UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Form 10-K
ANNUAL REPORT
PURSUANT TO SECTIONS 13 OR 15(d)
OF THE SECURITIES EXCHANGE ACT OF 1934
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ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
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For the fiscal year ended December 31, 2005 |
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OR |
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
For the transition period
from to |
Commission File Number: 1-8944
Cleveland-Cliffs Inc
(Exact name of registrant as specified in its charter)
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Ohio |
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34-1464672 |
(State or other jurisdiction of
incorporation) |
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(I.R.S. Employer
Identification No.) |
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1100 Superior Avenue,
Cleveland, Ohio
(Address of principal executive offices) |
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44114-2589
(Zip Code) |
Registrants telephone number, including area code:
(216) 694-5700
Securities Registered Pursuant to Section 12(b) of the
Act:
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Title of Each Class |
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Name of Each Exchange on Which Registered |
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Common Shares, par value $.50 per share
Rights to Purchase Common Shares |
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New York Stock Exchange and Chicago Stock Exchange
New York Stock Exchange and Chicago Stock Exchange |
Securities Registered Pursuant to Section 12(g) of the
Act:
NONE
Indicate by check mark if the registrant is a well-known
seasoned issuer, as defined in Rule 405 of the Securities
Act. Yes o No þ
Indicate by check mark if the registrant is not required to file
reports pursuant to Section 13 or Section 15(d) of the
Act. Yes o No þ
Indicate by check mark whether the registrant: (1) has
filed all reports required to be filed by Section 13 or
15(d) of the Securities Exchange Act of 1934 during the
preceding 12 months (or for such shorter period that the
registrant was required to file such reports), and (2) has
been subject to such filing requirements for the past
90 days. Yes þ No o
Indicate by check mark if disclosure of delinquent filers
pursuant to Item 405 of the
Regulation S-K is
not contained herein, and will not be contained, to the best of
registrants knowledge, in definitive proxy or information
statements incorporated by reference in Part III of this
Form 10-K or any
amendment to this
Form 10-K. þ
Indicate by check mark whether the registrant is an accelerated
filer (as defined in Exchange Act
Rule 12b-2). Yes þ No o
Indicate by check mark whether the registrant is a large
accelerated filer, or a non-accelerated filer.
Large accelerated
filer þ Accelerated
filer o Non-accelerated
filer o
Indicate by check mark whether the registrant is a shell company
(as defined in
Rule 12b-2 of the
Exchange
Act). Yes o No þ
As of June 30, 2005, the aggregate market value of the
voting and non-voting stock held by non-affiliates of the
registrant, based on the closing price of $57.61 per share
as reported on the New York Stock Exchange Composite
Index was $1,223,691,317 (excluded from this figure is the
voting stock beneficially owned by the registrants
officers and directors).
The number of shares outstanding of the registrants Common
Shares, par value $.50 per share, was 21,918,001 as of
February 16, 2006.
DOCUMENTS INCORPORATED BY REFERENCE
Portions of registrants Proxy Statement for the Annual
Meeting of Shareholders scheduled to be held on May 9, 2006
are incorporated by reference into Part III.
TABLE OF CONTENTS
PART I
Introduction
Founded in 1847, Cleveland-Cliffs Inc (the Company,
we, us, our, and
Cliffs) is the largest producer of iron ore pellets
in North America. We sell the majority of our pellets to
integrated steel companies in the United States and Canada. On
April 19, 2005, Cleveland-Cliffs Australia Pty Limited, an
indirect wholly owned subsidiary of the Company, completed the
acquisition of 80.4 percent of Portman Limited
(Portman), the third-largest iron ore mining company
in Australia. The acquisition was initiated on March 31,
2005 by the purchase of approximately 68.7 percent of the
outstanding shares of Portman.
Our headquarters are located at 1100 Superior Avenue,
Cleveland, Ohio 44114-2589, and our telephone number is
(216) 694-5700.
Our website address is www.cleveland-cliffs.com. Information
contained on our website does not constitute part of this
Form 10-K. We make
available, free of charge through our website, our annual report
on Form 10-K,
quarterly reports on
Form 10-Q and
current reports on
Form 8-K, as well
as amendments to those reports, as soon as reasonably
practicable after we file such reports with, or furnish such
reports to, the Securities and Exchange Commission (the
SEC).
North America
We manage and operate six North American iron ore mines located
in Michigan, Minnesota and Eastern Canada that currently have a
rated capacity of 37.5 million tons of iron ore pellet
production annually, representing approximately 46 percent
of total North American pellet production capacity. Based on our
percentage ownership of the North American mines we operate, our
share of the rated pellet production capacity is currently
23.0 million tons annually, representing approximately
28 percent of total North American annual pellet capacity.
The following chart summarizes the estimated annual production
capacity and percentage of total North American pellet
production capacity for each of the North American iron ore
pellet producers as of December 31, 2005:
North American Iron Ore Pellet
Annual Rated Capacity Tonnage
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Current Estimated Capacity | |
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(Gross tons of raw ore | |
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Percent of Total | |
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in thousands) | |
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North American Capacity | |
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All Cliffs Managed Mines
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37,500 |
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45.9 |
% |
Other U.S. Mines
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U.S. Steels Minnesota Ore Operations
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Minnesota Taconite
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14,600 |
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17.9 |
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Keewatin Taconite
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5,400 |
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6.6 |
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Total U.S. Steel
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20,000 |
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24.5 |
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Mittal USA Minorca Mine
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2,900 |
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3.6 |
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Total Other U.S. Mines
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22,900 |
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28.1 |
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Other Canadian Mines
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Iron Ore Company of Canada
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12,300 |
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15.1 |
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Quebec Cartier Mining Co.
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8,900 |
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10.9 |
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Total Other Canadian Mines
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21,200 |
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26.0 |
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Total North American Mines
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81,600 |
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100.0 |
% |
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1
We sell our share of North American iron ore production to
integrated steel producers, generally pursuant to term supply
agreements with various price adjustment provisions.
For the year ended December 31, 2005, we produced a total
of 35.9 million tons of iron ore pellets, including
22.1 million tons for our account and 13.8 million
tons on behalf of the steel company owners of the mines.
Australia
Portman was founded in 1925 and had undergone a number of
management and business changes before establishing itself as a
mineral producer in the early 1990s. Following the sale of
its Queensland based coking coal operations in 1999, Portman
focused on its Western Australia iron ore deposits at the
Koolyanobbing operations and Cockatoo Island. Portmans
100 percent owned Koolyanobbing mining operations and its
50 percent interest in the Cockatoo Island Joint Venture
represent Portmans only significant operations. Portman
serves the Asian iron ore markets with direct-shipping fines and
lump ore. Portmans 2005 production (excluding its
..6 million metric ton (tonne) share of the
Cockatoo Island joint venture) was approximately six million
tonnes. Portman currently has a $61 million project
underway that is expected to increase its wholly owned
production capacity to eight million tonnes per year by the end
of the first quarter of 2006. The production is fully committed
to steel companies in China and Japan for approximately four
years.
The Companys acquisition of Portman represents another
significant milestone in our long-term strategy to seek
additional iron ore mine investment opportunities and to
continue our transition from primarily a mine management company
and mineral holder to an international merchant mining company.
Business Segments
As a result of the Portman acquisition, we have organized into
two operating and reporting segments: North American and
Australian. The North American segment, comprised of our mining
operations in the United States and Canada, represented
approximately 86 percent of our consolidated revenues for
the nine-month period following the Portman acquisition. The
Australian segment, comprised of our acquired 80.4 percent
Portman interest in Western Australia, represents approximately
14 percent of our consolidated revenues for the same
period. There have been no intersegment revenues since the
acquisition.
North American Segment
The North American segment is comprised of our six iron ore
mining operations in Michigan, Minnesota and Eastern Canada. We
manufacture 13 grades of iron ore pellets, including standard,
fluxed and high manganese, for use in our customers blast
furnaces as part of the steel-making process. The variation in
grades results from the specific chemical and metallurgical
properties of the ores at each mine and whether or not fluxstone
is added in the process. Although the grade or grades of pellets
currently delivered to each customer are based on that
customers preferences, which depend in part on the
characteristics of the customers blast furnace, in most
cases our iron ore pellets can be used interchangeably. Industry
demand for the various grades of iron ore pellets depends on
each customers preferences and changes from time to time.
In the event that a given mine is operating at full capacity,
the terms of most of our pellet supply agreements allow some
flexibility to provide our customers iron ore pellets from
different mines.
Standard pellets require less processing, are generally the
least costly pellets to produce and are called
standard because no ground fluxstone (i.e.,
limestone, dolomite, etc.) is added to the iron ore concentrate
before turning the concentrates into pellets. In the case of
fluxed pellets, fluxstone is added to the concentrate, which
produces pellets that can perform at higher productivity levels
in the customers specific blast furnace and will minimize
the amount of fluxstone the customer may be required to add to
the blast furnace. High manganese pellets are the
pellets produced at our Canadian operation, Wabush Mines
(Wabush), where there is more natural manganese in
the crude ore than is found at our other operations. The
manganese contained in the iron ore mined at Wabush cannot be
entirely removed during the concentrating process. Wabush
produces pellets with two levels of manganese, with the lower
manganese content being preferred by our customers.
2
It is not possible to produce pellets with identical physical
and chemical properties from each of our mining and processing
operations. The grade or grades of pellets purchased by and
delivered to each customer are based on that customers
preferences and availability.
Each of our North American mines is located near the Great Lakes
or, in the case of Wabush, near the St. Lawrence Seaway, which
is connected to the Great Lakes. Iron ore is transported via
railroads to loading ports for shipment via vessel to Canada,
the United States or other international destinations or shipped
as concentrates for sinter feed.
North American Iron Ore Customers
More than 97 percent of our North American revenues are
derived from sales of iron ore pellets to the North American
integrated steel industry, consisting of 10 current or potential
customers. Generally, we have multi-year supply agreements with
our customers. Sales volume under these agreements is largely
dependent on customer requirements, and in many cases, we are
the sole supplier of iron ore pellets to the customer. Each
agreement has a base price that is adjusted annually using one
or more adjustment factors. Factors that can adjust price
include measures of general industrial inflation, steel prices
and international pellet prices. One of our supply agreements
has a provision that limits the amount of price increase or
decrease in any given year.
During 2005 and 2004, we sold 22.3 million and
22.6 million tons of iron ore pellets, respectively, from
our share of the production from our North American iron ore
mines. Sales in 2005 were to eight North American, one European
and one Chinese steel producer.
The following five customers together accounted for a total of
93 percent and 94 percent of North American
Product sales and services revenues for the years
2005 and 2004, respectively:
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Percent of | |
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Sales | |
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Revenues* | |
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Customer |
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2005 | |
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2004 | |
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Mittal Steel USA Inc. (Mittal Steel USA)
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43 |
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56 |
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Algoma Steel Inc. (Algoma)
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22 |
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14 |
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Severstal North America, Inc. (Severstal)
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12 |
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13 |
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WCI Steel Inc. (WCI)
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8 |
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6 |
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Stelco Inc. (Stelco)
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8 |
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5 |
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Total
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93 |
% |
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94 |
% |
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* |
Excluding freight and venture partners cost reimbursements. |
Our term supply agreements expire between 2006 and 2018. The
weighted average duration is eight years.
Our sales are influenced by seasonal factors in the first
quarter of the year as shipments and sales are restricted by
weather conditions on the Great Lakes. During the first quarter,
we continue to produce our products, but we cannot ship those
products via lake freighter until the Great Lakes are passable,
which causes our first quarter inventory levels to rise. Our
practice of shipping product to ports on the lower Great Lakes
and/or to customers facilities prior to the transfer of
title has somewhat mitigated the seasonal effect on first
quarter inventories and sales.
In 2005, 68 percent of our North American product revenues
(80 percent in 2004) were derived from sales to our
U.S. customers. See Operations and Customers in
Item 7, Managements Discussion and Analysis of
Financial Conditions and Operations for further
information regarding our customers.
3
Australian Segment
The Portman operations include production facilities at the
Koolyanobbing operations and a 50 percent interest in a
joint venture at Cockatoo Island, producing lump ore and
direct-shipping fines for our customers in China and Japan. The
Koolyanobbing facility has crushing and screening facilities
used in the production process. Production is fully committed to
steel companies in China and Japan for approximately four years.
The Koolyanobbing operations are located 425 kilometers east of
Perth and approximately 50 kilometers northeast of the town of
Southern Cross. All of the ore mined at the Koolyanobbing
operations is transported by rail to the Port of Esperance, 578
kilometers to the south for shipment to Asian customers.
Cockatoo Island is located off the Kimberley coast of Western
Australia, approximately 3,000 kilometers north of Perth.
Portman sells its ore into the global seaborne trade market.
Australian Iron Ore Customers
A limited spot market exists for seaborne iron ore as most
production is sold under long-term contracts with annual
benchmark prices driven from negotiations between the major
suppliers and the Chinese and Japanese steel mills. The three
major iron ore producers, Companhia Vale do Rio Doce
(CVRD), Rio Tinto and BHP Billiton
(BHP), dominate the seaborne iron ore trade and
together account for approximately three-fourths of the global
supply to the seaborne market.
Portman has long-term supply contracts with steel producers in
China and Japan that account for approximately 73 percent,
and 27 percent, respectively, of sales. Sales volume under
the agreements is partially dependent on customer requirements.
Each agreement is priced based on the benchmark pricing
established for Australian producers. The rapid growth in
Chinese demand, particularly in more recent years, was
underestimated by the major producers and has led to demand
outstripping supply. This market imbalance has recently led to
high spot prices for iron ore and a 71.5 percent increase
in 2005 benchmark prices for Brazilian and Australian producers
for iron ore lump and fines.
Since the acquisition, we sold 4.9 million tonnes of iron
ore to 15 Chinese and three Japanese customers. No customer
comprises more than 15 percent of Portman sales or
10 percent of our consolidated sales. Portmans five
largest customers account for approximately 50 percent of
Portmans sales.
Segment Results
We primarily evaluate performance based on segment operating
income, defined as revenues less expenses identifiable to each
segment. We have classified certain administrative expenses as
unallocated corporate expenses.
Additional information regarding our segment performance is
included in Item 7, Managements Discussion and
Analysis of Financial Condition and Results of Operations,
of this Annual Report on
Form 10-K. In
addition, selected financial data for our segments is available
in Note 5, Segment Reporting, included in
Item 8, Financial Statements and Supplementary
Data.
Strategy
Almost all iron ore is used in steelmaking. Iron ore consumption
is concentrated in a few areas of the world with the top five
regions/countries accounting for almost 85 percent of world
demand for iron ore. While steel production in many of these
areas has been relatively static over recent years, China has
experienced double digit growth in its crude steel production.
As a consequence, China has accounted for most of the growth in
world steel production over the past five years.
The rapid growth in steel production in China has not been met
by a corresponding increase in domestic Chinese iron ore
production. Chinese iron ore deposits, although substantial, are
of a lower grade (approximately half of the equivalent iron
content) than the current iron ore produced in Brazil and
Australia. China
4
has moved from a position where demand was largely satisfied by
domestic supply in the early 1990s to being a net importer
of iron ore in 2005.
While iron is an abundant element, iron ore production is
concentrated within five regions/countries (China, South America
(Brazil), Australia, Commonwealth of Independent States and
India) accounting for 83 percent of current annual
production. Brazil, Australia and to a lesser extent, India, are
the principal exporters into the global seaborne iron ore
market. These countries account for 80 percent of the
current global seaborne iron ore market. The increase in demand
has largely been met by expansion of supply from Brazil and
Australia, which together maintain dominance of supply to this
market and have the largest global reserves of high iron content
ores.
We advanced our strategic objective of serving high-growth steel
markets with the completion of our acquisition of
80.4 percent of Portman in April 2005. This acquisition
gives us a more diversified customer base and a foothold in the
worlds fastest growing steel markets with opportunities
for additional international growth. Portman is the
third-largest iron ore producer in Australia.
The North American integrated steel industry continues to
undergo a restructuring process. This process is producing a
stronger, more productive industry principally through
consolidation with some rationalization of less efficient
capacity. The North American iron ore industry also has been
restructuring to meet the changing needs of its customers. It
has been our strategy to lead this consolidation process and to
continue to improve the competitiveness of our operations.
We have repositioned ourselves from a manager of iron ore mines
on behalf of steel company owners to primarily a merchant of
iron ore to steel company customers. For example, in December
2003, together with Laiwu Steel Group, Ltd. (Laiwu)
of China, we, through our newly formed joint venture, United
Taconite Mining Company LLC (United Taconite),
purchased the assets of Eveleth Mines LLC (Eveleth
Mines) out of bankruptcy. In 2005, we completed an
expansion project at United Taconite to expand annual capacity
by approximately 1.0 million tons. Our plan to restart an
idled furnace to increase capacity by .8 million tons at
our wholly owned Northshore mine has been deferred until market
conditions warrant increased pellet production.
Our challenge in North America is to improve performance at all
of our mining operations. We have initiated programs to achieve
enterprise-wide cost savings through initiatives teams focusing
on all aspects of our cost structure. Key areas of focus include
maintenance spending, energy usage and procurement. We have also
implemented a new safety program with the objective of becoming
an injury-free place of employment. We are also initiating
comprehensive personnel plans that will address current talent
needs, meet future hiring requirements and identify specific
succession plans for key management positions.
Our strategic objectives are to:
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Seek Additional Investment Opportunities |
We intend to continue to pursue investment and management
opportunities to broaden our scope as a supplier of iron ore or
other raw materials to the integrated steel industry through the
acquisition of additional mining interests to strengthen our
market position. We are particularly focused on expanding our
international investments to capitalize on global demand for
steel and iron ore.
Much of the current increase in global demand for steel is due
to industrialization in countries such as China. China is
seeking foreign supplies of the raw materials it needs to
produce steel to build infrastructure, factories, hotels and
other buildings and to manufacture motor vehicles and
appliances. Chinas increased demand for those materials,
including iron ore pellets, has been a factor in increasing raw
material prices around the globe. Currently, China is the
worlds largest steel producer, with approximately
30 percent of global steel production, and Chinas
steel production is expected to continue to grow. Chinese iron
ore imports rose in excess of 30 percent in 2005 and are
expected to further increase in 2006. China has overtaken the
United States as the largest consumer of iron ore, steel and
copper, and currently accounts for 40 percent of
5
the worlds consumption of iron ore. We are attempting to
capitalize on Chinas industrial growth by acquiring
additional well-located iron ore properties and obtaining
agreements to supply China with iron ore on terms favorable to
us.
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Expand Our Leadership Position in the North American Iron Ore
Market |
We have substantially restructured the ownership interest in our
mines largely by converting mine partners into customers with
term supply agreements. Under our operating strategy, royalty
and management fee income has largely been replaced by profit
margin on pellet sales. It is our goal to continue to expand our
leadership position in the industry by focusing on high product
quality, technical excellence, superior relationships with our
customers and partners and improved operational efficiency
through year-over-year cost savings. By developing creative
solutions for our customers during the recent industry
restructuring, we have been able to generate term supply
agreements with many of these companies, which have benefited
our market position. Our creative solutions included acquisition
of our partners interests in the mines largely for the
assumption of certain mine liabilities, thereby allowing
partners to focus on their core steelmaking business and become
our customers by entering into term supply agreements with us.
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Achieve Demonstrated Savings through Productivity
Improvements, Enterprise-wide Cost Reductions and Strategic
Sourcing |
Rising costs are a threat to profits and limit our strategic
flexibility. Our mining costs have increased 57 percent
between 2003 and 2005. In particular, we have seen large
increases in energy, capital and employment costs. This recent
trend has affected the global mining industry as well. To
mitigate the effect of these surging costs, we have implemented
an aggressive cost savings program through a number of
Initiatives Teams.
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Strive to Continuously Improve Iron Ore Pellet Quality and
Develop Alternative Metallic Products |
With the overall goal of achieving cost savings and quality
improvements through pioneering process development at the mines
that we manage, we operate a fully-equipped research and
development facility located in Ishpeming, Michigan. Our
research and development group is staffed with experienced
engineers and scientists and is organized to support the
geological interpretation, process mineralogy, mine engineering,
mineral processing, pyrometallurgy, advanced process control and
analytical service disciplines. Our research and development
group is also utilized by iron ore pellet customers for
laboratory testing and simulation of blast furnace conditions.
Currently, almost all North American iron ore pellets are
consumed in blast furnaces, which is the first step in the
steelmaking process. The blast furnaces produce iron in molten
form, which is further processed in basic oxygen furnaces where
carbon is removed and steel scrap and other alloys are added to
produce molten steel. The molten steel is then cast into steel
shapes.
As part of our efforts to develop alternative metallic products,
we participated in Phase II of the Mesabi Nugget Project
(Project) to test and develop Kobe Steel,
Ltd.s technology for converting iron ore into nearly pure
iron in nugget form. The high-iron-content material could be
used as a steel scrap supplement as a raw material for electric
steel furnaces and blast furnaces or basic oxygen furnaces of
integrated steel producers or as feed-stock for the foundry
industry. See Other Related Items Mesabi
Nugget Project in Item 7 for a further discussion of
the Project.
Information regarding Operations, Competition, Environment,
Energy, Research and Development and Employees is presented
under the captions Operations,
Competition, Environment,
Energy, Research and Development and
Employees, respectively, all of which are included
in Item 2 and are incorporated by reference and made a part
hereof.
6
If the rate of steel consumption in China slows, the demand
for iron ore could decrease.
The world price of iron ore is strongly influenced by
international demand. The current growing level of international
demand for iron ore and steel is largely due to the rapid
industrial growth in China. A large quantity of steel is
currently being used in China to build roads, bridges, railroads
and factories. If the economic growth rate in China slows, which
may be difficult to forecast, less steel may be used in
construction and manufacturing, which could decrease demand for
iron ore. This could adversely impact the world iron ore market,
impact the North American and Australian iron ore market, and
adversely impact Portman, where approximately 73 percent of
our Australian revenues are generated. It could also adversely
impact our United Taconite joint venture with Laiwu and our
Wabush mine. A slowing of the economic growth rate in China
could also result in greater exports of steel out of China,
which if imported into North America could decrease demand for
domestically produced steel, thereby decreasing the demand for
iron ore produced in North America. China became a modest net
exporter of steel products in 2005.
Excess global capacity and the availability of competitive
substitute materials may result in intense competition in the
steel industry, which may reduce steel prices and decrease steel
production and our customers demand for iron ore
products.
More than 97 percent of our North American revenues are
derived from the North American integrated steel industry. From
time to time, global overcapacity in steel manufacturing has a
negative impact on North American steel sales and reduces the
production of steel and consequently the demand for iron ore.
Chinas domestic crude steel capacity is expected to climb
to 360 million tonnes in 2006 from 340 million tonnes
in 2005, according to the Chinese Securities Journal. Further,
production of steel by North American integrated steel
manufacturers may be replaced to a certain extent by production
of substitute materials by other manufacturers. In the case of
certain product applications, North American steel manufacturers
compete with manufacturers of other materials, including
plastic, aluminum, graphite composites, ceramics, glass, wood
and concrete. Most of our term supply agreements for the sale of
iron ore products are requirements-based or provide for
flexibility of volume above a minimum level. Reduced demand for
and consumption of iron ore products by integrated steel
producers have had and may continue to have a significant
negative impact on our sales, margins and profitability.
Increased imports of steel into the United States could
adversely impact North American steel sales, which could
adversely affect demand for our products and our sales, margins
and profitability.
From time to time, global overcapacity in steel manufacturing
and a weakening of certain foreign economies, particularly in
Eastern Europe, Asia and Latin America, may negatively impact
steel prices in those foreign economies and result in increased
levels of steel imports from those countries into the United
States at depressed prices. Based on the American Iron and Steel
Institutes Apparent Steel Supply (excluding semi-finished
steel products), imports of steel into the United States
constituted 21.6 percent (estimated), 22.3 percent and
16.5 percent of the domestic steel market supply for 2005,
2004 and 2003, respectively. Significant imports of steel into
the United States could substantially reduce sales, margins and
profitability of North American steel producers, and
consequently, reduce demand for iron ore. Decreased North
American steel sales could decrease demand for North American
iron ore products and have a substantial negative impact on our
sales, margins and profitability. The purchase by North American
steel producers of semi-finished steel products from foreign
suppliers could also decrease demand for our iron ore products.
The North American and global steel industries continue to
undergo a restructuring process that has resulted in industry
consolidation that could result in a reduction of integrated
steelmaking capacity over time, and thereby reduce iron ore
consumption.
The North American steel industry has undergone consolidation,
and that consolidation is likely to continue as evidenced by the
acquisition of International Steel Group by Mittal Steel USA ISG
Inc. (Mittal
7
Steel USA). Consolidation is also occurring globally, as
evidenced by Mittal Steels offer to acquire Arcelor S.A.
and Arcelor S.A.s pending acquisition of Dofasco Inc
(Dofasco). Consolidation of the North American and
global steel industries will result in fewer customers for iron
ore. The restructuring process may reduce integrated steelmaking
capacity, which would reduce demand for our North American iron
ore products and may adversely affect our sales. Further, if the
steel producers that have captive iron ore mines obtain a larger
share of North American steel production, they may obtain iron
ore from their own mines, if they have excess capacity, rather
than from us. These factors could adversely affect our sales,
margins and profitability.
Our sales and earnings are subject to significant
fluctuations as a result of the cyclical nature of the North
American steel industry.
In 2005 and 2004, 21.9 million and 22.2 million tons,
respectively, of our iron ore pellet sales were sold to North
American steel manufacturers, while only .4 million tons of
our pellets were sold outside of North America in each year. The
North American steel industry has been highly cyclical in
nature, influenced by a combination of factors, including
periods of economic growth or recession, strength or weakness of
the U.S. dollar, worldwide demand and production capacity,
the strength of the U.S. automotive industry, levels of
steel imports and applicable tariffs. The demand for steel
products is generally affected by macroeconomic fluctuations in
North America and the global economies in which steel companies
sell their products. For example, future economic downturns,
stagnant economies or currency fluctuations in the United States
or globally could decrease the demand for steel products or
increase the amount of imports of steel or iron ore into the
United States.
In addition, a disruption or downturn in the oil and gas, gas
transmission, construction, commercial equipment, rail
transportation, appliance, agricultural, automotive or durable
goods industries, all of which are significant markets for steel
products and are highly cyclical, could negatively impact sales
of steel by North American producers. These trends could
decrease the demand for North American iron ore products and
significantly adversely affect our sales, margins and
profitability.
If steelmakers use methods other than blast furnace
production to produce steel, or if their blast furnaces shut
down or otherwise reduce production, the demand for our iron ore
products may decrease, which would adversely affect our sales,
margins and profitability.
Demand for our iron ore products is determined by the operating
rates for the blast furnaces of steel companies. However, not
all finished steel is produced by blast furnaces; finished steel
also may be produced by other methods that do not require iron
ore products. For example, steel mini-mills, which
are steel recyclers, generally produce steel by using scrap
steel, not iron ore pellets, in their electric furnaces.
Production of steel by steel mini-mills was
approximately 55 percent of North American total finished
steel production in 2005. Steel producers also can produce steel
using imported iron ore or semi-finished steel products, which
eliminates the need for domestic iron ore. Environmental
restrictions on the use of blast furnaces also may reduce our
customers use of their blast furnaces. Maintenance of
blast furnaces can require substantial capital expenditures. Our
customers may choose not to maintain their blast furnaces, and
some of our customers may not have the resources necessary to
adequately maintain their blast furnaces. If our customers use
methods to produce steel that do not use iron ore products,
demand for our iron ore products will decrease, which could
adversely affect our sales, margins and profitability.
Natural disasters, equipment failures and other unexpected
events may lead our steel industry customers to curtail
production or shut down their operations.
Operating levels at our steel industry customers are subject to
conditions beyond their control, including raw material
shortages, weather conditions, natural disasters, interruptions
in electrical power or other energy services, equipment
failures, and other unexpected events. Any of those events could
also affect other suppliers to the North American steel
industry. In either case, those events could cause our steel
industry customers to curtail production or shut down a portion
or all of their operations, which could reduce their demand for
our North American iron ore products. For example, in 2005,
Mittal Steel USA permanently shut down its
8
Weirton blast furnaces. Similarly, in September 2005, Steel
Dynamics, Inc. suspended orders for some steel products that
require the use of hydrogen gas due to the effects of hurricane
Katrina on its hydrogen gas supplier. Also, in late 2003, a fire
occurred in a mine of a major coal supplier to U.S. Steel,
which supplies a majority of the coke, a processed form of coal,
used by our steel industry customers to operate their blast
furnaces. The fire caused U.S. Steel to curtail its
production of coke, and to reduce its coke shipments to at least
two of our steel industry customers. As a result, one of our
steel industry customers had to curtail its steel production,
and its demand for our iron ore products decreased. Decreased
demand for our iron ore products could adversely affect our
sales, margins and profitability.
We operate in a very competitive industry.
The iron mining business is highly competitive, with producers
in all iron-producing regions. Some of our competitors may have
greater financial resources than we have and may be better able
to withstand changes in conditions within the steel industry
than we are. In the future, we may face increasing competition.
As a result, we may face pressures on sales prices and volumes
of our products from competitors and large customers.
Capacity expansions could lead to lower global iron ore
prices.
The increased demand for iron ore, particularly from China, has
resulted in the major iron ore suppliers increasing their
capacity. In 2006, CVRDs board of directors approved a
capital expenditure budget of $4.6 billion, the highest in
its history, to expand production capacity in iron ore and other
materials. BHP announced expansion projects in Western Australia
and Brazil to increase iron ore capacity by a combined
28 million tonnes. An increase in our competitors
capacity could result in excess supply of iron ore, and
subsequently downward pressure on iron ore prices. A decrease in
pricing would adversely impact our sales, margins and
profitability.
Our sales and competitive position depend on the ability to
transport our products to our customers at competitive rates and
in a timely manner.
Our competitive position requires the ability to transport iron
ore to our markets at competitive rates. Disruption of the lake
freighter and rail transportation services because of
weather-related problems, including ice and winter weather
conditions on the Great Lakes, strikes, lock-outs or other
events, could impair our ability to supply iron ore pellets to
our customers at competitive rates or in a timely manner and,
thus, could adversely affect our sales and profitability.
Portman is in direct competition with the major world seaborne
exporters of iron ore and its customers face higher
transportation costs than most other Australian producers to
ship its products to the Asian markets because of the location
of its major shipping port on the south coast of Australia.
Further, increases in transportation costs, or changes in such
costs relative to transportation costs incurred by our
competitors, could make our products less competitive, restrict
our access to certain markets and have an adverse effect on our
sales, margins and profitability.
If a substantial portion of our term supply agreements
terminate and are not renewed, and we are unable to find
alternate buyers willing to purchase our products on terms
comparable to those in our existing term supply agreements, our
sales, margins and profitability will suffer.
A substantial majority of our sales are made under term supply
agreements, which are important to the stability and
profitability of our operations. In 2005, more than
96 percent of our North American sales volume was sold
under term supply agreements. All of Portmans sales are
made under existing contracts that have approximately four years
remaining. Portmans sales pricing is primarily based on
the benchmark pricing established for Australian producers. If a
substantial portion of our term supply agreements were modified
or terminated, we could be materially adversely affected to the
extent that we are unable to renew the agreements or find
alternate buyers for our iron ore at the same level of
profitability. We cannot assure you that we will be able to
renew or replace existing term supply agreements at the same
prices or with similar profit margins when they expire. A loss
of sales to our existing customers could have a substantial
negative impact on our sales, margins and profitability.
9
We depend on a limited number of customers, and the loss of,
or significant reduction in, purchases by our largest customers
would adversely affect our sales.
Five customers together accounted for a total of 93 percent
and 94 percent of our North American sales revenues
measured as a percent of Product sales and services
for the years ended 2005 and 2004, respectively.
If one or more of these customers were to significantly reduce
their purchases of iron ore products from us, or if we were
unable to sell iron ore products to them on terms as favorable
to us as the terms under our current term supply agreements, our
sales, margins and profitability could suffer materially due to
the high level of fixed costs and the high costs to idle or
close mines. The majority of the iron ore we manage and produce
is for our own account, and therefore we rely on sales to our
joint venture partners and other third-party customers for most
of our revenues. Mittal Steel USA idled its Weirton facility in
2005 and is contesting its minimum purchase requirement under
our supply agreement. The Weirton facility accounted for
approximately two percent of our North American sales in 2004.
In addition, WCI and Stelco are operating under bankruptcy
protection, as discussed below, and the bankruptcy or
reorganization of our customers could affect our sales, margins
and profitability.
Changes in demand for our products by our customers could
cause our sales, margins and profitability to fluctuate.
Our North American term supply agreements generally are
requirements contracts, the majority of which have no minimum
requirement provisions, and some of which provide for
flexibility of volume above minimum levels. Portmans sales
contracts are for fixed annual tonnages with customer options to
increase or decrease annual purchases. A decrease in one or more
of our customers requirements could cause our sales to
decline, as we may not be able to find other customers to
purchase our iron ore products as evidenced by Mittal Steel
USAs decision to idle its Weirton facility in 2005. In
addition, if our customers requirements decline, since
many of our production costs are fixed, our production costs per
ton may rise, which may affect our margins and profitability.
Unmitigated loss of sales would have a greater impact on margins
and profitability than on revenues, due to the high level of
fixed costs in the iron ore mining business and the high cost to
idle or close mines.
The provisions of our term supply agreements could cause our
sales, margins and profitability to fluctuate.
Our term supply agreements typically contain force majeure
provisions allowing temporary suspension of performance by the
customer during specified events beyond the customers
control, including raw material shortages, power failures,
equipment failures, adverse weather conditions and other events.
For example, one of our large customers notified us in January
2004 that it was reducing its requirements for iron ore pellets
in the first quarter of 2004 by 180,000 long tons pursuant to
the force majeure provisions of its term supply agreement with
us. That customer invoked the force majeure provision due to a
failure of U.S. Steel to ship the quantity of coke that the
customer had ordered due to shortages caused by a fire at a mine
that supplied coal to U.S. Steel.
Price escalators in our term supply agreements also expose us to
short-term price volatility, which can adversely affect our
margins and profitability. Our term supply agreements also
contain provisions requiring us to deliver iron ore pellets
meeting quality thresholds for certain characteristics, such as
chemical makeup. Failure to meet these specifications could
result in economic penalties. All of these contractual
provisions could adversely affect our sales, margins and
profitability.
We may have contractual disputes with our customers or
significant suppliers of energy, materials, or services that
could significantly impact our sales, revenue rates, production
or operating costs.
Most of our North American and Australian sales are under
multi-year term sales agreements. Australian benchmark prices
are driven from negotiations between the three major iron
producers, CVRD, Rio Tinto and BHP, and the Chinese and Japanese
steel mills. More than 97 percent of our North American
revenues are
10
derived from sales of iron ore pellets to the North American
integrated steel industry, consisting of 10 current or potential
customers. Sales volume under these agreements is largely
dependent on customer requirements, and in many cases, we are
the sole supplier of iron ore pellets to the customer. Each
agreement has a base price that is adjusted annually using one
or more adjustment factors. Factors that could result in price
adjustment include measures of general industrial inflation,
steel prices and international pellet prices. One of our supply
agreements has a provision that limits the amount of price
increase or decrease in any given year. Contractual disputes
with any of our significant customers could result in lower
sales volume or lower sales prices.
Additionally, we have significant contracts with suppliers of
energy, materials and services in North American and Australia.
Contractual disputes with significant suppliers could result in
production curtailments or significant cost increases which
could adversely impact our profitability.
Mine closures entail substantial costs, and if we close one
or more of our mines sooner than anticipated, our results of
operations and financial condition may be significantly and
adversely affected.
If we close any of our mines, our revenues would be reduced
unless we were able to increase production at any of our other
mines, which may not be possible. The closure of an open-pit
mine involves significant fixed closure costs, including
accelerated employment legacy costs, severance-related
obligations, reclamation and other environmental costs, and the
costs of terminating long-term obligations, including energy
contracts and equipment leases. We base our assumptions
regarding the life of our mines on detailed studies we perform
from time to time, but those studies and assumptions do not
always prove to be accurate. We recognize the costs of
reclaiming open pits, stockpiles, tailings ponds, roads and
other mining support areas based on the estimated mining life of
our property. If we were to reduce the estimated life of any of
our mines, the mine-closure costs would be applied to a shorter
period of production, which would increase production costs per
ton produced and could significantly and adversely affect our
results of operations and financial condition. Further, if we
were to close one or more of our mines prematurely, we would
incur significant accelerated employment legacy costs,
severance-related obligations, reclamation and other
environmental costs, as well as asset impairment charges, which
could materially and adversely affect our financial condition.
A North American mine closure would significantly increase
employment legacy costs, including our expense and funding costs
for pension and other postretirement benefit obligations. First,
retirement-eligible employees would be eligible for enhanced
pension benefits under certain pension plans upon a mine
closure. Second, the number of employees who are eligible for
retirement under the pension plans would increase under special
eligibility rules that apply upon a mine closure. Third, all
employees eligible for retirement under the pension plans at the
time of the mine closure also would be eligible for
postretirement health and life insurance benefits, thereby
accelerating our obligation to provide these benefits. Fourth, a
closure of the Empire or Tilden mine likely would trigger
withdrawal liability to the pension plan covering hourly
employees there. Finally, a mine closure could trigger
significant severance-related obligations. As a result, the
closure of one or more of our mines could adversely affect our
financial condition and results of operations.
The Cockatoo Island operation in Australia is scheduled to close
in 2007 and plans are in process to obtain all required
governmental approvals. Since all of the employees are
contractors, the cost of closing is significantly lower in
Australia than in North America. Performance bonds are in place
covering the estimated closure costs.
Applicable statutes and regulations require that mining property
be reclaimed following a mine closure in accordance with
specified standards and an approved reclamation plan. The plan
addresses matters such as removal of facilities and equipment,
regrading, prevention of erosion and other forms of water
pollution, revegetation and post-mining land use. We may be
required to post a surety bond or other form of financial
assurance equal to the cost of reclamation as set forth in the
approved reclamation plan. The establishment of the final mine
closure reclamation liability is based upon permit requirements
and requires various estimates and assumptions, principally
associated with reclamation costs and production levels.
Although our management believes, based on currently available
information, we are making adequate provisions for all expected
reclamation and other costs associated with mine closures for
which we will be responsible, our business,
11
results of operations and financial condition would be adversely
affected if such accruals were later determined to be
insufficient.
We have significantly reduced our ore reserve estimates for
the Empire mine and may close the Empire mine sooner than we had
anticipated, which could materially and adversely affect our
results of operations and financial condition.
We significantly decreased our ore reserve estimates for the
Empire mine from 116 million tons at December 31, 2001
to 63 million tons at December 31, 2002 and further to
29 million tons at December 31, 2003. As of
December 31, 2005, Empires estimated ore reserves
decreased to approximately 17 million tons as a result of
production in 2004 and 2005.
If we were to close the Empire mine sooner than currently
anticipated, we would incur significant mine closure costs,
employment legacy costs, severance-related obligations,
reclamation and other environmental costs and the costs of
terminating long-term obligations, including energy contracts
and equipment leases. A closure of the Empire mine sooner than
we anticipate could materially and adversely affect our results
of operations and financial condition.
We rely on the estimates of our recoverable reserves, and if
those estimates are inaccurate, our financial condition may be
adversely affected.
We regularly evaluate our iron ore reserves based on revenues
and costs and update them as required in accordance with SEC
Industry Guide 7. Portman has published reserves which
follow the Joint Ore Reserves Code (JORC) in
Australia, which is similar to United States requirements.
Changes to the reserve value to make them comply with SEC
requirements have been made. There are numerous uncertainties
inherent in estimating quantities of reserves of our mines, many
of which have been in operation for several decades, including
many factors beyond our control. Estimates of reserves and
future net cash flows necessarily depend upon a number of
variable factors and assumptions, such as production capacity,
effects of regulations by governmental agencies and future
prices for iron ore, future industry conditions and operating
costs, severance and excise taxes, development costs and costs
of extraction and reclamation costs, all of which may in fact
vary considerably from actual results. For these reasons,
estimates of the economically recoverable quantities of
mineralized deposits attributable to any particular group of
properties, classifications of such reserves based on risk of
recovery and estimates of future net cash flows prepared by
different engineers or by the same engineers at different times
may vary substantially as the criteria change. Estimated ore
reserves could be affected by future industry conditions,
geological conditions and ongoing mine planning. Actual
production, revenues and expenditures with respect to our
reserves will likely vary from estimates, and if such variances
are material, our sales and profitability could be adversely or
positively affected.
The price adjustment provisions of our North American term
supply agreements may prevent us from increasing our prices to
match international ore contract prices or to pass increased
costs of production on to our customers.
Our North American term supply agreements contain a number of
price adjustment provisions, or price escalators, including
adjustments based on general industrial inflation rates, the
price of steel and the international price of iron ore pellets,
among other factors, that allow us to adjust the prices under
those agreements generally on an annual basis. Our price
adjustment provisions are weighted and some are subject to
annual collars, which limit our ability to raise prices to match
international levels and fully capitalize on strong demand for
iron ore. Most of our North American term supply agreements do
not allow us to increase our prices and to directly pass through
higher production costs to our customers. An inability to
increase prices or pass along increased costs could adversely
affect our margins and profitability.
Our ability to collect payments from our customers depends on
their creditworthiness.
Our ability to receive payment for iron ore products sold and
delivered to our customers depends on the creditworthiness of
our customers. In North America, we ship iron ore products to
some of our customers
12
yards in advance of payment for those products. Our rationale
for shipping iron ore products to customers in advance of
payment for, and transfer title for the product is to more
closely relate timing of payment to consumption, thereby
providing additional liquidity to our customers, and to reduce
our financial risk to customer insolvency as title and risk of
loss with respect to those products does not pass to the
customer until payment for the pellets is received. Accordingly,
there is typically a period of time in which pellets, as to
which we have reserved title, are within our customers
control. As discussed below, several of our customers have
petitioned for protection under bankruptcy or other similar
laws, and most of our North American customers have
below-investment grade or no credit rating. Failure to receive
payment from our customers for products that we have delivered
could adversely affect our results of operations.
Our change from a manager of iron ore mines on behalf of
steel company owners to primarily a merchant of iron ore to
steel company customers has increased our obligations with
respect to those mines and has made our revenues, earnings and
profit margins more dependent on sales of iron ore products and
more susceptible to product demand and pricing fluctuations.
Until recent years, we had principally acted as a manager of
iron ore mines on behalf of steel company owners, and in that
capacity had been generally entitled to management fees,
royalties on reserves that we have leased or subleased to the
Empire and Tilden mines, and income from our sales of iron ore
products to our customers, including the other mine owners. Our
current business model is increased ownership in our co-owned
mines. In accordance with our revised business model, in 2002 we
increased our ownership in (1) the Empire mine from
47 percent to 79 percent, (2) the Tilden mine
from 40 percent to 85 percent, (3) the Hibbing
mine from 15 percent to 23 percent, and (4) the
Wabush mine from 23 percent to 27 percent. While we
have gained greater control of the mines we operate, we have
also increased our share of the operating costs, employment
legacy costs and financial obligations associated with those
mines. Our increased ownership of those mines has caused the
management fees and royalties due to us from our partners in the
mines to decline from $29.8 million in 2001 to
$13.1 million in 2005. The decline in royalties and
management fees has made our revenues, earnings and profit
margins more volatile and more dependent on sales of our iron
ore products to third-party customers.
We rely on our joint venture partners in our mines to meet
their payment obligations, and the inability of a joint venture
partner to do so could significantly affect our operating
costs.
We co-own five of our six North American mines with various
joint venture partners that are integrated steel producers or
their subsidiaries, including Dofasco, Mittal Steel USA, Laiwu
and Stelco. While we are the manager of each of the mines we
co-own, we rely on our joint venture partners to make their
required capital contributions and to pay for their share of the
iron ore pellets that we produce. Most of our venture partners
are also our customers and are subject to the creditworthiness
risks described above. If one or more of our venture partners
fail to perform their obligations, the remaining venturers,
including ourselves, may be required to assume additional
material obligations, including significant pension and
postretirement health and life insurance benefit obligations. On
January 29, 2004, Stelco applied and obtained
bankruptcy-court protection from creditors in Ontario Superior
Court under the Companies Creditors Arrangement Act.
Stelco is a 44.6 percent participant in the Wabush Mines
Joint Venture, and U.S. subsidiaries of Stelco (which have
not filed for bankruptcy protection) own 14.7 percent of
Hibbing and 15 percent of Tilden. Stelco has met its cash
call requirements at the mining ventures to date. The premature
closure of a mine due to the failure of a joint venture partner
to perform its obligations could result in significant fixed
mine-closure costs, including severance, employment legacy costs
and other employment costs, reclamation and other environmental
costs, and the costs of terminating long-term obligations,
including energy contracts and equipment leases.
Unanticipated geological conditions and natural disasters
could increase the cost of operating our business.
A portion of our production costs are fixed regardless of
current operating levels. Our operating levels are subject to
conditions beyond our control that can delay deliveries or
increase the cost of mining at particular mines for varying
lengths of time. These conditions include weather conditions
(for example, extreme winter
13
weather, floods and availability of process water due to
drought) and natural disasters, pit wall failures, unanticipated
geological conditions, including variations in the amount of
rock and soil overlying the deposits of iron ore, variations in
rock and other natural materials and variations in geologic
conditions and ore processing changes. Portmans Cockatoo
Island operation is located in an area affected by tropical
storms and operates a pit below sea level that is protected by a
constructed seawall. Storms in this area could affect both our
operation and the operations of our major Australian
competitors. These conditions could impair our ability to
fulfill our plan to operate our mines at full capacity, which
could materially adversely affect our ability to meet the
expected demand for our iron ore products.
Many of our mines are dependent on a single-source energy
supplier, and interruption in energy services may have a
significant adverse effect on our sales, margins and
profitability.
Many of our mines are dependent on one source for electric power
and for natural gas. For example, Minnesota Power is the sole
supplier of electric power to our Hibbing and United Taconite
mines; Wisconsin Energy Corporation is the sole supplier of
electric power to our Tilden and Empire mines; and our
Northshore mine is largely dependent on its wholly owned power
facility for its electrical supply. A significant interruption
in service from our energy suppliers due to terrorism, weather
conditions, natural disasters, or any other cause can result in
substantial losses that may not be fully covered by our business
interruption insurance. For example, in May 2003, we incurred
approximately $11.1 million in fixed costs relating to lost
production when our Empire and Tilden mines were idled for
approximately five weeks due to loss of power stemming from the
failure of a dam in the Upper Peninsula of Michigan. One natural
gas pipeline serves all of our Minnesota and Michigan mines, and
a pipeline failure may idle those operations. Any substantial
unmitigated interruption of our business due to these conditions
could materially adversely affect our sales, margins and
profitability.
Our mines and processing facilities have been in operation
for several decades. Equipment failures and other unexpected
events at our facilities may lead to production curtailments or
shutdowns.
Interruptions in production capabilities will inevitably
increase our production costs and reduce our profitability. We
do not have meaningful excess capacity for current production
needs, and we are not able to quickly increase production at one
mine to offset an interruption in production at another mine. In
addition to equipment failures, our facilities are also subject
to the risk of loss due to unanticipated events such as fires,
explosions or adverse weather conditions. The manufacturing
processes that take place in our mining operations, as well as
in our crushing, concentrating and pelletizing facilities,
depend on critical pieces of equipment, such as drilling and
blasting equipment, crushers, grinding mills, pebble mills,
thickeners, separators, filters, mixers, furnaces, kilns and
rolling equipment, as well as electrical equipment, such as
transformers. This equipment may, on occasion, be out of service
because of unanticipated failures. In addition, many of our
mines and processing facilities have been in operation for
several decades, and the equipment is aged. For example, in
November 2003, our Tilden facility experienced a crack in a kiln
riding ring that required the shutdown of that kiln in its
pelletizing plant, resulting in a production loss of
approximately .3 million tons in 2003. In the future, we
may experience additional material plant shutdowns or periods of
reduced production because of equipment failures. Material plant
shutdowns or reductions in operations could materially adversely
affect our sales, margins and profitability. Further,
remediation of any interruption in production capability may
require us to make large capital expenditures that could have a
negative effect on our profitability and cash flows. Our
business interruption insurance would not cover all of the lost
revenues associated with equipment failures. Further,
longer-term business disruptions could result in a loss of
customers, which could adversely affect our future sales levels,
and therefore our profitability.
We are subject to extensive governmental regulation, which
imposes, and will continue to impose, significant costs and
liabilities on us, and future regulation could increase those
costs and liabilities or limit our ability to produce iron ore
products.
We are subject to various federal, provincial, state and local
laws and regulations on matters such as employee health and
safety, air quality, water pollution, plant and wildlife
protection, reclamation and restoration of mining properties,
the discharge of materials into the environment, and the effects
that mining
14
has on groundwater quality and availability. Numerous
governmental permits and approvals are required for our
operations. We cannot be assured that we have been or will be at
all times in complete compliance with such laws, regulations and
permits. If we violate or fail to comply with these laws,
regulations or permits, we could be fined or otherwise
sanctioned by regulators.
Prior to commencement of mining, we must submit to, and obtain
approval from, the appropriate regulatory authority of plans
showing where and how mining and reclamation operations are to
occur. These plans must include information such as the location
of mining areas, stockpiles, surface waters, haul roads,
tailings basins and drainage from mining operations. All
requirements imposed by any such authority may be costly and
time-consuming and may delay commencement or continuation of
exploration or production operations. See Item 2.
Properties. Environment.
In addition, new legislation and/or regulations and orders,
including proposals related to the protection of the
environment, to which we would be subject or that would further
regulate and/or tax our customers, namely the North American
integrated steel producer customers, may also require us or our
customers to reduce or otherwise change operations significantly
or incur costs. Such new legislation, regulations or orders (if
enacted) could have a material adverse effect on our business,
results of operations, financial condition or profitability. In
particular, we are subject to the rules promulgated by the
United States Environmental Protection Agency (EPA)
that will require us to utilize Maximum Achievable Control
Technology (MACT) standards for our air emissions by
2006. The costs, including capital expenditures that we will
incur in order to meet the new MACT standards may be
substantial. See Item 2. Properties.
Environment.
Further, we are subject to a variety of potential liability
exposures arising at certain sites where we do not currently
conduct operations. These sites include sites where we formerly
conducted iron ore mining or processing or other operations,
inactive sites that we currently own, predecessor sites,
acquired sites, leased land sites and third-party waste disposal
sites. While we believe our liability at sites where claims have
been asserted will not have a material adverse effect on our
financial condition, liquidity or results of operations, we may
be named as a responsible party at other sites in the future,
and we cannot assure you that the costs associated with these
additional sites will not be material. See Item 2.
Properties. Environment.
We also could be held liable for any and all consequences
arising out of human exposure to hazardous substances used,
released or disposed of by us or other environmental damage,
including damage to natural resources. In particular, we and
certain of our subsidiaries are involved in various claims
relating to the exposure of asbestos and silica to seamen who
sailed on the Great Lakes vessels formerly owned and operated by
certain of our subsidiaries. The full impact of these claims, as
well as whether insurance coverage will be sufficient and
whether other defendants named in these claims will be able to
fund any costs arising out of these claims, continues to be
unknown. Based on currently available information, however, we
believe the resolution of currently pending claims in the
aggregate would not reasonably be expected to have a material
adverse effect on our financial position. See Item 3.
Legal Proceedings.
Our expenditures for postretirement benefit and pension
obligations could be materially higher than we have predicted if
our underlying assumptions prove to be incorrect, if there are
mine closures or our joint venture partners fail to perform
their obligations that relate to employee pension plans.
We provide defined benefit pension plans and other
postretirement benefits (OPEB) to eligible union and
non-union employees, including our share of expense and funding
obligations with respect to unconsolidated ventures. Our pension
expense and our required contributions to our pension plans are
directly affected by the value of plan assets, the projected
rate of return on plan assets, the rate of return on plan assets
and the actuarial assumptions we use to measure our defined
benefit pension plan obligations, including the rate that future
obligations are discounted to a present value (discount
rate).
We cannot predict whether changing market or economic
conditions, regulatory changes or other factors will increase
our pension expenses or our funding obligations, diverting funds
we would otherwise apply to other uses.
15
We calculate our total accumulated postretirement benefit
obligation (APBO) for our OPEB benefits under
Statement of Financial Accounting Standards No. 106,
Employers Accounting for Postretirement Benefits
Other Than Pensions. The unfunded APBO obligation had a
present value of $231.7 million at December 31, 2005.
We have calculated the unfunded obligation based on a number of
assumptions. Discount rate, return on plan assets, and mortality
assumptions parallel those utilized for pensions.
If our assumptions do not materialize as expected, cash
expenditures and costs that we incur could be materially higher.
Moreover, we cannot assure that regulatory changes will not
increase our obligations to provide these or additional
benefits. These obligations also may increase substantially in
the event of adverse medical cost trends or unexpected rates of
early retirement, particularly for bargaining unit employees for
whom there is currently no retiree healthcare cost cap. Early
retirement rates likely would increase substantially in the
event of a mine closure.
Additionally, our pension and postretirement health and life
insurance benefit obligations, expenses and funding costs would
increase significantly if one or more of the mines in which we
have invested is closed, or if one or more of our joint venture
partners at one or more mines are unable to perform its
obligations. A mine closure would trigger accelerated pension
and OPEB obligations, and the failure of joint venture partners
to perform its obligations could shift additional pension and
OPEB liabilities to us. Any of these events could significantly
adversely affect our financial condition and results of
operations.
We are a related party to certain companies that were
operators and are required under the Coal Industry Retiree
Health Benefit Act of 1992 (the Coal Retiree Act) to
make premium payments to the United Mine Workers Association
Combined Benefit Fund (the Combined Fund), and our
obligations to the Combined Fund could increase if other coal
mine operators file for bankruptcy protection or become
insolvent.
We are a related-party to certain companies that were coal mine
operators. As a result, we are subject to the Coal Retiree Act
and are obligated to make premium payments to the Combined Fund
for health and death benefits paid by the Combined Fund to
retired coal miners. At December 31, 2005, the net present
value of our estimated liability to the Combined Fund was
$5.6 million. We are assessed premiums for unassigned or
orphan retirees on a pro rata basis with other coal
mine operators and related parties. If other coal mine operators
and related parties file for bankruptcy protection or become
insolvent, our pro rata portion of the liability to the Combined
Fund could increase, which could have an adverse effect on our
results of operation and financial condition, sales, margins and
profitability.
Our profitability could be negatively affected if we fail to
maintain satisfactory labor relations.
The USWA represents all hourly employees at our Empire, Hibbing,
Tilden and United Taconite mines, as well as Wabush in Canada. A
four-year labor agreement was reached in August 2004 with our
U.S. labor force and a five-year agreement that runs until
March 2009 was reached with our Canadian work force. Hourly
employees at the railroads we own that transport products among
our facilities are represented by multiple unions with labor
agreements that expire at various dates. If the collective
bargaining agreements relating to the employees at our mines or
railroad are not successfully renegotiated prior to this
expiration, we could face work stoppages or labor strikes.
Our operating expenses could increase significantly if the
price of electrical power, fuel or other energy sources
increases.
Operating expenses at our mining locations are sensitive to
changes in electricity prices and fuel prices, including diesel
fuel and natural gas prices, which represent 27 percent of
our North American operating costs. Prices for electricity,
natural gas and fuel oils can fluctuate widely with availability
and demand levels from other users. During periods of peak
usage, supplies of energy may be curtailed and we may not be
able to purchase them at historical market rates. While we have
some long-term contracts with electrical suppliers, we are
exposed to fluctuations in energy costs that can affect our
production costs. Although we enter into forward fixed-price
supply contracts for natural gas and diesel fuel for use in our
operations, those contracts
16
are of limited duration and do not cover all of our fuel needs,
and price increases in fuel costs could cause our profitability
to decrease significantly.
Equipment and supply shortages may impact our production.
We have recently experienced longer lead times on equipment,
tires, and supply needs due to the increased demand for these
resources. As our competitors increase their capacity, demand
for these resources will increase, potentially resulting in
higher prices, equipment shortages, or both.
We may encounter labor shortages for critical operational
positions, which could affect our ability to produce iron ore
products.
At our North American locations, many of our mining operational
employees are approaching retirement age. As these experienced
employees retire, we may have difficulty replacing them at
competitive wages. In Western Australia, the large number of
expansion projects currently in progress has created turnover
principally for our contractors employees. As a result,
wages are increasing to address the turnover.
Our profitability could be affected by the failure of outside
contractors to perform.
Portman uses contractors to handle many of the operational
phases of its mining and processing operations and therefore is
subject to the performance of outside companies on key
production areas. Portmans Cockatoo Island operation is a
joint venture with Henry Walker Eltin (HWE), a
company that entered receivership in late 2004. As of
February 1, 2006, HWEs mining assets were sold to
Leighton Contractors Pty Ltd (Leighton), an
Australian-based mining and construction contractor. Leighton
also purchased HWEs subsidiary that owned its
50 percent interest in the Cockatoo Island joint venture
and is continuing to manage the operation. The inability of any
contractor to perform will directly impact our financial results.
Our profitability could be affected due to uncertainties
related to the appraisal of acquisitions and the related
allocation of purchase price to the acquired assets and assumed
liabilities.
In April 2005, we completed the acquisition of 80.4 percent
of Portman. As part of the purchase accounting process, we
retained an outside consultant to perform an appraisal of
Portman and the related acquired assets and assumed liabilities.
The allocation, which is preliminary and subject to change, is
expected to be finalized prior to March 31, 2006. Any
subsequent changes to the allocation could adversely impact our
reported earnings.
Our profitability and liquidity could be adversely impacted
by a failed auction in the securities market.
We hold investments in highly liquid auction rate securities
(ARS) in order to generate higher returns than
typical money market investments. ARS typically are high credit
quality, generally achieved with municipal bond insurance.
Credit risks are eased by the historical track record of bond
insurers, which back a majority of this market. Although rare,
sell orders for any security traded through a Dutch auction
process could exceed bids. Such instances are usually the result
of a drastic deterioration of issuer credit quality. Should
there be a failed auction, we may be unable to liquidate our
position in the securities in the near term.
17
|
|
Item 1B. |
Unresolved Staff Comments. |
We have no unresolved comments from the SEC.
The following map shows the locations of our North American
mines:
We directly or indirectly own and operate interests in the
following six North American iron ore mines:
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Ownership Interest as of | |
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December 31, | |
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| |
Location and Name |
|
2005 | |
|
2004 | |
|
2003 | |
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| |
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| |
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| |
Michigan (Marquette Range)
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Empire Iron Mining Partnership
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79.0 |
% |
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79.0 |
% |
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79.0 |
% |
|
Tilden Mining Company L.C. (Tilden)
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85.0 |
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85.0 |
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85.0 |
|
Minnesota (Mesabi Range)
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Hibbing Taconite Company Joint Venture
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23.0 |
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23.0 |
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23.0 |
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Northshore Mining Company
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100.0 |
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100.0 |
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100.0 |
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United Taconite
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70.0 |
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70.0 |
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70.0 |
|
Canada (Newfoundland and Quebec)
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Wabush Mines Joint Venture
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26.8 |
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26.8 |
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26.8 |
|
We increased our ownership in these mines (other than Northshore
and United Taconite) in 2002 through assumption of the
liabilities associated with the mine interests from their steel
company owners.
Empire Mine. The Empire mine is located on the Marquette
Iron Range in Michigans Upper Peninsula approximately
15 miles west-southwest of Marquette, Michigan and is
accessed via a paved road off State Highway 35. The mine has
been in operation since 1963. We entered into an agreement with
Ispat Inland Inc. (Ispat) effective
December 31, 2002 that restructured the ownership of the
Empire mine. Under the agreement, we acquired the
25 percent interest rejected by LTV Corporation in its
chapter 11 bankruptcy proceedings and a 19 percent
interest from Ispat. Currently, we manage the mine and have a
79 percent interest; Mittal Steel USA has a 21 percent
interest in the mine and has the right to require us to purchase
all of its interest under certain circumstances after 2007. We
and Mittal Steel USA take our respective share of production pro
rata; however, provisions in the partnership agreement allow
additional or reduced production to be delivered under certain
circumstances. We own directly approximately one-half of the
remaining ore reserves at the Empire mine and lease them to
Empire. The Empire mine leases the balance of its reserves from
the other owners of such reserves. Over the past five years, the
Empire mine has produced between 3.6 million and
5.7 million tons of iron ore pellets annually.
18
Tilden Mine. The Tilden mine is located on the Marquette
Iron Range in Michigans Upper Peninsula approximately five
miles south of Ishpeming, Michigan. The main entrance to the
Tilden mine is accessed by means of a paved road off of County
Road 476. The Tilden mine has been in operation since 1974. On
January 31, 2002, we increased our ownership of the Tilden
mine to 85 percent by acquiring Algoma Steel Inc.s
(Algoma) 45 percent interest in the mine and
executing a term supply agreement under which we are
Algomas sole supplier of iron ore pellets for
15 years. Currently, we manage the mine and have an
85 percent interest, and Stelco has a 15 percent
interest in the mine. See Operations and Customers
in Item 7 for further information regarding Algoma and
Stelco. Each partner takes its share of production pro rata;
however, provisions in the partnership agreement allow
additional or reduced production to be delivered under certain
circumstances. We own all of the ore reserves at the Tilden mine
and lease them to Tilden. Over the past five years, the Tilden
mine has produced between 6.4 million and 7.9 million
tons of iron ore pellets annually.
The Empire and Tilden mines are located adjacent to each other.
Our increase in ownership of our Michigan mines facilitated
consolidation of operations and management, which offer
operational and cost benefits that were not achievable under the
previous ownership structure. These benefits include a
consolidated transportation system, more efficient employee and
equipment operating schedules, reduction in redundant facilities
and workforce and best practices sharing.
Hibbing Mine. The Hibbing mine is located in the center
of Minnesotas Mesabi Iron Range and is approximately ten
miles north of Hibbing, Minnesota and five miles west of
Chisholm, Minnesota. The main entrance to the Hibbing mine is
accessed by means of a paved road and is located off County Road
5. The Hibbing mine has been in operation since 1976. In 2002,
we acquired from Bethlehem Steel Corporation an eight percent
interest in the Hibbing mine, which increased our ownership to
23 percent. Currently, we manage the mine and have a
23 percent interest. Mittal Steel USA has a
62.3 percent interest and Stelco has a 14.7 percent
interest in the mine. Each partner takes its share of production
pro rata; however, provisions in the joint venture agreement
allow additional or reduced production to be delivered under
certain circumstances. Over the past five years, the Hibbing
mine has produced between 6.1 million and 8.5 million
tons of iron ore pellets annually.
Northshore Mine. The Northshore mine is located in
northeastern Minnesota, approximately two miles south of
Babbitt, Minnesota on the northeastern end of the Mesabi iron
formation. Northshores processing facilities are located
in Silver Bay, Minnesota, near Lake Superior, on
U.S. Highway 61. The main entrance to the Northshore mine
is accessed by means of a gravel road and is located off County
Road 20. The Northshore mine has been in continuous operation
since 1990. The Northshore mine began production under our
management and ownership on October 1, 1994. Currently, we
own 100 percent of the mine. Over the past five years, the
Northshore mine has produced between 2.8 million and
5.0 million tons of iron ore pellets annually.
The Northshore mine has a long history. It was first discovered
in 1871 and operated in the 1920s as the Mesabi Iron
Company, one of the first commercial attempts at mining
taconite. The property was operated for over 30 years by
Reserve Mining Co. (Reserve), one of the two
pioneering large scale pellet operations in Minnesota. Poor
economic conditions in the steel industry forced the shutdown
and bankruptcy of Reserve in 1986. The Reserve assets were
purchased by Cyprus Minerals in 1989, and the property restarted
operation in 1990. We purchased the property from Cyprus
Minerals in 1994.
United Taconite. The United Taconite mine is located on
Minnesotas Mesabi Iron Range in and around the city of
Eveleth, Minnesota, west of U.S. Highway 53. The main
entrance to the United Taconite mine is accessed by means of a
paved road and is located off Route 37. The mine has been
operating since 1965. On November 26, 2003, the
U.S. Bankruptcy Court for the District of Minnesota
approved the purchase of the assets of Eveleth Mines by United
Taconite. Eveleth Mines ceased mining operations earlier in 2003
and was acquired by United Taconite effective as of
December 1, 2003. Currently, we manage the mine and hold a
70 percent interest; Laiwu holds a 30 percent
interest. Over the past five years, the United Taconite mine has
produced between 1.6 million and 4.9 million tons of
iron ore pellets annually.
19
Wabush Mines. The Wabush mine and concentrator is located
in Wabush, Labrador, Canada, and the pellet plant is located in
Pointe Noire, Quebec, Canada. The main entrance to the Wabush
mine is accessed by means of a paved road and is located on
Highway 530, about three miles west of the town of Wabush. The
pellet plant is accessed by a paved road off Highway 138, about
ten miles west of the town of Sept-Iles, Quebec. The Wabush mine
has been in operation since 1965. In 1997, we acquired
Ispats interest in the Wabush mine. In August 2002, we
acquired our proportionate share (approximately
4.05 percent) of the 15.09 percent interest rejected
by Acme Metals Incorporated in its bankruptcy proceedings. As a
result of these two events, we increased our ownership in the
mine from 7.7 percent to 26.8 percent. We also manage
the mine. Stelco has a 44.6 percent interest and Dofasco
has a 28.6 percent interest in the mine. Over the past five
years, Wabush has produced between 3.8 million and
5.2 million tons of iron ore pellets annually. Wabush
currently has initiated actions to increase annual pellet
production to a 5.7 million ton rate by the end of 2006.
Production for 2006 is estimated at approximately
5.3 million tons.
The following map shows the locations of our Australian mines:
Koolyanobbing. The Koolyanobbing operations are located
425 kilometers east of Perth and approximately 50 kilometers
northeast of the town of Southern Cross. Koolyanobbing produces
lump and fine iron ore with a current capacity of approximately
six million tonnes annually. The capacity of the Koolyanobbing
operations is in the process of being expanded to eight million
tonnes per year. This expansion is primarily driven by the
development of iron ore resources at Mt. Jackson and Windarling,
approximately 100 kilometers north of the existing Koolyanobbing
operations. The upgrade in capacity is expected to be completed
by the end of the first quarter of 2006.
Cockatoo Island. The Cockatoo Island operation is located
six kilometers to the west of Yampi Peninsula, in the Buccaneer
Archipelago, and 140 kilometers north of Derby in the West
Kimberley region of Western Australia. The island has been mined
for iron ore since 1951, with a break in operations between 1985
and 1993.
Portman commenced a beneficiation project in 1993 that was
completed in mid-2000. Portman and HWE Cockatoo Pty Ltd then
formed a 50:50 joint venture to mine remnant iron ore deposits
on mining tenements held by BHP and mined by BHP from 1951 to
1985. Mining from this phase of the operation commenced in late
2000 and is expected to continue, based on current reserves,
until the first quarter of 2007. The current phase of this
operation involved construction of a seawall and mine pit
dewatering to enable access to ore located below sea level. Ore
is hauled by haul truck to the stockpiles, crushed and screened
and then transferred by conveyor to the shiploader. Annual
production since 2000 has ranged from .3 million tonnes to
1.1 million tonnes at the 100 percent ownership level.
20
Transportation
Two railroads, one of which is wholly owned by us, link the
Empire and Tilden mines with Lake Michigan at the loading port
of Escanaba, Michigan and with the Lake Superior loading port of
Marquette, Michigan. From the Mesabi Range, Hibbing pellets are
transported by rail to a shiploading port at Superior,
Wisconsin. United Taconite pellets are shipped by railroad to
the port of Duluth, Minnesota. At Northshore, crude ore is
shipped by a wholly owned railroad from the mine to processing
facilities at Silver Bay, Minnesota. In Canada, there is an
open-pit mine and concentrator at Wabush, Labrador, Newfoundland
and a pellet plant and dock facility at Pointe Noire, Quebec. At
the Wabush mine, concentrates are shipped by rail from the
Scully mine at Wabush to Pointe Noire where they are pelletized
for shipment via vessel to Canada, the United States and other
international destinations or shipped as concentrates for sinter
feed.
All of the ore mined at the Koolyanobbing operations is
transported by rail to the Port of Esperance, 578 kilometers to
the south for shipment to Asian customers. Direct ship premium
fines mined at Cockatoo Island are loaded at a local dock.
We have a corporate policy relating to internal control and
procedures with respect to auditing and estimating ore reserves.
The procedures include the calculation of ore reserves at each
mine by mining engineers and geologists under the direction of
our Chief Mining Engineer. Our General Manager-Technical
Services compiles, reviews, and submits the calculations to
Corporate Accounting, who prepares the disclosures for our
annual and quarterly reports based on those calculations and
submits the draft disclosures to our General Manager-Technical
Services of Mine Technology for further review and approval. The
draft disclosures are then reviewed and approved by our Chief
Financial Officer and Chief Executive Officer before inclusion
in our annual and quarterly reports. Additionally, the
long-range mine planning and ore reserve estimates are reviewed
annually by our Audit Committee. Furthermore, all changes to ore
reserve estimates, other than those due to production, are
documented by our General Manager-Technical Services and are
submitted to our President and Chief Operating Officer for
review and approval. Finally, we perform periodic reviews of
long-range mine plans and ore reserve estimates at mine staff
meetings and senior management meetings.
Operations
During 2005, 2004 and 2003, we produced 22.1 million tons,
21.7 million tons and 18.1 million tons of pellets,
respectively, for our account and 13.8 million tons,
12.7 million tons and 12.2 million tons, respectively,
on behalf of the steel company owners of the mines. The
4.0 million ton increase in our share of tons produced in
2005 compared to 2003 principally reflected the acquisition in
December 2003 and full-year production in 2005 of United
Taconite and increased customer demand. The following is a
summary of total North American production and our share of that
production:
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Total Production Tons | |
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in Millions(1) | |
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| |
Location and Name |
|
2005 | |
|
2004 | |
|
2003 | |
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| |
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| |
|
| |
Michigan (Marquette Range)
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|
|
|
|
|
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|
|
|
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Empire
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4.8 |
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5.4 |
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5.2 |
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Tilden
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7.9 |
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7.8 |
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7.0 |
|
Minnesota (Mesabi Range)
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Hibbing
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8.5 |
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8.3 |
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8.0 |
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Northshore
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4.9 |
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5.0 |
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4.8 |
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United Taconite(2)
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4.9 |
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4.1 |
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1.6 |
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Canada (Newfoundland and Quebec)
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Wabush
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4.9 |
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3.8 |
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5.2 |
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Total(3)
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35.9 |
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34.4 |
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30.3 |
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21
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(1) |
Tons are long tons of pellets of 2,240 pounds. |
|
(2) |
Total production at United Taconite in 2003 includes production
of Eveleth before it was acquired by United Taconite in the
fourth quarter of 2003. |
|
(3) |
Excludes 1.5 million tons in 2003 produced by Eveleth prior
to its acquisition by United Taconite in the fourth quarter of
2003. |
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Our Share of Total | |
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Production Tons in | |
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Millions(1) | |
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Location and Name |
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2005 | |
|
2004 | |
|
2003 | |
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| |
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| |
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Michigan (Marquette Range)
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|
|
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|
|
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|
|
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Empire
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3.8 |
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4.2 |
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4.0 |
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Tilden
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6.7 |
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6.7 |
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6.0 |
|
Minnesota (Mesabi Range)
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Hibbing
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2.0 |
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1.9 |
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1.8 |
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Northshore
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4.9 |
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5.0 |
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4.8 |
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United Taconite
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3.4 |
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2.9 |
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0.1 |
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Canada (Newfoundland and Quebec)
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Wabush
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1.3 |
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1.0 |
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1.4 |
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Total
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22.1 |
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21.7 |
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18.1 |
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(1) |
Tons are long tons of pellets of 2,240 pounds. |
At Portman, we produced 5.2 million tonnes since the
March 31, 2005 acquisition. Following is a summary of total
Australian production:
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Total Production Tonnes | |
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in Millions(1) | |
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Location and Name |
|
2005 | |
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| |
Koolyanobbing
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4.7 |
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Cockatoo Island(2)
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.5 |
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|
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Total
|
|
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5.2 |
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(1) |
Tonnes are metric tons of 2,205 pounds. |
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(2) |
Production represents Portmans 50 percent share. |
Our business is subject to a number of operational factors that
can affect our future profitability. Significant mining
challenges include the following:
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a) Uncertainties regarding mine life and estimates of ore
reserves; |
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b) Uncertainties relating to iron ore pricing and
fluctuations in currency exchange rates; |
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c) Unanticipated geological conditions, natural disasters,
interruptions in electrical or other power sources, equipment
failures, unanticipated capital requirements and maintenance
costs, or other unexpected events that could cause shutdowns or
production curtailments for us or for our steel industry
customers; |
|
|
d) Uncertainties relating to production costs, including
increases in our costs of electrical power, fuel or other energy
sources; |
22
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e) Uncertainties relating to governmental regulation of our
mines and processing facilities, including under environmental
laws; and |
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f) Uncertainties relating to labor relations. |
A more detailed description of these risks is contained in
Item 1A Risk Factors.
Mine Capacity and Iron Ore Reserves. The following tables
reflect expected current annual capacity and economic ore
reserves for our North American and Australian iron ore mines as
of December 31, 2005. The estimated ore reserves and full
production rates could be affected by, among other things,
future industry conditions, geological conditions, and ongoing
mine planning. Maintenance of effective production capacity of
the ore reserves could require increases in capital and
development expenditures. Alternatively, changes in economic
conditions or in the expected quality of ore reserves could
decrease capacity or mineral reserves. Technological progress
could alleviate such factors or increase capacity or ore
reserves. Our 2006 ore reserve estimates for our iron ore mines
as of December 31, 2005 were estimated from fully-designed
pits developed using three-dimensional modeling techniques.
These fully designed pits incorporate design slopes, practical
mining shapes and access ramps to assure the accuracy of our
reserve estimates.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Tons in Millions(1) | |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Mineral | |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reserves(2)(3) | |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
Current | |
|
|
|
Mineral Rights | |
|
|
|
|
|
|
|
|
Iron Ore | |
|
Annual | |
|
Current | |
|
Previous | |
|
| |
|
Method of Reserve | |
|
Operating | |
|
|
Mine |
|
Mineralization | |
|
Capacity | |
|
Year | |
|
Year | |
|
Owned | |
|
Leased | |
|
Estimation | |
|
Since | |
|
Infrastructure | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
Empire
|
|
Negaunee Iron Formation (Magnetite) |
|
|
5.5 |
|
|
|
17 |
|
|
|
23 |
|
|
|
57 |
% |
|
|
43 |
% |
|
Geologic Block Model |
|
|
1963 |
|
|
Mine, Concentrator, Pelletizer |
Tilden
|
|
Negaunee Iron Formation (Hematite/Magnetite) |
|
|
8.0 |
|
|
|
266 |
|
|
|
273 |
|
|
|
100 |
% |
|
|
0 |
% |
|
Geologic Block Model |
|
|
1974 |
|
|
Mine, Concentrator, Pelletizer, Railroad |
Hibbing Taconite
|
|
Biwabik Iron Formation (Magnetite) |
|
|
8.0 |
|
|
|
161 |
|
|
|
166 |
|
|
|
3 |
% |
|
|
97 |
% |
|
Geologic Block Model |
|
|
1976 |
|
|
Mine, Concentrator, Pelletizer |
Northshore
|
|
Biwabik Iron Formation (Magnetite) |
|
|
4.8 |
|
|
|
310 |
|
|
|
315 |
|
|
|
0 |
% |
|
|
100 |
% |
|
Geologic Block Model |
|
|
1989 |
|
|
Mine, Concentrator, Pelletizer, Railroad |
United Taconite
|
|
Biwabik Iron Formation (Magnetite) |
|
|
5.2 |
|
|
|
123 |
|
|
|
130 |
|
|
|
0 |
% |
|
|
100 |
% |
|
Geologic Block Model |
|
|
1965 |
|
|
Mine, Concentrator, Pelletizer |
Wabush
|
|
Wabush Iron Formation (Hematite) |
|
|
6.0 |
|
|
|
51 |
|
|
|
57 |
|
|
|
0 |
% |
|
|
100 |
% |
|
Geologic Block Model |
|
|
1965 |
|
|
Mine, Concentrator, Pelletizer, Railroad |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
|
|
37.5 |
|
|
|
928 |
|
|
|
964 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
Tons are long tons of pellets of 2,240 pounds. |
|
(2) |
Estimated standard equivalent pellets, including both proven and
probable reserves. |
|
(3) |
We regularly evaluate our ore reserve estimates and update them
as required in accordance with the SEC Industry Guide 7. |
23
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Tonnes in Millions(1) | |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
Current | |
|
Mineral | |
|
Mineral Rights | |
|
Method of | |
|
|
|
|
|
|
|
|
Annual | |
|
Reserves(2)(3) | |
|
| |
|
Reserve | |
|
Operating | |
|
|
Mine Project |
|
Iron Ore Mineralization | |
|
Capacity | |
|
Current Year | |
|
Owned | |
|
Leased | |
|
Estimation | |
|
Since | |
|
Infrastructure | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
Koolyanobbing(4)
|
|
Banded Iron Formations Southern Cross Terrane Yilgarn Mineral Field (Hematite, Goethite) |
|
|
6.0 |
|
|
|
87.5 |
|
|
|
0 |
% |
|
|
100 |
% |
|
Geologic Block Model |
|
|
1994 |
|
|
Mine, Train Haulage Road, Crushing-Screening Plant |
Cockatoo Island JV(5)
|
|
Sandstone Yampi Formation Kimberley Mineral Field (Hematite) |
|
|
1.2 |
|
|
|
1.7 |
|
|
|
0 |
% |
|
|
100 |
% |
|
Geologic Block Model |
|
|
1994 |
|
|
Mine Crushing-Screening Plant, Shiploader |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
|
|
7.2 |
|
|
|
89.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
Tonnes are metric tons of 2,205 pounds. |
|
(2) |
Reported ore reserves restricted to proven and probable tonnages
based on life of mine operating schedules. Koolyanobbing
reserves are sourced from 14 separate deposits in the project
area. 7.0 million tonnes of the Koolyanobbing reserves are
sourced from current long-term stockpiles. |
|
(3) |
Portmans ore reserve estimates are regularly updated in
accordance with SEC Industry Guide 7 and the 2004 Edition of the
JORC code. |
|
(4) |
An expansion project has been initiated that is expected to
increase annual production capacity to eight million tonnes. |
|
(5) |
Portman has a 50 percent interest in the Cockatoo Island
joint venture. Capacity and reserve totals represent
100 percent. |
General Information about the Mines
Leases. Mining is conducted on multiple mineral leases
having varying expiration dates. Mining leases are routinely
renegotiated and renewed as they approach their respective
expiration dates.
Exploration and Development. All mining operations are
open-pit mines that are well past the exploration stage and are
in production. Additional pit development is underway at each
mine as required by long-range mine plans. Drilling programs are
conducted periodically for the purpose of refining guidance
related to ongoing operations. An exploration program targeting
extensions to Portmans known iron ore resources as well as
regional exploration targets in the Yilgarn Mineral Field was
active in 2005 and will continue in 2006.
The Biwabik, Negaunee, and Wabush Iron Formations are classified
as Lake Superior type iron-formations that formed under similar
sedimentary conditions in shallow marine basins approximately
two billion years ago. Magnetite and/or hematite are the
predominant iron oxide ore minerals present, with lesser amounts
of goethite and limonite. Chert is the predominant waste mineral
present, with lesser amounts of silicate and carbonate minerals.
The ore minerals readily liberate from the waste minerals upon
fine grinding.
The mineralization at the Koolyanobbing operations is
predominantly hematite and goethite replacements in
greenstone-hosted banded iron-formations. Individual deposits
tend to be small with complex ore-waste contact relationships.
The Koolyanobbing operations reserves are derived from 14
separate mineral deposits distributed over a 100-kilometer
operating radius. The mineralization at Cockatoo Island is
predominantly friable, hematite-rich sandstone that produces
premium high grade, low impurity direct shipping fines.
Geologic models are developed for all mines to define the major
ore and waste rock types. Computerized block models are then
constructed that include all relevant geologic and metallurgical
data. These are used to generate grade and tonnage estimates,
followed by detailed mine design and life of mine operating
schedules.
Mine Facilities and Equipment. Each of the North American
mines has crushing, concentrating, and pelletizing facilities.
There are crushing and screening facilities at Koolyanobbing and
Cockatoo Island. The
24
facilities at each site are in satisfactory condition, although
they require routine capital and maintenance expenditures on an
ongoing basis. Certain mine equipment generally is powered by
electricity, diesel fuel or gasoline. The total cost of the
property, plant and equipment, net of applicable accumulated
amortization and depreciation as of December 31, 2005, for
each of the North American mines is set forth in the chart below.
|
|
|
|
|
|
|
|
Total Historical Cost of Mine | |
|
|
Plant and Equipment (Excluding | |
|
|
Real Estate and Construction in | |
|
|
Progress), Net of Applicable | |
|
|
Accumulated Amortization and | |
Location and Name |
|
Depreciation | |
|
|
| |
|
|
(In millions) | |
Michigan (Marquette Range)
|
|
|
|
|
|
Empire
|
|
$ |
113.5 |
(1) |
|
Tilden
|
|
|
211.9 |
(2) |
Minnesota (Mesabi Range)
|
|
|
|
|
|
Hibbing
|
|
|
451.3 |
(3) |
|
Northshore
|
|
|
78.6 |
(4) |
|
United Taconite
|
|
|
33.6 |
(5) |
Canada (Newfoundland and Quebec)
|
|
|
|
|
|
Wabush
|
|
|
359.6 |
(3) |
Portman
|
|
|
102.9 |
(6) |
|
|
|
|
|
Total
|
|
$ |
1,351.4 |
|
|
|
|
|
|
|
(1) |
Includes capitalized financing costs of $11.5 million, net
of accumulated amortization. |
|
(2) |
Includes capitalized financing costs of $22.2 million, net
of accumulated amortization. |
|
(3) |
Does not reflect depreciation, which is recorded by the
individual venturers. |
|
(4) |
As noted above, the assets of the Northshore mine were purchased
from Cyprus Minerals in 1994. |
|
(5) |
As noted above, the assets of the Eveleth Taconite mine were
purchased out of bankruptcy by United Taconite in 2003. |
|
(6) |
Represents appraised value of plant and equipment at
Koolyanobbing. Plant and equipment at Cockatoo Island is minimal. |
We directly own approximately one-half of the remaining ore
reserves at the Empire mine and approximately three percent of
the reserves at the Hibbing mine, and lease or sublease the
balance of the reserves from their owners. We own all of the ore
reserves at the Tilden mine. The ore reserves at Northshore,
United Taconite and Wabush Mines are owned by others and leased
or subleased directly to those mines. The Koolyanobbing
operations and Cockatoo Island ore reserves are derived from
Crown lands owned and managed by the Western Australia state
government.
In 2005, there were modest reductions to the estimated ore
reserve at Empire, United and Wabush and an increase in the ore
reserves at Hibbing Taconite. The ore reserves at Empire were
reduced by 2 million tons to eliminate difficult processing
ore having a high stripping ratio in the
CD-II deposit. At
United Taconite, the ore reserves decreased by 2 million
tons reflecting minor adjustments and corrections to the
previous estimate completed in 2004. The ore reserves at Wabush
were reduced by less than 1 million tons due to higher than
anticipated operating costs. At Hibbing Taconite, a completely
revised and updated ore reserve estimate increased the reserve
by 4 million tons.
The reduction in our ore reserve estimates for the Empire mine
is due to the inability to develop effective mine plans that
produce cost-justified combinations of production volume, ore
quality and stripping requirements with our 2003 reserve base. A
more detailed description of the reduction in ore reserve
estimates for the Empire mine is contained in
Item 1A Risk Factors. The reduction in our ore
reserve estimates for Wabush is largely a reflection of
increased operating costs, the impact of currency exchange rates
and a
25
reduction in maximum mining depth due to dewatering capabilities
based on a hydroanalysis evaluation. Partially offsetting these
impacts was the impact of higher Eastern Canadian pellet
pricing. A more detailed description of the reduction in ore
reserve estimates for Wabush is contained in
Item 1A Risk Factors.
Competition
We compete with several iron ore producers in North America,
including Iron Ore Company of Canada, Quebec Cartier Mining
Company and U.S. Steel, as well as other steel companies
that own interests in iron ore mines may have excess iron ore
inventories. In addition, significant amounts of iron ore have,
since the early 1980s, been shipped to the United States from
Brazil and Venezuela in competition with iron ore produced by us.
As the North American steel industry continues to consolidate, a
major focus of the consolidation is on the continued life of the
integrated steel industrys raw steelmaking operations,
i.e., blast furnaces and basic oxygen furnaces that
produce raw steel. Some steelmakers are importing semi-finished
steel slabs as an alternative to using blast furnaces and basic
oxygen furnaces to produce steel because of the costs associated
with relining blast furnaces and maintaining coke ovens. These
imported steel slabs can be converted and finished in the
steelmakers downstream finishing facilities. If the trend
continues, and more slabs are imported, the demand for pellets
that are used primarily in blast furnaces would diminish. In
addition, other competitive forces have become a large factor in
the iron ore business. Electric furnaces built by
mini-mills, which are steel recyclers, generally
produce steel by using scrap steel, not iron ore pellets, in
their electric furnaces.
Competition among the sellers of iron ore pellets is predicated
upon the usual competitive factors of price, availability of
supply, product performance, service and transportation cost to
the consumer.
Portman is the third largest iron ore mining company in
Australia and exports iron ore products to China and Japan, in
the world seaborne trade. Portman competes with major iron ore
exporters from Australia, Brazil and India.
Environment
In the construction of our facilities and in their operation,
substantial costs have been incurred and will continue to be
incurred to avoid undue effect on the environment. Our North
American capital expenditures relating to environmental matters
were $8.3 million in 2005 and $7.3 million in 2004. It
is estimated that approximately $17.3 million will be spent
in 2006 for capital environmental control facilities.
Various legislative bodies and federal and state agencies are
continually promulgating new laws and regulations affecting us,
our customers, and our suppliers in many areas, including waste
discharge and disposal, hazardous classification of materials
and products, air and water discharges, and many other
environmental, health and safety matters. Although we believe
that our environmental policies and practices are sound and do
not expect that the application of any current laws or
regulations would be reasonably expected to result in a material
adverse effect on our business or financial condition, we cannot
predict the collective adverse impact of the expanding body of
laws and regulations.
The iron ore industry has been identified by the EPA as an
industrial category that emits pollutants established by the
1990 Clean Air Act Amendments. These pollutants included over
200 substances that are now classified as hazardous air
pollutants (HAP). The EPA is required to develop
rules that would require major sources of HAP to utilize MACT
standards for their emissions. Pursuant to this statutory
requirement, the EPA published a final rule on October 30,
2003 imposing emission limitations and other requirements on
taconite iron ore processing operations. We must comply with the
new requirements no later than October 30, 2006. Our
projected capital expenditures in 2006 to meet the MACT
standards are approximately $4.4 million. In December 2003,
we filed a Petition to Delist Taconite Iron Ore Processing from
MACT under Section 112 of the Clean Air Act based upon
extensive data analyses, human health and ecological risk
assessments that are believed to demonstrate that a MACT
regulation for taconite operations is not warranted.
26
Typically, the EPAs consideration of a petition is an
iterative process extending over several months, with a longer
period for controversial subjects. On January 23, 2004, the
National Wildlife Federation, Minnesota Conservation Federation,
Lake Superior Alliance and Save Lake Superior Association filed
a petition for review of the EPAs final MACT rule in the
United States Court of Appeals for the District of Columbia.
This petition challenges the EPAs decision not to impose
standards for mercury and asbestos and monitoring of
formaldehyde from taconite indurating furnaces. We filed a
petition to intervene in this case. Subsequently, the Court
remanded to EPA the asbestos and mercury rules. The National
Wildlife Federation also voluntarily dismissed the petition with
respect to the formaldehyde rules.
Our environmental liability includes our obligations related to
five North American sites which are independent of our iron
mining operations, three former iron ore-related sites, two
leased land sites where we are lessor, and miscellaneous
remediation obligations at our operating units. Included in our
December 31, 2005 obligation is $5.2 million for the
estimated remaining
clean-up costs related
to a PCB spill at the Tilden Mine in the fourth quarter of 2005.
The obligation also includes federal and state sites where we
are named as a potentially responsible party (PRP),
such as the Milwaukee Solvay site and the Rio Tinto mine site in
Nevada, described in Item 3. Legal Proceedings,
and where significant site cleanup activities have taken place,
and the Kipling and Deer Lake sites in Michigan.
On February 10, 2006, our Northshore mine received a Notice
of Violation (Notice) from the EPA. The Notice cites
four alleged violations: (1) that Northshore violated the
Prevention of Significant Deterioration (PSD)
requirements of the Clean Air Act in the 1990 restart of
Furnaces 11 and 12; (2) that Northshore mine violated the
PSD Regulations in the 1995 restart of Furnace 6;
(3) Title V operating permit violations for not
including in the Title V permit all applicable requirements
(including a compliance schedule for PSD and Best Available
Control Technology (BACT) requirements associated
with the furnace restarts); and (4) failure to comply with
calibration of monitoring equipment as required under
Northshores Title V permit. The alleged violations
relating to the restart of Furnaces 11 and 12 occurred prior to
our acquisition of Northshore (formerly Cyprus Northshore Mining
Company) in a share purchase in 1994. We are currently
investigating the allegations contained in the Notice.
Australia
Portman achieved significant progress in environmental
management during 2005. As production activity from the new
operations at Mt. Jackson and Windarling consolidated, the
emphasis in environmental management shifted from control of
mine establishment and construction activities to implementation
and ongoing development of the Koolyanobbing Project
Environmental Management System and conservation initiatives.
The key elements of a number of environmental management plans
that were required under governmental approvals were
consolidated into one system manual in 2005. The environmental
management system was reviewed in October 2005 and determined to
be on schedule to achieve certification to the ISO14001 Standard
within the following 18 months.
For additional information on our environmental matters, see
Item 3. Legal Proceedings and Note 6 in
the Notes to our Consolidated Financial Statements for the year
ended December 31, 2005.
Energy
Electricity. The Empire and Tilden mines each have
electric power supply contracts with Wisconsin Electric Power
Company (WEPCO) that are effective through 2007 and
include an energy price cap and certain power curtailment
features. We are currently in dispute with WEPCO regarding
certain pricing provisions of our contract. See
Item 3. Legal Proceedings.
Electric power for the Hibbing mine and the United Taconite mine
is supplied by Minnesota Power, Inc., under agreements that
continue to December 2008 and October 2008, respectively.
Silver Bay Power Company, an indirect wholly owned subsidiary of
ours, with a 115 megawatt power plant, provides the majority of
Northshores energy requirements, has an interconnection
agreement with
27
Minnesota Power, Inc. for backup power, and sells 40 megawatts
of excess power capacity to Northern States Power Company under
a contract that extends to 2011.
Wabush owns a portion of the Twin Falls Hydro Generation
facility that provides power for Wabushs mining operations
in Newfoundland. We have a
20-year agreement with
Newfoundland Power, which continues until December 31,
2014. This agreement allows an interchange of water rights in
return for the power needs for Wabushs mining operations.
The Wabush pelletizing operations in Quebec are served by Quebec
Hydro on an annual contract.
Koolyanobbing and its associated satellite mines draw power from
independent diesel fuelled power stations and generators. The
primary Koolyanobbing power supply contract has been extended
beyond its original term, with temporary additional power being
installed to assist with immediate expansion requirements.
Portmans longer term power supply options are currently
under review.
Electrical supply on Cockatoo Island is diesel generated. The
powerhouse adjacent to the processing plant powers the
shiploader, fuel farm and the processing plant. The workshop and
administration office is powered by a separate generator.
Process Fuel. We have contracts providing for the
transport of natural gas for our United States iron ore
operations. The Empire and Tilden mines have the capability of
burning natural gas, coal, or, to a lesser extent, oil. The
Hibbing and Northshore mines have the capability to burn natural
gas and oil. The United Taconite mine has the ability to burn
coal, natural gas and coke breeze. Although all of the
U.S. mines have the capability of burning natural gas, with
higher recent natural gas prices, the pelletizing operations for
the U.S. mines utilize alternate fuels when practicable.
Wabush Mines has the capability to burn oil and coke breeze.
Research and Development
We have been a leader in iron ore mining technology for more
than 150 years. We operated some of the first mines on
Michigans Marquette Iron Range and pioneered early
open-pit and underground mining methods. From the first
application of electrical power in Michigans underground
mines to the use today of sophisticated computers and global
positioning satellite systems, we and our managed mines have
been leaders in the application of new technology to the
centuries-old business of mineral extraction.
We maintain research facilities in Ishpeming, Michigan at our
Cliffs Technology Center. It was at these facilities that the
current concentrating and pelletizing process was developed in
the 1950s. This successful development allowed for what was once
considered millions of tons of useless rock to be turned into an
iron ore reserve that provides the basis for our operations
today. Today our engineering and technical staffs are engaged in
full-time technical support of our operations and improvement of
existing products.
As part of our efforts to develop alternative metallic products,
we participated in Phase II of the Mesabi Nugget Project to
test and develop technology for converting iron ore into nearly
pure iron in nugget form. See Other Related
Items Mesabi Nugget Project in Item 7 for
a further discussion of the Project.
Portman does not have any material research and development
projects.
28
Employees
As of December 31, 2005, there were a total of 4,085
employees:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Mining Operations |
|
Salaried | |
|
Hourly | |
|
Total | |
|
|
| |
|
| |
|
| |
Empire
|
|
|
108 |
|
|
|
520 |
|
|
|
628 |
|
Tilden
|
|
|
112 |
|
|
|
566 |
|
|
|
678 |
|
LS&I Railroad
|
|
|
12 |
|
|
|
120 |
|
|
|
132 |
|
|
|
|
|
|
|
|
|
|
|
|
Subtotal(1)
|
|
|
232 |
|
|
|
1,206 |
|
|
|
1,438 |
|
Hibbing
|
|
|
122 |
|
|
|
566 |
|
|
|
688 |
|
Northshore
|
|
|
138 |
|
|
|
361 |
|
|
|
499 |
|
Wabush
|
|
|
171 |
|
|
|
627 |
|
|
|
798 |
|
United Taconite
|
|
|
84 |
|
|
|
382 |
|
|
|
466 |
|
Portman
|
|
|
62 |
|
|
|
12 |
|
|
|
74 |
|
Corporate/ Support Services
|
|
|
122 |
|
|
|
|
|
|
|
122 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Total(2)
|
|
|
931 |
|
|
|
3,154 |
|
|
|
4,085 |
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
We combined the workforces of the Empire and Tilden mines and
LS & I Railroad for administrative purposes in 2003. |
|
(2) |
Includes our employees and the employees of the North American
joint ventures. |
Hourly employees at our North American mining operations (other
than Northshore) are represented by the USWA under collective
bargaining agreements. In August 2004, four-year labor
agreements were ratified between each of the Hibbing, Tilden,
United Taconite and Empire mines and the USWA covering the
period to August 1, 2008. Also, in October 2004, we entered
into a five-year agreement with the USWA covering the employees
of the Wabush mine, which expires on March 1, 2009. Hourly
employees of one of our wholly owned railroads are represented
by six unions with labor agreements expiring at various dates.
As part of Cleveland-Cliffs Inc Core Values, the Company
continues to pursue safety through the enterprise-wide safety
initiatives. A reportable incident rate of 2.0 was established
as our North American safe production goal for 2005. Although
the target was not achieved at all of our mines, the overall
incident rate of 2.56 was the second best safety performance in
the Companys history as defined by the MSHA for total
reportable incidents. According to MSHA, the industry frequency
rate for total reportable incidents for U.S. mines, mills
and shops (excluding coal) was 3.96 per 200,000 employee
hours worked in 2005. Our frequency rate for lost-time incidents
in 2005 was the best in company history at 1.3 per 200,000
employee hours worked. Unfortunately, during the year a tragic
accident occurred at one of the Michigan mining operations when
an employee was fatally injured while working at the production
plant.
At the Koolyanobbing operation, the Lost Time Injury Frequency
Rate (LTIFR) for the year was 4.0, which is slightly
below the Australian metalliferous open pit mining average of
4.1. During 2005, four Lost Time Injuries
(LTIs) were recorded, regrettably including
one fatality. At Cockatoo Island, two LTIs were incurred,
resulting in a LTIFR of 7.29 for the year.
|
|
Item 3. |
Legal Proceedings. |
Wisconsin Electric Power Company. Two of the
Companys mines, Tilden and Empire (the Mines),
currently purchase their electric power from WEPCO pursuant to
the terms of special contracts specifying prices based on
WEPCOs actual costs. Effective April 1,
2005, WEPCO unilaterally changed its method of calculating the
energy charges to the Mines. It is the Mines contention
that WEPCOs new billing methodology is inconsistent with
the terms of the parties contracts and a dispute has
arisen between WEPCO and the Mines over the pricing issue. On
September 20, 2005, the Mines filed a Demand for
Arbitration with the American Arbitration Association with
respect to the dispute as provided for in their contracts with
WEPCO. WEPCO filed its reply on October 8, 2005, which
included a counterclaim for damages in an
29
amount of in excess of $4.1 million resulting from an
alleged failure of Tilden to notify WEPCO of planned production
in excess of seven million tons per year. We consider
WEPCOs counterclaim to be without merit and intend to
defend the counterclaim vigorously. Pursuant to the terms of the
relevant contracts, the undisputed amounts are being paid to
WEPCO, while the disputed amounts are being deposited into an
interest-bearing escrow account maintained by a bank. For the
period ending December 31, 2005, the Mines have deposited
$75.8 million into the escrow account, of which
$5.3 million was deposited in January 2006. An amount of
$73.0 million, of which $61.3 million is included in
the escrow deposit and $11.7 million has been paid directly
to WEPCO, is expected to be recovered in early-2006; however, we
have been advised by WEPCO that they will oppose any release of
these recoverable amounts from the escrow until completion of
the arbitration.
Maritime Asbestos Litigation. Two new maritime asbestos
cases were brought against subsidiaries of the Company in the
third quarter of 2005. As has been previously disclosed, The
Cleveland-Cliffs Iron Company (Iron) and/or The
Cleveland-Cliffs Steamship Company have been named defendants in
483 actions brought from 1986 to date by former seamen (or their
administrators) in which the plaintiffs claim damages under
federal law for illnesses allegedly suffered as the result of
exposure to airborne asbestos fibers while serving as crew
members aboard the vessels previously owned or managed by our
entities until the mid-1980s. All of these actions have been
consolidated into multidistrict proceedings in the Eastern
District of Pennsylvania, whose docket now includes a total of
over 30,000 maritime cases filed by seamen against ship-owners
and other defendants. All of these cases have been
administratively dismissed without prejudice, but can be
reinstated upon application by plaintiffs counsel. The
claims against our entities are insured, subject to self-insured
retentions by the insured in amounts that vary by policy year;
however, the manner in which these retentions will be applied
remains uncertain. Our entities continue to vigorously contest
these claims and have made no settlements on these claims.
Milwaukee Solvay Coke. In September 2002, we received a
draft of a proposed Administrative Order by Consent from the
EPA, for clean-up and
reimbursement of costs associated with the Milwaukee Solvay coke
plant site in Milwaukee, Wisconsin. The plant was operated by a
predecessor of ours from 1973 to 1983, which predecessor we
acquired in 1986. In January 2003, we completed the sale of the
plant site and property to a third party. Following this sale,
an Administrative Order by Consent (Solvay Consent
Order) was entered into with the EPA by us, the new owner
and another third party who had operated on the site. In
connection with the Solvay Consent Order, the new owner agreed
to take responsibility for the removal action and agreed to
indemnify us for all costs and expenses in connection with the
removal action. In the third quarter of 2003, the new owner,
after completing a portion of the removal, experienced financial
difficulties. In an effort to continue progress on the removal
action, we expended approximately $.9 million in the second
half of 2003 and $2.1 million in 2004. In September 2005,
we received a notice of completion from the EPA documenting that
all work has been fully performed in accordance with the Consent
Order.
On August 26, 2004, we received a Request for Information
pursuant to Section 104(e) of CERCLA relative to the
investigation of additional contamination below the ground
surface at the Milwaukee Solvay site. The Request for
Information was also sent to 13 other PRPs. On July 14,
2005, we received a General Notice Letter from the EPA notifying
us that the EPA believes we may be liable under CERCLA and
requesting that we, along with other PRPs, voluntarily perform
clean-up activities at
the site. We have responded to the General Notice Letter
indicating that there had been no communications with other PRPs
but also indicating our willingness to begin the process of
negotiation with the EPA and other interested parties regarding
a Consent Order. Subsequently, on July 26, 2005, we
received correspondence from the EPA with a proposed Consent
Order and informing us that three other PRPs had also expressed
interest in negotiating with the EPA. At this time, the nature
and extent of the contamination, the required remediation, the
total cost of the
clean-up and the cost
sharing responsibilities of the PRPs cannot be determined,
although the EPA has advised us that it has incurred
$.5 million in past response costs, which the EPA will seek
to recover from us and the other PRPs. We increased our
environmental reserve for Milwaukee Solvay by $.5 million
in 2005 for potential additional exposure.
On December 23, 2005, we entered into a letter of intent
with Kinnickinnic Development Group LLC (KK Group)
pursuant to which the KK Group would acquire and redevelop the
Milwaukee Solvay site.
30
Under the terms of the letter of intent, KK Group would acquire
our mortgage on the site in consideration for the assumption of
all our environmental obligations with respect to the site and a
cash payment of $2,250,000. In addition, KK Group would be
required to deposit $4 million into an escrow account to
fund any remaining environmental
clean-up activities on
the site and to purchase insurance coverage with a
$5 million limit. We are currently drafting definitive
agreements documenting this agreement. Closing of the
transaction would occur within sixty-one days of signing
definitive agreements.
Rio Tinto
The Rio Tinto Mine Site is a historic underground copper mine
located near Mountain City, NV, where tailings were placed in
Mill Creek, a tributary to the Owyhee River. Remediation work is
being conducted in accordance with a Consent Order between the
Nevada Department of Environmental
Protection (NDEP) and the Rio Tinto Working
Group (RTWG) composed of the Company, Atlantic
Richfield Company, Teck Cominco American Incorporated, and E. I.
du Pont de Nemours and Company. The Consent Order provides for
technical review by the U.S. Department of the Interior
Bureau of Indian Affairs, the U.S. Fish & Wildlife
Service, U.S. Department of Agriculture Forest Service, the
NDEP and the Shoshone-Paiute Tribes of the Duck Valley
Reservation (collectively, Rio Tinto Trustees)
located downstream on the Owyhee River. The Consent Order is
currently projected to continue through 2006 with the objective
of supporting the selection of the final remedy for the Site.
Costs are shared pursuant to the terms of a Participation
Agreement between the parties of the RTWG, who have reserved the
right to renegotiate any future participation or cost sharing
following the completion of the Consent Order.
The Rio Tinto Trustees have made available for public comment
their plans for the assessment of Natural Resource Damages
(NRD). The RTWG commented on the plans and also are
in discussions with the Rio Tinto Trustees informally about
those plans. The notice of plan availability is a step in the
damage assessment process. The studies presented in the plan may
lead to a NRD claim under CERCLA. There is no monetized NRD
claim at this time.
During 2005, the focus of the RTWG has been on development of
alternatives for remediation of the mine site. A draft of an
alternatives study has recently been reviewed with the Rio Tinto
Trustees and the alternatives have essentially been reduced to
three: (1) no action; (2) long-term water treatment,
and (3) removal of the tailings. The estimated costs range
from approximately $1 million to $27 million. In
recognition of the potential for an NRD claim, the parties are
exploring the possibility of a global settlement that would
encompass both the site decision and the NRD issues and thereby
avoid the lengthy litigation typically associated with NRD. The
Companys recorded reserve of approximately
$1.2 million reflects its estimated costs for completion of
the existing Consent Order and the minimum no action
alternative based on the current Participation Agreement.
Northshore Notice of Violation
On February 10, 2006, our Northshore mine received a Notice
from the EPA. The Notice cites four alleged violations:
(1) that Northshore violated the PSD requirements of the
Clean Air Act in the 1990 restart of Furnaces 11 and 12;
(2) that Northshore mine violated the PSD Regulations in
the 1995 restart of Furnace 6; (3) Title V operating
permit violations for not including in the Title V permit
all applicable requirements (including a compliance schedule for
PSD and BACT requirements associated with the furnace 12
restarts); and (4) failure to comply with calibration of
monitoring equipment as required under Northshores
Title V permit. The alleged violations relating to the
restart of Furnaces 11 and 12 occurred prior to our acquisition
of Northshore (formerly Cyprus Northshore Mining Company) in a
share purchase in 1994. We are currently investigating the
allegations contained in the Notice.
31
|
|
Item 4. |
Submission of Matters to a Vote of Security
Holders. |
None.
EXECUTIVE OFFICERS OF THE REGISTRANT
|
|
|
|
|
|
|
Name |
|
Position with Cleveland-Cliffs Inc as of February 17, 2006 |
|
Age | |
|
|
|
|
| |
J. S. Brinzo
|
|
Chairman and Chief Executive Officer |
|
|
64 |
|
D. H. Gunning
|
|
Vice Chairman |
|
|
63 |
|
J. A. Carrabba
|
|
President and Chief Operating Officer |
|
|
53 |
|
W. R. Calfee
|
|
Executive Vice President-Commercial |
|
|
59 |
|
D. J. Gallagher
|
|
Executive Vice President, Chief Financial Officer and Treasurer |
|
|
53 |
|
R. L. Kummer
|
|
Senior Vice President-Human Resources |
|
|
49 |
|
J. A. Trethewey
|
|
Senior Vice President-Business Development |
|
|
61 |
|
There is no family relationship between any of our executive
officers, or between any of our executive officers and any of
our Directors. Officers are elected to serve until successors
have been elected. All of the above-named executive officers
were elected effective on the dates listed below for each such
officer.
The business experience of the persons named above for the last
five years is as follows:
|
|
|
|
|
|
|
|
J.S. Brinzo |
|
|
Chairman and Chief Executive Officer, Cleveland-Cliffs Inc, |
|
|
|
|
|
|
January 1, 2000 to June 30, 2003 |
|
|
|
|
Chairman, President and Chief Executive Officer,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
July 1, 2003 to May 23, 2005. |
|
|
|
|
Chairman and Chief Executive Officer, Cleveland-Cliffs Inc, |
|
|
|
|
|
|
May 23, 2005 to date. |
|
D.H. Gunning |
|
|
Consultant and Private Investor |
|
|
|
|
|
|
December 1997 to April 15, 2001. |
|
|
|
|
Vice Chairman, Cleveland-Cliffs Inc, |
|
|
|
|
|
|
April 16, 2001 to date. |
|
J.A. Carrabba |
|
|
General Manager, Weipa Bauxite Operation, Comalco Aluminum |
|
|
|
|
|
|
March 1, 2000 to April 20, 2003. |
|
|
|
|
President and Chief Operating Officer, Diavik Diamond Mines, |
|
|
|
|
|
|
April 21, 2003 to May 22, 2005. |
|
|
|
|
President and Chief Operating Officer, Cleveland-Cliffs Inc, |
|
|
|
|
|
|
May 23, 2005 to date. |
|
W.R. Calfee |
|
|
Executive Vice President Commercial,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
October 1, 1995 to date. |
|
D.J. Gallagher |
|
|
Vice President Sales, Cleveland-Cliffs Inc, |
|
|
|
|
|
|
August 1, 1998 to July 28, 2003. |
|
|
|
|
Senior Vice President, Chief Financial Officer and Treasurer,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
July 29, 2003 to May 9, 2005. |
|
|
|
|
Executive Vice President, Chief Financial Officer and Treasurer,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
May 10, 2005 to date. |
32
|
|
|
|
|
|
|
|
R.L. Kummer |
|
|
Vice President, Human Resources, Government and Public Affairs,
Kennecott Energy Company, |
|
|
|
|
|
|
June 1, 1999 to August 31, 2000. |
|
|
|
|
Vice President Human Resources, Cleveland-Cliffs Inc, |
|
|
|
|
|
|
September 5, 2000 to December 31, 2002. |
|
|
|
|
Senior Vice President Human Resources,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
January 1, 2003 to date. |
|
J.A. Trethewey |
|
|
Senior Vice President Operations Services,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
June 1, 1999 to March 15, 2001. |
|
|
|
|
Senior Vice President Business Development,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
March 15, 2001 to April 23, 2003. |
|
|
|
|
Senior Vice President Operations Improvement,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
April 24, 2003 to May 31, 2004. |
|
|
|
|
Senior Vice President Business Development,
Cleveland-Cliffs Inc, |
|
|
|
|
|
|
June 1, 2004 to date. |
PART II
|
|
Item 5. |
Market for Registrants Common Equity, Related
Stockholder Matters and Issuer Purchases of Equity
Securities. |
Stock Exchange Information
Our Common Shares (ticker symbol CLF) are listed on the New York
Stock Exchange. The shares are also listed on the Chicago Stock
Exchange.
Common Share Price Performance and Dividends
All per-share information has been adjusted retroactively to
reflect the two-for-one stock split effective December 31,
2004.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2005 | |
|
2004 | |
|
|
| |
|
| |
|
|
High | |
|
Low | |
|
Dividends | |
|
High | |
|
Low | |
|
Dividends | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
First Quarter
|
|
$ |
88.35 |
|
|
$ |
46.80 |
|
|
$ |
.10 |
|
|
$ |
34.04 |
|
|
$ |
21.28 |
|
|
$ |
|
|
Second Quarter
|
|
|
75.50 |
|
|
|
51.14 |
|
|
|
.10 |
|
|
|
33.84 |
|
|
|
19.71 |
|
|
|
|
|
Third Quarter
|
|
|
88.67 |
|
|
|
56.85 |
|
|
|
.20 |
|
|
|
40.25 |
|
|
|
25.03 |
|
|
|
|
|
Fourth Quarter
|
|
|
99.25 |
|
|
|
70.90 |
|
|
|
.20 |
|
|
|
53.56 |
|
|
|
33.35 |
|
|
|
.10 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year
|
|
|
99.25 |
|
|
|
46.80 |
|
|
$ |
.60 |
|
|
|
53.56 |
|
|
|
19.71 |
|
|
$ |
.10 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
At February 14, 2006, we had 1,631 shareholders of
record.
Unregistered Sales of Equity Securities and Use of
Proceeds.
On September 30, 2005, October 14, 2005, and
November 15, 2005, pursuant to the Cleveland-Cliffs Inc
Voluntary Non-Qualified Deferred Compensation Plan (VNQDC
Plan), the Company sold a total of 25 shares of
common stock, par value $.50 per share, of Cleveland-Cliffs
Inc (Common Shares) for an aggregate consideration
of $2,195.50 to the Trustee of the Trust maintained under the
VNQDC Plan. These sales were made in reliance on Rule 506
of Regulation D under the Securities Act of 1933 pursuant
to an election made by one managerial employee under the VNQDC
Plan.
33
Issuer Purchases of Equity Securities
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(d) | |
|
|
|
|
|
|
|
|
Maximum | |
|
|
|
|
|
|
|
|
Number (or | |
|
|
|
|
|
|
(c) | |
|
Approximate | |
|
|
|
|
|
|
Total Number of | |
|
Dollar Value) of | |
|
|
(a) | |
|
(b) | |
|
Shares (or Units) | |
|
Shares (or | |
|
|
Total Number of | |
|
Average Price Paid | |
|
Purchased as Part | |
|
Units) that May | |
|
|
Shares (or | |
|
per Share (or | |
|
of Publicly | |
|
Yet be Purchased | |
|
|
Units) Purchased | |
|
Unit) | |
|
Announced Plans or | |
|
Under the Plans | |
Period |
|
(1) | |
|
$ | |
|
Programs (2) | |
|
or Programs | |
|
|
| |
|
| |
|
| |
|
| |
October 1-31, 2005
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
November 1-30, 2005
|
|
|
15,614 |
|
|
|
95.07 |
|
|
|
|
|
|
|
|
|
December 1-31, 2005
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
|
15,614 |
|
|
|
95.07 |
|
|
|
|
|
|
|
|
|
|
|
(1) |
Shares were acquired by the Company from certain employees in
connection with the vesting of restricted stock. Whole shares
were repurchased to satisfy the tax withholding obligations of
the employees on November 30, 2005. |
|
(2) |
The Company did not repurchase any of its equity securities
during the period covered by this report pursuant to any
publicly announced plan or program. |
34
|
|
Item 6. |
Selected Financial Data. |
Summary of Financial and Other Statistical Data
Cleveland-Cliffs Inc and Consolidated Subsidiaries
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2005 (a) | |
|
2004 | |
|
2003 | |
|
2002 | |
|
2001 | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
Financial Data (In Millions, Except Per Share Amounts and
Employees)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Operating Income (Loss) From Continuing Operations (Pre-Tax)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenue From Product Sales and Services
|
|
$ |
1,739.5 |
|
|
$ |
1,203.1 |
|
|
$ |
825.1 |
|
|
$ |
586.4 |
|
|
$ |
319.3 |
|
|
Cost of Goods Sold and Operating Expenses
|
|
|
(1,350.5 |
) |
|
|
(1,053.6 |
) |
|
|
(835.0 |
) |
|
|
(582.7 |
) |
|
|
(358.7 |
) |
|
Other Operating Income (Expense)
|
|
|
(32.5 |
) |
|
|
(31.9 |
) |
|
|
(38.4 |
) |
|
|
(65.4 |
) |
|
|
10.0 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Operating Income (Loss)
|
|
|
356.5 |
|
|
|
117.6 |
|
|
|
(48.3 |
) |
|
|
(61.7 |
) |
|
|
(29.4 |
) |
Income (Loss) From Continuing Operations
|
|
|
273.2 |
|
|
|
320.2 |
|
|
|
(34.9 |
) |
|
|
(66.4 |
) |
|
|
(19.5 |
) |
Income (Loss) From Discontinued Operations
|
|
|
(.8 |
) |
|
|
3.4 |
|
|
|
|
|
|
|
(108.5 |
) |
|
|
(12.7 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (Loss) Before Extraordinary Gain and Cumulative Effect of
Accounting Changes
|
|
|
272.4 |
|
|
|
323.6 |
|
|
|
(34.9 |
) |
|
|
(174.9 |
) |
|
|
(32.2 |
) |
Extraordinary Gain
|
|
|
|
|
|
|
|
|
|
|
2.2 |
|
|
|
|
|
|
|
|
|
Cumulative Effect of Accounting Changes Income (Loss)(b)
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
|
|
(13.4 |
) |
|
|
9.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Income (Loss)
|
|
|
277.6 |
|
|
|
323.6 |
|
|
|
(32.7 |
) |
|
|
(188.3 |
) |
|
|
(22.9 |
) |
Preferred Stock Dividends
|
|
|
(5.6 |
) |
|
|
(5.3 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (Loss) Applicable to Common Shares
|
|
|
272.0 |
|
|
|
318.3 |
|
|
|
(32.7 |
) |
|
|
(188.3 |
) |
|
|
(22.9 |
) |
Earnings (Loss) Per Common Share Basic(c) Continuing
Operations
|
|
|
12.32 |
|
|
|
14.78 |
|
|
|
(1.70 |
) |
|
|
(3.29 |
) |
|
|
(.97 |
) |
|
Discontinued Operations
|
|
|
(.04 |
) |
|
|
.16 |
|
|
|
|
|
|
|
(5.36 |
) |
|
|
(.63 |
) |
|
Cumulative Effect of Accounting Changes and Extraordinary Gain
|
|
|
.24 |
|
|
|
|
|
|
|
.10 |
|
|
|
(.66 |
) |
|
|
.46 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Earnings (Loss) Applicable to Common Shares
|
|
|
12.52 |
|
|
|
14.94 |
|
|
|
(1.60 |
) |
|
|
(9.31 |
) |
|
|
(1.14 |
) |
Earnings (Loss) Per Common Share Diluted(c)
Continuing Operations
|
|
|
9.81 |
|
|
|
11.68 |
|
|
|
(1.70 |
) |
|
|
(3.29 |
) |
|
|
(.97 |
) |
|
Discontinued Operations
|
|
|
(.03 |
) |
|
|
.12 |
|
|
|
|
|
|
|
(5.36 |
) |
|
|
(.63 |
) |
|
Cumulative Effect of Accounting Changes and Extraordinary Gain
|
|
|
.19 |
|
|
|
|
|
|
|
.10 |
|
|
|
(.66 |
) |
|
|
.46 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Earnings (Loss) Per Common Share(c)(d)
|
|
|
9.97 |
|
|
|
11.80 |
|
|
|
(1.60 |
) |
|
|
(9.31 |
) |
|
|
(1.14 |
) |
Total Assets
|
|
|
1,746.7 |
|
|
|
1,232.3 |
|
|
|
881.6 |
|
|
|
718.1 |
|
|
|
818.5 |
|
Debt Obligations Effectively Serviced(e)
|
|
|
49.6 |
|
|
|
9.1 |
|
|
|
34.6 |
|
|
|
67.4 |
|
|
|
173.9 |
|
Net Cash From (Used By) Operating Activities
|
|
|
514.6 |
|
|
|
(141.4 |
) |
|
|
42.7 |
|
|
|
40.9 |
|
|
|
28.9 |
|
Redeemable Cumulative Convertible Perpetual Preferred Stock
|
|
|
172.5 |
|
|
|
172.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Distributions to Preferred Shareholders Cash Dividends
|
|
|
5.6 |
|
|
|
5.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Distributions to Common Shareholders Cash Dividends
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Per Share(c)
|
|
|
.60 |
|
|
|
.10 |
|
|
|
|
|
|
|
|
|
|
|
.20 |
|
|
Total
|
|
|
13.1 |
|
|
|
2.2 |
|
|
|
|
|
|
|
|
|
|
|
4.1 |
|
|
Repurchases of Common Shares
|
|
|
|
|
|
|
6.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Pro Forma Results Assuming Accounting Changes Made
Retroactively(f) Net Income (Loss)
|
|
|
|
|
|
|
322.4 |
|
|
|
(32.4 |
) |
|
|
(186.9 |
) |
|
|
(24.0 |
) |
|
Per Share(c)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic
|
|
|
|
|
|
|
14.88 |
|
|
|
(1.58 |
) |
|
|
(9.25 |
) |
|
|
(1.19 |
) |
|
|
Diluted
|
|
|
|
|
|
|
11.76 |
|
|
|
(1.58 |
) |
|
|
(9.25 |
) |
|
|
(1.19 |
) |
North American Iron Ore Production and Sales Statistics (Tons
in Millions North America; Tonnes in
Millions Australia )
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Production Tons North America
|
|
|
35.9 |
|
|
|
34.4 |
|
|
|
30.3 |
|
|
|
27.9 |
|
|
|
25.4 |
|
35
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2005 (a) | |
|
2004 | |
|
2003 | |
|
2002 | |
|
2001 | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
Tonnes Australia
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Companys Share of Iron Ore Production North
America (tons)
|
|
|
22.1 |
|
|
|
21.7 |
|
|
|
18.1 |
|
|
|
14.7 |
|
|
|
7.8 |
|
|
Australia (tonnes)
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales Tons North America
|
|
|
22.3 |
|
|
|
22.6 |
|
|
|
19.2 |
|
|
|
14.7 |
|
|
|
8.4 |
|
|
Tonnes Australia
|
|
|
4.9 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Common Shares Outstanding (Millions)(c)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Average for Year
|
|
|
21.7 |
|
|
|
21.3 |
|
|
|
20.5 |
|
|
|
20.2 |
|
|
|
20.2 |
|
|
At Year-End
|
|
|
21.9 |
|
|
|
21.6 |
|
|
|
21.0 |
|
|
|
20.2 |
|
|
|
20.2 |
|
Employees at Year-End(g)
|
|
|
4,085 |
|
|
|
3,777 |
|
|
|
3,956 |
|
|
|
3,858 |
|
|
|
4,302 |
|
|
|
(a) |
On April 19, 2005, we completed the acquisition of
80.4 percent of Portman, the third largest iron ore mining
company in Australia. The acquisition was initiated on
March 31, 2005 by the purchase of approximately
68.7 percent of Portmans outstanding shares. Results
for 2005 include Portmans results since the acquisition. |
|
|
|
(b) |
|
Effective January 1, 2005, we adopted
EITF 04-6,
Accounting for Stripping Costs Incurred during Production
in the Mining Industry. Effective January 1, 2002 we
adopted SFAS No. 143, Accounting for Asset
Retirement Obligations and effective January 1, 2001
we changed our method of accounting for investment gains and
losses on pension assets for the recognition of pension expense. |
|
(c) |
|
On November 9, 2004 the Board of Directors of the Company
approved a two-for-one stock split of its Common Shares. The
record date for the stock split was December 15, 2004 with
a distribution date of December 31, 2004. Accordingly, all
Common Shares and per share amounts have been adjusted
retroactively to reflect the stock split. Additionally, all
diluted per share amounts reflect the
as-if-converted effect of our convertible preferred
stock as required by Emerging Issues Task Force Consensus 04-8. |
|
(d) |
|
In 2003 we recognized a $2.2 million extraordinary gain in
the acquisition of the assets of Eveleth Mines;
$3.3 million acquisition and startup costs for this same
mine, renamed United Taconite and $8.7 million of
restructuring charges related to a salaried employee reduction
program. Results for 2002 include a $95.7 million and $52.7
for impairment charges relating to discontinued operation and
impairment of mining assets, respectively. |
|
(e) |
|
Includes our share of unconsolidated ventures and equipment
acquired on capital leases; includes short-term portion. |
|
(f) |
|
The pro forma results include the effect on prior years for the
retroactive impact of changes in accounting methods related to:
(1) adoption in 2002 of the asset retirement obligation (expense
of $.8 million or $.04 per share in 2001); and
(2) adoption at January 1, 2005, of the accounting for
stripping costs; Income (expense) of ($1.2) million,
$.3 million, $1.4 million and ($.3) million for
2004, 2003, 2002 and 2001, respectively; and related diluted per
share amounts ($.04), $.02, $.06 and ($.01). |
|
(g) |
|
Includes employees of managed mining ventures. |
|
|
Item 7. |
Managements Discussion and Analysis of Financial
Condition and Results of Operations |
Overview
Cleveland-Cliffs Inc (the Company, we,
us, our, and Cliffs) is the
largest producer of iron ore pellets in North America. We sell
the majority of our pellets to integrated steel companies in the
United States and Canada. We manage and operate six North
American iron ore mines located in Michigan, Minnesota, and
Eastern Canada that currently have a rated capacity of
37.5 million tons of iron ore pellet production annually,
representing 45.9 percent of the current North American
pellet production capacity. The other iron ore mines in the U.S.
and Canada have an aggregate rated capacity of 22.9 million
tons and 21.2 million tons, respectively. Based on our
percentage ownership in the mines we operate, our share of the
rated pellet production capacity is currently 23.0 million
tons annually, representing approximately 28 percent of
total North American annual pellet capacity.
36
On April 19, 2005, Cleveland-Cliffs Australia Pty Limited
(Cliffs Australia), an indirect wholly owned
subsidiary of the Company, completed the acquisition of
80.4 percent of Portman Limited (Portman), the
third-largest iron ore mining company in Australia. The
acquisition was initiated on March 31, 2005 by the purchase
of approximately 68.7 percent of the outstanding shares of
Portman. Portman serves the Asian iron ore markets with
direct-shipping fines and lump ore from two iron ore projects,
both located in Western Australia. Portmans full-year 2005
production (excluding its .6 million metric ton
(tonne) share of the 50 percent-owned Cockatoo
Island joint venture) was approximately 6.0 million tonnes.
Portman currently has a $61 million project underway that
is expected to increase its wholly owned production capacity to
eight million tonnes per year by the end of the first quarter of
2006. The production is committed to steel companies in China
and Japan for approximately four years.
The Portman acquisition represents another significant milestone
in our long-term strategy to seek additional iron ore mine
investment opportunities and to transition our Company from
primarily a mine management company and mineral holder to an
international merchant mining company.
The purchase price for the 80.4 percent interest in Portman
was $433.1 million, including $12.4 million of
acquisition costs. Additionally, we incurred $9.8 million
of foreign currency hedging costs related to the transaction,
which were charged to operations in the first quarter of 2005.
The acquisition and related costs were financed with existing
cash and marketable securities and $175 million of interim
borrowings under a new three-year $350 million revolving
credit facility. The outstanding balance was repaid in full on
July 5, 2005.
Our statement of consolidated financial position as of
December 31, 2005, reflects the acquisition of Portman,
effective March 31, 2005, under the purchase method of
accounting. Assets acquired and liabilities assumed have been
recorded at estimated fair values as of the acquisition date as
determined by our management based on the information currently
available. An appraisal of assets and liabilities has not yet
been finalized, and is expected to be complete by March 31,
2006. While we do not expect any material changes, the purchase
price allocation remains subject to revision through the
allocation period ending in the first quarter of 2006. A
significant portion of the purchase price was allocated to iron
ore reserves, which will be depleted on a
unit-of-production
basis over the productive life of the reserve.
As a result of the Portman acquisition, we now operate in two
reportable segments: the North American segment and the
Australian segment, also referred to as Portman.
Prior to 2002, we primarily held a minority interest in the
mines we managed, with the majority interest in each mine held
by various North American steel companies. Our earnings were
principally comprised of royalties and management fees paid by
the partnerships, along with sales of our equity share of the
mine pellet production. Faced with marked deterioration in the
financial condition of many of our partners and customers, we
embarked on a strategy to reposition ourselves from a manager of
iron ore mines on behalf of steel company partners to primarily
a merchant of iron ore through increasing our ownership
interests in our managed mines.
Our successful navigation of numerous customer and partner
bankruptcies and the corresponding consolidation of the industry
in recent years have resulted in our emerging with new long-term
supply agreements, at more favorable pricing, with steel company
partners and customers that are financially stronger than their
predecessors. One premier example is the former International
Steel Group, Inc. (ISG), which consolidated several
bankrupt steel companies. In 2002, we invested
$13.0 million in ISG to support its acquisition of bankrupt
LTV Corporations idled steelmaking assets, receiving a
seven percent stake in return. We also entered into a
15-year term sales
agreement to supply all of ISGs pellet requirements for
its Cleveland and Indiana Harbor plants. Later in 2002, we
invested another $4.4 million to support ISGs
acquisition of the steelmaking assets of Acme Metals
Incorporated (Acme) and invested another
$10.7 million of pension trust assets in 2003 to support
ISGs acquisition of Bethlehem Steel Corporations
(Bethlehem) assets. In conjunction with its
acquisition of Bethlehem, ISG acquired Bethlehems
62.3 percent equity interest in the Hibbing Taconite
Company Joint Venture (Hibbing). Through
these investments, we received 5.9 million shares
(5.1 million shares of directly-held and .8 million
shares held in
37
our pension trust) in return for our original investment. In
2004, we realized a $152.7 million pre-tax
($99.3 million after-tax) gain on the sale of our
5.1 million shares of directly-held ISG common stock. Also
in 2004, ISG acquired the bankrupt assets of Weirton Steel
Corporation (Weirton) and Georgetown Steel
Corporation. In conjunction with its acquisition of Weirton, ISG
assumed our term supply agreement with Weirton with some
modifications.
ISG agreed to merge with Mittal Steel Company N.V.
(Mittal), the parent company of Ispat Inland Inc.
(Ispat), in 2005, resulting in the worlds
largest steel company. Effective January 3, 2006, Ispat was
merged with and into Mittal Steel USA ISG Inc. and renamed
Mittal Steel USA Inc. (Mittal Steel USA).
In 2004, we also significantly improved our liquidity initially
through our January, 2004 offering of $172.5 million of
redeemable cumulative convertible perpetual preferred stock. The
proceeds from the issuance were utilized to repay the remaining
$25 million balance of our unsecured notes and to fund
$76.1 million into our underfunded salaried and hourly
pension funds and retiree healthcare accounts
(VEBAs). Additionally, the proceeds from the sale of
ISG stock and cash flow from operations provided us with the
liquidity for capital expenditures to maintain and expand our
production capacity and to complete the acquisition of Portman.
We intend to continue to pursue investment and operations
management opportunities to broaden our scope as a supplier of
iron ore to the integrated steel industry through the
acquisition of additional mining interests to strengthen our
market position. We are particularly focused on expanding our
international investments to capitalize on global demand for
steel and iron ore.
Our strategic redirection and acceptance of additional risks of
increased mine ownership followed by significant increases in
iron ore demand and pricing culminated in record operating
income in 2004 and again in 2005, solid financial condition, and
a strong base for future growth.
Our share of North American production in 2005 was a record
22.1 million tons. Mine operating costs on a per-ton basis
increased by approximately 14 percent in 2005 versus 2004
primarily due to higher energy, supply pricing and royalties.
From a safety standpoint, 2005 was the second best safety
performance in the companys 158 year history at
2.56 per 200,000 employee hours worked as defined by the
Mine Safety and Health Administration (MSHA) for
total reportable incidents. According to MSHA, the industry
frequency rate for total reportable incidents for
U.S. mines, mills and shops (excluding coal) was
3.96 per 200,000 employee hours worked in 2005. Our
frequency rate for lost-time incidents in 2005 was the best in
company history at 1.3 per 200,000 employee hours worked.
Unfortunately, during the year a tragic accident occurred at one
of the Michigan mining operations when an employee was fatally
injured while working at the production plant.
At the Koolyanobbing operation, the Lost Time Injury Frequency
Rate (LTIFR) for the year was 4.0, which is slightly
below the Australian metalliferous open pit mining industry
average of 4.1. During 2005, four Lost Time Injuries
(LTIs) were recorded at the Koolyanobbing
operation, regrettably including one fatality. At Cockatoo
Island, two LTIs were incurred, resulting in a LTIFR of
7.29 for the year. Portmans safety statistics include
employees and contractors.
Our operating objectives are to maximize safe production,
efficiency and productivity at our mines. All of the mines and
processing facilities have been in existence for several decades
and are energy and labor intensive operations. Energy comprises
approximately 27 percent of our mine production costs. We
continue to strive for employment productivity improvements to
offset rising energy and employee medical and legacy costs.
Employees at the Empire Iron Mining Partnership
(Empire) and Tilden Mining Company L.C.
(Tilden) in Michigan and Hibbing Taconite and United
Taconite mines in Minnesota, represented by the United
Steelworkers of America (USWA), ratified four-year
labor agreements that are comparable to other USWA contracts in
the industry. The agreements provide for wage increases and
additional funding into employee pension plans and VEBAs in
exchange for employees and future retirees sharing in healthcare
insurance costs and certain other provisions that will continue
to improve productivity. (See Labor Contracts.)
38
Two-for-One Stock Split
On November 9, 2004, the Board of Directors of the Company
approved a two-for-one stock split of its Common Shares with a
corresponding decrease in par value from $1.00 to $.50. The
record date for the stock split was December 15, 2004 with
a distribution date of December 31, 2004. Accordingly, all
Common Shares, per-share amounts, stock compensation plans and
preferred stock conversion rates have been adjusted
retroactively to reflect the stock split. Additionally, all
diluted per-share amounts reflect the
as-if-converted effect of the Companys
convertible preferred stock as required by Emerging Issues Task
Force
Consensus 04-8,
The Effect of Contingently Convertible Instruments on
Dilute Earnings per Share.
Key Operating and Financial Indicators
Following is a summary of the Companys key operating and
financial indicators for the years 2005, 2004 and 2003:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2005 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
North American Pellet Sales (Million Tons)
|
|
|
22.3 |
|
|
|
22.6 |
|
|
|
19.2 |
|
Australian Iron Ore Sales (Million Tonnes)
|
|
|
4.9 |
|
|
|
|
|
|
|
|
|
Revenues from Iron Ore Sales and Services (Millions)*
|
|
$ |
1,512.2 |
|
|
$ |
995.0 |
|
|
$ |
686.8 |
|
Pellet Production (Million Tons)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
|
35.9 |
|
|
|
34.4 |
|
|
|
30.3 |
|
|
Companys Share
|
|
|
22.1 |
|
|
|
21.7 |
|
|
|
18.1 |
|
Australian Iron Ore Production (Million Tonnes)
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
Sales Margin (Loss) (Millions)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
North America
|
|
$ |
358.6 |
|
|
$ |
149.5 |
|
|
$ |
(9.9 |
) |
|
Australia
|
|
$ |
30.4 |
|
|
|
|
|
|
|
|
|
Income (Loss) from Continuing Operations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Amount (Millions)
|
|
$ |
273.2 |
|
|
$ |
320.2 |
|
|
$ |
(34.9 |
) |
|
Per Share (Diluted)
|
|
$ |
9.81 |
|
|
$ |
11.68 |
|
|
$ |
(1.70 |
) |
Net Income (Loss)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Amount (Millions)
|
|
$ |
277.6 |
|
|
$ |
323.6 |
|
|
$ |
(32.7 |
) |
|
Per Share (Diluted)
|
|
$ |
9.97 |
|
|
$ |
11.80 |
|
|
$ |
(1.60 |
) |
|
|
* |
The Company also received revenues of $227.3 million,
$208.1 million and $138.3 million in 2005, 2004 and
2003, respectively, related to freight and venture
partners cost reimbursements. |
North American iron ore pellet sales decreased .3 million
tons from the previous record of 22.6 million tons sold in
2004. The sales decrease primarily reflected a slowdown in the
North American steel industry in mid-2005 brought on by
production reductions at North American steel companies
undertaken to mitigate lower global steel pricing. Iron ore
pellet production for our account increased .4 million tons
largely due to the full-year production at United Taconite,
which was acquired in December 2003, and higher production at
all mines except Empire and Northshore.
Our increase in 2005 North American sales margin from 2004 was
principally due to an increase in sales prices partially offset
by higher production costs and lower volume. The increase in
sales prices reflected the effect on term sales contract
escalators of higher steel prices, an increase in international
pellet prices, and higher Producers Price Indices
(PPI). Production costs were adversely affected by
higher energy and supply pricing, increased maintenance costs
and higher royalty rates due to increased pellet sales pricing.
On a year-over-year basis, these factors were partly offset by
the fixed-cost effect of a
14-week labor stoppage
at Wabush Mines (Wabush) in the third quarter of
2004, the impact of a weaker U.S. dollar on our share of
Wabush production costs, and costs incurred related to 2004
U.S. labor negotiations.
Portmans sales of lump ore and fines were 4.9 million
tonnes since the acquisition. Iron ore production was
4.7 million tonnes, excluding .5 million tonnes at
Cockatoo Island, since the acquisition.
39
Our business is affected by a number of factors, which are
described in detail under Item 1A. Risk Factors. As we have
increased our role as a merchant of iron ore to steel company
customers, we have become more dependent on the revenues from
our term supply agreements. Because our agreements are largely
requirements contracts, those revenues are heavily dependent on
customer consumption of iron ore. Customer requirements may be
affected by increased use of iron ore substitutes, including
imported semi-finished steel, customer rationalization or
financial failure, and decreased North American steel production
resulting from increased imports or lower steel consumption.
Further, our North American sales are concentrated with
relatively few customers. Unmitigated loss of sales would have a
significantly greater impact on operating results and cash flow
than revenue, due to the high level of fixed costs in the iron
ore mining business and the high cost to idle or close mines. In
the event of a venture participants failure to perform,
remaining solvent venturers, including us, may be required to
assume additional fixed costs and record additional material
obligations. The premature closure of a mine due to the loss of
a significant customer or the failure of a joint venture
participant would accelerate substantial employment and mine
shutdown costs.
Results of Operations
Following is a summary of results for 2005, 2004 and 2003:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
Income (loss) from continuing operations(a)
|
|
$ |
273.2 |
|
|
$ |
320.2 |
|
|
$ |
(34.9 |
) |
Income (loss) from discontinuing operations(b)
|
|
|
(.8 |
) |
|
|
3.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) before extraordinary gain and cumulative effect of
accounting changes(b)
|
|
|
272.4 |
|
|
|
323.6 |
|
|
|
(34.9 |
) |
Extraordinary gain(b)
|
|
|
|
|
|
|
|
|
|
|
2.2 |
|
Cumulative effect of accounting changes(c)
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
amount
|
|
$ |
277.6 |
|
|
$ |
323.6 |
|
|
$ |
(32.7 |
) |
|
|
|
|
|
|
|
|
|
|
|
per share basic(d)
|
|
$ |
12.52 |
|
|
$ |
14.94 |
|
|
$ |
(1.60 |
) |
|
|
|
|
|
|
|
|
|
|
|
per share diluted
|
|
$ |
9.97 |
|
|
$ |
11.80 |
|
|
$ |
(1.60 |
) |
|
|
|
|
|
|
|
|
|
|
Average number of shares (in thousands)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
basic
|
|
|
21,728 |
|
|
|
21,308 |
|
|
|
20,512 |
|
|
diluted(e)
|
|
|
27,836 |
|
|
|
27,421 |
|
|
|
20,512 |
|
|
|
(a) |
Includes charges for impairments of mining assets of
$5.8 million in 2004 and $2.6 million in 2003, an
after-tax gain on sale of ISG common stock, $99.3 million
in 2004, and reversals of deferred tax asset valuation
allowances of $8.9 million and $113.8 million in 2005
and 2004, respectively. |
|
|
|
(b) |
|
Net of tax and minority interest. |
|
(c) |
|
Net of tax. |
|
(d) |
|
Adjusted for preferred dividend effect of $5.6 million and
$5.3 million in 2005 and 2004, respectively. |
|
(e) |
|
Includes 5.578 and 5.566 million shares in 2005 and 2004,
respectively for the weighted average of as-if
converted convertible preferred. |
2005 Versus 2004
The decrease in net income primarily reflected last years
after-tax gain of $99.3 million ($152.7 million
pre-tax) on the sale of all directly-held ISG stock and the
fourth-quarter 2004 reversal of $113.8 million of deferred
tax asset valuation allowance, largely offset by higher North
American sales margins and the inclusion of earnings from
Portman since March 31, 2005, when we acquired a
controlling interest.
40
The $47.0 million decrease in income from continuing
operations reflected higher income taxes of $119.8 and
$10.1 million of income attributable to the minority
interest owners of Portman, partially offset by higher income
before income taxes and minority interest of $82.9 million.
The pre-tax earnings increase from 2004 principally reflected
higher North American sales margins of $209.1 million and
the inclusion of Portmans sales margin of
$30.4 million since the March 31, 2005 acquisition
partially offset by last years gain on the sale of ISG
common stock of $152.7 million. Following is a summary of
the sales margin:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
|
|
| |
|
|
|
|
|
|
Increase (Decrease) | |
|
|
|
|
| |
|
|
2005 | |
|
2004 | |
|
Amount | |
|
Percent | |
|
|
| |
|
| |
|
| |
|
| |
North American iron ore pellet sales (tons)
|
|
|
22.3 |
|
|
|
22.6 |
|
|
|
(.3 |
) |
|
|
(1.3 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
Australian iron ore sales (tonnes)
|
|
|
4.9 |
|
|
|
|
|
|
|
4.9 |
|
|
|
N/M |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues from iron ore sales and services
|
|
$ |
1,512.2 |
|
|
$ |
995.0 |
|
|
$ |
517.2 |
|
|
|
52.0 |
% |
Cost of goods sold and operating expenses
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Excluding production curtailments
|
|
|
1,123.2 |
|
|
|
840.3 |
|
|
|
282.9 |
|
|
|
33.7 |
|
|
Costs of production curtailments
|
|
|
|
|
|
|
5.2 |
|
|
|
(5.2 |
) |
|
|
(100.0 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Costs
|
|
|
1,123.2 |
|
|
|
845.5 |
|
|
|
277.7 |
|
|
|
32.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales margin
|
|
$ |
389.0 |
|
|
$ |
149.5 |
|
|
$ |
239.5 |
|
|
|
160.2 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
North American Iron Ore
|
|
|
Revenues from Iron Ore Sales and Services |
Sales revenue (excluding freight and venture partners cost
reimbursements) increased $312.7 million or
31 percent. The increase in sales revenue was due to higher
sales prices, $328.0 million, partially offset by a sales
volume decrease of $15.3 million. The 33 percent
increase in sales prices primarily reflected the effect on
Cliffs term sales contract price adjustment factors of an
approximate 86 percent increase in international pellet
pricing, higher steel pricing, higher PPI and other contractual
increases, including base price increases and lag-year
adjustments. Included in 2005 revenues was approximately
..9 million tons of 2005 sales at 2004 contract prices and
$2.4 million of price adjustments on 2004 sales.
|
|
|
Cost of Goods Sold and Operating Expenses |
Cost of goods sold and operating expenses (excluding freight and
venture partners costs) increased $103.6 million from
2004. The increase primarily reflected higher unit production
costs of $116.6 million. Lower sales volume reduced costs
$13.0 million. The increases in unit production costs
included higher energy pricing, $50.4 million; increased
maintenance costs, $18.7 million; higher supply prices,
$16.6 million; and higher royalty rates,
$13.2 million, due to increased pellet sales pricing.
Production costs in 2004 were impacted by the labor stoppage at
Wabush in the third quarter of 2004 of $5.2 million, a
$3.4 million exchange rate effect due to the impact of a
weaker U.S. dollar on our share of Wabush production costs,
and $3.0 million related to 2004 U.S. labor
negotiations.
The sales margin improvement of $209.1 million in 2005 was
principally due to an increase in sales price, partially offset
by lower volume and higher production costs.
Australian Iron Ore
|
|
|
Revenues from Iron Ore Sales and Services |
Sales revenue of $204.5 million on 4.9 million tonnes
of Portmans sales reflects results since the
March 31, 2005, acquisition. Sales revenues for the
nine-month period represent a record for Portman. At
41
acquisition, Portman had currency derivatives used to hedge its
currency exposure for a portion of its sales receipts
denominated in U.S. dollars. Although Portman carried a
hedge reserve, the reserve was not recognized in the allocation
of purchase price. Pre-acquisition contracts, with a fair value
of $13.0 million, therefore, are expensed upon delivery.
Through December 31, 2005, $9.8 million of hedge
contracts were settled and recognized as a reduction of revenues.
|
|
|
Cost of Goods Sold and Operating Expenses |
Cost of goods sold and operating expenses of $174.1 million
for the nine-month period reflected the recognition of
$38.6 million of basis adjustments to inventory and mineral
rights due to the preliminary allocation of the
$433.1 million purchase price. We continue to refine our
purchase accounting developed with the assistance of an outside
consultant. The current allocation of the 80.4 percent
interest in Portman allocated $23.1 million to product and
work in process inventories, of which approximately
$19.9 million has been included in cost of goods sold
through December 31, 2005. Most of the $3.2 million
remaining inventory
step-up is expected to
be expensed prior to the end of 2006. The $18.7 million
balance of the basis adjustments principally reflected increased
depletion of mineral rights.
The sales margin of $30.4 million on 4.9 million
tonnes of Portmans sales reflects results since the
March 31, 2005 acquisition.
Other Operating Income
The pre-tax earnings changes for 2005 versus the comparable 2004
period also included:
|
|
|
|
|
A business interruption insurance recovery of $12.3 million
related to a five-week production curtailment at the Empire and
Tilden mines in 2003 due to the loss of electric power as a
result of flooding in the Upper Peninsula of Michigan. Future
recoveries may be forthcoming from a claim for reimbursement of
insurance deductibles through subrogation. |
|
|
|
Higher royalties and management fee revenue of
$1.8 million, primarily reflecting higher Wabush management
fees due to the approximate 86 percent increase in Eastern
Canadian pellet prices. |
|
|
|
Higher administrative, selling and general expense of
$14.8 million reflecting higher stock-based compensation
and the inclusion of $5.5 million of Portmans 2005
expense since the March 31, 2005 acquisition. |
|
|
|
Lower impairment of mining asset charges, $5.8 million. Due
primarily to the significant increase in 2005 pellet pricing, we
have determined, based on a cash flow analysis, that our Empire
mine is no longer impaired; accordingly, capital additions at
Empire in 2005 were not charged to expense. |
|
|
|
Provision for customer bankruptcy exposures, $3.6 million.
Results for 2005 included a $1.9 million recovery from WCI
Steel Inc. (WCI). Results for 2004 included a
first-quarter charge related to a subsidiary of Weirton,
$1.6 million. |
|
|
|
Miscellaneous net expense, $9.1 million higher
than the same period last year. Miscellaneous net
includes $5.2 million to clean a PCB spill at the Tilden
mine in November 2005, and $1.9 million of expense at
Portman since the March 31 acquisition. |
|
|
|
|
|
Last years results included a $152.7 million gain on
the sale of directly-held ISG common stock. |
|
|
|
A 2005 gain of $9.5 million on the sale of certain assets
to PolyMet Mining Inc. (PolyMet). (See Other Related
Items PolyMet). |
|
|
|
Increased interest income of $2.4 million reflecting higher
average cash and short-term marketable securities balances and
slightly higher rates. |
42
|
|
|
|
|
Increased interest expense of $3.7 million includes
$2.0 million of interest expense at Portman since the
March 31 acquisition, and interim borrowings in 2005 under
Cliffs new $350 million revolving credit facility to
supplement funds required for the Portman acquisition. |
|
|
|
Higher other-net expense of $11.5 million primarily
reflected $9.8 million of currency hedging costs associated
with the Portman acquisition. |
We entered 2005 with a valuation allowance to reduce a deferred
tax asset related to $25.4 million of net operating losses
attributable to pre-consolidation separate return years of one
of our subsidiaries. In the fourth quarter of 2005, we
determined, based on the existence of sufficient evidence, that
we no longer required this valuation allowance. During 2005, an
$8.9 million adjustment to reverse this valuation allowance
was recognized. However, through our acquisition of Portman, we
acquired a deferred tax asset of $11.1 million related to
capital loss carryforwards with a corresponding
$11.1 million deferred tax asset valuation allowance due to
uncertainty about utilization of these carryforwards.
In the fourth quarter of 2004, we determined, based on the
existence of sufficient evidence, that we no longer required a
valuation allowance other than $8.9 million related to net
operating loss carryforwards described above. During 2004, a
$113.8 million adjustment to reduce the valuation allowance
was recognized.
Excluding the $8.9 million and $113.8 million
valuation reversals in 2005 and 2004, respectively, income tax
expense of $93.7 million in 2005 was $14.9 million
higher than the comparable amount last year. The increase was
due to higher pre-tax income in 2005, partially offset by a
lower effective tax rate.
Our arrangements with C.V.G. Ferrominera Orinoco C.A. of
Venezuela (Ferrominera), a government-owned company
responsible for the development of Venezuelas iron ore
industry, to provide technical assistance in support of
improving operations of a 3.3 million tonne per year
pelletizing facility were terminated in the third quarter of
2005. We recorded after-tax expense of $1.7 million related
to this contract in 2005.
On July 23, 2004, Cliffs and Associates Limited
(CAL), an affiliate of the Company jointly owned by
a subsidiary of the Company (82.3945 percent) and Outokumpu
Technology GmbH (17.6055 percent), a German company
(formerly known as Lurgi Metallurgie GmbH), completed the sale
of CALs Hot Briquette Iron (HBI) facility
located in Trinidad and Tobago to ISG. Terms of the sale
included a purchase price of $8.0 million plus assumption
of liabilities. CAL may receive up to $10 million in future
payments contingent on HBI production and shipments. In 2005, we
received payments totaling $.6 million and at
December 31, 2005, we have a receivable balance of
$.5 million. Mittal Steel USA closed this facility at the
end of 2005 and it is unlikely we will receive further payments
related to this transaction. We recorded after-tax income of
approximately $.9 million in 2005.
2004 Versus 2003
The increase in net income reflected higher North American sales
margins and a $152.7 million pre-tax gain on the sale of
directly-held ISG common stock. The increase in net income also
included a $3.4 million increase in after-tax income
related to discontinued operations and a $2.2 million
after-tax extraordinary gain related to the United Taconite
acquisition of the Eveleth mine assets in December 2003.
43
The $355.1 million increase in income from continuing
operations reflected improved pre-tax results of
$320.4 million and an increase in the income tax credit of
$34.7 million. The increased tax credit in 2004 reflected a
$113.8 million reversal of deferred tax valuation allowance
partly offset by the current years tax provision. Included
in the pre-tax increase of $320.4 million was
$152.7 million relating to a gain on sale of directly-held
ISG common stock and higher sales margins of
$159.4 million. Following is a summary of the sales margin:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
|
|
| |
|
|
|
|
|
|
Increase (Decrease) | |
|
|
|
|
| |
|
|
2004 | |
|
2003 | |
|
Amount | |
|
Percent | |
|
|
| |
|
| |
|
| |
|
| |
Iron ore pellet sales (tons)
|
|
|
22.6 |
|
|
|
19.2 |
|
|
|
3.4 |
|
|
|
18% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues from iron ore sales and services*
|
|
$ |
995.0 |
|
|
$ |
686.8 |
|
|
$ |
308.2 |
|
|
|
45% |
|
Cost of goods sold and operating expenses*
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Excluding production curtailments
|
|
|
840.3 |
|
|
|
685.6 |
|
|
|
154.7 |
|
|
|
22.6 |
|
|
Costs of production curtailments
|
|
|
5.2 |
|
|
|
11.1 |
|
|
|
(5.9 |
) |
|
|
(53.2) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Costs
|
|
|
845.5 |
|
|
|
696.7 |
|
|
|
148.8 |
|
|
|
21.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales margin (loss)
|
|
$ |
149.5 |
|
|
$ |
(9.9 |
) |
|
$ |
159.4 |
|
|
|
N/M |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
* |
The Company also received revenues and recognized expenses of
$208.1 million and $138.3 million in 2004 and 2003,
respectively, for freight charges paid on behalf of customers
and cost reimbursement from venture partners. |
|
|
|
Revenues from Iron Ore Sales and Services |
Sales revenue (excluding freight and venture partners cost
reimbursements) increased $308.2 million or
45 percent. The increase in sales revenue was due to higher
sales prices and the 3.4 million ton, or 18 percent,
increase in pellet sales volume in 2004. The 22.6 million
tons sold in 2004 was a record, surpassing the previous record
of 19.2 million tons sold in 2003. The increase in sales
price realization resulted from term sales contract escalators,
primarily higher steel prices and an approximate 20 percent
increase in international pellet prices.
|
|
|
Cost of Goods Sold and Operating Expenses |
Cost of goods sold and operating expenses increased
$148.8 million, or 21 percent, from 2003, principally
due to higher sales and production volume of
$122.8 million, increased energy and supply pricing of
$19.9 million, the fixed-cost effect of a
14-week labor stoppage
at Wabush in third-quarter 2004 of $5.2 million, a
$3.4 million exchange rate effect due to the impact of a
weaker U.S. dollar on our share of Wabush production costs,
and $3.0 million related to 2004 U.S. labor
negotiations. Operating costs in 2003 included an
$11.1 million fixed-cost impact caused by a five-week
production curtailment at the Empire and Tilden mines relating
to the loss of electric power due to flooding in the Upper
Peninsula of Michigan.
The sales margin improvement of $159.4 million in 2004 was
principally due to an increase in sales prices and volume, and
was partially offset by higher production costs.
The pre-tax earnings changes for 2004 versus the comparable 2003
period also included:
|
|
|
|
|
Higher royalties and management fee revenue of $.7 million,
primarily reflecting higher Wabush management fees and
management fees from United Taconite production. |
44
|
|
|
|
|
Higher administrative, selling and general expense of
$8.0 million reflecting higher stock-based and incentive
compensation of $8.5 million. |
|
|
|
Higher impairment of mining asset charges, $3.2 million.
Empires long-lived assets were impaired in 2002.
Approximately $2.2 million of the 2004 Empire fixed asset
additions were related to an increase in the asset retirement
obligation reflecting a one year decrease in the estimated mine
life due to a change in annual production levels. |
|
|
|
Lower provision for customer bankruptcy exposures,
$5.9 million, related to the Weirton and WCI Steel Inc.
bankruptcies. |
|
|
|
Miscellaneous net expense, $2.2 million lower
than the same period last year. The decrease primarily reflected
lower coal retiree expense of $1.6 million, decreased
business development cost of $1.0 million, and debt
restructuring fees in 2003 of $.8 million partially offset
by lower rental income of $.9 million. |
|
|
|
|
|
In third-quarter 2003, we initiated a salaried reduction program
as part of our cost-reduction initiatives. The action resulted
in a reduction of 136 staff employees at our corporate, central
services and various mining operations, which represented an
approximate 20 percent decrease in salaried workforce at
our U.S. operations (prior to the acquisition of United
Taconite). Accordingly, we recorded a restructuring charge of
$8.7 million in 2003, which included non-cash pension and
OPEB obligations of $6.2 million and one-time severance
benefits of $2.5 million. Less than $1.6 million
required cash funding in 2003, leaving a remaining severance
liability of approximately $.9 million at December 31,
2003. In 2004, we expended $.7 million and recorded a
credit of $.2 million in satisfaction of the obligation. |
|
|
|
|
|
Interest expense decreased $3.8 million from 2003. The
decrease principally reflected the repayment of our senior
unsecured notes in January 2004. |
|
|
|
Other income of $4.2 million in 2004 was $2.9 million
less than in 2003. The decrease primarily related to
non-strategic Michigan land sales in 2003. |
Through the third quarter of 2004, we maintained a valuation
allowance to reduce our deferred tax asset in recognition of
uncertainty regarding utilization. In the fourth quarter of
2004, we determined, based on the existence of sufficient
evidence, that we no longer required a valuation allowance other
than $8.9 million related to net operating loss
carryforwards of $25.4 million that will begin to expire in
2021, which are attributable to pre-consolidation separate
return years of one of our subsidiaries. As a result, a
$113.8 million adjustment to reduce the valuation allowance
was recognized. Excluding the $113.8 million valuation
reversal, income tax expense in 2004 of $78.9 million was
$79.2 higher than 2003 principally reflecting higher pre-tax
income.
We recorded after-tax income of $3.1 million related to CAL
in 2004. The gain is classified under Discontinued
Operations in the Statement of Consolidated Operations.
Income in 2004 from Ferrominera, whose operations were
terminated in the third quarter of 2005, was $.3 million.
45
Cash Flow and Liquidity
At December 31, 2005, we had cash and cash equivalents of
$192.8 million, including $54.7 million at Portman.
Following is a summary of 2005 cash flow activity:
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
| |
Investment in Portman (net of $24.1 million cash acquired)
|
|
$ |
(409.0 |
) |
Capital expenditures
|
|
|
(106.3 |
) |
Dividends common and preferred stock
|
|
|
(18.7 |
) |
Payment of currency hedges
|
|
|
(9.8 |
) |
Net cash from operating activities
|
|
|
514.6 |
|
Other
|
|
|
7.3 |
|
|
|
|
|
|
Decrease in cash and cash equivalents from continuing operations
|
|
|
(21.9 |
) |
Cash used by discontinued operations
|
|
|
(2.2 |
) |
|
|
|
|
|
Decrease in cash and cash equivalents
|
|
$ |
(24.1 |
) |
|
|
|
|
Following is a summary of key liquidity measures:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
At December 31 | |
|
|
(In Millions) | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
Cash and cash equivalents
|
|
$ |
192.8 |
|
|
$ |
216.9 |
|
|
$ |
67.8 |
|
|
|
|
|
|
|
|
|
|
|
Marketable securities-trading
|
|
$ |
9.9 |
|
|
$ |
182.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Debt
|
|
$ |
(7.7 |
) |
|
|
|
|
|
$ |
(25.0 |
) |
|
|
|
|
|
|
|
|
|
|
Working capital
|
|
$ |
273.3 |
|
|
$ |
474.3 |
|
|
$ |
97.2 |
|
|
|
|
|
|
|
|
|
|
|
Net cash from operating activities of $514.6 million
included $68.3 million related to Portman. Included in net
cash from operating activities is a $172.8 million net
decrease in short-term marketable securities, classified as
trading, which we utilize to increase our rate of return on
short-term funds. The $172.8 million net decrease in
marketable securities primarily reflects the proceeds from the
sale of $182.7 million of highly liquid marketable
securities used in connection with our acquisition of Portman,
net of $9.9 million purchases of investments with
35-day auction reset
dates. The Company invests in auction rate securities to provide
higher short-term returns than traditional money market
investments with minimal risk of loss of capital. Cash flow from
operations also reflects $86.2 million of income tax
payments, $55.8 million of contributions to pension plans
and VEBAs and $70.6 million of excess electric power
company payments pending the outcome of an arbitration of our
dispute with Wisconsin Electric Power Companys
(WEPCO) unilateral increase in the electric power
energy rates it charges to the Empire and Tilden mines under the
terms of existing electric power agreements between the parties.
Approximately $67.6 million of power payments are
recoverable in early 2006; however, we have been advised by
WEPCO that they will oppose any release of these recoverable
amounts from the escrow until completion of the arbitration.
(See Wisconsin Electric Power Company Dispute.)
At December 31, 2005, there were 3.3 million tons of
pellets in inventory, approximately the same as last year, at a
cost of $105.3 million, or a decrease of $3.0 million
from December 31, 2004. At December 31, 2005, Portman
had .6 million tonnes of finished product inventory at a
cost of $13.8 million.
On March 28, 2005, we entered into a $350 million
unsecured credit agreement with a syndicate of 13 financial
institutions. The new facility provides $350 million in
borrowing capacity under a revolving credit line, with a choice
of interest rates and maturities subject to the three-year term
of the agreement. The $350 million credit agreement
replaced an existing $30 million unsecured revolving credit
facility, which was scheduled to expire on April 29, 2005.
The new facility has various financial covenants based on
earnings, debt, total capitalization, and fixed cost coverage.
Interest rates range from LIBOR plus 1.25 percent to
46
LIBOR plus 2.0 percent, based on debt and earnings, or the
prime rate. We were in compliance with the covenants in the
credit agreement as of December 31, 2005.
Portman is party to a A$40 million credit agreement. The
facility has various covenants based on earnings, asset ratios
and fixed cost coverage. The floating interest rate is
80 basis points over the
90-day bank bill swap
rate in Australia. Under this facility, Portman has remaining
borrowing capacity of A$29.0 million at December 31,
2005, after reduction of A$11.0 million for commitments
under outstanding performance bonds. Portman was in compliance
with its debt covenants as of December 31, 2005.
Portman secured five-year financing from its customers in China
as part of its long-term supply agreements to assist with the
funding of the expansion of its Koolyanobbing mining operation.
The borrowings, totaling $7.7 million, accrue interest
annually at five percent. The borrowings require a
$.8 million principal payment plus accrued interest to be
made each January 31 for the next four years with the
remaining balance due in full in January 2010.
We anticipate that our share of capital expenditures related to
the iron ore business, which was $107.9 million in 2005,
will increase to approximately $174 million in 2006. We
expect to fund our capital expenditures from available cash and
current operations. The anticipated increase in capital
expenditures is primarily due to the capacity expansion to eight
million tonnes at the Koolyanobbing operation,
$41.3 million and approximately $15 million for the
Mesabi Nugget Project. (See Other Related Items
Mesabi Nugget Project).
|
|
|
Issuance of Preferred Stock |
In January 2004, we completed an offering of $172.5 million
of redeemable cumulative convertible perpetual preferred stock,
without par value, issued at $1,000 per share. The
preferred stock pays quarterly cash dividends at a rate of
3.25 percent per annum, has a liquidation preference of
$1,000 per share and is convertible into our common shares
at an adjusted rate of 32.3354 common shares (32.6652 at
February 17, 2006) per share of preferred stock, which is
equivalent to an adjusted conversion price of $30.93 per
share at December 31, 2005 ($30.61 at February 17,
2006), subject to further adjustment in certain circumstances.
Each share of preferred stock may be converted by the holder if
during any fiscal quarter ending after March 31, 2004 the
closing sale price of our common stock for at least
20 trading days in a period of 30 consecutive trading
days ending on the last trading day of the preceding quarter
exceeds 110 percent of the applicable conversion price on
such trading day ($34.02 at December 31, 2005; this
threshold was met as of December 31, 2005). The
satisfaction of this condition allows conversion of the
preferred stock during the fiscal quarter ending March 31,
2006 only. Holders of preferred stock may also convert:
(1) if during the five business day period after any five
consecutive trading-day period in which the trading price per
share of preferred stock for each day of that period was less
than 98 percent of the product of the closing sale price of
our common stock and the applicable conversion rate on each such
day; (2) upon the occurrence of certain corporate
transactions; or (3) if the preferred stock has been called
for redemption. On or after January 20, 2009, we, at our
option, may redeem some or all of the preferred stock at a
redemption price equal to 100 percent of the liquidation
preference, plus accumulated but unpaid dividends, but only if
the closing price exceeds 135 percent of the conversion
price, subject to adjustment, for 20 trading days within a
period of 30 consecutive trading days ending on the trading day
before the date we give the redemption notice. We may also
exchange the preferred stock for convertible subordinated
debentures in certain circumstances. We have reserved
approximately 5.6 million common treasury shares for
possible future issuance for the conversion of the preferred
stock. Our shelf registration statement with respect to the
resale of the preferred stock, the convertible subordinated
debentures that we may issue in exchange for the preferred stock
and the common shares issuable upon conversion of the preferred
stock and the convertible subordinated debentures was declared
effective by the SEC on July 22, 2004. The Company is no
longer contractually obligated to maintain the effectiveness of
the registration statement due to the expiration of the
effectiveness period. Accordingly, on February 14, 2006,
the Company deregistered 92,655 shares of Preferred Stock,
$172,500,000 in aggregate principal amount of debentures and
approximately 5.6 million common shares that have not been
resold. The preferred stock is classified as temporary
equity reflecting certain provisions of the agreement that
could, under remote circumstances, require us to redeem the
preferred stock for cash. The net proceeds after offering
47
expenses were approximately $166 million. A portion of the
proceeds was utilized to repay the remaining outstanding
$25.0 million in principal amount of our senior unsecured
notes in the first quarter of 2004. We also used approximately
$63.0 million to fund our underfunded pension plans and
contributed $13.1 million to our VEBAs in 2004.
Off-Balance Sheet Arrangements and Contractual Obligations
Other than operating leases primarily utilized for certain
equipment and office space, we do not have any off-balance sheet
financing. Following is a summary of our contractual obligations
at December 31, 2005:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Payments due by Period(1) (Millions) | |
|
|
| |
|
|
|
|
Less than | |
|
|
|
More than | |
Contractual Obligations |
|
Total | |
|
1 Year | |
|
1-3 Years | |
|
3-5 Years | |
|
5 Years | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
Long-term debt
|
|
$ |
7.7 |
|
|
$ |
.8 |
|
|
$ |
1.5 |
|
|
$ |
5.4 |
|
|
$ |
|
|
Capital Lease Obligations
|
|
|
41.2 |
|
|
|
5.9 |
|
|
|
10.1 |
|
|
|
7.0 |
|
|
|
18.2 |
|
Operating Leases
|
|
|
41.3 |
|
|
|
14.8 |
|
|
|
15.8 |
|
|
|
8.4 |
|
|
|
2.3 |
|
Purchase Obligations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Open Purchase Orders
|
|
|
94.6 |
|
|
|
93.5 |
|
|
|
.8 |
|
|
|
.3 |
|
|
|
|
|
|
Minimum Take or Pay Purchase Commitments(2)
|
|
|
460.9 |
|
|
|
124.7 |
|
|
|
134.7 |
|
|
|
106.6 |
|
|
|
94.9 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Purchase Obligations
|
|
|
555.5 |
|
|
|
218.2 |
|
|
|
135.5 |
|
|
|
106.9 |
|
|
|
94.9 |
|
Other Long-Term Liabilities
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension Funding Minimums
|
|
|
180.2 |
|
|
|
46.0 |
|
|
|
80.7 |
|
|
|
21.0 |
|
|
|
32.5 |
|
|
OPEB Claim Payments
|
|
|
231.7 |
|
|
|
37.6 |
|
|
|
58.3 |
|
|
|
57.6 |
|
|
|
78.2 |
|
|
Mine Closure Obligations
|
|
|
95.1 |
|
|
|
3.5 |
|
|
|
19.9 |
|
|
|
3.7 |
|
|
|
68.0 |
|
|
Coal Industry Retiree Health Benefits
|
|
|
6.5 |
|
|
|
.6 |
|
|
|
1.4 |
|
|
|
1.2 |
|
|
|
3.3 |
|
|
Personal Injury
|
|
|
16.5 |
|
|
|
4.9 |
|
|
|
5.9 |
|
|
|
1.9 |
|
|
|
3.8 |
|
|
Other(3)
|
|
|
192.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Other Long-Term Liabilities
|
|
|
722.8 |
|
|
|
92.6 |
|
|
|
166.2 |
|
|
|
85.4 |
|
|
|
185.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
$ |
1,368.5 |
|
|
$ |
332.3 |
|
|
$ |
329.1 |
|
|
$ |
213.1 |
|
|
$ |
301.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
Includes our consolidated obligations and our ownership share of
unconsolidated ventures obligations. |
|
(2) |
Includes minimum electric power demand charges, minimum coal and
natural gas obligations, and minimum railroad transportation
obligations. |
|
(3) |
Primarily includes deferred income taxes payable and other
contingent liabilities for which payment timing is
non-determinable. |
Operations and Customers
Our pellet sales for the year 2005 were 22.3 million tons
which is the second highest volume ever, surpassed only by last
years record sales of 22.6 million tons. The decrease
in pellet sales was primarily due to a slowdown in the North
American steel industry in the middle of 2005. We ended the year
2005 with 3.3 million tons of iron ore pellet inventory,
approximately the same as last year. Our 2006 North American
sales volume is projected to be approximately 21 million
tons. We are largely committed under term supply agreements,
which are subject to changes in customer requirements.
Portman sold 4.9 million tonnes of lump and fine ore since
the acquisition and ended the year with .6 million tonnes
of finished goods inventory. Portmans 2006 sales volume is
projected to be 7.9 million tonnes, reflecting the project
to increase capacity at the wholly owned Koolyanobbing operation
to eight million tonnes per annum. The production is fully
committed to steel companies in China and Japan for
48
approximately four years. Revenue per tonne is driven under
annual benchmark prices between the major seaborne suppliers and
the Chinese and Japanese steel mills.
Mittal Steel USA
On December 17, 2004, Ispat International N.V. completed
its acquisition of LNM Holdings N.V. to form Mittal. On
April 13, 2005, Mittal completed its acquisition of ISG,
subsequently renamed Mittal Steel USA. At the time of the
acquisition of ISG, the Company had three different sales
contracts with steel companies that became part of Mittal Steel
USA:
|
|
|
|
|
Ispat. Ispat was a wholly owned subsidiary of Ispat
International N.V. On December 31, 2002, we entered into a
Pellet Sale and Purchase Agreement with Ispat (the Ispat
Contract), which provides that we are the sole outside
supplier of iron ore pellets to Ispat. The Ispat Contract runs
through January 2015. |
|
|
|
Mittal ISG. We entered into a Pellet Sale and Purchase
Agreement with ISG on April 10, 2002, which runs through
2016 (the ISG Contract), under which we are the sole
supplier of iron ore pellets for the former ISGs Cleveland
and Indiana Harbor Works. The ISG Contract was subsequently
amended in December 2004. |
|
|
|
Mittal Steel-Weirton (formerly Weirton). Prior to the
acquisition of ISG by Mittal, ISG had acquired Weirton, which
was in chapter 11 bankruptcy at the time. The Company was
one of two suppliers of iron ore pellets to Weirton. At the time
of ISGs acquisition of Weirton, we entered into an Amended
and Restated Pellet Sale and Purchase Agreement dated
May 17, 2004, with both ISG and Weirton (the Weirton
Contract). The Weirton Contract runs through 2018. |
In December 2005, Mittal merged Ispat into Mittal Steel USA and
Mittal Steel USA assumed Ispats obligations under the
Ispat Contract. Mittal Steel USA is a 62.3 percent equity
participant in Hibbing and a 21 percent equity partner in
Empire.
During 2005, our North American pellet sales totaled
approximately 22.3 million tons, with pellet sales to
Mittal Steel USA representing approximately 48 percent of
North American sales volume. Currently, 2006 pellet sales are
projected to be approximately 21 million tons, not
including any sales to Mittal Steel-Weirton.
In 2005 Mittal Steel USA shut down Mittal Steel-Weirtons
blast furnace. The Weirton Contract has a minimum annual
purchase obligation and requires Mittal Steel-Weirton to
purchase for the years 2004 and 2005 the greater of
67 percent of Mittal Steel-Weirtons total annual iron
ore pellet requirements, or 1.5 million tons and, for the
years 2006 through and including 2018, a tonnage amount equal to
Mittal Steel-Weirtons total annual iron ore pellet tonnage
requirements, with a minimum annual purchase obligation of
2.0 million tons per year, required for consumption in
Mittal Steel-Weirtons iron and steel making facilities in
any year at Mittal Steel-Weirton. Over the past few months
we have been in discussions with Mittal Steel USA regarding the
terms of the Weirton Contract in response to Mittal Steel
USAs request for relief from the minimum purchase
obligation. These discussions have resulted in no agreement
between the Company and Mittal Steel USA as to the Mittal
Steel-Weirton minimum purchase obligation. Mittal Steel-Weirton
purchased approximately 325,000 tons of iron ore pellets less
than its 1.5 million minimum purchase obligation for 2005,
and as a result we invoiced Mittal Steel-Weirton approximately
$17 million for this remaining tonnage. The sale of this
tonnage would be recorded in 2006. Payment for this tonnage was
due on January 30, 2006 and has not been received. Mittal
Steel USA has advised us that the Mittal Steel-Weirton blast
furnace has been permanently shut down and will not be
restarted. Mittal Steel-Weirton has also taken the position that
it has no future obligation to purchase pellets under the
Weirton Contract.
Mittal Steel USA has also claimed that in 2004 it overpaid a
supplemental steel price sharing provision (the Special
Steel Payment) under the Weirton and ISG Contracts. Mittal
claims that, prior to the acquisition of ISG by Mittal,
surcharges were improperly included in the average annual
unprocessed hot band
49
steel pricing for purposes of calculating the Special Steel
Payment under both contracts, despite the fact that ISG itself
calculated the amount of the Special Steel Payment, included
surcharges in that calculation, and did not claim that it was
making or had made any overpayment. Mittal Steel USA has claimed
an overpayment of approximately $8.7 million with respect
to the Weirton Contract and approximately $49.6 million
with respect to the ISG Contract. We are confident that the
Special Steel Payment calculation properly included all revenue
including surcharges. We believe that Mittal Steel USAs
positions with respect to the minimum purchase obligation and
the Special Steel Payment are without merit.
We are currently negotiating with Mittal Steel USA in an attempt
to resolve the foregoing disputes. We are also currently
reviewing all of our legal options, including the possible
initiation of an arbitration proceeding under the Weirton
Contract.
Algoma
We have a 15-year term
supply agreement under which we are Algomas sole supplier
of iron ore pellets through 2016. Algoma is Canadas
third-largest steelmaker. We sold 3.8 million tons and
3.3 million tons to Algoma in 2005 and 2004, respectively.
Severstal
On October 23, 2003, Rouge Industries, Inc.
(Rouge), a significant pellet sales customer of
ours, filed for chapter 11 bankruptcy protection. On
January 30, 2004, Rouge sold substantially all of its
assets to Severstal North America, Inc. (Severstal).
Severstal, as part of the acquisition of assets of Rouge,
assumed our term supply agreement with Rouge with minimal
modifications. On January 1, 2006, we entered into an
amended and restated agreement whereby we will be the sole
supplier of iron ore pellets through 2012, with certain minimum
purchase requirements for certain years. We sold
3.6 million tons, 3.3 million tons and
3.0 million tons to Severstal in 2005, 2004 and 2003,
respectively.
WCI
On September 16, 2003, WCI petitioned for protection under
chapter 11 of the U.S. Bankruptcy Code. At the time of
the filing, we had a trade receivable exposure of
$4.9 million, which was fully reserved in the third quarter
of 2003. On October 14, 2004, the Company and the current
owners of WCI reached agreement (the 2004 Pellet
Agreement) for us to supply 1.4 million tons of iron
ore pellets in 2005 and, in 2006 and thereafter, to supply
100 percent of WCIs annual requirements up to a
maximum of two million tons of iron ore pellets. The 2004 Pellet
Agreement is for a ten-year term, which commenced on
January 1, 2005 and provides for full recovery of our
$4.9 million receivable plus $.9 million of subsequent
pricing adjustments. The 2004 Pellet Agreement was approved by
the Bankruptcy Court on November 16, 2004. The receivable
and subsequent pricing adjustments are to be paid in three equal
annual installments of approximately $1.9 million. The
first payment, due on November 16, 2005, was timely
received and classified as Customer bankruptcy recoveries on the
Consolidated Statement of Operations. We sold 1.4 million
tons and 1.7 million tons to WCI in 2005 and 2004,
respectively.
Previously, the Bankruptcy Court denied confirmation of both of
two competing plans of reorganization filed by (i) WCI,
jointly with its current owner (which plan was supported by the
USWA, the union representing WCIs hourly employees, and
(ii) a group of WCIs secured noteholders.
Subsequently, the secured noteholders amended their plan of
reorganization (the New Noteholder Plan) and
obtained the support of the USWA for the New Noteholder Plan.
Under the terms of the New Noteholder Plan, an entity controlled
by the secured noteholders would acquire the steelmaking assets
and business of WCI and assume the 2004 Pellet Agreement,
including the obligation to cure the remaining unpaid
pre-bankruptcy trade receivable owed to the Company by WCI. A
hearing before the Bankruptcy Court on the confirmation of the
New Noteholder Plan is scheduled to commence on March 13,
2006. WCIs current owner and the Pension Benefit Guaranty
Corporation oppose confirmation of the New Noteholder Plan.
50
Stelco
On January 29, 2004, Stelco Inc. (Stelco)
applied and obtained Bankruptcy Court protection from creditors
in Ontario Superior Court under the Companies Creditors
Arrangement Act (CCAA). Pellet sales to Stelco
totaled 1.4 million tons, 1.2 million tons, and
..1 million tons in 2005, 2004 and 2003, respectively.
Stelco is a 44.6 percent participant in Wabush, and
U.S. subsidiaries of Stelco (which have not filed for
bankruptcy protection) own 14.7 percent of Hibbing and
15 percent of Tilden. At the time of the filing, we had no
trade receivable exposure to Stelco. Additionally, Stelco has
continued to operate and has met its cash call requirements at
the mining ventures to date.
Throughout the fall of 2005, Stelco worked to come to agreement
with key stakeholders on a reorganization plan. On
December 9, 2005, the Third Amended and Restated Plan of
Compromise and Arrangement (the Plan) was agreed to.
On December 10, the creditors affected by the Plan (the
Affected Creditors) approved the Plan by
substantially more than the statutorily-mandated minimum
approval levels. On January 20, 2006, on motion by Stelco,
the Honorable Mr. Justice Farley of the Superior Court of
Ontario sanctioned the Plan as being fair and reasonable in all
the circumstances. On February 14, 2006, Justice Farley
issued an order approving the proposed reorganization. Stelco is
now in the process of reorganizing pursuant to the Plan so as to
be in a position to emerge from bankruptcy protection shortly.
The current stay of proceedings against Stelco expires on
March 31, 2006.
The Company, by agreement with Stelco, is not an Affected
Creditor under the Plan. We did not vote on the approval of the
Plan, and our claim against Stelco will not be released when
Stelco emerges from bankruptcy protection. However, the Plan
contemplates that $350 million (Canadian) of new financing
will be invested in Stelco. The investor may require, as a
condition of such financing, that Stelco be reorganized into
limited-partnership operating subsidiaries, one of which would
be a mining subsidiary. Such a reorganization may
affect the nature of the contractual and joint venture
relationship between Stelco and the Company, and may require
changes to those relationships. To date, we have not been
approached by Stelco in this regard, but continue to monitor the
situation closely.
North American Production
Following is a summary of 2005, 2004 and 2003 mine production
and our ownership:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Production (Million Tons) | |
|
|
|
|
| |
|
|
|
|
Companys Share | |
|
Total Production | |
|
|
Companys | |
|
| |
|
| |
Mine |
|
Ownership* | |
|
2005 | |
|
2004 | |
|
2003 | |
|
2005 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
Empire
|
|
|
79.0 |
% |
|
|
3.8 |
|
|
|
4.3 |
|
|
|
4.0 |
|
|
|
4.8 |
|
|
|
5.4 |
|
|
|
5.2 |
|
Tilden
|
|
|
85.0 |
|
|
|
6.7 |
|
|
|
6.6 |
|
|
|
6.0 |
|
|
|
7.9 |
|
|
|
7.8 |
|
|
|
7.0 |
|
Hibbing
|
|
|
23.0 |
|
|
|
2.0 |
|
|
|
1.9 |
|
|
|
1.8 |
|
|
|
8.5 |
|
|
|
8.3 |
|
|
|
8.0 |
|
Northshore
|
|
|
100.0 |
|
|
|
4.9 |
|
|
|
5.0 |
|
|
|
4.8 |
|
|
|
4.9 |
|
|
|
5.0 |
|
|
|
4.8 |
|
United Taconite**
|
|
|
70.0 |
|
|
|
3.4 |
|
|
|
2.9 |
|
|
|
0.1 |
|
|
|
4.9 |
|
|
|
4.1 |
|
|
|
1.6 |
|
Wabush
|
|
|
26.8 |
|
|
|
1.3 |
|
|
|
1.0 |
|
|
|
1.4 |
|
|
|
4.9 |
|
|
|
3.8 |
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Production***
|
|
|
|
|
|
|
22.1 |
|
|
|
21.7 |
|
|
|
18.1 |
|
|
|
35.9 |
|
|
|
34.4 |
|
|
|
30.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
* |
Represents the Companys ownership at December 31,
2005, 2004 and 2003. |
|
** |
1.5 million tons produced during the first five months of
2003 occurred under the management of the previous mine owners
and prior to the acquisition by United Taconite in December 2003. |
|
*** |
Excludes United Taconite production under previous mine
ownership. |
We preliminarily expect total mine production in 2006 to be
approximately 35 million tons; our share of production is
currently estimated to be approximately 22 million tons.
The decrease in 2006 estimated production principally reflects
slightly lower production levels at all mines, except United
Taconite and Wabush, based upon expected customer demand, which
is subject to change. Production costs per ton are
51
expected to increase approximately 15 percent from the 2005
cost of goods sold and operating expenses (excluding freight and
venture partners cost reimbursements) of $42.65 per
ton.
During 2004, we initiated capacity expansion projects at our
United Taconite and Northshore mines in Minnesota. An idled
pellet furnace at United Taconite was restarted in the fourth
quarter of 2004 to add approximately 1.0 million tons (our
share .7 million tons) to annual production capacity. Our
plan to restart an idled furnace to increase capacity by
..8 million tons at our wholly owned Northshore mine in
mid-2005 was deferred until market conditions warrant increased
pellet production.
As a result of a 2004 work stoppage (See Labor Contracts),
Wabush lost approximately 1.7 million tons of production
(our share .5 million tons). Operations resumed on
October 11, 2004.
Australian Production
Portmans production totaled 5.2 million tonnes
(including its .5 million tonne share of the Cockatoo
Island joint venture) since the acquisition. Portmans
current estimate of total year 2006 production is
8.0 million tonnes (.6 million tonnes from Cockatoo
Island). Portman currently has a $61 million project
underway to increase its wholly owned production capacity to
eight million tonnes per year by the end of the first quarter of
2006.
Increased North American Mine Ownership
Effective December 1, 2003, United Taconite purchased the
ore mining and pelletizing assets of Eveleth Mines, LLC. Eveleth
Mines had ceased mining operations in May 2003 after filing for
chapter 11 bankruptcy protection on May 1, 2003. Under
the terms of the purchase agreement, United Taconite purchased
all of Eveleth Mines assets for $3 million in cash
and the assumption of certain liabilities, primarily mine
closure-related environmental obligations. As a result of this
transaction, we, after assigning appropriate values to assets
acquired and liabilities assumed, were required to record an
extraordinary gain of $2.2 million, net of
$.5 million tax and $1.2 million minority interest. In
conjunction with this transaction, the Company and its Wabush
Mines venture partners entered into pellet sales and trade
agreements with Laiwu to optimize shipping efficiency. Sales to
Laiwu under these contracts totaled .3 million tons and
..2 million tons in 2005 and 2004, respectively.
Effective December 31, 2002, we increased our ownership in
Empire from 46.7 percent to 79 percent in exchange for
assumption of all mine liabilities. Under the terms of the
agreement, we indemnified Ispat from obligations of Empire in
exchange for certain future payments to Empire and to us by
Ispat of $120.0 million, recorded at a present value of
$59.8 million at December 31, 2005 ($64.1 million
at December 31, 2004) with $47.8 million classified as
Long-term receivable with the balance current, over
the 12-year life of the
supply agreement. A subsidiary of Mittal Steel USA has retained
a 21 percent ownership in Empire, which it has a unilateral
right to put to us in 2008. We are the sole outside supplier of
pellets purchased under the Ispat agreement, assumed by Mittal
Steel USA, for the term of the supply agreement.
On January 31, 2002, we increased our ownership in Tilden
from 40 percent to 85 percent with the acquisition of
Algomas interest in Tilden for assumption of mine
liabilities associated with the interest. The acquisition
increased our share of the annual production capacity by
3.5 million tons. Concurrently, a term supply agreement was
executed that made us the sole supplier of iron ore pellets
purchased by Algoma for a
15-year period.
52
In July 2002, we acquired (effective retroactive to
January 1, 2002) an eight percent interest in Hibbing from
Bethlehem for the assumption of mine liabilities associated with
the interest. The acquisition increased our ownership of Hibbing
from 15 percent to 23 percent. This transaction
reduced Bethlehems ownership interest in Hibbing to
62.3 percent. In October 2001, Bethlehem filed for
protection under chapter 11 of the U.S. Bankruptcy
Code. At the time of the filing, we had a trade receivable of
approximately $1.0 million, which has been written off. In
May 2003, ISG purchased the assets of Bethlehem, including
Bethlehems 62.3 percent interest in Hibbing.
In August 2002, Acme Steel Company, a wholly-owned subsidiary of
Acme, which had been under chapter 11 bankruptcy protection
since 1998, rejected its 15.1 percent interest in Wabush.
As a result, our interest increased to 26.83 percent. Acme
had discontinued funding its Wabush obligations in August 2001.
Effect of Mine Ownership Increases
While none of the increases in mine ownerships during 2002
required cash payments, the ownership changes resulted in our
recognizing net obligations of approximately $93 million at
December 31, 2002. Additional consolidated obligations
assumed totaled approximately $163 million at
December 31, 2002, primarily related to employment and
legacy obligations at the Empire and Tilden mines, partially
offset by non-capital non-current assets, principally the
$58.8 million Ispat long-term receivable. United
Taconites acquisition of the Eveleth mine assets in
December 2003 was for $3 million cash and assumption of
certain liabilities, primarily mine closure-related
environmental obligations.
Labor Contracts
In August 2004, employees at the Empire and Tilden mines in
Michigan and the Hibbing Taconite and United Taconite mines in
Minnesota, represented by the USWA, ratified four-year labor
agreements that are comparable to other USWA contracts in the
industry. The agreements provide employees a nine percent wage
increase over the four-year term and for us and our partners to
increase funding into pension plans and VEBAs during the term of
the contracts. Accelerated funding of these plans will better
secure employee retiree benefits and reduce our future
years employment legacy costs. The agreements also provide
that employees and future retirees share in healthcare insurance
cost, with our share of future retirees healthcare
premiums capped at 2008 levels for 2009 and beyond. In addition,
the union agreed to certain workforce flexibility provisions and
other work rule modifications that will improve productivity.
On July 5, 2004, the USWA initiated a strike that idled
Wabush mining and concentrating facilities in Labrador,
Newfoundland and pelletizing and shipping facilities in Pointe
Noire, Quebec. As a result of the work stoppage, Wabush lost
approximately 1.7 million tons of production (our share
..5 million tons). On October 10, 2004, a five-year
labor agreement was ratified by the USWA, representing hourly
employees at Wabush. The agreement provides for increases in
wages and benefits that are expected to be partially offset by
improved productivity associated with increased worker
flexibility provisions. Operations resumed on October 11,
2004.
Other Related Items
The iron ore industry has been identified by the United States
Environmental Protection Agency (EPA) as an
industrial category that emits pollutants established by the
1990 Clean Air Act Amendments. These pollutants included over
200 substances that are now classified as hazardous air
pollutants (HAP). The EPA is required to develop
rules that would require major sources of HAP to utilize Maximum
Achievable Control Technology (MACT) standards for
their emissions. Pursuant to this statutory requirement, the EPA
published a final rule on October 30, 2003 imposing
emission limitations and other requirements on taconite iron ore
processing operations. We must comply with the new requirements
not later
53
than October 30, 2006. Our projected capital expenditures
in 2006 to meet the proposed MACT standards are approximately
$4.4 million.
In 2002, we agreed to participate in Phase II of the Mesabi
Nugget Project (Project). Other participants include
Kobe Steel, Ltd., Steel Dynamics, Inc., Ferrometrics, Inc. and
the State of Minnesota. Construction of a $16 million pilot
plant at our Northshore mine, to test and develop Kobe
Steels technology for converting iron ore into nearly pure
iron in nugget form, was completed in May 2003. The
high-iron-content product could be utilized to replace steel
scrap as a raw material for electric steel furnaces and blast
furnaces or basic oxygen furnaces of integrated steel producers
or as feedstock for the foundry industry. A third operating
phase of the pilot plant test in 2004 confirmed the commercial
viability of this technology. The pilot plant ended operations
August 3, 2004. The product was used by four electric
furnace producers and one foundry with favorable results.
Preliminary construction engineering and environmental
permitting activities have been initiated for two potential
commercial plant locations (one in Butler, Indiana near Steel
Dynamics steelmaking facilities and one at our Cliffs Erie
site in Hoyt Lakes, Minnesota). A non-binding term sheet for a
commercial plant was executed in March 2005, and a decision to
proceed with construction engineering was made in April. On
July 26, 2005, the Minnesota Pollution Control Agency
Citizens Board unanimously approved environmental
permitting for the Cliffs Erie site. We would be the supplier of
iron ore and have a minority interest in the first commercial
plant. Our contribution to the project to-date has totaled
$6.3 million ($1.0 million in 2005), including
significant contributions of in-kind facilities and services. In
January 2006, our board of directors authorized $50 million
in capital expenditures for the project, subject to the Project
obtaining non-recourse financing for its capital requirements in
excess of equity investments made by the Project participants
and the Project participants reaching mutually agreed upon
terms. Our equity interest in the venture is expected to be
approximately 23 percent. Included in our boards
authorization is $21 million for construction and operation
of the commercial nugget plant, $25 million to expand the
Northshore concentrator to provide the iron ore concentrate, and
$4.4 million for railroad improvements to transport the
concentrate. Negotiations are continuing.
On February 16, 2004, we entered into an option agreement
with PolyMet that granted PolyMet the exclusive right to acquire
certain land, crushing and concentrating and other ancillary
facilities located at our Cliffs Erie site (formerly owned by
LTV Steel Mining Company (LTVSMC)). The iron ore
mining and pelletizing operations were permanently closed in
January 2001.
PolyMet is a non-ferrous mining company located in Vancouver,
B.C. Canada. Its stock trades Over-The-Counter in the
U.S. under the symbol POMGF.OB.
Under terms of the agreement, we received $.5 million and
one million shares of PolyMet for maintaining certain identified
components of the facility, while PolyMet conducted a
feasibility study on the development of its Northmet
PolyMetallic non-ferrous ore deposits located near the Cliffs
Erie site. PolyMet had until June 30, 2006 to exercise its
option and acquire the assets covered under the agreement for
additional consideration. We recorded the $.5 million
option payment and one million common shares (valued at
approximately $.2 million on the agreement date) under the
deposit method and deferred recognition of the gain. We
classified the PolyMet shares as available for sale and recorded
mark-to-market changes
in the value of the shares to other comprehensive income.
On November 15, 2005, we reached an agreement with PolyMet
regarding the terms for the early exercise of PolyMets
option to acquire the assets under the agreement and closed the
sales transaction resulting in a $9.5 million pre-tax gain.
Under the terms of the agreement, we received cash of
$1.0 million and approximately 6.2 million common
shares of PolyMet, which closed that day at $1.25 per
share. The additional PolyMet shares received in this
transaction are classified as available for sale in Other
Assets. We intend to hold our shares of PolyMet indefinitely. We
expect to receive additional cash proceeds of $2.4 million
in quarterly installments by and according to the terms of the
contract for deed executed by the
54
parties. As a final component of the purchase price, PolyMet
will assume certain on-going site-related environmental and
reclamation obligations.
Wisconsin Electric Power Company Dispute
Two of our mines, Tilden and Empire (the Mines),
currently purchase their electric power from WEPCO pursuant to
the terms of special contracts specifying prices based on WEPCO
actual costs. Effective April 1, 2005, WEPCO
unilaterally changed its method of calculating the energy
charges to the Mines. It is the Mines contention that
WEPCOs new billing methodology is inconsistent with the
terms of the parties contracts and a dispute has arisen
between WEPCO and the Mines over the pricing issue. Pursuant to
the terms of the relevant contracts, the undisputed amounts are
being paid to WEPCO, while the disputed amounts are being
deposited into an interest-bearing escrow account maintained by
a bank. The dispute has been submitted to binding arbitration
under the terms of the contracts. For the period ending
December 31, 2005, the Mines have deposited
$75.8 million into an escrow account of which
$5.3 million was deposited in January 2006. An amount of
$73.0 million, of which $61.3 million was included in
the escrow deposits and $11.7 million has been paid to
WEPCO, will be recovered in early 2006; however, we have been
advised by WEPCO that they will oppose any release of these
recoverable amounts from the escrow until completion of the
arbitration. Additionally, WEPCO is disputing whether we have
complied with the notification provisions related to
Tildens annual pellet production in excess of seven
million tons.
Strategic Investments
We intend to continue to pursue investment and operations
management opportunities to broaden our scope as a supplier of
iron ore and other raw materials to the integrated steel
industry through the acquisition of additional mining interests
to strengthen our market position. We are particularly focused
on expanding our international investments to capitalize on
global demand for steel and iron ore. Our innovative United
Taconite joint venture with Laiwu Steel Group, Ltd. and our
Portman acquisition are examples of our ability to expand
geographically, and we intend to continue to pursue similar
opportunities in other regions. In the event of any future
acquisitions or joint venture opportunities, we may consider
using available liquidity or other sources of funding to make
investments.
Portman Acquisition
On April 19, 2005, Cliffs Australia completed the
acquisition of 80.4 percent of the outstanding shares of
Portman, a Western Australia-based independent iron ore mining
and exploration company. The acquisition was initiated on
March 31, 2005 by the purchase of approximately
68.7 percent of the outstanding shares of Portman. The
assets consist primarily of iron ore inventory, land, mineral
rights and iron ore reserves. The purchase price of the
80.4 percent interest was $433.1 million, including
$12.4 million of acquisition costs. Additionally, we
incurred $9.8 million of foreign currency hedging costs
related to this transaction, which were charged to first-quarter
2005 operations. The acquisition increased our customer base in
China and Japan and established our presence in the Australian
mining industry. Portmans full-year 2005 production
(excluding its .6 million tonne share of the
50 percent-owned Cockatoo Island joint venture) was
approximately 6.0 million tonnes. Portman currently has a
$61 million project underway that is expected to increase
its wholly owned production capacity to eight million tonnes per
year by the end of the first quarter of 2006. The production is
fully committed to steel companies in China and Japan for
approximately four years. Portmans reserves total
approximately 89 million tonnes at December 31, 2005,
and it has an active exploration program underway to increase
its reserves.
The acquisition and related costs were financed with existing
cash and marketable securities and $175 million of interim
borrowings under a new three-year $350 million revolving
credit facility. The outstanding balance was repaid in full on
July 5, 2005. See NOTE 7 Credit facilities.
The statement of consolidated financial position of the Company
as of December 31, 2005 reflects the acquisition of
Portman, effective March 31, 2005, under the purchase
method of accounting. Assets acquired
55
and liabilities assumed have been recorded at estimated fair
values as of the March 31, 2005 initial acquisition date as
determined by preliminary results of an appraisal, which is
substantially complete.
We continue to refine our purchase accounting to reflect a
preliminary allocation developed with the assistance of an
outside consultant. The current allocation increased
Portmans iron ore inventory values by $49.1 million
to reflect a market-based valuation. Of the $49.1 million
inventory basis adjustment, $23.1 million was allocated to
product and work in process inventories, of which approximately
$19.9 million has been included in cost of goods sold
through December 31, 2005. Most of the $3.2 million
remaining inventory basis adjustment is expected to be expensed
prior to the end of 2006. Additionally, a long-term lease was
classified as a capital lease resulting in an increase in
property, plant and equipment, and capital lease obligations, of
$26.7 million. The valuation also resulted in assignment of
goodwill, $8.8 million, and a $20.2 million increase
in the value of our 50 percent interest in Cockatoo Island.
The increase in value of Cockatoo Island was based upon a
discounted cash flow analysis over the remaining two-year life
of its iron ore reserves. These changes reduced the value
assigned to Portmans iron ore reserves by
$90.8 million. Such amounts are subject to adjustment based
on the finalization of the valuations and appraisals prior to
March 31, 2006. Accordingly, the revised preliminary
purchase price is subject to further revision. A comparison of
the revised purchase price allocation to the initial allocation
is as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
| |
|
|
Revised | |
|
Initial | |
|
|
|
|
Allocation | |
|
Allocation | |
|
Change | |
|
|
| |
|
| |
|
| |
ASSETS
|
|
|
|
|
|
|
|
|
|
|
|
|
Current Assets
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash
|
|
$ |
24.1 |
|
|
$ |
24.1 |
|
|
$ |
|
|
|
Iron Ore Inventory
|
|
|
54.8 |
|
|
|
29.0 |
|
|
|
25.8 |
|
|
Other
|
|
|
35.3 |
|
|
|
35.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Current Assets
|
|
|
114.2 |
|
|
|
88.4 |
|
|
|
25.8 |
|
Property, Plant and Equipment
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Iron Ore Reserves
|
|
|
413.5 |
|
|
|
504.3 |
|
|
|
(90.8 |
) |
|
Other
|
|
|
69.1 |
|
|
|
34.7 |
|
|
|
34.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Property Plant and Equipment
|
|
|
482.6 |
|
|
|
539.0 |
|
|
|
(56.4 |
) |
Long-term Stockpiles
|
|
|
38.7 |
|
|
|
15.4 |
|
|
|
23.3 |
|
Investment in Cockatoo Island
|
|
|
24.8 |
|
|
|
4.6 |
|
|
|
20.2 |
|
Other Assets
|
|
|
5.8 |
|
|
|
6.7 |
|
|
|
(.9 |
) |
Goodwill
|
|
|
8.8 |
|
|
|
|
|
|
|
8.8 |
|
|
|
|
|
|
|
|
|
|
|
Total Assets
|
|
$ |
674.9 |
|
|
$ |
654.1 |
|
|
$ |
20.8 |
|
|
|
|
|
|
|
|
|
|
|
|
LIABILITIES
|
|
|
|
|
|
|
|
|
|
|
|
|
Current Liabilities
|
|
$ |
35.8 |
|
|
$ |
34.7 |
|
|
$ |
1.1 |
|
Long-Term Liabilities
|
|
|
178.8 |
|
|
|
158.1 |
|
|
|
20.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Liabilities
|
|
|
214.6 |
|
|
|
192.8 |
|
|
|
21.8 |
|
|
|
|
|
|
|
|
|
|
|
Net Assets
|
|
|
460.3 |
|
|
|
461.3 |
|
|
|
(1.0 |
) |
Minority Interest
|
|
|
(27.2 |
) |
|
|
(27.5 |
) |
|
|
.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Purchase Price
|
|
$ |
433.1 |
|
|
$ |
433.8 |
|
|
$ |
(.7 |
) |
|
|
|
|
|
|
|
|
|
|
Environmental and Closure Obligations
At December 31, 2005, we had environmental and closure
obligations, including our share of the obligations of ventures,
of $113.0 million ($99.0 million at December 31,
2004), of which $13.4 million is
56
current. Payments in 2005 were $5.6 million
($6.4 million in 2004). The obligations at
December 31, 2005 include certain responsibilities for
environmental remediation sites, $17.8 million, closure of
LTVSMC, $30.4 million, and obligations for closure of our
six North American operating mines, $59.3 million, and
$5.5 million for Portman.
The LTVSMC closure obligation resulted from an October 2001
transaction where our subsidiaries received a net payment of
$50 million and certain other assets and assumed
environmental and certain facility closure obligations of
$50.0 million, which obligations have declined to
$30.4 million at December 31, 2005, as a result of
expenditures totaling $19.6 million since 2001.
In September 2002, we received a draft of a proposed
Administrative Order by Consent from the EPA, for
clean-up and
reimbursement of costs associated with the Milwaukee Solvay coke
plant site in Milwaukee, Wisconsin. The plant was operated by a
predecessor of the Company from 1973 to 1983, which predecessor
was acquired by the Company in 1986. In January 2003, we
completed the sale of the plant site and property to a third
party. Following this sale, an Administrative Order by Consent
(Consent Order) was entered into with the EPA by the
Company, the new owner and another third party who had operated
on the site. In connection with the Consent Order, the new owner
agreed to take responsibility for the removal action and agreed
to indemnify us for all costs and expenses in connection with
the removal action. In the third quarter of 2003, the new owner,
after completing a portion of the removal, experienced financial
difficulties. In an effort to continue progress on the removal
action, we expended approximately $1.8 million in the
second half of 2003, $2.1 million in 2004 and
$.4 million in 2005. In September 2005, we received a
notice of completion from the EPA documenting that all work has
been fully performed in accordance with the Consent Order.
On August 26, 2004, we received a Request for Information
pursuant to Section 104(e) of the Comprehensive
Environmental Response, Compensation and Liability Act
(CERCLA) relative to the investigation of additional
contamination below the ground surface at the Milwaukee Solvay
site. The Request for Information was also sent to 13 other
potentially responsible parties (PRPs). On
July 14, 2005, we received a General Notice Letter from the
EPA notifying us that the EPA believes we may be liable under
CERCLA and requesting that we, along with other PRPs,
voluntarily perform
clean-up activities at
the site. We have responded to the General Notice Letter
indicating that there had been no communications with other PRPs
but also indicating our willingness to begin the process of
negotiation with the EPA and other interested parties regarding
a Consent Order. Subsequently, on July 26, 2005, we
received correspondence from the EPA with a proposed Consent
Order and informing us that three other PRPs had also expressed
interest in negotiating with the EPA. At this time, the nature
and extent of the contamination, the required remediation, the
total cost of the
clean-up and the
cost-sharing responsibilities of the PRPs cannot be determined,
although the EPA has advised us that it has incurred
$.5 million in past response costs, which the EPA will seek
to recover from us and the other PRPs. We increased our
environmental reserve for Milwaukee Solvay by $.5 million
in 2005 for potential additional exposure.
On December 23, 2005, we entered into a letter of intent
with Kinnickinnic Development Group LLC (KK Group)
pursuant to which the KK Group would acquire and redevelop the
Milwaukee Solvay Site. Under the terms of the letter of intent,
KK Group would acquire our mortgage on the site in consideration
for the assumption of all our environmental obligations with
respect to the site and a cash payment of approximately
$2.3 million. In addition, KK Group would be required to
deposit $4 million into an escrow account to fund any
remaining environmental
clean-up activities on
the site and to purchase insurance coverage with a
$5 million limit. We are currently drafting definitive
agreements documenting this agreement. Closing of the
transaction would occur within 61 days of signing
definitive agreements.
The Rio Tinto Mine Site is a historic underground copper mine
located near Mountain City, NV, where tailings were placed in
Mill Creek, a tributary to the Owyhee River. Remediation work is
being conducted in accordance with a Consent Order between the
Nevada Department of Environmental
Protection (NDEP)
57
and the Rio Tinto Working Group (RTWG) composed of
the Company, Atlantic Richfield Company, Teck Cominco American
Incorporated, and E. I. du Pont de Nemours and Company. The
Consent Order provides for technical review by the
U.S. Department of the Interior Bureau of Indian Affairs,
the U.S. Fish & Wildlife Service,
U.S. Department of Agriculture Forest Service, the NDEP and
the Shoshone-Paiute Tribes of the Duck Valley Reservation
(collectively, Rio Tinto Trustees) located
downstream on the Owyhee River. The Consent Order is currently
projected to continue through 2006 with the objective of
supporting the selection of the final remedy for the Site. Costs
are shared pursuant to the terms of a Participation Agreement
between the parties of the RTWG, who have reserved the right to
renegotiate any future participation or cost sharing following
the completion of the Consent Order.
The Rio Tinto Trustees have made available for public comment
their plans for the assessment of Natural Resource Damages
(NRD). The RTWG commented on the plans and also are
in discussions with the Rio Tinto Trustees informally about
those plans. The notice of plan availability is a step in the
damage assessment process. The studies presented in the plan may
lead to a NRD claim under CERCLA. There is no monetized NRD
claim at this time.
During 2005, the focus of the RTWG has been on development of
alternatives for remediation of the mine site. A draft of an
alternatives study has recently been reviewed with the Rio Tinto
Trustees and the alternatives have essentially been reduced to
three: (1) no action; (2) long-term water treatment,
and (3) removal of the tailings. The estimated costs range
from approximately $1 million to $27 million. In
recognition of the potential for an NRD claim, the parties are
exploring the possibility of a global settlement that would
encompass both the site decision and the NRD issues and thereby
avoid the lengthy litigation typically associated with NRD. The
Companys recorded reserve of approximately
$1.2 million reflects its estimated costs for completion of
the existing Consent Order and the minimum no action
alternative based on the current Participation Agreement.
|
|
|
Northshore Notice of Violation |
On February 10, 2006, our Northshore mine received a Notice
of Violation (Notice) from the EPA. The Notice cites
four alleged violations: (1) that Northshore violated the
Prevention of Significant Deterioration (PSD)
requirements of the Clean Air Act in the 1990 restart of
Furnaces 11 and 12; (2) that Northshore mine violated the
PSD Regulations in the 1995 restart of Furnace 6;
(3) Title V operating permit violations for not
including in the Title V permit all applicable requirements
(including a compliance schedule for PSD and Best Available
Control Technology (BACT) requirements associated
with the furnace restarts); and (4) failure to comply with
calibration of monitoring equipment as required under
Northshores Title V permit. The alleged violations
relating to the restart of Furnaces 11 and 12 occurred prior to
our acquisition of Northshore (formerly Cyprus Northshore Mining
Company) in a share purchase in 1994. We are currently
investigating the allegations contained in the Notice.
Market Risk
We are subject to a variety of market risks, including those
caused by changes in market value of equity investments,
commodity prices, foreign currency exchange rates and interest
rates. We have established policies and procedures to manage
risks; however, certain risks are beyond our control.
Our investment policy relating to cash and cash equivalents is
to preserve principal and liquidity while maximizing the return
through investment of available funds. The carrying value of
these investments approximates fair value on the reporting dates.
We hold investments in highly liquid auction rate securities
(ARS) in order to generate higher than typical money
market investments. ARS typically are high credit quality,
generally achieved with municipal bond insurance. Credit risks
are eased by the historical track record of bond insurers, which
back a majority of this market. Although rare, sell orders for
any security traded through a Dutch auction process could exceed
bids. Such instances are usually the result of a drastic
deterioration of issuer credit quality. Should there be a failed
auction, we may be unable to liquidate our position in the
securities in the near term.
58
The rising cost of energy is an important issue for us as it
comprises approximately 27 percent of our North American
production costs. Our North American mining ventures consumed
approximately 13.6 million mmbtus (million
btus) of natural gas and 26.5 million gallons of
diesel fuel (Company share 9.6 million mmbtus and
16.6 million gallons of diesel fuel) in 2005. In 2005, the
average price paid by the North American mining ventures was
$8.00 per mmbtu for natural gas and $1.95 per gallon
for diesel fuel. Recent trends indicate that electric power,
natural gas and oil costs can be expected to increase over time,
although the direction and magnitude of short-term changes are
difficult to predict. Our strategy to address increasing energy
rates includes improving efficiency in energy usage and
utilizing the lowest cost alternative fuel. We also use forward
purchases of natural gas and diesel fuel to stabilize
fluctuations in near-term prices. For 2006, we purchased or have
forward purchase contracts for 7.8 million mmbtus of
natural gas at an average price of $9.86 per mmbtu and
3.2 million gallons of diesel fuel at $2.05 per gallon
for our North American mining ventures.
Our mining ventures enter into forward contracts for certain
commodities, primarily natural gas and diesel fuel, as a hedge
against price volatility. Such contracts, which are in
quantities expected to be delivered and used in the production
process, are a means to limit exposure to price fluctuations. At
December 31, 2005, the notional amounts of the outstanding
forward contracts were $28.6 million (our share
$24.7 million), with an unrecognized fair value loss of
$5.2 million (our share $4.4 million)
based on December 31, 2005 forward rates. The contracts
mature at various times through December 2006. If the forward
rates were to change 10 percent from the year-end
rate, the value and potential cash flow effect on the contracts
would be approximately $2.0 million (our share
$1.7 million).
Our share of Wabush Mines operation in Canada represented
approximately six percent of our North American pellet
production. This operation is subject to currency exchange
fluctuations between the U.S. and Canadian dollars; however, we
do not hedge our exposure to this currency exchange fluctuation.
Between 2003 and 2005, the value of the Canadian dollar rose
against the U.S. dollar from $.64 U.S. dollar per
Canadian dollar at the beginning of 2003 to $.86
U.S. dollars per Canadian dollar at December 31, 2005,
an increase of 34 percent. The average exchange rate
increased to $.83 U.S. dollar per Canadian dollar in 2005
from an average of $.77 U.S. dollar per Canadian dollar for
2004, an increase of eight percent. We do not believe that the
recent increase in the U.S./ Canadian exchange rate is a trend
that will continue in the long-term; however, short-term
fluctuations cannot reasonably be predicted.
We are subject to changes in foreign currency exchange rates in
Australia as a result of our operations at Portman, which could
impact our financial condition. Foreign exchange risk arises
from our exposure to fluctuations in foreign currency exchange
rates because our reporting currency is the United States
dollar. We do not hedge our exposure to this currency exchange
fluctuation. A 10 percent movement in quoted foreign
currency exchange rates could result in a fair value change of
approximately $44 million in our net investment.
Portman hedges a portion of its United States
currency-denominated sales in accordance with a formal policy.
The primary objective for using derivative financial instruments
is to reduce the earnings volatility attributable to changes in
Australian and United States currency fluctuations. The
instruments are subject to formal documentation, intended to
achieve qualifying hedge treatment, and are tested at inception
and at each reporting period as to effectiveness. Changes in
fair value for highly effective hedges are recorded as a
component of other comprehensive income. Ineffective portions
are charged to operations. At December 31, 2005, Portman
had outstanding A$370.1 million in the form of call
options, collars, convertible collars and forward exchange
contracts with varying maturity dates ranging from January 2006
to October 2008, and a fair value loss based on the
December 31, 2005 exchange rate of A$.9 million. A one
percent increase in rates from the month-end rate would increase
the fair value and cash flow by approximately A$2.0 million
and a one percent decrease would decrease the fair value and
cash flow by approximately A$3.6 million.
Outlook
Although production schedules are subject to change, most
operations are expected to operate at or near capacity in 2006
and total North American pellet production is expected to be
approximately 35 million tons with our share representing
approximately 21 million tons.
59
Our 2006 North American sales volume is projected to be
approximately 21 million tons, compared with
22.3 million tons in 2005. Revenue per ton from iron ore
sales and services is dependent upon several price adjustment
factors included in our term sales contracts, primarily the
percentage change from 2005 to 2006 in the international pellet
price for blast furnace pellets, PPI and actual revenue for
steel sales for one of our customers.
Following is the estimated impact to our average North American
revenue per ton from iron ore sales and services (excluding
freight and venture partners cost reimbursements) based on
2005 realization of $58.77 per ton:
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|
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|
|
|
|
|
|
|
|
|
2006 Revenue Effect | |
|
|
(Change from 2005) | |
|
|
| |
|
|
|
|
Price Per | |
|
|
Percent | |
|
Ton | |
|
|
| |
|
| |
Potential Increase (Decrease):
|
|
|
|
|
|
|
|
|
|
Each 10 Percent Change in International Pellet Price
|
|
|
3.5 |
% |
|
$ |
2.05 |
|
|
Each 10 Percent Change in PPI Industrial
Commodities less Fuel
|
|
|
2.1 |
|
|
|
1.25 |
|
|
Each 10 Percent Change in PPI Fuel and Related
Products
|
|
|
1.1 |
|
|
|
.64 |
|
|
Each $10 Per Ton Change from $520 Per Ton
|
|
|
|
|
|
|
|
|
|
|
Average Hot Rolled Coil Price Realization*
|
|
|
.5 |
|
|
|
.29 |
|
Known Year-Over-Year Increase**
|
|
|
5.6 |
|
|
|
3.28 |
|
|
|
|
|
* |
Valid for decreases through $400 per ton; no upper limit. |
|
|
** |
Increase represents a combination of contractual base price
increase, lag year adjustments and capped pricing on one
contract. |
Portmans estimate of 2006 sales is 7.9 million
tonnes. Portmans estimate of 2006 production is
8.0 million tonnes, including .6 million from Cockatoo
Island.
North American production costs per ton are expected to increase
approximately 15 percent from the 2005 cost of goods sold
and operating expenses (excluding freight and venture
partners cost reimbursements) of $42.65 per ton.
As we look forward to 2006, we are concerned about the rising
costs of much of our purchased energy and materials. While PPI
escalation factors in our North American sales contracts will
recover some of the expected inflation, we will need continued
levels of solid steel pricing and an improved international iron
ore price in order to maintain our sales margins.
Critical Accounting Policies
Managements discussion and analysis of financial condition
and results of operations is based on our consolidated financial
statements, which have been prepared in accordance with
accounting principles generally accepted in the United States
(GAAP). Preparation of financial statements requires
management to make assumptions, estimates and judgments that
affect the reported amounts of assets, liabilities, revenues,
costs and expenses, and the related disclosures of
contingencies. Management bases its estimates on various
assumptions and historical experience, which are believed to be
reasonable; however, due to the inherent nature of estimates,
actual results may differ significantly due to changed
conditions or assumptions. On a regular basis, management
reviews the accounting policies, assumptions, estimates and
judgments to ensure that our financial statements are fairly
presented in accordance with GAAP. However, because future
events and their effects cannot be determined with certainty,
actual results could differ from our assumptions and estimates,
and such differences could be material. Management believes that
the following critical accounting estimates and judgments have a
significant impact on the Companys financial statements.
60
See Accounting Policies in Item 8, Financial
Statements and Supplementary Data, for a complete discussion of
our revenue recognition policy.
Most of our term supply agreements contain provisions for annual
pricing adjustments. These provisions vary from agreement to
agreement but typically include adjustments based upon changes
in specified PPI including those for all commodities, industrial
commodities, energy and steel, as well as changes in
international pellet prices. For example, one of our term supply
agreements contains a price adjustment provision that is based
on changes in the world pellet price, as well as the PPI for all
commodities and for steel. Each component constitutes one-third
of the price adjustment. Other term supply agreements contain
different adjustment factors, such as the PPI for fuel and
related products, the Eastern Canadian Pellet Prices and steel
prices. The adjustments generally operate in the same manner,
with each factor typically comprising a portion of the price
adjustment, although the weighting of each factor differs from
agreement to agreement. One of our term supply agreements
contains price collars, which typically limit the percentage
increase or decrease in prices for our iron ore pellets during
any one year. In most cases, these adjustment factors have not
been finalized at the time our product is sold; we routinely
estimate these adjustment factors for purposes of revenue
recognition. Certain supply agreements with one customer include
provisions for supplemental revenue or refunds based on the
customers annual steel pricing at the time the product is
consumed in the customers blast furnaces. We estimate
these amounts for recognition at the time of sale. Our 2005
revenues included $9.0 million of supplemental revenue on
2005 sales based on estimates of the customers 2006 steel
pricing.
Estimated supplemental payments, totaling $9.2 million,
related to sales to one of the customers indefinitely
idled facilities, have not been included in revenue. The pellets
sold to this facility in 2005 have not been consumed and no
definitive timetable for consumption or other disposition of
these pellets has been determined.
Our rationale for shipping North American iron ore products to
some customers in advance of payment for the products is to more
closely relate timing of payment by customers to consumption,
which also provides additional liquidity to our customers.
Generally, our North American term supply agreements specify
that title and risk of loss pass to the customer when payment
for the pellets is received. This is a revenue recognition
practice utilized to reduce our financial risk to customer
insolvency. This practice is not believed to be widely used
throughout the balance of the industry.
Revenue is recognized on services when the services are
performed.
Where we are joint venture participants in the ownership of a
North American mine, our contracts entitle us to receive
royalties and management fees, which we earn as the pellets are
produced.
Portmans sales revenue is recognized at the F.O.B. point,
which is generally when the product is loaded into the vessel.
Foreign currency revenues are converted to Australian dollars at
the currency exchange rate in effect at the time of the
transaction.
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|
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Self-Insurance/Deductible Reserves |
We are largely self-insured with respect to employee
non-occupational medical claims, and maintain workers
compensation and general liability insurance programs where we
retain an obligation for a portion of the claims through
self-insured retentions or deductibles. We maintain an accrual
for the estimated cost to settle open claims as well as incurred
but not reported claims. These estimates take into consideration
valuations provided by third-party actuaries and administrators,
historical claims experience and current trends in claim costs,
applicable deductible or retention levels under insured
programs, changes in our business and workforce, and general
economic factors and other assumptions that are reasonable to
the circumstances. The estimated accruals for these liabilities
could be affected if future occurrences and claims differ from
assumptions used and historical trends. These accruals are
reviewed on a quarterly basis, or more frequently if factors
dictate a more frequent review is warranted.
61
We are subject to proceedings, lawsuits and other claims. We are
required to assess the likelihood of any adverse judgments or
outcomes to these matters as well as the potential ranges of
probable losses. A determination of the amount of accrual
required, if any, for these contingencies is made after careful
analysis of each matter. The required accrual may change in the
future due to new developments in each matter or changes in
approach, such as a change in settlement strategy in dealing
with these matters. We do not believe that any such matter will
have a material adverse effect on our financial condition or
results of operations.
Domestic and foreign tax authorities periodically audit our
income tax returns. These audits include questions regarding our
tax-filing positions, including the timing and amount of
deductions and allocation of income among various tax
jurisdictions. At any time, multiple tax years are subject to
audit by the various tax authorities. In evaluating the
exposures associated with our various tax-filing positions, we
record reserves for exposures on a probable basis. A number of
years may elapse before a particular matter, for which we have
established a reserve, is audited and fully resolved. When the
actual results of a settlement with tax authorities differs from
our established reserve for a matter, we adjust our tax
contingencies reserve and income tax provision in the period in
which the income tax matter is resolved.
We regularly evaluate our economic iron ore reserves and update
them as required in accordance with SEC Industry Guide 7. The
estimated ore reserves could be affected by future industry
conditions, geological conditions and ongoing mine planning.
Maintenance of effective production capacity or the ore reserve
could require increases in capital and development expenditures.
Generally as mining operations progress, haul lengths and lifts
increase. Alternatively, changes in economic conditions, or the
expected quality of ore reserves could decrease capacity or ore
reserves. Technological progress could alleviate such factors,
or increase capacity or ore reserves. Based on revised economic
mine-planning studies, we reduced the estimates of the ore
reserves at the Empire mine from 116 million tons at
December 31, 2001 to 63 million tons at
December 31, 2002 and further to 29 million tons at
December 31, 2003. There was no change in 2004 except for
production of 5.4 million tons, but in 2005, the estimated
ore reserves were decreased to approximately 17 million
tons. The 2005 reduction was due to production of
4.8 million tons and 2.0 million tons for the
elimination of the remaining reserve in the
CD-II deposit because
these ores were found to be too difficult to process and had
high incremental costs.
We also completed revised economic mine planning studies in the
fourth quarter of 2002 for Wabush, and reduced the estimate of
ore reserves at Wabush from 244 million tons to
94 million tons due to increasing mining and processing
costs. Based on an update to those studies completed in the
fourth quarter of 2003, we further significantly reduced the
Wabush mine ore reserve estimate to 61 million tons. Our
reserves at Wabush were approximately 51 million tons at
December 31, 2005, with the reduction since 2003 primarily
attributable to production and increased operating costs. The
revised Wabush estimate is largely a reflection of increased
operating costs, especially due to dewatering, and the impact of
currency exchange rate changes.
We use our ore reserve estimates to determine the mine closure
dates utilized in recording the fair value liability for asset
retirement obligations. See Note 6
Environmental and Mine Closure Obligations Mine
Closure in the Notes to Consolidated Financial Statements. Since
the liability represents the present value of the expected
future obligation, a significant change in ore reserves would
have a substantial effect on the recorded obligation. We also
utilize economic ore reserves for evaluating potential
impairments of mine assets and in determining maximum useful
lives utilized to calculate depreciation and amortization of
long-lived mine assets. Decreases in ore reserves could
significantly affect these items.
|
|
|
Asset Retirement Obligations |
The accrued mine closure obligations for our active mining
operations reflect the adoption of SFAS No. 143,
Accounting for Asset Retirement Obligations,
effective January 1, 2002 to provide for
62
contractual and legal obligations associated with the eventual
closure of the mining operations. Our obligations are determined
based on detailed estimates adjusted for factors that an outside
party would consider (i.e., inflation, overhead and profit),
which were escalated (at an assumed three percent) to the
estimated closure dates, and then discounted using a
credit-adjusted risk-free interest rate of 10.25 percent
(12.0 percent for United Taconite and 5.5 percent for
Portman). The estimates at December 31, 2005 were revised
using a three percent escalation factor and a six percent
credit-adjusted risk-free discount rate for the incremental
increases in the closure cost estimates. The closure date for
each location was determined based on the exhaustion date of the
remaining iron ore reserves. The estimated obligations are
particularly sensitive to the impact of changes in mine lives
given the difference between the inflation and discount rates.
Changes in the base estimates of legal and contractual closure
costs due to changed legal or contractual requirements,
available technology, inflation, overhead or profit rates would
also have a significant impact on the recorded obligations. See
Note 6 Environmental and Mine Closure
Obligations Mine Closure in the Notes to
Consolidated Financial Statements.
We monitor conditions that indicate that the carrying value of
an asset or asset group may be impaired. We determine impairment
based on the assets ability to generate cash flow greater
than its carrying value, utilizing an undiscounted
probability-weighted analysis. If the analysis indicates the
asset is impaired, the carrying value is adjusted to fair value.
Fair value can be determined by market value and also comparable
sales transactions or using a discounted cash flow method. The
impairment analysis and fair value determination can result in
significantly different outcomes based on critical assumptions
and estimates including the quantity and quality of remaining
economic ore reserves, and future iron ore prices and production
costs. See Note 1 Operations and
Customers Empire Mine and Wabush Mines and
Note 4 Discontinued Operation in the Notes to
Consolidated Financial Statements.
|
|
|
Environmental Remediation Costs |
We have a formal code of environmental protection and
restoration. Our obligations for known environmental problems at
active and closed mining operations and other sites have been
recognized based on estimates of the cost of investigation and
remediation at each site. If the estimate can only be estimated
as a range of possible amounts, with no specific amount being
most likely, the minimum of the range is accrued. Management
reviews its environmental remediation sites quarterly to
determine if additional cost adjustments or disclosures are
required. The characteristics of environmental remediation
obligations, where information concerning the nature and extent
of clean-up activities
is not immediately available, or changes in regulatory
requirements, result in a significant risk of increase to the
obligations as they mature. Expected future expenditures are not
discounted to present value. Potential insurance recoveries are
not recognized until realized.
|
|
|
Employee Retirement Benefit Obligations |
The Company and its mining ventures sponsor defined benefit
pension plans covering substantially all employees. These plans
are largely noncontributory, and except for U.S. salaried
employees, benefits are generally based on employees years
of service and average earnings for a defined period prior to
retirement.
Additionally, the Company and its ventures provide
postretirement medical and life insurance benefits
(OPEBs) to most full-time employees who meet certain
length-of-service and
age requirements. Our pension and medical costs (including OPEB)
have increased substantially over the past several years. Lower
interest rates, lower asset returns and continued escalation of
medical costs have been the predominant causes of the increases.
We have taken actions to control pension and medical costs.
Effective July 1, 2003, we implemented changes to
U.S. salaried employee plans to reduce costs by more than
an estimated $8.0 million on an annualized basis. Benefits
under the current defined benefit formula were frozen for
affected U.S. salaried employees and a new cash balance
formula was instituted. Increases in affected U.S. salaried
retiree healthcare co-pays became effective for retirements
after June 30, 2003. A cap on our share of annual
63
medical premiums was also implemented for existing and future
U.S. salaried retirees. Pursuant to the four-year
U.S. labor agreements reached with the USWA, effective
August 1, 2004, OPEB expense for 2004 and the accumulated
postretirement benefit obligation (APBO) decreased
$4.9 million and $48.0 million, respectively, to
reflect negotiated plan changes, which capped our share of
future bargaining unit retirees healthcare premiums at
2008 levels for the years 2009 and beyond. OPEB expense
decreased $10.6 million in 2005 as a result of the
agreement. The new agreements also provide that the Company and
its partners fund an estimated $220 million into bargaining
unit pension plans and VEBAs during the term of the contracts.
On December 8, 2003, Congress passed the Medicare
Prescription Drug, Improvement and Modernization Act of 2003
(Medicare Act). In May 2004, FASB issued Staff
Position No. 106-2
(FSP 106-2),
Accounting and Disclosure Requirements Related to the
Medicare Prescription Drug, Improvement and Modernization Act of
2003, which supersedes
FSP 106-1.
FSP 106-2 provides
guidance on the accounting for the effects of the Medicare Act
for employers that sponsor postretirement health care plans that
provide prescription drug benefits and requires certain
disclosures regarding the effect of the subsidy provided by the
Medicare Act. We adopted FSP 106-2 in the second quarter of 2004
and applied the retroactive transition method. As a result,
annual OPEB expense reflected annual pre-tax cost reductions of
approximately $3.6 million and $4.1 million in 2005
and 2004, respectively.
Following is a summary of our defined benefit pension and OPEB
funding and expense for the years 2003 through 2006:
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
| |
|
|
Pension | |
|
OPEB | |
|
|
| |
|
| |
|
|
Funding | |
|
Expense | |
|
Funding | |
|
Expense | |
|
|
| |
|
| |
|
| |
|
| |
2003
|
|
$ |
6.4 |
|
|
$ |
32.0 |
|
|
$ |
17.0 |
|
|
$ |
29.1 |
|
2004
|
|
|
63.0 |
|
|
|
23.1 |
|
|
|
30.9 |
|
|
|
28.5 |
|
2005
|
|
|
40.6 |
|
|
|
20.7 |
|
|
|
31.8 |
|
|
|
17.9 |
|
2006 (Estimated)
|
|
|
46.2 |
|
|
|
23.1 |
|
|
|
37.6 |
|
|
|
16.6 |
|
Assumptions used in determining the benefit obligations and the
value of plan assets for defined benefit pension plans and
postretirement benefit plans (primarily retiree healthcare
benefits) offered by the Company and its unconsolidated ventures
are evaluated periodically by management in conjunction with
outside actuaries. Critical assumptions, such as the discount
rate used to measure the benefit obligations, the expected
long-term rate of return on plan assets, and the medical care
cost trend are reviewed annually. At December 31, 2005 we
reduced our discount rate for U.S. plans to
5.50 percent from 5.75 percent at December 31,
2004, and reduced our discount rate for Canadian plans to
5.00 percent from 5.75 percent at December 31,
2004. Additionally, at December 31, 2005, we adopted the
1994 Group Annuity Mortality (GAM) table to
determine the expected life of our plan participants, replacing
the 1983 GAM table. Following are sensitivities on estimated
2006 pension and OPEB expense of potential further changes in
these key assumptions:
|
|
|
|
|
|
|
|
|
|
|
Increase in 2006 | |
|
|
Expense | |
|
|
(In Millions) | |
|
|
| |
|
|
Pension | |
|
OPEB | |
|
|
| |
|
| |
Decrease discount rate .25 percent
|
|
$ |
1.8 |
|
|
$ |
.5 |
|
Decrease return on assets 1 percent
|
|
|
5.7 |
|
|
|
1.1 |
|
Increase medical trend rate 1 percent
|
|
|
N/A |
|
|
|
4.8 |
|
Changes in actuarial assumptions, including discount rates,
employee retirement rates, mortality, compensation levels, plan
asset investment performance, and healthcare costs, are selected
by the Company after consulting with outside actuaries. Changes
in actuarial assumptions and/or investment performance of plan
assets can have a significant impact on our financial condition
due to the magnitude of our retirement obligations. See
Note 9 Retirement Related Benefits in the Notes
to Consolidated Financial Statements.
64
|
|
|
Accounting for Business Combinations |
During 2005, we completed the acquisition of 80.4 percent
of Portman. We allocated the purchase price to assets acquired
and liabilities assumed based on their relative fair value at
the date of acquisition, pursuant to SFAS No. 141,
Business Combinations. In estimating the fair value
of the assets acquired and liabilities assumed, we consider
information obtained during our due diligence process and
utilize various valuation methods, including market prices,
where available, appraisals, comparisons to transactions for
similar assets and liabilities and present value of estimated
future cash flows. We are required to make subjective estimates
in connection with these valuations and allocations.
Forward-Looking Statements
This report contains statements that constitute
forward-looking statements. These forward-looking
statements may be identified by the use of predictive,
future-tense or forward-looking terminology, such as
believes, anticipates,
expects, estimates, intends,
may, will or similar terms. These
statements speak only as of the date of this report, and we
undertake no ongoing obligation, other than that imposed by law,
to update these statements. These statements appear in a number
of places in this report and include statements regarding our
intent, belief or current expectations of our directors or our
officers with respect to, among other things:
|
|
|
|
|
trends affecting our financial condition, results of operations
or future prospects; |
|
|
|
estimates of our economic iron ore reserves; |
|
|
|
our business and growth strategies; |
|
|
|
our financing plans and forecasts; and |
|
|
|
the potential existence of significant deficiencies or material
weaknesses in internal controls over financial reporting that
may be identified during the performance of testing under
Section 404 of the Sarbanes-Oxley Act of 2002. |
You are cautioned that any such forward-looking statements are
not guarantees of future performance and involve significant
risks and uncertainties, and that actual results may differ
materially from those contained in the forward-looking
statements as a result of various factors, some of which are
unknown. The factors that could adversely affect our actual
results and performance include, without limitation:
|
|
|
|
|
decreased steel production in North America caused by global
overcapacity of steel, intense competition in the steel
industry, increased imports of steel into the United States,
consolidation in the steel industry, cyclicality in the steel
market and other factors, all of which could result in decreased
demand for our iron ore products; |
|
|
|
use by steel makers of products other than North American and
Australian iron ore in the production of steel; |
|
|
|
uncertainty about the continued demand for steel to support
rapid industrial growth in China; |
|
|
|
the highly competitive nature of the iron ore mining industry; |
|
|
|
our dependence on our North American term supply agreements with
a limited number of customers as the North American and global
steel industries consolidation continues (as evidenced by the
merger of ISG and Ispat to form Mittal and the pending
acquisition of Arcelor S.A. and Dofasco Inc.); |
|
|
|
changes in demand for our products under the requirements
contracts we have with our customers; |
|
|
|
the provisions of our North American term supply agreements,
including price adjustment provisions that may not allow us to
match international prices for iron ore products; |
|
|
|
fluctuations in international prices for iron ore that may
negatively impact our profitability; |
65
|
|
|
|
|
the substantial costs of mine closures, and the uncertainties
regarding mine life and estimates of ore reserves; |
|
|
|
uncertainty relating to our North American customers
pending bankruptcies or reorganization proceedings, and the
creditworthiness of our customers; |
|
|
|
uncertainty relating to the outcome of any contractual disputes
with our customers; |
|
|
|
our change in strategy from a manager of iron ore mines to
primarily a merchant of iron ore to steel company customers; |
|
|
|
increases in the cost or length of time required to complete
capacity expansions; |
|
|
|
inability of the capacity expansions to achieve expected
additional production volumes; |
|
|
|
our reliance on our joint venture partners to meet their
obligations; |
|
|
|
unanticipated geological conditions, natural disasters, the
nature and extent of disruptions in the economy from terrorist
activities, interruptions in electrical or other power sources
and equipment failures, which could cause shutdowns or
production curtailments for us or our steel industry customers; |
|
|
|
increases in our costs and availability of equipment, supplies,
electrical power, fuel or other energy sources; |
|
|
|
uncertainties relating to governmental regulation of our mines
and our processing facilities, including under environmental
laws; |
|
|
|
uncertainties relating to our pension plans; |
|
|
|
uncertainties relating to our ability to identify and consummate
any strategic investments; |
|
|
|
adverse changes in currency values; |
|
|
|
uncertainties related to the appraisal of acquisitions and the
related allocation of purchase price to the acquired assets and
assumed liabilities; |
|
|
|
uncertainties relating to labor relations, including the
potential for, and duration of, work stoppages; |
|
|
|
uncertainty relating to contractual disputes with any of our
significant energy, material or service providers; and |
|
|
|
the success of cost-savings efforts. |
You are urged to carefully consider these factors and the
Risks Relating to the Company above. All
forward-looking statements attributable to us are expressly
qualified in their entirety by the foregoing cautionary
statements.
|
|
Item 7A. |
Qualitative and Quantitative Disclosures About Market
Risk |
Information regarding our Market Risk is presented under the
caption Market Risk, which is included in
Item 7 and is incorporated by reference and made a part
hereof.
66
|
|
Item 8. |
Financial Statements and Supplementary Data |
Statement of Consolidated Operations
Cleveland-Cliffs Inc and Consolidated Subsidiaries
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31 | |
|
|
(In Millions, Except Per Share | |
|
|
Amounts) | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
REVENUES FROM PRODUCT SALES AND SERVICES
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Iron Ore
|
|
$ |
1,512.2 |
|
|
$ |
995.0 |
|
|
$ |
686.8 |
|
|
Freight and venture partners cost reimbursements
|
|
|
227.3 |
|
|
|
208.1 |
|
|
|
138.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
1,739.5 |
|
|
|
1,203.1 |
|
|
|
825.1 |
|
COST OF GOODS SOLD AND OPERATING EXPENSES
|
|
|
(1,350.5 |
) |
|
|
(1,053.6 |
) |
|
|
(835.0 |
) |
|
|
|
|
|
|
|
|
|
|
|
SALES MARGIN
|
|
|
389.0 |
|
|
|
149.5 |
|
|
|
(9.9 |
) |
OTHER OPERATING INCOME (EXPENSE)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Royalties and management fee revenue
|
|
|
13.1 |
|
|
|
11.3 |
|
|
|
10.6 |
|
|
Casualty insurance recoveries
|
|
|
12.3 |
|
|
|
|
|
|
|
|
|
|
Administrative, selling and general expenses
|
|
|
(47.9 |
) |
|
|
(33.1 |
) |
|
|
(25.1 |
) |
|
Impairment of mining assets
|
|
|
|
|
|
|
(5.8 |
) |
|
|
(2.6 |
) |
|
Customer bankruptcy recoveries (exposures)
|
|
|
2.0 |
|
|
|
(1.6 |
) |
|
|
(7.5 |
) |
|
Restructuring (charge) credit
|
|
|
|
|
|
|
.2 |
|
|
|
(8.7 |
) |
|
Miscellaneous net
|
|
|
(12.0 |
) |
|
|
(2.9 |
) |
|
|
(5.1 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
(32.5 |
) |
|
|
(31.9 |
) |
|
|
(38.4 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
OPERATING INCOME (LOSS)
|
|
|
356.5 |
|
|
|
117.6 |
|
|
|
(48.3 |
) |
OTHER INCOME (EXPENSE)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gain on sale of ISG common stock
|
|
|
|
|
|
|
152.7 |
|
|
|
|
|
|
Gain on sale of asset to PolyMet
|
|
|
9.5 |
|
|
|
|
|
|
|
|
|
|
Interest income
|
|
|
13.9 |
|
|
|
11.5 |
|
|
|
10.6 |
|
|
Interest expense
|
|
|
(4.5 |
) |
|
|
(.8 |
) |
|
|
(4.6 |
) |
|
Other net
|
|
|
(7.3 |
) |
|
|
4.2 |
|
|
|
7.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
11.6 |
|
|
|
167.6 |
|
|
|
13.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
INCOME (LOSS) FROM CONTINUING OPERATIONS BEFORE INCOME
TAXES AND MINORITY INTEREST
|
|
|
368.1 |
|
|
|
285.2 |
|
|
|
(35.2 |
) |
INCOME TAX CREDIT (EXPENSE)
|
|
|
(84.8 |
) |
|
|
35.0 |
|
|
|
.3 |
|
MINORITY INTEREST (net of tax $5.4 million)
|
|
|
(10.1 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
INCOME (LOSS) FROM CONTINUING OPERATIONS
|
|
|
273.2 |
|
|
|
320.2 |
|
|
|
(34.9 |
) |
INCOME (LOSS) FROM DISCONTINUED OPERATIONS (net of tax
$.4 million in 2005 and $.3 million in 2004)
|
|
|
(.8 |
) |
|
|
3.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
INCOME (LOSS) BEFORE EXTRAORDINARY GAIN AND CUMULATIVE
EFFECT OF ACCOUNTING CHANGE
|
|
|
272.4 |
|
|
|
323.6 |
|
|
|
(34.9 |
) |
EXTRAORDINARY GAIN (Net of: tax $.5 million; minority
interest $1.7)
|
|
|
|
|
|
|
|
|
|
|
2.2 |
|
CUMULATIVE EFFECT OF ACCOUNTING CHANGE (net of tax
$2.8 million)
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
NET INCOME (LOSS)
|
|
|
277.6 |
|
|
|
323.6 |
|
|
|
(32.7 |
) |
|
PREFERRED STOCK DIVIDENDS
|
|
|
(5.6 |
) |
|
|
(5.3 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
INCOME (LOSS) APPLICABLE TO COMMON SHARES
|
|
$ |
272.0 |
|
|
$ |
318.3 |
|
|
$ |
(32.7 |
) |
|
|
|
|
|
|
|
|
|
|
EARNINGS (LOSS) PER COMMON SHARE BASIC
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Continuing operations
|
|
$ |
12.32 |
|
|
$ |
14.78 |
|
|
$ |
(1.70 |
) |
|
Discontinued operations
|
|
|
(.04 |
) |
|
|
.16 |
|
|
|
|
|
|
Extraordinary gain
|
|
|
|
|
|
|
|
|
|
|
.10 |
|
|
Cumulative effect of accounting changes
|
|
|
.24 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
EARNINGS (LOSS) PER COMMON SHARE BASIC
|
|
$ |
12.52 |
|
|
$ |
14.94 |
|
|
$ |
(1.60 |
) |
|
|
|
|
|
|
|
|
|
|
EARNINGS (LOSS) PER COMMON SHARE DILUTED
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Continuing operations
|
|
$ |
9.81 |
|
|
$ |
11.68 |
|
|
$ |
(1.70 |
) |
|
Discontinued operations
|
|
|
(.03 |
) |
|
|
.12 |
|
|
|
|
|
|
Extraordinary gain
|
|
|
|
|
|
|
|
|
|
|
.10 |
|
|
Cumulative effect of accounting changes
|
|
|
.19 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
EARNINGS (LOSS) PER COMMON SHARE DILUTED
|
|
$ |
9.97 |
|
|
$ |
11.80 |
|
|
$ |
(1.60 |
) |
|
|
|
|
|
|
|
|
|
|
AVERAGE NUMBER OF SHARES (In thousands)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic
|
|
|
21,728 |
|
|
|
21,308 |
|
|
|
20,512 |
|
|
Diluted
|
|
|
27,836 |
|
|
|
27,421 |
|
|
|
20,512 |
|
See notes to consolidated financial statements.
67
Statement of Consolidated Financial Position
Cleveland-Cliffs Inc and Consolidated Subsidiaries
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31 | |
|
|
(In Millions) | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
|
| |
|
| |
ASSETS |
CURRENT ASSETS
|
|
|
|
|
|
|
|
|
|
Cash and cash equivalents
|
|
$ |
192.8 |
|
|
$ |
216.9 |
|
|
Marketable securities
|
|
|
9.9 |
|
|
|
182.7 |
|
|
Trade accounts receivable net
|
|
|
53.7 |
|
|
|
54.1 |
|
|
Receivables from associated companies
|
|
|
5.4 |
|
|
|
3.5 |
|
|
Product inventories
|
|
|
119.1 |
|
|
|
108.2 |
|
|
Work in process inventories
|
|
|
56.7 |
|
|
|
15.8 |
|
|
Supplies and other inventories
|
|
|
70.5 |
|
|
|
59.6 |
|
|
Deferred and refundable taxes
|
|
|
12.1 |
|
|
|
41.5 |
|
|
Deposits in escrow
|
|
|
73.0 |
|
|
|
16.5 |
|
|
Other
|
|
|
42.8 |
|
|
|
32.6 |
|
|
|
|
|
|
|
|
|
|
TOTAL CURRENT ASSETS
|
|
|
636.0 |
|
|
|
731.4 |
|
PROPERTIES
|
|
|
|
|
|
|
|
|
|
Plant and equipment
|
|
|
557.5 |
|
|
|
416.5 |
|
|
Land rights and mineral rights
|
|
|
421.8 |
|
|
|
20.9 |
|
|
|
|
|
|
|
|
|
|
|
979.3 |
|
|
|
437.4 |
|
|
Allowances for depreciation and depletion
|
|
|
(176.5 |
) |
|
|
(153.5 |
) |
|
|
|
|
|
|
|
|
|
NET PROPERTIES
|
|
|
802.8 |
|
|
|
283.9 |
|
OTHER ASSETS
|
|
|
|
|
|
|
|
|
|
Prepaid pensions salaried
|
|
|
80.4 |
|
|
|
71.2 |
|
|
Long-term receivables
|
|
|
48.7 |
|
|
|
52.1 |
|
|
Deferred income taxes
|
|
|
66.5 |
|
|
|
44.2 |
|
|
Deposits and miscellaneous
|
|
|
53.8 |
|
|
|
20.8 |
|
|
Other investments
|
|
|
34.0 |
|
|
|
15.6 |
|
|
Intangible pension asset
|
|
|
13.9 |
|
|
|
12.6 |
|
|
Marketable securities
|
|
|
10.6 |
|
|
|
.5 |
|
|
|
|
|
|
|
|
|
|
TOTAL OTHER ASSETS
|
|
|
307.9 |
|
|
|
217.0 |
|
|
|
|
|
|
|
|
|
|
|
TOTAL ASSETS
|
|
$ |
1,746.7 |
|
|
$ |
1,232.3 |
|
|
|
|
|
|
|
|
See notes to consolidated financial statements.
68
Statement of Consolidated Financial Position
Cleveland-Cliffs Inc and Consolidated
Subsidiaries (Continued)
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31 | |
|
|
(In Millions) | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
|
| |
|
| |
LIABILITIES AND SHAREHOLDERS EQUITY |
CURRENT LIABILITIES
|
|
|
|
|
|
|
|
|
|
Accounts payable
|
|
$ |
122.9 |
|
|
$ |
73.3 |
|
|
Accrued employment costs
|
|
|
47.4 |
|
|
|
41.3 |
|
|
Pensions
|
|
|
45.3 |
|
|
|
31.0 |
|
|
Other postretirement benefits
|
|
|
36.6 |
|
|
|
34.9 |
|
|
Income taxes
|
|
|
29.1 |
|
|
|
15.0 |
|
|
State and local taxes
|
|
|
22.2 |
|
|
|
21.9 |
|
|
Environmental and mine closure obligations
|
|
|
13.4 |
|
|
|
6.0 |
|
|
Accrued expenses
|
|
|
28.9 |
|
|
|
21.7 |
|
|
Payables to associated companies
|
|
|
7.7 |
|
|
|
4.6 |
|
|
Other
|
|
|
9.2 |
|
|
|
7.4 |
|
|
|
|
|
|
|
|
|
|
TOTAL CURRENT LIABILITIES
|
|
|
362.7 |
|
|
|
257.1 |
|
POSTEMPLOYMENT BENEFIT LIABILITIES
|
|
|
|
|
|
|
|
|
|
Pensions, including minimum pension liability
|
|
|
119.6 |
|
|
|
113.9 |
|
|
Other postretirement benefits
|
|
|
85.2 |
|
|
|
102.7 |
|
|
|
|
|
|
|
|
|
|
TOTAL POSTEMPLOYMENT BENEFIT LIABILITIES
|
|
|
204.8 |
|
|
|
216.6 |
|
ENVIRONMENTAL AND MINE CLOSURE OBLIGATIONS
|
|
|
87.3 |
|
|
|
82.4 |
|
DEFERRED INCOME TAXES
|
|
|
116.7 |
|
|
|
|
|
OTHER LIABILITIES
|
|
|
79.4 |
|
|
|
49.7 |
|
|
|
|
|
|
|
|
|
|
TOTAL LIABILITIES
|
|
|
850.9 |
|
|
|
605.8 |
|
MINORITY INTEREST
|
|
|
71.7 |
|
|
|
30.0 |
|
3.25% REDEEMABLE CUMULATIVE CONVERTIBLE PERPETUAL PREFERRED
STOCK ISSUED 172,500 SHARES
|
|
|
172.5 |
|
|
|
172.5 |
|
SHAREHOLDERS EQUITY
|
|
|
|
|
|
|
|
|
|
Preferred stock no par value
|
|
|
|
|
|
|
|
|
|
|
Class A 3,000,000 shares authorized,
172,500 issued and outstanding
|
|
|
|
|
|
|
|
|
|
|
Class B 4,000,000 shares authorized and
unissued
|
|
|
|
|
|
|
|
|
|
Common Shares par value $.50 a share
|
|
|
|
|
|
|
|
|
|
|
Authorized 56,000,000 shares;
|
|
|
|
|
|
|
|
|
|
|
Issued 33,655,882 shares
|
|
|
16.8 |
|
|
|
16.8 |
|
|
Capital in excess of par value of shares
|
|
|
93.9 |
|
|
|
86.3 |
|
|
Retained Earnings
|
|
|
824.2 |
|
|
|
565.3 |
|
|
Cost of 11,740,385 Common Shares in treasury (2004
12,057,110 shares)
|
|
|
(164.3 |
) |
|
|
(169.4 |
) |
|
Accumulated other comprehensive income (loss)
|
|
|
(125.6 |
) |
|
|
(81.0 |
) |
|
Unearned compensation
|
|
|
6.6 |
|
|
|
6.0 |
|
|
|
|
|
|
|
|
|
|
TOTAL SHAREHOLDERS EQUITY
|
|
|
651.6 |
|
|
|
424.0 |
|
|
|
|
|
|
|
|
|
|
TOTAL LIABILITIES AND SHAREHOLDERS EQUITY
|
|
$ |
1,746.7 |
|
|
$ |
1,232.3 |
|
|
|
|
|
|
|
|
See notes to consolidated financial statements.
69
Statement of Consolidated Cash Flows
Cleveland-Cliffs Inc and Consolidated Subsidiaries
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31 | |
|
|
(In Millions, Brackets | |
|
|
Indicate Cash Decrease) | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
CASH FLOW FROM CONTINUING OPERATIONS
|
|
|
|
|
|
|
|
|
|
|
|
|
|
OPERATING ACTIVITIES
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss)
|
|
$ |
277.6 |
|
|
$ |
323.6 |
|
|
$ |
(32.7 |
) |
|
|
|
(Income) loss from discontinued operations
|
|
|
.8 |
|
|
|
(3.4 |
) |
|
|
|
|
|
|
|
Extraordinary gain
|
|
|
|
|
|
|
|
|
|
|
(2.2 |
) |
|
|
|
Cumulative effect of accounting change
|
|
|
(5.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from continuing operations
|
|
|
273.2 |
|
|
|
320.2 |
|
|
|
(34.9 |
) |
|
|
Adjustments to reconcile net income (loss) from continuing
operations to net cash from (used by) operations:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Depreciation and amortization:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Consolidated
|
|
|
48.6 |
|
|
|
25.0 |
|
|
|
25.3 |
|
|
|
|
|
|
Share of associated companies
|
|
|
4.2 |
|
|
|
4.3 |
|
|
|
3.7 |
|
|
|
|
|
Minority interest
|
|
|
10.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss on currency hedges
|
|
|
9.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Impairment of mining assets
|
|
|
|
|
|
|
5.8 |
|
|
|
2.6 |
|
|
|
|
|
Environmental and closure obligation
|
|
|
6.0 |
|
|
|
4.6 |
|
|
|
3.6 |
|
|
|
|
|
Provision for customer bankruptcy exposures
|
|
|
|
|
|
|
1.6 |
|
|
|
7.5 |
|
|
|
|
|
Gain on sale of ISG common stock
|
|
|
|
|
|
|
(152.7 |
) |
|
|
|
|
|
|
|
|
Gain on sale of assets to PolyMet
|
|
|
(9.5 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
Deferred income taxes
|
|
|
(4.4 |
) |
|
|
(86.7 |
) |
|
|
.5 |
|
|
|
|
|
Pensions and other postretirement benefits
|
|
|
(35.2 |
) |
|
|
(48.0 |
) |
|
|
42.1 |
|
|
|
|
|
Gain on sale of assets
|
|
|
(1.8 |
) |
|
|
(4.2 |
) |
|
|
(7.1 |
) |
|
|
|
|
Other
|
|
|
5.6 |
|
|
|
5.1 |
|
|
|
4.7 |
|
|
|
|
|
Changes in operating assets and liabilities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales of marketable securities
|
|
|
182.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Purchases of marketable securities
|
|
|
(10.0 |
) |
|
|
(182.7 |
) |
|
|
|
|
|
|
|
|
|
Inventories and prepaid expenses
|
|
|
(56.0 |
) |
|
|
(3.4 |
) |
|
|
(12.0 |
) |
|
|
|
|
|
Receivables
|
|
|
27.7 |
|
|
|
(50.7 |
) |
|
|
(2.1 |
) |
|
|
|
|
|
Payables and accrued expenses
|
|
|
63.5 |
|
|
|
20.4 |
|
|
|
8.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net cash from (used by) operating activities
|
|
|
514.6 |
|
|
|
(141.4 |
) |
|
|
42.7 |
|
|
INVESTING ACTIVITIES
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Purchase of property, plant and equipment:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Consolidated
|
|
|
(97.8 |
) |
|
|
(54.4 |
) |
|
|
(16.1 |
) |
|
|
|
Share of associated companies
|
|
|
(8.5 |
) |
|
|
(6.3 |
) |
|
|
(5.5 |
) |
|
|
Investment in Portman Limited
|
|
|
(409.0 |
) |
|
|
|
|
|
|
|
|
|
|
Payment of currency hedges
|
|
|
(9.8 |
) |
|
|
|
|
|
|
|
|
|
|
Proceeds from sale of ISG common stock
|
|
|
|
|
|
|
170.1 |
|
|
|
|
|
|
|
Proceeds from sale of assets to PolyMet
|
|
|
1.0 |
|
|
|
|
|
|
|
|
|
|
|
Proceeds from steel company debt
|
|
|
|
|
|
|
10.0 |
|
|
|
|
|
|
|
Proceeds from sale of assets
|
|
|
3.4 |
|
|
|
4.4 |
|
|
|
8.9 |
|
|
|
Proceeds from Weirton investment
|
|
|
|
|
|
|
3.8 |
|
|
|
|
|
|
|
Purchase of EVTAC assets
|
|
|
|
|
|
|
|
|
|
|
(2.0 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net cash from (used by) investing activities
|
|
|
(520.7 |
) |
|
|
127.6 |
|
|
|
(14.7 |
) |
|
FINANCING ACTIVITIES
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Borrowings under revolving credit facility
|
|
|
175.0 |
|
|
|
|
|
|
|
|
|
|
|
Repayments under revolving credit facility
|
|
|
(175.0 |
) |
|
|
|
|
|
|
|
|
|
|
Proceeds from Convertible Preferred Stock
|
|
|
|
|
|
|
172.5 |
|
|
|
|
|
|
|
Proceeds from stock options exercised
|
|
|
5.7 |
|
|
|
17.9 |
|
|
|
6.0 |
|
|
|
Contributions by minority interest
|
|
|
2.1 |
|
|
|
9.7 |
|
|
|
2.0 |
|
|
|
Repayment of long-term debt
|
|
|
|
|
|
|
(25.0 |
) |
|
|
(30.0 |
) |
|
|
Issuance cost Convertible Preferred Stock
|
|
|
|
|
|
|
(6.6 |
) |
|
|
|
|
|
|
Issuance cost Revolving credit
|
|
|
(2.7 |
) |
|
|
|
|
|
|
|
|
|
|
Repurchases of Common Stock
|
|
|
|
|
|
|
(6.5 |
) |
|
|
|
|
|
|
Preferred Stock dividends
|
|
|
(5.6 |
) |
|
|
(3.9 |
) |
|
|
|
|
|
|
Common Stock dividends
|
|
|
(13.1 |
) |
|
|
(2.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net cash from (used by) financing activities
|
|
|
(13.6 |
) |
|
|
155.9 |
|
|
|
(22.0 |
) |
|
EFFECT OF EXCHANGE RATE CHANGES ON CASH
|
|
|
(2.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
CASH FROM (USED BY) CONTINUING OPERATIONS
|
|
|
(21.9 |
) |
|
|
142.1 |
|
|
|
6.0 |
|
CASH FROM (USED BY) DISCONTINUED
OPERATIONS OPERATING
|
|
|
(5.2 |
) |
|
|
.3 |
|
|
|
|
|
INVESTING
|
|
|
3.0 |
|
|
|
6.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
INCREASE (DECREASE) IN CASH AND CASH EQUIVALENTS
|
|
|
(24.1 |
) |
|
|
149.1 |
|
|
|
6.0 |
|
CASH AND CASH EQUIVALENTS AT BEGINNING OF YEAR
|
|
|
216.9 |
|
|
|
67.8 |
|
|
|
61.8 |
|
|
|
|
|
|
|
|
|
|
|
CASH AND CASH EQUIVALENTS AT END OF YEAR
|
|
$ |
192.8 |
|
|
$ |
216.9 |
|
|
$ |
67.8 |
|
|
|
|
|
|
|
|
|
|
|
Taxes paid on income
|
|
$ |
86.2 |
|
|
$ |
57.1 |
|
|
$ |
2.7 |
|
Interest paid on debt obligations
|
|
$ |
2.0 |
|
|
$ |
.2 |
|
|
$ |
3.6 |
|
See notes to consolidated financial statements.
70
Statement of Consolidated Shareholders Equity
Cleveland-Cliffs and Consolidated Subsidiaries
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
| |
|
|
|
|
Capital | |
|
|
|
|
|
|
in | |
|
|
|
Other | |
|
|
|
|
|
|
Excess | |
|
|
|
Compre- | |
|
|
|
|
|
|
of Par | |
|
|
|
Common | |
|
hensive | |
|
Unearned | |
|
|
|
|
Common | |
|
Value of | |
|
Retained | |
|
Shares in | |
|
Income | |
|
Compens- | |
|
|
|
|
Shares | |
|
Shares | |
|
Earnings | |
|
Treasury | |
|
(Loss) | |
|
ation | |
|
Total | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
January 1, 2003
|
|
$ |
16.8 |
|
|
$ |
69.7 |
|
|
$ |
288.4 |
|
|
$ |
(182.2 |
) |
|
$ |
(110.7 |
) |
|
$ |
(2.7 |
) |
|
$ |
79.3 |
|
|
Comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss
|
|
|
|
|
|
|
|
|
|
|
(32.7 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(32.7 |
) |
|
|
Other comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Unrealized gain on securities
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
144.9 |
|
|
|
|
|
|
|
144.9 |
|
|
|
|
Minimum pension liability
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
22.2 |
|
|
|
|
|
|
|
22.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
134.4 |
|
|
Stock options exercised
|
|
|
|
|
|
|
1.1 |
|
|
|
|
|
|
|
4.9 |
|
|
|
|
|
|
|
|
|
|
|
6.0 |
|
|
Stock and other incentive plans
|
|
|
|
|
|
|
3.5 |
|
|
|
|
|
|
|
3.7 |
|
|
|
|
|
|
|
1.2 |
|
|
|
8.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, 2003
|
|
|
16.8 |
|
|
|
74.3 |
|
|
|
255.7 |
|
|
|
(173.6 |
) |
|
|
56.4 |
|
|
|
(1.5 |
) |
|
|
228.1 |
|
|
Comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income
|
|
|
|
|
|
|
|
|
|
|
323.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
323.6 |
|
|
|
Other comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Minimum pension liability
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
7.3 |
|
|
|
|
|
|
|
7.3 |
|
|
|
|
Unrealized gain on securities
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
.2 |
|
|
|
|
|
|
|
.2 |
|
|
|
|
Reclassification adjustment
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
included in net income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(144.9 |
) |
|
|
|
|
|
|
(144.9 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
186.2 |
|
|
Stock options exercised
|
|
|
|
|
|
|
8.1 |
|
|
|
|
|
|
|
9.8 |
|
|
|
|
|
|
|
|
|
|
|
17.9 |
|
|
Stock and other incentive plans
|
|
|
|
|
|
|
3.9 |
|
|
|
|
|
|
|
.9 |
|
|
|
|
|
|
|
7.5 |
|
|
|
12.3 |
|
|
Issuance cost Convertible Preferred Stock
|
|
|
|
|
|
|
|
|
|
|
(6.5 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(6.5 |
) |
|
Repurchases of Common Stock
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(6.5 |
) |
|
|
|
|
|
|
|
|
|
|
(6.5 |
) |
|
Preferred Stock dividends
|
|
|
|
|
|
|
|
|
|
|
(5.3 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(5.3 |
) |
|
Common Stock dividends
|
|
|
|
|
|
|
|
|
|
|
(2.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(2.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, 2004
|
|
|
16.8 |
|
|
|
86.3 |
|
|
|
565.3 |
|
|
|
(169.4 |
) |
|
|
(81.0 |
) |
|
|
6.0 |
|
|
|
424.0 |
|
|
Comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income
|
|
|
|
|
|
|
|
|
|
|
277.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
277.6 |
|
|
|
Other comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Minimum pension liability
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(19.5 |
) |
|
|
|
|
|
|
(19.5 |
) |
|
|
|
Unrealized gain on securities
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
1.5 |
|
|
|
|
|
|
|
1.5 |
|
|
|
|
Unrealized loss on Foreign
Currency Translation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(24.7 |
) |
|
|
|
|
|
|
(24.7 |
) |
|
|
|
Hedge reserve
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1.9 |
) |
|
|
|
|
|
|
(1.9 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total comprehensive income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
233.0 |
|
|
Stock options exercised
|
|
|
|
|
|
|
3.2 |
|
|
|
|
|
|
|
2.4 |
|
|
|
|
|
|
|
|
|
|
|
5.6 |
|
|
Stock and other incentive plans
|
|
|
|
|
|
|
4.4 |
|
|
|
|
|
|
|
2.7 |
|
|
|
|
|
|
|
.6 |
|
|
|
7.7 |
|
|
Preferred Stock dividends
|
|
|
|
|
|
|
|
|
|
|
(5.6 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(5.6 |
) |
|
Common Stock dividends
|
|
|
|
|
|
|
|
|
|
|
(13.1 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(13.1 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, 2005
|
|
$ |
16.8 |
|
|
$ |
93.9 |
|
|
$ |
824.2 |
|
|
$ |
(164.3 |
) |
|
$ |
(125.6 |
) |
|
$ |
6.6 |
|
|
$ |
651.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
See notes to consolidated financial statements.
71
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial Statements
Two-for-One Stock Split
On November 9, 2004, the Board of Directors of
Cleveland-Cliffs Inc (the Company, we,
us, our, and Cliffs)
approved a two-for-one stock split of our Common Shares with a
corresponding decrease in par value from $1.00 to $.50. The
record date for the stock split was December 15, 2004 with
a distribution date of December 31, 2004. Accordingly, all
Common Shares, per share amounts, stock compensation plans and
preferred stock conversion rates have been adjusted
retroactively to reflect the stock split.
Accounting Policies
Business: We are the largest supplier of iron ore pellets
to integrated steel companies in North America. We manage and
own interests in North American mines and own ancillary
companies providing transportation and other services to the
mines.
On April 19, 2005, Cleveland-Cliffs Australia Pty Limited
(Cliffs Australia), an indirect wholly owned
subsidiary of the Company, completed the acquisition of
80.4 percent of Portman Limiteds
(Portman) common stock. The acquisition was
initiated on March 31, 2005 by the purchase of
approximately 68.7 percent of the outstanding shares of
Portman. The Statement of Consolidated Financial Position of the
Company as of December 31, 2005 reflects the acquisition of
Portman, effective March 31, 2005, under the purchase
method of accounting. The 2005 results include revenue and
expenses of Portman since the date of acquisition. See
NOTE 3 Portman Acquisition for further
discussion.
Basis of Consolidation: The consolidated financial
statements include the accounts of the Company and its
majority-owned subsidiaries, including:
|
|
|
|
|
Tilden Mining Company L.C. (Tilden) in Michigan;
consolidated since January 31, 2002, when we increased our
ownership from 40 percent to 85 percent; |
|
|
|
Empire Iron Mining Partnership (Empire) in Michigan;
consolidated effective December 31, 2002, when we increased
our ownership from 46.7 percent to 79 percent; |
|
|
|
United Taconite LLC (United Taconite) in Minnesota;
consolidated since December 1, 2003, when we acquired a
70 percent ownership interest; (see Note 1
Operations and Customers United Taconite). |
|
|
|
Portman in Western Australia; consolidated since March 31,
2005 when we initiated an acquisition by the purchase of
approximately 68.7 percent of the outstanding shares. On
April 19, 2005 we completed the acquisition of an
additional 11.7 percent of the outstanding shares,
increasing our ownership to 80.4 percent of Portmans
common stock. |
Intercompany accounts are eliminated in consolidation.
Investments in joint ventures in which our ownership is
50 percent or less, or in which we do not have control but
have the ability to exercise significant influence over
operating and financial policies, are accounted for under the
equity method. Our share of equity income (if any) is eliminated
against consolidated product inventory upon production, and
against cost of goods sold and operating expenses when sold.
This effectively reduces our cost for our share of the mining
ventures production to its cost, reflecting the cost-based
nature of our participation in non-consolidated ventures.
Other Investments include our 26.83 percent
equity interest in Wabush Mines (Wabush) and related
entities; and Portmans 50 percent interest in the
Cockatoo Island Joint Venture, which we do not control. Our
23 percent equity interest in Hibbing Taconite Company
(Hibbing), an unincorporated joint venture in
Minnesota, which we do not control, was a net liability, and
accordingly, was classified as Other Liabilities.
Cliffs and Associates Limited (CAL) results are
included in Discontinued Operations in the Statement
of Consolidated Operations. See Note 4
Discontinued Operations.
72
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
Revenue Recognition: Revenue is recognized on the sale of
products when title to the product has transferred to the
customer in accordance with the specified terms of each term
supply agreement. Generally, our North American term supply
agreements provide that title transfers to the customer when
payment is received. Under some term supply agreements, we ship
the product to ports on the lower Great Lakes and/or to the
customers facilities prior to the transfer of title.
Certain sales contracts with one customer include provisions for
supplemental revenue or refunds based on the customers
annual steel pricing at the time the product is consumed in the
customers blast furnaces. We estimate these amounts for
recognition at the time of sale when it is deemed probable that
they will be realized. Estimated supplemental payments (on
1.1 million tons), which at current pricing would have
amounted to approximately $9.2 million, related to sales to
one of the customers indefinitely idled facilities, have
not been included in revenue. The pellets sold to this facility
in 2005 have not been consumed and no definitive timetable for
consumption or other disposition of these pellets has been
determined. Revenue for the year from product sales includes
reimbursement for freight charges
($70.5 million 2005;
$71.7 million 2004;
$59.2 million 2003) paid on behalf of
customers and cost reimbursement
($156.8 million 2005;
$136.4 million 2004;
$79.1 million 2003) from venture partners
for their share of mine costs.
Our rationale for shipping iron ore products to customers in
advance of payment for the products is to more closely relate
timing of payment by customers to consumption, thereby providing
additional liquidity to our customers. Title and risk of loss do
not pass to the customer until payment for the pellets is
received. This is a revenue recognition practice utilized to
reduce our financial risk to customer insolvency. This practice
is not believed to be widely used throughout the balance of the
industry.
Revenue is recognized on the sale of services when the services
are performed.
Where we are joint venture participants in the ownership of a
mine, our contracts entitle us to receive royalties and
management fees, which we earn as the pellets are produced.
Portmans sales revenue is recognized at the F.O.B. point,
which is generally when the product is loaded into the vessel.
Revenues denominated in a foreign currency are converted to
Australian dollars at the currency exchange rate in effect at
the time of the transaction.
Business Risk: The major business risk we face is lower
customer consumption of iron ore from our mines, which may
result from competition from other iron ore suppliers; increased
use of iron ore substitutes, including imported semi-finished
steel; customers rationalization or financial failure; or
decreased North American steel production, resulting from
increased imports or lower steel consumption. Our pellet sales
are concentrated with a relatively few number of customers.
Unmitigated loss of sales would have a greater impact on
operating results and cash flow than revenue, due to the high
level of fixed costs in the iron ore mining business and the
high cost to idle or close mines. In the event of a venture
participants failure to perform, remaining solvent
venturers, including the Company, may be required to assume and
record additional material obligations. The premature closure of
a mine due to the loss of a significant customer or the failure
of a venturer would accelerate substantial employment and mine
shutdown costs. See Note 1 Operations and
Customers.
Use of Estimates: The preparation of financial
statements, in conformity with accounting principles generally
accepted in the United States of America, requires management to
make estimates and assumptions that affect the reported amounts
of assets and liabilities and 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. Actual results could differ from estimates.
Cash Equivalents: We consider investments in highly
liquid debt instruments with an initial maturity of three months
or less at the date of purchase to be cash equivalents.
73
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
Marketable Securities: We determine the appropriate
classification of debt and equity securities at the time of
purchase and re-evaluate such designation as of each balance
sheet date. At December 31, 2005 and 2004, we had
$9.9 million and $182.7 million, respectively, in
highly-liquid auction rate securities (ARS),
classified as trading with changes in market value, if any,
included in income. We invest in ARS to generate higher returns
than traditional money market investments. Although these
securities have long-term stated contractual maturities, they
can be presented for redemption at auction when rates are reset
which is typically every 7, 28 or 35 days. As a
result, we classify these securities as current assets. We had
no realized or unrealized gains or losses related to these
securities during the years ended December 31, 2005 and
2004. All income, including any gains or losses related to these
investments was recorded as interest income. In accordance with
our investment policy, we only invest in ARS with high credit
quality issuers and limit the amount of investment exposure to
any one issuer.
At December 31, 2005 and 2004, we had $10.6 million
and $.5 million, respectively, of non-current marketable
securities, classified as available for sale, which
are stated at fair value, with unrealized holding gains and
losses included in other comprehensive income. See
Note 15 Fair Value of Financial
Instruments for further information.
Derivative Financial Instruments: In the normal course of
business, we enter into forward contracts for the purchase of
commodities, primarily natural gas and diesel fuel, which are
used in our operations. Such contracts are in quantities
expected to be delivered and used in the production process and
are not intended for resale or speculative purposes.
Portman, our Australian subsidiary, uses forward exchange
contracts, options, collars and convertible collars to hedge its
foreign currency exposure for a portion of its sales receipts
denominated in United States currency. The primary objective for
the use of these instruments is to reduce the volatility of
earnings due to changes in the Australian/United States currency
exchange rate, and to protect against undue adverse movement in
these exchange rates. All hedges are tested for effectiveness at
inception and at each reporting period thereafter.
Inventories: North American product inventories are
stated at the lower of cost or market. Cost of iron ore
inventories is determined using the
last-in, first-out
(LIFO) method. The excess of current cost over LIFO
cost of iron ore inventories was $39.9 million and
$17.6 million at December 31, 2005 and 2004,
respectively. During 2005, the inventory balances declined
resulting in liquidation of LIFO layers. The effect of the
inventory reduction decreased cost of goods sold and
operating expenses by $.9 million. At
December 31, 2005 and 2004, we had approximately
1.2 million tons and 1.9 million tons, respectively,
stored at ports on the lower lakes Great Lakes to service
customers. We maintain ownership of the inventories until title
has transferred to the customer, usually when payment is made.
Maintaining iron ore products at ports on the lower Great Lakes
reduces risk of non-payment by customers, as we retain title to
the product until payment is received from the customer. It also
assists the customers by more closely relating the timing of the
customers payments for the product to the customers
consumption of the products and by providing a portion of the
three-month supply of inventories of iron ore the customers
require during the winter when product shipments are curtailed
over the Great Lakes. We track the movement of the inventory and
have the right to verify the quantities on hand. Supplies and
other inventories reflect the average cost method. North
American finished product, work-in-process and supplies
inventories as of December 31, 2005, were valued at
$193.9 million, of which $105.3 million, or
54 percent (59 percent in 2004), is finished product.
At acquisition, the fair value of Portmans iron ore
inventory was assessed by reference to the selling price less
costs of realization and an appropriate margin for selling
efforts and costs to complete, with the exception of lower grade
stockpiles. The net realizable value has been discounted to
present value using a weighted average cost of capital, where
appropriate. Optimal use of the lower grade stockpiles of high
phosphorous ore is dependent on future production of standard
ore for blending into saleable product. These stockpiles are
scheduled to be utilized in the mine plan progressively over the
life of the mine. Given the nature of these
74
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
stockpiles and their dependence on future production, they have
been assessed on the same basis as mineral rights associated
with mining operations adjusted for the costs incurred to date
to extract the ore and to reflect the benefits to Portman of
having this ore available as an alternative to in-ground
reserves. We maintain ownership of the inventories until title
has transferred to the customer at the F.O.B. point, which is
generally when the product is loaded into the vessel. Finished
product,
work-in-process and
supplies inventories as of December 31, 2005, were valued
at $52.3 million, of which $13.8 million, or
26 percent, is finished product.
Deposits in Escrow: Our Empire and Tilden mines purchase
their electric power pursuant to the terms of special contracts.
Effective April 1, 2005, the supplier unilaterally changed
its method of calculating the energy charges. We are disputing
the pricing and have filed a demand for arbitration under the
terms of the contracts. Pursuant to the terms of the contracts,
the disputed amounts, as well as a recoverable amount under the
capped portion of the contracts, are being deposited in an
interest-bearing escrow account maintained by a bank. For 2005,
$73.0 million has been paid pursuant to these contracts, of
which $61.3 million is included in the escrow deposits
under the terms of the contracts, all of these amounts are
expected to be recovered in early 2006; however we have been
advised by Wisconsin Electric Power Company that they will
oppose any release of these recoverable amounts from the escrow
until completion of the arbitration. For 2004,
$16.5 million was paid to the supplier and recovered in the
first quarter of 2005, pursuant to the terms of the contract.
Iron Ore Reserves: We review the iron ore reserves based
on current expectations of revenues and costs, which are subject
to change. Iron ore reserves include only proven and probable
quantities of ore which can be economically mined and processed
utilizing existing technology. Asset retirement obligations
reflect remaining economic iron ore reserves.
Properties: North American properties are stated at cost.
Depreciation of plant and equipment is computed principally by
straight-line methods based on estimated useful lives, not to
exceed the estimated economic iron ore reserves. Depreciation is
provided over the following estimated useful lives:
|
|
|
|
|
Buildings
|
|
|
45 Years |
|
Mining Equipment
|
|
|
10 to 20 Years |
|
Processing Equipment
|
|
|
15 to 45 Years |
|
Information Technology
|
|
|
2 to 7 Years |
|
Depreciation is not adjusted when operations are temporarily
idled.
Portmans properties were preliminarily valued under
purchase accounting using the depreciated replacement cost
(DRC) approach as the primary valuation methodology.
This method was utilized as it recognizes the value of
specialized equipment and improvements as part of an ongoing
business. When assessing the DRC of an asset, the expected
remaining useful life was determined based on the shorter of the
estimated remaining life of the asset and the life of the mine.
Depreciation is provided over the following estimated useful
lives:
|
|
|
|
|
Asset Class |
|
Basis |
|
Life |
|
|
|
|
|
Plant and equipment
|
|
Straight line |
|
5 13 years |
Plant and equipment and mine assets
|
|
Production output |
|
13 years |
Motor vehicles, furniture & equipment
|
|
Straight line |
|
3 5 years |
75
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
The following table indicates the value of each of the major
classes of our depreciable assets as of December 31, 2005
and 2004:
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
December 31 | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
|
| |
|
| |
Land rights and mineral rights
|
|
$ |
421.8 |
|
|
$ |
20.9 |
|
Office and information technology
|
|
|
29.4 |
|
|
|
20.6 |
|
Buildings
|
|
|
32.4 |
|
|
|
24.8 |
|
Mining equipment
|
|
|
80.8 |
|
|
|
65.4 |
|
Processing equipment
|
|
|
175.8 |
|
|
|
160.6 |
|
Railroad equipment
|
|
|
75.4 |
|
|
|
52.6 |
|
Electric power facilities
|
|
|
28.9 |
|
|
|
28.6 |
|
Port facilities
|
|
|
37.4 |
|
|
|
|
|
Interest capitalized during construction
|
|
|
19.0 |
|
|
|
18.8 |
|
Land improvements
|
|
|
11.1 |
|
|
|
11.1 |
|
Other
|
|
|
5.3 |
|
|
|
5.3 |
|
Construction in progress
|
|
|
62.0 |
|
|
|
28.7 |
|
|
|
|
|
|
|
|
|
|
|
979.3 |
|
|
|
437.4 |
|
Allowance for depreciation and depletion
|
|
|
(176.5 |
) |
|
|
(153.5 |
) |
|
|
|
|
|
|
|
|
|
$ |
802.8 |
|
|
$ |
283.9 |
|
|
|
|
|
|
|
|
Amortization of interest capitalized during construction is at
the rate of approximately $2 million per year.
The costs capitalized and classified under the caption
Land rights and mineral rights represent lands where
we own the surface and/or mineral rights. The value of the land
rights is split between surface only, surface and minerals, and
minerals only.
Portmans interest in iron ore reserves and resources were
preliminarily valued using a discounted cash flow method. Fair
value was estimated based upon the present value of the expected
future cash flows from iron ore operations over the economic
lives of the mines.
The approximate net book value of the land rights and mineral
rights is as follows:
|
|
|
|
|
|
|
|
|
|
|
|
(In Millions) | |
|
|
December 31 | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
|
| |
|
| |
Land rights
|
|
$ |
4.8 |
|
|
$ |
6.0 |
|
|
|
|
|
|
|
|
|
Mineral rights:
|
|
|
|
|
|
|
|
|
|
Cost
|
|
$ |
417.0 |
|
|
$ |
14.9 |
|
|
Less depletion
|
|
|
19.3 |
|
|
|
5.5 |
|
|
|
|
|
|
|
|
Net mineral rights
|
|
$ |
397.7 |
|
|
$ |
9.4 |
|
|
|
|
|
|
|
|
Accumulated depletion relating to mineral rights, which was
recorded using the
unit-of-production
method, is included in Allowance for depreciation and
depletion.
Goodwill: Based on our preliminary purchase price
allocation for our Portman acquisition, we have identified
approximately $8.8 million of excess purchase price over
the fair value of assets acquired. This allocation is subject to
further refinement as additional information becomes available.
As required by
76
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
SFAS No. 142, Goodwill and Other Intangible
Assets (SFAS 142), goodwill was allocated
to our Portman segment. SFAS 142 requires us to compare the
fair value of the reporting unit to its carrying value on an
annual basis to determine if there is potential goodwill
impairment. If the fair value of the reporting unit is less than
its carrying value, an impairment loss is recorded to the extent
that the fair value of the goodwill within the reporting unit is
less than the carrying value of its goodwill.
Preferred Stock: In January 2004, we issued
172,500 shares of redeemable cumulative convertible
perpetual preferred stock, without par value, issued at
$1,000 per share. The preferred stock pays quarterly cash
dividends at a rate of 3.25 percent per annum and can be
converted into our common shares at an adjusted rate of 32.3354
common shares (32.6652 at February 17, 2006) per share of
preferred stock. The preferred stock is classified as
temporary equity reflecting certain provisions of
the agreement that could, under remote circumstances, require us
to redeem the preferred stock for cash. See
Note 11 Preferred Stock for a more detailed
discussion.
Asset Impairment: We monitor conditions that may affect
the carrying value of our long-lived and intangible assets when
events and circumstances indicate that the carrying value of the
assets may be impaired. We determine impairment based on the
assets ability to generate cash flow greater than the
carrying value of the asset, using an undiscounted
probability-weighted analysis. If projected undiscounted cash
flows are less than the carrying value of the asset, the asset
is adjusted to its fair value. See Note 1
Operations and Customers Empire Mine and
Note 4 Discontinued Operations.
Repairs and Maintenance: The cost of major power plant
overhauls is amortized over the estimated useful life, which is
the period until the next scheduled overhaul, generally
5 years. All other planned and unplanned repairs and
maintenance costs are expensed during the year incurred.
Income Taxes: Income taxes are based on income (loss) for
financial reporting purposes and reflect a current tax liability
(asset) for the estimated taxes payable
(recoverable) for all open tax years and changes in
deferred taxes. In evaluating any exposures associated with our
various tax filing positions, we record liabilities for
exposures on a probable basis. Deferred tax assets or
liabilities are determined based on differences between
financial reporting and tax bases of assets and liabilities and
are measured using enacted tax laws and rates. A valuation
allowance is provided on deferred tax assets if it is determined
that it is more likely than not that the asset will not be
realized.
Environmental Remediation Costs: We have a formal code of
environmental protection and restoration. Our obligations for
known environmental problems at active and closed mining
operations, and other sites have been recognized based on
estimates of the cost of investigation and remediation at each
site. If the cost can only be estimated as a range of possible
amounts with no specific amount being most likely, the minimum
of the range is accrued. Costs of future expenditures are not
discounted to their present value. Potential insurance
recoveries have not been reflected in the determination of the
liabilities.
Stock Compensation: Effective January 1, 2003, we
adopted the fair value method of recording stock-based employee
compensation as contained in Statement of Financial Accounting
Standards (SFAS) No. 123, Accounting for
Stock-Based Compensation. As prescribed in
SFAS No. 148, Accounting for Stock-Based
Compensation Transition and Disclosure, we
elected to use the prospective method. The
prospective method requires expense to be recognized for all
awards granted, modified or settled beginning in the year of
adoption. Historically, we applied the intrinsic method as
provided in Accounting Principles Board (APB)
Opinion No. 25, Accounting for Stock Issued to
Employees and related interpretations and accordingly, no
compensation cost had been recognized for stock options in prior
years. As a result of adopting the fair value method for stock
compensation, all future awards will be expensed over the stock
options vesting period. The adoption did not have a
significant financial effect in 2003. The following illustrates
the
77
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
pro forma effect on net income and earnings per share as if we
had applied the fair value recognition provisions of
SFAS No. 123 to all awards unvested in each period:
|
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pro Forma | |
|
|
(In Millions) | |
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|
| |
|
|
2005 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
Net income (loss) as reported
|
|
$ |
277.6 |
|
|
$ |
323.6 |
|
|
$ |
(32.7 |
) |
Stock-based employee compensation:
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|
|
|
|
|
|
|
|
|
|
|
|
|
Add expense included in reported results
|
|
|
8.5 |
|
|
|
6.6 |
|
|
|
6.0 |
|
|
Deduct fair value-based method
|
|
|
(6.1 |
) |
|
|
(5.4 |
) |
|
|
(3.8 |
) |
|
|
|
|
|
|
|
|
|
|
Pro forma net income (loss)
|
|
$ |
280.0 |
|
|
$ |
324.8 |
|
|
$ |
(30.5 |
) |
|
|
|
|
|
|
|
|
|
|
Earnings (loss) per share:
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|
|
|
|
|
|
|
|
|
|
|
|
|
Basic as reported
|
|
$ |
12.52 |
|
|
$ |
14.94 |
|
|
$ |
(1.60 |
) |
|
|
|
|
|
|
|
|
|
|
|
Basic pro forma
|
|
$ |
12.63 |
|
|
$ |
14.99 |
|
|
$ |
(1.49 |
) |
|
|
|
|
|
|
|
|
|
|
|
Diluted as reported
|
|
$ |
9.97 |
|
|
$ |
11.80 |
|
|
$ |
(1.60 |
) |
|
|
|
|
|
|
|
|
|
|
|
Diluted pro forma
|
|
$ |
10.06 |
|
|
$ |
11.84 |
|
|
$ |
(1.49 |
) |
|
|
|
|
|
|
|
|
|
|
The market value of restricted stock awards and performance
shares is charged to expense over the vesting period.
In December, 2004, the Financial Accounting Standards Board
(FASB) issued SFAS No. 123R,
Share-Based Payment (SFAS 123R),
which replaces SFAS 123 and supersedes APB 25.
SFAS 123R requires all share-based payments to employees be
recognized in the financial statements. With limited exceptions,
the amount of compensation cost will be measured based on the
grant-date fair value of the equity or liability instruments
issued. In addition, liability awards will be re-measured each
reporting period. Compensation costs will be recognized over the
period that an employee provides service in exchange for the
award. SFAS 123R is effective for periods beginning after
December 15, 2005. We are currently evaluating the
provisions of this Statement to determine the impact on our
consolidated financial statements. It is, however, expected to
reduce consolidated net income.
Research and Development Costs: Research and development
costs, principally relating to the Mesabi Nugget project at the
Northshore mine in Minnesota, are expensed as incurred. Mesabi
Nugget project costs of $1.8 million, $.9 million and
$1.6 million in 2005, 2004 and 2003, respectively, were
included in Miscellaneous net. Mine
development costs (stripping) are included in the
cost of production as incurred. See Accounting and
Disclosure Changes.
Earnings Per Common Share: Basic earnings per common
share is calculated on the average number of common shares
outstanding during each period. Diluted earnings per common
share is based on the average number of common shares
outstanding during each period, adjusted for the effect of
outstanding stock options, restricted stock and performance
shares, including the as-if-converted effect of the
convertible preferred stock.
Reclassifications: Certain prior year amounts have been
reclassified to conform to current year presentations. In the
fourth quarter of 2005, we reclassified results for our
operations in Venezuela to Discontinued Operations.
Accounting and Disclosure Changes: In May 2005, FASB
issued Statement No. 154, Accounting Changes and
Error Corrections (SFAS 154).
SFAS 154, which replaces APB Opinion No. 20,
Accounting Changes and SFAS No. 3,
Reporting Accounting Changes in Interim Financial
Statements,
78
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
establishes new standards on accounting for changes in
accounting principles. Pursuant to the new rules, all such
changes must be accounted for by retrospective application to
the financial statements of prior periods unless it is
impracticable to do so. The statement is effective for
accounting changes and correction of errors made in fiscal years
beginning after December 15, 2005. Early adoption is
permitted. Adoption of SFAS 154 is not expected to
materially affect our consolidated financial statements.
In March 2005, FASB issued Interpretation No. 47,
Accounting for Conditional Asset Retirement
Obligations (FIN 47). FIN 47
clarifies that an entity is required to recognize a liability
for the fair value of a conditional asset retirement obligation
when incurred if the liabilitys fair value can be
reasonably estimated. The Interpretation is effective for years
ending after December 15, 2005 with earlier adoption
encouraged. Adoption of FIN 47 in the first quarter of 2005
did not impact our consolidated financial statements.
On March 17, 2005, the Emerging Issues Task Force
(EITF) reached consensus on Issue No. 04-6,
Accounting for Stripping Costs Incurred during Production
in the Mining Industry,
(EITF 04-6).
The consensus clarifies that stripping costs incurred during the
production phase of a mine are variable production costs that
should be included in the cost of inventory. The consensus,
which is effective for reporting periods beginning after
December 15, 2005, permits early adoption. We elected to
adopt EITF 04-6 in
the first quarter ending March 31, 2005. As a result, we
recorded an after-tax cumulative effect adjustment of
$4.2 million, $.15 per diluted share, and increased
product inventory by $6.4 million effective January 1,
2005. At its June 29, 2005 meeting, FASB ratified a
modification to
EITF 04-6 to
clarify that the term inventory produced means
inventory extracted. In the fourth quarter, we
recorded an additional after-tax cumulative effect adjustment of
$1.0 million, $.04 per diluted share, and increased
work-in-process
inventory by $1.6 million effective January 1, 2005 to
comply with the modification.
In December 2004, FASB issued SFAS No. 153,
Exchange of Nonmonetary Assets an amendment of APB Opinion
No. 29. SFAS 153 eliminates the exception from
fair value measurement for nonmonetary exchanges of similar
productive assets and replaces it with an exception for
exchanges that do not have commercial substance. The Statement
is effective for nonmonetary exchanges occurring in fiscal
periods beginning after June 15, 2005. Implementation of
the Statement did not have a significant effect on our
operations.
In November 2004, FASB issued SFAS No. 151,
Inventory Costs which amends the guidance in ARB
No. 43, Chapter 4, Inventory Pricing.
SFAS 151 clarifies the accounting for abnormal amounts of
idle facility expense, freight, handling costs, and wasted
material (spoilage) and requires such costs to be
recognized as current-period charges. Additionally,
SFAS 151 requires that allocation of fixed production
overhead costs be based on normal capacity. The statement is
effective for years beginning after June 15, 2005, with
early adoption permitted. The implementation of this standard in
the fourth quarter of 2004 did not have an impact on our
consolidated financial statements.
On October 13, 2004, FASB ratified
EITF 04-8,
The Effect of Contingently Convertible Debt on Diluted
Earnings Per Share,
(EITF 04-8).
The consensus specified that the dilutive effect of contingently
convertible debt and preferred stock (CoCos) should
be included in dilutive earnings per share computations (if
dilutive), regardless of whether the market price trigger has
been met. Previously, CoCos were only required to be included in
the calculation of diluted earnings per share when the
contingency was met. The effective date for
EITF 04-8
implementation was for reporting periods ending after
December 15, 2004. Earnings per share for 2004 have been
adjusted from the date of issuance of our preferred stock.
In March 2004, the EITF reached consensus on
Issue 04-3,
Mining Assets: Impairment and Business Combinations
(EITF 04-3).
EITF 04-3 relates
to estimating cash flows used to value mining assets or assess
those assets for impairment. We assess impairment on
economically recoverable ore utilizing existing technology. The
release, which was effective for business combinations and
impairment testing after March 31, 2004, did not have a
significant impact on our consolidated financial results.
79
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
In December 2003, FASB modified SFAS Statement No. 132
(originally issued in February 1998), Employers
Disclosures about Pensions and Other Postretirement
Benefits, to improve financial statement disclosures for
defined benefit plans. The change replaces the existing SFAS
disclosure requirements for pensions. The standard requires that
companies provide more details about their plan assets, benefit
obligations, cash flows, benefit costs and other relevant
information. The guidance is effective for fiscal years ending
after December 15, 2003. Accordingly, our footnote
disclosure regarding our pension and other postretirement
(OPEB) benefits has been updated to conform to the
requirements of SFAS No. 132R. See
Note 9 Retirement Related Benefits.
In May 2003, FASB issued SFAS No. 150,
Accounting for Certain Financial Instruments with
Characteristics of both Liabilities and Equity
(SFAS 150), to establish standards for how an
issuer classifies and measures certain financial instruments
with characteristics of both liabilities and equity.
SFAS 150 requires an issuer to classify a financial
instrument that is within its scope as a liability, or an asset,
which may have previously been classified as equity. We adopted
SFAS 150 effective June 30, 2003, as required. The
adoption of the Statement did not have an impact on our
consolidated financial statements.
In January 2003 (as revised December 2003), FASB issued
Interpretation No. 46, Consolidation of Variable
Interest Entities (FIN 46). FIN 46
clarifies the application of Accounting Research
Bulletin No. 51, Consolidated Financial
Statements, for certain entities in which equity investors
do not have the characteristics of a controlling financial
interest or do not have sufficient equity at risk for the entity
to finance its activities without additional subordinated
financial support from other parties. FIN 46 requires that
variable interest entities, as defined, should be consolidated
by the primary beneficiary, which is defined as the entity that
is expected to absorb the majority of the expected losses,
receive the majority of the gains, or both. FIN 46 requires
that companies disclose certain information about a variable
interest entity created prior to February 1, 2003 if it is
reasonably possible that the enterprise will be required to
consolidate that entity. The application of FIN 46, which
was previously required on July 1, 2003 for entities
created prior to February 1, 2003 and immediately for any
variable interest entities created subsequent to
January 31, 2003, has been deferred until years ending
after December 31, 2003, except for those companies which
previously issued financial statements implementing the
provisions of FIN 46. We have evaluated our unconsolidated
entities and do not believe that any entity in which we have an
interest, but do not currently consolidate, meets the
requirements for a variable interest entity to be consolidated.
|
|
Note 1 |
Operations and Customers |
Effective December 1, 2003, United Taconite, a newly formed
company owned 70 percent by a subsidiary of the Company and
30 percent by a subsidiary of Laiwu Steel Group Limited
(Laiwu) of China, purchased the ore mining and
pelletizing assets of Eveleth Mines LLC (Eveleth
Mines). Eveleth Mines had ceased mining operations in May
2003 after filing for chapter 11 bankruptcy protection on
May 1, 2003. Under the terms of the purchase agreement,
United Taconite purchased all of Eveleth Mines assets for
$3 million in cash and the assumption of certain
liabilities, primarily mine closure-related environmental
obligations. As a result of this transaction, the assets
acquired exceeded the cost of the acquisition, resulting in an
extraordinary gain of $2.2 million, net of $.5 million
tax and $1.2 million minority interest. In conjunction with
this transaction, the Company and its Wabush venture partners
entered into pellet sales and trade agreements with Laiwu to
optimize shipping efficiency. Pellet sales to Laiwu under these
contracts totaled .3 million tons and .2 million tons
in 2005 and 2004, respectively.
The mine began production in late December 2003 and produced
4.1 million tons (our share 2.9 million tons) in 2004
and 4.9 million tons in 2005 (our share 3.4 million
tons). In 2005, we completed a production capacity expansion
project that added approximately 1.0 million tons (our
share .7 million tons) of annual
80
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
production capacity with capital expenditures of
$13.3 million expended each year in 2005 and 2004.
Production for 2006 is estimated to approximate 5.2 million
tons (our share 3.6 million tons).
Effective December 31, 2002, we increased our ownership in
Empire from 46.7 percent to 79 percent in exchange for
assumption of all mine liabilities. Under terms of the
agreement, we indemnified Ispat Inland Inc. (Ispat)
from obligations of Empire in exchange for certain future
payments to Empire and to the Company by Ispat of
$120.0 million, recorded at a present value, including
accrued interest at 12.4 percent, of $59.8 million at
December 31, 2005 ($64.1 million at December 31,
2004) with $47.8 million classified as Long-term
receivable and the balance current, over the
12-year life of the
supply agreement. A subsidiary of Ispat retained a
21 percent ownership in Empire, for which it has the
unilateral right to put the interest to us in 2008. We are the
sole supplier of pellets purchased by Ispat for the term of the
supply agreement.
On December 17, 2004, Ispat International N.V. completed
its acquisition of LNM Holdings N.V. to form Mittal Steel
(Mittal). On April 13, 2005, Mittal completed
its acquisition of ISG, subsequently renamed Mittal Steel USA.
At the time of the acquisition of ISG, the Company had three
different sales contracts with steel companies that became part
of Mittal Steel USA:
|
|
|
|
|
Ispat. Ispat was a wholly owned subsidiary of Ispat
International N.V. On December 31, 2002, we entered into a
Pellet Sale and Purchase Agreement with Ispat (the Ispat
Contract), which provides that we are the sole outside
supplier of iron ore pellets to Ispat. The Ispat Contract runs
through January 2015. |
|
|
|
Mittal ISG. We entered into a Pellet Sale and Purchase
Agreement with ISG on April 10, 2002, which runs through
2016 (the ISG Contract), under which we are the sole
supplier of iron ore pellets for the former ISGs Cleveland
and Indiana Harbor Works. The ISG Contract was subsequently
amended in December 2004. |
|
|
|
Mittal Steel-Weirton (formerly Weirton). Prior to the
acquisition of ISG by Mittal, ISG had acquired Weirton, which
was in chapter 11 bankruptcy at the time. The Company was
one of two suppliers of iron ore pellets to Weirton. At the time
of ISGs acquisition of Weirton, we entered into an Amended
and Restated Pellet Sale and Purchase Agreement dated
May 17, 2004, with both ISG and Weirton (the Weirton
Contract). The Weirton Contract runs through 2018. |
In December 2005, Mittal merged Ispat into Mittal Steel USA and
Mittal Steel USA assumed Ispats obligations under the
Ispat Contract. Mittal Steel USA is a 62.3 percent equity
participant in Hibbing and a 21 percent equity partner in
Empire.
During 2005, our North American pellet sales totaled
approximately 22.3 million tons, with pellet sales to
Mittal Steel USA representing approximately 48 percent of
North American sales volume. Currently, 2006 pellet sales are
projected to be approximately 21 million tons, not
including any sales to Mittal Steel-Weirton.
In 2005 Mittal Steel USA shut down Mittal Steel-Weirtons
blast furnace. The Weirton Contract has a minimum annual
purchase obligation and requires Mittal Steel-Weirton to
purchase for the years 2004 and 2005 the greater of
67 percent of Mittal Steel-Weirtons total annual iron
ore pellet requirements, or 1.5 million tons and, for the
years 2006 through and including 2018, a tonnage amount equal to
Mittal Steel-Weirtons total annual iron ore pellet tonnage
requirements, with a minimum annual purchase obligation of
2.0 million tons per year, required for consumption in
Mittal Steel-Weirtons iron and steelmaking facilities in
any year at Mittal Steel-Weirton. Over the past few months
we have been in discussions with Mittal Steel USA regarding the
terms of the Weirton Contract in response to Mittal Steel
USAs request for relief from the minimum purchase
obligation. These discussions have resulted in no agreement
between the Company and Mittal Steel USA as to the Mittal
Steel-Weirton minimum purchase obligation. Mittal Steel-Weirton
81
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
purchased approximately 325,000 tons of iron ore pellets less
than its 1.5 million minimum purchase obligation for 2005,
and as a result we invoiced Mittal Steel-Weirton approximately
$17 million for this remaining tonnage. The sale of this
tonnage would be recorded in 2006. Payment for this tonnage was
due on January 30, 2006 and has not been received. Mittal
Steel USA has advised us that the Mittal Steel-Weirton blast
furnace has been permanently shut down and will not be
restarted. Mittal Steel-Weirton has also taken the position that
it has no future obligation to purchase pellets under the
Weirton Contract.
Mittal Steel USA has also claimed that in 2004 it overpaid a
supplemental steel price sharing provision (the Special
Steel Payment) under the Weirton and ISG Contracts. Mittal
claims that, prior to the acquisition of ISG by Mittal,
surcharges were improperly included in the average annual
unprocessed hot band steel pricing for purposes of calculating
the Special Steel Payment under both contracts, despite the fact
that ISG itself calculated the amount of the Special Steel
Payment, included surcharges in that calculation, and did not
claim that it was making or had made any overpayment. Mittal
Steel USA has claimed an overpayment of approximately
$8.7 million with respect to the Weirton Contract and
approximately $49.6 million with respect to the ISG
Contract. We are confident that the Special Steel Payment
calculation properly included all revenue including surcharges.
We believe that Mittal Steel USAs positions with respect
to the minimum purchase obligation and the Special Steel Payment
are without merit.
We are currently negotiating with Mittal Steel USA in an attempt
to resolve the foregoing disputes. We are also currently
reviewing all of our legal options, including the possible
initiation of an arbitration proceeding under the Weirton
Contract.
As a result of increasing production costs at the Empire mine,
revised economic mine planning studies were completed in the
fourth quarter of 2002 and updated in the fourth quarter of
2003. Based on the outcome of these studies, the ore reserve
estimates at Empire were reduced from 116 million tons at
December 31, 2001 to 63 million tons at
December 31, 2002 and 29 million tons at
December 31, 2003. Ore reserves were approximately
23 million tons at December 31, 2004, reflecting 2004
production. In 2005, the ore reserves at Empire were reduced by
production and by 2 million tons to eliminate difficult
processing ore having a high stripping ratio in the CD-II
deposit. The reduction in our ore reserve estimates for the
Empire mine is due to the inability to develop effective mine
plans that produce cost-justified combinations of production
volume, ore quality and stripping requirements.
As a result of an impairment analysis, we concluded that the
assets of Empire were impaired and accordingly recorded an
impairment charge in 2002 of $52.7 million to write-off the
carrying value of the long-lived assets of Empire. We calculated
estimated future net cash flows for purposes of assessing and
measuring impairment by utilizing the guidance provided in
SFAS 144, Accounting for the Impairment or Disposal
of Long-Lived Assets. We utilized an undiscounted
probability-weighted cash flow analysis to determine whether the
Empire mine could generate cash flows greater than the carrying
value of its long-lived assets. In our analysis, we based our
revenue estimate on unescalated contractual pricing under the
Ispat 12-year pellet
supply agreement and included special payments of up to
$120 million by Ispat to Empire and the Company over the
duration of the contract. The Ispat pellet revenue rate was
utilized because Mittal Steel USA purchases the majority of
Empires production. Our analysis was limited to the
recovery of proven and probable ore reserves, reflected
alternate annual production levels and unescalated production
and capital costs (based on the production-level adjusted
current year budget and five-year forecast) net of royalties and
management fees paid to the Company. The analysis also
incorporated funding requirements for employment legacy and
environmental and mine closure obligations. The cash flow
analysis indicated that the Empire assets were impaired and that
the fair value of the Empire long-lived assets was determined to
be zero. In 2004 and 2003, we recorded additional impairment
charges of $5.8 million and $2.6 million,
respectively, for fixed asset additions. Due primarily to the
significant increase in 2005 pellet pricing, we determined,
based on a cash flow analysis, that our Empire mine is no longer
impaired; accordingly, capital additions at Empire in 2005 were
not charged to expense.
82
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
Our plan to re-start an idled furnace to increase capacity by
..8 million tons to 5.6 million tons per year at our
wholly owned Northshore mine has been deferred until market
conditions warrant increased pellet production.
On January 31, 2002, we increased our ownership in Tilden
from 40 percent to 85 percent with the acquisition of
Algoma Steel Inc.s (Algoma) interest in Tilden
for assumption of mine liabilities associated with the interest.
The acquisition increased our annual production capacity by
3.5 million tons. Concurrently, a term supply agreement was
executed that made us the sole supplier of iron ore pellets
purchased by Algoma for a
15-year period. Sales
to Algoma totaled 3.8 million tons in 2005
(3.3 million tons in both 2004 and 2003).
In July 2002, we acquired (effective retroactive to
January 1, 2002) an eight percent interest in Hibbing from
Bethlehem Steel Corporation (Bethlehem) for the
assumption of mine liabilities associated with the interest. The
acquisition increased our ownership of Hibbing from
15 percent to 23 percent. This transaction reduced
Bethlehems ownership interest in Hibbing to
62.3 percent. In October 2001, Bethlehem filed for
protection under chapter 11 of the U.S. Bankruptcy
Code. In May 2003, ISG purchased the assets of Bethlehem,
including Bethlehems 62.3 percent interest in Hibbing.
Economic ore reserves at Wabush were reduced to 94 million
tons at December 31, 2002 and further reduced to
61 million tons at December 31, 2003. Wabush ore
reserves at December 31, 2004 decreased to 57 million
tons, reflecting 2004 production. In 2005, the ore reserves at
Wabush Mines were reduced by production and by less than
1 million tons due to higher than anticipated operating
costs. The reduction in our ore reserve estimates for Wabush is
largely a reflection of increased operating costs, the impact of
a decrease in the value of the U.S. dollar and a reduction
in maximum mining depth due to dewatering capabilities based on
a hydroanalysis evaluation. Impairment analyses were prepared in
2003 and 2004 with results indicating that our long-lived assets
at Wabush were not impaired. As directly related to Wabush, we
believe that our ten-year supply agreement with Laiwu should
ensure that Wabush operates at capacity for the foreseeable
future.
Koolyanobbing Operations
Koolyanobbing, acquired in the acquisition of Portman, has a
current capacity of approximately 6.0 million metric tons
(tonnes) annually. The capacity of the Koolyanobbing
operations is in the process of being expanded to eight million
tonnes per year. This expansion is primarily driven by the
development of iron ore resources at Mt Jackson and Windarling.
The upgrade in capacity is expected to be completed by the end
of the first quarter of 2006.
Cockatoo Island
Cockatoo Island, acquired in the acquisition of Portman, is a
joint venture with mining contracting group, Henry Walker Eltin
(HWE), a company that entered receivership in late
2004. Both parties hold a 50 percent interest in the joint
venture. As of February 1, 2006, HWEs mining assets
were sold to Leighton Contractors Pty Ltd
(Leighton), an Australian-based mining and
construction contractor. Leighton also purchased HWEs
subsidiary that owned its 50 percent interest in the
Cockatoo Island joint venture and is
83
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
continuing to manage the operation. Current mining at Cockatoo
Island commenced in late 2002 with a three year mine life and
production of approximately 1.2 million tonnes per year.
Mining is scheduled for completion in 2007. There is limited
opportunity for further expansion.
|
|
|
Effect of Mine Ownership Increases |
While none of the increases in North American mine ownerships
during 2002 required cash payments or assumption of debt, the
ownership changes resulted in the Company recognizing net
obligations of approximately $93 million at
December 31, 2002. Additional consolidated obligations
assumed totaled approximately $163 million at
December 31, 2002, primarily related to employment and
legacy obligations at Empire and Tilden mines, partially offset
by non-capital long-term assets, principally the
$59 million Ispat long-term receivable. United
Taconites acquisition of the Eveleth Mines assets in
Minnesota in December 2003 was for $3 million cash and
assumption of certain liabilities, primarily mine
closure-related environmental expenses.
On October 23, 2003, Rouge Industries, Inc.
(Rouge), a significant pellet sales customer of the
Company, filed for chapter 11 bankruptcy protection. On
January 30, 2004, Rouge sold substantially all of its
assets to Severstal North America, Inc. (Severstal).
Severstal, as part of the acquisition of assets of Rouge,
assumed our term supply agreement with Rouge with minimal
modifications. In January, 2006, we entered into an amended and
restated agreement with Severstal. The contract provides that we
would be the sole supplier of iron ore pellets through 2012,
with certain minimum purchase requirements for certain years. We
sold 3.6 million tons, 3.3 million tons and
3.0 million tons to Severstal in 2005, 2004 and 2003,
respectively. Additionally, in the first quarter 2004, Rouge
repaid a $10 million secured loan balance outstanding plus
accrued interest.
On September 16, 2003, WCI Steel Inc. (WCI)
petitioned for protection under chapter 11 of the
U.S. Bankruptcy Code. At the time of the filing, we had a
trade receivable exposure of $4.9 million, which was fully
reserved in the third quarter of 2003. On October 14, 2004,
the Company and the current owners of WCI reached agreement (the
2004 Pellet Agreement) for us to supply
1.4 million tons of iron ore pellets in 2005 and, in 2006
and thereafter, to supply one hundred percent of WCIs
annual requirements up to a maximum of two million tons of iron
ore pellets. The 2004 Pellet Agreement is for a ten-year term,
which commenced on January 1, 2005 and provides for full
recovery of our $4.9 million receivable plus
$.9 million of subsequent pricing adjustments. The 2004
Pellet Agreement was approved by the Bankruptcy Court on
November 16, 2004. The receivable and subsequent pricing
adjustments are to be paid in three equal installments of
approximately $1.9 million. The first payment due on
November 16, 2005, was timely received and has been
classified as Customer bankruptcy recoveries in the Statement of
Consolidated Operations. We sold 1.4 million tons and
1.7 million tons to WCI in 2005 and 2004, respectively.
Previously, the Bankruptcy Court denied confirmation of both of
two competing plans of reorganization filed by (i) WCI,
jointly with its current owner (which plan was supported by the
USWA, the union representing WCIs hourly employees, and
(ii) a group of WCIs secured noteholders.
Subsequently, the secured noteholders amended their plan of
reorganization (the New Noteholder Plan) and
obtained the support of the USWA for the New Noteholder Plan.
Under the terms of the New Noteholder Plan, an entity controlled
by the secured noteholders would acquire the steelmaking assets
and business of WCI and assume the 2004 Pellet Agreement,
including the obligation to cure the remaining unpaid
pre-bankruptcy trade receivable owed to the Company by WCI. A
hearing before the Bankruptcy Court on the confirmation of the
New Noteholder Plan is scheduled to commence on March 13,
2006. WCIs current owner and the Pension Benefit Guaranty
Corporation oppose confirmation of the New Noteholder Plan.
84
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
On January 29, 2004, Stelco Inc. (Stelco)
applied for and obtained Bankruptcy Court protection from
creditors in Ontario Superior Court under the Companies
Creditors Arrangement Act (CCAA). At the time of the
filing, we had no trade receivable exposure to Stelco.
Additionally, Stelco has continued to operate and has met its
cash call requirements at the Tilden, Hibbing and Wabush mining
ventures to date.
Throughout the fall of 2005, Stelco worked to come to agreement
with key stakeholders on a reorganization plan. On
December 9, 2005, the Third Amended and Restated Plan of
Compromise and Arrangement (the Plan) was agreed to.
On December 10, the creditors affected by the Plan (the
Affected Creditors) approved the Plan by
substantially more than the statutorily-mandated minimum
approval levels. On January 20, 2006, on motion by Stelco,
the Honorable Mr. Justice Farley of the Superior Court of
Ontario sanctioned the Plan as being fair and reasonable in all
the circumstances. On February 14, 2006, Justice Farley
issued an order approving the proposed reorganization. Stelco is
now in the process of reorganizing pursuant to the Plan so as to
be in a position to emerge from bankruptcy protection shortly.
The current stay of proceedings against Stelco expires on
March 31, 2006.
Stelcos existing shareholders have filed an appeal. We
sold 1.4 million tons, 1.2 million tons and
..1 million tons to Stelco in 2005, 2004 and 2003,
respectively. Stelco is a 44.6 percent participant in the
Wabush Mines joint venture, and U.S. subsidiaries of Stelco
(which have not filed for bankruptcy protection) own
14.7 percent of Hibbing and 15 percent of Tilden.
In the third quarter 2003, we initiated a salaried employee
reduction program in order to place us in a better position to
address long-term strategic issues. The action resulted in a
reduction of 136 staff employees at our corporate, central
services and various mining operations, which represented an
approximate 20 percent decrease in salaried workforce at
our U.S. operations (prior to the acquisition of United
Taconite). Accordingly, we recorded restructuring charges of
$8.7 million in 2003. Our share of the restructuring
charges is principally related to pension and OPEB obligations,
$6.2 million, and one-time severance benefits,
$2.5 million. Included in the long-term restructuring
charge was an OPEB plan curtailment credit of $1.5 million.
The programs impact on the long-term pension and OPEB
obligations was accounted for through the benefit plans in which
the individual employees participated. Less than
$1.6 million of the one-time severance benefits required
cash funding in 2003 leaving a remaining severance liability of
approximately $.9 million at December 31, 2003. In
2004, we expended $.7 million and recorded a
$.2 million credit to the restructuring charge in
satisfaction of the obligation. The recognition of the one-time
severance benefits were accounted for under
SFAS No. 146, Accounting for Costs Associated
with Exit or Disposal Activities.
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Note 3 |
Portman Acquisition |
On April 19, 2005, Cliffs Australia completed the
acquisition of 80.4 percent of the outstanding shares of
Portman, a Western Australia-based independent iron ore mining
and exploration company. The acquisition was initiated on
March 31, 2005 by the purchase of approximately
68.7 percent of the outstanding shares of Portman. The
assets consist primarily of iron ore inventory, land and mineral
rights, and iron ore reserves. The purchase price of the
80.4 percent interest was $433.1 million, including
$12.4 million of acquisition costs. Additionally, we
incurred $9.8 million of foreign currency hedging costs
related to this transaction, which were included in
Other-net in the Statement of Consolidated
Operations. The acquisition increased our customer base in China
and Japan and established our presence in the Australian mining
industry. Portmans 2005 production (excluding its
..6 million tonne share of the 50 percent-owned
Cockatoo Island joint venture) was approximately
6.0 million tonnes. Portman currently has a
$61 million project underway that is expected to increase
its wholly owned production capacity to eight million tonnes per
year by the end of the first quarter of 2006. The production is
fully committed to steel companies in China and Japan for
approximately four years.
85
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
Portmans reserves total approximately 89 million
tonnes at December 31, 2005, and it has an active
exploration program underway to increase its reserves.
The acquisition and related costs were financed with existing
cash and marketable securities and $175 million of interim
borrowings under a new three-year $350 million revolving
credit facility. The outstanding balance was repaid in full with
a $50 million payment on July 5, 2005. See
NOTE 7 Credit Facilities.
The Statement of Consolidated Financial Position of the Company
as of December 31, 2005 reflects the acquisition of
Portman, effective March 31, 2005, under the purchase
method of accounting. Assets acquired and liabilities assumed
have been recorded at estimated fair values as of the
acquisition date as determined by preliminary results of an
appraisal of assets and liabilities currently underway, which is
expected to be finalized by March 31, 2006. At acquisition,
Portman had currency derivatives used to hedge its currency
exposure for a portion of its sales receipts denominated in
U.S. dollars. Although Portman carried a hedge reserve, the
reserve was not established in the allocation of purchase price.
Settlement of the pre-acquisition contracts, with a fair value
of $13.0 million, therefore, are expensed upon delivery.
Through December 31, 2005, $9.8 million of hedge
contracts were settled. As a result, we recognized the
$9.8 million as a reduction of revenues.
In the fourth quarter, we refined our purchase accounting to
reflect our preliminary allocation with the assistance of an
outside consultant. The adjustment since our initial allocation
of the 80.4 percent interest in Portman, increased
Portmans iron ore inventory values by $49.1 million
to reflect a market-based valuation. Of the $49.1 million
inventory basis adjustment, $23.1 million was allocated to
product and work in process inventories, of which approximately
$19.9 million has been included in cost of goods sold
through December 31, 2005. Most of the $3.2 million
remaining inventory basis adjustment is expected to be expensed
prior to the end of 2006. Additionally, a long-term lease was
classified as a capital lease resulting in an increase in plant
and equipment, and capital lease obligations, of
$26.7 million. The valuation also resulted in assignment of
goodwill, $8.8 million, and a $20.2 million increase
in the value of our 50 percent interest in our investment
in Cockatoo Island. The goodwill is not deductible for tax
purposes. The increase in value of Cockatoo Island was based
upon a discount cash flow analysis over the remaining two-year
life of its iron ore reserves. These changes reduced the value
assigned to Portmans iron ore reserves by
$90.8 million. The $.7 million reduction in purchase
price was attributable to the re-allocation of transaction costs
to debt acquisition costs, which are being amortized over the
three-year term of the credit facility. Such amounts are subject
to adjustment based on the finalization of the valuations and
appraisals. Accordingly, the revised
86
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
preliminary purchase price is subject to further revision. A
comparison of the revised purchase price allocation to the
initial allocation is as follows:
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|
|
|
|
|
|
|
|
|
|
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|
(In Millions) | |
|
|
| |
|
|
Revised | |
|
Initial | |
|
|
|
|
Allocation | |
|
Allocation | |
|
Change | |
|
|
| |
|
| |
|
| |
ASSETS
|
|
|
|
|
|
|
|
|
|
|
|
|
CURRENT ASSETS
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash
|
|
$ |
24.1 |
|
|
$ |
24.1 |
|
|
$ |
|
|
|
Iron Ore Inventory
|
|
|
54.8 |
|
|
|
29.0 |
|
|
|
25.8 |
|
|
Other
|
|
|
35.3 |
|
|
|
35.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
TOTAL CURRENT ASSETS
|
|
|
114.2 |
|
|
|
88.4 |
|
|
|
25.8 |
|
Property, Plant and Equipment
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Iron Ore Reserves
|
|
|
413.5 |
|
|
|
504.3 |
|
|
|
(90.8 |
) |
|
Other
|
|
|
69.1 |
|
|
|
34.7 |
|
|
|
34.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
TOTAL PROPERTY PLANT AND EQUIPMENT
|
|
|
482.6 |
|
|
|
539.0 |
|
|
|
(56.4 |
) |
Long-term Stockpiles
|
|
|
38.7 |
|
|
|
15.4 |
|
|
|
23.3 |
|
Investment in Cockatoo Island
|
|
|
24.8 |
|
|
|
4.6 |
|
|
|
20.2 |
|
Other Assets
|
|
|
5.8 |
|
|
|
6.7 |
|
|
|
(.9 |
) |
Goodwill
|
|
|
8.8 |
|
|
|
|
|
|
|
8.8 |
|
|
|
|
|
|
|
|
|
|
|
Total Assets
|
|
$ |
674.9 |
|
|
$ |
654.1 |
|
|
$ |
20.8 |
|
|
|
|
|
|
|
|
|
|
|
|
LIABILITIES
|
|
|
|
|
|
|
|
|
|
|
|
|
Current Liabilities
|
|
$ |
35.8 |
|
|
$ |
34.7 |
|
|
$ |
1.1 |
|
Long-Term Liabilities
|
|
|
178.8 |
|
|
|
158.1 |
|
|
|
20.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Liabilities
|
|
|
214.6 |
|
|
|
192.8 |
|
|
|
21.8 |
|
|
|
|
|
|
|
|
|
|
|
Net Assets
|
|
|
460.3 |
|
|
|
461.3 |
|
|
|
(1.0 |
) |
Minority Interest
|
|
|
(27.2 |
) |
|
|
(27.5 |
) |
|
|
.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Purchase Price
|
|
$ |
433.1 |
|
|
$ |
433.8 |
|
|
$ |
(.7 |
) |
|
|
|
|
|
|
|
|
|
|
87
Cleveland-Cliffs Inc and Consolidated Subsidiaries
Notes to Consolidated Financial
Statements (Continued)
The following pro forma information summarizes the results of
operations for the year-ended December 31, 2005 and 2004,
as if the Portman acquisition had been completed as of the
beginning of 2004. The pro forma information gives effect to
actual operating results prior to the acquisition. Adjustments
made to revenues for hedging contracts, cost of goods sold for
depletion amortization costs incurred and inventory effects,
reflecting the allocation of purchase price to iron ore reserves
and inventory, interest expense, income taxes and minority
interest related to the acquisition, are reflected in the pro
forma information. These pro forma amounts do not purport to be
indicative of the results that would have actually been obtained
if the acquisition had occurred as of the beginning of the
periods presented or that may be obtained in the future.
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|
|
|
|
|
|
|
|
|
Pro Forma | |
|
|
(In Millions, Except | |
|
|
Per Common Share) | |
|
|
| |
|
|
2005 | |
|
2004 | |
|
|
| |
|
| |
Total Revenues
|
|
$ |
1,802.2 |
|
|
$ |
1,329.5 |
|
Income Before Cumulative Effect of Accounting Change
|
|
|
279.0 |
|
|
|
313.1 |
|
Cumulative Effect of Accounting Change
|
|
|
5.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|