
| | | | | | | | | | |
| | | | | | | | | | |
| | | | | | | | | | |
1.2.2 Manganese ferroalloys operations and production
We conduct our manganese ferroalloys business through our wholly owned subsidiary Vale Manganês. The production of manganese ferroalloys consumes significant amounts of electricity, which is provided through power purchase agreements.
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We produce several types of manganese ferroalloys, such as high carbon and medium carbon ferro-manganese and ferro-silicon manganese.
Plant | Location | Description/History | Nominal capacity | Power source | ||||
---|---|---|---|---|---|---|---|---|
Minas Gerais Plants |
Cities of Barbacena and Ouro Preto | Barbacena has six furnaces, two of which are refining furnaces and a briquetting plant. Ouro Preto has three furnaces, two of which are currently not operating due to market conditions. | Barbacena: 66,000 tons per year (54,000 tons per year of ferro-silicon manganese and 12,000 tons per year of ferro-manganese medium carbon). Ouro Preto: 64,000 tons per year of ferro-silicon manganese. | Supplied through the national electricity grid. Acquired from FurnasCentrais Elétricas S.A. through power purchase agreements. | ||||
Bahia Plant |
City of Simões Filho | Four furnaces, two converters and a sintering plant. | 135,000 tons per year (42,000 tons per year of ferro-silicon manganese and 93,000 tons per year of high carbon ferro-manganese). The plant has a capacity to refine until 40,000 tons per year of ferro-manganese high carbon to produce ferro-manganese medium carbon alloy, according to market demand. | Supplied through the national electricity grid. Acquired from Companhia Hidrelétrica do São Francisco (CHESF) or through power purchase agreements. |
The following table sets forth information about our manganese ferroalloys production.
|
| Production for the year ended December 31(1), | ||||
---|---|---|---|---|---|---|
Plant | | 2015 | | 2016 | | 2017 |
|
| (thousand metric tons) | ||||
Barbacena |
| 6 | | 48 | | 58 |
Ouro Preto |
| 1 | | | | |
Simões Filho |
| 92 | | 77 | | 88 |
| | | | | | |
Total |
| 99 | | 124 | | 146 |
| | | | | | |
| | | | | | |
| | | | | | |
1.2.3 Manganese ore and ferroalloys: sales and competition
The markets for manganese ore and ferroalloys are highly competitive. Competition in the manganese ore market takes place in two segments. High- and medium-grade manganese ore competes on a global seaborne basis, while low-grade ore competes on a regional basis. For some manganese ferroalloys, especially ferromanganese, higher-grade manganese ores are required to achieve competitive quality and cost, while medium- to lower-grade ores may be used in silicomanganese production. The main suppliers of high-grade ores are located in South Africa, Gabon, Australia and Brazil. The main producers of low-grade ores are located in the Ukraine, China, South Africa, Ghana, Kazakhstan, India and Mexico.
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We compete in the seaborne market with both high- and medium-grade ores from the Azul and Urucum mines, where we benefit from extensive synergies with our iron ore operations, from mine to rail to port to vessel operations. Our main competitors in this segment are South32 (Australia and South Africa) and Eramet (Gabon). Our lower-grade ores, especially those from Morro da Mina, are consumed internally in our ferroalloy smelters.
The manganese ferroalloy market is characterized by a large number of participants who compete primarily on the basis of price. Our competitors are located principally in countries that produce manganese ore or carbon steel. Potential entrants and substitutes come from silicon or chrome ferroalloys, which can occasionally shift their furnaces to manganese alloys, and from electrolytic manganese producers. Competitors may be either integrated smelters like us, who feed manganese ore from their own mines, or non-integrated smelters. The principal competitive factors in this market are the costs of manganese ore, electricity, logistics and reductants such as coke, coal and charcoal. We compete with both stand-alone and integrated producers.
Focusing mainly in the Brazilian, South and North American steelmaking customers, our ferroalloys operations also benefit from synergies with our iron ore sales, marketing, procurement and logistics activities. We buy our energy and coke supplies at reasonable market prices both though medium-and long-term contracts. Competitors in the Brazilian market are about a dozen smelters with capacities from five to 90 thousand tons per year, most of which are not integrated and some of which are customers of our manganese ores. We have a distinctive advantage in comparison to them in producing ferroalloys with higher manganese content.
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2.1 Nickel
2.1.1 Operations
We conduct our nickel operations primarily through our wholly owned subsidiary Vale Canada, which operates two nickel production systems, one in the North Atlantic region and the other in the Asia Pacific region. We also produce copper as a coproduct in our nickel operations in Canada and, through Vale S.A., operate a third nickel production system, Onça Puma, in the South Atlantic region. Our nickel operations are set forth in the following table.
Company/Mining System | Location | Description/History | Operations | Mining title | Power source | Access/ Transportation |
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North Atlantic: | ||||||||||||
Vale Canada | Canada Sudbury, Ontario | Integrated mining, milling, smelting and refining operations to process ore into finished nickel with a nominal capacity of 66,000 metric tons of refined nickel per year and additional nickel oxide feed for the refinery in Wales and our nickel plants in Asia. Mining operations in Sudbury began in 1885. We acquired the Sudbury operations in 2006. | Nickel. Primarily underground mining operations with nickel sulfide ore bodies, which also contain some copper, cobalt, PGMs, gold and silver. We also process external feeds from third parties and from our Voisey's Bay operation. By the end of 2017, we ceased receiving Voisey's Bay feed in Sudbury. In addition to producing finished nickel in Sudbury, we ship a nickel oxide intermediate product to our nickel refinery in Wales for processing to final products. In September 2017, as part of our efforts to reduce sulfur dioxide and other air emissions to meet regulatory changes in Ontario and Manitoba, and to rationalize our smelting and refining assets across Canada, we modified our processes including switching to a single flash furnace in Sudbury.
Copper. We produce two intermediate copper products, copper concentrate and copper anode, and we also produce a finished electrowon copper cathode product. In September 2017, we switched to a single flash furnace in Sudbury, and as a result, we ceased copper anode production resulting in increased production of copper concentrate and copper matte. |
Patented mineral rights with no expiration date; mineral leases expiring between 2018 and 2037; and mining licenses of occupation with indefinite expiration date(1). | Supplied by Ontario's provincial electricity grid and produced directly by Vale via hydro generation. | Located by the Trans-Canada highway and the two major railways that pass through the Sudbury area. Finished products are delivered to the North American market by truck. For overseas customers, the products are loaded into containers and travel intermodally (truck/rail/containership) through both east and west coast Canadian ports. |
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Company/Mining System | Location | Description/History | Operations | Mining title | Power source | Access/ Transportation |
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---|---|---|---|---|---|---|---|---|---|---|---|---|
Vale Canada | Canada Thompson, Manitoba | Integrated mining, milling, smelting and refining operations to process ore into finished nickel. We intend to phase out smelting and refining activities in Thompson during 2018. Thompson mineralization was discovered in 1956, and Thompson operations were acquired by us in 2006. | Nickel. Primarily underground mining operations with nickel sulfide ore bodies, which also contain some copper and cobalt. In 2017, we permanently shut down one of the two furnaces in Thompson and the other will be shut down in 2018. By the end of 2017, we had ceased processing Voisey's Bay feed in Thompson. Starting in the second half of 2018, we plan to send the majority of the nickel concentrate from Thompson to be refined in Sudbury and Long Harbour. Smelting and refining activities in Thompson are being phased out in 2018, primarily due to the capital costs associated with the federal sulfur dioxide emission limits defined under the pollution prevention plan under the Canadian Environmental Protection Act (CEPA), as well as to declining feed availability. We have secured an extension for implementation of our current sulfur dioxide emission reduction plan, which permits smelting and refining through 2018, subject to negotiated emission limits. |
Order in Council leases expiring between 2020 and 2025; mineral leases expiring in 2034. | Supplied by Manitoba's provincial utility company. | Finished products are delivered to market by truck in North America. For overseas customers, the products are loaded into containers and travel intermodally (truck/rail/containership) to final destination through both west coast and east coast Canadian ports. |
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Company/Mining System | Location | Description/History | Operations | Mining title | Power source | Access/ Transportation |
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---|---|---|---|---|---|---|---|---|---|---|---|---|
Vale Newfoundland & Labrador Limited | Canada Voisey's Bay and Long Harbour, Newfoundland and Labrador | Integrated open-pit mining and milling operation at Voisey's Bay producing nickel and copper concentrates with refining of nickel concentrate at Long Harbour into finished metal products with an expected nominal capacity of approximately 50,000 metric tons of refined nickel per year upon ramp-up. Voisey's Bay's operations started in 2005 and was purchased by us in 2006. | Comprised of the Ovoid open pit mine, and deposits for underground operations at a later stage. We mine nickel sulfide ore bodies, which also contain copper and cobalt. The Long Harbour facility continued to ramp up in 2017 while processing feed from Voisey's Bay concentrate exclusively. In 2017, as a result of the continuing ramp-up of the Long Harbour nickel refinery, copper cathode and cobalt rounds were produced for the first time. The portion of mid-grade and high-grade concentrate not shipped to Long Harbour in 2017 was shipped to our Sudbury and Thompson operations for final processing (smelting and refining) while copper concentrate was sold to the market. Shipments of nickel concentrate to Sudbury and Thompson ceased at the end of 2017. We expect the ramp-up to continue at Long Harbour during 2018. | Mining lease expiring in 2027, with a right of further renewals for 10-year periods. | Power at Voisey's Bay is 100% supplied through Vale owned diesel generators. Power at the Long Harbour refinery is supplied by the Newfoundland and Labrador provincial utility company. | The nickel and copper concentrates from Voisey's Bay are transported to the port by haulage trucks and then shipped by drybulk vessels to either overseas markets or to our Long Harbour and other Canadian operations for further refining. | ||||||
Vale Europe Limited | U.K. Clydach, Wales | Stand-alone nickel refinery (producer of finished nickel), with nominal capacity of 40,000 metric tons per year. The Clydach refinery commenced operations in 1902 and was acquired by us in 2006. | Processes a nickel intermediate product, nickel oxide, supplied from our Sudbury and Matsuzaka operations to produce finished nickel in the form of powders and pellets. | | Supplied through the national electricity grid. | Transported to final customer in the UK and continental Europe by truck. Products for overseas customers are trucked to the ports of Southampton and Liverpool and shipped by ocean container. |
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Company/Mining System | Location | Description/History | Operations | Mining title | Power source | Access/ Transportation |
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---|---|---|---|---|---|---|---|---|---|---|---|---|
Asia/Pacific | ||||||||||||
PT Vale Indonesia Tbk ("PTVI") |
Indonesia Sorowako, Sulawesi |
Open cast mining area and related processing facility (producer of nickel matte, an intermediate product) with a nominal capacity of approximately 80,000 metric tons of nickel in matte per year. PTVI's shares are traded on the Indonesia Stock Exchange. We indirectly hold 59.27% of PTVI's share capital, Sumitomo Metal Mining Co., Ltd ("Sumitomo") holds 20.09%, Sumitomo Corporation holds 0.1% and the public holds 20.49%. PTVI was established in 1968, commenced its commercial operations in 1978 and was acquired by us in 2006. |
PTVI mines nickel laterite ore and produces nickel matte, which is shipped primarily to our nickel refinery in Japan. Pursuant to life-of-mine off-take agreements, PTVI sells 80% of its production to our wholly owned subsidiary Vale Canada and 20% of its production to Sumitomo. |
Contract of work expiring in 2025, entitled to two consecutive ten-year extensions, subject to approval of the Indonesian government. See Regulatory mattersMining rights and regulation of mining activities. |
Produced primarily by PTVI's low-cost hydroelectric power plants on the Larona River (there are currently three facilities). PTVI has thermal generating facilities in order to supplement its hydroelectric power supply with a source of energy that is not subject to hydrological factors. |
Trucked approximately 55 km to the river port at Malili and then loaded onto barges in order to load break-bulk vessels for onward shipment. |
||||||
Vale Nouvelle- Calédonie S.A.S ("VNC") | New Caledonia Southern Province | Mining and processing operations (producer of nickel oxide, nickel hydroxide and cobalt carbonate). We hold 95% of VNC's shares and the remaining 5% is held by Société de Participation Minière du Sud Calédonien SAS ("SPMSC"). SPMSC has an obligation to increase its stake in VNC to 10% within two years after the startup of commercial production. | The ongoing ramp-up of our nickel operation in New Caledonia is expected to continue in the coming years. VNC utilizes a high-pressure acid leach process to treat limonitic laterite and saprolitic laterite ores. As part of the ramp-up, VNC is undertaking a review of the capacity of different units of the plant to identify and eliminate bottlenecks. We expect to continue to ramp up VNC over the next five to six years to reach nominal production capacity of 57,000 metric tons per year of nickel contained in nickel oxide, which will be further processed in our refineries in Asia, and hydroxide cake form (IPNM), and 4,500 metric tons of cobalt in carbonate form. | Mining concessions expiring between 2022 and 2051(2). | Supplied through the national electricity grid and by independent producers. | Products are packed into containers and are trucked approximately 4 km to Prony port and shipped by ocean container. |
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Company/Mining System | Location | Description/History | Operations | Mining title | Power source | Access/ Transportation |
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---|---|---|---|---|---|---|---|---|---|---|---|---|
Vale Japan Limited | Japan Matsuzaka | Stand-alone nickel refinery (producer of intermediate and finished nickel), with a nominal capacity of 60,000 metric tons per year. We own 87.2% of the shares, and Sumitomo owns the remaining shares. The refinery was built in 1965 and was acquired by us in 2006. | Produces intermediate products for further processing in our refineries in Asia and the UK, and finished nickel products using nickel matte sourced from PTVI. | | Supplied through the national electricity grid. Acquired from regional utility companies. | Products trucked over public roads to customers in Japan. For overseas customers, the product is loaded into containers at the plant and shipped from the ports of Yokkaichi and Nagoya. | ||||||
Vale Taiwan Limited | Taiwan Kaoshiung | Stand-alone nickel refinery (producer of finished nickel), with nominal capacity of 18,000 metric tons per year. The refinery commenced production in 1983 and was acquired by us in 2006. | Produces finished nickel for the stainless steel industry, primarily using intermediate products from our Matsuzaka and New Caledonian operations. The plant was put on care and maintenance during 2017. | | Supplied through the national electricity grid. Acquired from regional utility companies. | Trucked over public roads to customers in Taiwan. For overseas customers, the product is loaded into containers at the plant and shipped from the port of Kaoshiung. | ||||||
Vale Nickel (Dalian) Co., Ltd | China Dalian, Liaoning | Stand-alone nickel refinery (producer of finished nickel), with nominal capacity of 32,000 metric tons per year. We own 98.3% of the equity interest and Ningbo Sunhu Chemical Products Co., Ltd. owns the remaining 1.7%. The refinery commenced production in 2008. | Produces finished nickel for the stainless steel industry, primarily using intermediate products from our Matsuzaka and New Caledonian operations. | | Supplied through the national electricity grid. Acquired from regional utility companies. | Product transported over public roads by truck and by railway to customers in China. It is also shipped in ocean containers to overseas and some domestic customers. |
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Company/Mining System | Location | Description/History | Operations | Mining title | Power source | Access/ Transportation |
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---|---|---|---|---|---|---|---|---|---|---|---|---|
South Atlantic | ||||||||||||
Vale/Onça Puma | Brazil Ourilândia do Norte, Pará | Mining and smelting operation producing a high-quality ferronickel for application within the stainless steel industry. | The Onça Puma mine is built on lateritic nickel deposits of saprolitic laterite ore. The operation produces ferronickel via the rotary kiln-electric furnace process. We are currently operating a single line with one electric furnace and two lines of calcine and rotary kilns, with nominal capacity estimated at 27,000 metric tons per year. We will evaluate opportunities to restart the second line operations in light of market conditions and the associated business case. | Mining concession for indefinite period. | Supplied through the national electricity grid. Produced directly by Vale or acquired through power purchase agreements. | The ferro-nickel is transported by truck to the Vila do Conde maritime terminal in the Brazilian state of Pará, and exported in ocean containers. |
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2.1.2 Production
The following table sets forth our annual mine production by operating mine (or, on an aggregate basis in the case of the Sulawesi operating areas operated by PTVI in Indonesia, because it is organized by mining areas rather than individual mines) and the average percentage grades of nickel and copper. The mine production at Sulawesi represents the product from PTVI's screening station delivered to PTVI's processing plant and does not include nickel losses due to drying and smelting. For our Sudbury, Thompson and Voisey's Bay operations, the production and average grades represent the mine product delivered to those operations' respective processing plants and do not include adjustments due to beneficiation, smelting or refining. For our Onça Puma operation in Brazil and VNC operation in New Caledonia the production and average grade represents in-place ore production and does not include losses due to processing.
|
| 2015(1) | | 2016(1) | | 2017(1) | ||||||||||||
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|
| |
| Grade | | |
| Grade | | |
| Grade | ||||||
|
| Production | | Copper | | Nickel | | Production | | Copper | | Nickel | | Production | | Copper | | Nickel |
Ontario operating mines |
| | | | | | | | | |||||||||
Copper Cliff North |
| 1,138 | | 1.42 | | 1.38 | | 979 | | 1.44 | | 1.26 | | 814 | | 1.40 | | 1.30 |
Creighton |
| 774 | | 2.00 | | 2.33 | | 832 | | 2.17 | | 2.76 | | 595 | | 2.91 | | 3.17 |
Stobie |
| 1,471 | | 0.63 | | 0.73 | | 1,373 | | 0.57 | | 0.64 | | 448 | | 0.53 | | 0.62 |
Garson |
| 778 | | 1.39 | | 1.94 | | 711 | | 1.34 | | 1.91 | | 635 | | 1.48 | | 1.93 |
Coleman |
| 1,309 | | 2.95 | | 1.56 | | 1,209 | | 3.76 | | 1.47 | | 1,007 | | 3.76 | | 1.53 |
Ellen |
| 165 | | 0.70 | | 0.95 | | 75 | | 0.42 | | 0.88 | | | | | | |
Totten |
| 528 | | 1.88 | | 1.62 | | 671 | | 1.86 | | 1.43 | | 710 | | 1.90 | | 1.33 |
| | | | | | | | | | | | | | | | | | |
Total Ontario operations |
| 6,164 | | 1.64 | | 1.46 | | 5,850 | | 1.84 | | 1.47 | | 4,210 | | 2.18 | | 1.65 |
| | | | | | | | | | | | | | | | | | |
Manitoba operating mines |
| | | | | | | | | |||||||||
Thompson |
| 1,163 | | | | 1.82 | | 1,140 | | | | 1.97 | | 1,229 | | | | 1.94 |
Birchtree |
| 564 | | | | 1.47 | | 503 | | | | 1.36 | | 329 | | | | 1.30 |
| | | | | | | | | | | | | | | | | | |
Total Manitoba operations |
| 1,727 | | | | 1.71 | | 1,643 | | | | 1.78 | | 1,557 | | | | 1.81 |
| | | | | | | | | | | | | | | | | | |
Voisey's Bay operating mines |
| | | | | | | | | |||||||||
Ovoid |
| 2,328 | | 1.51 | | 2.57 | | 2,392 | | 1.44 | | 2.62 | | 2,378 | | 1.44 | | 2.56 |
| | | | | | | | | | | | | | | | | | |
Sulawesi operating mines |
| | | | | | | | | |||||||||
Sorowako |
| 4,694 | | | | 1.99 | | 4,708 | | | | 1.93 | | 4,569 | | | | 1.89 |
| | | | | | | | | | | | | | | | | | |
New Caledonia operating mines |
| | | | | | | | | |||||||||
VNC |
| 2,561 | | | | 1.41 | | 2,919 | | | | 1.53 | | 3,030 | | | 1.47 | |
| | | | | | | | | | | | | | | | | | |
Brazil operating mines |
| | | | | | | | | |||||||||
Onça Puma |
| 1,024 | | | | 2.13 | | 1,710 | | | | 2.04 | | 964 | | | | 2.05 |
| | | | | | | | | | | | | | | | | | |
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The following table sets forth information about our nickel production, including: nickel refined through our facilities and intermediates designated for sale. The numbers below are reported on a contained nickel ore-source basis.
|
| |
| Finished production by ore source for the year ended December 31, |
||||
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Mine | | Type | | 2015 | | 2016 | | 2017 |
|
| |
| (thousand metric tons contained nickel) |
||||
Sudbury |
| Underground | | 54.4 | | 80.4 | | 61.9 |
Thompson |
| Underground | | 24.8 | | 26.5 | | 23.0 |
Voisey's Bay(1) |
| Open pit | | 53.0 | | 49.0 | | 51.8 |
Sorowako(2) |
| Open cast | | 79.5 | | 81.1 | | 73.1 |
Onça Puma |
| Open pit | | 24.4 | | 24.1 | | 24.7 |
New Caledonia(3) |
| Open pit | | 26.9 | | 34.3 | | 40.3 |
External(4) |
| | | 26.7 | | 15.6 | | 13.1 |
| | | | | | | | |
Total(5) |
| | 290.6 | | 311.0 | | 288.2 | |
| | | | | | | | |
2.1.3 Customers and sales
Our nickel customers are broadly distributed on a global basis. In 2017, 45% of our refined nickel sales were delivered to customers in Asia, 24% to Europe, 24% to North America and 7% to other markets. We have short-term fixed-volume contracts with customers for the majority of our expected annual nickel sales. These contracts generally provide stable demand for a significant portion of our annual production.
Nickel is an exchange-traded metal, listed on the London Metal Exchange ("LME") and Shanghai Futures Exchange ("SHFE"), and most nickel products are priced according to a discount or premium to the LME price, depending primarily on the nickel product's physical and technical characteristics. Our finished nickel products represent what is known in the industry as "primary" nickel, meaning nickel produced principally from nickel ores (as opposed to "secondary" nickel, which is recovered from recycled nickel-containing material). Finished primary nickel products are distinguishable in terms of the following characteristics, which determine the product price level and the suitability for various end-use applications:
In 2017, the principal end-use applications for nickel were:
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In 2017, 63% of our refined nickel sales were made into non-stainless steel applications, compared to the industry average for primary nickel producers of 31%. This brings more diversification and sales volume stability to our nickel revenues. As a result of our focus on higher-value segments, our average realized nickel prices for refined nickel have typically exceeded LME cash nickel prices.
We offer sales and technical support to our customers on a global basis through an established marketing network headquartered at our head office in Toronto (Canada). We have a well-established global marketing network for finished nickel, based at our head office in Toronto (Canada). We also have sales and technical support distributed around the world with primary back offices in Singapore and Toronto (Canada) and have sales managers located in St.Prex (Switzerland), Paramus, New Jersey (United States) and at several sites throughout Asia. For information about demand and prices, see Operating and financial review and prospectsMajor factors affecting prices.
2.1.4 Competition
The global nickel market is highly competitive. Our key competitive strengths include our long-life mines, our low cash costs of production relative to other nickel producers, sophisticated exploration and processing technologies, and a diversified portfolio of products. Our global marketing reach, diverse product mix, and technical support direct our products into applications and geographic regions that offer the highest margins for our products.
Our nickel deliveries represented 13% of global consumption for primary nickel in 2017. In addition to us, the largest mine-to-market integrated suppliers in the nickel industry (each with its own integrated facilities, including nickel mining, processing, refining and marketing operations) are Nornickel, Glencore, Jinchuan Nonferrous Metals Corporation and BHP Billiton. Together with us, these companies accounted for about 39% of global refined primary nickel production in 2017.
While stainless steel production is a major driver of global nickel demand, stainless steel producers can obtain nickel with a wide range of nickel content, including secondary nickel (scrap). The choice between primary and secondary nickel is largely based on their relative prices and availability. See Operating and Financial Review and ProspectsMajor factors affecting pricesNickel.
Competition in the nickel market is based primarily on quality and reliability of supply and price. We believe our operations are competitive in the nickel market because of the high quality of our nickel products and our relatively low production costs.
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2.2 Copper
2.2.1 Operations
We conduct our copper operations at the parent-company level in Brazil and through our subsidiaries in Canada.
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