Sunday, July 21, 2013

Establishing a Marble City near Chinese Border


Establishing A Marble City Near Chinese Border

1.     Introduction

This investment project envisages creation of a marble city upstream of Atta Abad Lake, in Hunza-Nagar District, Gilgit-Baltsitan (GB), closer to Pak-China border for export. The project is designed to capture value from proven marble resources and low cost hydropower potential, by exporting processed and semi-processed marble to China.
2.     Project location and justification
Gojal or Upper Hunza forms Pakistan’s northern most borders with Afghanistan and China. Until Attabad disaster[1], Gojal had been developing at a rapid pace and was known as a role model community for its social and economic progress and environmental awareness. The local economy was driven by the Dry Port at Sost, border trade with China, international trophy hunting, community share in the entrance fees to Khunjarab National Park, and tourism and transportation services on KKH. People in Gojal, with the highest education rates in the country, were also the early adopters of new agricultural technologies and the largest suppliers of high quality seed potatoes in Pakistan.
The economic basis of this area has suddenly failed, due to a single natural occurrence, the Attabad landslide and the formation of the Lake. The new costs and risks associated with trans-shipping and handling of bulky goods like potatoes and heavy consignments of consumer goods imported from China over the lake, have reduced incentives for border and local trade. As a result, all economic activities have come to a standstill. According to a recent survey, many people are leaving the area, and the remaining reverting back to their traditional pastoral way of life. Access to Gojal is difficult from the downstream of the lake, especially during winters when sub zero temperatures meet notoriously chilly winds, and the lake freezes in different degrees and densities, making travel and trade even more costly and risky.
The Chinese government is providing food and fuel aid to the entire population of 25,000 for the last three years at the request of GoP. The Chinese government is more likely to invest in the area and ease trade restrictions, rather than continue these subsidies. The Chinese Government has offered to realign the KKH above the lake water level, estimated to cost around PKR 3 billion. Under a previous agreement between the two governments, the Chinese are upgrading the KKH from the Khunjarab border to Raikot Bridge, near Chilas in the first phase of a full KKH up-gradation plan.
The Chinese Government is taking active steps to develop its remote western border areas. It has established a free trade zone at Taxghorghan, near the Khunjarab border and has opened a new trade route with Tajikistan close to Pakistan border.
Strengths:
-    Proximity with large market in China
-    Availability of good quality marble and water for hydropower
Opportunities:
-    Literate workforce and social capital
-    Potential for energy- intensive productive uses
-    Accessing hi-end technology and export markets
Weaknesses:
-    Lack of energy, skills and technology
-    Lack of investment capital
Threats (under current scenario):
-    Unemployment
-    Outmigration
In the long-term, these border areas of Pakistan, China and Tajikistan are expected to be important staging and transiting posts for trade and commerce at the cross roads of Asia along the ancient Silk Route, needing services in trade, travel and commerce. The Chinese government is investing heavily in developing infrastructure on its side of the border region. However, Pakistan has been slow to develop the potential of its border areas, despite having rich mineral resources, including dimension stone, which have a huge demand in China.
Border trade through Khujrab Pass is currently only a fraction of the total trade between China and Pakistan, and it is one-sided. Pakistan hardly exports anything to China, and local fruit such as fresh cherries which have good demand in China are difficult to export to China, because Pakistan does not have quarantine and certification facilities on its side of the border. Despite many complexities involved in exporting anything to China, there are some good opportunities. For instance, marble, onyx and granite are potential value added export products for middle class consumers in China.
A recent survey conducted by an NGO in Gojal has identified the following inventory of resources that can be developed through a combination of community engagement, technology transfer, and public and private sector investments.
Resource
Location
Area/
Capcity
Soft stone:
Marble, (white, back, grey)
Passu, Khyber and Murkhun.
400 sq km
Soft Stone: Granite and soap stone
Gulmit,  Hussaini, Ghulkin
200 sq km
Gold zone
Shimshal
1000 sq km
Rare earth materials
Chiporsan
800 sq km

Hydropower
 Murkhun  Ghalpan, Khyber)

250 kva

Misgar source
(Misgar, Chiporsan, khudabad)

2 MW
1 MW
Passu Hussaini, Ghulkin, gulmit
10 MW

Shishkat Source: Shishkat, sarat,
300 KVA
Business parks/
Growth pools
Murkhun Business park
200 kanal land
Passu Business parks
300 kanal land
Source: AKRSP Survey, 2012

3.     Establishing a model marble quarry

Around the world the natural stone industry is growing rapidly. Since the beginning of the 1990s, production has risen annually by an average 7.3% and international trade has even increased by an average 8.7%. Worldwide natural stone extraction is meanwhile estimated at 150 million tons gross per year. Annual production after deduction of waste and cutting losses amounts to about 820 million square-meters. The total production value is estimated at USD 40 billion.
The majority of world consumption comes from material that is quarried in different countries than those where it is eventually installed. The leading producers—China, India, Italy, Spain and Portugal account for 53% of world quarrying production.
Dimensional stone is one of the key raw resources of Pakistan. According to national estimates Pakistan has over 297 billion tons of marble and granite reserves and more than 100 types of colors and verities of marble and granite are available. However, rising cost of energy, low quality of skills and technology are key barriers on development. As a result, this sector contributes less than half a percent to Pakistan’s GNP.
Marble industry in Pakistan is seeing a renaissance in recent years, thanks to a number of donor-funded projects aimed at technology transfer and skill development. Marble exports reached a record level in 2011 with an export value of USD 60.620 million. The annual average exports of marble and granite mostly in the form of blocks and boulders was around USD 22 million during 2005-06 to 2007-08. Since 2008-09, square blocks have constituted the bulk of exports, resulting in an increase of USD 35 million. The continuing improvement in export value has been the result of investments in new technology by many small companies, facilitated by Pakistan Stone Development Corporation (PASDEC), a state and donor supported company specialized in technology and skill development.
Although detailed surveys are not available, a significant part of marble and granite deposits are believed to be located in the mountain areas of northern Pakistan, including, FATA, KPK and GB. Estimates of deposits in these areas include 87% marble, 1% Granite and 12% slate. There are wide varieties of dimensional stone with huge reserves.
While little formal research exists on the quantum, quality and value of this resource in GBC, private Pakistani and Chinese companies, already scouring the area for mineral resources, have reportedly found some high quality deposits at various locations in GBC. Private sector estimates have indicated the availability of 414 million ton of marketable granite reserves in GB alone[2]. Actual deposits of marble, onyx and granite with multiple shades can be manifold. GB’s marble has been used in the refurbishing of Lahore Marriott, and experts have rated its quality to be high.
In lower Chitral, which is closer to main markets in Pakistan, marble quarrying is an established industry. However, the low-tech operations result in high quarry wastage ranging from 60-80% in addition to poor quality, mainly due to unwieldy blasting techniques, and production of lumps rather than blocks. For instance, raw marble supplied from Chitral fetches USD 40/t, while finished marble slabs exported by processing industry to USA get USD 466/t. Value is also lost by non-transparent practices, such as black marketing of lease permits, which are then sold to genuine investors for higher prices.
In GB, small quarrying operations have sprouted in recent years and some already failed. This is consistent with global and national experience, which suggests that dimensional stone as a commodity faces tough competition, especially because of high transportation costs over long distances. Raw material is available in huge quantities in most countries. The winners are those who employ new technology and go for value added production.
3.1  Opportunity rationale
The basic rationale is availability, variety and good quality of deposits, and potential availability of low cost renewable energy in GBC, especially in the long-term. However, these reasons alone may not be enough to justify investment. Other attributes must be added to make a value proposition. Value addition will be the key, and GBC can further refine its business model by specializing in fair and environmentally sensitive production and trade practices, and branding.
Proximity to China gives potential access to a large and growing market. China has a soft corner for GBC for historical and strategic reasons, and is likely to provide market access for semi-processed goods, such as marble and granite. Pakistan already has a captive market in China and it is currently negotiating with the Chinese government to include semi-processed marble and granite in the zero tariff list of their bilateral trade agreement.
The neighbouring Xinjiang Region of China is developing rapidly with rising demand for good quality marble. Overland transportation to China is also cheap, as containers bringing goods to Sost Dry Port, mostly go back empty[3]. The overland distance between Sost and Kashghar is just 450 km, and KKH is upgraded on both side of the border, while the sea route between Karachi and Chinese ports is 10,000 nautical miles. The energy advantage of GBC is further boosted by chronic shortages and rising cost of energy in the mainland Pakistan.
3.2  Business description and marketing strategy
The proposal is to create a model quarry for marble at a suitable and accessible location in Gojal, The product mix includes marble cubes and slabs in the initial phase, with more refine products being included after detailed market research. Waste material and coloured stones abundantly available in the area, will be used to make attractive mosaic products as a home-based cottage industry for women.
Wastage is the main efficiency factor in marble industry. Blasting results in 50% of the waste at source and another 30% during subsequent processing. Blasting also kills the entire quarry after a few years, by causing micro fractures. The business will follow best industry practices and employ high-end technology imported from China, and skilled workers also from China, who will train educated local youth, both men and women. PASDEC would be approached for technical support, training and certification. A professional firm would be hired for brand development.
The marketing strategy is to establish an auction market at Sost, near the Dry Port, which is frequented by Chinese business people. An open bidding method for both the product and transportation will keep the market fair and transparent. Other suppliers from different parts of GBC will also use the auction market, thus contributing to the bottom-line. Eventually, the auction market can also include other commodities, such as iron ore, copper, antimony, etc, in upgraded form.
Local communities, represented by their LSOs will be included as equity partners. However, the business would be professionally managed as a private company, not as a cooperative. Other potential investors may include PASDEC and the Government of GB.
3.3  Cost-benefit analysis
Energy input
Developing hydropower in isolated and off-grid areas is challenging on at least two accounts. Firstly, the upfront investment cost is high and the level of utilization or Plant Load Factor is substantially lower in an off-grid environment. Still, the cost of hydropower for productive uses is much cheaper, compared to diesel, which the other option, and provides the overall justification for investment.
Tables 3 A & B provide comparison of energy input and cost of hydroelectricity and diesel for marble quarrying and processing.
Energy Type
Quarrying (per ton)
Processing (per ton)
Diesel
2.8 liters
10 liters
Electricity
5.71 kWh
100 kWh
Energy Type
Quarrying (PKR/ ton)
Processing (PKR/ ton)
Diesel @110/ltr
308
1,100
Electricity @ 7.2 kWh
41
720
Source: Ibid. Cost of diesel and hydroelectricity changed to local prices from the original model.
Energy production
Start Year
2013
Capacity (MW)
1.00
Max Annual Energy (GWh)
 8.76
Actual Annual Energy (GWh)
 3.50
Plant Life (years)
30
Plant Load Factor
40%
The capital cost of building a 1 MW plant in the Gojal cluster is PKR 192 m. With a plant load factor of 40%, the total energy available will be an estimated 3.5 GWh per year. Energy consumption for targeted marble extraction and processing will be 280,000 kWh or about 8% in year one, and stabilize at 945,000 kWh, or 27% from year five. Other commercial uses are expected to account for an average of 50% over the plant life, and the leftover will be used for domestic purposes.
Tariff rates are assumed as PKR 7.2 per kWh for commercial users and PKR 3.5 for domestic consumption, respectively, with a 5% annual inflation from year two.
Marble production and processing unit
The main productive use renewable energy investment proposal is creating a model quarry and processing unit in Gojal area, close to the border, targeting production at export market in China. The quarry will employ state of the art technology, and produce 5,000 ton of blocks in year one, double this capacity in year two, and increase production by 20% every year until year five.
Fifty per cent of the blocks will be directly sold in the proposed auction market at Sost, the border town, while the other 50% will be further processed into slabs. The price for one ton of block is assumed at PKR 7,680 (US$80), while the price per meter square of 3 cm slab is taken as PKR 2,400 (US$ 25), with 7% increase per annum. Depreciation is taken as 10% per annual.
Technical support in establishing the model quarry, including selection of technology for extraction and processing, will have to be arranged from PASDEC, either as an equity partner, or as public sector support, which is part of its mandate.
Capital Expenditure
The total capital investment required for quarry and processing unit is PKR 193 m, or slightly above USD 2 m, as detailed in Annexes 1-2
Profit and loss (income statement)
Gross revenue from the sale of blocks is PKR 19.2 m, and slabs PKR 58.8 m, or a total of PKR 78 m, in year one. Gross revenue reaches PKR 353.35 m, by year five, and PKR 496 m in year ten. Operating expenses for both products amount to PKR 29.52 in year one and PKR 75.2 m in year five.
Earning before interest and taxes (EBIT) is PKR 31.2 m and PKR 206.7, for year 1 and five, respectively. Net income is PKR 17.2 in year one, and PKR 159.69 in year five.
Profit margin is 22% in year one and 45% in year five. Details on income and expenses for five years are detailed in Table 25. Profit margin is expected to reach 50% and taper off from year 10. Internal rate of return (IRR) is 6% in year 3, and reaches 70% in year ten.
Calculations on profit and loss and IRR for the full ten-year life of the investment are provided in Annexes.
4      Next steps
·      Undertake detailed survey of identified sites, estimate reserves, test quality and variety, and send samples to potential buyers
·      Select model quarry location, and design appropriate infrastructure, office and processing facilities
·      Develop a PC1 and a detailed business plan, explore financing options, and explore export market in China



ANNEXURES
ANNEX 1: Marble Quarry and Processing Unit - Profit & Loss (Income Statement)
Quantities
UoM
Unit Cost /Price
Year 1
Year 2
Year 3
Year 4
Year 5
Blocks
Ton
 2,500
 5,000
 6,000
 7,200
 8,640
Slabs
Sq. meter
 24,500
 49,000
 58,800
 70,560
 84,672
Revenues
Blocks
Ton
 7,680.00
19,200,000
 41,088,000
 52,756,992
 67,739,978
 86,978,131
Slabs
Sq. meter
 2,400.00
58,800,000
125,832,000
161,568,288
207,453,682
266,370,527
Gross Revenues
78,000,000
166,920,000
214,325,280
275,193,660
353,348,659
Costs – Quarry
Labour
Per ton
 960.00
 2,400,000
 5,040,000
 6,350,400
 8,001,504
 10,081,895
Royalty
Per ton
 768.00
 3,840,000
 8,064,000
 10,160,640
 12,802,406
 16,131,032
Energy Cost
Per ton
 41.11
 205,560
 431,676
 543,912
 685,329
 863,514
Spare parts & maintenance
Per ton
 576.00
 1,440,000
 3,024,000
 3,810,240
 4,800,902
 6,049,137
Depreciation
Capital Cost
10%
 7,393,728
 7,393,728
 7,393,728
 7,393,728
 7,393,728
Costs - Slab Processing
Labour
Per sq. meter
 92.16
 2,257,920
 4,741,632
 5,974,456
 7,527,815
 9,485,047
Energy Cost
Per sq. meter
 58.78
 1,800,000
 3,780,000
 4,762,800
 6,001,128
 7,561,421
Maintenance & Spares
Per sq. meter
 50.88
 1,246,560
 2,617,776
 3,298,398
 4,155,981
 5,236,536
Abrasives (for polishing)
Per sq. meter
 28.80
 705,600
 1,481,760
 1,867,018
 2,352,442
 2,964,077
Packaging
Per sq. meter
 19.20
 470,400
 987,840
 1,244,678
 1,568,295
 1,976,051
Depreciation
Capital Cost
10%
 7,756,800
 7,756,800
 7,756,800
 7,756,800
 7,756,800
Operating Expenses
29,516,568
 45,319,212
 53,163,070
 63,046,331
 75,499,239
Transportation – Quarry
Per ton
 384.00
 1,920,000
 3,840,000
 4,608,000
 5,529,600
 6,635,520
Transportation - Slab Processing
Per sq. meter
 626.94
15,360,000
 32,256,000
 40,642,560
 51,209,626
 64,524,128
EBIT
31,203,432
 85,504,788
115,911,650
155,408,103
206,689,771
Interest Expense – Quarry
 4,824,864
 4,556,496
 4,254,583
 3,914,930
 3,532,821
Interest Expense - Slab Processing


 4,838,400
 4,569,280
 4,266,519
 3,925,914
 3,542,732
EBT
21,540,168
 76,379,012
107,390,548
147,567,259
199,614,218
Taxes (20%

20%
 4,308,034
 15,275,802
 21,478,110
 29,513,452
 39,922,844
Net Income
17,232,134
 61,103,210
 85,912,438
118,053,807
159,691,374
Profit Margin
22%
37%
40%
43%
45%
Prices are taken from prevailing market rates.


COSTS – QUARRY
UoM
$
PKR
Year 1
Year 2
Year 3
Year 4
Year 5
Labor
Per ton
10
960
960
1,008
1,058
1,111
1,166
Royalty
Per ton
8
768.00
768
806.40
846.72
889.06
933.51
Energy Cost
Per ton
0.43
41.11
41
43.17
45.33
47.59
49.97
Spare parts & maintenance
Per ton
6
576
576
605
635
667
700
Depreciation
Capital Cost
10%
Transportation
Per ton
4
384
384
384
384
384
384
Taxes
EBT
20%
Inflation per annum
5%
COSTS – PROCESSING
Labor
Per sq. meter
0.96
92
92
97
102
107
112
Royalty
Energy Cost
Per sq. meter
0.61
59
59
62
65
68
71
Spare parts & maintenance
Per sq. meter
0.53
51
51
53
56
59
62
Depreciation
Capital Cost
10%
Transportation
Per sq. meter
6.53
623
627
658
691
726
762
Abrasives (for polishing)
Per sq. meter
0.30
29
29
30
32
33
35
Packaging
Per sq. meter
0.20
19
19
20
21
22
23
Taxes
EBT
20%
Inflation per year
5%
Quantities
Blocks
Ton
5000
10,000
12,000
14,400
17,280
Increase per annum
20%
20%
20%
20%
0%
Block Sale
50%
2,500
5,000
6,000
7,200
8,640
Transferred to Slab Processing
50%
2,500
5,000
6,000.00
7,200
8,640
Price
80
7,680
7,680
8,218
8,793
9,408
10,067
Increase per annum
7%
Slab (Sq. meter) Calculation
Per ton
12.25
30,625
61,250
73,500
88,200
105,840
Processing Loss
20%
20%
20%
0.20
20%
20%
Net Output
24,500
49,000
58,800
70,560
84,672
Price / sq. meter
25
2,400
2,400
2,568
2,748
2,940
3,146
Increase per annum
7%
Exchange Rate
96
ENERGY REQUIREMENTS
Quarry
kWh
28,550
57,100
68,520
82,224
98,669
Processing
kWh
250,000
500,000
600,000
720,000
864,000
Total Energy Requirement (kWh)
kWh
278,550
557,100
668,520
802,224
962,669

Annex 3: Marble Production and Processing - Capital Expenditure
Description 
Unit/#
USD
PKR
Electric Air compressor 750cfm @135psi
1
23,000
2,208,000
Drilling and cutting set
2
320,000
30,720,000
6" high pressure water pump
2
32,000
3,072,000
3" high pressure water pump
2
15,000
1,440,000
50000 liter steel water tank
1
9,000
864,000
6" steel pipes with fittings
2500 meters
79,680
7,649,280
3" steel pipes with fittings
1500 meters
31,500
3,024,000
60 ton crawler crane w/ 60' boom
1
160,000
15,360,000
Cat 977 pay loader
1
98,000
9,408,000
Flood lights
6
2,000
192,000
Total equipment cost – Quarry

770,180
73,937,280
Land (m2) 5000
5000
10000
960,000
Building (m2) 750
750
100,000
9,600,000
Carts for stone 10
10
10000
960,000
Tracks (meters) 100
100
10,000
960,000
Wheeled crane 40 tons 1
1
40,000
3,840,000
Total Infrastructure cost - Slab Processing Plant

 170,000
 16,320,000
Gang saw (70-80 blades) 1
1
300,000
28,800,000
Slab Polishing line 1
1
150,000
14,400,000
Multiblade disc cutter 1
1
40,000
3,840,000
Mono blade block cutting machine 1
1
40,000
3,840,000
250 KVA generator 1
1
50,000
4,800,000
Equipment installation (10% of cost)

58,000
5,568,000
Total equipment cost – Processing

638,000
 61,248,000
Road improvements – Quarry

35,000
 3,360,000
Working Capital- Quarry

200,000
19,200,000
Working Capital- Processing

200,000
19,200,000
Working Capital

400,000
38,400,000
Total cost

2,013,180
193,265,280
Source: Pakistan Stone Development Company (PASDEC).



[1] On January 4, 2010, a landslide destroyed several villages, blocked the Hunza River and formed a 22-km Lake, submerging many more villages and sections of KKH, this cutting off Gojal from the rest of Hunza. The disaster remains unmitigated despite many attempts and many hundred millions of rupees to unblock the river and drain the lake. It will take several years and billions of rupees to realign the KKH.
[2] 2nd Segmite International Conference Report. 1994 pp35-43

[3] Currently, there are grey areas with regard to haulage