LSB Industries Inc. said May 9 that its maintenance-idled Pryor, Okla., urea plant will likely be down most of the second quarter, coming up by the end of June. The plant went down for unplanned maintenance in March, and on April 25 the company determined that the urea plant reactor’s stainless steel lining was non-repairable and had to be replaced. This replacement will take most of the second quarter.
“It’s extremely unfortunate that we experienced this failure at the height of the season for UAN,” Barry Golsen, LSB chairman and president, told analysts. “However, when you’re dealing with high-pressure vessels, high-temperatures, and corrosive materials, you cannot take any chances. Safety and soundness dictate the course of action.”
LSB operating income was $8.7 million lower in first-quarter 2012 than the year-ago quarter, including a $13.1 million ($2.1 million maintenance and repair costs; $8 million lost gross profit and absorption; $3 million embedded losses on firm sales commitments) negative impact of downtime as a result of the planned and unplanned downtime at Pryor.
Pryor had an operating loss of $1.1 million in the first quarter, compared to a year-ago income of $11.3 million.
During January, the facility was offline so a planned improvement project could be performed to increase anhydrous ammonia production levels. However, in March there was unplanned downtime at both the ammonia and urea plants. The ammonia plant was down only eight days, resuming production March 22 and producing 600 st/d, which has been sold into the market. Prior to its January upgrade, the ammonia plant was running at 500 st/d. The eventual goal is to get it to 700 st/d. Another turnaround is planned for the Pryor complex in the third quarter.
The repair undertaken at the urea plant began Feb. 27. The urea plant is needed to produce UAN and uses ammonia as a feedstock. As a result, the Pryor facility has not produced UAN since Feb. 27, 2012. LSB currently lists Pryor UAN capacity at 325,000 st/y.
In the meantime, LSB said that it recently received permits to expand ammonia production at Pryor by 60,000 st/y. Some of the work has already been done, and the company targets this production for the third or fourth quarters.
The Pryor downtime was partly offset by increases in agricultural and industrial sales volumes and margin in the rest of LSB’s Chemical segment.
LSB said its Cherokee, Ala., and El Dorado, Ark., plants ran and produced very efficiently during the quarter and continue to do so into the second quarter, benefiting from strong customer demand.
LSB second-quarter net income applicable to common shares was $14 million ($0.61 per diluted share) on sales of $190.2 million, down from the year-ago $20.6 million ($0.90 per share) on sales of $177.5 million. Operating income was $23.1 million, down from $34 million. EBITDA was $28.3 million, down from $38.9 million.
Chemical operating income was $20.3 million on sales of $124.2 million, compared to the year-ago $29.1 million on sales of $111.4 million. Gross profit was $24 million, down from $31.5 million. EBITDA dropped to $24.3 million from $32.6 million. The 11.5 percent overall sales increase included agricultural sales of $60.3 million, up from the year-ago $51.1 million. Industrial acid and other sales were up about 10 percent versus year-ago levels, while mining sales were about level due to lower demand for coal because of the warm winter.
Going forward, LSB said the current outlook for its Chemical unit is positive, with the market fundamentals for its fertilizer products favorable. It expects ag sales to be strong for the balance of 2012. It also expects an increase in industrial acid sales, though it says mining sales may be lower than 2011.
Results were also off at LSB’s Climate Control busi