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Simplot withdraws permit application

Boise-The J.R. Simplot Co. has withdrawn its application for a modified air quality permit that would remove production limits at one of the Don Plant’s two sulfuric acid plants near Pocatello, where it produces phosphate fertilizer. In an Oct. 16 letter sent to Mike Simon, the Idaho Department of Environmental Quality’s air quality division program manager, Simplot Don Plant Environmental Manager Kirk Adkins said the company was withdrawing its application, which was submitted in June 2006. No reason was given in the letter. IDEQ said Simplot does plan to submit a revised application later. In June 2006, Simplot submitted its Permit to Construct Modification application requesting removal of a 1,750-tons-per-day production limit for its No. 300 sulfuric acid plant. The company estimates it would produce 2,000 tons of sulfuric acid per day without the restriction. Simplot’s Don Plant discharges about 565 tons of sulfur dioxide annually. Simplot anticipates that would have increased to 602 tons if the sulfuric acid production limit were removed, but still be well below the 750 tons allowed each year under federal standards. Increasing the No. 300 sulfuric acid plant’s production would reduce the amount of sulfuric acid Simplot acquires from other sources, but reportedly would not affect the production rates of other processes at the plant. In 1998, Simplot bought about 42,185 tons of sulfuric acid offsite to compensate for shortfalls. It purchased 50,489 tons in 1999, and 2,643 tons in 2004 for use in other plant processes. At a public hearing in May, some citizens criticized Simplot’s proposal and IDEQ’s regulation of the company’s fertilizer plant.

USDA projects higher corn stocks

Washington, D.C.-The USDA’s World Agricultural Supply and Demand Estimates report, released on Dec. 11, shows a projected 350 million bushel, or 31 percent, increase in the amount of corn forecast to be left at the end of the marketing year next summer. The ending stocks increase reflects a 300 million bushel drop in the expected use of corn for ethanol production and a 100 million bushel cut in exports. Despite the increase in projected corn stocks, U.S. corn and soybean futures rose on Thursday due to the weak dollar and a crude oil rally. Corn futures on the Chicago Board of Trade for December delivery ended 11.25 cents, or 3 percent, higher at $3.38/bushel, while CBOT January soybeans rose 27 cents, or 3 percent, to $8.564/bu. The dollar slipped to a seven-week low against the euro, and crude oil closed up $4 a barrel to near $48 due to the weaker dollar and expectations that OPEC will cut more oil supply. USDA kept its forecast for U.S. soybean stocks for the marketing year-end at 205 million bushels, the tightest supply in five years. USDA increased its export forecast for soybeans on Thursday due to strong demand for U.S. soybeans from China, but also predicted that domestic processors will crush fewer soybeans due to poor profit margins. USDA projected a season-average farm price for corn at $3.65-$4.35/bu, down on both ends of the range from last month’s $4.00-$4.80/bu. The season-average soybean price range for 2008/09 was projected at 8.25-$9.75/bu, down $0.85/bu on both ends. The report also projected higher feed grain ending stocks for 2008/09 for barley and oats, and also shows a slight increase in wheat production, with the domestic all-wheat season average farm price projected at $6.40-$7.00/bu, down 15 cents.

ARA Conference draws record numbers; speakers highlight market volatility

Some 650 attendees were on hand in Austin, Texas, Dec. 2-4 for the 2008 Agricultural Retailers Association Conference and Exposition. The attendance was a record for the event, organizers said, and reflected the interest and concerns that industry representatives have for what conference emcee Dr. Dave Downey of Purdue University described as the “volatile, highly chaotic market we live in today.”

Attendees listened to a range of speakers during the event, from production company CEOs to a panel of both small and large retailers. Nearly all of the speakers highlighted the challenging environment facing the agri-retail industry at the moment and the abrupt change in market conditions that the industry has experienced in the last year. “It’s like somebody just dropped a bomb, and caused everything to be so different from what it was just a few months ago,” Downey said.

Jim Prokopanko, president and CEO of The Mosaic Co., spotlighted both the challenges and opportunities facing the industry. While the global financial crisis, crop nutrient market recalibration, and late U.S. harvest dominate the former category, Prokopanko said biofuels, population growth, and income growth remain positives for the industry. “People still eat during economic downturns,” he said.

Prokopanko said grain and oilseed demand has accelerated, and will continue to do so. “The world adds the equivalent of another Thailand and Laos to global population each year,” he said, and people upgrade their diets as income climbs. Prokopanko said one billion people are projected to join the middle class in China and India by 2025, and that is “good for crop nutrient demand prospects.”

Prokopanko said global nutrient use will increase to more than 230 million mt by 2020 due to the demands of biofuels and food production. The long-term outlook continues to look “rock solid to us,” he said.

Despite those positive fundamentals, Prokopanko said a “perfect storm” of negative variables has hit in recent months, including slower economic growth, the credit crunch that has limited sales, and the commodity sell-off that has eroded farm economics and nutrient demand. He cited a “free-fall” in raw materials costs, noting sulfur prices as a case study. Plunging DAP and urea prices have resulted in a stalemate at the retail and wholesale level as buyers step out of the market, he said.

Prokopanko highlighted the ongoing uncertainties facing the industry: will we see another “perfect storm” next spring; will the poor fall result in a large spring fertilizer season; will the financial markets stabilize and credit availability increase; can the supply chain move the volume needed next spring; is this the year when “the sky really is falling.” Prokopanko likened the market volatility of the last year to an Everest expedition, noting that “more people die on the descent from Mount Everest than they do on the ascent.”

Prokopanko fielded several questions from the audience, several of which focused on managing risks as well as relationships at all points along the distribution chain, from producer to farmer. “How do you finance large inventories at high prices for long periods of time? I don’t have an answer for that,” he said. Prokopanko also addressed charges that producers had decoupled themselves from their real customer – the farmer – as fertilizer prices marched up in 2008. “Many of the people in our organization have a real connection to agriculture,” he said.

Greg Page, president and CEO of Cargill Inc., used his presentation to answer questions submitted in advance by ARA members, ranging from the impact of ethanol to food safety issues. He noted that the incoming administration under Barack Obama is supportive of free trade, and referred to Rahm Emmanuel, Obama’s chief of staff designate, as an “ardent” free-trader. “We should all be encouraged by that,” Page said.

Hugh Grant, president and CEO of Monsanto, highlighted his company’s progress on new soybean and cotton platforms, as well as the development of first-generation, drought-tolerant corn seeds by 2012-13. Grant said doubling the yields of corn, soy, and cotton by 2030 remains a primary goal. “We need to produce more, with less, on a shrinking resource,” he said. “The thing that we are really focused on is driving yield.” Grant said the world “will depend on American, Argentinean and Brazilian farm production, and the ingenuity of the American farmer, for years to come.”

John Lagemann, vice president of sales for John Deere, also highlighted the need to increase agricultural productivity, and noted world protein demand and renewable energy as positive ag fundamentals. “Global food demand is a sustainable, longterm proposition,” he said. Lagemann cautioned, however, that “market volatility is here to stay,” although “hopefully not the spikes we’ve seen in the last six months.”

Jack Eberspacher, ARA president and CEO, alerted attendees to ARA’s legislative successes in 2008, including the inclusion of the Agricultural Chemicals Security Tax Credit in the new Farm Bill. Sen. Pat Roberts (R-Kan.) was the recipient of ARA’s Legislator of the Year award for his support of the tax credit bill.

Eberspacher also highlighted ongoing concerns, including the Chemical Facility Anti-Terrorism standards and efforts to revisit inherently safer technologies mandates when Congress considers permanent chemical security legislation; transportation issues such as the hours of service exemption, which expires at the end of 2009, and the railroads’ efforts to get out of their common carrier obligation to transport toxic-by-inhalation chemicals such as anhydrous ammonia; and environmental issues such as spray drift, nurse tank testing, and the prospect of cap-and-trade climate change legislation.

The conference also featured a lively and candid panel discussion by four ag retailers, including Kevin Still of Co-Alliance LLP, Johnny Council of The Lyman Group, Dean Williams of Agrium Inc., and Jim Davis of Meherrin Chemicals. The discussion focused on credit and pricing issues, as well as strategies for inventory management and price risk management. All four noted the current stalemate between retailers with plenty of high-priced inventory under the roof and farmers who are aware of the falling markets.

Explosion, fire hit Yara plant; more closures made as economic woes unfold

Yara International ASA said a Dec. 3 fire at its Porsgrunn #3 NPK plant in Herøya, Norway, was quickly put under control after an earlier explosion. Five people were injured, but none of the injuries were life threatening. Two individuals who were taken to the hospital were discharged shortly afterwards.

The police and fire crews who attended the emergency earlier in the day left the site in the afternoon. Yara said everyone who registered as entering the area was accounted for, and there are no missing persons. The affected area will remain evacuated, and staff debriefing was to continue on Dec. 4.

Yara said the cause of the explosion is not yet known, but there was no production ongoing at the plant at the time of the blast. An inquiry has been launched into the incident and will be carried out according to Yara procedures. Yara said it is too early to say anything about material damages.

There is no production at the facility as of Dec. 4. Yara told Green Markets that there is currently no assessment as to when the complex will return to operation.

The Porsgrunn site covers 1.5 square kilometers and is the largest industrial site in Norway. The complex has Yara and Europe’s largest installed production capacity for NPK complex fertilizers. The site has one ammonia plant, three nitric acid plants, two NPK plants, and one calcium nitrate (CN) plant. The facilities produce a wide range of NPK and calcium nitrate. About half of the volumes produced are sold overseas, mainly in Asia, with the balance sold in various countries in Europe. The ammonia, nitric acid, and fertilizer facilities also produce a range of gases and chemicals for industrial applications.

Yara said Dec. 1 it will permanently close its NPK plant in Kedainiai, Lithuania. NPK production at Yara’s site in Ravenna, Italy, will be temporarily stopped by mid-December.

The Kedainiai plant has an annual NPK production capacity of 250,000 mt. Yara says it is an old, sub-scale landlocked plant that became a Yara plant with the acquisition of Kemira GrowHow last year. The plant produces low-nitrogen NPK, PK, and P fertilizer based on purchased nutrients. The plant, which has 128 employees, has no competitive market advantage, lacks access to competitively priced raw materials, and would need significant investments to bring it up to Yara efficiency and quality standards.

The Ravenna plant has an annual production capacity of 300,000 mt NPK. The decision to stop production temporarily is related to the current slowdown in NPK deliveries. The timing of a restart will depend on market developments.

Yara said it will continue to fulfill customer contracts from built-up stock and alternative product sourcing, demonstrating Yara’s flexible business model.

Other recent shutdowns at Yara include Le Havre, France, (400,000 mt/y ammonia and 350,00 mt/y urea); Sluiskil, The Netherlands (900,000 mt/y ammonia and 200,000 mt/y urea); and Ferraro, Italy (600,000 mt/y ammonia and 500,000 mt/y urea). The company has also taken its Tringen II ammonia plant in Trinidad down for one month.

Friends, foes line up for proposed Idaho fertilizer plant; to break ground in late 2009

Environmental and tribal groups worried about carbon dioxide emissions and community leaders eager for an economic boost have submitted opinions about Southeast Idaho Energy’s (SIE) plan for a $1 billion coal-gasified fertilizer plant near American Falls. The Idaho Department of Environmental Quality’s deadline for public comments about the controversial project closed Nov. 24.

The Shoshone-Bannock Tribes, the Sierra Club, Earthjustice, the Idaho Conservation League, and the Greater Yellowstone Coalition officially oppose the Power County Advanced Energy Center, while the American Falls City Council and American Falls School Board are among those to throw their support behind it.

The comment period was extended a month at the request of the Sierra Club and Pocatello resident Greg Helm, who opposes the project. The Sierra Club requested the extra time to verify calculations in SIE’s permit to construct.

SIE, a subsidiary of Refined Energy Holdings of New York, estimates it would need to import about 2,000 tons of coal daily, mostly from Colorado, for the plant, which would use advanced technology to keep emissions reduced. Opponents, however, say the plant would discharge 2.3 million tons of carbon dioxide annually, contributing to global warming.

IDEQ has determined that the plant’s operation under a proposed permit will not cause or contribute to violating ambient air quality standards, nor harm nor affect human or animal life or local vegetation.

During a September meeting, IDEQ officials said the plant’s operations shouldn’t exceed air quality standards for several controlled emissions, including particulates, carbon monoxide, nitrogen oxides, and sulfur dioxide, but it will release significant amounts of carbon dioxide, which is not regulated as a pollutant.

The project will produce up to 500 st/d of anhydrous ammonia, up to 1,800 st/d of granular urea, up to 1,600 st/d of UAN, and up to 500 st/d of sulfuric acid. SIE has decided against producing diesel fuel or generating electricity at the site as originally planned.

Justin Hayes, program director for the Idaho Conservation League in Boise, said the plant’s carbon dioxide emissions would account for nearly 5 percent of total CO2 emissions in the state.

Roger Turner, Shoshone-Bannock air quality manager, said SIE plans to vent the carbon dioxide directly into the air, although company officials have said they hope to eventually pipe the CO2 to Wyoming for enhanced oil recovery. He said the tribes also have concerns about mercury pollution.

“We expect to meet CO2 regulations when they become applicable to our plant,” said John Burk, SIE spokesman. “As you know, there currently are no federal or state laws or regulations concerning CO2. The project is environmentally, financially and technically sound, and we expect to seek financing and break ground late next year.”

School Superintendent Ron Bolinger said he was instructed by the American Falls School Board to send a letter to IDEQ in support of the project because it would increase the school district’s tax revenue significantly and support the American Falls community.

Planned for about two miles west of American Falls near ConAgra’s Lamb Weston potato processing plant, the fertilizer complex daily would gasify coal and coal/petcoke blends to produce ammonia, urea, and UAN. Elemental sulfur, sulfuric acid, and slag byproducts also would be sold.

Bolinger said the school board has drafted a plan to cope with an anticipated influx of new students who would move to the district due to the plant’s construction and operation. Any additional infrastructure needs would be more than covered by extra taxes generated by the plant, he said.

An estimated 1,000 construction workers, many of whom would live in Pocatello and commute, would come to the area. When the plant is running, an estimated 150 full-time workers would be employed there.

Cheryl Robinson, staff engineer with IDEQ’s air quality division, said her department usually responds to public concerns within 15 days after the closing of public comment periods, but because of the volume and depth of comments, that could be longer in this case. If approved, plant construction could start in 2009.

Simplot gets “green light” for mine expansion

U.S. Magistrate Mikel Williams has denied a preliminary injunction (GM Nov. 10, p. 13) requested by environmental groups to block expansion of J.R. Simplot Co.’s Smoky Canyon phosphate mine on the Idaho/Wyoming border near Afton, Wyo. In his Nov. 26 ruling, Williams said there is little likelihood the environmentalists could prevail on the merits of their case. His denial gives the green light for the mine’s expansion on the Caribou-Targhee National Forest.

Simplot spokesman Rick Phillips said his company will do everything it can as soon as possible to begin the project, depending on the weather. He said Williams’s ruling validates the professionalism of the U.S. Forest Service and Bureau of Land Management, which approved the mine’s expansion last summer.

The Greater Yellowstone Coalition said it plans to appeal the ruling. Earlier this year, it filed suit against the expansion on behalf of the Natural Resources Defense Council, Sierra Club, Defenders of Wildlife, and other environmental groups. Earthjustice Legal Defense Fund attorneys argued in court against expanding the mine. That lawsuit named federal agencies and top administrators as defendants.

Marv Hoyt, the Greater Yellowstone Coalition’s Idaho director, said his organization plans to ask Williams to reconsider his decision to halt the injunction. If he declines, it will then appeal the case to the 9th Circuit Court of Appeals. He said Simplot plans to start installing a forest haul road soon.

Smoky Canyon is the sole source of phosphate ore for Simplot’s phosphate fertilizer plant near Pocatello. Simplot officials say Smoky Canyon ore deposits are expected to be exhausted by 2010, but expansion will allow the company to keep the mine and fertilizer plant operating through 2025.

On Nov. 13, Williams allowed nine parties to intervene on behalf of Simplot ?Çô the cities of Pocatello, Chubbuck, and Afton; Bannock, Caribou, Power, and Lincoln counties; United Steel Workers Local 632; and the Idaho Farm Bureau Federation.

Annual wages and salaries paid at the mine and plant exceed $52 million. Of the 375 employees at the Pocatello plant, 250 belong to the steelworkers union. About 200 workers are employed at the mine. Another estimated 1,450 people are indirectly employed by the operations, whose annual property taxes exceed $3 million.

Simplot has mined at Smoky Canyon since 1984. Each year, about 1.5 million st of phosphate ore are removed from the mine and converted into slurry pumped through nearly 90 miles of pipeline to Simplot’s Pocatello processing plant, where it’s converted into liquid and dry fertilizers used throughout North America.

Mosaic may make more cuts in DAP production

The Mosaic Co. said Dec. 1 it may have to further cut DAP production due to market conditions. The company gave a preview of its fiscal 2009 second quarter ended Nov. 30, 2008.

Due to soft market conditions, phosphate sales volumes for the second quarter were approximately 1.3 million mt, or about 800,000 mt lower than the volume sold during the company’s first quarter in fiscal 2009. The average selling price for DAP during the quarter was within the company’s estimated guidance range of $1,020 to $1,080 per mt. However, phosphate gross margins are expected to be impacted due to high cost raw materials used to produce phosphates in the second quarter.

Potash sales volumes for the second quarter were approximately 1.7 million mt. The average MOP selling price was approximately $525 per mt compared to the company’s estimated guidance range of $560 to $620 per mt during the second quarter, primarily due to the mix of products sold internationally.

“Several factors have impacted worldwide crop nutrient demand, including lower grain and oilseed prices, a late North American harvest, congested distribution supply chains, and the unprecedented global economic and credit downturn which has seen business moderate in nearly all sectors,” stated Jim Prokopanko, Mosaic president and CEO. “We are confident in the long-term fundamentals for our business. The world’s growing population needs to eat, so although purchases of vital crop nutrients that increase grain and oilseed yields may be delayed, they can’t be avoided like most discretionary purchases.”

As announced in October, Mosaic is reducing phosphate production by approximately one million mt through December 2008. In addition, the company announced that it is prepared to further reduce phosphate production by up to an additional one million mt during the remainder of fiscal 2009 if market conditions continue slower than normal.

Mosaic advised that fiscal 2009 third-quarter sales volumes are expected to remain soft, followed by a strong recovery in the fourth quarter, and that it expects to record an operating loss for the second quarter in its Offshore business segment due to inventory valuation adjustments. Mosaic further indicated that due to uncertainties in the global economy, the company has withdrawn fiscal 2009 sales volume guidance for phosphates and potash. The company said that it will resume providing sales volume guidance when the market returns to a more normalized condition.

“Fortunately, the actions we have taken during the past two years, including our operating discipline and the dramatic improvement of our balance sheet, position us well for when this market rebounds,” said Prokopanko. Mosaic indicated that it remains in excellent financial condition, with more than $2.5 billion of cash on hand, no borrowings under its revolving credit facility, and only minimal short-term debt maturities as of November 30, 2008.

The company also noted that it expects to record an after-tax gain of approximately $1.00 per share during the second fiscal quarter resulting from the sale of its interest in Saskferco Products ULC in October 2008.

The company will provide more information in its second fiscal quarter earnings release, scheduled to be issued in early January 2009.

Jamaica gets bad whiff after trying to cut corners

An effort by the Jamaican government to help sugar cane growers deal with the rising price of fertilizer backfired to the tune of just over $1 million. The government imported 2,500 mt of an NPK mix through a Jamaican trading house based in the U.S. Reportedly, the product used city sewage sludge as filler. Local media reports said government and agriculture association officials on hand to receive the test shipment fainted when the container was opened at the Kingston wharf. Warehouse workers handling the product have also reported vomiting and nausea.

The government stepped into the NPK procurement when the only fertilizer company in Jamaica – Newport-Fersan – was accused of gouging local buyers, an accusation the company denies. Fersan executives said the high prices of fertilizer around the world set the price. The company is owned by Fersan of the Dominican Republic and a Jamaican partner. Disputes between the fertilizer company on one hand and the Jamaican government and Jamaica Cane Product Sales on the other have been brewing for more than a year.

Newport-Fersan imports the components of its blended fertilizer from a variety of sources, including the FSU. The record increases in urea and other inputs during the past 18 months affected the NPK blends the company made for the Jamaican market.

The Jamaican agriculture minister complained about the high prices and vowed to help the country’s struggling agricultural sector. The first step was to find another source for fertilizer. The Sugar Cane Growers Association decided to try the sample shipment from New York City.

In the end, the buyers paid a deposit of $1.4 million to the trading house. When the shipment did not arrive on time, the buyers tried to retrieve their deposit plus a $250,000 commission paid to the trading house.

Government officials have reportedly opened talks with traders to import Russian NPK at a lower price than what Fersan had initially offered. The growers are desperate for fertilizer in time for the next application season.

Fersan officials say they are once again in talks with the Jamaican government and growers associations to supply the needed fertilizer.

Hintzsche building UAN terminal in Peru, Ill.

Peru, Ill.-Hintzsche Fertilizer Inc. of Maple Park, Ill., is completing the construction of an 11,000 st UAN tank and adjoining covered loading bay on the Illinois River in Peru, Ill. The facility, situated on approximately three acres leased from the Peru Terminal, will be supplied by barge but also has access to the Illinois Railway. The two-million gallon UAN tank, under construction since September, was just completed several weeks ago, according to John Hintzsche, vice president of fertilizer. The two-bay, enclosed loading structure is currently being built, and will serve as a loading site for trucks. Hintzsche said the company was in need of more UAN storage at four Illinois retail locations in Minooka, Maple Park, Kirkland, and Scarborough. “Instead of doing this multiple times, we’re doing it one time at this site,” he told Green Markets. “We can deliver to our other locations upon need.” Hintzsche said the four full-service locations cover roughly 11 counties in northern Illinois. Initially the Peru facility will handle liquid fertilizer only, but Hintzche said it does have the potential to store dry products as well. “That’s in our plans, but a little ways down the road yet,” he said. He noted as well that there is room at the site for two more solutions tanks, which would allow expansion to more than 30,000 tons of UAN capacity.