To print this page, click here. To return to normal view, click here.
Printable version of http://www.potashcorp.com/sustainability/reports/2006/facilities/phosphate/weeping_water/
Go button
Weeping Water
My Shortcuts  What is this?
Add icon
Weeping Water

Box 171, Weeping Water, Nebraska 68463 | (402) 267-2915
William Donohue, Operations Manager | E-mail William

Operations

Weeping Water produces the animal feed ingredients dicalcium phosphate (18.5 percent P), monocalcium phosphate (21 percent P) and coarse monocalcium phosphate. It has an annual capacity of 230 thousand tons.

Limestone is accessed from an underground mine located between 125 feet and 145 feet below the surface. Approximately 125,000 tons of limestone rock are removed annually, with reserves expected to last more than 60 years.

Significant Achievements

Arc flash standards were put in place and employees were trained in arc flash procedures.

Motor Control Centers (MCCs) were upgraded to bring operations to National Fire Protection Association 70 compliance.

Extra cameras, fencing and gates were installed to upgrade plant security to Safe Feed/Safe Food standards.

Community Relations

The plant manager met with the mayor of Weeping Water several times during the year, on topics ranging from new city ball parks to lights for the new city sign.

The site sponsors underground mine tours during the Limestone Days celebration and information about the facility is presented at the local Community Center. Employees volunteer to assist with the tours.

The facility participated at the Cass County Fair and distributed informational material about the site to visitors.

Community Contributions

Cash donations to local community organizations in 2006 totaled $11,618. The top five recipients were Daniel J. Gross High School, United Way of the Midlands, Lofte Community Theatre, Cass County Agricultural Society and Cass County DARE (which teaches children to say no to drugs, alcohol, tobacco and violence).

In-kind contributions totaled $4,120 and went to the City of Weeping Water, Weeping Water School, Cass County Fair, Alegent Hospital Auxiliary and Limestone Days.

The site gave a grant to refurbish the existing auditorium, which had not been used in years. When the refurbishment is completed, the city plans to use the facility for offices, group meetings, a senior citizens center and various other activities.

Awards

Weeping Water received a number of safety awards in 2006, including, for the 11th year, a platinum award of honor with distinction from the National Safety Council of Greater Omaha.

The Sentinels of Safety Award was presented by the Mine Safety and Health Administration.

Environmental Initiatives

The plant continues to take steps to increase throughput, which will help use less energy and reduce GHG emissions per unit of production. The underground limestone mine now operates on 50 percent biodiesel fuel to help reduce greenhouse gas emissions.

Local Procurement

The value of all goods, materials and services purchased locally by the site (excluding raw materials and energy) was $2.0 million, 71 percent of total purchases.

Performance Trends – Weeping Water
  2003 2004 2005 2006
Annual Production(000 tons)
Dicalcium/Monocalcium phosphate 160.9 134.5 131.2 129.3
Employment
Number of employees 45 43 34 33
Number of female employees 3 3 3 3
Gender ratio (% female/total employees) 7 7 9 9
Average tenure (years) 20 20 20 20
Absenteeism rate (% hours absent) 4.9 3.8 3.7 3.1
Employee training provided (hours per employee) 21 22 44 65
Safety Performance (per 200,000 hours)
Lost-time frequency 2.33 2.46 0.00 0.00
Recordable frequency 4.67 2.46 3.17 3.05
Greenhouse Gas Emissions
GHG emissions (000 tons CO2 equivalent) 36.8 42.1 29.6 28.0
Normalized GHGs (GHGs/ton production) 0.2 0.3 0.2 0.2
Criteria/Significant Air Pollutants (tons)
Nitrogen oxides 15.2 12.3 12.1 11.9
Carbon monoxide 3.6 3.9 3.8 3.7
Particulates (dust) 14.7 25.1 19.4 18.2
Waste (tons)
Solid waste 0.0 5.5 5.1 5.0
Water Used (million gallons)
Water withdrawn n/a 25.1 24.6 16.2
Water recycled 0.0 0.0 0.0 0.0
Environmental Expenditures ($000)
Operating expenditures 62.4 48.0 128.7 41.2
Capital expenditures 0.0 43.3 9.9 23.2
Energy
Energy costs ($ million) 1.8 1.7 1.7 1.7
Energy used (000 MMBtus) 262.3 233.9 214.7 205.3
Energy efficiency (MMBtus/ton production) 1.6 1.7 1.6 1.6
Procurement ($ million)
Local purchasing 1.1 1.0 1.1 2.0
n/a = not available
Source: PotashCorp
PCS Weeping Water