Aurora
1530 NC HWY 306 South, Aurora, North Carolina 27806 | (252) 322-4111
Richard Atwood, General Manager | E-mail Richard
View Plant Sustainability Brochures
Operations
Aurora mines phosphate ore and refines it into phosphate rock, which is mixed with sulfuric acid to produce phosphoric acid. It has an annual capacity of 1.3 million tons of phosphoric acid.
Significant Events
A new-technology silicon tetrafluoride unit, linked to two phosphoric acid reactors, started up successfully and on time in 2007.
Annual production records were set in 2007 in fluosilic acid, ammonium polyphosphate, sulfuric acid, low-alkali purified phosphoric acid (PAP) and blended gypsum.
Phosphoric acid evaporator production was close to a record, despite the fact that several evaporators were retrofitted with fluosilic acid production units, which required significant downtime and potentially restricted evaporator capacity.
In 2007, 155 new employees were hired at Aurora, and the turnover rate was 14.8 percent, which stretched training and other resources.
The site reduced recordable injuries by 14 percent and operated throughout 2007 with no permit excursions or reportable quantity releases.
Community Relations
There continued to be strong public support for the mine continuation permitting process. With the help of several community and civic groups, tremendous support was generated during the comment period for Aurora's supplemental environmental impact statement.
Aurora also has an active program of engagement with community leaders and state legislators, and held 84 meetings with state legislators, regulators or their aides in 2007. Issues discussed included mine continuation permits, air quality permits and regulations and regulatory inspections.
Community Support
The value of cash donations to local community organizations in 2007 was $212,253. The main beneficiaries were the United Way, Aurora Fossil Museum, East Carolina University, Capital Area YMCA and Public Radio East.
In-kind contributions totaled $43,375 and went to Pungo Volunteer Fire Department, Belhaven Fire Department, Beaufort County Schools, City of Washington and Aurora Fossil Museum.
The site is a Partner in Education with Beaufort, Craven and Pamlico County schools.
Aurora entered into partnerships with North Carolina State University and Virginia Tech to establish an Engineering Co-op Program at the site. The first co-op students from each university started in June of 2007.
Aurora also entered into partnership with Beaufort Community College and Pitt Community College. The first groups of Instrumentation/Electrical co-op students reported in January 2007.
Awards
Eighteen departments received North Carolina Department of Labor Safety Awards.
Community recognition involved the 2007 Hero Award from the American Red Cross; the 2006 Public Safety Award from the Town of Aurora; a silver award from the Craven County American Cancer Relay for Life; a gold award – Beaufort and Pamlico County American Cancer Relay for Life; Marine Corps Reserve Award for Outstanding contributions for Toys for Tots; Community Leader of the Year award from the Washington Beaufort County Chamber of Commerce; Partners in Hope Award from the Children’s Miracle Network; and the Home Run Award from Habitat for Humanity.
Environmental Initiatives
Increased cooling tower capacity has allowed a higher percentage of cooling water to be recycled. The migration to low flow seals on the phosphoric evaporators has reduced water consumption.
Local Procurement
The total cost of all goods, materials and services purchased locally in 2007 (excluding raw materials, transportation and energy) was $148.4 million, which represents 69 percent of total procurement by the site.
| Performance Trends – Aurora |
| |
2004 |
2005 |
2006 |
2007 |
| Annual Production (tons) |
| Phosphate rock |
4,370,000 |
4,869,000 |
5,045,000 |
4,504,000 |
| Phosphoric acid |
1,122,000 |
1,155,000 |
1,190,000 |
1,194,000 |
| Employment |
| # of employees |
1,045 |
1,034 |
1,039 |
1,071 |
| # of female employees |
41 |
46 |
48 |
51 |
| Gender ratio (% female/total employees) |
3.9 |
4.4 |
4.6 |
4.8 |
| Average tenure (years) |
16.8 |
18.0 |
19.1 |
16.2 |
| Absenteeism rate (% hours absent) |
3.5 |
4.0 |
3.5 |
3.5 |
| Employee training (hrs per employee) |
66 |
36 |
34 |
67 |
| Safety Performance |
| Lost-time frequency (per 200,000 hrs) |
0.09 |
0.27 |
0.38 |
0.38 |
| Recordable frequency (per 200,000 hrs) |
1.33 |
1.44 |
1.61 |
1.37 |
| Greenhouse Gas Emissions |
| GHG emissions (000 tons) |
525 |
634 |
629 |
811 |
| Normalized GHGs (GHGs/ton production) |
0.5 |
0.5 |
0.5 |
0.7 |
| Criteria/Significant Air Pollutants (tons) |
| Nitrogen oxides |
618 |
699 |
688 |
742 |
| Carbon monoxide |
409 |
410 |
436 |
537 |
| Particulates (dust) |
257 |
309 |
286 |
732 |
| Sulfur dioxide |
5,780 |
6,142 |
5,127 |
4,785 |
| Ammonia |
492 |
504 |
552 |
715 |
| Hydrogen sulfide |
1,510 |
1,403 |
1,426 |
1,315 |
| Waste to Land (000 tons) |
| Gypsum |
6,185 |
6,381 |
6,578 |
6,561 |
| Water Use (million gallons) |
| Water withdrawn |
21,941 |
20,427 |
21,973 |
23,525 |
| Recycled water |
121,557 |
130,893 |
135,333 |
127,052 |
| Environmental Expenditures ($ million) |
| Operating expenditures |
29.8 |
39.1 |
42.7 |
45.1 |
| Capital expenditures |
1.7 |
2.4 |
0.8 |
3.3 |
| Energy |
| Energy costs ($ million) |
29.3 |
35.7 |
43.1 |
49.3 |
| Energy use (BBtu) |
4,874 |
5,209 |
4,982 |
4,901 |
| Energy efficiency (MMBtu/ton production) |
4.8 |
5.0 |
4.6 |
4.1 |
| Procurement |
| Local purchasing ($ million) |
61.6 |
79.2 |
122.7 |
148.4 |
