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CHINA’S IMPACT ON THE GLOBAL

ALUMINUM INDUSTRY
A STRATEGIC PERSPECTIVE

PREPARED BY
INDUSTRY ANALYSIS DEPARTMENT — ALCAN INC.
OCTOBER 2002
3 WILL CHINA BE A DESTABILIZING 3

FACTOR IN THE YEARS AHEAD?

Some analysts have expressed the opinion that China could constitute a destabilizing force in the primary
metal market by becoming a significant net exporter of aluminum, beginning in 2002 and continuing in the
years ahead. Such an eventuality would increase the net imports of metal originating from the former East
Bloc, push up the Western World metal supply and thus have a depressing effect on the real long-term price
of aluminum. In the opinion of these analysts, China’s aluminum industry might well play a role in the current
decade similar to the one played by Russia’s aluminum industry during the first half of the 1990s.

What are the facts? Do they support the view of these analysts? What would have to change for this view to be
a reflection of the future? These are the questions this text will attempt to answer from Alcan’s perspective.
EXECUTIVE SUMMARY 1

A number of analysts have expressed the opinion that China could emerge as a significant net exporter of
aluminum over the next few years — a development they fear would have a destabilizing influence on the
primary metal market, pushing up Western World supply and thereby driving down prices. In the opinion of
these analysts, China might well play a spoiler role in the current decade similar to the one played by former
East Bloc producers during the so called “Russian metal shock” of the early 1990s.

The China scenario is an admittedly complex one. What are the facts of the matter? In order to shed some light
on a situation that could have a crucial impact on the outlook for the global industry, Alcan industry analysts
undertook an intensive, segment-by-segment study of China’s burgeoning aluminum industry.

Highlights of their findings are summarized below for your convenience.

China’s Economic and Social Environment


The People’s Republic of China is a country of 1.28 billion inhabitants
spread over an area of 9.6 million km2. It boasts one of the fastest
growing economies in the world with gross domestic product (GDP)
increasing at reported average annual rate of 7.9% since 1996. China’s
recent admission to the World Trade Organization (WTO) has provided
the potential for a level playing field for competition, while creating
immense business opportunities and providing access to one of the
largest markets in the world.

A Capsule Look at China’s Aluminum Industry


Given China’s economic growth rate and the reluctance of its government
to rely too heavily on imports of strategic materials, the country has
evolved into a major player in the world aluminum industry. Highlighted
here in capsule form is Alcan’s assessment of key segments of the
Chinese industry.
2

Bauxite:
China’s bauxite supplies are abundant but expensive to process. Chinese
bauxite is predominantly diaspore, which is high in silica with an alumina
content of 55% to 65%. Because of its low quality and the high process-
ing costs entailed, China’s bauxite is not exported, but refined locally
using a soda-lime sinter process.

Alumina:
For a variety of economic, financial and quality reasons, China will remain
a net importer of alumina in the years ahead. Current excess demand of
more than 3 million tonnes could reach the 5-million-tonne level by 2006.
Nevertheless, China’s increasing reliance on imported alumina will be
gradual, as the government will almost certainly continue to protect
state-controlled Chalco’s high-cost sintering facilities, notwithstanding
reduced import tariffs.

Aluminum Production:
With production of some 3.5 million tonnes in 2001, China currently ranks
as the largest aluminum producer in the world, thanks to idled capacity in
the U.S. Pacific Northwest. However, most of its 130-plus smelters are
characterized by high costs, small scale, outdated technology and signif-
icant pollution problems. With the exception of four larger facilities,
Chinese smelters are all located on the upper right-hand side of the
aluminum cost curve. While there has been a rapid expansion of China’s
smelting capacity, the surge has resulted largely from inducements
(mainly subsidies by provincial governments) rather than any “natural”
comparative advantages. Current government policy and WTO require-
ments should combine to reverse this surge in output.
3

The Power Situation:


Despite being the world’s second largest generator of electricity, the
transmission of power from regions of China that enjoy surplus capacity
to areas which are short is constrained. Most of the country’s power
grids are still not interconnected. But this situation is changing and a
reduction in electricity rates is expected, provided that contemplated
reforms in the energy sector proceed. This should encourage even more
development of large-scale smelters in China’s eastern provinces,
further exacerbating the comparative disadvantages of smaller-scale,
highly polluting smelters.

Aluminum Consumption:
China’s aluminum consumption has been growing at an annual rate of
about 14% since 1997. The higher consumption has been driven mainly
by growth in the construction (32% of total aluminum use), trans-
portation (12%) and power (12%) sectors. Imports of remelt ingot, scrap
and semi-fabricated products fill the gap between China’s surging
demand and its domestic supply of aluminum.

Imports vs. Exports:


China has been a net importer of unwrought aluminum every single year
except in 1998. Over the past seven years, China’s net imports of
unwrought metal averaged 230 thousand tonnes (kt). Imports dropped to
120 kt last year, reflecting a surge in aluminum production capacity,
increased tolling activity by Chinese smelters and a slowdown in metal con-
sumption. For the first eight months of this year, however, China has been
a net exporter of unwrought metal, with net exports amounting to 146 kt.
4

Demand/Supply Situation (2002-2006):


Going forward, we expect that China’s aluminum consumption should
increase by 10-11% a year. At that rate, consumption should exceed
5,800 kt by 2006. On the supply side, after increasing by 24% in 2001
and 2002, China’s aluminum production also should continue to increase
but at a slower pace, in the range of 8-9%. Consequently, even if
production exceeds demand for the next two or three years, China
should once again become a net importer of unwrought metal by the
middle of the decade.

Summary:
Given the above assumptions, the possibility of China becoming a long-
term net exporter of unwrought aluminum seems remote. Thus, we
believe that China will not be a major destabilizing factor in the years ahead.
1 CHINA’S ECONOMIC 5

AND SOCIAL ENVIRONMENT

The People’s Republic of China is a country of 1.28 billion inhabitants spread over an area of 9.6 million km2.
It is divided into 22 provinces, five autonomous regions, and three municipalities (Beijing, Tianjin, Shanghai) under
the direct control of the State Council. Population density has increased by 37% over the last quarter of a
century to 133 inhabitants/km2, which explains the priority accorded by the Chinese government to population-
control measures. This policy evidently has been quite successful, given that the population growth rate
declined from 2.6% during the 1960-1975 period to about 1% towards the end of the ‘90s. China’s population
used to be essentially agricultural. In 1975, for instance, 76% of the population was classified in the agricultural
sector, while the industrial and services sectors accounted for 12% each. Today, the service sector provides
work for almost 35% of the population, while the relative share of the agricultural sector has dropped to 47%.

As concerns the economic environment, Using the purchasing power parity potential for a level playing field
China is one of the fastest growing (PPP) concept, China’s per-capita for competition and creating immense
economies in the world with gross GDP jumped from $US273 in 1975 business opportunities, along with
domestic product (GDP) reportedly to more than $3,600 in 2000. On other access to one of the largest markets
growing at an average annual rate fronts, China’s inflation rate is under in the world. The following table
of 7.9% since 1996. China’s industrial control. And it enjoys a substantial compares China’s performance with
production for August 2002 was up surplus in its trade balance and cur- a selected group of developed and
12% on a year-over-year basis, which rent account, while its foreign reserves developing countries for the years
represented by far the best performance exceed $200 billion. Finally, China 1975 and 2000:
in Asia and a much higher rate than has recently joined the World Trade
in most Western World countries. Organization (WTO), providing the

ECONOMIC INDICATORS: CHINA AND A SELECTED GROUP OF DEVELOPED AND DEVELOPING COUNTRIES, 1975 - 2000

Public Expenditure
GDP Inflation Rate Debt Service/Exports on Education
Per Capita Annual Growth Rate
($,PPP) (%) (%) (%) (% of GDP)
1975 2000 1975 2000 1975 2000 1975 2000 1975 2000

China 273 3,617 9.4 8,0 1.1 0.4 4.3 9.0 1.7 2.3

Developed Countries
Canada 7,339 27,389 2.9 4.8 10.8 2.7 7.6 6.9
Japan 5,626 24,835 3.8 1.9 11.8 -0.6 5.5 3.6
United States 9,132 35,048 3.0 5.2 9.1 3.3 7.4 5.4

Developing Countries
Brazil 2,302 7,037 2.9 4.2 28.9 7.0 41.3 110.9 3.1 5.1
India 464 2,248 5.9 6.4 5.7 4.0 15.3 15.0 2.7 3.2
Mexico 2,555 8,820 2.2 7.0 15.2 9.5 41.1 25.1 3.5 4.9
Thailand 809 6,132 7.3 4.3 5.3 1.6 12.0 22.0 3.5 4.8
Source: The World Situation, Éditions La Découverte, Montreal, 2001.
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2 CHINA’S
ALUMINUM INDUSTRY

Given China’s economic growth rate and the reluctance of central authorities to rely too heavily on foreign
imports, the country has evolved into a major player in the world aluminum industry. After reviewing the main
characteristics of China’s aluminum industry (bauxite and alumina, aluminum production and consumption, the
power situation, and the evolution of net imports during the last decade), this text will assess the main drivers
of future aluminum consumption and production in China and examine the conditions under which, going
forward, it might prove to be a net exporter or importer of unwrought aluminum.

a) Bauxite • Because of the low quality, China


• Abundant — but expensive to pro- does not export any metallurgical
cess — is the best way to describe grade bauxite. Moreover, the miner-
Chinese bauxite. As of 2001, China alogy and level of silica impurity in
had total bauxite reserves of 2.27 bil- Chinese bauxite mean that it cannot
lion tonnes (representing roughly be easily processed in conventional
2% of the world’s bauxite reserves). Bayer plants. This has forced the
Of this total, 703 million tonnes were Chinese to perfect a soda-lime sinter
classified as proven reserves (equiv- process. This Sintering and Hybrid
alent to 50 times the current annual process requires a lot of energy —
consumption) and 1.57 billion tonnes up to 45 gigajoules (GJ) per tonne
as probable reserves. of alumina as against 13 GJ for a
typical Western plant — and
• China’s bauxite deposits are concen- large quantities of soda (114 kg
trated in two areas in the south and per tonne of alumina on average).
north of the country, with Shanxi
Province having the largest deposits, • In 2001, China’s total bauxite con-
followed by Henan, Guizhou, sumption was estimated at 14 million
Guangxi and Shandong Province. tonnes. The country’s bauxite mines
mainly supply domestic alumina
• China’s bauxite is predominantly refineries, which are all owned by
“diaspore” — that is high in silica, Chalco, the state-controlled alu-
with an alumina content of 55% to minum company. Of Chalco’s total
65%. Three-quarters of the reserves annual bauxite requirements in 2001,
have an average alumina-to-silica 59% was sourced from small inde-
ratio of 6:1. By way of comparison, pendent mines and 23% from their
the typical ratio of commercially own mines.
available bauxite in the West is 10:1.
7

BAUXITE RESERVES IN SELECTED PROVINCES (in million tonnes)

Shanxi

750
190

Shandong

24
20
Beijing

Henan

197
178

Shanghai Guizhou

240
128

Guangxi

240
Possible reserves
Hong Kong 119
Explored reserves

Various sources. 0 200 400 600 800

Bauxite Summary:
China’s bauxite is abundant but expensive to process. It is predominantly
diaspore, which is high in silica with an alumina content of 55% to 65%.
Because of its low quality and the high processing costs entailed, China’s
bauxite is not exported, but refined locally using a soda-lime sinter process.
8

ALUMINA CAPACITY, PRODUCTION & TECHNOLOGY (in million tonnes)

Shanxi

1.20 Bayer 58%


1.32
Sinter 42%

Great Wall (Zhongzhou)

0.44
0.53 Sinter 100%

Great Wall (Zhengzhou)

0.95
Bayer 68%
1.06
Sinter 32%

Shandong

0.73
Bayer 18%
0.81
Sinter 82%

Guizhou

0.45
Bayer 61%
0.50
Sinter 39%
Capacity

Production Pingguo
Bauxite
0.40
0.44 Bayer 100%
Various sources.

0 1 2 3

b) Alumina • As suggested above, four of Chalco’s of 2002 reached 2.37 million tonnes.
• China is the second largest producer six alumina refineries use Hybrid The gap between alumina demand
of alumina in the world with pro- technology, one uses the Sintering and domestic production will most
duction in 2001 reaching 4.7 million process and one (Pingguo) the certainly increase over time, as alu-
tonnes. Chalco owns all of China’s Bayer technology. minum production (and thus alu-
six alumina refineries. mina requirements) is expected
• Those six refineries supply nearly
to increase faster than domestic
• Chinalco, representing China’s 70% of China’s total annual alumina
alumina production. Import needs
central government, is the con- requirements. Given that domestic
are expected to total about 5 million
trolling shareholder of Chalco, demand for alumina reached 7 mil-
tonnes by 2006.
having assumed ownership of lion tonnes in 2001, the difference
all shares resulting from a recent must be imported, mainly from • All six of China’s alumina refineries
restructuring (debt-to-equity Australia (86% of total imports in are high-cost plants. Compared
swap). Chalco’s ownership struc- 2000), India and occasionally from with other refineries around the
ture now is as follows: the Americas. In 2001, alumina world, they would rank in the high-
imports exceeded 3 million tonnes, est cost quartile. Chinese alumina
Chinalco 72% as the market price remained below also tends to be relatively low quality
Institutional investors 20% $150/t for most of the year. Total
Alcoa 8% imports for the first seven months
9

in that it is fine, or floury, and rich in


ALUMINA SUPPLY/DEMAND
impurities. On the other hand, aver-
age freight charges from Australia HISTORIC, CURRENT AND PROJECTED SUPPLY AND DEMAND — CHINA
to principal ports in China amount
to about $15/t. An import duty of 12,000
Demand
12% (equivalent to $20.50/t in 2002) Supply
and average port-handling charges 10,000
of $10/t also have to be considered.
Even when all these items are taken 8,000
into account (including a value-added
tax paid by Chinese producers), the 6,000
domestic price of alumina is still
higher than the material imported
4,000
from Australia.
• Although China’s demand for alumina 2,000
exceeds local production, resulting
in a rapid increase and reliance on ('000
tonnes)
imports, the latter are subject to 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
import tariffs. By increasing the price
Various sources.
of alumina imports, these tariffs and
quotas also have the effect of increas-
ing the relative competitiveness of (the exchange of alumina for metal) facilities. If tariffs are no longer a
the domestic raw material. However, has proved to be an effective means first best option, several non-tariff
with China having recently joined to alleviate working capital require- trade barriers (import quotas, dual
the WTO, the import tariff has been ments. This is particularly true if the exchange rates, procurement poli-
reduced from 18% to 12% for 2002. alumina in question can be processed cies, an alumina import registration
Additional cuts are scheduled to take without the need for major capital policy, etc.) are still available to help
place over the next two years. investment. Finally, bank financing is discourage producers from switch-
available to smelters with acceptable ing too fast from domestic to
2001 2002 2003 2004 economies of scale. imported alumina.
18% 12% 10% 8%
• However, everything else is not likely
• If everything else were to remain to remain the same. One should
the same, this would be an incentive assume that the Chinese government’s
for China’s aluminum producers intention is to continue protecting
to rely even more heavily on foreign Chalco’s high-cost alumina sintering
imports in the years ahead, spurning
domestic alumina production. After
all, it is well known that most smelters
prefer imported alumina for eco-
nomic (cheaper) and quality (more
sandy) reasons. Also, capital may
no longer be a major hurdle in terms Alumina Summary:
of switching to imports, as tolling Thus for economic, financial and quality reasons, China is likely to remain
a net importer of alumina in the years ahead. Current excess demand of
more than 3 million tonnes could reach the 5-million-tonne level by 2006.
Nevertheless, China’s increasing reliance on imported alumina will be gradual,
as the government will almost certainly continue to protect Chalco’s high-cost
sintering facilities, notwithstanding the reduced import tariffs.
10

SMELTER CAPACITY AND LOCATION

Total Smelters: 133


Total Installed Capacity: 3,850 kt
Yellow River
Beijing Total Operating Smelters: 133
Total Production Capacity: 3,450 kt

> 100 kt (9 smelters)


50 - 100 kt (12 smelters)
< 50 kt (112 smelters)
Yangtse River
Shanghai Alumina refineries
Bauxite

Various sources.

Hong Kong

CHINA’S SMELTERS RELATIVE COST POSITION

2,000
Excludes the roughly 100 smaller Chinese smelters 1) Pingguo
located at the extreme right-hand of the cost curve.
2) Guizhou
1,800
3) Qinghai
10)
9) 4) Qingtongxia
1,600 7)
8)
5) 6) 5) Lanzhou, LianCheng, Baotou
4) 6) Yunnan
1,400 3)
1) 2)
7) Fushun, Baiyin

1,200 8) Danjiang

9) Tongchuan
1,000 10) Zhengzhou, Jiaozuo Wanfang, Shandong

800
2000 full
operating cost
0 5 10 15 20 25
(US$/t) Cumulative capacity (Mt) Source: CRU International Ltd.
11

c) Primary Aluminum Production SMELTERS APPROVED BY CENTRAL GOVERNMENT BETWEEN 1997–2001


• There are 133 smelters in China, Additional Project Approved
with a combined production capac- No. Name of Plant Capacity (kmt) Type Technology by
ity in 2001 of 3.5 million tonnes. 1 Shenyang Kangping 10.00 G 60kA Soderberg Local
A good number of them are located 2 Baotou 30.00 B 60kA Soderberg Local
around the Yangtse and Yellow Rivers. 3 Luqian 20.00 G 135kA PB Local
Most (112) have a capacity of less 4 Taiyuan Dongfeng 15.00 G 60kA Soderberg Local
than 50 kt, and only nine of the 5 Yangqian 30.00 G 60kA Soderberg Local
smelters have installed capacities 6 Zhengxin 15.00 G 60kA Soderberg Local
exceeding 100 kt. Nevertheless, that 7 Jinxin 5.00 G 60kA Soderberg Local
latter group of large smelters is 8 Guan Aluminum 80.00 B 190kA PB Local
responsible for almost 40% of 9 Shanhe 13.00 G 60kA Soderberg Local
China’s total aluminum production 10 Shandong 10.00 B 80kA PB Local
capacity. Three of those large facili- 11 Conglin 10.00 G 60kA Soderberg Local
ties (Guizhou, 230 kt/y capacity; 12 Luxi 60.00 G 190kA PB Local
Qinghai, 200 kt/y; Pingguo, 127 kt/y) 13 Zhouping 60.00 G 230kA PB Local
are owned by Chalco, whose five 14 NanShan 25.00 G 160kA PB Local
smelters together accounted for
15 Sanmenxia 60.00 B 190kA PB Local
nearly 20%, or 680 kt/y, of China’s
16 Gongyi No. 1 Power 30.00 G 160kA PB Local
primary capacity in 2001. The lowest-
17 Jiaozuo 70.00 B 280kA PB Central
cost facilities are, in increasing order,
18 Shenhuo 60.00 B 200kA PB Local
those of Pingguo, Guizhou, Qinghai
19 Shangdian 15.00 B 75kA PB Local
and Qingtongxia. All smelters with
20 Qingyang 12.00 B 60kA Soderberg Local
a capacity of less than 50 kt can be
found at the extreme upper right- 21 Xinwang 43.00 G 160kA PB Local
hand of the cost curve. 22 Huamao 15.00 G 60kA Soderberg Local
23 Huanghe 25.00 G 60kA Soderberg Local
• Between 1998 and 2001, China’s pri- 24 Dengfeng Power and smelter 50.00 G 80kA PB Local
mary aluminum production grew 25 Long Xiang 50.00 G 155kA PB Local
at an average annual rate of 12.7%. 26 Dengfeng Al Smelter 25.00 G 80kA PB Local
Thus, total production has almost
27 Changcheng 20.00 G 60kA Soderberg Local
doubled over the past six years, with
28 Mianchi 60.00 G 160kA PB Local
new investments adding 1.6 million
29 Xin An 60.00 G 160kA PB Local
t/y of capacity. Total installed capac-
30 Gongyi No. 2 Power 20.00 G 160kA PB Local
ity reached 3.8 million t/y in 2001,
31 Danjiangkou 35.00 B 120kA PB Local
while production reached 3.5 million
32 Lanzhou 120.00 B 200kA PB Central
tonnes. More than 50% of overall
production was attributed to the 33 Haibei 25.00 B 120kA PB
country’s 18 largest smelters. The 34 Baihe (Huangzhong) 6.00 B 75kA PB
adjacent table details the increase 35 Qinghai 55.00 B 200kA PB
in smelting capacity over the 1997- 36 Changqi 30.00 G 60kA Soderberg
2001 period. The additional capacity 37 Qingtongxia 130.00 B 200kA PB Central
of 1.6 million tonnes is identified by 38 Pingguo 30.00 B 320kA PB Central
technology, project type and approv- 39 Guizhou 70.00 B 186kA PB Central
ing agency. A total of about $2.2 bil- 40 Yun Nan 110.00 B 186kA PB Central
lion was spent to bring forward this 1,609.00
additional smelting capacity. * All projects denoted in “blue” are approved by the Central Government.
* G = Greenfield
B = Brownfield
Various sources.
12

• More than 100 of China’s smelters be increasingly difficult to apply


(totalling 1,600 kt/y of capacity) are and the number of small, uneco-
operating with less than 50 kt/y capac- nomic, polluting smelters will
ity. About 85 smelters (1,300 kt/y of likely decline substantially in the
capacity) use outmoded Soderberg intermediate term.
technology. These small-scale smelters
• What are the main reasons
are both uneconomic and highly
behind China’s rapid expansion
polluting. Given the increasing pres-
in smelter capacity?
sure to comply with environmental
regulations and a reduced willingness - Average growth of aluminum con-
to continue financing substandard sumption was about 14% per year
operations in the wake of China’s over this period, as China expe-
accession to the WTO, it seems very rienced rapid industrialization
unlikely that these small-scale smelters coupled with special policies imple-
will survive economically. Might they mented to encourage domestic
survive “uneconomically”? Should consumption and thus fuel higher
the respective local governments opt economic growth. For example,
to continue subsidizing them with liberalization of the housing market,
low-cost electricity, while exempting accelerated implementation of
them from environmental protection urbanization projects and large-
requirements, then they might sur- scale projects aimed at upgrading
vive in the short term. Nevertheless, the national power network all
with China having joined the WTO, had a significant impact on alu-
the local protective policies that have minum consumption.
been keeping such facilities alive will
- In order to strengthen the com-
petitiveness of Chinese business
in preparation for the keen com-
petition expected to follow WTO
admission, the government began
ALUMINUM SMELTER PRODUCTION
as far back as 1998 to provide
interest-free loans to develop the
HISTORIC, CURRENT AND PROJECTED SMELTER PRODUCTION — CHINA
country’s economic infrastructure
6,000 and encourage modernization of
Aluminum
capital equipment through technol-
5,000 ogy upgrading, capacity expansion
and new product development.
4,000 Many such loans were approved
for larger smelters, with capacities
3,000 close to or exceeding 100 kt/y.

2,000
- Moreover, in order to take advan-
tage of the availability of interest-
1,000
free loans and local government

('000
tonnes)
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

Various sources and estimates.


13

support for modernization projects, survival — and with the blessing


numerous other enterprises have of local governments — these
been bypassing the required central- small-scale power plants invested
government approval procedures. in aluminum smelters as a justifica-
Instead, they managed to gain tion for maintaining full power-
approval for smelter expansions generation capacities to support the
by phasing their projects into smelters’ operational requirements.
smaller scale initiatives that fit
• What about the cost competitiveness
within provincial and regional
of the larger Chinese aluminum
government loan limits.
smelters? Despite a number of pref-
- Whereas, in the Western World, erential electricity-supply policies
new smelter capacity requires an introduced over the years by the cen-
investment of between $3,500- tral government for the benefit of the
$4,500/t-Al, recent projects in 15 largest smelters, electricity tariffs
China have averaged (according generally remain higher than for
to Chalco) less than $1,500/t-Al. smelters in the majority of industri-
Thus, Chinese capital costs are at alized countries. Thus, operating
least $2,000/t-Al lower than in the costs would place most large Chinese
West (using current exchange rates), smelters in the top quartile of the
which implies lower ($80/t-Al) inter- world’s primary aluminum capacity.
est payments and reduced require- (Such costs exclude working capital,
ments in terms of return on capital. social welfare charges and transport
of the metal to market.)
- Finally, China’s central government,
towards the end of the ’90s, restricted • Given China’s high relative position
the purchase of large volumes of on the industry cost curve, domes-
electricity from power plants oper- tic producers have been protected
ating with unacceptable economies against foreign competition by a
of scale (below 50 MW), so as to tariff of 9% on imported primary
achieve a better utilization of coal aluminum. As a condition for join-
resources. In order to ensure their ing the WTO, that tariff will decrease
over time. It has been established
at 5% for the current year.

Aluminum Production Summary:


To sum up, even though China currently ranks as the largest aluminum producer in the world (because of idled capacity in
the U.S. Pacific Northwest), with a production level of about 3.5 million tonnes in 2001, most of its 133 smelters are char-
acterized by high costs, small scale, outdated technology and significant pollution problems. With the exception of four
larger facilities (Pingguo, Guizhou, Qinghai and Qingtongxia), Chinese smelters are all located on the upper right-hand side
of the aluminum cost curve. True, there has been a recent, rapid expansion of China’s smelting capacity. However, the
surge in output reflects much more a change in “induced” (mainly subsidies by provincial governments) rather than
“natural” comparative advantages. Current government policy and WTO requirements will likely combine to reverse
this surge in output, as smaller, uneconomic smelters are closed in rough proportion to new capacity introductions.
14

d) The Power Situation in China each of which encompasses a num- Major smelters (over 100 kt/y) have
• How about the power situation ber of provinces. Most of these grids been granted preferential rates in
in China? Since 1980, the country are not interconnected. But the gov- order to maintain their competitive-
has added close to 12,000 MW per ernment has started a program to ness relative to rivals abroad. A rate
year to installed capacity, to the correct this and it is expected that increase in 2000 reflected a sudden
point where it has now exceeded a unified grid will be in place by increase in the price of coal, which
300,000 MW, generating an out- 2010. In the mean time, the trans- resulted from a shortage caused by
put of 1,350 billion kwh. China’s mission of power from those regions government actions to close small-
installed capacity should reach that do have surplus capacity to scale coal mining operations (a pol-
490,000 MW in the year 2010, with areas that are short is constrained. icy similar to that just announced
an output of 2,140 billion kwh. But Over all, electricity demand exceeds for small, inefficient smelters).
despite being the world’s second supply by 15% to 20% but the bal-
• Concerning the future, a further
largest generator of electricity, there ance varies from region to region.
reduction in electricity rates is
are still millions of rural residents • How does this affect the develop- expected, provided contemplated
who are not connected to an electric- ment of the aluminum industry? reforms in the energy sector (aimed
ity network. And many more people For the time being, the most severe at facilitating free competition by
and businesses across the country power shortages are in the East and separating the distribution network
have access to only an irregular or South regions, the same areas that from power generating stations)
limited supply. How to explain this currently support nearly half of proceed. As stable, large-volume
apparent paradox? Not unlike other China’s aluminum smelting capacity. consumers, smelters will likely be
logistics-related problems in China, Nevertheless, the situation is improv- considered as preferred customers.
this situation is related to the local- ing. A general increase in installed Major smelters have been able to
ization of power resources versus power capacity has brought negotiate long-term, lower-priced
the need to distribute power equi- prices down: electricity contracts. However,
tably over a large geographic area. since most of the installed smelters
Average Price Range are located in Central and Western
• Representing the central govern- (mills/kwh) (mills/kwh)
ment, China National Power China while demand is greatest with
1997 42.2 32.5 - 56.6
Company is owner of the National the Eastern coastal provinces, China
1998 38.6
Power Network (NPN) as well as needs to continue with its upgrading
1999 36.1
major power generation plants. project so as to develop a more effi-
2000 37.3
The distribution of electricity is cient and properly inter-connected
2001 37.3 28.9 - 44.6
accomplished through several system for transmitting power
Various sources and estimates.
provincial networks and six regional from west to east.
grids (Northwest Power Company,
Northeast, North China, South
China, East China and Southwest),
Power Summary:
To sum up, despite being the world’s second largest generator of elec-
tricity, the transmission of power from regions of China that have surplus
capacity to areas which are short (yet support nearly half of China’s
smelting capacity) is constrained. Most of the country’s power grids are
still not interconnected. This situation is changing and a reduction in elec-
tricity rates is expected if contemplated reforms in the energy sector
proceed. That should encourage even more development of large-scale
smelters in China’s Eastern provinces, near major markets and thus fur-
ther exacerbate the comparative disadvantages of smaller-scale, highly
polluting smelters.
15
ALUMINUM TOTAL CONSUMPTION BY END-USE MARKETS (2001)

e) Aluminum Consumption TOTAL ALUMINUM CONSUMPTION BY END-USE MARKETS (2001)


• China’s aluminum consumption
grew at a compound annual rate
Western World 26,859 kt China 5,200 kt
of 14% from 1997 to 2000, compared
to a world average (excluding China) Building & construction

of 3.9% for the same period. The Consumer durables


10.1% 18.2%
increased consumption has been Electrical products
6.2% 32.0%
driven mainly by the growth of Machinery & equipement
8.6% 34.0%
China’s construction, transporta- Cans and other packaging
29.5%
10.0%
9.2%
tion and power industries, as well Transportation
18.2% 12.0%
as by growth in the domestic pro- Other
12.0%

duction of consumer products.


Various sources.
• China’s estimated primary alu-
minum consumption in 2001 was
3.6 million tonnes. If secondary America. Confronted with this prob- • Domestic production of manufac-
aluminum is included, estimated lem, Chinese can makers have little tured and semi-manufactured
total consumption reached 5.2 mil- alternative but to import the metal. products also benefits from import
lion tonnes during the same period. This explains why sheet and plate tariffs, as follows. However, these
In 2001, the main end-use markets make up the majority of imported tariffs are being reduced to comply
were building and construction semi-fabricated aluminum products. with WTO requirements:
(32%), transportation (12%),
electrical conductors (12%) and
durable goods (10%). Extrusions IMPORT TARIFFS — FABRICATED PRODUCTS
represented almost 30% of total
consumption, followed by castings 2001 2002 2003 2004
(20%) and sheet & plate (19%). Flat rolled products:
0.2-0.36 mm 12% 6%
• In recent years, annual aluminum can stock 12%
demand growth has been parti- Aluminum cans 34% 30%
cularly robust for the following Aluminum containers 14-15% 12%
products: new homes (31%), air Foil (less than 0.22 mm) 18% 10.8% 8.4% 6%
conditioning units (30%), cars and Aluminum windows/doors 30% 25%
light vehicles (12%), transmission Aluminum fabricated
lines (10%) and refrigerators (5%). (structural) 15% 9.6% 7.8% 6%
Aluminum products
• To satisfy overall demand, China (general purpose) 18% 14% 12% 10%
imports aluminum in the form Various sources.
of remelt ingot, scrap and semi-
fabricated products. The latter are
the largest of the three forms and
China purchases around 350 kt each
year. The poor quality of domestic
metal makes it quite often unsuitable Aluminum Consumption Summary:
for further processing in modern China’s aluminum consumption has been growing at an annual rate of about
high-speed rolling mills. This is 14% since 1997. The higher consumption has been driven mainly by
particularly true for the thin-gauge, growth in the construction (32% of total aluminum use), transportation
can-making equipment China has (12%) and power (12%) sectors. Imports of remelt ingot, scrap and semi-
imported from Europe and North
fabricated products fill the gap between China’s surging demand and its
domestic supply of aluminum.
16

f) Filling the Gap Between net exports of unwrought metal of


Demand and Domestic Supply: 146 kt. If one looks to net imports
Imports of Aluminum of semis, the flow has remained posi-
tive throughout the period. They
Monthly data on China’s net imports increased continuously between 1995
of unwrought aluminum (unalloyed and 1999-2000, when they stabilized
primary plus alloyed metal) and alu- at around 330 kt before declining
minum semis have been published somewhat last year to 269 kt, because
since 1995. The country has been a of the economic slowdown. Imports
net importer of unwrought aluminum and exports of aluminum scrap have
every single year except 1998 (-20 kt). also been monitored, but only over
Net unwrought imports were slightly the past two years. Total net imports
below 200 kt in 1995, reached a high of scrap reached almost 800 kt in 2000,
of 705 kt in 2000 and declined last before declining last year to 360 kt.
year to 120 kt. During the first eight About one-third of those imports
months of 2002, China registered were comprised of automotive parts.

CHINA UNWROUGHT ALUMINUM NET IMPORTS

100 450
China unwrought aluminum net imports
Alumina prices
80 400
China net unwrought aluminum imports (kt)

60
350

Alumina prices ($/tonne)


40
300
20
250
0

200
-20

-40 150
1996 1997 1998 1999 2000 2001 2002
-60 100
256.7 40.4 (19.9) 327.4 705.0 120.6 (19.5) YTD
Total imports / (exports) (kt)
Source: Reuters, CRU International Ltd.
17

• How do we account for last year’s - Second, exports of unwrought


decrease in net imports of unwrought metal almost doubled in 2001 (from
metal? The drop may be explained 205 kt to about 400 kt) because alu-
by the following reasons: minum production capacity surged
by about 600 kt during the course
- First of all, 2000 was not a typical
of the year. Also, Chinese smelters
year, since net imports of unwrought
were actively tolling alumina for
metal surged during that period for
aluminum, because the domestic
reasons related to:
alumina price was much higher
- the very high price of alumina
than that for imported alumina.
(which stimulated imports, as illus-
On the other hand, imports of
trated in the graph on page 16);
unwrought metal dropped from
- a reduction of the aluminum
910 kt in 2000 to 520 kt the follow-
import tariff from 12% to 6%
ing year because of a decline in
in order to promote broader trade
metal consumption related to
between Russia and China (this
the global economic slowdown.
triggered the importation of
Aluminum demand increased by
about 600 kt of metal through
17% in 2000 as compared to 1999,
the Russian/Chinese border
to reach 3,400 kt. In 2001, how-
in Northeast China).
ever, demand increased only 7%
- Consequently, unwrought imports
over the previous year, to 3,640 kt.
went from 530 to 910 kt, while
Consequently, net imports dropped
exports remained more or less
from 705 kt to about 120 kt.
unchanged at around 205 kt.

CHINA’S UNWROUGHT ALUMINUM SUPPLY/DEMAND BALANCE*

Year Demand Production Imports Exports Net Imports


1999 2,900 kt 2,620 kt 530 kt 210 kt 320 kt
2000 3,400 kt 2,830 kt 910 kt 205 kt 705 kt
2001 3,640 kt 3,420 kt 520 kt 400 kt 120 kt
* Excluding stock variations.

Imports/Exports Summary:
China has been a net importer of unwrought aluminum every single year
except 1998. Over the past seven years, China’s net imports of unwrought
metal averaged 230 kt. Imports dropped to 120 kt last year, reflecting a
surge in aluminum production capacity, increased tolling activity by Chinese
smelters and a slowdown in metal consumption. For the first eight months
of this year, however, China has been a net exporter of unwrought metal,
with net exports amounting to 146 kt.
18
3 THAT WAS THE PAST.
WHAT ABOUT THE FUTURE?

Utilizing a given set of explicit assumptions about the future, China’s aluminum production is forecast
to exceed demand for the next two to three years, as new capacity is expected to increase at a faster rate
than consumption. By the middle of the decade, however, consumption is expected to exceed production,
turning China once again into a net importer of unwrought metal. What are the assumptions about demand
and supply underlying such a scenario? And under what other set of assumptions might China become a
net exporter of aluminum?

ALUMINUM PRODUCTION/DEMAND

HISTORIC, CURRENT AND PROJECTED PRODUCTION


AND DEMAND — CHINA
7,000
Demand
Supply
6,000

5,000

4,000

3,000

2,000

1,000

('000
tonnes)
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

a) On the demand side, given the facilities (tailored for domestic as well
current social/political stability as foreign markets), we assume the
in China, the growing purchasing country will continue with its histori-
power of its emerging “middle class” cal pattern of robust economic growth
and an expected increase in foreign in the years ahead. More explicitly:
direct investment in manufacturing

AVERAGE ANNUAL GROWTH

2002 2003 2004 2005 2006-2020


Real GDP 6.7% 7.4% 7.6% 7.6% 6.7%
Industrial production 8.1% 9.2% 9.0% 8.1% 8.0%
Source: DRI-WEFA, First-Quarter 2002.
19

China’s aluminum consumption has As well, we continue to assume that is likely to grow at the same time
increased over the past four years at the government will invest significantly as small, inefficient producers close
an annual rate of 14%. However, given in developing a west-to-east electricity or merge with bigger players. With
that its per-capita consumption of alu- transmission network. The construc- improved economies of scale and
minum slightly exceeds 2 kg (as com- tion of new “high-voltage” power trans- stronger demand from increasingly
pared to 35 kg in the U.S.A.), there mission lines will intertwine the six affluent consumers, more efficient
is still ample room for further growth. regional power grids mentioned above. processes will be adopted. This is
Looked at from another perspective, This should help generate higher likely to lead to an increase in
China’s aluminum consumption has demand for aluminum in the years demand for aluminum because of
been increasing over the past 10 years to come. Demand from the transport more intensive use of the metal in
at a rate about 1.5-1.6 times faster and construction and building sec- each vehicle, reinforced by stronger
than real GDP. Such “income-elasticity” tors is also expected to continue grow- demand for automobiles.
is not unlike that experienced by other ing strongly.
In the case of the construction sector,
less-developed countries at similar
In the former case, China’s automo- rising incomes, combined with a
stages in their development. Per-capita
tive industry is theoretically capable growing population will put pressure
consumption may slightly decline
of producing some 2.5 million cars, on housing — both in terms of the
over time as the economic infrastruc-
trucks and buses each year. But plant size of individual units and the num-
ture gets built and the basic needs of
utilization is very low and there are ber of new houses. During the past
China’s consumers are satisfied. But
only a few large-scale producers. China two decades, the living space of
the annual growth rate should remain
lists some 120 enterprises capable of the average Chinese household has
in the 10-11% range well into the
producing complete motor vehicles. increased by a factor of 2.5. Sustained
future. At that rate, China’s annual
However, many of those have annual income growth and increased urban-
aluminum consumption, estimated
outputs of less than 1,000 units and ization should support a continuation
at 3,640 kt for 2001, should exceed
only seven are capable of producing of this trend, so the construction
5,800 kt by 2006.
more than 100,000 units per year. of houses and apartments — along
The same drivers that are shifting the with the demand for aluminum —
Chinese economy away from heavy should continue to grow.
industry are likely to promote the
rationalization of fragmented indus-
tries such as car production. Output
20

b) On the supply side, domestic • The large number of small-scale • Because of rich coal deposits and
aluminum production increased smelters operating under local- superior power-generating capaci-
by more than 600 kt/y (or 24%) in government jurisdiction. Due to ties, there is a concentration of alu-
2001 for the reasons outlined above. a lack of competitive advantage, minum smelters in Henan (20%
It should go up by another 24%, or these smelters are constrained to of all smelters), Shandong (7%),
820 kt/y, in 2002, to exceed 4.3 million producing low-value, commodity Shanxi (6%), and in Northwest (30%)
tonnes. And we expect production grade aluminum ingots while facing and Southwest (20%) provinces
will continue to rise after that, but new international competition (see table). As well, a majority of
at a slower pace of 8-9%. The assump- resulting from China’s entry into the planned smelter expansions that
tions behind such a scenario are the WTO. This should limit their have been announced are slated to
the following: potential for growth. take place in more or less the same
provinces. The government of China
has the obligation to guarantee long-
SMELTER LOCATIONS IN CHINA (AT THE END OF 2001)
term supplies of electricity to prop-
Ranking Region Province Smelters Capacity (kmt) Percentage erly approved projects. However,
1 Central China Henan 27 791.00 20.17% neither the National Power Network
2 Northwest Gansu 8 404.00 10.30% nor government-owned power plants
3 Northwest Qinghai 10 310.00 7.90% will guarantee normal supplies of
4 Southwest Guizhou 4 271.00 6.91% electricity to those smelters that do
5 Northwest Ning Xia 2 250.00 6.37% not have central government approval
6 North China Shanxi 11 220.50 5.62% — even those situated in energy-rich
7 Eastern China Shandong 7 278.20 7.09%
areas — should their existing supply
8 Southwest Guangxi 5 202.50 5.16%
sources be unexpectedly interrupted.
This could be the case, for instance,
9 South China Hubei 9 176.00 4.49%
if the government decided, for envi-
10 Southwest Yun Nan 6 165.00 4.21%
ronmental or economic reasons, to
11 Northwest Neimengguo 2 138.00 3.52%
implement its stated policy of closing
12 Northeast Liaoning 3 130.00 3.31%
all power plants with a capacity of
13 Southwest Chongqing 4 94.00 2.40%
less than 50 MW. So the long-term
14 Northeast Jilin 3 103.00 2.63%
15 Southwest Sichun 4 66.00 1.68%
16 Northwest Shaanxi 4 61.00 1.56%
17 South China Hunan 7 50.50 1.29%
18 North China Hebei 4 51.50 1.31%
19 Eastern China Zhejiang 2 37.50 0.96%
20 South China Fujian 1 32.00 0.82%
21 Eastern China Anhui 2 21.00 0.54%
22 South China Jiangxi 2 16.50 0.42%
23 Eastern China Jiangsu 2 12.00 0.31%
24 Northeast Heilongjiang 1 10.00 0.25%
25 Northwest Xin Jiang 3 31.40 0.80%
Total 133.00 3923 100%
Various sources.
21

availability of power for many of serve to further increase the overall concerned parties, Premier Zhu
those announced expansions is far operating costs of small-scale Chinese Rongji has issued a directive to
from guaranteed. smelters that have no access to inter- the Ministers responsible for the
national markets. State Development and Planning
• The availability of alumina may also
Commission, the State Economic
limit the continued expansion of Moreover, the expansion of Chinese
and Trade Commission, the Ministry
smelting capacity in China. Currently, smelter capacity may well trigger
of Environmental Protection and
China has sufficient alumina capac- a global alumina shortage, or at least
the People’s Bank of China, demand-
ity to meet about 70% of total domes- greatly contribute to a reduction of
ing immediate actions to correct
tic demand, relying for the rest on the current market surplus, thereby
the ongoing expansion situation.
imports from international markets. pushing up the market or import
But surplus alumina capacity on these price of alumina, which would serve The following actions were included
markets is not unlimited. Moreover, to accelerate smelter closures in China. in his directives:
it is subject to unpredictable price
• The final argument supporting our - Enforcing the closure of smelters
swings, as was experienced in 2000,
hypothesis of a lower growth rate for that do not meet environmental
when alumina prices reached $450/t.
Chinese smelting capacity relative protection regulatory requirements
Based on Chalco’s development plan,
to aluminum consumption is more (emission and effluent targets)
domestic production of alumina
political. The State Council has been and/or are operating with unac-
should increase by less than 3 million
warned about the problems and ceptable economies of scale;
tonnes between now and 2006. The
consequences that may result from
increase may be even lower, consid-
the current expansion of aluminum
ering China’s high production costs
capacity. Potential problems include
relative to international alumina
environmental pollution resulting
producers. There is even a possibil-
from smelters operating with 60 KA
ity that China’s existing, higher-cost
cells or lower; the misallocation of
refineries may be forced to cease
China’s limited energy and capital
operation if the current low global
resources; lower long-term domestic
market prices for alumina persist.
prices for aluminum which, just
The resulting rise in the price of
as is the case with other industries,
domestic alumina supplies would
may force many small-scale opera-
tors to phase out or cease their oper-
ations. Consequently, at the urging
of Chalco, Minmetals and other
22

- Restricting and returning to The State Economic and Trade there has been a tightening of the
the central government the right Commission has issued an order central government’s alumina-import
to approve all smelter expan- to suspend financing for all ongo- registration policy since May. The
sion projects; ing and planned smelter projects more restrictive policy means that
except for the following, which were only eight companies (Minmetals,
- Holding leaders of state financial
approved by the Central government: Chalco and six smelters) are qualified
institutions (particularly commer-
to import alumina in the conven-
cial banks) liable for providing Fushun Smelter 120 kt Start up in 2002
tional sense (as against tolling).
financial support to unapproved Liacheng Smelter 120 kt Start up in 2003
Smelters that are not allowed to
smelter projects; Boatou Smelter 100 kt Start up in 2002
import alumina directly can still
- Introducing a tax-sharing scheme Qingtongxia purchase from Minmetals. However,
— Phase 2 100 kt Feasibility Study
designed to dampen local govern- under the new legislation, those
Yunnan Smelter 130 kt Completed
ments’ enthusiasm for supporting smelters must now pay Minmetals
Guan Smelter 80 kt Completed
ill-advised expansion projects; and in advance rather than on delivery,
Also, the order clearly stated that which has an adverse impact on
- Finally, reviewing and possibly
approvals for planned expansion proj- their working-capital requirements.
halting previously approved expan-
ects involving the Lanzhou Smelter Thus, it seems that, through the
sion projects if they do not meet
(150 kt) and the Yunnan Smelter control of imported alumina, the
the following assessment criteria:
(150 kt) have been cancelled. Both central government now has a pow-
capacity must be over 100 kt/y;
projects now must undergo reassess- erful tool to achieve its goals vis-à-vis
and the projects must have secured
ment by the Central government the aluminum industry.
reliable and committed (stable)
supplies of power and alumina suf- before proceeding any further.
ficient to support planned produc- Finally, the State Council is consid-
tion capacity. ering options for the closure of
all Soderberg smelters. This would
affect about 1,000 kt of capacity if
all such facilities were to be closed.
It should be noted that about 1,100 kt
of locally approved expansion plans
have been classified as unacceptable,
and that the Central government is
taking action to reassess and halt those
projects that do not measure up. Also,

China’s Demand/Production (2002-2006) Summary:


China’s aluminum consumption should continue to grow during the years ahead at a rate in the 10-11% range. At that
pace, consumption should exceed 5,800 kt by 2006. On the supply side, after increasing by 24% in 2001 and another
24% in 2002, China’s aluminum production should continue to increase but at a slower pace, in the range of 8-9%/y,
given the economic (cost structure, availability of alumina and power) and political factors mentioned above.
Consequently, even should its production exceed demand for the next two or three years, by the middle of the
decade China should once again become a net importer of unwrought metal.
4 CONCLUDING 23

REMARKS

Given the above assumptions, the possibility of China becoming a long-term net exporter of unwrought
aluminum seems remote.

Nevertheless, one cannot totally rule out the possibility of such a scenario developing under a different set
of assumptions. China could conceivably develop a surplus of metal and thus become a net exporter of
unwrought aluminum in the years ahead if, for instance:

• Chinese domestic aluminum production were to increase by 15-20%


per year. This could occur only if there was unlimited cash for smelter
expansion projects, as well as reliable and unconstrained supplies of
alumina and power — neither of which is likely;

• Or if China were to experience a drastic reduction in domestic


consumption due to social instability or public policy restricting the use
of aluminum. To date though, China’s “socialist capitalism” model has
been able to substantially improve per-capita income, therefore
lessening economic discontent;

• Or, finally, if the LME price climbed high enough to cover domestic
production costs or, even better, exceeded the domestic price. Such a
scenario could result from a devaluation of China’s currency coupled
with a monetary policy designed to limit the ensuing inflation. Again,
the odds against seeing such a policy implemented seem very long,
given that it would set off a series of other devaluations in the region.
24

On balance, this different set of assumptions simply does not jibe with
the facts presented earlier.

Assuming annual growth in aluminum consumption at a rate of 11%,


China would need to develop 450 kt/y of new smelter output just to keep
pace with the expected demand. Much higher output would be needed
to overflow the international aluminum market with its exports and
depress aluminum market prices. China may well increase its production
capacity to keep output in line with forecast consumption, but not
exceed it. China has no economic interests in exporting its scarce
resources (energy, alumina, and capital), or in depressing domestic metal
prices by creating a situation of excess production.

On the other hand, China’s provinces and cities do have a political


interest in tussling with the central government over the right to
continue operating their small-scale, polluting smelters. The latter may
be uneconomic from a profit-maximization point of view, but the
provinces and cities are certainly making money out of them —
particularly if some costs can be shifted to the central authorities or
public utilities. The same caveat applies to WTO implementation. Here it
would also be unwise to assume rapid or uniform implementation.
Nevertheless, in the medium term, “economic rationale” should prevail.

Thus, we believe that China will not be a major destabilizing factor in


the years ahead.

Industry Analysis Department


Alcan Inc.
October 2002
This document represents Alcan’s views as prepared by the Industry Analysis Department of Alcan Inc. and is being distributed for information purposes only.
It incorporates facts, views and opinions deemed relevant, which were obtained from various sources.
Alcan Inc.
1188 Sherbrooke Street West Mailing Address:
Montreal, Quebec H3A 3G2 P.O. Box 6090
Canada Montreal, Quebec H3C 3A7
Canada
Telephone: (514) 848-8000
www.alcan.com Telecopier: (514) 848-8115
Printed in Canada

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