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Reynolds Metals Company (1928-2000)

- File

Bauxite mining in St. Elizabeth, viewed in 1980 by David Reynolds (in silhouette), chairman of Reynolds Metal Company. He toured the Alpart plant as part of his visit for talks with the Government on a $100 million development programme for Alpart, a consortium of Reynolds, Kaiser and Anaconda.

Carlton Davis, Contributor

The announcement on May 3, 2000 that the United States Department of Justice and the European Union had approved the acquisition of Reynolds' assets by Alcoa, and the de-listing of the former from the New York Stock Exchange marked the demise of what had hitherto been one of the six great transnational aluminium companies for most of the period since the Second World War, and which through two of its subsidiaries, was a significant producer of bauxite and aluminia in Jamaica.

As I have written in detail elsewhere, the predecessor to the Reynolds Metals Company was the United Foil Company which Richard Reynolds founded in December 1919 at Louisville, Kentucky. United Foil's principal activity was the production of lead and tin foil for the packaging of tobacco, an industry in which Richard Reynolds's uncle, R.T. Reynolds was established. The company began to produce aluminium foil in 1926, reportedly because it was finer and of better appearance than the tin and lead foil. Its name was changed in 1928 to Reynolds Metals Company which embarked upon a decade of growth. The headquarters which was transferred from Louisville to New York in 1936, was transferred permanently to Richmond, Virginia in 1938.

The Second World War and, in particular, the U.S.'s role in it used to have a major impact on, among other things, increased demand for aluminium.

Richard Reynolds foresaw the entry of the U. S. in the conflict and the role which the metal would play in it, and along with others, worked ceaselessly to ensure a greater role for Reynolds in the aluminium industry.

The War was to stimulate great demand for aluminium for aircraft manufacture, tanks and automotive parts, ordinance, packaging, barracks, bridges, etc. The United States for example, produced 278,000 military aircraft using some 1.5 million tonnes of aluminium between 1942 and 1945. By way of comparison, in 1939, the year when the war in Europe started, production was just over 2,000 aircraft.

Beginning

The beginning of this mobilisation was the call by President F.D. Roosevelt, in August 1940, for the production of some 50,000 planes per year. Following this call, he created the National Defence Advisory Commission (NDAC) ­ the first of several control agencies established between 1940 and 1945 to direct the country's production effort. In respect of aluminium, it invested some US$739 million (of course, worth several times that amount in today's terms) in a number of facilities, including two alumina plants (which were subsequently to be supplied, wholly or in part by bauxite from Jamaica); nine aluminium smelters; and a number of fabrication facilities.

Despite this huge investment by the U.S. Government, Alcoa, one of the founders of the modern aluminium industry (as the Pittsburgh Reduction Company in 1888) by virtue of being holders of the patent for reduction of the metal from its oxide, still dominated aluminium production in the United States, as almost all the plants constructed by the Government were operated by that company.

Richard Reynolds tried to break Alcoa's dominance by seeking the sponsorship of the NDAC to build a primary aluminium facility, but was unsuccessful. However, he persisted, and through the intervention of Senator Lister Hill of Alabama, the company obtained a loan of US$20 million in August 1940 to construct smelters at Listerhill (named after the Senator, it was said, as a "thank you") Alabama, and Longview, Washington for US$15.8 million and US$4.2 million respectively.

Following the War, the U.S. Government's Surplus Property Board (authorised by the Surplus Property Act of 1944) was charged with the disposal of Government-owned property. A number of influences were brought to bear in the formulation of the Act and subsequently, the composition, operation and focus of the Board. The U.S. House of Representatives and Senate held somewhat divergent views on this matter. The House favoured a bill that would result in a speedy disposal of surplus property with the highest possible cash return to the Government, while the Senate favoured a bill that would emphasise the fostering of competition.

The view of the Senate, (and that of the Bonneville Power Administration which supplied electricity to aluminium plants, other industrial facilities, and individual homes in the Pacific Northwest) more or less prevailed. The result was that, in respect of the aluminium industry, the policy adopted by the Board required that:

  • Prospective competitors of Alcoa were to have first choice of plant and equipment;

  • Preference was to be given to bidders with the organisation experience and financial resources that afforded the greatest prospects for successful survival and maximum production in the industry;

  • Alcoa was to have an opportunity of taking over certain facilities subject to the approval of the attorney general and only under conditions which would give it no competitive advantage.

    Reynolds (as did Kaiser) eventually benefited from this arrangement. It was able to lease or purchase the Hurricane Creek, Arkansas, alumina plant, the Listerhill, Alabama, sheet mill, and the Troutdale, Oregon, smelter. Reynolds also got the right to purchase bauxite from the U.S Government's stockpile for the Hurricane Creek, Arkansas, alumina plant, and the right to the use of Alcoa's patents royalty-free at the plant. In addition, both Kaiser and itself benefited from rental terms varying from 4 per cent to 8 per cent of the fair value of the plant's capacity used over a five-year lease period and the granting of lease renewal and purchase options.

    Advances

    Despite these advances by Reynolds, an important link was missing: access to bauxite reserves. Alcoa and Alcan (which at the time were closely related), had 'shared' the bauxite reserves in the Guianas - the then known main source of economic reserves in the Western Hemisphere - Alcoa, in Dutch Guiana (later Suriname) and Alcan, in British Guiana (later Guyana).

    Reynolds clearly recognised the strategic importance of access of bauxite reserves and accordingly, from as early as November 1942, through its vice-president, Walter Rice, wrote the US Secretary of State Cordell Hull, seeking the State Department's support by linking the access by the company to Jamaican bauxite (which was positively identified by 1942, and over which Alcan especially, and Billiton of the Netherlands, had begun preliminary investigations) to the United States' strategic interests. Rice wrote, in part:

    'The combination of these huge deposits (Jamaica's) with low-cost power and the billion pound aluminium plant in Saguenay River in Canada would enable the British Empire to dominate the international aluminium markets for perhaps a hundred years, and would stifle the development of a large competitive aluminium industry in the United States... The problem is much larger than our company. Since we know of no ore discovery in recent years, of comparable strategic importance, we believe the freedom to mine and ship bauxite from Jamaica to the United States is vitally important to the industrial future of our country and our national security, and the issue cannot await the termination of the war.'

    This letter was followed by one to the U.S. Bureau of Mines, in January 1943, seeking information on the bauxite in Jamaica. The Bureau responded by giving it some information of where it believed some deposits were located, the size of the ore bodies, and the chemical characteristics.

    In the very same month, Reynolds wrote yet another letter, this time to John Huggins (later Sir John, Governor of Jamaica from 1943 to 1950), who was then with the Anglo-American Commission in Washington, formally requesting the co-operation of the Jamaican Government in exploring, acquiring and mining ore.

    This was followed by a visit to Jamaica, in February 1943, by Mr. Rice and the chief geologist O.C. Schmedeman. They met with the Governor, Sir Arthur Richards during this visit, and requested equal treatment with Alcan and Billiton.

    Among other things, the Reynolds team stressed the significance of exploiting the ore for the war effort:

    Urgent

    Since it is urgent to produce high-grade bauxite in order to obtain maximum output of aluminium required for military aircraft, we would like to have permission to proceed at the earliest date.

    Sir Arthur wrote the British Secretary of State for the Colonies in March 1943 passing on Reynolds' requests, and supported the company on the grounds that it was undesirable to give Alcan a concession over the whole island. (It was clear that there was never any intention to allow Billiton to become seriously involved in the Jamaican industry, and, as it turned out, the company soon left Jamaica for good). Support was also given by U.S consular and other representatives.

    In the event, the Secretary of State for the Colonies, wired the Governor to say that the matter was referred to the Aluminium Committee of the Combined Raw Materials Board (this Board was set up after Japan's attack on Pearl Harbour on December 7, 1941, by the U.S. and U.K. Govern-ments to co-ordinate their policies in purchasing and allocating raw materials). The Board, comprised Sir Richard Fairy of the British Aluminium Company, Mr. G.C. Bateman, the Canadian Metals Controller, and Mr. C.E. Wilson, of the US War Production Board.

    Apparently, the Board gave Reynolds the 'thumbs down'. This decision was regarded as likely by Jamaican officials, because British Aluminium was closely allied with Alcan, and the Canadian Metals Controller would be hard put to go against his country's aluminium flagship, Alcan.

    Reynolds learned from U.S. Government officials in May 1943, that tests of bauxite shipped by Alcan to Alcoa's East St. Louis, Illinois, alumina plant, could not be processed by the technology that had been used to process bauxite from the United States and the Guianas. It also learned from the State Department that the Aluminium Committee of the Combined Raw Materials Board had rescinded its earlier decision in regard to their application to explore and mine bauxite in Jamaica.

    The inability to process the ore, and, in the event, the 'turning of the tide' in favour of the Allies resulted in Jamaican bauxite not being required for the war effort. So, by late 1944, all hurdles to Reynolds' participation in the Jamaican industry had been removed. Clearance was given to begin exploration, and, in November of that year, the Company secured options on 15,000 acres of land. It later purchased lands (ultimately some 60,000 acres) and undertook research on the economic processing of Jamaican ore.

    It moved to commercial operations on the bases of: (a) its ability to develop an appropriate processing technology; (b) the receipt of "Marshall Plan" Funds (as did Alcan) from the United States Economic Co-operation Administration; (c) attractive taxation regimes, both in the United States and Jamaica; (d) the stockpiling of bauxite by the U.S. Government; (e) increase in the demand for aluminium for peace time uses as well as a result of the War in Korea.

    The round of expansion to meet the Korean War effort as well as the stockpile of the metal by the U.S. Government were particularly significant in creating the need for more bauxite, alumina, and alumina capacity. One outcome of this need was the construction of the Corpus Christi, Texas alumina plant, by Reynolds to process Jamaican bauxite.

    The company established its mining facility at Lydford, St. Ann, and a port at Ocho Rios. It had the distinction of being the first exporter of commercial quantities of bauxite from Jamaica. This happened on June 5, 1952.

    Major player

    It became a major player in Jamaica's economic life in three distinct respects:

  • Mining and shipping bauxite for thirty-two unbroken years largely to Corpus Christi, Texas, until the changing circumstances in the world aluminium industry, including the worst recession in its history, resulted in the closure of the Lydford operations in December 1984;

  • Through the Alpart plant with which it shared joint ownership (first with Kaiser and Anaconda, and later when Anaconda divested its share, with Kaiser only) between 1969 and 1985.

  • As the largest beef cattle producer (mainly the famous Santa Gertrudis breed in Jamaica until it sold out to the Government of Jamaica consequent on the negotiations in the early 1970s).

    From its early full dependence on Jamaican ore, Reynolds later became a more diversified company with facilities in various parts of the world, including nearby Guyana where it mined and shipped bauxite.

    When Alcoa made its take-over bid last year, Reynolds had: (a) nearly 3 million tonnes of alumina capacity (7.5 per cent of the world's total); (b) 1.1 million tonnes of primary aluminium capacity (6 per cent of the world total); (c) 250,000 tonnes of falt-rolled product capacity (1.5 per cent of the world total; and (d) interests in extrusions, packaging, castings and secondary smelting.

    Its bauxite and alumina interests included:

  • A long term purchase agreement under which it could buy from a third party an aggregate of approximately 19 million tonnes of Australian bauxite through the year 2021;

  • A five per cent interest in the Brazilian operation, Miner-acao, Rio Do Norte SA (MRN).

  • A six per cent interest in the HALCO Inc. which in turn owns 49 per cent of Compagne des Bauxites de Guinee (CBG).

  • A 50 per cent partnership with the Government of Guyana in the Berbice region of that country.

    Although Reynolds terminated its operations in Jamaica, it was still being supplied with Jamaican bauxite from the Kaiser Jamaica Bauxite Mining operations in St. Ann. Indeed, consequent on the closure of the Gramercy plant, present operations at that mine are largely for the Reynolds, Corpus Christi, plant. The arrangement calls for the supply of some 5.4 million tonnes from 1999 through 2001.

    A condition of the merger with, or takeover of Reynolds, is that Alcoa must dispose of all of the former's alumina assets, viz: 100 per cent of the Corpus Christi, Texas, alumina plant; 5 per cent of the Stade, Germany, alumina plant; and 56 per cent of the Worsley (one of the world's best), Australia, alumina plant. Alcoa must also divest 25 per cent of the Longview, Washington smelter.

    The demise of Reynolds and the concomitant enhancement of Aloca pose some interesting opportunities and challenges for Jamaica. The opportunities lie in the prospect of Jamaica playing a larger role in Alcoa's world raw materials system. Currently (in alumina terms) the country only supplies some 4 per cent of that company's needs.

    The challenge is whether our supply of bauxite to the Corpus Christi alumina plant will be required by the new owner when the contract to supply expires at the end of 2001.

    The demise of a once-great company like Reynolds is part and parcel of the enormous transformations which are taking place in the world economy, in the great process of "globalisation".

    It is incumbent on us to understand these changes; to recognise that we are by no means immune from them; and to do all we can to be fit enough to survive with some comfort.

    Dr. Carlton Davis is Cabinet Secretary, chairman of Clarendon Alumina Production and former director of the Jamaica Bauxite Institute.

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