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Developments in the silicon metal market Kevin Fowkes Managing Consultant Argus European Light Metals Conference Dusseldorf, 4 th November 2015
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  • Developments in the silicon metal market

    Kevin FowkesManaging Consultant

    Argus European Light Metals ConferenceDusseldorf, 4th November 2015

  • 0

    1

    2

    3

    Solar &semiconductors

    Silicones

    Aluminium

    The ups and downs of the solar industry have driven silicon metal demand trends since 2009 – solar is in a strong growth phase once more

    World silicon metal consumption by end-use sector(Mt)

    Source: AlloyConsult

    2009-2011First solar

    boom

    2011-2013Solar

    depression

    2013-Solar

    growth resumes

  • 0%

    30%

    60%

    Though the growth of solar has been the big story of the past 10 years, aluminium and silicones remain the largest end-uses for silicon metal

    Share of world silicon metal consumption by end-use sector(%)

    Source: AlloyConsult

    Solar & semiconductors

    Silicones

    Aluminium

    52%

    31%

    16%

    59%

    37%

    3%

  • 80

    100

    120

    140

    160

    180

    200

    220

    240

    Aluminium production has outpaced silicon metal consumption in aluminium – despite a declining silicon scrap usage rate

    Index (2000=100)

    Source: AlloyConsult, World Aluminium

    World aluminiumproduction

    (CAGR=5.8%)

    World consumption of silicon metal in

    aluminium(CAGR=4.5%)

    0%

    10%

    20%

    30%

    % of silicon in global aluminium production deriving from scrap

    Linearregression trend line

  • The transport sector accounts for about 60% of the silicon metal used in aluminium

    China

    Division of aluminium alloys by sector and type

    Silicon metal used in aluminium by estimated end-use

    China39% TRANSPORT

    (Motor vehicles)

    TRANS-PORT(Other)

    NON-TRANSPORT(Machinery, consumer durbs,electrical,constructionetc)

    0%

    25%

    50%

    75%

    100%

    Transportalloys

    Non-transport

    alloys

    Mill products(avg 0.5% Si)

    Cast products(avg 8% Si)

    Source: AlloyConsult, Roskill

  • 0

    100

    200

    300

    Permissable CO2 emissions from vehicles will decline substantially in the next 10 years, especially in regions where limits are less strict at present

    Permissable CO2 emissions frompassenger cars (g CO2 per car per km)

    Source: Roskill, ICCT

    USA

    China

    EU

    Japan

    − The EU and Japan have so far led the world in terms of automotive fuel efficiency / CO2 emission standards

    − Over the next 10 years, standards in China and the USA will become much more strict, and will close the gap with the EU and Japan

    − Lower CO2 emissions requires greater fuel efficiency, which requires a lighter automobile

    − Other pressures on automakers add weight to cars – eg. greater crash resistance & better specification

    − Using lighter materials with same strength is the best solution(good for aluminium, bad for iron & mild carbon steels)

  • 0

    100

    200

    The average aluminium content of a European car has nearly tripledsince 1990, and will rise by a further 15-30% by 2020

    Average aluminium content of cars producedin Europe (kg per car)

    Source: Roskill, European Aluminium Association

    High case

    Low case

    − Aluminium’s superior strength-to-weight ratio makes it more effective for building fuel-efficient cars than steel or iron

    − Main disadvantage of aluminium is higher cost – but legislation forces auto makers to act

    − Average aluminium content of European-produced cars has nearly tripled since 1990

    − There will be a further increase of 15-30% by 2020, and faster increases in other regions

    − Automotive-related alloys account for the highest amount of silicon used in aluminium

  • Silicone consumption is driven by disposable income – significant growth potential exists from developing countries growing their middle class

    China

    Construction & renovation Chemical industry

    Health & medicine Automotive

    Energy & electronics Plastics

    Textiles Paper

    Other

    World silicone consumption by end-use (value basis)

    Source: Roskill

    − Extremely wide array of consuming sectors; approx 10,000 individual applications – more constantly being developed

    − Many are driven by consumer disposable income (eg. beauty, health, home renovation) – most consumption still in west, but substantial growth potential from developing countries building a bigger and richer middle class(especially China)

    − Complex upstream & downstream production process – silicon metal most important raw material(approx 0.5kg/t of silicone)

  • The silicone industry is highly consolidated, with the top 5 producers accounting for approx. 85% of world output

    China

    World silicone production by company (value basis)

    Source: Wacker Factbook, Roskill

    − World silicone production is extremely consolidated – the top 5 producers control approx. 85% of world output

    − Until recent years, most upstream capacity was in US, Europe & Japan, with developing world largely served from exports

    − Massive investment in integrated silicone plants in China in recent years – much of it JVs with big 5

    − Increased efforts to integrate upstream into silicon metal production over past 15 years(DC, Holla, Simcoa, Elkem-BS)

    Dow Corning

    WackerMomentive

    Shin Etsu

    BlueStar

    Others

  • 0

    100

    200

    300

    The solar sector now seems to be following a more sustainable growth path, with massive growth potential over the coming decades

    World polysilicon production(kt)

    Source: AlloyConsult, Viridis IQ

    +71%

    +67%

    +60%

    +50%

    -8%

    +11%

    +8%

    − The solar sector has returned to growth following the “solar depression” of 2011-13

    − Growth in demand now more driven by unsubsidised PV installations, mostly in Asia. As such, growth is therefore likely to be more sustainable and less volatile than in the past

    − Growth of ~10%pa expected over the long term, requiring hundreds of thousands of tonnes of extra silicon(stark contrast with flat demand outlook for steel)

    +5%

  • 0

    1

    2

    3

    Other

    Germany

    Spain

    Canada

    S.Africa

    Thailand

    Russia

    Australia

    France

    USA

    Brazil

    Norway

    China

    World silicon metal production is expected to decline slightly to reach 2.54 Mt in 2015, with China now accounting for 65% of global output

    World silicon metal production(Mt)

    Source: AlloyConsult

    65%

    56%

    46%

    29%

  • 0

    600

    1,200

    1,800

    Exports

    Domesticsales

    Unlike most ferroalloys, China’s rising silicon metal output has been export-driven in recent years, though exports have fallen slightly in 2015

    Chinese silicon metal production(kt)

    Source: AlloyConsult

  • 0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    Other

    Middle East

    Europe

    Other Asia

    S.Korea

    Japan

    Chinese exports almost doubled from 2012 to 2014. Though exports have fallen slightly in 2015, exports to Japan and Europe have continued to rise

    Chinese silicon metal exports(kt)

    Source: AlloyConsult

    Cancellation of export tax

    (1st Jan 2013)

  • 0

    100

    200

    300

    Outside of China, the main development in silicon metal production has been reduced Brazilian output, due to electricity shortages

    Silicon metal production(kt)

    Source: AlloyConsult

    64%

    56%

    46%

    29%

    Brazil

    Norway

    USA

    France

    − Brazilian output has halved since 2011, due to electricity shortages

    − Following expiry of long-term power contracts at end-2014, many producers were unable to secure competitively priced power, and idled their production

    − Higher output in Norway, partly due to furnace conversion from FeSi

    − New furnace in Australia, on-stream since 2012

    − Overall, non-Chinese output has been broadly stable for 15 years

    − New projects proposed in Canada and Iceland

  • In Minas Gerais:CBCC (Dow Corning)RIMA Capitao Eneas

    RIMA Varzea da PalmaMinasligas

    LIASANova Era

    ItalmagnesioBozel

    In Bahia:Ferbasa

    In Para:CCM (Dow Corning)

    Location of main silicon metal and FeSi plants in Brazil:

    Many silicon metal plants in Brazil are in the southern state of Minas Gerais, where the electricity situation has been particularly bad

  • • The impact of the electricity shortages has been very uneven across Brazilian producers in 2015

    • Northern plants have been producing at close to normal levels whilst most capacity in Minas Gerais has been idle; in essence Dow Corning has been least impacted whilst most smaller producers have been badly affected

    • Ferroalloy plants in northern Brazil negotiated favourable power contracts in mid-2015 lasting into the 2030s, average tariff in USD lower than in 2014 due to weak local currency

    • Plants in Minas Gerais reported to be in the midst of negotiating new power agreements. Some production likely to return in Q4-2015, though dependent on the state of the market

    • Brazilian output in 2016 highly likely to increase relative to 2015

    Summary of recent developments in Brazil

  • • New company has estimated value of US$3.1bn

    • Transaction expected to close in Q4-2015

    • New company to be headquartered in London, listed in New York

    • To be led by Alan Kestanbaum (Globe executive chairman); Joint CEOs will be Jeff Bradley (Globe CEO) and Pedro Larrea Paguaga (Ferroatlantica chairman and CEO)

    • Expected cost savings of US$65M per year; debt expected to fall by US$30M over 3 years and cash flow to improve by US$100M (more efficient management of working capital and other efficiency savings)

    • Approved by shareholders of Globe Specialty Metals in Sep 2015; still subject to approval by regulators in relevant jurisdictions

    Proposed Globe-Ferroatlantica merger:Summary of publicly-released information

  • 0 250 500

    Ferroatlantica + Globe

    Ferroatlantica

    BlueStar / Elkem

    Dow Corning

    Hubei Sanxin

    Gansu Sanxin

    Xinjiang Hesheng

    Guizhou Shibing Hengsheng

    Globe Specialty Metals

    Zhejiang Kaihua Yuantong Silicon

    Maoxian Panda Silicon

    The proposed merged company’s silicon metal capacitywould be twice that of the second-largest producer

    Source: Roskill

    World top-10 silicon metal producersby capacity (kt)

    Ferroatlantica already world’s biggest producer of silicon metal

    Globe currently world’s 8th

    biggest producer (3rd largest non-Chinese owned producer)

    New company will have silicon metal capacity approx. twice the size of the second largest producer

  • 0%

    25%

    50%

    75%

    100%

    World World exc.China

    EU USA

    Others

    Chinese

    Ferroatlantica

    Globe

    The merged company’s biggest impact on silicon metalmarket share will be in the USA

    Source: AlloyConsult

    Estimated silicon metal market share by supplier (2014)

    6% 8% 2%

    41%

    8%11%

    30%

    15%

  • Silicon metal anti-dumping update

    • EU anti-dumping duties against Chinese silicon metal expire in 2015, and the investigation into their potential renewal is at an advanced stage

    • US anti dumping duties against Russian and Chinese silicon metal are not (ordinarily) scheduled for review until 2017/18

    AD duties on Chinese silicon metal also in place in Canada and Australia

  • 500

    1,000

    1,500

    2,000

    2,500

    3,000

    3,500

    4,000

    EU USA China export

    Silicon metal spot prices – 10 year history

    Source: AlloyConsult

    Silicon metal spot prices(US$/t)

  • -20%

    0%

    20%

    40%

    60%

    80%

    100%

    120%

    EU vs China US vs China US vs EU

    Source: AlloyConsult

    Silicon metal spot price premiums – 10 year history

  • Silicon metal prices have significantly outperformed Mn alloys & FeCrsince 2008, and have maintained a very close correlation with FeSi

    Source: AlloyConsult

    20

    40

    60

    80

    100

    120

    140

    160

    180

    Si metal

    FeSi

    SiMn

    HC FeMn

    HC FeCr

    European bulk ferroalloy prices(Index, Jan 2008=100)

  • 0%

    25%

    50%

    75%

    100%

    Si metal(globalavg)

    Si metal(Europe)

    Si metal(Brazil)

    Si metal(China)

    Labour & other Quartz ElectrodesReductants Electricity

    Silicon metal production costs are driven by electricity and reductant costs….average cash costs have declined significantly in 2015

    Source: AlloyConsult

    Ex-plant cash costs by component (2015)

    50

    100

    150

    200

    250

    300

    350

    Electricity Electrodes

    Reductants Quartz

    Labour Total cash cost

    Silicon metal cash costs by component(Index, 2000=100)

  • 0

    1,000

    2,000

    3,000

    Average cash cost,China (ex plant)

    Average cash cost+10%

    Chinese siliconmetal price(CIF Japan basis)

    The level of Chinese silicon metal prices is increasingly being set by the average cash production cost

    US$/t

    Source: AlloyConsult

    Solar boom2007-8 commodities

    boom

    Export tax rebates

  • Thank you for your attention