Marseilles
2660 East US Route 6, Marseilles, IL 61341 |
(815) 795-5111
Bob Startzer, Operations Manager | E-mail Bob
Operations
This feed plant combines limestone and phosphoric acid to manufacture dicalcium phosphate (DCP) and monocalcium phosphate (MCP) animal feed ingredients. Its annual capacity is 306,000 tons.
Achievements
Production was increased to meet the additional shipments to Tampa and Port Manatee – and the rail hopper car fleet was also increased.
With the increased production demand, less time was available for phosphoric acid car washing. Heels in the acid cars were increasing and their removal became an issue. Some equipment modifications were made, and wash time was increased.
A process control system was installed at the limestone milling operation and the feed ingredients plant. Employees were trained on how to operate this new system.
Community Relations
The site is a member of the Marseilles-Ottawa-Seneca Community Advisory Panel (MOSCAP).
Concerns were raised by the Prairie River Network to the State of Illinois regarding renewal of Marseilles' NPDES permit. The state provided our permit information indicating all required permit limitations were met.
Environment
The site planted grass and installed a silt fence in front of the two outfalls to reduce suspended solids.
Community Support
In 2007, the value of cash donations to local community organizations was $6,155.The top recipient organizations were the United Way of Eastern LaSalle County, Community Safety Net (a drug prevention program), Seneca Ambulance Service, Seneca Fire Department and Ottawa River Rescue.
In-kind contributions totaled $800. The major recipients were the I&M Canal (employees have adopted a one-mile stretch of a trail on the I&M Canal), Securitas, Ottawa Salvation Army, and Marseilles Food Pantry.
Local Procurement
In 2007, the value of all goods, materials and services purchased locally (excluding raw materials, transportation and energy) totaled $2.2 million. This represents 72 percent of procurement by the site.
Performance Trends |
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| 2003 | 2004 | 2005 | 2006 | 2007 | |
Annual Production (tons) |
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| Dicalcium/monocalcium phosphate | 166,000 | 152,000 | 140,000 | 131,000 | 146,000 |
Employment |
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| # of employees | 35 | 34 | 24 | 25 | 25 |
| # of female employees | 3 | 3 | 2 | 2 | 2 |
| Gender ratio (% female/total employees) | 8.6 | 8.8 | 8.3 | 8.0 | 8.0 |
| Average tenure (years) | 13 | 14 | 15 | 16 | 17 |
| Absenteeism rate (% hours absent) | 2.7 | 4.0 | 1.1 | 0.7 | 1.1 |
| Employee training provided (hrs per employee) | 25 | 17 | 35 | 47 | 37 |
Safety Performance |
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| Lost-time frequency (per 200,000 hrs) | 2.8 | 0 | 0 | 0 | 0 |
| Recordable frequency (per 200,000 hrs) | 5.59 | 8.94 | 7.9 | 0 | 7.5 |
Greenhouse Gas Emissions |
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| GHG emissions (000 tons) | 40.3 | 37.9 | 34.1 | 31.8 | 36.4 |
Criteria Air Pollutants (tons) |
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| Nitrogen oxides | 10 | 9.3 | 8.5 | 8.0 | 9.0 |
| Carbon monoxide | 8.6 | 8.8 | 7.2 | 6.7 | 3.6 |
| Particulates (dust) | 19.7 | 18.0 | 16.6 | 15.5 | 17.2 |
Water Use (million gallons) |
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| Water withdrawn | 23 | 17.4 | 16.2 | 15.5 | 12.6 |
| Recycled water | n/a | 12.4 | 11.7 | 11.0 | 4.8 |
Environmental Expenditures ($) |
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| Operating expenditures | 61,200 | 83,300 | 38,200 | 44,500 | 133,800 |
| Capital expenditures | 0 | 74,500 | 0 | 196,700 | 0 |
Energy |
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| Energy costs ($ million) | 1.9 | 1.9 | 2.0 | 1.9 | 2.0 |
| Energy use (BBtu) | 242 | 231 | 203 | 191 | 216 |
Procurement |
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| Local purchasing ($) | 572,000 | 508,000 | 482,000 | 856,000 | 2,156,000 |
| n/a = not available Source: PotashCorp |
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