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~~~ (I s?vu a;-;6-| RESTRICTED ReportNo. PI- 10 RL' Public Disclosure Authorized Thisreport s for official use only by the BankGroup and specificallyauthorized ornizations or personL It may not be publed, quoted or cited without Bank Group authorization. The BankGroup does not acceptresponbity for the accuracyor completenessof the report. INTERNATIONALBANK FOR RECONSTRUCTIONAND DEVELOPMENT INTERNATIONALDEVELOPMENT ASSOCIATION Public Disclosure Authorized APPRAISAL OF THE MBR IRON ORE PROJECT MINERACOES BRASILEIRAS REUNIDAS S. A. BRAZIL Public Disclosure Authorized June 16, 1971 Public Disclosure Authorized Industrial Projects Department Currency Equivalents Exceptwhere otherwise stated all figures are quoted in U.S. dollars (US$). The project cost estimate is shown in both US$ and New Cruzeiros (NCr$) of 1969. US$1 = Nr$4.06 NCr$1 = US$o.246 NCr$1 rmillion = US$246,305 Weights and Measures Except where otherwise stated, all tonnages are expressed in Long Tons (LT): 1 Long Ton 1.016 Metric Tons 1 Long Ton = 1.120 Short Tons 1 Long Ton 22,240 Pounds 1 Kilometer(Km) = 0.62 vales Principal Abbreviations and Acronyms Used MBR = MineracoesBrasileiras Reunidas S.A. RFFSA = Rede Ferroviaria Federal CAEMI Cia. Auxiliar de Erapresasde Mineracao ICO4 a Industria e Cozerciode M4ineriosS.A. EEM = EmpreendimentosBrasileiros de Mineracao S.A. CMN = Cia. de Mineracao Novalimense SOMISA - Sociedad Mixta Siderurgia Fiscal Year April 1 - March 31 BRAZIL APPRAISAL OF THE MBR IRON ORE PROJECT TABLE OF CONTENTS Page No. SUMMARYAND CONCLUSION§ ............................ i I. INTRODUCTION ................. 1........................ II. THE SPONSORS AND THE COMPANY .... ........................ A. CAEMI .............................................. 2 B. St. John D'el Rey Mining Company ............... 2 C. Hanna Mining Company ................. ... ........... 2 D. Genesis of the Project .................. 3 E. The Borrower - MBR ., ..... ......... 3 III. WORLD IRON ORE MARKETS ...... ...................... 5 A. General Background .... 5 B. Brazilian Iron Ore Production .............. 5 C. Supply and Prices ................. 0 6 IV. THE PROJECT AND ITS EXECUTION . .......... 7 A. The Mine - Aguas Claras ..... .................. 7 B. The Ocean Terminal ................................. 8 C. Environmental Considerations ................ 8 D. Construction Schedules .................. 9 E. Management, Staff and Labor ........................ 9 V. CAPITAL COSTS - FINANCIAL PLAN - PROCUREMENT ............ 10 A. Capital Costs . ........................ ... 10 B. Financing Plan ...6 ................................. 12 C. Procurement and Disbursement ....................... 15 VI. REVENUES - OPERATING COSTS - FINANCIAL ANIALYSIS ......... 16 A. Revenues ..........................................16 B. Aguas Claras Operating Costs .......... .. ........... 17 C. Profitability and Financial Position ............... 18 D. Effects of Expansion on Profitability .............. 20 This report has been prepared by Messrs. R. N. Pigossi, J. W. P. Jaffe, and R. L. Bosson of the Industrial Projects Department and Mr. G. F. Bain of the Transportation Projects Department. Table of Contents (Cont'd) Page No. VII. ECONOaIC JUSTIFICATION - RETURNS TO GOVERNMENT AND SHAREHOLDERS- SENSITIVITY ANALYSIS ............. ... 20 A. Internal Economic Return . ......................... 20 B. Beneflts to Government . ................... ...... 220 C. Returns to MIBRShareholders ........................ 21 D. Split of Project Benefits . .23 E. Foreign Exchange Benefits . 23 F. Sensitivity Analysis. 24 VIII.AGREEMENTS REACHEDDURING NEGOTIATIONS .... .............. 24 TABLES 1. Reconstructed Consolidated Income and Cash Flow Statements for All Companies Being Merged into MBR (1966-1971). 2. Reconstructed Consolidated Balance Sheets for all Compaie Being Plerged into MBR (1966-71). 3. Protected Income Statements for Aguas Claras Operation (FY 1974-89). 4. Depletion Allowance for Aguas Claras Operation (FY 1974-84). 5. Projected Cash Flow Statements for Aguas Claras Operation (FY 1971- 89). 6. Projected Cash Flow Statements for Combined Iron Ore Operations (FY 1971-89). 7. Projected Balance Sheets for Combined Iron Ore Operation. (FY 1971- 89). 8. Distribution of Earnings from Aguas Claras Operation (FY 1972-89). 9. Internal Financial Rate of Return, Aguas Claras Operation. 10. Return on Investment for MBR Shareholders and Brazilian Government at Ultimate Production Levels of 10 and 15 million Tons per year. 11. Estimated Split of Net Project Benefits (FY 1972-89). 12. Net Foreign Exchange Earnings from Aguas Claras Operations - Base Project with Sales Buildup to 10 Million Tons per Year. 13. Net Foreign Exchange Earnings from Aguas Claras Operations - Expansion Project with Sales Buildup to 15 Million Tons per Year. ANNEXES 1-1. MBROwnership and Control 1-2. ICOMI Financial Indicators 1-3. Hanna Mining Company Financial Indicators 1960-70 2-1. Marketing Annex - The Outlook for Iron Ore 2-2. Brazilian Iron Ore Production and Exports 2-3. Trends in Japanese Ore Supplies 3. The Mine 3a. List of Major Units of Mining Equipment Table of Contents (Cont'd) 3b. Mine Facilities Pictorial Flow Sheet 4. Ocean Terminal 5. EnvironmentalConsiderations 6. ImplementationSchedule 7. Detail of Capital Investment 8. Estimated Value of MBR equity as of March 31, 1971 9-1. Equipment to be Financed by World Bank 9-2. ConstructionMaterials to be Financed by World Bank 9-3. Computationof Probable Foreign Exchange Content of Internationally-BidCivil Works That Can Be Financed by the Bank 10. Estimated Schedule of Disbursements 11. Ore Sales 12. Average Operating Costs for Aguas Claras Operations 13-1. Sensitivity Analysis 13-2. Notes to Sensitivity Analysis 13-3. Cash and Profit Break-Even Prices at Constant Sales Level of 9 Million Tons per Year 13-4. Cash and Profit Break-Even Sales Levels at Constant Ore Price of US$8.38/Long Ton Maps 1. General Location 2. Ore Deposits in the Iron Quadrangle 3. Location of Sepetiba Terminal BRAZIL APPRAISAL OF THE MBR IRON ORE PROJECT SUMMARYAND CONCLUSIONS i. MineracoesBrasileiras Reunidas, S.A. (MBR), a private Braziliah company, has requested a Bank loan of US$50 million to cover one-third of the cost of a project to mine and export a minimum of 10 million tons of iron ore per year beginning in late 1973 from a large deposit near Belo Horizonte in the State of Minas Gerais. Tht ore will be shipped over a largely existing railroad to a new marine ti!rminalsome 640 km away to be constructedon Sepetiba Bay, about 100 km west of Rio de Janeiro. The terminalwill be able to handle bulk ore vessels of up to 250,000 DWT, among the largest presently being built. Transport from mine to port will be provided by the Federal Railways (Rede FerroviariaFederal - RFFSA) which has requested another IBRD loan of US$46 million to finance part of the new rolling stock and spur lines needed to serve the MBR project. The RFFSA loan is appraised in IBRD Report PTR-77a; the present report is con- cerned only with the appraisal of the loan to MBR for the mine and ocean terminal. ii. The project sponsors are Cia. Auxiliar de Empresas de Mineracao (CAEMI),a private Brazilian holding company engaged primarily in minerals developmentand steel production,and Hanna Mining Company of the U.S., which also was a sponsor of the Alcominas Aluminum Project in Brazil, to which the Bank made a loan of US$22 million in 1968 and which started op- erations in the fall of 1970 about on schedule and within budgeted cost. CAEZI, and therefore Braziliannationals, will control MBR. Total initial MBR equity will be US$80 million, consistingof existing fixed assets val- ued at US$50 million and US$30 million in new cash investmentsby the spon- sors, a consortiumof Japanese steel and trading companies,and a U.S.- owned shipping company. iii. MBR's ore reserves are high grade and are estimated at over 1.6 bil- lion tons. Aguas Claras, the largest of 36 deposits in MBR's concessionarea and the mine upon which the project is based, contains over 375 million tons (proven and inferred) of mineable hematite ore with an average iron content of 68 percent. The deposit has been explored adequately,has very little overburden,and is well suited to the open-pit mining operation envisaged. Engineering design and project executionwill benefit from the sponsors' experiencewith similar large-scalemining projects in the U.S., Canada and Brazil. Hanna will provide technicalassistance at cost during the con- struction and operating phases. The ecological implicationsof the project have been examined in detail and it is judged that the project can be carried out with minimum adverse effects on the regions surrounding the mine and ocean terminal, provided that certain precautionsare taken. - ii - iv. Total project Costs are estimated at about US$143 million, with the foreign exchange component varying between 45 and 52%, depending on the degree of participationin procurement by Brazilian manufacturersand con- tractors. Project costs will be salit about evenly between the mine and the terminal. v. Financing requirements for the project are estimated at about US$155 million, of which US$30 million will be financed by equity and the remainder by loans from IBRD (US$50 million), five Japanese trading companies (US$50 mil- lion), the Japanese Eximbank (US$7 million), and the U.S. Eximbank (US$18 million). There will be no Brazilian loans made for the project, but the US$50 million Japanese loan will be untied and can be used for expenditures