MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION
AND RESULTS OF OPERATIONS
You should read the following discussion and analysis of our financial
condition and results of operations in conjunction with our financial statements
and related notes included elsewhere in this prospectus. This discussion and
analysis contains forward-looking statements that involve risks, uncertainties
and assumptions. Our actual results may differ materially from those anticipated
in these forward-looking statements as a result of a number of factors,
including, but not limited to those set forth under "Risk Factors" and elsewhere
in this prospectus.
Overview and Executive Summary
We are one of the largest independent high complexity petroleum refiners and
marketers in the mid-continental U.S. and the lowest cost producer and marketer
of upgraded nitrogen fertilizer products in North America. Our operations are
organized into two business segments: petroleum and nitrogen fertilizer. Our
petroleum business includes a complex oil refinery in Coffeyville, Kansas, a
crude oil gathering system throughout Kansas and Northern Oklahoma, and storage
and terminalling facilities for asphalt and refined fuels in Phillipsburg,
Kansas. Our refinery operates in close proximity to our primary customer base
and benefits from favorable crude oil supply and product distribution logistics.
Our nitrogen fertilizer business in Coffeyville, Kansas, includes a petroleum
coke gasification plant that produces high purity hydrogen that is converted to
ammonia at our ammonia plant and upgraded to urea ammonium nitrate (UAN) at our
UAN plant. We operate the only nitrogen fertilizer plant in North America
utilizing a coke gasification process to generate hydrogen feedstock that is
further converted to ammonia for the production of nitrogen fertilizers. This
currently provides us with a significant competitive advantage due to the high
prevailing and volatile natural gas prices.
Factors Affecting Comparability
Our results over the past three years and over the nine months ended
September 30, 2003 and 2004 have been influenced by the following factors, which
are fundamental to understanding comparisons of our period-to-period financial
performance.
Coffeyville Group Holdings, LLC was formed in 2003 by an investor group led
by Pegasus specifically for the acquisition Farmland's petroleum business and a
nitrogen fertilizer plant. On March 3, 2004, Coffeyville Group Holdings, LLC
completed the acquisition of certain assets of Farmland that comprise our
business. As a result, financial information as of and for the periods prior to
March 3, 2004 discussed below and included elsewhere in this prospectus was
derived from the financial statements and reporting systems of Farmland. Prior
to March 3, 2004, Farmland's petroleum division was primarily comprised of our
current petroleum business. Our nitrogen fertilizer plant, however, was only one
facility within Farmland's eight-plant nitrogen fertilizer manufacturing and
marketing division.
A new basis of accounting was established on the date of the transaction
and, therefore, the financial position and operating results after March 3, 2004
are not consistent with the operating results before the acquisition date.
However, management believes the most practical way to comment on the results of
operations due to the short period from January 1, 2004 to March 2, 2004 is to
compare the sum of the operating results for both periods in 2004 with the
corresponding period in 2003.
Our financial statements prior to March 3, 2004 reflect an allocation of
certain general corporate expenses of Farmland, including general and corporate
insurance, property insurance, corporate retirement and benefits, human resource
and payroll department salaries, facility costs, information services, and
information systems support. For the years ended December 31, 2001, 2002 and
2003, and for the 62 day period ending March 2, 2004, these costs allocated to
our businesses were approximately $4.2 million, $6.3 million, $12.7 million and
$3.8 million, respectively. Our financial statements prior to March 2, 2004 also
reflect an allocation of interest expense from Farmland. These allocations were
39
made by Farmland on a basis deemed meaningful for their internal management
needs and may not be representative of the actual expense levels required to
operate the businesses at that time or as they have been operated after March 3,
2004.
The financial statements for our nitrogen fertilizer business prior to
February 2002 reflect the impact of an operating lease structure utilized by
Farmland to finance our nitrogen fertilizer plant. The cost of this plant under
the operating lease was $263.0 million and the rental payments were
$18.7 million and $0.3 million for the periods ended December 31, 2001 and 2002,
respectively. In February 2002, Farmland refinanced the operating lease into a
secured loan structure, which effectively terminated the lease and all of
Farmland's obligations under the lease.
During 2002, our refinery was shut down for approximately six weeks in order
to perform planned major maintenance. We reported costs of $17.0 million
associated with this shutdown using the direct expense method of accounting and
included this expense in the cost of sales during 2002. We have planned major
maintenance scheduled at our refinery for late in the third quarter or early in
the fourth quarter in 2006 and 2010.
In December 2002, Farmland implemented Statement of Financial Accounting
Standards (SFAS) No. 144, resulting in a reorganization expense from the
impairment of long-lived assets. Under this Statement, recoverability of assets
to be held and used is measured by comparison of the carrying amount of an asset
to the estimated undiscounted future net cash flows expected to be generated by
the asset. It was determined that the carrying amount of the petroleum assets
and the carrying amount of our nitrogen fertilizer plant in Coffeyville exceeded
their estimated future undiscounted net cash flows and, as a result, impairment
charges of $144.3 million and $230.8 million were recognized for each of the
refinery and fertilizer assets, based on Farmland's best assumptions regarding
the use and eventual disposition of those assets. In 2003, as a result of
additional information acquired through the bankruptcy court's sales process,
Farmland revised its estimate for the amount to be generated from the
disposition of these assets, and an additional impairment charge was taken. The
charge to earnings in 2003 was $4.0 million and $5.7 million, respectively, for
the refinery and fertilizer assets.
During the first 11 months of 2001, Farmland operated a joint venture with
CHS, Inc. called Country Energy, LLC. During this period, our refinery's output
was marketed on an agency basis and sales for Farmland's petroleum business
included 41% of all sales sold through Country Energy. These sales included
CHS's portion of the output of the NCRA refinery at McPherson, Kansas, CHS's
refinery at Laurel, Montana and our refinery, as well as gasoline and
distillates purchased from third parties for resale, and wholesale propane,
lubricants and petroleum products. After the termination of the joint venture,
Farmland entered into a propane marketing and sale agreement with CHS which also
had an impact on the financial results of Farmland's petroleum division during
that 11 month period. Country Energy's and Farmland's interests in the propane
marketing and sale agreement were sold to CHS in November 2001 for a gain of
$18.0 million. After these transactions, the petroleum business revenue
consisted primarily of the output of the Coffeyville refinery.
In December 2001, Farmland entered into an agreement to sell to CHS all of
Farmland's refined products produced at the Coffeyville refinery through
November 2003. The selling price for this production was set by reference to
daily market prices within a defined geographic region. Subsequent to the
expiration of this contract, the petroleum business began marketing its refined
products in the open market to multiple customers.
During the first quarter of 2001, our nitrogen fertilizer plant was in the
startup and commissioning phase. As a result, our intermittent operations of the
plant and production during that quarter are not representative of the current
operations of our nitrogen fertilizer plant.
For the periods ending December 31, 2001, 2002, 2003 and the first 62 days
of 2004, Farmland's sales of nitrogen fertilizer products were subject to a
marketing agreement with Agriliance, LLC. Under the agreement, Agriliance was
responsible for marketing substantially all of Farmland's nitrogen
40
fertilizer products in return for a commission, represented as a percentage of
dollar sales volume. Over this period, the stated commission rate varied from
7.0% to 2.5% depending on the time period, the product and the customer. In 2001
through 2003 the favorable impact on gross margins would have been in the range
of $2.0 million to $4.5 million per year. In addition to the direct impact of
the discounts offered to Agriliance, there were indirect impacts on the earnings
as result of the business being a part of a larger marketing effort and product
being shipped longer distances to avoid competing with other Farmland facilities
or facilities from which Agriliance was acquiring product. Such effects are
difficult to quantify and may make period to period comparisons of our results
less meaningful. Subsequent to our acquisition of the nitrogen fertilizer
business, we began selling our nitrogen fertilizer products directly to dealers
and distributors and focused on customers that were the most freight logical to
our facility.
On May 31, 2002, Farmland filed for bankruptcy. One of the most significant
consequences to the petroleum business was the inability of Farmland to acquire
its desired crude slate and the necessity for Farmland to prepay for crude oil.
We have not been required to make similar prepayments for our crude oil supply
since we commenced operations as a stand-alone entity. The impact of this and
other factors is difficult to quantify and may make period to period comparisons
of our results less meaningful.
Industry Factors
Earnings for our petroleum business depend largely on refining industry
margins, which have been and continue to be volatile. Crude oil and refined
product prices depend on factors beyond our control. While it is impossible to
predict refining margins due to the uncertainties associated with global crude
oil supply and global and domestic demand for refined products, we believe that
refining margins for U.S. refineries will generally remain above those
experienced in the period from and including 1998 through 2003 as growth in
demand for refining products in the U.S., particularly transportation fuels,
continues to exceed the ability of domestic refiners to increase capacity. In
addition, global supply and other factors have constricted the extent to which
product importation to the U.S. can relieve domestic supply deficits. This
phenomenon is more pronounced in our marketing region, where demand for refined
products has exceeded refining production by approximately 38% since 1997.
Over the first nine months of 2004, the market price of distillates relative
to crude oil was above average due to low industry inventories and strong
consumer demand brought about by the relatively cold winter weather in the
Midwest and high natural gas prices. This phenomenon led to an increase in
industrial users switching from natural gas to fuel oil and the markets
anticipation of a fuel oil deficit in the winter of 2003-2004. In addition,
gasoline margins were above average, and substantially so during the spring and
summer driving seasons, primarily because of very low pre-driving season
inventories exacerbated by high demand growth. The increased demand for refined
products due to the relatively cold winter and the decreased supply due to high
turnaround activity led to increasing refining margins during the early part of
2004.
When product demand spikes, this demand is met largely by refineries capable
of processing only light/sweet crude. This is due to the fact that a majority of
refineries are equipped to process only light/sweet crude. This puts upward
pressure on light/sweet crude pricing. As a result, refineries such as ours,
which can process heavy/sour crudes are able to benefit. This is evident in
market conditions such as those that existed in 2004 when refining margins
widened.
Average discounts for sour and heavy sour crude oil compared to sweet crude
increased in the first nine months of 2004 from already favorable 2003 levels
due to increasing worldwide production of sour and heavy sour crude oil relative
to the worldwide production of light sweet crude oil coupled with the continuing
demand for light sweet crude oil. In 2003, the discount for West Texas Sour
(WTS) versus West Texas Intermediate (WTI) widened to $2.75 per barrel and this
sweet/sour spread continues to exceed recent average historic levels. WTI
continues to trade at a premium to WTS due to continued
41
high demand for sweet crude oil resulting from the more stringent fuel
specifications implemented in the United States and Europe and the higher
margins for light products. We expect to continue to recognize significant
benefits from our ability to meet current fuel specifications using
predominantly heavy and medium sour crude oil feedstocks as the discount for
heavy and medium sour crude oil compared to WTI continues at its current level.
We expect refined product supply and demand balances to tighten worldwide as
growth in demand for refined products is expected to exceed net capacity growth,
particularly for transportation fuels. We expect that a portion of the supply
growth due to new capacity built by foreign refiners and the continued
de-bottlenecking and expansion of existing refineries will likely be offset by
more stringent environmental specifications that will place further supply
pressure on clean fuel availability resulting from the high capital requirements
to meet worldwide low-sulfur gasoline and diesel specifications. We expect that
the worldwide growth in the production of sour and heavy sour crude oil will
continue to exceed increases in the production of light sweet crude oil and that
this, along with the continuing demand for light sweet crude oil, will support a
wide spread between the prices of light sweet and heavy sour crude oil. Our
refinery is able to extract economic benefit under these conditions because of
its ability to accommodate heavy crude in the crude slate and retain value from
the by-products of that refining process.
Earnings for our nitrogen fertilizer business depend largely on the prices
of nitrogen fertilizer products, the floor price of which is directly influenced
by natural gas prices. Natural gas prices have been and continue to be volatile.
We expect nitrogen fertilizer product prices to remain high by historical
standards as well as continued growth in demand for nitrogen fertilizer products
in the U.S., particularly for UAN. This trend is more pronounced in our region,
the Midwest, where demand for nitrogen fertilizer products has exceeded
production and there is limited fertilizer transportation infrastructure. We
believe this will continue to provide us with relatively high margins on our
nitrogen fertilizer products.
Factors Affecting Results
Petroleum Business
In our petroleum business, earnings and cash flow from operations are
primarily affected by the relationship between refined product prices and the
prices for crude oil and other feedstocks. The cost to acquire feedstocks and
the price for which refined products are ultimately sold depends on factors
beyond our control, including the supply of, and demand for, crude oil, as well
as gasoline and other refined products which, in turn, depend on, among other
factors, changes in domestic and foreign economies, weather conditions, domestic
and foreign political affairs, production levels, the availability of imports,
the marketing of competitive fuels and the extent of government regulation.
While our net sales fluctuate significantly with movements in crude oil prices,
these prices do not generally have a direct long-term relationship to net
earnings. Because we apply first-in, first-out accounting to value our
inventory, crude oil price movements may impact net earnings in the short term
because of instantaneous changes in the value of the minimally required,
unhedged on hand inventory. The effect of changes in crude oil prices on our
results of operations is influenced by the rate at which the prices of refined
products adjust to reflect such changes.
Feedstock and refined product prices are also affected by other factors,
such as product pipeline capacity, local market conditions and the operating
levels of competing refineries. Crude oil costs and the price of refined
products have historically been subject to wide fluctuations. An expansion or
upgrade of our competitors' facilities, price volatility, international
political and economic developments and other factors beyond our control are
likely to continue to play an important role in refining industry economics.
These factors can impact, among other things, the level of inventories in the
market resulting in price volatility and a reduction in product margins.
Moreover, the industry typically experiences seasonal fluctuations in demand for
refined products, such as increases in the demand for
42
gasoline during the summer driving season and for home heating oil during the
winter, primarily in the Northeast. For further details on the economics of
refining, see "Industry Overview-Oil Refining-Industry Economics of Refining."
In order to assess our operating performance, we compare our gross margin
against an industry gross margin benchmark. The industry gross margin is
calculated by assuming that five barrels of benchmark light sweet crude oil is
converted, or cracked, into three barrels of conventional gasoline and two
barrels of distillate. This is referred to as the 5-3-2 crack spread. Because we
calculate the benchmark margin using the market value of New York gasoline and
diesel fuel against the market value of West Texas Intermediate crude oil, we
refer to the benchmark as the New York 5-3-2 crack spread, or simply, the 5-3-2
crack spread. The 5-3-2 crack spread is expressed in dollars per barrel and is a
proxy for the per barrel margin that a sweet crude refinery would earn assuming
it produced and sold the benchmark production of conventional gasoline and
distillate.
Because our refinery has certain feedstock costs and/or logistical
advantages as compared to a benchmark refinery, our gross margin generally
exceeds the 5-3-2 crack spread by a significant amount. Our refinery is able to
process significant quantities of heavy and medium sour crude oil that has
historically cost less than WTI crude oil. We measure the cost advantage of our
crude oil slate by calculating the spread between the price of our delivered
crude oil, to the price of WTI crude oil, a light crude oil. The spread is
referred to as our consumed crude differential. Our consumed crude differential
will move directionally with changes in the WTS differential to WTI and the Maya
differential to WTI as both these differentials indicate the relative price of
heavier, more sour slate to WTI. The correlation between our consumed crude
differential and published differentials will vary depending on the volume of
heavy medium sour crude we purchase as a percent of our total crude volume and
will correlate more closely with such published differentials the heavier and
more sour the crude oil slate.
The value of our products is also an important consideration in
understanding our results. We produce a high volume of premium products, such as
gasoline, diesel and heating oil. Our refined products benefit from the fact
that our marketing region consumes more refined products than it produces so
that the market prices of our products have to be high enough to cover the
logistics cost for Gulf Coast refineries to ship into our region.
Our operating cost structure is also important to our profitability. Major
operating costs include energy, employee labor, maintenance, contract labor, and
environmental compliance. Our predominant variable cost is energy and the most
important benchmark for energy costs is the value of natural gas. Our variable
operating costs are largely energy related and therefore sensitive to the
movements of crude price. We believe our fixed operations costs are low as
compared to our peers, partially because of the flexibility our current union
contracts provide us.
Consistent, safe, and reliable operations at our refineries are key to our
financial performance and results of operations. Unplanned downtime of our
refinery may result in lost margin opportunity, increased maintenance expense
and a temporary increase in working capital investment and related inventory
position. The financial impact of planned downtime, such as major turnaround
maintenance, is mitigated through a diligent planning process that takes into
account margin environment, the availability of resources to perform the needed
maintenance, feedstock logistics and other factors.
Other than crude we gather ourselves, we purchase crude oil from third
parties using a credit intermediation agreement. Our credit intermediation
agreement is structured such that we take title, and the price of the crude oil
is set, when it is delivered at the crude oil tank farm adjacent to our
refinery. This agreement significantly reduces the investment that we are
required to maintain in petroleum inventories relative to our competitors and
reduces the time we are exposed to market fluctuations before the inventory is
priced to a customer. Because petroleum feedstocks and products are essentially
commodities, we have no control over the changing market value of our
investment. Therefore, the lower target inventory we are able to maintain
significantly reduces the impact of
43
commodity price volatility on our hydrocarbon inventory position relative to
other refiners. This target inventory position is generally not hedged. To the
extent our inventory position deviates from the target level, we consider risk
mitigation activities usually through the purchase or sale of futures contracts
on the New York Mercantile Exchange (NYMEX). Our hedging activities carry
customary time, location and product grade basis risks generally associated with
hedging activities. Because most of our titled inventory is valued under the
first-in, first-out costing method, price fluctuations on our target level of
titled inventory have a major effect on our financial results unless the market
value of our target inventory is increased above cost.
Nitrogen Fertilizer Business
In our nitrogen fertilizer business, earnings and cash flow from operations
are primarily affected by the relationship between nitrogen fertilizer product
prices and operating costs. Unlike our competitors, we use minimal natural gas
as feedstock and, as a result, are not directly heavily impacted in terms of
cost, by high or volatile swings in natural gas prices. Instead, our coke
feedstock is primarily supplied by our adjacent oil refinery. The price for
which nitrogen fertilizer products are ultimately sold depends on numerous
factors beyond our control, including the supply of, and demand for, nitrogen
fertilizer products which, in turn, depend on, among other factors, the price of
natural gas, cost and availability of fertilizer transportation infrastructure,
changes in the world population, weather conditions, grain production levels,
the availability of imports, and the extent of government intervention in
agriculture markets. While our net sales could fluctuate significantly with
movements in natural gas prices during periods when fertilizer markets are weak
and sell at the floor price, high natural gas prices do not force us to shut
down our operations because we employ coke as a feedstock to produce ammonia and
UAN.
Nitrogen fertilizer prices are also affected by other factors, such as local
market conditions and the operating levels of competing facilities. Natural gas
costs and the price of nitrogen fertilizer products have historically been
subject to wide fluctuations. An expansion or upgrade of our competitors'
facilities, price volatility, international political and economic developments
and other factors beyond our control are likely to continue to play an important
role in nitrogen fertilizer industry economics. These factors can impact, among
other things, the level of inventories in the market resulting in price
volatility and a reduction in product margins. Moreover, the industry typically
experiences seasonal fluctuations in demand for nitrogen fertilizer products.
For further details on the economics of fertilizer, see "Industry
Overview-Nitrogen Fertilizer Industry-Pricing of Fertilizer Products."
In order to assess our operating performance, we calculate netbacks, or
plant gate price, to determine our operating margin. Netbacks refers to the unit
price of fertilizer, in dollars per ton, offered on a delivered basis, excluding
shipment costs. Given our use of low cost petroleum coke, we are not presently
subjected to the high raw materials costs of competitors who use natural gas.
Instead of experiencing high variability in the cost of raw materials, we
utilize less than 1% of the natural gas relative to other natural gas based
fertilizers and we estimate that we maintain our competitive advantage at
natural gas spot prices in the range of $1.50 to $2.50 per million Btu and
above. The spot price for natural gas at Henry Hub on September 30, 2004 was
$5.84 per million Btu.
Because our fertilizer plant has certain logistical advantages relative to
end users of ammonia and UAN and demand relative to production remains high, we
can afford to target freight-advantaged destinations in the U.S. farm belt. We
do not incur any intermediate transfer, storage, barge freight or pipeline
freight charges. Currently, our freight advantage over U.S. Gulf Coast importers
is approximately $65 per ton for ammonia production and $37 per ton for UAN
production. Such cost differentials represent a significant portion of the
market price of these commodities. For example, since the end of 2003, ammonia
prices have fluctuated between $268 and $329 per ton, and UAN prices have
fluctuated between $156 and $195 per ton. Selling products to customers in close
proximity to our fertilizer plant while keeping transportation costs low is key
to maintaining profitability and understanding our results.
44
The value of our nitrogen fertilizer products is also an important
consideration in understanding our results. We upgrade two-thirds of our ammonia
production into UAN, a product that presently generates a greater value for the
upgraded ammonia. As the largest fully integrated single train UAN production
facility in North America, UAN production is a major contributor to our
profitability. Furthermore, given the high demand for UAN relative to production
and transportation costs that Gulf Coast importers face, we anticipate favorable
operating results from our UAN production capabilities.
Our operating cost structure is also important to our profitability. Using a
coke gasification process, we have higher fixed costs than natural gas based
fertilizer plants. Major operating costs include electrical energy, employee
labor, maintenance, including contract labor, and outside services. The
predominant variable cost is the cost of petroleum coke that we obtain primarily
from our refinery.
Consistent, safe, and reliable operations at our nitrogen fertilizer plant
are critical to our financial performance and results of operations. Unplanned
downtime of our nitrogen fertilizer plant may result in lost margin opportunity,
increased maintenance expense and a temporary increase in working capital
investment and related inventory position. The financial impact of planned
downtime, such as major turnaround maintenance, is mitigated through a diligent
planning process that takes into account margin environment, the availability of
resources to perform the needed maintenance, feedstock logistics and other
factors.
Results of Operations
The following tables provide supplementary income statement and operating
data and do not represent income statements presented in accordance with U.S.
generally accepted accounting principles (GAAP). Selected items in each of the
periods are discussed separately below.
Net sales consist principally of sales of refined fuel and nitrogen
fertilizer products. For the petroleum business, net sales are mainly affected
by crude oil and refined product prices, changes to the input mix and volume
changes caused by operations. Product mix refers to the percentage of production
represented by higher value light products, such as gasoline, rather than lower
value finished products, such as petroleum coke. In the nitrogen fertilizer
business, net sales are primarily impacted by manufactured tons and nitrogen
fertilizer prices.
Gross margin is net sales less raw material cost, inclusive of
transportation, and all other components of cost of sales except operating
expenses which are displayed separately for discussion purposes. Industry-wide
petroleum results are driven and measured by the relationship, or margin,
between refined products and the prices for crude oil referred to as crack
spreads, see "-Factors Affecting Results." We discuss our results of petroleum
operations in the context of per barrel consumed crack spreads and gross margin.
Our nitrogen fertilizer gross margin is principally driven by the relationship
or margin between nitrogen fertilizer products and the cost of petroleum coke.
In contrast to our petroleum business, gross margin is not a significant
indicator of profitability in the nitrogen business as the vast majority of
expenses associated with our nitrogen business are classified as operating
expenses.
We define Adjusted EBITDA as EBITDA plus or minus the following items:
(1) for the petroleum business, (a) during the year ended December 31, 2001, a
gain of $18.0 million, which was recorded for the disposition of our
Predecessor's share in Country Energy, LLC, (b) during the year ended
December 31, 2002 an asset impairment charge of $144.3 million related to the
write-down of our refinery to fair market value, (c) during the year ended
December 31, 2003, an additional charge of $3.9 million related to the asset
impairment of our refinery based on the expected sale price of the assets in the
Transaction, and (d) for the 212 day period ended September 30, 2004, a
write-off of $6.2 million of deferred financing costs in connection with
refinancing of our indebtedness on May 10, 2004, and (2) for the nitrogen
fertilizer business, (w) for the periods ended December 31, 2001 and 2002,
rental payments of $18.7 million and $0.3 million, respectively, to reflect the
termination of such rental payments under an operating lease structure utilized
by Farmland to finance the nitrogen
45
fertilizer plant, (x) during the year ended December 31, 2002 an asset
impairment charge of $230.8 million related to the write-down of our nitrogen
fertilizer plant to fair market value, (y) during the year ended December 31,
2003, an additional charge of $5.7 million related to the asset impairment of
our nitrogen fertilizer plant based on the expected sale price of the assets in
the Transaction, and (z) during the 212 day period ended September 30, 2004, a
write-off of $1.0 million of deferred financing costs in connection with
refinancing of our senior secured credit facility on May 10, 2004.
For a reconciliation of EBITDA and adjusted EBITDA to net income, see notes
3 and 4 to "Selected Historical Consolidated Financial Data."
Succesor and
Predecessor Predecessor Combined
Predecessor
Nine Months Ended Nine Months Ended
Year Ended December 31, September 30, September 30,
Consolidated -------------------------------- ------------------- ----------------------
Financial Results 2001 2002 2003 2003 2004
(in millions)
Net sales $ 1,630.2 $ 887.5 $ 1,262.2 $ 937.2 $ 1,231.7
Gross margin 189.5 125.3 205.7 147.7 216.2
Operating expenses 163.9 183.5 141.8 102.9 110.2
Depreciation and 19.1 30.8 3.3 2.7 2.0
amortization
Operating income (20.8 ) (449.9 ) 29.4 16.9 92.3
(loss)
Net income (loss) (19.4 ) (465.7 ) 27.9 15.3 51.1
EBITDA 18.0 (423.2 ) 32.5 19.3 86.2
Adjusted EBITDA 18.7 (47.8 ) 42.1 28.9 93.4
Succesor and
Predecessor Predecessor Combined
Predecessor
Nine Months Ended Nine Months Ended
Year Ended December 31, September 30, September 30,
Petroleum Business -------------------------------- ------------------- ----------------------
Financial Results 2001 2002 2003 2003 2004
(in millions)
Net sales $ 1,581.7 $ 829.0 $ 1,161.3 $ 865.5 $ 1,151.9
Gross margin 157.7 82.6 121.3 87.3 147.8
Operating expenses 103.8 112.8 82.2 60.5 66.2
Depreciation and 18.6 15.8 2.1 1.7 1.2
amortization
Operating income 31.8 (183.9 ) 21.5 12.1 74.2
(loss)
EBITDA 70.0 (172.1 ) 23.5 13.6 68.3
Adjusted EBITDA 51.9 (27.9 ) 27.4 17.5 77.0
Succesor and
Predecessor Predecessor Combined
Predecessor
Nine Months Ended Nine Months Ended
Nitrogen Fertilizer Year Ended December 31, September 30, September 30,
Business ------------------------------ ------------------- ---------------------
Financial Results 2001 2002 2003 2003 2004
(in millions)
Net sales $ 48.5 $ 58.5 $ 100.9 $ 71.7 $ 82.7
Gross margin 31.8 42.7 84.4 60.4 68.3
Operating expenses 60.1 70.7 59.6 42.4 44.0
Depreciation and 0.4 15.0 1.2 1.0 0.8
amortization
Operating income (52.5 ) (266.1 ) 7.8 4.8 18.1
(loss)
EBITDA (52.1 ) (251.1 ) 9.0 5.7 17.9
Adjusted EBITDA (33.3 ) (20.0 ) 14.7 11.4 19.3
46
Petroleum Business Results of Operations
Succesor and
Predecessor Predecessor Combined
Predecessor ------------------- ----------------------
------------------------------ Nine Months Ended Nine Months Ended
Year Ended December 31, September 30, September 30,
Market Indicators 2001 2002 2003 2003 2004
(dollars per barrel)
West Texas Intermediate
(WTI) crude oil $ 24.31 $ 25.33 $ 31.10 $ 30.77 $ 38.46
NYMEX 5-3-2 Crack
Spread $ 7.56 $ 5.68 $ 5.58 $ 6.13 $ 8.73
Crude Oil
Differentials:
WTI less WTS (sour) $ 2.81 $ 1.37 $ 2.75 $ 2.95 $ 3.91
WTI less Maya
(heavy sour) $ 8.85 $ 5.26 $ 6.95 $ 6.68 $ 12.00
WTI less Dated
Brent (foreign) $ 1.51 $ 1.11 $ 2.27 $ 2.32 $ 2.92
PADD 2 Group III versus
NYMEX Basis:
Gasoline $ 0.98 $ (0.16 ) $ 0.62 $ 0.64 $ (0.42 )
Heating Oil $ 2.06 $ 0.29 $ 0.52 $ 0.86 $ 1.55
Operating Statistics
(dollars per barrel)
Per barrel
margin/expense of crude
oil throughput:
Gross margin $ 5.12 $ 3.05 $ 3.89 $ 3.72 $ 5.92
Operating expense $ 3.36 $ 4.15 $ 2.63 $ 2.59 $ 2.65
(dollars per gallon)
Per gallon sales price:
Gasoline $ 0.86 $ 0.75 $ 0.91 $ 0.93 $ 1.17
Distillate $ 0.82 $ 0.71 $ 0.84 $ 0.84 $ 1.07
Succesor and
Predecessor Predecessor Combined
Predecessor
Nine Months Ended Nine Months Ended
Year Ended December 31, September 30, September 30,
Selected --------------------------------------------------- ------------------- -----------------------
Volumetric Data 2001 2002 2003 2003 2004
Barrels Barrels Barrels Barrels Barrels
Per Day % Per Day % Per Day % Per Day % Per Day %
Production:
Total 44,783 47.3 41,457 49.2 48,230 50.4 47,725 49.7 48,110 47.0
gasoline
Total 33,846 35.7 29,779 35.3 34,363 35.9 34,126 35.5 37,587 36.7
distillate
Total other 16,129 17.0 13,107 15.5 13,108 13.7 14,167 14.8 16,636 16.3
Total all 94,758 100.0 84,343 100.0 95,701 100.0 96,018 100.0 102,333 100.0
production
Crude oil 84,605 94.3 74,446 92.4 85,501 93.4 85,713 93.2 91,052 93.6
throughput
All other 5,122 5.7 6,109 7.6 6,085 6.6 6,215 6.8 6,200 6.4
inputs
Total 89,727 100.0 80,555 100.0 91,586 100.0 91,928 100.0 97,252 100.0
feedstocks
Succesor and
Predecessor Predecessor Combined
Predecessor
------------------------------------------------------------ Nine Months Ended Nine Months Ended
Year Ended December 31, September 30, 2003 September 30, 2004
Total Total Total Total Total
Barrels % Barrels % Barrels % Barrels % Barrels %
Crude oil
throughput by
crude type:
Sweet 15,039,853 48.7 14,991,867 55.2 18,187,215 58.3 13,616,265 58.2 12,172,642 48.8
Light/medium
sour 15,440,430 50.0 9,902,688 36.4 12,311,203 39.4 9,318,197 39.8 12,775,690 51.2
Heavy sour 400,577 1.3 2,278,275 8.4 709,300 2.3 465,200 2.0 - -
Total crude
oil throughput 30,880,860 100.0 27,172,830 100.0 31,207,718 100.0 23,399,662 100.0 24,948,332 100.0
47
Nine months ended September 30, 2004 compared to nine months ended
September 30, 2003.
Net Sales. Petroleum net sales increased $286.4 million or 33%, to
$1,151.9 million in the first nine months of 2004 from $865.5 million in the
corresponding period in 2003. This revenue increase is attributable to increased
production volumes and higher refined product prices, which reacted favorably to
the increase in global crude oil prices over the period. The higher prices
resulted in additional net sales of $224.0 million for the first nine months of
2004 over 2003. For the first nine months of 2004, crude oil throughput
increased by an average of 5,339 bpd, or 5.9%, versus the comparable period in
2003. The higher crude throughput experienced in the first nine months of 2004
compared to 2003 was directly attributable to Farmland's inability, because of
its impending reorganization, to purchase optimum crude oil blends necessary to
operate the refinery at 2004 levels in 2003. For the first nine months of 2004,
our petroleum business experienced increases in gasoline and distillate prices
of 26% and 28%, respectively compared to the same period in 2003.
Gross Margin. Petroleum gross margin increased by $60.5 million, or 69%, to
$147.8 million in the first nine months of 2004 from $87.3 million in the
corresponding period of 2003. This increase was attributable to historically
high differentials between refined products prices and crude oil prices as
exemplified in the average NYMEX crack spread of $8.73 per barrel for the first
nine months of 2004 and the increased discount for heavy crude oils demonstrated
by the $5.32, or 80%, increase in the spread between the WTI price, which is a
market indicator for the price of light sweet crude, and the Maya price, which
an indicator for the price of heavy crude, in the nine months ended
September 30, 2004 compared to the same period in 2003. The first nine months of
2004 also benefited from increased production volume versus the comparable
period of 2003. Gross margin per barrel increased by $2.20, or 59%, to $5.92 in
the first nine months of 2004 from $3.72 in the corresponding period in 2003.
Our gross margin for the nine months ending September 30, 2004 improved as a
result of the termination of a single customer product marketing agreement in
November 2003. During the first nine months of 2003 Farmland was party to a
marketing agreement that required them to sell all refined products to a single
customer at a fixed differential to an index price. Subsequent to the conclusion
of the contract, we have expanded our customer base and increased the realized
differential to that index. In addition, we have been able to supply value added
fuels such as boutique blends for Kansas City and Denver markets that trade at a
premium price to regular unleaded gasoline.
We blend light and heavy crude oil to create a medium gravity crude oil in
order to utilize our refinery's coking capacity to derive economic benefit from
the heavier crude. In 2004, we reduced the percent of light sweet WTI crude from
58.2% of the purchased crude in 2003 to 48.8%. Shifting from WTI crude to
heavier crude has allowed us to take advantage of the wider spread between light
and heavy crudes. In 2003 Farmland was restricted to one foreign cargo per month
due to its bankruptcy. As a result, our ability to optimize our crude slate to
take advantage of the discount associated with medium sour and medium heavy
crudes resulting in a lower total crude charge rate as well as a lower discount
to WTI was restricted.
Operating Expenses. Petroleum operating expenses increased by $5.7 million,
or 9%, to $66.2 million in the first nine months of 2004 from $60.5 million in
the corresponding period of 2003, primarily due to higher energy costs.
Operating expense per barrel for the nine months ended September 30, 2003 and
2004 remained essentially constant at $2.59 in 2003 and $2.65 in 2004.
Depreciation and Amortization. Petroleum depreciation and amortization
decreased by $0.5 million to $1.2 million in the first nine months of 2004
compared to the corresponding period in 2003. The decrease is primarily the
result of the assets being revalued at a lower amount subsequent to the our
acquisition.
48
Operating Income. Operating income increased $62.1 million, or 517%, to
$74.2 million in the first nine months of 2004 from $12.1 million in the
corresponding period in 2003. This increase was due to the factors discussed
above, and particularly driven by favorable market conditions in the domestic
refining industry.
Year ended December 31, 2003 compared to year ended December 31, 2002.
Net Sales. Petroleum net sales increased $332.3 million or 40%, to
$1,161.3 million in 2003 from $829.0 million in 2002. This revenue increase is
attributable to higher crude oil throughput of 85,501 barrels per day (bpd) in
2003 compared to 74,446 bpd in 2002, representing a 14.9% increase, and higher
refined fuel pricing in 2003. Higher refined fuel prices contributed
$164.6 million of the $332.3 million increase in revenue over this period.
Gasoline price increases were the largest contributor, increasing 21% from $0.75
per gallon to $0.91 per gallon, contributing $102.5 million to the revenue
increases. The price of distillate increased by 19% to $0.84 per gallon in 2003,
as compared to $0.71 per gallon in 2002.
Increased crude throughput during 2003 compared to 2002 was primarily the
result of a major maintenance turnaround at the refinery in March 2002, which
halted production at the refinery for four weeks. Problems with the start up of
the modified fluid catalytic cracking unit (FCCU) resulted in a delay in
reaching normal operations for an additional two week period in 2002. In 2003,
refined fuel production volume was 4.2 million barrels higher than 2002
resulting in a revenue increase of $157.7 million.
Gross Margin. Petroleum gross margin increased by $38.7 million, or 47%, to
$121.3 million in 2003 from $82.6 million in 2002. The increase was primarily
due to increased volume over 2002, as described above, during which a major
turnaround at the refinery was completed. In addition, earnings were favorably
impacted by an increase in the gross margin per barrel as a result of an
improved pricing in our marketing region and a widening crude oil differential
for heavy crude.
Crude oil throughput increased 15% to 31.2 million barrels in 2003 compared
to 27.2 million barrels in 2002 resulting in a margin increase of approximately
$15.7 million.
As demand in our marketing region increased by higher than historical rates,
the price basis in the region increased relative to the NYMEX price by an
average of $0.55 per barrel in 2003 over 2002 resulting in additional gross
margin. In addition, the spread between WTI and heavy medium sour crude oils
widened as indicated by the crude oil differentials. Both of these factors
contributed to an improved gross margin per barrel in a time the NYMEX crack
spread remained largely unchanged. The per barrel gross margin increased $0.84
to $3.89 in 2003 from $3.05 in 2002.
Operating Expenses. Petroleum operating expenses decreased by
$30.6 million, or 27%, to $82.2 million in 2003 from $112.8 million in 2002.
This decrease was principally attributable to expenses related to the major
maintenance turnaround in March 2002 of approximately $17.0 million. This
decrease in operating expenses was partially offset by higher usage of natural
gas in 2003 as compared to 2002 due to increased throughput. Operating expense
per barrel of total plant throughput decreased to $2.63 in 2003 from $4.15 in
2002.
Depreciation and Amortization. Petroleum depreciation and amortization
decreased $13.7 million to $2.1 million in 2003 from $15.8 million in 2002 This
change in depreciation and amortization is directly attributable to the
$144.3 million impairment charge to reduce the carrying amount of the fixed
assets of the petroleum business recorded in 2002, as more fully described in
Note 3 to our financial statements included elsewhere in this prospectus.
Operating Income. Petroleum operating income increased by $205.4 million to
$21.5 million in 2003 from an operating loss of $183.9 million in 2002.
Excluding the reorganization expense associated
49
with the impairment of property, plant and equipment in 2002 of $144.3 million
and $4.0 million in 2003, petroleum operating income increased by $65.1 million
in 2003 versus 2002, primarily as a result of the reasons described above.
Year ended December 31, 2002 compared to year ended December 31, 2001.
Net Sales. Petroleum net sales decreased $752.7 million or 48%, to
$829.0 million in 2002 from $1,581.7 million in 2001. This revenue decrease is
primarily attributable to the sale of Country Energy as described above in
"-Factors Affecting Comparability." In 2001, Farmland purchased and resold
6.7 million barrels of propane and 8.4 million barrels of gasoline and
distillate from Country Energy. The revenue for this purchased product was not
segregated, but we estimate the majority of the decrease in net sales was a
result of the discontinuation of purchased products.
In addition to the impact of the sale of Country Energy, both lower volumes
and lower prices impacted revenue in the petroleum business in 2002 compared to
2001. Our average sale price per gallon for gasoline and distillate decreased
12% and 13% respectively in 2002 as compared to 2001. Price decreases for
gasoline and distillate, excluding the impact of volume purchased and resold, in
2002 versus 2001 negatively impacted revenue by $133.1 million.
Crude oil throughput declined to 74,446 bpd in 2002 compared to 84,605 bpd
in 2001, which contributed significantly to lower revenue. Decreased crude
throughput during 2002 compared to 2001 was primarily the result of a major
maintenance turnaround at the refinery in March 2002, which halted production at
the refinery for four weeks. Complications with the startup of the modified FCCU
resulted in an additional two weeks of below normal operations in 2002.
Gross Margin. Petroleum gross margin decreased by $75.1 million, or 48%, to
$82.6 million in 2002 from $157.7 million in 2001. The decrease was principally
due to weak refining fundamentals as evidenced by a 25% reduction in the NYMEX
crack spread from 2002 as compared to 2001. In addition to the general weakening
of refinery economics, our consumed crude cost discount relative to WTI
decreased in 2002 compared to 2001 as result of a declining differential for
heavier more sour crude oil and a change in our crude oil mix from 49% light
sweet crude in 2001 to 55% in 2002. The reason for lighter slate was a direct
result of Farmland's bankruptcy and its inability to source more than one
foreign cargo per month. Due to factors described gross margin per barrel in
2002 decreased 40% to $3.05 per barrel from $5.12 per barrel in 2001 resulting
in a lower gross margin of $63.8 million dollars.
Total crude throughput declined by 3.7 million barrels in 2002 to
27.2 million barrels from 30.9 million barrels in 2001. The reduced barrels
impacted gross margin by more than $11.3 million.
Operating Expenses. Petroleum operating expenses increased by $9.0 million
or 9%, to $112.8 million in 2002 from $103.8 million in 2001 principally due to
expenses associated with the major maintenance turnaround in March 2002 of
approximately $17.0 million and increased environmental accruals of
approximately $8.0 million. This increase in operating expenses compared to 2001
was partially offset by an overall reduction in costs associated with natural
gas, production chemicals and catalyst. Operating expense per barrel increased
$0.79 per barrel of plant throughput, or 24% to $4.15 in 2002 from $3.36 in
2001.
Equity in Earnings (Losses) of Joint Ventures. Results in 2001 reflect
Farmland's loss in the joint venture interest of Country Energy, LLC of
$2.8 million. This joint venture was sold to CHS in November 2001.
Depreciation and Amortization. Petroleum depreciation and amortization
decreased $2.8 million, or 15%, to $15.8 million in 2002 from $18.6 million in
2001. This change in depreciation and
50
amortization is directly attributable to the $144.3 million impairment charge to
reduce the carrying amount of the fixed assets of the petroleum business in
2002.
Operating Income. Petroleum operating income decreased $215.7 million in
2002 to an operating loss of $183.9 million in 2002 from operating income of
$31.8 million in 2001. Excluding the reorganization expense associated with the
impairment of property, plant and equipment in 2002 of $144.3 million and joint
venture loss from Farmland's interest in Country Energy of $2.8 million,
petroleum operating income decreased by $68.6 million in 2002 versus 2001.
Nitrogen Fertilizer Business Results of Operations
Predecessor and Successor
Predecessor Combined
Nine Months Ended
Nine Months Ended September 30, September 30,
2001 2002 2003 2003 2004
Market Indicators ----------- ----------- -------- ------------- -------------
Natural gas (dollars per million Btu) $ 4.26 $ 3.22 $ 5.36 $ 5.62 $ 5.81
Ammonia - southern plains (dollars per ton) 247 168 272 273 287
UAN - corn belt (dollars per ton) 144 108 141 139 162
Production (thousand tons):
Ammonia 198.5 265.1 335.7 244.4 233.0
UAN 286.2 434.6 510.6 363.8 378.1
Total 484.7 699.7 846.3 608.2 611.1
Sales (thousand tons):
Ammonia 86.1 85.3 134.8 92.7 88.6
UAN 246.3 450.0 528.9 387.8 384.8
Total 332.4 535.3 663.7 480.5 473.4
Product pricing (plant gate) (dollars per
ton):
Ammonia $ 208 $ 147 $ 235 $ 233 $ 262
UAN 123 76 107 105 132
On-stream factor:
Gasification 66.8 % 78.6 % 90.1 % 89.7 % 91.2 %
Ammonia 63.6 % 75.3 % 89.6 % 87.5 % 80.3 %
UAN 66.8 % 78.6 % 81.6 % 79.1 % 80.3 %
Capacity utilization:
Ammonia 49.5 % 66.0 % 83.6 % 81.4 % 77.3 %
UAN 52.3 % 79.4 % 93.3 % 88.8 % 92.1 %
Nine months ended September 30, 2004 compared to nine months ended
September 30, 2003.
Net Sales. Nitrogen fertilizer net sales increased $11.0 million or 15%, to
$82.7 million in the first nine months of 2004 from $71.7 million in the
corresponding period in 2003. The revenue increase was entirely attributable to
increased nitrogen fertilizer prices, which more than offset a slight decline in
total production volume due to a planned turnaround in August 2004. For the
first nine months of 2004, southern plains ammonia and corn belt UAN prices
increased 5% and 17%, respectively versus the comparable period in 2003. In
addition, due to our direct marketing efforts, our actual netbacks relative to
the market indices presented above have improved substantially. This improvement
is the result of eliminating the reseller discount offered to Agriliance under
the terms of the prior marketing agreement and maximizing shipments to customers
that are more freight logical to our facility.
Operating Expenses. Nitrogen fertilizer operating expense increased by
$1.6 million, or 4%, to $44.0 million in the first nine months of 2004 from
$42.4 million in the corresponding period of 2003.
51
This increase was primarily due to the resumption of payments to our nitrogen
and oxygen supplier, BOC, subsequent to the Transaction, the turnaround expense
as discussed above, and an increase in costs allocated to the nitrogen
fertilizer business for insurance.
Depreciation and Amortization. Nitrogen fertilizer depreciation and
amortization decreased by $0.2 million, or 20%, to $0.8 million in the first
nine months of 2004 from $1.0 million in the comparable period of 2003. This
decrease was principally due to differences in the capitalized value of our
nitrogen fertilizer plant in 2003 versus our allocation of the purchase price to
the fixed assets of the nitrogen fertilizer plant completed in March 2004.
Operating Income. Operating income increased $13.3 million, or 277%, to
$18.1 million in the first nine months of 2004 from $4.8 million in the
corresponding period in 2003. This increase was due to continued strong market
conditions in the domestic nitrogen fertilizer industry described above. For the
212 day period ending September 30, 2004 the nitrogen fertilizer business was
charged $3.0 million for petroleum coke transferred from our refinery. During
the Predecessor period, petroleum coke was transferred at zero value.
Year ended December 31, 2003 compared to year ended December 31, 2002.
Net Sales. Nitrogen fertilizer net sales increased $42.4 million or 72%, to
$100.9 million in 2003 from $58.5 million in 2002. Prices accounted for
$21.1 million of the revenue increase while the remaining $21.3 million was
attributable to increased volume. In 2003, southern plains ammonia and corn belt
UAN prices increased 62% and 31%, respectively versus 2002.
The remaining $21.3 million attributable to increased volume directly
correlates to the improvement in operating days. The most significant factor was
our increased gasifier on-stream time due to improvements in our operations and
maintenance groups. Our ability to transition from our main gasifier to our
spare gasifier without discontinuing ammonia production significantly reduced
downtime.
Operating Expenses. Nitrogen fertilizer operating expenses decreased by
$11.0 million, or 16%, to $59.6 million in 2003 from $70.7 million in 2002. The
most significant factor in the decrease was $13.8 million reduction in
depreciation expense as result of the asset impairment charge of $230.8 million
in 2002, reductions in repairs and maintenance, reduced vendor fees associated
with oxygen and nitrogen supply and lower payments made for royalties and
operating assistance related to gasifier operations. This was offset by
increased expenses for refractory brick and electricity.
Electricity costs increased $1.0 million due to a 5% increase in power usage
in 2003 over 2002 as a result of the improved operating rates. Increased
refractory brick costs in 2003 of $1.9 million resulted from replacing damaged
brickwork in our gasifier.
The reduction in both oxygen and nitrogen supply payments and gasifier
royalty and operating assistance payments resulted in Farmland's election to
discontinue these payments subsequent to the bankruptcy filing. In both cases,
resolutions were reached between Farmland and the counterparty and payments have
already been made or agreed to by Farmland. These two items comprise
approximately $1.8 million in cost improvements in 2003 compared to 2002.
Depreciation and Amortization. Nitrogen fertilizer depreciation and
amortization decreased $13.8 million, or 91%, to $1.2 million from $15.0 million
in 2002. This decrease in depreciation and amortization is directly attributable
to the $230.8 million impairment charge to reduce the carrying amount of the
fixed assets of the nitrogen fertilizer plant in 2002.
Operating Income. Nitrogen fertilizer operating income increased
$273.9 million to $7.8 million in 2003 from a net loss of $266.0 million.
Excluding the reorganization expense associated with the impairment of the
nitrogen fertilizer plant in 2002 of $230.8 million and $5.8 million in 2003,
operating
52
income increased by $46 million to $10.7 million in 2003 from an operating loss
of $35.3 million in 2002, primarily for the reasons described above.
Year ended December 31, 2002 compared to year ended December 31, 2001.
Net Sales. Nitrogen fertilizer net sales increased by $10.0 million or 21%,
to $58.5 million in 2002 from $48.5 million in 2001. Increased production
volumes as a result of an increased on-stream factors at the nitrogen fertilizer
plant in 2002 compared to 2001 resulted in a revenue increase of $15.6 million.
The increase was offset by lower nitrogen prices. In 2002, Southern Plains
ammonia and corn belt UAN prices decreased 32% and 25%, respectively versus
2001.
Operating Expenses. Nitrogen fertilizer operating expenses increased by
$10.5 million, or 18%, to $70.7 million in 2002 from $60.1 million in 2001. This
increase was the result of $14.6 million of additional depreciation expense
offset by lower expenses of $3.6 million associated with the start-up and
commissioning of the nitrogen fertilizer plant in 2001. Outside services
decreased by $3.0 million in 2002 from 2001 primarily as a result of canceling
our operating and maintenance agreement with Texaco to operate and maintain our
gasifier.
Depreciation and Amortization. Nitrogen fertilizer depreciation and
amortization increased $14.6 million to $15.0 million in 2002 from $0.4 million
in 2001. This increase in depreciation and amortization was directly
attributable to the capitalization of the fixed assets of the nitrogen
fertilizer plant, which were previously reported as an operating lease. In
February 2002, Farmland prepaid the outstanding balance of the operating lease,
which financed the construction of our nitrogen fertilizer plant. This increase
was offset by the impairment charge of $230.8 million later in 2002.
Operating Income. Nitrogen fertilizer operating income decreased
$213.6 million in 2002 from an operating loss of $52.5 million in 2001.
Excluding the reorganization expense associated with property, plant and
equipment in 2002 of $230.8 million, nitrogen fertilizer operating income
increased by $17.2 million in 2002 versus 2001. This increase was principally
the result of improved on-stream factors at the nitrogen fertilizer plant offset
by an overall reduction in nitrogen fertilizer prices in 2002 as compared to
2001.
Consolidated Results of Operations
Selling, General and Administrative Expenses. Consolidated selling, general
and administrative expenses for the period from March 2, 2004 through
September 30, 2004 were $8.4 million. These expenses represent the cost
associated with corporate governance, legal expenses, treasury, accounting,
marketing, human resources and maintaining corporate offices in New York and
Kansas City. During the predecessor periods, Farmland allocated corporate
overhead based on internal needs, which may not be representative of the actual
cost to operate the businesses. In addition, during the nine months ended
September 2003, Farmland incurred a number of charges related to the bankruptcy.
As a result of the charges and issues related to allocations, a comparison of
selling, general and administrative expenses for the nine months ended
September 2004 to the nine months ended 2003 is not meaningful.
Interest Expense. For the Predecessor periods, all interest expense prior
to May 31, 2002, and interest on secured borrowings subsequent to May 31, 2002
were allocated to the Predecessor by Farmland based on identifiable net assets
of each of Farmland's divisions. Under bankruptcy law, payment of interest on
Farmland's unsecured debt was stayed beginning May 31, 2002. Accordingly,
Farmland did not allocate any interest on its unsecured borrowings to the
Predecessor since May 31, 2002. Interest expense in the Successor period
represents the interest recognized on our long-term borrowings and amortization
of deferred financing costs associated with these borrowings.
Provision for Income Taxes. The Predecessor was not a separate legal
entity, and its operating results were included with the operating results of
Farmland and its subsidiaries in filing consolidated
53
federal and state income tax returns. Farmland did not allocate income taxes to
its divisions. As a result, the Predecessor periods do not reflect any provision
for income taxes.
Nine months ended September 30, 2004 compared to nine months ended
September 30, 2003.
Net Income. Net income increased $35.8 million in the first nine months of
2004 to $51.0 million from $15.3 million for the comparable period in 2003. The
increase was due to both the change in ownership and improved results in both
the petroleum business and the nitrogen fertilizer business as discussed in
greater detail for each business above.
Year ended December 31, 2003 compared to year ended December 31, 2002.
Other Income (Expense). Other expense was $0.2 million in 2003 compared to
$4.1 million in 2002, primarily relating to changes in value of the
Predecessor's derivative contracts.
Reorganization Expense; Impairment of Property Plant and
Equipment. Reorganization expense represents the impairment of long-lived
assets in accordance with the SFAS No. 144 implemented by Farmland.
Recoverability of assets to be held and used is measured by comparison of the
carrying amount of an asset to the estimated undiscounted future net cash flows
expected to be generated by the asset. In 2003, Farmland determined the carrying
amount of the assets of the petroleum and nitrogen fertilizer business exceeded
the expected value to be received in a bankruptcy approved sale. As a result, an
impairment charge of $9.6 million was recognized.
Net Income. Net income increased $493.6 million in 2003 to $27.9 million
from a loss of $465.7 million in 2002. The asset impairment described above
accounted for $365.4 million of the improvement. In addition, both facilities
benefited from improved volumes, the nitrogen fertilizer market improved
dramatically, the refined fuel price in the region improved and crude
differentials improved.
Year ended December 31, 2002 compared to year ended December 31, 2001.
Selling, General and Administrative Expenses. Selling, general and
administrative expenses decreased by $8.4 million, or 34%, to $16.4 million in
2002 from $24.8 million in 2001. The decrease was principally the result of the
dissolution of the Country Energy joint venture and the elimination of the
Country Energy administrative fee, which was $9.1 million in 2001.
Equity in Loss of Joint Venture. In 2001, the Predecessor recognized
$2.8 million in expenses related to its share of Country Energy's losses.
Reorganization Expense; Impairment of Property, Plant, and Equipment. The
reorganization expense represents the impairment of long-lived assets in
accordance with the SFAS No. 144 implemented by Farmland. Recoverability of
assets to be held and used is measured by comparison of the carrying amount of
an asset to the estimated undiscounted future net cash flows expected to be
generated by the asset. In 2002, it was determined that the carrying amount of
the assets of our petroleum and nitrogen fertilizer businesses exceeded their
respective estimated future undiscounted net cash flows and, as a result, an
impairment charge of $375.1 million was recognized.
Gain on Sale of Joint Venture Interest. Results in 2001 reflect the gain on
the sale of Farmland's interest in Country Energy to CHS, Inc. in November 2001
for approximately $18.0 million.
Other Income (Expense). Other income (expense) decreased $5.6 million in
2002 to ($4.1) million, compared to $1.6 million of income in 2001, primarily
related to the changes in value of the Predecessor's derivative contracts.
54
Net Income. Net income decreased $446.3 million in 2002 to a loss of
$465.7 million from a loss of $19.4 million in 2001. The asset impairment
described above accounted for $375.1 million of the decline. In addition, the
crack spreads narrowed and the nitrogen fertilizer business experienced
significantly lower prices.
Critical Accounting Policies
The preparation of financial statements in accordance with GAAP requires
management to make estimates and assumptions that affect the amounts reported in
the financial statements and accompanying notes. Actual results could differ
from those estimates. The following summary provides further information about
our critical accounting policies and should be read in conjunction with the
Notes to Financial Statements, which summarizes our significant accounting
policies.
Major Maintenance Turnarounds. The direct-expense method of accounting is
used for planned major maintenance activities. Maintenance costs are recognized
as expense as maintenance services are performed. During 2002, our refinery was
shut down for approximately six weeks in order to perform planned major
maintenance. Costs associated with this shutdown are included in costs of goods
sold in 2002 and were approximately $17.0 million. Most refiners accrue for
future planned turnarounds or defer the costs associated with turnarounds, which
lessens the earnings impact in the year of the turnaround. As a result,
comparison of our results to other refineries must take into account the impact
of the difference in accounting for turnaround highlighted above. We expect that
our next major maintenance will occur in 2006 at an estimated cost of
approximately $12.0 million and $1.3 million for the petroleum business and
nitrogen fertilizer business, respectively.
Impairment of Long-Lived Assets. During 2001, Farmland accounted for
long-lived assets in accordance with Statement of Financial Accounting Standards
No. 121, Accounting for Impairment of Long-Lived Assets and for Long-Lived
Assets to be Disposed of (SFAS 121). SFAS 121 was superseded by SFAS 144,
Accounting for the Impairment or Disposal of Long-Lived Assets (SFAS 144), which
was adopted by Farmland effective January 1, 2002.
In accordance with both SFAS No. 144 and SFAS No. 121, Farmland reviewed its
long-lived assets for impairment whenever events or changes in circumstances
indicated that the carrying amount of an asset may not be recoverable.
Recoverability of assets to be held and used is measured by a comparison of the
carrying amount of an asset to estimate undiscounted future net cash flows
expected to be generated by the asset. If the carrying amount of an asset
exceeded its estimated future undiscounted net cash flows, an impairment charge
was recognized by the amount by which the carrying amount of the assets exceeded
the fair value of the assets. Assets to be disposed of are reported at the lower
of the carrying value or fair value less cost to sell, and are no longer
depreciated.
In its Plan of Reorganization, Farmland stated, among other things, its
intent to dispose of its petroleum and nitrogen assets. Despite this stated
intent, these assets were not classified as held for sale under SFAS 144 until
October 7, 2003 because, ultimately, any disposition must be approved by the
Court and the Court did not approve such disposition until that date. Since
Farmland determined that it was more likely than not that its assets would be
disposed of, those assets were tested for impairment in 2002 pursuant to
SFAS 144, using projected undiscounted net cash flows based on Farmland's best
assumptions regarding the use and eventual disposition of those assets. Based on
the tests, assumptions and determinations as of the impairment testing date, the
assets were determined to be impaired. Farmland's best estimate at December 31,
2002 was that the carrying value of these assets exceeded the fair value
expected to be received on disposition of these assets by approximately
$375.1million. Accordingly, an impairment charge was recognized for such amount
in 2002. The ultimate proceeds from disposition of these assets resulted from a
bidding and auction process conducted in the bankruptcy proceedings. This
process led to an additional impairment charge of $9.6 million recorded in
September of 2003 when Farmland management's estimate was refined to reflect
additional current information regarding the ultimate disposition of these
assets.
55
Derivative Commodity Instruments. We use futures contracts, options, and
forward contracts primarily to reduce our exposure to changes in crude oil
prices and to provide economic hedges of inventory positions and forecasted
transactions. Although management considers these derivatives economic hedges,
these instruments have not been designated as hedges for accounting purposes and
are recorded at fair value in the balance sheet. Accordingly, changes in the
fair value of these derivative instruments are recorded into earnings as a
component of other income (expense) in the period of change. Our petroleum
business recorded net gains from derivative instruments of $0.9 million and
$0.3 million in other income (expense) for the 212 days ended September 30, 2004
and the year ended December 31, 2003.
Environmental Expenditure. Liabilities related to remediation of
contaminated properties are recognized when the related costs are considered
probable and can be reasonably estimated. Estimates of these costs are based
upon currently available facts, existing technology, site-specific costs, and
currently enacted laws and regulations. In reporting environmental liabilities,
no offset is made for potential recoveries. All liabilities are monitored and
adjusted as new facts or changes in law or technology occur. Environmental
expenditures are capitalized when such costs provide future economic benefits.
Changes in laws, regulations or assumptions used in estimating these costs could
have a material impact to our financial statements. The amount recorded for
environmental obligations at September 30, 2004 totaled $9.8 million.
Purchase Price Accounting and Allocation. The transaction described in
Note 1 to our financial statements related to the purchase of our assets from
Farmland has been accounted for using the purchase method of accounting as of
March 3, 2004. The allocation of the purchase price to the net assets acquired
has been performed in accordance with SFAS 141, Business Combinations. In
connection with the allocation of the purchase price, management used estimates
and assumptions to determine the fair value of the assets acquired and
liabilities assumed. Changes in these assumptions and estimates such as discount
rates and future cash flows used in the appraisal process could have a material
impact on how the purchase price was allocated at the date of acquisition.
Valuation of Our Equity. In connection with the Transaction, Coffeyville
Group Holdings, LLC issued preferred and common units. The preferred units
required a preference distribution of $63.2 million plus a preferred yield prior
to any distribution to the residual interests, which was split 85% to the
preferred and 15% to the common. Management determined the fair value of the
equity based on the amount paid to Farmland in the Chapter 11 auction process
less the amount borrowed. The fair value allocated to the preferred and common
was estimated based on the estimated relative fair values on March 3, 2004.
Changes in the assumptions used and the use of a different valuation technique
could have a material impact on the financial statements.
Liquidity and Capital Resources
Our principal sources of liquidity are from cash and cash equivalents, cash
from operations and borrowings under our senior secured credit agreement
Cash Balance and Other Liquidity
As of September 30, 2004, we had cash, cash equivalents and short-term
investments of $13.0 million. Prior to March 3, 2004, Farmland centralized its
cash management operations and did not segregate cash balances by business. We
believe our September 30, 2004 cash levels as well as the availability of
borrowings under our revolving credit agreement are adequate to fund our cash
requirements for the foreseeable future. As of September 30, 2004, we had
available up to $74.5 million under our revolving credit facility, which is
discussed in more detail below.
56
Debt
Our current debt structure is used to fund our business operations, and our
revolving credit facility is a source of liquidity. At September 30, 2004, our
long-term debt, including current maturities, totaled $149.3 million. Debt
outstanding under the term loan, and the revolving credit facility bore interest
at variable rates. We also had capital lease obligations of $1.2 million at
September 30, 2004.
On May 10, 2004, we completed a refinancing of substantially all of our
outstanding long-term debt with a new $150.0 million senior secured term loan
due in 2010 and a senior secured $75.0 million revolving credit facility which
terminates in 2009. We used the net proceeds from the term loan to:
º •
º repay $34.3 million for all outstanding amounts under our
then-existing revolving credit facility and term loan, including
accrued and unpaid interest, fees and a $1.1 million make-whole
premium to the previous lenders;
º •
º pay $9.3 million in costs associated with the refinancing that were
capitalized and that will be amortized over the term of the new debt;
º •
º fund $6.4 million of cash into our operating account and a debt
service account; and
º •
º distribute $100.0 million to shareholders for earnings distributions,
preferred returns and return of capital.
The senior secured revolving credit facility provides for direct cash
borrowings and the issuance of letters of credit up to the lesser of: (i) the
borrowing base calculated with respect to our cash and eligible cash
equivalents, eligible accounts receivables and eligible inventories, and
(ii) $75.0 million. Letters of credit issued under the revolving loans are
subject to an issuance sub-limit of $30.0 million. After May 2006, the issuance
sub-limit will increase to $50 million. As of September 30, 2004, we had
$3.1 million of standby letters of credit issued and outstanding under this
facility. Borrowings under the revolving loans are secured by a first priority
security interest in our accounts receivable and inventory and contract rights,
chattel paper, instruments, documents, deposit accounts and intangible assets
related thereto. We had $71.9 million of available borrowing capacity at
September 30, 2004 under the credit agreement. The $75.0 million senior secured
revolving loans bear interest at either LIBOR plus 3.00%, or prime rate plus
1.00% subject to a 0.5% per annum unused capacity commitment fee. We had
outstanding borrowings of $72,000 at September 30, 2004 under the senior secured
facility.
The senior secured term loan is subject to quarterly principal amortization
of payments of approximately $0.4 million that began on June 30, 2004 with the
balance due at maturity in 2010. Mandatory prepayments are required to be made
with the proceeds of certain asset sales and casualty events subject, in some
instances, to reinvestment provisions. In addition, the senior secured credit
facility also requires prepayment of any outstanding balance subject to excess
cash flow provisions as determined under the credit agreement. The senior
secured term loan is secured by a first priority lien on all our property, plant
and equipment as well as a second priority lien on the primary collateral of the
senior secured revolving loans. The senior secured term loan bears interest at
LIBOR plus 5.00%, or at the prime rate plus 4.00%. The interest rate on the term
loan at September 30, 2004 was 6.95%.
Under the credit agreement and subject to a prepayment penalty, we may
prepay all or part of the senior secured term loans. The prepayment penalty is
calculated as a declining percentage of the total senior secured term debt or
senior secured revolving commitment retired. The prepayment penalty is dependent
upon the actual date the prepayment occurs. No prepayment penalties exist for
the senior revolving loans and the senior secured term loan after May 10, 2006
and May 10, 2007, respectively.
The credit agreement contains customary covenants and events of default.
Accordingly, this agreement imposes significant operating and financial
restrictions on us. These restrictions, among other things, limit incurrence of
additional indebtedness, payment of dividends, significant investments
57
and sales of assets. These limitations are subject to a number of important
qualifications and exceptions.
The credit agreement requires us to maintain specified financial ratios as
follows:
º •
º Minimum Fixed Charge Ratio of 1.25 to 1.00;
º •
º Maximum Leverage Ratio of 3.50 to 1.00; and
º •
º Minimum Interest Coverage Ratio of 2.00 to 1.00.
In addition, the credit agreement limits the amount of capital spending (as
defined therein) to $35.0 million, $45.0 million and $60.0 million in 2004, 2005
and 2006 respectively and $30.0 million for each year after 2006. The provision
limiting this capital spending allows for flexibility in the timing of the
expenditure.
For all calendar years through and including 2007, subject to meeting
certain employment levels which we currently exceed, we are abated from any ad
valorem real estate and personal property tax liability on our nitrogen
fertilizer assets that were part of the original construction of the facility.
Beginning in 2008, we will be subject to ad valorem real estate and personal
property taxes on the facility at the then applicable rate on the assessed value
to be determined by the county appraiser. The actual amount cannot be determined
until an assessed value for the assets is established.
Capital Spending
We divide our capital spending needs into two categories, non-discretionary,
which is either capitalized or expensed, and discretionary, which is
capitalized. Non-discretionary capital spending, such as for planned turnarounds
and other maintenance, is required to maintain safe and reliable operations or
to comply with environmental, health and safety regulations. We estimate that
our total non-discretionary capital spending needs, including turnaround
expenditures, will be approximately $56 million in 2005, approximately
$71 million in 2006 and approximately $84 million in the aggregate over the
three-year period beginning 2007. These estimates include the capital costs
necessary to comply with environmental regulations, including Tier II gasoline
standards and on-road diesel regulations.
We estimate that compliance with the Tier II gasoline and on-road diesel
standards will require us to spend approximately $34 million in 2005,
approximately $43 million in 2006, approximately $20 million during 2008 and
2009 and an additional $15 million thereafter. See "Business-Environmental
Matters-The Clean Air Act-Fuel Regulations-Tier II, Low Sulfur Fuels."
The following table sets forth our estimate of our non-discretionary capital
spending for the years presented:
Cumulative
2005 2006 2007 2008 2009 Through 2009
(in millions)
Environmental capital needs $ 36.5 $ 45.8 $ 3.0 $ 13.2 $ 33.0 $ 131.4
Sustaining capital needs 19.7 11.6 11.3 11.6 10.0 64.2
Planned turnaround capital needs - 13.3 - 1.6 - 14.9
Total estimated capital needs $ 56.2 $ 70.6 $ 14.2 $ 26.4 $ 43.0 $ 210.4
We undertake capital spending based on the expected return on incremental
capital employed. Discretionary capital projects generally involve an expansion
of existing capacity, improvement in product yields, and/or a reduction in
operating costs. As of December 31, 2004, we had committed approximately
$13.7 million towards discretionary capital spending in 2005.
58
Cash Flows
Operating Activities
Nine months ended September 30, 2004 compared to nine months ending
September 30, 2003.
Operating activities generated $98.0 million in the first nine months of
2004 versus $35.4 million for the comparable period in 2003. The $62.6 million
improvement in operating cash flow was due to a $36.3 million improvement in net
income and favorable changes in working capital. For purposes of this cash flow
discussion, we define working capital as accounts receivable, inventories,
prepaids and other assets less accounts payable, other current liabilities and
deferred revenue. Changes in components of working capital generated
$32.3 million of cash flow in the first nine months of 2004, compared to cash
generated in the comparable period of 2003 of $0.8 million, an increase of
$31.5 million. In the first nine months of 2004, accounts receivable increased
$11.2 million and inventory increased by $13.2 million. The resulting effect on
operating cash flows was offset by an increase in accounts payable of
$26.1 million due to price increases and a returning to normal payment terms
with some vendors, an increase in accrued liabilities of $9.8 million and a
$17.4 million decrease in prepaids and other. The primary source for the
$35.4 million in cash flow generated in the first nine months of 2003 was
$32.0 million of cash flow generated from net income. This amount was adjusted
for the $9.6 million impairment of property, plant and equipment charge
resulting from the sales price of the petroleum assets and a $7.0 million
increase in a long-term environmental accrual.
Year ended December 31, 2003 compared to year ended December 31, 2002.
Operating activities generated $20.3 million in 2003 compared to a use of
cash of $1.7 million in 2002. The $22.0 million improvement in cash flows was
due to a $128.2 million improvement in income from operations, as adjusted for
the impairment charges of $375.1 million in 2002 and $9.6 million in 2003,
offset by unfavorable changes in working capital. Changes in components of
working capital used cash of $28.5 million in 2003, compared to $52.6 million of
cash provided in 2002, an increase of $81.1 million. In 2003, accounts
receivable increased by $25.3 million due to higher average selling prices and
an increase in volume from the nitrogen fertilizer segment, while prepaid and
other current assets increased by $23.8 million as a result of both increases in
the price and volume of prepaid crude oil. The resulting effect on operating
cash flows was offset by an increase in accounts payable of $8.3 million due to
price increases and returning to normal payment terms with some vendors as time
had elapsed from the bankruptcy of Farmland and a $10.4 million dollar decrease
in inventory primarily as a result of lower raw material prices. The primary
reason for the $52.6 million source of cash in components of working capital for
2002 was a $56.2 million increase in accounts payable as result of the
bankruptcy filing of Farmland and the suspension of terms by nearly all of
Farmland's raw material suppliers.
Year ended December 31, 2002 compared to year ended December 31, 2001.
Operating activities produced a cash outflow of $1.7 million in 2002
compared operating cash flow generation of $65.4 million in 2001. The decrease
of $67.1 million was primarily due to two substantial events. In 2002, Farmland
filed bankruptcy, which resulted in an increase in the accounts payable of
$56.2 million due to the suspension of paying pre-petition liabilities subject
to compromise. In 2001, working capital was impacted by the dissolution of
Cooperative Refining, LLC on December 31, 2000. On that date, Farmland purchased
excess inventory from Cooperative Refining of $59.7 million resulting in an
increase in the working capital position as of December 31, 2000. The excessive
working capital position was liquidated in 2001, resulting in cash generation
from working capital.
59
Investing Activities
Nine months ended September 30 2004 compared to nine months ended
September 30, 2003.
Net cash used in investing activities for the nine month period ending
September 30, 2004, was $127.1 million as compared to $0.8 million for the
comparable period of 2003. This difference is directly attributable to an
increase in capital expenditures and the acquisition of the Farmland assets
during the comparable periods. For the nine months ending September 30, 2003 and
throughout its bankruptcy, Farmland's management maintained capital expenditures
on the petroleum and nitrogen assets to a minimum.
Year ended December 31, 2003 compared to years ended December 31, 2002 and
2001.
Net cash from investing activities was a use of $0.8 million in 2003
compared to a use of $272.4 million in 2002 and a source of $17.9 million in
2001. Capital expenditures accounted for $0.8 million, $12.2 million and
$8.2 million, in 2003, 2002 and 2001, respectively. These capital expenditures
were related to operational improvements, maintenance capital, safety and
environmental related projects. In 2002, an additional $260.3 million was spent
acquiring the nitrogen fertilizer complex that had previously been financed
under an operating lease arrangement. In 2001, asset sales related to the sale
of Farmland's interest in the Country Energy, LLC and Farmland's interest in a
propane business generated cash proceeds of $18.9 million and $7.2 million,
respectively.
Financing Activities
Nine months ending September 30, 2004 compared to the nine months ended
September 30, 2003.
Net cash used by financing activities in the nine month period ending
September 30, 2004 was $42.0 million. The uses of cash for financing activities
over this period related primarily to the prepayment of the $22.7 million term
loan, a $100.0 million cash distribution to the holders of the preferred and
common units issued by Coffeyville Group Holdings, LLC, $16.2 million in
financing costs and $53.2 million in net divisional equity distribution to
Farmland. We used cash from operations and a new term loan for $150.0 million
completed on May 10, 2004 to finance the aforementioned cash outflows in 2004.
For the nine month period ending September 30, 2003, we used $34.6 million in
cash to fund a net divisional equity distribution.
Year ended December 31, 2003 compared to years ended December 31, 2002 and
2001.
For the 2003, 2002 and 2001, the petroleum and nitrogen fertilizer
businesses were financed by the parent company. All cash generated or used was
immediately disbursed to the parent, Farmland, in the form of a net divisional
equity distribution or contribution. Neither the petroleum business nor the
fertilizer business had incremental access to capital beyond that available from
Farmland.
Capital and Commercial Commitments
In addition to long-term debt, we are required to make payments relating to
various types of obligations. The following table summarizes our minimum
payments as of September 30, 2004 relating to long-term debt and unconditional
purchase obligations and operating leases for the quarter ending December 31,
2004, the five-year period following December 31, 2004 and thereafter.
Our ability to make payments on and to refinance our indebtedness and to
fund planned capital expenditures will depend on our ability to generate cash
flow in the future. This, to a certain extent, is subject to general economic
financial, competitive, legislative, regulatory and other factors that are
beyond our control. Based on our current level of operations, we believe our
cash flow from
60
operations, available cash and available borrowings under our revolving credit
facility will be adequate to meet our future liquidity needs for the foreseeable
future.
Payments Due by Period
Quarter
Ending
December 31,
Total 2004 2005 2006 2007 2008 2009 Thereafter
(in millions)
Contractual Obligations
Long-term debt (1) $ 149.3 $ 0.4 $ 1.5 $ 1.5 $ 1.5 $ 1.5 $ 1.5 $ 141.4
Capital lease 1.2 1.2 - - - - - -
Operating leases (2) 16.3 0.7 3.3 3.1 2.9 2.9 1.9 1.5
Unconditional purchase
obligations (3) 176.6 1.4 12.8 12.8 12.8 8.8 8.8 119.1
Other long-term
liabilities included in
the
balance sheet (4) 2.1 0.3 1.0 0.8 - - - -
Environmental liabilities
(5) 15.6 0.8 0.8 0.6 0.5 2.6 3.6 6.7
Interest payments (6) 56.6 2.6 10.3 10.3 10.1 10.0 9.9 3.4
Total $ 417.7 $ 7.4 $ 29.7 $ 29.1 $ 27.8 $ 25.8 $ 25.7 $ 272.2
Other Commercial Commitments
Standby letters of credit
(7) $ 3.1 $ - $ 3.1 $ - $ - $ - $ - $ -
º (1)
º Long-term debt amortization is based on the contractual terms of our credit
agreement.
º (2)
º We lease various facilities and equipment, primarily railcars for our
nitrogen fertilizer business under noncancelable operating leases for
various periods.
º (3)
º The amount includes (1) commitments under a pipeline construction,
operation and transportation agreement related to the delivery of crude oil
from Cushing, Oklahoma to our Broom Station pipeline system near Caney,
Kansas and (2) commitments under an electric supply agreement.
º (4)
º The amount includes contractual payments due to Farmland related to
rejection damages for the electricity contract with the City of
Coffeyville.
º (5)
º Environmental liabilities represents our estimated payments required by
Federal and/or state environmental agencies related to sites in Coffeyville
and Phillipsburg, Kansas.
º (6)
º Interest payments are based on interest rate in effect at September 30,
2004 and assume contractual amortization payments.
º (7)
º Standby letters of credit include our obligations under $3.1 million of
letters of credit issued in connection with environmental liabilities.
Our business may not generate sufficient cash flow from operations, and
future borrowings may not be available to us under our revolving credit facility
in an amount sufficient to enable us to pay our indebtedness or to fund our
other liquidity needs. We may need to refinance all or a portion of our
indebtedness on or before maturity. We may not be able to refinance any of our
indebtedness on commercially reasonable terms or at all.
Off-Balance Sheet Arrangements
As of September 30, 2004, we had several operating lease agreements with
payments due on a monthly, quarterly or annual basis. The primary assets
financed under these agreements were railcars utilized in the delivery of
finished products for the nitrogen fertilizer business. For the period ending
September 30, 2004, we had approximately 590 railcars subject to three separate
lease agreements.
61
Quantitative and Qualitative Disclosures About Market Risk
The risk inherent in our market risk sensitive instruments and positions is
the potential loss from adverse changes in commodity prices and interest rates.
None of our market risk sensitive instruments are held for trading.
Commodity Risk
Impact of Changing Prices. Our revenues and cash flows, as well as
estimates of future cash flows, are very sensitive to changes in energy prices.
Major shifts in the cost of crude oil and the price of refined products and
natural gas can result in large changes in the operating margin from refining
operations. These prices also determine the carrying value of our refinery's
inventories.
Our revenues, cash flows and estimates of future cash flows related to the
fertilizer business are sensitive to changes in nitrogen fertilizer prices,
which have shown strong correlation to natural gas prices.
Price Risk Management Activities. At times, we enter into commodity
derivative contracts to manage our price exposure to our inventory positions
that are in excess of our base level of operating inventories, to fix margins on
certain future production and fix differentials on crude oil. The commodity
derivative contracts we use may take the form of futures contracts or price
swaps and are entered into with reputable counterparties. We account for our
commodity derivative contracts under mark-to-market accounting, and gains or
losses on commodity derivative are recognized in other (income) expense in the
period incurred.
At September 30, 2004, we had the following open commodity derivative
contracts whose unrealized gains or losses are included in other (income)
expense in the consolidated statements of operations:
º •
º Derivative contracts on 80,000 barrels of heating oil crack spreads,
the price spread between crude oil and heating oil, to fix the margin
on forecasted sales in October and November 2004. These open contracts
had total unrealized net losses at September 30, 2004 of approximately
$82,000.
º •
º Derivative contracts on 870,000 barrels of unleaded gasoline crack
spreads, the price spread between crude oil and unleaded gasoline, to
fix the margin on forecasted sales in October, November and
December 2004. These open contracts had total unrealized net gains at
September 30, 2004 of approximately $298,000.
As of September 30, 2004, a $1.00 change in quoted futures price for the
crack spreads described above would result in a $950,000 change to the fair
market value of the derivative commodity position and the same change in
operating income.
During the nine months ended September 30, 2004 we utilized additional
derivative contracts on unleaded gasoline crack spreads and heating oil crack
spreads to fix the refining margin to the NYMEX spread between light crude oil
contract price and unleaded gasoline and heating oil price for a portion of
forecasted refined products production. During the nine months ended
September 30, 2004, we recorded realized losses of nearly $1.0 million (included
in other income (expense)) on these contracts. These losses are in addition to
the unrealized gains and losses on open positions described above.
Interest Rate Risk
Borrowings under our term loan and revolving credit facility bear a current
market rate of interest such that we are subject to interest rate risk on these
borrowings. As of September 30, 2004, a 100 basis point change in interest rates
on our floating rate loans, which totaled $149.3 million, would result in a
$1.5 million change in pretax income on an annual basis.
62
INDUSTRY OVERVIEW
Oil Refining Industry
Oil refining is the process of separating the wide spectrum of hydrocarbons
present in crude oil, and in certain processes, modifying the constituent
molecular structures, for the purpose of converting them into marketable
finished petroleum products optimized for specific end uses. According to the
Energy Information Association, as of January 1, 2004, there were 147 oil
refineries operating in the U.S., with the 16 smallest each having a capacity
under 13,000 bpd, and the 12 largest having capacities ranging from 300,000 to
550,000 bpd.
The current refining industry is characterized by capacity shortage, high
utilization rates, and reliance on imported products to meet the demand for
finished petroleum products. The last major oil refinery in the U.S. was built
in 1976. Over the past three decades, more than 150 generally small and
unsophisticated refineries that were unable to process heavy crude into a
marketable product mix were permanently closed down. According to the Energy
Information Association, while domestic refining capacity has decreased 1.5%,
from 6.5 billion barrels in 1983 to 6.4 billion barrels in 2003, domestic demand
for refined fuels has increased 30.4%, from 5.6 billion barrels to 7.3 billion
barrels over the same period.
The following overview explains the basics of the refining process and
certain factors that influence the refining industry.
Refining Basics
Refineries are uniquely designed to process and convert crude oils having a
specific range of characteristics into the products required by the market of
interest. In general, the different process units inside a refinery perform one
of three functions:
Distillation: Separating the many types of hydrocarbons present in crude
oil into distinct hydrocarbon fractions with specific boiling point ranges, such
as gasoline, diesel oil and heavier hydrocarbons. Atmospheric and vacuum
distillation are the primary distillation processes;
Conversion: Chemically changing the various hydrocarbon fractions into more
desirable products by (a) rearranging the molecular structure through catalytic
reforming, (b) creating larger, useable fractions from highly volatile light
components through alkylation and isomerization, and/or (c) catalytically or
thermally breaking down low value, very high molecular weight fractions into
lighter gasoline and distillate range materials through fluid catalytic cracking
and delayed coking; and
Treating: Removing unwanted contaminant elements and compounds such as
sulfur, nitrogen, metals, and aromatics, typically via hydrotreating and
contaminant recovery.
Each step in the refining process is designed to maximize the product
realization for each level of the feedstocks, particularly the crude oil,
processed through the refinery.
Typically, the first step in the refining process is to remove any chloride
and solid impurities from the crude oil that would prove to be destructive to
the downstream refining processes. This is accomplished in a water washing
process called desalting.
The desalted crude oil is then processed through an atmospheric distillation
unit where it is separated into various components based on the boiling ranges.
Two principal side streams are withdrawn, a naphtha fraction whose boiling point
range is similar to that of gasoline and the next heavier fraction, a middle
distillate cut whose boiling point is similar to those of diesel oil and heating
oil. The temperature at the bottom of the atmospheric distillation tower is held
at approximately 650 degrees Fahrenheit since the non volatilized tower bottoms
would thermally degrade at temperatures
63
above that level. Atmospheric distillation tower bottoms, generally referred to
as atmospheric residuum or long residuum, is that part of the crude oil that is
not volatile at 650 degrees Fahrenheit. Atmospheric residuum still contains
valuable fractions, which are processed through a vacuum distillation tower,
which allows, by virtue of the vacuum conditions, the useable hydrocarbons to
distill off at actual temperatures that do not exceed the degradation point, but
simulate the theoretical separation that would occur at a 1050 degree boiling
point. The principal side stream is a vacuum gas oil (VGO) that becomes further
upgraded in the refinery as it is charged to the fluid catalytic cracking unit.
The non-volatilized bottoms of the vacuum unit are generally referred to as
vacuum tower bottoms (VTBs) or asphaltic residuum.
Our Refinery Configuration
[[Image Removed: GRAPHIC]]
The next step in the refining process is to convert the major hydrocarbon
fractions into distinct and marketable products. These major fractions include
the naphtha and mid-distillate streams from the atmospheric distillation unit,
and the VGO and VTBs fractions from the vacuum distillation unit. The VGO stream
is processed in a fluid catalytic cracker (FCC) where it is chemically altered
to produce fractions that boil in the mid-distillate and gasoline boiling range.
Some of the material produced in the FCC is not of adequate quality to directly
produce gasoline and mid-distillate fuels, and cannot be recycled, so these
intermediates are withdrawn from the FCC and fed to the delayed coker for
further upgrading to a finished product. The VTBs, a very heavy tar, is
processed through a delayed coking unit where it is exposed to high temperature
and moderate pressure for long time periods. During that process, the vacuum
residuum is thermally fractionated into naphtha, distillate and gas oil streams
that get further upgraded to finished products, and to a solid coke byproduct.
The most important conversion units in this refinery are the delayed coking unit
and the fluid catalytic cracking unit, which combine to convert heavy crude oil
into gasoline and diesel oil range products.
The light end products from the delayed coking unit and FCC are upgraded
into high octane, low volatility, low aromaticity blend stocks in an alkylation
unit catalyzed with hydrofluoric acid.
The light portion of the naphtha is separated and processed in an
isomerization unit. In this unit the straight chain molecules are converted into
branched chain molecules that have more valuable blending properties.
64
Both the virgin heavy naphthas that are produced directly from the crude oil
as well as the cracked naphthas produced by the coker and the FCC are upgraded
to gasoline in the catalytic reformer where molecular structure is substantially
rearranged, creating octane value in the gasoline pool, and generating the
hydrogen needed in the refinery to reduce the sulfur content of the product
pool.
Refinery Products
Major refinery products include:
Gasoline. The most significant refinery product is motor gasoline. The most
important product characteristics of gasoline include octane level (high levels
of which command a premium), vapor pressure and sulfur content. Various gasoline
blendstocks are blended to achieve specifications for regular and premium grades
in both summer and winter gasoline formulations. Refiners also produce different
grades of reformulated gasoline from time to time as required by their markets.
Reformulated gasolines are special blends containing oxygenates, which contain
ethers such as Methyl Tertiary Butyl Ether or, more frequently, ethyl alcohol.
These formulations are tailored to areas of the country with severe ozone
pollution.
Distillate Fuels. Distillates are diesel fuels and domestic heating oils.
The most important characteristic of diesel fuel is its cetane number,
analogous, but diametrically opposite to octane number in gasoline, and sulfur
content. As with gasoline, the market pays a premium for high cetane fuels, but
unlike gasoline, there is a two tier sulfur content market