Incitec
Pivot Ltd. (IPL), Southbank, Victoria, will cease manufacturing at its
Brisbane, Queensland-based Gibson Island plant at the end of December 2022. The
company said “despite extensive efforts” it has been unable to secure
“an economically viable” long-term gas supply to its plant beyond its
current supply contract.
“After
50 years of continuous production and re-investment at Gibson Island, IPL was
disappointed it was unable to secure affordable gas for the plant,” said
IPL Managing Director and CEO Jeanne Johns in a Nov. 8 statement announcing the
decision.
IPL has
been under pressure from a sharp rise in the price of Australian East Coast gas
over recent years, and in the past has warned a production closure at Gibson
Island could not be ruled out if affordable gas could not be secured. As
recently as last month, the company said that international competitive gas
pricing is required to continue operations at Gibson Island after the current
gas contract expires
The
current contract with Australia Pacific LNG started in April 2020 and expires
on Dec. 31, 2022. It replaced a temporary one-year gas contract that expired on
Dec. 31, 2019.
Responding
to an analyst’s question at a company Business Update call on Nov. 8 following
the closure announcement, Johns said the company had been looking for a gas
contract to run from 2023 until 2027, given that complex manufacturing sites
need to do a thorough turnaround every four years. She said the Gibson Island
plant was faced with an investment of A$60 million to A$70 million that would
need to be remunerated over that period of time.
Johns
revealed the earnings of the Gibson Island operation are “slightly
underwater” with the current gas supply contract, but by the end of the
contract, it will be “slightly above water.”
IPL’s
Gibson Island site is currently Australia’s sole urea producer. The site has
capacity to produce 340,000 mt/y of granular urea, according to Green Markets data. It also produces
ammonia and ammonium sulfate, with nameplate capacity of 300,000 mt/y and
200,000 mt/y, respectively, according to IPL’s website.
The
company said urea, ammonium sulfate, and other specialty products will be
sourced from its existing international import supply chains to replace these
manufactured products, and that its Brisbane fertilizer distribution center
operation will continue beyond the closure of the manufacturing operations.
Johns
emphasized that the earnings of IPL’s distribution business are not expected to
be adversely impacted by the closure of the Gibson Island plant.
She
said IPL has an existing supply chain for imports to replace the supply of most
of the products produced at the Gibson Island plant, including urea and
granulated ammonium sulfate. But as the facility is moved to an import model,
the company will discontinue its ‘Big N’ manufactured product. Johns said the latter product on an import
basis given the current market and ammonia pricing does not make economic
sense.
However,
she said that IPL does have urea in Easy Liquids that are available as
“good replacements.”
IPL’s
Dyno Nobel Asia Pacific subsidiary will make alternative arrangements for
ammonium nitrate (AN) production at its Moranbah, Queensland, plant that utilizes
around 20,000 mt/y of ammonia currently supplied from Gibson Island.
Johns
said IPL is looking at different options for that – both the import of ammonia
and ammonia supply from domestic manufacturers – and is also looking at
replacing the AN production at Moranbah through domestic and import options.
The company is looking at use of existing storage infrastructure if it were to
go down the ammonia import route. But if that was not possible, Johns said the
economics would point to importing AN before investing in new ammonia import
infrastructure.
The
company said it currently is in advanced negotiations with third parties to
source ammonia or AN to replace the volume from Jan. 1, 2023
IPL
expects the financial impact of these alternative arrangements for the Moranbah
plant to range between A$5-A$10 million per year.
IPL’s
wholly-owned subsidiary, Incitec Fertilizers Pty Ltd. (IPF), this past May
inked a 20-year offtake agreement with junior producer Perdaman Chemicals and
Fertilisers Pty Ltd. with a commitment to take up to 2.3 million mt/y of
granular urea from Perdaman’s proposed urea plant at Karratha on Western
Australia’s Burrup Peninsula (GM May
7, p. 1). But the agreement is subject, among other conditions, to the Perdaman
plant being built, and first production is not expected before the first
quarter of 2025.
Johns
told participants at the Business Update call that the Perdaman supply contract
“would be a good substitute in time” for some of the imports IPL
currently source internationally. She is hopeful there will be more certainty
on the Perdaman plant in the coming months, but added that the facility is not
yet fully approved.
IPL
said the cash costs of closing the Gibson Island plant would be about A$83.5
million, including employee redundancies and costs associated with plant
decommissioning. The decision to close the production facilities is expected to
impact up to 170 employees.
The
company will write down the value of assets by about A$102.5 million,
representing the cost of the last turnaround and other maintenance. But
proceeds from land sales could range from A$0-A$45 million, depending on final
decisions about future use opportunities, including the use of the site for a
green ammonia plant.
In
addition to the cost of the alternative ammonia sourcing arrangements for Dyno
Nobel Asia Pacific, the impact of the Gibson Island manufacturing closure on
IPL’s earnings from January 2023 will include zero earnings contribution from
the site’s domestically manufactured products. Stranded Corporate and insurance
costs are expected to be about A$10 million per year.
“Despite
the decision to cease manufacturing with natural gas at Gibson Island at the
end of 2022, the feasibility study into industrial-scale production of green
ammonia at the site will be progressed to potentially re-purpose the
facility,” said Johns.
IPL
announced last month that it will partner with global green energy company
Fortescue Future Industries Pty Ltd. (FFI) on a feasibility study into
industrial-scale production of green ammonia at the Gibson Island fertilizer
manufacturing facility (GM Oct. 15,
p. 1).
The
building of a new water electrolysis facility at the Gibson Island site to
produce around 50,000 mt/y of renewable hydrogen, which would then be converted
into green ammonia for Australian and export markets, is being investigated,
the company said.
“By
investigating the re-purposing of Gibson Island, we can make use of the
existing manufacturing plant infrastructure, our established production
capabilities, and our highly skilled workforce,” said Johns.
Preliminary
results from the feasibility study are expected to be available at the end of
this year.
In an
associated development, IPL said on Nov. 5 it had signed a Memorandum of
Understanding (MOU) with Singapore’s Keppel Infrastructure Holdings Ltd. and
Singapore-based investment company Temasek to investigate the feasibility of
producing green ammonia in Queensland and New South Wales (NWS) for export.
IPL
said the three parties will work closely with the Queensland and NSW
governments to explore the feasibility of essential infrastructure, licenses,
and approvals to facilitate the production and export of green ammonia.
“Both
our Kooragang Island, NSW, site and a potential greenfield site in Gladstone,
Queensland, have the advantage of being nominated by the Australian government
as locations identified as clean hydrogen hubs under Australia’s ‘National
Hydrogen Strategy,'” IPL said.