COMPANY PROFILE
IMC, a
publicly traded Delaware corporation incorporated in 1987
,
is one of the worlds leading producers and distributors of crop nutrients to the domestic and international agricultural communities as well as one of the foremost manufacturers
and distributors of animal feed ingredients to the industry. The Company mines, processes and distributes potash in the United States (U.S.) and Canada and is the majority joint venture partner in IMC Phosphates Company (IMC Phosphates), a leading
producer, marketer and distributor of phosphate crop nutrients and animal feed ingredients. The Companys current operational structure consists of two continuing
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1
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All statements, other than statements of historical fact contained within this Form 10-K constitute "forward-looking statements" within the meaning of the Private
Securities Litigation Reform Act of 1995. In particular, forward-looking statements may include words such as "expect," "anticipate," "believe," "may," "should," "could" or "estimate." These statements involve certain risks and uncertainties that
may cause actual results to differ materially from expectations as of the date of this Form 10-K.
|
Factors that could cause actual results to differ materially from those expressed or implied by the forward-looking statements include, but are not
limited to, the following: general business and economic conditions and governmental policies affecting the agricultural industry in localities where the Company or its customers operate; weather conditions; the impact of competitive products;
pressure on prices realized by the Company for its products; constraints on supplies of raw materials used in manufacturing certain of the Company's products; capacity constraints limiting the production of certain products; difficulties or delays
in the development, production, testing and marketing of products; difficulties or delays in receiving, or increased costs of obtaining or satisfying conditions of, required governmental and regulatory approvals; market acceptance issues, including
the failure of products to generate anticipated sales levels; the effects of and change in trade, monetary, environmental and fiscal policies, laws and regulations; foreign exchange rates and fluctuations in those rates; the costs and effects of
legal proceedings, including environmental and administrative proceedings involving the Company; success in implementing the Company's various initiatives; the uncertain effects upon the global and domestic economies and financial markets of the
terrorist attacks in New York City and Washington, D.C. on September 11, 2001 and their aftermaths; and other risk factors reported from time to time in the Company's Securities and Exchange Commission reports. These factors are based upon the
Company's strategic plans and direction under its current Board of Directors and management. As described in Part I, Item 1, "Business," of this Annual Report on Form 10-K, the Company has entered into a business combination agreement with Cargill,
Incorporated. If the transactions contemplated thereby are consummated, the Company's business would be operated by a newly-formed public company going forward. The Board of Directors and management of the new public company may not be the same as
exists on the date hereof for the Company, and they may operate the business of the Company in a manner that differs from the Company's current operations. The factors listed above do not account for any such possible change in the Company's
operations.
-1-
business units corresponding to its major product lines as follows: IMC PhosFeed (PhosFeed), which
represents the phosphates and feed ingredients businesses, and IMC Potash (Potash). IMCs continuing operations are located in North America. As a result of the planned divestiture of the remaining portions of IMC Chemicals, the financial
information for this business is reflected as discontinued operations. See Note 5 of Notes to Consolidated Financial Statements in Part II, Item 8, Financial Statements and Supplementary Data, of this 2003 10-K for information with
respect to the status of this divestiture.
Mergers
In December 2003, the Company and PLP jointly announced
that the Company was considering making a proposal to merge an affiliate of the Company with PLP, with each publicly held partnership unit in PLP being converted into the right to receive 0.2 shares of IMC common stock (PLP unit exchange). In
addition, the Company and PLP announced that Alpine Capital, L.P., Keystone, Inc. and The Anne T. and Robert M. Bass Foundation (collectively, the largest public holders of PLP units) had agreed to support such a transaction. PLP is a publicly
traded limited partnership in which the Company indirectly holds partnership units representing an approximate 51.6 percent interest and of which PRP-GP LLC (PRP), a wholly owned subsidiary of the Company, is administrative managing general partner
and holder of 51.58 percent of the equity. PLP is the minority (43.5 percent) owner of IMC Phosphates. In January 2004, the Company presented the PLP unit exchange to the Board of Directors of PRP. On March 1, 2004, IMC and PLP announced that the
Board of Directors of PRP had unanimously approved the PLP unit exchange, and recommended that unitholders vote to approve the PLP unit exchange. The merger agreement relating to the PLP unit exchange is expected to be signed shortly, following the
final approval by the Board of Directors of the Company. Such approval is expected in the near future. The PLP unit exchange will be subject to certain conditions, including among other things, necessary regulatory approvals, action by the
unitholders of PLP, and other conditions which are customary for transactions of this nature involving publicly traded companies. The PLP unit exchange is not conditioned on the consummation of the Companys combination with Cargill Crop
Nutrition referred to below. If the combination with Cargill Crop Nutrition is consummated, and the Companys common stock is converted into the right to receive common stock of the newly formed company, then each former publicly held PLP unit
will be converted into the right to receive 0.2 shares of common stock of the newly created company.
In January 2004, the Company signed a definitive agreement with Cargill, Incorporated (Cargill) to combine the Companys and Cargills Crop
Nutrition businesses to create a new, publicly traded company (Newco). The combination will be effected by the contribution by Cargill to Newco of equity interests in entities owning all or substantially all of the assets, liabilities and
obligations of the Cargill Crop Nutrition businesses, in exchange for the issuance by Newco of shares of common stock and Class B common stock to Cargill. In addition, as part of the combination, a wholly owned subsidiary of Newco will be merged
with and into the Company, with the Company surviving as a wholly owned subsidiary of Newco. In the merger, each outstanding share of the Companys common stock and preferred stock will be converted into one share of Newco common stock or
preferred stock, as applicable. Cargill will own approximately 66.5 percent of Newcos common stock and IMCs common stockholders will own approximately 33.5 percent of Newcos common stock. The combination is subject to regulatory
approval in the U.S., Brazil, Canada, China and several other countries; the approval of the Companys stockholders; the completion of the PLP unit exchange; and satisfaction of other customary closing conditions. Subject to completion of the
closing conditions contained in the definitive agreement, the Company anticipates the transaction will close in the summer of 2004.
Strategy
The Company considers itself one of the most efficient North American producers of concentrated phosphates, potash and animal feed ingredients. IMCs
business strategy focuses on maintaining and enhancing its leading positions through continuous process improvements, an ongoing focus on customer service, a leveraging of its efficient distribution and transportation networks, as well as growth of
its core businesses globally.
In 2000, IMC launched a
Continuous Improvement Program based on Six Sigma and other similar methodologies for process improvement, cost reduction and customer satisfaction. Six Sigma is an overall methodology for driving business improvement. The Six Sigma process uses
data and rigorous statistical analysis to identify and
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eliminate defects or sources of variation in a process or product, resulting in the potential for
improved efficiency, improved quality, and lower costs. Currently IMC has approximately 250 employees trained in the identification and implementation of Six Sigma projects. In 2003, pre-tax and pre-minority interest savings and other benefits from
these initiatives were approximately $12.9 million through the completion of 36 formal projects and nearly 60 smaller projects known as work-outs. Project examples include improved process control to reduce input usage, improved yields and
efficiencies, optimized logistics, improved product quality and reduced waste. While primarily manufacturing-focused, the Company has recently expanded the scope of Six Sigma to improving transactional business processes such as order management and
invoicing.
In early 2003, IMC announced a new multi-year
program called Business Process Improvement, including Operational Excellence. This broad-based re-engineering initiative was designed to increase efficiency, reduce costs and enhance revenues through redesign and optimization of core business
processes. The focus of Business Process Improvement has included productivity improvement and cost reduction in manufacturing; optimization of profitability in sales and marketing; efficiency improvements and cost reduction in freight and
warehousing; and cost reduction and cost avoidance in procurement. Implementation of this major Company-wide initiative is being completed through teams and other full-time resources that are dedicated to process redesign. Examples of specific
projects, associated with this initiative, are: (i) the design and implementation of a new preventive and predictive maintenance program to reduce unnecessary costs associated with emergency repairs in the operations; and (ii) an inventory
optimization program designed to reduce the working capital necessary to support customer service.
Through these and other strategies, IMC remains focused on enhancing its leadership position as one of the most efficient North American producers of
concentrated phosphates, potash and animal feed ingredients. By leveraging its large and expansive logistics network, IMC can provide efficient and reliable service to its customers around the world. Coupled with a strong focus on world-class
customer service and product quality, IMC builds relationships with its customers that provide a basis for continuous growth.
Market
The three major nutrients required for plant growth are nitrogen, phosphorus, mined as phosphate rock, and potassium, mined as potash. Nitrogen is an
essential element for most organic compounds in plants. Phosphorus plays a key role in the photosynthesis process. Potassium is an important regulator of plants physiological functions. These elements occur naturally in the soil but need to be
replaced as crops remove them from the soil. Currently, no viable substitutes exist to replace the role of phosphate, potash and nitrogen in the development and maintenance of high-yield crops.
The crop nutrients industry is a global market, in which supply and demand
are dictated by worldwide factors. Demand is driven largely by economic and political conditions, demographics as well as limits on arable land. Population growth increases demand for grain, as do increases in disposable income and associated
improvements in diet. Improved diets include greater consumption of livestock and poultry, which together account for approximately 70 percent of the annual consumption of grain. Combined with limits on arable land, an increasing demand for grain
drives demand for higher crop yields through greater application of crop nutrients. Supply of crop nutrients is generally driven by higher global commodity prices, weather conditions and local government policies.
Given the commodity nature of the crop nutrients business, industry players
compete largely on the basis of low cost and, to a lesser extent, differentiated customer service. Low cost is principally a function of the quality of the ore; the state of a companys mining and processing technology; the ability to
strategically source raw material inputs and the breadth and cost of transportation infrastructure.
PhosFeed
PhosFeed is a leading U.S. miner of phosphate rock, one of the primary raw materials used in the production of concentrated phosphates, as well as a
leading U.S. producer of concentrated phosphates. PhosFeed is also one of the worlds three largest producers and marketers of phosphate and potash based animal feed ingredients.
-3-
PhosFeeds mines and related operations are located in central Florida, while the facilities that
produce concentrated phosphates and animal feed ingredients are located in central Florida and Louisiana. Such mines, concentrates plants and related facilities are owned or leased principally by IMC Phosphates, a general partnership of which the
Company is the majority owner. IMC Phosphates MP Inc. (MP Co.) manages the operations of IMC Phosphates. MP Co. is a wholly owned subsidiary of the Company and PLP. The Companys total interest (through wholly owned subsidiaries and through the
Companys interest in PLP) in IMC Phosphates is approximately 78.9 percent. Sales, marketing, customer service, distribution, administrative and other functions are in some cases furnished to IMC Phosphates and MP Co. by the Company and its
subsidiaries that include IMC USA Holdings Inc., IMC USA Inc. LLC and IMC Global Operations Inc.
Although PhosFeed sells phosphate rock to other crop nutrient and animal feed ingredient manufacturers, it primarily uses phosphate rock internally.
Domestically, PhosFeed sells its concentrated phosphates to crop nutrient manufacturers, distributors and retailers. Virtually all of PhosFeeds export sales are marketed through the Phosphates Chemicals Export Association (PhosChem), a
Webb-Pomerene Act organization. PhosFeed also uses concentrated phosphates and potash internally for the production of animal feed ingredients, which are supplied to poultry and livestock markets in North America, Latin America and Asia. PhosFeed
operates in a highly competitive global market.
Potash
Potash mines, processes and
distributes potash in the U.S. and Canada. Potash has four mines in Canada within the province of Saskatchewan and two in the U.S. located in New Mexico and Michigan. Each mine location has related facilities which refine the mined potash. Such
mines and related facilities are owned or leased and operated principally through Company subsidiaries corresponding to the location of each mine: IMC Canada ULC for the mine (Belle Plaine) at Belle Plaine, Saskatchewan; IMC Esterhazy Canada Limited
Partnership for the two interconnected mines (Esterhazy) at Esterhazy, Saskatchewan; IMC Potash Colonsay ULC for the mine (Colonsay) at Colonsay, Saskatchewan; IMC Potash Carlsbad Inc. for the mine (Carlsbad) at Carlsbad, New Mexico; and IMC USA
Inc. LLC for the mine (Hersey) at Hersey, Michigan Sales, marketing, customer service, distribution, administrative and other services are in some cases performed for Potash by the Company and its subsidiaries that include IMC USA Holdings Inc., IMC
USA Inc. LLC and IMC Global Operations Inc.
Potashs
products are marketed worldwide to crop nutrient manufacturers, distributors and retailers and also are used in the manufacture of crop nutrients and animal feed ingredients as well as sold to customers for industrial use. Its North American sales
are made through the Companys sales force. The agricultural sales are primarily to independent accounts, cooperatives and leading regional fertilizer buyers while non-agricultural sales are primarily to large industrial accounts and the animal
feed industry. Additionally, potash is sold as an ingredient in icemelter as well as a water softener regenerant. Potashs exports from Canada, except to the U.S., are made through Canpotex Limited (Canpotex), an export association of
Saskatchewan potash producers. Potash is a commodity available from many sources and, consequently, the market is highly competitive.
Other
For information on the Companys operating segments and its operations by geographic area, see Note 18 of Notes to Consolidated Financial Statements
in Part II, Item 8, Financial Statements and Supplementary Data, of this 2003 10-K.
For additional information on the Companys business structure, see Notes 1 and 5 of Notes to Consolidated Financial Statements in Part II, Item 8,
Financial Statements and Supplementary Data, of this 2003 10-K.
IMCs annual reports on Form 10-K, quarterly reports on Form 10-Q, current reports on Form 8-K, and amendments thereto, filed with the SEC pursuant to Section 13(a) of the Securities Exchange Act of 1934, as
amended, and the rules and regulations thereunder are made available free of charge, on IMCs website, (www.imcglobal.com), as soon as reasonably practicable after IMC electronically files such material with, or furnishes it to, the SEC. The
information contained on IMCs website is not being incorporated herein.
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BUSINESS UNIT INFORMATION
The following discussion of business unit operations should be read in conjunction with the information contained in Part II, Item 7, Managements Discussion and Analysis of Financial Condition and Results of Operations, of
this 2003 10-K.
PhosFeed
Net sales for PhosFeed were $1,417.5 million, $1,338.1 million and $1,245.9
million for the years ended December 31, 2003, 2002 and 2001, respectively. PhosFeed is a leading U.S. miner of phosphate rock, one of the primary raw materials used in the production of concentrated phosphates, with approximately 18 million tons of
annual capacity. PhosFeed is also a leading U.S. producer of concentrated phosphates with an annual capacity of approximately four million tons of phosphoric acid (P
2
O
5
)
2
. PhosFeeds concentrated phosphate products are marketed worldwide to crop nutrient manufacturers, distributors and
retailers. Additionally, PhosFeed is one of the worlds three largest producers and marketers of phosphate and potash-based animal feed ingredients with a total annual capacity approaching one million tons.
PhosFeeds facilities, which produce concentrated phosphates and animal
feed phosphates, are located in central Florida and Louisiana. Its annual capacity represents approximately 30 percent of total U.S. concentrated phosphate production capacity and approximately nine percent of world capacity. The Florida
concentrated phosphate facilities consist of two plants: New Wales and South Pierce. The New Wales complex is the second largest concentrated phosphate plant in the world with an estimated annual capacity of nearly two million tons of phosphoric
acid (P
2
O
5
equivalent). New Wales primarily produces two forms of concentrated phosphates and four forms of animal feed phosphates. Diammonium phosphate (DAP) and monoammonium phosphate (MAP, both granular and
powdered) are the fertilizer derivatives, while Biofos
®
, Dynafos
®
, Monofos
®
and Multifos
®
are the animal feed derivatives. The South Pierce plant produces phosphoric acid, merchant grade phosphoric acid and granular triple superphosphate. Additionally, PhosFeed sources potassium raw
materials from the Companys respective production facilities and markets Dyna-K
®
,
Dyna-K White
®
and Dynamate
®
as potassium-based feed ingredients.
The Louisiana concentrated phosphate facilities consist of three plants: Uncle Sam, Faustina and Taft. The Uncle Sam plant produces phosphoric acid. The
phosphoric acid is then shipped to the Faustina and Taft plants where it is used to produce DAP and granular monoammonium phosphate (GMAP). The Faustina plant manufactures phosphoric acid, DAP, GMAP and ammonia. The Taft facility manufactures DAP
and GMAP. Concentrated phosphate operations are managed to balance PhosFeeds output with customer needs. In response to then-current reduced market demand, PhosFeed suspended production at its Taft facility in July 1999 and suspended
phosphoric acid production at its Faustina facility in November 1999. From January 2001 until early August 2001, PhosFeed temporarily suspended its Uncle Sam phosphoric acid production as well as its Faustina DAP and GMAP production. In addition,
from January 2001 until June 2001, PhosFeed temporarily suspended its Faustina ammonia production. From June 2003 until early August 2003, PhosFeed temporarily suspended its Uncle Sam phosphoric acid production as well as its Faustina DAP, GMAP and
ammonia production. The Taft facility and Faustinas phosphoric acid production facilities remain temporarily idled.
Summarized below are descriptions of the principal raw materials used in the production of concentrated phosphates: phosphate rock, sulphur and ammonia.
Phosphate Rock
All of PhosFeeds phosphate mines and related mining operations are
located in central Florida. PhosFeed has four active mines, Kingsford, Four Corners, Hopewell and Fort Green and two planned future mines, Ona and Pine Level.
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2
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P
2
O
5
is an industry term indicating a product's phosphate content measured chemically in units of phosphorous pentoxide.
|
-5-
The phosphate deposits of Florida are of sedimentary origin and are part of a phosphate-bearing province
that extends from southern Florida north along the Atlantic coast into southern Virginia. PhosFeeds active mines are primarily in what is known as the Bone Valley Member of the Peace River Formation in the Central Florida Phosphate District,
having their origin from reworking of the host Hawthorn Group of middle Miocene age. The southern portions of the Four Corners and Fort Green mines are in what is referred to as the Undifferentiated Peace River Formation, in which the Ona and Pine
Level mines would be located. Phosphate mining has been conducted in the Central Florida Phosphate District since the late 1800s. The potentially mineable portion of the Central Florida Phosphate District encompasses an area approximately 80 miles
in length in a north-south direction and approximately 40 miles in width.
The map below shows the location of each of PhosFeeds mines.
PhosFeed extracts
phosphate ore using large surface mining machines that it owns called draglines. Prior to extracting the ore, the draglines must first remove a ten to fifty foot layer of sandy overburden. PhosFeed then processes the ore at beneficiation
plants that it owns at each active mine where the ore goes through washing, screening, sizing and flotation processes designed to separate the phosphate rock from sands, clays and other
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foreign materials
.
Prior to commencing operations at either of the planned future mines, PhosFeed
would need to acquire new draglines or move existing draglines to the mines and, unless the beneficiation plant at an existing mine were used, construct a beneficiation plant.
The following table shows the past three years of rock production volume and grade
3
for each of PhosFeeds active mines:
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
2003
|
|
2002
|
|
2001
|
|
|
|
Production
Tons
|
|
Average
BPL
|
|
Production
Tons
|
|
Average
BPL
|
|
Production
Tons
|
|
Average
BPL
|
|
|
|
(millions of tons)
|
|
|
|
(millions of tons)
|
|
|
|
(millions of tons)
|
|
|
|
Kingsford
|
|
3.0
|
|
65.8
|
|
3.6
|
|
66.2
|
|
2.5
|
|
66.2
|
|
Four Corners
|
|
7.5
|
|
61.7
|
|
7.8
|
|
64.2
|
|
6.5
|
|
65.3
|
|
Hopewell
|
|
0.7
|
|
67.7
|
|
0.9
|
|
66.8
|
|
0.7
|
|
70.2
|
|
Fort Green
|
|
4.0
|
|
61.9
|
|
5.4
|
|
63.9
|
|
4.3
|
|
63.5
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
15.2
|
|
62.9
|
|
17.7
|
|
64.6
|
|
14.0
|
|
65.2
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
In order to manage its
inventories, PhosFeed temporarily idled its mining operations in 2001 during the months of July and December. From late January 2003 through April 2003, PhosFeed temporarily idled its Fort Green mining operation in order to manage its inventories.
Although PhosFeed sells phosphate rock to other crop nutrient and animal feed ingredient manufacturers, it primarily uses phosphate rock internally in the production of concentrated phosphates. Tons used internally totaled approximately 12 million,
12 million and 11 million for the years ended December 31, 2003, 2002 and 2001, respectively, representing 73 percent, 70 percent and 69 percent, respectively, of total rock tons shipped. Rock shipments to customers totaled approximately four
million, five million and five million tons for each of the years ended December 31, 2003, 2002 and 2001, respectively.
Reserves
PhosFeed estimates its reserves based upon exploration core drilling as well as technical and economic analyses to determine that reserves so classified
can be economically mined. Proven (measured) reserves are those resources of sufficient concentration to meet minimum physical, chemical and economic criteria related to PhosFeeds current product standards and mining and production practices.
PhosFeeds estimates of probable (indicated) reserves are based on information similar to that used for proven reserves, but sites for drilling are farther apart or are otherwise less adequately spaced than for proven reserves, although the
degree of assurance is high enough to assume continuity between such sites. Proven reserves are determined using a minimum drill hole spacing of two sites per forty acre block. Probable reserves have less than two drill holes per forty acre block,
but geological data provides a high degree of assurance that continuity exists between sites.
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The standard industry term used to grade the quality of phosphate rock is BPL, which
literally means bone phosphate of lime.
|
-7-
The following table sets forth PhosFeeds proven and probable reserves as of December 31, 2003:
|
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|
|
|
|
|
|
|
|
|
|
Mine
|
|
Available Acres(a)
|
|
Mineable Acres(a)
|
|
Reserve Tons
|
|
|
Average BPL(g)
|
|
|
|
(in millions)(b)(c)
|
|
Active Mines
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Kingsford
|
|
1,578
|
|
1,425
|
|
9.2
|
(d)
|
|
65.2
|
|
Four Corners
|
|
20,500
|
|
16,001
|
|
96.1
|
|
|
63.8
|
|
Hopewell
|
|
932
|
|
723
|
|
4.5
|
(d)
|
|
67.9
|
|
Fort Green
|
|
9,842
|
|
8,328
|
|
79.9
|
(e)
|
|
61.9
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Active Mines
|
|
32,852
|
|
26,477
|
|
189.7
|
|
|
63.2
|
|
|
|
|
|
|
|
|
|
|
|
|
Future Mines
|
|
|
|
|
|
|
|
|
|
|
Ona
|
|
14,616
|
|
9,483
|
|
84.9
|
(e)
|
|
64.3
|
|
Pine Level
|
|
36,296
|
|
24,586
|
|
163.1
|
(f)
|
|
64.8
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Future Mines
|
|
50,912
|
|
34,069
|
|
248.0
|
|
|
64.6
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Mines
|
|
83,764
|
|
60,546
|
|
437.7
|
|
|
64.0
|
|
|
|
|
|
|
|
|
|
|
|
|
(a)
|
Available Acres reflect that part of the total deeded or controlled acreage that is fully accessible for mining. Available acres are free of surface or subsurface encumbrance, legal
setbacks, wetland preserves and other legal restrictions that preclude permittable access for mining, and are believed by PhosFeeds management to be permittable. Available Acres also exclude mined out acreage. Mineable Acres reflect that part
of Available Acres that meets specified minimum physical, economic and chemical criteria related to current mining and production practices. All reported reserves are within the Mineable Acres.
|
|
(b)
|
Reserve estimates are generally established by PhosFeed personnel, without a third party review. However, PhosFeed does retain an independent third party to prepare annual valuation
analyses, primarily for tax purposes, that include valuations of the reserves consistent with the information shown in the above table. The reserve estimates have been prepared in accordance with the standards set forth in Industry Guide 7
promulgated by the SEC.
|
|
(c)
|
Of the reserves shown, approximately 408.3 million tons are proven reserves, while 0.6 million tons at Ona and 28.8 million tons at Pine level are probable reserves.
|
|
(d)
|
Approximately 5.0 million of the tons shown for Kingsford and 2.2 million of the tons shown for Hopewell were purchased by PhosFeed in December 2002 pursuant to agreements that
provide for future payment of royalties of $78,000 per month through December 1, 2009 (which payments may be accelerated if production from such reserves exceeds 261,000 tons per calendar quarter). In addition, as part of such purchase, PhosFeed
purchased two clay settling ponds for payments of $63,000 per month through December 1, 2008 and leases certain plant and equipment for payments of $46,000 per month through December 1, 2009 pursuant to a lease that may thereafter be continued at
the election of PhosFeed.
|
|
(e)
|
Approximately 44.3 million of the tons shown for Fort Green and 3.0 million of the tons shown for Ona are subject to a purchase money mortgage with an outstanding principal balance
of $6.0 million as of December 31, 2003.
|
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(f)
|
In connection with the sale of certain of the surface rights related to approximately 53.8 million tons of the reported Pine Level reserves, PhosFeed agreed not to mine such
reserves until at least 2014. PhosFeeds current mining plans do not contemplate mining such reserves until at least that time.
|
|
(g)
|
BPL ranges from 50 percent to 78 percent.
|
-8-
PhosFeed generally owns the reserves shown in the table above, with the only significant exceptions being
the Pine Level reserves, approximately 12.3 million of the tons shown for the Fort Green mine and the reserves referred to in note (d) to the above table. PhosFeeds rights to approximately 109.2 million tons of the estimated reserves shown for
Pine Level are held pursuant to an option agreement that is described under Pine Level Property Reserves in Note 17 of Notes to Consolidated Financial Statements in Part II, Item 8, Financial Statements and Supplementary Data
of this 2003 10-K. The 12.3 million tons referred to above for the Fort Green mine are leased under a lease that PhosFeed has the right to extend through 2014 and for which PhosFeed has prepaid substantially all royalties. PhosFeeds rights to
the reserves referred to in note (d) to the above table are held pursuant to mineral rights that expire in 2012, except for a portion that expire in 2017. In light of the long-term nature of its rights to its reserves, PhosFeed expects to be able to
mine all reported reserves that are not currently owned prior to termination or expiration of PhosFeeds rights.
PhosFeed also owns or controls non-reserve phosphate materials at its mines. These non-reserve phosphate materials have been delineated by appropriately
spaced drilling and/or underground sampling to support a sufficient tonnage and average grade of product. Such non-reserve phosphate materials are mineralized deposits that may become economically recoverable. However, additional geostatistical
analyses, including further exploration, permitting and mining feasibility studies, changes in current market conditions, and/or changes in the mining technology currently used by PhosFeed, are required before such deposits may be classified as
reserves. The following table sets forth information concerning such non-reserve phosphate materials:
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Mine
|
|
Non-Reserve Phosphate
Material Tons
|
|
Average BPL
|
|
|
|
(in millions)
|
|
|
|
Active Mines
|
|
|
|
|
|
|
|
|
|
Kingsford
|
|
4.5
|
|
63.9
|
|
Four Corners
|
|
29.8
|
|
49.7
|
|
Hopewell
|
|
0.7
|
|
58.7
|
|
Fort Green
|
|
64.5
|
|
51.6
|
|
|
|
|
|
|
|
Total Active Mines
|
|
99.5
|
|
51.7
|
|
|
|
|
|
|
|
Future Mines
|
|
|
|
|
|
|
|
|
|
Ona
|
|
158.1
|
|
52.4
|
|
Pine Level
|
|
148.4
|
|
45.1
|
|
|
|
|
|
|
|
Total Future Mines
|
|
306.5
|
|
48.9
|
|
|
|
|
|
|
|
Total Mines
|
|
406.0
|
|
49.5
|
|
|
|
|
|
|
PhosFeeds
preliminary analyses of these non-reserve phosphate materials indicate that they differ in physical and chemical characteristics from those historically mined by PhosFeed and are uneconomic under current market conditions using the mining technology
currently used by PhosFeed.
Sulphur
Sulphur is used at the New Wales, South Pierce, Uncle Sam and (when
producing phosphoric acid) Faustina plants to produce sulphuric acid primarily for use in PhosFeeds production of phosphoric acid. Until June 2002, a significant portion of PhosFeeds sulphur requirements was provided by Freeport-McMoRan
Sulphur LLC (FMS) under a supply agreement with the Company, while PhosFeeds remaining sulphur requirements were provided by market contracts. In June 2002, PhosFeed completed the acquisition of the sulphur transportation and terminaling
assets of FMS through Gulf Sulphur Services Ltd., LLLP (Gulf Services), a 50-50 joint venture with Savage Industries Inc. Concurrently with this acquisition, and instead of purchasing a majority of its annual sulphur tonnage through FMS, PhosFeed
negotiated new supply agreements to purchase sulphur directly from recovered sulphur producers. Additionally, the Company, CF Industries, Inc. and Cargill Fertilizer, Inc. have
-9-
formed a separate joint venture to construct a facility for remelting sulphur for use at their respective
Florida phosphate fertilizer operations. The remelt facility was expected to be operational in 2005, however the three companies have slowed the development process until further discussions are held during 2004. The remelt facility would provide
PhosFeed additional flexibility by allowing it to diversify and procure a portion of its sulphur from the much larger and previously inaccessible offshore solid sulphur market.
Ammonia
PhosFeeds ammonia needs are supplied by its Faustina ammonia production facility and by world suppliers, primarily under annual and multi-year
contracts. Production from the Faustina plant, which has an estimated annual capacity of 560,000 tons of anhydrous ammonia, is principally used internally to produce certain concentrated phosphates. Ammonia for the New Wales plant and third party
ammonia customers of PhosFeed is terminaled through an ammonia facility at Port Sutton, Florida that is leased by PhosFeed for a term expiring in 2013 which PhosFeed may extend for up to five additional years. In connection with the sale of
PhosFeeds Port Sutton fertilizer and feed warehouse and marine export facility (Port Sutton) in December 2003 that is adjacent to the Port Sutton ammonia facility, PhosFeed entered into an agreement with the buyer for the buyer to also operate
the Port Sutton ammonia facility. The agreement expires in 2013 but may be extended by PhosFeed for an unlimited number of additional five year terms, as long as the parties are entitled to operate the ammonia facility.
Sales and Marketing
Domestically, PhosFeed sells its concentrated phosphates to crop nutrient
manufacturers, distributors and retailers. PhosFeed also uses concentrated phosphates internally for the production of animal feed ingredients. Virtually all of PhosFeeds export sales of phosphate crop nutrients are marketed through PhosChem
which the Company administers on behalf of itself and two other member companies. PhosChem believes that its sales represent approximately 41 percent of total U.S. exports of concentrated phosphates. The countries that account for the largest amount
of PhosChems sales of concentrated phosphates include China, Brazil, Australia and Japan. During 2003, PhosFeeds concentrated phosphates exports to Asia were 34 percent of total shipments by volume, with China representing 35 percent of
export shipments. PhosFeed, with a strong brand position in a $1.0 billion feed ingredients global market, also supplies phosphate and potassium-based feed ingredients for poultry and livestock to markets in North America, Latin America and Asia.
The table below shows PhosFeeds shipments of
concentrated phosphates in thousands of dry product tons, primarily DAP:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2003
|
|
2002
|
|
2001
|
|
|
|
Tons
|
|
%
|
|
Tons
|
|
%
|
|
Tons
|
|
%
|
|
Domestic
|
|
2,657
|
|
44
|
|
2,857
|
|
46
|
|
2,689
|
|
45
|
|
Export
|
|
3,373
|
|
56
|
|
3,331
|
|
54
|
|
3,313
|
|
55
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total shipments
|
|
6,030
|
|
100
|
|
6,188
|
|
100
|
|
6,002
|
|
100
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of December 31,
2003, PhosFeed had contractual commitments for 2004 from non-affiliated customers for the shipment of approximately three million tons of concentrated phosphates and approximately five million tons of phosphate rock. PhosFeed also had contractual
commitments from non-affiliated customers for the shipment of phosphate feed and feed grade potassium products amounting to approximately 500,000 tons in 2004.
In connection with the Port Sutton sale, PhosFeed entered into an agreement with the buyer pursuant to which at least 70 percent (75 percent if the
buyer meets certain customer requirements) of the bulk marine export requirements for DAP and MAP and 100 percent of the bulk marine export requirements for animal feed ingredients from New Wales will be shipped through the Port Sutton facility and
the buyers Port Manatee, Florida, warehouse and marine export facility. The agreement expires in 2013 but may be extended by PhosFeed for an unlimited number of additional five year terms.
Competition
PhosFeed operates in a highly competitive global market. Among the
competitors in the global phosphate crop nutrient market are domestic and foreign companies, as well as foreign government-supported producers.
-10-
Phosphate crop nutrient producers compete primarily based on price and, to a lesser extent, product
quality and innovation. Major integrated producers of feed phosphates and feed grade potassium are located in the U.S., Europe and China. Many smaller producers are located in emerging markets around the world. Many of these smaller producers are
not manufacturers of phosphoric acid and are required to purchase this raw material on the open market. Competition in this global market is also driven by price, quality and service.
As one of the largest miners of phosphate rock in the U.S., and one of the worlds largest producers of concentrated
phosphates, PhosFeed enjoys an advantage over some competitors as the scale of operations effectively reduces production costs per unit. PhosFeed is also vertically integrated to captively supply one of its key raw materials, phosphate rock, to its
concentrated phosphate production facilities. In addition, it produces another raw material, ammonia, to captively supply its Faustina concentrates facility. As a 50 percent owner of Gulf Services, PhosFeed is well-positioned to ensure an adequate,
flexible and cost-effective supply of its third key raw material, sulphur.
With production facilities in both Central Florida near the Port of Tampa and in Louisiana on the Mississippi River, PhosFeed is logistically positioned to supply both domestic and international customers. In
addition, those multiple production points afford PhosFeed the flexibility to optimally balance supply and demand.
With no captive ammonia production in Florida, PhosFeed is subject to significant volatility in its purchase price of ammonia from world markets. In
addition, PhosFeed is subject to many environmental laws and regulations in the state of Florida that are often more stringent than those with which producers in other states or foreign countries must comply.
Potash
Net sales for the Companys potash business unit were $855.5 million,
$805.9 million, and $811.2 million for the years ended December 31, 2003, 2002 and 2001, respectively.
Potash mines, processes and distributes potash in the U.S. and Canada. The term potash applies generally to the common salts of potassium.
Potashs products are marketed worldwide to crop nutrient manufacturers, distributors and retailers and are also used in the manufacture of mixed crop nutrients and, to a lesser extent, animal feed ingredients (see PhosFeed). Potash also sells
potash to customers for industrial use. Potash operates four potash mines in Canada as well as two potash mines in the U.S. In addition, Potashs products are used for icemelter and water softener regenerant. Potash has total capacity in excess
of 11 million tons of product per year. In 2003, Potashs operations accounted for approximately 15 percent of world capacity on a K
2
O
4
basis.
|
4
|
Because the amount of potassium in the common salts of potassium varies, the industry has established a common standard of measurement of defining a product's
potassium content, or grade, in terms of equivalent percentages of potassium oxide (K
2
O). A K
2
O equivalent of 60 percent, 50 percent and 22 percent is the customary minimum standard for muriate of potash, sulphate of
potash and double sulphate of potash magnesia products, respectively.
|
-11-
The map below shows the location of each of Potashs mines.
Potash owns related facilities at
each of the mines, which we refer to as refineries, which refine the mined potash.
The following table shows the past three years production of ore, grade and finished product for each of Potashs mines:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2003 Production
|
|
2002 Production
|
|
2001 Production
|
|
|
|
Annual
Capacity(2)
|
|
Ore Mined
(millions
of tons)
|
|
Grade
% K2O
|
|
Product
(millions
of tons)
|
|
Annual
Capacity(2)
|
|
Ore Mined
(millions
of tons)
|
|
Grade
% K2O
|
|
Product
(millions
of tons)
|
|
Annual
Capacity(2)
|
|
Ore Mined
(millions
of tons)
|
|
Grade
% K2O
|
|
Product
(millions
of tons)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Canadian Mines
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Belle Plaine - MOP
|
|
3.0
|
|
9.7
|
|
18.0
|
|
2.6
|
|
3.0
|
|
9.4
|
|
18.0
|
|
2.6
|
|
2.5
|
|
9.8
|
|
18.0
|
|
2.5
|
|
Colonsay - MOP
|
|
2.0
|
|
3.7
|
|
26.5
|
|
1.4
|
|
2.0
|
|
3.8
|
|
26.7
|
|
1.5
|
|
1.6
|
|
3.5
|
|
27.0
|
|
1.4
|
|
Esterhazy - MOP
|
|
4.2
|
|
11.2
|
|
24.1
|
|
3.9
|
|
4.1
|
|
10.1
|
|
24.4
|
|
3.6
|
|
4.1
|
|
10.3
|
|
23.9
|
|
3.5
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
sub-totals
|
|
9.2
|
|
24.6
|
|
22.1
|
|
7.9
|
|
9.1
|
|
23.3
|
|
22.2
|
|
7.7
|
|
8.2
|
|
23.6
|
|
21.9
|
|
7.4
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
United States Mines
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Carlsbad - MOP
|
|
0.4
|
|
3.6
|
|
12.4
|
|
0.3
|
|
0.4
|
|
4.0
|
|
12.7
|
|
0.3
|
|
0.4
|
|
3.4
|
|
13.1
|
|
0.3
|
|
Carlsbad - K-Mag
|
|
1.1
|
|
3.8
|
|
7.8
|
|
0.9
|
|
1.1
|
|
3.6
|
|
7.8
|
|
0.9
|
|
1.1
|
|
3.5
|
|
7.9
|
|
0.8
|
|
Carlsbad - SOP (1)
|
|
0.2
|
|
n/a
|
|
n/a
|
|
0.1
|
|
0.2
|
|
n/a
|
|
n/a
|
|
0.2
|
|
0.2
|
|
n/a
|
|
n/a
|
|
0.1
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Carlsbad - Total
|
|
1.7
|
|
7.4
|
|
10.0
|
|
1.3
|
|
1.7
|
|
7.6
|
|
10.4
|
|
1.4
|
|
1.7
|
|
6.9
|
|
10.4
|
|
1.2
|
|
Hersey - MOP
|
|
0.2
|
|
0.5
|
|
26.6
|
|
0.1
|
|
0.2
|
|
0.5
|
|
26.6
|
|
0.1
|
|
0.2
|
|
0.5
|
|
26.6
|
|
0.1
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
sub-totals
|
|
1.9
|
|
7.9
|
|
11.1
|
|
1.4
|
|
1.9
|
|
8.1
|
|
11.4
|
|
1.5
|
|
1.9
|
|
7.4
|
|
11.5
|
|
1.3
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Totals
|
|
11.1
|
|
32.5
|
|
19.4
|
|
9.3
|
|
11.0
|
|
31.4
|
|
19.4
|
|
9.2
|
|
10.1
|
|
31.0
|
|
19.4
|
|
8.7
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1)
|
MOP & K-Mag are used to make SOP
|
|
(2)
|
millions of tons of finished product (KCl)
|
-12-
Reserves
Potashs estimates of its reserves and non-reserve potash mineralization are based on exploration drill hole data,
seismic data and actual mining results during the past 35 to 40 years (15 years in the case of Hersey). Proven reserves are estimated by identifying material in place that is delineated on at least two sides and material in place within a half-mile
radius or distance from an existing sampled mine entry or exploration core hole. Probable reserves are estimated by identifying material in place within a one mile radius or distance from an existing sampled mine entry or exploration core hole.
Historical extraction ratios from the many years of mining results are then applied to both types of material to estimate the proven and probable reserves. Potash believes that all reserves and non-reserve potash mineralization reported below are
potentially recoverable using existing production shaft and refinery locations.
Potashs estimated recoverable reserves and non-reserve potash mineralization as of December 31, 2003 for each of its mines is as follows:
|
|
|
|
|
|
|
|
|
|
|
Reserves (1)(2)
|
|
Non-Reserve
Potash Mineralization (1)(3)
|
|
|
|
Millions of
recoverable tons
|
|
Average Grade
(% K2O)
|
|
Millions of potentially
recoverable tons
|
|
Canadian Mines
|
|
|
|
|
|
|
|
Belle Plaine
|
|
723
|
|
18.0
|
|
2,058
|
|
Colonsay
|
|
278
|
|
28.3
|
|
167
|
|
Esterhazy
|
|
554
|
|
24.5
|
|
252
|
|
|
|
|
|
|
|
|
|
sub-totals
|
|
1,555
|
|
22.2
|
|
2,477
|
|
|
|
|
|
|
United States Mines
|
|
|
|
|
|
|
|
Carlsbad
|
|
130
|
|
9.8
|
|
|
|
Hersey
|
|
47
|
|
26.6
|
|
|
|
|
|
|
|
|
|
|
|
sub-totals
|
|
177
|
|
14.3
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Totals
|
|
1,732
|
|
21.4
|
|
2,477
|
|
|
|
|
|
|
|
|
|
(1)
|
There has been no third party review of reserve estimates within the last three years. The reserve estimates have been prepared in accordance with the standards set forth in
Industry Guide 7 promulgated by the U.S. Securities and Exchange Commission.
|
|
(2)
|
Includes both proven and probable reserves.
|
|
(3)
|
The non-reserve potash mineralization reported in the above table in some cases extends to the boundaries of the mineral rights owned or leased by Potash. Such boundaries are up to
14 miles from the closest existing sampled mine entry or exploration core hole.
|
As discussed more fully below, Potash either owns the reserves and mineralization shown above or leases them pursuant to mineral leases that generally remain in effect or are renewable at the option of Potash, or are
long-term leases. Accordingly, Potash expects to be able to mine all reported reserves that are leased prior to termination or expiration of the existing leases.
Canadian Mines
Potash has three Canadian potash facilities, all in the southern half of the Province of Saskatchewan: the mine at Belle Plaine, the two interconnected
shaft mines at Esterhazy and the mine at Colonsay.
Extensive
potash deposits are found in the southern half of the Province of Saskatchewan. The potash ore is contained in a predominantly rock salt formation known as the Prairie Evaporites. The evaporite deposits are
-13-
bounded by limestone formations and contain the potash beds. Three potash deposits of economic importance
occur in the Province, the Esterhazy, Belle Plaine and Patience Lake members. The Patience Lake member is mined at Colonsay, and the Esterhazy member at Esterhazy. At Belle Plaine all three members are mined. The major potash members each contain
several potash beds of different thicknesses and grades. The particular beds mined at Colonsay and Esterhazy have a mining height of eleven and eight feet, respectively. At Belle Plaine several beds of different thicknesses are mined.
Potashs four mines in Canada produce muriate of potash exclusively.
Esterhazy and Colonsay utilize shaft mining while Belle Plaine utilizes solution mining technology. Traditional potash shaft mining takes place underground at depths of over three thousand feet where continuous mining machines cut out the ore face
and load it on to conveyor belts. The ore is then crushed, moved to storage bins and then hoisted to refineries above ground. In contrast, Potashs solution mining process involves heated water, which is pumped through a cluster to
dissolve the potash in the ore beds at a depth of approximately 5,000 feet. A cluster consists of a series of boreholes drilled into the potash ore by a portable, all-weather, electric drilling rig. A separate distribution center at each cluster
controls the brine flow. The solution containing dissolved potash and salt is pumped to a refinery where sodium chloride, a co-product of this process, is separated from the potash through the use of evaporation and crystallization techniques.
Concurrently, solution is pumped into a 130 acre cooling pond where additional crystallization occurs and the resulting product is recovered via a floating dredge. Refined potash is dewatered, dried and sized. The Canadian operations produce 22
different potash products, including industrial grades, many through proprietary processes.
Under a long-term contract with Potash Corporation of Saskatchewan (PCS), Potash mines and refines PCS reserves for a fee plus a pro rata share of production costs. The specified quantities of potash to be produced
for PCS may, at the option of PCS, amount to an annual maximum of approximately one million tons and a minimum of approximately five hundred thousand tons per year. The current contract extends through June 30, 2006 and is renewable at the option of
PCS for four additional five-year periods.
Potashs
mineral rights in Saskatchewan consist of :
|
|
|
|
|
|
|
|
|
|
|
|
|
Belle Plaine
|
|
Colonsay
|
|
Esterhazy
|
|
Total
|
|
Acres
|
|
|
|
|
|
|
|
|
|
Owned in fee
|
|
12,733
|
|
6,748
|
|
109,205
|
|
128,686
|
|
Leased from Province
|
|
47,840
|
|
60,106
|
|
70,613
|
|
178,559
|
|
Leased from others
|
|
|
|
320
|
|
22,837
|
|
23,157
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
60,573
|
|
67,174
|
|
202,655
|
|
330,402
|
|
|
|
|
|
|
|
|
|
|
Potashs
management believes that its mineral rights in Saskatchewan are potentially sufficient to support current operations for more than a century. Leases are generally renewable at the option of Potash for successive terms, generally of 21 years each,
except that certain of the acres shown above as Leased from others are leased under long-term leases with terms (including renewals at the option of Potash) that expire from 2094 to 2142. Royalties, established by regulation of the
province of Saskatchewan, amounted to $8.1 million in 2003 and approximately $8.0 million in 2002 and 2001.
The Belle Plaine and Colonsay facilities, including owned and leased mineral rights, respectively, are subject to the mortgage granted under the
Companys senior secured credit facility. For further information, see
Capital Resources and Liquidity
in Part II, Item 7, Managements Discussion and Analysis of Financial Condition and Results of Operations, of
this 2003 10-K.
Since December 1985, Potash has experienced
an inflow of water into one of its two interconnected potash mines at Esterhazy, Saskatchewan. As a result, Potash has incurred expenditures, certain of which, due to their nature, have been capitalized while others have been charged to expense, to
control the inflow. Since the initial discovery of the inflow, Potash has been able to meet all sales obligations from production at the mines. Potash has considered alternatives to the operational methods employed at Esterhazy. However, the
procedures utilized to control the water inflow have proven successful to date, and Potash currently intends to continue conventional shaft mining. Despite the relative success of these measures, there can be no assurance that the amounts required
-14-
for remedial efforts will not increase in future years or that the water inflow or remediation costs will
not increase to a level which would cause Potash to change its mining process or abandon the mines. While shaft mining, in general, poses safety risks to employees, it is the opinion of Potash and its independent advisors that the water inflow at
Esterhazy does not create an unacceptable nor unmanageable risk to employees. The current operating approach and related risks are reviewed on a regular basis by management and the Board of Directors.
Potashs underground mine operations are presently insured against
business interruption and risk from catastrophic perils, including collapse, floods and other property damage with the exception of flood coverage at Esterhazy. Due to the ongoing water inflow problem at Esterhazy, underground operations at this
facility are currently not insurable for water incursion problems. Like other potash producers shaft mines, the Colonsay mine is also subject to the risks of inflow of water as a result of its shaft mining operations.
United States Mines
Potash has two U.S. potash facilities: the Carlsbad shaft mine located in
Carlsbad, New Mexico and the Hersey solution mine located in Hersey, Michigan.
The Carlsbad ore reserves are of two types: (1) sylvinite, a mixture of potassium chloride and sodium chloride, the same as the ore mined in Saskatchewan, and (2) langbeinite, a double sulfate of potassium and
magnesium. These two types of potash reserves occur in a predominantly rock salt formation known as the Salado Formation. The McNutt Member of this formation consists of eleven units of economic importance, of which IMC mines three. The McNutt
Members evaporite deposits are interlayered with anhydrite, polyhalite, potassium salts, clay, and minor amounts of sandstone and siltstone.
Continuous underground mining methods are utilized for the ore to be extracted. In the mining sections, drum type mining machines are used to cut the
sylvinite and langbeinite ores from the face. Mining heights are as low as four and one-half feet. Ore from the continuous sections is loaded onto conveyors, transported to storage areas, and then hoisted to the surface for further processing at the
refinery.
Two types of potash are produced at the Carlsbad
refinery: muriate of potash, which is the primary source of potassium for the crop nutrient industry; and double sulfate of potash magnesia, marketed under the brand name K-Mag
®
, containing significant amounts of sulphur, potassium and magnesium, with low levels of chloride. Production by the
Company of a third type of potash, sulfate of potash (SOP), was discontinued in November 2003 in connection with the sale of the SOP business line. See Note 2 of Notes to Consolidated Financial Statements in Part II, Item 8, Financial
Statements and Supplementary Data, of this 2003 10-K.
Potashs mineral rights in the United States consist of:
|
|
|
|
|
|
|
|
|
|
|
Carlsbad
|
|
Hersey
|
|
Total
|
|
Acres under control
|
|
|
|
|
|
|
|
owned in fee
|
|
|
|
581
|
|
581
|
|
long term leases
|
|
56,197
|
|
1,799
|
|
57,996
|
|
|
|
|
|
|
|
|
|
Total under control
|
|
56,197
|
|
2,380
|
|
58,577
|
|
|
|
|
|
|
|
|
At the Carlsbad
facility, Potash mines and refines potash from 56,197 acres of mineral rights. Potash controls these reserves pursuant to either (i) various leases from the U.S. Government that, in general, continue in effect at the option of Potash (subject to
readjustment by the U.S. Government every twenty years) or (ii) leases from the State of New Mexico that continue as long as Potash continues to produce from them. These reserves contain an estimated total of 129.5 million tons of potash
mineralization (calculated after estimated extraction losses) in three mining beds evaluated at thickness ranging from four and one-half feet to in excess of eleven feet. At average refinery rates, these ore reserves are estimated to be sufficient
to yield 7.1 million tons of concentrate from sylvinite with an average grade of approximately 60 percent K
2
O and
24.5 million tons of langbeinite concentrate with an average grade of approximately 22 percent K
2
O. At projected
rates of production, management estimates that Carlsbads reserves of sylvinite and langbeinite are sufficient to support operations for more than 12 years and 24 years, respectively.
-15-
At Hersey, Michigan, Potash operates a solution mining facility which produces salt and potash. Mining
occurs in the Michigan Basin in a predominantly rock salt formation called the Salina Group Evaporite. This formation is a clean salt deposit with interlayered beds of sylvinite and carbonate. At the Hersey facility, Potashs mineral rights
consist of 581 acres owned in fee and 1,799 acres controlled under leases that, in general, continue in effect at the option of Potash as long as Potash continues its operations at Hersey. These lands contain an estimated 47 million tons of potash
mineralization contained in two beds ranging in thickness from fourteen to thirty feet. Management estimates that these reserves are sufficient to yield 20.0 million tons of concentrate from sylvinite with an average grade of 60 percent
K
2
O. At current rates of production, management estimates that these reserves are sufficient to support operations
for more than 120 years.
The Hersey facility, including owned
and leased mineral rights, is subject to the mortgage granted under the Companys senior secured credit facility. For further information, see
Capital Resources and Liquidity
in Part II, Item 7, Managements Discussion
and Analysis of Financial Condition and Results of Operation, of this 2003 10-K.
Royalties for the U.S. operations, which are established by the U.S. Department of the Interior, Bureau of Land Management, in the case of the Carlsbad leases from the U.S. Government, and pursuant to provisions set
forth in the leases, in the case of the Carlsbad state leases and the Hersey leases, amounted to approximately $4.6 million in 2003 and $4.0 million in 2002 and 2001.
Natural Gas
Natural gas is a significant raw material used in the potash solution mining process. The purchase, transportation and storage of natural gas amounted to
approximately 16 percent of Potashs production costs for 2003. The two solution mines accounted for approximately 74 percent of Potashs total natural gas requirements for potash production. Potash purchases a portion of its requirements
through fixed price physical contracts and uses forward contracts to fix the price of an additional portion of future purchases. The remainder of its requirements is purchased either on the domestic spot market or under short-term contracts.
Sales and Marketing
Potashs North American potash sales are made through the
Companys sales force. North American agricultural sales are primarily to independent accounts, co-operatives and large regional fertilizer buyers while non-agricultural sales are primarily to large industrial accounts and the animal feed
industry. Additionally, potash is sold as an ingredient in icemelter as well as a water softener regenerant.
Potash is sold throughout the world, with Potashs largest amount of sales outside of North America made to China, Japan, India, South East Asia,
Australia, New Zealand and Latin America. Potashs exports from Canada, except to the U.S., are made through Canpotex. In general, Canpotex sales are allocated among the producer members based on production capacity. Potash currently supplies
approximately 36.7 percent of Canpotexs requirements. Potashs exports from Carlsbad are sold through Potashs sales force. In 2003, 85 percent of the potash produced by Potash was sold as crop nutrients, while 15 percent was sold
for non-agricultural uses.
-16-
The table below shows Potashs shipments of potash in thousands of tons:
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2003
|
|
2002
|
|
2001
|
|
|
|
Tons
|
|
%
|
|
Tons
|
|
%
|
|
Tons
|
|
%
|
|
Domestic
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Customers
|
|
5,330
|
|
62
|
|
5,227
|
|
66
|
|
5,050
|
|
65
|
|
Captive, to other business units
|
|
124
|
|
2
|
|
129
|
|
2
|
|
217
|
|
3
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
5,454
|
|
64
|
|
5,356
|
|
68
|
|
5,267
|
|
68
|
|
|
|
|
|
|
|
|
|
Export
|
|
3,132
|
|
36
|
|
2,588
|
|
32
|
|
2,466
|
|
32
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total shipments
|
|
8,586
|
|
100
|
|
7,944
|
|
100
|
|
7,733
|
|
100
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of December 31,
2003, Potash had contractual commitments for 2004 from non-affiliated customers for the shipment of potash amounting to approximately 1,380,000 tons.
Competition
Potash is a commodity available from many sources and consequently, the market is highly competitive. In addition to Potash, there are four large North
American producers: two in the U.S. and two in Canada. Through its participation in Canpotex, Potash competes outside of North America with various independent potash producers and consortia as well as other export organizations, including
state-owned organizations. Potashs principal methods of competition, with respect to the sale of potash include: pricing; offering consistent, high-quality products and superior service; as well as developing new industrial and consumer uses
for potash.
FACTORS AFFECTING DEMAND
The
Companys results of operations historically have reflected the effects of several external factors, which are beyond the Companys control and have in the past produced significant downward and upward swings in operating results. Revenues
are highly dependent upon conditions in the North American agriculture industry and can be affected by crop failure, changes in agricultural production practices, government policies and weather. Furthermore, the Companys crop nutrients
business is seasonal to the extent North American farmers and agricultural enterprises purchase more crop nutrient products during the spring and fall.
The Company sells products throughout the world. Unfavorable changes in trade protection laws, policies and measures, and other regulatory requirements
affecting trade; unexpected changes in tax and trade treaties; strengthening or weakening of foreign economies as well as political relations with the U.S. may cause sales trends to customers in one or more foreign countries to differ from sales
trends in the U.S.
The Companys foreign operations,
predominately in Canada, are subject to risks from changes in foreign currencies. The costs of the Canadian operations are principally denominated in the Canadian dollar while its sales are denominated in the U.S. dollar. As a result, significant
changes in the exchange rate of these two currencies can have a significant effect on the companys business and results of operations. For additional detail, see
Market Risk
in Part II, Item 7A, Quantitative and Qualitative
Disclosures about Market Risk, of this 2003 10-K.
OTHER MATTERS
Environmental Matters
For information
regarding environmental matters of the Company, see
Environmental, Health and Safety Matters
in Part II, Item 7, Managements Discussion and Analysis of Financial Condition and Results of Operations, of this 2003 10-K.
-17-
Employees
The Company had 5,017 employees as of December 31, 2003. The work force consisted of 1,373 salaried, 3,643 hourly employees
and one temporary or part-time employee.
Labor
Relations
Within North America, the Company has five
collective bargaining agreements with the affiliated local chapters of three international unions. As of December 31, 2003, approximately 91 percent of the hourly work force was covered under collective bargaining agreements. Three agreements were
re-negotiated during 2003. Two agreements will expire in 2004. The Company has not experienced a significant work stoppage in recent years and considers its labor relations to be good.
EXECUTIVE OFFICERS OF THE REGISTRANT
The ages and five-year employment history of the Companys executive officers as of March 1, 2004 was as follows:
E. Paul Dunn, Jr.
Age 50. Vice President, Finance and Treasurer of the Company since March 2002. From May 1998 to March 2002, Mr. Dunn served as Vice President and
Treasurer of the Company.
C. Steven Hoffman
Age 54. Senior Vice President of the Company since 1990
and President, IMC Sales and Marketing since March 2002. From September 1998 to March 2002, Mr. Hoffman served as President, International of the Company.
Mary Ann Hynes
Age 56. Senior Vice President and General Counsel of the Company since joining the Company in July 1999. Prior to joining the Company, Ms. Hynes served as
Vice President, General Counsel and Secretary of Sundstrand Corporation, a designer and manufacturer of aerospace and industrial technology-based components, from 1998 to July 1999.
Stephen P. Malia
Age 49. Senior Vice President, Human Resources of the Company since joining the Company in January 2000. Prior to joining the Company, Mr. Malia served as
Vice President, Human Resources-Exterior Systems Business for Owens Corning, a manufacturer of consumer and industrial building materials and composite systems, from 1997 through 1999.
Douglas A. Pertz
Age 49. Chairman and Chief Executive Officer of the Company since March 2002. From October 2000 to March 2002, Mr. Pertz served as Chairman, President and
Chief Executive Officer of the Company, and from October 1999 to October 2000, Mr. Pertz served as President and Chief Executive Officer of the Company. Mr. Pertz served as President and Chief Operating Officer of the Company from October 1998 to
October 1999.
J. Reid Porter
Age 54. Executive Vice President and Chief Financial Officer of the Company
since joining the Company in October 2001. Prior to joining the Company, Mr. Porter served as Vice President and partner of Hidden Creek Industries and Chief Financial Officer of Heavy Duty Holdings, both of Minneapolis, partnerships in the
automotive-related and heavy-duty commercial vehicle industries, respectively, from 1998 until October 2001.
Robert M. Qualls
Age 53. Vice President and Controller of the Company since March 2002. From January 2001 to March 2002, Mr. Qualls served as Vice President, Finance of
IMC Crop Nutrients. Mr. Qualls served as Vice President of Finance, Purchasing and Information Services of IMC Phosphates Company from October 1999 to January 2001, and as Vice President of Finance and Administration from February 1997 to October
1999.
-18-
All of the Companys executive officers are elected to serve until the next organizational meeting
of the Board of Directors of the Company, or until their respective successors are elected and qualified or until their earlier death, resignation or removal. No family relationships, as that term is defined in Item 401(d) of Regulation
S-K, exist among any of the listed officers.
-19-