Operations - Environmental Technologies
 
 
Half Year to 30th September
  %
  2009
£ million
2008
£ million
%
change
at constant
rates
line
Revenue 919 1,316 -30 -35
Sales excl. precious metals 564 596 -5 -12
Underlying operating profit 54.5 77.8 -30 -36
line
 
Environmental Technologies Division, which comprises Emission Control Technologies (ECT), Process Technologies and Fuel Cells, was particularly impacted by the global slowdown in automotive sales and as a result revenue decreased by 30% to £919 million. Sales excluding precious metals were 5% down at £564 million and underlying operating profit was 30% lower at £54.5 million. Translated at constant exchange rates, sales excluding precious metals decreased by 12% and operating profit was down 36%.

Emission Control Technologies’ sales excluding precious metals fell by 7% to £440 million. At constant exchange rates the decrease was 15%. This reduction was primarily due to lower sales of autocatalysts across North America and Europe and significantly lower sales of heavy duty diesel (HDD) catalysts. Autocatalyst sales in Asia were slightly lower, with a substantial decrease in Japan partly offset by continued very strong growth in China. Diesel particulate filter sales were slightly up on the first half of last year as their fitment to diesel cars in Europe continued to increase.

Return on sales (underlying operating profit / sales excluding precious metals) for ECT was significantly lower than in the first half of last year as a result of this fall in demand.

Global light duty vehicle sales fell by 5.4% in the six months to 30th September 2009 compared to the equivalent period last year. Sales fell by 22% in North America and 13% in Europe, where the most dramatic decline was 43% in Eastern Europe. However, sales in Asia grew by almost 26% with strong growth in China, up 55%, and India, 14% ahead, more than offsetting a 9% fall in sales in Japan. In Western Europe, sales of diesel engined cars were lower than those of cars fitted with petrol engines for the first time since 2005. This is likely to be due to the effect of government scrappage schemes that encouraged sales of smaller engined vehicles, where the economic benefits of diesel engines are less attractive, and de-stocking by the manufacturers, who had built up stocks of mainly petrol engined vehicles and offered better deals on them.

Global light duty vehicle production was 16% down in our first half, with all regions below the same period last year. North America was 36% down and Europe was almost 23% lower, reflecting major de-stocking by the vehicle manufacturers. Even Asia was down 2% with 42% growth in production in China and 15% growth in India failing to totally offset a 32% fall in production in Japan.

 
Estimated Light Duty Vehicle Sales and Production
 
      Half Year to 30th September  
      2009
millions
2008
millions
change
     


North America Sales   6.8 8.7 -21.8%
  Production   4.1 6.4 -35.9%
           
Europe Sales   9.4 10.8 -13.0%
  Production   8.6 11.1 -22.5%
           
Asia Sales   10.8 8.6 +25.6%
  Production   13.4 13.7 -2.2%
           
Global Sales   31.5 33.3 -5.4%
  Production   29.4 35.0 -16.0%
     


Source: IHS Global Insight
 
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As expected, ECT’s light duty catalyst business, which represents just under 80% of ECT’s sales excluding precious metals, was directly impacted by this reduction in vehicle production. Our light duty unit sales in North America and Europe fell broadly in line with overall vehicle production. Business in North America started the financial year slowly as reduced vehicle demand and de-stocking continued. However, US Government incentives, the so-called “Cash for Clunkers” scheme, resulted in a gradual improvement in sales through the summer months. Europe also had a slow start but autocatalyst sales have picked up on the back of government incentive schemes and in September our unit sales were ahead of the same period last year, the first time in 12 months. Sales in Asia have held up well on the back of increased demand in China, which also benefited from government incentives that are due to expire in December 2009. We are continuing to gain market share in China and in total Asia now accounts for approximately 16% of our light duty sales.

We are nearing completion of the first phase of our new, highly efficient production facility in Macedonia. Shipments from this facility commenced in October. Once fully commissioned, it will have the capacity to manufacture four million light duty catalysts per year. However, the site also gives us flexibility to expand production further if required.

Sales of HDD vehicles are historically more volatile than those of light duty vehicles as haulage and construction companies respond more rapidly to changes in the economic environment and adjust levels of investment accordingly. In addition, there have been no government incentive programmes for HDD vehicles and as a result vehicle sales fell significantly in both North America and Europe. Furthermore, whilst new, much tighter HDD legislation comes into force from 1st January 2010 in North America, there was no evidence of the anticipated “pre-buy” in the half year where vehicles are purchased ahead of the implementation of new legislation to avoid additional cost. Our unit sales of HDD catalysts in the period to 30th September were down approximately 55% on those in the first half of last year. Sales excluding precious metals of HDD catalysts fell accordingly and as a result represented some 17% of ECT’s total. While still early days, sales in October were, however, a little more encouraging.

 
Estimated HDD Truck Sales and Production
 
      Half Year to 30th September  
      2009
thousands
2008
thousands
change
     


North America Sales   117.1 201.3 -41.8%
  Production   106.1 200.8 -47.2%
           
Europe Sales   100.1 206.7 -51.6%
  Production   86.7 297.6 -70.9%
     


Source: JD Power
 

Despite the short term difficulties in the HDD market, we have recently commissioned our new HDD catalysts manufacturing plant in Smithfield, Pennsylvania, USA and are well positioned to benefit from future recovery in this market. The market for HDD catalysts is expected to show substantial growth over the next decade driven by tightening legislation in the developed markets of North America, Europe and Japan, the spread of legislation to developing markets, such as China, India and Brazil, and legislation covering non-road vehicles in Europe and North America which starts in 2011. We still believe that, after allowing for the impact of a sustained economic downturn, the market for HDD catalysts will grow to about US $2.5 billion in sales excluding the value of precious metals by the end of 2014.

Our Stationary Emissions Control (SEC) business, which includes our Powerplants business that manufactures catalysts used to reduce emissions of oxides of nitrogen (NOx) from power stations, has been impacted by a reduction in demand in the first half. This is due to our customers, in both China and the USA, delaying projects as they experienced lower demand for electricity due to the recession.

In October the group made a small bolt-on acquisition in this area, purchasing the assets of Applied Utility Systems Inc. for up to US $10 million. This acquisition complements our existing NOx emission control business and will enable us to expand the range of applications that we serve.

Process Technologies’ sales excluding precious metals were 1% higher than in the first half of the last financial year. At constant exchange rates sales decreased by 2%. While the long term fundamentals for our Process Technologies businesses remain strong, the current economic environment has resulted in a number of projects experiencing short term delays which have impacted the results of the business in the first half.

Within our Ammonia, Methanol, Oil and Gas business (AMOG), the ammonia and methanol markets have remained robust with continued investment in capacity, particularly in China and the Middle East. Demand for methanol catalysts continues to grow, partly due to the increasing use of methanol in transportation fuels in China. This is enabling the country to use its enormous coal reserves to reduce the amount of oil that it has to import. Investment has also continued in synthesis gas projects in the Middle East where we have seen expansion in ammonia production capacity to meet demand from fertiliser manufacturing. However, demand from oil refineries was significantly weaker than in the first half of last year, reflecting lower demand for transportation fuels, heating oil and gas as industrial activity contracted around the world.

The group’s investment in the expansion of our site at Clitheroe in the UK to manufacture the latest generation of syngas catalysts is nearing completion with final commissioning now underway. The initial launch of the new range of catalysts produced in this facility was made to the methanol industry in June and generated a great deal of customer enthusiasm about the benefits that they deliver. These new products reinforce our leading position in the market for methanol catalysts and technology and we are confident that sales will have a positive impact in 2010.

Davy Process Technology, which develops and licenses chemical processes, has had another good first half. Demand in China has been the key driver and during the first six months we have agreed two new licensing contracts in China and one in the USA.

In our Fuel Cells business, sales excluding precious metals, although still modest, have continued to grow in particular for natural gas powered fuel cells used in combined heat and power applications in large buildings and for portable power applications. However, Fuel Cells’ growth has been adversely impacted by the effects of the economic environment on some of our smaller customers.

 
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