As filed with the Securities and Exchange Commission on
August 8, 2008
Registration No. 333-145803
UNITED STATES SECURITIES AND
EXCHANGE COMMISSION
Washington, DC 20549
Amendment No. 5
to
Form S-4
REGISTRATION
STATEMENT
UNDER
THE SECURITIES ACT OF 1933
Sterling Chemicals,
Inc.
(Exact Name of Registrant as
Specified in Its Charter)
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| Delaware |
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2860 |
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72-0395707 |
(State or
Other Jurisdiction of Incorporation or Organization) |
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(Primary
Standard Industrial Classification Code Number) |
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(I.R.S.
Employer Identification Number)
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333 Clay Street,
Suite 3600 Houston, Texas 77002-4109 (713) 650-3700 (Address, including zip code, and telephone number
including area code, of registrant’s principal executive
offices) |
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Kenneth M. Hale Senior Vice
President, General Counsel and Corporate Secretary 333 Clay Street,
Suite 3600 Houston, Texas 77002-4109 (713) 650-3700 (Name, address, including zip code, and telephone
number, including area code, of agent for service) |
Copy to:
J. Michael Chambers
Akin Gump Strauss Hauer & Feld LLP
1111 Louisiana, 44th Floor
Houston, Texas 77002-5200
(713) 220-5800
Approximate date of commencement of proposed sale of the
securities to the public: As soon as practicable after this
Registration Statement becomes effective.
If the securities being registered on this form are being offered in
connection with the formation of a holding company and there is compliance with
General Instruction G, check the following box. o
If this form is filed to register additional securities for an
offering pursuant to Rule 462(b) under the Securities Act of 1933, as
amended, or the Securities Act, check the following box and list the Securities
Act registration statement number of the earlier effective registration
statement for the same offering. o
If this form is a post-effective amendment filed pursuant to
Rule 462(d) under the Securities Act, check the following box and list the
Securities Act registration statement number of the earlier effective
registration statement for the same offering. o
Indicate by check mark whether the registrant is a large accelerated
filer, an accelerated filer, a non-accelerated filer, or a smaller reporting
company. See the definitions of “large accelerated filer,” “accelerated filer”
and “smaller reporting company” in Rule 12b-2 of the Exchange Act.
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Accelerated filer o |
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Non-accelerated
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Smaller reporting company þ |
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(Do not check if a smaller reporting company)
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The Registrant hereby amends this Registration Statement on such
date or dates as may be necessary to delay its effective date until the
Registrant shall file a further amendment which specifically states that this
Registration Statement shall thereafter become effective in accordance with
Section 8(a) of the Securities Act of 1933 or until the Registration Statement
shall become effective on such date as the Securities and Exchange Commission,
acting pursuant to said Section 8(a), may determine.
Information
in this prospectus is not complete and may be changed. A registration
statement relating to these securities has been filed with the Securities
and Exchange Commission. We may not exchange these securities until the
registration statement is effective. This prospectus is not an offer to
sell or a solicitation of an offer to buy the securities in any state
where the offer or sale is not permitted.
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SUBJECT TO COMPLETION, DATED
AUGUST 8, 2008
PROSPECTUS
$150,000,000
Sterling Chemicals,
Inc.
101/4% Senior Secured Notes due 2015
This prospectus relates to our proposed exchange offer. We are
offering to exchange up to $150,000,000 aggregate principal amount of new and
freely transferable 101/4% Senior Secured Notes due 2015, which we
refer to as the registered notes, for any and all outstanding 101/4% Senior Secured Notes due 2015 issued in a
private offering on March 29, 2007, which we refer to as the unregistered
notes and which are subject to transfer restrictions. In this prospectus we
sometimes refer to the unregistered notes and the registered notes collectively
as the notes.
The terms of the registered notes are identical to the terms of the
unregistered notes in all material respects, except for the elimination of some
transfer restrictions, registration rights and additional interest provisions
relating to the unregistered notes. The registered notes will be issued under
the same indenture as the unregistered notes. All of our 101/4% Senior Secured Notes due 2015 outstanding
from time to time under the indenture are referred to as our senior secured
notes. The registered notes and the guarantees, if any, will rank senior in
right of payment to all existing and future subordinated indebtedness of us and
any guarantors, as applicable, and equal in right of payment with all existing
and future senior indebtedness of us and of such guarantors. Holders of
unregistered notes do not have any appraisal or dissenters’ rights in connection
with the exchange offer. The exchange of unregistered notes for registered notes
will not be a taxable event for United States federal income tax purposes.
We will exchange any and all unregistered notes that are validly
tendered and not validly withdrawn prior to 5:00 p.m. (New York City time)
on, , 2008, unless
extended.
We will not receive any cash proceeds from the exchange offer. You
will be required to make the representations described on page 23. We have
not applied, and do not intend to apply, for listing the notes on any national
securities exchange or automated quotation system.
Unregistered notes not exchanged in the exchange offer will remain
outstanding and will be entitled to the benefits of the indenture but, except
under certain circumstances, will have no further exchange or registration
rights under the registration rights agreement discussed in this prospectus.
Each broker-dealer that receives registered notes for its own
account pursuant to the exchange offer must acknowledge that it will deliver a
prospectus in connection with any resale of such registered notes. The letter of
transmittal states that by so acknowledging and by delivering a prospectus, a
broker-dealer will not be deemed to admit that it is an “underwriter” within the
meaning of the Securities Act of 1933, as amended, or the Securities Act. This
prospectus, as it may be amended or supplemented from time to time, may be used
by a broker-dealer in connection with resales of registered notes received in
exchange for unregistered notes where such unregistered notes were acquired by
such broker-dealer as a result of market-making activities or other trading
activities. We have agreed that, for such period of time as may be required
under the Securities Act to permit resales of registered notes, we will make
this prospectus available to any broker-dealer for use in connection with any
such resale. See “Plan of Distribution.”
Neither the Securities and Exchange Commission nor any state
securities commission has approved or disapproved of the notes or determined if
this prospectus is truthful or complete. Any representation to the contrary is a
criminal offense.
See “Risk Factors” beginning on page 16 of this prospectus
for a discussion of risks that you should consider before participating in this
exchange offer.
The date of this prospectus
is , 2008
TABLE OF
CONTENTS
ABOUT THIS
PROSPECTUS
This prospectus is part of a registration statement on Form S-4 under the Securities Act that
we filed with the Securities and Exchange Commission, or the SEC. In making your
decision whether to participate in the exchange offer, you should rely only on
the information contained in this prospectus and in the accompanying letter of
transmittal. We have not authorized any person to provide you with different
information. If anyone provides you with different or inconsistent information,
you should not rely on it. You should not assume that the information appearing
in this prospectus is accurate as of any date other than the date on the front
cover of this prospectus.
Moreover, this prospectus does not contain all of the information set
forth in the registration statement and the exhibits thereto. You may refer to
the registration statement and the exhibits thereto for more information.
Statements made in this prospectus regarding the contents of any contract or
document filed as an exhibit to the registration statement are not necessarily
complete and, in each instance, reference is hereby made to the copy of such
contract or document so filed. Each such statement is qualified in its entirety
by such reference.
WHERE YOU
CAN FIND MORE INFORMATION
We file annual, quarterly and special reports, proxy statements and
other information with the SEC. You may read and copy any reports, statements or
other information we file at the SEC’s public reference room at
100 F. Street N.E., NW, Washington, DC 20549. Please call the SEC at
1-800-SEC-0330 for further information
on the public
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reference room. Our SEC filings are also available to the public from
commercial document retrieval services and at the web site maintained by the SEC
at http://www.sec.gov. You can also
find more information about us at our Internet website located at http://www.sterlingchemicals.com. Our annual
report on Form 10-K, our quarterly
reports on Form 10-Q, our current
reports on Form 8-K, and any
amendments to those reports are available free of charge through our website.
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. Except for such reports
that may be specifically incorporated by reference in this prospectus,
information that has been filed with the SEC or that is contained on our website
does not constitute part of this prospectus.
This prospectus contains summaries of certain agreements, such as the
indenture and the agreements described under “Summary — Registered Notes,”
“Description of Notes,” and “Management’s Discussion and Analysis of Financial
Condition and Results of Operations.” The descriptions contained in this
prospectus of these agreements do not purport to be complete and are subject to,
or qualified in their entirety by reference to, the definitive agreements.
Copies of the definitive agreements will be made available without charge to you
by making a written or oral request to us at the following address:
Sterling Chemicals, Inc.
333 Clay Street,
Suite 3600
Houston, Texas 77002
Attention: Corporate Secretary
FORWARD-LOOKING
STATEMENTS
This prospectus contains “forward-looking statements” within the
meaning of Section 27A of the Securities Act and Section 21E of the
United States Securities Exchange Act of 1934, as amended, or the Exchange Act.
Forward-looking statements give our current expectations or forecasts of future
events. All statements other than statements of historical fact are, or may be
deemed to be, forward-looking statements. Such statements include, without
limitation, any statement that may project, indicate or imply future results,
events, performance or achievements, and may contain or be identified by the
words “expect,” “intend,” “plan,” “predict,” “anticipate,” “estimate,”
“believe,” “should,” “could,” “may,” “might,” “will,” “will be,” “will
continue,” “will likely result,” “project,” “forecast,” “budget” and similar
expressions. Statements in this prospectus that contain forward-looking
statements include, but are not limited to, information concerning our possible
or assumed future results of operations. While our management considers these
expectations and assumptions to be reasonable, they are inherently subject to
significant business, economic, competitive, regulatory and other risks,
contingencies and uncertainties, most of which are difficult to predict and many
of which are beyond our control. We disclose important factors that could cause
our actual results to differ materially from our expectations under “Risk
Factors,” “Management’s Discussion and Analysis of Financial Condition and
Results of Operations” and elsewhere in this prospectus. These risks,
contingencies and uncertainties relate to, among other matters, the following:
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the cyclicality of the petrochemicals industry; |
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current and future industry conditions and their effect on
our results of operations or financial position; |
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the extent, timing and impact of expansions of production
capacity of our products, by us or by our competitors; |
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the potential effects of market and industry conditions and
cyclicality on our competitiveness, business strategy, results of
operations or financial position; |
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the adequacy of our liquidity; |
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our environmental management programs and safety
initiatives; |
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our market sensitive financial instruments; |
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future uses of, and requirements for, financial resources;
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future contractual obligations; |
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future amendments, renewals or terminations of existing
contractual relationships; |
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business strategies; |
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growth opportunities; |
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competitive position; |
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expected financial position; |
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future cash flows or dividends; |
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budgets for capital and other expenditures; |
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plans and objectives of management; |
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outcomes of legal proceedings; |
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compliance with applicable laws; |
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our reliance on marketing partners; |
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adequacy of insurance coverage or indemnification rights;
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the timing and extent of changes in commodity prices for
our products or raw materials; |
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petrochemicals industry production capacity or operating
rates; |
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costs associated with the shut down and decommissioning of
our styrene facility; |
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increases in the cost of, or our ability to obtain, raw
materials or energy; |
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regulatory initiatives and compliance with governmental
laws or regulations, including environmental laws or regulations; |
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customer preferences; |
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our ability to attract or retain high quality employees;
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operating hazards attendant to the petrochemicals industry;
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casualty losses, including those resulting from weather
related events; |
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changes in foreign, political, social or economic
conditions; |
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risks of war, military operations, other armed hostilities,
terrorist acts or embargoes; |
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changes in technology, which could require significant
capital expenditures in order to maintain competitiveness or could cause
existing manufacturing processes to become obsolete; |
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effects of litigation; |
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cost, availability or adequacy of insurance; and |
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various other matters, many of which are beyond our
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The risks included here are not exhaustive. Other sections of this
prospectus, and our filings with the SEC, include additional factors that could
adversely affect our business, results of operations or financial performance.
See “Risk Factors.” Given these risks and uncertainties, investors should not
place undue reliance on forward-looking statements. Forward-looking statements
included in this prospectus are made only as of the date of this prospectus and
are not guarantees of future performance. Although we believe that the
expectations reflected in these forward-looking statements are reasonable, such
expectations may prove to have been incorrect. All written or oral
forward-looking statements attributable to us, or persons acting on our behalf,
are expressly qualified in their entirety by these cautionary statements.
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NOTICE TO
NEW HAMPSHIRE RESIDENTS
NEITHER THE FACT THAT A REGISTRATION STATEMENT OR AN APPLICATION
FOR A LICENSE HAS BEEN FILED UNDER CHAPTER 421-B OF THE NEW HAMPSHIRE
REVISED STATUTES WITH THE STATE OF NEW HAMPSHIRE NOR THE FACT THAT A SECURITY IS
EFFECTIVELY REGISTERED OR A PERSON IS LICENSED IN THE STATE OF NEW HAMPSHIRE
CONSTITUTES A FINDING BY THE SECRETARY OF STATE OF NEW HAMPSHIRE THAT ANY
DOCUMENT FILED UNDER RSA 421-B IS
TRUE, COMPLETE AND NOT MISLEADING. NEITHER ANY SUCH FACT NOR THE FACT THAT AN
EXEMPTION OR EXCEPTION IS AVAILABLE FOR A SECURITY OR A TRANSACTION MEANS
THAT THE SECRETARY OF STATE HAS PASSED IN ANY WAY UPON THE MERITS OR
QUALIFICATIONS OF, OR RECOMMENDED OR GIVEN APPROVAL TO, ANY PERSON, SECURITY OR
TRANSACTION. IT IS UNLAWFUL TO MAKE, OR CAUSE TO BE MADE, TO ANY PROSPECTIVE
PURCHASER, CUSTOMER OR CLIENT ANY REPRESENTATION INCONSISTENT WITH THE
PROVISIONS OF THIS PARAGRAPH.
INDUSTRY AND
MARKET DATA
Industry and market data used throughout this prospectus were
obtained through internal company research, surveys and studies conducted by
third parties and industry and general publications, including information from
Chemical Market Associates, Inc., or CMAI, and Tecnon OrbiChem, or Tecnon. We
have not independently verified market and industry data from third-party
sources. Furthermore, the research, surveys and studies provided by such third
party sources have been based in part on market and industry data that has not
in turn been independently verified by those third party sources. While we
believe internal company estimates are reliable, such estimates have not been
verified by any independent sources, and we do not make any representations as
to the accuracy of such estimates. Changes in factors upon which our estimates
or the analyses or forecasts contained in such third party reports, surveys or
studies referred to herein are based could effect the results of such estimates,
analyses and forecasts, and are inherently uncertain because of events or
combinations of events that cannot reasonably be foreseen, including the actions
of government, individuals, third parties and competitors.
PRODUCTION
CAPACITY
Unless we state otherwise, annual production capacity used throughout
this prospectus represents rated capacity at December 31, 2007. We
calculated rated capacity by estimating the number of days in a typical year
that a production unit of a plant is expected to operate, after allowing for
downtime for regular maintenance, and multiplying that number by the unit’s
optimal daily output based on the design feedstock mix. Because the rated
capacity of a production unit is an estimated amount, actual production volumes
may be more or less than the rated capacity.
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This summary is not complete and does not contain all of the
information that you should consider before investing in our notes. You should
read the entire prospectus carefully, including “Risk Factors” and our
consolidated financial statements and the related notes and other financial
information appearing elsewhere in this prospectus before you decide to invest
in our notes. Generally, references to “Sterling Chemicals,” “we,” “us” and
“our” mean Sterling Chemicals, Inc. and its consolidated subsidiaries. In
addition, in this prospectus our fiscal years ended December 31, 2005,
December 31, 2006, and December 31, 2007 are referred to as 2005, 2006
and 2007, respectively.
The
Company
We are a North American producer of selected petrochemicals used to
manufacture a wide array of consumer goods and industrial products. Our primary
products are acetic acid and plasticizers.
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. In addition, BP Chemicals
reimburses us for 100% of our fixed and variable costs of production. Prior to
August 2006, BP Chemicals also paid us a set monthly amount. However, under 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. 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. Acetic
acid production has two major raw material 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
required carbon monoxide 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 early termination
rights held by BASF that begin in 2010. Under our agreement with BASF, BASF
provides us with most of the required raw materials, 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
related to our plasticizers facility. In May 2008, we entered into an amended
production agreement with BASF (sometimes referred to in this prospectus as our
Amended Plasticizers Production Agreement). This amended agreement was entered
into in connection with BASF’s nomination of zero pounds of phthalic anhydride,
or PA, under the existing production agreement (sometimes referred to in this
prospectus as the Old Plasticizers Production Agreement) due to deteriorating
market conditions which were not expected to improve over the next few years,
which resulted in the shutdown of our PA unit. See “Management’s Discussion and
Analysis of Financial Condition and Results of Operations — Recent
Developments” and “Business — Contracts.”
Prior to December 3, 2007, we manufactured styrene. However, 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 this 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
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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 and the railcar agreement to become effective and triggered
a $60 million payment to us 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. After 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 until December of 2012. We operated our styrene
facility through early December 2007, as we completed our production of
inventory and exhausted our raw materials and purchase requirements, and sold
substantially all our inventory during the first quarter of 2008. During 2007
and the first quarter of 2008, we incurred closure costs to decommission our
styrene facility of approximately $1 million and $9 million,
respectively. We expect to incur up to $4 million in additional
decommissioning costs related to the closure of our styrene facility. In
mid-July, with the decontamination process for the styrene facility nearing
completion, we announced a reduction in work force in order to reduce our
staffing to a level appropriate for our existing operations and site development
projects. As a result, seven members of our salaried work force were immediately
laid off. In addition, we made offers for early retirement to several members of
our hourly work force and our salaried administrative and process supervisors.
Upon completion of the down-sizing of our hourly work force and our
administrative and process supervisor positions, which will occur after the
period for accepting offers of early retirement has closed in September, total
staff reductions are expected to be approximately 40 employees, and we
expect to recognize approximately $2.2 million in severance costs in the
third and fourth quarters of 2008, in accordance with SFAS No. 146,
“Accounting for Costs Associated with Exit of Disposal Activities.”
We manufacture all of our petrochemicals products at our Texas City
facility. In terms of production capacity, our Texas City site has the sixth
largest acetic acid facility in the world. The 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, 160 acres of available land zoned for heavy
industrial use and 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 key
raw material pipelines, as well as close proximity to a number of large refinery
complexes.
We own the acetic acid and plasticizers manufacturing units located
at our Texas City site. We also lease a portion of our Texas City site to
Praxair, who constructed a partial oxidation unit on that land, and we 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 lease space for our principal offices
located in Houston, Texas.
We intend to further expand the capacity of our acetic acid facility
and we are presently undertaking numerous initiatives to attract new
manufacturing and/or storage related businesses to our Texas City site. Given
our significant under-utilized infrastructure, land, materials handling,
utilities and storage, our Texas City site should be a favorable location for
companies looking to construct new manufacturing facilities on the Gulf Coast of
the United States. We believe that the construction of a new facility at our
site by another company would lower the amount of overall fixed costs allocated
to each of our operating units and provide us with additional profit.
Accordingly, we are seeking long-term contractual business arrangements or
partnerships that will provide us with an ability to realize the value of our
under-utilized assets through profit sharing or other cash generating
arrangements. For development projects that may have significant capital
expenditure requirements, we are considering joint ventures or other
arrangements where we would contribute certain of our assets and management
expertise to minimize our share of the capital costs.
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Current
Industry Conditions
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.
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
3
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.
CMAI currently 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 Corporation, or 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, in May of 2008,
Americas Styrenics LLC, a joint venture between The Dow Chemical Company and
Chevron Phillips Chemical Company, which includes selected styrene and
polystyrene assets of the two companies in North America and South America,
began operations.
Competitive
Strengths
World Class Acetic Acid Facility. Our acetic
acid facility, one of the largest in terms of production capacity in the world,
enjoys high reliability and we believe it is the second most efficient facility
in the world. With a rated annual production capacity of 1.1 billion
pounds, our acetic acid facility produces approximately 17% of total
North American capacity and approximately 5% of worldwide capacity. In
terms of production capacity, our acetic acid facility is the third largest
acetic acid facility in North America and the sixth largest in the world. Our
acetic acid facility produces acetic acid using BP Chemicals’ Cativa Technology,
which offers several advantages over competing production methods, including
lower energy requirements and lower fixed and variable costs.
Well-Positioned for Further Growth. Since 1986, we
and BP Chemicals have increased the annual rated production capacity of our
acetic acid facility by 126%, from 490 million pounds of annual production
capacity in 1986 to 1.1 billion pounds of annual production capacity today.
In 2007, our acetic acid facility operated at 99% of capacity, in part as a
result of its relatively low production costs and the efforts of BP Chemicals’
global sales organization. We also have undertaken projects with BP Chemicals to
ensure that we would be positioned to expand production capacity in the future.
For example, in 2003, we and BP Chemicals installed a larger reactor at our
acetic acid facility, which will continue to permit additional cost-effective
expansions of this facility. We expect a further expansion of the production
capacity of our facility to 1.2 billion pounds by 2009. Following this
expansion, we expect the facility to continue to operate at or near maximum
utilization rates.
Highly Contracted Sources of Cash Flows for Our Acetic Acid and
Plasticizers Products. Our business benefits from long-term
requirements contracts with BP Chemicals and BASF. We sell 100% of our acetic
acid production to BP Chemicals pursuant to the Production Agreement. Under the
Production Agreement, which runs through July 31, 2016, BP Chemicals
markets all of the acetic acid that we produce and pays us, among other amounts,
a portion of the profits earned from sales of the product. The Production
Agreement has allowed us to operate our acetic acid facility consistently at or
near full capacity and generate steadily growing cash flows. BP Chemicals’
largest customer for acetic acid produced at our acetic acid facility is
American Acetyls, a joint venture between BP Chemicals and The DOW Chemical
Company, which currently accounts for approximately 50% of the acetic acid we
produce. Sales to American Acetyls are made under a cost-plus contract that
extends until 2016. Much of the remaining sales of the acetic acid we produce
are made by BP Chemicals under multiple year contracts. This high percentage of
contractually committed volume has provided us with secure demand for our acetic
acid and steadily increasing cash flows.
Our long-term plasticizers business relationship with BASF,
established in 1986, was extended in 2006 until the end of 2013 subject to some
termination rights held by BASF beginning 2010. In December 2007, BASF caused
the shutdown of our PA unit by nominating zero pounds of PA in response to
deteriorating market conditions which are not expected to improve in the
foreseeable future. As a result of this shutdown, in May 2008, we entered into
an
4
amended production agreement with BASF, effective as of April 1,
2008. The amended agreement relieves BASF of most of its obligations related to
our PA manufacturing unit, requires that BASF pay approximately
$3.7 million to us for reimbursement of certain direct fixed and variable
costs associated with the shutdown and decontamination of our PA manufacturing
unit. The amended agreement also requires that BASF pay to us an aggregate
amount of approximately $3.2 million (the remaining $0.2 million of
which is required to be paid on or before August 15, 2008), subject to a
25%-75% refund right in BASF’s favor if we restart our PA unit before the end of
2010, depending on the year in which we restart the unit. Under the amended
agreement, BASF is still required to make the same quarterly fixed periodic
payments as previously required. In addition, under the amended production
agreement, the methods for calculating (i) payments required to be made by
BASF to us for achieving reductions in direct fixed and variable costs and
(ii) BASF’s right to terminate the agreement in the event that direct fixed
and variable costs exceed a specified threshold (unless we elect to cap BASF’s
reimbursement obligations), have both been modified to exclude costs savings and
direct fixed and variable costs pertaining to our PA manufacturing unit. The
amended agreement also removed all restrictions or rights BASF formerly had with
respect to our use or disposition of the PA manufacturing unit, including a
limited purchase right, the right to request capacity increases and consultation
rights regarding future capital expenditures with respect to our PA unit.
Additionally, in both contracts, principal raw materials are provided
by BP Chemicals and BASF, respectively, allow us to operate our business with
relatively low working capital requirements, including finished product
inventory requirements.
Well-Invested Production Assets. Over the past five
years, we and BP Chemicals invested $19 million in capital in our acetic
acid facility. A new and larger reactor was installed in 2003, which was sized
for an ultimate capacity in excess of 1.7 billion pounds of annual
production. A new and larger product column is expected to be installed during
the facility turnaround scheduled for 2009. All new capital investments for our
acetic acid facility are being made with a view to ultimately achieving
1.7 billion pound annual production capacity in a cost efficient manner. We
believe that the capital cost to expand our acetic acid facility to maximum
capacity would be significantly less than the cost for new capacity at a
greenfield location. In 2006, BASF invested approximately $4 million to
convert our plasticizers production unit over to a new range of esters as part
of the extension of its production agreement with us which runs until 2013. BASF
is responsible for all capital investment in the plasticizers, esters and
phthalic anhydride production facilities through the length of the agreement.
We and third parties subject to agreements with us invested a further
$22 million in site infrastructure capital over the past five years,
including the rebuilding of a ship dock and two barge docks. Given the condition
of our Texas City site and infrastructure, we anticipate spending only
approximately $2 million annually on utilities and services maintenance
over the next five years.
Attractive Logistics Assets and Infrastructure. Our
logistics assets include strategic access to the intercoastal waterway and the
Gulf of Mexico, a deep water dock capable of handling ships with up to a 40-foot
draft, as well as four barge docks, direct access to Union Pacific and
Burlington Northern Santa Fe railways with in-motion rail scales on site, truck
loading racks, weigh scales, stainless and mild steel storage tanks, three waste
deepwells, 160 acres of available land zoned for heavy industrial use and
additional land zoned for light industrial use and a supportive political
environment for growth. We are in the heart of one of the largest petrochemical
complexes on the Gulf Coast, in close proximity to a number of large refinery
complexes. As a result, we have on-site
access to a number of key raw material pipelines and convenient access to
several of our suppliers and customers. Currently, our dock facilities can
accommodate new uses and we have 31 tanks available for third party use. These
assets present a substantial opportunity to grow our business by attracting new
businesses to our Texas City site and significant opportunities for further
development.
Leading Market Position in Acetic Acid
Production. We have a leading market position in acetic acid. Our
rated annual production capacity for acetic acid of 1.1 billion pounds
represents 17% of the total North American production capacity and 5% of the
global production capacity. In acetic acid, we are the third largest producer in
North America with a low cost position derived from our use of BP Chemicals’
Cativa Technology, global sales and marketing network and acetyls know-how.
5
Experienced Management Team. Our senior management
team consists of five executives with an average of over 20 years of
experience in the chemicals industry, 11 years of which have been with us.
Our management team has demonstrated expertise in capturing cost efficiencies,
project development, improving profitability and expanding profitable production
capacity, while exiting unprofitable businesses through various economic cycles.
Business
Strategy
Grow Our Business. We believe that our acetic acid
facility is positioned for cost-effective future capacity expansions at lower
incremental cost due to previous investments made by us and BP Chemicals,
including the installation of a new reactor in 2003 that is capable of producing
up to 1.7 billion pounds of acetic acid annually. We intend to grow our
acetic acid business through capacity expansions that take advantage of this
positioning. Currently, we have low-cost debottlenecking opportunities which
could increase annual capacity of our acetic acid facility to approximately
1.2 billion pounds, an increase of approximately 7%.
Our Texas City site offers approximately 160 acres for future
expansion by us or by other companies that can benefit from our existing
infrastructure and facilities, and includes a greenbelt around the northern edge
of the plant site. Our Texas City site is strategically located on Galveston Bay
and we benefit 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, 160 acres of available
land zoned for heavy industrial use and 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 key raw material pipelines and are in close proximity to a
number of the larger refinery complexes.
Given our under-utilized infrastructure, our management and
engineering expertise, as well as ample unoccupied land, we believe that there
are significant opportunities for further development of our Texas City site. We
are currently pursuing numerous initiatives to attract new manufacturing and/or
storage related businesses to our Texas City site, including opportunities
involving renewable fuels projects, gasification, energy projects and chemicals
terminalling. Specifically, we are seeking long-term contractual business
arrangements or partnerships that will provide us with an ability to realize the
value of our under-utilized assets through profit sharing or other cash
generating arrangements. For development projects that may have significant
capital expenditure requirements, we are considering joint ventures or other
arrangements where we would contribute certain of our assets and management
expertise to minimize our share of the capital costs. In any case, we expect any
new facility constructed at our Texas City site to lower the amount of overall
fixed costs allocated to each of our operating units and provide us with
additional profit.
We plan to evaluate strategic acquisitions, focusing on chemical
businesses and assets which would allow us to increase our market share of
products we currently produce or those that would provide upstream or downstream
integration within our existing businesses.
Improve Organization Efficiency and Cost
Structure. We continually seek to improve our cost
competitiveness through organizational efficiencies, productivity enhancements,
operating controls and general cost reductions. We believe that the expansion of
our acetic acid business, the further development of our Texas City site and
acquisitions will lead to further cost efficiencies.
6
Recent
Developments
In May 2008, we entered into an amended production agreement with
BASF, effective as April 1, 2008. This amended agreement was entered into
in connection with BASF’s nomination of zero pounds of PA under the existing
production agreement due to deteriorating market conditions which were not
expected to improve over the next few years, which resulted in the shutdown of
our PA unit. See “Management’s Discussion and Analysis of Financial Condition
and Results of Operations — Recent Developments” and “Business —
Contracts.”
Effective as of May 27, 2008, John V. Genova was appointed as
our President and Chief Executive Officer and was elected as a member of our
Board of Directors. Mr Genova succeeded Richard K. Crump, who retired as
President and Chief Executive Officer as of May 27, 2008. Mr. Crump
will remain a member of our Board of Directors.
Principal
Executive Offices
Our principal executive offices are located at 333 Clay Street,
Suite 3600, Houston, Texas 77002-4109 and our telephone number is (713) 650-3700. Our corporate website
address is www.sterlingchemicals.com. The information contained on our corporate
website is not part of this prospectus.
7
THE EXCHANGE
OFFER
You are entitled to exchange in the exchange offer your
outstanding unregistered notes for registered notes with substantially identical
terms. The summary below describes the principal terms of the exchange offer.
Certain of the terms and conditions described below are subject to important
limitations and exceptions. You should read the discussion under the heading
“Description of Notes” for further information regarding the registered
notes.
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| The Exchange Offer |
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We are offering to exchange up to $150,000,000 aggregate
principal amount of our registered 101/4% Senior Secured Notes due 2015, for a
like principal amount of our unregistered 101/4% Senior Secured Notes due 2015, which
were issued on March 29, 2007. |
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| Registration Rights |
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Under the registration rights agreement executed as part
of the offering of the unregistered notes, we agreed to use our
commercially reasonable efforts to: |
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• file a
registration statement within 180 days after the issue date of the
unregistered notes, or by September 25, 2007, enabling holders of
unregistered notes to exchange the unregistered notes for registered notes
with substantially identical terms; |
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• cause the
registration statement to become effective within 270 days after the
issue date of the unregistered notes, or by December 24, 2007, and to
complete the exchange offer within 50 days after the effective date
of our registration statement; and |
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• file a shelf
registration statement for the resale of the notes if we cannot effect an
exchange offer within the time periods listed above and in other
circumstances. |
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The interest rate on the unregistered notes has
increased as we have not complied with our obligations under the
registration rights agreement and will continue at such increased rate
until the registration statement of which this prospectus forms a part is
declared effective. |
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| Resales |
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Based on an interpretation by the staff of the SEC set
forth in no-action letters issued to third parties, we believe that the
registered notes issued pursuant to the exchange offer in exchange for
unregistered notes may be offered for resale, resold and otherwise
transferred by you (unless you are our “affiliate” within the meaning of
Rule 405 of the Securities Act) without compliance with the
registration and prospectus delivery provisions of the Securities Act,
provided that you: |
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• are acquiring the
registered notes in the ordinary course of business; and |
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• have not engaged
in, do not intend to engage in and have no arrangement or understanding
with any person or entity, including any of our affiliates, to participate
in, a distribution of the registered notes. |
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In addition, each participating broker-dealer that
receives registered notes for its own account pursuant to the exchange
offer in exchange for unregistered notes that were acquired as a result of
market-making or other trading activity must also acknowledge that it will
deliver a prospectus in connection with any resale of the exchange notes.
For more information, see “Plan of
Distribution.” |
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Any holder of unregistered notes, including any
broker-dealer, who |
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• is our
affiliate, |
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• does not acquire
the registered notes in the ordinary course of its business,
or |
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• tenders in the
exchange offer with the intention to participate, or for the purpose of
participating, in a distribution of registered notes, |
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cannot rely on the position of the staff of the SEC
expressed in Exxon Capital Holdings Corporation, Morgan Stanley &
Co., Incorporated or similar no-action letters and, in the absence of an
exemption, must comply with the registration and prospectus delivery
requirements of the Securities Act in connection with the resale of the
registered notes. |
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| Expiration Time |
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The exchange offer will expire at 5:00 p.m., New
York City time,
on , 2008,
unless we extend the exchange offer in our sole discretion, in which case
the term “expiration time” means the latest date and time to which the
exchange offer is extended. We do not currently intend to extend the
expiration date. |
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| Conditions to the Exchange Offer |
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The exchange offer is subject to customary conditions,
some of which we may waive. For more information, see “The Exchange
Offer — Certain Conditions to the Exchange Offer.” |
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| Procedures for Tendering Unregistered Notes |
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If you wish to exchange your unregistered notes in the
exchange offer, you must complete, sign and date the accompanying letter
of transmittal, or a copy of the letter of transmittal, according to the
instructions contained in this prospectus and the letter of transmittal.
You must also mail or otherwise deliver the letter of transmittal, or the
copy, together with the unregistered notes and any other required
documents, to the exchange agent at the address set forth on the cover of
the letter of transmittal. If you hold unregistered notes through The
Depository Trust Company, or DTC, and wish to participate in the
exchange offer, you must comply with the Automated Tender Offer Program
procedures of DTC, by which you will agree to be bound by the letter of
transmittal. |
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By signing or agreeing to be bound by the letter of
transmittal, you will represent to us that, among other things: |
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• any registered
notes that you receive will be acquired in the ordinary course of your
business; |
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• you have no
arrangement or understanding with any person or entity, including any of
our affiliates, to participate in the distribution of the registered
notes; |
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• you are not our
“affiliate” as defined in Rule 405 of the Securities Act, or, if you
are an affiliate, you will comply with any applicable registration and
prospectus delivery requirements of the Securities Act; and |
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• if you are a
broker-dealer that will receive registered notes for your own account in
exchange for unregistered notes that were acquired as a result of
market-making activities, you will deliver a
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prospectus, as required by law, in connection with any
resale of the registered notes. |
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| Withdrawal of Tenders |
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A tender of unregistered notes pursuant to this exchange
offer may be withdrawn at any time prior to the expiration date. Any
unregistered notes not accepted for exchange for any reason will be
returned without expense to the tendering holder promptly after the
expiration or termination of this exchange offer. |
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| Guaranteed Delivery Procedures |
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If you wish to tender your unregistered notes and your
unregistered notes are not immediately available or you cannot deliver
your unregistered notes, the letter of transmittal or any other documents
required by the letter of transmittal or comply with the applicable
procedures under DTC’s Automated Tender Offer Program prior to the
expiration date, you must tender your unregistered notes according to the
guaranteed delivery procedures set forth in this prospectus under “The
Exchange Offer — Guaranteed Delivery.” |
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| Delivery of the Registered Notes |
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The registered notes issued pursuant to this exchange
offer will be delivered to holders who tender unregistered notes promptly
following the expiration time. |
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| Effect on Holders of Unregistered Notes |
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As a result of the making of, and upon acceptance for
exchange of all validly tendered unregistered notes pursuant to the terms
of the exchange offer, we will have fulfilled a covenant contained in the
registration rights agreement and, accordingly, we will not be obligated
to pay additional interest as described in the registration rights
agreement. If you are a holder of unregistered notes and do not tender
your unregistered notes in the exchange offer, you will continue to hold
such unregistered notes and you will be entitled to all the rights and
limitations applicable to the unregistered notes in the indenture, except
for any rights under the registration rights agreement that by their terms
terminate upon the consummation of the exchange offer. |
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| Consequences of Failure to Exchange |
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All untendered unregistered notes will continue to be
subject to the restrictions on transfer provided for in the unregistered
notes and in the indenture. In general, the unregistered notes may not be
offered or sold unless registered under the Securities Act, except
pursuant to an exemption from, or in a transaction not subject to, the
Securities Act and applicable state securities laws. Other than in
connection with this exchange offer, we do not anticipate that we will
register the unregistered notes under the Securities Act. |
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| Material United States Federal Income Tax
Consequences |
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The exchange of unregistered notes for registered notes
in the exchange offer should not be a taxable event for U.S. federal
income tax purposes. For more information, see “Material U.S. Federal
Income Tax Consequences.” |
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| Use of Proceeds |
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We will not receive any cash proceeds from the issuance
of the registered notes. |
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| Exchange Agent |
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U. S. Bank National Association is the exchange agent
for this exchange offer. The address and telephone number of the exchange
agent are set forth in the section captioned “The Exchange Offer —
Exchange Agent.” |
10
THE
REGISTERED NOTES
The summary below describes the principal terms of the registered
notes. Some of the terms and conditions described below are subject to important
limitations and exceptions. The “Description of Notes” section of this
prospectus contains a more detailed description of the terms and conditions of
the registered notes.
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| Issuer |
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Sterling Chemicals, Inc. |
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| Securities Offered |
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$150.0 million aggregate principal amount of
101/4% senior secured notes. |
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| Maturity Date |
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April 1, 2015. |
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| Interest |
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We will pay interest in cash on the principal amount of
the registered notes at an annual rate of 101/4%. Interest will be payable in cash
semi-annually in arrears on April 1 and October 1 of each year, beginning
October 1, 2007. |
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| Guarantees |
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The registered notes will be unconditionally guaranteed
by all of our domestic restricted subsidiaries on a senior secured basis.
Currently, we do not have any domestic restricted subsidiaries. |
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| Collateral |
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The registered notes and the guarantees, if any, will be
secured, subject to specified permitted liens, by a first priority lien on
substantially all of our and any guarantors’ fixed assets and certain
related assets, including, without limitation, all property, plant and
equipment. The first priority lien will not extend to assets securing our
revolving credit facility. The registered notes and any guarantees will be
secured, subject to specified permitted liens, by a second priority lien
on our and the guarantors’ other assets including, without limitation,
accounts receivable, inventory, capital stock of our and their respective
direct subsidiaries, certain intellectual property, deposit accounts and
investment property securing on a first priority basis the obligations
under our revolving credit facility. Consequently, the registered notes
and any guarantees will be effectively subordinated to the revolving
credit facility to the extent of the value of the assets securing our
revolving credit facility. See “Description of Notes —
Collateral.” |
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| Ranking |
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The registered notes will be: |
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• senior secured
obligations of the Issuer; |
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• equal in right of
payment with all existing and future senior indebtedness of the
Issuer; |
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• effectively senior
to all existing and future senior unsecured indebtedness of the Issuer to
the extent of the value of the assets securing the registered notes;
and |
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• senior in right of
payment to all existing and future subordinated indebtedness of the
Issuer. |
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The guarantee of any guarantor will be: |
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• senior secured
obligations of that guarantor; |
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• equal in right of
payment with all of that guarantor’s existing and future senior
indebtedness, including guarantees; |
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• effectively senior
to all of that guarantor’s existing and future senior unsecured
indebtedness to the extent of the value of the assets securing the
registered notes; and |
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• senior in right of
payment to all of that guarantor’s existing and future subordinated
indebtedness. |
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As of March 31, 2008, we had $150 million of
senior indebtedness, all of which would have represented outstanding
principal under the unregistered notes. The indenture governing the
registered notes permits us, subject to specified limitations, to incur
additional debt, some or all of which may be senior indebtedness. |
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| Optional Redemption |
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We may redeem some or all of the senior secured notes at
any time prior to April 1, 2011 at the make-whole redemption price
set forth in “Description of Notes.” We may redeem the senior secured
notes, in whole or in part, at any time on and after April 1, 2011 at
the redemption prices described in the section “Description of
Notes — Optional Redemption — Optional Redemption on or after
April 1, 2011,” plus accrued and unpaid interest to the date of
redemption. |
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In addition, prior to April 1, 2010, we may redeem
up to 35% of our senior secured notes with the net cash proceeds from
specified equity offerings at a redemption price equal to 110.25% of the
aggregate principal amount, plus accrued and unpaid interest to the date
of redemption, so long as at least 65% of the aggregate principal amount
of the senior secured notes issued under the indenture remain outstanding
immediately after the redemption. See “Description of Notes —
Optional Redemption — Optional Redemption Upon Equity
Offerings.” |
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| Change of Control Offer |
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If we undergo a change of control, we must offer to
repurchase the senior secured notes at a purchase price equal to 101% of
the aggregate principal amount, plus accrued and unpaid interest to the
date of repurchase. See “Description of Notes — Repurchase upon
Change of Control.” |
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| Asset Sale or Event of Loss Offer |
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If we engage in certain sales or suffer a loss of
material plant, property or equipment that constitutes collateral securing
the senior secured notes, we generally must invest the net cash proceeds
from such sales and losses in our business within 360 days or make an
offer to repurchase a principal amount of senior secured notes equal to
the net cash proceeds, in which case the purchase price of the senior
secured notes will be 100% of their aggregate principal amount, plus
accrued and unpaid interest to the date of such repurchase. See
“Description of Notes — Certain Covenants — Asset Sales” and
“Description of Notes — Event of Loss.” |
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| Certain Indenture Covenants |
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The registered notes will be issued under the same
indenture that governs our unregistered notes, which agreement restricts
our and any guarantor’s ability to, among other things: |
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• pay dividends,
redeem stock, prepay subordinated indebtedness or make other restricted
payments; |
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• incur indebtedness
or issue disqualified capital stock; |
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• make certain
investments; |
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• create liens on
assets; |
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• restrict dividend
payments or other payments from subsidiaries to us; |
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• consolidate or
merge; |
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• sell or otherwise
transfer or dispose of assets, including equity interests of restricted
subsidiaries; |
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• enter into
transactions with affiliates; |
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• designate
subsidiaries as unrestricted subsidiaries; |
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• use the proceeds
of permitted sales of assets; and |
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• change our line of
business. |
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These covenants are subject to a number of important
exceptions. For more details, see “Description of Notes — Certain
Covenants.” |
13
SUMMARY
HISTORICAL CONSOLIDATED FINANCIAL DATA
The following table sets forth our summary historical consolidated
financial data as of the dates and for the periods indicated. The historical
consolidated statement of operations data for each of the three fiscal years
ended December 31, 2005, December 31, 2006 and December 31, 2007
and the three months ended March 31, 2007 and 2008 and the historical
consolidated balance sheet data as of March 31, 2008 are derived from, and
are qualified in their entirety by, our historical consolidated financial
statements included elsewhere in this prospectus. The results of any interim
period are not necessarily indicative of the results that may be expected for
any other interim period or for the full fiscal year, and the historical results
set forth below do not necessarily indicate results expected for any future
period.
You should read the following summary and financial data together
with “Business,” “Selected Historical Consolidated Financial and Operating
Data,” “Management’s Discussion and Analysis of Financial Condition and Results
of Operations” and our consolidated financial statements and related notes
appearing elsewhere in this prospectus.
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 will exit the styrene
business to pursue other strategic initiatives. Due to the shut down of our
styrene plant, we have reported the operating results of the styrene business as
discontinued operations in our consolidated financial statements beginning in
the first quarter of 2008. All prior periods have been reclassified. The
selected financial data presented below includes our styrene business in
discontinued operations. In the following tables (including the footnotes
thereto), dollars are in thousands, except as otherwise indicated.
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
Three Months
Ended
|
|
| |
|
Year Ended December 31, |
|
|
March 31, |
|
| |
|
2005(1) |
|
|
2006(1) |
|
|
2007 |
|
|
2007(1) |
|
|
2008 |
|
| |
|
(Dollars in
thousands) |
|
| |
|
Statement of
Operations Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues |
|
$ |
128,098 |
|
|
$ |
141,259 |
|
|
$ |
129,813 |
|
|
$ |
32,715 |
|
|
$ |
38,199 |
|
|
Cost of goods sold
|
|
|
120,254 |
|
|
|
127,413 |
|
|
|
116,431 |
|
|
|
27,088 |
|
|
|
33,799 |
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross profit |
|
|
7,844 |
|
|
|
13,846 |
|
|
|
13,382 |
|
|
|
5,627 |
|
|
|
4,400 |
|
|
Selling, general and
administrative expenses |
|
|
6,548 |
|
|
|
7,073 |
|
|
|
8,679 |
|
|
|
2,298 |
|
|
|
2,418 |
|
|
Other expense (income)
|
|
|
— |
|
|
|
(724 |
) |
|
|
839 |
|
|
|
— |
|
|
|
— |
|
|
Interest and debt
related expenses, net of interest income |
|
|
10,090 |
|
|
|
10,079 |
|
|
|
15,706 |
|
|
|
3,385 |
|
|
|
2,887 |
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from continuing
operations before income tax |
|
$ |
(8,794 |
) |
|
$ |
(2,582 |
) |
|
$ |
(11,842 |
) |
|
$ |
(56 |
) |
|
$ |
(905 |
) |
|
Benefit for income
taxes |
|
|
(2,938 |
) |
|
|
(388 |
) |
|
|
(4,129 |
) |
|
|
— |
|
|
|
— |
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from continuing
operations |
|
$ |
(5,856 |
) |
|
$ |
(2,194 |
) |
|
$ |
(7,713 |
) |
|
$ |
(56 |
) |
|
$ |
(905 |
) |
|
Income (loss) from
discontinued operations, net of tax |
|
|
(23,712 |
) |
|
|
(103,465 |
) |
|
|
(11,215 |
) |
|
|
2,725 |
|
|
|
(6,224 |
) |
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss)
|
|
$ |
(29,568 |
) |
|
$ |
(105,659 |
) |
|
$ |
(18,928 |
) |
|
$ |
2,669 |
|
|
$ |
(7,129 |
) |
|
Other Financial
Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Depreciation and
amortization(2) |
|
|
33,342 |
|
|
|
30,476 |
|
|
|
10,908 |
|
|
|
2,729 |
|
|
|
2,635 |
|
|
Capital
expenditures(3) |
|
|
9,460 |
|
|
|
11,547 |
|
|
|
6,411 |
|
|
|
2,248 |
|
|
|
2,037 |
|
|
Ratio of earnings to
fixed charges(4) |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
|
| (1) |
|
We have restated our
consolidated financial statements and selected financial data for the
fiscal years ended December 31, 2006 and 2005 and three months ended
March 31, 2007. For further information, see Note 16 to the
consolidated financial statements for the year ended December 31, 2006 and
2005, and Note 15 to the consolidated financial statements for the quarter
ended March 31, 2007, found elsewhere in this prospectus.
|
| |
| (2) |
|
Includes depreciation and
amortization for discontinued operations for the years ended December 31,
2005, 2006 and 2007, and for the three months ended March 31, 2007 and
2008 of $23.8 million, $18.1 million, $1.0 million, $0.6 million and $0.1
million, respectively. |
14
|
|
|
| (3) |
|
Includes capital
expenditures for discontinued operations for the years ended December 31,
2005, 2006 and 2007 and for the three months ended March 31, 2007 and
2008 of $4.6 million, $6.6 million, $2.6 million, $1.5 million and zero,
respectively. |
| |
| (4) |
|
Additional pre-tax earnings
needed to achieve a 1:1 ratio for the years ended December 31, 2005,
2006 and 2007 and for the three months ended March 31, 2007 and 2008
were $8.8 million, $2.6 million, $11.8 million, less than
$0.1 million, and $0.9 million, respectively.
|
| |
|
|
|
|
| |
|
As of
March 31,
|
|
| |
|
2008 |
|
| |
|
Summary Balance
Sheet Data: |
|
|
|
|
|
Cash and cash
equivalents |
|
$ |
170,459 |
|
|
Accounts receivable,
net |
|
|
11,713 |
|
|
Inventories, net
|
|
|
5,211 |
|
|
Property, plant and
equipment, net |
|
|
76,678 |
|
|
Total assets |
|
|
287,225 |
|
|
Total liabilities
|
|
|
268,575 |
|
|
Redeemable preferred
stock |
|
|
104,137 |
|
|
Stockholders’
deficiency in assets |
|
|
(85,487 |
) |
15
RISK
FACTORS
An investment in the notes involves certain risks. You should
consider carefully these risks together with all of the other information
included in this prospectus before deciding whether this investment is suitable
for you.
Risks Related
to Our Business
Substantially all of our products
are 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 more of the long-term contracts
for the purchase of these products, or a material reduction in the amount of
product purchased under either of these contracts, could materially adversely
affect our overall business, financial condition, results of operations or cash
flows.
Our ability
to realize increases in our acetic acid production capacity made possible
through capacity expansions is limited by our 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 a partial oxidation unit
constructed by Praxair 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 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.
Moreover, the supply of sufficient quantities of carbon monoxide will likely
require the construction of a new supply pipeline, which will require numerous
third party and regulatory consents, or a substantial expansion of the Praxair
oxidation unit. The expansion of the Praxair 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 to
1.7 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:
|
|
|
| |
• |
pipeline or storage tank leaks and ruptures, explosions and
fires; |
| |
| |
• |
severe weather and natural disasters; |
| |
| |
• |
mechanical failures, unscheduled downtimes, labor
difficulties and transportation interruptions; |
| |
| |
• |
environmental remediation complications; and |
| |
| |
• |
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.
16
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 from
terrorist acts 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 can make no assurances that we can renew our
existing insurance coverages at commercially reasonable rates or that such
coverage will be adequate to cover future claims that may arise.
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 or property damage from exposure to hazardous
materials caused by a terrorist attack. Such loss of production, sales, or
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.
The attacks of September 11, 2001 and subsequent events,
including the current military action in Iraq, have caused 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, the terrorist attacks, subsequent events or future 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 future
terrorist attacks than other potential targets in the United States. As a
result, the chemical industry has responded to the issues surrounding the
terrorist attacks of September 11, 2001 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 because of 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,
17
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
to 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.
Approximately 39% 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 March 31, 2008, we had 236 employees, of whom
approximately 39% (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, 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 and cash flows.
18
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, or Series A 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:
|
|
|
| |
• |
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.
Risks Relating
to the Notes
Our
leverage and debt service obligations may adversely affect our cash flow and our
ability to make payments on the notes.
As of March 31, 2008, we had total long-term debt of
$150.0 million (consisting of outstanding principal on the unregistered
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 regulation. We cannot be
certain that our earnings will be
19
sufficient to allow us to pay the principal and interest on our debt,
including the 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 the 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 our indebtedness could result in an event of
default under such indebtedness, which could 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 payment of interest on and principal of our
debt in the future, including payments on the 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.
There may
not be sufficient collateral to pay all or any of the notes.
The notes and the related guarantees, if any, are secured, subject to
certain permitted liens, by a first priority lien on substantially all of our
and any guarantors’ fixed assets and certain related assets, or the primary
collateral, including, without limitation, all property, plant and equipment.
See “Description of Notes — Collateral.” Concurrently with the closing of
the offering of our unregistered notes, we amended and restated our revolving
credit facility. Our revolving credit facility has a first priority lien on all
assets that do not constitute primary collateral, or the secondary collateral,
including without limitation, accounts receivable, inventory, capital stock of
certain of our subsidiaries, intellectual property, deposit accounts and
investment property. The notes and any related guarantees are secured by a
second priority lien on the secondary collateral.
Although the noteholders may share in the proceeds of the secondary
collateral, the lenders under our revolving credit facility are entitled to
receive proceeds from any realization of their first priority collateral to
repay their obligations in full before the noteholders will receive any
repayment. Therefore, your security interest in the secondary collateral ranks
behind that of the lenders under our revolving credit facility. In addition, the
noteholders will not generally have any control over the secondary collateral
even if the notes are in default.
We cannot assure you of the value of the primary collateral and
secondary collateral, or the collateral. We further cannot assure you that the
net proceeds of a sale of the collateral would be sufficient to repay all of the
notes following a foreclosure upon the collateral (and any payments in respect
of prior liens) or a liquidation of our assets or the assets of any guarantors
that may grant these security interests. As of March 31, 2008, the book
value of the primary collateral was $76.7 million. The value of the
collateral at any time will depend upon market and other economic conditions,
including the availability of suitable buyers for the collateral. By their
nature, some of the pledged assets may be illiquid and may have no readily
ascertainable market value. The value of the assets constituting the collateral
could be impaired in the future as a result of changing economic conditions and
other factors beyond our control. In the event of a foreclosure, liquidation,
bankruptcy or similar proceeding, the proceeds from any sale or liquidation of
the collateral may be insufficient to pay our obligations under the notes in
full.
If the net proceeds received from the sale of the collateral, after
payment of our creditors having first priority security interests in the
collateral for which the noteholders hold a second priority lien, are not
sufficient to repay all amounts due with respect to the notes, you would, to the
extent of the insufficiency, have only an unsecured claim against any
guarantors’ remaining assets, if any. Moreover, the ability of the trustee for
the notes to foreclose upon the collateral securing the notes would be delayed
if we, or any future guarantors, were subject to proceedings under applicable
bankruptcy law.
The
security documents allow us to remain in possession of the
collateral.
The security documents allow us and our subsidiaries to remain in
possession of, retain exclusive control over, freely operate, and collect,
invest and dispose of any income from the collateral securing the notes. In
addition, to
20
the extent we sell any assets that constitute collateral, the
proceeds from such sale will be subject to the liens securing the notes only to
the extent such proceeds would otherwise constitute “collateral” securing the
notes under the security documents. To the extent the proceeds from any such
sale of collateral do not constitute “collateral” under the security documents,
the pool of assets securing the notes would be reduced and the notes would not
be secured by such proceeds.
In the
event of a bankruptcy, the ability of the noteholders to realize upon the
collateral will be subject to certain bankruptcy law limitations.
The ability of noteholders to realize upon the collateral will be
subject to certain bankruptcy law limitations in the event of our bankruptcy or
the bankruptcy of any guarantors. Under applicable federal bankruptcy laws,
secured creditors are prohibited from repossessing their security from a debtor
in a bankruptcy case, or from disposing of security repossessed from such a
debtor, without bankruptcy court approval. Moreover, applicable federal
bankruptcy laws generally permit the debtor to continue to retain collateral
even though the debtor is in default under the applicable debt instruments,
provided generally that the secured creditor is given “adequate protection.” The
meaning of the term “adequate protection” may vary according to the
circumstances, but is intended in general to protect the value of the secured
creditor’s interest in the collateral at the commencement of the bankruptcy case
and may include cash payments or the granting of additional security, if and at
such times as the court in its discretion determines, for any diminution in the
value of the collateral as a result of the stay of repossession or disposition
of the collateral by the debtor during the pendency of the bankruptcy case. In
view of the lack of a precise definition of the term “adequate protection” and
the broad discretionary powers of a bankruptcy court, we cannot predict whether
payments under the notes would be made following commencement of and during a
bankruptcy case, whether or when the collateral agent, on behalf of the trustee
and the noteholders, could foreclose upon or sell the collateral or whether or
to what extent noteholders would be compensated for any delay in payment or loss
of value of the collateral through the requirement of “adequate protection.”
Furthermore, in the event the bankruptcy court determines that the value of the
collateral is not sufficient to repay all amounts due on the notes, noteholders
would hold “undersecured claims.” Applicable federal bankruptcy laws do not
permit the payment or accrual of interest, costs and attorney’s fees for
“undersecured claims” during a debtor’s bankruptcy case.
The
intercreditor agreement limits the ability of the noteholders to realize upon
the collateral.
Concurrently with the closing of the offering of our unregistered
notes on March 29, 2007, U. S. Bank National Association, in its
capacity as the collateral agent, entered into an intercreditor agreement with
the credit facility agent under our revolving credit facility. Under the terms
of the intercreditor agreement, your security interest in the secondary
collateral is subordinated to the security interest held by the lenders under
our revolving credit facility.
If we incur any other secondary collateral loans, the applicable
lender will enter into a counterpart to the intercreditor agreement, or
agreement similar to the existing intercreditor agreement, with the collateral
agent. The terms of the intercreditor agreement provide that you will generally
have no rights in the secondary collateral (including any rights in the manner
of disposing the secondary collateral) until all of our obligations owing to the
lenders under our revolving credit facility have been paid in full. See
“Description of Notes — Collateral — Intercreditor Agreement.” The
lenders who are secured by the first priority security interests in the
secondary collateral will generally have control over releasing those assets
subject to the terms of the intercreditor agreement with the collateral agent.
These lenders may have significantly different interests than the noteholders
and may have very little indebtedness outstanding. The credit facility agent and
the lenders under our revolving credit facility are under no obligation to take
the interests of the noteholders into account in determining whether to exercise
their rights in respect of the secondary collateral, subject to the
intercreditor agreement, and their interests may differ or be adverse from
yours. See “Description of Notes — Collateral — Intercreditor
Agreement.”
Rights of
noteholders in the collateral may be adversely affected by the failure to
perfect security interests in certain collateral existing or acquired in the
future.
The security interest in the collateral securing the notes includes
domestic assets, both tangible and intangible, whether now owned or acquired or
arising in the future. There can be no assurance that the trustee or the
collateral agent will monitor, or that we will inform the trustee or the
collateral agent of, the future acquisition of property and
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rights that constitute collateral, and that the necessary action will
be taken to properly perfect the security interest in such after acquired
collateral. The failure to perfect a security interest in respect of such
acquired collateral may result in the loss of the security interest therein or
the priority of the security interest in favor of the notes against third
parties.
If we or any guarantor were to become subject to a bankruptcy
proceeding after the issue date of the notes, any liens recorded or perfected
after the issue date of the notes would face a greater risk of being invalidated
than if they had been recorded or perfected on the issue date. If a lien is
recorded or perfected after the issue date, it may be treated under bankruptcy
law as if it were delivered to secure previously existing debt. In bankruptcy
proceedings commenced within 90 days of lien perfection, a lien given to
secure previously existing debt is materially more likely to be avoided as a
preference by the bankruptcy court than if delivered and promptly recorded on
the issue date of the notes. Accordingly, if we or any guarantor were to file
for bankruptcy after the issue date of the notes and the liens had been
perfected less than 90 days before commencement of such bankruptcy
proceeding, the liens securing the notes may be especially subject to challenge
as a result of having been delivered after the issue date of the notes. To the
extent that such challenge succeeded, you would lose the benefit of the security
that the collateral was intended to provide.
Federal and
state statutes allow courts, under specific circumstances, to void guarantees
and require noteholders to return payments received from
guarantors.
Under the federal bankruptcy law and comparable provisions of state
fraudulent transfer laws, a guarantee could be voided, or claims in respect of a
guarantee could be subordinated to all other debts of that guarantor if, among
other things, the guarantor, at the time it incurred the indebtedness evidenced
by its guarantee:
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received less than reasonably equivalent value or fair
consideration for the incurrence of such guarantee; |
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was insolvent or rendered insolvent by reason of such
incurrence; |
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was engaged in a business or transaction for which the
guarantor’s remaining assets constituted unreasonably small
capital; or |
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intended to incur, or believed that it would incur, debts
beyond its ability to pay such debts as they mature. |
In addition, any payment by that guarantor pursuant to its guarantee
could be voided and required to be returned to the guarantor, or to a fund for
the benefit of the creditors of the guarantor.
The measures of insolvency for purposes of these fraudulent transfer
laws will vary depending upon the law applied in any proceeding to determine
whether a fraudulent transfer has occurred. Generally, however, a guarantor
would be considered insolvent if:
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the sum of its debts, including contingent liabilities, was
greater than the fair saleable value of all of its assets; |
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if the present fair saleable value of its assets was less
than the amount that would be required to pay its probable liability on
its existing debts, including contingent liabilities, as they become
absolute and mature; or |
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it could not pay its debts as they become due.
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We may not
have the ability to raise the funds necessary to finance any change of control
offer required by the indenture.
Upon the occurrence of certain specific kinds of change of control
events, we are required to offer to repurchase all of our outstanding senior
secured notes at 101% of the aggregate principal amount thereof plus accrued and
unpaid interest to the date of repurchase. We cannot assure you that we will
have sufficient funds at the time of the change of control to make the required
repurchase of all the senior secured notes. Any such failure to comply with this
offer and repurchase obligation would constitute an event of default under the
indenture. See “Description of Notes — Repurchase upon Change of Control.”
22
THE EXCHANGE
OFFER
Purpose and
Effect of the Exchange Offer
We entered into a registration rights agreement with the initial
purchasers of the unregistered notes, in which we agreed to file a registration
statement relating to an offer to exchange the unregistered notes for the
registered notes. The registration statement of which this prospectus forms a
part was filed in compliance with this obligation. We also agreed to use our
commercially reasonable efforts to cause the registration statement to become
effective under the Securities Act. The registered notes will have terms
substantially identical to the unregistered notes except that the registered
notes will not contain terms with respect to transfer restrictions, registration
rights and additional interest payable for the failure to comply with our
obligations under the registration rights agreement. Unregistered notes in an
aggregate principal amount of $150.0 million were issued on March 29,
2007.
Each holder of unregistered notes that wishes to exchange such
unregistered notes for transferable registered notes in the exchange offer will
be required to make the following representations:
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that any registered notes to be received by it will be
acquired in the ordinary course of its business; |
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that at the time of the commencement of the exchange offer
it has no arrangement or understanding with any person to participate in
the distribution (within the meaning of Securities Act) of the registered
notes in violation of the Securities Act; |
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that it is not our “affiliate” (as defined in Rule 405
promulgated under the Securities Act), or, if it is an affiliate, that it
will comply with any applicable registration and prospectus delivery
requirements of the Securities Act; |
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if such holder is not a broker-dealer, that it is not
engaged in, and does not intend to engage in, the distribution of
registered notes; and |
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if such holder is a broker-dealer that will receive
registered notes for its own account in exchange for notes that were
acquired as a result of market-making or other trading activities, that it
will deliver a prospectus in connection with any resale of such registered
notes. |
In addition, the SEC has taken the position that each broker-dealer
that receives registered notes for its own account in exchange for unregistered
notes, where such unregistered notes were acquired by such broker-dealer as a
result of market-making activities or other trading activities, may fulfill
their prospectus delivery requirements with respect to the registered notes
(other than a resale of an unsold allotment from the original sale of the
registered notes) by delivering a prospectus in connection with any resale of
such registered notes. See “Plan of Distribution.”
Resale of
Registered Notes
Based on interpretations of the SEC staff set forth in no-action
letters issued to unrelated third parties, we believe that registered notes
issued in the exchange offer in exchange for unregistered notes may be offered
for resale, resold and otherwise transferred by any exchange note holder without
compliance with the registration and prospectus delivery provisions of the
Securities Act, if:
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such holder is not an “affiliate” of ours within the
meaning of Rule 405 under the Securities Act; |
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such registered notes are acquired in the ordinary course
of the holder’s business; and |
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the holder does not intend to participate in the
distribution of such registered notes. |
Any holder who tenders in the exchange offer with the intention of
participating in any manner in a distribution of the registered notes:
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cannot rely on the position of the staff of the SEC set
forth in “Exxon Capital Holdings Corporation” or similar interpretive
letters: and |
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must comply with the registration and prospectus delivery
requirements of the Securities Act in connection with a secondary resale
transaction. |
23
If, as stated above, a holder cannot rely on the position of the
staff of the SEC set forth in “Exxon Capital Holdings Corporation” or similar
interpretive letters, any effective registration statement used in connection
with a secondary resale transaction must contain the selling security holder
information required by Item 507 of Regulation S-K under the Securities Act.
This prospectus may be used for an offer to resell, for the resale or
for other retransfer of registered notes only as specifically set forth in this
prospectus. With regard to broker-dealers, only broker-dealers that acquired the
unregistered notes as a result of market-making activities or other trading
activities may participate in the exchange offer. Each broker-dealer that
receives registered notes for its own account in exchange for unregistered
notes, where such unregistered notes were acquired by such broker-dealer as a
result of market-making activities or other trading activities, must acknowledge
that it will deliver a prospectus in connection with any resale of the
registered notes. Please read the section captioned “Plan of Distribution” for
more details regarding these procedures for the transfer of registered notes. We
have agreed that, for the period required by the Securities Act after the
exchange offer is consummated, we will make this prospectus available to any
broker-dealer for use in connection with any resale of the registered notes.
Terms of the
Exchange Offer
Upon the terms and subject to the conditions set forth in this
prospectus and in the letter of transmittal, we will accept for exchange any
unregistered notes properly tendered and not withdrawn prior to the expiration
date. We will issue up to $150,000,000 in principal amount of registered notes,
in the aggregate, in exchange for an equal principal amount of the unregistered
notes surrendered under the exchange offer. Unregistered notes may be tendered
for the registered notes only in integral multiples of $1,000.
The form and terms of the registered notes will be substantially
identical to the form and terms of the unregistered notes except that the
registered notes will be registered under the Securities Act, will not bear
legends restricting their transfer and will not provide for any Additional
Interest upon our failure to fulfill our obligations under the registration
rights agreement to file, and cause to become effective, a registration
statement. The registered notes will evidence the same debt as the unregistered
notes. The registered notes will be issued under and entitled to the benefits of
the same indenture that authorized the issuance of the unregistered notes.
Consequently, each series of notes will be treated as a single class of debt
securities under the applicable indenture.
The exchange offer is not conditioned upon any minimum aggregate
principal amount of unregistered notes being tendered for exchange.
As of the date of this prospectus, $150.0 million aggregate
principal amount of the unregistered notes are outstanding. This prospectus and
the letter of transmittal are being sent to all registered holders of
unregistered notes. There will be no fixed record date for determining
registered holders of unregistered notes entitled to participate in the exchange
offer.
We intend to conduct the exchange offer in accordance with the
provisions of the registration rights agreement, the applicable requirements of
the Securities Act and the Exchange Act, and the rules and regulations of the
SEC. Unregistered notes that are not tendered for exchange in the exchange offer
will remain outstanding and continue to accrue interest and will be entitled to
the rights and benefits such holders have under the indenture relating to the
unregistered notes.
We will be deemed to have accepted for exchange properly tendered
unregistered notes when we have given oral or written notice of the acceptance
to the exchange agent. The exchange agent will act as agent for the tendering
holders for the purposes of receiving the registered notes from us and
delivering registered notes to such holders. Subject to the terms of the
registration rights agreement, we expressly reserve the right to amend or
terminate the exchange offer, and not to accept for exchange any unregistered
notes not previously accepted for exchange, upon the occurrence of any of the
conditions specified below under the caption “— Certain Conditions to the
Exchange Offer.”
Holders who tender unregistered notes in the exchange offer will not
be required to pay brokerage commissions or fees, or, subject to the
instructions in the letter of transmittal, transfer taxes with respect to the
exchange of unregistered notes. We will pay all charges and expenses, other than
those transfer taxes described below, in
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connection with the exchange offer. It is important that you read the
section labeled “— Fees and Expenses” below for more details regarding fees
and expenses incurred in the exchange offer.
Expiration
Date; Extensions; Amendments
The exchange offer will expire 5:00 p.m. (New York City time)
on , 2008, unless we
extend it in our sole discretion. However, we will not extend the exchange offer
for more than 50 days after the date of this prospectus.
In order to extend the exchange offer, we will notify the exchange
agent orally or in writing. In addition, we will notify the registered holders
of unregistered notes, in writing, by public announcement or both, of the
extension no later than 9:00 a.m. (New York City time) on the business day
after the previously scheduled expiration date.
We reserve the right, in our sole discretion:
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to delay accepting for exchange any unregistered notes
before expiration or termination of the exchange offer, including any
extensions; |
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to extend the exchange offer or to terminate the exchange
offer and to refuse to accept unregistered notes not previously accepted
if any of the conditions set forth below under “— Certain Conditions
to the Exchange Offer” have not been satisfied, by giving oral or written
notice of such delay, extension or termination to the exchange
agent; or |
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subject to the terms of the registration rights agreement,
to amend the terms of the exchange offer in any manner.
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Any such delay in acceptance, extension, termination or amendment
will be followed as promptly as practicable by giving notice or public
announcement thereof to the registered holders of unregistered notes. Holders of
unregistered notes that tender before or after the offer is extended will have
until the new expiration date to withdraw their notes. If we amend the exchange
offer in a manner that we determine to constitute a material change, including a
waiver of what we determine to be a material condition, we will promptly
disclose such amendment in a manner reasonably calculated to inform the holders
of unregistered notes of such amendment and extend the exchange offer for a
period deemed adequate by us to permit holders to withdraw their unregistered
notes. In any event, the extension will be at least five business days. If we
amend the exchange offer to condition our offer on valid tenders from a
specified percentage of unregistered notes or increase or decrease this
percentage we will extend the exchange offer by at least 10 days. If we
terminate this exchange offer as provided in this prospectus before accepting
any unregistered notes for exchange or if we amend the terms of this exchange
offer in a manner that constitutes a material change in the information set
forth in the registration statement of which this prospectus forms a part, we
will promptly file a post-effective amendment to the registration statement of
which this prospectus forms a part and, if necessary, recirculate a revised
prospectus. In addition, we will in all events comply with our obligation to
promptly issue registered notes for all unregistered notes properly tendered and
accepted for exchange in the exchange offer upon expiration of the exchange
offer and will return unregistered notes not accepted for exchange promptly upon
termination or expiration of the exchange offer.
Without limiting the manner in which we may choose to make public
announcements of any delay in acceptance, extension, termination or amendment of
the exchange offer, we shall not have any obligation to publish, advertise or
otherwise communicate any such public announcement, other than by filing a
Current Report on Form 8-K with
the SEC or issuing a timely press release to a financial news service.
Certain
Conditions to the Exchange Offer
Despite any other terms of the exchange offer, we will not be
required to accept for exchange, or exchange any registered notes for, any
unregistered notes, and we may terminate the exchange offer as provided in this
prospectus before accepting any unregistered notes for exchange if:
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the exchange offer, or the making of any exchange by a
holder of unregistered notes, would violate applicable law or any
applicable interpretation of the staff of the SEC; |
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any action or proceeding is instituted or threatened in any
court or by or before any governmental agency with respect to the exchange
offer which, in our sole judgment, might materially impair our ability to
proceed with the exchange offer; |
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any material adverse development has occurred in any
existing action or proceeding with respect to us; or |
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any governmental approval has not been obtained, which
approval we, in our sole discretion, deem necessary for the consummation
of the exchange offer as contemplated by this prospectus.
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In addition, we will not be obligated to accept for exchange the
unregistered notes of any holder that has not made:
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the representations described under “— Purpose and
Effect of the Exchange Offer,” “— Procedures for Tendering” and “Plan
of Distribution;” and |
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such other representations as may be reasonably necessary
under applicable SEC rules, regulations or interpretations to make
available to us an appropriate form for registration of the registered
notes under the Securities Act. |
We expressly reserve the right, at any time or at various times on or
prior to the scheduled expiration date of the exchange offer, to extend the
period of time during which the exchange offer is open. Consequently, we may
delay acceptance of any unregistered notes by giving oral or written notice of
such extension to the registered holders of the unregistered notes. During any
such extensions, all unregistered notes previously tendered will remain subject
to the exchange offer, and we may accept them for exchange unless they have been
previously withdrawn. We will return any unregistered notes that we do not
accept for exchange for any reason without expense to their tendering holder
promptly after the expiration or termination of the exchange offer.
We expressly reserve the right to amend or terminate the exchange
offer on or prior to the scheduled expiration date of the exchange offer, and to
reject for exchange any unregistered notes not previously accepted for exchange,
upon the occurrence of any of the conditions of the exchange offer specified
above. We will give notice of or publicly announce any extension, amendment,
non-acceptance or termination to the registered holders of the unregistered
notes as promptly as practicable. In the case of any extension, such notice will
be issued no later than 9:00 a.m. (New York City time) on the business day
after the previously scheduled expiration date. We will in all events comply
with our obligation to promptly issue registered notes for all unregistered
notes properly tendered and accepted for exchange in the exchange offer upon
expiration of the exchange offer or to promptly return unregistered notes not
accepted for exchange upon termination or expiration of the exchange offer.
These conditions are for our sole benefit and we may, in our sole
discretion, assert them regardless of the circumstances that may give rise to
them or waive them in whole or in part at any or at various times (provided
that, if we waive a condition for one participant in the exchange offer, we must
waive that condition for all participants). All conditions to the exchange
offer, however, must be satisfied or waived by us prior to the expiration of the
exchange offer.
In addition, we will not accept for exchange any unregistered notes
tendered, and will not issue registered notes in exchange for any such
unregistered notes, if at such time any stop order is threatened or in effect
with respect to the registration statement of which this prospectus constitutes
a part or the qualification of the indenture under the Trust Indenture Act
of 1939, as amended.
Procedures for
Tendering
Only a holder of unregistered notes may tender such unregistered
notes in the exchange offer. To tender in the exchange offer, a holder must:
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complete, sign and date the letter of transmittal, or a
facsimile of the letter of transmittal, have the signature on the letter
of transmittal guaranteed if the letter of transmittal so requires and
mail or deliver such letter of transmittal or facsimile to the exchange
agent prior to the expiration date; or |
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comply with DTC’s Automated Tender Offer Program procedures
described below. |
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In addition, either:
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the exchange agent must receive unregistered notes along
with the letter of transmittal; |
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the exchange agent must receive, prior to the expiration
date, a timely confirmation of book-entry transfer of such unregistered
notes into the exchange agent’s account at DTC according to the procedures
for book-entry transfer described below or a properly transmitted agent’s
message; or |
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the holder must comply with the guaranteed delivery
procedures described below. |
To be tendered effectively, the exchange agent must receive any
physical delivery of the letter of transmittal and other required documents at
the address set forth below under “— Exchange Agent” prior to the expiration
date.
The tender by a holder that is not withdrawn prior to the expiration
date will constitute an agreement between such holder and us in accordance with
the terms and subject to the conditions set forth in this prospectus and in the
letter of transmittal.
The method of delivery of unregistered notes, the letter of
transmittal and all other required documents to the exchange agent is at the
holder’s election and risk. Rather than mail these items, we recommend that
holders use an overnight or hand delivery service. In all cases, holders should
allow sufficient time to assure delivery to the exchange agent before the
expiration date. Holders should not send us the letter of transmittal or
unregistered notes. Holders may request their respective brokers, dealers,
commercial banks, trust companies or other nominees to effect the above
transactions for them.
Any beneficial owner whose unregistered notes are registered in the
name of a broker, dealer, commercial bank, trust company or other nominee and
who wishes to tender should contact the registered holder promptly and instruct
it to tender on the owners’ behalf. If such beneficial owner wishes to tender on
its own behalf, it must, prior to completing and executing the letter of
transmittal and delivering its unregistered notes, either:
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make appropriate arrangements to register ownership of the
unregistered notes in such owner’s name; or |
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obtain a properly completed bond power from the registered
holder of unregistered notes. |
Depending on the facts and circumstances applicable to a particular
beneficial owner, including the nominee in whose name the notes are registered
and applicable state laws, the transfer of registered ownership may take an
indeterminable amount of time and may not be completed prior to the expiration
date.
Signatures on a letter of transmittal or a notice of withdrawal
described below must be guaranteed by a member of the Medallion Signature
Guarantee Program or by any other “eligible guarantor institution” within the
meaning of Rule 17Ad-15 under the
Exchange Act (each are referred to as an “eligible institution”) unless the
unregistered notes tendered pursuant thereto are tendered:
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by a registered holder who has not completed the box
entitled “Special Issuance Instructions” or “Special Delivery
Instructions” on the letter of transmittal; or |
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for the account of an eligible institution.
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If the unregistered notes are registered in the name of a person
other than the signer of the letter of transmittal or if unregistered notes not
accepted for exchange or not tendered are to be returned to a person other than
the registered holder, then the signatures on the letter of transmittal
accompanying the tendered unregistered notes must be guaranteed by an eligible
institution as described above. See Instructions 1 and 5 of the letter of
transmittal.
If the letter of transmittal or any unregistered notes or bond powers
are signed by trustees, executors, administrators, guardians, attorneys-in-fact,
officers of corporations or others acting in a fiduciary or representative
capacity, such persons should so indicate when signing. Unless waived by us,
they should also submit evidence satisfactory to us of their authority to
deliver the letter of transmittal.
The exchange agent and DTC have confirmed that any financial
institution that is a participant in DTC’s system may use DTC’s Automated Tender
Offer Program to tender. Participants in the program may, instead of physically
completing and signing the letter of transmittal and delivering it to the
exchange agent, transmit their acceptance of the exchange offer electronically.
They may do so by causing DTC to transfer the unregistered notes
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to the exchange agent in accordance with its procedures for transfer.
DTC will then send an agent’s message to the exchange agent. The term “agent’s
message” means a message transmitted by DTC, received by the exchange agent and
forming part of the book-entry confirmation, to the effect that:
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DTC has received an express acknowledgment from a
participant in its Automated Tender Offer Program that is tendering
unregistered notes that are the subject of such book-entry confirmation;
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such participant has received and agrees to be bound by the
terms of the letter of transmittal (or, in the case of an agent’s message
relating to guaranteed delivery, that such participant has received and
agrees to be bound by the applicable notice of guaranteed
delivery); and |
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the agreement may be enforced against such participant.
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We will determine in our sole discretion all questions as to the
validity, form, eligibility (including time of receipt), acceptance of tendered
unregistered notes and withdrawal of tendered unregistered notes. Our
determination will be final and binding. We reserve the absolute right to reject
any unregistered notes not properly tendered or any unregistered notes the
acceptance of which would, in the opinion of our counsel, be unlawful. We also
reserve the right to waive any defects, irregularities or conditions of tenders
as to particular unregistered notes. Our interpretation of the terms and
conditions of the exchange offer (including the instructions in the letter of
transmittal) will be final and binding on all parties. Unless waived, any
defects or irregularities in connection with tenders of unregistered notes must
be cured within such time as we shall determine. Although we intend to notify
holders of defects or irregularities with respect to tenders of unregistered
notes, neither we, the exchange agent nor any other person will incur any
liability for failure to give such notification. Tenders of unregistered notes
will not be deemed made until such defects or irregularities have been cured or
waived. Any unregistered notes received by the exchange agent that are not
properly tendered and as to which the defects or irregularities have not been
cured or waived will be returned without cost to the tendering holder, unless
otherwise provided in the letter of transmittal, promptly following the
expiration or termination date.
In all cases, we will issue registered notes for unregistered notes
that we have accepted for exchange under the exchange offer only after the
exchange agent timely receives:
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unregistered notes or a timely book-entry confirmation of
such unregistered notes into the exchange agent’s account at DTC; and
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a properly completed and duly executed letter of
transmittal and all other required documents or a properly transmitted
agent’s message. |
By signing the letter of transmittal, each tendering holder of
unregistered notes will represent that, among other things:
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that any registered notes to be received by it will be
acquired in the ordinary course of its business; |
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that at the time of the commencement of the exchange offer
it has no arrangement or understanding with any person to participate in
the distribution (within the meaning of Securities Act) of the registered
notes in violation of the Securities Act; |
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that it is not our “affiliate” (as defined in Rule 405
promulgated under the Securities Act), or, if it is an affiliate, that it
will comply with any applicable registration and prospectus delivery
requirements of the Securities Act; |
| |
| |
• |
if such holder is not a broker-dealer, that it is not
engaged in, and does not intend to engage in, the distribution of
registered notes; and |
| |
| |
• |
if such holder is a broker-dealer that will receive
registered notes for its own account in exchange for notes that were
acquired as a result of market-making or other trading activities, that it
will deliver a prospectus in connection with any resale of such registered
notes. |
In addition, the SEC has taken the position that each broker-dealer
that receives registered notes for its own account in exchange for unregistered
notes, where such unregistered notes were acquired by such broker-dealer as a
result of market-making activities or other trading activities, may fulfill
their prospectus delivery requirements with
28
respect to the registered notes (other than a resale of an unsold
allotment from the original sale of the registered notes) by delivering a
prospectus in connection with any resale of such registered notes. See “Plan of
Distribution.”
Book-Entry
Transfer
The exchange agent will make a request to establish an account with
respect to the unregistered notes at DTC for purposes of the exchange offer
promptly after the date of this prospectus and any financial institution
participating in DTC’s system may make book-entry delivery of unregistered notes
by causing DTC to transfer such unregistered notes into the exchange agent’s
account at DTC in accordance with DTC’s procedures for transfer. Holders of
unregistered notes who are unable to deliver confirmation of the book-entry
tender of their unregistered notes into the exchange agent’s account at DTC or
all other documents of transmittal to the exchange agent on or prior to the
expiration date must tender their unregistered notes according to the guaranteed
delivery procedures described below.
Guaranteed
Delivery Procedures
Holders wishing to tender their unregistered notes but whose
unregistered notes are not immediately available or who cannot deliver their
unregistered notes, the letter of transmittal or any other required documents to
the exchange agent or comply with the applicable procedures under DTC’s
Automated Tender Offer Program prior to the expiration date may tender if:
|
|
|
| |
• |
the tender is made through an eligible institution; |
| |
| |
• |
prior to the expiration date, the exchange agent receives
from such eligible institution either a properly completed and duly
executed notice of guaranteed delivery by facsimile transmission, mail or
hand delivery or a properly transmitted agent’s message and notice of
guaranteed delivery: |
|
|
|
| |
• |
stating that the tender is being made thereby; |
| |
| |
• |
guaranteeing that, within three New York Stock Exchange
trading days after the expiration date, the letter of transmittal or
facsimile thereof together with the unregistered notes or a book-entry
confirmation, and any other documents required by the letter of
transmittal will be deposited by the eligible institution with the
exchange agent; and |
| |
| |
• |
setting forth the name and address of the holder, the
registered number(s) of such unregistered notes and the principal amount
of unregistered notes tendered; and |
|
|
|
| |
• |
the exchange agent receives such properly completed and
executed letter of transmittal or facsimile thereof, as well as all
tendered unregistered notes in proper form for transfer or a book-entry
confirmation, and all other documents required by the letter of
transmittal, within three New York Stock Exchange trading days after the
expiration date. |
Upon request to the exchange agent, a notice of guaranteed delivery
will be sent to holders who wish to tender their unregistered notes according to
the guaranteed delivery procedures set forth above.
Withdrawal of
Tenders
Except as otherwise provided in this prospectus, holders of
unregistered notes may withdraw their tenders at any time prior to the
expiration date.
For a withdrawal to be effective:
|
|
|
| |
• |
the exchange agent must receive a written notice of
withdrawal, which notice may be by facsimile transmission or letter, at
one of the addresses set forth below under “— Exchange
Agent”; or |
| |
| |
• |
holders must comply with the appropriate procedures of
DTC’s Automated Tender Offer Program system. |
Any such notice of withdrawal must:
|
|
|
| |
• |
specify the name of the person who tendered the
unregistered notes to be withdrawn; |
29
|
|
|
| |
• |
identify the unregistered notes to be withdrawn, including
the principal amount of such unregistered notes; and |
| |
| |
• |
where certificates for unregistered notes have been
transmitted, specify the name in which such unregistered notes were
registered, if different from that of the withdrawing holder.
|
If certificates for unregistered notes have been delivered or
otherwise identified to the exchange agent, then, prior to the release of such
certificates, the withdrawing holder must also submit:
|
|
|
| |
• |
the serial numbers of the particular certificates to be
withdrawn; and |
| |
| |
• |
a signed notice of withdrawal with signatures guaranteed by
an eligible institution unless such holder is an eligible institution.
|
If unregistered notes have been tendered pursuant to the procedure
for book-entry transfer described above, any notice of withdrawal must specify
the name and number of the account at DTC to be credited with the withdrawn
unregistered notes and otherwise comply with the procedures of such facility. We
will determine all questions as to the validity, form and eligibility, including
time of receipt of such notices, and our determination shall be final and
binding on all parties. We will deem any unregistered notes so withdrawn not to
have been validly tendered for exchange for purposes of the exchange offer. Any
unregistered notes that have been tendered for exchange but which are not
exchanged for any reason will be returned to the holder thereof without cost to
such holder (or, in the case of unregistered notes tendered by book-entry
transfer into the exchange agent’s account at DTC according to the procedures
described above, such unregistered notes will be credited to an account
maintained with DTC for unregistered notes) promptly after withdrawal, rejection
of tender or termination of the exchange offer. Properly withdrawn unregistered
notes may be retendered by following one of the procedures described under
“— Procedures for Tendering” above at any time prior to the expiration
date.
Exchange
Agent
U. S. Bank National Association has been appointed as exchange
agent for the exchange offer. You should direct questions and requests for
assistance, requests for additional copies of this prospectus or of the letter
of transmittal and requests for the notice of guaranteed delivery to the
exchange agent addressed as follows:
U. S. Bank National Association
Westside Operations Center
60
Livingston Avenue
St. Paul, MN 55107
Attention: Specialized Finance
DELIVERY OF THE LETTER OF TRANSMITTAL TO AN ADDRESS OTHER THAN AS SET
FORTH ABOVE OR TRANSMISSION VIA FACSIMILE OTHER THAN AS SET FORTH ABOVE DOES NOT
CONSTITUTE A VALID DELIVERY OF SUCH LETTER OF TRANSMITTAL.
Fees and
Expenses
We will bear the expenses of soliciting tenders. The principal
solicitation is being made by mail; however, we may make additional
solicitations by telephone or in person by our officers and regular employees
and those of our affiliates.
We have not retained any dealer-manager in connection with the
exchange offer and will not make any payments to broker-dealers or others
soliciting acceptances of the exchange offer. We will, however, pay the exchange
agent reasonable and customary fees for its services and reimburse it for its
related reasonable out-of-pocket expenses.
Our expenses in connection with the exchange offer include:
|
|
|
| |
• |
SEC registration fees; |
| |
| |
• |
fees and expenses of the exchange agent and trustee;
|
30
|
|
|
| |
• |
accounting and legal fees and printing costs; and
|
| |
| |
• |
related fees and expenses. |
Transfer
Taxes
In general, we will pay all transfer taxes, if any, applicable to the
exchange of unregistered notes under the exchange offer. The tendering holder,
however, will be required to pay any transfer taxes, whether imposed on the
registered holder or any other person, if:
|
|
|
| |
• |
certificates representing unregistered notes for principal
amounts not tendered or accepted for exchange are to be delivered to, or
are to be issued in the name of, any person other than the registered
holder of unregistered notes tendered; |
| |
| |
• |
tendered unregistered notes are registered in the name of
any person other than the person signing the letter of
transmittal; or |
| |
| |
• |
a transfer tax is imposed for any reason other than the
exchange of unregistered notes under the exchange offer.
|
If satisfactory evidence of payment of such taxes is not submitted
with the letter of transmittal, the amount of such transfer taxes will be billed
to that tendering holder.
In addition, holders who instruct us to register registered notes in
the name of, or request that unregistered notes not tendered or not accepted in
the exchange offer be returned to, a person other than the registered tendering
holder will be required to pay any applicable transfer taxes.
Consequences
of Failure to Exchange
Holders of unregistered notes who do not exchange their unregistered
notes for registered notes under the exchange offer, including as a result of
failing to timely deliver unregistered notes to the exchange agent, together
with all required documentation, including a properly completed and signed
letter of transmittal, will remain subject to the restrictions on transfer of
such unregistered notes:
|
|
|
| |
• |
as set forth in the legend printed on the unregistered
notes as a consequence of the issuance of the unregistered notes pursuant
to the exemptions from, or in transactions not subject to, the
registration requirements of the Securities Act and applicable state
securities laws; and |
| |
| |
• |
otherwise as set forth in the offering circular distributed
in connection with the private offering of the unregistered notes.
|
In addition, you will no longer have any registration rights or be
entitled to Additional Interest with respect to the unregistered notes.
Therefore, you should allow sufficient time to ensure timely delivery of the
unregistered notes and you should carefully follow the instructions on how to
tender your unregistered notes.
In general, you may not offer or sell the unregistered notes unless
they are registered under the Securities Act, or if the offer or sale is exempt
from registration under the Securities Act and applicable state securities laws.
Except as required by the registration rights agreement, we do not intend to
register resales of the unregistered notes under the Securities Act. Based on
interpretations of the SEC staff, registered notes issued pursuant to the
exchange offer may be offered for resale, resold or otherwise transferred by
their holders, other than any such holder that is our “affiliate” within the
meaning of Rule 405 under the Securities Act, without compliance with the
registration and prospectus delivery provisions of the Securities Act, provided
that the holders acquired the registered notes in the ordinary course of the
holders’ business and the holders have no arrangement or understanding with
respect to the distribution of the registered notes to be acquired in the
exchange offer. Any holder who tenders in the exchange offer for the purpose of
participating in a distribution of the registered notes:
|
|
|
| |
• |
cannot rely on the applicable interpretations of the
SEC; and |
| |
| |
• |
must comply with the registration and prospectus delivery
requirements of the Securities Act in connection with a secondary resale
transaction. |
31
After the exchange offer is consummated, if you continue to hold any
unregistered notes, you may have difficulty selling them.
Accounting
Treatment
We will record the registered notes in our accounting records at the
same carrying value as the unregistered notes, as reflected in our accounting
records on the date of exchange. Accordingly, we will not recognize any gain or
loss for accounting purposes in connection with the exchange offer. We will
expense the costs of this exchange offer as incurred.
Other
Participation in the exchange offer is voluntary, and you should
carefully consider whether to accept. You are urged to consult your financial
and tax advisors in making your own decision on what action to take.
We may in the future seek to acquire untendered unregistered notes in
the open market or privately negotiated transactions, through subsequent
exchange offers or otherwise. We have no present plans to acquire any
unregistered notes that are not tendered in the exchange offer or to file a
registration statement to permit resales of any untendered unregistered notes.
32
USE OF
PROCEEDS
This exchange offer is intended to satisfy some of our obligations
under the registration rights agreement. We will not receive any cash proceeds
from the issuance of the registered notes in the exchange offer. In
consideration for issuing the registered notes contemplated in this prospectus,
we will receive unregistered notes in like principal amount, the form and terms
of which are the same as the form and terms of the registered notes, except that
the registered notes will not contain transfer restrictions or registration
rights. Unregistered notes surrendered in exchange for registered notes will be
retired and cancelled and will not be reissued. Accordingly, the issuance of the
registered notes will not result in any change in our outstanding indebtedness.
The net proceeds from the offering of the unregistered notes, after
deducting fees and expenses, was $142.0 million. We used those proceeds to
purchase and redeem all of our outstanding 10% Senior Secured Notes due
2007, or our 2007 secured notes, and for general corporate purposes.
The following table sets forth the sources and uses of funds in
connection with the offering of the unregistered notes:
| |
|
|
|
|
|
|
|
|
|
|
|
Sources
of Funds |
|
|
|
|
Uses
of Funds |
|
|
|
| |
|
Unregistered notes
offered |
|
$ |
150,000 |
|
|
2007 secured notes(1) |
|
$ |
103,961 |
|
| |
|
|
|
|
|
General corporate purposes |
|
|
38,013 |
|
| |
|
|
|
|
|
Fees and expenses |
|
|
8,026 |
|
| |
|
|
|
|
|
|
|
|
|
|
|
Total sources of
funds |
|
$ |
150,000 |
|
|
Total uses of funds |
|
$ |
150,000 |
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
| (1) |
|
Includes the repurchase and
redemption of all of our 2007 secured notes at par plus accrued interest
thereon. |
33
CAPITALIZATION
The following table sets forth our cash and cash equivalents and
capitalization at March 31, 2008, and should be read in conjunction with
our historical consolidated financial statements and related notes,
“Management’s Discussion and Analysis of Financial Conditions and Results of
Operations” and other financial information included elsewhere in this
prospectus.
| |
|
|
|
|
| |
|
At March 31, 2008 |
|
| |
|
(Dollars in thousands) |
|
| |
|
Cash and cash
equivalents |
|
$ |
170,459 |
|
| |
|
|
|
|
|
Long-term debt,
including current maturities: |
|
|
|
|
|
Revolving credit
facility |
|
|
— |
|
|
Senior secured notes
due 2015 |
|
|
150,000 |
|
| |
|
|
|
|
|
Total long-term debt
|
|
|
150,000 |
|
|
Redeemable preferred
stock |
|
|
104,137 |
|
|
Stockholders’ equity
(deficiency in assets) |
|
|
(85,487 |
) |
| |
|
|
|
|
|
Total
capitalization |
|
$ |
168,650 |
|
| |
|
|
|
|
34
SELECTED
CONSOLIDATED FINANCIAL AND OPERATING 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, “Management’s Discussion and Analysis of Financial
Condition and Results of Operations” and other financial information included
elsewhere in this prospectus.
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 will exit the styrene
business to pursue other strategic initiatives. Due to the shut down of our
styrene plant, we have reported the operating results of the styrene business as
discontinued operations in our consolidated financial statements beginning in
the first quarter of 2008. All prior periods have been reclassified. The
selected financial data presented below includes our styrene business in
discontinued operations.
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Three Months
|
|
|
Three Months
|
|
|
Year Ended
|
|
|
Year Ended
|
|
|
Year Ended
|
|
|
Year Ended
|
|
|
Year Ended
|
|
| |
|
Ended
March 31,
|
|
|
Ended
March 31,
|
|
|
December 31,
|
|
|
December 31,
|
|
|
December 31,
|
|
|
December 31,
|
|
|
December 31,
|
|
| |
|
2008 |
|
|
2007(1) |
|
|
2007 |
|
|
2006(1) |
|
|
2005(1) |
|
|
2004(1) |
|
|
2003(1) |
|
| |
|
(In thousands, except per
share data) |
|
|
|
|
|
|
|
| |
|
Operating Data:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues |
|
$ |
38,199 |
|
|
$ |
32,715 |
|
|
$ |
129,813 |
|
|
$ |
141,259 |
|
|
$ |
128,098 |
|
|
$ |
125,624 |
|
|
$ |
109,949 |
|
|
Gross profit |
|
|
4,400 |
|
|
|
5,627 |
|
|
|
13,382 |
|
|
|
13,846 |
|
|
|
7,844 |
|
|
|
10,886 |
|
|
|
4,522 |
|
|
Loss from continuing
operations(2)
|
|
|
(905 |
) |
|
|
(56 |
) |
|
|
(7,713 |
) |
|
|
(2,194 |
) |
|
|
(5,856 |
) |
|
|
(42,212 |
) |
|
|
(9,761 |
) |
|
Income (loss) from
discontinued operations(3) |
|
|
(6,224 |
) |
|
|
2,725 |
|
|
|
(11,215 |
) |
|
|
(103,465 |
) |
|
|
(23,712 |
) |
|
|
(20,432 |
) |
|
|
(4,438 |
) |
|
Per Share Data:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss attributable to
common stockholders |
|
$ |
(4.03 |
) |
|
$ |
(0.14 |
) |
|
$ |
(12.90 |
) |
|
$ |
(41.52 |
) |
|
$ |
(16.46 |
) |
|
$ |
(27.08 |
) |
|
$ |
(8.38 |
) |
|
Net loss from continuing
operations attributable to common stockholders |
|
|
(1.83 |
) |
|
|
(1.10 |
) |
|
|
(8.93 |
) |
|
|
(4.94 |
) |
|
|
(8.08 |
) |
|
|
(19.85 |
) |
|
|
(6.80 |
) |
|
Cash dividends |
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
Ratio of earnings to
fixed charges(4) |
|
$ |
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
Balance Sheet
Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Working capital(5) |
|
$ |
157,917 |
|
|
$ |
131,902 |
|
|
$ |
166,264 |
|
|
$ |
99,110 |
|
|
$ |
208,179 |
|
|
$ |
248,166 |
|
|
$ |
289,491 |
|
|
Total assets |
|
|
287,225 |
|
|
|
321,224 |
|
|
|
306,444 |
|
|
|
245,823 |
|
|
|
386,594 |
|
|
|
473,553 |
|
|
|
550,503 |
|
|
Long-term debt |
|
|
150,000 |
|
|
|
150,000 |
|
|
|
150,000 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
Redeemable preferred
stock(6)
|
|
|
104,137 |
|
|
|
58,767 |
|
|
|
99,866 |
|
|
|
82,316 |
|
|
|
70,542 |
|
|
|
53,559 |
|
|
|
39,701 |
|
|
Stockholders’ equity
(deficiency in assets)(7) |
|
|
(85,487 |
) |
|
|
(22,347 |
) |
|
|
(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 and the
three months ended March 31, 2007. For further information, see
Note 16 to the consolidated financial statements for the years ended
December 31, 2006 and 2005, and Note 15 to the consolidated
financial statements for the quarter ended March 31, 2007, found
elsewhere in this prospectus. |
| (2) |
|
During 2004, we recorded a
$48.5 million goodwill impairment charge. Also during 2004, we
recorded a pension curtailment gain of $13 million. |
| (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 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. |
| (4) |
|
Additional pre-tax earnings
needed to achieve a 1:1 ratio for the three months ended March 31,
2008 and 2007 and the years ended December 31, 2007, 2006, 2005, 2004
and 2003 were $0.9 million, less than $0.1 million,
$11.8 million, $2.6 million, $8.8 million,
$42.3 million and $15.6 million, respectively. |
| (5) |
|
Working capital as of
March 31, 2008 and 2007, December 31, 2007, 2006, 2005, 2004 and
2003 includes net assets (liabilities) of discontinued operations of
$(5.7) million, $85.5 million $60.2 million,
$88.3 million, $181.6 million, $290.1 million and
$266.2 million, respectively. |
| (6) |
|
Our Series A Preferred
Stock is not currently redeemable or probable of redemption. If our
Series A Preferred Stock had been redeemed as of March 31, 2008,
the redemption amount would have been approximately $79.7 million.
The liquidation value of our Series A Preferred Stock as of
March 31, 2008 is $68.7 million. |
| (7) |
|
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 SFAS No. 158, “Employers’ Accounting for Defined Benefit
Pension and Other Postretirement Plans”. |
35
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 and the three
months ended March 31, 2007 for the matters discussed more fully in
Note 15 to the consolidated financial statements for the quarter ended
March 31, 2007, and Note 16 to the consolidated financial statements
for the years ended December 31, 2006 and 2005, included elsewhere in this
prospectus.
The following information should be read in conjunction with our
historical consolidated financial statements and related notes and other
financial information included elsewhere in this prospectus.
Overview
Business
We are a North American producer of selected petrochemicals used to
manufacture a wide array of consumer goods and industrial products. We currently
operate in two segments: acetic acid and plasticizers.
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 the Production Agreement that began in 1986 and extends to
2016, all of our acetic acid production is sold to 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.
In addition, BP Chemicals reimburses us for 100% of our fixed and variable costs
of production. Prior to August 2006, BP Chemicals also paid us a set monthly
amount. However, under 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. 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’ 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 related to our
acetic acid business and then invoice BP Chemicals for its portion. The net
amount that is not reimbursed by BP Chemicals represents our basis in the
property, plant and equipment related to our acetic acid business, which is
capitalized and depreciated over its useful life. Acetic acid production has two
major raw material 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 required carbon monoxide is
supplied by 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 pursuant to a long-term production agreement that
extends until 2013, subject to some early termination rights held by BASF that
begin in 2010. Under our agreement with BASF, BASF provides us with most of the
required raw materials, 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 related to our plasticizers
facility. In May 2008, we entered into an amended production agreement with
BASF, effective as of April 1, 2008. This amended agreement was entered
into in connection with BASF’s nomination of zero pounds of PA under the
existing production agreement due to deteriorating market conditions which were
not expected to improve over the next few years, which resulted in the shutdown
of our PA unit. For further discussion of the amended agreement with BASF, see
“— Recent Developments.”
Prior to December 3, 2007, we manufactured styrene. However, 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
this 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,
36
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 and the
railcar agreement to become effective and triggered a $60 million payment
to us 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. After 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 facility.
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 until December of 2012. We operated our styrene facility
through early December 2007, as we completed our production of inventory and
exhausted our raw materials and purchase requirements, and sold substantially
all our inventory during the first quarter of 2008. During 2007 and the first
quarter of 2008, we incurred closure costs to decommission our styrene facility
of approximately $1 million and $9 million, respectively. We expect to
incur up to $4 million in additional decommissioning costs related to the
closure of our styrene facility. In mid-July, with the decontamination process
for the styrene facility nearing completion, we announced a reduction in work
force in order to reduce our staffing to a level appropriate for our existing
operations and site development projects. As a result, seven members of our
salaried work force were immediately laid off. In addition, we made offers for
early retirement to several members of our hourly work force and our salaried
administrative and process supervisors. Upon completion of the down-sizing of
our hourly work force and our administrative and process supervisor positions,
which will occur after the period for accepting offers of early retirement has
closed in September, total staff reductions are expected to be approximately
40 employees, and we expect to recognize approximately $2.2 million in
severance costs in the third and fourth quarters of 2008, in accordance with
SFAS No. 146, “Accounting for Costs Associated with Exit of Disposal
Activities.”
We manufacture all of our petrochemicals products at our Texas City
facility. 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, 160 acres of available land zoned for heavy
industrial use and 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.
Given our under-utilized infrastructure, our management and
engineering expertise, as well as ample unoccupied land, we believe that there
are significant opportunities for further development of our Texas City site. We
are currently pursuing numerous initiatives to attract new manufacturing and/or
storage related businesses to our Texas City site, including opportunities
involving renewable fuels projects, gasification, energy projects and chemicals
terminalling. Specifically, we are seeking long-term contractual business
arrangements or partnerships that will provide us with an ability to realize the
value of our under-utilized assets through profit sharing or other cash
generating arrangements. For development projects that may have significant
capital expenditure requirements, we are considering joint ventures or other
arrangements where we would contribute certain of our assets and management
expertise to minimize our share of the capital costs. In any case, we expect any
new facility constructed at our Texas City site to lower the amount of overall
fixed costs allocated to each of our operating units and provide us with
additional profit.
We plan to evaluate strategic acquisitions, focusing on chemical
businesses and assets which would allow us to increase our market share of
products we currently produce or those that would provide upstream or downstream
integration within our existing businesses.
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.
37
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.
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 PA, unit by nominating zero pounds of PA in response to deteriorating market
conditions which are not expected to improve in the foreseeable future. As a
result of this shutdown, in May 2008, we entered into an amended production
agreement with BASF, effective April 1, 2008. The amended agreement
relieves BASF of most of its obligations related to our PA
38
manufacturing unit, requires that BASF pay approximately
$3.7 million to us for reimbursement of certain direct fixed and variable
costs associated with the shutdown and decontamination of our PA manufacturing
unit. The amended agreement also requires that BASF pay to us an aggregate
amount of approximately $3.2 million (the remaining $0.2 million of
which is required to be paid on or before August 15, 2008), subject to a
25%-75% refund right in BASF’s favor if we restart our PA unit before the end of
2010, depending on the year in which we restart the unit. Under the amended
agreement, BASF is still required to make the same quarterly fixed periodic
payments as previously required. In addition, under the amended production
agreement, the methods for calculating (i) payments required to be made by BASF
to use for achieving reductions in direct fixed and variable costs and (ii)
BASF’s right to terminate the agreement in the event that direct fixed and
variable costs exceed a specified threshold (unless we elect to cap BASF’s
reimbursement obligations), have both been modified to exclude costs savings and
direct fixed and variable costs pertaining to our PA manufacturing unit. The
amended agreement also removed all restrictions of rights BASF formerly had with
respect to our use or disposition of the PA manufacturing unit, including a
purchase right, the right to request capacity increases and consultation rights
regarding future capital expenditures with respect to our PA unit. For further
discussion of the amended agreement with BASF, see “— Recent Developments.”
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.
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 Corporation, or 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
39
polystyrene assets, and, in May of 2008, Americas Styrenics LLC,
a joint venture between The Dow Chemical Company and Chevron Phillips Chemical
Company, which includes selected styrene and polystyrene assets of the two
companies in North America and South America, began operations.
Recent
Developments
On May 27, 2008, we entered into our Amended Plasticizers
production agreement with BASF, with an effective date of April 1, 2008.
The Amended Plasticizers Production agreement amends certain provisions of the
Old Plasticizers Production Agreement. The Amended Plasticizers Production
Agreement was entered into in connection with BASF’s nomination of zero pounds
of PA under the Old Plasticizers Production Agreement in response to
deteriorating market conditions which were not expected to improve over the next
few years, causing the shutdown of our PA unit.
The Amended Plasticizers Production Agreement relieves BASF of most
of its obligations under the Old Plasticizers Production Agreement related to
our PA manufacturing unit. BASF’s obligations under the Old Plasticizers
Production Agreement related to our esters manufacturing unit were not affected
by the Amended Plasticizers Production Agreement and are continuing in
accordance with the same terms as existed under the Old Plasticizers Production
Agreement. In exchange for being relieved of its obligations related to our PA
manufacturing unit, BASF is required to pay us an aggregate amount of
approximately $3.2 million, $3.0 million of which was paid in May
2008, and the balance of which is due and payable on or before August 15,
2008. However, we are obligated to refund 75% of this amount if we restart our
PA manufacturing unit before January 1, 2009, 50% of this amount if we
restart our PA manufacturing unit during 2009 and 25% of this amount if we
restart our PA manufacturing unit during 2010. The $3.2 million represents
the termination of BASF’s obligations under the Old Plasticizers Production
Agreement with respect to the operation of our PA manufacturing unit, and will
be recognized using the straight-line method over the restricted period of
April 1, 2008 through December 31, 2010 under the Amended Plasticizers
Production Agreement. During the first half of 2008, BASF is also required to
pay us approximately $3.7 million for reimbursement of certain direct fixed
and variable costs associated with the shutdown and decontamination of our PA
manufacturing unit, which amounts are not subject to refund. All direct fixed
and variable costs associated with the shutdown and decontamination of our PA
unit have been incurred and expensed, and the $3.7 million in cost
reimbursements has been recognized as revenue in the first six months of 2008.
The quarterly fixed periodic payments under the Old Plasticizers Production
Agreement with respect to the operation of our PA and esters manufacturing units
will not change; however, the quarterly fixed periodic payments are now related
to the operation of our esters manufacturing unit under the Amended Plasticizers
Production Agreement.
In addition, under the Amended Plasticizers Production Agreement,
(i) the methods for calculating payments required to be made by BASF for
achieving reductions in direct fixed and variable costs and (ii) BASF’s
right to terminate the Amended Plasticizers Production Agreement in the event
that direct fixed and variable costs exceed a specified threshold (unless we
elect to cap BASF’s reimbursement obligations) have both been modified to
exclude costs savings and direct fixed and variable costs pertaining to our PA
manufacturing unit.
After April 1, 2008, the Amended Plasticizers Production
Agreement also removed all restrictions or rights BASF formerly had during the
term of the Old Plasticizers Production Agreement with respect to our use or
disposition of the PA manufacturing unit, including a limited purchase right,
the right to request capacity increases and consultation rights regarding future
capital expenditures with respect to our PA manufacturing unit.
As a result of the Amended Plasticizers Production Agreement and
subsequent permanent shutdown of our PA unit by BASF, our management determined
that a triggering event, as defined in SFAS No. 144, “Accounting for
the Impairment or Disposal of Long-Lived Assets,” had occurred and during the
second quarter of 2008, we performed an asset impairment analysis on our PA
manufacturing unit. We analyzed the undiscounted cash flow stream from our PA
business over the remaining life of the PA manufacturing unit and compared it to
the $6.6 million net book carrying value of our PA manufacturing unit. This
analysis showed that the undiscounted projected cash flow stream from our PA
business was less than the net book carrying value of our PA manufacturing unit.
As a result, we performed a discounted cash flow analysis and subsequently
concluded that our PA manufacturing unit was
40
impaired and should be written down to zero. This write-down caused
us to record an impairment of $6.6 million in June 2008.
Other than the impairment discussed above, we do not believe the
shutdown of our PA manufacturing unit will have a material adverse affect on our
financial position, results of operations or cash flows as the required
quarterly fixed periodic payments previously related to the PA manufacturing
unit will continue throughout the original term of the contract and have been
allocated to the operation of the esters manufacturing unit, and all
decontamination and shutdown costs were reimbursed by BASF.
Effective as of May 27, 2008, John V. Genova was appointed as
our President and Chief Executive Officer and was elected as a member of our
Board of Directors. Mr Genova succeeded Richard K. Crump, who retired as
President and Chief Executive Officer as of May 27, 2008. Mr. Crump
will remain a member of our Board of Directors.
Discontinued
Operations
We operated our styrene manufacturing unit through early December, as
we completed our production of inventory and exhausted our raw materials and
purchase requirements and sold substantially all of our inventory during the
first quarter of 2008. During 2007 and the first quarter of 2008, we incurred
closure costs to decommission our styrene facility of approximately
$1 million and $9 million, respectively. We expect to incur up to
$4 million in additional decommissioning costs related to the closure of
our styrene facility. In mid-July, with the decontamination process for the
styrene facility nearing completion, we announced a reduction in work force in
order to reduce our staffing to a level appropriate for our existing operations
and site development projects. As a result, seven members of our salaried work
force were immediately laid off. In addition, we made offers for early
retirement to several members of our hourly work force and our salaried
administrative and process supervisors. Upon completion of the down-sizing of
our hourly work force and our administrative and process supervisor positions,
which will occur after the period for accepting offers of early retirement has
closed in September, total staff reductions are expected to be approximately
40 employees, and we expect to recognize approximately $2.2 million in
severance costs in the third and fourth quarters of 2008, in accordance with
SFAS No. 146, “Accounting for Costs Associated with Exit of Disposal
Activities.”
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.
Accordingly, consistent with the guidance EITF Abstracts, Topic No. D-104, “Clarification of Transition
Guidance in Paragraph 51 of FASB Statement No. 144,” we have reported
the operating results of these businesses as discontinued operations in our
consolidated financial statements for the years ended December 31, 2007,
2006 and 2005 and the three months ended March 31, 2008 and 2007,
respectively.
Results of
Operations
The following table sets forth revenues, gross profit (loss) and net
loss from continuing operations for 2007, 2006 and 2005 and the three months
ended March 31, 2008 and 2007:
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year Ended December 31, |
|
|
Three Months Ended March 31, |
|
| |
|
2007 |
|
|
2006 |
|
|
2005 |
|
|
2008 |
|
|
2007 |
|
| |
|
(Dollars in thousands)
|
|
| |
|
Revenues |
|
$ |
129,813 |
|
|
$ |
141,259 |
|
|
$ |
128,098 |
|
|
$ |
38,199 |
|
|
$ |
32,715 |
|
|
Gross profit |
|
|
13,382 |
|
|
|
13,846 |
|
|
|
7,844 |
|
|
|
4,400 |
|
|
|
5,627 |
|
|
Loss from continuing
operations |
|
|
(7,713 |
) |
|
|
(2,194 |
) |
|
|
(5,856 |
) |
|
|
(905 |
) |
|
|
(56 |
) |
41
Three
Months Ended March 31, 2008 Compared to Three Months Ended March 31,
2007
Revenues and
income (loss) from continuing operations
Our revenues were $38.2 million for the first quarter of 2008, a
17% increase from the $32.7 million in revenues we recorded for the first
quarter of 2007. We recorded a net loss from continuing operations of
$0.9 million for the first quarter of 2008, compared to a net loss from
continuing operations of less than $0.1 million in the first quarter of
2007.
Revenues from acetic acid operations were $28.9 million for the
first quarter of 2008, a 17% increase from the $24.8 million in revenues we
received from these operations in the first quarter of 2007. This increase in
acetic acid revenues in the first quarter of 2008 resulted primarily from an
increase in cost reimbursements received from BP Chemicals due to an increase in
the costs allocated to our acetic acid operating segment as a result of our exit
from the styrene business. Gross profit from our acetic acid operations
decreased $1.8 million during the first quarter 2008 compared to the first
quarter of 2007. This decrease in gross profit was primarily due to an increase
in the costs allocated to our acetic acid operating segment as a result of our
exit from the styrene business.
Revenues from plasticizers operations were $9.0 million in the
first quarter of 2008, a 20% increase from the $7.5 million in revenues we
recorded from these operations in 2007. Gross profit for our plasticizers
operations increased $1.7 million in the first quarter of 2008. These
increases in revenues and gross profit resulted primarily from reimbursement by
BASF for cost savings approved in 2008 by BASF.
Interest and
debt related expenses
Our interest expense for the first quarter of 2008 was
$4.2 million, compared to $3.5 million for the first quarter of 2007.
This increase in the first quarter of 2008 was primarily due to the higher
principal amount of our senior secured notes compared to our 2007 secured notes.
Interest
income
Our interest income for the first quarter of 2008 was
$1.3 million compared to the $0.1 million during the first quarter of
2007. This increase in interest income was primarily due to the higher average
cash balances in the first quarter of 2008 compared to the same period in 2007.
Discontinued
operations
During the first quarter of 2008, net loss from discontinued
operations was $6.2 million in the first quarter of 2008 compared to net
income of $2.7 million in the first quarter of 2007. This increase in net
loss was primarily due to the costs associated with the decommissioning of our
styrene unit that was shut down beginning in December 2007.
Comparison
of 2007 to 2006
Revenues and
loss from continuing operations
Our revenues were $129.8 million in 2007, a decrease of 8% over
the $141.3 million in revenues we recorded in 2006. This decrease in
revenues resulted primarily from a decrease in plasticizers sales in 2007 due to
the shutdown of our oxo-alcohols facility in 2006, partially offset by a slight
increase in acetic acid revenues in 2007. We recorded a net loss from continuing
operations of $7.7 million in 2007, compared to a net loss of
$2.2 million in 2006. The increase in our net loss was primarily due to
increased interest and debt related expenses associated with the exchange of
$100 million of our 2007 secured notes for $150 million of new senior
secured notes in early 2007.
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 below in
“Business — 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.
42
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.
Selling,
general & administrative expenses
Our selling, general and administrative expenses were
$8.7 million in 2007, compared to $7.1 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.
Other expense
(income)
Other expense was $0.8 million in 2007, compared to other income
of $0.7 million for 2006. The decrease in 2007 was due to other expense of
$0.8 million that was recorded in 2007 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, and other income of $0.7 million recorded in 2006 for an
insurance claim related to damages caused by a barge incident in 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 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
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 $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.
Loss from
discontinued operations, net of tax
We recorded a net loss from discontinued operations of
$11.2 million in 2007 compared to a net loss of $103.5 million in
2006. The net loss in 2006 was primarily due to the $127.7 million
impairment charge to our styrene assets that we recorded in the fourth quarter
of 2006, partially offset by a one-time reimbursement of $15 million in
2006 for an insurance claim related to the 2005 fire in the styrene unit. There
were no such transactions in 2007.
Comparison
of 2006 to 2005
Revenues and
loss from continuing operations
Our revenues were $141.3 million in 2006, an increase of 10%
over the $128.1 million in revenues we recorded in 2005. This increase in
revenues resulted primarily from an increase in the acetic acid sales prices.
Gross profit increased to $13.8 million during 2006 from $7.8 million
in 2005. We recorded a net loss from continuing operations of $2.2 million
in 2006, compared to the net loss of $5.9 million we recorded in 2005. This
decrease in our net loss was primarily due to improved gross profit from our
acetic acid operations partially offset by a decrease in our benefit for income
taxes discussed below.
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
43
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 below in “Business — 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.
Other expense
(income)
We recorded other income of $0.7 million in 2006, which
primarily consisted of reimbursement for an insurance claim related to damages
caused by a barge incident in 2005.
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
$103.5 million in 2006 compared to a loss of $23.7 million in 2005.
The increase in our net loss in 2006 was due to an impairment of
$127.7 million to write down our styrene production unit in 2006, partially
offset by improved gross profit for our styrene unit and a one-time
reimbursement of $15 million in 2006 for an insurance claim related to the
2005 fire in our styrene unit.
Liquidity and
Capital Resources
During March and April, 2007, we repurchased all $100.6 million
of our outstanding 2007 secured notes, pursuant to a tender offer and
redemption. Concurrently with our tender offer, we solicited consents from the
holders of our 2007 secured notes to, among other things, eliminate certain
covenants contained in the indenture governing our 2007 secured notes and
related security documents. On March 30, 2007, we repurchased
$58 million in aggregate principal amount of 2007 secured notes which were
validly tendered prior to the expiration of our tender offer, and paid the
accrued interest thereon and $0.1 million in consent fees. On
April 27, 2007, we redeemed all of our 2007 secured notes that were not
tendered pursuant to our tender offer for $44 million, which included
$1.5 million in accrued interest.
On March 29, 2007, pursuant to a purchase agreement, or the
Purchase Agreement, we sold $150 million aggregate principal amount of
unregistered senior secured notes to Jefferies & Company, Inc. and CIBC
World Markets Corp., as initial purchasers. Sterling Chemicals Energy, Inc., or
Sterling Energy, one of our wholly-owned subsidiaries, was also a party
to the Purchase Agreement as a guarantor. On May 6, 2008, Sterling Energy was
merged with and into Sterling Chemicals, Inc. Upon consummation of the merger,
Sterling Energy no longer had independent existence and, consequently, our
senior secured notes are no longer guaranteed by Sterling Energy. On
March 29, 2007, we completed a private offering of the unregistered senior
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, of which this prospectus forms a
part, to exchange our unregistered senior 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. This prospectus forms a part of a registration statement
that was filed to comply with our obligations under the registration rights
agreement. However, as the registration statement was not declared effective by
December 24, 2007, the interest rate on our senior secured notes increased
by 0.25% per annum on each of December 25, 2007, March 24, 2008 and
June 23, 2008. The interest on our senior secured notes will increase by
44
an additional 0.25% per annum on August 21, 2008 if the registration
statement is not declared effective by that date. As such, penalty interest is
expected to be between $0.4 million and $0.5 million depending upon
the effectiveness date of the registration statement, of which $0.2 million
was accrued as of March 31, 2008, and we expect to accrue an additional
$0.2 million in the second quarter of 2008. All of this additional interest
will cease to accrue when the registration statement is declared effective by
the SEC and the interest rate on our senior secured notes will automatically
decrease back to the face amount of 101/4% per annum.
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 occurs and is continuing, other than an event of default triggered upon
certain bankruptcy events, the trustee under our indenture or the holders of at
least 25% in principal amount of our outstanding senior secured notes may
declare the senior 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 senior 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 currently in compliance with all of the covenants
contained in our indenture.
Interest is due on our outstanding senior secured notes on April 1
and October 1 of each year. Our outstanding senior 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 senior secured notes are secured
(i) on a first priority basis by all of any guarantors’ fixed assets and
certain related assets, including, without limitation, all property, plant and
equipment, and (ii) on a second priority basis by any guarantors’ other
assets, including, without limitation, accounts receivable, inventory, capital
stock of our domestic restricted subsidiaries, intellectual property, deposit
accounts and investment property.
On December 19, 2002, we entered into a Revolving Credit
Agreement 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. Our revolving credit facility is
secured by first priority liens on all of our accounts receivable, inventory and
other specified assets, and was also secured by all of the issued and
outstanding capital stock of Sterling Energy before it was merged into us. 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 of our revolving credit facility. Available credit under our revolving
credit facility is subject to a monthly borrowing base of 70% 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, since that time, the monetization of
accounts receivable and inventory associated with our exit from the styrene
business significantly decreased the borrowing base under our revolving credit
facility. In response to the expected continued lower levels of accounts
receivable and inventory, as well as our lesser need for a working capital
facility, on June 30, 2008, we reduced our commitment under our revolving
credit facility to $25 million. As of March 31, 2008, total credit
available under our revolving credit facility was limited to $9.5 million.
As of March 31, 2008, there were no loans outstanding under our revolving
credit facility, and we had $4.1 million in letters of credit outstanding
resulting in borrowing availability of $5.4 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 would be 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
45
default thereunder. Our revolving credit facility does not require us
to maintain any financial ratios or satisfy any financial maintenance tests. We
are currently 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 $176 million at
March 31, 2008, an increase of $38 million compared to our liquidity
at December 31, 2007. This increase was primarily due to the monetization
of the working capital from our prior styrene business. As a result of our exit
from the styrene business, we expect our future cash flows from operations to be
significantly less volatile than previous years. We expect to have positive cash
flows from continuing operations for the reasonably foreseeable future, and we
believe that our cash on hand and cash generated from continuing operations,
along with credit available under our revolving credit facility, will be
sufficient to meet our short-term and long-term liquidity needs for the
reasonably foreseeable future.
Working
Capital
Our working capital, excluding assets and liabilities from
discontinued operations, was $163.7 million as of March 31, 2008, an
increase of $57.7 million from our working capital of $106.0 million
on December 31, 2007. This increase in working capital from continuing
operations resulted primarily from the monetization of the working capital from
our discontinued styrene business.
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 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.
Net cash provided by our operations was $72.3 million for the first
quarter of 2008, compared to the $8.6 million in net cash provided by our
operations during the first quarter of 2007. This improvement in net cash flow
in the first quarter of 2008 was primarily due to the monetization of the
working capital from our prior styrene business of approximately $66 million.
Net cash flow used in our investing activities was $2.0 million during the first
quarter of 2008, compared to the $46.2 million during the first quarter of 2007,
primarily due to a change in our restricted cash associated with the debt
refinancing discussed above. There was zero cash flow provided by financing
activities in the first quarter of 2008 compared to $85.2 million in the first
quarter of 2007 related to our debt refinancing discussed above.
46
Capital
Expenditures
Our capital expenditures in continuing operations were $3.8 million,
$4.9 million and $4.9 million in 2007, 2006 and 2005, respectively, and for
discontinued operations were $2.6 million, $6.6 million and $4.6 million in
2007, 2006 and 2005, respectively. Our capital expenditures during the first
quarter of 2008 and 2007 for continuing operations were $2.0 million and
$0.7 million, respectively, and for discontinued operations were zero and
$1.5 million, respectively, and were primarily for routine safety,
environmental and replacement capital.
We expect our remaining capital expenditures in 2008 to be
approximately $6.0 million, including $4.0 million for a capital
project to prevent the discharge of process wastewater during periods of heavy
rain at our Texas City site, and an additional $2.0 million for routine
safety, environmental and replacement capital.
Our capital expenditures for environmentally related prevention,
containment and process improvements to continuing operations were $0.5 million,
$1.5 million and $1.0 million in 2007, 2006, 2005, respectively, and were zero,
$0.5 million and $1.0 million for discontinued operations in 2007, 2006 and
2005, respectively.
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)
|
|
| |
|
Senior 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 25, 2007,
March 24, 2008 and June 23, 2008, the interest rate on our
senior secured notes increased by 0.25% per annum because our registration
statement to exchange our unregistered notes for registered notes having
the same terms and conditions had not been declared effective by the SEC.
The interest on our senior secured notes will increase by an additional
0.25% per annum on August 21, 2008 if the registration statement is
not declared effective by this date. As such, penalty interest is expected
to be between $0.4 million and $0.5 million depending upon the
effectiveness date of the registration statement, of which
$0.2 million was accrued as of March 31, 2008. |
| |
| (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.
|
As of March 31, 2008, there have been no significant changes to
the contractual obligations disclosed above.
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” for the year
ended December 31, 2007 and the quarter ended March 31, 2008, included
in this
47
prospectus. 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 produce acetic acid and plasticizers and recognize revenues (and
the related costs) when persuasive evidence of an arrangement exists, delivery
has occurred, the sales price is fixed and determinable, and collectibility is
reasonably assured.
Acetic Acid. Pursuant to a production agreement,
all acetic acid produced is sold to BP Chemicals, who takes delivery, title and
risk of loss at the time the acetic acid is produced. BP Chemicals, in turn,
markets and sells the acetic acid and pays us a portion of the profits derived
from those sales. BP Chemicals reimburses us monthly for 100% of our fixed and
variable costs (excluding direct depreciation associated with machinery and
equipment used in the manufacturing of acetic acid) of production and the
revenue associated with the reimbursement of these costs is matched against our
costs as they are incurred. We recognize revenue related to the profit sharing
component of the production agreement based on quarterly estimates received from
BP Chemicals. These estimates are based on the profits from sales of the acetic
acid purchased from our acetic acid plant.
Plasticizers. We generate revenues from our
plasticizers operations through a tolling agreement with BASF. BASF purchases
all of our plasticizers and takes delivery, title, and risk of loss at the time
of production. We receive fixed, level quarterly payments which are recognized
on a straight-line basis. In addition, BASF reimburses us monthly for our actual
fixed and variable production costs (excluding direct depreciation associated
with machinery and equipment used in the manufacturing of plasticizers), and the
revenue associated with the reimbursement of these costs is matched against our
costs as they are incurred.
Deferred revenue. 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
$11 million and $10 million, respectively, related to continuing
operations, which primarily represent 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. As of December 31, 2007, in discontinued operations, we had a
balance in deferred income of approximately $59 million pertaining to the
terminated NOVA supply agreement, which is being amortized using the
straight-line method over the contractual non-compete period and is reflected in
discontinued operations.
As of March 31, 2008, we had a balance in deferred income of
approximately $10 million related to continuing operations which primarily
pertained to the oxo-alcohols payment referred to above, and in discontinued
operations, we had a balance of $57 million pertaining to the terminated
NOVA supply agreement referred to above.
Styrene. Styrene revenue was recognized from sales
in the open market, raw materials conversion agreements and long-term supply
contracts. 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.
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 in
discontinued operations 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. For the
quarter-ended March 31, 2008, there were no such adjustments. 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.
48
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 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. Assumptions utilized in the
Black-Scholes model include:
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
2008 |
|
|
2007 |
|
|
2006 |
|
|
2005 |
|
| |
|
Risk-free interest rate
|
|
|
2.5 |
% |
|
|
3.5 |
% |
|
|
4.7 |
% |
|
|
4.4 |
% |
|
Volatility |
|
|
54.5 |
% |
|
|
55.5 |
% |
|
|
46.2 |
% |
|
|
50.3 |
% |
|
Dividend yield
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
Expected term |
|
|
5.0 |
|
|
|
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 and
March 31, 2008, our valuation allowance was $36.2 million, for each
period, which resulted in an overall net deferred tax asset/liability balance of
zero as of December 31, 2007 and March 31, 2008. 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
49
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,” or SFAS No. 158, 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 No. 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 2