Form 6-K
United States
Securities and Exchange Commission
Washington, D.C. 20549
FORM 6-K
Report of Foreign Private Issuer
Pursuant to Rule 13a-16 or 15d-16
of the
Securities Exchange Act of 1934
For the month of
October 2009
Vale S.A.
Avenida Graça Aranha, No. 26
20030-900 Rio de Janeiro, RJ, Brazil
(Address of principal executive office)
(Indicate by check mark whether the registrant files or will file annual reports under cover of
Form 20-F or Form 40-F.)
(Check One) Form 20-F þ Form 40-F o
(Indicate by check mark if the registrant is submitting the Form 6-K in paper
as permitted by Regulation S-T Rule 101(b)(1))
(Check One) Yes o No þ
(Indicate by check mark if the registrant is submitting the Form 6-K in paper
as permitted by Regulation
S-T Rule 101(b)(7))
(Check One) Yes o No þ
(Indicate by check mark whether the registrant by furnishing the information contained in this Form
is also thereby furnishing information to the Commission pursuant to Rule 12g3-2(b) under the
Securities Exchange Act of 1934.)
(Check One) Yes o No þ
(If Yes is marked, indicate below the file number assigned to the registrant in connection with
Rule 12g3-2(b). 82- .)
TABLE OF CONTENTS
Vale to invest US$ 12.9 billion in 2010
Rio de Janeiro, October 19, 2009 Vale S.A. (Vale) announces that its Board of Directors has
approved the investment budget for 2010, involving capital expenditures of US$ 12.9
billion1 dedicated to sustaining existing operations and to fostering growth through
research and development (R&D) and project execution.
The capex budget for 2010 represents an increase of 29.3% over the US$ 10 billion invested in the
last twelve-month period ended at June 30, 20092. The investment plan continues to
reflect the focus on organic growth as the priority of our growth strategy: 76.6% of the budget is
allocated to finance R&D and greenfield and brownfield project execution against an average of
71.1% over the last five years.
Given the existing assets and those which will come on stream in the near future we expect to
maintain production growing at a brisk pace. Our output index, which encompasses the operational
performance of all minerals and metals produced by Vale, is estimated to increase at an annual
average rate of 12.6% in 2010-2014, a higher rate of expansion than the already high 11.2% per
annum for 2003-2008.
Although iron ore and nickel will continue to be our main businesses, we plan to boost the
production capacity of copper, coal and fertilizers, creating a more diversified portfolio of
world-class assets. Given the current project pipeline, we expect to reach the following production
flows in 2014: 450 million metric tons of iron ore, 380,000 metric tons of nickel, 650,000 metric
tons of copper, 30 million metric tons of coal, 3.1 million metric tons of potash and 6.6 million
metric tons of phosphate rock3.
To enhance the competitiveness of our operations, we will continue to invest a sizeable amount of
funds in our railroads, maritime terminals, shipping and power generation.
Based on a long-term view of the market fundamentals for minerals and metals and rigorous
discipline in capital allocation, Vale has invested US$ 59.5 billion4 over the last five
years, creating significant shareholder value. As we strongly believe that the global recession did
not affect the fundamentals, we will continue to pursue growth and value creation through
investment in a fairly large number of organic growth options.
One of the most striking features of the last global economic cycle was the rapid pace of emerging
economies growth, at 6.1% per annum, much faster than developed economies, where GDP increased by a
yearly rate of only 2.4%.
Faster economic expansion and more intensive utilization led emerging economies to be the main
drivers of the consumption of minerals and metals. For example, in this decade emerging economies
were responsible for almost all of the worlds consumption growth of iron ore, carbon steel,
aluminum, copper and nickel.
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1 |
|
The capex budget includes financial disbursements in consolidated format according to
generally accepted US accounting principles (US GAAP). The main subsidiaries consolidated according
to US GAAP are: Vale Inco, MBR, Cadam, PPSA, Alunorte, Albras, Valesul, Vale Manganês S.A., Vale
Manganèse France, Vale Manganese Norway AS, Urucum Mineração S.A., Ferrovia Centro-Atlântica (FCA),
Vale Australia, Vale International, and CVRD Overseas. |
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2 |
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The US$ 10 billion figure does not include expenditures of US$ 1.5 billion to acquire
copper, coal, potash and iron ore assets. |
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3 |
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Unexpected changes in demand and involuntary delays in project development can cause
signification deviations from the production targets. |
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4 |
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This includes US$ 23.7 billion spent on acquisitions. |
1
The share of emerging economies in global consumption of base metals increased to 59% in 2008 from
32% in 1993. China, the largest and fastest growing emerging economy, increased its market share in
the seaborne trade of iron ore to 53.8% last year from only 9.7% fifteen years ago.
Rapidly growing emerging economies tend to make large investments in housing, infrastructure and
industrialization, which are intensive consumers of minerals and metals. Real income growth from
low levels leads to significant changes in consumption patterns, resulting in a much larger demand
for consumer durables, metal intensive goods.
At the same time, increasing per capita income in emerging economies produces diet changes towards
a larger intake of protein, thus stimulating the demand for fertilizers, key ingredients for grain
crops.
In a long-term perspective, emerging economies tend to grow faster than developed mature economies
to make their per capita incomes converge over time to the levels reached by the wealthiest
economies. Convergence is primarily determined by the higher rates of return on physical and human
capital, the faster increase of labor force and the stronger productivity growth in emerging
economies.
As a matter of fact, convergence has been taking place in the post-World War II period, being more
pronounced in the 60s and 70s and more recently, from the
late 90s until now. Emerging economies
withstood the global financial shock much better than expected. As the global economy is starting a
synchronized recovery, they are further ahead on the road to recovery. The rebound is primarily
driven by China, India, Indonesia, other Asian emerging economies and Brazil.
Unless there is a major deterioration in the quality of macroeconomic policies, we expect
convergence to remain for the foreseeable future, with emerging economies continuing to play a key
role in the demand for minerals and metals.
In addition to factors directly linked to economic growth, the initiatives to change the energy
matrix to reduce world reliance on sources of climate-changing greenhouse gases also tend to cause
a positive impact on the long-term demand for minerals and metals.
The move towards an increasing production of biofuels creates another source of demand growth for
potash, given its importance for the production of sugar cane, corn and palm.
Solar, wind and nuclear power, which are free of CO2 emissions, are likely to increase
their shares in the global energy matrix and the building of a meaningful capacity will contribute
to boost the demand for metals.
The automobile industry seems to be in the initial stage of a new era, in which electric cars are
expected to become its dominant product. Sales of hybrid electric vehicles (HEV) have been booming
and Vale is the leading supplier of nickel for their batteries. This is still a very small market
for nickel but it has great potential to expand over time.
On the supply side, geological factors make the availability of new world-class assets increasingly
scarce and institutional factors pose barriers to mining investment, turning capacity expansion
less responsive to price incentives.
The prospects for minerals and metals demand depend increasingly on growth in emerging economies,
given their large shares in global consumption. This is particularly important to the extent that
they tend, as we have seen, to grow faster than developed economies. Moreover, the demand for
minerals and metals in emerging economies is more elastic to real income increase. At the same
time, new technologies focused on the rise of non-climate changing sources of energy are likely to
add further pressure on the demand for minerals and metals.
2
Accommodating continuous demand expansion will require substantial new capacity build-up.
Geological and institutional constraints tend to contribute to a slow market adjustment and to
generate the need to invest in higher-cost and lower-quality sources of supply.
Vale is best positioned to benefit from the strong long-term fundamentals of minerals and metals,
given its world-class, long-life and low cost assets, wealth growth options in various segments of
the metals and mining industry supplied by an exciting project pipeline and a global
multi-commodity mineral exploration program, a long and successful track record in project
development, discipline in capital allocation and financial strength.
The implementation over the near future of our investment plans, anchored on our values and
extensive competitive advantages, is expected to create significant shareholder value across
business cycles and multiple opportunities for economic and social mobility for the communities
where we develop our operations.
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The 2010 investment budget |
The program for 2010 involves investments of US$ 12.894 billion, of which US$ 9.876 billion will
finance organic growth, corresponding to 76.6% of total spending, with US$ 8.647 billion allocated
to project execution and US$ 1.228 billion to R&D.
Budgeted expenditures with R&D allow for US$ 621 million to finance our global mineral exploration
program, US$ 488 million for conceptual, pre-feasibility and feasibility studies to develop mineral
deposits already identified, and US$ 119 million to be invested in new processes, technological
innovation and adaptation.
Investments to sustain existing operations are budgeted at US$ 3.019 billion, which represents 4.8%
of our asset base in June 2009.
The largest financial disbursements in 2010 are dedicated to the following projects: Carajás Serra
Sul mine S11D (US$ 1.126 billion), Salobo (US$ 600 million), Moatize (US$ 595 million), Onça Puma
(US$ 510 million), Oman (US$ 484 million), Carajás Additional 30 Mtpy (US$ 480 million),
Long-Harbour (US$ 441 million), and Rio Colorado (US$ 304 million).
Several projects are scheduled to be concluded in 2010: Carajás Additional 10Mtpy (iron ore), Oman
(pellet plant and iron ore distribution center), Onça Puma (nickel), Bayóvar (phosphate), Tres
Valles (copper), Estreito (power generation) and CSA (steel). In 2009, we concluded the Vargem
Grande pelletizing plant and we are already in the initial stage of ramping up Goro, the nickel
project in New Caledonia.
On the other hand, various projects will start to be developed in 2010: Conceição Itabiritos (iron
ore), Vargem Grande Itabiritos (iron ore), Long-Harbour (nickel), Konkola North (copper), Rio
Colorado (potash), Teluk Rubiah (distribution center in Malaysia), ALPA (steel) and Biofuels
(energy).
In 2010, US$ 4.075 billion will be invested in non-ferrous minerals, representing 31.6% of the
total capex for 2010, while ferrous minerals will demand US$ 3.863 billion, 30.0% of total capex.
Expenditures in infrastructure are comprised of US$ 834 million for power generation and natural
gas exploration and US$ 2.654 billion for logistics, in which the bulk will be dedicated to
supporting the iron ore business capacity. We plan to invest US$ 892 million in the coal business
in 2010 and US$ 343 million in steel projects.
3
INVESTMENT BUDGET US$ million
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By category |
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2010 |
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% |
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Organic growth |
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9,876 |
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76.6 |
% |
Projects |
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8,647 |
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67.1 |
% |
R&D |
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1,228 |
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9.5 |
% |
Support of existing operations |
|
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3,019 |
|
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23.4 |
% |
Total |
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12,894 |
|
|
|
100.0 |
% |
|
|
|
|
|
|
|
|
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By business area |
|
2010 |
|
|
% |
|
Ferrous minerals |
|
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3,863 |
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|
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30.0 |
% |
Non-ferrous minerals |
|
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4,075 |
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|
|
31.6 |
% |
Logistics |
|
|
2,654 |
|
|
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20.6 |
% |
Coal |
|
|
892 |
|
|
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6.9 |
% |
Power generation |
|
|
834 |
|
|
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6.5 |
% |
Steel |
|
|
343 |
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|
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2.7 |
% |
Others |
|
|
235 |
|
|
|
1.8 |
% |
Total |
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12,894 |
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|
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100.0 |
% |
A large part of the capex budget, US$ 8.165 billion, representing 63.3%, will be invested in Brazil
and US$ 1.153 billion in Canada. The program for 2010 also involves investments in Argentina,
Australia, Chile, China, Indonesia, Malaysia, Mozambique, Oman, and Peru, among others.
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Focus on corporate social responsibility |
In line with our strategic priorities, investments in corporate social responsibility in 2010 will
amount to US$ 999 million, of which US$ 829 million will be invested in environmental protection
and conservation, and US$ 170 million in social projects.
New platforms of value creation
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Ferrous minerals leveraging on Carajás wealth |
The future of our iron ore capacity increase relies on Carajás. It is one of the richest mineral
provinces in the world, with 7.2 billion metric tons of proven and probable reserves and huge
resources of the best iron ore, with high iron content and very low impurities. The focus on
Carajás is an important move towards maximizing the profitability of our ferrous minerals
operations, given the lower operational costs and the price premium over other iron ores arising
from its superior value-in-use to the steel industry.
Our investment plans for iron ore involve a capacity expansion of 176 million metric tons per year
(Mtpy) to be delivered over the next five years. A major part of this planned expansion, 130 Mtpy,
will be sourced from Carajás. This entails the development of new mines, the building of processing
plants and, particularly, the enlargement of the logistics infra-structure. Given the very large
volumes, a highly efficient logistics system is extremely important for the competitiveness of the
iron ore operations.
4
We are exploiting the long-term upward trend of pellets consumption, which is driven by
environmental concerns reduction of CO2 emissions -, increasing scarcity of lump ores
and DRI capacity increases. This will be pursued through the construction of pellet plants either
close to our iron
ore mines, in Brazil, or to the consumers, in the Middle East and Asia, supplied by the increasing
output of pellet feed in the Southeastern and Southern Systems. Currently, we are building two new
plants, Tubarão VIII and
Oman, that will add 16.5 Mtpy to our capacity of 43.5 Mtpy not including the capacity of our
joint ventures, 21.0 Mtpy of Samarco JV, 4.5 Mtpy of Hispanobras and 1.2 Mtpy of
Zhuhai5.
Carajás Additional 10 Mtpy is a brownfield project with a relatively low capex cost per ton, US$
29. It is being developed in the northern range of Carajás and scheduled to start-up in the first
half of 2010. Investment is estimated to be US$ 90 million in 2010.
Carajás Additional 30 Mtpy, also being developed in the northern range of Carajás, has an estimated
capex of US$ 2.478 billion and expected start-up for 1H12, still depending on environmental
licensing. It involves a new beneficiation plant and investments in logistics assets to increase
discharge, storage and shipment capacity at the Ponta da Madeira maritime terminal. For 2010, the
capex budget is US$ 480 million.
Carajás Serra Sul (mine S11D) is the largest greenfield project in the history of Vale and also in
the global iron ore industry. It will add 90 Mtpy to our production capacity and its estimated
capex is US$ 11.297 billion. A major part of the cost, about US$ 7.8 billion, is related to
expansion of the logistics infrastructure railroad and maritime terminal to increase the
Northern Systems shipment capacity to 230 Mtpy by 2015.
The Carajás railroad will be extended by 100 km to be connected to the southern range of Carajás,
there will be a duplication of 605 km of tracks and the building of the fourth pier of the Ponta da
Madeira maritime terminal. The investment in the port facilities is expected to demand US$ 2.6
billion, being the largest investment in port infrastructure in Latin America.
Large investments in infrastructure account for the relatively high cost of capex per ton of Serra
Sul. However, it paves the way for future low-capex cost brownfield projects while contributing to
lower our average operational costs as its stripping ratio is only 0.4 and the high iron grades
eliminate the need for concentration.
The conclusion of Carajás Serra Sul (mine S11D) is expected for the second half of 2013. In 2010,
investments will be US$ 1.126 billion, US$ 360 million will be spent on the mine and beneficiation
mill, while US$ 766 million will be allocated to logistics. The project is subject to approval by
the Board of Directors.
In the Southeastern and Southern Systems, Vale is developing Apolo, a greenfield project, and will
start the development of two brownfield projects, Conceição Itabiritos and Vargem Grande
Itabiritos. Both Conceição Itabiritos and Vargem Grande Itabiritos aim to increase pellet feed
capacity through the processing of low grade itabirites.
Apolo has a nominal capacity of 24 Mtpy and expected start-up for 1H14. Its estimated total capex
amounts to US$ 2.509 billion, of which US$ 38 million will be spent in 2010. The project is subject
to approval by the Board of Directors.
Conceição Itabiritos involves the construction of a concentration plant to add 12 Mtpy to the
current nominal capacity of pellet feed, using as feed run-of-mine (ROM) from the Conceição mine,
in the Itabira complex, Southeastern System. The estimated total capex is US$ 1.170 billion, of
which US$ 184 million is budgeted for 2010. The expected start-up is 2H12. The project is subject
to approval by the Board of Directors.
Vargem Grande Itabiritos, in the Southern System, also involves the construction of a concentration
plant, which will be fed by itabirites produced by the Aboboras mine, with a nominal capacity of 10
Mtpy of pellet feed. The estimated total capex for Vargem Grande Itabiritos is US$ 975 million, of
which US$ 79 million in 2010. The expected start-up is 2H12. The project is subject to approval by the Board
of Directors.
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5 |
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Vale owns 50% of Samarco, 50.9% of Hispanobras and 25% of Zuhai. |
5
We are analyzing the capacity expansion of the recently acquired iron ore assets in Corumbá, which
reserves have high Fe content and a substantial volume of lump ore that can be employed in the
direct reduction process. The project could increase Corumbás capacity up to 15.0 Mtpy from the
current 2.5 Mtpy. The project is subject to approval by the Board of Directors.
Tubarão VIII will be the eighth pelletizing plant at the port of Tubarão, in Vitória, in the state
of Espírito Santo, Brazil. Its start-up is scheduled for 2H12 with a nominal production capacity of
7.5 Mtpy. The total cost of this project is US$ 636 million. In 2010, expenditures are planned to
reach US$ 122 million.
The Oman project encompasses the construction of a pelletizing plant with production capacity of 9
Mtpy of direct reduction pellets and a distribution center with capacity to handle 40 Mtpy at the
Sohar port in Oman. The total capex is US$ 1.356 billion, with investments of US$ 484 million for
2010. The start-up is planned for 2H10.
Our joint venture in China Zuhai is expanding capacity to 3.2 Mtpy from the current 1.2 Mtpy.
The estimated capex is US$ 100 million, of which US$ 5 million is budgeted for 2010.
In addition to these three projects under execution, we have devised several growth options through
the construction of a pellet plant in Malaysia, a future expansion of Oman operations and several
joint ventures under study in China.
The implementation of the new marketing policy requires additional investments. US$ 631 million is
budgeted for building of our low cost portfolio of maritime freight to enhance competitiveness in
the Asian market.
Another important component of our marketing policy is the building of distribution centers in
Asia. These centers will act as virtual mines, which will improve our ability to serve clients in
terms of timing and customization, an important enhancement of our competitiveness given the long
geographic distance between our iron ore mines in Brazil and Asia. Simultaneously, we will use
these facilities to customize our iron ore products through blending aiming to increase our market
share in the fast growing Asian market.
In addition to the center in Oman, in 2010 we will start the construction of our distribution
facilities in Malaysia, in Teluk Rubiah, near the Strait of Malacca, state of Perak. The Malaysian
project comprises of a maritime terminal with enough depth to receive 400,000 dwt ore carriers and
a stockyard capable of handling up to 30 million metric tons of iron ore in an initial phase. There
is potential to expand it up to 90 million metric tons in the future.
The capex for this first phase is US$ 900 million, with disbursements of US$ 98 million for 2010.
The start-up is planned for 1H13. The project is subject to approval by the Board of Directors. As
mentioned before, we are studying the construction in the same site of a pellet plant with a
capacity of 9 Mtpy of direct reduction and blast furnace pellets.
6
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Nonferrous minerals multiple growth options across- the- board |
Vale is in a privileged position for maintaining long-term profitable growth in non-ferrous
minerals due to the availability of multiple attractive growth options in nickel, copper, bauxite
and fertilizers.
We are the mining company with the highest potential for nickel production growth, given the size
and quality of proven and probable reserves the worlds largest and with a balance of sulphide
and lateritic deposits and our global portfolio of projects in Brazil, Canada, New Caledonia and
Indonesia. Currently, we have four projects to come on stream: Goro, Onça Puma, Totten and
Long-Harbour.
The Goro project, in Southern province of New Caledonia, is due to start the ramp up process
through the feed to the first autoclave in the near term. It has a nominal production capacity of
60,000 metric tons per year (tpy) of nickel oxide and 4,600 tpy of cobalt. Capex cost totaled US$
4.3 billion.
Onça Puma, in the state of Pará, Brazil, will be commissioned in 3Q10, with the start of commercial
production in 2011. It is built on deposits of nickel lateritic saprolitic and expected to reach a
nominal capacity of 58,000 tpy of nickel contained in ferronickel, its final product. The
investment for this project is estimated at US$ 2.297 billion, with US$ 510 million to be spent in
2010.
Usually 60% of our nickel sales are destined to non-stainless steel applications non-ferrous
alloys, alloy steels, plating, foundry and other. The operations of Goro and Onça Puma will make
feasible a more balanced sales distribution between stainless steel and non-stainless steel
applications of nickel.
We are developing the Totten project, in Sudbury, Ontario, Canada. This is the re-opening of the
old Totten mine, closed in 1972. It is expected to produce 8,200 tpy of nickel, alongside copper
and precious metals as by-products. The total cost is estimated at US$ 362 million, with completion
forecast for the first half of 2011. Disbursement in 2010 will be US$ 146 million.
Pursuant to a commitment with the Government of the Province of Newfoundland and Labrador, Canada,
Vale is building a nickel processing facility, the Long-Harbour plant. It will have a nominal
capacity to produce 50,000 tpy of finished nickel, utilizing the feed from the Ovoid mine of our
Voiseys Bay site. The total estimated capex is US$ 2.821 billion and start-up is scheduled for
1H13. The capex budgeted for 2010 is US$ 441 million.
We are developing three copper projects Salobo, Salobo expansion (Salobo II) and Tres Valles
and next year we will begin the development of Konkola North. In addition, Vale has several
projects to be developed over the next few years Salobo III, Alemão, Cristalino, and Polo, all
of them in Carajás. The projects and growth options will enable us to achieve a capacity to produce
one million metric tons of copper per year.
In the first phase of development of the Salobo project, in Carajás, state of Pará, Brazil, the
nominal capacity is estimated to reach 127,000 tpy of copper contained in concentrates, with
130,000 ounces of gold per year as a by-product. The capex for the project is estimated at US$
1.152 billion, US$ 600 million of which to be spent in 2010. Salobo is scheduled to come on stream
in the second half of 2011.
At the same time, we are developing the expansion of Salobo (Salobo II), with an additional output
of 127,000 tpy of copper in concentrates. The estimated capex is US$ 855 million, of which US$ 66
million will be disbursed in 2010. The conclusion of Salobo II is scheduled for the second half of
2013.
Tres Valles, in the Coquimbo region of Chile, will have an estimated nominal production capacity of
18,000 tpy of copper cathodes, using SX-EW (solvent extraction electrowinning) processing plant.
The total cost of the project is US$ 102 million, with a disbursement for 2010 of US$ 27 million
and conclusion scheduled for the first half of the next year.
Konkola North, estimated to be the second-largest known resource in the Zambian Copperbelt, is an
open-pit mine, with an estimated nominal production capacity of 44,000 tpy of copper in
concentrates. Konkola North is part of our 50/50 joint venture with ARM in Africa. Vales total
investment in the project is US$ 145 million, with a disbursement for 2010 of US$ 50 million.
Project conclusion is scheduled for 2013. This project is subject to Board approval.
7
Simultaneously to project development, we are running UHC, a copper processing plant located in
Carajás, built as part of our initiatives in technological innovation to optimize the utilization
of copper resources. It is a plant with industrial scale, nominal capacity of 10,000 tpy of copper
cathode, in which a new technology hydro-metallurgical technology is being tested to process
copper ores with a higher degree of impurities.
As recently announced, we will build a new alumina refinery, Companhia de Alumina do Pará (CAP),
supported by the expansion of the Paragominas bauxite mine (Paragominas III), both located in the
Brazilian state of Pará.
The CAP refinery, which is 61%-owned by Vale, will be located in Barcarena, close to the operations
of our subsidiary Alunorte.
The initial production capacity of the refinery will be 1.86 Mtpy of alumina, through two lines of
930,000 tpy each. The new refinery has potential for future capacity expansions up to 7.4 Mtpy. The
estimated total capex for phase one of CAP is US$ 2.2 billion, of which US$ 60 million will be
spent in 2010. Startup is expected to take place in the second half of 2012.
Paragominas III will supply the bauxite to be consumed by the CAP refinery. The estimated total
capex is US$ 487 million and it will increase the capacity of the Paragominas mine to 14.85 Mtpy
from the current 9.9 Mtpy. Paragominas III is expected to start-up operations simultaneously with
the first stage of CAP, in the second half of 2012. There will be no disbursement in 2010.
In the fertilizer business we have been operating only one potash mine since 1992,
Taquari-Vassouras, in the state of Sergipe, Brazil, which has capacity to produce 850,000 tpy.
However, Vale does have large growth potential deriving from a rich project pipeline. In the potash
business we have Carnalita, near Taquari-Vassouras, Rio Colorado and Neuquén, in Argentina, and
Regina, in Canada. In phosphates there is Bayóvar, Bayóvar II, both in Peru, and Evate, in
Mozambique. As a consequence, there is potential to reach an output over 12 Mtpy of potash and 9
Mtpy of phosphate rock, a scale that would turn Vale into one of the leading global producers of
fertilizer inputs.
We will start the development of Rio Colorado in 2010. It comprises an operation with an initial
nominal capacity of 2.4 Mtpy of potash (potassium chloride, KCl), and potential to expand up to
4.35 Mtpy, the construction of a railway spur of 350 km, port facilities and a power plant. The
estimated total capex for phase one of Rio Colorado is US$ 4.118 billion, of which US$ 304 million
is budgeted for 2010. The start-up is expected to take place in 2H13. This project is subject to
Board approval.
Vale is developing the Bayóvar project, in Sechura, department of Piura, Peru. Bayóvar is an
open-pit mine, with nominal production capacity of 3.9 Mtpy of phosphate rock, supported by a
maritime terminal. Estimated total capex is US$ 479 million, with expenditures of US$ 219 million
in 2010. Conclusion is planned for the second half of 2010.
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Coal building a new business |
Coal is a new business for Vale as we entered the industry in 2007 through the acquisition of
Australian assets. However, as in the fertilizer business we have potential to multiply our current
production capacity, being able to reach 40 Mtpy by 2016. The increase is underpinned by the ramp
up of current operations and the development of Moatize, Moatize II, both in Mozambique,
Ellensfield, Eagle Downs and Belvedere6, in the Bowen Basin, state of Queensland,
Australia.
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6 |
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Vale owns 100% of Ellensfield, 50% of Eagle Downs and 51% of Belvedere and has a call
option to buy the remaining 49% of the last one. |
8
After the installation of a longwall and the expansion of the CHPP (coal handling preparation
plant), Carborough Downs, an underground mine in the Bowen Basin, state of Queensland, Australia,
is ramping up to reach its nominal capacity of 4.8 Mtpy in 2011. El Hatillo, located in Cesar
department, Colombia, is also ramping up to reach its nominal capacity of 4.5 Mtpy in 2012.
The Moatize project, in the province of Tete, Mozambique, involves an investment of US$ 1.322
billion, of which US$ 595 million is budgeted to be spent in 2010. It will have a nominal capacity
to produce 11 Mtpy of coal, of which 8.5 Mtpy of metallurgical coal hard coking coal and 2.5
Mtpy of thermal coal. The start-up is expected for 1H11.
Moatize coal output will be transported by 600 km Sena-Beira railroad to a new maritime terminal in
the port of Beira, province of Sofala, Mozambique. The coal terminal will be built by a
concessionary owned by the Mozambican government.
At Moatize, Vale is building one of the largest CHPPs in the world on an operational site, with
capacity to process 26 Mtpy of coal, to allow for the expansion of Moatize.
Given the limited capacity of the Sena Beira railroad, the feasibility of the second phase of
Moatize will depend on a different logistic solution. In this context, we are studying the
construction of a new railroad from Moatize to Nacala, in the north of Mozambique, with
approximately 200 km of extension, and a maritime terminal in Nacala.
Meanwhile, we are completing the feasibility studies for two Australian projects: Ellensfield, with
potential for a nominal capacity of 4.5 Mtpy, and Eagle Downs, 2.4 Mtpy.
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Steel carrying out the strategy |
The strategy for the steel industry is to incentivize new steelmaking projects in Brazil, one of
the lowest-cost steel producing countries, investing in temporary minority stakes with the goal of
being exclusive supplier of iron ore and pellets to the mills.
CSA will produce 5 million metric tons of steel slabs in a plant under construction in the state of
Rio de Janeiro, Brazil, jointly with a maritime terminal and a thermal power plant. It will demand
8.5 million metric tons of iron ore and pellets per year to be exclusively supplied by Vale.
Start-up is scheduled for the first half of 2010.
In a partnership with Dongkuk Steel, Vale is studying the feasibility of the CSP project to build a
steel slab plant in the Brazilian state of Ceará. It will have a nominal production capacity of 3
Mtpy, with potential to be expanded to 6 Mtpy in a second phase. The first stage has an estimated
total investment of US$ 4.0 billion, in which the size of Vales investment will depend on its
final stake in the project. Start-up is expected for 2013. The development of this project depends
on the conclusion of feasibility studies and the approval of its shareholders.
Vale is studying the construction of an integrated slab plant project to be located in the
Brazilian state of Espírito Santo, the CSU project, with a nominal production capacity of 5 Mtpy.
Start-up is expected for 2014. Simultaneously to the ongoing feasibility study, we are looking for
potential partners for the project. CSU is subject to Board of Directors approval.
We are also taking several steps to implement the ALPA project, which involves the construction of
a steel plant in Marabá, state of Pará, Brazil, with a nominal capacity of 2.5 Mtpy of
semi-finished steel. Total estimated investment is US$ 2.760 billion and start-up is expected for
2013. The feasibility study is currently being conducted and investment expected for 2010 is US$
192 million. The development of
this project will be associated to various public investments in infrastructure. The project is
subject to Board of Directors approval.
9
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Power generation enhancing the infrastructure |
Energy management and generation is a key priority. As a large consumer of energy, we believe that
investing in power generation to meet our consumption needs is an efficient way to protect against
price volatility, regulatory uncertainties and supply risks.
Currently, we generate 34% of our global electricity consumption from our own power plants located
in Brazil, Canada and Indonesia.
We aim to diversify and optimize our energy matrix by using hydropower, seeking to identify natural
gas deposits in Brazil and studying the usage of renewable fuels, such as biodiesel.
We are building two hydroelectric power plants: Karebbe, in Indonesia, and Estreito, in Brazil.
Karebbe, located on the Larona River, will be the third hydropower plant to support our nickel
operations on the island of Sulawesi, Indonesia. It is intended to reduce operational costs and
generate power to allow the potential expansion of production to 90,000 tpy of nickel in matte. The
total capex is estimated at US$ 410 million, with US$ 126 million to be disbursed in 2010. Karebbe
is expected to come on stream in the first half of 2011.
The Estreito hydroelectric power plant, located on the Tocantins River, on the border of the
Brazilian states of Maranhão and Tocantins, will have an installed capacity of 1,087 MW. Estreito
is expected to come on stream in the second half of 2010. We own a 30% stake in the consortium that
has the concession to build and operate the plant. Our estimated share of the total investment is
US$ 514 million, with US$ 186 million to be disbursed in 2010.
We are investing in biodiesel, through a consortium. Vales stake in the consortium, whose goal is
to produce 500,000 metric tons of palm oil per year, is 41%. The oil production related to our
stake will be used to feed our own biodiesel plant, which will be 100% built and operated by Vale,
with estimated capacity of 160,000 metric tons of biodiesel per year.
Vales total investment in the consortium and the building of the biodiesel plant will be US$ 305
million, of which US$ 55 million will be disbursed in 2010.
Our biodiesel output will be dedicated to supplying the fleet of locomotives in the Carajás
railroad and the bulk equipment of Carajás mines. This initiative complies in advance to the
regulation which requires the use of B20 by 2020.
We will continue to invest in natural gas exploration in Brazil, with budgeted expenditures of US$
300 million for 2010.
10
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Description of the main projects |
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Budget |
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US$ million |
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Business |
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Project |
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2010 |
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Total |
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Status |
Ferrous
Minerals/Logistics
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Carajás
Additional 30
Mtpy
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480 |
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2,478 |
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This project will add 30 Mtpy to current capacity. It comprises
investments in the installation of a new plant, composed of primary
crushing, processing and classification units and significant
investments in logistics. Start-up planned for 1H12, depending on
concession of environmental licenses. |
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Carajás
Additional 10
Mtpy
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90 |
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290 |
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This project will add 10 Mtpy of iron ore to current capacity. It involves
investment in the overhauling of a dry plant and the acquisition of a
new one. Start-up expected for 1H10. |
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Carajás Serra
Sul (mine
S11D)
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1,126 |
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11,297 |
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Located on the Southern range of Carajás, in the Brazilian state of
Pará, this project will have a capacity of 90 Mtpy. Completion is
scheduled for 2H13, subject to obtaining the environmental licenses.
The project is still subject to approval by the Board of Directors. |
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Apolo
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38 |
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2,509 |
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Project in the Southeastern System with a production capacity of 24
Mtpy of iron ore. Start-up expected for 1H14. The project is still
subject to approval by the Board of Directors. |
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Conceição
Itabiritos
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184 |
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1,170 |
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This project in the Southeastern System will add 12 Mtpy of iron ore to
current capacity. It involves investment in a new concentration plant,
which will receive ROM from the Conceição mine. Start-up expected
for 2H12. The project is still subject to approval by the Board of
Directors. |
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Vargem
Grande
Itabiritos
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79 |
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975 |
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This project in the Southern System will add 10 Mtpy of iron ore to
current capacity. It involves investment in a new iron ore treatment
plant, which will receive low grade iron ore from the Aboboras mine.
Start-up expected for 2H12. The project is still subject to approval by
the Board of Directors. |
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Tubarão VIII
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122 |
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636 |
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Pelletizing plant to be built at the port of Tubarão, in the Brazilian state
of Espírito Santo, with a 7.5 Mtpy capacity. Start-up scheduled for
2H12. |
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Oman
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484 |
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1,356 |
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Project for the construction of a pelletizing plant in the Sohar industrial
district, Oman, in the Middle East, for the production of 9 Mtpy of
direct reduction pellets and a distribution center with capacity to
handle 40 Mtpy. Start-up planned for 2H10. |
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Teluk Rubiah
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98 |
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900 |
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It involves the construction of a maritime terminal that will be able to
receive 400,000 dwt vessels and a distribution center with a capacity
to handle up to 30 million metric tons of iron ore in this first phase, and
the possibility to expand it up to 90 million metric tons in the future.
Start-up is planned for 1H13. The project is subject to approval by the
Board of Directors. |
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11
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Budget |
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US$ million |
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Business |
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Project |
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2010 |
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Total |
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Status |
Non-
Ferrous
Minerals
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Onça Puma
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510 |
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2,297 |
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The project will have a nominal production capacity of 58,000 metric
tons per year of nickel in ferronickel form, its final product. Start-up
expected for 2H10. |
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Totten
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146 |
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362 |
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Mine in Sudbury, Canada, aiming to produce 8,200 tpy of nickel,
copper and precious metals as by-products. Project being
implemented and conclusion planned for 1H11. |
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Long-Harbour
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441 |
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2,821 |
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Nickel processing facility in the province of Newfoundland and
Labrador, Canada, to produce 50,000 metric tons of finished nickel
per year, together with up to 5,000 metric tons of copper and 2,500
metric tons of cobalt, using the ore from the Ovoid mine in our
Voiseys Bay mining site. The start-up is scheduled for 1H13. |
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Salobo
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600 |
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1,152 |
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The project will have a production capacity of 127,000 metric tons of
copper in concentrate. Project implementation under way and civil
engineering has started. Conclusion of work scheduled for 2H11. |
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Salobo
expansion
(Salobo II)
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66 |
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855 |
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The project will expand the Solobo mine annual production capacity
from 127,000 to 254,000 metric tons of copper in concentrate.
Conclusion is estimated for 2H13. |
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Tres Valles
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27 |
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102 |
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Located in the Coquimbo region in Chile, with an annual production
capacity of 18,000 metric tons of copper cathode. Conclusion
expected for 1H10. |
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Konkola North
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50 |
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145 |
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Located in the Zambian copper belt, this is an open-pit mine and will
have an estimated nominal production capacity of 44,000 tpy of
copper in concentrate. This project is part of our 50/50 joint venture
with ARM in Africa. Project conclusion is scheduled for 2013. This
project is subject to Board approval. |
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Bayóvar
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219 |
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479 |
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Open pit mine in Peru with nominal capacity of 3.9 million metric tons
per year of phosphate rock. Project under implementation with
conclusion scheduled for 2H10. |
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Rio Colorado
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304 |
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4,118 |
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The project includes the development of a mine with an initial nominal
capacity of 2.4 Mtpy of potash KCl, with potential for a future
expansion to 4.35 Mtpy, construction of a railway spur of 350 km, port
facilities and a power plant. Start-up is expected to take place in the
2H13. This project is subject to Board approval. |
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CAP
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60 |
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2,200 |
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The new alumina refinery will be located in Barcarena, in the Brazilian
state of Pará. The plant will have a production capacity of 1.86 Mtpy of
alumina, with potential for future expansion to produce up to 7.4 Mtpy.
Completion is expected in 2H12. |
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Paragominas III
|
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487 |
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Paragominas III will add 4.95 Mtpy of bauxite to existing capacity,
which completion scheduled for 2H12. |
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Coal
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Moatize
|
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|
595 |
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1,322 |
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This project is located in Mozambique and will have a production
capacity of 11 million tons, of which 8.5 million tons of metallurgic coal
and 2.5 million tons of thermal coal. Completion is scheduled for
1H11. |
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Energy
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Estreito
|
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|
186 |
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514 |
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Hydroelectric power plant on the Tocantins river, between the states
of Maranhão and Tocantins, Brazil. Has already obtained the
implementation license, and is being built. Vale has a 30% share in
the consortium that will build and operate the plant, which will have a
capacity of 1,087 MW. Completion is planned for 2H10. |
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Karebbe
|
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|
126 |
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|
410 |
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Karebbe hydroelectric power plant in Sulawesi, Indonesia, aims to
supply 90 MW for the Indonesian operations, targeting production cost
reduction by substitution of oil as fuel. Work started and main
equipment purchased. Scheduled to start-up in 1H11. |
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Biofuel
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55 |
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|
305 |
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Consortium with Biopalma to invest in biodiesel to supply our mining
and logistics operations in the Northern region of Brazil, using the B20
mix (20% of biodiesel and 80% of ordinary diesel), from 2014
onwards. Vales stake in the consortium is 41%. The oil production
related to our stake will be used to feed our own biodiesel plant, with
estimated capacity of 160,000 metric tons of biodiesel per year. |
12
For further information, please contact:
+55-21-3814-4540
Roberto Castello Branco: roberto.castello.branco@vale.com
Alessandra Gadelha: alessandra.gadelha@vale.com
Patricia Calazans: patricia.calazans@vale.com
Samantha Pons: samantha.pons@vale.com
Theo Penedo: theo.penedo@vale.com
This press release may include declarations that present Vales expectations in relation to future
events or results. All declarations, when based upon future expectations and not on historical
facts involve various risks and uncertainties. Vale cannot guarantee that such declarations will
come to be correct. These risks and uncertainties include factors related to the following: (a)
countries where we operate, mainly Brazil and Canada; (b) global economy; (c) capital markets; (d)
iron ore and nickel businesses and their dependence upon the global steel industry, which is
cyclical by nature; (e) high degree of global competition in the markets which Vale operates. To
obtain further information on factors that may give origin to results different from those
forecasted by Vale, please consult the reports filed with the Brazilian Securities and Exchange
Commission (CVM), the Autorité des Marchés Financiers (AMF), and with the U.S. Securities and
Exchange Commission (SEC), including the most recent Annual Report Vale Form 20F and 6K forms.
13
Signatures
Pursuant to the requirements of the Securities Exchange Act of 1934, the registrant has duly caused
this report to be signed on its behalf by the undersigned, thereunto duly authorized.
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Vale S.A.
(Registrant)
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Date: October 19, 2009 |
By: |
/s/ Roberto Castello Branco
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Roberto Castello Branco |
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Director of Investor Relations |
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