Properties
Our manufacturing facilities and principal
products are set forth below. Except as noted, we own each of
these facilities. Our Lake Charles and Calvert City facilities
have been pledged to secure our term loan.
|
|
|
|
|
Location
|
|
Principal Products
|
|
|
|
|
Lake Charles, Louisiana
|
|
Ethylene, polyethylene, styrene
|
|
Calvert City, Kentucky(1)
|
|
PVC, VCM, chlorine, caustic soda, ethylene
|
|
Geismar, Louisiana(2)
|
|
PVC, VCM and EDC
|
|
Booneville, Mississippi
|
|
PVC pipe
|
|
Springfield, Kentucky
|
|
PVC pipe
|
|
Litchfield, Illinois
|
|
PVC pipe
|
|
Wichita Falls, Texas
|
|
PVC pipe
|
|
Van Buren, Arkansas
|
|
PVC pipe
|
|
Evansville, Indiana
|
|
Fence and deck components
|
|
Calgary, Alberta, Canada(3)
|
|
Window and patio door components
|
|
Pawling, New York
|
|
Window, patio door and fence components
|
|
|
|
|
(1)
|
We lease a portion of our Calvert City facilities.
|
|
|
|
(2)
|
We started the EDC portion of the Geismar
facility in the fourth quarter of 2003. We plan to operate part
or all of the remainder of the facility when market conditions
support utilization of the additional capacity.
|
|
|
|
(3)
|
We lease our Calgary facility.
|
Our Lake Charles complex consists of three tracts
on over 1,300 acres in Lake Charles, Louisiana, each within
two miles of one another. The complex includes two ethylene
plants, two polyethylene plants and a styrene monomer plant. The
combined capacity of our two ethylene plants is approximately
2.4 billion pounds per year. The capacity of our two
polyethylene plants is approximately 1.4 billion pounds per
year and the capacity of our styrene plant is approximately
450 million pounds per year. We operate some of the newest
manufacturing facilities in North America and focus on
continually improving our asset portfolio and cost position. Our
newest polyethylene plant has two production units that use gas
62
phase technology to manufacture both LLDPE and
HDPE. Our styrene monomer plant is being modernized with
state-of-the-art technology and underwent debottlenecking in the
second quarter of 2003 for additional capacity.
Our Lake Charles complex includes a marine
terminal that provides for worldwide shipping capabilities. The
complex also is located near rail transportation facilities,
which allows for efficient delivery of raw materials and prompt
shipment of our products to customers. In addition, the complex
is connected by pipeline systems to our ethylene feedstock
sources in both Texas and Louisiana. Within the complex, our
ethylene plants are connected by pipeline systems to our
polyethylene and styrene plants. Our location, combined with our
integration in ethylene and our new and modernized plant
facilities, allows for low-cost production and distribution of
products in our Olefins business.
Our Calvert City complex is situated on
550 acres on the Tennessee River in Kentucky and includes
an ethylene plant, a chlor-alkali plant, a VCM plant and a PVC
plant. The capacity of our Calvert City ethylene plant is
450 million pounds per year and of our chlor-alkali plant
is 410 million pounds of chlorine and 450 million
pounds of caustic soda per year. In 2002, we modernized and
expanded our chlorine plant by replacing the mercury cell
technology with a more efficient, state-of-the-art membrane
technology. Our VCM plant has a capacity of 1.3 billion
pounds per year and our Calvert City PVC plant has a capacity of
800 million pounds per year.
We currently operate eight fabricated products
plants, consisting of five PVC pipe plants, a fence and deck
plant and two window and patio door profiles plants. The
majority of our plants are strategically located near our
Calvert City complex and serve customers throughout the middle
United States. One of our profiles plants is located in Calgary,
Alberta and the other is in Pawling, New York. The combined
capacity of our fabricated products plants is 600 million
pounds per year. Our Pawling, New York plant also
fabricates fence.
In 2002, we acquired a vinyls facility in
Geismar, Louisiana. The facility was purchased for
$5 million in cash plus a percentage of future earnings not
to exceed $4 million. The site includes a PVC plant with a
potential capacity of 600 million pounds per year and a VCM
plant with a potential capacity of 600 million pounds per
year with related EDC capacity. We started the EDC portion of
the facility in the fourth quarter of 2003. We plan to operate
part or all of the remainder of the facility when market
conditions support utilization of the additional capacity.
We believe that our current facilities are
adequate to meet the requirements of our present and foreseeable
future operations.
Our principal executive offices are located in
Houston, Texas. Our office space is leased, at market rates,
from an affiliate under a lease expiring on December 31,
2004. See Certain Relationships and Related Party
Transactions.