Attached files
file | filename |
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EX-31.1 - EXHIBIT 31.1 - Molycorp, Inc. | c16514exv31w1.htm |
EX-31.2 - EXHIBIT 31.2 - Molycorp, Inc. | c16514exv31w2.htm |
EX-32.1 - EXHIBIT 32.1 - Molycorp, Inc. | c16514exv32w1.htm |
Table of Contents
UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549
FORM 10-Q
(Mark One)
þ | QUARTERLY REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the quarterly period ended March 31, 2011
OR
o | TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the transition period from
to
Commission File Number 001-34827
Molycorp, Inc.
(Exact name of registrant as specified in its charter)
Delaware | 27-2301797 | |
(State or other jurisdiction of incorporation or organization) | (I.R.S. Employer Identification No.) | |
5619 Denver Tech Center Parkway, Suite 1000 | ||
Greenwood Village, Colorado | 80111 | |
(Address of principal executive offices) | (Zip Code) |
(303) 843-8040
(Registrants telephone number, including area code)
(Registrants telephone number, including area code)
Indicate by check mark whether the registrant (1) has filed all reports required to be filed by
Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for
such shorter period that the registrant was required to file such reports), and (2) has been
subject to such filing requirements for the past 90 days. Yes þ No o
Indicate by check mark whether the registrant has submitted electronically and posted on its
corporate Web site, if any, every Interactive Data File required to be submitted and posted
pursuant to Rule 405 of Regulation S-T during the preceding 12 months (or for such shorter period
that the registrant was required to submit and post such files). Yes o No o
Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, a
non-accelerated filer, or a smaller reporting company. See the definitions of large accelerated
filer, accelerated filer and smaller reporting company in Rule 12b-2 of the Exchange Act.
Large accelerated filer o | Accelerated filer o | Non-accelerated filer þ | Smaller reporting company o | |||
(Do not check if a smaller reporting company) |
Indicate by check mark whether the registrant is a shell company (as defined by Rule 12b-2 of the
Exchange Act). Yes o No þ
As of May 9, 2011, the registrant had 83,895,501 shares of common stock, par value $0.001 per
share, outstanding.
MOLYCORP, INC.
INDEX
PAGE | ||||||||
3 | ||||||||
4 | ||||||||
5 | ||||||||
6 | ||||||||
7 | ||||||||
16 | ||||||||
28 | ||||||||
30 | ||||||||
31 | ||||||||
31 | ||||||||
31 | ||||||||
31 | ||||||||
32 | ||||||||
32 | ||||||||
33 | ||||||||
Exhibit 31.1 | ||||||||
Exhibit 31.2 | ||||||||
Exhibit 32.1 |
2
Table of Contents
MOLYCORP, INC.
(A Company in the Development Stage)
(A Company in the Development Stage)
Condensed Consolidated Balance Sheets
(Unaudited)
(In thousands, except
share and per share amounts)
March 31, 2011 | December 31, 2010 | |||||||
ASSETS |
||||||||
Current assets: |
||||||||
Cash and cash equivalents |
$ | 492,495 | $ | 316,430 | ||||
Trade accounts receivable |
17,581 | 16,421 | ||||||
Inventory (Note 4e) |
24,363 | 20,511 | ||||||
Prepaid expenses and other |
2,633 | 1,759 | ||||||
Total current assets |
537,072 | 355,121 | ||||||
Non-current assets: |
||||||||
Deposits |
$ | 27,700 | $ | 26,200 | ||||
Property, plant and equipment, net (Note 4g) |
133,752 | 93,966 | ||||||
Inventory (Note 4e) |
3,194 | 5,212 | ||||||
Intangible asset, net |
622 | 639 | ||||||
Other assets |
111 | 111 | ||||||
Total non-current assets |
165,379 | 126,128 | ||||||
Total assets |
$ | 702,451 | $ | 481,249 | ||||
LIABILITIES AND STOCKHOLDERS EQUITY |
||||||||
Current liabilities: |
||||||||
Trade accounts payable |
$ | 29,988 | $ | 13,009 | ||||
Accrued expenses (Note 4j) |
6,408 | 4,225 | ||||||
Short-term borrowing related party (Note 8) |
2,870 | 3,085 | ||||||
Current portion of asset retirement obligation (Note 4k) |
394 | 393 | ||||||
Total current liabilities |
39,660 | 20,712 | ||||||
Non-current liabilities: |
||||||||
Asset retirement obligation (Note 4k) |
$ | 12,774 | $ | 12,078 | ||||
Other non-current liabilities |
148 | 257 | ||||||
Total non-current liabilities |
12,922 | 12,335 | ||||||
Total liabilities |
$ | 52,582 | $ | 33,047 | ||||
Commitments and contingencies (Note 5) |
||||||||
Stockholders equity: |
||||||||
Common stock, $0.001 par value; 350,000,000 shares
authorized at March 31, 2011 (Note 4m) |
82 | 82 | ||||||
Preferred stock, $0.001 par value;
5,000,000 shares authorized at March 31, 2011 (Note 4m) |
2 | | ||||||
Additional paid-in capital |
742,440 | 539,866 | ||||||
Deficit accumulated during the development stage |
(92,655 | ) | (91,746 | ) | ||||
Total stockholders equity |
649,869 | 448,202 | ||||||
Total liabilities and stockholders equity |
$ | 702,451 | $ | 481,249 | ||||
See accompanying notes to the condensed, consolidated financial statements.
3
Table of Contents
MOLYCORP, INC.
(A Company in the Development Stage)
(A Company in the Development Stage)
Condensed Consolidated Statements of Operations
(Unaudited)
(In thousands, except share and per share amounts)
Total from | ||||||||||||
Three Months Ended | June 12, 2008 | |||||||||||
March 31, | (Inception) Through | |||||||||||
2011 | 2010 | March 31, 2011 | ||||||||||
Sales |
$ | 26,261 | $ | 3,018 | $ | 70,648 | ||||||
Operating costs and expenses: |
||||||||||||
Cost of goods sold |
(15,388 | ) | (5,950 | ) | (86,102 | ) | ||||||
Selling, general and administrative |
(8,339 | ) | (4,480 | ) | (42,386 | ) | ||||||
Stock-based compensation |
(2,899 | ) | | (32,029 | ) | |||||||
Depreciation and amortization |
(83 | ) | (95 | ) | (612 | ) | ||||||
Accretion expense |
(234 | ) | (263 | ) | (2,402 | ) | ||||||
Operating loss |
(682 | ) | (7,770 | ) | (92,883 | ) | ||||||
Other income (expense): |
||||||||||||
Other income (expense) |
(168 | ) | 21 | 222 | ||||||||
Interest income, net of amount capitalized |
140 | | 205 | |||||||||
(28 | ) | 21 | 427 | |||||||||
Loss before income taxes |
(710 | ) | (7,749 | ) | (92,456 | ) | ||||||
Provision for income taxes |
(199 | ) | | (199 | ) | |||||||
Net loss |
$ | (909 | ) | $ | (7,749 | ) | $ | (92,655 | ) | |||
Weighted average shares outstanding (Common shares) (1) |
||||||||||||
Basic |
82,253,700 | 48,155,533 | 51,296,217 | |||||||||
Diluted |
82,253,700 | 48,155,533 | 51,296,217 | |||||||||
Loss per share of common stock: |
||||||||||||
Basic |
$ | (0.03 | ) | $ | (0.16 | ) | $ | (1.81 | ) | |||
Diluted |
$ | (0.03 | ) | $ | (0.16 | ) | $ | (1.81 | ) | |||
(1) | Weighted average shares outstanding include the retroactive treatment of exchange ratios for conversion of Class A common stock and Class B common stock to common stock in conjunction with the initial public offering. |
See accompanying notes to the condensed, consolidated financial statements.
4
Table of Contents
MOLYCORP, INC.
(A Company in the Development Stage)
(A Company in the Development Stage)
Condensed Consolidated Statement of Stockholders Equity
(Unaudited)
(In thousands, except
share and per share amounts)
Deficit | ||||||||||||||||||||||||||||
Accumulated | ||||||||||||||||||||||||||||
Series A Mandatory | Additional | During the | Total | |||||||||||||||||||||||||
Common Stock | Convertible Preferred Stock | Paid-In | Development | Stockholders | ||||||||||||||||||||||||
Shares | Amount | Shares | Amount | Capital | Stage | Equity | ||||||||||||||||||||||
Balance at December 31, 2010 |
82,291,200 | $ | 82 | | $ | | $ | 539,866 | $ | (91,746 | ) | $ | 448,202 | |||||||||||||||
Sale of
Series A mandatory convertible preferred
stock at $100.00 per share,
net of underwriting fees and
other offering costs |
| | 2,070,000 | 2 | 199,640 | | 199,642 | |||||||||||||||||||||
Stock-based compensation expense |
9,410 | | | | 2,934 | | 2,934 | |||||||||||||||||||||
Net loss |
| | | | | (909 | ) | (909 | ) | |||||||||||||||||||
Balance at March 31, 2011 |
82,300,610 | $ | 82 | 2,070,000 | $ | 2 | $ | 742,440 | $ | (92,655 | ) | $ | 649,869 | |||||||||||||||
See accompanying notes to the condensed, consolidated financial statements.
5
Table of Contents
MOLYCORP, INC.
(A Company in the Development Stage)
(A Company in the Development Stage)
Condensed Consolidated Statements of Cash Flows
(Unaudited)
(In thousands)
Total from | ||||||||||||
Period Ended | June 12, 2008 | |||||||||||
March 31, | (Inception) through | |||||||||||
2011 | 2010 | March 31, 2011 | ||||||||||
Cash flows from operating activities: |
||||||||||||
Net loss |
$ | (909 | ) | $ | (7,749 | ) | $ | (92,655 | ) | |||
Adjustments
to reconcile net loss to net cash provided by/ (used
in) operating activities: |
||||||||||||
Depreciation and amortization |
2,100 | 1,004 | 12,947 | |||||||||
Accretion of asset retirement obligation |
234 | 263 | 2,402 | |||||||||
Non-cash inventory write-downs |
630 | 574 | 22,647 | |||||||||
Non-cash share-based compensation expense |
2,934 | | 32,064 | |||||||||
Impairment of fixed assets |
| | 3,114 | |||||||||
(Gain) loss on sale of assets and settlement of ARO |
| 13 | (57 | ) | ||||||||
Changes in operating assets and liabilities: |
||||||||||||
Accounts receivable |
(1,160 | ) | (202 | ) | (18,132 | ) | ||||||
Inventory |
(2,464 | ) | (32 | ) | (28,022 | ) | ||||||
Prepaid expenses and other |
(874 | ) | (733 | ) | (1,897 | ) | ||||||
Accounts payable |
2,803 | 2,086 | 6,988 | |||||||||
Asset retirement obligation |
(165 | ) | | (1,184 | ) | |||||||
Accrued expenses |
2,074 | (2,170 | ) | 8,560 | ||||||||
Net cash
provided by/ (used in) operating activities |
5,203 | (6,946 | ) | (53,225 | ) | |||||||
Cash flows from investing activities: |
||||||||||||
Acquisition of the Mountain Pass facility |
| | (82,150 | ) | ||||||||
Proceeds from sale of investment in joint venture |
| | 9,700 | |||||||||
Deposits |
(1,500 | ) | | (27,700 | ) | |||||||
Capital expenditures |
(26,345 | ) | (2,840 | ) | (67,080 | ) | ||||||
Other assets |
| | (111 | ) | ||||||||
Proceeds from sale of assets |
| 9 | 14 | |||||||||
Net cash
used in investing activities |
(27,845 | ) | (2,831 | ) | (167,327 | ) | ||||||
Cash flows
from financing activities: |
||||||||||||
Capital contributions from original stockholders |
| 10,000 | 125,004 | |||||||||
Repayments of short-term borrowings related party |
(935) | | (2,042 | ) | ||||||||
Net proceeds from sale of common stock in conjunction with
the initial public offering |
| | 378,633 | |||||||||
Net proceeds from sale of preferred stock |
199,642 | | 199,642 | |||||||||
Payment of deferred financing costs |
| | (185 | ) | ||||||||
Proceeds from exercise of options |
| 300 | 350 | |||||||||
Proceeds from short-term borrowings related party |
| | 11,645 | |||||||||
Net cash
provided by financing activities |
198,707 | 10,300 | 713,047 | |||||||||
Net change in cash and cash equivalents |
176,065 | 523 | 492,495 | |||||||||
Cash and cash equivalents at beginning of the period |
316,430 | 6,929 | | |||||||||
Cash and cash equivalents at end of period |
$ | 492,495 | $ | 7,452 | $ | 492,495 | ||||||
Supplemental disclosure of non-cash activities: |
||||||||||||
Change in accrued capital expenditures |
$ | 14,896 | $ | 492 | ||||||||
See accompanying notes to the condensed, consolidated financial statements.
6
Table of Contents
MOLYCORP, INC.
(A Company in the Development Stage)
(A Company in the Development Stage)
Notes to Condensed Consolidated Financial Statements
March 31, 2011
(Unaudited)
(1) Company Background
Molycorp, Inc. was formed on March 4, 2010 for the purpose of continuing the business of
Molycorp, LLC in corporate form. On April 15, 2010, the members of Molycorp, LLC contributed either
(a) all of their member interests in Molycorp, LLC or (b) all of their equity interest in entities
that held member interests in Molycorp, LLC (and no other assets or liabilities) to Molycorp, Inc.
in exchange for Molycorp, Inc. Class A common stock. Accordingly, Molycorp, LLC and Molycorp
Minerals, LLC became subsidiaries of Molycorp, Inc. (the Corporate Reorganization). On June 15,
2010, Molycorp LLC was merged with and into Molycorp Minerals, LLC. On July 9, 2010, Molycorp, Inc.
completed a 38.23435373-for-one stock split, which has been retroactively reflected in the
historical financial data for all periods presented. On August 3, 2010, Molycorp, Inc. completed
its initial public offering (IPO) of common stock. In connection with its IPO, Molycorp Inc.
issued 29,128,700 shares of common stock at $14.00 per share (including 1,003,700 shares issued in
connection with the underwriters option to purchase additional shares). Total net proceeds of the
offering were $378.6 million after underwriting discounts and commissions and
offering expenses payable to Molycorp, Inc. Immediately prior to the consummation of the IPO, all
of the shares of Class A common stock and Class B common stock were converted into shares of common
stock. The conversion ratios for the Class A common stock and the Class B common stock have been
retroactively reflected in the historical financial information for all periods presented.
Molycorp, Inc., together with its subsidiaries is referred to herein as the Company or
Molycorp.
Molycorp Minerals, previously known as Rare Earth Acquisition LLC (which was formed on June
12, 2008), acquired the Mountain Pass, California rare earth deposit and associated assets (the
Mountain Pass facility) and assumed certain liabilities from Chevron Mining, Inc. (Chevron) on
September 30, 2008.
The Mountain Pass facility is located in San Bernardino County, California and is the only
significant developed rare earth resource in the western world. Rare earth elements (REEs) are a
group of specialty elements with unique properties that make them critical to many existing and
emerging applications including:
| Clean-energy technologies such as hybrid and electric vehicles, wind turbines and compact florescent lighting; | ||
| High-technology applications including cell phones, personal digital assistant devices, digital music players, hard disk drives used in computers, computing devices, ear bud speakers and microphones, as well as fiber optics, lasers and optical temperature sensors; | ||
| Critical defense applications such as guidance and control systems, communications, global positioning systems, radar and sonar; and | ||
| Advanced water treatment applications including those for industrial, military, homeland security, domestic and foreign aid use. |
The REE group includes 17 elements, namely the 15 lanthanide elements, which are lanthanum,
cerium, praseodymium, promethium (which does not occur naturally), neodymium, samarium, europium,
gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium, and two
elements that have similar chemical properties to the lanthanide elements yttrium and scandium.
The oxides produced from processing REEs are collectively referred to as rare earth oxides
(REOs). Bastnasite is a mineral that contains REEs.
Operations at the Mountain Pass facility began in 1952 under Molybdenum Corporation of America
(MCA). MCA was purchased by Union Oil of California (Unocal) in 1977. In 2002, mining
operations were suspended at the Mountain Pass facility primarily due to softening prices for REOs
and a lack of additional tailings disposal capacity. Chevron Corporation purchased Unocal in 2005.
Prior to the acquisition, operations at the Mountain Pass facility had been suspended with the
exception of a pilot processing project to recover neodymium from lanthanum stockpiles produced
prior to Chevrons ownership of the Mountain Pass facility. The neodymium from lanthanum (NFL)
pilot processing project was undertaken to improve the facilitys REE processing techniques. Since
June 12, 2008 (Inception) through March 31, 2010, revenue was generated primarily from the sale of
products associated with the NFL pilot processing project, which concluded in February 2010. In
April 2010, the Company commenced the second pilot processing campaign to recover cerium,
lanthanum, neodymium, praseodymium and samarium/europium/gadolinium concentrate from bastnasite
concentrate stockpiles.
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Table of Contents
(2) Basis of Presentation
The Companys acquisition of the Mountain Pass facility has been accounted for as an
acquisition of net assets and not a business combination. As described below, the Companys current
business plan includes investing substantial capital to restart mining operations, construct and
refurbish processing facilities and other infrastructure, and to expand into metal and alloy
production. Molycorp will continue as a development stage company until these activities have been
completed, which is currently expected to be by the end of 2012.
The accompanying unaudited condensed consolidated financial statements have been prepared in
accordance with accounting principles generally accepted in the United States of America (GAAP)
for interim financial information and Regulation S-X promulgated under the Securities Exchange Act
of 1934. While the December 31, 2010 balance sheet information was derived from the Companys
audited financial statements, for interim periods, GAAP and Regulation S-X do not require all
information and notes that are required in the annual financial statements, and all disclosures
required by GAAP for annual financial statements have not been included. Therefore, the
accompanying unaudited condensed consolidated financial statements should be read in conjunction
with Molycorps consolidated financial statements and related notes for the year ended December 31,
2010, and the period from June 12, 2008 (Inception) through December 31, 2010, included in
Molycorps Form 10-K for the fiscal year ended December 31, 2010. The accompanying unaudited
condensed consolidated financial statements reflect all adjustments, which are normal and recurring
in nature, and which, in the opinion of management, are necessary for the fair presentation of
Molycorps financial position, results of operations and cash flows at March 31, 2011, and for all
periods presented. The accompanying unaudited condensed consolidated financial statements include
the accounts of the Company and its wholly-owned subsidiaries. All intercompany balances and
transactions have been eliminated in consolidation.
(3) Capital Requirements
Most of the facilities and equipment acquired with the Mountain Pass facility are at least 20
years old and must be modernized or replaced. Under its initial modernization and expansion plan,
the Company intends to spend approximately $531 million through 2012 to restart mining operations,
construct and refurbish processing facilities and other infrastructure at the Mountain Pass
facility and expand into metal and alloy production. Capital expenditures, on an accrual basis,
under this plan totaled $31.4 million in 2010 and $39.6 million during
the three months ended March 31, 2011. In January 2011, the Companys Board of Directors approved a
second-phase capacity expansion plan. Upon the completion of this capacity expansion plan, by the
end of 2013, we expect to have the ability to produce up to approximately 40,000 mt of REO per year
at our Mountain Pass facility, or approximately double the amount we will be able to produce upon
completion of our initial expansion and modernization plan. We have estimated, based on
consultation with our project manager, that we will incur approximately $250 million of capital
costs in connection with the second-phase capital expansion plan in addition to the $531 million
estimated for the initial modernization and expansion effort.
The Company expects to finance its remaining capital expenditures under the initial
modernization and expansion and the second phase expansion plans as well as its working capital
requirements, with its available cash balances of $492.5 million as of March 31, 2011, anticipated
revenue from operations and traditional debt financing, project financing, and/or government
programs, including the U.S. Department of Energy (DOE) loan guarantee program. The Company
submitted a Part I application on June 2010 for up to $280 million. On July 21, 2010, the DOE
deemed the Companys application eligible for submission of a part II application, which was
submitted on December 31, 2010. The DOE is currently conducting a due diligence review and has
provided the Company with a preliminary term sheet. On December 10, 2010, we entered into a
memorandum of understanding with Sumitomo Corporation (Sumitomo), pursuant to which Sumitomo
agreed to, among other things, purchase $100 million of the Companys common stock and arrange for
$30 million of debt financing. Sumitomo is currently conducting a due diligence review and the
consummation of these transactions with Sumitomo is subject to the satisfaction of numerous
conditions and finalization of definitive agreements.
(4) Summary of Significant Accounting Policies
(a) Use of Estimates
The preparation of the financial statements, in accordance with GAAP, requires management to
make estimates and assumptions that affect the reported amounts of assets and liabilities, the
disclosure of contingent assets and liabilities at the date of the financial statements and the
reported amounts of revenues and expenses during the reporting period. Management bases its
estimates on the
Companys historical experience and on various other assumptions that are believed to be reasonable
under the circumstances. Actual results may differ significantly from these estimates under
different assumptions and conditions.
8
Table of Contents
Significant estimates made by management in the accompanying financial statements include the
collectability of accounts receivable, the recoverability of inventory, the useful lives and
recoverability of long-lived assets such as property, plant and equipment, and the adequacy of the
Companys asset retirement obligations.
(b) Revenue and Cost of Goods Sold
Revenue is recognized when persuasive evidence of an arrangement exists, the risks and rewards
of ownership have been transferred to the customer, which is generally when title passes, the
selling price is fixed or determinable, and collection is reasonably assured. Title generally
passes upon shipment of product from the Mountain Pass facility. Prices are generally set at the
time of, or prior to, shipment. Transportation and distribution costs are incurred only on sales
for which the Company is responsible for delivering the product.
Cost of goods sold includes the cost of production as well as write-downs to the extent of
inventory costs in excess of market values. Primary production costs include labor, supplies,
maintenance costs, depreciation, and plant overhead.
(c) Cash and Cash Equivalents
Cash and cash equivalents consist of cash and liquid investments with an original maturity of
three months or less. At March 31, 2011 cash and cash equivalents included $469 million of funds
held in money market accounts.
(d) Trade Accounts Receivable
Trade accounts receivable are recorded at the invoiced amount and do not bear interest. The
Company reviews its allowance for doubtful accounts on a quarterly basis. As of March 31, 2011 and
December 31, 2010, an allowance for doubtful accounts was not required.
(e) Inventories
Inventories consist of work-in-process, finished goods, stockpiles of bastnasite and lanthanum
concentrate, and materials and supplies. Inventory cost is determined using the lower of weighted
average cost or estimated net realizable value. Inventory expected to be sold in the next 12 months
is classified as a current asset in the consolidated balance sheets.
Molycorp evaluates its production levels and costs to determine if any should be deemed
abnormal, and therefore excluded from inventory costs. For the three months ended March 31, 2011
and 2010, and cumulatively for the period from June 12, 2008 (Inception) through March 31, 2011,
Molycorp determined that $2.6 million, $2.4 million and $16.1 million, respectively,
of production costs would have been allocated to additional metric tons produced, assuming Molycorp
had been operating at normal production rates. As a result, these costs were excluded from
inventory and instead expensed during the applicable periods. The assessment of normal production
levels is judgmental and is unique to each quarter. Molycorp models normal production levels and
evaluates historical ranges of production in assessing what is deemed to be normal.
Write-downs to estimated net realizable value are charged to cost of goods sold. Many factors
influence the market prices for REOs and, in the absence of established prices contained in
customer contracts, management uses an independent pricing source to evaluate market prices for
REOs at the end of each quarter. For the three months ended March 31, 2011 and 2010, and
cumulatively for the period from June 12, 2008 (Inception) through March 31, 2011, the Company
recognized write-downs of $0.6 million and $0.6 million, and $21.6 million, respectively, as a
result of production costs in excess of certain REO market prices.
The Company evaluates the carrying value of materials and supplies inventories each quarter
giving consideration to slow-moving items, obsolescence, excessive levels, and other factors and
recognizes related write-downs as necessary.
9
Table of Contents
At March 31, 2011 and December 31, 2010, inventory consisted of the following (in thousands):
March 31, | December 31, | |||||||
2011 | 2010 | |||||||
Current: |
||||||||
Concentrate stockpiles |
$ | 5,252 | $ | 4,206 | ||||
Work in process |
8,019 | 5,271 | ||||||
Finished goods |
9,096 | 9,307 | ||||||
Materials and supplies |
1,996 | 1,727 | ||||||
Total current |
$ | 24,363 | $ | 20,511 | ||||
Long-term: |
||||||||
Concentrate stockpiles |
$ | 3,126 | $ | 5,108 | ||||
Finished goods |
68 | 104 | ||||||
Total long-term |
$ | 3,194 | $ | 5,212 | ||||
(f) Deposits
The
Company currently has $27.7 million in deposits reported as Non-current
assets on the Consolidated Balance Sheet as of March 31, 2011. Of this amount, $18.2 million is due to
collateral used to secure surety bonds placed with the California state and regional agencies
relating to our Mountain Pass facility closure and reclamation obligations. The remaining deposits
consist of $8.0 million under an escrow arrangement for the Companys facilities agreement with
Kern River Gas Transmission Company and $1.5 million related to the Companys construction
insurance program.
(g) Property, Plant and Equipment, net
Property, plant and equipment associated with the acquisition of the Mountain Pass facility
was recorded at estimated fair value as of the acquisition date. Expenditures for new property,
plant and equipment and improvements that extend the useful life or functionality of the asset are
capitalized. The Company capitalized $41.3 million and $3.4 million in plant modernization costs
for the three months ended March 31, 2011 and 2010, respectively. Our anticipated project cost
through 2012 to restart the mining operations, construct and refurbish processing facilities and to
expand into the production of metals and alloys is $531 million, which includes a $20 million
increase over our previous estimate. The increase is due to the increased scope of the project
including the acceleration of the construction of the new crushing and milling facility and other
design changes to allow a faster conversion to 40,000 metric tons per year than would otherwise be
possible.
Mineral properties at March 31, 2011 and December 31, 2010, represent the purchase price
allocated to mineral resources associated with the Mountain Pass facility and mineral property
development costs.
At March 31, 2011 and December 31, 2010, property, plant and equipment consisted of the
following (in thousands):
March 31, | December 31, | |||||||
2011 | 2010 | |||||||
Land |
$ | 800 | $ | 800 | ||||
Land improvements (15 years) |
15,748 | 15,415 | ||||||
Buildings and improvements (4 to 27 years) |
7,241 | 6,892 | ||||||
Plant and equipment (2 to 12 years) |
21,338 | 19,560 | ||||||
Vehicles (7 years) |
1,127 | 1,049 | ||||||
Computer software (5 years) |
1,871 | 1,563 | ||||||
Furniture and fixtures (3 years) |
193 | 170 | ||||||
Construction in progress |
73,810 | 34,809 | ||||||
Mineral properties |
23,968 | 23,968 | ||||||
Property, plant and equipment at cost |
146,096 | 104,226 | ||||||
Less accumulated depreciation |
(12,344 | ) | (10,260 | ) | ||||
Property, plant and equipment, net |
$ | 133,752 | $ | 93,966 | ||||
In accordance with ASC 360, Property Plant and Equipment, long-lived assets such as property,
plant, and equipment, mineral properties and purchased intangible assets subject to amortization,
are reviewed for impairment whenever events or changes in circumstances indicate that the carrying
amount of an asset may not be recoverable. There were no events or changes in circumstances
indicating that the carrying amount of the Companys long-lived assets as of March 31, 2011 may not
be recoverable.
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In connection with an update of the asset retirement obligation as of March 31, 2011, the
Company recognized additional asset retirement costs of $0.6 million.
(h) Mineral Properties and Development Costs
Mineral properties and development costs, which are referred to collectively as mineral
properties, include acquisition costs, drilling costs, and the cost of other development work, all
of which are capitalized. The Company amortizes mineral properties using the units of production
method over estimated proven and probable reserves. Molycorps proven and probable reserves are
based on extensive drilling, sampling, mine modeling, and mineral recovery from which economic
feasibility has been determined. The reserves are estimated based on information available at the
time the reserves are calculated. Proven and probable reserves are based on estimates, and no
assurance can be given that the indicated levels of recovery of REOs will be realized or that
production costs and estimated future development costs will not exceed the net realizable value of
the products. Reserve estimates may require revisions based on actual production experience. Market
price fluctuations of REOs, as well as increased production costs or reduced recovery rates, could
render proven and probable reserves containing relatively lower grades of mineralization uneconomic
to exploit and might result in a reduction of reserves.
(i) Intangible Asset
The Company acquired its trade name in connection with the Mountain Pass facility acquisition.
Amortization is provided using the straight-line method based on an estimated useful life of 12
years. Amortization expense for the three months ended March 31, 2011 and 2010, and cumulatively
for the period from June 12, 2008 (Inception) through March 31, 2011 was $16,370, $16,250 and
$163,734, respectively. Amortization expense is estimated to be $65,000 annually for the following
five years.
(j) Accrued Expenses
Accrued expenses at March 31, 2011 and December 31, 2010 consisted of the following (in
thousands):
March 31, | December 31, | |||||||
2011 | 2010 | |||||||
Defined contribution plan |
$ | 1,433 | $ | 1,199 | ||||
Accrued tolling fees |
1,580 | 404 | ||||||
Other accrued expenses |
3,395 | 2,622 | ||||||
Total accrued expenses |
$ | 6,408 | $ | 4,225 | ||||
(k) Asset Retirement Obligation
The Company accounts for reclamation costs, along with other costs related to the closure of
the Mountain Pass facility, in accordance with ASC 410-20, Asset Retirement Obligations. This
standard requires the Company to recognize asset retirement obligations at estimated fair value in
the period in which the obligation is incurred. The Company recognized an asset retirement
obligation and corresponding asset retirement cost of $13.3 million in connection with the Mountain
Pass facility acquisition. The liability was initially measured at fair value and is subsequently
adjusted for accretion expense and changes in the amount or timing of the estimated cash flows. The
asset retirement cost was capitalized as part of the carrying amount of the related long-lived
assets and is being depreciated over the assets remaining useful lives.
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During the first quarter of 2011, the Company recognized additional asset retirement
obligations of $0.6 million related to additional disturbances that occurred during the first
quarter of 2011. Depreciation expense associated with the asset retirement cost was $0.3 million,
$0.3 million and $2.9 million for the three months ended March 31, 2011 and 2010, and cumulatively
for the period from June 12, 2008 (Inception) through March 31, 2011, respectively. The following
table presents the activity in our asset retirement obligation (in thousands):
Three Months | ||||
Ended | ||||
March 31, 2011 | ||||
Balance at beginning of period |
$ | 12,471 | ||
Obligations settled |
(165 | ) | ||
Accretion expense |
234 | |||
Revisions in estimated cash flows |
628 | |||
Balance at end of period |
$ | 13,168 | ||
The Company is required to provide the applicable governmental agencies with financial
assurances relating to its closure and reclamation obligations. As of March 31, 2011, the Company
had financial assurance requirements of $27.4 million which were satisfied with surety bonds placed
with the California state and regional agencies.
(l) Income Taxes
Prior to the Corporate Reorganization, the taxable income and losses of Molycorp, LLC were reported
on the income tax returns of its members. Molycorp, Inc. is subject to federal and state income
taxes and files consolidated income tax returns. Molycorp recognizes income taxes under the asset
and liability method. Deferred tax assets and liabilities are recognized for the estimated future
tax consequences attributable to difference between the financial statement carrying amounts of
assets and liabilities and their respective tax basis. Deferred tax assets and liabilities are
measured using the enacted tax rates expected to apply to taxable income in the periods in which
the deferred tax liability or asset is expected to be settled or recognized. Molycorp records a
valuation allowance if, based on available information, it is deemed more likely than not that its
deferred income tax asset will not be realized in full. As of March 31, 2011, the Companys net
loss of $42.2 million since the Corporate Reorganization included $31.6 million in stock-based
compensation expense, which is a permanent difference between its losses for financial reporting
and income tax purposes. Other permanent differences include legal and due diligence fees related
to the acquisitions that were completed in April 2011 as well as costs related to the registration
of common stock sold by certain stockholders in a secondary offering during the first quarter of
2011. Molycorp has generated net deferred income tax assets of $21.3 million as of March 31, 2011.
However, as realization of these tax assets is not assured, we have established a full valuation
allowance against these assets. A significant portion of the net
operating losses (NOLs) of $14
million will expire in the year 2030. Molycorp recorded income tax expenses of $81 thousand, as a
result of federal alternative minimum tax, and California state income tax of $118 thousand, as a
result of the use of NOLs being temporally disallowed in California.
(m) Stockholders Equity
As of March 31, 2011 and December 31, 2011, the Company had 82,300,610 and 82,291,200 shares
of common stock outstanding, respectively.
On February 16, 2011, Molycorp completed a public offering of its 5.50% Series A Mandatory
Convertible Preferred Stock, $0.001 par value per share. In connection with this offering, the
Company issued 1,800,000 shares of Series A Mandatory Convertible Preferred Stock for $100.00 per
share. In addition, Molycorp granted the underwriters an option to purchase up to 270,000
additional shares of Series A Mandatory Convertible Preferred Stock to cover over-allotments. The
underwriters exercised their option to purchase the additional shares of Series A Mandatory
Convertible Preferred Stock on March 16, 2011. Each share of the Series A Mandatory Convertible
Preferred Stock will automatically convert on March 1, 2014 into between 1.6667 and 2.0000 shares
of Molycorps common stock, subject to anti-dilution adjustments. At any time prior to March 1,
2014, holders may elect to convert each share of the Series A Mandatory Convertible Preferred Stock
into shares of common stock at the minimum conversion rate of 1.6667 shares of common stock per
share of Series A Mandatory Convertible Preferred Stock, subject to anti-dilution adjustments.
Dividends on the Series A Mandatory Convertible Preferred Stock are payable on a cumulative basis
when, as and if declared by the Companys Board of Directors or an authorized committee of such
Board, at an annual rate of 5.50% on the liquidation preference of
$100.00 per share. The Company may pay declared dividends in cash,
common stock or any combination of cash and common stock, subject to
certain limitations,
on March 1, June 1,
September 1 and December 1 of each year, starting on June 1, 2011 and to, and including, March 1,
2014. The Series A Mandatory Convertible Preferred Stock is not redeemable.
Paid-in capital in the consolidated balance sheets represents amounts paid by stockholders or
interests earned under certain stock compensation agreements. For the three months ended March 31,
2011, Molycorp received net proceeds from the Series A Mandatory Convertible Preferred Stock
offering totaling $199.6 million after underwriter discounts and commissions and offering expenses
paid by Molycorp, Inc.
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(n) Earnings (loss) per Share
Basic loss per share is computed by dividing the Companys net loss by the weighted average
number of shares of common stock outstanding during the period. For the three months ended March
31, 2011, the cumulative undeclared dividend on the Series A Mandatory Convertible Preferred Stock was added to the net loss in the period for the purpose of computing the basic loss per
share.
Three Months | ||||
Ended | ||||
(In thousands, except share and per share amounts) | March 31, 2011 | |||
Net loss |
$ | (909 | ) | |
Cumulative undeclared dividends on preferred stock |
(1,245 | ) | ||
Loss attributed to common stockholders basic |
(2,154 | ) | ||
Weighted average common shares outstanding |
82,253,700 | |||
Basic loss per share |
$ | (0.03 | ) | |
Diluted loss per share reflects the dilutive impact of potential common stock and unvested
restricted shares of common stock in the weighted average number of common shares outstanding
during the period, if dilutive. For this purpose, the treasury stock method and if converted
method, as applicable, are used for the assumed proceeds upon the exercise of common stock
equivalents at the average selling prices of the shares during the period. All potential common
stock as of March 31, 2011 and December 31, 2010 were antidilutive in nature; consequently, the
Company does not have any adjustments between earnings per share and diluted earnings per share.
(o) Comprehensive Income (Loss)
The Company does not have any items entering into the determination of comprehensive income
(loss) other than net loss for the three-month ended March 31, 2011 and 2010.
(5) Commitments and Contingencies
(a) Future Operating Lease Commitments
The Company has certain operating leases for office space and certain equipment. Remaining
annual minimum payments under these leases at March 31, 2011 were $0.3 million in 2011, $0.2
million in 2012, $0.2 million in 2013, $0.2 million in 2014, $0.2 million in 2015 and $0.2 million
thereafter, totaling $1.3 million.
(b) Labor Contract
Certain Mountain Pass facility employees are covered by a collective bargaining agreement with
the United Steelworkers of America which expires on March 15, 2012. At March 31, 2011, 81
employees, or approximately 40% of the Companys workforce, were covered by this collective
bargaining agreement.
(c) Reclamation Surety Bonds
At March 31, 2011, Molycorp had placed $27.4 million of surety bonds with California state and
regional agencies to secure its Mountain Pass facility closure and reclamation obligations.
(d) Licenses and Permits
The Company is subject to numerous and detailed federal, state and local environmental laws,
regulations and permits including health and safety, environmental, and air quality. The Company is
subject to strict conditions, requirements and obligations relating to various environmental and
health and safety matters in connection with the current permits, and the Company may be subject to
additional conditions, requirements and obligations associated with its permits and future
operations. Certain conditions could be imposed in order to maintain the required permits including
requirements to conduct additional environmental studies and collect and present data to government
authorities pertaining to the potential impact of current and future operations upon the
environment. Accordingly, the required permits may not be maintained or renewed in a timely fashion
if at all, or may be renewed upon conditions that restrict the Companys ability to conduct its
operations economically. Any failure, significant delay or significant change in
conditions that is required to maintain or renew permits, could have a material adverse effect on
the Companys business, results of operations and financial condition.
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(6) Stock-Based Compensation
Molycorp accounts for stock-based compensation based upon the fair value of the awards at the
time of grant. The expense associated with such awards is recognized over the service period
associated with the issuance. There are no performance conditions associated with these awards.
Effective November 1, 2009, Molycorp LLC issued 5,880,000 incentive shares to certain
employees and independent directors of the Company. At the time of issuance, due to Molycorp
Minerals, LLCs option to repurchase vested shares of terminated participants at a price other than
fair value, these incentive shares were classified as liabilities and were valued at zero using the
intrinsic value method. On April 15, 2010, all holders of incentive shares contributed their
incentive shares to Molycorp, Inc. in exchange for an aggregate of 3,012,420 shares of Class B common stock of
Molycorp, Inc., 1,004,140 shares of which vested immediately with an additional 1,004,140 shares
vesting on September 30, 2010 and the remaining 1,004,140 shares vesting on September 30, 2011. The
shares of Class B common stock were non-transferable and the Company had the right to repurchase
vested shares upon the termination of employment for any reason.
The shares of Class B common stock automatically converted into shares of common stock, based
on a conversion factor, immediately prior to completion of the IPO. On August 3, 2010, Molycorp
completed an IPO of common stock at an offering price of $14.00 per share. At that time, the shares
of Class B common stock were converted into an aggregate of 2,232,740 shares of common stock, 744,247 of which
remained vested with the remaining 1,488,493 vesting over a period of six months following the IPO.
Stock-based compensation associated with these shares was $2.6 million for the three months ended
March 31, 2011 and $28.7 million for the year ended December 31, 2010.
On November 4, 2010, the Compensation Committee of the Board of Directors of the Company
approved the grant of 37,500 shares of restricted stock with a
three-year cliff vesting period to
certain executive officers and a director of the Company. The $1.4 million fair value of the awards
was determined using the stock price on the date of grant and is recognized straight-line over the
three-year vesting period. The stock-based compensation associated with these awards was $0.1
million for the three months ended March 31, 2011.
On January 13, 2011, the Company granted 9,557 shares of restricted stock and 32,637
restricted stock units with a three-year cliff vesting period to certain employees and executive
officers of the Company. The total $1.9 million fair value of the restricted stock and restricted
stock units was determined using the Companys stock price on the date of grant and is recognized
straight-line over the three-year vesting period. On the same day, the Company granted 52,819 stock
options that vest in equal installments annually over a three-year period to certain employees and
executive officers of the Company. The $1.4 million fair value of the stock options was determined
using the Black Scholes option valuation model and the Companys stock price on the date of grant
and is recognized straight-line over the three year vesting period. The total stock-based
compensation associated with the awards granted on January 13, 2011 was $0.2 million for the three
months ended March 31, 2011.
Approximately $35,000 of the
stock-based compensation associated with these equity awards was allocated to cost of goods sold for the
three months ended March 31, 2011.
(7) Concentrations
(a) Limited Number of Products
The Companys current operations are primarily limited to the production and sale of REOs from
stockpiled concentrates and purchasing and reselling REOs from other producers. The Company does
not have and will not have the capability to significantly alter its product mix prior to
completing the modernization and expansion of the Mountain Pass facility and the restart of mining
operations. Sales for the Companys most significant products for the three months ended March 31,
2011 and 2010, in (thousands), were as follows:
Three Months | Three Months | |||||||
Ended | Ended | |||||||
March 31, 2011 | March 31, 2010 | |||||||
Lanthanum products |
$ | 11,466 | $ | 2,751 | ||||
Ceric Hydrate |
$ | 7,868 | | |||||
Didymium products |
$ | 4,693 | $ | 105 | ||||
Cerium products |
$ | 1,185 | $ | 14 | ||||
Other |
$ | 1,049 | $ | 148 |
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(b) Limited Number of Customers
There is a limited market for the lanthanum products currently produced by the Company from
stockpiled concentrate. Sales to the Companys largest customers, for the three months ended March
31, 2011 and 2010, in (thousands), were as follows:
Three Months | Three Months | |||||||
Ended | Ended | |||||||
March 31, 2011 | March 31, 2010 | |||||||
Mitsubishi Unimetals USA |
$ | 7,767 | | |||||
W.R. Grace & Co. Conn. |
$ | 6,196 | $ | 2,308 | ||||
Hitachi Metals, Ltd. |
$ | 5,785 | | |||||
Toyota Tsusho Corporation |
$ | 2,600 | | |||||
Treibacher Industrie AG |
$ | 1,184 | |
(c) Single Geographic Location
Currently, the Companys only mining and production facility is the Mountain Pass facility and
the Companys viability is based on the successful modernization and expansion of its operations.
The deterioration or destruction of any part of the Mountain Pass facility, or legal restrictions
related to current or anticipated operations at the Mountain Pass facility, may significantly
hinder the Companys ability to reach or maintain full planned production rates within the expected
time frame, if at all.
(8) Related-Party Transactions
In February 2009, certain of the Companys stockholders incurred certain costs in providing
letters of credit and/or cash collateral to secure the surety bonds issued for the benefit of
certain regulatory agencies related to the Companys Mountain Pass facility closure and reclamation
obligations. The total amount of collateral provided by stockholders was $18.2 million. Under the
terms of the agreement with its stockholders, the Company agreed to pay each such stockholder a 5%
annual return on the amount of collateral provided, and the stockholders were entitled to receive
quarterly payments, delay payments, or receive payments-in-kind. In September 2010, the Company
issued its own collateral in the amount of $18.2 million in replacement of the letters of credit
and cash collateral provided by the stockholders. The Company paid fees due to stockholders in the
amount of $0.8 million in September 2010.
In June 2010, the Company entered into an inventory financing arrangement with Traxys North
America LLC (Traxys), the parent of one of its stockholders, TNA Moly Group, LLC, under which it
borrowed approximately $5.0 million, secured by certain product inventories. Borrowings under this
arrangement required an initial interest rate of 6% based on three-month LIBOR plus a margin, which
is subject to adjustment every three months. No adjustments have been made to the interest rate
since the agreement was signed. At March 31, 2011 and December 31, 2010 interest payable associated
with the arrangement totaled $71,200 and $9,000, respectively. Principal and interest
under this arrangement are payable from revenue generated from sales of the product inventories.
During the third quarter of 2010, both parties agreed that 50% of all didymium oxide sales will be
subject to this arrangement. The Company made principal payments of $0.9 million for the three
months ended March 31, 2011. The outstanding amounts payable to Traxys under this arrangement were
$2.9 million reported on the Condensed Consolidated Balance Sheet as Short-term borrowing
related party and $0.6 million in Trade accounts payable related to the sales made, but not
remitted to Traxys and affiliates as of March 31, 2011.
The Company and Traxys and affiliates jointly market and sell certain lanthanum oxide, cerium
oxide and erbium oxide products. Per the terms of this arrangement, the Company and Traxys split
gross margin equally once all costs associated with the sale are recovered by both parties. As a
result of this arrangement ending March 31, 2011, we have recorded a related party receivable from
Traxys and affiliates of $116,000. The Company recorded an expense of $176,000 during the first
quarter of 2011 and had an outstanding related payable to Traxys and affiliates in the amount of
$297,000 as of March, 31, 2011. Revenues and expenses related to these settlements are presented on
a net basis in Other Income on the Statement of Operations. In addition, for the three months ended
March 31, 2011, the Company made purchases of lanthanum oxide from Traxys and affiliates in the
amount of $4.3 million. The related-party payable associated with product purchases was $0.3
million as of March 31, 2011.
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(9) Subsequent Events
(a) Acquisitions
On April 1, 2011, Molycorp completed the acquisition of a 90.023% controlling stake in AS
Silmet, one of only two rare earth processing facilities in Europe, in a transaction valued at
approximately $89 million. Molycorp acquired 80% of the outstanding shares of AS Silmet (now
Molycorp Silmet AS) from AS Silmet Grupp in exchange for 1,593,419 shares of Molycorp common stock.
AG Silmet Grupp will retain a 9.977% ownership interest in Molycorp Silmet AS. Molycorp acquired the
other 10.023% from Treibacher Industrie AG for $9.0 million in cash. The Silmet acquisition
provides Molycorp with a European base of operations and doubles the Companys
current rare earth production capacity from approximately 3,000 mt per year of REO equivalent to
approximately 6,000 mt. AS Silmet will begin sourcing rare earth feed stocks for
production of its products from Molycorps Mountain Pass, California rare earth mine and processing
facility. The facilitys main focus will be on the production of rare earth oxides and metals,
including didymium metal, a critical component in the manufacture of neodymium-iron-boron permanent
rare earth magnets. AS Silmets manufacturing operation
is located in Sillamäe, Estonia. The company currently sells products to customers in Europe, North
and South America, Asia, Russia, and other former Soviet Union countries.
On April 15, 2011, Molycorp completed the acquisition from Santoku Corporation (Santoku) of
all the issued and outstanding shares of capital stock of Santoku America, Inc., an Arizona-based
corporation, in an all-cash transaction for $17.5 million. The acquisition provides Molycorp with
access to certain intellectual properties relative to the development, processing and manufacturing
of Neodymium and Samarium magnet alloy products. As part of the stock purchase agreement, Santoku
will provide consulting services to Molycorp for the purpose of maintaining and enhancing the
quality of Molycorps products.
On the same date, Molycorp entered into a
non-exclusive marketing and distribution agreement with Santoku for the sale and distribution of
neodymium and samarium magnet alloy products.
The allocation of the purchase price for both acquisitions will be completed later in 2011.
(b) Declared Dividend
On May 4, 2011, the
Company declared a cash dividend of $1.604 per share on the Series A Mandatory Convertible
Preferred Stock. The dividend will be paid on June 1, 2011 for holders of record at the
close of business on May 15, 2011. The Company elected to pay the $3.3 million dividend
in cash given its current cash balance and its anticipated revenue and earnings.
ITEM 2. | MANAGEMENTS DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS. |
In this Quarterly Report on Form 10-Q, unless the context requires otherwise, references to
Molycorp, we, our or us refer to Molycorp, LLC, and its consolidated subsidiaries prior to
our corporate reorganization (as described under the heading Overview Presentation below) and
Molycorp, Inc. and its consolidated subsidiaries after the corporate reorganization (as described
below). As used herein, a ton is equal to 2,000 pounds, the term mt means a metric tonne (equal
to 2,205 pounds), and the term Rest of World means the entire world except China. For definitions
of certain rare earth-related and mining terms, see Glossary of Selected Mining Terms.
This Quarterly Report on Form 10-Q contains forward-looking statements that represent our
beliefs, projections and predictions about future events or our future performance. You can
identify forward-looking statements by terminology such as may, will, would, could,
should, expect, intend, plan, anticipate, believe, estimate, predict, potential,
continue or the negative of these terms or other similar expressions or phrases. These
forward-looking statements are necessarily subjective and involve known and unknown risks,
uncertainties and other important factors that could cause our actual results, performance or
achievements or industry results to differ materially from any future results, performance or
achievement described in or implied by such statements. Factors that may cause actual results to
differ materially from expected results described in forward-looking statements include, but are
not limited to: our ability to secure sufficient capital to implement our business plans; our
ability to complete our modernization and expansion efforts and reach full planned production rates
for rare earth oxides and other planned downstream products; uncertainties associated with our
reserve estimates and non-reserve deposit information; uncertainties regarding global supply and
demand for rare earth materials; our ability to maintain appropriate relations with unions and
employees; our ability to successfully implement our mine-to-magnets strategy; commercial
acceptance of our new products, such as XSORBX®, environmental laws, regulations and
permits affecting our business, directly and indirectly, including, among others, those relating to
mine reclamation and restoration, climate change, emissions to the air and water and human exposure
to hazardous substances used, released or disposed of by us; uncertainties associated with
unanticipated geological conditions related to mining; and those risks discussed and referenced in
the section entitled Risk Factors described in Part II, Item 1A of this Quarterly Report on Form
10-Q.
Any forward-looking statement you read in this Quarterly Report on Form 10-Q reflects our
current views with respect to future events and is subject to these and other risks, uncertainties
and assumptions relating to our operations, operating results, growth strategy and liquidity. You
should not place undue reliance on these forward-looking statements because such statements speak
only
as to the date when made. We assume no obligation to publicly update or revise these
forward-looking statements for any reason, or to update the reasons actual results could differ
materially from those anticipated in these forward-looking statements, even if new information
becomes available in the future, except as otherwise required by applicable law.
16
Table of Contents
The following discussion and analysis should be read in conjunction with our unaudited
condensed consolidated financial statements and related notes included herein. The historical
financial data discussed below prior to the completion of the initial public offering, or IPO, of
Molycorp, Inc. reflects the historical results of operations and financial position of Molycorp,
LLC and, for any time period prior to the formation of Molycorp, LLC on September 9, 2009, those of
Molycorp Minerals, LLC, or Molycorp Minerals. The historical financial data does not, unless
otherwise noted, give effect to the completion of the IPO and corporate reorganization.
This Quarterly Report on Form 10-Q also contains statistical data and estimates we obtained
from industry publications and reports generated by third parties. Although we believe that the
publications and reports are reliable, we have not independently verified their data.
Overview
Presentation
Molycorp Minerals, LLC, a Delaware limited liability company formed on June 12, 2008, acquired
the Mountain Pass, California rare earth deposits and associated assets, or the Mountain Pass
facility, from Chevron Mining Inc., a subsidiary of Chevron Corporation, on September 30, 2008.
Molycorp, Inc. was formed on March 4, 2010, and through a corporate reorganization on April 15,
2010, Molycorp Minerals, LLC became an indirect wholly owned subsidiary of Molycorp, Inc.
On August 3, 2010, Molycorp, Inc. completed its initial public offering of common stock
through the issuance of 29,128,700 shares of common stock at $14.00 per share. Total net proceeds
of the offering were $378.6 million after underwriting discounts and commissions and offering
expenses payable by Molycorp, Inc.
In the first quarter of 2011, Molycorp completed a public offering
of its 5.50% Series A Mandatory Convertible Preferred Stock, $0.001 par value per share. In
connection with this offering, the Company issued 2,070,000 shares of Series A Mandatory
Convertible Preferred Stock for $100.00 per share. Total net proceeds of the offering were $199.6
million after underwriting discounts and commissions and offering expenses payable by Molycorp,
Inc. Each share of the Series A Mandatory Convertible Preferred Stock will automatically convert
on March 1, 2014 into between 1.6667 and 2.0000 shares of Molycorps common stock, subject to
anti-dilution adjustments. At any time prior to March 1, 2014, holders may elect to convert each
share of the Series A Mandatory Convertible Preferred Stock into shares of common stock at the
minimum conversion rate of 1.6667 shares of common stock per share of Series A Mandatory
Convertible Preferred Stock, subject to anti-dilution adjustments. The Series A Mandatory
Convertible Preferred Stock is not redeemable.
On April 1, 2011, Molycorp completed the acquisition of a 90.023% controlling stake in AS
Silmet, one of only two rare earth processing facilities in Europe, in a transaction valued at
approximately $89 million. Molycorp acquired 80% of the outstanding shares of AS Silmet (now
Molycorp Silmet AS) from AS Silmet Grupp in exchange for 1,593,419 shares of Molycorp common stock.
AG Silmet Grupp will retain a 9.977% ownership interest in Molycorp Silmet AS. Molycorp acquired the
other 10.023% from Treibacher Industrie AG for $9.0 million in cash. The Silmet acquisition
provides Molycorp with a European base of operations and doubles the Companys current rare earth
production capacity from approximately 3,000 mt per year of REO equivalent to approximately 6,000
mt. AS Silmet will begin sourcing rare earth feed stocks for production of its products from
Molycorps Mountain Pass, California rare earth mine and processing facility. The facilitys main
focus will be on the production of rare earth oxides and metals, including didymium metal, a
critical component in the manufacture of neodymium-iron-boron permanent rare earth magnets. AS
Silmets manufacturing operation is located in Sillamäe, Estonia. The company currently sells
products to customers in Europe, North and South America, Asia, Russia, and other former Soviet
Union countries.
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On April 15, 2011, Molycorp completed the acquisition from Santoku Corporation (Santoku) of all
the issued and outstanding shares of capital stock of Santoku America, Inc. (SAI and now known as Molycorp Metals
and Alloys (MMA)), an Arizona-based corporation, in an all-cash transaction for $17.5 million. The acquisition provides
Molycorp with access to certain intellectual properties relative to the development, processing and
manufacturing of Neodymium and Samarium magnet alloy products. As part of the stock purchase
agreement, Santoku will provide consulting services to Molycorp for the purpose of maintaining and
enhancing the quality of Molycorps products. On the same date, Molycorp entered into a
non-exclusive marketing and distribution agreement with Santoku for the sale and distribution of
neodymium and samarium magnet alloy products.
Our Business
We are the only REO producer in the Western hemisphere and own one of the worlds largest,
most fully developed rare earth projects outside of China. Following the execution of our
mine-to-magnets strategy and completion of our modernization and expansion efforts, we expect to
be one of the worlds most integrated producers of rare earth products, including oxides, metals,
alloys and magnets. Our rare earths are critical inputs in many existing and emerging applications
including: clean energy technologies, such as hybrid and electric vehicles and wind power turbines;
multiple high-tech uses, including fiber optics, lasers and hard disk drives; numerous defense
applications, such as guidance and control systems and global positioning systems; and advanced
water treatment technology for use in industrial, military and outdoor recreation applications.
Global demand for REEs is projected to steadily increase both due to continuing growth in existing
applications and increased innovation and development of new end uses.
Our goals are to:
| develop innovative rare earth technologies and products vital to green energy, high-tech, defense and industrial applications; | ||
| be commercially sustainable, globally competitive, profitable and environmentally superior; | ||
| act as a responsible steward of our rare earth resources; and | ||
| use our technology to improve the daily lives of people throughout the world. |
We have made significant investments, and expect to continue to invest, in developing
technologically advanced and proprietary applications for individual REEs. Under our
mine-to-magnets strategy, we plan to integrate the rare earths supply chain: mining; oxide
processing; production of metals and alloys; and production of rare earth-based magnets. We are in
the process of modernizing and expanding our production capabilities at our Mountain Pass,
California facility, and our recent acquisitions of Molycorp Silmet AS
and MMA. provide us with additional capacity for the production of rare earth oxides as well as the ability to produce
rare earth metals and alloys.
Our vision is to be the rare earth products and technology company recognized for its ETHICS
Excellence, Trust, Honesty, Integrity, Creativity and Safety. Since July 2005, the Mountain Pass
facility has not had a lost-time accident and has received the coveted Sentinels of Safety award
from the Mine Safety and Health Administration, or MSHA for three of the last six years.
Our Mine Process and Development Plans
We recommenced mining operations in December 2010 and are preparing to recommence milling
operations, which we expect to occur in the first quarter of 2012. Recommencement of mining and
milling operations is coincident with our initial modernization and expansion plan, which will give
us the capacity to efficiently produce at a rate of approximately 19,050 mt of REO per year by the
end of 2012. Additionally, upon the completion of our capacity expansion plan, we expect to have
the ability to produce up to approximately 40,000 mt of REO per year by the end of 2013. Prior to
the expected completion of our initial modernization and expansion efforts, we expect to produce
approximately 3,000 mt per year in the aggregate of cerium products, lanthanum concentrate,
didymium oxide and heavy rare earth concentrates from stockpiled feedstock.
We currently produce rare earth metals outside of the United States through a third-party
tolling arrangement. Additionally, through our acquisitions of
Molycorp Silmet AS and
MMA in April 2011, we added facilities and equipment for
metal conversion and alloy production within the Molycorp organization. We intend to transport
cerium, lanthanum, neodymium, praseodymium, dysprosium, terbium and samarium oxide products from
our Mountain Pass facility to Molycorp Silmet AS and MMA to produce rare earth metals and alloys.
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In December 2010, we entered into a non-binding letter of intent with Hitachi to form joint
ventures for the production of rare earth alloys and magnets in the United States and to acquire a
license for certain technology related to the production of rare earth metals, alloys and magnets.
We have completed a joint feasibility study with Hitachi and we are currently negotiating the joint
venture agreements. Additionally, we have entered into a non-binding letter of intent with Neo
Material that, among other things, contemplates a technology transfer agreement pursuant to which
Neo Material may provide us with technical assistance and know-how with respect to the production
of rare earth metals, alloys and magnets.
Our proposed joint ventures with Hitachi would provide us with additional access to the
technology, people and facilities to convert our rare earth materials into rare earth alloys and
high-performance permanent rare earth magnets required for production of hybrid and electric
vehicles, wind power turbines, high-tech applications and numerous advanced defense systems on
which the U.S. economy and national security depend. The consummation of such joint ventures, in
conjunction with our current modernization plans, our recent
acquisitions of Molycorp Silmet AS and MMA and
the potential technology transfer agreement with Neo Material, is expected to provide us with the
capability to mine, process, separate and alloy individual REEs and manufacture them into neodymium
iron boron, or NdFeB, magnets. This downstream integration would make us the only fully integrated
producer of NdFeB magnets outside of China, helping to secure a rare earth supply chain for the
Rest of World.
We anticipate the cost to restart mining operations, construct and refurbish processing
facilities and other infrastructure at the Mountain Pass facility and expand into metal and alloy
production in connection with our initial modernization and expansion plan to be approximately $531
million through 2012. Additionally, we estimate, based on consultation with our project manager,
that we will incur approximately $250 million of capital costs through 2013 in connection with the
second-phase capacity expansion plan. Our estimated capital expenditures of $781 million do not
include corporate, selling, general and administrative expenses, which we estimate to be an
additional $20 million to $25 million per year. We expects to finance our remaining capital
expenditures under the initial modernization and expansion and the second phase expansion plans as
well as our working capital requirements, with our available cash balances of $492.5 million as of
March 31, 2011, anticipated revenue from operations and traditional debt financing, project
financing, and/or government programs, including the DOE loan
guarantee program. We submitted a Part I application on June 2010 for up to $280 million. On July
21, 2010, the DOE deemed the Companys application eligible
for submission of a part II application, which was submitted on December 31, 2010. The DOE is currently conducting a
due diligence review and has provided us with a preliminary term sheet. On December 10, 2010, we
entered into a memorandum of understanding with Sumitomo Corporation (Sumitomo), pursuant to
which Sumitomo agreed to, among other things, purchase $100 million of the Companys common stock
and arrange for $30 million of debt financing. Sumitomo is currently conducting a due diligence
review and the consummation of these transactions with Sumitomo is subject to the satisfaction of
numerous conditions and finalization of definitive agreements.
Our Products and Markets
Since our acquisition of the Mountain Pass facility, we have been producing and selling small
quantities of certain rare earth products from our pilot processes using stockpiled feedstocks. The
purpose of this effort has been to significantly improve our solvent extraction technology and to
develop other key technologies that will be utilized in the new process. In the first quarter of
2010, we completed our initial pilot processing of stockpiled lanthanum rich feedstock to produce
didymium oxide (a combination of neodymium and praseodymium) and a higher purity lanthanum
concentrate than we previously produced. Lanthanum products processed from the stockpiled
material, which we sell to customers in the fluid catalytic cracking industry, has been our largest
source of revenue to date.
We commenced a second pilot processing campaign in the second quarter of 2010 in an effort to
commercially demonstrate our new cracking technology and to further optimize our processing
technologies and improve recovery rates compared to historical operations at the Mountain Pass
facility. Due to the success of this effort, we are producing cerium and lanthanum products, as
well as didymium oxide from bastnasite concentrate stockpiles. In July 2010, we began selling our
didymium oxide primarily to customers in the magnet industry. During the third quarter of 2010, we
began selling our cerium products to customers in the automobile emissions catalyst production
industry and we completed our initial sale of XSORBX ® to the water treatment industry.
Additionally, in the fourth quarter of 2010, we commenced production of didymium metal from our
oxide through a third-party processor and began selling this product primarily to customers in the
magnet industry during the first quarter of 2011. Also, in the first quarter of 2011, in
anticipation of our acquisition, AS Silmet commenced contract tolling for us of mixed rare earth
carbonates into lanthanum oxide, cerium carbonate, neodymium and praseodymium, which we began
selling in 2011. With these products, we have begun expanding and diversifying our product mix and
our customer base. As a result of these events, our product mix has been diversified and we are
realizing revenues from increasing sales volumes and higher REO pricing.
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Key Industry Factors
Demand for Rare Earth Products
Global consumption of REEs is projected to steadily increase due to continuing growth in
existing applications and increased innovation and development of new end uses. For example, the
integration of rare earth permanent magnet drives into wind power turbines has substantially
reduced the need for gearboxes, which increases overall efficiency and reliability. If Mountain
Pass and other rare earth projects do not commence production when anticipated, there will continue
to be a gap between current and forecasted demand and supply. We believe that this anticipated
market dynamic will underpin continued strong pricing.
As a result of the global economic crisis, rare earth product prices declined by approximately
50% during 2008 and through the third quarter of 2009. According to Metal-Pages, from October 2009
through March 2011, prices for rare earths have risen by approximately 1,500% on average.
Furthermore, over the same period, prices for some of the most common rare earths (cerium oxide,
lanthanum oxide, neodymium oxide, and praseodymium oxide) have risen by more than 2,000% on
average.
Prices ($/Kg) | ||||||||||||
Rare Earth Oxides | October 1, 2009 |
March 31, 2011 |
Change | |||||||||
Lanthanum |
4.65 | 121 | 2,502 | % | ||||||||
Cerium |
3.75 | 121 | 3,127 | % | ||||||||
Praseodymium |
14 | 196 | 1,300 | % | ||||||||
Neodymium |
14.25 | 201 | 1,311 | % | ||||||||
Samarium |
4.5 | 106.5 | 2,267 | % | ||||||||
Europium |
480 | 940 | 96 | % | ||||||||
Gadolinium |
5.25 | 147 | 2,700 | % | ||||||||
Terbium |
350 | 990 | 183 | % | ||||||||
Dysprosium |
107.5 | 640 | 495 | % | ||||||||
Yttrium |
10.25 | 143 | 1,295 | % |
Supply of Rare Earth Products
China has dominated the global supply of REOs for the last ten years and, according to IMCOA,
it is estimated that China accounted for approximately 96% of global REO production in 2008. Even
with our planned production, global supply is expected by analysts to remain tight due to the
combined effects of growing demand and actions taken by the Chinese government to restrict exports.
The Chinese government heightened international supply concerns beginning in August 2009 when
Chinas Interior Ministry first signaled that it would further restrict exports of Chinese rare
earth resources. Citing the importance of REE availability to internal industries and the desire to
conserve resources, the Chinese government has announced export quotas, increased export tariffs
and introduced a mining quotas policy that, in addition to imposing export quotas and export
tariffs, also imposes production quotas and limits the issuance of new licenses for rare earth
exploration. On July 8, 2010, Chinas Ministry of Industry and Information Technology issued the
export quota for the second half of 2010, which reduced exports by 72% compared with the second
half of 2009 and 40% for the year ended December 31, 2010 as compared to the year ended December
31, 2009. On December 28, 2010, Chinas Ministry of Industry and Information Technology further
reduced the export quota for the first half of 2011, reducing exports by 35% compared with the
first half of 2010 and 20% for the twelve months ended June 30, 2011 as compared to the twelve
months ended June 30, 2010. Chinas internal consumption of rare earths is expected to continue to
grow, leaving the Rest of World with less supply during a period of increasing global demand. China
also dominates the manufacture of rare earth metals, producing substantially all of the worlds
supply, and the manufacture of NdFeB magnets, producing approximately 80% of the worlds supply.
Neither capability currently exists in the United States.
China has announced a national stockpile program, as has South Korea. Additionally, Japan has
increased its national stockpile program. In December 2010, the U.S. Department of Energy released
a study concluding that five rare earth metals, including dysprosium, neodymium, terbium, europium
and yttrium, are critical to clean energy technologies in the short term due to their importance to
the clean energy economy and risk of supply disruption. The report emphasizes that diversified
global supply chains for these critical materials are essential, and calls for steps to be taken to
facilitate extraction, processing and manufacturing in the United States. Additionally, the U.S.
Department of Defense is conducting a study to determine its rare earth requirements and supply
chain vulnerabilities and whether to build a strategic stockpile. These stockpile programs will
likely accelerate the pace of the current and projected global REE supply deficit.
As a result of the internal industrial development, as well as economic, environmental and
regulatory factors in China, there is uncertainty with respect to the availability of rare earth
products from China. Although Chinese production of rare earth materials is increasing, export
quotas imposed by the Chinese government are decreasing, thus reducing the amount of rare earth
materials that China may export to the rest of the world. This reduction is occurring at a time
when the demand for REEs is growing significantly.
Factors Affecting Our Results
Modernization and Expansion of Mountain Pass Facility
We anticipate a dramatic change in our business and results of operations upon the completion
of our planned modernization and expansion of our Mountain Pass facility in connection with our
initial modernization and expansion plan and the commencement of metal, alloy, and magnet
production in 2012. For example, we expect to produce and sell a significantly expanded slate of
products, including specialty cerium products for water treatment, neodymium and praseodymium
metal, neodymium iron boron and samarium cobalt alloys for magnets, europium, gadolinium, and
terbium oxides for phosphors, and dysprosium and terbium for magnets.
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We acquired the Mountain Pass facility on September 30, 2008 from Chevron Mining Inc., which
became the owner of the Mountain Pass facility in 2005 after Unocal Corporation merged with Chevron
Corporation. Unocal Corporation had suspended most operations at the Mountain Pass facility by 2002
and, except for pilot processing activities, they remained suspended under Chevron Mining Inc.s
ownership. Additionally, significant reclamation work was completed at the Mountain Pass facility
under Chevron Mining Inc.s ownership.
We plan to utilize the assets we acquired from Chevron Mining Inc. as a foundation to build an
integrated rare earth products and technology company, which requires considerable additional
capital investment. We believe the application of improved technologies, along with the capital
investment, will allow us to create a sustainable business by cost effectively producing high
purity rare earth products. Between now and the start-up of the new processing facility, we anticipate further diversifying our product line through the
production of samarium/europium/gadolinium concentrate from bastnasite concentrate stockpiles. Upon
completion of the modernization and expansion of the Mountain Pass facility, we expect to produce
lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium and
yttrium in various chemical compounds and/or metal forms, including alloys. In addition to the
modernization and expansion of the Mountain Pass facility and our
acquisition of Molycorp Silmet AS and MMA, we expect to significantly broaden our operations through the addition of a number of downstream
activities and products, including rare earth metal production and NdFeB and samarium cobalt
alloys. We intend to use some of the NdFeB alloy and dysprosium metal product in a magnet
production facility, which we anticipate developing through a joint venture arrangement.
Accordingly, upon full implementation of our mine-to-magnets strategy, we expect our new products
to have significantly more applications and a broader market base than our current products.
Revenues
In the second quarter of 2010, we commenced a second pilot processing campaign to commercially
demonstrate our new cracking technology and to further optimize our processing technologies and
improve our recovery rates compared to historical operations at the Mountain Pass facility. Due to
the success of this second pilot processing campaign, we are producing cerium and lanthanum
products as well as didymium oxide from bastnasite concentrate stockpiles. In the fourth quarter of
2010, we commenced production of didymium metal from our oxide through a third-party processor. In
the first quarter of 2011, AS Silmet commenced tolling for us of mixed rare earth carbonates into
lanthanum oxide, cerium carbonate, neodymium and praseodymium. The addition of these new products
has significantly increased the diversity of our product mix. The following is a summary of the
percentage of revenue by significant product line for the three months ended March 31, 2011 and
2010.
Three Months Ended | ||||||||
March 31 | ||||||||
2011 | 2010 | |||||||
Lanthanum products |
44 | % | 91 | % | ||||
Ceric Hydrate |
30 | % | 0 | % | ||||
Didymium products |
18 | % | 3 | % | ||||
Other cerium products |
5 | % | 1 | % |
Our prices and product mix are determined by a combination of global and regional supply and
demand factors. Our revenue increased significantly for the three months ended March 31, 2011 as
compared to the three months ended March 31, 2010, due to the combination of a general increase in
the market prices of REOs, and higher sales volumes of ceric hydrate and didymium products, which
have significantly higher values than the lanthanum products that comprised substantially all of
our sales in 2010. Sales for the three months ended March 31, 2011 included 696 metric tons of REOs,
including purchased REOs,
at an average price of $37.73 per kilogram compared to sales of 423 metric tons of REO at an
average price of $7.13 per kilogram for the three months ended March 31, 2010. The quantities we
sell are determined by the production capabilities of the Mountain Pass facility and by demand for
our product, which is also influenced by the level of purity and consistency we are able to
achieve. Our revenue also includes sales of finished products acquired as part of our acquisition
of the Mountain Pass facility.
Pursuant to a contract with one of our largest customers, we are supplying a significant
amount of our REOs, through mid-2012 at market-based prices subject to a ceiling based on market
prices at June 1, 2010, and a floor. Under a second contract, we will supply the same customer with
approximately 75% of our phase one lanthanum product production per year at market-based prices
subject to a floor for a three-year period commencing upon the achievement of expected annual
production rates under our initial modernization and expansion plan, which may be extended at the
customers option for an additional three-year period. Upon execution of definitive agreements
pursuant to our memorandum of understanding with Sumitomo, we also expect to provide Sumitomo with
approximately 1,500 mt per year (and following completion of our initial modernization and
expansion plan, approximately 1,750 mt per year) of
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cerium and lanthanum-based products and 250 mt
per year of didymium oxide for a period ending five years after the completion of
our initial modernization and expansion of the Mountain Pass facility, at market-based prices
subject to a floor. Although prices for REOs have generally increased since October 2009, this
increase followed a period of generally lower prices corresponding with the global financial crisis
beginning in 2008. Many factors influence the market prices for REOs and, in the absence of
established pricing in customer contracts, our sales revenue will fluctuate based upon changes in
the prevailing prices for REOs. We use various industry sources, including certain publications, in
evaluating prevailing market prices and establishing prices for our products because there are no
published indices for rare earth products, including alloys or magnets.
Cost of Goods Sold
Our cost of goods sold reflects the cost allocated to our inventory acquired as part of our
acquisition of the Mountain Pass facility and, with respect to our recent sales of lanthanum and
cerium products and didymium oxide, the subsequent processing costs incurred to produce the
product. Because many of our costs are fixed costs as opposed to variable costs, as our production
increases or decreases, our average cost per metric ton decreases or increases, respectively.
Primary production costs include direct labor and benefits, maintenance, natural gas, electricity,
operating supplies, chemicals, depreciation and amortization and other plant overhead expenses.
Currently, our most significant variable costs are chemicals and electricity. In the future,
we intend to produce more of our chemicals at a plant on-site, which will reduce our variable
chemical costs. We also intend to build a co-generation facility to provide power. Following such
steps, natural gas will substantially replace third-party electricity costs and become one of our
most significant variable costs.
We expect our labor and benefit costs to increase through 2013 due to the addition of
personnel and consultants required to increase production to a rate of approximately 19,050 mt of
REO per year by the end of 2012 in connection with our initial modernization and expansion plan and
up to approximately 40,000 mt of REO per year by the end of 2013 in connection with our capacity
expansion plan. In addition to volume fluctuations, our variable costs, such as electricity,
operating supplies and chemicals, are influenced by general economic conditions that are beyond our
control. Other events outside our control, such as power outages, have in the past interrupted our
operations and increased our total production costs, and we may experience similar events in the
future.
Selling, General and Administrative Expenses
Our selling, general and administrative expenses consist primarily of: personnel and related
costs; legal, accounting and other professional fees; occupancy costs; and information technology
costs. We continue to experience increased selling, general and administrative expenses as we
expand our business and operate as a publicly traded company. These expenses include increasing our
staffing as we construct our new facilities and pursue other business development activities to execute
our mine-to-magnets business plan. We have also experienced additional legal, compliance and
corporate governance expenses, as well as additional accounting and audit expenses, stock exchange
listing fees, transfer agent and other stockholder-related fees and increased premiums for certain
insurance policies, among others. We have also incurred significant professional fees and other
costs in connection with the business acquisitions that we completed in April 2011.
Income Taxes
Prior to our corporate reorganization, we operated entirely within limited liability
companies, which were not directly liable for the payment of federal or state income taxes and our
taxable income or loss was included in the state and federal tax returns of Molycorp, LLCs
members. Molycorp, Inc. is subject to U.S. federal and state income taxes. For the three months
ended March 31, 2011, we incurred $ 0.2 million in income tax expenses and have placed a 100% reserve on our deferred tax assets.
Environmental
Our operations are subject to numerous and detailed federal, state and local environmental
laws, regulations and permits, including those pertaining to employee health and safety,
environmental permitting and licensing, air quality standards, GHG emissions, water usage and
pollution, waste management, plant and wildlife protection, handling and disposal of radioactive
substances, remediation of soil and groundwater contamination, land use, reclamation and
restoration of properties, the discharge of materials into the environment and groundwater quality
and availability.
We retain, both within Molycorp and outside Molycorp, the services of reclamation and
environmental, health and safety, or EHS, professionals to review our operations and assist with
environmental compliance, including with respect to product management, solid
and hazardous waste management and disposal, water and air quality, asbestos abatement,
drinking water quality, reclamation requirements, radiation control and other EHS issues.
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We have spent, and anticipate that we will continue to spend, financial and managerial
resources to comply with environmental requirements. For example, we have acquired enough air
emission offset credits for both our initial modernization and expansion plan and our second phase
capacity expansion plan. In addition, in the quarter ended March 31, 2011 and 2010, we incurred
operating expenses of approximately $1.0 million and $1.3 million, respectively, associated with
environmental compliance requirements. The costs expected to be incurred as part of our on-going
remediation, which is expected to continue throughout the Mountain Pass facilitys operating,
closure and post-closure periods, are included as part of our asset retirement obligations. See
Critical Accounting Policies and Estimates Reclamation.
We cannot predict the impact of new or changed laws, regulations or permit requirements,
including the matters discussed below, or changes in the way such laws, regulations or permit
requirements are enforced, interpreted or administered. Environmental laws and regulations are
complex, change frequently and have tended to become more stringent over time. It is possible that
greater than anticipated environmental expenditures will be required in 2011 or in the future. We
expect continued government and public emphasis on environmental issues will result in increased
future investment for environmental controls at our operations. Additionally, with increased
attention paid to emissions of GHGs, including carbon dioxide, current and future regulations are
expected to affect our operations. We will continue to monitor developments in these various
programs and assess their potential impacts on our operations.
Violations of environmental laws, regulations and permits can result in substantial penalties,
court orders to install pollution-control equipment, civil and criminal sanctions, permit
revocations, facility shutdowns and other sanctions. In addition, environmental laws and
regulations may impose joint and several liability, without regard to fault, for costs relating to
environmental contamination at our facility or from wastes disposed of at third-party waste
facilities. The proposed expansion of our operations is also conditioned upon securing the
necessary environmental and other permits and approvals. In certain cases, as a condition to
procuring such permits and approvals, we are required to comply with financial assurance
requirements. The purpose of these requirements is to assure the government that sufficient company
funds will be available for the ultimate closure, post-closure care and/or reclamation at our
facilities. We typically obtain bonds as financial assurance for these obligations and, as of March
31, 2011, we had placed a total of $27.4 million of surety bonds with California state and regional
agencies. These bonds are collateralized by $18.2 million in cash, which we have placed in an
escrow account. These bonds require annual payment and renewal. The EPA has announced its intention
to establish a new financial assurance program for hardrock mining, extraction and processing
facilities under the Federal Comprehensive Environmental Response Compensation and Liability Act,
known as CERCLA, or the Superfund law, which may require us to establish additional bonds or
other sureties. We cannot predict the effect of any such requirements on our operations at this
time.
Results of Operations
Three Months Ended March 31, 2011 and 2010 (In thousands)
Three Months Ended | ||||||||||||
March 31 | ||||||||||||
2011 | 2010 | Change | ||||||||||
Sales |
$ | 26,261 | $ | 3,018 | $ | 23,243 | ||||||
Cost of goods sold |
(15,388 | ) | (5,950 | ) | (9,438 | ) | ||||||
Selling, general and administrative expenses |
(8,339 | ) | (4,480 | ) | (3,859 | ) | ||||||
Stock-based compensation |
(2,899 | ) | | (2,899 | ) | |||||||
Depreciation and amortization expense |
(83 | ) | (95 | ) | 12 | |||||||
Accretion expense |
(234 | ) | (263 | ) | 29 | |||||||
Operating loss |
(682 | ) | (7,770 | ) | 7,088 | |||||||
Other income (expense) |
||||||||||||
Other (expense) income |
(168 | ) | 21 | (189 | ) | |||||||
Interest income |
140 | | 140 | |||||||||
Loss before income taxes |
(710 | ) | (7,749 | ) | 7,039 | |||||||
Provision for income taxes |
(199 | ) | | (199 | ) | |||||||
Net loss |
$ | (909 | ) | $ | (7,749 | ) | $ | 6,840 | ||||
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Revenues
For the three months ended March 31, 2011 and 2010, our sales were $26.3 million
and $3.0 million, respectively. This significant increase in revenue is due to the combination of a
general increase in the price of REO products, as well as our diversification into new products,
such as ceric hydrate and higher sales volumes of cerium and didymium products, which have much
higher sale prices per kilogram than the lanthanum products that comprised substantially all our
sales in 2010. The following is a summary of the revenue percentages by significant product for the
three months ended March 31, 2011 and 2010.
Three Months Ended | ||||||||
March 31 | ||||||||
2011 | 2010 | |||||||
Lanthanum products |
44 | % | 91 | % | ||||
Ceric Hydrate |
30 | % | 0 | % | ||||
Didymium products |
18 | % | 3 | % | ||||
Other cerium products |
5 | % | 1 | % |
Lanthanum sales for the three months ended March 31, 2011 consisted primarily of lanthanum
oxide, which has a relatively higher sales price per kilogram compared to sales for the three
months ended March 31, 2010, which consisted primarily of lanthanum concentrate that has a
relatively lower sales price per kilogram. Both ceric hydrate and didymium products, which have a
relatively higher sales price per kilogram as compared to our other products, accounted for 30% and
18%, respectively, of our total revenue for the three months ended March 31, 2011 as compared to
zero and 3% for the three months ended March 31, 2010, respectively. With the commencement of our
second pilot processing campaign, the production of lanthanum concentrate has been replaced by
lanthanum chlorohydrate, which is a more marketable product. In total, for the three months ended
March 31, 2011, we sold 696 metric tons of REO products at an average sales price of
$37.73 per kilogram compared to sales of 423 metric tons of REO
products at an average sales price of $7.13 per kilogram for the three months ended
March 31, 2010. We anticipate cerium products, including XSORBX®, lanthanum products
and didymium products to make up a significant percentage of our total revenue until we complete
the modernization and expansion of the Mountain Pass facility.
Cost of Goods Sold
Our cost of goods sold was $15.4 million and $6.0 million for the three months
ended March 31, 2011 and 2010, respectively. The higher costs for the three months ended March 31,
2011, compared to the three months ended March 31, 2010, were due to higher sales and higher
production costs. Lower of cost or market inventory write-downs were $0.6 million for
the three months ended March 31, 2011 and 2010, respectively.
Total production costs charged to inventory were $7.9 million and $3.0 million for the three
months ended March 31, 2011 and 2010, respectively. Inventory purchases were $6.0 million and $0.2
million for the three months ended March 31, 2011 and 2010, respectively. The primary products we
purchased during those periods were lanthanum oxide, cerium oxide, didymium metal and praseodymium
oxide.
The following is a summary of the production and purchased quantities in metric tons by
significant product for the three months ended March 31, 2011 and the corresponding production and
purchased quantities for the three months ended March 31, 2010 (in metric tons).
Three Months | ||||||||
Ended | ||||||||
March 31 | ||||||||
2011 | 2010 | |||||||
Lanthanum products |
415 | 239 | ||||||
Ceric Hydrate |
170 | | ||||||
Didymium products |
122 | 69 | ||||||
Other cerium products |
23 | |
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Production costs charged to inventory were higher during the three months ended March 31, 2011
as compared to the three months ended March 31, 2010, due to increased production levels. We expect
to attain increased production levels throughout 2011.
Chemical costs allocated to production were $2.3 million and $0.4 million for
the three months ended March 31, 2011 and 2010, respectively. Chemical costs in the first quarter
of 2011 were higher compared to the same period in 2010 due to higher production levels, despite
improved processing techniques that reduced chemical usage, and an increase in prices for
chemicals.
Labor costs, including related employee benefits, allocated to production were
$2.7 million and $1.9 million the three months ended March 31, 2011 and 2010, respectively. As of
March 31, 2011 we had a total of 165 employees compared to 114 employees at March 31, 2010, which
led to higher wage and employee related benefit expenses. During the first quarter of 2011, we also
experienced increase in labor costs as compared to the first quarter of 2010, due to the annual
wage increase required under our union contract in March 2011.
Maintenance costs, including maintenance labor and supplies, were $0.7 million
and $0.5 million for the three months ended March 31, 2011 and 2010, respectively. Utility charges,
which primarily include electricity, were $0.8 million and $0.4 million for the three months ended
March 31, 2011 and 2010, respectively.
Other costs allocated to production, including depreciation, were $4.7 million
and $2.4 million for three months ended March 31, 2011 and 2010, respectively. These costs were
higher in the first quarter of 2011 due to the significant increase in depreciation expense from
the placement of assets into service of over $7.0 million related to the second pilot processing
campaign during the second quarter of 2010. These assets are being depreciated over a 32-month
period as they will be decommissioned with the full restart of the mine at the end of 2012.
In March 2010, we also began blending our existing didymium oxide inventory, which, prior to
blending, contained varying percentages of neodymium and praseodymium, to create a more consistent
content which better meets customer specifications. As of March 31, 2011, approximately 500 metric
tons were blended. Blended inventory is reclassified from work in process to finished goods.
Selling, General and Administrative Expenses
Selling, general and administrative expenses (excluding share-based compensation) were $8.3
million and $4.5 million for the quarters ended March 31, 2011 and 2010, respectively. Beginning in
the first quarter of 2010, we experienced a significant increase in professional fees primarily due
to increasing our staffing as we prepared to start construction of our new facilities in January
2011 and other business development activities to execute our mine-to-magnets business plan. We
have also experienced increased spending for accounting, information technology consulting and
engineering services.
In addition, we recognized $2.9 million and $0 in stock-based compensation in
the three months ended March 31, 2011 and 2010, respectively.
Net Losses
Since our inception and our acquisition of the Mountain Pass facility, we have incurred
significant net losses. Our net losses for the three months ended March 31, 2011 and 2010 were
$0.9 million and $7.7 million, respectively.
Capital Expenditures
Our capital expenditures, on an accrual basis, totaled $41.3 million and $3.4 million for the
three months ended March 31, 2011 and 2010, respectively. Most of the capitalized costs incurred
during the three months ended March 31, 2010 are related to our second pilot processing campaign,
which commenced in April 2010, and most of the capitalized costs for the three months ended March
31, 2011 relate to our modernization and expansion project at the Mountain Pass facility.
Outlook for the Remainder of 2011
For the next three quarters of 2011, we anticipate China-based producers and suppliers will
continue to limit the quantity of REOs available outside of China, supporting strong pricing for
REOs. We believe this trend will create opportunities for us to increase sales volumes and improve
pricing terms for our products. While we expect the recent earthquake/tsunami in Japan and its
aftermath may have a short-term negative impact on market demand in the second and third quarters,
we expect full recovery of demand by the fourth quarter. While the REO products we are currently
able to produce remain limited by the capability of our existing production facilities, we
anticipate further expanding our products and markets throughout the remainder of the year,
including market penetration of our
XSORBX® technology into the water treatment industry. We also anticipate supplying Molycorp Silmet AS and MMA with rare earth concentrates and REOs
from our Mountain Pass facility to utilize their production capabilities and maximize value from
these acquisitions. We believe that our revenue
for the next nine months will be sufficient to fund our operating activities for the remainder of
the year, which includes corporate selling, general and administrative expense.
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Capital Investments
We
are incurring significant capital expenditures under our plan to modernize and expand our
Mountain Pass facility, as well as consistent expenditures to replace assets necessary to sustain
safe and reliable production. Most of the facilities and equipment acquired in connection with the
acquisition of the Mountain Pass facility are at least 20 years old. We are executing an
accelerated modernization plan that includes the refurbishment of the Mountain Pass mine and
related processing facilities through 2012 in order to increase REO production. We expect to incur
approximately $531 million in property, plant and equipment additions in connection with our
initial modernization and expansion plan prior to December 31, 2012, and up to an additional $250
million in property, plant and equipment to build additional production capacity in connection with
our capacity expansion plan, prior to December 31, 2013.
All of the amounts for future capital spending described above are initial estimates that are
subject to change as the projects are further developed. Total capital spending in 2011 is expected
to be approximately $295 million.
Liquidity and Capital Resources
Under our current business plan, we intend to spend approximately $531 million through the end
of 2012 to restart mining operations, construct and refurbish processing facilities and other
infrastructure at the Mountain Pass facility and expand into metal, alloy and magnet production in
connection with our initial modernization and expansion plan. In addition, we expect to spend
approximately $250 million in capital costs to expand production capacity through the end of 2013.
We expects to finance our remaining capital expenditures under the initial modernization and
expansion and the second phase expansion plans as well as our working capital requirements, with
our available cash balances of $492.5 million as of March 31, 2011, anticipated revenue from
operations and traditional debt financing, project financing, and/or government programs, including
the DOE loan guarantee program. We submitted a Part I application on June 2010 for up to $280
million. On July 21, 2010, the DOE deemed the Companys application eligible for submission of
a part II application, which was submitted on December 31, 2010. The DOE is currently conducting a
due diligence review and has provided us with a preliminary term sheet. On December 10, 2010, we
entered into a memorandum of understanding with Sumitomo Sumitomo pursuant to which Sumitomo agreed
to, among other things, purchase $100 million of the Companys common stock and arrange for $30
million of debt financing. Sumitomo is currently conducting a due diligence review and the
consummation of these transactions with Sumitomo is subject to the satisfaction of numerous
conditions and finalization of definitive agreements.
Our estimated capital expenditures of $781 million do not include corporate, selling, general
and administrative expenses, which we estimate to be an additional $20 million to $25 million per
year. We currently expect that the cash acquired as part of our purchase of the controlling stake
in AS Silmet on April 1, 2011 and of all the issued and outstanding shares of capital stock of
SAI on April 15, 2011, will be retained within those companies to fund their
respective working capital needs.
Contractual Obligations
During the three months ended March 31, 2011, there were no material changes to the
contractual obligations as reported in our Annual Report on Form 10-K for the year ended December
31, 2010, except that we made payments for certain purchase obligations of $27 million, and entered
into additional purchase obligations for materials and services from vendors, net of payments and
accrued liabilities, of approximately $61 million. All of these obligations primarily will be paid
by the first quarter of 2012.
Off-Balance Sheet Arrangements
As of March 31, 2011, our only off-balance sheet arrangements are the operating leases
reported in our Annual Report on Form 10-K for the year ended December 31, 2010.
Recent Accounting Pronouncements
In December 2010, the FASB issued ASU 2010-29: Disclosure of Supplementary Pro Forma Information
for Business Combinations. The amendments in this update specify that if a public entity presents
comparative financial statements, the entity should disclose revenue and earnings of the combined
entity as though the business combination(s) that occurred during the current year had occurred as
of the beginning of the comparable prior annual reporting period only. The amendments also expand
the supplemental pro forma disclosures to include a description of the nature and amount of
material, nonrecurring pro forma adjustments directly attributable to the business combination
included in the reported pro forma revenue and earnings. The amendments affect any public entity as
defined by Topic 805 that enters into business combinations that are material on an individual or
aggregate basis. The Company is evaluating the potential impact of adopting this guidance on the
Companys consolidated financial position, results of operations and cash flows.
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GLOSSARY OF SELECTED MINING TERMS
The following is a glossary of selected mining terms used in this quarterly report that may be
technical in nature:
Assay
|
The analysis of the proportions of metals in ore, or the testing of an ore or mineral for composition, purity, weight, or other properties of commercial interest. | |
Bastnasite
|
Bastnasite is a mixed Lanthanide fluoro-carbonate mineral (Ln F CO3) that currently provides the bulk of the worlds supply of the light REEs. Bastnasite and monazite are the two most common sources of cerium and other REEs. Bastnasite is found in carbonatites, igneous carbonate rocks that melt at unusually low temperatures. | |
Cerium
|
Cerium (Ce) is a soft, silvery, ductile metal which easily oxidizes in air. Cerium is the most abundant of the REEs, and is found in a number of minerals, including monazite and bastnasite. Cerium has two relatively stable oxidation states, enabling both the storage of oxygen and its widespread use in catalytic converters. Cerium is also widely used in glass polish. | |
Concentrate
|
A mineral processing product that generally describes the material that is produced after crushing and grinding ore effecting significant separation of gangue (waste) minerals from the desired metal and/or metal minerals, and discarding the waste minerals. The resulting concentrate of minerals typically has an order of magnitude higher content of minerals than the beginning ore material. | |
Cut-off grade
|
The lowest grade of mineralized material that qualifies as ore in a given deposit. The grade above which minerals are considered economically mineable considering the following parameters: | |
estimates over the relevant period of mining costs, ore treatment costs, general and administrative costs, refining costs, royalty expenses, by-product credits, process and refining recovery rates and price. | ||
Didymium
|
Didymium is a combination of neodymium and praseodymium, approximately 75% neodymium and approximately 25% praseodymium. | |
Dysprosium
|
Dysprosium (Dy) is used in high power neodymium iron boron magnets to enhance thermal stability. | |
Europium
|
Europium (Eu) is desirable due to its photon emission. Excitation of the europium atom, by absorption of electrons or by UV radiation, results in changes in energy levels that create a visible emission. Almost all practical uses of europium utilize this luminescent behavior. | |
Gadolinium
|
Gadolinium (Gd) absorbs neutrons and therefore is used for shielding in neutron radiography and in nuclear reactors. Because of its paramagnetic properties, solutions of organic gadolinium complexes and gadolinium compounds are the most popular intravenous medical magnetic resonance imaging contrast agents in MRI. | |
Grade
|
The average REE content, as determined by assay of a metric ton of ore. | |
Lanthanum
|
Lanthanum (La) is the first member of the Lanthanide series. Lanthanum is a strategically important rare earth element due to its use in fluid bed cracking catalysts, FCCs, which are used in the production of transportation and aircraft fuel. Lanthanum is also used in fuel cells and batteries. | |
Mill
|
A processing plant that produces a concentrate of the valuable minerals contained in an ore. | |
Mineralization
|
The extent and form of metal atom deposition as found in rocks or ore or the process by which the metals came to be deposited there. | |
Monazite
|
Monazite is a reddish-brown phosphate mineral. Monazite minerals are typically accompanied by concentrations of uranium and thorium. This has historically limited the processing of Monazite, however this mineral is becoming more attractive because it typically has elevated concentrations of heavy rare earths. | |
Neodymium
|
Neodymium (Nd) is used in the production of NdFeB permanent magnets. These permanent magnets, which maximize the power/cost ratio, are used in a large variety of motors and mechanical systems. Cellular phones, vehicle systems and certain lasers contain both neodymium magnets and capacitors, which produce powerful electronic generation and boost the power of these devices. |
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Ore
|
That part of a mineral deposit which could be economically and legally extracted or produced at the time of reserve determination. | |
Overburden
|
In surface mining, overburden is the material that overlays an ore deposit. Overburden is removed prior to mining. | |
Praseodymium
|
Praseodymium (Pr) comprising about 4% of the lanthanide content of bastnasite, is a common coloring pigment. Along with neodymium, praseodymium is used to filter certain wavelengths of light. Praseodymium is used in photographic filters, airport signal lenses, and welders glasses. As part of an alloy, praseodymium is used in permanent magnet systems designed to make smaller and lighter motors. Praseodymium is also used in automobile and other internal combustion engine pollution control catalysts. | |
Probable reserves
|
Reserves for which quantity and grade and/or quality are computed from information similar to that used for proven reserves, but the sites for inspection, sampling, and measurement are farther apart or are otherwise less adequately spaced. The degree of assurance, although lower than that for proven reserves, is high enough to assume continuity between points of observation. | |
Proven reserves
|
Reserves for which (a) quantity is computed from dimensions revealed in outcrops, trenches, workings or drill holes; grade and/or quality are computed from the results of detailed sampling; and (b) the sites for inspection, sampling and measurement are spaced so closely and the geologic character is so well defined that size, shape, depth and mineral content of reserves are well established. | |
Recovery
|
The percentage of contained metal actually extracted from ore in the course of processing such ore. | |
Reserves
|
That part of a mineral deposit which could be economically and legally extracted or produced at the time of the reserve determination. Same definition as ore | |
Samarium
|
Samarium (Sm) is predominantly used to produce high temperature, high power samarium cobalt magnets. Although these magnets are less powerful than NdFeB magnets, they can be used over a wider range of conditions. | |
Strike
|
The direction of the line of intersection of a mineral deposit with the horizontal plane of the ground. The strike of a deposit is the direction of a straight line that connects two points of equal elevation on the deposit. | |
Tailings
|
That portion of the mined material that remains after the valuable minerals have been extracted. | |
Terbium
|
Terbium (Tb) is a lanthanide series element used in x-ray and color television tubes as well as high grade rare earth magnets. | |
Yttrium
|
Yttrium (Y), although not a lanthanide series element, is often considered to be a rare earth element and its behavior is similar to heavy rare earth elements. It is predominantly utilized in lighting applications and ceramics. Other uses include resonators, lasers, microwave communication devices and other electronic devices. |
ITEM 3. | QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK. |
Our operations may be impacted by commodity prices, geographic concentration, changes in
interest rates and foreign currency exchange rates.
Commodity Price Risk
Our principal products, including cerium, lanthanum, praseodymium, neodymium, europium,
samarium, gadolinium, dysprosium, and terbium, are commodities but are not traded on any commodity
exchange. As such, direct hedging of the prices for future production cannot be undertaken. We
generally do not currently have any long-term sales contracts with customers, so prices typically
will vary with the transaction and individual bids received. Our products are primarily marketed to
manufacturers as component materials. Prices will vary based on the demand for the end products
being produced with the mineral resources we mine and process.
Our sales and profitability are determined principally by the price of the rare earth products
that we produce and, to a lesser extent by the price of natural gas and other supplies used in the
production process. The prices of our rare earth products are influenced by the price and demand of
the end products that our products support, including clean energy technologies. A significant
decrease in the
global demand for these products may have a material adverse effect on our business. We
currently have no hedging contracts in place and intend to consider hedging strategies in future.
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Our costs and capital investments are subject to market movements in other commodities such as
natural gas and chemicals. We may enter into derivative contracts for a portion of the expected
usage of these products, but we do not currently have any derivative contracts and we do not
currently anticipate entering into derivative agreements.
Interest Rate Risk
We do not currently have any debt obligations except our inventory financing arrangement with
Traxys North America, LLC in the amount of $2.9 million as of March 31, 2011. Our exposure to
interest rate risk as a result of this agreement would result in a roughly $30,000
increase/decrease in interest rate expense for every 1% increase/decrease in the underlying
interest rate. Due to our limited borrowings, we are not significantly impacted by variations in
interest rates at this time. Our exposure to interest rate risk would increase if, for example, we
obtain and utilize debt facilities in the future.
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ITEM 4. | CONTROLS AND PROCEDURES. |
In accordance with Rule 13a-15(b) of the Exchange Act, the Companys management, with the
participation of the Chief Executive Officer and the Chief Financial Officer, carried out an
evaluation of the effectiveness of the Companys disclosure controls and procedures, as defined
in Rules 13a-15(e) and 15d-15(e) of the Exchange Act, as of the end of the period covered by this
report. Based on that evaluation, the Companys Chief Executive Officer and Chief Financial Officer
concluded that the Companys disclosure controls and procedures were effective as of March 31,
2011.
Our management is responsible for establishing and maintaining adequate internal control over
financial reporting, as defined in Exchange Act Rules 13a-15(f) and 15d-15(f). Our management,
including the Chief Executive Officer and Chief Financial Officer does not expect that our internal
controls will prevent all error and all fraud. A control system, no matter how well conceived and
operated, can provide only reasonable, not absolute, assurance that the objectives of the control
system are met. Further, the design of a control system must reflect the fact that there are
resource constraints and the benefits of controls must be considered relative to their costs.
Because of the inherent limitations in all control systems, no evaluation of controls can provide
absolute assurance that all control issues and instances of fraud, if any, within the Company have
been detected.
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PART II. OTHER INFORMATION
ITEM 1. | LEGAL PROCEEDINGS. |
From time to time, we may become subject to various legal proceedings that are incidental to
the ordinary conduct of our business. We are not currently party to any material legal proceedings.
ITEM 1A. | RISK FACTORS. |
Our Annual Report on Form 10-K for the fiscal year ended December 31, 2010 includes a detailed
discussion of our risk factors. The information presented below updates these risks and should be
read in conjunction with the risk factors and information disclosed in that Form 10-K.
We face a variety of risks associated with acquiring and integrating new business operations that
could have a significant negative impact on our business, financial condition and results of
operations.
In
April 2011, we acquired a 90.023% controlling stake in AS Silmet in order to increase our rare
earth production capacity and acquired SAI in order to provide us with the
capability to immediately begin manufacturing and selling rare earth alloys for the production of
NdFeB and samarium cobalt magnets, as well as a variety of other specialty alloys and products. We
may in the future pursue other strategic acquisitions that we believe would expand our product
offerings and capabilities or complement our business. We have limited experience making such
acquisitions. Any acquisition that we make will be accompanied by the risks commonly encountered
in acquisitions of businesses. The process of integrating acquired businesses, products or
technologies may create unforeseen operating difficulties and expenditures. We may have difficulty
integrating and assimilating the operations and personnel of any acquired companies, realizing
anticipated synergies and maximizing the financial and strategic position of the combined
enterprise. We may incur costs necessary to reorganize, expand or otherwise modify existing
operations to meet future production needs, and we may also incur closure, demolition and carrying
costs for portions of properties, for which we have no operational uses. We may also have
difficulty maintaining uniform standards, policies and controls across the organization. The
process of integrating acquired businesses may also result in a diversion of managements attention
and cause an interruption of, or loss of momentum in, our activities. Additionally, any
acquisition that we make may result in the assumption of material liabilities. Properties we
acquire may be in an unexpected condition and may subject us to increased costs and liabilities,
including environmental liabilities. We may assume unknown liabilities that could have a material
adverse effect on our business, financial condition and results of operations. Foreign
acquisitions involve risks in addition to those mentioned above, including those related to
integration of operations across different cultures and languages, currency risks and the
particular economic, political and regulatory risks associated with specific countries. As a
result of these risks, the anticipated benefits of these acquisitions may not be fully realized, if
at all, and the acquisitions could have a material adverse effect on our business, financial
condition and results of operations.
ITEM 2. | UNREGISTERED SALES OF EQUITY SECURITIES AND USE OF PROCEEDS. |
(a) Use of Proceeds
Our IPO of common stock, par value $0.001 per share, was effected through a Registration
Statement on Form S-1 (Registration No. 333-166129) that was declared effective by the SEC on July
29, 2010. There has been no material change in the planned use of proceeds from our IPO from that
described in the final prospectus related to the IPO dated July 29, 2010 filed by us with the SEC
pursuant to Rule 424(b). Through March 31, 2011, we have used
approximately $55.5 million, $27.7 million
and $9.0 million of the net proceeds from the IPO for capital expenditures including
construction and refurbishment of the Mountain Pass facilities, cash collateral deposit
requirements and working capital, respectively. Pending application of the remaining net proceeds
to fund a portion of our modernization and expansion of the Mountain
Pass facility, through March 31,
2011, we have invested $270.1 million of net proceeds from the offering in in a variety of capital
preservation investments, including short-term interest-bearing obligations, investment-grade
instruments, certificates of deposit and direct guaranteed obligations of the United States.
ITEM 3. | DEFAULTS UPON SENIOR SECURITIES. |
None.
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ITEM 4. | [REMOVED AND RESERVED]. |
ITEM 5. | OTHER INFORMATION. |
Mine Safety Practices
Our operations at the Mountain Pass facility are subject to the Federal Mine Safety and Health
Act of 1977, as amended by the Mine Improvement and New Emergency Response Act of 2006, which we
refer to as the Mine Act, and the regulations adopted by the California Occupational Safety and
Health Administration, which impose stringent health and safety standards on numerous aspects of
mineral extraction and processing operations, including the training of personnel, operating
procedures, operating equipment and other matters.
The Mountain Pass facility maintains a rigorous safety program. Our employees and contractors are
required to complete 24 hours of initial safety training, as well as an 8 hour annual refresher
sessions, which cover all of the potential hazards that may be present at the facility. During the
training, our commitment to a safe work environment is reinforced through our Stop Work Authority
program, which allows any employee or contractor at the facility to stop work that they deem to be
unsafe or out of compliance. As a direct result of this commitment to safety, the Mountain Pass
facility has an exceptional safety record, which as of March 31, 2011, stood at 2089 days worked
without a lost-time or restricted work accident. The lost-time incidence rate is an industry
standard used to describe occupational injuries that result in loss of one or more days from an
employees scheduled work. Our lost-time incidence rate for all Molycorp employees through March
31, 2011 was zero as compared to the national average of 1.82 reported by MSHA for the 2010
calendar year. Since July 2005, the Mountain Pass facility has not had a lost-time accident and has
received the coveted Sentinels of Safety award from the MSHA for three of the last six years.
Within the last six years, the Mountain Pass facility has received numerous awards for safety,
including: the MSHA Sentinels of Safety Award (2008, 2006 and 2004); the National Safety Council
Awards Perfect Record (2008, 2007, 2006, 2004); and the National Safety Council Awards
Occupational Excellence achievement award (2009, 2007 and 2004).
Section 1503 of Dodd-Frank Wall Street Reform and Consumer Protection Act: Reporting Requirements
regarding Coal or Other Mine Safety.
Section 1503(a) of the Dodd-Frank Wall Street Reform and Consumer Protection Act, which was
enacted on July 21, 2010, requires that mine operators provide certain safety information in their
periodic reports filed with the SEC.
Below is information regarding the safety of our sole rare earth mine located at Mountain
Pass, California for the three months ended March 31, 2011:
(A) Total number of alleged violations of mandatory health or safety standards that
could significantly and substantially contribute to the cause and effect of a mine
safety or health hazard under Section 104 of the Mine Act for which we received a
citation from the MSHA |
0 | |||
(B) Total number of orders issued under Section 104(b) of the Mine Act |
0 | |||
(C) Total number of citations and orders for alleged unwarrantable failure by us to
comply with mandatory health or safety standards under Section 104(d) of the Mine Act |
0 | |||
(D) Total number of alleged flagrant violations under Section 110(b)(2) of the Mine Act |
0 | |||
(E) Total number of imminent danger orders issued under Section 107(a) of the Mine Act |
0 | |||
(F) Total dollar value of proposed assessments from the MSHA under the Mine Act |
0 | |||
(G) Total number of mining-related fatalities |
0 |
During the three months and year ended March 31, 2011, we did not receive written notice from
the MSHA of (i) a pattern of violations of mandatory health or safety standards that are of such
nature as could have significantly and substantially contributed to the cause and effect of mine
health or safety hazards under Section 104(e) of the Mine Act, or (ii) the potential to have such a
pattern with respect to our sole rare earth mine located at Mountain Pass, California.
As of March 31, 2011, we had one pending legal action before the Federal Mine Safety and
Health Review Commission involving our sole rare earth mine at Mountain Pass, California. On June
24, 2010, we filed a Notice to Contest Citation with the Federal Mine Safety and Health Review
Commission pursuant to Section 105(d) of the Mine Act to contest a modification to a citation that
was issued after we had paid the penalty assessment due on such citation. MSHA filed an answer on
August 24, 2010, claiming that the citation was properly issued. The matter is still pending before
the Federal Mine Safety and Health Review Commission.
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ITEM 6. | EXHIBITS |
Except as otherwise noted, the following exhibits are furnished with this Quarterly Report on
Form 10-Q:
Exhibit | ||||
Number | Description | |||
2.1 | Stock Purchase Agreement, dated as of April 1, 2011, by and among Molycorp, Inc., Molycorp Minerals, LLC and
Aktsiaselts Silmet Grupp (filed as Exhibit 2.1 to Molycorp, Inc.s Current Report on Form 8-K filed on April 7,
2011 (File No. 00134827) and incorporated herein by reference) |
|||
2.2 | Stock Purchase Agreement, dated as of April 1, 2011, by and between Molycorp Minerals, LLC and Treibacher
Industrie AG (filed as Exhibit 2.2 to Molycorp, Inc.s Current Report on Form 8-K filed on April 7, 2011 (File
No. 00134827) and incorporated herein by reference) |
|||
3.1 | Amended and Restated Certificate of Incorporation of Molycorp, Inc., dated as of August 3, 2010 (filed as Exhibit
3.1 to Molycorp, Inc.s Current Report on Form 8-K filed on August 6, 2010 (File No. 00134827) and incorporated
herein by reference) |
|||
3.2 | Bylaws of Molycorp, Inc., amended as of August 3, 2010 (filed as Exhibit 3.2 to Molycorp, Inc.s Current Report
on Form 8-K filed on August 6, 2010 (File No. 00134827) and incorporated herein by reference) |
|||
10.1 | Summary of Molycorp, Inc. 2011 Annual Incentive Plan (filed as Exhibit 10.1 to Molycorp, Inc.s Current Report on
Form 8-K filed on January 19, 2011 (File No. 00134827) and incorporated herein by reference) |
|||
10.2 | Executive Employment Agreement, dated January 24, 2011, between Molycorp, Inc. and John K. Bassett (filed as
Exhibit 10.26 to Molycorp, Inc.s Registration Statement on Form S-1 filed with the Securities and Exchange
Commission on February 7, 2011 (Registration No. 333-171827) and incorporated by reference) |
|||
10.3 | Change Order to Purchase Agreement, dated as of February 28, 2011, between Molycorp Minerals, LLC and Quinn
Process Equipment Co. (filed as Exhibit 10.27 to Molycorp, Inc.s Annual Report on Form 10-K filed on March 9,
2011 (File No. 00134827) and incorporated herein by reference) |
|||
31.1 | * | Certification of Chief Executive Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 |
||
31.2 | * | Certification of Chief Financial Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 |
||
32.1 | ** | Certification pursuant to U.S.C. Section 1350 as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002 |
* | Filed with this Quarterly Report on Form 10-Q. | |
** | Furnished with this Quarterly Report on Form 10-Q. |
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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 hereunto duly authorized.
MOLYCORP, INC. |
||||
May 10, 2011 | By: | /s/ Mark A. Smith | ||
Mark A. Smith | ||||
President and Chief Executive Officer (Authorized Officer) |
||||
May 10, 2011 | By: | /s/ James S. Allen | ||
James S. Allen | ||||
Chief Financial Officer and Treasurer (Principal Financial Officer) |
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EXHIBIT INDEX
Exhibit | ||||
Number | Description | |||
2.1 | Stock Purchase Agreement, dated as of April 1, 2011, by and among Molycorp, Inc., Molycorp Minerals, LLC and
Aktsiaselts Silmet Grupp (filed as Exhibit 2.1 to Molycorp, Inc.s Current Report on Form 8-K filed on April 7,
2011 (File No. 00134827) and incorporated herein by reference) |
|||
2.2 | Stock Purchase Agreement, dated as of April 1, 2011, by and between Molycorp Minerals, LLC and Treibacher
Industrie AG (filed as Exhibit 2.2 to Molycorp, Inc.s Current Report on Form 8-K filed on April 7, 2011 (File
No. 00134827) and incorporated herein by reference) |
|||
3.1 | Amended and Restated Certificate of Incorporation of Molycorp, Inc., dated as of August 3, 2010 (filed as Exhibit
3.1 to Molycorp, Inc.s Current Report on Form 8-K filed on August 6, 2010 (File No. 00134827) and incorporated
herein by reference) |
|||
3.2 | Bylaws of Molycorp, Inc., amended as of August 3, 2010 (filed as Exhibit 3.2 to Molycorp, Inc.s Current Report
on Form 8-K filed on August 6, 2010 (File No. 00134827) and incorporated herein by reference) |
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10.1 | Summary of Molycorp, Inc. 2011 Annual Incentive Plan (filed as Exhibit 10.1 to Molycorp, Inc.s Current Report on
Form 8-K filed on January 19, 2011 (File No. 00134827) and incorporated herein by reference) |
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10.2 | Executive Employment Agreement, dated January 24, 2011, between Molycorp, Inc. and John K. Bassett (filed as
Exhibit 10.26 to Molycorp, Inc.s Registration Statement on Form S-1 filed with the Securities and Exchange
Commission on February 7, 2011 (Registration No. 333-171827) and incorporated by reference) |
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10.3 | Change Order to Purchase Agreement, dated as of February 28, 2011, between Molycorp Minerals, LLC and Quinn
Process Equipment Co. (filed as Exhibit 10.27 to Molycorp, Inc.s Annual Report on Form 10-K filed on March 9,
2011 (File No. 00134827) and incorporated herein by reference) |
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31.1 | * | Certification of Chief Executive Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 |
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31.2 | * | Certification of Chief Financial Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 |
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32.1 | ** | Certification pursuant to U.S.C. Section 1350 as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002 |
* | Filed with this Quarterly Report on Form 10-Q. | |
** | Furnished with this Quarterly Report on Form 10-Q. |
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