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Nitrogen

(All dollar values are US)

Lima

Operations

Lima is ISO 9001:2000 certified.
In January 2008, PCS Nitrogen assumed operating responsibility for Lima, which was previously operated by INEOS.
Annual capacity – 648,000 tons of ammonia
Products – ammonia, nitric acid, urea solutions, prill and granular urea, ammonium nitrate liquid and urea/ammonium nitrate solutions

Performance

Significant Achievements

  • Developed SHE, maintenance, engineering, accounting and HR department policies and procedures after assuming operating responsibility from INEOS.
  • Reached, in nine months, our first labor contract and continued to develop a relationship with United Steel Workers.
  • Implemented our own behavior-based safety process named GOOSE (Great Observations Obtain Safer Environments), which was well received and supported by all employees; we were able to achieve our goals for active observations and contact rates.
  • Lima passed two million work hours without a lost-time injury in 2008; nested contract employees exceeded three years without a recordable injury.

Community Relations

  • We continue to be a member of the Environmental Advisory Committee (EAC) and a regular member of the Ottawa River Coalition. At the EAC, each facility gives a SHE update, reports spills, leaks, injury rates and, if appropriate, any information about shutdowns and turnarounds. There is also an opportunity for dialogue with citizens.
  • The Ottawa River Coalition includes members from industry and government. Meetings generally consist of water quality reports, updates on upcoming EPA testing and any reports of illegal dumping or leaks affecting the water quality. The group has also been addressing wetlands issues.
  • PotashCorp representatives meet regularly with the Local Emergency Planning Commission and Lima Area Security and Emergency Response, which also involve local industry, fire and police departments, the sheriff's department, FBI and Department of Homeland Security.
  • A community survey revealed that the community wants us to be more visible. In response, we have made efforts to be more active in the Allen County 4-H program, Big Brothers/Big Sisters of Allen County, the United Way and other local organizations. Participants appreciated the jobs we provide and showed an appetite for expanding our operations.

Community Donations

  • Many donations of time and money to local non-profit organizations and local schools have helped the community learn more about what we do.
  • Lima is a sponsor of the United Way of Lima campaign; we exceeded our goal for total donations.
  • Cash donations to community organizations in 2008 totaled $40,000. In addition to the United Way, beneficiaries were the Melanoma Research Foundation and Science Enhancement for Science Advancement (SESA). The SESA program targets students in local elementary schools and is supported financially and with voluntary time by PCS Lima and four other local manufacturing companies.
  • In-kind contributions to local community organizations totaled $10,500. We participated in the Extreme Community Makeover Contest and made improvements and repairs to the Big Brothers/Big Sisters Agency of Lima. Other beneficiaries included Children's Developmental Center, classroom science experiments conducted in local schools by employees as part of SESA and donation of laboratory equipment to Lima city schools.

Awards and Recognition

  • Received a Trendsetter Award from the United Way of Lima for increasing our contribution by 15 percent.
  • Reached two million work hours without a lost-time injury.

Environment

  • We continued our study on reducing emissions through low NOx burners.

Local Procurement

  • Made local purchases in 2008 of goods, materials and services totaling $14.0 million, or 41 percent of expenditures (excluding major expansions, raw materials, energy and transportation).

  2004 2005 2006 2007 2008
Annual Production (000 tons)          
Ammonia 507 421 374 585 592
Urea solids 216 204 168 321 345
Nitrogen solutions 94 72 64 90 86
Nitric acid n/a n/a 108 110 107
           
Employment*          
# of employees 5 4 6 13 119
# of female employees 1 1 1 3 11
Gender ratio (% female/total employees) 20 20 17 23 9
Average tenure (years) 11 11 9 5 10
Absenteeism rate (% hours absent) n/a n/a n/a n/a 5
Employee training provided (hrs per employee) 73 12 n/a 2 399
           
Safety Performance          
Lost-time frequency (per 200,000 hrs)
Recordable frequency (per 200,000 hrs) 2.9 2.3 0.9 1.8 0.7
           
Greenhouse Gas Emissions          
GHG emissions (000 tonnes) 996 1,242 982 1,167 803
Normalized GHGs (GHGs/tonne production) 2.58 3.60 3.09 2.43 1.62
           
Criteria/Significant Air Pollutants (tons)          
Nitrogen oxides 1.48 1.33 1.21 1.38 1.49
Carbon monoxide 0.25 0.23 0.19 0.26 0.24
Ammonia 0.96 0.86 0.76 1.34 1.14
           
Emissions to Water (tons)          
Ammonia as N 5.9 2.8 2.1 3.3 18.0
Total nitrogen as N 50.2 32.4 42.0 65.8 28.0
           
Water Use (million gallons)          
Water withdrawn 2,312 2,401 1,904 2,122 1,564
Recycled water 1,455 134
           
Environmental Expenditures ($ 000)          
Operating expenditures 457 520 454 285 750
Capital expenditures 34 277 412
           
Energy          
Energy costs ($ million) 120.4 128.1 93.0 146.7 195.4
Energy use (BBtu) 19,065 16,307 13,067 20,601 26,831
Energy efficiency (MMBtu/ton NH3) 35.3 40.8 32.1 31.8 33.0
           
Procurement          
Local purchasing ($ million) 11.1 12.5 5.7 4.7 14.0
n/a= not available
Source: PotashCorp
* Until January 2008, INEOS operated the Lima facility. Employment data before 2008 refers only to PotashCorp employees seconded to INEOS.