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Aurora
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Aurora

1530 NC HWY 306 South, Aurora, North Carolina 27806 | (252) 322-4111
Richard Atwood, General Manager | E-mail Richard

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 1,325 thousand tons of phosphoric acid.

Significant Achievements

Annual production records were set in 2006 in fluosilic acid, ammonium polyphosphate, sulfuric acid, low-alkali purified phosphoric acid (PAP) and blended gypsum.

Capital projects included the start-up of PAP #4 and relocation of the highway, railroad and utilities so the mine expansion could take place.

There was strong public support for the mine continuation permitting process.

A railcar tracking system that was designed and installed in 2006 has improved efficiency of data entry and fleet utilization.

Aurora achieved one million safe work hours on May 3, 2006.

It was recertified for the North Carolina Department of Labor Star and Mining Star.

Community Relations

The site held 40 public meetings with the local community to discuss mine continuation permitting, environmental stewardship and responsibilities, and socio-economic benefits.

It has an active program of engagement with community leaders and state legislators, and 66 meetings were held with state legislators, regulators or their aides in 2006. Issues discussed included safety and security, mine continuation permitting, environmental stewardship and responsibilities, and socio-economic benefits.

Community Support

Cash donations to local community organizations in 2006 totaled $206,362. The main beneficiaries were the Beaufort County United Way, Aurora Fossil Museum, Town of Aurora, East Carolina University and Children's Miracle Network.

In-kind contributions totaled $34,310 and went to Craven County Schools, Beaufort County Schools, Pamlico Community College, Terra Ceia Christian School and Arapahoe Fire Department.

Aurora is a Partner in Education with Beaufort, Craven and Pamlico county schools. It recently joined with Beaufort Community College and Pitt Community College to establish a co-op program, with the first four co-op students beginning in January 2007.

Awards

In 2006, Aurora received numerous awards for training, community involvement, safety and environment:

  • A number of employees received special recognition from the North Carolina Department of Labor for achievements under the company's Master Craftsman Program.
  • Community recognition involved the Hero's Award from the American Red Cross; a Distinguished Service Award from the Beaufort County Committee of 100; the 2006 Public Safety Award from the Town of Aurora; three gold awards from the American Cancer Societies of Beaufort, Pamlico and Carteret Counties; and the Pacesetter Award from the United Way.

Environmental Initiatives

Wetlands mitigation was developed for the Bay City and McMullan/Smith projects.

The tank farm system was upgraded by raising the tanks from ground level to sit on concrete bases, and installing a leak detection system.

Energy Initiatives

Aurora produced more electricity from cogeneration in 2006 than in 2005, which reduced the amount that had to be purchased.

Sixty new energy-efficient electric motors were purchased.

Local Procurement

The total cost of goods, materials and services purchased locally in 2006 (excluding raw materials and energy) was $122.7 million, which represents 60 percent of total procurement by the site.

Performance Trends – Aurora
  2003 2004 2005 2006
Annual Production (000 tons)
Phosphate rock 3,394.0 4,369.5 4,868.9 5,045.2
Phosphoric acid 1,013.0 1,122.0 1,155.0 1,190.6
Employment
Number of employees 1,033 1,045 1,034 1,039
Number of female employees 40 41 46 48
Gender ratio (% female/total employees) 3.9 3.9 4.4 4.6
Average tenure (years) 16.6 16.8 18.0 19.1
Absenteeism rate (% hours absent) 5.6 3.5 4.0 3.5
Employee training provided (hours per employee) 42 66 36 34
Safety Performance (per 200,000 hours)
Lost-time frequency 0.28 0.09 0.27 0.38
Recordable frequency 1.85 1.33 1.35 1.61
Greenhouse Gas Emissions
GHG emissions (000 tons CO2 equivalent) 568.7 476.7 575.5 571.4
Normalized GHGs (GHGs/ton phosphoric acid production) 0.6 0.4 0.4 0.5
Criteria/Significant Air Pollutants (tons)
Nitrogen oxides 769.8 618.0 699.0 688.0
Carbon monoxide 461.7 409.0 410.0 436.0
Particulates (dust) 415.0 257.0 309.0 286.0
Sulfur dioxide 4,726.6 5,780.0 6,142.0 5,127.0
Ammonia n/a 492.0 504.0 552.0
Hydrogen sulfide 1,542.7 1,510.0 1,403.0 1,426.0
Waste to Land (000 tons)
Process waste (gypsum) 5,642.6 6,185.0 6,381.0 6,578.0
Non-process waste 0.6 1.1 1.1 0.8
Emissions to Water (tons)
Phosphorus compounds
(as phosphorus)
16.5 16.0 14.0 19.0
Water Used (million gallons)
Water withdrawn 20,954.0 21,941.0 20,427.0 21,973.0
Water recycled 101,137.0 121,557.0 130,893.0 135,333.0
Environmental Expenditures ($ million)
Operating expenditures 27.0 29.8 39.1 42.7
Capital expenditures 3.0 1.7 2.4 7.9
Energy
Energy costs ($ million) 23.7 29.3 35.7 43.1
Energy used (000 MMBtus) 4,863.8 4,873.9 5,209.2 4,982.2
Energy efficiency (MMBtus/ton phosphoric acid production) 4.8 4.3 4.5 4.2
Procurement ($ million)
Local purchasing 59.0 61.6 79.2 122.7

n/a = not available
Source: PotashCorp

PCS Aurora