Nitrogen
All monetary amounts are in US dollars.
All units of measure are English.
Lima
Operations
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
ISO 9001:2000 certified.
Performance
Significant Events
- Passed 4 million work hours without a lost-time injury in December 2009
- Trained 110 observers under the site’s behavior-based safety process
- Expanded nitric acid capacity from 300 tons per day to 350 tons
- Set an ammonia production record of 612,084 tons as the result of improved reliability
- Established a production record of 193,360 tons of granular bulk urea
- Worked to cultivate a new plant culture in first full year as a PotashCorp-operated facility
- Provided an average of 440 hours of classroom and on-the-job training for each hourly employee
- Undertook significant capital investments during 2009 to improve reliability of ammonia, urea and ammonium nitrate plants
Community Relations
- Participated in the Ottawa River clean-up, including trimming, mowing and picking up litter
- Made a one-time donation of $20,000 to keep the Allen County 4H program running
- Participated in the United Way Extreme Community Makeover program, with employees completing renovations and repairs to the Literacy Council building
Community Donations
- Contributed time and materials to several organizations, including Toys for Tots, “Cram the Van,” Coats for Kids and Relay for Life
- Donated $80,000 to community organizations in 2009, including Allen County 4H, the United Way, Science Enhancement for Science Advancement (SESA), Carter’s Crusade and the Children’s Developmental Center
- Contributed $200,000 of in-kind goods and services to the Literacy Council, Allen County Schools, Ottawa River clean-up and the Children’s Developmental Center
Educational Initiatives
- Provided two local scholarships worth $10,000 each
- Continued to support the Science Enhancement for Science Advancement program, which provides hands-on inquiry-based programs to enhance elementary and middle school science education in Allen County
Awards and Recognition
- Received a Trendsetter Award from the 2009 United Way of Lima for increasing our contribution by 510 percent
- Received the Norfolk Southern Railroad Thoroughbred Safety Award
- Received Platinum Award of Excellence from United Way of Lima for a combined company and employee gift of $250-$399 per employee
- Received Certificate of Appreciation from the US Marine Corps Toys for Tots
- Received a Golden Hammer award from the Extreme Community Makeover program
Energy and Environment
- Traveled to the Subaru facility in Indiana to study their “Zero Waste to Landfills” program in advance of undertaking a study to evaluate our current disposal and recycling methods
Local Procurement
- Made local purchases in 2009 of $17.4 million, or 39 percent of total expenditures (excluding major expansions, raw materials, energy and transportation)
| Lima | |||||
|---|---|---|---|---|---|
| Source: PotashCorp | |||||
| 2005 | 2006 | 2007 | 2008 | 2009 | |
| Annual Production (000 tons) | |||||
| Ammonia | 421 | 374 | 585 | 593 | 612 |
| Urea solids | 204 | 168 | 322 | 346 | 389 |
| Nitrogen solutions | 72 | 64 | 90 | 86 | 116 |
| Nitric acid | NA | 108 | 110 | 107 | 88 |
| Employment | |||||
| # of employees* | 4 | 6 | 13 | 119 | 129 |
| Gender ratio (% female/total employees) | 20 | 17 | 23 | 9 | 10 |
| Average tenure (years) | 11 | 9 | 5 | 10 | 11.7 |
| Absenteeism rate (% hours absent) | NA | NA | NA | 0.3 | 0.4 |
| Employee training (hrs per employee) | NA | NA | NA | 399 | 442 |
| Safety Performance | |||||
| Lost-time frequency (per 200,000 hrs) | — | — | — | — | — |
| Recordable frequency (per 200,000 hrs) | 2.3 | 0.9 | 1.8 | 0.7 | 1.2 |
| Greenhouse Gas Emissions | |||||
| GHG emissions (000 tons) | 807 | 615 | 868 | 898 | 885 |
| Normalized GHGs (GHGs/ton production) | 2.3 | 1.9 | 1.8 | 1.8 | 1.8 |
| Criteria/Significant Air Pollutants (000 tons) | |||||
| Nitrogen oxides | 1,327 | 1,215 | 1,384 | 1,493 | 1,458 |
| Carbon monoxide | 226 | 188 | 257 | 240 | 223 |
| Ammonia | 865 | 758 | 1,344 | 1,142 | 1,200 |
| Emissions to Water (tons) | |||||
| Ammonia as N | 3 | 2 | 3 | 18 | 25 |
| Total nitrogen as N | 32 | 42 | 66 | 28 | 46 |
| Water Use (million gallons) | |||||
| Water withdrawn | 2,401 | 1,904 | 2,122 | 1,564 | 1,737 |
| Recycled water | 134 | 134 | 134 | 134 | 125 |
| Environmental Expenditures ($ 000) |
|||||
| Operating expenditures | 520 | 454 | 285 | 750 | 928 |
| Capital expenditures | 34 | — | 277 | 412 | 4,322 |
| Energy | |||||
| Energy costs ($ million) | 128.1 | 93.3 | 146.7 | 195.4 | 97.5 |
| Energy use (BBtu) | 16,307 | 13,067 | 20,601 | 21,448 | 22,739 |
| Procurement | |||||
| Local purchasing ($ million) | 12.5 | 5.7 | 4.7 | 14.0 | 17.4 |
| * | Until January 2008, INEOS operated the Lima facility. Employment data before 2008 refers only to PotashCorp employees seconded to INEOS. |
