ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d)
For the fiscal year ended December 31, 2003
Potash Corporation of Saskatchewan Inc.
|
Canada (State or other jurisdiction of incorporation or organization) |
N/A (I.R.S. employer identification no.) |
122 1st Avenue South
Securities registered pursuant to Section 12(b) of the Act:
| Title of each class | Name of exchange on which registered | |
| Common Shares, No Par Value | New York Stock Exchange |
The Common Shares are also listed on the Toronto Stock Exchange in Canada
Securities registered pursuant to Section 12(g) of the Act: none
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 x No o
Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of the registrants knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K. x
Indicate by check mark whether the registrant is an accelerated filer (as defined in Exchange Act Rule 12b-2). Yes x No o
At June 30, 2003, the aggregate market value of the 52,183,854 Common Shares held by non-affiliates of the registrant was approximately $3,339,766,680.
At February 29, 2004, the registrant had 53,367,413 Common Shares outstanding.
DOCUMENTS INCORPORATED BY REFERENCE
Portions of the registrants Annual Report to Shareholders for the fiscal year ended December 31, 2003 (the 2003 Annual Report), filed as Exhibit 13, are incorporated by reference into Part II.
Portions of the registrants Proxy Circular for its Annual Meeting of Shareholders to be held on May 6, 2004 (the 2004 Proxy Circular), attached as Exhibit 99, are incorporated by reference into Part III.
DEFINED TERMS
Potash Corporation of Saskatchewan Inc. is a corporation organized under the laws of Canada. As used in this document, the term PCS refers to Potash Corporation of Saskatchewan Inc. and the terms we, us, our, PotashCorp and the Company refer to PCS and, as applicable, PCS and its direct and indirect subsidiaries as a group.
FORWARD-LOOKING STATEMENTS
This document, including the documents incorporated by reference, contain forward-looking statements within the meaning of the U.S. Private Securities Litigation Reform Act of 1995 that relate to future events or our future financial performance. Statements containing words such as could, expect, may, anticipate, believe, intend, estimate, plan and similar expressions constitute forward-looking statements. We disclaim any intention or obligation to update or revise any forward-looking statements, whether as a result of new information, future events or otherwise, except as required by applicable securities laws.
Forward-looking statements are subject to important risks, uncertainties and assumptions that are difficult to predict. The results or events predicted in forward-looking statements may differ materially from actual results or events. Some of the factors that could cause actual results or events to differ from current expectations include the following:
| | fluctuations in supply and demand for fertilizer, including fluctuations as a result of economic or political conditions in our markets, which can cause volatility in the prices of our fertilizer products; | |
| | changes in competitive pressures, including pricing pressure; | |
| | unexpected or adverse weather conditions, which can impact demand for fertilizer and timing of fertilizer sales during the year; | |
| | volatility in the price of natural gas, which is the primary raw material used for our nitrogen products, and risks associated with our continued ability to manage natural gas costs in the United States through hedging activities; | |
| | fluctuations in the prices and availability of other raw materials, including sulfur, which is a primary input in our phosphate operations; | |
| | fluctuations in the cost of transportation and distribution of our raw materials and products, including ocean freight; | |
| | unexpected geological conditions; | |
| | changes in capital markets and in currency and exchange rates; | |
| | the outcome of legal proceedings; | |
| | changes in government regulations, including environmental regulations, which could increase our costs of compliance and otherwise affect our business; and | |
| | acquisitions we may undertake in the future. |
We sell to a diverse group of customers both by geography and by end product. Market conditions will vary on a year-over-year basis, and sales can be expected to shift from one period to another.
As a result of these and other factors, there is no assurance that any of the events, circumstances or results anticipated by forward-looking statements included or incorporated by reference into this document will occur or, if they do, of what impact they will have on our business or on our results of operations and financial condition.
| PART I | ||||||||
| PART II | ||||||||
| PART III | ||||||||
| PART IV | ||||||||
| SIGNATURES | ||||||||
| Exhibit 11 | ||||||||
| Exhibit 12 | ||||||||
| Exhibit 13 | ||||||||
| Exhibit 21 | ||||||||
| Exhibit 23 | ||||||||
| Exhibit 31(A) | ||||||||
| Exhibit 31(B) | ||||||||
| Exhibit 32 | ||||||||
| Exhibit 99 | ||||||||
PART I
ITEMS 1 and 2. Business and Properties.
General
We are one of the worlds largest integrated fertilizer and related industrial and feed products companies. In 2003, our potash operations represented an estimated 16% of global production, 23% of global potash capacity and 69% of global potash excess capacity. We are the fourth largest producer of phosphates worldwide by capacity. In 2003, our phosphate operations represented an estimated 6% of world phosphoric acid production. We are the third largest producer of nitrogen products worldwide by capacity. In 2003, our nitrogen operations represented an estimated 2% of world ammonia production.
Our potash is produced from six mines in Saskatchewan and one mine in New Brunswick. Of these mines, we own and operate five in Saskatchewan and the one in New Brunswick.
Our phosphate operations include the manufacture and sale of solid and liquid phosphate fertilizers, animal feed supplements and purified phosphoric acid, which is used in food products and industrial processes. We believe that our North Carolina facility is the worlds largest integrated phosphate mine and processing plant. We also have a phosphate mine and two chemical plant complexes in northern Florida, three stand alone phosphate feed plants in the United States and one feed plant in Brazil. In addition, we produce a variety of phosphate products at our Geismar, Louisiana facility.
Our nitrogen operations involve the production of nitrogen fertilizers and nitrogen feed and industrial products, including ammonia, urea, nitrogen solutions, ammonium nitrate and nitric acid. We have nitrogen facilities in Georgia, Louisiana, Ohio, Tennessee and Trinidad.
Through Florida Favorite Fertilizer in Florida and Farmers Favorite Fertilizer in Georgia and Alabama, we manufacture, process and distribute fertilizer and other agricultural supplies from plants located in Florida, Alabama and Georgia.
We are organized under the laws of Canada. Our principal executive offices are located at 122 1st Avenue South, Suite 500, Saskatoon, Saskatchewan, Canada S7K 7G3, and our telephone number is (306) 933-8500.
History
PCS is a corporation continued under the Canada Business Corporations Act and is the successor to a corporation without share capital established by the Province of Saskatchewan in 1975. Between 1976 and 1990, we acquired substantial interests in the Saskatchewan potash industry. We purchased the Cory mine in 1976, the Rocanville and Lanigan mines in 1977, and, by 1990, 100% of the Allan mine when we acquired all of the outstanding shares of Saskterra Fertilizers Ltd.
In 1989, the Province of Saskatchewan privatized PCS. While the Province initially retained an ownership interest in PCS, this interest had been reduced to zero by the end of 1993. Since 1993, we have made the following acquisitions of significance to the development of our company:
| | the New Brunswick potash mine and port facilities and our Patience Lake mine in Saskatchewan in 1993; | |
| | PCS Phosphate Company, Inc. (formerly Texasgulf Inc.) and White Springs Agricultural Chemicals, Inc., phosphate fertilizer and feed producers, in 1995; | |
| | Arcadian Corporation, a producer of nitrogen fertilizer, industrial and feed products in 1997; | |
| | PCS Cassidy Lake, a potash mill facility located at Clover Hill, New Brunswick in 1998; | |
| | PCS Yumbes S.C.M. (formerly Minera Yolanda S.C.M.), a Chilean sodium nitrate and potassium nitrate producer, in 1999; | |
| | PCS Purified Phosphates (formerly a joint venture we had with Albright & Wilson Americas Inc.), a phosphoric acid joint venture, in 2000; |
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| | an animal feed plant in Brazil in March 2000 from Mitsui Company; | |
| | 20% of the total outstanding equity of Sociedad Química y Minera de Chile S.A., or SQM, a Chilean specialty fertilizer, iodine and lithium company, in transactions in October 2001 and April and May of 2002; and | |
| | an animal feed plant in Joplin, Missouri together with a related animal feed distribution business in March 2002. |
In 2003, we made the following significant acquisitions and dispositions: In October 2003, we purchased 26% of the shares of Arab Potash Company from Jordan Investment Corporation, an arm of the Jordanian government, for approximately $178 million. In November 2003, we entered into an agreement with SQM to sell the shares of PCS Yumbes for an aggregate purchase price of $35 million, subject to adjustments. This transaction is expected to close no later than December 31, 2004.
Potash Operations
Our potash operations include the mining and production of potash, which is predominantly used as fertilizer.
Properties
All potash produced by the Company in Saskatchewan is in the southern half of the Province, where extensive potash deposits are found. The potash ore is contained in a predominantly rock salt formation known as the prairie evaporites, which lie about 3,000 feet below the surface. The evaporite deposits, which are bounded by limestone formations and contain the potash beds of approximately 8 to 17 feet thickness. Three potash deposits of economic importance occur in the Province, the Esterhazy, Belle Plaine and Patience Lake members. The Patience Lake member is mined at the Lanigan, Allan, Patience Lake and Cory mines, and the Esterhazy member is mined at the Rocanville and Esterhazy mines.
Under a long-term mining and processing agreement effective through December 31, 2026, IMC Esterhazy Canada Limited Partnership (IMC) mines and processes our mineral rights at the Esterhazy mine. We have the option to terminate this agreement every five years. The next opportunity to terminate is December 31, 2006, for which notice must be given no later than June 30, 2006. IMC has the option to abandon the mine at any time after December 31, 2011, thus terminating the mining and processing agreement. In each year the maximum finished product we are permitted to take under the mining and processing agreement is 952,500 tonnes and the minimum required amount is 453,600 tonnes. For the year ending December 31, 2004, we have notified IMC that we require 952,500 tonnes of finished product. Water inflow at the Esterhazy mine has continued, to a greater or lesser degree, since December 1985. We share, on an annual basis, in such water inflow remediation costs.
We also produce potash at our mine near Sussex, New Brunswick from the flank of an elongated salt structure. We produce granular product at our Cassidy Lake, New Brunswick facility using standard grade product from certain of our other mine sites. We also hold an interest in certain oil and gas rights within the vicinity of the New Brunswick mine. Natural gas has been discovered and we, in conjunction with Corridor Resources Inc., now supply the New Brunswick facility with natural gas to meet its fuel needs. During the investigation for natural gas in the vicinity of the Sussex division, potash was detected to the south and east of the existing mine operations. Exploration permits have been obtained and preliminary seismic and drilling has taken place. We are exploring this potash deposit for possible future development.
We control the right to mine 613,559 acres of land in Saskatchewan. Included in these holdings are mineral rights to 506,803 acres contained in blocks around the six mines in which we have an interest, of which acres we own approximately 36%, approximately 50% are under lease from the Province of Saskatchewan and approximately 14% are leased from other parties. Our remaining 106,756 acres are located elsewhere in Saskatchewan. Our leases with the Province of Saskatchewan are for 21 year terms, renewable at our option. Our significant leases with other parties are also for 21 year terms. Such leases are renewable at our option, providing generally that production is continuing or, in one case, that there is continuation of the
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The following map shows the location of our Canadian mining operations.
PCS Yumbes, which we acquired in 1999, holds mining concessions on certain sodium nitrate deposits in the Atacama desert in northern Chile. In November 2003, we entered into an agreement with SQM to sell our interest in PCS Yumbes.
Production
We produce potash using both conventional and solution mining methods. In conventional operations, shafts are sunk to the ore body and mining machines cut out the ore, which is lifted to the surface for processing. In solution mining, the potash is dissolved in warm brine and pumped to the surface for processing. Approximately 12 grades of potash are produced to suit different preferences of the various markets.
In 2003, our conventional potash operations (including Esterhazy) mined 18.9 million tonnes of ore at an average grade of 22.76% potassium oxide (K2O). In 2003, our potash production from all our operations (including Esterhazy) consisted of 7.094 million tonnes of potash (KCl) with an average grade of 61.06% K2O, representing 44% of North American production.
Our present annual potash production capacity is approximately 12.1 million tonnes KCl, which includes maximum annual production under the Mining and Processing Agreement with IMC of 952,500 tonnes at Esterhazy. In 2003, our production capacity represented an estimated 53% of the North American total capacity while our excess capacity was an estimated 75% of North American excess production capacity. We allocate production among our mines on the basis of various factors, including cost efficiency and the grades of product that can be produced. The Patience Lake mine, which was originally a conventional underground mine, now employs a solution mining method, while the other Saskatchewan mines we own or in which we have an interest employ conventional underground mining methods.
The New Brunswick mine is a conventional cut and fill mine. In addition to potash production, this mine also produced 0.57 million tonnes of sodium chloride (salt) in 2003. We continue to incur costs at the New Brunswick division in relation to management of a brine inflow.
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The following table sets forth, for each of the past three years, the production of ore, grade and finished product for each of our mines.
| 2003 Production | 2002 Production | 2001 Production | ||||||||||||||||||||||||||||||||||||||
| Finished | Finished | Finished | ||||||||||||||||||||||||||||||||||||||
| Ore | Product | Ore | Product | Ore | Product | |||||||||||||||||||||||||||||||||||
| Annual | (millions | Grade | (millions | (millions | Grade | (millions | (millions | Grade | (millions | |||||||||||||||||||||||||||||||
| Capacity(3) | of tonnes) | % K2O | of tonnes) | of tonnes) | % K2O | of tonnes) | of tonnes) | % K2O | of tonnes) | |||||||||||||||||||||||||||||||
|
Lanigan
|
3.828 | 5.359 | 20.63 | 1.488 | 4.947 | 19.92 | 1.424 | 4.756 | 20.82 | 1.354 | ||||||||||||||||||||||||||||||
|
Rocanville
|
2.295 | 5.999 | 23.50 | 1.989 | 5.060 | 23.26 | 1.700 | 4.767 | 23.21 | 1.593 | ||||||||||||||||||||||||||||||
|
Allan
|
1.885 | 2.790 | 24.78 | 0.934 | 2.537 | 24.43 | 0.864 | 2.352 | 24.11 | 0.768 | ||||||||||||||||||||||||||||||
|
Cory
|
1.361 | 2.459 | 25.03 | 0.730 | 2.376 | 24.96 | 0.677 | 2.515 | 25.08 | 0.747 | ||||||||||||||||||||||||||||||
|
Patience Lake(1)
|
1.033 | 0.251 | 0.230 | 0.241 | ||||||||||||||||||||||||||||||||||||
|
New Brunswick
|
0.785 | 2.311 | 23.21 | 0.749 | 1.828 | 22.97 | 0.599 | 1.876 | 22.83 | 0.609 | ||||||||||||||||||||||||||||||
|
Totals(2)
|
18.918 | 6.141 | 16.748 | 5.494 | 16.266 | 5.312 | ||||||||||||||||||||||||||||||||||
| (1) | Solution mine. |
| (2) | Does not include Finished Product from Esterhazy of .953 for each of 2003 and 2002 and .816 for 2001. |
| (3) | million tonnes of Finished Product (KCl). |
The mining of potash is a capital-intensive business subject to the normal risks and capital expenditure requirements associated with mining operations. The processing of ore may be subject to delays and costs resulting from mechanical failures and such hazards as unusual or unexpected geological formations, subsidence, floods and other water inflows, and other conditions involved in mining ore.
Reserves
The Companys estimates for its conventional mining operations in Saskatchewan are based on exploration drill hole data, seismic data and actual mining results during the past 25 years. Reserves are estimated by identifying material in place that is delineated on at least two sides and material in place within a one mile radius or distance from an existing sampled mine entry. A historical extraction ratio from the thirty to thirty five years of mining results is then applied to estimate the reserves. Mineral Resources beyond the reserve calculations are contained within a seven to ten mile economic radius of the existing shafts depending upon travel conditions. The Companys estimated recoverable ore as of December 31, 2003 for each of our Saskatchewan mines is as follows:
| Reserves | Mineral Resources | |||||||||||
| Tonnes(1)(2)(3) | Average | Tonnes | ||||||||||
| (millions of tonnes | Grade | (millions of tonnes of | ||||||||||
| of recoverable ore) | (K2O) | recoverable ore)(2)(3) | ||||||||||
|
Allan
|
253 | 25.9% | 960 | |||||||||
|
Cory
|
202 | 25.1% | 830 | |||||||||
|
Lanigan
|
437 | 22.0% | 1,300 | |||||||||
|
Rocanville
|
386 | 22.5% | 200 | |||||||||
| (1) | There has been no third party review of reserve estimates within the last three years. |
| (2) | The extraction ratio of recoverable ore to in place material for each mine is as follows: Allan 0.32, Cory 0.26, Lanigan 0.30 and Rocanville 0.33 |
| (3) | The concentration of recoverable ore tonnes to finished product (KCl) for each of the divisions is as follows: Allan 2.904, Cory 3.39, Lanigan 3.5, Rocanville 3.003. |
The Company believes that, based on its estimates of reserves and resources and with production rates at full capacity and utilizing current technology, each of the Allan, Cory and Lanigan mines has a life in excess of 100 years and the Rocanville mine has a life in excess of 84 years.
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Given the characteristics of the solution mining method employed at the Patience Lake mine, it is not possible to estimate definitively the productive capacity of or the recoverable ore from this operation. However, based on information obtained upon the acquisition of the mine, current technology and the present mining area for this operation, the Company believes that the mine has a life of at least 40 years for the existing mine workings. Estimates are made utilizing the ore surfaces available for dissolution in the abandoned mine workings, the concentration of the circulated brine recovered from the mine, annual evaporation rates from the ponds and the annual rate of KCL recovered from the ponds.
Based on geophysics, exploration drill hole data, definition drilling underground and actual mining results, the Company estimates reserves of 89.5 million tonnes of recoverable ore at an average grade of 25.6% and 29.3 million tonnes of estimated finished product (KCI) at its New Brunswick mine. The Company believes that, based upon its reserve and resource estimates, the New Brunswick mine has a life of approximately 80 years with production at full capacity.
Phosphate Operations
We mine phosphate ore and manufacture solid and liquid fertilizers, animal feed supplements and purified phosphoric acid which is used in food products and industrial processes.
Properties
We conduct our phosphate operations primarily at two facilities, one a 35,000-acre facility near Aurora, North Carolina and the other a 100,580-acre facility near White Springs in northern Florida. We believe the Aurora facility to be the largest integrated phosphate mine and phosphate processing complex at one site in the world. The Aurora facility includes a six million tonne per-year mining operation, four sulfuric acid plants, four phosphoric acid plants, a purified acid plant, a liquid fertilizer plant, a superphosphoric acid (SPA) plant, two diammonium phosphate (DAP) plants, a defluorinated phosphate (DFP) animal feed plant and a solid fertilizer plant capable of producing DAP, granular triple superphosphate (GTSP) or monoammonium phosphate (MAP). Expansion of our purified phosphoric acid production plant at Aurora was completed in the first quarter of 2003. The expansion increased capacity by 83,000 tonnes to 251,000 tonnes P2O5.
The White Springs facility is the third largest P2O5 producer, by capacity, in the United States. The White Springs facility includes a mine and two production facilities, Suwannee River and Swift Creek, with two sulfuric acid plants, three phosphoric acid plants, two DAP plants, a SPA plant, a dicalcium phosphate plant and a DFP plant located at the Suwannee River complex and two sulfuric acid plants, a phosphoric acid plant and superphosphoric plant located at the Swift Creek complex.
The location of our Aurora and White Springs mining operations are as shown on the following map.
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At our Geismar, Louisiana facility, we manufacture a variety of phosphate products that are used for agricultural and industrial purposes. The Geismar facility has a sulfuric acid plant, a phosphoric acid plant, a SPA plant, and a liquid fertilizer plant. A significant portion of the phosphoric acid produced at the Geismar facility is sold as feedstock to Rhodia Inc. for use in its neighboring purified acid plant. Our other phosphate properties include:
| | animal feed plants in Marseilles, Illinois; Weeping Water, Nebraska; Joplin, Missouri; and Sao Vincente, Brazil; | |
| | a technical and food grade phosphate plant in Cincinnati, Ohio; and | |
| | terminal facilities at Morehead City, North Carolina and Savannah, Georgia. |
The animal feed plant at Kinston, North Carolina ceased production during the first quarter of 2003.
| Plant Locations | Phosphate Products Produced | |||
|
Aurora, North Carolina
|
DAP, GTSP, MAP, SPA, Animal Feed, Merchant Grade Phosphoric Acid (MGA), purified acid |
|||
|
White Springs, Florida
|
SPA, DAP, MAP, MGA, Animal Feed | |||
|
Cincinnati, Ohio
|
Blended purified acid products | |||
|
Geismar, Louisiana
|
MGA, SPA, liquid fertilizer | |||
|
Marseilles, Illinois
|
Animal Feed | |||
|
Weeping Water, Nebraska
|
Animal Feed | |||
|
Joplin, Missouri
|
Animal Feed | |||
|
Sao Vincente, Brazil
|
Animal Feed | |||
Production
We extract phosphate ore using surface mining techniques. At each mine site, the ore is mixed with recycled water to form a slurry, which is pumped from the mine site to our processing facilities. The ore is then screened to remove coarse materials, washed to remove clay and floated to remove sand to produce phosphate rock. The annual production capacity of our mines is currently 9.6 million tonnes of phosphate rock. During 2003, the Aurora facilitys total production of phosphate rock was 3.08 million tonnes and the White Springs facilitys total production of phosphate rock was 2.69 million tonnes. The sequence for mining portions of the Aurora property has been identified in the permit issued by the U.S. Army Corps of Engineers in 1997.
Phosphate rock is the major input in our phosphorus processing operations. Substantially all of the phosphate rock produced is used internally for the production of phosphoric acid, SPA, chemical fertilizers, purified phosphoric acid and animal feed products. Unlike the Aurora and White Springs operations, the Geismar facility does not mine phosphate rock. Presently, the Geismar facility purchases phosphate rock from Morocco pursuant to a long-term agreement with a Moroccan government-owned company, wherein prices are reset at prescribed dates through negotiation.
In addition to phosphate ore, the principal raw materials we require are sulfur, sulfuric acid and ammonia. The production of phosphoric acid requires substantial quantities of sulfur, which we purchase from third parties. In December 1997, we entered into a ten-year supply contract with an offshore supplier to supply a portion of our sulfur requirements. In connection therewith, we built a multipurpose ocean-going vessel to ship such sulfur and to handle sulfuric acid, phosphoric acid and other chemicals. We produce sulfuric acid at the Aurora facility, White Springs facility and Geismar facility and purchase additional sulfuric acid from unaffiliated sellers. We also transport surplus production of sulfuric acid at the White Springs facility to the Aurora facility as needed.
Our phosphate operations purchase all of their ammonia from or through PCS Nitrogen and PCS Sales (USA), Inc., which are our wholly owned subsidiaries. Phosphoric acid is reacted with ammonia to produce DAP and MAP as well as liquid fertilizers. In addition, ammonia operations include the purchase, sale and terminalling of anhydrous ammonia. Most of the ammonia that we purchase from third parties is produced in
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We produce MGA at Aurora, White Springs and Geismar. Some MGA is sold to foreign and domestic fertilizer producers and industrial customers. We further process the balance of the MGA to make solid fertilizer (DAP and MAP), liquid fertilizers, animal feed supplements for the poultry and livestock markets, and purified phosphoric acid for use in a wide variety of food, technical and industrial applications.
The following table sets forth, for each of the last three years, the Companys production of phosphate rock (including tonnage and grade) and the production of phosphoric acid.
Phosphate Rock
| 2003 | 2002 | 2001 | ||||||||||||||||||||||||||
| Annual | ||||||||||||||||||||||||||||
| Capacity | Production | %P2O5 | Production | %P2O5 | Production | %P2O5 | ||||||||||||||||||||||
|
Aurora, NC
|
6.0 | 3.078 | 27.40 | 3.444 | 26.91 | 3.938 | 26.94 | |||||||||||||||||||||
|
White Springs, FL
|
3.6 | 2.686 | 30.76 | 1.547 | 30.16 | 1.677 | 30.19 | |||||||||||||||||||||
|
Geismar, LA
|
| | | | | | | |||||||||||||||||||||
|
Total
|
9.6 | 5.764 | 4.991 | 5.615 | ||||||||||||||||||||||||
Phosphoric Acid
| Annual | 2003 | 2002 | 2001 | |||||||||||||
| Capacity | Production | Production | Production | |||||||||||||
|
Aurora, NC
|
1.202 | 0.919 | 0.852 | 0.916 | ||||||||||||
|
White Springs, FL
|
1.093 | 0.777 | 0.480 | 0.473 | ||||||||||||
|
Geismar, LA
|
0.202 | 0.165 | 0.180 | 0.184 | ||||||||||||
|
Total
|
2.497 | 1.861 | 1.512 | 1.573 | ||||||||||||
Reserves
Our phosphate deposits in North Carolina occur in a formation known as the Pungo River formation of the middle Miocene age. The formation, typically 75 to 125 below ground surface, is composed of interbedded phosphatic sands, silts and clays, diatomaceous clays, and phosphatic limestone. Phosphate of value in the ore horizon occurs as pellets of brown and black sand-sized particles, with flat-sided angular quartz grams and variable amounts of silt, clay and interbedded limestone. The phosphate ore (matrix) horizon throughout is distinguished by its relative uniformity in thickness, % P2O5 and other quality characteristics.
Our White Springs operations are in Hamilton County, Florida. The Hamilton County phosphate deposits in the North Florida Phosphate District are reported to be of the middle Miocene and Pliocene ages. Because of partial reworking during the Pliocene age, these deposits tend to be more variable than middle Miocene deposits, such as those found in North Carolina.
In estimating our phosphate reserves, we had previously retained a third party to prepare reports of the estimated phosphate ore reserves at Aurora and White Springs. Based on (i) a review and assessment of the Companys land-ownership maps, (ii) drilling and technical assays and assessments, (iii) discussions with Company personnel familiar both with the geology of the phosphate ore deposits and each sites mining operations and (iv) judgments regarding the recoverability of phosphate from the ore deposits based on economic and technical factors such as the ore grade, mining, transportation and beneficiation issues and environmental and regulatory factors, the reserve estimates set forth in the reports were developed.
Since receipt of the reports (1995 for Aurora and 1997 for White Springs) we have annually adjusted and updated the ore reserve estimates for both the Aurora and White Springs operations by making adjustments
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The following table sets forth the Companys estimated proven and probable phosphate reserves for Aurora and White Springs as at December 31, 2003 at an average grade of 30.7% P2O5.
| Tonnes of | ||||||||
| Phosphate Rock | Average Grade | |||||||
| (millions of tonnes) | % P2O5 | |||||||
|
Aurora
|
366 | 30.7% | ||||||
|
White Springs
|
58 | 30.7% | ||||||
|
Total
|
424 | |||||||
The reserves set forth above for Aurora would permit mining to continue at normal rates for about 75 years. The Aurora phosphate mine has an estimated annual capacity of 6.0 million tonnes of phosphate rock and its processing plants have the capacity to produce 1.2 million P2O5 tonnes of phosphoric acid. Prior to our acquisition of Texasgulf in April 1995, Texasgulf transferred approximately 408 million tonnes of phosphate reserves to a newly established company, the common stock of which was transferred to Elf Aquitaine, Inc. and Williams Acquisition Holding Company, Inc. We were granted a 20-year right of first refusal (from April 10, 1995) in the event that the newly established company proposes to sell the reserves. In addition, the newly established company and Elf and Williams agreed, for a period of ten years from April 10, 1995, not to compete with us with respect to those reserves.
At White Springs, we estimate that additional recoverable reserves equivalent to 6 million tonnes of phosphate rock could be purchased at market rates from nearby owners. Accordingly, the total reserves and available purchase rock of 64 million tonnes of phosphate rock at White Springs would sustain the mine for 18 years at a mining rate of 3.6 million tonnes per year. The White Springs mine has an estimated annual capacity of 3.6 million tonnes of phosphate rock and the processing plants have the capacity to produce annually 1.1 million P2O5 tonnes of phosphoric acid.
Nitrogen Operations
Our nitrogen operations include production of nitrogen fertilizers and nitrogen chemicals. These products are used for agricultural, industrial and animal nutrition purposes.
Properties
PCS Nitrogen has five nitrogen production facilities, of which four are located in the United States and one is located in Trinidad. The following table sets forth the facility locations and production capabilities:
| Plant Locations | Nitrogen Products Produced | |
|
Augusta, Georgia
|
Ammonia, urea, nitric acid, ammonium nitrate and nitrogen solutions | |
|
Geismar, Louisiana*
|
Ammonia, nitric acid and nitrogen solutions | |
|
Lima, Ohio
|
Ammonia, urea, nitric acid and nitrogen solutions | |
|
Memphis, Tennessee*
|
Ammonia and urea | |
|
Point Lisas, Trinidad
|
Ammonia and urea |
| * | In June 2003, PCS Nitrogen indefinitely shut down its Memphis plant and suspended production of ammonia and nitrogen solutions at Geismar due to high U.S. natural gas costs and low product margins. |
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Production
Unlike potash and phosphate, nitrogen is not mined. It is taken from the air and reacted with a hydrogen source, usually natural gas reformed with steam, to produce ammonia. PCS Nitrogen produces ammonia at all domestic plants and in Trinidad. The ammonia is used to produce a full line of upgraded nitrogen products, including urea, nitrogen solutions, ammonium nitrate and nitric acid. Ammonia, urea, ammonium nitrate and nitrogen solutions are sold as fertilizers to agricultural customers and to industrial customers for various applications, while nitric acid is sold to industrial customers as an intermediate chemical feedstock. Urea is also sold for animal feed applications.
Service Agreements
BP Chemicals, Inc. (BPC) operates the Lima plant on PCS Nitrogens behalf under an operating agreement that can be terminated by either party with nine months notice. PCS Nitrogens payments to BPC under the operating agreement are generally based on an agreed annual budget and are made through the reimbursement of expenses incurred by BPC in providing such operating services. Such expenses do not include natural gas procurement or transportation costs. In addition, due to the mutual interdependence of the Lima plant and BPCs operations, PCS Nitrogen and BPC have agreed to provide each other with certain manufacturing support services at cost pursuant to a contract extending for as long as the plants continue to operate and either party is required to provide support services thereunder.
The Geismar plant is integrated with a larger chemical manufacturing complex owned by Honeywell International, Inc. (Honeywell). PCS Nitrogen and Honeywell have an agreement to provide certain support services to each other, including the provision of utilities, the discharge of wastewater, security, dock and emergency services, and other essential services.
At Augusta, PCS Nitrogen uses contract labor personnel provided by Augusta Services Company, Inc., which is owned 50% by PCS Nitrogen and 50% by DSM Chemicals North America, Inc., to provide purchasing, stores and spare parts management, maintenance, repair, shipping and certain other services for the Augusta plant.
Despite our belief that most of the services described above are available from other sources, the termination of or the need to replace certain of those services (such as steam, well water supply and dock services) could, in the aggregate, involve potentially significant capital expenditures, increased operating costs and disruption to the operation of the affected plant.
Raw Materials
Natural gas is the primary raw material used for the production of nearly all of PCS Nitrogens products. For 2003, the purchase and transport of natural gas, excluding purchased product, comprised over half of PCS Nitrogens total cost of goods sold, including the gain on our 2003 natural gas hedges in the U.S. of $89.9 million. In the U.S., PCS Nitrogen employs natural gas hedges with the goal of minimizing risk from volatile gas prices. In Trinidad, natural gas is purchased pursuant to long-term contracts using pricing formulas related to the market price of ammonia. With the exception of the Trinidad facility, PCS Nitrogen purchases most of its natural gas from producers or marketers at the point of delivery of the natural gas into the pipeline system, then pays the pipeline company and, where applicable, the local distribution company to transport the natural gas to PCS Nitrogens facilities. Approximately 75% of PCS Nitrogens domestic consumption of natural gas is delivered pursuant to firm transportation contracts, which do not permit the pipeline or local distribution company to interrupt service to, or divert natural gas from, the plant.
PCS Joint Venture
We indirectly hold all outstanding interests in PCS Joint Venture, LP (PCS Joint Venture), a limited partnership doing business in Florida as Florida Favorite Fertilizer and in Georgia and Alabama as Farmers Favorite Fertilizer. Potash Corporation of Saskatchewan (Florida), Inc. is the general partner of PCS Joint
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Marketing
The following table summarizes our net sales from potash, phosphate and nitrogen products (by geographical distribution) in the past three calendar years. Certain of the prior years figures have been reclassified to conform with the current years presentation.
| 2003 | 2002 | 2001 | |||||||||||
| (millions of dollars) | |||||||||||||
|
Potash(1)
|
|||||||||||||
|
Canada
|
$ | 36.1 | $ | 23.7 | $ | 24.0 | |||||||
|
United States
|
214.0 | 206.2 | 212.7 | ||||||||||
|
Canpotex(2)
|
260.6 | 241.2 | 237.6 | ||||||||||
|
Other
|
108.4 | 73.4 | 57.5 | ||||||||||
|
Total
|
$ | 619.1 | $ | 544.5 | $ | 531.8 | |||||||
|
Phosphates
|
|||||||||||||
|
Canada
|
$ | 70.1 | $ | 61.3 | $ | 60.5 | |||||||