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Start-up details fertilizer terminal plans in Arkansas

Agricultural Solutions LLC, the start-up company that announced plans in May to build a fertilizer terminal on the Mississippi River in Osceola, Ark., says construction of the 35,000-40,000 ton dry facility will begin this fall for a scheduled completion in Autumn 2011.

Don Opal, one of the company’s two owners, told Green Markets in May (GM May 31, p. 1) that construction was likely to begin in August on a dry fertilizer blending and distribution facility on 44 acres of barge-accessible land that it owns in Osceola. Michael Brito-Amador, the other owner of the company, said last week that groundbreaking has been pushed back to Fall 2010. Brito-Amador said he has assumed all responsibilities for the company, and that Opal is taking a hiatus due to health issues.

“My partner’s health in no way has deterred our vision or our ability for this facility to be built,” Brito-Amador told Green Markets. “I want to proceed with caution and I only want to build it once. I don’t want to build something that is too big or too small, or is inefficient, so I’ve slowed the process down slightly. I don’t want to rush to put this building up just to be operational by Spring 2011.”

Brito-Amador said Agricultural Solutions expects to be selling products out of the terminal by the end of next year, and to be well positioned to supply farmers and dealers in northeastern Arkansas with fertilizer products for the 2012 spring planting season. He expects to run 140,000-150,000 tons through the facility annually. “Spring 2012 is really our coming-out party, but I want the facility up and running towards the end of next year so we can work the bugs out and have it ready,” he said.

Brito-Amador also said the facility will handle liquid fertilizers in addition to dry, though 90 percent of its capacity will be focused on dry – at least at the start. “Ninety percent of everything we get will be delivered by barge,” he said. “Given our location, it will be 100 percent domestic product. I feel strongly that the facility that we’re going to build will more than handle the current problem in the Osceola market.”

The problem in that location, according to Brito-Amador, is that the majority of wholesalers are spending $8-$10 per ton in trucking expenses to provide fertilizer products to dealers and growers in the northeastern Arkansas corridor. Opal reported in May that the construction plans for the Osceola terminal call for a barge dock and conveyor system at the site. The location also has highway access and a rail spur to the BNSF main line.

Brito-Amador said A. J. Sackett & Sons Company in Baltimore, Md., Marcus Construction Company of Prinsburg, Minn., and Waconia Manufacturing Inc. of Waconia, Minn., are among the companies Agricultural Solutions has consulted for the design and construction of the facility.

He said Agricultural Solutions has ambitious plans for a second distribution facility to be located in Mexico, and is also planning a second location in Arkansas within five years.

Brito-Amador noted that the initial announcement of the Osceola terminal prompted “overwhelming feedback” and a “tremendous response” from the industry. “The demand is there,” he said.

CF eyes increased N & P consumption, corn acreage in 2011; new UAN capacity up soon

“We see everything lined up to having a really terrific spring planting season with good crop fundamentals,” CF Industries Holdings Inc. Chairman, President, and CEO Stephen Wilson told analysts Aug. 6. Wilson said 2011 nitrogen consumption should be up 2-2.5 percent and phosphate up 4-4.5 percent. He expects corn acreage to be somewhere north of 90 million acres.

As for the fall, “The market seems to be strong in all of our products today, and that’s because we’re looking forward to an early harvest.”

CF told analysts that it would no longer release quarterly data regarding the status of its Forward Purchase Program (FPP). In the past, CF would release information on forward nitrogen and phosphate sales when it released its quarterly earnings. CF said it originally began releasing the FPP information because it was a new company and it wanted to provide investors with insight into risk mitigation actions in the context of high and volatile natural gas costs. Now, said CF, it is a much larger company, and it has a very different and more stable risk profile. In addition, it believes the forward order position is competitively sensitive information.

“With respect to natural gas, we maintain our discipline of essentially backing forward orders with committed gas so that we lock in our margin and we mitigate the risk associated with being exposed on one side or the other,” said Wilson. He said CF would never get into a gas position that exceeded its physical need for gas, adding that the company bought some options to cap its gas exposure in the months of Aug.-Oct. just to be prudent with respect to hurricane risk.

CF reiterated that it does plan to continue to use the FPP as a marketing tool, and doesn’t expect the patterns it has shown in the past to be much different than those in the future.

Wilson also noted that the company’s Woodward, Okla., expansion is expected to come online soon. Woodward, which came to CF via Terra Industries Inc., was expected to see its UAN expansion come up by the end of 2010 (GM May 12, 2008). When asked by Green Markets to quantify the date, a company spokesman said that the facility is supposed to be up by the end of the year. The $180 million expansion will consist of the addition of a 1,500 st/d Weatherly-design UAN facility. The project will affect the Woodward facility’s annual output as follows: ammonia capacity will remain at 440,000 st; because the plant will upgrade more of its ammonia production to UAN, ammonia available for sale as a finished product will decrease from 310,000 to 100,000 st; UAN capacity will increase from 300,000 to 825,000 st (32 percent nitrogen basis); and the expansion will require the addition of approximately 10 employees.

Wilson said the company has plenty of material to take care of traditional CF and Terra customers, as well as to respond to opportunities in the marketplace. He assessed the legacy CF customer as being a large wholesale customer that is relationship-driven. Wilson said Terra had a substantial number of smaller customers downstream, also with very good, long-term relationships. He also noted that Terra had a substantial percentage of its business from the industrial market. “We have a full range of nitrogen products now, and we have multiple locations at which to produce them. And we’ll be looking to put every ton to its highest and best use.”

CF was asked if it could supply its Florida neighbor – The Mosaic Co. – with phosphate rock should Mosaic have to buy rock this fall due to the court injunction against Mosaic mining its new permit in Hardee County (GM Aug. 9, p. 14). “We do not have excess rock production,” said Wilson. “And certainly, the production that we have right now is earmarked for Plant City and on to our customers.”

Addressing its potential nitrogen complex in Peru, CF said the current hurdle is whether there will be a natural gas pipeline to its potential plant site. “There’s been no work on that and we, obviously, are dependent upon that. We wouldn’t make a decision on a project in the absence of that, and no one would lend us any money for the project even if we wanted to make a decision.”

Rentech results hit by lower prices; company upbeat due to stronger N market

Lower nitrogen prices put a major dent in results for Rentech Inc. for the third quarter ending June 30, 2010. Rentech owns nitrogen producer Rentech Energy Midwest Corp. (REMC), which contributes much of the cash flow for Rentech’s alternative-fuel technology business.

Rentech reported a third-quarter net loss of $1.7 million ($.01 per basic and diluted share) on sales of $49.8 million, compared to year-ago net income of $33.5 million ($.20 per basic and diluted share) on sales of $93.3 million. Rentech reported a nine-month loss of $33.1 million ($.15 per share) on sales of $96.1 million, versus the year-ago net income of $7.2 million ($.04 per share) on sales of $160.9 million.

Despite these lower results, Rentech still expects fiscal year 2010 operating income to exceed $20 million, and EBITDA to exceed $30 million.

Rentech says REMC will benefit from significantly improved product prices and margins for the remainder of the year due to positive fundamental factors, including higher corn prices, strong farmer income, and reasonably priced natural gas.

The average sales price per ton in the third quarter was down by 51 percent for anhydrous ammonia and by 37 percent for UAN versus the year-ago quarter. These two products comprised approximately 89 percent and 93 percent of the product sales for the three months ended June 30, 2010, and 2009, respectively.

Third-quarter 2010 ammonia sales were 51,000 st with $20.8 million in revenues, versus the year-ago 67,000 st and $55.3 million. UAN sales were 112,000 st and $23.2 million, versus last year’s 93,000 st and $30.7 million.

Nine-month ammonia sales were 118,000 st and $43.7 million versus the year-ago 115,000 st and $87.5 million, while UAN was 195,000 st and $35.7 million versus the year-ago 163,000 st and $53.3 million.

On ammonia, Rentech says it has now sold product at $500/st for fall delivery. It noted that without higher gas prices, which are remaining below $5.00/mmBtu, margins should expand.

In other news, Rentech recently announced that REMC has entered into a $20 million incremental loan agreement and amended its existing $62.5 million term loan. Credit Suisse was the sole lead arranger of the incremental loan. All of the net proceeds from the $20 million incremental loan will be available to Rentech for general corporate purposes, including development of the company’s technology and synthetic fuels and power projects. The incremental term loan will mature in 2014 on the same schedule as the existing term loan, and is expected to be repaid from cash flows generated by REMC.

CVR sees aggressive buying, stable-to-improving markets

CVR Energy Inc. told analysts Aug. 5 that it has seen aggressive buying in its markets. “We haven’t seen the retailers pull back at all in terms of purchasing intentions and positioning themselves for the spring,” said Stanley Riemann, CVR chief operating officer.

He added that inventories are down. “We went into the second quarter with probably higher ammonia inventories than we normally do and we blew through those in April during the ammonia run. So it was a good call, with respect to our fertilizer marketing team.” As for UAN inventory, he said normally inventories should be somewhat stagnant; while they started out higher, they have drawn down to only 5-6,000 st.

“We’re now taking fill orders rather than spot orders,” added CEO and President John “Jack” Lipinski. “Last year, our forward book at this time was in the range of $130/st for UAN. This year our forward book is roughly $40/st higher. Our current fiscal book will carry us through the end of the year, and we foresee a continuing positive fertilizer market.” He added that agriculture was not as heavily impacted by the recession as other industries, and that fertilizer markets are stable-to-improving.

CVR said it is planning a fertilizer turnaround during the fourth quarter at a cost of $3.8 million, which will be expensed as incurred.

Scotts strong despite weather; expects higher prices; eyes fate of one business; loses some Walmart sales

Scotts Miracle-Gro Co. reported net income of $175.9 million ($2.59 per diluted share) on sales of $1.24 billion for the third quarter ending July 3, 2010, compared to the year-ago net income of $147.8 million ($2.24 per diluted share) on sales of $1.23 billion.

Nine-month net income was $236.7 million ($3.51 per share) on sales of $2.66 billion, versus the year-ago $168.2 million ($2.55 per share) on sales of $2.46 billion.

Scotts said it has been a strong year, though it has not been the best year for weather. It pointed to bad weather in January-March in some areas and then euphoria in April, when it saw a huge increase in sales. The company said its nimbleness and region-by-region presence allowed it to go after the business when it was available. “It is not a business for folks who don’t like roller coaster rides,” said Chairman and CEO Jim Hagedorn, or “for the faint of heart.”

Scotts told analysts that it is exploring strategic alternatives for its Global Professional business unit. “I think it is a good business,” said Hagedorn. “I’m not sure that we are the best owner necessarily of that business.” He said the company is carefully examining whether the unit should remain in the Scotts portfolio.

Scotts said it would continue to focus on its Global Consumer business. “Our consumer business is our heart and soul. That is who we are,” said Hagedorn.

Third-quarter Global Consumer income was $292.7 million on sales of $1.085 billion, up from the year-ago income of $265.2 million on sales of $1.083 billion. Nine-month net income was $510.2 million on sales of $2.31 billion, up from the year-ago income of $429.2 million on sales of $2.11 billion.

Global Professional income for the third quarter was $6.9 million on sales of $71.9 million, versus the year-ago income of $5.2 million on sales of $69.5 million. Income was down for the first nine months, to $15.3 million from the year-ago $26.8 million, while sales were up 4 percent, to $205.3 million from $196.5 million.

Scotts LawnService 3Q income was $22.8 million on sales of $81.3 million, up from the year-ago income of $21.6 million on sales of $78.9 million. Nine-month income was $1.5 million on sales of $144.9 million, up from the year-ago loss of $2.3 million on sales of $150.5 million.

Scotts said it is seeing higher prices for next year and it expects to pass them on to consumers – at least modestly. “We know we have some price increases coming our way and for sure we are not going to let that affect our margin,” said Hagedorn. He said Scotts is looking at modest price increases, in the low single-digits in selected categories. “I don’t think we’re afraid to be sort of alone on pricing, especially where we see cost increases coming down the road. On the other hand, if the consumer is not willing to pay that price, and we see differentials get to a point where we’re not comfortable, we’ll make adjustments in season if we have to.” He noted that the company is operating in a period of historic consumer weakness, which adds more pressure not to make a mistake.

That said, Scotts said sales are up 6 percent year-to-date in four states with some of the worst economic pain – Florida, California, Nevada, and Pennsylvania ?Çô and they were up 5 percent in another – Michigan.

Scotts also confirmed that Walmart is planning to pick another supplier for some or all of its private label fertilizer business instead of Scotts. Scotts picked up private label business when Spectrum Brands Inc. went out of business (GM June 29, 2009). However, Scotts assured analysts it would still do an “awesome” quantity of branded business with Walmart. “Walmart is committed to our branded business and we have excellent programs in the queue for next year in regard to our branded fertilizer program,” said Mark Baker, Scotts president and chief operating officer. “So I feel very good about that. I do like the private business, largely because we have one truck coming in, we can deliver everything together, it’s more efficient for them …. But the retailers can make the choices they want, and there’s a price below which we’re not going to do it.”

In other news, Scotts said that by the end of summer it will open new regional offices in Chicago and New York. Overall sales growth is expected to be 5-7 percent this fiscal year, which is down from earlier estimates of 7-8 percent.

Scotts also announced last week that its board authorized it to repurchase up to $500 million worth of common shares over the next four years. The board also voted to increase the quarterly dividend paid to shareholders to $.25 per share, double the current level.

Intrepid sees tighter supplies, higher prices going forward

Intrepid Potash Inc. told analysts Aug. 5 that almost every dealer it spoke with at the Southwestern Fertilizer Conference said they intentionally finished the spring season with their storage bins as empty as possible.

“Over the last few weeks, we have seen a significant uptick in order activity,” said R. L. Moore, Intrepid senior vice president for marketing and sales. “There seems to be recognition in the marketplace that we may experience an early harvest, which means there should be a more favorable application window for potash.

“With the rail orders that were generated in July, coupled with our commitment to supply our consignment warehouse customers and truckload customers, we will likely come close to depleting existing inventories and production through the end of the third quarter.” Moore said current demand patterns are more typical of a normal year.

“Going into the fall, dealers are now indicating a willingness to take inventory risk, are more confident that demand has returned to normal patterns, and are not expressing concerns about current price levels.”

The only market that has been off for Intrepid has been the Rocky Mountain industrial market, which uses standard product. Intrepid is adding granulation capacity to its Moab, Utah, facility so as to provide better flexibility, i.e., sell more granular when standard is in lower demand. The granulation upgrade is expected by the end of the year. The current Intrepid sales ratio is 72% agricultural, 18% industrial, and 10% feed.

Intrepid denied analysts’ suggestions that Agrium Inc. might be taking away some of its market share in the U.S. Robert Jornayvaz, Intrepid’s chairman of the board and CEO, said that the Canadians had inventory that they probably weren’t sure they were going to sell, and that they were aggressive in certain areas because Intrepid had the opportunity to make more sales and it chose not to. “We were thinking that the market was going to firm and is going to continue to firm, and so we chose to pass on certain sales looking forward to what we think is going to be a good third and fourth quarter.”

Intrepid reiterated that it was the Canadians that first started dropping prices in late 2009, not Intrepid, which was selling at higher numbers.

David Honeyfield, Intrepid president and CFO, said the company sold the same number of tons in 2Q 10 as in 2Q 09, while Agrium sold about 10 times as much in the recent quarter than a year ago. Intrepid also suggested that Agrium might have been filling up its own retail outlets with part of the tonnage.

Honeyfield said Intrepid had a better average net realized sales price compared to other North American producers, in part due to its geographic location and the corresponding transportation advantage. He added that granular inventories are currently at prudent levels going into the fall buying season, and that the opportunities to sell exceed anticipated production. Honeyfield said that the company is holding back some tons for its truck markets, because those do tend to be higher margin sales. The company said it matched PotashCorp and Agrium price lists in some areas this summer, but not in others.

Intrepid said it has hired new personnel, and that the Carlsbad West and East facilities should be at full production.

On granular Trio, Intrepid said that every ton it can produce in the second half is spoken for. The company noted that Carlsbad East Mine langbeinite production was slowed down for 14 days in July due to heavy rains. The company’s Trio price goes up $15/st on Sept. 1.

Pryor start-up still good deal, says LSB; company signs new labor agreement

Despite the slower-than-expected progress in bringing up the long-idled Pryor, Okla., nitrogen plant, LSB Industries Inc. President Barry Golsen told analysts Aug. 6 that Pryor is a valuable asset that will contribute to earnings for many years to come. “Even considering the delays and increased costs at Pryor, we anticipate completing Pryor for a fraction of the cost of a comparable new plant.”

Golsen added that LSB is enthusiastic about its relationship with Koch Nitrogen Co. on this project, which should facilitate the growth of this business for LSB. Koch has the contract to market the product from Pryor.

Pryor’s latest delay was caused by a fire in the primary reformer of the ammonia plant in June. LSB expects the plant to be back up by the end of September, and said that the delay is due to lead time to get replacement parts. While the plant began producing ammonia early in the year and produced some 14,000 st of UAN before the fire, LSB said it had not achieved full production.

Once it achieves full production, the Pryor ammonia plant is expected to start off producing 525 st/d. After upgrades to UAN, some 35,000 st/y should be available for the market. UAN production is expected to be 325,000 st/y. Thereafter, the company can boost that to a rate of 700 st/d. The company has the option in the future to bring up two smaller ammonia plants at the site as well. Their capacity is a combined 200 st/d, which would make a total ammonia production of 900 st/d possible.

LSB said the combined ammonia and UAN sales from Pryor in the second quarter were $5.7 million. Operating expenses were $6.2 million, while Pryor had an operating loss of $2 million. Pryor capital expenditure requirements for the rest of 2010 are about $14 million, most of which will occur in the third quarter. This amount includes $8 million to rebuild and repair the damaged reformer, and $6 million for other rebuilds and improvements. LSB expects that most of the costs to rebuild the reformer will be covered by insurance, with a $1 million deductible.

The company said it had a significant increase in agricultural product sales volumes in the second quarter, which was due to strong demand as a result of a late start to the spring season. Ag product sales were $51 million, up 48 percent from year-ago levels. Total ag product shipped was 45 percent higher than a year ago. Industrial chemical sales were $32.8 million, up 53 percent from year-ago levels; however, tons shipped were up only 44 percent. Mining product sales were $22.6 million, up 61 percent from year-ago levels, while tons shipped were up 33 percent.

Going forward, LSB said its entire nitrogen distribution system is virtually empty. “Our plants are currently sold out and we’re optimistic about the near-term future,” said Golsen. “We also remain bullish about the long-term demand for agricultural products we produce.”

In other news, LSB announced that it has signed a three-year labor contract with the union at its El Dorado, Ark., nitrogen plant.

On the Climate Control side of the business, LSB said that it will not be proceeding with the purchase of a heating and air-conditioning business in China. “What we found while doing our due diligence was not what we expected to find,” said Jack Golsen, LSB chairman and CEO.

BHP eyes U.S. port for potash export terminal

Vancouver, Wash.-Port of Vancouver USA said Aug. 11 that discussions are underway with BHP Billiton regarding the potential location of a potash export facility at the port’s Terminal 5. The port and BHP Billiton have reached a preliminary agreement to proceed and are working to finalize terms and a lease agreement. The project would include handling, storage, dock, and rail facilities for potash export from BHP Billiton’s first mine to be developed in Canada’s Saskatchewan Basin. BHP Billiton has selected Terminal 5, together with rail proposals from Canadian Pacific Railway and BNSF Railway, as the preferred option to export potash from its Jansen Project in Saskatchewan when that project goes into production. “Designing and developing an efficient, world-class port and logistics system is an important part of achieving our goal of building a successful low-cost potash business,” said Mark Young, BHP Billiton port and logistics manager. “The Port of Vancouver’s Terminal 5 location is an attractive site, which would be capable of handling the anticipated production from the Jansen development.” “To say we are pleased our port has been selected as the preferred option is an understatement,” said Larry Paulson, Port of Vancouver executive director. “The opportunity to work with BHP Billiton, recognized around the world as a company that respects the environment and the communities in which they operate, on a project that will add significantly to the port’s customer and revenue base, is very exciting.” Strategic investments by the port in Terminal 5 will provide BHP Billiton with land for the company’s storage and dock facilities, and the port’s commitment to rail improvement demonstrated by its ongoing West Vancouver Freight Access project makes the site particularly appealing to this type of private sector investment, according to the port. Once a final agreement has been reached, approval is required from BHP Billiton and the port’s board of commissioners. While this is exciting news for the port, industry sources note that any shipments from BHP will be years away, as it will take years for the mine to be completed.

USDA projects record corn, soybean crops

Washington-U.S. farmers are on pace to produce the largest corn and soybean crops in history, according to the Crop Production report released Aug. 12 by USDA’s National Agricultural Statistics Service (NASS). Corn production is forecast at 13.4 billion bushels and soybean production at 3.43 billion bushels, both up 2 percent from the previous records set in 2009. Based on conditions as of Aug. 1, corn yields are expected to average a record-high 165 bushels/acre, up 0.3 bushel from last year’s previous record. Forecast corn yields are higher than last year across the upper Mississippi Valley and upper Great Lakes region, where moderate temperatures and adequate soil moisture provided favorable growing conditions, the report said. Expected corn yields were also higher compared with last year across the Southern Plains and lower Mississippi Valley. Soybean yields are expected to equal last year’s record of 44 bushels/acre. Compared with last year, soybean yields are forecast higher across the Northern Tier States and the Delta States, but the largest increase in yield from 2009 is expected in Texas, where the yield is forecast to be up 9 bushels from last year. The Mid-Atlantic States are expecting the largest soybean yield declines from last year, NASS said, as Delaware, Maryland, and Virginia are all expecting yields to be down more than 10 bushels from 2009 due to very hot and dry weather this summer. Soybean area for harvest in the U.S. is forecast at 78.0 million acres, unchanged from June but up 2 percent from 2009. Cotton production in the U.S. is expected to jump 52 percent from last year, to 18.5 million 480-pound bales. Average yield is forecast at 837 pounds per harvested acre, up 60 pounds from last year. Texas cotton producers are expecting a record-high production of 8.80 million 480-pound bales, a 90 percent increase from last year. All wheat production, at 2.26 billion bushels, is up 2 percent from the July forecast and up 2 percent from 2009. Based on Aug. 1 conditions, the U.S. wheat yield is forecast at 46.9 bushels per acre, up 1.0 bushel from last month and 2.5 bushels above last year. If realized, this will be the highest yield on record, 2.0 bushels above 2008. NASS surveyed approximately 27,000 producers between July 25 and Aug. 6, and also took objective field measurements in the major crop-producing states.

Mag reports more potash in the Congo

Toronto-MagMinerals Potash Corp. has completed a National Instrument 43-101 compliant Technical Scoping Report for the 1,111 square kilometer Makola exploration license on the Atlantic coast of the Republic of Congo. The report, by Ercosplan Ingenieurgesellschaft Geotechnik and Bergbau mbH, estimates inferred resources of 9.2 billion mt of carnallitite at an average K2O grade of 12.1 percent, for a total inferred resource of 1.7 billion mt of potash (KCl). The report also estimates inferred resources of 70 million tons of sylvinite at an average K2O grade of 20.7 percent, for a total inferred resource of 23 million mt of potash (KCl). These sylvinite resources are located in the area of the underground Holle Potash Mine, which produced from 1969 to 1977 and which lies within the Makola exploration license. MagMinerals acquired the Makola exploration license in 2009 through the purchase of all of the shares of Potasse du Congo (PdC), a Congolese company. In addition, PdC holds the Tchizalamou and Loango exploration licenses, which are also undergoing preliminary assessment. The total area of the three PdC exploration licenses (Makola, Tchizalamou, and Loango) is 2,056 square kilometers, all of which is underlain by multiple potash-bearing horizons. The Makola exploration license surrounds the 136 square kilometer Mengo mining license, which is under preliminary development by MagMinerals for a 1.2 million mt per year potash operation.