licensing or
development of such additional capacity. We believe the limited availability of
this technology also creates a significant barrier to entry into the acetic acid
industry by potential competitors.
Global production capacity of acetic
acid as of December 31, 2007 was approximately 24 billion pounds per
year, with current North American production capacity at approximately
7 billion pounds per year. The North American acetic acid market is mature
and well developed and is dominated by four major producers that account for
approximately 94% of the acetic acid production capacity in North America.
Demand for acetic acid is linked to the demand for vinyl acetate monomer, a key
intermediate in the production of a wide array of polymers. Vinyl acetate
monomer is the largest derivative of acetic acid, representing over 40% of
global demand. Annual global production of vinyl acetate monomer is expected to
increase from 10.4 billion pounds in 2005 to 12.2 billion pounds in
2010, although the recent difficulties in the housing and automotive sectors
will likely cause reduced demand for vinyl acetate monomer in North America in
the short term. The North American acetic acid industry tends to sell most of
its products through long-term sales agreements having “cost plus” pricing
mechanisms, eliminating much of the volatility seen in other petrochemicals
products and resulting in more stable and predictable earnings and profit
margins.
Plasticizers. Plasticizers are
produced from either ethylene-based linear alpha-olefins feedstocks or
propylene- based technology. Linear plasticizers typically receive a premium
over competing propylene-based branched products for customers that require
enhanced performance properties. However, the markets for competing plasticizers
may be affected by the cost of the underlying raw materials, especially when the
cost of one olefin rises faster than the other, or by the introduction of new
products. Over the last few years, the price of linear alpha-olefins has
increased sharply as supply has declined, which has caused many consumers to
switch to lower cost branched products, despite the loss of some performance
properties. Ultimately, we expect branched plasticizers to replace linear
plasticizers for most applications over the long-term. In addition, in 2005, BP
Chemicals announced the permanent closure of its linear alpha-olefins production
facility in Pasadena, Texas, the primary source of supply of this feedstock to
the oxo-alcohols production unit at our plasticizers facility. As a result, we
modified our plasticizers facilities during the third quarter of 2006 to produce
branched plasticizers products.
Styrene. The North American
styrene industry is currently in a protracted down cycle, primarily as a result
of over-supply. This extended down cycle resulted from two major developments.
Initially, export demand, which historically has represented over 20% of North
American production capacity, has significantly diminished. In recent months,
U.S. styrene producers have seen an increase in styrene exports largely due to
delays in the start up of announced new capacity in the Middle East. However,
this increase is expected to reverse itself after the new styrene plant being
constructed in Al Jubail, Saudi Arabia is completed, which is currently expected
to occur later in 2008. Regional cost pressures, in addition to new production
capacity being added in Asia and the Middle East, have made it difficult for
North American producers to compete in these export markets on a continuous
basis. In addition, a significant amount of styrene capacity has been added
globally over the past five to ten years by producers of propylene oxide using
so-called PO-SM technology, which produces styrene as a co-product. Propylene
oxide is a key intermediate in the production of polyurethane, and polyurethane
demand growth has been significantly greater than demand growth for styrene,
exacerbating the over-supply of styrene. During periods of over-supply,
production rates for styrene producers decrease significantly. When production
rates are low, unit production costs increase due to the allocation of fixed
costs over a lower production volume and a reduction in the efficiency of the
manufacturing unit, both in energy usage and in the conversion rates for raw
materials. Compounding these cost impacts, prices for the principal styrene raw
materials, benzene and ethylene, are currently near historical highs, putting
pressure on margins on styrene sales even though styrene contract prices are at
near historic highs.
Over the last five years, China has
been the driver for growth in styrene demand, representing approximately 75% of
the world’s styrene demand growth in that period. Historically, we positioned
ourselves to take advantage of peaks in the Asian styrene markets, with a large
portion of our styrene capacity not being committed under long-term
arrangements. However, over the last several years, relatively high benzene and
domestic natural gas prices significantly limited our ability to sell styrene
into the Asian markets, and high styrene prices have reduced styrene global
demand growth rates. In addition, several of our competitors announced their
intention to build new styrene production units outside the United States,
further complicating our ability to sell styrene into the Asian markets. In
2006, our competitors added 2.6 billion pounds of new styrene capacity in
Asia and an additional 1.6 billion pounds in 2007. The remaining announced
construction projects are scheduled to start up in 2008 and beyond. If and when
these new units are completed, we anticipate more difficult market conditions,
especially in the export markets, until the additional supply is absorbed by
growth in styrene demand or significant capacity rationalization occurs.
Chemical Market Associates, Inc., or
CMAI, currently is projecting no additional capacity increases in North America
through 2010, with operating rates reaching a trough of 75% in 2007, and less
than 80% operating rates projected through 2010, without any further industry
restructuring. Although we believe an improved North American
7
industry outlook is
possible, this largely depends on a significant industry restructuring.
Previously, styrene and polystyrene industry participants, including The DOW
Chemical Company and NOVA have announced a desire to seek transactions which
would restructure the North American styrene and polystyrene industries, thereby
improving the balance of supply and demand in North America. More recently, on
October 1, 2007, NOVA Chemicals expanded its European joint venture with
INEOS to include North American styrene and solid polystyrene assets, and The
DOW Chemical Company announced on April 10, 2007, that it had signed a
non-binding memorandum of understanding with Chevron Phillips Chemical Co. to
form a joint venture involving selected styrene and polystyrene assets of the
two companies in North America and South America.
Product Summary
The following table summarizes our
principal products, including our capacity, the primary end uses for each
product, the raw materials used to produce each product and the major
competitors for each product. “Capacity” represents rated annual production
capacity as of December 31, 2007, which is calculated by estimating the
number of days in a typical year that a production facility is capable of
operating after allowing for downtime for regular maintenance, and multiplying
that number of days by an amount equal to the facility’s optimal daily output
based on the design feedstock mix. As the capacity of a facility is an estimated
amount, actual production may be more or less than capacity, and the following
table does not reflect actual operating rates of any of our production
facilities for any given period of time.
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Intermediate |
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Products |
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Primary End Products |
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Raw
Materials |
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Major
Competitors |
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Acetic
Acid (1.1 billion pounds per year) |
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Vinyl acetate monomer, terephthalic acid, and
acetate solvents |
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Adhesives, PET bottles, fibers and surface
coatings |
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Methanol and Carbon Monoxide |
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Celanese AG, Eastman Chemical Company and
Lyondell Chemical Company |
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Plasticizers (200 million
pounds of esters) |
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Flexible polyvinyl chloride, or PVC |
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Flexible plastics, such as shower curtains and
liners, floor coverings, cable insulation, upholstery and plastic molding
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Oxo-Alcohols and Orthoxylene |
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ExxonMobil Corporation, Eastman Chemical Company
and BASF Corporation |
Products
Acetic Acid. Our acetic acid is
used primarily to manufacture vinyl acetate monomer, which is used in a variety
of products, including adhesives and surface coatings. We have the third largest
production capacity for acetic acid in North America. Our acetic acid unit has a
rated annual production capacity of approximately 1.1 billion pounds, which
represents approximately 17% of total North American capacity. All of our acetic
acid production is sold to BP Chemicals, and we are BP Chemicals’ sole source of
production in the Americas. We sell our acetic acid to BP Chemicals pursuant to
a Production Agreement that extends until 2016. For a further description of our
agreement with BP Chemicals, please refer to “Acetic Acid-BP Chemicals”
under “Contracts.”
Plasticizers. Our plasticizers
business is comprised of two separate products: phthalate esters and phthalic
anhydride, together commonly referred to as plasticizers. Our phthalate esters
are made from phthalic anhydride and oxo-alcohols, and phthalic anhydride is
also sold as a separate product. All of our plasticizers, which are used to make
flexible plastics such as shower curtains, floor coverings, automotive parts and
construction materials, are sold to BASF pursuant to a long-term production
agreement that extends until 2013, subject to some limited early termination
rights held by BASF beginning in 2010. In December 2007, BASF caused the
shutdown of our phthalic anhydride unit by nominating zero pounds of phthalic
anhydride in response to deteriorating market conditions which are not expected
to improve in the foreseeable future. This shutdown will not have a material
adverse affect on our financial conditions or results of operations. For a
further description of our agreement with BASF, please refer to
“Plasticizers-BASF” under “Contracts.”
Styrene. Until recently, styrene
was one of our principal products. Styrene is a commodity chemical used to
produce intermediate products such as polystyrene, expandable polystyrene resins
and ABS plastics, which are used in a wide variety of products such as household
goods, foam cups and containers, disposable food service items, toys, packaging
and other consumer and industrial products. As previously discussed, we
permanently shut down our styrene plant in the fourth quarter of 2007 and exited
the styrene business in 2008.
8
Sales and
Marketing
Our petrochemicals products are
generally sold to customers for use in the manufacture of other chemicals and
products, which in turn are used in the production of a wide array of consumer
goods and industrial products throughout the world. We have long-term agreements
that provide for the dedication of 100% of our production of acetic acid and
plasticizers, each to one customer. Under our acetic acid Production Agreement,
we are reimbursed for our actual fixed and variable manufacturing costs and also
receive an agreed share of the profits earned from this business. Under our
plasticizers agreement, we are reimbursed for our manufacturing costs and also
receive a quarterly “facility fee” for each production unit included in our
plasticizers business, but do not share in the profits or losses from that
business. These agreements are intended to:
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optimize our capacity utilization rates; |
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lower our selling, general and administrative expenses; |
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reduce our working capital requirements; |
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insulate the financial results from our plasticizers operations from
the effects of declining markets and changes in raw materials prices;
and |
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in some cases, gain access to certain improvements in manufacturing
process technology. |
Prior to the effectiveness of the
long-term styrene supply contract with NOVA discussed above, we previously sold
styrene through multi-year contracts, conversion agreements and spot
transactions in both domestic and international markets.
For information regarding our export
sales, see Note 10 of the “Notes to Consolidated Financial Statements” included
in Item 8 of Part II of this Form 10-K.
Contracts
Our significant multi-year contracts
are described below.
Acetic Acid-BP Chemicals
In 1986, we entered into the long-term
acetic acid Production Agreement with BP Chemicals, which has since been amended
several times. BP Chemicals markets all of the acetic acid that we produce and
pays us, among other amounts, a portion of the profits derived from its sales of
the acetic acid we produce. Prior to August 2006, BP Chemicals also paid us
a set monthly amount. In addition, BP Chemicals reimburses us for 100% of our
fixed and variable costs of production. Pursuant to the terms of this Production
Agreement, beginning in August 2006, the portion of the profits we receive
from the sales of acetic acid produced at our plant increased and BP Chemicals
was no longer required to pay us the set monthly amount that we had received
prior to that time. However, this change in payment structure did not affect BP
Chemicals’ obligation to reimburse us for all of our fixed and variable costs of
production.
Plasticizers-BASF
Since 1986, we have provided all of our
plasticizers production exclusively to BASF pursuant to a production agreement,
which has been amended several times. Under this production agreement, BASF
provides us with most of the required raw materials and markets the plasticizers
we produce, and is obligated to make certain fixed quarterly payments to us and
to reimburse us monthly for our actual production costs and capital expenditures
relating to our plasticizers facility. Effective January 1, 2006, we
amended this production agreement to extend the term of the agreement until
2013, subject to some limited early termination rights held by BASF beginning in
2010, increase the quarterly payments made to us by BASF and eliminate our
participation in the profits and losses realized by BASF in connection with the
sale of the plasticizers we produce. Additionally, on April 28, 2006, BASF
notified us that it was exercising its right under the amended production
agreement to terminate its future obligations with respect to the operation of
our oxo-alcohols production unit effective July 31, 2006. In
December 2007, BASF caused the shutdown of our phthalic anhydride unit by
nominating zero pounds of phthalic anhydride in response to deteriorating market
conditions which are not expected to improve in the foreseeable future. This
shutdown will not have a material adverse affect on our financial conditions or
results of operations.
Sales to major customers constituting
10% or more of total revenues are included in Note 10 of the “Notes to
Consolidated Financial Statements” included in Item 8, Part II of this
Form 10-K.
9
Raw Materials and
Energy Resources
The aggregate cost of raw materials and
energy resources used in the production of our products is far greater than the
total of all other costs of production combined. As a result, an adequate supply
of raw materials and energy at reasonable prices and on acceptable terms is
critical to the success of our business. Although we believe that we will
continue to be able to secure adequate supplies of raw materials and energy, we
may be unable to do so at acceptable prices or payment terms. See “Risk
Factors.” Under our agreements with BP Chemicals and BASF, BP Chemicals is
required to provide our methanol requirements to produce acetic acid and BASF is
required to provide us with most of the major raw materials necessary to produce
plasticizers. These sources of raw materials tend to mitigate certain risks
typically associated with obtaining raw materials, as well as decrease our
working capital requirements.
Acetic Acid. Acetic acid is
manufactured primarily from carbon monoxide and methanol. Praxair is our sole
source for carbon monoxide and supplies us with all of the carbon monoxide we
require for the production of acetic acid from its partial oxidation unit
located on land leased from us at our Texas City site. Currently, our methanol
requirements are supplied by BP Chemicals under the Production Agreement.
Plasticizers. The primary raw
materials for plasticizers are oxo-alcohols and orthoxylene, which are supplied
by BASF under our production agreement.
Technology and
Licensing
In 1986, we acquired our Texas City
site from Monsanto Company, or Monsanto. In connection with that acquisition,
Monsanto granted us a non-exclusive, irrevocable and perpetual right and license
to use Monsanto’s technology and other technology Monsanto acquired through
third-party licenses in effect at the time of the acquisition. We use these
licenses in the production of acetic acid and plasticizers and also previously
used these licenses in the production of styrene.
During 1991, BP Chemicals Ltd., or
BPCL, purchased Monsanto’s acetic acid technology, subject to existing licenses.
Under a technology agreement with BP Chemicals and BPCL, BPCL granted us a
non-exclusive, irrevocable and perpetual right and license to use acetic acid
technology owned by BPCL and some of its affiliates at our Texas City site,
including any new acetic acid technology developed by BPCL at its acetic acid
facilities in England or pursuant to the research and development program
provided by BPCL under the terms of such agreement.
Although we do not engage in
alternative process research, we do monitor new technology developments and,
when we believe it is necessary, we typically seek to obtain licenses for
process improvements.
Competition
There are only four large producers of
acetic acid in North America and historically these producers have made capacity
additions in a disciplined and incremental manner, primarily using small
expansion projects or exploiting debottlenecking opportunities. In addition, the
leading technology required to manufacture acetic acid is controlled by two
global companies, which permits these companies to control the pace of new
capacity additions through the licensing or development of such additional
capacity. The limited availability of this technology also creates a significant
barrier to entry into the acetic acid industry by potential competitors. The
North American plasticizers industry is a mature market, with phthalate esters
like those produced by us being subject to excess production capacity and
diminishing demand due to the ability of consumers to substitute different raw
materials based on relative costs at the time, as well as increasing health
concerns regarding these products. You will find a list of our principal
competitors in the “Product Summary” table above.
Environmental,
Health and Safety Matters
Our operations involve the handling,
production, transportation, treatment and disposal of materials that are
classified as hazardous or toxic and that are extensively regulated by
environmental and health and safety laws, regulations and permit requirements.
Environmental permits required for our operations are subject to periodic
renewal and may be revoked or modified for cause or when new or revised
environmental requirements are implemented. Changing and increasingly strict
environmental requirements can affect the manufacturing, handling, processing,
distribution and use of our chemical products and, if so affected, our business
and operations may be materially and adversely affected. In addition, changes in
environmental requirements may cause us to incur substantial costs in upgrading
or redesigning our facilities and processes, including our waste treatment,
storage, disposal and other waste handling practices and equipment.
10
A business risk inherent in chemical
operations is the potential for personal injury and property damage claims from
employees, contractors and their employees and nearby landowners and occupants.
While we believe our business operations and facilities generally are operated
in compliance with all applicable environmental and health and safety
requirements in all material respects, we cannot be sure that past practices or
future operations will not result in material claims or regulatory action,
require material environmental expenditures or result in exposure or injury
claims by employees, contractors or their employees or the public. Some risk of
environmental costs and liabilities is inherent in our operations and products,
as it is with other companies engaged in similar businesses.
Our operating expenditures for
environmental matters, mostly waste management and compliance, were
$17.8 million and $20.4 million in 2007 and 2006, respectively. We
also spent $0.5 million and $1.9 million for environmentally-related
capital projects in 2007 and 2006, respectively. In 2008, we anticipate spending
approximately $4 million for capital projects related to waste management,
incident prevention and environmental compliance. We do not expect to make any
capital expenditures in 2008 related to remediation of environmental conditions.
In light of our historical expenditures
and expected future results of operations and sources of liquidity, we believe
we will have adequate resources to conduct our operations in compliance with
applicable environmental, health and safety requirements. Nevertheless, we may
be required to make significant site and operational modifications that are not
currently contemplated in order to comply with changing facility permitting
requirements and regulatory standards. Additionally, we have incurred, and may
continue to incur, a liability for investigation and cleanup of waste or
contamination at our own facilities or at facilities operated by third parties
where we have disposed of waste. We continually review all estimates of
potential environmental liabilities, but we may not have identified or fully
assessed all potential liabilities arising out of our past or present operations
or the amount necessary to investigate and remediate any conditions that may be
significant to us. It is our policy to make environmental, health and safety and
replacement capital expenditures a priority in order to ensure adequate
environmental, health and safety compliance at all times. In the event we should
not have available to us, at any time, liquidity sources sufficient to fund any
of these expenditures, prudent business practice might require that we cease
operations at the affected facility to avoid exposing our employees and contract
workers, the surrounding community or the environment to potential harm.
Air emissions from our Texas City
facility are subject to certain permit requirements and self-implementing
emission limitations and standards under state and federal laws. Our Texas City
facility is subject to the federal government’s June 1997 National Ambient
Air Quality Standards, or NAAQS, which lowered the ozone and particulate matter
concentration thresholds for attainment. Our Texas City facility is located in
an area that the Environmental Protection Agency, or EPA, has classified as not
having attained the NAAQS for ozone, either on a 1-hour or an 8-hour basis.
Ozone is typically controlled by reduction of volatile organic compounds, or
VOCs, and nitrogen oxide, or NOx, emissions. The Texas Commission for
Environmental Quality, or TCEQ, has imposed strict requirements on regulated
facilities, including our Texas City facility, to ensure that the air quality
control region will achieve the ambient air quality standards for ozone. Local
authorities may also impose new ozone and particulate matter standards.
Compliance with these stricter standards may substantially increase our future
NOx, VOCs and particulate matter emissions control costs, the amount and full
impact of which cannot be determined at this time.
In 2002, the TCEQ adopted a revised
State Implementation Plan, or SIP, in order to achieve compliance with the
“1-hour” ozone standard of the Clean Air Act by 2007. The EPA approved this
“1-hour” SIP, which implemented an 80% reduction of NOx emissions, and extensive
monitoring of emissions of highly reactive volatile organic carbons, or HRVOCs,
such as ethylene, in the Houston-Galveston-Brazoria, or HGB, area. We are in
full compliance with these regulations. However, the HGB area failed to attain
compliance with the 1-hour ozone standard, and Section 185 of the Clean Air
Act requires implementation of a program of emissions-based fees until the
standard is attained. These “Section 185 fees” will be due on all NOx and
VOCs emissions in 2008 and beyond in the HGB area, which are in excess of 80% of
the baseline year. The method for calculating baseline emissions as well as
other details of the program have not yet been developed. At the present time,
our forecasted emissions for 2008 are small enough that no fee payment is
anticipated.
In April 2004, the HGB region was
designated a “moderate” non-attainment area with respect to the “8-hour” ozone
standard of the Clean Air Act, and compliance with this standard is required no
later than June 15, 2010 for “moderate” areas. However, on June 15,
2007, the Governor of the State of Texas requested that the EPA reclassify the
HGB region as a “severe” non-attainment area, which would require compliance
with the 8-hour standard by June 15, 2019 and the EPA has begun the process
of reclassification. On May 23, 2007, the TCEQ formally adopted revisions
to the SIP designed to achieve compliance with the “8-hour” ozone standard in
the HGB area, as a “moderate” non-attainment area. This “8-hour” SIP calls for
relatively modest additional controls which will require very little expense on
our part. However, the SIP will have to be revised again once the HGB area is
reclassified from “moderate” to “severe.” Timing and content of this revised
“8-hour” SIP have not yet been determined. Based on these
11
developments, it is
difficult to predict our final cost of compliance. However, given the permanent
shutdown of our styrene and ethylbenzene facilities, we estimate the additional
cost of compliance will range from zero to $4 million for capital
expenditures and allowance purchases, depending on the terms of the final
“8-hour” SIP.
To reduce the risk of offsite
consequences from unanticipated events, we acquired a greenbelt buffer zone
adjacent to our Texas City site in 1991. We also participate in a regional air
monitoring network to monitor ambient air quality in the Texas City community.
Employees
As of December 31, 2007, we had
248 employees, of whom approximately 38% (all of our hourly employees at our
Texas City site) were represented by the Texas City, Texas Metal Trades Council,
AFL-CIO, or the Union. On May 1, 2007, we entered into a new collective
bargaining agreement with the Union which is effective through May 1, 2012.
Under the new collective bargaining agreement, we and the Union agreed to the
scope of work of the employees, hours of work, increases in wages, benefits,
vacation time, sick leave and other customary terms. The new collective
bargaining agreement also specifies grievance procedures should any disputes
arise between us and any of our represented employees.
Insurance
We maintain insurance coverage at
levels that we believe are reasonable and typical for our industry. A portion of
our insurance coverage is provided by a captive insurance company maintained by
us and a few other chemical companies. However, we are not fully insured against
all potential hazards incident to our business. Additionally, we may incur
losses beyond the limits of, or outside the coverage of, our insurance. We
maintain full replacement value insurance coverage for property damage to our
facilities and business interruption insurance. Nevertheless, a significant
interruption in the operation of one or more of our facilities could have a
material adverse effect on our business. As a result of market conditions,
premiums and deductibles for certain insurance policies can increase
substantially and, in some instances, certain insurance may become unavailable
or available only for reduced amounts of coverage.
We do not currently carry terrorism
coverage on our Texas City site. After the terrorist attacks of
September 11, 2001, many insurance carriers (including ours) created
exclusions for losses from terrorism from “all risk” property insurance
policies. While separate terrorism insurance coverage is available, the premiums
for such coverage are very expensive, especially for chemical facilities, and
these policies are subject to very high deductibles. In addition, available
terrorism coverage typically excludes coverage for losses from acts of foreign
governments, as well as nuclear, biological and chemical attacks. Consequently,
we believe that it is not economically prudent to obtain terrorism insurance on
the terms currently being offered in the industry.
Access to
Filings
Access to our annual reports on Form
10-K, quarterly reports on Form 10-Q, current reports on Form 8-K and amendments
to those reports filed with or furnished to the SEC pursuant to Section 13(a) of
the Exchange Act, as well as reports filed electronically pursuant to Section
16(a) of the Exchange Act, may be obtained through our website
(http://www.sterlingchemicals.com). Our website provides a hyperlink to a
third-party website where these reports may be viewed and printed at no cost as
soon as reasonably practicable after we have electronically filed such material
with the SEC. The contents of our website (or the third-party websites
accessible through the hyperlinks) are not, and shall not be deemed to be,
incorporated into this report.
Item 1A.
Risk Factors
In addition to the other information
contained in this report, the following risk factors should be considered
carefully in evaluating our business. Our business, financial condition or
results of operations could be materially adversely affected by any of these
risks.
Risks Related to
Our Business
Each of our
products is sold to only one customer.
In 2007, a single customer, BP
Chemicals, accounted for 100% of our acetic acid revenues while another
customer, BASF, accounted for 100% of our plasticizers revenues. The termination
of one or both of these long-term contracts, or
12
a material reduction in
the amount of product purchased under our acetic acid Production Agreement,
could materially adversely affect our overall business, financial condition,
results of operations or cash flows.
Our ability to
expand the capacity of our acetic acid production facility is limited by the
current inability to obtain sufficient quantities of carbon monoxide.
Carbon monoxide is one of the principal
raw materials required for acetic acid production. Currently, all of the carbon
monoxide we use in the production of acetic acid is supplied by Praxair from its
partial oxidation unit located on land leased from us at our Texas City site.
Although our new acetic acid reactor installed in 2003 is capable of producing
up to 1.7 billion pounds of acetic acid annually, Praxair’s partial
oxidation unit is not capable of supplying carbon monoxide in quantities
sufficient for more than approximately 1.2 billion pounds of annual acetic
acid production. The supply of additional quantities of carbon monoxide will
likely require the construction of a new supply pipeline, which will require
numerous third party and regulatory consents, or an expansion of the Praxair
partial oxidation unit. An expansion of the Praxair partial oxidation unit may
not be cost effective and we may not be able to contract for the supply of
carbon monoxide in quantities sufficient to increase our annual acetic acid
production above 1.2 billion pounds. Furthermore, the construction of a supply
pipeline may require a substantial period of time.
We depend upon
the continued operation of a single site for all of our production.
All of our products are produced at our
Texas City site. Significant unscheduled downtime at our Texas City site could
have a material adverse effect on our business, financial condition, results of
operations or cash flows. Unanticipated downtime can occur for a variety of
reasons, including equipment breakdowns, interruptions in the supply of raw
materials, power failures, sabotage, natural forces or other hazards associated
with the production of petrochemicals. Although we maintain business
interruption insurance, this insurance does not provide coverage for business
interruptions of less than 45 days and is limited in its overall coverage.
Our operations
involve risks that may increase our operating costs, which could reduce our
profitability.
Although we take precautions to enhance
the safety of our operations and minimize the risk of disruptions, our
operations are subject to hazards inherent in the manufacturing and marketing of
chemical products. These hazards include:
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pipeline or storage tank leaks and ruptures, explosions and
fires; |
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severe weather and natural disasters; |
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mechanical failures, unscheduled downtimes, labor difficulties and
transportation interruptions; |
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environmental remediation complications; and |
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chemical spills and discharges or releases of toxic or hazardous
substances or gases. |
Many of these hazards
can cause bodily injury or loss of life, severe damage to or destruction of
property or equipment or environmental damage, and may result in suspension of
operations or the imposition of civil or criminal penalties and liabilities.
Furthermore, we are subject to present and future claims with respect to
workplace exposure of our employees or contractors on our premises or other
persons located nearby, workers’ compensation and other matters.
Our operations
are subject to operating hazards and unforeseen interruptions for which we may
not be adequately insured.
We maintain insurance coverage at
levels that we believe are reasonable and typical for our industry, portions of
which are provided by a captive insurance company maintained by us and a few
other chemical companies. However, we are not fully insured against all
potential hazards incident to our business. Accordingly, our insurance coverage
may be inadequate for any given risk or liability, such as property damage
suffered in hurricanes or business interruption incurred from a loss of our
supply of electricity or carbon monoxide. In addition, our insurance companies
may be incapable of honoring their commitments if an unusually high number of
claims are concurrently made against their policies. As a result of market
conditions, premiums and deductibles for certain insurance policies can increase
substantially and, in some instances, certain insurance may become unavailable
or available only for reduced amounts of coverage. If we were to incur a
significant liability for which we were not fully insured, it could have a
material adverse effect on our business, financial condition, results of
operations or cash flows. We may not be able to renew our existing insurance
coverages at commercially reasonable rates and our existing coverages may not be
adequate to cover future claims that may arise.
13
In addition, concerns about terrorist
attacks, as well as other factors, have caused significant increases in the cost
of our insurance coverage. We have determined that it is not economically
prudent to obtain terrorism insurance and we do not carry terrorism insurance on
our property at this time. In the event of a terrorist attack impacting one or
more of our production units, we could lose the production and sales from one or
more of these facilities, and the facilities themselves, and could become liable
for contamination or personal injury or property damage from exposure to
hazardous materials caused by a terrorist attack. Such loss of production,
sales, facilities or incurrence of liabilities could materially adversely affect
our business, financial condition, results of operations or cash flows.
Terrorist
attacks, the current military action in Iraq, general instability in various
OPEC member nations and other attacks or acts of war in the United States and
abroad may adversely affect the markets in which we operate.
Terrorist activities and the current
military action in Iraq have contributed to instability in the United States and
other financial markets and have led, and may continue to lead, to further armed
hostilities, prolonged military action in Iraq or further acts of terrorism in
the United States or abroad, which could cause further instability in the
financial markets and in the markets for our products. Current regional tensions
and conflicts in various OPEC member nations, including the current military
action in Iraq, have caused, and may continue to cause, increased raw materials
costs, specifically raising the prices of oil and gas, which are used in our
operations or affect the prices of our raw materials. Furthermore, terrorist
activities and other events or developments in any of these areas may result in
reduced demand from our customers for our products. These developments could
subject our operations to increased risks and, depending on their magnitude,
could have a material adverse effect on our business, financial condition,
results of operations or cash flows.
New regulations
concerning the transportation of hazardous chemicals and the security of
chemical manufacturing facilities could result in higher operating
costs.
Chemical manufacturing facilities may
be at greater risk of terrorist attacks than other potential targets in the
United States. As a result, the chemical industry has responded to these issues
by starting new initiatives relating to the security of chemicals industry
facilities and the transportation of hazardous chemicals in the United States.
Simultaneously, local, state and federal governments have begun a regulatory
process that could lead to new regulations impacting the security of chemical
plant locations and the transportation of hazardous chemicals. Our business or
our customers’ businesses could be adversely affected by the cost of complying
with new security regulations.
We are subject
to many environmental and safety regulations that may result in significant
unanticipated costs or liabilities or cause interruptions in our
operations.
Our operations involve the handling,
production, transportation, treatment and disposal of materials that are
classified as hazardous or toxic and that are extensively regulated by
environmental and health and safety laws, regulations and permit requirements.
We may incur substantial costs, including fines, damages and criminal or civil
sanctions, or experience interruptions in our operations for actual or alleged
violations or compliance requirements arising under environmental laws, any of
which could have a material adverse effect on our business, financial condition,
results of operations or cash flows. Our operations could result in violations
of environmental laws, including spills or other releases of hazardous
substances into the environment. In the event of a catastrophic incident, we
could incur material costs. Furthermore, we may be liable for the costs of
investigating and cleaning up environmental contamination on or from our
properties or at off-site locations where we disposed of or arranged for the
disposal or treatment of hazardous materials. Based on available information, we
believe that the costs to investigate and remediate known contamination will not
have a material adverse effect on our business, financial condition, results of
operations or cash flows. However, if significant previously unknown
contamination is discovered, or if existing laws or their enforcement change,
then the resulting expenditures could have a material adverse effect on our
business, financial condition, results of operations or cash flows.
Environmental, health and safety laws,
regulations and permit requirements, and the potential for further expanded
laws, regulations and permit requirements may increase our costs or reduce
demand for our products and thereby negatively affect our business.
Environmental permits required for our operations are subject to periodic
renewal and may be revoked or modified for cause or when new or revised
environmental requirements are implemented. Changing and increasingly strict
environmental requirements and the potential for further expanded regulation may
increase our costs and can affect the manufacturing, handling, processing,
distribution and use of our products. If so affected, our business and
operations may be materially and adversely affected. In addition, changes in
these requirements may cause us to incur substantial costs in upgrading or
redesigning our facilities and processes, including our waste treatment,
storage, disposal and other waste handling practices and equipment. For these
reasons, we may need to make capital expenditures beyond those currently
anticipated to comply with existing or future environmental or safety laws.
14
Approximately
38% of our employees are covered by a collective bargaining agreement that
expires on May 1, 2012. Disputes with the Union representing these
employees or other labor relations issues may negatively affect our
business.
As of December 31, 2007, we had
248 employees, of whom approximately 38% (all of our hourly employees at our
Texas City site) were represented by the Union, and are covered by a collective
bargaining agreement which expires on May 1, 2012. Although we believe our
relationship with our hourly employees is generally good, we locked out these
employees for 16 weeks in 2002 and our hourly employees engaged in a
one-week strike in 2004, in both cases in connection with efforts to reach new
collective bargaining agreements. Future strikes or other labor disturbances
could have a material adverse effect on our business, financial condition,
results of operations or cash flows.
A failure to
retain our key employees could adversely affect our business.
We are dependent on the services of the
members of our senior management team to remain competitive in our industry.
There is a risk that we will not be able to retain or replace these key
employees. Our current key employees are subject to employment conditions or
arrangements that permit the employees to terminate their employment without
notice. The loss of any member of our senior management team could materially
adversely affect our business, financial condition, results of operations or
cash flows.
Transactions
consummated pursuant to our plan of reorganization could result in the
imposition of material tax liabilities.
Prior to our emergence from bankruptcy
in 2002, we eliminated our holding company structure by merging Sterling
Chemicals Holdings, Inc. with and into us. We believe that this merger qualifies
as a tax-free reorganization pursuant to Section 368(a)(1)(G) of the
Internal Revenue Code (commonly referred to as a “G Reorganization”) for United
States federal income tax purposes. However, a judicial determination that this
merger did not qualify as a G Reorganization would result in additional federal
income tax liability which could materially adversely affect our business,
financial condition, results of operations or cash flows.
We may not
successfully implement our acquisition strategy, and acquisitions that we pursue
may present unforeseen integration obstacles or costs, increase our leverage or
negatively impact our performance.
We may not be able to identify suitable
acquisition candidates, and the expense incurred in consummating acquisitions of
related businesses, or our failure to integrate such businesses successfully
into our existing businesses, could affect our growth or result in our incurring
unanticipated expenses and losses. Furthermore, we may not be able to realize
any anticipated benefits from acquisitions. From time to time we evaluate
potential acquisitions and may complete one or more significant acquisitions in
the future. To finance an acquisition we may need to incur debt or issue equity.
However, we may not be able to obtain favorable debt or equity financing to
complete an acquisition, or at all. In particular, the lack of an active trading
market in our common stock, as well as the dilutive terms of our outstanding
Series A convertible preferred stock, may make our common stock
unattractive as consideration for an acquisition. The process of integrating
acquired operations into our existing operations may result in unforeseen
operating difficulties and may require significant financial resources that
would otherwise be available for the ongoing development or expansion of
existing operations. Some of the risks associated with our acquisition strategy,
which could materially adversely affect our business, financial condition,
results of operations or cash flows, include:
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• |
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potential disruption of our ongoing business and distraction of
management; |
| |
| |
• |
|
unexpected loss of key employees or customers of an acquired
business; |
| |
| |
• |
|
conforming an acquired business’ standards, processes, procedures or
controls with our operations; |
| |
| |
• |
|
coordinating new product and process development; |
| |
| |
• |
|
hiring additional management or other critical personnel; |
| |
| |
• |
|
encountering unknown contingent liabilities which could be material;
and |
| |
| |
• |
|
increasing the scope, geographic diversity and complexity of our
operations. |
Our acquisition
strategy may not be favorably received by customers, and we may not realize any
anticipated benefits from acquisitions.
15
Risks Relating to
Our Indebtedness
Our leverage and
debt service obligations may adversely affect our cash flow and our ability to
make payments on our indebtedness.
As of December 31, 2007, we had
total long-term debt of $150.0 million (consisting of outstanding principal
on our 101/4% Senior Secured Notes due 2015, or our Secured
Notes). The terms and conditions governing our indebtedness, including our notes
and our revolving credit facility:
| |
• |
|
require us to dedicate a substantial portion of our cash flow from
operations to service our existing debt service obligations, thereby
reducing the availability of our cash flow to fund working capital,
capital expenditures and other general corporate expenditures; |
| |
| |
• |
|
increase our vulnerability to adverse general economic or industry
conditions and limit our flexibility in planning for, or reacting to,
competition or changes in our business or our industry; |
| |
| |
• |
|
limit our ability to obtain additional financing; |
| |
| |
• |
|
place restrictions on our ability to make certain payments or
investments, sell assets, make strategic acquisitions, engage in mergers
or other fundamental changes and exploit business opportunities; and |
| |
| |
• |
|
place us at a competitive disadvantage relative to competitors with
lower levels of indebtedness in relation to their overall size or less
restrictive terms governing their indebtedness. |
Our ability to meet our expenses and
debt obligations will depend on our future performance, which will be affected
by financial, business, economic, regulatory and other factors. We will not be
able to control many of these factors, such as economic conditions and
governmental regulations. We cannot be certain that our earnings will be
sufficient to allow us to pay the principal and interest on our debt, including
our Secured Notes, and meet our other obligations. If we do not have enough
money, we may be required to refinance all or part of our existing debt,
including our Secured Notes, sell assets, borrow more money or raise equity. We
may not be able to refinance our debt, sell assets, borrow more money or raise
equity on terms acceptable to us, if at all. Further, failing to comply with the
financial and other restrictive covenants in the agreements governing our
indebtedness could result in an event of default under such indebtedness, which
could materially adversely affect our business, financial condition, results of
operations or cash flows.
Any failure to
meet our debt obligations could harm our business, financial condition, results
of operations or cash flows.
If our cash flow and capital resources
are insufficient to fund our debt obligations, we may be forced to sell assets,
seek additional equity or debt capital or restructure our debt. In addition, any
failure to make scheduled payments of interest and principal on our outstanding
indebtedness would likely result in a reduction of our credit rating, which
could harm our ability to incur additional indebtedness on acceptable terms. Our
cash flow and capital resources may be insufficient for payments of interest or
principal on our debt in the future, including payments on our Secured Notes,
and any such alternative measures may be unsuccessful or may not permit us to
meet scheduled debt service obligations, which could cause us to default on our
obligations and impair our liquidity.
Risks Relating to
the Ownership of Our Common Stock
Our common stock
is thinly traded. There is no active trading market for our common stock and an
active trading market may not develop.
Our common stock is not listed on any
national or regional securities exchange. Quotations for shares of our common
stock are listed by certain members of the National Association of Securities
Dealers, Inc. on the OTC Electronic Bulletin Board. In recent years, the trading
volume of our common stock has been very low and the transactions that have
occurred were typically effected in transactions for which reliable market
quotations have not been available. An active trading market may not develop or,
if developed, may not continue for our equity securities, and a holder of any of
these securities may find it difficult to dispose of, or to obtain accurate
quotations as to the market value of such securities.
16
We have a
significant stockholder which has the ability to control our actions.
Resurgence Asset Management, L.L.C. and
its and its affiliates’ managed funds and accounts (collectively, “Resurgence”)
own in excess of 99% of our preferred stock and over 60% of our common stock,
representing ownership of over 84% of the total voting power of our equity. The
interests of Resurgence may differ from our other stockholders and Resurgence
may vote their interests in a manner that may adversely affect our other
stockholders. Through their direct and indirect interests in us, Resurgence is
in a position to influence the outcome of most matters requiring a stockholder
vote. This concentrated ownership makes it less likely that any other holder or
group of holders of common stock would be able to influence the way we are
managed or the direction of our business. These factors also may delay or
prevent a change in our management or voting control.
Our preferred
stock pays a quarterly stock dividend that is dilutive to the holders of our
common stock.
Our shares of preferred stock carry a
cumulative dividend rate of 4% per quarter, payable in additional shares of
preferred stock. Our shares of preferred stock are convertible at the option of
the holder into shares of our common stock and vote as if so converted on all
matters presented to the holders of our common stock for a vote. Consequently,
each dividend paid in additional shares of our preferred stock has a dilutive
effect on our shares of common stock and increases the percentage of the total
voting power of equity owned by Resurgence. In 2007, we issued an additional
695.874 shares of our preferred stock (which is convertible into 695,874 shares
of our common stock) in dividends, which represents 9.1% of the current total
voting power of our equity securities.
The existence of
our preferred stock and limited liquidity of our common stock may limit our
ability to utilize our equity to pursue strategic initiatives that may otherwise
exist.
The existence of our preferred stock
and the limited trading market of our common stock (as discussed above) could
make it more difficult to use these instruments as part of implementing our
strategy to grow the business.
Item 2.
Properties
Our petrochemicals site is located in
Texas City, Texas, approximately 45 miles south of Houston, on a 290-acre site
on Galveston Bay near many other chemical manufacturing complexes and
refineries. We own all of the real property which comprises our Texas City site
and we own the acetic acid, plasticizers and styrene manufacturing facilities
located at the site. We also lease a portion of our Texas City site to Praxair,
who constructed a partial oxidation unit on that land, and lease a portion of
our Texas City site to S&L Cogeneration Company, a 50/50 joint venture
between us and Praxair Energy Resources, Inc., who constructed a cogeneration
facility on that land. Our Texas City site offers approximately 135 acres for
future expansion by us or by other companies who could benefit from our existing
infrastructure and facilities, and includes a greenbelt around the northern edge
of the plant site. We own 73 railcars and, at our Texas City site, we have
facilities to load and unload our products and raw materials in ocean-going
vessels, barges, trucks and railcars.
Substantially all of our Texas City,
Texas site, and the tangible properties located thereon, are subject to a lien
securing our obligations under our Secured Notes.
We lease the space for our principal
executive offices, located at 333 Clay Street, Suite 3600 in Houston,
Texas.
We believe our properties and equipment
are sufficient to conduct our business.
Item 3.
Legal Proceedings
On July 5, 2005, Patrick B.
McCarthy, an employee of Kinder-Morgan, Inc., or Kinder-Morgan, was seriously
injured at Kinder-Morgan, Inc.’s facilities near Cincinnati, Ohio while
attempting to offload a railcar containing one of our plasticizers products. On
October 28, 2005, Mr. McCarthy and his family filed a suit in the
Court of Common Pleas, Hamilton County, Ohio (Case No. A0509 144) against
us and six other defendants. Since that time, the plaintiffs have added two
additional defendants to this lawsuit. In addition, we and some of the other
defendants have brought Kinder-Morgan into this lawsuit as a third-party
defendant. The plaintiffs are seeking in excess of $32 million in alleged
compensatory and punitive damages. Discovery is ongoing in this case as to the
underlying cause of the accident and the parties’ respective liabilities, if
any. At this time, it is impossible to determine what, if any, liability we will
have for this incident and we will vigorously defend the suit. We believe that
all, or substantially all, of any
17
liability imposed upon
us as a result of this suit and our related out-of-pocket costs and expenses
will be covered by our insurance policies, subject to a $1 million
deductible which was met in January 2008. We do not believe that this
incident will have a material adverse affect on our business, financial
position, results of operations or cash flows, although we cannot guarantee that
a material adverse effect will not occur.
On August 17, 2006, we initiated
an arbitration proceeding against BP Chemicals to resolve a dispute involving
the interpretation of provisions of our acetic acid Production Agreement with BP
Chemicals. Under the Production Agreement, BP Chemicals reimburses our
manufacturing expenses and pays us a percentage of the profits derived from the
sales of the acetic acid we produce. Historically, the costs of manufacturing
charged to our acetic acid business, and reimbursed by BP Chemicals, included
the amounts we paid Praxair for carbon monoxide, hydrogen and a blend of carbon
monoxide and hydrogen commonly referred to as “blend gas.” Our acetic acid
business has always used all of the carbon monoxide produced by Praxair, other
than the small amount of carbon monoxide included in the blend gas. Until
July 1, 2006, all of the blend gas produced by Praxair was used by the
oxo-alcohols plant included in our plasticizers business. During the period when
the oxo-alcohols plant was operating, BP Chemicals was compensated for the use
of this blend gas by our oxo-alcohols plant through a credit to the amount of
our manufacturing expenses reimbursed by BP Chemicals. Effective July 1,
2006, we permanently closed our oxo-alcohols plant. BP Chemicals has taken the
position that it is entitled to continue to deduct a portion of the blend gas
credit from the reimbursement of our manufacturing expenses, even though our
oxo-alcohols plant has been closed and is no longer taking any blend gas and the
Praxair facilities have been modified so that the carbon monoxide previously
used in blend gas can be used in our acetic acid operations. Effective
August 1, 2006, BP Chemicals began short paying our invoices for
manufacturing expenses by the portion of the credit that BP Chemicals claims
should continue through July 31, 2016. The disputed portion of the credit
averaged approximately $0.3 million per month during 2006 and 2007, before
adjusting for the portion of the profits we receive from BP Chemicals’ sale of
the acetic acid we produce. We are also seeking additional damages from BP
Chemicals in the arbitration based on what we believe are breaches of duty by BP
Chemicals. The parties have abated the arbitration proceedings while they
attempt to reach a negotiated settlement. As part of the agreement to abate the
arbitration proceedings, BP Chemicals reimbursed us $0.8 million on
February 5, 2007, which was 50% of the disputed credit through that date,
and has continued and will continue to pay 50% of the disputed amount each month
during the period of negotiation. As of December 31, 2007, the disputed
amount is $5.6 million and we have received payments totaling
$2.7 million. We are not recording any revenue related to any portion of
the disputed amount until the matter is resolved. The parties have stipulated
that the payments are made without prejudice, in that BP Chemicals is not
admitting liability and continues to insist that we remain liable for the
disputed portion of the blend gas credit. According to the agreement, either
party may reinstate the arbitration process at any time after August 1,
2007. If the arbitration is reinstated and an award is made, the amounts paid by
BP Chemicals will be credited against any sums awarded to us or refunded by us
to BP Chemicals, depending on the ruling of the arbitration panel. We believe
that our acetic acid Production Agreement does not contemplate the continuation
of any portion of the blend gas credit under these circumstances and will
vigorously pursue our position. Although we are in a dispute with BP Chemicals
over the interpretation of this contractual provision, we believe that we
continue to have a constructive working relationship with BP Chemicals, as has
been the case since 1986. As part of the on-going settlement negotiations over
the blend gas issue, we are discussing an extension of the term of the acetic
acid Production Agreement.
On February 21, 2007, we received
a summons naming us, several benefit plans and the plan administrators for those
plans as defendants in a class action suit, Case No. H-07-0625 filed in the
United States District Court, Southern District of Texas, Houston Division. The
plaintiffs seek to represent a proposed class of retired employees of Sterling
Fibers, Inc., one of our former subsidiaries that we sold in connection with our
emergence from bankruptcy in 2002. The plaintiffs are alleging that we were not
permitted to increase their premiums for retiree medical insurance based on a
provision contained in the asset purchase agreement between us and Cytec
Industries Inc. and certain of its affiliates governing our purchase of our
former acrylic fibers business in 1997. During our bankruptcy case, we
specifically rejected this asset purchase agreement and the bankruptcy court
approved that rejection. The plaintiffs are claiming that we violated the terms
of the benefit plans and breached fiduciary duties governed by the Employee
Retirement Income Security Act and are seeking damages, declaratory relief,
punitive damages and attorneys’ fees. We moved to dismiss the plaintiffs’ claims
in their entirety on July 6, 2007, based on the rejection of the asset
purchase agreement in our bankruptcy case. However, the court denied our motion
to dismiss, motion for reconsideration and our request to allow us to take an
interlocutory appeal. Discovery in this matter is in its beginning stages and we
are vigorously defending this action. We are unable to state at this time if a
loss is probable or remote and are unable to determine the possible range of
loss related to this matter, if any.
18
On March 4, 2008, Gulf Hydrogen
and Energy, L.L.C., or Gulf Hydrogen, filed suit against us in the 212th District Court of
Galveston County, Texas (Cause No. 08CV0220) to enforce the provisions of a
Memorandum of Understanding, or MOU, entered into between us and Gulf Hydrogen
involving the possible sale of our outstanding equity interests to Gulf Hydrogen
for approximately $390 million. This lawsuit also names certain of our
officers, a director and our primary stockholder as defendants. Gulf Hydrogen
does not allege a specific amount of money damages in the lawsuit but has asked
the court to enforce certain MOU provisions which expired on March 1, 2008.
Gulf Hydrogen alleges that the defendants breached the terms of the MOU and made
certain misrepresentations in connection therewith. We are vigorously defending
this lawsuit, which we believe is completely without merit. We also intend to
file counterclaims against Gulf Hydrogen and its principals for damages
resulting from their conduct.
We are subject to various other claims
and legal actions that arise in the ordinary course of our business. We do not
believe that any of these claims and actions, separately or in the aggregate,
will have a material adverse effect on our business, financial position, results
of operation or cash flows, although we cannot guarantee that a material adverse
effect will not occur.
Item 4.
Submission of Matters to a Vote of Security Holders
No matters were submitted to a vote of
security holders during the fourth quarter of 2007.
19
PART II
Item 5.
Market for Registrant’s Common Equity and Related Stockholder
Matters
Our common stock, par value $0.01 per
share, is currently quoted on the Over-the-Counter, or OTC, Electronic Bulletin
Board maintained by the National Association of Securities Dealers, Inc. under
the symbol “SCHI.” The following table contains information about the high and
low sales prices per share of our common stock for the last two years.
Information about OTC Electronic Bulletin Board bid quotations represents prices
between dealers, does not include retail mark-ups, mark-downs or commissions and
may not necessarily represent actual transactions. Quotations on the OTC
Electronic Bulletin Board are sporadic, and currently there is no established
public trading market for our common stock.
| |
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|
|
|
|
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|
| |
|
First |
|
Second |
|
Third |
|
Fourth |
| |
|
Quarter |
|
Quarter |
|
Quarter |
|
Quarter |
|
2007 High |
|
$ |
12.75 |
|
|
$ |
26.00 |
|
|
$ |
24.75 |
|
|
$ |
23.00 |
|
|
Low |
|
$ |
8.55 |
|
|
$ |
10.98 |
|
|
$ |
17.25 |
|
|
$ |
17.00 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2006 High |
|
$ |
11.50 |
|
|
$ |
15.00 |
|
|
$ |
14.90 |
|
|
$ |
15.00 |
|
|
Low |
|
$ |
10.00 |
|
|
$ |
10.25 |
|
|
$ |
13.10 |
|
|
$ |
12.48 |
|
The last reported sale
price per share of our common stock as reported on the OTC Electronic Bulletin
Board on March 21, 2008 was $16.00. As of March 21, 2008, there were
308 holders of record of our common stock. This number does not include
stockholders for whom shares are held in a nominee or “street” name.
Dividend Policy
We have not declared or paid any cash
dividends with respect to our common stock since we emerged from bankruptcy in
December 2002. We do not presently intend to pay cash dividends with
respect to our common stock for the foreseeable future. In addition, we cannot
pay dividends on our shares of common stock under the indenture for our Secured
Notes or under our revolving credit facility. The payment of cash dividends, if
any, will be made only from assets legally available for that purpose, and will
depend on our financial condition, results of operations, current and
anticipated capital requirements, general business conditions, restrictions
under our existing debt instruments and other factors deemed relevant by our
Board of Directors.
Equity Compensation
Plan
Under our 2002 Stock Plan, officers,
key employees and consultants, as designated by our Board of Directors or
Compensation Committee, may be issued stock options, stock awards, stock
appreciation rights or stock units. Our 2002 Stock Plan is administered by our
Board of Directors, in consultation with our Compensation Committee, and may be
amended or modified from time to time by our Board of Directors in accordance
with its terms. Our Board of Directors or Compensation Committee determines the
exercise price of stock options, any applicable vesting provisions and other
terms and provisions of each grant in accordance with our 2002 Stock Plan.
Options granted under our 2002 Stock Plan become fully exercisable in the event
of the optionee’s termination of employment by reason of death, disability or
retirement, and may become fully exercisable in the event of a “change of
control.” No option may be exercised after the tenth anniversary of the date of
grant or the earlier termination of the option. We have reserved 363,914 shares
of our common stock for issuance under the 2002 Stock Plan (subject to
adjustment). On February 11, 2003, we granted certain of our officers and
key employees options to purchase 326,000 shares of our common stock under our
2002 Stock Plan at an exercise price of $31.60 per share, 15,833 of which have
been exercised and 92,167 of which have lapsed or expired without being
exercised. On November 5, 2004, we granted one of our officers options to
purchase 27,500 shares of our common stock under our 2002 Stock Plan at an
exercise price of $31.60 per share. We have not made any other awards under our
2002 Stock Plan.
20
The following table provides
information regarding securities authorized for issuance under our 2002 Stock
Plan as of December 31, 2007:
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| |
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|
Number of securities |
|
| |
|
|
|
|
|
|
|
|
|
remaining available for |
|
| |
|
Number of securities to |
|
|
Weighted-average |
|
|
future issuance under equity |
|
| |
|
be issued upon exercise |
|
|
exercise price of |
|
|
compensation plans |
|
| |
|
of outstanding options, |
|
|
outstanding options, |
|
|
(excluding securities |
|
| Plan
Category |
|
warrants and rights |
|
|
warrants and rights |
|
|
reflected in first column |
|
|
Equity compensation
plans approved by security holders (1) |
|
|
245,500 |
|
|
$ |
31.60 |
|
|
|
118,414 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Equity compensation
plans not approved by security holders |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
|
245,500 |
|
|
$ |
31.60 |
|
|
|
118,414 |
|
|
|
|
| (1) |
|
Our 2002 Stock Plan was authorized and established under our Plan of
Reorganization, which became effective on December 19, 2002. Our Plan
of Reorganization provided that, without any further act or authorization,
confirmation of our Plan of Reorganization and entry of the confirmation
order was deemed to satisfy all applicable federal and state law
requirements and all listing standards of any securities exchange for
approval by the board of directors or the stockholders of our 2002 Stock
Plan. No additional stockholder approval of our 2002 Stock Plan has been
obtained. |
Performance
Graph
The following performance graph
compares our cumulative total stockholder return on shares of our common stock
for a four-year period with the cumulative total return of the Standard &
Poor’s 500 Stock Index, or the S & P 500 Index, and the Standard &
Poor’s Diversified Chemicals Index, or the S & P Chemicals Index. The graph
assumes the investment of $100 on December 31, 2002 in shares of our common
stock, the S & P 500 Index and the S & P Chemicals Index and the
reinvestment of dividends.
COMPARISON OF 5
YEAR CUMULATIVE TOTAL RETURN*
Among Sterling Chemicals Inc., The S&P
500 Index
And The S&P Diversified Chemicals Index
* $ 100 invested on
1/3/03 in stock or on 12/31/02 in index-including reinvestment of dividends.
Fiscal year ending December 31.
Copyright © 2008, Standard &
Poor’s, a division of The McGraw-Hill Companies, Inc. All rights reserved.
www.researchdatagroup.com/S&P.htm
21
Item 6.
Selected Financial Data
The following table sets forth selected
financial data with respect to our consolidated financial condition and
consolidated results of operations and should be read in conjunction with our
historical consolidated financial statements and related notes, “Item 7.
Management’s Discussion and Analysis of Financial Condition and Results of
Operations” and our Financial Statements and Supplementary Data included in
Item 8 of this Form 10-K.
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
Year ended |
|
Year ended |
|
Year ended |
|
Year ended |
| |
|
Year ended |
|
December 31, |
|
December 31, |
|
December 31, |
|
December 31, |
| |
|
December 31, |
|
2006 |
|
2005 |
|
2004 |
|
2003 |
| |
|
2007 |
|
(1) |
|
(1) |
|
(1) |
|
(1) |
| |
|
(In Thousands, Except Per Share
Data) |
|
Operating
Data(2): |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues |
|
$ |
811,326 |
|
|
$ |
665,923 |
|
|
$ |
641,886 |
|
|
$ |
655,353 |
|
|
$ |
518,772 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross profit
(loss) |
|
|
9,574 |
|
|
|
11,205 |
|
|
|
(11,248 |
) |
|
|
22,344 |
|
|
|
23,790 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from
continuing operations(3) |
|
|
(16,535 |
) |
|
|
(104,662 |
) |
|
|
(18,508 |
) |
|
|
(39,881 |
) |
|
|
1,270 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from discontinued
operations(4) |
|
|
(2,393 |
) |
|
|
(997 |
) |
|
|
(11,060 |
) |
|
|
(22,763 |
) |
|
|
(15,469 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Per Share
Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss attributable
to common stockholders |
|
$ |
(12.90 |
) |
|
$ |
(41.52 |
) |
|
$ |
(16.46 |
) |
|
$ |
(27.08 |
) |
|
$ |
(8.38 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss from
continuing operations attributable to common stockholders |
|
|
(12.05 |
) |
|
|
(41.17 |
) |
|
|
(12.55 |
) |
|
|
(19.02 |
) |
|
|
(2.90 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash dividends |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Ratio of earnings to
fixed charges(5) |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
1.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance Sheet
Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Working capital(6) |
|
$ |
166,214 |
|
|
$ |
96,680 |
|
|
$ |
76,605 |
|
|
$ |
106,767 |
|
|
$ |
137,412 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total assets |
|
|
306,444 |
|
|
|
245,823 |
|
|
|
386,594 |
|
|
|
473,553 |
|
|
|
550,503 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Long-term debt |
|
|
150,000 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Redeemable preferred
stock(7) |
|
|
99,866 |
|
|
|
82,316 |
|
|
|
70,542 |
|
|
|
53,559 |
|
|
|
39,701 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Stockholders’ equity
(deficiency in assets)(8) |
|
|
(74,087 |
) |
|
|
(48,575 |
) |
|
|
58,045 |
|
|
|
107,813 |
|
|
|
185,029 |
|
|
|
|
| |
| (1) |
|
We have restated our consolidated financial statements and selected
financial data for the fiscal years ended December 31, 2006, 2005,
2004 and 2003. For further information, see Note 16 to the Consolidated
Financial Statements found in Item 8. “Financial Statements and
Supplementary Data.” |
| |
| (2) |
|
On September 17, 2007, we entered into a long-term exclusive
styrene supply agreement and a related railcar purchase and sale agreement
with NOVA. On November 13, 2007, we announced that we were exiting
the styrene business to pursue other strategic initiatives. Due to the
shut down of our styrene plant, we will report the operating results of
our former styrene business as discontinued operations in our consolidated
financial statements in the first quarter of 2008 when these operations
have ceased. The revenues and gross losses from our styrene
operations are summarized below: |
22
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
2007 |
|
2006 |
|
2005 |
|
2004 |
|
2003 |
| |
|
|
|
Revenues |
|
$ |
681,513 |
|
|
$ |
524,664 |
|
|
$ |
513,788 |
|
|
$ |
529,729 |
|
|
$ |
408,823 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross loss |
|
|
(16,468 |
) |
|
|
(15,510 |
) |
|
|
(30,277 |
) |
|
|
136 |
|
|
|
8,953 |
|
|
|
|
| (3) |
|
During 2006, we recorded a $127.7 million impairment charge to
our styrene assets and a related deferred tax benefit of $45 million.
This tax benefit was offset by deferred tax expense of $28 million in
connection with the recording of a valuation allowance against our
deferred tax assets. During 2004, we recorded a $48.5 million
goodwill impairment charge. Also during 2004, we recorded a pension
curtailment gain of $13 million. |
| |
| (4) |
|
During 2005, we announced that we were exiting the acrylonitrile
business and related derivatives operations. During 2004, we recorded a
$22 million pre-tax impairment charge related to our acrylonitrile
long-lived assets. Loss from discontinued operations during 2007 and 2006
reflects costs associated with the dismantling of our acrylonitrile
unit. |
| |
| (5) |
|
Additional pre-tax earnings needed to achieve a 1:1 ratio for the
years ended December 31, 2007, 2006, 2005 and 2004 were
$22.4 million, $120.1 million, $30.2 million and
$33.6 million, respectively. |
| |
| (6) |
|
Working capital as of December 31, 2007, 2006, 2005, 2004 and
2003 includes net assets (liabilities) of discontinued operations of
$(0.3) million, $(0.2) million, $(2) million, $55 million and
$57 million, respectively. |
| |
| (7) |
|
Our Series A Preferred Stock is not currently redeemable or
probable of redemption. If our Series A Preferred Stock had been
redeemed as of December 31, 2007, the redemption amount would have
been approximately $83.9 million. The liquidation value of our
Series A Preferred Stock as of December 31, 2007 is
$66.1 million. |
| |
| (8) |
|
The balance as of December 31, 2006 includes a change in
stockholders’ equity (deficiency in assets) of $6.8 million (net of
tax) due to the adoption of Statement of Financial Accounting Standards
No. 158, “Employers’ Accounting for Defined Benefit Pension and Other
Postretirement Plans”. |
23
Item 7.
Management’s Discussion and Analysis of Financial Condition and
Results of Operations
Restatement
We have restated our previously issued
consolidated financial statements for the years ended December 31, 2006 and
2005 for the matters discussed more fully in Note 16 to the consolidated
financial statements included in this Form 10-K. The restatement also required
the restatement of previously issued Quarterly Financial Data for 2007 and 2006
presented in the Supplemental Data at the end of Item 8 in this Form 10-K
and the restatement of Management’s Discussion and Analysis of Financial
Condition and Results of Operations.
Overview
Business
We are a North American producer of
selected petrochemicals used to manufacture a wide array of consumer goods and
industrial products throughout the world. We currently operate in three
segments: acetic acid, plasticizers and styrene.
Our acetic acid is used primarily to
manufacture vinyl acetate monomer, which is used in a variety of products,
including adhesives and surface coatings. Pursuant to a long-term contract, or
Production Agreement, that began in 1986 and extends to 2016, all of our acetic
acid production is sold to BP Amoco Chemical Company, or BP Chemicals, and we
are BP Chemicals’ sole source of acetic acid production in the Americas. BP
Chemicals markets all of the acetic acid that we produce and pays us, among
other amounts, a portion of the profits derived from its sales of the acetic
acid we produce. Prior to August 2006, BP Chemicals also paid us a set
monthly amount. In addition, BP Chemicals reimburses us for 100% of our fixed
and variable costs of production. Pursuant to the terms of this Production
Agreement, beginning in August 2006, the portion of the profits we receive
from the sales of acetic acid produced at our plant increased and BP Chemicals
is no longer required to pay us the set monthly amount that we had received
prior to that time. However, this change in payment structure did not affect BP
Chemicals’ obligation to reimburse us for all of our fixed and variable costs of
production. We believe that we have one of the lowest cost acetic acid
facilities in the world. Our acetic acid facility utilizes BP Chemicals’
proprietary carbonylation technology, or Cativa Technology, which we believe
offers several advantages over competing production methods, including lower
energy requirements and lower fixed and variable costs. We also jointly invest
with BP Chemicals in capital expenditures related to our acetic acid facility in
the same percentage as the profits from the business are divided. We initially
pay for 100% of the capital expenditures and then invoice BP Chemicals for its
portion. The net amount represents our basis in the property, plant and
equipment, which is capitalized and depreciated over its useful life. Acetic
acid production has two major raw materials requirements — methanol and carbon
monoxide. BP Chemicals, a producer of methanol, supplies 100% of our methanol
requirements related to our production of acetic acid. All of the carbon
monoxide we use in the production of acetic acid is supplied by Praxair Hydrogen
Supply, Inc., or Praxair, from a partial oxidation unit constructed by Praxair
on land leased from us at our site in Texas City, Texas.
All of our plasticizers, which are used
to make flexible plastics, such as shower curtains, floor coverings, automotive
parts and construction materials, are sold to BASF Corporation, or BASF,
pursuant to a long-term production agreement that extends until 2013, subject to
some limited early termination rights held by BASF beginning in 2010. Under our
agreement with BASF, they provide us with most of the required raw materials,
market the plasticizers we produce and are obligated to make certain fixed
quarterly payments to us and to reimburse us monthly for our actual production
costs and capital expenditures relating to our plasticizers facility.
Until early 2008 our primary products
also included styrene. Styrene is a commodity chemical used to produce
intermediate products such as polystyrene, expandable polystyrene resins and ABS
plastics, which are used in a wide variety of products such as household goods,
foam cups and containers, disposable food service items, toys, packaging and
other consumer and industrial products. Over the last five years, we had
generated approximately $31 million of cumulative negative cash flows from
our styrene operations, and we anticipated negative cash flows from our styrene
operations for the foreseeable future. Due to the current and future expected
market conditions for styrene discussed in greater detail below, we explored
several possible strategic transactions involving our styrene business and, on
September 17, 2007, we entered into a long-term exclusive styrene supply
agreement and a related railcar purchase and sale agreement with NOVA Chemicals
Inc., or NOVA. Under the supply agreement, NOVA had the exclusive right to
purchase 100% of our styrene production (subject to existing contractual
commitments), the amount of styrene supplied in any particular period being at
NOVA’s option, based on a full-cost formula. In November 2007, the styrene
supply agreement with NOVA, which was subsequently assigned by NOVA to INEOS
NOVA LLC, or INEOS NOVA, obtained clearance under the Hart-Scott-Rodino Act.
This clearance caused the supply agreement to become effective and triggered a
$60 million payment obligation to us, which was paid by INEOS NOVA in
November 2007. In
24
addition, in accordance
with the terms of the supply agreement, INEOS NOVA assumed substantially all of
our contractual obligations for future styrene deliveries. Once the supply
agreement became effective, INEOS NOVA nominated zero pounds of styrene under
the supply agreement for the balance of 2007, and in response we exercised our
right to terminate the supply agreement and permanently shut down our styrene
plant. As a result of our decision to permanently shut down our styrene plant,
we expect to incur closure costs of $10 million to $15 million and we
will have no future cash flows from our styrene operations except for
liquidation of our working capital and any potential plant salvage value. For a
description of this agreement and its effect on our business, see “Recent
Developments” below.
We manufacture all of our
petrochemicals products at our site in Texas City, Texas. In terms of production
capacity, our Texas City site has the sixth largest acetic acid facility in the
world. Our Texas City site covers an area of 290 acres, is strategically located
on Galveston Bay and benefits from a deep-water dock capable of handling ships
with up to a 40-foot draft, as well as four barge docks and direct access to
Union Pacific and Burlington Northern Santa Fe railways with in-motion rail
scales on site. Our Texas City site also has truck loading racks, weigh scales,
stainless and mild steel storage tanks, three waste deepwells, 135 acres of
available land zoned for heavy industrial use, additional land zoned for light
industrial use and a supportive political environment for growth. In addition,
we are in the heart of one of the largest petrochemical complexes on the Gulf
Coast and, as a result, have on-site access to a number of raw material
pipelines, as well as close proximity to a number of large refinery complexes.
Our rated annual production capacity is
among the highest in North America for acetic acid. As of December 31,
2007, our annual production capacity was 1.1 billion pounds, which
represents 17% of total North American capacity, and in terms of production
capacity, makes our acetic acid facility the third largest in North America.
Our petrochemicals products are
generally sold to customers for use in the manufacture of other chemicals and
products, which in turn are used in the production of a wide array of consumer
goods and industrial products throughout the world.
Acetic Acid. The North American
acetic acid industry has enjoyed a period of sustained domestic demand growth,
as well as substantial export demand. This has led to current North American
industry utilization rates of 86% and Tecnon projects utilization rates to
increase to over 98% by 2013, although the recent difficulties in the housing
and automotive sectors will likely cause reduced demand for vinyl acetate
monomer, and consequently acetic acid, in North America in the short term. The
North American acetic acid industry is inherently less cyclical than many other
petrochemical products due to a number of important factors.
There are only four large producers of
acetic acid in North America and historically these producers have made capacity
additions in a disciplined and incremental manner, primarily using small
expansion projects or exploiting debottlenecking opportunities. In addition, the
leading technology required to manufacture acetic acid is controlled by two
global companies, which permits these companies to control the pace of new
capacity additions through the licensing or development of such additional
capacity. The limited availability of this technology also creates a significant
barrier to entry into the acetic acid industry by potential competitors.
Global production capacity of acetic
acid, as of December 31, 2007, was approximately 24 billion pounds per
year, with current North American production capacity at approximately
7 billion pounds per year. The North American acetic acid market is mature
and well developed and is dominated by four major producers that account for
over 94% of the production capacity of acetic acid in North America. Demand for
acetic acid is linked to the demand for vinyl acetate monomer, a key
intermediate in the production of a wide array of polymers. Vinyl acetate
monomer is the largest derivative of acetic acid, representing over 40% of total
demand. Annual global production of vinyl acetate monomer is expected to
increase from 10.4 billion pounds in 2005 to 12.2 billion pounds in
2010, although the recent difficulties in the housing and automotive sectors
will likely cause reduced demand for vinyl acetate monomer in North America in
the short term. The North American acetic acid industry tends to sell most of
its products through long-term sales agreements having “cost plus” pricing
mechanisms, eliminating much of the volatility seen in other petrochemicals
products and resulting in more stable and predictable earnings and profit
margins.
Several acetic acid capacity additions
have occurred since 1998, including an expansion of our acetic acid unit from
800 million pounds of rated annual production capacity to 1.1 billion
pounds during 2005. These capacity additions were somewhat offset by reductions
of approximately 1.6 billion pounds in annual global capacity from the shutdown
of various outdated acetic acid plants from 1999 through 2001. In 2006, BP
Chemicals closed two of its outdated acetic acid production units in Hull,
England that had a combined annual capacity of approximately 500 million
pounds (which had been sold primarily in Europe and South America). We and BP
Chemicals are reviewing further expansion of our acetic acid plant in 2008 or
2009.
25
Plasticizers. Historically, we
produced ethylene-based linear plasticizers, which typically receive a premium
over competing branched propylene-based products for customers that require
enhanced performance properties. However, the markets for competing plasticizers
can be affected by the cost of the underlying raw materials, especially when the
cost of one olefin rises faster than the other, or by the introduction of new
products. One of the raw materials for linear plasticizers is a product known as
linear alpha-olefins. Over the last few years, the price of linear alpha-olefins
has increased sharply as supply has declined, which has caused many consumers to
switch to lower cost branched products, despite the loss of some performance
properties. Ultimately, we expect branched plasticizers to replace linear
plasticizers for most applications over the long-term. As a result, we modified
our plasticizers facilities during the third quarter of 2006 to produce lower
cost branched plasticizers products.
In 2005, BP Chemicals announced the
permanent closure of its linear alpha-olefins production facility in Pasadena,
Texas, the primary source of supply of this feedstock to the oxo-alcohols
production unit at our plasticizers facility. After pursuing various alternative
uses for our oxo-alcohols unit, we were unable to secure an alternative use for
this facility. As a result, we permanently shut down our oxo-alcohols production
unit on July 31, 2006. Due to the closure of our oxo-alcohols unit and our
conversion to the production of branched plasticizers, the phthalate esters
production unit at our plasticizers facility now uses oxo-alcohols supplied by
BASF that have a different chemical composition. In December 2007, BASF
caused the shutdown of our phthalic anhydride, or PA, unit by nominating zero
pounds of PA in response to deteriorating market conditions which are not
expected to improve in the foreseeable future. We expect future non-discounted
cash flows from BASF, derived over the term of the PA contract, to be greater
than the net book value of the long-lived assets associated with the PA unit,
which have a value of $7.3 million as of December 31, 2007. This shutdown
will not have a material adverse affect on our financial conditions or results
of operations.
Styrene. The North American
styrene industry is currently in a protracted down cycle, primarily as a result
of over-supply. This extended down cycle resulted from two major developments.
Initially export demand, which historically has represented over 20% of North
American production capacity, has significantly diminished. In recent months,
U.S. styrene producers have seen an increase in styrene exports, largely due to
delays in the start up of announced new capacity in the Middle East. However,
this increase is expected to reverse itself after the styrene plant being
constructed in Al Jubail, Saudi Arabia is completed, which is currently expected
to occur later in 2008. Regional cost pressures, in addition to new production
capacity being added in Asia and the Middle East, have made it difficult for
North American producers to compete in these export markets on a continuous
basis. In addition, a significant amount of styrene capacity has been added
globally over the past five to ten years by producers of propylene oxide using
so-called PO-SM technology, which produces styrene as a co-product. Propylene
oxide is a key intermediate in the production of polyurethane, and polyurethane
demand growth has been significantly greater than demand growth for styrene,
exacerbating the over-supply of styrene. During periods of over-supply,
production rates for styrene producers decrease significantly. When production
rates are low, unit production costs increase due to the allocation of fixed
costs over a lower production volume and a reduction in the efficiency of the
manufacturing unit, both in energy usage and in the conversion rates for raw
materials. Compounding these cost impacts, prices for the principal styrene raw
materials, benzene and ethylene, are currently near historical highs, putting
pressure on margins on styrene sales even though styrene contract prices are at
near historic highs.
Over the last five years, China has
been the driver for growth in styrene demand, representing approximately 75% of
the world’s styrene demand growth in that period. Historically, we positioned
ourselves to take advantage of peaks in the Asian styrene markets, with a large
portion of our styrene capacity not being committed under long-term
arrangements. However, over the last several years, relatively high benzene and
domestic natural gas prices have significantly limited our ability to sell
styrene into the Asian markets, and high styrene prices have reduced styrene
global demand growth rates. In addition, several of our competitors announced
their intention to build new styrene production units outside the United States,
further complicating our ability to sell styrene into the Asian markets. In
2006, our competitors added 2.6 billion pounds of new styrene capacity in
Asia and an additional 1.6 billion pounds in 2007. The remaining announced
construction projects are scheduled to start up in 2008 and beyond. If and when
these new units are completed, we anticipate more difficult market conditions,
especially in the export markets, until the additional supply is absorbed by
growth in styrene demand or significant capacity rationalization occurs.
Chemical Market Associates, Inc., or
CMAI, currently is projecting no additional capacity increases in North America
through 2010, with operating rates reaching a trough of 75% in 2007, and less
than 80% operating rates projected through 2010, without any further industry
restructuring. Although we believe an improved North American industry outlook
is possible, this largely depends on a significant industry restructuring.
Previously, styrene and polystyrene industry participants, including The DOW
Chemical Company and NOVA Chemicals, have announced a desire to seek
transactions which would restructure the North American styrene and polystyrene
industries, thereby improving the balance of supply and demand in North America.
More recently, on October 1, 2007, NOVA Chemicals expanded its European
joint venture with INEOS to include North American styrene and solid polystyrene
assets, and
26
The DOW Chemical
Company announced on April 10, 2007, that it had signed a non-binding
memorandum of understanding with Chevron Phillips Chemical Co. to form a joint
venture involving selected styrene and polystyrene assets of the two companies
in North America and South America.
Recent
Developments
On September 17, 2007, we entered
into a long-term exclusive styrene supply agreement and a related railcar
purchase and sale agreement with NOVA. Under the supply agreement, NOVA had the
exclusive right to purchase 100% of our styrene production (subject to existing
contractual commitments), the amount of styrene supplied in any particular
period being at NOVA’s option, based on a full-cost formula. In
November 2007, the styrene supply agreement with NOVA, which was
subsequently assigned by NOVA to INEOS NOVA, obtained clearance under the
Hart-Scott-Rodino Act. This clearance caused the supply agreement to become
effective and triggered a $60 million payment obligation to us, which was
paid by INEOS NOVA in November 2007. In addition, in accordance with the
terms of the supply agreement, INEOS NOVA assumed substantially all of our
contractual obligations for future styrene deliveries. Once the supply agreement
became effective, INEOS NOVA nominated zero pounds of styrene under the supply
agreement for the balance of 2007, and in response we exercised our right to
terminate the supply agreement and permanently shut down our styrene plant.
Under the supply agreement, we are responsible for the closure costs of our
styrene facility and are also subject to a long-term commitment to not reenter
the styrene business for a period of time. The closure costs of the styrene
facility are expected to be between $10 million and $15 million. These
expected costs include $4 million to $5 million in severance payments
for workforce reductions and $6 million to $10 million in inventory
disposal costs for inventory produced subsequent to September 30, 2007.
Severance costs have not been accrued in the consolidated balance sheets as we
have not met the requirement to accrue a liability under Statement of Financial
Accounting Standards, or SFAS, No. 146, “Accounting for Costs Associated
with Exit or Disposal Activities (as amended);” in addition, we are currently
evaluating business alternatives at our Texas City facility, and if successful,
some portion of the severance costs may not occur. The inventory disposal costs
are not accrued in the consolidated balance sheet as we are not legally
obligated to incur them, and therefore, these expected costs do not represent
asset retirement obligations under SFAS No. 143, “Accounting for Asset
Retirement Obligations.” Approximately $1 million of these costs were
expensed during the fourth quarter of 2007, with the balance expected to be
expensed during 2008. The cash flow impact of these costs will be offset by
approximately $90 million expected from the monetization of styrene-related
working capital by the end of the first quarter of 2008. We recorded an
impairment charge of $4 million (before taxes) during the fourth quarter of
2007 related to incomplete capital projects associated with our styrene
operations.
Unless certain strategic initiatives
being pursued are implemented, we anticipate reducing our workforce over the
next nine months in connection with our exit from the styrene business. This
reduction of workforce would result in severance costs of between
$4 million and $5 million. In an effort to mitigate these disruptions,
reduce costs and add value to our Texas City site, we are actively engaged in
third-party discussions regarding strategic initiatives that would require the
services of many of our dedicated styrenics employees. If one or more of these
strategic initiatives are consummated over the next few months, the reduction to
our workforce, the amount of severance payments and the other styrene business
closure costs could be reduced.
Discontinued
Operations
On September 16, 2005, we
announced that we were exiting the acrylonitrile business and related derivative
operations. Our decision was based on a history of operating losses incurred by
our acrylonitrile and derivatives businesses, and was made after a full review
and analysis of our strategic alternatives. Our acrylonitrile and derivatives
businesses had sustained losses in recent years and had been shut down since
February of 2005. In accordance with SFAS No. 144, “Accounting for the
Impairment or Disposal of Long-Lived Assets,” or SFAS No. 144, we have
reported the operating results of these businesses as discontinued operations in
our consolidated financial statements.
We operated our styrene manufacturing
unit through early December, as we completed our production of inventory and
exhausted our raw materials and purchase requirements. In 2008, significant
effort was put forth for a number of activities including; selling styrene and
co-products from our inventory, shipping product to customers, billing and
collecting for sales activity and decommissioning and decontamination of the
styrene production facility and related tanks and storage areas. Our
styrene-related personnel continue to work in and support the styrene business
by performing activities necessary to sell the remaining products (including
marketing, fulfillment of sales orders and delivery of product) and to
permanently shut down and decommission the unit. We have not developed plans for
a reduction in workforce at this time as we hope to transition these employees
to new business ventures after their work in styrene is complete. Our last sale
of styrene was made in January 2008 and sales of by-products have continued
through
27
the first quarter of
2008. Additionally, we expect significant cash flow from operations to be
generated from the collection of styrene-related accounts receivable during the
first quarter of 2008.
Accordingly, consistent with the
guidance EITF Abstracts, Topic No. D-104 “Clarification of Transition
Guidance in Paragraph 51 of FASB Statement No. 144”, we will report
the operating results of the styrene business as discontinued operations in our
consolidated financial statements beginning in the first quarter of 2008. The
revenues for the styrene operations for the years ended December 31, 2007,
2006 and 2005 were $681.5 million, $524.7 million and
$513.8 million, respectively.
Results of
Operations
The following table sets forth
revenues, gross profit (loss) and net loss from continuing operations for
2007, 2006, and 2005:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year ended December 31, |
| |
|
2007 |
|
2006 |
|
2005 |
| |
|
(Dollars in Thousands) |
|
Revenues |
|
$ |
811,326 |
|
|
$ |
665,923 |
|
|
$ |
641,886 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross profit
(loss) |
|
|
9,574 |
|
|
|
11,205 |
|
|
|
(11,248 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from continuing
operations |
|
|
(16,535 |
) |
|
|
(104,662 |
) |
|
|
(18,508 |
) |
Comparison of
2007 to 2006
Revenues and loss
from continuing operations
Our revenues were $811.3 million
in 2007, an increase of 22% over the $665.9 million in revenues we recorded
in 2006. This increase in revenues resulted primarily from an increase in
styrene sales volumes, largely attributable to our styrene unit having been shut
down in the first quarter of 2006 to repair the damage caused by a fire that
occurred in the unit in September 2005, and increased acetic acid revenues.
The increased revenues from styrene and acetic acid sales in 2007 was partially
offset by a decrease in plasticizers sales in 2007 due to the shutdown of our
oxo-alcohols facility in 2006. We recorded a net loss from continuing operations
of $16.5 million in 2007, compared to the net loss from continuing
operations of $104.7 million in 2006. The improvement in 2007 versus 2006
was due in large part to the $127.7 million impairment charge to our
styrene assets that we recorded in the fourth quarter of 2006.
Revenues from acetic acid operations
were $100.8 million in 2007, a 4% increase from the $96.7 million in
revenues we recorded from these operations in 2006. The increase in acetic acid
revenues in 2007 resulted from increased profit sharing revenue and an increase
in cost reimbursements received from our customer. Gross profit from our acetic
acid operations decreased $2.5 million during 2007 compared to 2006. This
decrease was due to the impact of the blend gas dispute with BP Chemicals
discussed in Part I, Item 3. “Legal Proceedings” along with the
absence of a one-time $2.4 million utility cost reimbursement in 2006,
partially offset by the $3.4 million favorable impact (year-over-year) of
the previously discussed conversion to higher profit sharing under the
Production Agreement that occurred in August 2006.
Revenues from plasticizers operations
were $28.1 million in 2007, a 37% decrease from $44.5 million in
revenues we recorded from these operations in 2006. This decrease in revenue in
2007 was primarily due to the permanent shut down of our oxo-alcohols unit in
the second half of 2006. Gross profit for our plasticizers operations increased
$1.7 million in 2007 primarily due to an increase in cost reimbursements
received from our customer, partially offset by decreased revenue.
Revenues from our styrene operations
were $681.5 million in 2007, a 30% increase over the $524.7 million in
revenues we recorded from the operations in 2006. Direct sales prices for
styrene increased 6% from those realized during 2006. Spot prices for styrene, a
component of our direct sales prices, ranged from $0.53 to $0.60 per pound
during 2007 compared to $0.45 to $0.60 per pound during 2006. This increase in
revenues resulted primarily from an increase in our styrene sales volumes,
largely attributable to our styrene unit having been shut down in the first
quarter of 2006 to repair damage caused by a fire that occurred in the unit in
September 2005. As our styrene production facility was already shut down in
the first quarter of 2006 to repair the damage caused by the September 2005
fire, we
28
decided to perform our
normal recurring styrene turnaround earlier than planned. As we expense the
costs of turnarounds as they are incurred, we recorded approximately
$9 million of expenses associated with this turnaround of our styrene unit
during the first quarter of 2006. During 2007, prices for benzene and ethylene,
the two primary raw materials required for styrene production, increased 8% and
26%, respectively, from the prices we paid for these products in 2006. Average
costs for natural gas, another major component in the cost of manufacturing
styrene, increased 9% during 2007 compared to average natural gas costs during
2006. Margins on our styrene sales in 2007 decreased $2.8 million from
those realized in 2006, primarily due to increased raw material prices in 2007
combined with our write-down of inventory in December 2007 due to the
anticipated shutdown of the styrene unit, offset by the reduced depreciation
during 2007 of approximately $12 million resulting from the impairment
discussed below. During the fourth quarter of 2006, we performed an asset
impairment analysis on our styrene production unit. This analysis was performed
due to recent industry forecasts, forecasted negative cash flow generated by our
styrene business over the next few years and the uncertainty surrounding the
ability of the North American styrene industry to successfully restructure. Our
management determined that a triggering event, as defined in SFAS No. 144,
had occurred and an asset impairment analysis was performed. We analyzed the
undiscounted cash flow stream from our styrene business over the next seven
years, which represented the remaining book life of our styrene assets, and
compared it to the $127.7 million net book carrying value of our styrene
unit and related assets. This analysis showed that the undiscounted projected
cash flow stream from our styrene business was less than the net book carrying
value of our styrene unit and related assets. As a result, we performed a
discounted cash flow analysis and subsequently concluded that our styrene unit
and related assets were impaired and should be written down to zero. This
write-down caused us to record an impairment of $127.7 million in December
2006.
Selling, general
& administrative expenses
Our selling, general and administrative
expenses were $11.8 million in 2007, compared to $8.3 million in 2006. This
increase in 2007 was largely due to the incurrence of over $1 million for
professional fees in connection with our pursuit of potential new business
opportunities and severance expense of $0.6 million.
Impairment of
long-lived assets
In 2007, we recorded $4.3 million
for the impairment of long-lived assets related to the shut down of our styrene
unit. During the fourth quarter of 2006, we performed an asset impairment
analysis on our styrene production unit and subsequently concluded that our
styrene unit and related assets were impaired, which resulted in an impairment
of $127.7 million in December 2006.
Other expense
(income)
Other income was $0.2 million in
2007, compared to $15.7 million for 2006. The other income recorded in 2007
was $1.1 million for amortization of deferred income relating to the
$60 million paid to us by NOVA under the styrene supply agreement and
related rail car purchase and sale agreement discussed above offset by other
expense of $0.8 million for the write-down of our cost-method investment in
an e-commerce commodity trading business to its fair value of less than
$0.2 million after receiving notice of a distribution pursuant to the
pending sale of the business. The other income recorded in 2006 primarily
consisted of the settlement of claims and payments received under our property
damage and business interruption insurance policies related to the fire that
occurred in our styrene unit in September 2005.
Interest and debt
related expenses, net of interest income
Our interest expense was
$15.7 million in 2007 and $10.1 million in 2006. The increase in 2007
was associated with higher debt levels after our debt refinancing that occurred
in the first quarter of 2007, partially offset by a $1.0 million increase
in interest income received as a result of higher average cash balances.
Provision
(benefit) for income taxes
During 2007, our effective tax rate was
negative 23% compared to 12% in 2006. Income tax benefit of $5.5 million in
2007 represents a $5.9 million tax benefit offset by $0.4 million of
federal alternative minimum tax and less than $0.1 million of state income
taxes. The 2007 effective rate of negative 23% resulted in a decrease in the
valuation allowance for other comprehensive income adjustments related to
amendments to our benefit plans and a full valuation allowance recorded against
our 2007 net loss. In 2006, the effective rate was impacted by a
$28 million increase in our valuation allowance as a result of our analysis
of the recoverability of our deferred tax assets at December 31, 2006.
Deferred tax assets are regularly assessed for recoverability based on both
historical and anticipated earnings levels, and a valuation allowance is
recorded when it is more likely than not that these amounts will not be
recovered. As a result of our analysis, we concluded that a valuation allowance
was needed against our deferred tax assets. As of December 31, 2007, our
valuation allowance was
29
$36.2 million, an
increase of $6.6 million from December 31, 2006, which resulted in an
overall net deferred tax asset/liability balance of zero as of December 31,
2007.
Comparison of
2006 to 2005
Revenues and loss from continuing operations
Our revenues were $665.9 million
in 2006, an increase of 4% over the $641.9 million in revenues we recorded
in 2005. This increase in revenues resulted primarily from an increase in acetic
acid and styrene sales prices. Gross profit increased to $11.2 million
during 2006 from a gross loss of $11.2 million in 2005. We recorded a net
loss from continuing operations of $104.7 million in 2006, compared to the net
loss of $18.5 million we recorded in 2005. This increase in net loss was
primarily due to the $127.7 million impairment charge to our styrene assets
that we recorded in 2006.
Revenues from acetic acid operations
were $96.7 million in 2006, a 12% increase over the $86.1 million in
revenues we recorded from these operations in 2005. This increase in revenues
was primarily due to increases in sales prices. Gross profit from our acetic
acid operations increased $5.0 million during 2006 compared to 2005. The
increase in gross profit was due to increased sales volumes and sales margins
during 2006, a one-time utility cost reimbursement of $2.4 million; along
with the $1.3 million favorable impact of the previously discussed
conversion to higher profit sharing under the Production Agreement that occurred
in August 2006, partially offset by the impact of the blend gas dispute
with BP Chemicals discussed in Part I, Item 3. “Legal Proceedings”.
Revenues from plasticizers operations
were $44.5 million in 2006, a 6% increase over the $42.0 million in
revenues we recorded from these operations in 2005. This increase was primarily
due to increases in cost reimbursements received from our customer. Gross profit
for our plasticizers business was essentially unchanged between these two
periods.
Revenues from our styrene operations
were $524.7 million in 2006, an increase of 2% over the $513.8 million
in revenues we recorded in 2005. Direct sales prices for styrene increased 10%
from those realized during 2005. Spot prices for styrene, a component of our
direct sales prices, ranged from $0.45 to $0.60 per pound during 2006, compared
to $0.44 to $0.62 per pound during 2005. Our total sales volumes for styrene in
2006 were 7% lower than in 2005. Gross loss from our styrene operations improved
$14.8 million during 2006 compared to 2005. This improvement was primarily
due to the increase in revenues discussed above partially offset by increases in
raw material costs and the impact of Hurricane Rita and the resulting fire in
our styrene facility in 2005. During 2006, prices for benzene, one of the
primary raw materials required for styrene production, increased 10% over the
prices we paid for benzene in 2005, and prices for ethylene, the other primary
raw material required for styrene production, increased 2% over the prices we
paid for ethylene in 2005. Average costs for natural gas, another major
component in the cost of manufacturing styrene, decreased 13% during 2006
compared to average natural gas costs during 2005. Margins on our styrene sales
in 2006 increased from those realized in 2005, primarily due to slightly
improved market conditions. Due to decreasing benzene and styrene prices from
December 2005 to January 2006, a lower-of-cost-or-market adjustment was
recorded totaling $2.7 million as of December 31, 2005. No such
adjustment was necessary as of December 31, 2006. During the fourth quarter
of 2006, we performed an asset impairment analysis on our styrene production
unit. This analysis was performed due to recent industry forecasts, forecasted
negative cash flow generated by our styrene business over the next few years and
the uncertainty surrounding the ability of the North American styrene industry
to successfully restructure. This analysis led us to conclude that our styrene
assets should be written down to zero. This write-down caused us to record an
impairment of $127.7 million in December 2006.
Other expense
(income)
We recorded other income of
$15.7 million in 2006, which primarily consisted of the recognition of
final settlement of our claims under our property damage and business
interruption insurance policies related to the September 2005 fire that
occurred in our styrene unit.
Provision
(benefit) for income taxes
During 2006, our effective tax rate was
12% compared to 37% in 2005. This change in the effective rate was the result of
a $28 million increase in the valuation allowance during 2006.
Loss from
discontinued operations, net of tax
We recorded a net loss from
discontinued operations of $1.0 million in 2006 compared to a loss of
$11.1 million in 2005. The $1.0 million loss in 2006 represents
closure costs related to our acrylonitrile business, partially offset by asset
sales related to that business. The loss of $11.1 million in 2005 included
costs of $9.0 million related to our exit from the acrylonitrile and
related derivatives businesses.
30
Liquidity and
Capital Resources
On March 1, 2007, we commenced an
offer, or our tender offer, to repurchase all $100.6 million of our
outstanding 10% Senior Secured Notes due 2007, or our Old Secured Notes.
Concurrently with our tender offer, we solicited consents from the holders of
our Old Secured Notes to, among other things, eliminate certain covenants
contained in the indenture governing our Old Secured Notes and related security
documents. On March 15, 2007, after receiving enough consents from the
holders of our Old Secured Notes, we and Sterling Chemicals Energy, Inc., or
Sterling Energy, one of our wholly-owned subsidiaries, and the trustee entered
into a supplemental indenture amending the indenture and the related security
documents to eliminate most of the restrictive covenants contained therein, as
well as certain events of default and repurchase rights. These amendments became
effective when we accepted for purchase the Old Secured Notes held by the
consenting holders pursuant to our tender offer and paid those holders an
aggregate of $0.1 million in consent fees. Our tender offer expired at
12:00 midnight, New York City time, on March 28, 2007. We accepted for
repurchase $58 million in aggregate principal amount of Old Secured Notes
which were validly tendered prior to the expiration of our tender offer, and we
repurchased those Old Secured Notes and paid the accrued interest thereon
together with the consent fee, on March 30, 2007. On March 27, 2007, we
issued a notice of redemption for all of our Old Secured Notes that were not
tendered pursuant to our tender offer and, on April 27, 2007, we purchased
those remaining Old Secured Notes for an aggregate amount equal to
$44 million, which included $1.5 million in accrued interest.
On March 26, 2007, we entered into
a purchase agreement, or the Purchase Agreement, with respect to the sale of
$150 million aggregate principal amount of unregistered 101/4% Senior Secured Notes due 2015, or our Secured
Notes, to Jefferies & Company, Inc. and CIBC World Markets Corp., as initial
purchasers. Sterling Energy was also a party to the Purchase Agreement as a
guarantor. On March 29, 2007, we completed a private offering of the
unregistered Secured Notes pursuant to the Purchase Agreement. In connection
with that offering, we entered into an indenture, dated March 29, 2007, among
us, Sterling Energy, as guarantor, and U.S. Bank National Association, as
trustee and collateral agent. On August 30, 2007, we made an initial filing
of an exchange offer registration statement to exchange our unregistered Secured
Notes for a new issue of substantially identical debt securities registered
under the Securities Act. Pursuant to a registration rights agreement among us,
Sterling Energy and the initial purchasers, we agreed to use commercially
reasonable efforts to cause the registration statement to become effective by
December 24, 2007, and complete the exchange offer within 50 days of
the effective date of the registration statement. However, as the registration
statement was not declared effective by December 24, 2007, the interest
rate on our Secured Notes increased by 0.25% per annum on December 25, 2007
and on March 24, 2008, and unless and until the registration statement is
declared effective, will increase by an additional 0.25% per annum at the
beginning of each subsequent 90-day period if such failure continues, subject to
a maximum increase of 1.0% per annum. As such, penalty interest is expected to
be between $0.1 million and $0.2 million depending upon the
effectiveness date of the registration statement, of which $0.1 million was
accrued as of December 31, 2007. All of this additional interest will cease
to accrue when the registration statement is declared effective.
Our indenture contains affirmative and
negative covenants and customary events of default, including payment defaults,
breaches of covenants and certain events of bankruptcy, insolvency and
reorganization. If an event of default, other than an event of default triggered
upon certain bankruptcy events, occurs and is continuing, the trustee under our
indenture or the holders of at least 25% in principal amount of the outstanding
Secured Notes may declare our Secured Notes to be due and payable immediately.
Upon an event of default, the trustee may also take actions to foreclose on the
collateral securing our outstanding Secured Notes, subject to the terms of an
intercreditor agreement dated March 29, 2007, among us, Sterling Energy,
the trustee and The CIT Group/Business Credit, Inc. Our indenture does not
require us to maintain any financial ratios or satisfy any financial maintenance
tests. We are in compliance with all of the covenants contained in our
indenture.
Interest is due on our outstanding
Secured Notes on April 1 and October 1 of each year, with our first interest
payment having been made on October 1, 2007. Additional interest of 0.25%
per annum is currently accruing on our outstanding Secured Notes as a result of
our failure to have the registration statement declared effective by
December 24, 2007, as discussed above. Our outstanding Secured Notes, which
mature on April 1, 2015, are senior secured obligations and rank equally in
right of payment with all of our existing and future senior indebtedness.
Subject to specified permitted liens, our outstanding Secured Notes are secured
(i) on a first priority basis by all of our and Sterling Energy’s fixed
assets and certain related assets, including, without limitation, all property,
plant and equipment, and (ii) on a second priority basis by all of our and
Sterling Energy’s other assets, including, without limitation, accounts
receivable, inventory, capital stock of our domestic restricted subsidiaries
(including Sterling Energy), intellectual property, deposit accounts and
investment property.
31
On December 19, 2002, we entered
into a Revolving Credit Agreement, or our revolving credit facility, with The
CIT Group/Business Credit, Inc., as administrative agent and a lender, and
certain other lenders. Our revolving credit facility had an initial term ending
on September 19, 2007. Under our revolving credit facility, we and Sterling
Energy are co-borrowers and are jointly and severally liable for any
indebtedness thereunder. Our revolving credit facility is secured by first
priority liens on all of our accounts receivable, inventory and other specified
assets, as well as all of the issued and outstanding capital stock of Sterling
Energy. On March 29, 2007, we amended and restated our revolving credit
facility to, among other things, extend the term of our revolving credit
facility until March 29, 2012, reduce the maximum commitment thereunder to
$50 million, make certain changes to the calculation of the borrowing base
and lower the interest rates and fees charged thereunder. Borrowings under our
revolving credit facility now bear interest, at our option, at an annual rate of
either a base rate plus 0.0% to 0.50% or the LIBOR rate plus 1.50% to 2.25%,
depending on our borrowing availability at the time. We are also required to pay
an aggregate commitment fee of 0.375% per year (payable monthly) on any unused
portion. Available credit under our revolving credit facility is subject to a
monthly borrowing base of 85% of eligible accounts receivable plus 65% of
eligible inventory. As of December 31, 2007, our borrowing base exceeded
the maximum commitment under our revolving credit facility, making the total
credit available under our revolving credit facility $50 million. However,
the monetization of accounts receivable and inventory associated with our exit
from the styrene business is expected to significantly decrease the borrowing
base under our revolving credit facility with the total credit available
expected to be between $10 million and $20 million (after giving
effect to our outstanding letters of credit) after the collection of outstanding
styrene receivables. As of December 31, 2007, there were no loans
outstanding under our revolving credit facility, and we had $12 million in
letters of credit outstanding, resulting in borrowing availability of
$38 million. Pursuant to Emerging Issues Task Force Issue No. 95-22,
“Balance Sheet Classification of Borrowings under Revolving Credit Agreements
That Include both a Subjective Acceleration Clause and a Lock-Box Arrangement,”
any balances outstanding under our revolving credit facility are classified as a
current portion of long-term debt.
Our revolving credit facility contains
numerous covenants and conditions, including, but not limited to, restrictions
on our ability to incur indebtedness, create liens, sell assets, make
investments, make capital expenditures, engage in mergers and acquisitions and
pay dividends. Our revolving credit facility also includes various circumstances
and conditions that would, upon their occurrence and subject in certain cases to
notice and grace periods, create an event of default thereunder. Our revolving
credit facility does not require us to maintain any financial ratios or satisfy
any financial maintenance tests. We are in compliance with all of the covenants
contained in our revolving credit facility.
Our liquidity (i.e., cash and cash
equivalents plus total credit available under our revolving credit facility) was
$138 million at December 31, 2007, an increase of $47 million
compared to our liquidity at December 31, 2006. This increase was primarily
due to the $60 million INEOS NOVA payment. We believe that our cash on
hand, credit available under our revolving credit facility and the increase in
liquidity resulting from the continued working capital reduction due to the
shutdown of our styrene plant, will be sufficient to meet our short-term and
long-term liquidity needs for the reasonably foreseeable future. We continue to
pursue our strategic growth initiatives and are currently exploring
opportunities which may require additional capital requirements beyond our
contribution of certain of our assets and management expertise and are currently
evaluating these projects and their required capital investment. We believe the
short payments on the blend gas credit dispute with BP Chemicals which is
approximately $0.3 million per month and $5.6 million in the aggregate
as of December 31, 2007, have not had nor will have a significant impact on
our liquidity.
Working
Capital
Our working capital, excluding assets
and liabilities from discontinued operations, was $166.5 million as of
December 31, 2007, an increase of $69.7 million from December 31,
2006. This increase in working capital resulted primarily from the
$60 million payment received from INEOS NOVA, an increase in accounts
receivable and a decrease in current liabilities, partially offset by a decrease
in inventories.
Cash
Flow
Net cash provided by our operations was
$44.3 million in 2007, compared to the net cash used in our operations of
$14.2 million in 2006. This improvement in net cash flow in 2007 was
primarily driven by the cash payment received from INEOS NOVA discussed above
and a portion of the monetization of the styrene-related working capital as we
shut down the styrene unit during the fourth quarter of 2007.
Net cash flow used in our investing
activities was $6.2 million and $7.3 million in 2007 and 2006,
respectively. In 2007, the $6.2 million was primarily for capital
expenditures, whereas 2006 included insurance proceeds of $2.0 million
32
and proceeds from the
sale of fixed assets of $3.0 million, which partially offset the
$11.5 million of capital expenditures.
Net cash provided by financing
activities was $41.4 million in 2007 compared to zero in 2006, and was due
to our debt refinancing discussed above.
Net cash used in our operations was
$14.2 million in 2006, compared to net cash provided by our operations of
$68 million in 2005. This reduction in net cash flow provided by our
operations in 2006 was primarily driven by an increase in accounts receivable
and inventories due to an increase in styrene production and sales volumes. As
of December 31, 2005, styrene production and sales volumes were negatively
affected by a fire in our styrene unit which resulted in partial closure of our
styrene unit while repairs were being conducted.
Net cash flow used in our investing
activities was $7 million in 2006 and $10 million in 2005. Cash flows
from investing activities in 2006 included insurance proceeds of $2 million
and proceeds from the sale of fixed assets of $3 million.
There were no net repayments under our
revolving credit facility during 2006 compared to $18 million of net repayments
in 2005.
Capital
Expenditures
Our capital expenditures were
$6.4 million in 2007, $11.5 million in 2006 and $9.5 million in
2005. Capital expenditures are expected to be approximately $7 million in
2008. These capital expenditures will be primarily for routine safety,
environmental and replacement capital.
Our capital expenditures for
environmentally related prevention, containment and process improvements were
$0.5 million in 2007 and $2 million in both 2006 and 2005. We
anticipate spending approximately $4 million on these types of expenditures
during 2008.
Contractual Cash
Obligations
The following table summarizes our
significant contractual obligations at December 31, 2007, and the effect
such obligations are expected to have on our liquidity and cash flows in future
periods:
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Less than 1 |
|
|
|
|
|
|
|
|
|
More than |
|
|
| |
|
year(1) |
|
1-3 years |
|
4-5 years |
|
5 years |
|
Total |
| |
|
(Dollars in Thousands) |
|
Secured Notes |
|
$ |
— |
|
|
$ |
— |
|
|
$ |
— |
|
|
$ |
150,000 |
|
|
$ |
150,000 |
|
|
Interest payments on
debt(2) |
|
|
15,690 |
|
|
|
46,638 |
|
|
|
31,092 |
|
|
|
23,319 |
|
|
|
116,739 |
|
|
Operating
leases |
|
|
293 |
|
|
|
879 |
|
|
|
513 |
|
|
|
— |
|
|
|
1,685 |
|
|
Purchase
obligations(3) |
|
|
35,000 |
|
|
|
70,000 |
|
|
|
64,000 |
|
|
|
117,000 |
|
|
|
286,000 |
|
|
Pension and other
postretirement benefits |
|
|
4,458 |
|
|
|
2,346 |
|
|
|
2,279 |
|
|
|
4,959 |
|
|
|
14,042 |
|
|
Contractual obligations
of discontinued operations |
|
|
325 |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
325 |
|
| |
|
|
|
Total(4)(5) |
|
$ |
55,766 |
|
|
$ |
119,863 |
|
|
$ |
97,884 |
|
|
$ |
295,278 |
|
|
$ |
568,791 |
|
| |
|
|
|
|
|
| (1) |
|
Payment obligations under our revolving credit facility are not
presented because there were no outstanding borrowings as of
December 31, 2007, and interest payments fluctuate depending on the
interest rate and outstanding balance under our revolving credit facility
at any point in time. |
| |
| (2) |
|
On December 24, 2007, the interest rate on our Secured Notes
increased by 0.25% per annum because our registration statement to
exchange our unregistered Secured Notes for registered secured notes
having the same terms and conditions had not been declared effective by
the SEC, and will increase by an additional 0.25% per annum on
March 22, 2008 and at the beginning of each subsequent 90-day period
if such failure continues, subject to a maximum increase of 1.0% per
annum. As such, penalty interest is expected to be between
$0.1 million and $0.2 million depending upon the effectiveness
date of the registration statement, of which $0.1 million was accrued
as of December 31, 2007. |
33
|
|
|
| (3) |
|
For the purposes of this table, we have considered contractual
obligations for the purchase of goods or services as agreements involving
more than $1 million that are enforceable and legally binding and
that specify all significant terms, including: fixed or minimum quantities
to be purchased, fixed, minimum or variable price provisions and the
approximate timing of the transaction. Most of the purchase obligations
identified include variable pricing provisions. We have estimated the
future prices of these items, utilizing forward curves where available.
The pricing estimated for use in this table is subject to market
risk. |
| |
| (4) |
|
Our Series A Preferred Stock is excluded from our contractual
cash obligations as it is not currently redeemable or probable of
redemption. If the Series A Preferred Stock had been redeemable as of
December 31, 2007, the redemption amount would have been
approximately $83.9 million. The liquidation value of our
Series A Preferred Stock as of December 31, 2007 is
$66.1 million. |
| |
| (5) |
|
Unrecognized tax benefits are not included in the table due to the
high degree of uncertainty associated with the realization of our net
operating loss carryforward. |
Critical Accounting
Policies, Use of Estimates and Assumptions
A summary of our significant accounting
policies is included in Note 1 of the “Notes to Consolidated Financial
Statements” included in Item 8, Part II of this Form 10-K. We believe
that the consistent application of these policies enables us to provide readers
of our financial statements with useful and reliable information about our
operating results and financial condition. The following accounting policies are
the ones we believe are the most important to the portrayal of our financial
condition and results and require our most difficult, subjective or complex
judgments.
Revenue
Recognition
We generate revenues through a profit
sharing arrangement with respect to our acetic acid operations and these
revenues are estimated and accrued monthly. We generate revenues from our
plasticizers operations through a tolling agreement. Deferred credits are
amortized over the life of the contracts which gave rise to them. As of
December 31, 2007 and 2006, we had a balance in deferred income of
approximately $70 million and $10 million, respectively. For 2007, the
$70 million balance primarily consisted of approximately $59 million of
deferred income pertaining to the NOVA supply agreement discussed above that is
being amortized using the straight-line method over the contractual non-compete
period of five years and is reflected in other income, and $6 million which
represents certain payments received for our oxo-alcohol operations, which were
part of our plasticizers business, that are being amortized on a straight-line
method over the remaining life of the contract of six years. As of
December 31, 2006, the $10 million balance in deferred income
primarily consisted of $7 million pertaining to the oxo-alcohols payments
referred to above. Styrene revenue was recognized from sales in the open market,
raw materials conversion agreements and long-term supply contracts at the time
the products were shipped and title passed, the price was fixed and determinable
and collectibility was reasonably assured. Styrene revenue (and corresponding
cost of sales) from raw materials conversion agreements were recognized on a
gross basis and does not include raw material components supplied by our
customers.
Inventories
Inventories are carried at the
lower-of-cost-or-market value. Cost is primarily determined on a first-in,
first-out basis, except for stores and supplies, which are valued at average
cost. The comparison of cost to market value involves estimation of the market
value of our products. For the years ended December 31, 2007, 2006 and
2005, this comparison led to a lower-of-cost-or-market adjustment of
$1.4 million, zero and $2.7 million, respectively. The adjustments in
2007 and 2005 were due to decreasing benzene and styrene prices from December to
January during each period. Prior to exiting the styrene business, we entered
into agreements with other companies to exchange chemical inventories in order
to minimize working capital requirements and to facilitate distribution
logistics. Balances related to quantities due to or payable by us in connection
with these exchange agreements are included in inventory. However, we do not
expect to have any significant exchange balances or activity subsequent to 2007.
Preferred stock
dividends
We record preferred stock dividends on
our Series A Convertible Preferred Stock, or our Series A Preferred Stock,
in our consolidated statements of operations based on the estimated fair value
of dividends at each dividend accrual date. Our Series A Preferred Stock
has a dividend rate of 4% per quarter of the liquidation value of the
outstanding shares of our Series A Preferred Stock, and is payable in
arrears in additional shares of our Series A Preferred Stock on the first
business day of each calendar quarter. The liquidation value of each share of
our Series A Preferred Stock is $13,793.11 per share, and each share of
Series A Preferred Stock is convertible into shares of our common stock (on
a one to 1,000 share basis, subject to adjustment). The carrying value of our
redeemable preferred stock in our consolidated balance sheets represents the
cumulative balance of the initial fair value at original issuance in 2002 plus
the fair value of each of the quarterly dividends paid since issuance.
34
The fair value of our
preferred stock dividends is determined each quarter using valuation techniques
that include a component representing the intrinsic value of the dividends
(which represents the greater of the liquidation value of the preferred shares
being issued or the fair value of the common stock into which the shares could
be converted) and an option component (which is determined using a Black-Scholes
Option Pricing Model). These dividends are recorded in our consolidated
statements of operations, with an offset to redeemable preferred stock in our
consolidated balance sheets. As we are in an accumulated deficit position, these
dividends are treated as a reduction to additional paid-in capital. Assumptions
utilized in the Black-Scholes model include:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
2007 |
|
2006 |
|
2005 |
| |
|
|
|
Risk-free interest
rate |
|
|
3.5 |
% |
|
|
4.7 |
% |
|
|
4.4 |
% |
|
Volatility |
|
|
55.5 |
% |
|
|
46.2 |
% |
|
|
50.3 |
% |
|
Dividend yield |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
Expected term |
|
|
5.0 |
|
|
|
5.0 |
|
|
|
5.0 |
|
Long-Lived
Assets
We assess our long-lived assets for
impairment whenever facts and circumstances indicate that the carrying amount
may not be fully recoverable. To analyze recoverability, we project undiscounted
net future cash flows over the remaining life of the assets. If the projected
cash flows from the assets are less than the carrying amount, an impairment
would be recognized. Any impairment loss would be measured based upon the
difference between the carrying amount and the fair value of the relevant
assets. For these impairment analyses, impairment is determined by comparing the
estimated fair value of these assets, utilizing the present value of expected
net cash flows, to the carrying value of these assets. In determining the
present value of expected net cash flows, we estimate future net cash flows from
these assets and the timing of those cash flows and then apply a discount rate
to reflect the time value of money and the inherent uncertainty of those future
cash flows. The discount rate we use is based on our estimated cost of capital.
The assumptions we use in estimating future cash flows are consistent with our
internal planning.
Income
Taxes
Deferred income taxes are provided for
revenue and expenses which are recognized in different periods for income tax
and financial statement purposes. Deferred tax assets are regularly assessed for
recoverability based on both historical and anticipated earnings levels, and a
valuation allowance is recorded when it is more likely than not that these
amounts will not be recovered. As a result of our analysis, we concluded that a
valuation allowance was needed against our deferred tax assets. As of
December 31, 2007, our valuation allowance was $36.2 million, an
increase of $6.6 million from December 31, 2006, which resulted in an
overall net deferred tax asset/liability balance of zero as of December 31,
2007. In July 2006, the Financial Accounting Standards Board, or the FASB,
issued FASB Interpretation No. 48, “Accounting for Uncertainty in Income
Taxes–an interpretation of FASB Statement No. 109,” or FIN 48, to clarify the
accounting for uncertain tax positions accounted for in accordance with FASB
Statement No. 109, “Accounting for Income Taxes.” This interpretation
prescribes a two-step approach for recognizing and measuring tax benefits and
requires explicit disclosure of any uncertain tax position. We adopted the
provisions of FIN 48 as of January 1, 2007, which had no impact on our
accumulated deficit.
Employee Benefit
Plans
We sponsor domestic defined benefit
pension and other postretirement plans. Major assumptions used in the accounting
for these employee benefit plans include the discount rate, expected return on
plan assets and health care cost increase projections. Assumptions are
determined based on our historical data and appropriate market indicators, and
are evaluated each year as of the plans’ measurement dates. A change in any of
these assumptions would have an effect on net periodic pension and
postretirement benefit costs reported in our financial statements. As mentioned
below, in accordance with SFAS No. 158, “Employers’ Accounting for Defined
Benefit Pension and Other Postretirement Plans,” as of our fiscal year-ended
December 31, 2006, we recognized the funded status of our defined benefit
postretirement plans in our balance sheet and provided the required disclosures.
We also measured the assets and benefit obligations of our defined benefit
postretirement plans as of December 31, 2006. The effect of the adoption of
SFAS 158 was a reduction in our liabilities of $10 million and a change in
stockholders’ equity (deficiency in assets), net of tax, of $7 million.
Effective July 1, 2007, we froze
all accruals under our defined benefit pension plan for our hourly employees,
which resulted in a plan curtailment under SFAS No. 88 “Employers’
Accounting for Settlement and Curtailments of Defined Benefit Pension Plans and
for Termination Benefits.” As a result, we recorded a pre-tax curtailment gain
of $0.1 million in the second quarter of 2007. During the third quarter of
2007, we approved an amendment (to be effective December 31, 2007) to our
postretirement medical plan which ended Medicare-supplemental medical and
prescription drug coverage for retirees who are Medicare eligible. This
amendment affects the majority of participants currently enrolled in the
Sterling Retiree Medical Plan who are either enrolled in Medicare due to
disability or because they are 65 or over, and was communicated to the
participants during the third quarter of 2007. This plan amendment reduced our
other postretirement benefit plan liability by $13 million with a
corresponding increase to accumulated other comprehensive income.
35
Plant Turnaround
Costs
As a part of normal recurring
operations, each of our manufacturing units is completely shut down from time to
time, for a period typically lasting two to four weeks, to replace catalysts and
perform major maintenance work required to sustain long-term production. These
periods are commonly referred to as “turnarounds” or “shutdowns.” Costs of
turnarounds are expensed as incurred. As expenses for turnarounds can be
significant, the impact of expensing turnaround costs as they are incurred can
be material for financial reporting periods during which the turnarounds
actually occur. Turnaround costs expensed during 2007, 2006 and 2005 were less
than $0.1 million, $10 million and $4 million, respectively.
New Accounting
Standards
In September 2006, the FASB issued
SFAS No. 157, “Fair Value Measurements,” or SFAS No. 157. This
statement establishes a framework for measuring fair value in generally accepted
accounting principles and expands disclosures about fair value measurements for
financial assets and liabilities, as well as for any other assets and
liabilities that are carried at fair value on a recurring basis in financial
statements. SFAS No. 157 is effective for financial statements issued for
fiscal years beginning after November 15, 2007, and interim periods within
those fiscal years. There is a one year deferral for the implementation of SFAS
No. 157 for other non-financial assets and liabilities. We will adopt SFAS
No. 157 beginning January 1, 2008. We are currently evaluating the
impact on our consolidated financial statements.
In February 2007, the FASB issued
SFAS No. 159, “The Fair Value Option for Financial Assets and Financial
Liabilities,” or SFAS No. 159. SFAS No. 159, which amends SFAS
No. 115, “Accounting for Certain Investments in Debt and Equity
Securities,” allows certain financial assets and liabilities to be recognized,
at our election, at fair market value, with any gains or losses for the period
recorded in the statement of operations. SFAS No. 159 is effective
for fiscal years beginning after November 15, 2007, and we do not believe
it will have a material impact on our financial statements.
In December 2007, the FASB issued
SFAS No. 141 (revised 2007), “Business Combinations,” or SFAS 141R. SFAS
141R broadens the guidance of SFAS 141, extending its applicability to all
transactions and other events in which one entity obtains control over one or
more other businesses. It broadens the fair value measurement and recognition of
assets acquired, liabilities assumed, and interests transferred as a result of
business combinations. SFAS 141R expands on required disclosures to improve the
statement users’ abilities to evaluate the nature and financial effects of
business combinations. SFAS 141R is effective for fiscal years beginning after
December 15, 2008. We do not expect the adoption of SFAS 141R to have a material
impact on our financial statements.
In December 2007, the FASB issued
SFAS No. 160, “Noncontrolling Interests in Consolidated Financial
Statements; an amendment of ARB No. 51,” or SFAS No. 160. This
statement establishes the accounting and reporting standards for a
noncontrolling interest in a subsidiary and for the deconsolidation of a
subsidiary. This statement clarifies that a noncontrolling interest in a
subsidiary is an ownership interest in the consolidated entity that should be
reported as equity in the consolidated financial statements. SFAS No. 160
requires retroactive adoption of the presentation and disclosure requirements
for existing minority interests and applies prospectively to business
combinations for fiscal years beginning after December 15, 2008 and will
not have a material impact on our financial statements.
In March 2008, the FASB issued
SFAS No. 161, “Disclosures About Derivative Instruments and Hedging
Activities,” or SFAS No. 161. This statement requires enhanced disclosures
about an entity’s derivative and hedging activities, with the intent to provide
users of financial statements with an enhanced understanding of (a) how and
why an entity uses derivative instruments, (b) how derivative instruments
and related hedged items are accounted for under SFAS No. 133, “Accounting
for Derivative Instruments and Hedging Activities ”and its related
interpretations and (c) how derivative instruments and related hedged items
affect an entity’s financial position, financial performance and cash flows.
SFAS No. 161 is effective for fiscal years beginning after
November 15, 2008. We are currently evaluating the impact on our
consolidated financial statements.
36
Item 7A.
Quantitative and Qualitative Disclosures about Market Risk
The table below provides information
about our market sensitive financial instruments and constitutes a
“forward-looking statement.”
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Expected Maturity Dates |
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fair Value |
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December |
| |
|
2008 |
|
2009 |
|
2010 |
|
2011 |
|
2012 |
|
Thereafter |
|
Total |
|
31, 2007 |
| |
|
(Dollars in Thousands) |
|
Liability |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Secured Notes |
|
$ |
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
150,000 |
|
|
$ |
150,000 |
|
|
$ |
152,250 |
|
The fair value of our Secured Notes is
based on broker quotes for private transactions.
37
Item 8.
Financial Statements and Supplementary Data
INDEX TO
FINANCIAL STATEMENTS
Sterling Chemicals,
Inc.
38
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF
OPERATIONS
(Dollars in Thousands, Except Share
Data)
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year ended December 31, |
|
| |
|
|
|
|
|
2006 (As Restated, |
|
|
2005 (As Restated, |
|
| |
|
2007 |
|
|
see Note 16) |
|
|
see Note 16) |
|
| |
|
|
|
Revenues |
|
$ |
811,326 |
|
|
$ |
665,923 |
|
|
$ |
641,886 |
|
|
Cost of goods
sold |
|
|
801,752 |
|
|
|
654,718 |
|
|
|
653,134 |
|
| |
|
|
|
Gross profit
(loss) |
|
|
9,574 |
|
|
|
11,205 |
|
|
|
(11,248 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Selling, general and
administrative expenses |
|
|
11,843 |
|
|
|
8,347 |
|
|
|
7,811 |
|
|
Impairment of
long-lived assets |
|
|
4,288 |
|
|
|
127,653 |
|
|
|
— |
|
|
Other income |
|
|
(225 |
) |
|
|
(15,724 |
) |
|
|
— |
|
|
Interest and debt
related expenses (net of interest income of $1,607, $601 and $679,
respectively)
|
|
|
15,706 |
|
|
|
10,079 |
|
|
|
10,090 |
|
| |
|
|
|
Loss from continuing
operations before income tax |
|
|
(22,038 |
) |
|
|
(119,150 |
) |
|
|
(29,149 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Benefit for income
taxes |
|
|
(5,503 |
) |
|
|
(14,488 |
) |
|
|
(10,641 |
) |
| |
|
|
|
Loss from continuing
operations |
|
|
(16,535 |
) |
|
|
(104,662 |
) |
|
|
(18,508 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from discontinued
operations, net of tax |
|
|
(2,393 |
) |
|
|
(997 |
) |
|
|
(11,060 |
) |
| |
|
|
|
Net loss |
|
|
(18,928 |
) |
|
|
(105,659 |
) |
|
|
(29,568 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Preferred stock
dividends |
|
|
17,550 |
|
|
|
11,774 |
|
|
|
16,984 |
|
| |
|
|
|
Net loss attributable
to common stockholders |
|
$ |
(36,478 |
) |
|
$ |
(117,433 |
) |
|
$ |
(46,552 |
) |
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss per share of
common stock attributable to common stockholders, basic and
diluted: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from continuing
operations |
|
$ |
(12.05 |
) |
|
$ |
(41.17 |
) |
|
$ |
(12.55 |
) |
|
Loss from discontinued
operations |
|
|
(0.85 |
) |
|
|
(0.35 |
) |
|
|
(3.91 |
) |
| |
|
|
|
Net loss per share,
basic and diluted |
|
$ |
(12.90 |
) |
|
$ |
(41.52 |
) |
|
$ |
(16.46 |
) |
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average shares
outstanding: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic and
diluted |
|
|
2,828,460 |
|
|
|
2,828,460 |
|
|
|
2,827,795 |
|
The accompanying
notes are an integral part of the consolidated financial statements.
39
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED BALANCE
SHEETS
(Dollars in Thousands, Except Share
Data)
| |
|
|
|
|
|
|
|
|
| |
|
December 31, |
|
| |
|
|
|
|
|
2006 (As |
|
| |
|
|
|
|
|
Restated, |
|
| |
|
2007 |
|
|
see Note 16) |
|
|
ASSETS |
|
|
|
|
|
|
|
|
|
Current
assets: |
|
|
|
|
|
|
|
|
|
Cash and cash
equivalents |
|
$ |
100,183 |
|
|
$ |
20,690 |
|
|
Accounts receivable,
net of allowance of $39 and $367, respectively |
|
|
85,152 |
|
|
|
63,289 |
|
|
Inventories,
net |
|
|
20,753 |
|
|
|
62,078 |
|
|
Prepaid expenses and
other current assets |
|
|
3,129 |
|
|
|
3,215 |
|
|
Deferred tax
asset |
|
|
5,029 |
|
|
|
3,044 |
|
|
Assets of discontinued
operations |
|
|
— |
|
|
|
20 |
|
|
|
|
|
|
|
|
|
|
Total current
assets |
|
|
214,246 |
|
|
|
152,336 |
|
|
|
|
|
|
|
|
|
|
|
|
Property, plant and
equipment, net |
|
|
77,677 |
|
|
|
83,833 |
|
|
Other assets,
net |
|
|
14,521 |
|
|
|
9,654 |
|
|
|
|
|
|
|
|
|
|
Total assets |
|
$ |
306,444 |
|
|
$ |
245,823 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
LIABILITIES AND
STOCKHOLDERS’ DEFICIENCY IN ASSETS |
|
|
|
|
|
|
|
|
|
Current
liabilities: |
|
|
|
|
|
|
|
|
|
Accounts
payable |
|
$ |
17,078 |
|
|
$ |
39,123 |
|
|
Accrued
liabilities |
|
|
30,629 |
|
|
|
16,316 |
|
|
Liabilities of
discontinued operations |
|
|
325 |
|
|
|
217 |
|
|
|
|
|
|
|
|
|
|
Total current
liabilities |
|
|
48,032 |
|
|
|
55,656 |
|
|
|
|
|
|
|
|
|
|
|
|
Long-term debt |
|
|
150,000 |
|
|
|
100,579 |
|
|
Deferred income tax
liability |
|
|
5,029 |
|
|
|
— |
|
|
Deferred credits and
other liabilities |
|
|
77,604 |
|
|
|
55,847 |
|
|
Commitments and
contingencies (Note 9) |
|
|
|
|
|
|
|
|
|
Redeemable preferred
stock |
|
|
99,866 |
|
|
|
82,316 |
|
|
Stockholders’
equity: |
|
|
|
|
|
|
|
|
|
Common stock, $.01 par
value (shares authorized 20,000,000; shares issued and outstanding
2,828,460) |
|
|
28 |
|
|
|
28 |
|
|
Additional paid-in
capital |
|
|
141,174 |
|
|
|
158,691 |
|
|
Accumulated
deficit |
|
|
(232,542 |
) |
|
|
(213,614 |
) |
|
Accumulated other
comprehensive income |
|
|
17,253 |
|
|
|
6,320 |
|
|
|
|
|
|
|
|
|
|
Total stockholders’
deficiency in assets |
|
|
(74,087 |
) |
|
|
(48,575 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total liabilities and
stockholders’ deficiency in assets |
|
$ |
306,444 |
|
|
$ |
245,823 |
|
|
|
|
|
|
|
|
|
The accompanying
notes are an integral part of the consolidated financial statements.
40
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS
OF
CHANGES IN STOCKHOLDERS’ EQUITY
(DEFICIENCY IN ASSETS)
(Amounts in Thousands)
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accumulated |
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
Additional |
|
|
|
|
|
|
Other |
|
|
|
|
| |
|
Common Stock |
|
|
Paid-In |
|
|
Accumulated |
|
|
Comprehensive |
|
|
|
|
| |
|
Shares |
|
|
Amount |
|
|
Capital |
|
|
Deficit |
|
|
Income (Loss) |
|
|
Total |
|
|
Balance,
December 31, 2004 (As reported) |
|
|
2,825 |
|
|
$ |
28 |
|
|
$ |
199,408 |
|
|
$ |
(78,387 |
) |
|
$ |
(966 |
) |
|
$ |
120,083 |
|
|
Prior period adjustment
(see Note 16) |
|
|
— |
|
|
|
— |
|
|
|
(12,270 |
) |
|
|
— |
|
|
|
— |
|
|
|
(12,270 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance,
January 1, 2005 (As restated, see Note 16) |
|
|
2,825 |
|
|
$ |
28 |
|
|
$ |
187,138 |
|
|
$ |
(78,387 |
) |
|
$ |
(966 |
) |
|
$ |
107,813 |
|
|
Comprehensive
loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
(29,568 |
) |
|
|
— |
|
|
|
|
|
|
Other comprehensive
loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension adjustment, net
of tax of $(1,846) |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
(3,373 |
) |
|
|
|
|
|
Comprehensive
loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(32,941 |
) |
|
Preferred stock
dividends (as restated, see Note 16) |
|
|
— |
|
|
|
— |
|
|
|
(16,984 |
) |
|
|
— |
|
|
|
— |
|
|
|
(16,984 |
) |
|
Exercised stock
options |
|
|
3 |
|
|
|
— |
|
|
|
157 |
|
|
|
— |
|
|
|
— |
|
|
|
157 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance,
December 31, 2005 (As restated, see Note 16) |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
170,311 |
|
|
$ |
(107,955 |
) |
|
$ |
(4,339 |
) |
|
$ |
58,045 |
|
|
Comprehensive
loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
(105,659 |
) |
|
|
— |
|
|
|
|
|
|
Other comprehensive
loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Benefit adjustment, net
of tax of $2,249 |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
3,903 |
|
|
|
|
|
|
Comprehensive
loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(101,756 |
) |
|
SFAS 158 adoption, net
of tax of $3,719 |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
6,756 |
|
|
|
6,756 |
|
|
Preferred stock
dividends (as restated, see Note 16) |
|
|
— |
|
|
|
— |
|
|
|
(11,774 |
) |
|
|
— |
|
|
|
— |
|
|
|
(11,774 |
) |
|
Stock-based
compensation |
|
|
— |
|
|
|
— |
|
|
|
154 |
|
|
|
— |
|
|
|
— |
|
|
|
154 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance,
December 31, 2006 (As restated, see Note 16) |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
158,691 |
|
|
$ |
(213,614 |
) |
|
$ |
6,320 |
|
|
$ |
(48,575 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Comprehensive
loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
(18,928 |
) |
|
|
— |
|
|
|
|
|
|
Other comprehensive
loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Benefit adjustment, net
of tax of $5,887 |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
10,933 |
|
|
|
|
|
|
Comprehensive
loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(7,995 |
) |
|
Preferred stock
dividends |
|
|
— |
|
|
|
— |
|
|
|
(17,550 |
) |
|
|
— |
|
|
|
— |
|
|
|
(17,550 |
) |
|
Stock-based
compensation |
|
|
— |
|
|
|
— |
|
|
|
33 |
|
|
|
— |
|
|
|
— |
|
|
|
33 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance,
December 31, 2007 |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
141,174 |
|
|
$ |
(232,542 |
) |
|
$ |
17,253 |
|
|
$ |
(74,087 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The accompanying
notes are an integral part of the consolidated financial statements.
41
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF CASH
FLOWS
(Dollars in Thousands)
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year ended December 31, |
|
| |
|
2007 |
|
|
2006 |
|
|
2005 |
|
| |
|
|
|
Cash flows from
operating activities: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(18,928 |
) |
|
$ |
(105,659 |
) |
|
$ |
(29,568 |
) |
|
Adjustments to
reconcile net loss to net cash provided by (used in) operating
activities: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Bad debt
benefit |
|
|
(213 |
) |
|
|
(571 |
) |
|
|
(2,133 |
) |
|
Depreciation and
amortization |
|
|
10,908 |
|
|
|
30,476 |
|
|
|
33,342 |
|
|
Interest
amortization |
|
|
933 |
|
|
|
400 |
|
|
|
400 |
|
|
Unearned income
amortization |
|
|
(1,064 |
) |
|
|
— |
|
|
|
— |
|
|
Impairment of
long-lived assets |
|
|
4,288 |
|
|
|
127,653 |
|
|
|
— |
|
|
Lower-of-cost-or-market
adjustment |
|
|
1,363 |
|
|
|
— |
|
|
|
2,738 |
|
|
Deferred tax
benefit |
|
|
— |
|
|
|
(8,438 |
) |
|
|
(18,905 |
) |
|
Gain on disposal of
property, plant and equipment |
|
|
(182 |
) |
|
|
(4,917 |
) |
|
|
— |
|
|
Other |
|
|
1,066 |
|
|
|
154 |
|
|
|
156 |
|
|
Change in
assets/liabilities: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Accounts
receivable |
|
|
(21,630 |
) |
|
|
(4,514 |
) |
|
|
56,983 |
|
|
Inventories |
|
|
39,933 |
|
|
|
(22,608 |
) |
|
|
45,772 |
|
|
Prepaid
expenses |
|
|
86 |
|
|
|
1,673 |
|
|
|
(690 |
) |
|
Other assets |
|
|
(2,160 |
) |
|
|
(2,105 |
) |
|
|
(1,003 |
) |
|
Accounts
payable |
|
|
(21,933 |
) |
|
|
(4,140 |
) |
|
|
(23,348 |
) |
|
Accrued
liabilities |
|
|
18,106 |
|
|
|
(10,314 |
) |
|
|
4,396 |
|
|
Other
liabilities |
|
|
33,754 |
|
|
|
(11,298 |
) |
|
|
(33 |
) |
| |
|
|
|
Net cash provided by
(used in) operating activities |
|
|
44,327 |
|
|
|
(14,208 |
) |
|
|
68,107 |
|
| |
|
|
|
Cash flows used in
investing activities: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Capital expenditures
for property, plant and equipment |
|
|
(6,411 |
) |
|
|
(11,547 |
) |
|
|
(9,460 |
) |
|
Insurance proceeds
relating to property, plant and equipment |
|
|
— |
|
|
|
1,960 |
|
|
|
— |
|
|
Cash used for
dismantling |
|
|
— |
|
|
|
(669 |
) |
|
|
(667 |
) |
|
Net proceeds from the
sale of property, plant and equipment |
|
|
182 |
|
|
|
2,957 |
|
|
|
— |
|
| |
|
|
|
Net cash used in
investing activities |
|
|
(6,229 |
) |
|
|
(7,299 |
) |
|
|
(10,127 |
) |
| |
|
|
|
Cash flows provided by
(used in) financing activities: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Repayment of Old
Secured Notes |
|
|
(100,579 |
) |
|
|
— |
|
|
|
— |
|
|
Proceeds from the
issuance of Secured Notes |
|
|
150,000 |
|
|
|
— |
|
|
|
— |
|
|
Debt issuance
costs |
|
|
(8,026 |
) |
|
|
— |
|
|
|
— |
|
|
Net repayments under
the revolving credit facility |
|
|
— |
|
|
|
— |
|
|
|
(17,684 |
) |
| |
|
|
|
Net cash provided by
(used in) financing activities |
|
|
41,395 |
|
|
|
— |
|
|
|
(17,684 |
) |
| |
|
|
|
Net increase
(decrease) in cash and cash equivalents |
|
|
79,493 |
|
|
|
(21,507 |
) |
|
|
40,296 |
|
|
Cash and cash
equivalents beginning of year |
|
|
20,690 |
|
|
|
42,197 |
|
|
|
1,901 |
|
| |
|
|
|
Cash and cash
equivalents end of year |
|
$ |
100,183 |
|
|
$ |
20,690 |
|
|
$ |
42,197 |
|
| |
|
|
|
Supplemental
disclosures of cash flow information: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Interest paid, net of
interest income received |
|
$ |
11,438 |
|
|
$ |
10,508 |
|
|
$ |
10,726 |
|
|
Cash paid for income
taxes |
|
|
299 |
|
|
|
60 |
|
|
|
59 |
|
The accompanying
notes are an integral part of the consolidated financial statements.
42
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS
1. BASIS OF
PRESENTATION AND SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES
Unless otherwise indicated, references
to “we,” “us,” “our” and “ours” refer collectively to Sterling Chemicals, Inc.
and its wholly-owned subsidiaries. We own or operate facilities at our
petrochemicals complex located in Texas City, Texas, approximately 45 miles
south of Houston, on a 290-acre site on Galveston Bay near many other chemical
manufacturing complexes and refineries. Currently, we produce acetic acid and
plasticizers and prior to the shutdown of our styrene operations in
December 2007, we also produced styrene. We own all of the real property
which comprises our Texas City facility and we own the acetic acid, styrene and
plasticizers manufacturing units located at the site. Our Texas City site offers
approximately 135 acres for future expansion by us or by other companies that
could benefit from our existing infrastructure and facilities, and includes a
greenbelt around the northern edge of the plant site. We also lease a portion of
our Texas City site to Praxair Hydrogen Supply, Inc., or Praxair, who
constructed a partial oxidation unit on that land, and lease a portion of our
Texas City site to S&L Cogeneration Company, a 50/50 joint venture between
us and Praxair Energy Resources, Inc., who constructed a cogeneration facility
on that land. We generally sell our petrochemicals products to customers for use
in the manufacture of other chemicals and products, which in turn are used in
the production of a wide array of consumer goods and industrial products. As of
December 31, 2007, we reported our operations in three segments: acetic
acid, plasticizers and styrene.
Principles of
Consolidation
The consolidated financial statements
include the accounts of our wholly-owned subsidiaries, with all significant
intercompany accounts and transactions having been eliminated. Our 50% equity
investment in a cogeneration joint venture, which is accounted for under the
equity method, is not material to our financial position or results of
operations.
Cash and Cash
Equivalents
We consider all investments having an
initial maturity of three months or less to be cash equivalents.
Allowance for
Doubtful Accounts
Accounts receivable is presented net of
allowance for doubtful accounts. We regularly review our accounts receivable
balances and, based on estimated collectibility, adjust the allowance account
accordingly. As of December 31, 2007 and 2006, the allowance for doubtful
accounts was less than $0.1 million and $0.4 million, respectively.
Bad debt expense for 2007, 2006 and 2005 was a credit of $0.2 million,
$0.6 million and $2 million, respectively.
Inventories
Inventories are stated at the
lower-of-cost-or-market. Cost is primarily determined on a first-in, first-out
basis, except for stores and supplies, which are valued at average cost. The
comparison of cost to market value involves estimation of the market value of
our products. For the years ended December 31, 2007, 2006 and 2005, a
lower-of-cost-or-market adjustment was recorded of $1.4 million, zero and
$2.7 million, respectively. The adjustments in 2007 and 2005 were due to
decreasing benzene and styrene prices from December to January during each
period. Previously while our styrene unit was running, we would enter into
agreements with other companies to exchange chemical inventories in order to
minimize working capital requirements and to facilitate distribution logistics.
Balances related to quantities due to or payable by us are included in
inventory; however, we do not expect to have any significant exchange balances
or activity subsequent to 2007.
Property, Plant
and Equipment
Property, plant and equipment are
recorded at cost. Major renewals and improvements, which extend the useful lives
of equipment, are capitalized. For certain capital projects, our customers
reimburse us for a portion of the project cost. For such capital expenditures
reimbursed by our customers, we treat the reimbursements as a reduction of our
cost basis. Disposals are removed at carrying cost less accumulated depreciation
with any resulting gain or loss reflected in operations. Depreciation is
provided using the straight-line method over estimated useful lives ranging from
five to 25 years, with the predominant life of plant and equipment being
15 years. We capitalize interest costs, which are incurred
43
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
as part of the cost of
constructing major facilities and equipment. The amount of interest capitalized
for 2007, 2006 and 2005 was $0.2 million, $0.8 million and
$1.0 million, respectively.
Plant Turnaround
Costs
As a part of normal recurring
operations, each of our manufacturing units is completely shut down from time to
time, for a period typically lasting two to four weeks, to replace catalysts and
perform major maintenance work required to sustain long-term production. These
periods are commonly referred to as “turnarounds” or “shutdowns.” Costs of
turnarounds are expensed as incurred. As expenses for turnarounds can be
significant, the impact of expensing the costs of turnarounds can be material
for financial reporting periods during which the turnarounds actually occur.
Turnaround costs expensed during 2007, 2006 and 2005 were less than
$0.1 million, $10 million and $4 million, respectively.
Long-Lived
Assets
We assess our long-lived assets for
impairment whenever facts and circumstances indicate that the carrying amount
may not be fully recoverable. To analyze recoverability, we project undiscounted
net future cash flows over the remaining life of the assets. If the projected
cash flows from the assets are less than the carrying amount, an impairment
would be recognized. Any impairment loss would be measured based upon the
difference between the carrying amount and the fair value of the relevant
assets. For these impairment analyses, impairment is determined by comparing the
estimated fair value of these assets, utilizing the present value of expected
net cash flows, to the carrying value of these assets. In determining the
present value of expected net cash flows, we estimate future net cash flows from
these assets and the timing of those cash flows, and then apply a discount rate
to reflect the time value of money and the inherent uncertainty of those future
cash flows. The discount rate we use is based on our estimated cost of capital.
The assumptions we use in estimating future cash flows are consistent with our
internal planning.
During the fourth quarter of 2006, we
performed an asset impairment analysis on our styrene production unit. This
analysis was performed due to contemporaneous industry forecasts, forecasted
negative cash flow generated by our styrene business over the next few years and
the uncertainty surrounding the ability of the North American styrene industry
to successfully restructure. Our management determined that a triggering event,
as defined in Statement of Financial Accounting Standards No. 144,
“Accounting for the Impairment or Disposal of Long Lived Assets,” had occurred
and an asset impairment analysis was performed. We analyzed the undiscounted
cash flow stream from our styrene business over the next seven years, which
represented the remaining book life of our styrene assets, and compared it to
the $128 million net book carrying value of our styrene unit and related
assets. This analysis showed that the undiscounted projected cash flow stream
from our styrene business was less than the net book carrying value of our
styrene unit and related assets. As a result, we performed a discounted cash
flow analysis and subsequently concluded that our styrene unit and related
assets were impaired and should be written down to zero. This write-down caused
us to record an impairment of $128 million in December 2006.
During the fourth quarter of 2007 in
anticipation of the shutdown of our styrene unit, we wrote down all construction
in progress that had been capitalized in 2007 pertaining to that unit and the
catalyst which we were using in production. This write-down resulted in an
impairment expense of $4.3 million.
Debt Issue
Costs
Debt issue costs relating to long-term
debt are amortized over the term of the related debt instrument using the
straight-line method, which is materially consistent with the effective interest
method, and are included in other assets. Debt issue cost amortization, which is
included in interest and debt-related expenses, was $0.9 million,
$0.4 million and $0.4 million for the years ended December 31,
2007, 2006 and 2005, respectively.
Income
Taxes
Deferred income taxes are provided for
revenue and expenses which are recognized in different periods for income tax
and financial statement purposes. Deferred tax assets are regularly assessed for
recoverability based on both historical and anticipated earnings levels, and a
valuation allowance is recorded when it is more likely than not that these
amounts will not be recovered. As a result of our analysis, we concluded that a
valuation allowance was needed against our deferred tax assets. As of
December 31, 2007, our valuation allowance was $36.2 million, an
increase of
44
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
$6.6 million from
December 31, 2006, which resulted in an overall net deferred tax
asset/liability balance of zero as of December 31, 2007.
Environmental
Costs
Environmental costs are expensed as
incurred, unless the expenditures extend the economic useful life of the related
assets. Costs that extend the economic useful life of assets are capitalized and
depreciated over the remaining book life of those assets. Liabilities are
recorded when environmental assessments or remedial efforts are probable and the
cost can be reasonably estimated.
Revenue
Recognition
We generate revenues through a profit
sharing arrangement with respect to our acetic acid operations and these
revenues are estimated and accrued monthly. We generate revenues from our
plasticizers operations through a tolling agreement. Deferred credits are
amortized over the life of the contracts which gave rise to them. As of
December 31, 2007 and 2006, we had a balance in deferred income of
approximately $70 million and $10 million, respectively. For 2007, the
$70 million balance primarily consisted of approximately $59 million of
deferred income pertaining to the NOVA supply agreement discussed in
“Management’s Discussion and Analysis of Financial Condition and Results of
Operations—Recent Developments,” that is being amortized using the straight-line
method over the contractual non-compete period of five years and is reflected in
other income, and $6 million which represents certain payments received for our
oxo-alcohol operations, which were part of our plasticizers business, that are
being amortized using the straight-line method over the remaining life of the
contract of six years. As of December 31, 2006, the $10 million
balance in deferred income primarily consisted of $7 million pertaining to
the oxo-alcohols payments referred to above. Styrene revenue was recognized from
sales in the open market, raw materials conversion agreements and long-term
supply contracts at the time the products were shipped and title passed, the
price was fixed and determinable and collectibility was reasonably assured.
Styrene revenue (and corresponding cost of sales) from raw materials conversion
agreements was recognized on a gross basis and does not include raw material
components supplied by our customers.
Preferred stock
dividends
We record preferred stock dividends on
our Series A Convertible Preferred Stock, or our Series A Preferred Stock,
in our consolidated statements of operations based on the estimated fair value
of dividends at each dividend accrual date. Our Series A Preferred Stock
has a dividend rate of 4% per quarter of the liquidation value of the
outstanding shares of our Series A Preferred Stock, and is payable in
arrears in additional shares of our Series A Preferred Stock on the first
business day of each calendar quarter. The liquidation value of each share of
our Series A Preferred Stock is $13,793.11 per share, and each share of
Series A Preferred Stock is convertible into shares of our common stock (on
a one to 1,000 share basis, subject to adjustment). The carrying value of our
redeemable preferred stock in our consolidated balance sheets represents the
cumulative balance of the initial fair value at original issuance in 2002 plus
the fair value of each of the quarterly dividends paid since issuance. The fair
value of our preferred stock dividends is determined each quarter using
valuation techniques that include a component representing the intrinsic value
of the dividends (which represents the greater of the liquidation value of the
preferred shares being issued or the fair value of the common stock into which
the shares could be converted) and an option component (which is determined
using a Black-Scholes Option Pricing Model). These dividends are recorded in our
consolidated statements of operations, with an offset to redeemable preferred
stock in our consolidated balance sheets. As we are in an accumulated deficit
position, these dividends are treated as a reduction to additional paid-in
capital.
Earnings (Loss)
Per Share
Basic earnings per share, or EPS, is
computed using the weighted-average number of shares outstanding during the
year. Diluted EPS includes common stock equivalents, which are dilutive to
earnings per share. For the years ending December 31, 2007, 2006 and 2005,
we had no dilutive securities outstanding due to all common stock equivalents
having an anti-dilutive effect during these periods.
Disclosures
about Fair Value of Financial Instruments
In preparing disclosures about the fair
value of financial instruments, we have concluded that the carrying amount
approximates fair value for cash and cash equivalents, accounts receivable,
accounts payable and certain accrued liabilities due to the short maturities of
these instruments. The fair values of long-term debt instruments are estimated
45
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
based upon broker
quotes for private transactions or on the current interest rates available to us
for debt with similar terms and remaining maturities.
Accounting
Estimates
The preparation of financial statements
in conformity with accounting principles generally accepted in the United States
of America requires management to make estimates and assumptions that affect the
reported amounts of assets and liabilities and disclosure of contingent assets
and liabilities at the date of the financial statements and the reported amounts
of revenues and expenses during the reported periods. Significant estimates
include impairment considerations, allowance for doubtful accounts, inventory
valuation, preferred stock dividend valuation, revenue recognition related to
profit sharing accruals, environmental and litigation reserves and provision for
income taxes.
Reclassifications
Certain amounts reported in the
consolidated financial statements for the prior periods have been reclassified
to conform with the current consolidated financial statement presentation with
no effect on net loss or stockholders’ equity (deficiency in assets). For the
years ended December 31, 2006 and 2005, we have reclassed amounts between
bad debt benefit and accounts receivable and for the year ended
December 31, 2006, we have reclassed amounts between accrued liabilities
and other liabilities on the statement of cash flows.
2. STOCK-BASED
COMPENSATION PLAN
On December 19, 2002, we adopted
our 2002 Stock Plan and reserved 363,914 shares of our common stock for issuance
under the plan (subject to adjustment). Under our 2002 Stock Plan, officers and
key employees, as designated by our Board of Directors, may be issued stock
options, stock awards, stock appreciation rights or stock units. There are
currently options to purchase a total of 245,500 shares of our common stock
outstanding under our 2002 Stock Plan, all at an exercise price of $31.60, and
an additional 118,414 shares of common stock available for issuance under our
2002 Stock Plan.
On January 1, 2006, we adopted
Statement of Financial Accounting Standards, or SFAS No. 123-Revised 2004,
“Share-Based Payments,” or SFAS No. 123(R), using the modified prospective
method. SFAS No. 123(R) is a revision of SFAS No. 123, “Accounting for
Stock-Based Compensation,” or SFAS No. 123, and superseded
Accounting Principles Board No. 25, “Accounting for Stock Issued to
Employees,” or APB No. 25. Under SFAS No. 123(R), the cost of employee
services received in exchange for a stock-based award is determined based on the
grant-date fair value (with limited exceptions). That cost is then recognized
over the period during which the employee is required to provide services in
exchange for the award (usually the vesting period).
On January 1, 2006, using the
modified prospective method under SFAS No. 123(R), we began recognizing
expense on any unvested awards under our 2002 Stock Plan that were granted prior
to that time. Any awards granted under our 2002 Stock Plan after
December 31, 2005 will be expensed over the vesting period of the award.
Stock based compensation expense was $32,970 and $153,809 for the years ended
December 31, 2007 and 2006, respectively.
Prior to January 1, 2006, we had
adopted the “disclosure-only” provisions of SFAS No. 123 and accounted for
substantially all of our stock-based compensation using the intrinsic value
method prescribed in APB No. 25. Under APB No. 25, no compensation
expense was recognized for any of our stock option grants because all of the
stock options issued under our 2002 Stock Plan were granted with exercise prices
at or above fair value at the time of grant.
A summary of our stock option activity
for the years ended December 31, 2007, 2006 and 2005 is presented below:
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
December 31, 2007 |
|
|
December 31, 2006 |
|
|
December 31, 2005 |
|
| |
|
|
|
|
|
Weighted- |
|
|
|
|
|
|
Weighted- |
|
|
|
|
|
|
Weighted- |
|
| |
|
|
|
|
|
average |
|
|
|
|
|
|
average |
|
|
|
|
|
|
average |
|
| |
|
Shares |
|
|
exercise price |
|
|
Shares |
|
|
exercise price |
|
|
Shares |
|
|
exercise price |
|
|
Outstanding at
beginning of year |
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
294,334 |
|
|
$ |
31.60 |
|
|
Forfeited |
|
|
(33,000 |
) |
|
|
31.60 |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
Exercised |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
(15,834 |
) |
|
|
31.60 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Outstanding at end of
year |
|
|
245,500 |
|
|
$ |
31.60 |
|
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Options exercisable at
end of year |
|
|
245,500 |
|
|
|
|
|
|
|
269,333 |
|
|
|
|
|
|
|
176,500 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As noted above, no options were granted
in 2007, 2006 or 2005 and as of December 31, 2007 all options were vested.
46
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
The following table illustrates the
effect on our net loss and loss per share attributable to common stockholders
for the year ended December 31, 2005 if compensation costs for stock
options had been recorded pursuant to SFAS No. 123(R), for the years prior
to adoption: (Dollars in Thousands, Except Share Data)
| |
|
|
|
|
|
Net loss attributable
to common stockholders |
|
$ |
(46,552 |
) |
| |
|
Add: Stock-based
employee compensation expense included in reported net loss, net of
related tax effects |
|
|
157 |
|
| |
|
Deduct: Total
stock-based employee compensation expense determined under fair value
based method for all awards, net of related tax effects |
|
|
(606 |
) |
|
|
|
|
|
|
Pro forma net
loss |
|
$ |
(47,001 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
Loss per share
attributable to common stockholders: |
|
|
|
|
|
As reported |
|
$ |
(16.46 |
) |
|
Pro forma |
|
|
(16.62 |
) |
3. DISCONTINUED
OPERATIONS
On September 16, 2005, we
announced that we were exiting the acrylonitrile business and related derivative
operations, which included sodium cyanide and disodium iminodiacetic acid, or
DSIDA, production, and had been shut down since February 2005. As a result
of the exit from these businesses, we shut down production and have dismantled
these facilities. Our decision was based on a history of operating losses
incurred by our acrylonitrile and derivatives businesses, and was made after a
full review and analysis of our strategic alternatives.
In accordance with SFAS No. 144,
“Accounting for the Impairment and Disposal of Long Lived Assets,” we have
reported the operating results of these businesses as discontinued operations in
our consolidated financial statements.
The carrying amounts of the major
classes of assets and liabilities related to discontinued operations as of
December 31, 2007 and 2006 were as follows:
| |
|
|
|
|
|
|
|
|
| |
|
Year ended December 31, |
| |
|
2007 |
|
2006 |
| |
|
(Dollars in Thousands) |
|
Assets of
discontinued operations: |
|
|
|
|
|
|
|
|
|
Accounts receivable,
net |
|
$ |
— |
|
|
$ |
20 |
|
|
|
|
|
|
|
|
|
|
|
|
Liabilities of
discontinued operations: |
|
|
|
|
|
|
|
|
|
Accrued
liabilities |
|
$ |
325 |
|
|
$ |
217 |
|
Revenues and pre-tax losses from
discontinued operations for the years ended December 31, 2007, 2006 and
2005 are presented below:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year ended December 31, |
| |
|
2007 |
|
2006 |
|
2005 |
| |
|
(Dollars in Thousands) |
|
Revenues |
|
$ |
— |
|
|
$ |
258 |
|
|
$ |
43,374 |
|
|
Loss before income
taxes |
|
|
2,393 |
|
|
|
1,134 |
|
|
|
17,420 |
|
47
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
Current severance and
contractual obligations are detailed below:
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
Accrued as of |
|
|
|
|
|
Accrued as of |
| |
|
Accrued as of |
|
|
|
|
|
Cash |
|
December 31, |
|
Accrued in |
|
December 31, |
| |
|
December 31, 2005 |
|
Accrued in 2006 |
|
payments |
|
2006 |
|
2007 |
|
2007 |
| |
|
|
|
Severance
accrual |
|
$ |
477 |
|
|
$ |
386 |
|
|
$ |
(646 |
) |
|
$ |
217 |
|
|
$ |
108 |
|
|
$ |
325 |
|
|
DSIDA contractual
obligation |
|
|
2,853 |
|
|
|
147 |
|
|
|
(3,000 |
) |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
DSIDA dismantling
costs |
|
|
496 |
|
|
|
62 |
|
|
|
(558 |
) |
|
|
— |
|
|
|
— |
|
|
|
— |
|
| |
|
|
|
Totals |
|
$ |
3,826 |
|
|
$ |
595 |
|
|
$ |
(4,204 |
) |
|
$ |
217 |
|
|
$ |
108 |
|
|
$ |
325 |
|
| |
|
|
On September 17, 2007, we entered
into a long-term exclusive styrene supply agreement and a related railcar
purchase and sale agreement with NOVA. Under the supply agreement, NOVA had the
exclusive right to purchase 100% of our styrene production (subject to existing
contractual commitments), the amount of styrene supplied in any particular
period being at NOVA’s option, based on a full-cost formula. In
November 2007, the styrene supply agreement with NOVA, which was
subsequently assigned by NOVA to INEOS NOVA, LLC, or INEOS NOVA obtained
clearance under the Hart-Scott-Rodino Act. This clearance caused the supply
agreement to become effective and triggered a $60 million payment
obligation to us, which was paid by INEOS NOVA in November 2007. In
addition, in accordance with the terms of the supply agreement, INEOS NOVA
assumed substantially all of our contractual obligations for future styrene
deliveries. Once the supply agreement became effective, INEOS NOVA nominated
zero pounds of styrene under the supply agreement for the balance of 2007 and in
response, we exercised our right to terminate the supply agreement and
permanently shut down our styrene plant. Under the supply agreement, we are
responsible for the closure costs of our styrene facility and are also subject
to a long-term commitment to not reenter the styrene business for a period of
time. The closure costs of the styrene facility are expected to be between
$10 million and $15 million, which include the payment of employee
severance costs and decommissioning costs. Approximately $1 million of
these costs were expensed during the fourth quarter of 2007, with the balance
expected to be expensed during 2008. We operated our styrene manufacturing unit
through early December, as we completed our production of inventory and
exhausted our raw materials and purchase requirements. In 2008, significant
effort was put forth for a number of activities including; selling styrene and
co-products from our inventory, shipping product to customers, billing and
collecting for sales activity and decommissioning and decontamination of the
styrene production facility and related tanks and storage areas. Our
styrene-related personnel continue to work in and support the styrene business
by performing activities necessary to sell the remaining products (including
marketing, fulfillment of sales orders and delivery of product) and to
permanently shut down and decommission the unit. We have not developed plans for
a reduction in workforce at this time as we hope to transition these employees
to new business ventures after their work in styrene is complete. Our last sale
of styrene was made in January 2008 and sales of by-products have continued
through the first quarter of 2008. Additionally, we expect significant cash flow
from operations to be generated from the collection of styrene-related accounts
receivable during the first quarter of 2008.
Accordingly, consistent with the
guidance EITF Abstracts, Topic No. D-104 “Clarification of Transition
Guidance in Paragraph 51 of FASB Statement No. 144”, we will report
the operating results of the styrene business as discontinued operations in our
consolidated financial statements beginning in the first quarter of 2008. The
revenues and gross losses from our styrene operations are summarized below:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
2007 |
|
2006 |
|
2005 |
| |
|
|
|
|
|
|
|
Revenues |
|
$ |
681,513 |
|
|
$ |
524,664 |
|
|
$ |
513,788 |
|
|
Gross loss |
|
|
(16,468 |
) |
|
|
(15,510 |
) |
|
|
(30,277 |
) |
48
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
4. DETAIL OF
CERTAIN BALANCE SHEET ACCOUNTS
| |
|
|
|
|
|
|
|
|
| |
|
December 31, |
|
| |
|
2007 |
|
|
2006 |
|
| |
|
(Dollars in Thousands) |
|
|
Inventories: |
|
|
|
|
|
|
|
|
|
Finished
products |
|
$ |
14,621 |
|
|
$ |
38,485 |
|
|
Raw materials |
|
|
2,231 |
|
|
|
17,841 |
|
|
|
|
|
|
|
|
|
|
Inventories at
lower-of-cost-or-market |
|
|
16,852 |
|
|
|
56,326 |
|
|
Inventories under
exchange agreements |
|
|
(95 |
) |
|
|
1,818 |
|
|
Stores and supplies
(net of obsolescence reserve of $1,472 and $2,149, respectively) |
|
|
3,996 |
|
|
|
3,934 |
|
|
|
|
|
|
|
|
|
|
|
|
$ |
20,753 |
|
|
$ |
62,078 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Property, plant and
equipment, net: |
|
|
|
|
|
|
|
|
|
Land |
|
$ |
7,149 |
|
|
$ |
7,149 |
|
|
Buildings |
|
|
4,809 |
|
|
|
4,506 |
|
|
Plant and
equipment |
|
|
311,691 |
|
|
|
306,352 |
|
|
Construction in
progress |
|
|
2,470 |
|
|
|
1,761 |
|
|
Less: accumulated
depreciation |
|
|
(248,442 |
) |
|
|
(235,935 |
) |
|
|
|
|
|
|
|
|
|
|
|
$ |
77,677 |
|
|
$ |
83,833 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other assets,
net: |
|
|
|
|
|
|
|
|
|
S&L Cogen joint
venture |
|
$ |
5,483 |
|
|
$ |
4,733 |
|
|
Debt issuance
costs |
|
|
7,673 |
|
|
|
283 |
|
|
Deferred
catalyst |
|
|
50 |
|
|
|
1,959 |
|
|
Long-term deferred tax
asset |
|
|
— |
|
|
|
641 |
|
|
Other |
|
|
1,315 |
|
|
|
2,038 |
|
|
|
|
|
|
|
|
|
|
|
|
$ |
14,521 |
|
|
$ |
9,654 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accrued
liabilities: |
|
|
|
|
|
|
|
|
|
Employee compensation
and benefits |
|
|
6,425 |
|
|
$ |
6,878 |
|
|
Deferred
income |
|
|
11,219 |
|
|
|
3,009 |
|
|
Interest
payable |
|
|
4,036 |
|
|
|
470 |
|
|
Property taxes |
|
|
3,089 |
|
|
|
4,301 |
|
|
Advances from
customers |
|
|
3,726 |
|
|
|
— |
|
|
Other |
|
|
2,134 |
|
|
|
1,658 |
|
|
|
|
|
|
|
|
|
|
|
|
$ |
30,629 |
|
|
$ |
16,316 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Deferred credits and
other liabilities: |
|
|
|
|
|
|
|
|
|
Accrued postretirement,
pension and post employment benefits |
|
$ |
16,067 |
|
|
$ |
42,152 |
|
|
Deferred
income |
|
|
59,089 |
|
|
|
7,000 |
|
|
Advances from
customers |
|
|
1,000 |
|
|
|
1,000 |
|
|
Other |
|
|
1,448 |
|
|
|
5,695 |
|
|
|
|
|
|
|
|
|
|
|
|
$ |
77,604 |
|
|
$ |
55,847 |
|
|
|
|
|
|
|
|
|
49
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
5. VALUATION AND
QUALIFYING ACCOUNTS
Below is a summary of valuation and
qualifying accounts related to continuing operations for the years ended
December 31, 2007, 2006 and 2005:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
December 31, |
|
| |
|
2007 |
|
|
2006 |
|
|
2005 |
|
|
Allowance for doubtful
accounts: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at beginning of
year |
|
$ |
(367 |
) |
|
$ |
(953 |
) |
|
$ |
(3,092 |
) |
|
Add: bad debt
benefit |
|
|
213 |
|
|
|
571 |
|
|
|
2,133 |
|
|
Deduct: written-off
accounts |
|
|
115 |
|
|
|
15 |
|
|
|
6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at end of
year |
|
$ |
(39 |
) |
|
$ |
(367 |
) |
|
$ |
(953 |
) |
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
December 31, |
|
| |
|
2007 |
|
|
2006 |
|
|
2005 |
|
|
Reserve for inventory
obsolescence: |
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at beginning of
year |
|
$ |
2,149 |
|
|
$ |
2,573 |
|
|
$ |
1,938 |
|
|
Add: obsolescence
accrual |
|
|
163 |
|
|
|
81 |
|
|
|
1,492 |
|
|
Deduct: disposal of
inventory |
|
|
(840 |
) |
|
|
(505 |
) |
|
|
(857 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
Balance at end of
year |
|
$ |
1,472 |
|
|
$ |
2,149 |
|
|
$ |
2,573 |
|
|
|
|
|
|
|
|
|
|
|
|
6. DEBT
On March 1, 2007, we commenced an
offer, or our tender offer, to repurchase all $100.6 million of our
outstanding 10% Senior Secured Notes due 2007, or our Old Secured Notes.
Concurrently with our tender offer, we solicited consents from the holders of
our Old Secured Notes to, among other things, eliminate certain covenants
contained in the indenture governing our Old Secured Notes and related security
documents. On March 15, 2007, after receiving enough consents from the
holders of our Old Secured Notes, we and Sterling Chemicals Energy, Inc., or
Sterling Energy, one of our wholly-owned subsidiaries, and the trustee entered
into a supplemental indenture amending the indenture and the related security
documents to eliminate most of the restrictive covenants contained therein, as
well as certain events of default and repurchase rights. These amendments became
effective when we accepted for purchase the Old Secured Notes held by the
consenting holders pursuant to our tender offer and paid those holders an
aggregate of $0.1 million in consent fees. Our tender offer expired at
12:00 midnight, New York City time, on March 28, 2007. We accepted for
repurchase $58 million in aggregate principal amount of Old Secured Notes
which were validly tendered prior to the expiration of our tender offer, and we
repurchased those Old Secured Notes and paid the accrued interest thereon
together with the consent fee, on March 30, 2007. On March 27, 2007,
we issued a notice of redemption for all of our Old Secured Notes that were not
tendered pursuant to our tender offer and, on April 27, 2007, we purchased
those remaining Old Secured Notes for an aggregate amount equal to
$44 million, which included $1.5 million in accrued interest.
On March 26, 2007, we entered into
a purchase agreement, or the Purchase Agreement, with respect to the sale of
$150 million aggregate principal amount of unregistered 101/4% Senior Secured Notes due 2015, or our Secured
Notes, to Jefferies & Company, Inc. and CIBC World Markets Corp., as initial
purchasers. Sterling Energy was also a party to the Purchase Agreement as a
guarantor. On March 29, 2007, we completed a private offering of the
unregistered Secured Notes pursuant to the Purchase Agreement. In connection
with that offering, we entered into an indenture, dated March 29, 2007, among
us, Sterling Energy, as guarantor, and U.S. Bank National Association, as
trustee and collateral agent. On August 30, 2007, we made an initial filing
of an exchange offer registration statement to exchange our unregistered Secured
Notes for a new issue of substantially identical debt securities registered
under the Securities Act. Pursuant to a registration rights agreement among us,
Sterling Energy and the initial purchasers, we agreed to use commercially
reasonable efforts to cause the registration statement to become effective by
December 24, 2007, and complete the exchange offer within 50 days of
the effective date of the registration statement. However, as the registration
statement was not declared effective by December 24, 2007, the interest
rate on our Secured Notes increased by 0.25% per annum on December 25, 2007
and on March 24, 2008, and unless and until the registration statement is
declared effective, will increase by an additional 0.25% per annum at the
beginning of each subsequent
50
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
90-day period if such
failure continues, subject to a maximum increase of 1.0% per annum. As such,
penalty interest is expected to be between $0.1 million and
$0.2 million depending upon the effectiveness date of the registration
statement, of which $0.1 was accrued as of December 31, 2007. All of this
additional interest will cease to accrue when the registration statement is
declared effective.
Our indenture contains affirmative and
negative covenants and customary events of default, including payment defaults,
breaches of covenants and certain events of bankruptcy, insolvency and
reorganization. If an event of default, other than an event of default triggered
upon certain bankruptcy events, occurs and is continuing, the trustee under our
indenture or the holders of at least 25% in principal amount of the outstanding
Secured Notes may declare our Secured Notes to be due and payable immediately.
Upon an event of default, the trustee may also take actions to foreclose on the
collateral securing our outstanding Secured Notes, subject to the terms of an
intercreditor agreement dated March 29, 2007, among us, Sterling Energy,
the trustee and The CIT Group/Business Credit, Inc. Our indenture does not
require us to maintain any financial ratios or satisfy any financial maintenance
tests. We are in compliance with all of the covenants contained in our
indenture.
Interest is due on our outstanding
Secured Notes on April 1 and October 1 of each year, with our first interest
payment having been made on October 1, 2007. Additional interest of 0.25%
per annum is currently accruing on our outstanding Secured Notes as a result of
our failure to have the registration statement declared effective by
December 24, 2007, as discussed above. Our outstanding Secured Notes, which
mature on April 1, 2015, are senior secured obligations and rank equally in
right of payment with all of our existing and future senior indebtedness.
Subject to specified permitted liens, our outstanding Secured Notes are secured
(i) on a first priority basis by all of our and Sterling Energy’s fixed
assets and certain related assets, including, without limitation, all property,
plant and equipment, and (ii) on a second priority basis by all of our and
Sterling Energy’s other assets, including, without limitation, accounts
receivable, inventory, capital stock of our domestic restricted subsidiaries
(including Sterling Energy), intellectual property, deposit accounts and
investment property.
On December 19, 2002, we entered
into a Revolving Credit Agreement, or our revolving credit facility, with The
CIT Group/Business Credit, Inc., as administrative agent and a lender, and
certain other lenders. Our revolving credit facility had an initial term ending
on September 19, 2007. Under our revolving credit facility, we and Sterling
Energy are co-borrowers and are jointly and severally liable for any
indebtedness thereunder. Our revolving credit facility is secured by first
priority liens on all of our accounts receivable, inventory and other specified
assets, as well as all of the issued and outstanding capital stock of Sterling
Energy. On March 29, 2007, we amended and restated our revolving credit
facility to, among other things, extend the term of our revolving credit
facility until March 29, 2012, reduce the maximum commitment thereunder to
$50 million, make certain changes to the calculation of the borrowing base and
lower the interest rates and fees charged thereunder. Borrowings under our
revolving credit facility now bear interest, at our option, at an annual rate of
either a base rate plus 0.0% to 0.50% or the LIBOR rate plus 1.50% to 2.25%,
depending on our borrowing availability at the time. We are also required to pay
an aggregate commitment fee of 0.375% per year (payable monthly) on any unused
portion. Available credit under our revolving credit facility is subject to a
monthly borrowing base of 85% of eligible accounts receivable plus 65% of
eligible inventory. As of December 31, 2007, our borrowing base exceeded
the maximum commitment under our revolving credit facility, making the total
credit available under our revolving credit facility $50 million. However,
the monetization of accounts receivable and inventory associated with our exit
from the styrene business is expected to significantly decrease the borrowing
base under our revolving credit facility with the total credit available
expected to be between $10 million and $20 million (after giving
effect to our outstanding letters of credit) after the collection of outstanding
styrene receivables. As of December 31, 2007, there were no loans
outstanding under our revolving credit facility, and we had $12 million in
letters of credit outstanding, resulting in borrowing availability of
$38 million. Pursuant to Emerging Issues Task Force Issue No. 95-22,
“Balance Sheet Classification of Borrowings under Revolving Credit Agreements
That Include both a Subjective Acceleration Clause and a Lock-Box Arrangement,”
any balances outstanding under our revolving credit facility are classified as a
current portion of long-term debt.
Our revolving credit facility contains
numerous covenants and conditions, including, but not limited to, restrictions
on our ability to incur indebtedness, create liens, sell assets, make
investments, make capital expenditures, engage in mergers and acquisitions and
pay dividends. Our revolving credit facility also includes various circumstances
and conditions that would, upon their occurrence and subject in certain cases to
notice and grace periods, create an event of default thereunder. Our revolving
credit facility does not require us to maintain any financial ratios or satisfy
any financial maintenance tests. We are in compliance with all of the covenants
contained in our revolving credit facility.
51
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
Debt
Maturities
Our Secured Notes, which had an
aggregate principal balance of $150 million outstanding as of
December 31, 2007, are due on April 1, 2015.
7. INCOME TAXES
A reconciliation of federal statutory
income taxes to our effective tax benefit is as follows:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year Ended December 31, |
|
| |
|
2007 |
|
|
2006 |
|
|
2005 |
|
| |
|
(Dollars in Thousands) |
|
|
Benefit for income
taxes at statutory rates |
|
$ |
(8,551 |
) |
|
$ |
(42,100 |
) |
|
$ |
(16,299 |
) |
|
Non-deductible
expenses |
|
|
23 |
|
|
|
19 |
|
|
|
19 |
|
|
State income
taxes |
|
|
13 |
|
|
|
(1,262 |
) |
|
|
(956 |
) |
|
Change in valuation
allowance |
|
|
3,021 |
|
|
|
27,621 |
|
|
|
— |
|
|
Other |
|
|
(9 |
) |
|
|
1,096 |
|
|
|
235 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Effective tax
benefit |
|
$ |
(5,503 |
) |
|
$ |
(14,626 |
) |
|
$ |
(17,001 |
) |
|
|
|
|
|
|
|
|
|
|
|
The income tax benefit
for continuing operations and discontinued operations is shown below:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year Ended December 31, |
|
| |
|
2007 |
|
|
2006 |
|
|
2005 |
|
| |
|
(Dollars in Thousands) |
|
|
Tax benefit –
continuing operations |
|
$ |
(5,503 |
) |
|
$ |
(14,488 |
) |
|
$ |
(10,641 |
) |
|
Tax benefit –
discontinued operations |
|
|
— |
|
|
|
(138 |
) |
|
|
(6,360 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
Total tax
benefit |
|
$ |
(5,503 |
) |
|
$ |
(14,626 |
) |
|
$ |
(17,001 |
) |
|
|
|
|
|
|
|
|
|
|
|
The income tax
benefit is composed of the following:
| |
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year Ended December 31, |
|
| |
|
2007 |
|
|
2006 |
|
|
2005 |
|
| |
|
(Dollars in Thousands) |
|
|
Current
federal |
|
$ |
364 |
|
|
$ |
299 |
|
|
$ |
— |
|
|
Deferred
federal |
|
|
(5,887 |
) |
|
|
(13,685 |
) |
|
|
(16,066 |
) |
|
Current and deferred
state |
|
|
20 |
|
|
|
(1,240 |
) |
|
|
(935 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
Total tax
benefit |
|
$ |
(5,503) |
|
|
$ |
(14,626 |
) |
|
$ |
(17,001 |
) |
|
|
|
|
|
|
|
|
|
|
|
The components of our deferred income
tax assets and liabilities are summarized below:
| |
|
|
|
|
|
|
|
|
| |
|
December 31, |
|
| |
|
2007 |
|
|
2006 |
|
| |
|
(Dollars in Thousands) |
|
|
Deferred tax
assets: |
|
|
|
|
|
|
|
|
|
Accrued
liabilities |
|
$ |
1,496 |
|
|
$ |
1,292 |
|
|
Accrued postretirement
cost |
|
|
2,236 |
|
|
|
7,518 |
|
|
Accrued pension
cost |
|
|
— |
|
|
|
4,537 |
|
|
Tax loss and credit
carry forwards |
|
|
26,846 |
|
|
|
32,506 |
|
|
State deferred
taxes |
|
|
98 |
|
|
|
77 |
|
|
Unearned
revenue |
|
|
23,656 |
|
|
|
2,450 |
|
|
Other |
|
|
719 |
|
|
|
1,347 |
|
|
|
|
|
|
|
|
|
|
Total deferred tax
assets |
|
$ |
55,051 |
|
|
$ |
49,727 |
|
|
|
|
|
|
|
|
|
52
STERLING
CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO
CONSOLIDATED FINANCIAL STATEMENTS—(Continued)
| |
|
|
|
|
|
|
|
|
| |
|
December 31, |
|
| |
|
2007 |
|
|
2006 |
|
| |
|
(Dollars in Thousands) |
|
|
Deferred tax
liabilities: |
|
|
|
|
|
|
|
|
|
Property, plant and
equipment |
|
$ |
(17,609 |
) |
|
$ |
(16,458 |
) |
|
Accrued pension
cost |
|
|
(1,277 |
) |
|
|
— |
&nbs |