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Marseilles
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Marseilles

2660 East US Route 6, Marseilles, Illinois 61341 | (815) 795-5111
Bob Startzer, Operations Manager | E-mail Bob

Operations

The Marseilles feed plant combines limestone and phosphoric acid to manufacture dicalcium phosphate (DCP) and monocalcium phosphate (MCP) animal feed supplements. Its annual capacity is 306 thousand tons.

Achievements

Marseilles completed a number of capital projects in 2006, including replacing the rotary dryer and the pug mill scrubber in the feed ingredient plant.

Employees completed the year with no lost-time or recordable injuries, and on June 16, 2006 completed three years without a lost-time injury.

Community Relations

The Marseilles-Ottawa-Seneca Community Advisory Panel held two meetings in 2006. The EPAs worst-case scenario for LaSalle County was reviewed, and there was discussion of Hazmat teams merging, moving the headquarters of the mutual aid box alarm system and changes in the emergency update system.

Community Support

In 2006, $5,500 was donated to local community organizations. The top recipients were the United Way, Community Safety Net (a drug prevention program), Canal Corridor Association, Seneca Summerfest and Marseilles Memorial Association.

In-kind contributions totaled $800. The major recipient was the I&M Canal, where employees have adopted a one-mile stretch of trail.

Local Procurement

In 2006, the value of all goods, materials and services purchased locally (excluding raw materials and energy) totaled $856,000, 47 percent of procurement by the site.

Performance Trends – Marseilles
  2003 2004 2005 2006
Annual Production (000 tons)
Dicalcium/Monocalcium phosphate 166.4 152.1 140.0 131.2
Employment
Number of employees 35 34 24 25
Number of female employees 3 3 2 2
Gender ratio (% female/total employees) 9 9 8 8
Average tenure (years) 13 14 15 16
Absenteeism rate (% hours absent) 2.7 4.0 1.1 0.7
Employee training provided (hours per employee) 25 17 35 47
Safety Performance (per 200,000 hours)
Lost-time frequency 2.80 0.00 0.00 0.00
Recordable frequency 5.59 8.94 7.90 0.00
Greenhouse Gas Emissions
GHG emissions (000 tons CO2 equivalent) 36.6 34.5 31.0 29.0
Normalized GHGs (GHGs/ton production) 0.2 0.2 0.2 0.2
Criteria/Significant Air Pollutants (tons)
Nitrogen oxides 10 9.3 8.5 8.0
Carbon monoxide 8.4 14.5 7.2 6.7
Particulates (dust) 18.9 18.0 16.6 15.5
Waste (tons)
Solid waste n/a 20.8 26.7 36.8
Water Used (million gallons)
Water withdrawn 23.0 17.4 16.2 15.5
Water recycled n/a 12.4 11.7 11.0
Environmental Expenditures ($000)
Operating expenditures 61.2 83.3 38.2 44.5
Capital expenditures 0.0 74.5 0.0 196.7
Energy
Energy costs ($ million) 1.9 1.9 2.0 1.9
Energy used (000 MMBtus) 242.1 230.9 203.0 191.3
Energy efficiency (MMBtus/ton production) 1.5 1.5 1.5 1.5
Procurement ($ million)
Local purchasing 0.6 0.5 0.5 0.9

n/a = not available
Source: PotashCorp

PCS Marseilles