Phosphate
All monetary amounts are in US dollars.
All units of measure are English.
Weeping Water
Operations
Animal feed ingredients plant
About 125,000 tons of limestone is mined on site annually at 125 feet and 145 feet below the surface and used as a raw material to make the products
Annual capacity — 230,000 tons of dicalcium phosphate, monocalcium phosphate and coarse monocalcium phosphate
Performance
Significant Achievements
- Achieved five years without a lost-time accident and three years, six months without a recordable injury
- Hosted presentations by the National Safety Council on distracted driving (primarily cell phone use) at the plant site and at the local school
- Conducted a customer audit which revealed no significant customer complaints
- Offered urea as a new product; modified storage units, built a new loadout shelter and installed new augers for loading product
- Increased efficiency in truck loading so two trucks can be loaded at once
- Installed a new 6,000-gallon double wall fuel containment tank with a monitoring device between the two tank walls to detect a leak; the outer wall also provides thermal protection to the contents in case of fire
- Continued to eliminate straight ladders in the plant and replace them with stairs and work platforms to reduce injury risk
Community Relations
- Continued to be active in the Chamber of Commerce
- Continued our support of the project to renovate the old city auditorium, which will be used as a community resource
- Sponsored plant site tours during the Limestone Day celebration
- Continued to support youth organizations throughout the area in sports and academics
- Received media coverage in the county newspaper for monetary contributions for warm-up jackets to the Weeping Water High School girls’ basketball team, sponsoring the Weeping Water Little League Wrestling program and donation to the Lofte Community Theater
Community Donations
- Donated more than $4,800 to local organizations, including the United Way, Lofte Community Theater, City of Weeping Water, Weeping Water School, Weeping Water Building Foundation and Murray-Conestoga Schools
- Contributed $3,570 of in-kind goods and services to the Cass County Fair, City of Weeping Water, Limestone Days, Murray Fire & Rescue, Syracuse-Dunbar-Avoca School Board, Syracuse Volunteer Fire Department and Weeping Water Public Schools
School Partnerships
- Participated in the Science Fair and other school projects with Weeping Water schools
- Involved in Support Our Schools with Elmwood-Murdock Schools; supplied elementary classrooms in Murray-Conestoga Public Schools with smart boards
- Awarded one PotashCorp divisional scholarship worth $2,500
Awards
- Received a platinum award with distinction from the National Safety Council of Greater Omaha for the 15th consecutive year
- Received the Star Award from the Nebraska Safety Council
- Awarded for the fifth consecutive year the “Sentinels of Safety Award” for having the lowest no days lost (NDL) injury incidence rate
- Received the Pinnacle Award from Union Pacific Railroad for chemical transportation safety
- Presented with PotashCorp’s Award of Excellence in Safety in December 2009
Energy and Environment
- Installed new lights that use less energy throughout the plant; also installed light sensors to reduce energy consumption
- Reduced dust emissions by installing a new dust collector at the truck loadout station
Local Procurement
- Made local purchases in 2009 of $1.8 million, or 71 percent of total expenditures (excluding major expansions, raw materials, energy and transportation)
| Weeping Water | |||||
|---|---|---|---|---|---|
| Source: PotashCorp | |||||
| 2005 | 2006 | 2007 | 2008 | 2009 | |
| Annual Production (000 tons) | |||||
| Dicalcium/monocalcium phosphate | 131 | 129 | 121 | 110 | 87 |
| Employment | |||||
| # of employees | 34 | 33 | 34 | 35 | 35 |
| Gender ratio (% female/total employees) | 8.8 | 9.1 | 8.8 | 8.6 | 8.6 |
| Average tenure (years) | 20 | 19 | 20 | 18 | 19 |
| Absenteeism rate (% hours absent) | 3.7 | 3.1 | 1.1 | 1.1 | 1.6 |
| Employee training (hrs per employee) | 44 | 65 | 66 | 215 | 133 |
| Safety Performance | |||||
| Lost-time frequency (per 200,000 hrs) | — | — | — | — | — |
| Recordable frequency (per 200,000 hrs) | 3.2 | 3.0 | — | — | — |
| Greenhouse Gas Emissions | |||||
| GHG emissions (000 tons) | 33.3 | 33.0 | 31.2 | 28.7 | 22.7 |
| Criteria/Significant Air Pollutants (tons) | |||||
| Nitrogen oxides | 12.1 | 11.9 | 22.4 | 20.9 | 16.7 |
| Carbon monoxide | 3.8 | 3.7 | 3.2 | 3.0 | 2.4 |
| Particulates (dust) | 19.4 | 18.2 | 17.8 | 15.5 | 13.5 |
| Water Use (million gallons) | |||||
| Water withdrawn | 24.4 | 15.8 | 17.4 | 18.0 | 15.1 |
| Environmental Expenditures ($ 000) | |||||
| Operating expenditures | 128.7 | 41.2 | 49.0 | 57.6 | 50.0 |
| Capital expenditures | 9.9 | 23.2 | — | 77.2 | 145.0 |
| Energy | |||||
| Energy costs ($ million) | 1.7 | 1.7 | 1.6 | 1.7 | 1.0 |
| Energy use (BBtu) | 215 | 205 | 196 | 181 | 148 |
| Procurement | |||||
| Local purchasing ($ million) | 1.1 | 2.0 | 2.3 | 3.4 | 1.8 |





