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U.S. SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549
Form 10-K
ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d)
OF THE SECURITIES EXCHANGE ACT OF 1934
For the fiscal year ended December 31, 2004
Commission file number 1-10351
Potash Corporation of Saskatchewan Inc.
(Exact name of the registrant as specified in its charter)
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Canada
(State or other jurisdiction of
incorporation or organization) |
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N/A
(I.R.S. employer
identification no.) |
122 1st Avenue South
Saskatoon, Saskatchewan, Canada S7K 7G3
306-933-8500
(Address and telephone number of the registrants
principal executive offices)
Securities registered pursuant to Section 12(b) of the
Act:
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Name of exchange on which registered |
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Common Shares, No Par Value |
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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, 2004, the aggregate market value of the 53,620,914
(107,241,828 post August 2004 stock split) Common Shares held by
non-affiliates of the registrant was approximately
$5,195,866,568.73.
At
February 28, 2005, the registrant had 111,290,020 Common
Shares outstanding.
DOCUMENTS INCORPORATED BY REFERENCE
Portions
of the registrants Annual Report to Shareholders for the
fiscal year ended December 31, 2004 (the 2004 Annual
Report), filed as Exhibit 13, are incorporated by
reference into Part II.
Portions
of the registrants Proxy Circular for its Annual and
Special Meeting of Shareholders to be held on May 5, 2005
(the 2005 Proxy Circular), attached as
Exhibit 99, are incorporated by reference into
Part III.
TABLE OF CONTENTS
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:
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fluctuations in supply and demand for fertilizer, including
fluctuations as a result of economic or political conditions in
our markets, which, among other things, can cause volatility in
the prices of our fertilizer products; |
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changes in competitive pressures, including pricing pressure; |
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unexpected or adverse weather conditions, which can impact
demand for fertilizer and timing of fertilizer sales during the
year; |
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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; |
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fluctuations in the prices and availability of other raw
materials, including sulfur, which is a primary input in our
phosphate operations; |
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fluctuations in the cost and availability of transportation and
distribution for our raw materials and products, including ocean
freight; |
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unexpected geological conditions; |
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changes in capital markets and in currency and exchange rates; |
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the outcome of legal proceedings; |
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changes in government regulations, including environmental
regulations, which could increase our costs of compliance and
otherwise affect our business; and |
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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.
In addition to the factors mentioned above, the information
under Risk Management on pages 44 and 45 in our
2004 Annual Report, included here as Exhibit 13, is
incorporated herein by reference. 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
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Business and Properties. |
General
We are one of the worlds largest integrated fertilizer and
related industrial and feed products companies. We are the
largest producer of potash worldwide by capacity. In 2004, our
potash operations represented an estimated 16% of global
production, 22% of global potash capacity and 85% of global
potash excess capacity. We are the third largest producer of
phosphates worldwide by capacity. In 2004, our phosphate
operations represented an estimated 6% of world phosphoric acid
production. We are the fourth largest producer of nitrogen
products worldwide by capacity. In 2004, 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 industrial 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, six 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.
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:
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the New Brunswick potash mine and port facilities and our
Patience Lake mine in Saskatchewan in 1993; |
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PCS Phosphate Company, Inc. (formerly Texasgulf Inc.) and
White Springs Agricultural Chemicals, Inc., phosphate fertilizer
and feed producers, in 1995; |
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Arcadian Corporation, a producer of nitrogen fertilizer,
industrial and feed products in 1997; |
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PCS Cassidy Lake, a potash mill facility located at Clover Hill,
New Brunswick in 1998; |
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in 1999, PCS Yumbes, a producer of potassium nitrate, sodium
nitrate and iodine, which we then sold to Sociedad Química
y Minera de Chile S.A. (SQM), a Chilean
specialty fertilizer, iodine and lithium company, in December
2004; |
I-1
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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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20% of the total outstanding equity of SQM in transactions in
October 2001 and April and May of 2002. In 2004, we sold a
portion of this investment and subsequently acquired Israel
Chemicals Ltd.s entire indirect interest in SQM, resulting
in a current indirect holding of 24.99% of the outstanding
equity of SQM; |
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26% of the shares of Arab Potash Company from Jordan Investment
Corporation, an arm of the Jordanian government, in October of
2003. |
Potash Operations
Our potash operations include the mining and production of
potash, which is predominantly used as fertilizer.
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 Evaporite, which lies about
3,000 feet below the surface. The evaporite deposits, which
are bounded by limestone formations, 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, Mosaic Potash Esterhazy Limited
Partnership (Mosaic) mines and processes our mineral
rights at the Esterhazy mine. We are currently in the process of
reviewing the extent, location and mining history of those
mineral rights. 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. Mosaic 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,
2005, we have notified Mosaic 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 area for possible future
development.
We control the right to mine 614,065 acres of land in
Saskatchewan. Included in these holdings are mineral rights to
507,309 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 and that there is
continuation of the applicable Crown lease. In New Brunswick, we
mine pursuant to a mining lease with the Province of New
Brunswick. The lease is for a term of 21 years from 1978
with renewal provisions for three additional 21 year
periods.
I-2
The following map shows the location of our Canadian mining
operations.
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 9 grades of potash are produced to
suit different preferences of the various markets.
In 2004, our conventional potash operations (excluding
Esterhazy) mined 21.49 million tonnes of ore at an average
grade of 22.97% potassium oxide (K2O). In 2004, our
potash production from all our operations (including Esterhazy)
consisted of 7.914 million tonnes of potash (KCl) with an
average grade of 60.98% K2O, representing 44% of
North American production.
Our present annual potash production capacity is approximately
12.5 million tonnes KCl, which includes maximum annual
production under the mining and processing agreement with Mosaic
of 952,500 tonnes at Esterhazy. This also includes a 400,000
tonne expansion at Rocanville which came on stream in the first
quarter of 2005. In 2004, our production capacity represented an
estimated 54% of the North American total capacity while our
excess capacity was an estimated 95% 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
0.59 million tonnes of sodium chloride (salt) in 2004.
We continue to incur costs at the New Brunswick division in
relation to management of a brine inflow.
I-3
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.
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2004 Production | |
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2003 Production | |
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2002 Production | |
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Finished | |
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Finished | |
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Finished | |
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Ore | |
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Product | |
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Ore | |
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Product | |
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Ore | |
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Product | |
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Annual | |
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(Millions | |
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Grade | |
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(Millions | |
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(Millions | |
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Grade | |
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(Millions | |
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(Millions | |
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Grade | |
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(Millions | |
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Capacity(4) | |
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of tonnes) | |
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% K2O | |
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of tonnes) | |
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of tonnes) | |
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% K2O | |
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of tonnes) | |
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of tonnes) | |
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% K2O | |
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of tonnes) | |
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Lanigan
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3.828 |
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7.372 |
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20.11 |
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2.025 |
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5.359 |
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20.63 |
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1.488 |
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4.947 |
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19.92 |
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1.424 |
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Rocanville(1)
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2.695 |
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5.334 |
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24.25 |
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1.833 |
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5.999 |
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23.50 |
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1.989 |
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5.060 |
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23.26 |
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1.700 |
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Allan
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1.885 |
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3.862 |
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25.22 |
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1.344 |
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2.790 |
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24.78 |
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0.934 |
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2.537 |
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24.43 |
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0.864 |
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Cory
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1.361 |
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2.531 |
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24.95 |
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0.738 |
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2.459 |
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25.03 |
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0.730 |
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2.376 |
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24.96 |
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0.677 |
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Patience Lake(2)
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1.033 |
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0.239 |
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0.251 |
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0.230 |
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New Brunswick
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0.785 |
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2.371 |
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23.24 |
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0.782 |
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2.311 |
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23.21 |
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0.749 |
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1.828 |
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22.97 |
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0.599 |
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Totals(3)
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21.470 |
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6.961 |
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18.918 |
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6.141 |
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16.748 |
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5.494 |
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| (1) |
Includes a 400,000 tonne expansion at Rocanville which came on
stream in the first quarter of 2005. |
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| (2) |
Solution mine. |
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Does not include Finished Product from Esterhazy of .953 for
each of 2004, 2003 and 2002. |
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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.
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 30
to 35 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 30 to
35 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,
2004 for each of our Saskatchewan mines is as follows:
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Reserves | |
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Mineral Resources | |
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Tonnes(1)(2)(3) | |
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Average | |
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Tonnes | |
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(Millions of tonnes | |
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Grade | |
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(Millions of tonnes of | |
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of recoverable ore) | |
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(K2O) | |
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recoverable ore)(2)(3) | |
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Allan
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242 |
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25.9% |
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989 |
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Cory
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207 |
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25.1% |
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743 |
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Lanigan
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424 |
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22.0% |
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1,355 |
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Rocanville
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356 |
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22.5% |
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393 |
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There has been no third party review of reserve estimates within
the last three years. Current estimates reflect refinements and
adjustments to analysis conducted during 2004 using the above
described methodology. |
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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. |
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The concentration of recoverable ore Tonnes to finished product
(KCl) for each of the divisions is as follows: Allan 2.98, Cory
3.43, Lanigan 3.53, Rocanville 2.92. |
I-4
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 98 years.
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 39 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 87.1 million tonnes of recoverable
ore at an average grade of 25.6% and 28.5 million tonnes of
estimated finished product (KCl) 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
79 years with production at full capacity.
Phosphate Operations
We mine phosphate ore and manufacture phosphoric acid, solid and
liquid fertilizers, animal feed supplements and purified
phosphoric acid which is used in food products and industrial
processes.
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, with a capacity of
1.2 million tonnes P2O5 per
year, 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). We are currently in the process of expanding
the Companys purified phosphoric acid production plant at
Aurora, with completion scheduled for the second quarter of
2006. The expansion, which will not increase the plants
overall capacity in phosphoric acid production, will increase
the plants purified phosphoric acid capacity by 82,000
tonnes to 333,000 tonnes of purified phosphoric acid.
The White Springs facility is the third largest phosphoric acid
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, an 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.
I-5
The location of our Aurora and White Springs mining operations
are as shown on the following map.
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, an SPA plant, and a liquid fertilizer
plant. A significant portion of the phosphoric acid produced at
the Geismar facility is sold as feedstock to Innophos, Inc. for
use in its neighboring purified acid plant. Our other phosphate
properties include:
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animal feed plants in Marseilles, Illinois; Weeping Water,
Nebraska; Joplin, Missouri; and Sao Vincente, Brazil; |
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a technical and food grade phosphate plant in Cincinnati,
Ohio; and |
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terminal facilities at Morehead City, North Carolina and
Savannah, Georgia. |
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| Plant Locations |
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Phosphate Products Produced |
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Aurora, North Carolina
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DAP, GTSP, MAP, SPA, Animal Feed, Liquid Fertilizer, purified acid, Merchant Grade Phosphoric Acid (MGA) |
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White Springs, Florida
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SPA, DAP, MAP, MGA, Animal Feed |
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Cincinnati, Ohio
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Blended purified acid products |
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Geismar, Louisiana
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MGA, SPA, liquid fertilizer |
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Marseilles, Illinois
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Animal Feed |
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Weeping Water, Nebraska
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Animal Feed |
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Joplin, Missouri
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Animal Feed |
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Sao Vincente, Brazil
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Animal Feed |
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 2004, the Aurora facilitys total production
of phosphate rock was 3.96 million tonnes and the White
Springs facilitys total production of phosphate rock was
2.75 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
I-6
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 at market
rates 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. Much of
the ammonia that we purchase from third parties is produced in
Russia and imported through an ammonia terminal which we operate
located within the port of Savannah (Garden City, Georgia).
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
(Million Tonnes)
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2004 | |
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2003 | |
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2002 | |
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Annual | |
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|
Capacity | |
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Production | |
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%P2O5 | |
|
Production | |
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%P2O5 | |
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Production | |
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%P2O5 | |
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Aurora, NC
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6.0 |
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3.964 |
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27.49 |
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3.078 |
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27.40 |
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3.444 |
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26.91 |
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White Springs, FL
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3.6 |
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2.745 |
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30.96 |
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2.686 |
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30.76 |
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1.547 |
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30.16 |
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Geismar, LA
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Total
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9.6 |
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6.709 |
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28.91 |
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5.764 |
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28.96 |
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4.991 |
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27.92 |
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Phosphoric Acid
(Million Tonnes P2O5)
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Annual | |
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2004 | |
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2003 | |
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2002 | |
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Capacity | |
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Production | |
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Production | |
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Production | |
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Aurora, NC
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1.202 |
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1.018 |
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0.919 |
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0.852 |
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White Springs, FL
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1.093 |
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0.773 |
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0.777 |
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0.480 |
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Geismar, LA
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0.202 |
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0.171 |
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0.165 |
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0.180 |
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Total
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2.497 |
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1.962 |
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1.861 |
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1.512 |
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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 feet to 125 feet 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
I-7
(matrix) horizon throughout is distinguished by its
relative uniformity in thickness, percent
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 annually adjusted and updated the ore reserve
estimates for both the Aurora and White Springs operations by
making adjustments for ore consumed, number of tons sterilized
(i.e., bypassed), deletions (for property sold, traded or agreed
to be set aside for environmental or other purposes), additions
(based on land and mineral right acquisitions) and other
appropriate adjustments. There has been no third party review of
the estimates within the last three years.
The following table sets forth the Companys estimated
proven and probable phosphate reserves for Aurora and White
Springs as at December 31, 2004 at an average grade of
30.7% P2O5.
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Tonnes of | |
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Phosphate Rock | |
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Average Grade | |
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(millions of tonnes) | |
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% P2O5 | |
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Aurora
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361 |
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30.7% P2O5 |
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White Springs
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57 |
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30.7% P2O5 |
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Total
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418 |
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The reserves set forth above for Aurora would permit mining to
continue at normal rates for about 74 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 6.0 million tonnes of phosphate rock
could be purchased at market rates from nearby owners.
Accordingly, the total reserves and available purchase rock of
63 million tonnes of phosphate rock at White Springs would
sustain the mine for 17 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.
I-8
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:
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| Plant Locations |
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Nitrogen Products Produced |
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Augusta, Georgia
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Ammonia, urea, nitric acid, ammonium nitrate and nitrogen
solutions |
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Geismar, Louisiana*
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Ammonia, nitric acid and nitrogen solutions |
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Lima, Ohio
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Ammonia, urea, nitric acid and nitrogen solutions |
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Memphis, Tennessee*
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Ammonia and urea |
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Point Lisas, Trinidad
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Ammonia and urea |
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| * |
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. |
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 can
produce 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, and nitrogen solutions are sold
as fertilizers to agricultural customers and to industrial
customers for various applications, while nitric acid and
ammonium nitrate is sold to industrial customers for various
applications. Urea is also sold for animal feed applications.
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 within 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.
Natural gas is the primary raw material used for the production
of nearly all of PCS Nitrogens products. For 2004, the
purchase and transport of natural gas comprised over half of PCS
Nitrogens total cost of goods
I-9
sold, including the gain on our 2004 natural gas hedges in the
U.S. of $43 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 90% 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 Venture. PCS Joint Venture
manufactures, processes and distributes fertilizer and other
agricultural supplies from plants located in Florida, Alabama
and Georgia.
Marketing
The following table summarizes our 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.
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2004 | |
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2003 | |
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2002 | |
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(millions of dollars) | |
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Potash
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Canada
|
|
$ |
48.3 |
|
|
$ |
41.1 |
|
|
$ |
27.8 |
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United States
|
|
|
445.8 |
|
|
|
326.6 |
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|
310.7 |
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Canpotex(1)
|
|
|
421.9 |
|
|
|
260.6 |
|
|
|
241.2 |
|
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Other
|
|
|
140.1 |
|
|
|
130.4 |
|
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89.3 |
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Total
|
|
$ |
1,056.1 |
|
|
$ |
758.7 |
|
|
$ |
669.0 |
|
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Phosphates
|
|
|
|
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Canada
|
|
$ |
|