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Management's Discussion and Analysis
of Financial Condition and Results of Operations
FORWARD-LOOKING STATEMENTS
This discussion contains forward-looking statements that involve risks,
uncertainties and assumptions. Falconbridge's actual financial condition and
results of operations could differ materially from those that may be
contemplated by these forward-looking statements as a result of those risks,
uncertainties and assumptions. These risks include, but are not limited to,
fluctuations in the prices for copper, nickel, or other metals produced by
Falconbridge; mining and processing risks; domestic and foreign laws,
particularly environmental legislation; labour relations; geological and
metallurgical assumptions and estimates; fluctuations in currency exchange
rates, principally the Canadian/U.S. dollar exchange rate; interest rate and
counter- party risks; energy supply and prices; foreign operations; market
access; production and processing technology; legal proceedings; raw material
procurement; and other risks and hazards associated with mining operations. For
additional information regarding these factors, please see "Trends, Risks and
Uncertainties" below.
The following discussion and analysis should be read in conjunction with
the consolidated financial statements of Falconbridge Limited ("Falconbridge" or
"the Corporation") and related notes for the year ended December 31, 2003 and
the unaudited consolidated financial statements for the three months ended
March 31, 2004.
The Corporation's consolidated financial statements are prepared in
accordance with Canadian generally accepted accounting principles ("GAAP"). The
Corporation's unaudited consolidated financial statements for the three months
ended March 31, 2003 have been restated to reflect the adoption of the new
Canadian Institute of Chartered accountants (CICA) standard to account for asset
Retirement Obligations (ARO). Effective July 1, 2003 the Corporations functional
and reporting currency was converted to U.S. dollars. Unless otherwise noted,
all amounts in this report are expressed in U.S. dollars.
In the following discussion and analysis, Falconbridge uses "net debt",
"net debt plus equity" and "operating cash costs" which are non-GAAP financial
measures. The most directly comparable GAAP financial measures are "total debt",
"total debt plus equity" and "operating costs", respectively. Reconciliations of
these non-GAAP measures to the most directly comparable financial measures
presented in accordance with GAAP may be found on pages 37 and 38.
Information contained in this discussion is given as of May 7, 2004,
unless otherwise indicated.
1
Overview
Falconbridge is an international mining corporation engaged in the
exploration, development, mining, processing and marketing of metals and
minerals; with primary focus on nickel and copper. The Corporation is also
engaged in the custom feed business through the processing and recycling of
third-party materials. The Corporation believes that it is the third-largest
producer of refined nickel and the twelfth largest copper producer in the world.
Products and marketing
Falconbridge's principal products are nickel, ferronickel, copper, zinc
and cobalt. Other products include silver, gold, platinum group metals, cadmium,
indium and sulphuric acid. Falconbridge markets and sells nickel and cobalt and
certain other of its products internationally through marketing and sales
offices in the United States, Belgium and Japan. Noranda Inc. acts as sales
agent for all products from the Kidd Creek operations. Falconbridge markets
copper concentrate and cathode from the Chilean operations through a marketing
group in Santiago, Chile to customers around the world.
Mining and processing operations
Falconbridge has mining and mineral processing facilities in Canada
(Sudbury, Raglan and Kidd Creek operations), Norway (Nikkelverk), the Dominican
Republic (Falconbridge Dominicana, C. por A. (Falcondo)) and Chile (Compaa
Minera Doa Ins de Collahuasi S.C.M. (Collahuasi) and Compaa Minera Falconbridge
Lomas Bayas (Lomas Bayas)).
These activities are conducted through six segments - the Integrated
Nickel Operations (INO), Kidd Creek, Falcondo, Collahuasi, Lomas Bayas and
Corporate.
º •
º The INO encompasses all of our operations engaged in the integrated
operations of mining, milling, smelting, refining and marketing of
metals mainly derived from Sudbury and Raglan nickel/copper ores and
its custom feed business.
º •
º Kidd Creek mines, mills, smelts and refines its own copper-zinc ores
from the Kidd Mine and processes Sudbury copper concentrate and custom
feed materials.
º •
º Falcondo mines, mills, smelts and refines its own nickel laterite
ores.
º •
º Collahuasi mines and mills its sulphide ores into concentrate and
mines and leaches copper oxide ores to produce copper cathode.
Falconbridge owns 44% of Collahuasi.
º •
º Lomas Bayas mines and refines its own copper ores.
º •
º The Corporate segment accounts for the Corporation's general and
administrative expenditures, exploration activities, research and
process development expenditures, foreign exchange gains and losses,
and other income and expenses items.
Exploration activities
The Falconbridge exploration team conducts worldwide exploration focused
primarily on nickel and platinum group metals. Its mandate is to discover and
delineate mineral resources that ultimately merit the Board of Directors'
approval to proceed to development and production. The team targets mineral
resources of strategic size, in locations with acceptable country risk, with
after-tax rates of return on investment of at least 15% and operating costs
below the industry mid-point. Its goal is to conduct safe and environmentally
responsible exploration utilizing the latest technological advances in
exploration methodology to improve efficiency and the likelihood of success.
Joint-venture arrangements are pursued with both junior and senior mining
companies to increase the level of focused activity and to share cost and risk.
2
Business development
The business development function plays a critical role in several
aspects of the Corporation's management. First, it works in tandem with the
various business units, exploration group and project development teams to plan,
coordinate and implement long-term strategies to replace the resources that are
depleted in the normal course of mining operations and to grow the business
throughout the cycle. Business development regularly evaluates opportunities for
growth. These objectives are achieved by, amongst other things, evaluating
potential acquisitions of mining properties or assets, investing in junior
mining companies, partnering with other companies to develop growth
opportunities, developing long-term strategic, commercial relationships or
examining potential brownfield expansions within the Corporation's existing
asset base. Furthermore, the Corporation focuses on the development of long-term
relationships that bring the Corporation's technical, operational, project
development, financial, managerial and commercial strengths to bear, so that
significant value, in addition to cash resources, can be deployed to
successfully realize potential growth opportunities. The Corporation also
focuses on growth opportunities that create additional synergies with its
existing asset base.
Safety and Health
Providing a safe and healthy workplace is a priority at Falconbridge.
Operations continue to implement effective safety training programs and
management systems. Safety performance is strongly supported by senior
management and the Board of Directors. Safety and health policies are in place
at all Falconbridge operations and safety responsibilities are part of all job
descriptions, job procedures and performance reviews.
Sustainable development
Falconbridge is a strong proponent of sustainable development where
economic prosperity, environmental quality and social equity drive business
activities. This commitment is reflected in the Corporation's Sustainable
Development Policy. See further discussion page 24.
Our focus, objectives and business strategy
Falconbridge is focused on the production of nickel and copper, two
metals which have positive long-term fundamentals and positive near-term
outlooks. Both of these metals have competitive attributes which have led to
diversified usage in the world's economy and have had an average annual
long-term consumption growth rate of over 4% for nickel and 3% for copper.
Falconbridge has a unique position in these markets as one of the world's
largest producers of both metals and substantial operational, technical,
exploration and development experience. In addition, the Corporation has the
potential to increase its production as a result of the development of a number
of new projects.
3
Falconbridge's objective is to increase returns to shareholders as
measured by returns on net assets and on shareholders' equity. To achieve this
goal, Falconbridge's business strategy is to continuously improve operating
efficiencies to reduce costs, obtain maximum returns on existing assets and
acquire, develop and mine high quality ore reserves. The Corporation believes
that a conservative financial structure and financial flexibility are important
in order to accommodate the capital intensive and cyclical nature of the
business.
Nature of our business and markets
The nature of our business, which in essence is the production and
marketing of a commodity and the treatment of custom feed material in
international markets, means that our profitability and cash flows from
operations are determined primarily by the price of the metals we sell and our
ability to produce at a low cost.
Price and Markets
Historically, we have experienced and expect to continue to be subject
to volatile prices, which are influenced primarily by the world supply-demand
balance, for our products and services, and related factors such as speculative
activities, production activities at our competitors, political and economic
conditions as well as production costs in major producing regions. Since our
products are marketed in all major geographical markets, the realized price for
our metals is also influenced by regional supply-demand factors, the
availability and price of secondary or metal containing scrap material, and
other substitute commodity products. Falconbridge generally accepts market
prices and does not hedge the price it realizes on the sale of its own
production.
A detailed analysis of our markets is discussed on page 38 - Markets.
Production costs
The other primary determinant of profitability and cash flow from
operations is our ability to produce at a low cost. Production costs are largely
influenced by ore grades, mine planning, processes technology and the byproduct
credit revenues.
Business Risks
The primary risks facing Falconbridge are
º •
º Changes in metal prices
º •
º Reliance on third-party feed
º •
º Mining and processing risks
º •
º Environmental risks
º •
º Labour relations
º •
º Uncertainty of reserve and production estimates
º •
º Exchange rate fluctuations
º •
º Interest rate and counter-party risks
º •
º Energy supply and prices
º •
º Foreign operations
º •
º Treatment and refining charges
º •
º Legal proceedings
The nature, implications and tools used to manage these risks are
discussed fully starting on page 41 - Trends, risks and uncertainties.
4
Capital
Our business is capital intensive with significant costs involved in our
exploration activities, and the development of mining and metallurgical
facilities. As such, securing low cost capital is instrumental in profitability.
Historically, Falconbridge has sourced capital from common and preferred
equity markets, public debt markets and bank debt.
Overall Performance
Earnings, cash flows and financial condition
Earnings for the first quarter of 2004 were $184 million or $1.02 per
common share ($1.01 per share on a diluted basis), almost a fivefold increase
over the $38 million or $0.21 per common share reported in the first quarter of
2003. Operating income in the first quarter was $268 million compared to
$61 million for the same period in 2003. Cash generated from operating
activities before working capital changes totalled $262 million, compared to
$106 million for the corresponding quarter in 2003. All of these increases
reflect the higher average realized nickel, copper and zinc prices, which
increased 80%, 55% and 33% respectively, over the same period in 2003, offset in
part by lower copper sales volumes and the impact of the stronger Canadian
dollar, which was 14% stronger compared to the first quarter of 2003, on
Canadian operating costs.
There are many factors, that influence the price we receive for our
commodities (see market discussion on page 38). Growing worldwide industrial
production and continued strong growth from China has increased demand for
metals. Falling inventories, combined with little new additional supply have
been the catalyst for the rising metal prices.
In the first quarter, the Corporation's balance sheet improved in the
first quarter of 2004, as the ratio of net debt to net debt plus equity improved
to 32% from 37% at December 31, 2003 and from 41% the previous March 31st. Cash
and cash equivalents were $415 million at March 31, 2004. We believe that our
balance sheet will continue to improve over the balance of the year and that
cash flows will be sufficient to cover all of our obligations for the balance of
the year.
Other Developments
On March 11, 2004, the Corporation announced that it would proceed with
an underground definition program at Nickel Rim South. The five-year,
$368-million program commenced immediately with production expected to start in
2008. Once completed, a further $185 million will be required to bring the mine
into production. After taking into account pre-production revenues of
$141 million, the overall net capital cost is expected to be $413 million.
Inferred resources at Nickel Rim South consist of 13.2 million tonnes grading
1.7% nickel, 3.5% copper, 0.04% cobalt, 0.8 grams per tonne gold, 1.9 grams per
tonne platinum and 2.2 grams per tonne palladium. A decision on the bankable
feasibility study for the exploration program will be taken in 2004. The
addition of the new resources will extend the operating life of the Sudbury
mines and smelter by several more years. It is expected that the Nickel Rim
South deposit will support mining operations for approximately 13 years starting
in 2008.
5
Falconbridge Limited and Agnico-Eagle Limited announced that they have
signed a life-of-mine zinc concentrate supply and processing agreement. Under
the terms of the agreement, Falconbridge's Kidd Creek operations in Timmins,
Ontario will process 60% to 75%, up to a maximum of 125,000 tonnes per year, of
the precious-metal-bearing zinc concentrate production from the LaRonde mine,
located south-east of Rouyn-Noranda, Quebec. In addition to the sharing of
freight savings, Falconbridge anticipates that it will derive benefits through
the improvement in capacity utilization and precious metal recovery at Kidd
Creek. Falconbridge will immediately begin to retrofit the Kidd zinc refinery in
order to establish its capability to recover precious metals.
In 2003 and through the first quarter of 2004, Falconbridge continued to
advance its important development programs at Collahuasi and Kidd Creek,
ensuring that copper production levels are maintained for at least the next
17 years. Work on the Collahuasi expansion project progressed as planned and is
scheduled for completion in June of 2004. Work also continued on the Mine D
project at Kidd Creek. Initial is expected by year-end 2004 with project
completion by 2006.
The Montcalm nickel project in northern Ontario was started in November
with construction expected to take approximately 15 months. It will add 8,000
tonnes of nickel production per year beginning in 2005. Going forward in nickel,
our focus will be on the advancement of the Koniambo project in New Caledonia,
Nickel Rim South and Fraser Morgan in Sudbury, Ontario and Kabanga in Tanzania,
and the potential expansion of Falcondo. In copper, further expansions at Lomas
Bayas and Collahuasi are being assessed.
Ore reserves and resources
Falconbridge has significant proven ore reserves. A discussion of
reserves is included with the discussion of each business segment later in this
analysis.
The following table sets forth certain ore reserves and mineral resource
data as of December 31, 2003. Falconbridge assesses it reserves on an annual
basis at the end of each year. Changes to this data through the quarter ended
March 31, 2004 would represent the impact of ongoing production activities
and/or new exploration results. There has been no other known material
adjustment to the December 31, 2003 data as presented.
6
Summary of Mineral Reserves and Mineral Resources1
Percentage Thousand
Operation Ownership Category Tonnes % Nickel % Copper % Zinc g/t Silver
Mineral Reserves
NICKEL DEPOSITS
Sudbury 100% Proven 5,588 1.40 1.34 - -
Probable 8,503 1.22 1.24 - -
Total 14,091 1.29 1.28 - -
Raglan 100% Proven 8,308 2.86 0.77 - -
Probable 9,355 2.86 0.80 - -
Total 17,663 2.86 0.78 - -
Montcalm 100% Proven 0 - - - -
Probable 5,113 1.46 0.71 - -
Total 5,113 1.46 0.71 - -
Falcondo2 85.26% Proven 49,271 1.19 - - -
Probable 11,656 1.16 - - -
Total 60,927 1.18 - - -
COPPER DEPOSITS
Kidd Creek 100% Proven 12,585 - 1.86 5.60 71
Probable 8,239 - 2.23 7.00 53
Total 20,824 - 2.01 6.15 64
Lomas Bayas 100% Proven 54,760 - 0.40 - -
Probable 309,171 - 0.33 - -
Total 363,931 - 0.34 - -
Collahuasi2 44% Proven 254,146 - 1.01 - -
Probable 1,554,075 - 0.90 - -
Total 1,808,221 - 0.91 - -
Mineral Resources (in addition to Mineral Reserves)
NICKEL DEPOSITS
Sudbury 100% Measured 683 1.31 0.80 - -
Indicated 20,477 2.27 0.99 - -
Total 21,160 2.24 0.98 - -
Inferred 28,200 1.70 2.70 - -
Raglan 100% Measured 228 1.47 0.37 - -
Indicated 2,972 2.18 0.76 - -
Total 3,200 2.13 0.74 - -
Inferred 4,000 2.90 0.90 - -
Montcalm 100% Measured 0 - - - -
Indicated 0 - - - -
Total 0 - - - -
Inferred 700 1.70 0.70 - -
Falcondo2 85.26% Measured - - - - -
Indicated 13,840 1.53 - - -
Total 13,840 1.53 - - -
Inferred 6,400 1.40 - - -
COPPER DEPOSITS
Kidd Creek 100% Measured 276 - 1.34 6.00 47
Indicated 77 - 2.82 8.54 52
Total 353 - 1.66 6.55 48
Inferred 14,200 - 3.40 4.90 91
Lomas Bayas 100% Measured 5,654 - 0.28 - -
Indicated 246,898 - 0.27 - -
Total 252,552 - 0.27 - -
Inferred 41,700 - 0.32 - -
Collahuasi2 44% Measured 48,102 - 0.57 - -
Indicated 429,564 - 0.63 - -
Total 477,666 - 0.63 - -
Inferred 1,840,000 - 0.72 - -
7
Notes:
º 1.
º The mineral reserve and resource estimates are prepared in accordance with
the CIM Standards On Mineral Resources and Mineral Reserves, Definitions
And Guidelines, adopted by CIM Council on August 20, 2000, using classical
and/or geostatistical methods, plus economic and mining parameters
appropriate to each project.
º 2.
º The mineral reserves and resources at Collahuasi and Falcondo are shown on
a 100% basis.
There are no known environmental, permitting, legal, taxation, political or
other relevant issues that would materially affect the estimates of the
mineral reserves.
The mineral resources have reasonable prospects for economic extraction but
have not yet had complete formal evaluation, or do not have demonstrated
economic viability under current conditions.
The mineral reserve and mineral resource estimates are compiled and
verified by Chester Moore, Director, Mineral Reserve Estimation and
Reporting, a member of the Professional Geoscientists of Ontario with over
30 years experience as a geologist. The mineral reserves and resources at
Collahuasi are estimated and provided by the operator of the joint venture
based on a copper price of $US0.95/lb. The mineral reserves and resources
are estimated and classified to industry standards following the
Australasian Institute of Mining and Metallurgy's Joint Ore Reserve
Committee code. These estimates have been restated to conform to CIM
mineral reserve and resource definitions. Chester Moore inspects the
estimates annually.
Excludes Kabanga, Tanzania.
Results of Operations - Three Months Ended March 31, 2004
Earnings for the quarter ended March 31, 2004 were $184 million ($1.02
per common share - $1.01 on a diluted basis), compared to earnings of
$38 million ($0.21 per common share - on a basic and diluted basis) for the same
period of 2003. Operating income of $268 million for the quarter ended March 31,
2004 compared to $61 million for the same period of 2003. The significant
increase in operating income and earnings is attributable to the following
factors:
º •
º Consolidated revenues of $734 million increased from $472 million in
the first quarter of 2003. The increase reflects higher average
realized nickel, copper and zinc prices, which increased 80%, 55% and
33%, respectively, over the same period in 2003, partially offset by
lower copper sales volumes.
º •
º Costs of metal and other product sales increased by $72 million, or
19%, to $461 million, mainly reflecting higher sales volumes, higher
mining costs and higher acquisition costs for custom feed, as well as
the impact of a stronger Canadian dollar relative to the U.S. dollar.
º •
º Selling, general and administrative costs increased by 14% to
$24 million primarily as a result of the impact of the stronger
Canadian dollar in the first quarter of 2004 relative to the same
period in 2003.
º •
º Exploration expenditures for the first quarter of 2004 were $3 million
compared with $2 million in 2003, mainly to additional drilling at the
Nickel Rim South deposit to further define the resource and the impact
of the stronger Canadian dollar.
8
º •
º Research and process development expenditures of $2 million were the
same in both the first quarter of 2003 and 2004.
º •
º Other income of $24 million in 2004 compared with other income of
$4 million in 2003. The primary components of other income in 2004 are
(a) a $13 million mark-to-market gain on interest rate swaps not
eligible for hedge accounting, (b) $6 million net interest income on
interest rate swaps not eligible for hedge accounting, and (c) an
unrealized and realized foreign exchange gain of $5 million.
Income and expenses were provided from the following non-operating
sources:
º •
º Interest, net, of $10 million in the first quarter of 2004 compared to
$12 million in the same period of 2003. This decrease is attributable
to lower interest rates and higher average expenditures on projects
for which interest costs are capitalized. These savings were offset by
higher average debt balances during 2004 relative to 2003.
º •
º Income and mining taxes were $69 million in 2004, compared with
$10 million in 2003. This resulted from higher income in 2004.
º •
º Non-controlling interest in earnings of subsidiaries increased by
$4 million, reflecting higher earnings at our ferronickel operations
in the Dominican Republic.
9
Earnings by Segment
The following table summarizes the unaudited segmented results of
operations for the first quarter of 2004 and 2003:
Three months ended March 31,
2004 2003
(unaudited - in thousands of
United States dollars)
Principal operations -
Integrated Nickel Operations (INO) $ 130,428 $ 43,830
Falconbridge Dominicana, C. por A. 55,416 3,987
Nickel Operations 185,844 47,817
Kidd Creek Operations 3,018 (13,547 )
Collahuasi 45,239 27,503
Lomas Bayas 23,500 5,870
Copper Operations 71,757 19,826
Corporate costs (10,172 ) 6,549
Operating income 267,773 61,094
Interest 10,358 12,065
Income and mining taxes 69,063 10,315
Non-controlling interest in earnings of subsidiaries 4,044 254
Earnings for the period 184,308 38,460
Dividends on preferred shares 1,965 2,043
Earnings attributable to common shares $ 182,343 $ 36,417
Nickel Operations
Falconbridge is the third-largest producer of refined nickel in the
world, accounting for roughly 9% of world supply in 2003.
Operating income of the total nickel business of $186 million in the
first quarter of 2004 was almost four times larger than $48 million in the first
quarter of 2003. Refined nickel production was 26,900 tonnes in the first
quarter of 2004, 2% lower than 27,500 tonnes in the same period in 2003. The
operating cash cost per pound of mined nickel for all of Falconbridge was 8%
higher in the first quarter of 2004 at $2.72, compared with $2.51 in the same
period for 2003.
Falconbridge has two nickel divisions. The INO produces LME-registered
nickel. Falcondo produces ferronickel.
Integrated Nickel Operations (INO)
The INO includes mines and plants in Sudbury and Raglan in Canada, a
smelter in Sudbury, a refinery at Kristiansand in Norway and a significant
custom feed business.
10
The following table sets forth certain unaudited financial data with
respect to Falconbridge's Integrated Nickel Operations for the periods
indicated.
Three months ended March 31,
2004 2003
Sales (tonnes)
Nickel 18,100 20,300
Copper 13,200 14,500
Cobalt 900 800
Revenues ($ millions) 379 231
Operating cash cost ($ per pound of nickel)* 2.60 2.16
Operating income ($ millions) 130 44
º *
º Operating cash cost includes all cash production and selling costs, net of
byproduct credits, but excludes interest, corporate, exploration costs and
custom feed profits. Costs incurred during shutdowns or strikes are
excluded. See "Reconciliation of Non-GAAP Measures" page 37).
Revenues: Sales volumes of nickel and copper decreased in the first
quarter of 2004 by 11%, while the volume of cobalt sales increased 14% over the
same period in 2003. Realized nickel prices in the first quarter of 2004
increased by 80%, copper prices improved by 55%, and cobalt prices rose 201%.
Precious metals revenues increased by $2 million to $22 million. In the first
quarter of 2004, consolidated revenues for the INO increased 64% to $379 million
from $231 million in the same period for 2003.
Costs: The operating cash cost of producing a pound of nickel from
INO mines was $2.60 compared to $2.16 for the same period in 2003. The $0.44, or
20%, increase over 2003 costs was the result of the stronger Canadian dollar,
increased costs to access the ore in the Canadian operations and lower ore
grades, which were partially offset by higher byproduct credits.
Operating income: The INO's first quarter 2004 operating income was
$130 million compared with $44 million for the first quarter of 2003. The
$86 million increase was mainly due to higher metal prices and sales volumes,
which were offset by higher depreciation and amortization charges, higher
administrative charges and higher unit costs, caused in part by the
strengthening of the Canadian dollar.
11
INO Production and Sales
The following table sets forth certain segmented sales and production
data with respect to Falconbridge's Integrated Nickel Operations for the periods
indicated.
Three months ended March 31,
2004 2003
Ore tonnes Ni Cu Ore tonnes Ni Cu
(x 1,000) % % (x 1,000) % %
Production
Sudbury mines - ore processed 362 1.46 1.15 560 1.37 1.46
Raglan mine 225 3.45 0.98 218 3.57 1.02
Ni Cu Co Ni Cu Co
Metal in concentrate (tonnes)
Sudbury mine output 4,404 3,803 107 6,221 7,264 152
Raglan mine output 6,668 1,733 101 6,740 1,797 106
Metal in copper concentrate 10 2,141 29 5,430
Smelter, refinery
Smelter (tonnes)
Mines
- Sudbury 3,225 1,131 69 6,053 2,078 140
- Montcalm 89 25 3
- Raglan 6,397 1,665 78 7,975 2,202 125
Custom 1,693 1,413 212 823 907 253
Total 11,404 4,234 362 14,851 5,187 518
Refinery (tonnes)
Mines
- Sudbury 5,049 1,764 154 7,441 2,731 203
- Raglan 6,884 2,039 113 7,202 1,508 110
Custom 6,926 5,943 891 5,920 4,296 819
Total 18,859 9,746 1,158 20,563 8,535 1,132
Ni Cu Co Ni Cu Co
Sales (tonnes)
Mines
- Sudbury 4,793 5,033 137 7,274 8,625 158
- Raglan 6,466 2,097 93 6,105 1,611 76
Custom 6,859 6,067 684 6,945 4,234 570
Total 18,118 13,197 914 20,325 14,470 804
Production: Sudbury mines production was 4,404 tonnes during the
first quarter of 2004 compared with 6,221 tonnes in the first quarter of 2003.
The shortfall in production was attributable to a three-week strike. The
production ramp-up after the strike was completed ahead of schedule. For 2004,
nickel in concentrate production is now forecast at 22,000 tonnes (original
target was 25,000 tonnes).
At Raglan, nickel in concentrate production in the quarter was at 6,668
tonnes and copper production was 1,733 tonnes, modestly below 2003 due to lower
ore grades.
At the Sudbury smelter, nickel in matte production decreased to 11,404
tonnes in the first three months of 2004 from 14,851 tonnes in the same period
of 2003 as a result of a three-week long labour strike. The ramp-up following
the strike went smoothly. The smelter will begin an eight-week maintenance
shutdown starting June 14.
At Nikkelverk, the first-quarter nickel production level of 18,859
tonnes was lower than in the first quarter of 2003 due to lower shipments of
material from Sudbury. For 2004, refined nickel production is now forecast at
72,000 tonnes (previously 75,000 tonnes).
12
Other Developments: The collective agreement with the production and
maintenance workers expired on January 31, 2004. The employees went on strike
starting on February 1, 2004 for a period of three weeks. A new collective
agreement was completed on February 22, 2004. A new agreement with the office,
clerical and technical workers was completed on February 29, 2004.
The collective agreements with the workers at the refinery in
Kristiansand expire May 31, 2004.
Reserves & exploration: With the recent important addition to
resources from discoveries such as Nickel Rim South and Fraser Morgan, nickel
production at Sudbury mines is expected to be significantly extended. It is
anticipated that a significant portion of the mineral resources will be
converted to mineral reserves and will extend the life of the operation from
seven years to a minimum of 13 to 15 years.
In 2003, the Sudbury Division's proven and probable mineral reserves
decreased by 1.0 million tonnes after production of 2.0 million tonnes. The loss
of reserves resulted from a 1.2 million tonne write-down of reserves at Craig
Mine due to changes in mining plans and parameters. This loss was partially
offset by mining gains in reserves at the Thayer Lindsley mine. At December 31,
2003, total proven and probable reserves were 14.1 million tonnes.
In Sudbury, total mineral resources increased significantly in 2003 from
39.0 to 49.4 million tonnes with large additions at Nickel Rim South and Fraser
Morgan, and smaller additions at the mining operations. Approximately
5.5 million tonnes were added at Nickel Rim South in 2003 and a further
1.5 million tonnes in the first quarter of 2004. The Nickel Rim South inferred
resource is now estimated to contain 13.2 million tonnes grading 1.7% nickel,
3.5% copper, 0.04% cobalt, 1.9 grams/tonne platinum, 2.2 grams/tonne palladium
and 0.8 grams/tonne gold. Fraser Morgan now has an indicated resource of
4.4 million tonnes, grading 1.72% nickel and 0.49% copper, and an inferred
resource of 2.5 million tonnes, grading 1.4% nickel and 0.4% copper. Exploration
work continues at both sites.
At Raglan, the mineral reserves are equal to approximately 19 years of
production at current operating rates. In combination with production of 834,000
tonnes and reserve adjustments, the overall mineral reserves decreased by only
0.4 million tonnes in 2003. Discovery of approximately 260,000 tonnes of mineral
reserves in Zone 3 plus other mining gains, replaced a large part of the annual
production. At December 31, 2003, total proven and probable reserves at Raglan
were 17.7 million tonnes. Total mineral resources increased by over 900,000
tonnes in 2003 to 7.2 million tonnes due to discoveries at Zones 2, 3, 5-8,
Donaldson and Katinniq.
At the planned operating rates, mineral reserves at Montcalm are equal
to approximately eight years of production. The Montcalm deposit will be put
into production based on probable mineral reserves totalling 5.1 million tonnes
grading 1.46% nickel and 0.71% copper. The probable reserves have been
established from the 7.0 million tonnes of measured and indicated mineral
resources previously reported. Inferred resources totalling 0.7 million tonnes
remain at the same level as before.
13
Falcondo
Located in the Dominican Republic, Falcondo mines, mills, smelts and
refines its own nickel laterite ores. Falconbridge owns 85.26% of Falcondo.
The following table sets forth certain unaudited financial data with
respect to Falcondo for the periods indicated.
Three months ended March 31,
2004 2003
Sales of ferronickel (tonnes) 6,800 6,500
Production (tonnes) 8,000 6,900
Revenues ($ millions) 102 53
Operating cash cost ($ per pound of nickel) 2.95 3.18
Operating income ($ millions) 55 4
Revenues: Revenues of $102 million at Falcondo in the first quarter
of 2004 were 92% higher compared to $53 million in the same period of 2003, due
to the 5% increase in sales to 6,800 tonnes from 6,500 tonnes and the impact of
an 86% increase in the realized ferronickel price.
Costs: Falcondo's operating cash cost per pound of ferronickel
decreased by 7% in the first quarter of 2004 to $2.95, mainly due to the
decrease in oil prices and non-fuel operating costs. It is estimated that a
change of $1 in the price of a barrel of oil results in approximately $0.07 in
operating cash cost per pound of ferronickel.
Operating income: Falcondo's first quarter 2004 operating income was
$55 million, compared with $4 million in for the same period in 2003. The
$51 million higher contribution reflects a higher ferronickel selling price and
increased sales volumes.
Production: In the first quarter of 2004, Falcondo produced 8,000
tonnes of nickel in ferronickel compared to 6,900 tonnes in the first quarter of
2003.
Reserves & exploration: At planned operating rates, the proven and
probable mineral reserves are equal to approximately 18 years of production. The
proven and probable mineral reserves at Falcondo showed a net decrease of
3.2 million tonnes after production of 3.8 million tonnes in 2003. The decrease
due to production was partly offset by the discovery of 0.6 million tonnes in
previously un-drilled areas in Lomas Caribe and Larga. At December 31, 2003,
total proven and probable reserves were 60.9 million tonnes.
Copper Operations
Falconbridge is also an important copper producer, ranking 12th in the
world in mined production during 2003. The Corporation's copper operations
include Kidd Creek in Canada and Collahuasi and Lomas Bayas in Chile.
14
Operating income of the copper business more than tripled to $72 million
in the first quarter of 2003 compared with $20 million in the same period for
2003. Copper production from the mines was 65,900 tonnes in the first quarter
2003 compared with 78,600 tonnes in 2003. The operating cash cost per pound of
copper was $0.48 compared with $0.45 in 2003.
Kidd Creek
Kidd Creek is an integrated processing facility engaged in the mining,
milling, smelting and refining of its own copper and zinc ores and in the
processing of custom feed.
Low treatment charges for third-party concentrates and the appreciation
of the Canadian dollar relative to the U.S. dollar have adversely impacted the
integrated Kidd operations. Profitability is expected to improve in 2004 as a
result of cost reduction initiatives implemented in 2003; the securing of
higher-margin complex concentrates from third parties and from higher metal
prices.
The following table sets forth certain unaudited financial data with
respect to Falconbridge's Kidd Creek operations for the periods indicated.
Three months ended March 31,
2004 2003
Sales (tonnes)
Copper (in metal and concentrate) 28,969 28,773
Zinc (in metal and concentrate) 26,525 35,517
Revenues ($ millions) 133 97
Operating cash cost ($ per pound of copper) 0.88 0.73
Operating income/(loss) ($ millions) 3 (14 )
Revenues: Revenues of $133 million in the first quarter of 2004 were
37% higher than the $97 million realized in the same period for 2003 reflecting
higher realized prices for copper and zinc, which were offset by lower sales
volumes for zinc.
Costs: The first quarter 2004 operating cash costs at the Kidd Mine
increased to $0.88 per pound from $0.73 per pound for the same period in 2003.
The increase reflects primarily higher labour, contractor and energy costs, and
the impact of a stronger Canadian dollar.
Operating income: Kidd Creek operations reported first quarter 2004
operating income of $3 million compared to an operating loss of $14 million for
the first quarter of 2003. The $17 million increase in operating income reflects
higher base metal prices, improved realizations for by-products and lower cost
of sales offset in part by the impact of lower treatment and refining charges,
lower sales volumes for zinc and the strengthening of the Canadian dollar.
15
Kidd Creek Production and Sales
The following table sets forth certain segmented sales and production
data with respect to Falconbridge's Kidd Creek operations for the periods
indicated.
Three months ended March 31,
2004 2003
Ore tonnes Cu Zn Ag Ore tonnes Cu Zn Ag
(x 1,000) % % g/t (x 1,000) % % g/t
Production
Total mined 513 1.81 5.05 105 512 1.94 4.72 59
Total - ore 523 542
processed
Cu Cu Cu Cu
Cu Cathode Blister Zn Ag Cu Cathode Blister Zn Ag
Kidd Mining
Division
Metal in
concentrate
(tonnes except
000 troy ounces
for Ag) 9,296 20,792 1,194 10,792 21,172 739
Kidd Metallurgical
Division
(tonnes except
000 troy ounces
for Ag)
Mines 12, 336 12,289 17,350 597 14,011 13,939 26,330 445
Custom - Sudbury 2,957 2,946 46 6,098 6,067 21
Custom - other 18,432 18,362 11,108 282 16,850 16,762 11,604 762
Total 33,722 33,597 28,458 925 36,959 36,768 37,934 1,228
Cu Zn Cu Zn
Cu in conc. Zn in conc. Ag Cu in conc. Zn in conc. Ag
Sales
(tonnes except
000 troy ounces
for Ag)
Mines 12,533 16,439 732 12,212 25,904 1,045
Custom - other 16,436 10,176 271 16,561 9,613 159
Purchased metal
Total 28,969 26,525 1,004 28,773 35,517 1,204
Production: Copper and zinc production from the Kidd Mine during the
first quarter of 2004 totalled 9,296 and 20,792 tonnes, respectively. A stope
blockage and maintenance issues associated with the ore handling system
negatively impacted mine production. Copper and zinc ore grades were 1.81% and
5.05%, respectively. The copper and zinc mine production forecast for 2004 have
been revised to 43,000 tonnes and 90,000 tonnes, respectively.
Copper cathode production for the first quarter of 2004 was 33,722
tonnes and refined zinc production was 28,458 tonnes, reflecting the impact of
lower mine production and difficulties sourcing profitable third-party feed. For
2004, zinc production is now forecast to be 120,000 tonnes as a result of
securing additional custom feed.
Other Developments
During the quarter, the Corporation reached an agreement with Agnico
Eagle for a life-of-mine contract to process the majority of their annual
production of zinc concentrate. This will ultimately provide the zinc operations
at Kidd with an annual supply of over 100,000 tonnes of precious metal-bearing
zinc concentrate, and will enable it to run with improved margins at full
capacity.
16
At the beginning of July 2004, the copper and zinc operations will take
maintenance shutdowns of five and seven weeks respectively.
Work at Mine D is advancing as planned with first ore production
expected in the second half of 2004 with continuous ramp-up during 2005 and
2006. Mine D will improve operational reliability and predictability and
maintain the mining rate at 2.4 million tonnes per year.
Reserves: At December 31, 2003, reserves totalled 20.8 million tonnes
grading 2.0% copper and 6.1% zinc. Reserves decreased 2.8 million tonnes after
production of 2.1 million tonnes and a revision of the previous estimate by
0.7 million tonnes. At current operating rates, the mineral reserves are equal
to approximately nine years based on current proven and probable mineral
reserves.
Collahuasi
Compaa Minera Doa Ins de Collahuasi S.C.M., in which Falconbridge holds
a 44% interest, operates the Collahuasi mine in northern Chile. Collahuasi mines
and mills copper sulphide ores into concentrate and mines and leaches copper
oxide ores to produce cathodes. Collahuasi continues to be a strong performer
and exceeded targeted production for 2003.
The following table sets forth certain unaudited financial data with
respect to Collahuasi for the periods indicated.
Three months ended March 31,
2004 2003
Falconbridge share
Sales of copper (tonnes) 28,879 44,429
Production (tonnes) 35,369 44,211
Revenues ($ millions) 77 66
Operating cash cost ($ per pound of copper) 0.40 0.34
Operating income ($ millions) 45 28
Revenues: Falconbridge's share of revenues at Collahuasi in the first
quarter of 2004 was $77 million, compared with $66 million in the first quarter
of 2003. The increase of $11 million is due to an increase in the realized
copper prices, which offset the decrease in sales volumes.
Costs: The operating cash cost of $0.40 per pound of copper in the
first quarter of 2004 increased by six cents US per pound, compared to the same
period in 2003. Lower treatment and refining charges more than offset the
increase in mining costs from lower grades and the strengthening Chilean peso.
17
Operating income: The Corporation's share of Collahuasi's first
quarter 2004 operating income was $45 million, compared with $28 million in the
same period for 2003. The positive variance is mostly attributable to higher
copper prices.
Production: Falconbridge's share of annual copper production totalled
35,369 tonnes, 20% lower than the production of 44,211 tonnes in the first
quarter of 2003. Falconbridge's share of cathode from the oxide plant was 6,152
tonnes while production of copper in concentrate was 29,217 tonnes. The decrease
in first quarter 2004 production was anticipated and attributable to lower ore
grades compared to 2003. Falconbridge's share of total copper production in 2004
is forecast at 206,000 tonnes.
Other Developments
The construction of a new grinding circuit at the Ujina concentrator and
the shifting of mining operations from the Ujina to the Rosario ore body are
near completion. The project will increase Collahuasi's concentrator design
capacity to 110,000 tonnes per day from 70,000 tonnes per day, compensating for
an expected decline in ore grade and thereby enabling Collahuasi to maintain
copper production at current levels. The total capital cost of the transition
and concentrator expansion project is estimated at $654 million, with
Falconbridge's 44% share of this cost totalling $288 million. The project to
move the operations from the Ujina pit to the new Rosario open pit and the
expansion of the Ujina concentrator is on schedule and on budget. The project is
expected to achieve mechanical completion in June 2004.
Reserves & exploration: The December 31, 2003, total proven and
probable mineral reserves at Collahuasi of 1,808 million tonnes decreased by
30.5 million tonnes due to mine production.
Lomas Bayas
Compaa Minera Falconbridge Lomas Bayas mines and leaches copper oxide
ores to produce cathodes. During 2003 Lomas Bayas achieved a record level of
production.
The following table sets forth certain unaudited financial data with
respect to Lomas Bayas for the periods indicated.
Three months ended March 31,
2004 2003
Sales of copper (tonnes) 15,935 14,578
Production (tonnes) 15,728 14,572
Revenues ($ millions) 44 25
Operating cash cost ($ per pound of copper) 0.47 0.45
Operating income ($ millions) 24 6
Revenues: Revenues in the first quarter of 2004 were $44 million,
compared to $25 million in the first quarter of 2003. The increase of
$19 million was attributable to the impact of higher realized metal prices and
higher sales volumes.
18
Costs: The operating cash cost of producing a pound of copper in the
first quarter of 2004 increased to $0.47 per pound from $0.45 per pound in the
first quarter of 2003. The increase in the cash cost resulted from higher
sulphuric acid prices and the strengthening of the Chilean peso against the
U.S. dollar.
Operating income: Lomas Bayas' first quarter 2004 operating income of
$24 million, increased by $18 million over the same period for 2003. Higher
sales prices and volumes offset the impact of higher production costs.
Production: Lomas Bayas produced a 15,728 tonnes of copper cathode in
the first quarter of 2004, compared to 14,572 tonnes in the first quarter of
2003. Copper production in 2004 is forecast at 60,000 tonnes.
Reserves & exploration: The December 31, 2003, total proven and
probable mineral reserves of 363.9 million tonnes at Lomas Bayas decreased by
33.4 million tonnes due primarily to mine production, which utilized
30.4 million tonnes. A total of 81.2 million tonnes of mineral resources were
added during 2003 as a result of new modeling of the area.
Corporate and other
Corporate and other includes corporate general and administrative costs,
exploration, research and development expenditures, foreign exchange gains and
losses and other income and expenses.
During the quarter ended March 31, 2004, the Corporate segment generated
income of $10 million versus costs of $7 million for the same period of 2003.
Increases of $14 million in other income and $8 million in foreign exchange
gains, relative to the first quarter of 2003, were offset by increased spending
on general and administrative expenses, which were exacerbated by the impact of
the stronger Canadian dollar. The increase in other income is due to the
recognition of a $13 million mark-to-market gain on our interest rate swaps not
eligible for hedge accounting, and the recognition of $6 million in net interest
income on interest rate swaps not eligible for hedge accounting; offset by lower
metals trading gains quarter over quarter.
Business Development
Growth opportunities
Over the last decade, Falconbridge has assembled a significant portfolio
of growth projects. Some are closer to its operations and easier to execute
(e.g. brownfield projects); others are new projects unrelated to existing
operations (e.g. greenfield projects).
Projects in development
Collahuasi, Chile - The joint venture is completing a major investment
project to expand concentrator capacity and move mining operations to a
higher-grade open pit (see page 18).
19
Kidd Mine D, Timmins, Canada - (See page 17).
Montcalm, Timmins, Canada - The Montcalm mineral reserves consist of
5.1 million tonnes of 1.46% nickel and 0.71% copper. This underground
development project is accessed via a ramp system and is expected to be
operational in the first quarter of 2005, producing 8,000 tonnes of nickel per
year, for seven years.
Brownfield projects
NICKEL
Nickel Rim South, Sudbury, Canada - This high-grade deposit is close to
existing operations and could be put in production in late 2008 or early 2009.
Surface diamond drilling during 2003 resulted in the tonnage increasing by 87%.
The updated inferred mineral resource estimate as of March 31, 2004, is
13.2 million tonnes of 1.7% nickel, 3.5% copper and significant palladium and
platinum. The mineral deposit remains open in an up-dip direction and additional
surface diamond drilling is planned.
An underground definition program has been approved and site preparation
has begun. The five-year, $368-million program has already gone ahead, with
production expected to start in 2008. Once completed, a further $185 million
will be required to bring the mine into production. After taking into account
pre-production revenues of $141 million, the overall net capital cost will be
$413 million.
Fraser Morgan - Diamond drilling at the Fraser Mine has resulted in an
indicated mineral resource of 4.4 million tonnes of 1.72% nickel and 0.49%
copper and an inferred mineral resource of 2.5 million tonnes grading 1.4%
nickel and 0.4% copper. Diamond drilling continues in 2004. The mineral deposit
is accessible from existing Fraser Mine infrastructure.
Raglan, Nunavik, Quebec - The Corporation is evaluating the possibility
of increasing annual production by 40% to 1.3 million tonnes of ore per year. A
scoping study will be completed in 2004. A focused exploration program continues
on the Corporation's large property holdings in the area of the Raglan mine.
COPPER
Collahuasi, Chile - Currently, the fourth-largest copper mine in the
world, Collahuasi has sufficient reserves and resources for further expansion
after the current Phase II project is completed in June 2004. Water rights to
enable further expansion have been secured. Furthermore, the Rosario ore body
contains significant molybdenum giving rise to an investment opportunity to
construct a molybdenum recovery circuit.
Lomas Bayas, Chile - The acquisition of an adjacent deposit, called
Fortuna de Cobre, is being considered. If developed, total annual production
would increase by 50% to 90,000 tonnes and extend mine life by five years. A
decision on the option to buy the deposit must be made by 2006.
20
The following table sets forth mineral reserve estimates and certain
other data with respect to Falconbridge's advanced development projects.
Advanced projects - mineral resources1
Resource Percentage Million Nickel Copper Cobalt Zinc
DECEMBER 31, 2003 Project location ownership Category tonnes % % % %
Nickel deposits
Nickel Rim South2 Sudbury 100% Inferred 11.7 1.6 3.7 0.04 -
Fraser Morgan2 Sudbury 100% Indicated 3.8 1.71 0.52 0.06 -
Inferred 2.5 1.4 0.4 0.05 -
Onaping Depth2 Sudbury 100% Indicated 14.6 2.52 1.15 0.06 -
Inferred 1.2 3.6 1.2 0.07 -
Cte d'Ivoire Ivory Coast 85% Indicated 123.9 1.57 - 0.10 -
Inferred 134.0 1.4 - 0.12 -
Koniambo3 New Caledonia 49% Measured 32.4 2.21 - 0.07 -
Indicated 109.7 2.10 - 0.07 -
Total 142.1 2.13 - 0.07 -
Inferred 156.0 2.2 - 0.08 -
Copper deposits
Mine D4 Timmins 100% Inferred 14.1 - 3.4 - 4.9
Fortuna de Cobre5 Chile 100% Measured 125.2 - 0.31 - -
Indicated 345.1 - 0.28 - -
Total 470.3 - 0.29 - -
Inferred 150.0 - 0.21 - -
Notes:
º 1.
º The mineral resource estimates were prepared in accordance with the "CIM
Standards on Mineral Resources and Mineral Reserves, Definitions and
Guidelines", adopted by CIM Council on August 20, 2000, using classical
and/or geostatistical methods, plus economic and mining parameters
appropriate to each project. The mineral resources have been compiled under
the supervision of Chester Moore, Director, Mineral Reserve Estimation and
Reporting, a member of the Professional Geoscientists of Ontario with
30 years experience as a geologist.
The mineral resources have reasonable prospects for economic extraction but
have not yet had complete formal evaluation, or do not have demonstrated
economic viability under current conditions.
º 2.
º Also included as part of the Sudbury mineral resources on the Mineral
Reserves and Mineral Resources table.
º 3.
º Option to earn. At a 2.0% nickel cut-off grade the deposit contains
Measured plus Indicated mineral resources of 75.6 million tonnes grading
2.47% nickel and 0.06% cobalt.
º 4.
º Also included as part of the Kidd Creek mineral resources on the Mineral
Reserves and Mineral Resources table.
º 5.
º Option to purchase.
Key assumptions for mineral resource and reserve estimation
Refer to Summary of Mineral Reserves and Mineral Resources on Page 7
and Advanced Projects on page 21.
21
Bulk density: the factor used to convert volume into tonnage. This
factor is a function of the mineralogy and physical characteristics of a
deposit. Formulae are developed using regression analyses on a suitably large
number of individual determinations.
Cut-off grade: the grade that ensures the revenue from the metal
content of the lowest grade parcel included in a deposit will be at least equal
to the anticipated prime operating costs of producing this revenue. These costs
include mining, milling, smelting, refining, selling and all transportation and
administration costs. The cut-off grade will vary greatly from property to
property due to a range of factors including deposit size and shape, metal
content and prime cost structure.
Exchange rate (US$ to Cdn$): 1.50
Long-term metal prices (US$ per pound): Nickel $3.25, Copper $0.90,
Zinc $0.50
Minimum mining width: the smallest horizontal thickness used in an
estimation based on the selected mining method and the minimum opening size
required by mining equipment used. The grade across this minimum width must
equal or exceed the cutoff grade.
Mining dilution*: all external material with grades lower than the
cut-off grade that must be removed with the ore. The amount of this diluting
material can vary considerably and depends upon mining method and the location,
attitude, size, shape and wall rocks of the ore zone.
Mining recovery*: the proportion of the ore that is extracted after
accounting for mining losses. The mining recovery can vary widely both within a
single mine and from property to property due to a range of factors including
deposit geometry and mining method.
* Used for mineral reserve estimation only.
Greenfield projects
Kabanga, Tanzania - In early February 2004, Falconbridge and Barrick
Gold Corporation reached a preliminary agreement under which Barrick would grant
Falconbridge an option to acquire 50% of its interest in the Kabanga and Kagera
nickel properties in Tanzania. This option requires Falconbridge to meet certain
spending and work plan milestones. Kabanga, located in western Tanzania about
1,500 kilometres from Dar Es Salaam, has a high-grade mineral resource of more
than 26 million tonnes at 2.6% nickel, with significant upside potential.
Kabanga, together with the Kagera property, provides a significant land position
on the highly prospective Kagera nickel belt. Falconbridge and Barrick have
agreed on a work plan to advance the Kabanga nickel project towards a
development decision within 36 months. Depending on the additional resources
found during the exploration program, a mine could produce between 30,000 and
35,000 tonnes of nickel in concentrate annually.
Koniambo, New Caledonia - Work continued throughout the year on the
Koniambo ferronickel project in the Northern Province of New Caledonia, near the
provincial capital of Kone. With measured and indicated saprolite mineral
resources estimated to be 142.1 million tonnes of 2.13% nickel and inferred
mineral resources of 156 million tonnes of 2.2% nickel, the Koniambo deposit is
one of the largest and highest grade laterite resources in the world. In
addition, the project has an inferred limonite mineral resource estimated to
consist of 95 million tonnes of 1.6% nickel and 0.2% cobalt that could be
developed at a later date.
22
In 1998, Falconbridge entered into a joint-venture agreement with Socit
Minire du Sud Pacifique S. A. (SMSP) and its controlling shareholder, Socit de
Financement et d'Investissement de la Province Nord, for the evaluation and
development of the 60,000-tonne per year nickel in ferronickel mining and
smelting complex. Falconbridge has a right to earn a 49% interest in the project
with SMSP owning 51%. Governance of the project will be on a 50/50 basis.
The Corporation has assembled an experienced project development and
execution team. A pre-feasibility study was completed in 2003 and indicates a
capital cost of $1.57 billion and operating costs of $1.27 per pound. A bankable
feasibility study is in progress, which will refine the capital and operating
cost estimates through greater detailed engineering and will adjust for foreign
exchange rate movements. The bankable feasibility study will be completed in the
third quarter of 2004. The Koniambo ferronickel project would use a well-known
smelting process with modern, updated technologies.
Further geological drilling, completed in March 2003, was undertaken to
delineate 25 years of measured resources and indicated resources.
In 2003, $28 million was spent on the project, bringing total
expenditure to date to $123 million. A formal application was made in 2003 under
the French "Loi Girardin' incentive program for investments in overseas
territories. Discussions are continuing with the Government of France and with
our partner, SMSP.
Exploration
Exploration is being carried out primarily in Canada, Brazil, South
Africa, Norway and Australia. Advanced nickel exploration is focused in Sudbury,
Ontario and Raglan, Quebec near existing operations. Diamond drilling at the
Nickel Rim South discovery at Sudbury has increased the estimated inferred
mineral resource from 6.3 million tonnes to 13.2 million tonnes of 1.7% nickel,
3.5% copper, 0.4% cobalt, 1.9 grams/tonne platinum, 2.2grams/tonne palladium and
0.8grams/tonne gold. Exploration at Raglan during 2003 has resulted in
1.7 million tonnes being added to the mineral reserves/resources.
The Falconbridge exploration budget for 2004 is forecast to be
$22 million, of which $3 million has been spent through March 31, 2004. The
financial investment of worldwide joint-venture participants plus tax credits
provided by the Quebec provincial government to stimulate exploration activity
is expected to provide external funding that will leverage the internal budget
to an estimated $28 million.
23
Energy
In 2003, energy costs represented approximately 21% of the cash cost
breakdown for all of Falconbridge's operations. Significant quantities of
electricity, natural gas, and petroleum products are procured from commodities
markets and regulated energy providers in the U.S., Canada, Norway, Mexico and
Chile.
Corporation profitability is sensitive to energy price volatility. Where
energy is purchased in a commodities market, risk management practices are
applied in order to stabilize prices and enhance energy cost management. Of
particular concern in the mid term are world oil prices, the availability of
sweet crude oil in the Gulf of Mexico and the tight supply situation for natural
gas in North America.
A formal strategy has been established for strengthening the effective
use of energy throughout Falconbridge's operations. The operations are provided
with an infrastructure that effectively measures consumption and performance.
Additionally, awareness workshops are being held at each facility to help
employees understand how energy use can be controlled.
Furthermore, energy is being defined as a managed variable within
operations management systems. Energy performance indicators are being developed
for each level in the organization so that production processes can be operated
to consumption benchmarks. Senior management has endorsed an energy intensity
improvement target of 1% per year. Finally, Six Sigma methodology and techniques
were also applied to reduce consumption.
Sustainable Development
Falconbridge is a strong proponent of sustainable development where
economic prosperity, environmental quality and social equity drive business
activities. This commitment is reflected in the Corporation's Sustainable
Development Policy.
Providing a safe and healthy workplace is a priority at Falconbridge.
Operations continue to implement effective safety training programs and
management systems. Safety performance is strongly supported by senior
management and the Board of Directors. Under the 2003 Safety, Health and
Leadership program, five Falconbridge operations were visited by senior
management to assess, promote and reinforce the importance of a safe workplace.
These initiatives, among others, have resulted in enhanced safety performance in
2003 as the lost-time injury frequency (a measure of the number of compensable
injuries per 200,000 hours worked) declined to 1.26 versus 1.45 in 2002.
For more details on our progress towards sustainability please refer to
the 2003 Falconbridge Limited Sustainable Development Report, which is available
on the Corporation's website.
24
Selected Financial Data
Year ended December 31,
(US$ millions, except per share data) 2003 2002 2001
Total Revenues 2,083 1,525 1,385
Income (loss) 191 50 17
Basic net income (loss) per share 1.03 0.24 0.05
Diluted net income (loss) per share 1.03 0.24 0.05
Total assets 4,171 3,398 3,293
Long-term financial liabilities 1,427 1,280 1,173
Cash dividends declared - common shares (Cdn) 0.40 0.40 0.40
- Preferred shares series 1 (Cdn) 0.08 0.08 0.08
- Preferred shares series 2 (Cdn) 1.4688 1.4688 1.4688
- Preferred shares series 3 - - -
Earnings of $191 million for the year ended December 31, 2003 compared
to earnings of $50 million for 2002. The increase of $141 million is
attributable to the following:
º •
º Higher realized prices for nickel, copper, zinc, cobalt, platinum, and
sulphuric acid.
º •
º Higher sales volumes for nickel, cobalt, precious metals and sulphuric
acid, offset by lower sales volumes for copper and zinc.
º •
º Lower interest expense due to lower interest rates and higher
capitalized interest costs. These savings were partially offset by
higher average debt balances during 2003 relative to 2002.
The above favourable items were offset by the following.
º •
º Higher mining costs and higher acquisition costs for custom feed
º •
º The impact of a stronger Canadian dollar, relative to the U.S. dollar,
on Canadian mining and administrative costs.
º •
º Higher income and mining taxes attributable to higher income in 2003
relative to 2002.
Summary of Quarterly Results
March 31, June 30, September 30, December 31,
(Unaudited - US$ millions, except ------------------ ----------- --------------- --------------
per share data) 2004 2003 2002 2003 2002 2003 2002 2003 2002
Total Revenues 734 472 329 490 406 484 346 637 443
Income (loss) 184 38 14 39 28 19 (15 ) 95 23
Basic net income (loss) per share 1.02 0.21 0.07 0.21 0.14 0.10 (0.10 ) 0.52 0.12
Diluted net income (loss) per 1.01 0.21 0.07 0.21 0.14 0.10 (0.10 ) 0.52 0.12
share
Our financial results for the last eight quarters reflect rising
realized prices for nickel, copper, zinc, cobalt, platinum and acid, higher
sales volumes for nickel, cobalt precious metals and acid offset by lower sales
volumes for copper and zinc and rising cash costs. These trends are discussed
elsewhere in this report.
25
Liquidity and Capital Resources
The Corporation's cash position and changes in cash for the quarter
ended March 31, 2004 compared to the same quarter in 2003 are summarized below:
Quarter ended March 31,
millions 2004 2003
Cash provided by operating activities 231 55
Cash used in investing activities (103 ) (67 )
Cash (used in) provided by financing activities (11 ) 16
Cash provided during the quarter 117 4
Cash and cash equivalents, beginning of period 298 165
Cash and cash equivalents, end of period 415 169
Liquidity and Cash Flow
Consolidated cash and cash equivalents increased by $117 million to
$415 million at March 31, 2004, compared with $169 at the end of the first
quarter of 2003. These items were invested primarily in high-quality short-term
money market instruments and liquidity funds.
In the first quarter of 2004, the Corporation's balance sheet improved
as the ratio of net debt to net debt plus equity improved to 32% from 37% at the
end of 2003. Cash and cash equivalents were $415 million at March 31, 2004.
Falconbridge has significant liquidity and financial flexibility,
including unused bank lines of credit totalling $403 million. As a result, the
Corporation has unused credit and cash available in excess of $800 million. In
addition, the Corporation has no major debt maturities until 2005.
Working capital increased to $791 million at the end of first quarter of
2004 from $649 million at the end of December 2003.
Cash generated from operations before working capital changes totalled
$262 million compared with $106 million for the first quarter of 2003.
The ratio of current assets to current liabilities was 3:1 at March 31,
2004.
Based on planned production levels, estimated LME prices and forecasted
Canadian/U.S. dollar exchange rates, it is anticipated that funds provided from
operations, available cash, and proceeds from existing lines of credit will be
sufficient to finance committed obligations, and planned capital expenditures in
2004 and the dividends declared to date.
26
Significant Future Obligations
The following table sets out Falconbridge's significant contractual
obligations, as of March 31, 2004, for the period indicated.
Significant obligations by year due
April to
December
Nature of Obligation 2004 2005 2006 2007 2008 2009 Thereafter Total
Long-term debt 64 283 299 49 167 58 498 1,418
Asset retirement obligation 11 8 6 3 12 13 398 451
Employee future benefits (1) 372
Operating leases 1 2 2 2 2 2 14 25
Total contractual obligations 76 293 307 54 181 73 910 2,266
º (1)
º Due to the nature of the obligation for employee future benefits, the
timing of the settlement of this liability is not readily determinable.
(See also critical accounting estimates). The obligation for employee
future benefits represents the unfunded obligation as of March 31, 2004.
Capital expenditures and deferred project costs
Capital expenditures in the first quarter of 2004 were directed towards
development of Mine D at the Kidd Mining Division, the Collahuasi transition
from Ujina to Rosario, the crusher expansion at Lomas Bayas, evaluation work at
Koniambo and to maintain and improve productive capacity at all locations.
Capital expenditures for the balance of 2004 will primarily be used to
proceed with the continued development of Mine D at the Kidd Mining Division,
the Collahuasi transition from Ujina to Rosario, the development of the Montcalm
deposit, the underground exploration program at the Nickel Rim South ore body,
continued evaluation work at Koniambo and to maintain and improve productive
capacity at all locations. Expenditures will be financed from internal sources
and existing lines of credit.
The following table summarizes the expenditures incurred or planned for
the periods indicated:
Total Q1 Q1
$ MILLIONS 2004F 2004 2003
Investment projects
Nickel
Montcalm 75 5 0
Koniambo 52 13 5
Nickel Rim South 77 1 0
Copper
Kidd 105 31 19
Collahuasi 91 30 31
Total investment projects 400 80 55
Maintenance and other 100 21 10
Total 500 101 65
27
Outstanding Indebtedness
Total debt decreased to $1,418 million at March 31, 2004 from
$1,427 million at the end of 2003. The decrease was attributable to debt
repayments of $7.5 million and an unrealized foreign exchange gain on Canadian
dollar denominated debt, from the weakening of the Canadian dollar at March 31,
2004 relative to December 31, 2003. The current portion of long-term debt is
$77 million.
The ratio of net debt (debt minus cash and temporary investments) to net
debt plus equity improved to 32% at the end of March 2004 from 37% at the end of
2003.
Capital Resources and Financial Flexibility
The Corporation believes that a conservative financial structure and
financial flexibility are important in order to accommodate the capital
intensive and cyclical nature of the business.
The Corporation has three-year committed revolving Credit Facilities
with various banks totalling $420 million at March 31, 2004. Borrowings may be
in many forms including Letters of Credit, which offset amounts available under
the Credit Facilities. As at March 31, 2004 the Corporation had no borrowings
and had drawn Letters of Credit totalling $17 million. The Corporation also has
Letters of Credit outstanding of $16 million under an uncommitted facility.
The Corporation has a Commercial Paper Program. Unused lines of credit
and cash on hand are used to support the Commercial Paper Program. As at
March 31, 2004 the Corporation had no Commercial Paper outstanding.
Off Balance Sheet Arrangements
The Corporation does not have any unconsolidated affiliates. We do not
enter into off-balance sheet arrangements with special purpose entities in the
normal course of our business. Our only significant off-balance sheet
arrangements consist of our Canadian dollar expenditure hedges discussed under
the heading financial instruments and other instruments below.
Transactions with Related Parties
At March 31, 2004 Noranda Inc. (Noranda) owned, directly and indirectly,
approximately 58.9% of the common shares of the Corporation. During 2002, a
process was initiated to integrate certain operations of Noranda and
Falconbridge with the objective of reducing costs and further extracting value
from the respective assets. The initiatives undertaken have included the
combination of various corporate support services and greater coordination
between operations. Transactions between Falconbridge and the Noranda group
are negotiated on an arms length basis at market terms.
28
Falconbridge has entered into an agreement with a subsidiary of Noranda,
whereby it acts as sales agent for all products, other than sulphuric acid and
indium, produced at Falconbridge's Kidd Creek Operations. Falconbridge has
entered into a supply agreement with another subsidiary of Noranda, which will
purchase and resell Falconbridge's output of sulphuric acid. Accounts
receivable, in the consolidated statements of financial position, includes
$38.2 million (2003 - $34.2 million) in receivables from Noranda relating to
amounts being collected under the sales agreements and $5.4 million
(2003 - $5.2 million) from net purchases of material by Noranda.
Falconbridge has agreements with various Noranda group companies for the
purchase of custom feeds; the toll treatment of copper concentrates, blister
copper and refinery slimes; and the sale of metals. The following table details
related party production and marketing transactions with Noranda Group
Companies.
March 31,
2004 2003
Sale of materials and technology to Noranda (a) 28,294 18,603
Purchase of materials from and smelting and refining fees paid 27,788 33,825
to Noranda (b)
Included in the Corporation's unaudited consolidated financial statements for
the three months ended March 31, 2004 in (a) Revenues; (b) Cost of metal and
other product sales.
Proposed Transactions
There are no significant proposed transactions that have not been
discussed elsewhere in this document.
Critical Accounting Estimates
Management is required to make estimates in preparing its financial
statements in conformity with Canadian GAAP. These estimates affect the reported
amounts of assets and liabilities and the disclosure of contingent assets and
liabilities at the date of the financial statements and the reported amounts of
revenues and expenses during the reporting period. Changes to these estimates
would result in material changes to these line items. The critical accounting
estimates made by Falconbridge relate to our accounting for the following items:
º •
º Property, plant and equipment
º •
º The determination of mineral reserves
º •
º Impairment assessments of long-lived assets
º •
º Amortization of property, plant and equipment
º •
º Employee future benefits
º •
º Asset retirement obligations
º •
º The determination of taxes
29
Property, plant and equipment
As of March 31, 2004, property, plant and equipment with a carrying
value of $3 billion, represented 67% of our asset base. As such the estimates
used in accounting for property, plant and equipment and the related
depreciation and amortization charges are critical and have a material impact on
our financial condition and earnings. Property, plant and equipment and related
capitalized interest and development and pre-production expenditures are
recorded at cost and in addition, includes the fair value amount related to
asset retirement obligations. Property, plant and equipment are subject to
impairment testing as discussed below.
Determination of mineral reserves
One of the most significant estimates which impacts the accounting for
property, plant and equipment and the related depreciation and amortization, is
the estimate of proven and probable ore reserves. The process of estimating
reserves is complex; requiring significant assumptions, estimates and decisions
regarding economic (i.e. metal prices, production costs, and exchange rates),
engineering, geophysical and geological data. A material revision to existing
reserve estimates could occur because of changes to any of these inputs. Changes
in reserves could result in impairment of the carrying amount of property, plant
and equipment (see below) and a change in amortization expense (see below).
Impairment assessments of long-lived assets
We review and evaluate our long-lived assets for impairment when events
or changes in circumstances indicate that the carrying amount may not be
recoverable. There were no impairment losses on long-lived assets recorded in
2003 nor in the first quarter of 2004. Asset impairment is considered to exist
if the total estimated future cash flows on an undiscounted basis are less than
the carrying amount of the asset. An impairment loss is measured and recorded
based on recoverable minerals, expected commodity prices (considering current
and historical prices, price trends and related factors), production levels,
availability of custom feed, capital and reclamation costs, all based on
detailed life-of-mine plans. The term "recoverable minerals" refers to the
estimated amount of metal that will be obtained from proven and probable
ore/mineral reserves, after taking into account losses during ore processing and
treatment. Significant management judgment is involved in estimating these
factors, which include inherent risks and uncertainties. The assumptions we use
are consistent with our internal planning. Management periodically evaluates and
updates the estimates based on the conditions that influence these factors. The
variability of these factors depends on a number of conditions, including
uncertainty about future events, and thus our accounting estimates may change
from period to period. If other assumptions and estimates had been used in the
current period, the asset balances could have been materially impacted. If
management uses different assumptions or if different conditions occur in future
periods, future operating results could be materially impacted.
In estimating future cash flows, assets are grouped at the lowest levels
for which there are identifiable cash flows that are largely independent of
future cash flows from other asset groups, taking into consideration movements
of intermediate products to ensure the utilization of available capacity across
our operations. All assets at a particular operation are considered together for
purposes of estimating future cash flows.
30
Amortization of property, plant and equipment
The Corporation generally depreciates plant and equipment on a
straight-line basis over the lesser of their useful service lives or the lives
of the producing mines to which they relate. At the Kidd Creek Operations, mine
facilities are depreciated over the estimated lives of the mines based on the
unit of production basis. Depletion of resource properties is provided over the
estimated lives of the resources recoverable from the properties on the unit of
production basis. Development and pre-production expenditures, together with
certain subsequent capitalized development expenditures, are amortized over
periods not exceeding the lives of the producing mines and properties.
The most critical estimates which impact the above accounting policy is
the estimated quantity of proven and probable mineral reserves, which is the
underlying basis for the calculation of the depletion of resource properties
using the unit of production method. Changes in the quantity of reserves would
result in changes in amortization expense in the periods subsequent to the
revision.
Employee future benefits
Assets are valued at current market value. The expected return on plan
assets, currently 7%, is based on current bond yields and expected long-term
rate of return on equities. The long-term rate of return on assets assumption is
reviewed on an annual basis.
Liabilities are determined as a present value of future anticipated cash
flows using a discount rate based on corporate AA bond yields at the valuation
date and an inflation expectation consistent with the corporate AA bond yield
curve. Differences between the estimated future results and actual future
results are amortized (to the extent that the cumulative experience gain or loss
is in excess of the permitted 10% corridor under Canadian GAAP) over the
expected average remaining service life (EARSL) of the active members. This 10%
corridor represents 10% of the greater of the post-retirement benefits
obligations and the fair value of plan assets. The return on assets assumption
and the discount rate, salary and inflation assumptions used to value the
liabilities are reviewed annually and are determined based on a consistent
framework from year-to-year. The most significant risk is that the assumption
will prove to be either too high or too low in the long term. It is reasonable
to assume that there will be a significant variation between the assumptions
(which are set within the framework of a long-term commitment) and actual
experience in any one year, but are expected to produce an appropriate
reflection of costs over the long-term.
For post-employment benefits other than pensions, the discount rate is
the same as for pensions. The inflation rate assumed for medical costs is based
on our history of healthcare spending. The assumption for the ultimate health
care trend rates relates to the overall economic trends.
We currently estimate that a 0.5% increase or decrease in the return on
assets assumption would result in a corresponding $3 million increase or
decrease in annual pension expense. Changes to the return on asset assumption
would have no significant effect on funding requirements, as our contributions
are primarily determined based on the applicable Canadian regulatory solvency
funding requirements. Under this valuation methodology, liabilities for solvency
valuation are based on market bond yields and the excess of liabilities over
assets must be amortized over a five-year period. We estimate that a 0.5%
increase or decrease in the discount rate assumption would result in a
corresponding $2 million increase or decrease in the pension expense.
31
Asset retirement obligations (ARO)
As a result of our mining activities, we incur legal obligations
associated with the retirement of tangible long-lived assets, from the
acquisition, construction, development or normal operations of those assets,
which an entity is required to settle as a result of an existing or enacted law
or contract. CICA 3110 ARO, which was adopted January 1, 2004, requires that,
when a legal obligation is incurred, we record as a liability the fair value of
our estimated asset retirement obligations and a corresponding deferred charge
presented as an asset grouped with property plant and equipment. The liability
is accreted to full value over time through a charge to earnings. The asset is
depreciated over the useful life of the associated long-lived asset. The fair
value of the obligation as of March 31, 2004 was $131 million. Period to period
adjustments due to circumstances or changes in estimates are recorded as
determined.
The fair value of these obligations are determined by discounting the
projected cash flows required to settle the legal obligations at our credit
adjusted risk free interest rate over the time periods over which the
obligations were incurred. The future cash flows required to settle the
obligations were determined by detailed engineering and environmental reviews
assuming the most probable outcome based on present facts, circumstances and
legislation.
Critical estimates and judgments were made by management in the
determination of the fair value of our obligation. Cash outflows to settle these
obligations will be incurred during periods ranging from one to 62 years. Due to
the combined effect of the uncertainty associated with such extended time
periods, the estimated discount and inflation factors, and potential changes to
applicable legislation, the fair value of our asset retirement obligations could
materially change from period to period impacting the amount charged to
operations.
Income and mining taxes
The provision or relief for income taxes is calculated based on the
expected tax treatment of transactions recorded in our consolidated financial
statements. The objectives of accounting for income and mining taxes are to
recognize the amount of taxes payable or refundable for the current year and
deferred tax liabilities and assets for the future tax consequences of events
that have been recognized in our consolidated financial statements or tax
returns. In determining both the current and future components of income and
mining taxes, we interpret tax legislation in a variety of jurisdictions as well
as make assumptions about the expected timing of the reversal of future tax
assets and liabilities. The Corporation also makes assumptions about the
repatriation of its earnings or their redeployment offshore and the related
withholding taxes thereon. If our interpretations or assumptions differ from
those of tax authorities or if the timing of reversals is not anticipated, the
provision or relief for income and mining taxes could increase or decrease in
future periods. In estimating deferred income and mining tax assets, a valuation
allowance is determined to reduce the future income tax assets to the amount
that is more likely than not to be realized.
32
Changes in Accounting Policies Including Initial Adoption
Effective January 1, 2004 the Corporation adopted three new accounting
standards and guidelines issued by the Canadian Institute of Chartered
Accountants, Asset Retirement Obligations (CICA 3110), Hedging Relationships
(AcG 13) and Impairment of Long-lived Assets (CICA 3063).
Asset retirement obligations
Under the previous policy, costs related to ongoing site restoration
programs were expensed when incurred, while a provision for mine closure and
site closure costs was charged to earnings during the life of the operations.
Under this new standard, a capital asset and corresponding long-term obligation,
equal to the fair value of the legal obligation for asset retirement, determined
at the date of adoption, is recorded. The key assumptions on which the fair
value of the asset retirement obligations is based, includes the estimated
future cash flows, the timing of those cash flows and the credit-adjusted
risk-free rate or rates at which the estimated cash flows have been discounted.
The Corporation uses discount rates ranging from 5 to 6.5%. Cash flows totalling
$450 million are expected to be incurred over a period ranging from one to
62 years. The capital asset is being depreciated and charged to earnings.
Interest on the obligation is being accreted with a corresponding charge to
earnings. This standard has been applied retroactively with restatement of prior
years.
As of January 1, 2003 the cumulative impact of the adoption of the
standard was to increase retained earnings by $13.7 million, increase property,
plant and equipment by $69.1 million, increase accumulated depreciation by
$14.0 million, increase the provision for asset retirement by $36.6 million, and
increase future income taxes by $5.1 million. The adoption of the new standard
resulted in decreases of $0.7 and $3.2 million respectively to previously
reported earnings for the first quarter of and year ended December 31, 2003,
respectively.
Hedging relationships
As of January 1, 2004 the corporation adopted CICA guideline AcG 13,
which establishes new standards for when hedge accounting may be applied. Under
the provisions of the standard, the Corporation's interest rate hedge contracts
and certain energy price contracts were not eligible for hedge accounting. As a
result upon the implementation of this standard on January 1, 2004, Falconbridge
recorded a deferred mark-to-market gain of $27.4 million on its interest rate
hedges while recording a long-term receivable and long-term payable of
$67.6 million and $40.2 million, for those contracts in a gain and loss
position, respectively. $1.3 million of this deferred gain was amortized into
income during the quarter ended March 31, 2004. In addition, Falconbridge
recorded a mark-to-market gain of $13.4 million for the quarter ended March 31,
2004. Since the interest rate contracts are not eligible for hedge accounting,
the net interest received/paid on these positions is no longer shown as a
reduction from/addition to interest, on the statement of earnings, but are shown
as a component of other income. For the quarter ended March 31, 2004,
$5.6 million of net swap income was included with other income.
33
Under the provisions of the new standard, the Corporation continued to
be eligible for hedge accounting for its forward contracts and option contracts
used as a currency hedge of Canadian dollar operating costs. Falconbridge did
not seek hedge accounting for its forward contracts and option contracts used as
an economic currency hedge of Canadian dollar monetary assets and liabilities.
These contracts continue to be marked to market.
Impairment of long-lived assets
CICA section 3063 establishes standards for the recognition, measurement
and disclosure of the impairment of long-lived assets. This standard is
effective for fiscal years commencing on or after April 1, 2003 and as such was
implemented by Falconbridge effective January 1, 2004. Under the provision of
the standard, a two-step process determines impairment of long-lived assets held
for use. The first step determines whether impairment exists, and if so, the
second step measures the amount of the impairment. An impairment loss is
recognized when the carrying amount of a long-lived asset exceeds the sum of the
undiscounted cash flows expected to result from its use and eventual
disposition. The amount of the impairment loss is determined as the amount by
which the long-lived assets carrying value exceeds its fair value. Falconbridge
did not recognize an impairment loss on any of its long-lived assets as a result
of the implementation of this standard.
34
Financial Instruments and Other Instruments
Falconbridge uses financial and other instruments in the following
instances.
Foreign currency exposure
Falconbridge uses forward foreign exchange and option contracts to hedge
the effect of exchange rate changes on identifiable foreign currency exposures.
Falconbridge hedges up to 50% of its current year Canadian dollar operating cost
and 25% of the subsequent year. Falconbridge may enter into futures and forward
contracts for the purchase or sale of currencies not designated as hedges. These
contracts are carried at estimated fair values and gains or losses arising from
the changes in the market values of these contracts are recognized in the
earnings of the period in which the changes occur. A summary of these positions
is tabled below.
Currency Hedges - Forward Contracts
Year of Maturity
Forward contracts as of March 31, 2004 2004 2005 2006 2007 Total
Expenditure hedges
Canadian dollar expenditures
USD $ forward contracts (millions) 159 198 357
Average price (U.S.$) 1.5489 1.3835 1.4572
Contract amount (in $ millions) CAD 246 274 521
Fair value (in $ millions) CAD 37 12 49
Chilean peso expenditures
USD $ forward contracts (millions) 45.2 16 61
Average price (U.S.$) 725 734 727
Contract amount (in $ millions) CHP 32,771 11,744 44,516
Fair value (in $ millions) USD 11
Norwegian Kroner expenditures
USD $ forward contracts (millions) 6 8 9 7 29
Average price (U.S.$) 7.9020 8.0200 8.0875 8.1300 8.0424
Contract amount (in $ millions) NOK 45 66 72 54 237
Fair value (in $ millions) USD 4
Balance sheet economic hedges
Canadian dollar net liability exposure
USD $ forward contracts (millions) 408 408
Average price (U.S.$) 1.3225 1.3225
Contract amount (in $ millions) CAD 540 540
Fair value (in $ millions) CAD 4 4
Currency Hedges - Option Contracts
Maturing in
Option contracts as of March 31, 2004 2004
Expenditure hedges
Canadian dollar expenditures
Option amount (in $ millions) CAD 50.6
Fair value (in $ millions) 0.01
Norwegian Kroner expenditures
Option amount (in $ millions) NOK 240
Fair value (in $ millions) USD 0.33
Commodity price exposure
Generally, Falconbridge does not hedge the price it realizes on the sale
of its own production and accepts realizations based on market prices prevailing
around the time of delivery of metals to customers. Under certain circumstances,
Falconbridge enters into futures and option contracts to hedge the effect of
price changes on a portion of the commodities it sells. Gains and losses on
these contracts are reported as a component of the related transactions.
Falconbridge may enter into futures and forward contracts for the purchase or
sale of commodities not designated as hedges for accounting purposes. These
contracts are carried at estimated fair values and gains or losses arising from
the changes in the market values of these contracts are recognized in the
earnings of the period in which the changes occur.
35
Interest-rate management
Falconbridge also enters into interest rate swap contracts, including
foreign exchange cross currency swaps, to modify the interest characteristics of
its outstanding debt. The differential to be paid or received, for interest rate
swaps for which we receive hedge accounting, is accrued and recognized as an
adjustment to interest expense related to the debt. The net interest on other
swaps is reflected in our financial statements as other income. A summary of
these positions is tabled below.
Interest-rate swap contracts at March 31, 2004 Total(1)
Maturity (2005) 400
Maturity (2006) 325
Maturity (2008) 2 136
Maturity (2012) 350
Maturity (2015) 150
Fair value 3 70
º (1)
º Notional principal amount of maturities and fair value are in millions of
U.S. dollars.
º (2)
º Includes a cross currency interest rate swap designated as a hedge of our
Canadian dollar debenture. The total fair value of this instrument at
March 31, 2004 was $33 million of which $22 million related to the
currency component of the swap and $11 million related to the interest
component.
º (3)
º Includes the total fair value of $33 million related to the cross currency
interest rate swap discussed above.
Energy Price Management
Falconbridge hedges a portion of the cost of electricity of its
operations in Ontario, Canada and Norway. The following tables summarize
outstanding contracts as of March 31, 2004.
Canadian electricity contracts 2004 2005 2006 2007
Rate $/MWh (CAD) 51.98 47.09 48.60 49.34
Amount (MW) 100 25 50 25
Fair value (in $CAD millions) 1.4 3.6 1.7 0.4
Norwegian electricity contracts 2004 2005 2006 2007 2008 2009 2010
Rate $/MWh (NOK) 184 - 190 190 190 190 190
Amount (MW) 10 - 5 5 5 5 5
Fair value (in $ NOK millions) 5.8 - 1.8 1.9 2.0 2.0 2.2
36
Reconciliation of Financial Measures
(i) Reconciliation of cost of metal and other product sales to operating cash
cost per pound
Three months ended December 31,
(unaudited - in millions of United States dollars except ------------------------------------
per lb. data) 2004 2003
Operating Costs
INO 213 156
Falcondo 43 45
Kidd Creek 113 94
Collahuasi 20 23
Lomas Bayas 16 14
Costs of metal and other product sales, as reported 405 332
Integrated Nickel Operations 213 156
By-product credits (40 ) (36 )
Delivery expense 1 1
Purchased feed costs (118 ) (63 )
Strike costs (14 ) 0
Canadian dollar cost hedges 13 0
Other operating costs 9 5
Cash costs 64 63
Production - Ni recoverable (000's lbs) 24,409 28,574
Cash cost per lb. Ni 2.60 2.16
Falcondo 43 45
Delivery expense 1 1
Other operating costs 7 3
Cash costs 51 49
Production - Ni recoverable (000's lbs) 17,634 15,183
Cash cost per lb. Ni 2.90 3.18
Kidd Creek 113 94
By-product credits (37 ) (22 )
Delivery expense 0 0
Feed acquisition costs (65 ) (45 )
Canadian dollar cost hedges 6 0
Other operating costs (1 ) (11 )
Cash costs 18 17
Production - Cu recoverable (000's lbs.) 20,055 23,005
0.88 0.73
Collahuasi 20 23
Delivery expense 3 3
Realization costs 9 9
Other operating costs 1 (1 )
Cash costs 33 34
Production - Cu recoverable (000's lbs.) 82,630 103,557
0.40 0.34
Lomas Bayas 16 14
Other operating costs 1 0
Cash costs 16 15
Production - Cu recoverable (000's lbs.) 34,674 32,126
0.47 0.45
37
(ii) Net Debt to Net Debt Plus Equity
March 31, December 31,
2004 2003
Long-term debt (including current portion) (a) 1,418 1,427
Cash and cash equivalents (415 ) (298 )
Net debt (b) 1,003 1,129
Shareholders' equity (c) 2,118 1,938
Net debt plus equity (d) = (b + c) 3,121 3,067
Net debt to net debt plus equity (b/d) 32% 37%
Total debt to total debt plus equity (a/a+c) 40% 42%
Outstanding Share Data
As at March 31, 2004 2003
Common shares 179,492,990 177,611,232
Preferred Shares Series 1 89,835 89,835
Preferred Shares Series 2 4,787,283 7,910,165
Preferred Shares Series 3 3,122,882 -
Markets
Nickel
The nickel price averaged $ 6.68/lb. during the first quarter of 2004.
This is the ninth consecutive month of sustained nickel prices above $ 4.00/lb.
breaking the trend of the nineties when nickel only briefly managed to stay
above this level. The first quarter saw evidence of increased scrap availability
and destocking by traders and consumers in response to the elevated nickel
price, but the underlying nickel consumption fundamentals continue to be robust.
The fears of the stainless steel mills that customers would stay away
from the market with the onset of high nickel surcharges were unfounded. Mills
in the U.S. and Europe reported strong demand. At the same time, scrap continued
to be readily available. The superalloy manufacturers were cautiously optimistic
that a pick-up in demand would be sustainable. In Japan, results |