4 Annual Report
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ANNUAL REPORT 05
AN INTERNATIONAL HIGH-TECH MINERALS GROUP
FORSKNING OCH UTVECKLING 4 LKAB ÅRSREDOVISNING 2005 LKAB in brief LKAB is an international high-tech minerals group, a world-leading producer of upgraded iron ore pro- ducts for the steel industry and a growing supplier of industrial minerals products to other sectors.
Most of the iron ore products are sold to European steelmills. Other important markets are North Africa, the Middle East and Southeast Asia. Sales of industrial minerals are mainly to custo- mers in Europe, but Asia and the USA are growing markets. The LKAB Group has more than 3,500 employees and consists of about 30 companies in 15 countries. There are iron ore mi- nes, processing plants and ore harbors in northern Sweden and northern Norway, and sales companies in Belgium, Germany and Singapore. Companies and production facilities for industrial minerals are located in Sweden, Finland, Greenland, the UK, Germany, the Netherlands, Greece, Turkey, Thailand, Hong Kong, China and the USA.
MISSION LKAB’s mission is, based on the Swedish Orefi elds, to manufac- ture and deliver to the world market upgraded iron ore products and services that create added value for its customers. Other closely related products and services that are based on LKAB’s know-how and support the main business can also be included in the company’s operations.
VISION LKAB will be perceived by the customers as the supplier that provides the most added value and is thereby the leader in its selected market segments.
OWNERSHIP AND MANAGEMENT LKAB is wholly owned by the Swedish state, represented by the Ministry of Industry, Employment and Communications. Chair- man of the Board: Björn Sprängare. President and Group CEO: Martin Ivert
ORGANIZATION Operations are organized in divisions: The Market Division sells iron ore products to the steel industry. The Mining Division mines and upgrades iron ore and delivers iron ore products. The Minerals Division develops, produces and markets industrial mineral products. The Special Businesses Division supports Group companies with services and technical development.
Cover photo: Ice sculpture of the new ore car outside Icehotel, Jukkasjärvi.
FORSKNING OCH UTVECKLING 5 LKAB ÅRSREDOVISNING 2005
Contents
3 Summary 4 President’s report 6 Strategies 10 Divisional operations 18 Markets and competition 20 Investments and development projects 24 Prospecting, ore reserves and mineral resources 26 Sustainability 38 Risks and risk management 40 Group overview 41 Report of the Directors 100 Auditors’ report 101 Corporate governance 106 Board of Directors and Auditors 108 Group Management 110 Addresses 111 Reporting dates 2006
Two generations of pelletizing plants in Malmberget. The steel belt plant (left) was built in 1973, and right, the new MK3, under construction. Highlights of 2005
• World production of crude steel increased by 6% and NET SALES AND OPERATING INCOME MSEK trade in seaborne iron ore by 12%. Iron ore prices in- 15 000 creased by 70-80%. • LKAB’s production of iron ore products increased by 12 000 1 million tonnes to 23.3 Mt. The price of LKAB’s blast 9 000 furnace pellets increased by 85%. Sales of industrial
minerals increased by 35%. 6 000 • The Group’s net sales increased by 60% to MSEK 14 337 (8 988). The profi t margin increased to 45%. Return on 3 000 equity amounted to 36.6%. 0 • Approved and ongoing capital expenditures totaling 01 02 03 04 05 10 billion kronor for increased pellet production capacity Net sales Operating income in Kiruna and Malmberget as well as a new ore harbor in Narvik. EARNING CAPACITY
• Start of olivine mining in Greenland, and of a production facility for mica in Finland. • Certifi ed quality management system throughout the en- tire group. Ongoing certifi cation of the environmental and energy management systems.
• Start of LKAB high school in the Orefi elds communities.
GROUP SUMMARY MSEK 2005 2004 2ETURN ON EQUITY Net sales 14 337 8 988 4ARGETED RETURN ON EQUITY Operating income 6 109 1 941 – operating margin, % 42.6 21.6 Income after fi nancial items 6 451 2 023 3PECIAL "USINESSES EXTERNAL SALES PER – profi t margin % 45.0 22.5 -INERALS DIVISION 2005 Tax -1 904 -456 The price increase on iron ore Net income for the year 4 547 1 567 products increased the Mining Division’s share of the Group’s Fixed assets 9 798 6 746 sales. Earnings for Special Busi- -INING Current assets 10 776 6 911 nesses derive mainly from Intra- Shareholders’ equity 14 802 10 044 Group sales.
Cash fl ow for the year * 544 -176 /THERS SALES PER Return on equity, % 36.6 16.5 !SIA MARKET REGION 2005 Equity/assets ratio, % 72.0 73.6 Both iron ore products and industrial Capital expenditures 2 648 965 minerals are sold mainly to customers Average number of employees 3 563 3 482 in Europe, but Minerals’ sales are growing in Asia. %UROPE
* According to IFRS, certain short- term investments cannot be re- LINES OF BUSINESS ported as part of liquid assets. In- MSEK Mining** Minerals Special Eliminations, stead, they are reported as part of Division Division Businesses adjustments Group investing activities. During the year, MSEK 1 846 (1 748) has been External revenue 12 191 2 018 128 14 337 placed in short-term investments. Intra-Group revenue 158 141 963 -1 262
Total revenue 12 349 2 159 1 091 -1 262 14 337 Operating income 5 720 148 100 141 6 109 ** Market Division’s sales included – operating margin, % 46.3 6.9 9.2 42.6 in sales for Mining Division. President’s report
With record-high production and earnings, 2005 was a fantastic year for LKAB. A return on equity of 36.6% exceeds the return requirement of 12% measured over a business cycle, by a wide margin. Targets for volumes, earnings and profi tability throughout the Group were also reached.
Driven by demand from China, the iron ore market saw planned production start-up during the fi rst half of 2008. continued strong growth. There was a shortage of ore, In the long term, this implies an increase in production which meant dramatic price increases of 70 to 80%. The capacity from a current 23 Mt to 30 Mt. price increases are, of course, the main reason for the Two thirds of our deliveries are shipped via the harbor strong earnings trend and the boost in sales for the Min- in Narvik. To improve effi ciency and environment, this fa- ing Division. cility will be rebuilt at a cost of nearly 1 billion kronor. To- The Minerals Division has also seen positive develop- taling 10 billion kronor, these three investment decisions ment, not least in China. During 2005, mining of olivine send a clear message to our customers that we are willing commenced in Greenland. Olivine sales complement the and able to meet their volume demands. iron ore business and have attracted great market interest. Three years ago, we set a goal for the Mining Division. FOCUS ON PRODUCTION AND MAINTENANCE By 2006, we would produce 23 million tonnes (Mt) of iron The strategy for the Mining Division is to develop pellet ore products per year – without appreciable increases in manufacture in terms of both volume and quality. Produc- capital expenditures and with the same number of em- tion increased in 2005 to 16.5 (16.0) Mt. Several produc- ployees. The division reached this target in 2005, produc- tion units set new volume records while maintaining or ing 23.3 Mt, which exceeded the previous year’s produc- improving the level of quality. tion by 1 Mt. A few years ago, we began a maintenance-improve- Despite the pressure to meet demand, costs have been ment program that has subsequently become a very stra- kept under control, a factor that has also contributed to tegically important activity. Developments in the past year the positive outcome. At the same time, we managed to have confi rmed that we chose the right path. The aim is maintain a high degree of service to our customers, which to stabilize manufacturing at a higher production level, is important, since quality and service are two of our key which will mean greater productivity, better quality, bet- competitive factors. ter delivery service and, not least, an improved working environment. CLEAR GROWTH STRATEGY, STRONG BELIEF IN THE FUTURE INDUSTRIAL MINERALS, COMPLEMENTARY BUSINESS For the Mining Division, we have a clearly defi ned stra- The Minerals Division has continued its investment in tegy based on the product that gives us the greatest com- industrial minerals. Olivine mining has commenced in petitive advantage: pellets. The strategy is scrutinized and Greenland, and the fi rst deliveries have been shipped to revised each year, a process which has led during the past customers and to our own pellet plants. year to several major investment decisions. Sales of magnetite to non-steel customers are also Fifty years ago, LKAB built the fi rst pelletizing plant in growing. Access to suffi cient quantities is the limiting fac- Malmberget. The route that was then chosen proved to tor, which is why it is strategically important to secure vol- be a prerequisite for the company’s long-term survival. umes for the Minerals Division. The focus on pellets has meant that LKAB has been able to stay in the competitive game, despite higher costs in COMMON VALUES AND SYSTEMS comparison to those of open-pit mining operations in Bra- In recent years, LKAB has grown from a Swedish iron ore zil and Australia. producer into an international minerals group with global In late-2004, the Board took the decision to invest 2.6 bil- operations. The Board has adopted several policies that lion kronor in a new pelletizing plant in Malmberget that have been communicated throughout the Group. The in- was to be operational at the turn of the year 2006/2007. tention is to make LKAB a group with shared values. The project has progressed well, and the production start- We have also decided to introduce a joint way of work- up will be about two months earlier than planned. This ing throughout the Group and to improve the effi ciency of is particularly positive, considering the prevailing market administrative processes. The fi rst step is to implement situation. a standardized business management system. Starting in At the same time, plans have been drawn up for a the fi rst half of 2006, this will be rolled out through the new pelletizing plant in Kiruna. In December 2005, the entire Group. Board approved an investment of 6.4 billion kronor and a
PRESIDENT`S REPORT 4 LKAB ANNUAL REPORT 2005 Certification of quality and forecasts that are revised after each quarter and control environmental management via key ratios. To be able to manage the company opti- As we see it, quality is not only a question of technical mally, the system of control via key ratios is refined on an quality; it also entails continuous improvement in all as- ongoing basis. pects and with the commitment of all employees. Despite By “taking the company’s temperature” in different the great pressure on production, the quality of our prod- ways after each shift, daily and weekly, we are able to de- ucts has improved and we have strengthened our posi- termine if we are on the right course or whether adjust- tion as a quality-leading company. ments have to be made. This approach is fundamentally The quality effort is largely a matter of maintaining important for developing a future, modern organization good order and following clearly-defined procedures. in which responsibilities and authority are delegated. By During 2005, all of our ISO 9001 certificates have been re- implementing key-ratio control, we can also break down assessed and approved. our strategies and thereby gain acceptance for them with- Certification of our ISO 14001 environmental manage- in the organization. ment system began during the year. Our operations in Our incentive program was modified in 2005 to support Svappavaara and our logistics operation, which includes this management process. This is based on how well we railways and harbors, have been certified. The goal is to meet our production and quality targets and how well we achieve full certification for the Group by 2007. At the succeed in our effort to improve occupational health and same time, implementation of an energy management safety. The important thing is that all of our employees system according to a new Swedish standard began. can influence these parameters. Here, Svappavaara was the first industrial operation in the The maximum reward is 30 000 kronor per year and country to be certified. full-time employee. For 2005, the reward amounted to Our organization is heavily burdened by the fact that 27 000 kronor, which is a good measure of our employees’ our production apparatus is operating under pressure of success. great demand at the same time as we are implementing major investments and introducing new management The outlook for 2006 systems. That we are succeeding is indicative of our de- We foresee continued positive trends for all of the Group’s termination, capability and commitment. I am very satis- lines of business, both in the coming year and in the long fied with the total effort. term. Growth is strong in Asia, in countries with large popula- A safer, healthier LKAB tions, where infrastructural expansion, housing construc- Several years ago, we raised our targets for improved oc- tion, etc., requires much steel. This means that we are now cupational health and safety and accident-free workplac- adapting to the new global market situation that has arisen. es. Zero accidents is the undisputed goal. Certainly, the iron ore and metal markets will fluctu- The driving force is, of course, consideration for the ate in the future, but our assessment is that this will take wellbeing of our employees; but we also want to be an place at a higher level than previously, and that total con- attractive company for future co-workers. Many people, sumption will remain high. not least of all young people, consider the mining indus- try to be hazardous. If we are to succeed in competing for the best people in the labor market, we must dispel this reputation. For 2005, we set the target of fewer than 10 accidents Martin Ivert per million working hours. We reduced the number to President 10.5, which is half as many accidents as there were a de- cade ago. The figures are moving in the right direction, but not quite quickly enough. Absenteeism due to illness has also been given a lot of attention, and here, too, we are witnessing a healthi- er trend. During the past three years, the rate of sickness absence has fallen from 6.2 to 4.3%. Short-term absence during the past year was 2.4%. In this regard, LKAB has become a healthier company.
Control via key ratios and incentives Two years ago, we abandoned the traditional budget method in favor of a system based on 12-month rolling
p r e s i d e n t ´ S r e p o r t L K A B A n n u A L r e p o r t 2 0 0 5 Strategies
During 2002 and 2003, LKAB’s mission, vision and strategies were subjected to a thorough review. This review resulted in an annual strategy process, which is revised in December when the Board establishes a new rolling plan for the coming three years.
It was found that the company’s most important assets is that the strategy be broken down into activities that can are the magnetite ore of the Orefi elds and the knowledge be realized at different points within the organization. This and expertise in production processes and products that is done in conjunction with the rolling prognoses that are has been amassed over the years. There are suffi cient ore revised after each interim report. Together with the rel- reserves to ensure mining far into the foreseeable future; evant business-ratio control, this makes for a more dy- just how long the operation will continue is more a ques- namic process than the classic budgetary control method tion of economics than of technology. The fundamental that was formerly applied. business concept, LKAB’s corporate mission, is essential- Each year, on about 20 occasions, the president gives ly unchanged, but it has been updated and approved by presentations for employees in Sweden and Norway, out- the Board. lining the strategy and the current status of the various activities. Achieving consensus in this way is a very con- MISSION siderable undertaking, but when introducing a new strat- LKAB’s mission is, based on the Swedish Orefi elds, to egy, one of the greatest obstacles is a lack of awareness manufacture and deliver to the world market upgraded or understanding among employees. iron ore products and services that create added value for The general assessment is that demand for iron ore its customers. Other closely related products and services products will remain high in the coming years. This has that are based on LKAB’s know-how and support the main created market conditions that will allow LKAB to grow by business can also be included in the company’s opera- investing in, among other things, new pelletizing plants tions. and main levels. Exploration drilling in both Kiruna and Malmberget VISION has indicated greater mineral resource potential at depth, LKAB will be perceived by the customers as the supplier which is, of course, a prerequisite for continued opera- that provides the most added value and is thereby the tion. In Kiruna, particularly, the mineralization at depth is leader in its selected market segments. high-grade, wide and with low impurity content. Another important factor is that LKAB can take advan- POLICIES tage of the strong fi nancial platform upon which it now An important aspect of the strategy review was to estab- stands. The earnings trend shows that the company is ca- lish policies for quality management, environmental and pable of fi nancing its extensive program of growth, pro- energy management and ethics. These have subsequent- vided the current dividend policy is maintained. ly been clearly communicated throughout the Group. Dur- LKAB will continue to have high fi xed costs in the form ing 2005, an information policy was established. of depreciation and amortization. Self-fi nancing of capital expenditures allows the company to avoid the fi xed costs THE STRATEGIC PROCESS that are associated with borrowing. The strategic plan is based on a thorough, annual busi- According to the above reasoning, LKAB’s fi nancial ness-intelligence analysis of markets and product, pro- strategy can best be expressed as: maintaining a high eq- cess and technological development. In addition, the uity-assets ratio that will enable self-fi nancing of capital company’s strengths, weaknesses, threats and opportuni- expenditures while retaining a buffer to alleviate the ef- ties are analyzed. The entire process results in the strat- fects of a possible cyclical downturn. egy document that is adopted by the Board at the Decem- ber meeting. OVERALL GROUP STRATEGY The strategy document contains various business-in- The LKAB Group’s overall strategy can be summarized as telligence analyses and the conclusions that have been follows: reached, all of which are expressed as a number of con- • Maintain a niche strategy based on pellets as the product, crete strategic activities. Finally, the strategy is comple- with added value for the customer. Pellets give us consid- mented with fi nancial forecasts and simulations. erable competitive and environmental advantages. An important aspect of the management of operations • Full utilization of production capacity. For reasons per-
STRATEGIES 6 LKAB ANNUAL REPORT 2005 Minerals has started mining olivine in Greenland. The Mining Division’s main product is iron ore pellets, a sample The fi rst delivery was shipped in December 2005. of which is shown here by Seija Forsmo.
taining to cost and quality, the facilities now in opera- fore, the groundwork is being laid for an Agglomeration tion will be run at full capacity. A program is now under Center (pelletizing center) linked to an experimental pel- way to enable greater production fl exibility, i.e., shift letizing plant. The experimental blast furnace (EBF) is now production between different plants in the event of an a valuable asset, and an experimental pelletizing plant economic downturn. will help to optimize the total process: concentrate-pel- • Volume growth through better utilization of plant and lets-blast furnace. human resources (lean growth). This program, based The importance of maintenance for production stabili- on an intensive maintenance effort, has been very suc- ty, in terms of both quality and volume, has been underes- cessful in recent years. timated in Swedish industry, even in the Mining Division. • Selective and ongoing ‘lean’ expansion of pellet capac- An ambitious program, begun in 2002, continues to have ity. The most recent examples are the investments in high priority. The production level is decided by the speed new pelletizing plants in Malmberget and Kiruna, which at which production facilities are operated, and it appears imply a dramatic boost in production volume. These in- to be possible to gradually increase the rate of production vestments are largely in line with our customers’ strat- without jeopardizing quality. egies and ambitions. The lean-growth philosophy will LKAB’s is a characteristically energy-intensive process also be applied to increase capacity in the new plants. industry in which energy issues are a primary concern, • Organizational development for greater productivity both in terms of cost and environment. In day-to-day op- and better work environment. We enable ‘good work’ erations and when new technology and new equipment is when we delegate responsibility and authority in a sys- introduced, optimization of energy effi ciency must always tematic way. Only by creating and offering attractive be in focus. workplaces can we attract future co-workers and, not One limiting factor is often the very extensive and time- least, increase the number of women in the company. consuming concession bargaining. Initially, the idea is to • Development of industrial minerals. The intention is take full advantage of existing concessions, and in future both to support the iron ore business (with among oth- to make use of simpler environmental impact assess- er things, olivine) and to respond to growing demand in ments for marginal volumes. interesting application areas for iron ore products such The most important activities during the coming years: as water treatment, coal washing and heavy concrete. • Commissioning of the new pelletizing plant in Malm- Potential for profi table growth is also foreseen for other berget. important industrial minerals for which we have know- • Construction of the new pelletizing plant in Kiruna. how and resources. • Construction of the new ore harbor in Narvik. • Successive introduction of new, modern work organi- MINING DIVISION zation. Increasing profi tability in order to satisfy the owner’s re- • Continued focus on the maintenance process. quirements cannot be realized simply by cutting costs; in- stead, growth must be achieved through greater volume MINERALS DIVISION and/or a higher degree of upgrading. Of decisive impor- The division produces and markets selected minerals, tance is the volume LKAB can produce in existing facili- customized for industries throughout the world. Control ties. over fi rst-class mineral assets is the basis for long-term Since Mining has recently introduced new products for stability. both blast furnaces and direct reduction, in the short term, For Minerals, the objective is to gain full control, from customers seek product care (uniform quality) and adap- raw-material source to end user, of several selected min- tations. To be able to maintain LKAB’s competitive posi- erals. At present, the selected minerals are magnetite, tion, continued efforts in product and process develop- bentonite, olivine, mica and minerals with fl ame retardant ment are also necessary. properties (UltraCarb). Research and development in pelletizing will assure a Products are often developed in collaboration with cus- leading position where products are concerned. There- tomers, and product differentiation is one of the keys to
STRATEGIES LKAB ANNUAL REPORT 2005 7 success. Within its organization, the division now has con- Wassara will establish the drilling systems on the mar- siderable expertise concerning the various minerals, and kets Mining and Construction within market niches in development of more products and services is ongoing. which rapid growth in sales volumes can be achieved. Growth areas for magnetite are, above all, applications Wassara will apply the technical knowledge gained from for heavy concrete, water treatment and coal washing. external markets so as to help LKAB to reduce its drilling Historically, the main market for Minerals has been costs over the long term. Wassara’s organization will be- Europe, but the future growth is expected to take place in come successively more market oriented. Asia and North America. Kiruna Grus och Stenförädling AB (KGS) upgrades Thanks to the acquisition of the Seqi olivine deposit in LKAB’s waste rock to road and concrete ballast, blasts, Greenland, the division has entered the market with its crushes and hauls mineral products, processes concrete own source of raw material. The customer structure is and works with rock reinforcement in the mining and somewhat similar to that of the Mining Division; i.e., the construction industry. KGS is planning for a dramatic in- European steel industry. Being able to supply both pellets crease in tunnel construction in the Mining Division, as and olivine, the Group has thereby strengthened its posi- well as increased concrete production. Shotcreting will be tion. Other major application areas for olivine are in the marketed in conjunction with Kimit’s sales of explosives foundry and refractory industries. for construction, mining and tunnel driving. Minelco Asia Pacifi c has worked mainly with marketing KGS Mekaniska fabricates technically advanced steel and sales of external suppliers’ mineral products on the structures and mechanical components for the engineer- Asian market. The strategy is to successively expand the ing, mining and construction industries. For KGS Me- product portfolio with the company’s own products. kaniska, together with the bogie manufacturer, a major When Likya Minelco was formed in Turkey in 2004, Min- activity is to realize LKAB’s transition to ore cars with a erals secured access to a signifi cant deposit of a unique 30-tonne axle load. mineral, thereby assuring the long-term supply of raw Kimit’s mission is to support LKAB’s iron ore operation material for the manufacture of fl ame retardants (Ultra- by developing, manufacturing, purchasing, stocking and Carb products). delivering explosives, as well as developing explosives With the acquisition of a mica plant in Finland, the divi- systems and providing consultancy services. sion has gained exclusive access to a unique high-grade Kimit’s main business is to supply LKAB with effective mineral deposit, thereby expanding its product portfolio. and effi cient explosives and related services. To be able Investment to increase capacity for fi ne wet-ground prod- to quickly meet an increasing demand, Kimit is improv- ucts in being implemented and a new plant will be opera- ing its fl exibility and production and distribution capacity. tional in Siilinjärvi, Finland, in mid-2006. This will mean a The technical and product know-how gained by Kimit is boost for the traditional markets for mica, with products transferred to LKAB and thereby strengthens the group’s for surface coating, building construction, sound damp- competitiveness. ening and plastics. Over the long term and with good profi tability, Fas- tighets AB Malmfälten (FAB) will provide customers with For Minerals, the most important activities in the coming well-maintained, well-situated residential properties in years are: the locations where LKAB operates. This is important fac- • Realization of full-scale olivine operations in Green- tor for future recruiting and is part of our strategy for cre- land. ating attractive working and living environments. • Establishment of upgrading of magnetite products in FAB is LKAB’s resource for the transition that is tak- the USA. ing place in the communities of Kiruna and Malmberget. Business is conducted with normal requirements for fi - nancial returns. With respect to the deformation caused SPECIAL BUSINESSES DIVISION by underground mining activities, FAB will establish and The mission for Special Businesses is to support the update a plan for developing and decommissioning hous- Group through services and technical development of ing in Kiruna and Malmberget-Gällivare. drilling systems, mining engineering and concrete work, explosives and property management. Operations are organized in the subsidiaries Wassara AB (owned jointly by Sandvik), AB Kiruna Grus och Sten- förädling, with Kimit and KGS Mekaniska, and Fastighets AB Malmfälten. With its main product, the patented Wassara Hammer, Wassara AB will develop and market systems that offer better total solutions for customers’ production drilling.
STRATEGIES 8 LKAB ANNUAL REPORT 2005 The new pelletizing plant in Malmberget is one of the major investment projects in the Orefi elds. The plant will be operational in autumn 2006.
STRATEGIES LKAB ANNUAL REPORT 2005 9 Divisional operations 2005
LKAB’s operations are organized in the divisions Market, Mining, Minerals and Special Businesses. The Market Division sells iron ore products to the steel industry and the Mining Division is responsible for mining, processing and logistics. The Minerals Division produces and markets customized industrial mineral products. Special Businesses supports Group companies with services and technical development.
MINING DIVISION The Mining Division mines and upgrades iron ore for facilities has increased in the past four years from 20 to products for steelmaking, principally pellets, which are 23 Mt/yr. the division’s main product, and magnetite products for the Minerals Division’s customers. Sales to steel produc- ers are the responsibility of the Market Division, which has MINING sales offi ces in Luleå, Essen, Brussels and Singapore. Large-scale is a keyword where LKAB’s mining operations The Mining Division’s process chain stretches all the are concerned. Concentration to fewer and larger produc- way from the iron ore deposits to the customers. It starts tion units has yielded considerable gains in effi ciency and with the production of crude ore in underground mines productivity. and upgrading of iron ore in processing plants at surface Efforts are concentrated on improving the yield from level, and continues with rail transport of fi nished prod- mining operations, i.e., minimizing ore losses and extract- ucts to shipping harbors and loading to vessels for deliv- ing the maximum amount of iron in relation to the quan- ery to the customers. tity of ore mined. Measures include improvements in drill- ing, blasting technology, loading and haulage. PRODUCTION RESULTS 2005 As the orebodies are mined, new main levels must be The focus during the year has been on improving capac- built to continue mining at depth. In the past, main lev- ity, speed and availability in the production facilities in els in the Kiruna mine have be built at the 275, 320, 420, order to increase the volume of mining and processing 540 and 775- meter levels (below the original peak of Ki- while maintaining high quality. irunavaara). The current main level is at 1 045 m. During In the underground mines in Kiruna and Malmberget, 2005, the decision was taken to begin preliminary work 36.6 Mt of crude ore was mined. The volume of iron ore for yet another new main level in Kiruna, at the 1 365-m products produced reached 23.3 Mt, which exceeded the level. previous year’s production by 1 Mt. Malmberget consists of several orebodies, which from Production of pellets was 16.5 (15.9) Mt and of fi nes 6.7 the beginning were mined at 50-meter intervals down to (6.3) Mt. Deliveries totaled 23.2 (22.8) Mt. 450 meters below the original peak of Välkomma. Sub- Through continuous improvement, greater effi ciency sequently, deeper levels have been built at 600, 815 and and the elimination of bottlenecks, production in existing 1 000 meters.
SALES PER MARKET REGION FINANCIAL HIGHLIGHTS – MINING DIVISION (Parent company)
MSEK 2005 2004 Net sales 12 349 7 560 Operating income 5 720 1 669 Fixed assets 8 015 6 273 Current assets 10 597 6 900 Adjusted shareholders’ equity 13 153 9 581 Return on equity % 45.2 30.6 Return on operating assets 69.6 23.3 Average number of employees 2 797 2 694 Production, Mt 23.3 22.3 %UROPE !SIA INCL 4URKEY /THERS Deliveries, Mt 23.2 22.8 More than 70% of Mining’s sales are to the Northern Stocks, Mt 1.9 2.3 European steel industry.
DIVISIONAL OPERATIONS 2005 10 LKAB ANNUAL REPORT 2005 In the concentrating plant, the ore is ground in rotating mills. From his control panel, Daniel Sedig controls loading of pellets to rail cars.
In 2005, the decision was taken to extend the 1000-me- from iron to steel. The DR process is based on the use of ter level. This presents special conditions, since sections natural gas and has become increasingly common in oil- of the community lie within the area affected by the exten- producing countries and other countries with access to sion. At the same time, planning of the next main level, at inexpensive natural gas. 1,250 m has commenced. Unlike pellets, fines must be sintered to form larger pieces before being used in the blast furnaces. In Kiru- Upgrading, products na, the fines product is produced by crushing and then In the ore processing plants at surface level, the crude ore grinding the crude ore to a sand-like consistency. Fines is upgraded to sinter fines and pellets. Pellets are the Min- from Malmberget is a screened product from the mine. It ing Division’s main product and account for more than is processed in sorting and concentrating plants by grind- 77% of ore sales. ing and separation. Pellets are produced by mixing finely ground iron ore The trend towards more customer-tailored products with various binders and additives, and then shaping the will continue. Considerable effort is therefore being de- mixture into centimeter-sized spheres, which are sintered voted to producing the same product in several pelletizing at a temperature of 1 250°C. LKAB’s magnetite-based pel- plants in order to ensure maximum flexibility. lets have high iron content and are less energy demand- Construction of a new pelletizing plant in Malmberget ing and therefore more environmentally friendly than (MK3) is now in progress, and the plant is expected to be competing pellet products. operational in the autumn of 2006. A new pelletizing plant Blast furnace pellets (BF pellets) are delivered mainly to in Kiruna (KK4) will be operational in 2008. steelmills in Europe and are used in the coke-based blast Following the expansion, the Kiruna processing plants furnace process, which is the most common method for will produce different types of iron ore pellets exclusively, producing hot metal, the first stage in the steelmaking which will simplify production flows at the Kiruna mine. process. Production capability for fines products will exist only in DR pellets are used in the direct reduction process to Malmberget. Pellets will continue to be the main product produce sponge iron, which in an alternative process from Malmberget. route, is also an initial stage in the chain of production Logistics The finished products are transported from the ore pro- cessing plants to customers by rail and by ship via the shipping ports at Narvik and Luleå. Rail transports are op- PRODUCTION AND PRODUCTIVITY erated under the company’s own management. -T 4ONNESEMPLOYEE During 2005, a total of about 23.4 Mt was hauled to Nar- vik and Luleå, the highest volume in 25 years. Disruptions in production and delivery have been minimal. The transport system is upgraded continually through the ongoing replacement of locomotives and ore cars. New so-called UADK-type cars have been taken into oper- ation during the year. Development of a new car designed
for a 30-tonne axle load is under way, and the first cars, with a 100-tonne payload, have been delivered. From the harbor in Luleå, ore products are delivered mainly to customers in the near-lying market. The Nar- 0RODUCTION -T 0RODUCTIVITY TONNESEMPLOYEE vik ore harbor can accommodate vessels of up to 350 000 Production volume increased by 4% during 2005. dwt. The Board has finalized a decision on major improve- Productivity has increased successively in recent years.
D i v i s i o n al o p e r at i o n s 2 0 0 5 L K A B A n n u A L r e p o r t 2 0 0 5 11 ments in effi ciency and modernization of the harbor in relations. Work also focuses on establishing best practice Narvik. The new harbor will operational in autumn 2008. and making production more fl exible to enable maximum capacity utilization. OBJECTIVES LKAB is exposed to tough competition from considerably larger iron ore producers who, in addition to their size, MARKET TRENDS 2005 also enjoy the cost advantages associated with open- During 2005, the global demand for iron ore remained pit mining. LKAB’s goal is to cope with competition and strong, pressing iron ore exporters to increase produc- ensure the company’s long-term survival by constantly tion to the limits of capacity. According to preliminary es- improving cost-effectiveness, raising the quality and timates, global trade in seaborne iron ore increased to 650 knowledge content of the products, and maintaining re- (580) Mt, of which China’s share of imports rose by over source-effi cient growth. 32% to about 275 Mt. Improving maintenance, including preventive mainte- Preliminary statistics from the International Iron and nance, is strategically very important. The aim is to stabi- Steel Institute indicate that world production of crude steel lize production at a higher and more consistent level. This increased in 2005 by 6%. Production thereby reached a is aided by greater use of new technology and a focus on new benchmark of more than 1.1 billion tonnes. Asia, the maintaining good order. Middle East and Africa accounted for most of the growth. The work of assuring quality in the company’s process- The greatest production increase was seen in China, es has high priority, and here, too, the keyword is stabil- where crude steel production reached about 350 Mt, an ity. Consistent quality, the right quality and delivery assur- increase of 25%. Japan realized about the same produc- ance are the most important success factors for customer tion fi gure as in 2004, while production in the EU 15 fell by slightly more than 4 Mt or 2.5%. During the year, Chinese authorities took measures to gain better control over the infl ow of iron ore. The intro- duction of import licences and restrictions on the number of importers did not appear to have any great impact on PRICE TRENDS, IRON ORE PRODUCTS iron ore imports. China was only able to assure its supply of ore by increasing production in its own high-cost mines 53 #ENTS and by buying expensive iron ore on the spot market. Globally, the production of hot metal, which is midway THE LARGEST STEEL-PRODUCING COUNTRIES Change ,+!" 0ELLETS FOB .ARVIK +IRUNA " &INES