e10vk
UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Form 10-K
|
|
|
þ |
|
ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the fiscal year ended December 31, 2009
Or
|
|
|
o |
|
TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the transition period from to
Commission File Number 000-50132
Sterling Chemicals, Inc.
(Exact name of registrant as specified in its charter)
|
|
|
Delaware
(State or other jurisdiction of
incorporation or organization)
|
|
76-0502785
(I.R.S. Employer Identification No.) |
|
|
|
333 Clay Street, Suite 3600
|
|
(713-650-3700) |
Houston, Texas 77002-4109
|
|
(Registrants telephone number, |
(Address of principal executive offices)
|
|
including area code) |
Securities registered pursuant to Section 12(b) of the Act: None
Securities registered pursuant to Section 12(g) of the Act:
Common Stock, par value $.01 per share
(Title of class)
Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule
405 of the Securities Act. Yes o No þ.
Indicate by check mark if the registrant is not required to file reports pursuant to Section
13 or Section 15(d) of the Act. Yes o No þ.
Indicate by check mark whether the registrant (1) has filed all reports required to be filed
by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or
for such shorter period that the registrant was required to file such reports) and (2) has been
subject to such filing requirements for the past 90 days. Yes þ No o.
Indicate by check mark whether the registrant has submitted electronically and posted on its
corporate Website, if any, every Interactive Data File required to be submitted and posted pursuant
to Rule 405 of Regulation S-T during the preceding 12 months (or for such shorter period that the
registrant was required to submit and post such files). Yes
o No o.
Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation
S-K is not contained herein and will not be contained, to the best of the registrants knowledge,
in definitive proxy or information statements incorporated by reference in Part III of this Form
10-K or any amendment to this Form 10-K. þ.
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, non-accelerated filer, and smaller reporting company
in Rule 12b-2 of the Exchange Act. (Check one):
|
|
|
|
|
|
|
Large accelerated filer o
|
|
Accelerated filer o
|
|
Non-accelerated filer o
|
|
Smaller reporting company þ |
|
|
|
|
(Do not check if a smaller reporting company) |
|
|
The aggregate market value of the registrants common stock, par value $.01 per share, held by
non-affiliates at June 30, 2009 (the last business day of the registrants most recently completed
second fiscal quarter), based upon the value of the last sales price of these shares as reported on
the OTC Electronic Bulletin Board maintained by the National Association of Securities Dealers,
Inc., was $10,221,032.
Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of
the Exchange Act). Yes o No þ.
As of February 28, 2010, Sterling Chemicals, Inc. had 2,828,460 shares of common stock
outstanding.
Portions of the definitive Proxy Statement relating to the 2010 Annual Meeting of Stockholders
of Sterling Chemicals, Inc. are incorporated by reference in Part III of this Form 10-K.
Forward-Looking Statements
This report contains forward-looking statements within the meaning of Section 27A of the
Securities Act of 1933, as amended, or 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. Forward-looking
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 report that contain forward-looking
statements include, but are not limited to, information concerning our possible or assumed future
results of operations and our future plans with respect to our plasticizers business and facility
and related disclosures. 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, Managements Discussion
and Analysis of Financial Condition and Results of Operations and elsewhere in this report.
In addition, our other filings with the Securities and Exchange Commission, or the SEC,
include additional factors that could adversely affect our business, results of operations or
financial performance. Given these risks and uncertainties, investors should not place undue
reliance on forward-looking statements. Forward-looking statements included in this Form 10-K are
made only as of the date of this Form 10-K 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 be 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.
Document Summaries
Descriptions of documents and agreements contained in this Form 10-K are provided in summary
form only, and such summaries are qualified in their entirety by reference to the actual documents
and agreements filed as exhibits to this Form 10-K or other periodic reports we file with the SEC.
PART I
Unless otherwise indicated, references to we, us, our and ours in this Form 10-K refer
collectively to Sterling Chemicals, Inc. and its wholly-owned subsidiaries.
Item 1. Business
We were formed in 1986 to acquire a petrochemicals facility located in Texas City, Texas that
was previously owned by Monsanto 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 and purified
terephthalic acid, which are used in a variety of products, including adhesives, surface coatings,
polyester fibers, and films and plastic bottle resins, respectively. Pursuant to our 2008 Amended
and Restated Acetic Acid Production Agreement, or our Acetic Acid Production Agreement, that
extends to 2031, all of our acetic acid production is sold to BP Amoco Chemical Company, or BP
Chemicals. 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 our acetic acid. In addition, BP Chemicals
reimburses us for 100% of our fixed and variable costs of production, other than specified indirect
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 we receive from BP Chemicals.
2
We own and operate one of the lowest cost acetic acid facilities in the world. Our acetic
acid facility utilizes BP Chemicals proprietary Cativa carbonylation technology, which we
believe offers several advantages over competing production methods, including lower energy
requirements and lower fixed and variable costs. 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 our requirements for
carbon monoxide are 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, or our Texas
City facility.
Our plasticizers business is comprised of two separate products: phthalate esters and
phthalic anhydride, together commonly referred to as plasticizers. 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. Since 1986, we have sold all of our
plasticizers production exclusively to BASF pursuant to our agreement with BASF, or our
Plasticizers Production Agreement, which has been amended several times. We also previously
produced phthalic anhydride, or PA, for BASF under the Plasticizers Production Agreement. Under
our Plasticizers Production Agreement, BASF provides us with most of the required raw materials,
markets the plasticizers that we produce and is obligated to make certain fixed quarterly payments
to us and reimburse us monthly for our actual production costs and capital expenditures relating to
our plasticizers facility. Effective as of April 1, 2008, we and BASF amended our Plasticizers
Production Agreement after BASF nominated zero pounds of PA under the prior version of the
agreement due to deteriorating market conditions, ultimately resulting in the closure of our PA
unit. The closure of our PA unit did not, however, impact our continued production of plasticizers
for BASF. On November 11, 2009, BASF elected to terminate our Plasticizers Production Agreement,
effective December 31, 2010, at which time we will no longer produce plasticizers for BASF. We
will not be subject to any early termination penalties in connection with BASFs termination of our
Plasticizers Production Agreement. BASF, on the other hand, will be required to pay us an early
termination fee of $9.8 million on December 31, 2010. In December 2010, in connection with the
termination of our Plasticizers Production Agreement, we will be required to refund BASFs $1.0
million pre-payment deposit previously paid by BASF. We are in the process of exploring and
evaluating our commercial options with respect to continuing our plasticizers business after the
termination of our Plasticizers Production Agreement with BASF. Since we are in the early stages
of evaluating our commercial options regarding our plasticizers business, we cannot predict
the ultimate outcome or the success of continuing the plasticizers business after December 31,
2010. In the event we conclude to permanently close our plasticizers facility, we have also
developed plans for restructuring our operating costs following the termination of our Plasticizers
Production Agreement. If we are unable to continue our plasticizers operations through other
viable commercial options for our plasticizers business or facility or restructure our operating
costs, or are unable to do so at or shortly after December 31, 2010, the termination of our
Plasticizers Production Agreement will likely have a material adverse effect on our financial
condition, results of operations and cash flows. However, we do not believe that these effects
will impact our ability to continue as a going concern. For a further description of our agreement
with BASF, see Plasticizers-BASF under Contracts and see Risk Factors.
Prior to 2008, we produced styrene as one of our principal products. 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., which was subsequently assigned by NOVA Chemicals Inc. to
INEOS NOVA LLC, or INEOS NOVA. 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 restricted from reentering the styrene business until November 2012. The
restricted period was initially eight years. However, on April 1, 2008, INEOS NOVA unilaterally
reduced the restricted period to five years.
We sold substantially all remaining styrene inventory during the first quarter of 2008. The
decommissioning process was completed by the end of 2008, with $18.9 million of the $19.6 million
in total costs associated with the decommissions being incurred in 2008. In July 2008, 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, we reduced our salaried work force
by 19 people and our hourly work force by 15 people and recognized and paid $1.4 million of
severance costs in 2008. In addition, as a result of our work force reduction, the accrual of
defined benefits for all future services of a significant number of employees was eliminated and we
recorded a curtailment loss of $1.2 million for our benefit plans in 2008. The revenues and gross
profit (loss) from our styrene operations, which are
3
reflected in discontinued operations, include $12.4 million of deferred income from the NOVA
supply agreement that is being amortized over the contractual non-compete period of five years
using the straight-line method, are summarized below:
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Revenues |
|
$ |
12,382 |
|
|
$ |
26,591 |
|
Gross profit (loss) |
|
|
10,903 |
|
|
|
(7,757 |
) |
We own the acetic acid and plasticizers manufacturing units located at our Texas City
facility. We lease a portion of our Texas City facility to Praxair, who constructed a partial
oxidation unit on that land. We also lease a portion of our Texas City facility to S&L
Cogeneration Company, a 50/50 joint venture between us and Praxair Energy Resources, Inc., or
Praxair Energy, which constructed a cogeneration facility on that land. However as our strategic
initiatives under consideration do not require utilization of the steam produced by the
cogeneration facility, we and Praxair Energy elected to terminate the joint venture and the Joint
Venture Agreement governing S&L Cogeneration Company, or the Joint Venture Agreement, was amended
to extend its term until the later of November 30, 2009 or upon completion of all final audits, and
to address several matters related to the sale of the cogeneration facility, the distribution of
the joint ventures assets and the termination and winding-up of its affairs. We expect the joint
venture to be terminated and wound-up during 2010. We lease space for our principal offices
located in Houston, Texas. As of December 31, 2009, we operated in two segments: acetic acid and
plasticizers.
Business Strategy
Our strategic objectives include:
|
|
|
safe, reliable and environmentally responsible operations; |
|
|
|
effective utilization of available capacity; |
|
|
|
superior expense and capital expenditure management; |
|
|
|
expansion of capacity through low cost or strategic investments; |
|
|
|
flawless execution of contract management and administration; |
|
|
|
monetization of under-utilized assets and infrastructure; |
|
|
|
capture of economic merger and acquisition opportunities; |
|
|
|
optimized capital structure, tax credits and governmental subsidies; |
|
|
|
top-quality human resource management, development and utilization; and |
|
|
|
leading shareholder returns. |
Operating Our Facilities Safely, Reliably and in an Environmentally Responsible Manner. We
believe in operating our facilities in a manner that earns the confidence of our employees and our
community. We have created a positive and open safety culture in which employee participation is
encouraged in an atmosphere of ownership and pride. We proactively protect the safety of our
employees, the community and the environment through the systematic identification, reduction and
management of risks. Expectations and accountabilities for safety have been defined for all levels
of our organization, and employees have aligned their personal goals to meet these
responsibilities. Management and employee variable compensation programs are partially dependent
on our individual and collective accomplishments. Our Board of Directors, or our Board, is
informed of our progress
4
towards maintaining and improving our process safety programs through the use of performance
metrics under our compensation programs and quarterly presentations
to the Environmental, Health & Safety Committee of our Board.
Profitably Grow Our Business. We believe that our acetic acid facility is well positioned for
cost-effective future capacity expansions at low relative incremental cost due to previous
investments made by us and BP Chemicals. These investments include the installation of a new
reactor in 2003 that is capable of producing up to 1.7 billion pounds of acetic acid annually and
the replacement of the primary column of our acetic acid facility in June 2009 with a column sized
in excess of existing capacity. Although slowdowns in the housing and automotive markets during
2009 resulted in reduced demand for vinyl acetate monomer and, consequently, acetic acid in North
America for the short-term, as demand for acetic acid recovers and grows, we intend to grow our
acetic acid business through capacity expansions that take advantage of this positioning.
Monetize Under-utilized Assets and Infrastructure. Our Texas City facility 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 facility also has
truck loading racks, weigh scales, stainless and carbon 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 also have approximately 240
excess tons of perpetual NOx allowances under the Texas Commission on Environmental Quality Mass
Emissions Cap and Trade Program which apply to the eight county Houston-Galveston-Brazoria, Texas
nonattainment area, which may be sold or used for development projects. 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 and our management, operational
and engineering expertise, as well as our ample unoccupied land, we believe that there are
significant opportunities for further development of our Texas City facility. We are currently
pursuing numerous initiatives to attract new manufacturing, distribution or storage related
businesses. 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 revenue 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, management and operational expertise
to minimize our share of the capital costs. In any case, we expect any new facility constructed at
our Texas City facility to lower the amount of overall fixed costs allocated to each of our
operating units and provide us with additional profit.
Pursue Economic Merger and Acquisition Opportunities. We are pursuing strategic acquisitions,
focusing on manufacturing businesses and assets which would allow us to increase the size and scope
of our business, while adding revenue diversification to our existing businesses. We believe that
the current economic environment has increased the potential number of acquisition targets and has
provided an ideal situation for us to acquire businesses on favorable terms.
Industry Overview
Acetic Acid. The North American acetic acid industry has enjoyed a long period of sustained
domestic demand growth, as well as substantial export demand. This has led to North American
industry utilization rates above 85% over the last six years. Although slowdowns in the housing
and automotive markets during 2009 resulted in reduced demand for vinyl acetate monomer, and
consequently acetic acid, in North America for the short-term, Tecnon OrbiChem, or Tecnon, projects
acetic acid utilization rates will increase to over 98% by 2013. 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.
Historically these producers have made capacity additions primarily through small expansion
projects or the exploitation of debottlenecking opportunities. Finally, the North American acetic
acid industry tends to sell most of its products through long-term sales agreements having formula
based pricing mechanisms, eliminating much of the volatility seen in other petrochemicals products
and resulting in more stable and predictable earnings and profit margins.
Global production capacity of acetic acid as of December 31, 2009 was approximately 31 billion
pounds per year, with current North American production capacity at approximately six billion
pounds per year. The North American acetic acid industry is mature and well developed, with the
four major acetic acid producers accounting
5
for approximately 94% of production capacity in North America. Demand for acetic acid is
linked to the demand for vinyl acetate monomer, a key intermediate in the production of a wide
array of polymers. Vinyl acetate monomer is the largest derivative of acetic acid, representing
over 35% of global demand. Although slowdowns in the housing and automotive markets over the last
year have reduced global demand for vinyl acetate monomer in the short-term, annual global
production of vinyl acetate monomer is expected to increase from 10.3 billion pounds in 2008 to
14.2 billion pounds in 2013.
Plasticizers. Plasticizers are produced from either ethylene-based linear alpha-olefins
feedstocks or propylene-based non-linear technology. We produce both linear and non-linear
plasticizers used to make flexible plastics such as shower curtains, floor coverings, automotive
parts and construction materials. Feedstocks for plasticizers consist of PA and oxo-alcohols.
Linear plasticizers have historically received a premium over competing propylene-based branched
products for customers that require enhanced performance properties. Although we have not been
exposed to fluctuations in costs or market conditions due to the contract terms in our Plasticizers
Production Agreement with BASF, the markets for competing plasticizers may be affected by the cost
of the underlying raw materials, especially when the cost of one olefin rises faster than the other
or by the introduction of new products. Over the last several years, the price of linear
alpha-olefins increased sharply, which caused many consumers to switch to lower cost branched
products such as propylene-based plasticizers, despite the loss of some performance properties. As
a result, we modified our plasticizer production facilities during the third quarter of 2006 to
include branched plasticizers production. Ultimately, we expect branched plasticizers to replace
linear plasticizers for most applications, although recently some branched plasticizers products
have been the subject of health related concerns. Following termination of the Plasticizers
Production Agreement, we may face greater cost fluctuations or exposure to market conditions if we
continue to operate the plasticizers business. For a further description of our agreement with
BASF, see Plasticizers-BASF under Contracts and see Risk Factors.
Product Summary
The following table summarizes our principal products, including our capacity, the primary end
uses for each product, the raw materials used to produce each product and the major competitors for
each product. Capacity represents rated annual production capacity as of December 31, 2009,
which is calculated by estimating the number of days in a typical year that a production facility
is capable of operating after allowing for downtime for regular maintenance, and multiplying that
number of days by an amount equal to the facilitys optimal daily output based on the design
feedstock mix. As the capacity of a facility is an estimated amount, actual production may be more
or less than capacity, and the following table does not reflect actual operating rates of any of
our production facilities for any given period of time.
|
|
|
|
|
|
|
|
|
Sterling Product |
|
Intermediate |
|
|
|
|
|
|
(Capacity) |
|
Products |
|
Primary End Products |
|
Raw Materials |
|
Major Competitors |
Acetic Acid
(1.3 billion pounds
per year)
|
|
Vinyl acetate
monomer,
terephthalic acid
and acetate
solvents
|
|
Adhesives, PET
bottles, fibers and
surface coatings
|
|
Methanol and Carbon
Monoxide
|
|
Celanese AG,
Eastman Chemical
Company and
Lyondell Basell
Chemical Company |
|
|
|
|
|
|
|
|
|
Plasticizers
(200 million pounds
per year of phthalate
esters)
|
|
Flexible polyvinyl
chloride, or PVC
|
|
Flexible plastics,
such as shower
curtains and
liners, floor
coverings, cable
insulation,
upholstery and
plastic molding
|
|
Oxo-Alcohols and
Phthalic Anhydride
|
|
ExxonMobil
Corporation,
Eastman Chemical
Company and BASF
Corporation |
Products
Acetic Acid. Our acetic acid is used primarily to manufacture vinyl acetate monomer and
purified terephthalic acid, which are used in a variety of products, including adhesives, surface
coatings, polyester fibers, and films and plastic bottle resins, respectively. We have the third
largest production capacity for acetic acid in North America. Our acetic acid unit has a rated
annual production capacity of approximately 1.3 billion pounds, which represents approximately 19%
of total North American capacity. All of our acetic acid production is sold to BP Chemicals, and
we are BP Chemicals sole source of production in the Americas. We sell all of our acetic acid to
BP Chemicals pursuant to our Acetic Acid Production Agreement that extends until 2031. For a
further description of our agreement with BP Chemicals, please refer to Acetic Acid-BP Chemicals
under Contracts.
Plasticizers. Our plasticizers business involves the production of phthalate esters, commonly
referred to as plasticizers, from PA and oxo-alcohols. 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 our Plasticizers Production Agreement. Since 1986, we have
sold all our plasticizers production exclusively to BASF
6
pursuant to our Plasticizers Production Agreement, which has been amended several times. We
also previously produced PA for BASF under the Plasticizers Production Agreement. Effective as of
April 1, 2008, we and BASF amended our Plasticizers Production Agreement after BASF nominated zero
pounds of PA under the prior version of the agreement, ultimately resulting in the closure of our
PA unit. The closure of our PA unit did not, however, impact our continued production of
plasticizers for BASF. On November 11, 2009, BASF elected to terminate our Plasticizers Production
Agreement, effective December 31, 2010, at which time we will no longer produce plasticizers for
BASF. We will not be subject to any early termination penalties in connection with BASFs
termination of our Plasticizers Production Agreement. BASF, on the other hand, will be required to
pay us an early termination fee of $9.8 million on December 31, 2010. In December 2010, in
connection with the termination of our Plasticizers Production Agreement, we will be required to
refund BASFs $1.0 million pre-payment deposit previously paid by BASF. We are in the process of
exploring and evaluating our commercial options with respect to continuing our plasticizers
business after the termination of our Plasticizers Production Agreement with BASF. Since we are in
the early stages of evaluating our commercial options regarding our plasticizers business, we
cannot predict the ultimate outcome or the success of continuing the plasticizers business after
December 31, 2010. In the event we conclude to permanently close our plasticizers facility, we
have also developed plans for restructuring our operating costs following the termination of our
Plasticizers Production Agreement. If we are unable to continue the plasticizers operations
through other viable commercial options for our plasticizers business or facility or restructure
our operating costs, or are unable to do so at or shortly after December 31, 2010, the termination
of our Plasticizers Production Agreement will likely have a material adverse effect on our
financial condition, results of operations and cash flows. However, we do not believe that these
effects will impact our ability to continue as a going concern. For a further description of our
agreement with BASF, see Plasticizers-BASF under Contracts and see Risk Factors.
Sales and Marketing
Our 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. Our Acetic Acid Production Agreement provides for the dedication of
100% of our production of acetic acid to BP Chemicals, and our Plasticizers Production Agreement
provides for the dedication of 100% of our production of plasticizers to BASF. Under our Acetic
Acid Production Agreement, we are reimbursed for our actual fixed and variable manufacturing costs
(other than specified indirect costs) and also receive an agreed share of the profits earned from
this business. Under our Plasticizers Production Agreement, we are reimbursed for our
manufacturing costs and also receive a quarterly facility fee for the production unit included in
our plasticizers business, but do not share in the profits or losses from that business.
Contracts
Our significant contracts are described below.
Acetic Acid-BP Chemicals
In 1986, we entered into the initial version of our Acetic Acid Production Agreement with BP
Chemicals, which has since been amended several times. We sell all of our acetic acid production
to BP Chemicals under our Acetic Acid Production Agreement 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 (other than specified indirect costs). Revenues from our acetic acid segment
were $87.3 million and $129.7 million for the years ended December 31, 2009 and 2008, respectively,
representing approximately 76% and 80%, respectively, of our total revenues for such period. Other
than our Acetic Acid Production Agreement, we do not have any material relationships with BP
Chemicals.
Plasticizers-BASF
Since 1986, we have sold all of our plasticizers production exclusively to BASF pursuant to
our Plasticizers Production Agreement, which has been amended several times. We also previously
produced PA for BASF under the Plasticizers Production Agreement. Under our Plasticizers
Production Agreement, BASF provides us with most of the required raw materials and markets the
plasticizers we produce, and is obligated to make certain fixed
7
quarterly payments to us and to reimburse us monthly for our actual production costs and
capital expenditures relating to our plasticizers facility. Effective as of April 1, 2008, our
Plasticizers Production Agreement was amended and restated in connection with BASFs nomination of
zero pounds of PA in response to deteriorating market conditions, ultimately resulting in the
closure of our PA unit. The closure of our PA unit did not, however, impact our continued
production of plasticizers for BASF. In exchange for being relieved of its obligations related to
our PA manufacturing unit, BASF paid us an aggregate amount of approximately $3.2 million.
However, we are obligated to refund 25% of this amount if we restart our PA manufacturing unit
during 2010. The $3.2 million payment from BASF was made in exchange for the termination of BASFs
obligations under our Plasticizers Production Agreement with respect to the operation of our PA
manufacturing unit and, consequently, is recognized using the straight-line method over the
restricted period from April 1, 2008 through December 31, 2010. In addition, during the first half
of 2008, BASF paid 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 manufacturing unit have been incurred and expensed, and the
$3.7 million in cost reimbursements was recognized as revenue in the first half of 2008.
On November 11, 2009, BASF elected to terminate our Plasticizers Production Agreement,
effective December 31, 2010. We will not be subject to any early termination penalties in
connection with BASFs termination of our Plasticizers Production Agreement. BASF, on the other
hand, will be required to pay us an early termination fee of $9.8 million on December 31, 2010, at
which time we will no longer produce plasticizers for BASF. In December 2010, in connection with
the termination of our Plasticizers Production Agreement, we will be required to refund BASFs $1.0
million pre-payment deposit previously paid by BASF. If we continue to operate the plasticizers
business after the termination of our Plasticizers Production Agreement, we will be required to
make payments to BASF for its undepreciated capital expenditures related to past capital projects
paid by BASF, over the remaining balance of the original term of our Plasticizers Agreement, based
on a straight line, 8-year life. As of December 31, 2010, we expect the total amount of these
undepreciated capital expenditures to be approximately $2.6 million, with approximately $1.0
million, $0.7 million, $0.6 million, and $0.3 million potentially to be paid in 2011, 2012, 2013,
and 2014, respectively. If within 90 days after the termination of our Plasticizers Production
Agreement, we provide written notice to BASF of our election to permanently close our plasticizers
facility, the undepreciated capital expenditures paid by BASF for all capital projects is deemed to
be zero, and we will not be required to make any payments to BASF. We are in the process of
exploring and evaluating our commercial options with respect to continuing our plasticizers
business after the termination of our Plasticizers Production Agreement with BASF. Since we are in
the early stages of evaluating our commercial options regarding our plasticizers business, we
cannot predict the ultimate outcome or the success of continuing the plasticizers business after
December 31, 2010. In the event we conclude to permanently close our plasticizers facility, we
have also developed plans for restructuring our operating costs following the termination of our
Plasticizers Production Agreement. If we are unable to continue the plasticizers operations
through other viable commercial options for our plasticizers business or facility or restructure
our operating costs, or are unable to do so at or shortly after December 31, 2010, the termination
of our Plasticizers Production Agreement will likely have a material adverse effect on our
financial condition, results of operations and cash flows. However, we do not believe that these
effects will impact our ability to continue as a going concern. Revenues from our plasticizers
segment were $26.0 million and $31.0 million for the years ended December 31, 2009 and 2008,
respectively, representing approximately 23% and 19%, respectively, of our total revenues for such
period. Gross profit from our plasticizers operations was $5.9 million in 2009 and $4.1 million in
2008. Other than our Plasticizers Production Agreement, we do not have any material relationships
with BASF.
Sales to major customers constituting 10% or more of total revenues are included in Note 11 of
the Notes to Consolidated Financial Statements included in Item 8, Part II of this Form 10-K.
Raw Materials and Energy Resources
The aggregate cost of raw materials and energy resources used in the production of our
products is far greater than the total of all other costs of production combined. As a result, an
adequate supply of raw materials and energy at reasonable prices and on acceptable terms is
critical to the success of our business. Although we believe that we will continue to be able to
secure adequate supplies of raw materials and energy, we may be unable to do so at
8
acceptable prices or payment terms. See Risk Factors. Acetic acid is manufactured
primarily from carbon monoxide and methanol. Praxair is our sole source for carbon monoxide and
supplies us with all of the carbon monoxide we require for the production of acetic acid from its
partial oxidation unit located on land leased from us at our Texas City site. Currently, our
methanol requirements are supplied by BP Chemicals under our Acetic Acid Production Agreement. The
primary raw materials for plasticizers are oxo-alcohols and orthoxylene, which are supplied by BASF
under our Plasticizers Production Agreement. These sources of raw materials tend to mitigate
certain risks typically associated with obtaining raw materials, as well as decrease our working
capital requirements.
Technology and Licensing
In 1986, we acquired our Texas City facility from Monsanto Company, or Monsanto. In
connection with that acquisition, Monsanto granted us a non-exclusive, irrevocable and perpetual
right and license to use Monsantos technology and other technology Monsanto acquired through
third-party licenses in effect at the time of the acquisition. This license included Monsantos
technology related to the production of acetic acid and plasticizers. During 1991, BP Chemicals
Ltd., or BPCL, purchased Monsantos acetic acid technology, subject to existing licenses. Under a
technology agreement with BP Chemicals and BPCL, BPCL granted us a non-exclusive, irrevocable and
perpetual right and license to use acetic acid technology owned by BPCL and some of its affiliates
at our Texas City facility, including any new acetic acid technology developed by BPCL at its
acetic acid facilities in England or pursuant to the research and development program provided by
BPCL under the terms of such agreement. We do not engage in alternative process research.
Competition
There are only four large producers of acetic acid in North America. Historically these
producers have made capacity additions primarily through small expansion projects or the
exploitation of debottlenecking opportunities. The North American plasticizers industry is a
mature market, with phthalate esters like those produced by us being subject to excess production
capacity and diminishing demand due to the ability of consumers to substitute different raw
materials based on relative costs at the time, as well as increasing health concerns regarding
these products. A list of our principal competitors is found in the Product Summary table above.
Environmental, Health and Safety Matters
Our operations involve the handling, production, transportation, treatment and disposal of
materials that are classified as hazardous or toxic and that are extensively regulated by
environmental and health and safety laws, regulations and permit requirements. Environmental
permits required for our operations are subject to periodic renewal and may be revoked or modified
for cause or when new or revised environmental requirements are implemented. Changing and
increasingly strict environmental requirements can affect the manufacturing, handling, processing,
distribution and use of our chemical products and, if so affected, our business and operations may
be materially and adversely affected. In addition, changes in environmental requirements may cause
us to incur substantial costs in upgrading or redesigning our facilities and processes, including
our waste treatment, storage, disposal and other waste handling practices and equipment.
A business risk inherent in chemical operations is the potential for personal injury and
property damage claims from employees, contractors and their employees and nearby landowners and
occupants. While we believe our business operations and facilities are operated in compliance with
applicable environmental and health and safety requirements in all material respects, we cannot be
sure that past practices or future operations will not result in material claims or regulatory
action, require material environmental expenditures or result in exposure or injury claims by
employees, contractors or their employees or the public. Some risk of environmental costs and
liabilities is inherent in our operations and products, as it is with other companies engaged in
similar businesses.
Our operating expenditures for environmental matters, primarily waste management and
compliance, were $14.5 million and $15.9 million in 2009 and 2008, respectively. During 2009 and
2008, we spent $1.8 million and $1.1 million, respectively, for environmentally-related capital
projects and anticipate spending approximately $0.3 million for capital projects related to waste
management, incident prevention and environmental compliance during 2010.
9
On December 13, 2007, the Texas Commission for Environmental Quality, or the TCEQ, issued an
agreed order requiring us to remove all process wastewater from a holding pond at our Texas City
facility in order to prevent discharges during heavy rain events. In order to comply with this
agreed order, we implemented a capital project at a total cost to us of $2.8 million, which
represented the majority of our environmentally-related capital projects in 2008 and 2009.
In light of our historical expenditures and expected future results of operations and sources
of liquidity, we believe we will have adequate resources to conduct our operations in compliance
with applicable environmental, health and safety requirements. Nevertheless, we may be required to
make significant site and operational modifications that are not currently contemplated in order to
comply with changing facility permitting requirements and regulatory standards. Additionally, we
have incurred, and may continue to incur, a liability for investigation and cleanup of waste or
contamination at our own facilities or at facilities operated by third parties where we have
disposed of waste. We continually review all estimates of potential environmental liabilities, but
we may not have identified or fully assessed all potential liabilities arising out of our past or
present operations or the amount necessary to investigate and remediate any conditions that may be
significant to us. Based on information available at this time and reviews undertaken to identify
potential exposure, we believe our amounts reserved for environmental matters are adequate to cover
our potential exposure for clean-up costs.
Air emissions from our Texas City facility are subject to certain permit requirements and
self-implementing emission limitations and standards under state and federal laws. Our Texas City
facility is subject to the federal governments June 1997 National Ambient Air Quality Standards,
or NAAQS, which lowered the ozone and particulate matter concentration thresholds for attainment.
Our Texas City facility is located in an area that the Environmental Protection Agency, or the EPA,
has classified as not having achieved attainment under the NAAQS for ozone, either on a 1-hour or
an 8-hour basis. Ozone is typically controlled by reduction of emissions of volatile organic
compounds, or VOCs, and nitrogen oxide, or NOx. The TCEQ has imposed strict requirements on
regulated facilities, including our Texas City facility, to ensure that the air quality control
region will achieve attainment status under the NAAQS for ozone. Local authorities may also impose
new ozone and particulate matter standards. Compliance with these stricter standards may
substantially increase our future control costs for emissions of NOx, VOCs and particulate matter,
the amount and full impact of which cannot be determined at this time.
In 2002, the TCEQ adopted a revised State Implementation Plan, or SIP, in order to achieve
compliance with the 1-hour ozone standard under the Clean Air Act by 2007. The EPA approved this
1-hour SIP, which required an 80% reduction of NOx emissions and extensive monitoring of emissions
of highly reactive VOCs or HRVOCs, in the Houston-Galveston-Brazoria area, or the HGB area.
Despite implementation of these programs, the HGB area failed to attain compliance with the 1-hour
ozone standard. As Section 185 of the Clean Air Act requires implementation of a program of
emissions-based fees until this standard is attained, Section 185 fees will be assessed on all
emissions of NOx and VOCs in 2008 and beyond in the HGB area which are in excess of 80% of the
baseline year. The final rules for administering this fee system will be adopted in 2010. Based
on the current draft rules, we do not expect to be assessed any fees in connection with emissions
from our Texas City facility.
In April 2004, the HGB area was designated a moderate non-attainment area with respect to
the 8-hour ozone standard of the Clean Air Act. On May 23, 2007, the TCEQ formally adopted
revisions to the SIP to bring the HGB area from moderate non-attainment status into attainment
status by June 15, 2010. This 8-hour SIP called for relatively modest additional controls at our
Texas City facility, which would require very little expense. However, in response to a request
from the Governor of Texas, the EPA has now reclassified the HGB area as a severe non-attainment
area, effective as of October 31, 2008. As a result, the new mandated compliance date for
attainment of the 8-hour ozone standard is June 15, 2019. A revised 8-hour SIP to address the HGB
areas severe non-attainment designation is expected to be submitted to the EPA by April 10, 2010.
The content of the revised 8-hour SIP is currently unknown, making it difficult to predict our
final cost of compliance with these regulations. However, given the permanent shutdown of our PA
and styrene facilities, we do not anticipate incurring any further cost of compliance in connection
with the revised 8-hour SIP.
The EPAs Greenhouse Gas, or GHG, reporting rules became effective on December 29, 2009.
Under these rules, GHG monitoring systems must either be in place by April 1, 2010 or an extension
request must be filed. We believe that we will be able to attain compliance with the GHG rules by
making capital expenditures of less than
10
$0.1 million in 2010. However, the rules for regulating GHG emissions have not yet been
defined and, consequently, we cannot predict what impact, if any, these rules may have on us.
To reduce the risk of offsite consequences from unanticipated events, we acquired a greenbelt
buffer zone adjacent to our Texas City site in 1991. We also participate in a regional air
monitoring network to monitor ambient air quality in the Texas City community.
Employees
As of December 31, 2009, we had 182 employees, of whom approximately 35% (all of our hourly
employees at our Texas City facility) were represented by the Texas City, Texas Metal Trades
Council, AFL-CIO, or the Union. On May 1, 2007, we entered into a collective bargaining agreement
with the Union which is effective through May 1, 2012.
Insurance
We maintain insurance coverage at levels that we believe are reasonable and typical for our
industry. A portion of our insurance coverage is provided by a captive insurance company
maintained by us and six other chemical companies. However, we are not fully insured against all
potential hazards incident to our business. Additionally, we may incur losses beyond the limits
of, or outside the coverage of, our insurance. We maintain full replacement value insurance
coverage for property damage to our facilities and business interruption insurance. Nevertheless,
a significant interruption in the operation of our acetic acid facility could have a material
adverse effect on our business. As a result of market conditions, premiums and deductibles for
certain insurance policies can increase substantially and, in some instances, certain insurance may
become unavailable or available only for reduced amounts of coverage.
We do not currently carry terrorism coverage on our Texas City facility as we believe it is
not economically justified on the terms currently being offered in the industry. While terrorism
insurance coverage is available, the premiums for such coverage are very expensive, especially for
chemical facilities, and these policies are subject to very high deductibles. In addition,
available terrorism coverage typically excludes coverage for losses from acts of foreign
governments, as well as nuclear, biological and chemical attacks.
On September 13, 2008, Hurricane Ike struck the Texas Gulf Coast very near our Texas City
facility. Our Texas City facility was shut down and secured prior to landfall and did not sustain
any significant structural damage, although we did sustain some minor damage to three of our barge
docks. Our Texas City facility lost all power and ancillary utilities during the storm, including
our steam boilers. The resulting production outage lasted approximately 15 days, with our Texas
City facility returning to normal operating levels on September 28, 2008. The losses we incurred
from Hurricane Ike during 2008 totaled $2.6 million, and we incurred additional expenses of $0.2
million in 2009 related to damages caused by Hurricane Ike. Our total loss from Hurricane Ike of
$2.8 million was less than the deductibles under our insurance policies and, as such, we did not
recover any of these losses under our insurance policies.
Access to Filings
Access to our annual reports on Form 10-K, quarterly reports on Form 10-Q and current reports
on Form 8-K, and amendments to those reports, filed with or furnished to the SEC pursuant to
Section 13(a) of the Exchange Act, as well as reports filed electronically pursuant to Section
16(a) of the Exchange Act, may be obtained through our website
(http://www.sterlingchemicals.com) at no cost, as soon as reasonably practicable after we
have electronically filed such material with the SEC. The contents of our website are not, and
shall not be deemed to be, incorporated into this Form 10-K.
11
Item 1A. Risk Factors
In addition to the other information contained in this report, the following risk factors
should be considered carefully in evaluating our business. Our business, financial condition or
results of operations could be materially adversely affected by any of these risks.
Risks Related to Our Business
Each of our products is sold to only one customer.
In 2009, a single customer, BP Chemicals, accounted for 100% of our acetic acid revenues. The
termination of this long-term contract, or a material reduction in the amount of product purchased
under our Acetic Acid Production Agreement, would materially adversely affect our overall business,
financial condition, results of operations or cash flows.
On November 11, 2009, BASF, which accounts for 100% of our plasticizers revenues, elected to
terminate our Plasticizers Production Agreement, effective December 31, 2010. Since we are in the
early stages of evaluating our commercial options regarding our plasticizers business, we cannot
predict the ultimate outcome or the success of continuing the plasticizers business after December
31, 2010. If we are unable to continue the plasticizers operations through other viable commercial
options for our plasticizers business or facility or restructure our operating costs, or are unable
to do so at or shortly after December 31, 2010, the termination of our Plasticizers Production
Agreement will likely have a material adverse effect on our financial condition, results of
operations and cash flows. See Managements Discussion and Analysis of Financial Condition and
Results of Operations Overview Business Plasticizers.
Our ability to realize increases in our acetic acid production capacity that could be made possible
through low-cost, incremental capacity expansions is dependent on the availability of sufficient,
economic 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 and operated by Praxair on land leased from us at
our Texas City site. Although our new reactor installed in 2003 is capable of producing up to 1.7
billion pounds of acetic acid annually and the new column installed in 2009 is capable of producing
1.6 billion pounds of acetic acid annually, Praxairs existing partial oxidation unit is capable of
supplying carbon monoxide in quantities sufficient for only 1.3 billion pounds of annual acetic
acid production. While additional carbon monoxide may become available by routing surplus syngas
from another Texas City source through a new supply pipeline or the use of an existing idled
pipeline or through an expansion of Praxairs partial oxidation unit, we may not be able to
implement any of these options on a cost effective basis.
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 facility. Significant unscheduled downtime
at our Texas City facility 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, recovery of losses is
subject to time element deductibles of up to 45 days and policy limits of up to $400 million.
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 of chemical
products. These hazards include:
|
|
|
severe weather and natural disasters; |
|
|
|
mechanical failures, unscheduled downtimes, labor difficulties and transportation
interruptions; |
|
|
|
environmental remediation complications;
|
12
|
|
|
chemical spills and discharges or releases of toxic or hazardous substances or gases;
and |
|
|
|
pipeline or storage tank leaks and ruptures, explosions and fires. |
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.
Volatility in asset values and liability costs related to our pension plans may reduce our
profitability and adversely impact current funding levels.
We sponsor defined benefit pension plans for our employees. Effective July 1, 2007 and
January 1, 2005, we froze all benefit accruals under these defined benefit pension plans for our
hourly and salaried employees, respectively. The cash contributions made to our defined benefit
pension plans are required to comply with minimum funding requirements imposed by laws governing
employee benefit plans. The projected benefit obligation and assets of our defined benefit pension
plans as of December 31, 2009 were $124.3 million and $86.8 million, respectively. The difference
between plan obligations and assets, or the funded status of the plans, is a significant factor in
determining pension expense and the ongoing funding requirements to those plans. Macroeconomic
factors, as well as changes in investment returns and discount rates used to calculate pension
expense and related assets and liabilities can be volatile and may have an unfavorable impact on
our costs and funding requirements. A decline in the market value of the assets in our defined
benefit pension plans, as was experienced in 2008, will increase the funding requirements under the
plans if the actual asset returns do not recover these declines in value in the near term.
Additionally, the liabilities of our defined benefit pension plans are sensitive to changes in
interest rates. As interest rates decrease, the liabilities of the plans increase, potentially
increasing funding requirements and pension expense. Changes in demographics, including increased
numbers of retirements or changes in life expectancy assumptions may also increase the funding
requirements and pension expense related to our defined benefit pension plans. Although we
actively seek to control increases in these costs and funding requirements, we may not be
successful in doing so. Future increases in pension expense and the contributions we are required
to make to our defined benefit pension plans as a result of one or more of these factors could
negatively affect our financial condition, results of operations or cash flows.
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 six
other chemical companies. However, we are not fully insured against all potential hazards incident
to our business. Accordingly, our insurance coverage may be inadequate for any given risk or
liability, such as property damage suffered in hurricanes or business interruption incurred from a
loss of our supply of electricity or carbon monoxide. In addition, our insurance companies may be
incapable of honoring their commitments if an unusually high number of claims are concurrently made
against their policies. As a result of market conditions, premiums and deductibles for certain
insurance policies can increase substantially and, in some instances, certain insurance may become
unavailable or available only for reduced amounts of coverage. If we were to incur a significant
liability for which we were not fully insured, it could have a material adverse effect on our
business, financial condition, results of operations or cash flows. We may not be able to renew
our existing insurance coverage at commercially reasonable rates or that coverage may not 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 injury or property
damage from exposure to hazardous materials caused by a terrorist attack. Such loss of production,
sales, facilities or incurrence of liabilities could materially adversely affect our business,
financial condition, results of operations or cash flows.
13
New regulations concerning the transportation of hazardous chemicals and the security of chemical
manufacturing facilities could result in higher operating costs.
Chemical manufacturing facilities may be at greater risk of terrorist attacks than other
potential targets in the United States. As a result, the chemical industry has responded to these
issues by starting new initiatives relating to the security of chemicals industry facilities and
the transportation of hazardous chemicals in the United States. Simultaneously, local, state and
federal governments have begun a regulatory process that could lead to new regulations impacting
the security of chemical plant locations and the transportation of hazardous chemicals. Our
business or our customers businesses could be adversely affected by the cost of complying with new
security regulations.
Impact of Greenhouse Gases and Climate Change
Our operations emit greenhouse gases. Proposed U.S. Federal legislation and regulations to
address greenhouse gas emissions, which are in various stages of review, discussion or
implementation, could adversely impact our business. While it is currently not possible to predict
the impact, if any, that these issues will have on us or the industry in general, such legislation
and regulation could result in increases in costs to operate and maintain our facilities, as well
as capital outlays for new emission control equipment. In addition, any regulation limiting
greenhouse gas emissions which specifically targets the petrochemicals manufacturing industry could
adversely affect our ability to conduct our business.
We are subject to many environmental and safety regulations that may result in significant
unanticipated costs or liabilities or cause interruptions in our operations.
Our operations involve the handling, production, transportation, treatment and disposal of
materials that are classified as hazardous or toxic and that are extensively regulated by
environmental and health and safety laws, regulations and permit requirements. We may incur
substantial costs, including fines, damages and criminal or civil sanctions, or experience
interruptions in our operations for actual or alleged violations or compliance requirements arising
under environmental laws, any of which could have a material adverse effect on our business,
financial condition, results of operations or cash flows. Our operations could result in
violations of environmental laws, including spills or other releases of hazardous substances into
the environment. In the event of a catastrophic incident, we could incur material costs.
Furthermore, we may be liable for the costs of investigating and cleaning up environmental
contamination on or from our properties or at off-site locations where we disposed of or arranged
for the disposal or treatment of hazardous materials. If significant previously unknown
contamination is discovered or we have underestimated the costs to investigate and remediate known
contamination, 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 35% 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.
14
As of December 31, 2009, we had approximately 182 employees, of whom approximately 35% (all of
our hourly employees at our Texas City facility) were represented by the Union and are covered by a
collective bargaining agreement which expires on May 1, 2012. 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 or attract 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 these key
employees or attract other 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.
Stock options or other equity awards offered to certain employees may not provide effective
incentives to remain with us due to the dilutive effect of the quarterly paid-in-kind dividends
paid on our Series A Convertible Preferred Stock, or our Preferred Stock, and the fact that our
common stock is not listed on any national or regional securities exchange. Quotations for shares
of our common stock are listed by certain members of the National Association of Securities
Dealers, Inc. on the Over-the-Counter, or OTC, Electronic Bulletin Board. In recent years, the
trading volume of our common stock has been very low and the transactions that have occurred were
typically effected in transactions for which reliable market quotations have not been available.
An active trading market may not develop or, if developed, may not continue for our equity
securities and a holder of any of these securities, including stock options or other equity awards,
could find it difficult obtain a positive return.
We may not successfully develop our under-utilized infrastructure at our Texas City facility.
We may be unable to identify or attract a long-term contractual business arrangement or
partnership to our Texas City facility that will provide us with an ability to realize the value of
our under-utilized assets. 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. Even if
we do identify a long-term contractual business arrangement or partnership, we may not be able to
come to agreeable terms or the capital costs for the project may be prohibitively high.
We may not successfully complete acquisitions that we are pursuing or any future acquisitions 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 or successfully complete
identified acquisitions, 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. 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, and we may not be unable
to secure the consent of our existing long-term debt holders to the incurrence of additional debt.
The lack of an active trading market in our common stock, as well as the dilutive terms of the
quarterly paid-in-kind dividends payable on our 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;
|
15
|
|
|
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.
We are unable to predict the impact of the recent downturn in the credit markets and the resulting
costs or constraints in obtaining financing on our business and financial results.
U.S. and global credit and equity markets have undergone significant disruption in the past 12
to 18 months, making it difficult for many businesses to obtain financing on acceptable terms. In
addition, equity markets are continuing to experience wide fluctuations in value. If these
conditions continue or worsen, our cost of borrowing may increase, and it may be more difficult to
obtain financing in the future. In addition, a number of financial institutions have reported
significant deterioration in their financial condition. If any of the financial institutions are
unable to perform their obligations under our contracts, and we are unable to find suitable
replacements on acceptable terms, our financial condition, results of operations, liquidity and
cash flows could be adversely affected. We also face challenges relating to the impact of the
disruption in the global financial markets on other parties with which we do business, such as
customers and suppliers. The inability of these parties to obtain financing on acceptable terms
could impair their ability to perform under their agreements with us and lead to various negative
affects on us, including business disruption, decreased revenues and increases in bad debt
write-offs. A sustained decline in the financial stability of these parties could have a material
adverse impact on our business, financial condition, results of operations and cash flows.
If we are unable to successfully prevent or address material weaknesses in our internal control
over financial reporting, or any other control deficiencies, our ability to report our financial
results on a timely and accurate basis and to comply with disclosure and other reporting
requirements may be adversely affected.
While we have taken actions designed to address compliance with the internal control,
disclosure control and other requirements of the Sarbanes-Oxley Act of 2002 and the rules and
regulations promulgated by the SEC implementing these requirements, there are inherent limitations
in our ability to control all circumstances. Our management, including our Chief Executive Officer
and Chief Financial Officer, does not expect that our internal controls and disclosure controls
will prevent all errors and all fraud. A control system, no matter how well conceived and operated,
can provide only reasonable, not absolute, assurance that the objectives of the control system are
met. For example, as of December 31, 2009, our management identified a material weakness in our
internal control over financial reporting resulting from a lack of effective controls over the
billing for utilities at our Texas City facility. If we are unable to successfully prevent or
address these and other material weaknesses in our internal control systems, our ability to report
our financial results on a timely and accurate basis and to comply with disclosure and other
reporting requirements may be adversely affected.
Risks Relating to Our Indebtedness
Our leverage and debt service obligations may adversely affect our cash flow and our ability to
make payments on our indebtedness.
As of December 31, 2009, we had total long-term debt of $125.0 million (consisting of
outstanding principal on our 101/4% Senior Secured Notes due 2015, or our Secured Notes). The terms
and conditions governing our indebtedness, including our Secured Notes:
|
|
|
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;
|
16
|
|
|
increase our vulnerability to adverse general economic or industry conditions and limit
our flexibility in planning for, or reacting to, competition or changes in our business or
our industry; |
|
|
|
limit our ability to obtain additional financing; |
|
|
|
place restrictions on our ability to make certain payments or investments, sell assets,
make strategic acquisitions, engage in mergers or other fundamental changes and exploit
business opportunities; and |
|
|
|
place us at a competitive disadvantage relative to competitors with lower levels of
indebtedness in relation to their overall size or less restrictive terms governing their
indebtedness. |
Our ability to meet our expenses and debt obligations will depend on our future performance,
which will be affected by financial, business, economic, regulatory and other factors. We will not
be able to control many of these factors, such as economic conditions and governmental regulations.
We cannot be certain that our earnings will be sufficient to allow us to pay the principal and
interest on our debt, including our Secured Notes, and meet our other obligations. Further,
failing to comply with the financial and other restrictive covenants in the agreements governing
our indebtedness could result in an event of default under such indebtedness, which could
materially adversely affect our business, financial condition, results of operations or cash flows.
Any failure to meet our debt obligations could harm our business, financial condition, results of
operations or cash flows.
If our cash flow and capital resources are insufficient to fund our debt obligations, we may
be forced to sell assets, seek additional equity or debt capital or restructure our debt, including
our Secured Notes. We may not be able to refinance or restructure our debt, raise equity or debt
capital or sell assets on terms acceptable to us, if at all. In addition, any failure to make
scheduled payments of interest or principal on our outstanding indebtedness would likely result in
a reduction of our credit rating, which could harm our ability to incur additional indebtedness on
acceptable terms. Our cash flow and capital resources may be insufficient for payments of interest
or principal on our debt in the future, including payments on our Secured Notes, and any such
alternative measures may be unsuccessful or may not permit us to meet scheduled debt service
obligations, which could cause us to default on our obligations and impair our liquidity.
Risks Relating to the Ownership of Our Common Stock
Our common stock is thinly traded. There is no active trading market for our common stock and an
active trading market may not develop.
Our common stock is not listed on any national or regional securities exchange. Quotations
for shares of our common stock are listed by certain members of the National Association of
Securities Dealers, Inc. on the OTC Electronic Bulletin Board. In recent years, the trading volume
of our common stock has been very low and the transactions that have occurred were typically
effected in transactions for which reliable market quotations have not been available. An active
trading market may not develop or, if developed, may not continue for our equity securities, and a
holder of any of these securities may find it difficult to dispose of, or to obtain accurate
quotations as to the market value of, such securities.
We have a significant stockholder which has the ability to control our actions.
Resurgence Asset Management, L.L.C. and its and its affiliates managed funds and accounts, or
collectively Resurgence, beneficially own in excess of 98% of our preferred stock and over 55% of
our common stock, representing ownership of 85% of the total voting power of our equity. The
interests of Resurgence may differ from our other stockholders and Resurgence may vote their
interests in a manner that may adversely affect our other stockholders. Through their direct and
indirect interests in us, Resurgence is in a position to influence the outcome of most matters
requiring a stockholder vote. This concentrated ownership makes it less likely that any other
holder or group of holders of common stock would be able to influence the way we are managed or the
direction of our business. These factors also may delay or prevent a change in our management or
voting control.
17
Our Preferred Stock pays a quarterly stock dividend that is dilutive to the holders of our common
stock.
Shares of our Preferred Stock carry a cumulative dividend rate of 4% per quarter, payable in
additional shares of our Preferred Stock. Our shares of Preferred Stock are convertible at the
option of the holder into shares of our common stock and vote as if so converted on all matters
presented to the holders of our common stock for a vote. Consequently, each dividend paid in
additional shares of our Preferred Stock has a dilutive effect on our shares of common stock and
increases the percentage of the total voting power of equity owned by Resurgence. Preferred Stock
dividends were 952.346 shares (which are convertible into 952,346 shares of our common stock)
during 2009, which represents 10.1% of the current total voting power of our equity securities.
Item 2. Properties
Our petrochemicals facility is located in Texas City, Texas, approximately 45 miles south of
Houston, on a 290-acre site on Galveston Bay near many other chemical manufacturing complexes and
refineries. We own all of the real property which comprises our Texas City facility and we own the
acetic acid and plasticizers manufacturing facilities located at the facility. We also lease a
portion of our Texas City facility to Praxair, who constructed a partial oxidation unit on that
land, and lease a portion of our Texas City facility to S&L Cogeneration Company, a 50/50 joint
venture between us and Praxair Energy, which constructed a cogeneration facility on that land. Our
Texas City facility offers approximately 160 acres for future expansion by us or by other companies
that could benefit from our existing infrastructure and facilities, and includes a greenbelt around
the northern edge of the plant facility. We own 49 railcars and, at our Texas City facility, we
have facilities to load and unload our products and raw materials in ocean-going vessels, barges,
trucks and railcars. Substantially all of our Texas City facility, and the tangible properties
located thereon, are subject to a lien securing our obligations under our Secured Notes. We lease
the space for our principal executive offices, located at 333 Clay Street, Suite 3600 in Houston,
Texas. We believe our properties and equipment are sufficient to conduct our business.
Item 3. Legal Proceedings
On July 5, 2005, Patrick B. McCarthy, an employee of Kinder-Morgan, Inc., or Kinder-Morgan,
was seriously injured at Kinder-Morgans facilities near Cincinnati, Ohio, while attempting to
offload a railcar containing one of our plasticizers products. On October 28, 2005, Mr. McCarthy
and his family filed a suit in the Court of Common Pleas, Hamilton County, Ohio (Case No. A0509
144) against us and six other defendants. During the case, five of the other defendants were
dismissed. The plaintiffs sought in excess of $42 million in alleged compensatory and punitive
damages from the defendants in the aggregate. On May 7, 2009, the jury found that we had not been
negligent in connection with the incident and rendered a take nothing verdict in favor of the
defendants. On June 24, 2009, the plaintiffs filed a motion for judgment notwithstanding the
verdict or, in the alternative, a new trial. On September 4, 2009, the Court denied plaintiffs
motion for judgment notwithstanding the verdict, but granted plaintiffs motion for a new trial.
We and the other remaining defendant timely filed notices of appeal of that order, as well as other
orders issued during the trial. We believe that all, or substantially all, of any liability
imposed upon us as a result of this suit and our related out-of-pocket costs and expenses will be
covered by our insurance policies, subject to a one million deductible, which was met in January
2008. We do not believe that this incident will have a material adverse effect on our business,
financial condition, results of operations or cash flows, although we cannot guarantee that a
material adverse effect will not occur.
On February 21, 2007, we, several of our benefit plans and the plan administrators for those
plans were sued in a class action suit, Case No. H-07-0625 filed in the United States District
Court, Southern District of Texas, Houston Division. The plaintiffs are seeking to represent a
proposed class of retired employees of Sterling Fibers, Inc., one of our former subsidiaries that
we sold in connection with our emergence from bankruptcy in 2002. The plaintiffs are alleging that
we were not permitted to increase their premiums for retiree medical insurance based on a provision
contained in the asset purchase agreement between us and Cytec Industries Inc. and certain of its
affiliates governing our purchase of our former acrylic fibers business in 1997. During our
bankruptcy case, we specifically rejected this asset purchase agreement and the bankruptcy court
approved that rejection. The plaintiffs are claiming that we violated the terms of the benefit
plans and breached fiduciary duties governed by the Employee Retirement Income Security Act and are
seeking damages, declaratory relief, punitive damages and attorneys fees. A trial for this
matter was held during the second week of November 2009 but the court has not yet as issued a
ruling. We are
18
vigorously defending this action and are unable to state at this time if a loss is
probable or remote and are unable to determine the possible range of loss related to this matter,
if any.
On February 4, 2008, we filed a Petition for Declaratory Judgment in the 212th District Court
of Galveston County, Texas (Case No. 08CV0108) against Marathon Petroleum Company LLC, or Marathon,
in connection with a dispute between Marathon and us under a Purchase Agreement for FCC Off-Gas, or
the Off-Gas Purchase Agreement. Under the Off-Gas Purchase Agreement, we purchase an amount of
off-gas each month from Marathon within a stated range at Marathons option. Following the closure
of certain production units at our Texas City facility, our demand for off-gas has been below the
low-end of the stated range. On July 31, 2007, and again on November 19, 2007, we invoked the
undue economic hardship clause of the Off-Gas Purchase Agreement and requested that Marathon enter
into good faith negotiations to modify its terms. After Marathon disputed the applicability of the
economic hardship provision and refused to renegotiate the terms of the Off-Gas Purchase Agreement,
we filed a declaratory judgment action to enforce the terms of the economic hardship provision, and
Marathon filed a counter-claim against us for breach of contract. Marathon contended that
Sterlings failure to take the minimum contract quantities has resulted in damages in the past,
which will continue in the future through the end of the term of the Off-Gas Purchase Agreement on
April 30, 2011. On February 26, 2010, we and Marathon entered into a confidential settlement
agreement with respect to this matter. We do not believe that this matter will have a material
adverse impact on our business, financial condition, results of operations or cash flows, although
a material adverse effect could occur.
We are subject to various other claims and legal actions that arise in the ordinary course of
our business. We do not believe that any of these claims and actions, separately or in the
aggregate, will have a material adverse effect on our business, financial condition, results of
operations or cash flows, although we cannot guarantee that a material adverse effect will not
occur.
As of December 31, 2008, we had a receivable of $1.3 million due from our insurance carriers
for reimbursement of legal costs that exceeded our insurance deductibles and were, therefore,
reimbursable through our insurance carriers. For the year ended December 31, 2009, we incurred
$2.1 million of legal costs that are reimbursable under our insurance policies and received $3.3
million of payments from our insurance carriers, resulting in a receivable balance of $0.1 million
as of December 31, 2009.
19
PART II
Item 5. Market for Registrants Common Equity, Related Stockholder Matters and Issuer Purchases of
Equity Securities
Our common stock, par value $0.01 per share, is currently quoted on the Over-the-Counter, or
OTC, Electronic Bulletin Board maintained by the National Association of Securities Dealers, Inc.
under the symbol SCHI. The following table contains information about the high and low sales
prices per share of our common stock for the last two years. Information about OTC Electronic
Bulletin Board bid quotations represents prices between dealers, does not include retail mark-ups,
mark-downs or commissions and may not necessarily represent actual transactions. Quotations on the
OTC Electronic Bulletin Board are sporadic, and currently there is no established public trading
market for our common stock.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
First |
|
|
Second |
|
|
Third |
|
|
Fourth |
|
|
|
|
|
|
|
Quarter |
|
|
Quarter |
|
|
Quarter |
|
|
Quarter |
|
2009 |
|
High |
|
$ |
11.00 |
|
|
$ |
10.00 |
|
|
$ |
11.00 |
|
|
$ |
9.50 |
|
|
|
Low |
|
$ |
8.50 |
|
|
$ |
8.25 |
|
|
$ |
8.25 |
|
|
$ |
5.00 |
|
2008 |
|
High |
|
$ |
21.00 |
|
|
$ |
17.00 |
|
|
$ |
17.25 |
|
|
$ |
17.25 |
|
|
|
Low |
|
$ |
14.95 |
|
|
$ |
13.00 |
|
|
$ |
9.00 |
|
|
$ |
8.90 |
|
The last reported sales price per share of our common stock as reported on the OTC
Electronic Bulletin Board on December 31, 2009 was $7.00. As of March 5, 2010, there were 263
holders of record of our common stock. This number does not include stockholders for whom shares
are held in a nominee or street name.
Dividend Policy
We have not declared or paid any cash dividends with respect to our common stock since we
emerged from bankruptcy in December 2002. We do not presently intend to pay cash dividends with
respect to our common stock for the foreseeable future. In addition, the ability to pay dividends
on our shares of common stock is limited under the indenture for our Secured Notes. The payment of
cash dividends, if any, will be made only from assets legally available for that purpose, and will
depend on our financial condition, results of operations, current and anticipated capital
requirements, general business conditions, restrictions under our existing debt instruments and
other factors deemed relevant by our Board of Directors.
Equity Compensation Plan
Under our Amended and Restated 2002 Stock Plan, or our 2002 Stock Plan, officers, key
employees and consultants, as designated by our Board of Directors or our Compensation Committee,
may be issued stock options, stock awards, stock appreciation rights or stock units. Our
Compensation Committee or, in the event that our Compensation Committee is not comprised solely of
non-employee directors (as such term is defined in Rule 16b-3(b)(3) of the Exchange Act), our
Board, administers our 2002 Stock Plan. Our 2002 Stock Plan may be amended or modified from time
to time by our Board of Directors in accordance with its terms. Our Board of Directors or
Compensation Committee determines the exercise price of stock options, any applicable vesting
provisions and other terms and provisions of each grant in accordance with our 2002 Stock Plan.
Options granted under our 2002 Stock Plan become fully exercisable in the event of the optionees
termination of employment by reason of death, disability or retirement, and may become fully
exercisable in the event of a change of control. No option may be exercised after the tenth
anniversary of the date of grant or the earlier termination of the option. We have reserved
1,363,914 shares of our common stock for issuance under our 2002 Stock Plan (subject to
adjustment). There were options to purchase a total of 224,167 shares of our common stock
outstanding under our 2002 Stock Plan as of December 31, 2009, each with an exercise price of
$31.60, and an additional 1,139,747 shares of common stock available for issuance under our 2002
Stock Plan.
The following table provides information regarding securities authorized for issuance under
our 2002 Stock Plan as of December 31, 2009:
20
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Number of securities remaining |
|
|
|
Number of securities to |
|
|
Weighted-average exercise |
|
|
available for future issuance |
|
|
|
be issued upon exercise |
|
|
price of outstanding |
|
|
under equity compensation |
|
|
|
of outstanding options, |
|
|
options, warrants and |
|
|
plans (excluding securities |
|
Plan Category |
|
warrants and rights |
|
|
rights |
|
|
reflected in first column) |
|
Equity compensation
plans approved by
security holders |
|
|
224,167 |
|
|
$ |
31.60 |
|
|
|
1,139,747 |
|
Equity compensation
plans not approved
by security holders |
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
|
224,167 |
|
|
$ |
31.60 |
|
|
|
1,139,747 |
|
21
Item 7. Managements Discussion and Analysis of Financial Condition and Results of Operations
Overview
Business
We were formed in 1986 to acquire a petrochemicals facility located in Texas City, Texas that
was previously owned by Monsanto 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 and purified
terephthalic acid, which are used in a variety of products, including adhesives, surface coatings,
polyester fibers, and films and plastic bottle resins, respectively. Pursuant to our 2008 Amended
and Restated Acetic Acid Production Agreement, or our Acetic Acid Production Agreement, that
extends to 2031, all of our acetic acid production is sold to BP Amoco Chemical Company, or BP
Chemicals. 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 our acetic acid. In addition, BP Chemicals
reimburses us for 100% of our fixed and variable costs of production, other than specified indirect
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 we receive from BP Chemicals.
Our
acetic
acid facility utilizes BP Chemicals proprietary Cativa carbonylation technology, which we
believe offers several advantages over competing production methods, including lower energy
requirements and lower fixed and variable costs. 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 our requirements for
carbon monoxide are 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, or our Texas
City facility.
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. Under our agreement with BASF, or our Plasticizers Production Agreement, BASF provides us
with most of the required raw materials, markets the plasticizers that we produce and is obligated
to make certain fixed quarterly payments to us and reimburse us monthly for our actual production
costs and capital expenditures relating to our plasticizers facility.
Our Texas City facility 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 facility also has truck loading racks, weigh scales, stainless and
carbon 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 and our management, operational and engineering expertise, as well as
our ample unoccupied land, we believe that there are significant opportunities for further
development of our Texas City facility. We are currently pursuing numerous initiatives to attract
new manufacturing, distribution or storage related businesses to our Texas City facility.
Specifically, we are seeking long-term contractual business arrangements or partnerships that will
provide us with the ability to realize the value of our under-utilized assets through profit
sharing or other revenue 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 our management and operational
expertise to minimize our share of the capital costs. In any case, we expect any new facility
constructed at our Texas City facility to lower the amount of overall fixed costs allocated to each
of our operating units and provide us with additional profit.
22
Our rated annual production capacity is among the highest in North America for acetic acid.
In mid-2009, we and BP Chemicals implemented an incremental expansion of our acetic acid plant to
1.3 billion pounds of annual capacity, which represents 17% of total North American capacity,
making our acetic acid facility the third largest acetic acid production facility in North America.
Our petrochemicals products are generally sold to customers for use in the manufacture of
other chemicals and products, which in turn are used in the production of a wide array of consumer
goods and industrial products throughout the world.
Acetic Acid. The North American acetic acid industry has enjoyed a long period of sustained
domestic demand growth, as well as substantial export demand. This has led to North American
industry utilization rates above 85% over the last six years. Although slowdowns in the housing
and automotive markets during 2009 resulted in reduced demand for vinyl acetate monomer, and
consequently acetic acid, in North America for the short-term, Tecnon OrbiChem, or Tecnon, projects
acetic acid utilization rates will increase to over 98% by 2013. 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.
Historically these producers have made capacity additions primarily through small expansion
projects or the exploitation of debottlenecking opportunities. Finally, the North American acetic
acid industry tends to sell most of its products through long-term sales agreements having formula
based pricing mechanisms, eliminating much of the volatility seen in other petrochemicals products
and resulting in more stable and predictable earnings and profit margins.
Global production capacity of acetic acid as of December 31, 2009 was approximately 31 billion
pounds per year, with current North American production capacity at approximately six billion
pounds per year. The North American acetic acid industry is mature and well developed, with the
four major acetic acid producers accounting for approximately 94% of production capacity in North
America. Demand for acetic acid is linked to the demand for vinyl acetate monomer, a key
intermediate in the production of a wide array of polymers. Vinyl acetate monomer is the largest
derivative of acetic acid, representing over 35% of global demand. Although slowdowns in the
housing and automotive markets over the last year have reduced global demand for vinyl acetate
monomer in the short-term, annual global production of vinyl acetate monomer is expected to
increase from 10.3 billion pounds in 2008 to 14.2 billion pounds in 2013.
Several acetic acid capacity additions have occurred globally 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 and from 1.1 billion pounds to 1.3 billion pounds of rated annual
production capacity in 2009. 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 and the closure by BP Chemicals of two of its outdated
acetic acid production units in Hull, England in 2006 that had a combined annual capacity of
approximately 500 million pounds (which had been sold primarily in Europe and South America).
In 1986, we entered into the initial version of our Acetic Acid Production Agreement with BP
Chemicals, which has since been amended several times. We sell all of our acetic acid production
to BP Chemicals under our Acetic Acid Production Agreement 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 (other than specified indirect costs). Revenues from our acetic acid segment
were $87.3 million and $129.7 million for the years ended December 31, 2009 and 2008, respectively,
representing approximately 76% and 80%, respectively, of our total revenues for such period. Other
than our Acetic Acid Production Agreement, we do not have any material relationships with BP
Chemicals.
Plasticizers. Plasticizers are produced from either ethylene-based linear alpha-olefins
feedstocks or propylene-based non-linear technology. We produce both linear and non-linear
plasticizers used to make flexible plastics such as shower curtains, floor coverings, automotive
parts and construction materials. Feedstocks for plasticizers consist of PA and oxo-alcohols.
Linear plasticizers have historically received a premium over competing propylene-based branched
products for customers that require enhanced performance properties. Although we have not been
exposed to fluctuations in costs or market conditions due to the contract terms in our Plasticizers
Production Agreement with BASF, the markets for competing plasticizers may be affected by the cost
of the underlying raw materials, especially when the cost of one olefin rises faster than the other
or by the introduction of new products. Over the last several
23
years, the price of linear alpha-olefins increased sharply, which caused many consumers to
switch to lower cost branched products such as propylene-based plasticizers, despite the loss of
some performance properties. As a result, we modified our plasticizer production facilities during
the third quarter of 2006 to include branched plasticizers production. Ultimately, we expect
branched plasticizers to replace linear plasticizers for most applications, although recently some
branched plasticizers products have been the subject of health related concerns. Following
termination of the Plasticizers Production Agreement, we may face greater cost fluctuations or
exposure to market conditions if we continue to operate the plasticizers business. For a further
description of our agreement with BASF, see Plasticizers-BASF under Contracts and see Risk
Factors.
Our plasticizers business is comprised of two separate products: phthalate esters and
phthalic anhydride, together commonly referred to as plasticizers. Since 1986, we have sold all of
our plasticizers production exclusively to BASF pursuant to our Plasticizers Production Agreement,
which has been amended several times. We also previously produced PA for BASF under the
Plasticizers Production Agreement. Under our Plasticizers Production Agreement, BASF provides us
with most of the required raw materials and markets the plasticizers we produce, and is obligated
to make certain fixed quarterly payments to us and to reimburse us monthly for our actual
production costs and capital expenditures relating to our plasticizers facility. Effective as of
April 1, 2008, our Plasticizers Production Agreement was amended and restated in connection with
BASFs nomination of zero pounds of PA in response to deteriorating market conditions, ultimately
resulting in the closure of our PA unit. The closure of our PA unit did not, however, impact our
continued production of plasticizers for BASF. In exchange for being relieved of its obligations
related to our PA manufacturing unit, BASF paid us an aggregate amount of approximately $3.2
million. However, we are obligated to refund 25% of this amount if we restart our PA manufacturing
unit during 2010. The $3.2 million payment from BASF was made in exchange for the termination of
BASFs obligations under our Plasticizers Production Agreement with respect to the operation of our
PA manufacturing unit and, consequently, is recognized using the straight-line method over the
restricted period from April 1, 2008 through December 31, 2010. In addition, during the first half
of 2008, BASF paid 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 manufacturing unit have been incurred and expensed, and the
$3.7 million in cost reimbursements was recognized as revenue in the first half of 2008.
On November 11, 2009, BASF elected to terminate our Plasticizers Production Agreement,
effective December 31, 2010, at which time we will no longer produce plasticizers for BASF. We
will not be subject to any early termination penalties in connection with BASFs termination of our
Plasticizers Production Agreement. BASF, on the other hand, will be required to pay us an early
termination fee of $9.8 million on December 31, 2010. In December 2010, in connection with the
termination of our Plasticizers Production Agreement, we will be required to refund BASFs $1.0
million pre-payment deposit previously paid by BASF. If we continue to operate our plasticizers
business after the termination of our Plasticizers Production Agreement, we will be required to
make payments to BASF for its undepreciated capital expenditures, related to past capital
projects paid by BASF, over the remaining balance of the original term of our Plasticizers
Agreement, based on a straight line, 8-year life. As of December 31, 2010, we expect the total
amount of these undepreciated capital expenditures to be approximately $2.6 million, with
approximately $1.0 million, $0.7 million, $0.6 million, and $0.3 million potentially to be paid in
2011, 2012, 2013, and 2014, respectively. If within 90 days after the termination of our
Plasticizers Production Agreement, we provide written notice to BASF of our election to permanently
close our plasticizers facility, the undepreciated capital expenditures paid by BASF for all
capital projects is deemed to be zero, and we will not be required to make any payments to BASF.
In the event we discontinue the plasticizers operations in 2011, we expect to incur approximately
$3.0 million in shutdown and decontamination costs, and the costs and timing for dismantling are
unknown at this time; however, they are not expected to be significant.
Revenues from our plasticizers segment were $26.0 million and $31.0 million for the years
ended December 31, 2009 and 2008, respectively, representing approximately 23% and 19%,
respectively, of our total revenues for such period. Gross profits from our plasticizers
operations were $5.9 million in 2009 and $4.1 million in 2008, representing approximately 53% and
14% of our total gross profits in 2009 and 2008, respectively. Under our Plasticizers Production
Agreement, BASF reimburses us for certain costs, including fixed costs, which are allocated among
our existing operations. In the event that we do not continue to operate our plasticizers facility
after December 31, 2010, the amount of our costs that will be allocated to our acetic acid
operations in accordance with our Acetic Acid Production Agreement will increase, which will
adversely affect our profit sharing payments under
24
that agreement starting January 1, 2011. In addition, some of the costs currently reimbursed
by BASF under our Plasticizers Production Agreement cannot be allocated to our acetic acid
operations. Consequently, to the extent we cannot reduce or eliminate these costs, these costs
will adversely affect our financial results starting January 1, 2011.
In December 2009, we performed an asset impairment analysis on our esters manufacturing unit.
We analyzed the undiscounted cash flow stream from our esters business over the remaining life of
the esters manufacturing unit and compared it to the $2.8 million net book carrying value of our
esters manufacturing unit. This analysis showed that the undiscounted projected cash flow stream
from our esters business was higher than the net book carrying value of our esters manufacturing
unit. Based on this analysis, we concluded that our esters manufacturing unit was not impaired as
of December 31, 2009, and that no write-down was necessary. We will, however, accelerate our
depreciation on our esters manufacturing unit in 2010 to ensure that it is fully depreciated by
December 31, 2010.
We are in the process of exploring and evaluating our commercial options with respect to
continuing our plasticizers business after the termination of our Plasticizers Production Agreement
with BASF. Since we are in the early stages of evaluating our
commercial options regarding our
plasticizers business, we cannot predict the ultimate outcome or the success of continuing the
plasticizers business after December 31, 2010. In the event we conclude to permanently close our
plasticizers facility, we have also developed plans for restructuring our operating costs following
the termination of our Plasticizers Production Agreement. If we are unable to continue the
plasticizers operations through other viable commercial options for our plasticizers business or
facility or restructure our operating costs, or are unable to do so at or shortly after December
31, 2010, the termination of our Plasticizers Production Agreement will likely have a material
adverse effect on our financial condition, results of operations and cash flows. We have not
decided whether we will continue to operate our plasticizers business following December 31, 2010.
However, we do not believe that these effects will impact our ability to continue as a going
concern. Other than our Plasticizers Production Agreement, we do not have any material
relationships with BASF.
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., or Praxair Energy, which constructed a cogeneration
facility on that land. The cogeneration facility was initially shut down in May 2007 due to the
uncertain future of our styrene unit and has remained idle since that time in order to conduct an
assessment of whether the future needs for the cogeneration facility justified incurring the major
maintenance costs required to restart the facility. As our strategic initiatives under
consideration do not require utilization of the steam produced by the cogeneration facility, we and
Praxair Energy amended the Joint Venture Agreement governing S&L Cogeneration Company, or the Joint
Venture Agreement, to extend its term until November 30, 2009 or upon completion of all final
audits, and to address several matters related to the sale of the cogeneration facility, the
distribution of S&L Cogeneration Companys assets and the termination and winding-up of its
affairs. Under the amended Joint Venture Agreement, we received distributions from S&L
Cogeneration Company of $5.0 million on August 15, 2008 and one-half of the Mass Emissions Cap and
Trade NOx Allowances attributed to the operation of the cogeneration facility. In October 2008,
the Board of Managers of S&L Cogeneration Company accepted a bid for the cogeneration facility
assets and we received a $1.0 million distribution in December 2008 from S&L Cogeneration Company
for the sale of those assets. As of December 31, 2009, our investment in S&L Cogeneration Company
is approximately $0.4 million and we expect to receive approximately $0.4 million from S&L
Cogeneration Company upon termination of the joint venture in 2010. Therefore we do not believe
our investment in S&L Cogeneration Company was impaired as of December 31, 2009.
On September 13, 2008, Hurricane Ike struck the Texas Gulf Coast very near our Texas City
facility. Our Texas City facility was shut down and secured prior to landfall and did not sustain
any significant structural damage, although we did sustain some minor damage to three of our barge
docks. Our Texas City facility lost all power and ancillary utilities during the storm, including
our steam boilers. The resulting production outage lasted approximately 15 days, with our Texas
City facility returning to normal operating levels on September 28, 2008. The losses we incurred
from Hurricane Ike during 2008 totaled $2.6 million, and we incurred additional expenses of $0.2
million in 2009 related to damages caused by Hurricane Ike. Our total loss from Hurricane Ike of
$2.8 million was less than the deductibles under our insurance policies and, as such, we did not
recover any of these losses under our insurance policies.
Discontinued Operations
25
Prior to December 3, 2007, we manufactured styrene monomer and, on September 17, 2007, we
entered into a long-term exclusive styrene supply agreement and a related railcar purchase and sale
agreement with NOVA Chemicals, Inc. to INEOS NOVA LLC, or INEOS NOVA. After the supply agreement
became effective, INEOS NOVA nominated zero pounds of styrene under the supply agreement for the
balance of 2007 and, 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 restricted from reentering the styrene business
until November 2012. The restricted period was initially eight years. However, on April 1, 2008,
INEOS NOVA unilaterally reduced the restricted period to five years.
We sold substantially all remaining styrene inventory during the first quarter of 2008. The
decommissioning process was completed by the end of 2008, with $18.9 million of the $19.6 million
in total costs associated with the decommissioning being incurred in 2008. We are not required to
dismantle our styrene facility but may elect to do so in connection with one or more of our
strategic initiatives. We believe the cost of dismantling will be minimal due to the scrap value
we can receive from the equipment being dismantled. In July 2008, 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, we reduced our salaried work force by 19 people and our hourly
work force by 15 people and recognized and paid $1.4 million of severance costs in 2008. In
addition, as a result of the work force reduction, the accrual of defined benefits for future
services of a significant number of employees was eliminated and we recorded a curtailment loss of
$1.2 million for our benefit plans in 2008.
As a result of our styrene facility being permanently shut down, we have no significant
continued involvement in the styrene business and have, therefore, reported the operating results
of these businesses as discontinued operations in our consolidated financial statements for the
years ended December 31, 2009 and December 31, 2008.
Results of Operations
The following table sets forth revenues, gross profit and loss from continuing operations for
2009 and 2008:
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Revenues |
|
$ |
114,334 |
|
|
$ |
161,675 |
|
Gross profit |
|
|
11,134 |
|
|
|
30,146 |
|
Loss from continuing operations |
|
|
(8,037 |
) |
|
|
(254 |
) |
Comparison of 2009 and 2008
Revenues and loss from continuing operations
Our revenues were $114.3 million for 2009, a 29% decrease from the $161.7 million in revenues
we recorded for 2008. We had a net loss from continuing operations of $8.0 million in 2009,
compared to a net loss from continuing operations of $0.3 million in 2008.
Revenues from our acetic acid operations were $87.3 million in 2009, a 33% decrease from the
$129.7 million in revenues we received from these operations in 2008. This decrease in acetic acid
revenues in 2009 compared to 2008 was due to $24.1 million in decreased cost reimbursements from BP
Chemicals primarily resulting from lower energy costs and reduced production of acetic acid. The reduced
acetic acid production occurred as a result of the shutdown of our acetic acid unit in January
2009, due to the economy, and in June and July 2009, for scheduled maintenance. In addition, our
revenues were $11.9 million lower in 2009 compared to 2008 primarily due to a decreased
contribution margin and the fact that revenues for 2008 included the $6.5 million we received from
BP Chemicals in connection with the settlement of a blend gas dispute under our Acetic Acid
Production Agreement. Gross profit from our acetic acid operations was $5.5 million for 2009
compared to $28.1 million for 2008. This $22.6 million
26
decrease in gross profit was primarily due to the decreased contribution margin discussed
above, increased project start-up costs, depreciation expense and overhead expenses of
approximately $4.2 million in 2009 compared to 2008 and the fact that 2008 included $6.5 million
for the blend gas dispute.
Revenues from our plasticizers operations were approximately $26.0 million in 2009, a 16%
decrease from the $31.0 million in revenues we received from these operations in 2008. Our
revenues decreased in 2009 compared to 2008 primarily due to our 2008 revenues including $3.7
million in cost reimbursements related to the closure of our phthalic anhydride, or PA, unit, as
well as $1.4 million in cost savings achieved in prior periods that was approved by BASF in the
first quarter of 2008. In addition, our revenues in 2009 were lower than 2008 due to decreased
cost reimbursements of $2.5 million resulting from lower energy costs in 2009 compared to 2008, offset by
$0.4 million of increased revenue amortization for the payment associated with BASFs termination
of their obligations related to our oxo alcohols facility as a result of BASF terminating the
Plasticizers Production Agreement effective December 31, 2010, and a $2.7 million increase in
revenue due to reimbursements for the 2009 capital project to redesign our process wastewater
treatment system. Gross profit from our plasticizers operations was $5.9 million in 2009 compared
to $4.1 million in 2008. This increase in gross profit was primarily due to $0.9 million for
favorable economic indices and contract gains applicable to various components of reimbursable costs under our
Plasticizers Production Agreement the $0.4 million of additional revenue amortization discussed
above and $0.1 million for cost savings recorded in 2009.
In addition, gross profit for 2008 included $0.5 million of depreciation expense for the PA unit before
it was written down to zero in June 2008, $0.6 million for start-up costs and $0.8 million for lawsuit expenses, offset by $1.4 million of cost savings discussed above.
Other gross profit was a loss of $0.3 million in 2009 compared to a loss of $2.1 million in
2008. This improvement was primarily a result of reversing a previous $1.0 million litigation
reserve in the third quarter of 2009 and a reduction in styrene residual costs, most of which were
re-allocated to our acetic acid and plasticizers segments in 2009.
Impairment of long-lived assets
We recorded zero and $7.4 million for impairment of long-lived assets for the years ended
December 31, 2009 and December 31, 2008, respectively. The impairments recorded in 2008 consisted
of a $6.6 million write-down of our PA assets as a result of the closure of our PA unit and a $0.8
million write-down of our turbo generator units which were permanently shut down in 2008.
Other income
Our other income was $3.5 million for 2009 compared to $2.0 million for 2008. This increase
in other income was primarily due to the receipt in 2009 of a $1.1 million previously disputed
contractual payment, a $0.4 million gain on the sale of assets and a $0.3 million gain from the
$23.8 million cash purchase in the fourth quarter of 2009 of $25.0 million in aggregate principal
amount of our 101/4% Senior Secured Notes due 2015, or our Secured Notes, net
of the amortization of a pro rata portion of the related debt issue costs of $0.9 million. The
increase in other income was partially offset by a $0.4 million decrease in reimbursements of legal
fees related to various lawsuits during 2009.
Interest and debt related expenses
We recorded $15.8 million and $17.2 million of interest and debt related expenses during 2009
and 2008, respectively. The reduction in interest and debt expense in 2009 was due to $0.2 million
of reduced interest related to the $23.8 million cash purchase in the fourth quarter of 2009 of
$25.0 million in aggregate principal amount of our Secured Notes and a $0.3 million increase in
capitalized interest as a result of the capital projects completed during the turn-around of our
acetic acid facility in 2009. In addition, interest and debt related expenses for 2008 included
$0.5 million of penalty interest paid on our Secured Notes prior to our exchange offer registration
statement being declared effective by the Securities and Exchange Commission and a $0.3 million
write-off of debt fees associated with the reduction of the commitment under our prior revolving
credit facility in the second quarter of 2008.
Interest income
We recorded $0.7 million of interest income during 2009 compared to $4.4 million during 2008.
This decrease was primarily due to significantly lower interest earned on our cash investments
during 2009 compared to 2008.
27
Provision (benefit) for income taxes
During 2009, our effective tax rate was 39.5% due to a change of $0.6 million in our valuation
allowance as a result of a change in tax law and a $4.6 million tax benefit in continuing
operations generated by utilizing income in discontinued operations and other comprehensive income
offset by a corresponding change in the valuation allowance related to continuing operations. In
2008, our continuing operations effective tax rate of 21.9% resulted from a change of less than
$0.1 million in our valuation allowance. We regularly assess our deferred tax assets for
recoverability based on both historical and anticipated earnings levels. 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 at December 31, 2009, we concluded that a valuation allowance was needed against our
deferred tax assets. As of December 31, 2009, our valuation allowance was $28.2 million, a decrease
of $3.2 million from December 31, 2008. This decrease included a valuation allowance adjustment of
$0.9 million for gains in other comprehensive income for adjustments to our benefits plans. As of
December 31, 2009, our overall net deferred tax asset/liability balance was zero.
Income (loss) from discontinued operations, net of tax
Net income from our discontinued operations, net of tax, was $8.5 million in 2009 compared to
a net loss from discontinued operations, net of tax, of $8.4 million in 2008. The difference was
primarily due to the $18.9 million of costs we incurred during 2008 to complete the decommissioning
of our styrene facility. In addition, we incurred tax expense of $2.7 million in 2009 compared to
zero tax expense in 2008.
Liquidity and Capital Resources
General
Our
working capital was $97.7 million as of December 31, 2009,
a decrease of $46.9 million
from our working capital of $144.6 million as of December 31, 2008. This decrease was primarily
due to the purchase of $25.0 million in aggregate principal amount of our Secured Notes for $23.8
million, increased capital expenditures of $4.1 million, a $6.1 million
increase in current portion of benefit liabilities resulting
from contribution requirements, turn-around costs of $3.1 million and an
$11.9 million decrease in revenue accruals in 2009, partially offset by the reversal of a $1.0
million litigation reserve and a decreased property tax accrual of $0.8 million.
Our liquidity (i.e., cash and cash equivalents plus total borrowing ability under our
revolving credit facility) was $127.8 million at December 31, 2009, a decrease of $39.4 million
compared to our liquidity at December 31, 2008. This decrease was primarily due to our purchase of
$25.0 million in aggregate principal amount of our Secured Notes in 2009 for $23.8 million, a $7.5
million decrease in our borrowing base as a result of reduced accounts receivable compared to
December 31, 2008 and $10.6 million in capital expenditures in 2009. We periodically review the
balance of our cash on hand in light of our strategic objectives and the restrictions on the use of
cash contained in the indenture for our Secured Notes. As opportunities arise, we intend to
utilize our cash as circumstances warrant, possibly in material amounts, to fund all or a portion
of the purchase price of mergers or acquisitions, engage in project development work, make
contributions to our defined benefit plans or purchase our outstanding Secured Notes on the open
market, in privately negotiated transactions or otherwise.
We invest our excess cash in various investments. Our cash is invested in money market funds
and certificates of deposit, however, we may invest cash in other high quality, highly liquid cash
equivalents from time to time.
Debt
On March 29, 2007, we completed a private offering of $150 million aggregate principal amount
of unregistered Secured Notes pursuant to a Purchase Agreement among us, Sterling Chemicals Energy,
Inc., or Sterling Energy, one of our former wholly-owned subsidiaries, and Jefferies & Company,
Inc. and CIBC World Markets Corp., as initial purchasers. 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 May 6, 2008, Sterling Energy was
merged with and into us. Upon consummation of the merger, Sterling Energy no longer had
independent existence and, consequently, our Secured Notes are no longer guaranteed by Sterling
Energy. Pursuant to a registration rights agreement among us, Sterling Energy and the initial
purchasers, we agreed to
28
exchange our unregistered Secured Notes for a new issue of substantially identical debt
securities registered under the Securities Act, to cause the registration statement for the
exchange offer to become effective by December 24, 2007, and to complete the exchange offer within
50 days of the effective date of the registration statement. On August 30, 2007, we made an
initial filing of the exchange offer registration statement. However, the registration statement
was not declared effective by December 24, 2007, and, as a result, the interest rate on our Secured
Notes increased by 0.25% per annum on each of December 25, 2007, March 24, 2008 and June 22, 2008.
The registration statement was declared effective on August 13, 2008, and the exchange offer was
closed on September 19, 2008. As a result, the interest rate on our Secured Notes reverted back to
the face amount of 101/4% per annum when the exchange offer closed. The
additional interest incurred from December 25, 2007 through the closing of the exchange offer was
approximately $0.5 million and was paid on April 1 and October 1, 2008.
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 Secured Notes may declare our Secured Notes to be
due and payable immediately. Upon an event of default, the trustee may also take actions to
foreclose on the collateral securing our outstanding Secured Notes, subject to the terms of an
intercreditor agreement dated March 29, 2007, among us, the trustee and The CIT Group/Business
Credit, Inc, or CIT. 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 Secured Notes on April 1 and October 1 of each year. Our
outstanding Secured Notes, which mature on April 1, 2015, are senior secured obligations and rank
equally in right of payment with all of our existing and future senior indebtedness. Subject to
specified permitted liens, our outstanding Secured Notes are secured (i) on a first priority basis
by all of our fixed assets and certain related assets, including, without limitation, all property,
plant and equipment and (ii) on a second priority basis by our other assets, including, without
limitation, accounts receivable, inventory, capital stock of our domestic restricted subsidiaries,
intellectual property, deposit accounts and investment property.
In the fourth quarter of 2009, we purchased $25.0 million in aggregate principal amount of our
Secured Notes for $23.8 million in cash in the open market resulting in a $1.2 million gain. This
gain was partially offset by the amortization of a pro rata portion of the related debt issue costs
of $0.9 million. In February 2010, we repurchased an additional $2.0 million in aggregate principal
amount of our Secured Notes for $1.9 million, and in the first
quarter of 2010, we will amortize less than $0.1 million for the pro rata portion
of the related debt issue costs. The $27.0 million
in aggregate principal purchase of our Secured Notes in the fourth quarter of 2009 and in February
2010 is expected to reduce interest expense for 2010 by approximately $2.7 million.
On December 19, 2002, we entered into a Revolving Credit Agreement, or our revolving credit
facility, with CIT as administrative agent and a lender, and certain other lenders. 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. On June 30, 2008, we reduced our commitment under our revolving
credit facility to $25 million. On November 7, 2008, we further amended our revolving credit
facility to substantially reduce restrictions and paid the administrative agent an amendment fee
plus expenses totaling approximately $0.1 million in connection with this amendment.
On
December 10, 2009, we elected to terminate our revolving credit
facility effective January 24,
2010 due to our substantial cash balances and low working capital needs. There were no penalties
or termination fees payable by us in connection with the early termination of our revolving credit
facility. The remaining associated debt issue costs of $0.2 million will be written off as of the
effective termination date.
As of December 31, 2009, total credit available under our revolving credit facility was $7.5
million, there were no loans outstanding and we had $3.5 million in letters of credit outstanding,
resulting in borrowing availability of $4.0 million.
29
On January 31, 2010, we entered into a $5 million Revolving Line of Credit for letters of
credit, or our LC Facility, with JP Morgan Chase Bank, N.A. or Chase, for the issuance of
commercial and standby letters of credit. Our LC Facility will expire January 31, 2014, and
letters of credit issued under this facility bear an annual fee of 1%. On January 31, 2010, we
also entered into an Assignment of Deposit Account Agreement with Chase providing collateral for
the LC facility with a $5 million deposit account. As of February 28, 2010, there were $3.3
million in standby letters of credit issued under the LC facility.
Cash Flow
Net cash provided by operations was $1.4 million in 2009, compared to $62.4 million in 2008.
This decrease in net cash flow provided by operations during 2009 was primarily due to the
monetization of our styrene working capital of approximately $67.0 million in 2008. Net cash flow
used in investing activities was $9.9 million in 2009 compared to $6.4 million in 2008. This
increase was primarily due to increased capital expenditures in 2009 primarily for capital projects
completed during the turn-around of our acetic acid facility and a capital project related to
improvements in our process wastewater treatment system. Net cash flow used in financing
activities was $23.8 million in 2009 compared to zero in 2008. This increase was due to the
purchase of $25.0 million aggregate principal amount of our Secured Notes in the fourth quarter of
2009 for $23.8 million.
Distress in the financial markets during 2008 and 2009 has had an adverse impact on financial
market activities including, among other things, volatility in security prices, diminished
liquidity and credit availability, rating downgrades of certain investments and declining
valuations of others. We have assessed the implications of these factors on our current business
and determined that there was not a significant impact to our financial condition, results of
operations or liquidity during 2009. We believe that our cash on hand and cash generated from
continuing operations will be sufficient to meet our short-term and long-term liquidity needs for
the reasonably foreseeable future.
Capital Expenditures
Our capital expenditures were $10.5 million during 2009 compared to $6.4 million during 2008.
Capital expenditures during 2009 were $5.0 million for our portion of acetic acid related projects,
including construction of an acetic acid pipeline and other replacement and debottlenecking
projects, and $1.8 million for a capital project to redesign our process wastewater treatment
system. Costs incurred for routine safety, environmental, replacement capital and profit
improvement projects were $3.7 million for 2009. We anticipate spending approximately $5.1 million
on these types of expenditures during 2010.
Pensions
Our projected benefit obligation under our defined benefit pension plan was $124.3 million and
$121.2 million as of December 31, 2009 and 2008, respectively. This increase in 2009 was primarily
due to an actuarial loss of $4.6 million, and interest costs of $7.2 million, partially offset by
benefit payments of $8.7 million.
Critical Accounting Policies, Use of Estimates and Assumptions
A summary of our significant accounting policies is included in Note 1 of the Notes to
Consolidated Financial Statements included in Item 7, Part II of this Form 10-K. We believe that
the consistent application of these policies enables us to provide readers of our financial
statements with useful and reliable information about our operating results and financial
condition. The following accounting policies are the ones we believe are the most important to the
portrayal of our financial condition and results of operations 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 collectability is reasonably assured.
30
Acetic Acid. Pursuant to our 2008 Amended and Restated Acetic Acid Production Agreement, or
our Acetic Acid Production Agreement, all of our acetic acid is sold to BP Amoco Chemical Company,
or 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 of production (excluding some indirect expenses and direct depreciation associated
with machinery and equipment used in the manufacturing of acetic acid) and the revenue associated
with the reimbursement of these costs is included in revenue and is matched against our costs as
they are incurred. We recognize revenue related to the profit sharing component under our Acetic
Acid Production Agreement based on quarterly estimates received from BP Chemicals. These estimates
are based on the profits from sales of acetic acid subject to our Acetic Acid Production Agreement.
Plasticizers. We generate revenues from our plasticizers operations through our Third Amended
and Restated Plasticizers Production Agreement, or our Plasticizers Production Agreement, with BASF
Corporation, or 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
costs of production (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 included in revenue and 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, 2009, related to continuing operations, we had a balance in
deferred income of approximately $4.8 million, which represents certain payments received from our
oxo-alcohol and PA operations, which previously were part of our plasticizers business. The oxo
alcohol payment was previously being amortized using the straight-line method over an eight year
life that ended on December 31, 2013, the original termination date of our Plasticizers Production
Agreement. As a result of BASFs election to terminate our Plasticizers Production Agreement,
effective December 31, 2010, the original eight year life was changed to five years and the
remaining unamortized balance of $3.6 million will be recognized in 2010. The PA payment is being
amortized using the straight-line method over the remaining life of our Plasticizers Production
Agreement of one year, and the remaining unamortized balance of $1.2 million will be recognized in
2010. In discontinued operations, as of December 31, 2009, we had a balance in deferred income of
approximately $35.4 million related to payments made to us under our exclusive styrene production
agreement with NOVA Chemicals Inc. which is being amortized using the straight-line method over the
contractual non-compete period of five years, of which approximately three years remain.
Approximately $12.4 million will be recognized in discontinued operations in 2010.
Preferred Stock Dividends
We record preferred stock dividends on our Preferred Stock in our consolidated statements of
operations based on the estimated fair value of dividends at each dividend accrual date. Our
Preferred Stock has a dividend rate of 4% per quarter of the liquidation value of the outstanding
shares of our Preferred Stock, and is payable in arrears in additional shares of our Preferred
Stock on the first business day of each calendar quarter. The liquidation value of each share of
our Preferred Stock is $13,793 per share, and each share of our 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 Preferred Stock in our consolidated balance sheets represents the initial fair value
at original issuance in 2002 plus the initial fair value of each of the quarterly dividends paid
since issuance. The fair value of our Preferred Stock
31
dividends is determined each quarter using valuation techniques that include a component
representing the intrinsic value of the dividends (which represent the greater of the liquidation
value of the shares of Preferred Stock being issued or the fair value of the common stock into
which those shares could be converted) and an option component (which is determined using a
Black-Scholes Option Pricing Model). These dividends are subtracted from net income in our
consolidated statements of operations, and added to the balance of 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: |
|
2009 |
|
|
2008 |
|
Risk-free interest rate |
|
|
2.7 |
% |
|
|
1.6 |
% |
Volatility |
|
|
72.2 |
% |
|
|
63.6 |
% |
Dividend yield |
|
|
|
|
|
|
|
|
Expected term |
|
|
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 is 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.
In the second quarter of 2008, as a result of the permanent shutdown of our phthalic
anhydride, or PA, manufacturing unit, our management determined that a triggering event, as defined
in the Financial Accounting Standards Board, or FASB, Accounting Standards Codification, or ASC,
Topic 360, Impairment or Disposal of Long-Lived Assets, had occurred and, as a result, 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 our 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 impaired and
should be written down to zero. This write-down caused us to record an impairment of $6.6 million
in June 2008.
In the third quarter of 2008, our management determined that a triggering event, as defined in
ASC Topic 360, had occurred as a result of the decision to permanently discontinue the use of some
of our turbo generator units located at our Texas City facility. This decision was based on an
economic analysis of the future use of the turbo generator units. During the third quarter of
2008, we performed an asset impairment analysis on these turbo generator units and determined the
best estimate of fair market value would be the anticipated sales proceeds. We estimated the
anticipated sales proceeds to be approximately $1.0 million. As a result, we concluded that our
turbo generator units were impaired and should be written down to $1.0 million. This write-down
resulted in an impairment charge of $0.8 million during the third quarter of 2008. During 2009,
one of the turbo generator units was utilized in a capital project to convert 650 pound steam to
250 pound steam and thus reduce our steam costs. We still plan to sell or utilize the remaining
turbo generator, and therefore believe no further impairment is necessary at this time.
In the fourth quarter of 2009, our management determined that a triggering event, as defined
in ASC Topic 360, had occurred as a result of BASF electing to terminate our Plasticizers
Production Agreement, effective December 31, 2010. In December 2009, we performed an asset
impairment analysis on our esters manufacturing unit. We analyzed the undiscounted cash flow
stream from our esters business over the remaining life of the esters
32
manufacturing unit and compared it to the $2.8 million net book carrying value of our esters
manufacturing unit. This analysis showed that the undiscounted projected cash flow stream from our
esters business was higher than the net book carrying value of our esters manufacturing unit.
Based on this analysis, we concluded that our esters unit was not impaired as of December 31, 2009,
and that no write-down is necessary. We will however accelerate our depreciation on our esters
manufacturing unit in 2010 to ensure it is fully depreciated by December 31, 2010.
Income Taxes
Deferred income taxes are provided for revenue and expenses which are recognized in different
periods for income tax and financial statement purposes. We regularly assess deferred tax assets
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 at December 31, 2009, we concluded that a valuation allowance was needed
against our deferred tax assets. As of December 31, 2009, our valuation allowance was $28.2
million, a decrease of $3.2 million from December 31, 2008. The decrease included a valuation
allowance adjustment of $1.4 million related to our state taxes and credits and $0.9 million due to
gains in other comprehensive income for adjustments to our benefits plans. As of December 31,
2009, our overall net deferred tax asset/liability balance was zero.
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
long-term rate of 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.
Accounting guidance applicable to pension plans does not require immediate recognition of the
current year effects of a deviation between these assumptions and actual experience. We
experienced significant negative pension asset returns in 2008, the result of which materially
increased our pension expense for 2009. In 2009, we were able to recover about one-half of the
negative pension asset returns from 2008. The 2009 pension expense, on a pre-tax basis, is $4.4
million, however a significant portion will be reimbursed through existing contractual
arrangements.
During the third quarter of 2008, as a result of our work force reduction announced in July
2008, and in accordance with ASC Topic 715, Compensation Retirement Benefits, or ASC Topic
715, we recorded plan curtailment losses in discontinued operations of $0.9 million for our defined
benefit pension plans and $0.3 million for our post-retirement medical plan.
Plant Turn-around Costs
As a part of normal recurring operations, each of our manufacturing units is completely shut
down from time to time, for a period typically lasting two to four weeks, to replace catalysts and
perform major maintenance work required to sustain long-term production. These periods are
commonly referred to as turn-arounds or shutdowns. Costs of turn-arounds are expensed as
incurred. As expenses for turn-arounds can be significant, the impact of expensing turn-around
costs as they are incurred can be material for financial reporting periods during which the
turn-arounds actually occur. Turn-around costs expensed during 2009 and 2008 that are included in
continuing operations were $3.1 million and $0.3 million, respectively.
New Accounting Standards
In September 2009, the FASB issued ASU No. 2009-12, an amendment to ASC Topic 820-10, Fair
Value Measurements and Disclosures Overall, or ASU No. 2009-12, to provide guidance on the fair
value measurement of investments in certain entities that calculate net asset value per share (or
its equivalent). ASU No. 2009-12 is effective for interim and annual reporting periods ending
after December 15, 2009. We do not believe the implementation of ASU 2009-12 will have a material
impact on our consolidated financial statements.
33
In January 2010, the FASB issued ASU No. 2010-06, an amendment to ASC Topic 820-10, Fair
Value Measurements and Disclosures (Topic 820): Improving Disclosures about Fair Value
Measurements, or ASU No. 2010-06. ASU No. 2010-06 requires some new disclosures and clarifies
some existing disclosure requirements about fair value measurement as set forth in Codification
Subtopic 820-10. The objective of ASU No. 2010-06 is to improve these disclosures and, thus,
increase the transparency in financial reporting. Specifically, ASU 2010-06 amends Codification
Subtopic 820-10 to now require:
|
|
|
a reporting entity to disclose separately the amounts of significant transfers in and
out of Level 1 and Level 2 fair value measurements and describe the reasons for the
transfers; and |
|
|
|
|
in the reconciliation for fair value measurements using significant unobservable
inputs, a reporting entity to present separately information about purchases, sales,
issuances and settlements. |
In addition, ASU 2010-06 clarifies the requirements of the following existing disclosures:
|
|
|
for purposes of reporting fair value measurement for each class of assets and
liabilities, a reporting entity needs to use judgment in determining the appropriate
classes of assets and liabilities; and |
|
|
|
|
a reporting entity should provide disclosures about the valuation techniques and
inputs used to measure fair value for both recurring and nonrecurring fair value
measurements. |
ASU 2010-06 is effective for interim and annual reporting periods beginning after December 15,
2009, except for the disclosures about purchases, sales, issuances and settlements in the roll
forward of activity in Level 3 fair value measurements. Those disclosures are effective for fiscal
years beginning after December 15, 2010 and for interim periods within those fiscal years. Early
application is permitted. We do not believe the implementation of ASU 2010-06 will have a material
impact on our consolidated financial statements.
34
Item 8. Financial Statements and Supplementary Data
INDEX TO HISTORICAL CONSOLIDATED FINANCIAL STATEMENTS
INDEX TO FINANCIAL STATEMENTS
Sterling Chemicals, Inc.
Audited Financial Statements
35
REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM
To the Board of Directors and Stockholders of Sterling Chemicals, Inc.:
We have audited the accompanying consolidated balance sheets of Sterling Chemicals, Inc. and
its subsidiaries (the Company) as of December 31, 2009 and 2008, and the related consolidated
statements of operations, changes in stockholders equity (deficiency in assets) and cash flows for
each of the two years in the period ended December 31, 2009. These financial statements are the
responsibility of the Companys management. Our responsibility is to express an opinion on these
financial statements based on our audits.
We conducted our audits in accordance with the standards of the Public Company Accounting
Oversight Board (United States). Those standards require that we plan and perform the audit to
obtain reasonable assurance about whether the financial statements are free of material
misstatement. The Company is not required to have, nor were we engaged to perform an audit of its
internal control over financial reporting. Our audit included consideration of internal control
over financial reporting as a basis for designing audit procedures that are appropriate in the
circumstances, but not for the purpose of expressing an opinion on the effectiveness of the
Companys internal control over financial reporting. Accordingly, we express no such opinion. An
audit also includes examining, on a test basis, evidence supporting the amounts and disclosures in
the financial statements, assessing the accounting principles used and significant estimates made
by management, as well as evaluating the overall financial statement presentation. We believe that
our audits provide a reasonable basis for our opinion.
In our opinion, the financial statements referred to above present fairly, in all material
respects, the financial position of Sterling Chemicals, Inc. as of December 31, 2009 and 2008, and
the results of its operations and its cash flows for each of the two years in the period ended
December 31, 2009 in conformity with accounting principles generally accepted in the United States
of America.
/s/ GRANT THORNTON LLP
Houston, Texas
March 24, 2010
36
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF OPERATIONS
(Dollars in Thousands, Except Share Data)
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
Revenues |
|
$ |
114,334 |
|
|
$ |
161,675 |
|
Cost of goods sold |
|
|
103,200 |
|
|
|
131,529 |
|
|
|
|
|
|
|
|
Gross profit |
|
|
11,134 |
|
|
|
30,146 |
|
Selling, general and administrative expenses |
|
|
12,875 |
|
|
|
12,331 |
|
Impairment of long-lived assets |
|
|
|
|
|
|
7,403 |
|
Interest and debt related expenses |
|
|
15,767 |
|
|
|
17,175 |
|
Interest income |
|
|
(742 |
) |
|
|
(4,408 |
) |
Other income |
|
|
(3,481 |
) |
|
|
(2,030 |
) |
|
|
|
|
|
|
|
Loss from continuing operations before income tax |
|
|
(13,285 |
) |
|
|
(325 |
) |
Benefit for income taxes |
|
|
(5,248 |
) |
|
|
(71 |
) |
|
|
|
|
|
|
|
Loss from continuing operations |
|
$ |
(8,037 |
) |
|
$ |
(254 |
) |
Income (loss) from discontinued operations, net of tax
expense of $2,679 and zero, respectively |
|
|
8,472 |
|
|
|
(8,366 |
) |
|
|
|
|
|
|
|
Net income (loss) |
|
$ |
435 |
|
|
$ |
(8,620 |
) |
Preferred stock dividends |
|
|
16,921 |
|
|
|
17,741 |
|
|
|
|
|
|
|
|
Net loss attributable to common stockholders |
|
$ |
(16,486 |
) |
|
$ |
(26,361 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(Loss) income per share of common stock attributable to
common stockholders, basic and diluted: |
|
|
|
|
|
|
|
|
Loss from continuing operations |
|
$ |
(8.83 |
) |
|
$ |
(6.36 |
) |
Income (loss) from discontinued operations, net of tax |
|
|
3.00 |
|
|
|
(2.96 |
) |
|
|
|
|
|
|
|
Basic and diluted loss per share |
|
$ |
(5.83 |
) |
|
$ |
(9.32 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average shares outstanding: |
|
|
|
|
|
|
|
|
Basic and diluted |
|
|
2,828,460 |
|
|
|
2,828,460 |
|
The accompanying notes are an integral part of the consolidated financial statements.
37
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED BALANCE SHEETS
(Dollars in Thousands, Except Share Data)
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
ASSETS |
|
|
|
|
|
|
|
|
Current assets: |
|
|
|
|
|
|
|
|
Cash and cash equivalents |
|
$ |
123,778 |
|
|
$ |
156,126 |
|
Accounts receivable, net of allowance of $58 and $18, respectively |
|
|
14,614 |
|
|
|
25,607 |
|
Inventories, net |
|
|
5,268 |
|
|
|
5,221 |
|
Prepaid expenses and other current assets |
|
|
2,539 |
|
|
|
2,473 |
|
Assets of discontinued operations, net |
|
|
24 |
|
|
|
166 |
|
|
|
|
|
|
|
|
Total current assets |
|
|
146,223 |
|
|
|
189,593 |
|
|
|
|
|
|
|
|
|
|
Property, plant and equipment, net |
|
|
68,182 |
|
|
|
67,811 |
|
Other assets, net |
|
|
5,760 |
|
|
|
7,838 |
|
|
|
|
|
|
|
|
Total assets |
|
$ |
220,165 |
|
|
$ |
265,242 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
LIABILITIES AND STOCKHOLDERS DEFICIENCY IN ASSETS |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Current liabilities: |
|
|
|
|
|
|
|
|
Accounts payable |
|
$ |
11,703 |
|
|
$ |
12,520 |
|
Accrued liabilities |
|
|
24,416 |
|
|
|
20,008 |
|
Liabilities of discontinued operations |
|
|
12,384 |
|
|
|
12,444 |
|
|
|
|
|
|
|
|
Total current liabilities |
|
|
48,503 |
|
|
|
44,972 |
|
|
|
|
|
|
|
|
|
|
Long-term debt |
|
|
125,000 |
|
|
|
150,000 |
|
Deferred credits and other liabilities |
|
|
41,084 |
|
|
|
59,103 |
|
Long-term liabilities of discontinued operations |
|
|
23,010 |
|
|
|
35,394 |
|
Commitments and contingencies (Note 9) |
|
|
|
|
|
|
|
|
Redeemable preferred stock |
|
|
134,528 |
|
|
|
117,607 |
|
Stockholders deficiency in assets: |
|
|
|
|
|
|
|
|
Common stock, $.01 par value (shares authorized 100,000,000;
shares issued
and outstanding 2,828,460) |
|
|
28 |
|
|
|
28 |
|
Additional paid-in capital |
|
|
106,948 |
|
|
|
123,740 |
|
Accumulated deficit |
|
|
(240,780 |
) |
|
|
(241,215 |
) |
Accumulated other comprehensive loss |
|
|
(18,156 |
) |
|
|
(24,387 |
) |
|
|
|
|
|
|
|
Total stockholders deficiency in assets |
|
|
(151,960 |
) |
|
|
(141,834 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total liabilities and stockholders deficiency in assets |
|
$ |
220,165 |
|
|
$ |
265,242 |
|
|
|
|
|
|
|
|
The accompanying notes are an integral part of the consolidated financial statements.
38
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF
CHANGES IN STOCKHOLDERS EQUITY (DEFICIENCY IN ASSETS)
(Amounts in Thousands)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accumulated |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Additional |
|
|
|
|
|
|
Other |
|
|
|
|
|
|
Common Stock |
|
|
Paid-In |
|
|
Accumulated |
|
|
Comprehensive |
|
|
|
|
|
|
Shares |
|
|
Amount |
|
|
Capital |
|
|
Deficit |
|
|
Income (Loss) |
|
|
Total |
|
Balance, December 31, 2007 |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
141,174 |
|
|
$ |
(232,595 |
) |
|
$ |
17,253 |
|
|
$ |
(74,140 |
) |
Comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(8,620 |
) |
|
|
|
|
|
|
|
|
Other comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Benefit adjustment, net
of tax of zero |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(41,640 |
) |
|
|
|
|
Comprehensive loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(50,260 |
) |
Preferred stock dividends |
|
|
|
|
|
|
|
|
|
|
(17,741 |
) |
|
|
|
|
|
|
|
|
|
|
(17,741 |
) |
Stock-based compensation |
|
|
|
|
|
|
|
|
|
|
307 |
|
|
|
|
|
|
|
|
|
|
|
307 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2008 |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
123,740 |
|
|
$ |
(241,215 |
) |
|
$ |
(24,387 |
) |
|
$ |
(141,834 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Comprehensive income: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
435 |
|
|
|
|
|
|
|
|
|
Other comprehensive income: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Benefit adjustment, net
of tax of $1,970 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
6,231 |
|
|
|
|
|
Comprehensive income: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
6,666 |
|
Preferred stock dividends |
|
|
|
|
|
|
|
|
|
|
(16,921 |
) |
|
|
|
|
|
|
|
|
|
|
(16,921 |
) |
Stock-based compensation |
|
|
|
|
|
|
|
|
|
|
129 |
|
|
|
|
|
|
|
|
|
|
|
129 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2009 |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
106,948 |
|
|
$ |
(240,780 |
) |
|
$ |
(18,156 |
) |
|
$ |
(151,960 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The accompanying notes are an integral part of the consolidated financial statements.
39
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF CASH FLOWS
(Dollars in Thousands)
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
Cash flows from operating activities: |
|
|
|
|
|
|
|
|
Net income (loss) |
|
$ |
435 |
|
|
$ |
(8,620 |
) |
Adjustments to reconcile net income (loss) to net cash provided by operating
activities: |
|
|
|
|
|
|
|
|
Stock compensation expense |
|
|
129 |
|
|
|
307 |
|
Blend gas deferred payments |
|
|
|
|
|
|
(2,653 |
) |
Bad debt expense (benefit) |
|
|
64 |
|
|
|
(5 |
) |
Benefit plans curtailment loss |
|
|
|
|
|
|
1,197 |
|
Depreciation and amortization |
|
|
9,852 |
|
|
|
9,475 |
|
Interest amortization |
|
|
1,091 |
|
|
|
1,347 |
|
Unearned income amortization |
|
|
(14,976 |
) |
|
|
(13,036 |
) |
Impairment of long-lived assets |
|
|
|
|
|
|
7,403 |
|
Lower-of-cost-or-market adjustment |
|
|
(31 |
) |
|
|
351 |
|
Gain on disposal of property, plant and equipment |
|
|
(635 |
) |
|
|
|
|
Net gain on purchase of Senior Secured Notes |
|
|
(291 |
) |
|
|
|
|
Other |
|
|
(149 |
) |
|
|
(353 |
) |
Change in assets/liabilities: |
|
|
|
|
|
|
|
|
Accounts and other receivables |
|
|
11,072 |
|
|
|
62,688 |
|
Inventories |
|
|
(236 |
) |
|
|
15,181 |
|
Prepaid expenses and other current assets |
|
|
(66) |
|
|
|
425 |
|
Other assets |
|
|
92 |
|
|
|
5,377 |
|
Accounts payable |
|
|
(143 |
) |
|
|
(4,604 |
) |
Accrued liabilities |
|
|
4,348 |
|
|
|
(1,865 |
) |
Other liabilities |
|
|
(9,196 |
) |
|
|
(10,255 |
) |
|
|
|
|
|
|
|
Net cash provided by operating activities |
|
|
1,360 |
|
|
|
62,360 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash flows used in investing activities: |
|
|
|
|
|
|
|
|
Capital expenditures for property, plant and equipment |
|
|
(10,529 |
) |
|
|
(6,417 |
) |
Net proceeds from the sale of property, plant and equipment |
|
|
635 |
|
|
|
|
|
|
|
|
|
|
|
|
Net cash used in investing activities |
|
|
(9,894 |
) |
|
|
(6,417 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash flows used in financing activities: |
|
|
|
|
|
|
|
|
Purchase of Senior Secured Notes |
|
|
(23,814 |
) |
|
|
|
|
|
|
|
|
|
|
|
Net cash used in financing activities |
|
|
(23,814 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net increase (decrease) in cash and cash equivalents |
|
|
(32,348 |
) |
|
|
55,943 |
|
Cash and cash equivalents beginning of year |
|
|
156,126 |
|
|
|
100,183 |
|
|
|
|
|
|
|
|
Cash and cash equivalents end of year |
|
$ |
123,778 |
|
|
$ |
156,126 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Supplemental disclosures of cash flow information: |
|
|
|
|
|
|
|
|
Interest paid |
|
$ |
15,866 |
|
|
$ |
15,849 |
|
Interest income received |
|
|
742 |
|
|
|
4,408 |
|
Income taxes paid |
|
|
(598 |
) |
|
|
313 |
|
The accompanying notes are an integral part of the consolidated financial statements.
40
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS
1. Basis of Presentation and Summary of Significant Accounting Policies
Unless otherwise indicated, references to we, us, our and ours refer collectively to
Sterling Chemicals, Inc. and its wholly-owned subsidiaries. We own or operate facilities at our
petrochemicals complex located in Texas City, Texas, or our Texas City facility, approximately 45
miles south of Houston, on a 290-acre site on Galveston Bay near many other chemical manufacturing
complexes and refineries. Currently, we produce acetic acid and plasticizers and, prior to the
shutdown of our styrene operations in December 2007, we also produced styrene. We own all of the
real property which comprises our Texas City facility and we own the acetic acid, plasticizers and
styrene manufacturing units located at the site. Our Texas City facility offers approximately 160
acres for future expansion by us or by other companies that could benefit from our existing
infrastructure and facilities, and includes a greenbelt around the northern edge of the site. We
also lease a portion of our Texas City facility to Praxair Hydrogen Supply, Inc., or 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 generally sell our petrochemicals products to
customers for use in the manufacture of other chemicals and products, which in turn are used in the
production of a wide array of consumer goods and industrial products. As of December 31, 2009, we
reported our operations in two segments: acetic acid and plasticizers.
Reclassifications and Revisions:
During the quarter ended March 31, 2009, we determined we had incorrectly accounted for
certain utility allocations at our Texas City facility, specifically accounting for the flow of
water throughout our facility. In December 2009 we reviewed our basis for the proper allocation of
our steam billings and determined that there were additional modifications to our steam billings.
We evaluated the materiality of the misstatements from qualitative and quantitative perspectives and
concluded that although the misstatements were immaterial to all
prior year financial statements, their
correction in fiscal 2009 would be material. Therefore, we revised the consolidated statement of
operations, statement of changes in stockholders equity (deficiency in assets) and the statement
of cash flows for the year ended December 31, 2008 and the consolidated balance sheet as of
December 31, 2008, to correct the utility allocation misstatement.
The following table summarizes the effects of the revisions on the applicable periods:
|
|
|
|
|
|
|
|
|
|
|
Year Ended |
|
|
|
December 31, 2008 |
|
|
|
(Dollars in Thousands, |
|
|
|
Except Per Share Data) |
|
|
|
Previously |
|
|
|
|
|
|
Reported |
|
|
As Revised |
|
Statement of Operations: |
|
|
|
|
|
|
|
|
Revenues |
|
$ |
161,452 |
|
|
$ |
161,675 |
|
Cost of goods sold |
|
|
131,154 |
|
|
|
131,529 |
|
Gross profit |
|
|
30,298 |
|
|
|
30,146 |
|
Loss from continuing operations before
income tax |
|
|
(173 |
) |
|
|
(325 |
) |
Loss from continuing operations |
|
|
(102 |
) |
|
|
(254 |
) |
Loss from discontinued operations, net of tax of zero |
|
|
(8,262 |
) |
|
|
(8,366 |
) |
Net loss |
|
|
(8,364 |
) |
|
|
(8,620 |
) |
Net loss attributable to common stockholders |
|
|
(26,105 |
) |
|
|
(26,361 |
) |
|
|
|
|
|
|
|
|
|
Loss per share of common stock attributable to
common stockholders, basic and diluted: |
|
|
|
|
|
|
|
|
41
|
|
|
|
|
|
|
|
|
|
|
Year Ended |
|
|
|
December 31, 2008 |
|
|
|
(Dollars in Thousands, |
|
|
|
Except Per Share Data) |
|
|
|
Previously |
|
|
|
|
|
|
Reported |
|
|
As Revised |
|
Loss from continuing operations |
|
$ |
(6.31 |
) |
|
$ |
(6.36 |
) |
Loss from discontinued operations, net of tax |
|
|
(2.92 |
) |
|
|
(2.96 |
) |
Basic and diluted loss per share |
|
$ |
(9.23 |
) |
|
$ |
(9.32 |
) |
|
|
|
|
|
|
|
|
|
|
|
Year Ended |
|
|
|
December 31, 2008 |
|
|
|
(Dollars in Thousands) |
|
|
|
Previously |
|
|
|
|
|
|
Reported |
|
|
As Revised |
|
Statement of Cash Flows: |
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(8,364 |
) |
|
$ |
(8,620 |
) |
Change in accounts and other receivables |
|
|
62,911 |
|
|
|
62,688 |
|
Change in accounts payable |
|
|
(5,083 |
) |
|
|
(4,604 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of December 31, 2008 |
|
|
|
(Dollars in Thousands) |
|
|
|
Previously |
|
|
As Revised |
|
|
|
|
|
|
Reported in |
|
|
in 2009 Form |
|
|
|
|
|
|
2008 Form 10-K |
|
|
10-Qs |
|
|
As Revised |
|
Balance Sheet: |
|
|
|
|
|
|
|
|
|
|
|
|
Accounts and other receivables, net of allowance |
|
$ |
22,080 |
|
|
$ |
23,163 |
|
|
$ |
25,607 |
|
Prepaid expenses and other current assets |
|
|
2,704 |
|
|
|
|
|
|
|
2,473 |
|
Total current assets |
|
|
186,297 |
|
|
|
187,380 |
|
|
|
189,593 |
|
Total assets |
|
|
261,946 |
|
|
|
263,029 |
|
|
|
265,242 |
|
Accounts payable |
|
|
8,915 |
|
|
|
|
|
|
|
12,520 |
|
Total current liabilities |
|
|
41,367 |
|
|
|
|
|
|
|
44,972 |
|
Accumulated deficit |
|
|
(240,906 |
) |
|
|
(239,823 |
) |
|
|
(241,215 |
) |
Total stockholders deficiency in assets |
|
|
(141,525 |
) |
|
|
(140,442 |
) |
|
|
(141,834 |
) |
Total liabilities and stockholders deficiency in assets |
|
|
261,946 |
|
|
|
263,029 |
|
|
|
265,242 |
|
|
|
|
|
|
|
|
|
|
|
|
As of December 31, 2008 |
|
|
|
(Dollars in Thousands) |
|
|
|
Previously |
|
|
|
|
|
|
Reported |
|
|
As Revised |
|
Statement of Changes in Stockholders
Equity (Deficiency in Assets): |
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(8,364 |
) |
|
$ |
(8,620 |
) |
Comprehensive loss |
|
|
(50,004 |
) |
|
|
(50,260 |
) |
Accumulated deficit |
|
|
(240,906 |
) |
|
|
(241,215 |
) |
Total stockholders deficiency in assets |
|
|
(141,525 |
) |
|
|
(141,834 |
) |
We have reclassified certain amounts on the consolidated statement of cash flows to stock
compensation expense from other adjustments to reconcile net income
(loss) to net cash provided by operating activities, and between
changes in other assets and other adjustments to reconcile net income
(loss) to net cash provided by operating activities, for the year ended December 31, 2008.
Principles of Consolidation
The consolidated financial statements include the accounts of our wholly-owned subsidiaries,
with all significant intercompany accounts and transactions having been eliminated. Our 50% equity
investment in S&L Cogeneration Company is accounted for under the equity method.
Our investment in S&L Cogeneration Company was $0.4 million as of
December 31, 2009 and 2008.
We recognized a
loss from this investment of $0.1 million and income of $1.1 million in 2009 and 2008,
respectively.
Cash and Cash Equivalents
We consider all investments having an initial maturity of three months or less to be cash
equivalents. Our cash is invested in money market funds and certificates of deposit, however, we
may invest cash in other high quality, highly liquid cash equivalents
from time to time. We maintain balances at financial institutions
which may
exceed Federal Deposit Insurance Corporation limits. We have not
experienced any losses in such accounts and do not believe we are
exposed to any significant risks on our cash or other investments.
42
Allowance for Doubtful Accounts
Accounts receivable are presented net of allowance for doubtful accounts. We regularly review
our accounts receivable balances and, based on estimated collectability, adjust the allowance
account accordingly. As of December 31, 2009 and December 31, 2008, the allowance for doubtful
accounts for continuing operations was $0.1 million and less
than $0.1 million, respectively, and less than $0.1
million and zero, respectively for discontinued operations. Bad debt expense for continuing
operations was less than $0.1 million for 2009 and bad debt benefit for continuing operations was
less than $0.1 million for 2008. Bad debt expense for discontinued operations was less than $0.1
million and zero for 2009 and 2008, respectively.
Inventories
Inventories include raw materials, supplies and spare parts which are valued at average cost.
Raw materials and supplies are carried at the lower-of-cost-or-market value. The comparison of
cost to market value involves estimation of the market value of our products. For the years ended
December 31, 2009 and December 31, 2008, this comparison led to a lower-of-cost-or-market
adjustment of less than $0.1 million and $0.4 million, respectively. Spare parts are examined for
obsolescence and are carried at their net realizable value. For the year ended December 31, 2009,
we increased our obsolescence accrual by $0.2 million for spare parts associated with operations
that have been shut down.
Property, Plant and Equipment
Property, plant and equipment are recorded at cost. Major renewals and improvements, which
extend the useful lives of equipment, are capitalized. For certain capital projects, our customers
reimburse us for a portion of the project cost. For capital expenditures reimbursed by our
customers, we treat the reimbursements as a reduction of our cost basis. Disposals are removed at
carrying cost less accumulated depreciation with any resulting gain or loss reflected in
operations. Depreciation is provided using the straight-line method over estimated useful lives
ranging from five to 25 years, with the predominant life of plant and equipment being 15 years. We
capitalize interest costs, which are incurred as part of the cost of constructing major facilities
and equipment. The amount of interest capitalized in continuing operations was $0.7 million and
$0.2 million for 2009 and 2008, respectively.
Plant Turn-around Costs
As a part of normal recurring operations, each of our manufacturing units is completely shut
down from time to time, for a period typically lasting two to four weeks, to replace catalysts and
perform major maintenance work required to sustain long-term production. These periods are
commonly referred to as turn-arounds or shutdowns. Costs of turn-arounds are expensed as
incurred. As expenses for turn-arounds can be significant, the impact of expensing turn-around
costs as they are incurred can be material for financial reporting periods during which the
turn-arounds actually occur. Turn-around costs expensed during 2009 and 2008 that are included in
continuing operations were $3.1 million and $0.3 million, respectively.
Long-Lived Assets
We assess our long-lived assets for impairment whenever facts and circumstances indicate that
the carrying amount may not be fully recoverable. To analyze recoverability, we project
undiscounted net future cash flows over the remaining life of the assets. If the projected cash
flows from the assets are less than the carrying amount, an impairment is 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.
43
In the second quarter of 2008, as a result of the permanent shutdown of our phthalic
anhydride, or PA, manufacturing unit, our management determined that a triggering event, as defined
in the Financial Accounting Standards Board, or FASB, Accounting Standards Codification, or ASC,
Topic 360, Impairment or Disposal of Long-Lived Assets, had occurred and, as a result, 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 our 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 impaired and
should be written down to zero. This write-down caused us to record an impairment of $6.6 million
in June 2008.
In the third quarter of 2008, our management determined that a triggering event, as defined in
ASC Topic 360, had occurred as a result of the decision to permanently discontinue the use of some
of our turbo generator units located at our Texas City facility. This decision was based on an
economic analysis of the future use of the turbo generator units. During the third quarter of
2008, we performed an asset impairment analysis on these turbo generator units and determined the
best estimate of fair market value would be the anticipated sales proceeds.
This determination of fair market value was based on Level 3 inputs that are not corroborated by observable market data.
We estimated the
anticipated sales proceeds to be approximately $1.0 million. As a result, we concluded that our
turbo generator units were impaired and should be written down to $1.0 million. This write-down
resulted in an impairment charge of $0.8 million during the third quarter of 2008. During 2009,
one of the turbo generator units was utilized in a capital project to convert 650 pound steam to
250 pound steam and thus reduce our steam costs. We still plan to sell or utilize the remaining
turbo generator, and therefore believe no further impairment is necessary at this time.
In the fourth quarter of 2009, our management determined that a triggering event, as defined
in ASC Topic 360, had occurred as a result of BASF electing to terminate our Plasticizers
Production Agreement, effective December 31, 2010. In December 2009, we performed an asset
impairment analysis on our esters manufacturing unit. We analyzed the undiscounted cash flow
stream from our esters business over the remaining life of the esters manufacturing unit and
compared it to the $2.8 million net book carrying value of our esters manufacturing unit. This
analysis showed that the undiscounted projected cash flow stream from our esters business was
higher than the net book carrying value of our esters manufacturing unit. Based on this analysis,
we concluded that our esters unit was not impaired as of December 31, 2009, and that no write-down
is necessary. We will however accelerate our depreciation on our esters manufacturing unit in 2010
to ensure it is fully depreciated by December 31, 2010.
Other Assets
Investee companies not accounted for under the consolidation or the equity method of
accounting are accounted for under the cost method of accounting. Under this method, our share of
earnings or losses from an investee company is not included in our consolidated balance sheet or
consolidated statement of operations. However, any impairment charges related to an investee
company would be recognized in our consolidated statement of operations, and if circumstances
suggested that the value of that investee company had subsequently recovered, such recovery would
not be recorded. At December 31, 2009 and 2008, we had a cost method investment of $0.5 million
included in other assets in our consolidated balance sheet.
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 collectability is reasonably assured.
Acetic Acid. Pursuant to our 2008 Amended and Restated Acetic Acid Production Agreement, or
our Acetic Acid Production Agreement, all of our acetic acid is sold to BP Amoco Chemical Company,
or 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 of production (excluding some indirect expenses and direct depreciation
44
associated with machinery and equipment used in the manufacturing of acetic acid) and the
revenue associated with the reimbursement of these costs is included in revenue and is matched
against our costs as they are incurred. We recognize revenue related to the profit sharing
component under our Acetic Acid Production Agreement based on quarterly estimates received from BP
Chemicals. These estimates are based on the profits from sales of acetic acid subject to our
Acetic Acid Production Agreement.
Plasticizers. We generate revenues from our plasticizers operations through our Third Amended
and Restated Plasticizers Production Agreement, or our Plasticizers Production Agreement, with BASF
Corporation, or 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
costs of production (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 included in revenue and 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, 2009, related to continuing operations, we had a balance in
deferred income of approximately $4.8 million, which represents certain payments received from our
oxo-alcohol and PA operations, which previously were part of our plasticizers business. The oxo
alcohol payment was previously being amortized using the straight-line method over an eight year
life that ended on December 31, 2013, the original termination date of our Plasticizers Production
Agreement. As a result of BASFs election to terminate our Plasticizers Production Agreement,
effective December 31, 2010, the original eight year life was changed to five years and the
remaining unamortized balance of $3.6 million will be recognized in 2010. The PA payment is being
amortized using the straight-line method over the remaining life of our Plasticizers Production
Agreement of one year, and the remaining unamortized balance of $1.2 million will be recognized in
2010. In discontinued operations, as of December 31, 2009, we had a balance in deferred income of
approximately $35.4 million related to payments made to us under our exclusive styrene production
agreement with NOVA Chemicals Inc. which is being amortized using the straight-line method over the
contractual non-compete period of five years, of which approximately three years remain.
Approximately $12.4 million will be recognized in discontinued operations in 2010.
Debt Issue Costs
Debt issue costs relating to long-term debt are amortized over the term of the related debt
instrument using the straight-line method, which is materially consistent with the effective
interest method, and are included in other assets. Debt issue cost amortization, which is included
in interest and debt-related expenses, was $1.1 million and $1.3 million for the years ended
December 31, 2009 and 2008, respectively. As a result of our purchase of $25.0 million aggregate
principal amount of our 10 1/4% Senior Secured Notes due 2015, or our Secured Notes, during the
fourth quarter of 2009, we amortized $0.9 million of the debt issue costs related to our Secured
Notes (See Note 5).
Income Taxes
Deferred income taxes are provided for revenue and expenses which are recognized in different
periods for income tax and financial statement purposes. We regularly assess deferred tax assets
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 at December 31, 2009, we concluded that a valuation allowance was needed
against our deferred tax assets. As of December 31, 2009, our valuation allowance was $28.2
million, a decrease of $3.2 million from December 31, 2008. The decrease included a valuation
allowance adjustment of $1.4 million related to our state taxes and credits and $0.9 million due to
gains in other comprehensive income for adjustments to our benefits plans. As of December 31,
2009, our overall net deferred tax asset/liability balance was zero.
Environmental Costs
Environmental costs are expensed as incurred, unless the expenditures extend the economic
useful life of the related assets. Costs that extend the economic useful life of assets are
capitalized and depreciated over the
45
remaining book life of those assets. Liabilities are recorded when environmental assessments
or remedial efforts are probable and the cost can be reasonably estimated.
Preferred Stock Dividends
We record preferred stock dividends on our Preferred Stock in our consolidated statements of
operations based on the estimated fair value of dividends at each dividend accrual date. Our
Preferred Stock has a dividend rate of 4% per quarter of the liquidation value of the outstanding
shares of our Preferred Stock, and is payable in arrears in additional shares of our Preferred
Stock on the first business day of each calendar quarter. The liquidation value of each share of
our Preferred Stock is $13,793 per share, and each share of our 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 Preferred Stock in our consolidated balance sheets represents the initial fair value
at original issuance in 2002 plus the initial 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 represent the greater of the liquidation value of the shares of Preferred Stock being issued
or the fair value of the common stock into which those shares could be converted) and an option
component (which is determined using a Black-Scholes Option Pricing Model). These dividends are
subtracted from net income in our consolidated statements of operations, and added to the balance
of Redeemable Preferred Stock in our consolidated balance sheets. As we are in an accumulated
deficit position, these dividends are treated as a reduction to additional paid-in capital.
Earnings (Loss) Per Share
Basic earnings per share, or EPS, is computed using the weighted-average number of shares
outstanding during the year. Diluted EPS includes common stock equivalents, which are dilutive to
earnings per share. For the years ending December 31, 2009 and December 31, 2008, we had no
dilutive securities outstanding due to all common stock equivalents having an anti-dilutive effect
during these periods.
Disclosures about Fair Value of Financial Instruments:
In preparing disclosures about the fair value of financial instruments, we have concluded that
the carrying amount approximates fair value for cash and cash equivalents, accounts receivable,
accounts payable and certain accrued liabilities due to the short maturities of these instruments.
The fair values of long-term debt instruments are estimated based upon broker quotes for private
transactions or on the current interest rates available to us for debt with similar terms and
remaining maturities.
Accounting Estimates
The preparation of financial statements in conformity with accounting principles generally
accepted in the United States of America requires management to make estimates and assumptions that
affect the reported amounts of assets and liabilities and disclosure of contingent assets and
liabilities at the date of the financial statements and the reported amounts of revenues and
expenses during the reported periods. Significant estimates include impairment considerations,
allowance for doubtful accounts, inventory valuation, pension plan assumptions, preferred stock
dividend valuation, revenue recognition related to profit sharing accruals, environmental and
litigation reserves and provision and valuation allowance for income taxes.
2. Discontinued Operations
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
NOVAs option. In November 2007, this supply agreement, which was subsequently assigned by NOVA to
INEOS NOVA, LLC, or INEOS NOVA, received 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 from INEOS NOVA. In accordance with the terms of
46
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 were responsible for the closure costs of our styrene facility and are
also restricted from reentering the styrene business until November 2012. The restricted period of
time was initially through 2015. However, effective April 1, 2008, INEOS NOVA unilaterally reduced
the restricted period to five years.
We operated our styrene facility through early December 2007, as we completed our production
of inventory and exhausted our raw materials and purchase requirements. We sold substantially all
of our remaining inventory during the first quarter of 2008. The decommissioning process was
completed by the end of 2008. $18.9 million of the $19.6 million in costs associated with the
decommissioning were incurred in 2008. In July 2008, 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, we reduced our salaried work force by 19 people and our hourly
work force by 15 people and we recognized and paid $1.4 million of severance costs. Additionally,
as a result of the work force reduction, we recorded a curtailment loss of $1.2 million for our
benefit plans in 2008.
As a result of our styrene facility being permanently shut down, we have no significant
continued involvement in the styrene business and have, therefore, reported the operating results
of this business as discontinued operations in our condensed consolidated financial statements.
The carrying amounts of assets and liabilities related to discontinued operations as of December
31, 2009 and December 31, 2008 were as follows:
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Assets of discontinued operations: |
|
|
|
|
|
|
|
|
Accounts receivable, net |
|
$ |
24 |
|
|
$ |
166 |
|
|
|
|
|
|
|
|
|
|
Liabilities of discontinued operations:(1) |
|
|
|
|
|
|
|
|
Liabilities of discontinued operations |
|
$ |
12,384 |
|
|
$ |
12,444 |
|
Long-term liabilities of discontinued operations |
|
|
23,010 |
|
|
|
35,394 |
|
|
|
|
|
|
|
|
Total |
|
$ |
35,394 |
|
|
$ |
47,838 |
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
As of December 31, 2009, represents deferred income from the NOVA supply
agreement that is being amortized over the contractual non-compete period of five years using
the straight-line method. Accrued liabilities represents the current portion of $12.4
million, and deferred credits and other liabilities include the long-term portion of the
deferred income of $23.0 million. |
Revenues
and income (loss) before income taxes from discontinued operations for the years ended December 31, 2009
and December 31, 2008 are presented below:
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Revenues |
|
$ |
12,382 |
|
|
$ |
26,591 |
|
Income (loss) before income taxes |
|
|
11,151 |
|
|
|
(8,366 |
) |
47
3. Detail of Certain Balance Sheet Accounts
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Inventories: |
|
|
|
|
|
|
|
|
Raw materials |
|
$ |
1,276 |
|
|
$ |
1,149 |
|
Stores and supplies (net of obsolescence reserve of $1,465
and $1,380, respectively) |
|
|
3,992 |
|
|
|
4,072 |
|
|
|
|
|
|
|
|
|
|
$ |
5,268 |
|
|
$ |
5,221 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Property, plant and equipment, net: |
|
|
|
|
|
|
|
|
Land |
|
$ |
7,149 |
|
|
$ |
7,149 |
|
Buildings |
|
|
4,824 |
|
|
|
4,824 |
|
Plant and equipment |
|
|
136,418 |
|
|
|
122,563 |
|
Construction in progress |
|
|
1,894 |
|
|
|
6,448 |
|
Less: accumulated depreciation |
|
|
(82,103 |
) |
|
|
(73,173 |
) |
|
|
|
|
|
|
|
|
|
$ |
68,182 |
|
|
$ |
67,811 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other assets, net: |
|
|
|
|
|
|
|
|
Investments |
|
$ |
500 |
|
|
$ |
511 |
|
Debt issuance costs |
|
|
4,629 |
|
|
|
6,615 |
|
Other |
|
|
631 |
|
|
|
712 |
|
|
|
|
|
|
|
|
|
|
$ |
5,760 |
|
|
$ |
7,838 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accrued liabilities: |
|
|
|
|
|
|
|
|
Employee compensation and benefits |
|
$ |
11,698 |
|
|
$ |
4,885 |
|
Deferred income |
|
|
5,583 |
|
|
|
2,965 |
|
Interest payable |
|
|
3,868 |
|
|
|
4,368 |
|
Property taxes |
|
|
1,401 |
|
|
|
2,193 |
|
Advances from customers |
|
|
1,000 |
|
|
|
3,572 |
|
Other |
|
|
866 |
|
|
|
2,025 |
|
|
|
|
|
|
|
|
|
|
$ |
24,416 |
|
|
$ |
20,008 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Deferred credits and other liabilities: |
|
|
|
|
|
|
|
|
Accrued postretirement, pension and post employment benefits |
|
$ |
39,031 |
|
|
$ |
51,319 |
|
Deferred income |
|
|
|
|
|
|
5,165 |
|
Advances from customers |
|
|
|
|
|
|
1,000 |
|
Other |
|
|
2,053 |
|
|
|
1,619 |
|
|
|
|
|
|
|
|
|
|
$ |
41,084 |
|
|
$ |
59,103 |
|
|
|
|
|
|
|
|
4. Valuation and Qualifying Accounts
Below is a summary of valuation and qualifying accounts for the years ended December 31, 2009
and 2008:
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Continuing Operations |
|
|
|
|
|
|
|
|
Allowance for doubtful accounts: |
|
|
|
|
|
|
|
|
Balance at beginning of year |
|
$ |
18 |
|
|
$ |
39 |
|
Add: bad
debt expense (benefit) |
|
|
40 |
|
|
|
(5 |
) |
Deduct: written-off accounts |
|
|
|
|
|
|
(16 |
) |
|
|
|
|
|
|
|
Balance at end of year |
|
$ |
58 |
|
|
$ |
18 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reserve for inventory obsolescence: |
|
|
|
|
|
|
|
|
Balance at beginning of year |
|
$ |
1,380 |
|
|
$ |
1,472 |
|
Add: obsolescence accrual |
|
|
256 |
|
|
|
36 |
|
Deduct: disposal of inventory |
|
|
(171 |
) |
|
|
(128 |
) |
|
|
|
|
|
|
|
Balance at end of year |
|
$ |
1,465 |
|
|
$ |
1,380 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Discontinued Operations |
|
|
|
|
|
|
|
|
Allowance for doubtful accounts: |
|
|
|
|
|
|
|
|
Balance at beginning of year |
|
$ |
|
|
|
$ |
|
|
Add: bad
debt expense (benefit) |
|
|
24 |
|
|
|
|
|
Deduct: written-off accounts |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at end of year |
|
$ |
24 |
|
|
$ |
|
|
|
|
|
|
|
|
|
48
5. Long-Term Debt
On March 29, 2007, we completed a private offering of $150.0 million aggregate principal
amount of our unregistered Secured Notes pursuant to a Purchase Agreement among us, Sterling
Chemicals Energy, Inc., or Sterling Energy, one of our former wholly-owned subsidiaries, and
Jefferies & Company, Inc. and CIBC World Markets Corp., as initial purchasers. 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 May 6, 2008,
Sterling Energy was merged with and into us. Upon consummation of the merger, Sterling Energy no
longer had independent existence and, consequently, our Secured Notes are no longer guaranteed by
Sterling Energy. Pursuant to a registration rights agreement among us, Sterling Energy and the
initial purchasers, we agreed to exchange our unregistered Secured Notes for a new issue of
substantially identical debt securities registered under the Securities Act of 1933, as amended, or
the Securities Act, to cause the registration statement for the exchange offer to become effective
by December 24, 2007, and to complete the exchange offer within 50 days of the effective date of
the registration statement. On August 30, 2007, we made an initial filing of the exchange offer
registration statement. However, the registration statement was not declared effective by December
24, 2007, and, as a result, the interest rate on our Secured Notes increased by 0.25% per annum on
each of December 25, 2007, March 24, 2008 and June 22, 2008. The registration statement was
declared effective on August 13, 2008, and the exchange offer was closed on September 19, 2008. As
a result, the interest rate on our Secured Notes reverted back to the face amount of
101/4% per annum when the exchange offer closed. The additional interest
incurred from December 25, 2007 through the closing of the exchange offer was approximately $0.5
million and was paid on April 1, 2008 and October 1, 2008.
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 Secured Notes may declare our Secured Notes to be
due and payable immediately. Upon an event of default, the trustee may also take actions to
foreclose on the collateral securing our outstanding Secured Notes. 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 Secured Notes on April 1 and October 1 of each year. Our
outstanding Secured Notes, which mature on April 1, 2015, are senior secured obligations and rank
equally in right of payment with all of our existing and future senior indebtedness. Subject to
specified permitted liens, our outstanding Secured Notes are secured (i) on a first priority basis
by all of our fixed assets and certain related assets, including, without limitation, all of our
property, plant and equipment and (ii) on a second priority basis by our other assets, including,
without limitation, accounts receivable, inventory, capital stock of our domestic restricted
subsidiaries, intellectual property, deposit accounts and investment property.
In the fourth quarter of 2009, we purchased $25.0 million in aggregate principal amount of our
Secured Notes for $23.8 million in cash in the open market resulting in a $1.2 million gain. This
gain was partially offset by the amortization of a pro rata portion of the related debt issue costs
of $0.9 million. In February 2010, we repurchased an additional $2.0 million in aggregate principal
amount of our Secured Notes for $1.9 million, and in the first
quarter of 2010, we will amortize less than $0.1 million for the
pro rata portion of the related debt issue costs.
On December 19, 2002, we entered into a Revolving Credit Agreement, or our revolving credit
facility, with The CIT Group/Business Credit, Inc, or CIT as administrative agent and a lender, and
certain other lenders. Under our revolving credit facility, we and Sterling Energy were
co-borrowers and were jointly and severally liable for any indebtedness thereunder. After the
merger of Sterling Energy with and into us, Sterling Energy ceased to be a co-borrower under our
revolving credit facility. Our revolving credit facility was secured by first priority liens on all
of our accounts receivable, inventory and other specified assets. 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 $50.0 million,
make certain changes to the calculation of the
49
borrowing base and lower the interest rates and fees charged thereunder. In response to
the expected continued lower levels of accounts receivable and inventory, as well as our lesser
need for a working capital facility, we reduced our commitment under our revolving credit facility
to $25.0 million on June 30, 2008. On November 7, 2008, we further amended our revolving credit
facility to substantially reduce restrictions, subject to minimum liquidity requirements, on
investment of cash and other assets, payment of cash dividends, repurchase of debt and equity
securities, modification of preferred stock terms, entry into affiliated transactions, disposition
of assets and engagement in certain business activities. We paid the administrative agent an
amendment fee plus expenses totaling approximately $0.1 million in connection with this amendment.
On December 10, 2009, we elected to terminate our revolving
credit facility effective January 24, 2010
due to our substantial cash reserves and low working capital needs. There were no penalties or
termination fees payable by us in connection with the early termination of our revolving credit
facility. The remaining associated debt issue costs of $0.2 million will be written off as of the
effective termination date.
As of December 31, 2009, total credit available under our revolving credit facility was
limited to $7.5 million, there were no loans outstanding and we had $3.5 million in letters of
credit outstanding, resulting in borrowing availability of $4.0 million. As our revolving credit
facility included both a subjective acceleration clause and a lock-box arrangement, any balances
outstanding under our revolving credit facility would have been classified as a current portion of
long-term debt.
On January 31, 2010, we entered into a $5 million Revolving Line of Credit for letters of
credit, or our LC Facility, with JP Morgan Chase Bank, N.A. or Chase, for the issuance of
commercial and standby letters of credit. Our LC Facility will expire January 31, 2014, and
letters of credit issued under this facility bear an annual fee of 1%. On January 31, 2010, we
also entered into an Assignment of Deposit Account Agreement with Chase providing collateral for
the LC facility with a $5 million deposit account. As of February 28, 2010, there were $3.3
million in standby letters of credit issued under the LC facility.
Debt Maturities
Our Secured Notes, which had an aggregate principal balance of $125.0 million outstanding as
of December 31, 2009, are due on April 1, 2015.
6. Income Taxes
A reconciliation of federal statutory income taxes to our effective tax benefit is as follows:
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Benefit for income taxes at statutory rates |
|
$ |
(4,650 |
) |
|
$ |
(113 |
) |
Non-deductible expenses |
|
|
11 |
|
|
|
19 |
|
State income taxes |
|
|
|
|
|
|
|
|
Change in valuation allowance |
|
|
4,041 |
|
|
|
29 |
|
Limitation on tax benefit of continuing operations |
|
|
(4,650 |
) |
|
|
|
|
Other |
|
|
|
|
|
|
(6 |
) |
|
|
|
|
|
|
|
Effective tax benefit |
|
$ |
(5,248 |
) |
|
$ |
(71 |
) |
|
|
|
|
|
|
|
The income tax benefit for continuing operations and all other components is shown below:
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Tax benefit continuing operations |
|
$ |
(5,248 |
) |
|
$ |
(71 |
) |
Tax expense all other components |
|
|
4,650 |
|
|
|
|
|
|
|
|
|
|
|
|
Total tax benefit |
|
$ |
(598 |
) |
|
$ |
(71 |
) |
|
|
|
|
|
|
|
50
The income tax benefit in continuing operations is composed of the following:
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Current federal |
|
$ |
(598 |
) |
|
$ |
(71 |
) |
Deferred federal |
|
|
(4,650 |
) |
|
|
|
|
Current and deferred state |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total tax benefit |
|
$ |
(5,248 |
) |
|
$ |
(71 |
) |
|
|
|
|
|
|
|
The components of our deferred income tax assets and liabilities are summarized below:
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Deferred tax assets: |
|
|
|
|
|
|
|
|
Accrued liabilities |
|
$ |
1,985 |
|
|
$ |
1,163 |
|
Accrued postretirement cost |
|
|
1,144 |
|
|
|
1,048 |
|
Accrued pension cost |
|
|
12,145 |
|
|
|
14,096 |
|
Tax loss and credit carry forwards |
|
|
22,511 |
|
|
|
25,319 |
|
State deferred taxes |
|
|
64 |
|
|
|
185 |
|
Unearned revenue |
|
|
1,658 |
|
|
|
2,566 |
|
Other |
|
|
940 |
|
|
|
670 |
|
|
|
|
|
|
|
|
Subtotal |
|
$ |
40,447 |
|
|
$ |
45,047 |
|
|
|
|
|
|
|
|
Less: valuation allowance |
|
$ |
(28,244 |
) |
|
$ |
(31,451 |
) |
|
|
|
|
|
|
|
Total deferred tax assets |
|
$ |
12,203 |
|
|
$ |
13,596 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Deferred tax liabilities: |
|
|
|
|
|
|
|
|
Property, plant and equipment |
|
$ |
(12,203 |
) |
|
$ |
(13,596 |
) |
|
|
|
|
|
|
|
Total deferred tax liabilities |
|
$ |
(12,203 |
) |
|
$ |
(13,596 |
) |
|
|
|
|
|
|
|
Net deferred tax assets |
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
As of December 31, 2009, we had an available U.S. federal income tax net operating loss,
or NOL, of approximately $94.8 million, which expires during the years 2023 through 2029. Under
the provisions of the revised Texas Franchise Tax, our existing State of Texas net operating loss
carry-forwards, or State NOLs, were converted into state tax temporary credits. As of December 31,
2009, we had state tax temporary credits of $4.5 million and state carry-forward investment tax
credits of $0.1 million resulting in a state valuation allowance of $1.4 million. As of December
31, 2008, we had state tax temporary credits of $4.6 million and state carry-forward investment tax
credits of $0.3 million resulting in a state valuation allowance of $2.7 million. The $1.3 million
change in our state valuation allowance was due to expired or utilized state tax credits and
current year activity.
We regularly assess our deferred tax assets 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 at December 31, 2009, we
concluded that a valuation allowance was needed against our deferred tax assets for $28.2 million,
including a valuation allowance of $13.7 million for cumulative losses in other comprehensive
income due to adjustments to our benefit plans, resulting in an overall net deferred tax
asset/liability balance of zero as of December 31, 2009.
At January 1, 2008, we had a $3.7 million contingent tax liability relating to tax positions
taken in previous tax returns. We concluded that these deductions do not meet the more likely than
not recognition threshold. Our accounting policy is to recognize any accrued interest or penalties
associated with unrecognized tax benefits as a component of income tax expense. Due to significant
net operating losses incurred during the tax periods associated with our uncertain tax positions,
no amount for penalties or interest has been recorded in our financial statements.
51
We do not believe the total amount of unrecognized tax benefits will change significantly
within the next twelve months. In addition, future changes in the unrecognized tax benefit will
have no impact on the effective tax rate due to the existence of the valuation allowance. As of
December 31, 2009, there were no changes to our uncertain tax positions.
A reconciliation of the beginning and ending amount of unrecognized tax benefits is as follows
(in thousands):
|
|
|
|
|
Balance, January 1, 2008 |
|
$ |
3,685 |
|
Additions for tax positions of the current year |
|
|
|
|
Additions for tax positions of prior years |
|
|
18 |
|
Reductions for tax positions of prior years for |
|
|
|
|
Changes in judgment |
|
|
|
|
Settlements during the period |
|
|
|
|
Lapses of applicable statute of limitation |
|
|
|
|
|
|
|
|
Balance, December 31, 2008 |
|
$ |
3,703 |
|
|
|
|
|
|
|
|
|
|
Balance, January 1, 2009 |
|
$ |
3,703 |
|
Additions for tax positions of the current year |
|
|
|
|
Additions for tax positions of prior years |
|
|
|
|
Reductions for tax positions of prior years for |
|
|
|
|
Changes in judgment |
|
|
|
|
Settlements during the period |
|
|
|
|
Lapses of applicable statute of limitation |
|
|
|
|
|
|
|
|
Balance, December 31, 2009 |
|
$ |
3,703 |
|
|
|
|
|
We file income tax returns in the United States federal jurisdiction and file income and
franchise tax returns in the State of Texas. We remain subject to federal examination for tax
years ended December 31, 2003 and subsequent years, and we remain subject to examination by the
State of Texas for tax years ended December 31, 2005 and subsequent years.
7. Employee Benefits
We have established the following benefit plans:
Retirement Benefit Plans
We have non-contributory pension plans which cover our salaried and hourly wage employees who
were employed by us on or before June 1, 2004. Under our hourly plan, the benefits are based
primarily on years of service and an employees pay as of the earlier of the employees retirement
or July 1, 2007. Under our salaried plan, the benefits are based primarily on years of service and
an employees pay as of the earlier of the employees retirement or January 1, 2005. Our funding
policy is consistent with the funding requirements of federal law and regulations.
Pension plan assets are invested in a balanced portfolio managed by an outside investment
manager. Our benefits plans committee has established an investment policy detailing the plans
guidelines and investment strategies, and regularly monitors the performance of the funds and
portfolio managers. Our investment guidelines address the following items: governance, general
investment beliefs and principles, investment objectives, specific investment goals, process for
determining and maintaining the asset allocation policy, long-term asset allocation, rebalancing,
investment restrictions and prohibited transactions (the use of derivatives and the use of leverage
as types of investments are generally prohibited), portfolio manager structure and diversification
(which addresses limits on the amount of investments held by any one manager to minimize risk),
portfolio manager selection criteria, plan evaluation, portfolio manager performance review and
evaluation, and risk management (including various measures used to evaluate risk tolerance).
Pension plan assets are invested as follows:
52
|
|
|
|
|
|
|
|
|
|
|
As of December 31, |
|
|
|
2009 |
|
|
2008 |
|
Equities |
|
|
61.4 |
% |
|
|
56.0 |
% |
Bonds |
|
|
35.6 |
% |
|
|
30.0 |
% |
Other |
|
|
3.0 |
% |
|
|
14.0 |
% |
|
|
|
|
|
|
|
Total |
|
|
100.0 |
% |
|
|
100.0 |
% |
|
|
|
|
|
|
|
Our investment strategy with respect to pension assets is to invest the assets in
accordance with applicable laws and regulations. The long-term primary objectives for our pension
assets are to: (1) provide for a reasonable amount of long-term growth of capital, with prudent
exposure to risk; and protect the assets from erosion of purchasing power; (2) provide investment
results that meet or exceed the plans actuarially assumed long-term rate of return; and (3) move
to matching the duration of the liabilities and assets of the plans to reduce the potential risk of
large employer contributions being necessary in the future. The plans strive to meet these
objectives by employing a consultant to advise the benefits plans committee on plans investments,
portfolio managers to manage assets within the guidelines and strategies set forth by the benefits
plans committee. Performance of these managers is compared to applicable benchmarks.
Information concerning the pension obligation, plan assets, amounts recognized in our
financial statements and underlying actuarial assumptions is stated below:
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Change in projected benefit obligation: |
|
|
|
|
|
|
|
|
Benefit obligation at beginning of year |
|
$ |
121,167 |
|
|
$ |
123,165 |
|
Interest cost |
|
|
7,191 |
|
|
|
7,188 |
|
Actuarial loss (gain) |
|
|
4,628 |
|
|
|
(1,575 |
) |
Curtailment loss |
|
|
|
|
|
|
907 |
|
Benefits paid |
|
|
(8,731 |
) |
|
|
(8,518 |
) |
|
|
|
|
|
|
|
Benefit obligation at end of year |
|
$ |
124,255 |
|
|
$ |
121,167 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Change in plan assets: |
|
|
|
|
|
|
|
|
Fair value at beginning of year |
|
$ |
77,807 |
|
|
$ |
118,383 |
|
Actual return on plan assets |
|
|
17,483 |
|
|
|
(35,247 |
) |
Employer contributions |
|
|
213 |
|
|
|
3,189 |
|
Benefits paid |
|
|
(8,731 |
) |
|
|
(8,518 |
) |
|
|
|
|
|
|
|
Fair value at end of year |
|
|
86,772 |
|
|
|
77,807 |
|
|
|
|
|
|
|
|
Funded status |
|
$ |
(37,483 |
) |
|
$ |
(43,360 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Amounts recognized in the balance sheet consist of: |
|
|
|
|
|
|
|
|
Current liabilities |
|
$ |
(6,299 |
) |
|
$ |
(212 |
) |
Non-current liabilities |
|
|
(31,184 |
) |
|
|
(43,148 |
) |
|
|
|
|
|
|
|
Net amount recognized in financial position |
|
$ |
(37,483 |
) |
|
$ |
(43,360 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Amount recognized in accumulated other comprehensive loss consists of (pre-tax): |
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(28,022 |
) |
|
$ |
(38,098 |
) |
|
|
|
|
|
|
|
Net amount
recognized in accumulated other comprehensive loss (1) |
|
$ |
(28,022 |
) |
|
$ |
(38,098 |
) |
|
|
|
|
|
|
|
|
|
|
(1) |
|
$1.9 million of actuarial loss in accumulated other
comprehensive loss as of December 31, 2009 is expected
to be recognized as a component of net pension costs
during 2010. $10.1 million of actuarial gain was recognized in other
comprehensive income during 2009. |
53
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
Weighted-average assumptions to determine benefit obligations: |
|
|
|
|
|
|
|
|
Discount Rate |
|
|
5.75 |
% |
|
|
6.25 |
% |
Rates of increase in salary compensation level |
|
|
|
|
|
|
|
|
All plans have projected benefit obligations in excess of plan assets as of December 31,
2009. The total accumulated benefit obligation was $124.3 million and $121.2 million as of
December 31, 2009 and 2008, respectively. Contributions expected to be paid in 2010 are estimated
to be approximately $6.3 million. The expected pension expense for 2010 is $4.1million.
During the third quarter of 2008, as a result of our work force reduction announced in July
2008, and in accordance with ASC Topic 715 Compensation Retirement Benefits, or ASC Topic 715,
we recorded plan curtailment losses in discontinued operations of $0.9 million for our defined
benefit pension plans.
Net periodic pension costs (benefit) consist of the following components:
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Components of net pension costs (benefit): |
|
|
|
|
|
|
|
|
Interest on prior years projected benefit obligation |
|
|
7,191 |
|
|
|
7,188 |
|
Expected return on plan assets |
|
|
(5,613 |
) |
|
|
(8,352 |
) |
Net amortization of actuarial loss |
|
|
2,832 |
|
|
|
31 |
|
Curtailment loss |
|
|
|
|
|
|
907 |
|
|
|
|
|
|
|
|
Net pension costs (benefit) |
|
$ |
4,410 |
|
|
$ |
(226 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Changes in plan assets and benefit obligations recognized in
accumulated other comprehensive loss (pre-tax): |
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(28,022 |
) |
|
$ |
(38,098 |
) |
|
|
|
|
|
|
|
Total |
|
$ |
(28,022 |
) |
|
$ |
(38,098 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Weighted-average assumptions to determine net periodic benefit cost: |
|
|
|
|
|
|
|
|
Discount Rate |
|
|
6.25 |
% |
|
|
6.00 |
% |
Expected long-term rate of return on plan assets |
|
|
7.50 |
% |
|
|
7.50 |
% |
A discount rate is used to determine the present value of our future benefit obligations.
The discount rate for our pension plans was determined by matching the expected cash flows to a
yield curve based on long-term, high quality fixed income debt instruments available as of the
measurement date.
54
The assumption for expected long-term rate of return on plan assets for our pension plans was
developed using a long-term projection of returns for each asset class, and taking into
consideration our target asset allocation. The expected return for each asset class is a function
of passive, long-term capital market assumptions and excess returns generated from active
management. The capital market assumptions used are provided by independent investment advisors,
while excess return assumptions are supported by historical performance, fund mandates and
investment expectations. In addition, we compare the expected return on asset assumption with the
average historical rate of return these plans have been able to generate.
The fair values of our pension benefit plan assets by asset category as of December 31, 2009
are presented below (in thousands), as well as the percentage that each category comprises of our
total plan assets and the respective target allocations.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Percentage of |
|
|
Target |
|
|
|
Level 1 |
|
|
Level 2 |
|
|
Level 3 |
|
|
Total Assets |
|
|
Plan Assets |
|
|
Allocation 2010 |
|
Asset Category: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash and cash equivalents |
|
$ |
2,611 |
|
|
$ |
|
|
|
$ |
|
|
|
$ |
2,611 |
|
|
|
3 |
% |
|
|
0-10 |
% |
Mutual Funds |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
International |
|
|
13,562 |
|
|
|
|
|
|
|
|
|
|
|
13,562 |
|
|
|
16 |
% |
|
|
10-20 |
% |
Large-Cap Value |
|
|
13,966 |
|
|
|
|
|
|
|
|
|
|
|
13,966 |
|
|
|
16 |
% |
|
|
10-20 |
% |
Small-Cap Growth |
|
|
2,570 |
|
|
|
|
|
|
|
|
|
|
|
2,570 |
|
|
|
3 |
% |
|
|
0-5 |
% |
Emerging Markets |
|
|
4,444 |
|
|
|
|
|
|
|
|
|
|
|
4,444 |
|
|
|
5 |
% |
|
|
0-10 |
% |
Mid-Cap Growth |
|
|
1,818 |
|
|
|
|
|
|
|
|
|
|
|
1,818 |
|
|
|
2 |
% |
|
|
0-5 |
% |
All Cap |
|
|
11,159 |
|
|
|
|
|
|
|
|
|
|
|
11,159 |
|
|
|
13 |
% |
|
|
10-15 |
% |
Small-Cap Value |
|
|
3,536 |
|
|
|
|
|
|
|
|
|
|
|
3,536 |
|
|
|
4 |
% |
|
|
0-5 |
% |
Mid-Cap Value |
|
|
2,224 |
|
|
|
|
|
|
|
|
|
|
|
2,224 |
|
|
|
2 |
% |
|
|
0-5 |
% |
Intermediate Fixed
Income/Core |
|
|
20,738 |
|
|
|
|
|
|
|
|
|
|
|
20,738 |
|
|
|
24 |
% |
|
|
20-40 |
% |
Long Duration Fixed Income |
|
|
2,519 |
|
|
|
|
|
|
|
|
|
|
|
2,519 |
|
|
|
3 |
% |
|
|
0-15 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Mutual Funds |
|
|
76,536 |
|
|
|
|
|
|
|
|
|
|
|
76,536 |
|
|
|
88 |
% |
|
|
|
|
Guaranteed Deposit Account |
|
|
|
|
|
|
|
|
|
|
7,625 |
|
|
|
7,625 |
|
|
|
9 |
% |
|
|
0 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Plan Assets |
|
$ |
79,147 |
|
|
$ |
|
|
|
$ |
7,625 |
|
|
$ |
86,772 |
|
|
|
100 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension assets utilizing Level 1 inputs include fair values of the mutual fund securities
that were determined by closing prices for those securities traded on national stock exchanges.
The estimated fair value for the Guaranteed Deposit Account is based on unobservable inputs
that are not corroborated by observable market data and are thus classified as Level 3. This
Guaranteed Deposit Account is a group annuity product offered by our prior investment manager. In
January 2010, $7.6 million was transferred from the Guaranteed Deposit Account into mutual funds to
be managed by our new investment manager.
A reconciliation of the 2009 beginning and ending fair value balances for our Guaranteed Deposit Account is as follows:
|
|
|
|
|
|
Fair value as of December 31, 2008 |
|
|
|
$ 7,798 |
|
Transfers |
|
|
|
8,328 |
|
Disbursements |
|
|
|
(8,643 |
) |
Return on plan assets |
|
|
|
142 |
|
|
|
|
|
|
|
Fair value as of December 31, 2009 |
|
|
|
$ 7,625 |
|
|
|
|
|
|
|
The
return on plan assets refers to income from assets held as of December
31, 2009.
Postretirement Benefits Other Than Pensions
We provide certain health care benefits and life insurance benefits for retired employees.
We
accrue the cost of these benefits during the period in which the employee renders the necessary
service.
Health care benefits are currently provided to employees hired prior to June 1, 2004 who
retire from us with ten or more years of credited service. Some of our employees are eligible for
postretirement life insurance, depending on their hire date. Postretirement health care benefit
plans are contributory. Benefit provisions for most hourly employees are subject to collective
bargaining. In general, retiree health care benefits are paid as covered expenses are incurred.
During the third quarter of 2007, we approved an amendment (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, which was communicated to the
participants during the third
55
quarter of 2007, affects the majority of the participants currently enrolled in our retiree
medical plan who are enrolled in Medicare because they are 65 or over. This plan amendment reduced
our other postretirement benefit plan liability by $13.0 million with a corresponding change to
accumulated other comprehensive (loss) income.
During the third quarter of 2008, as result of our work force reduction announced in July
2008, we recorded plan curtailment losses in discontinued operations of $0.3 million for our post
retirement medical plan.
On December 8, 2003, the Medicare Prescription Drug Improvement and Modernization Act of 2003,
or the Act, was passed. The Act introduced a prescription drug benefit under Medicare (Medicare
Part D), as well as a federal subsidy to sponsors of retiree health care benefit plans that provide
a benefit that is at least actuarially equivalent to Medicare Part D. We measured the effects of
the Act on our accumulated postretirement benefit obligation and determined that, based on the
regulatory guidance currently available, benefits provided by our postretirement plan are at least
actuarially equivalent to Medicare Part D, and accordingly, we expect to be entitled to the federal
subsidy through 2010. In 2009, we received a subsidy of less than $0.1 million under the Act.
Information concerning the plan obligation, the funded status, amounts recognized in our
financial statements and underlying actuarial assumptions are stated below:
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Change in projected benefit obligation: |
|
|
|
|
|
|
|
|
Benefit obligation at beginning of year |
|
$ |
8,144 |
|
|
$ |
11,019 |
|
Service cost |
|
|
45 |
|
|
|
55 |
|
Interest cost |
|
|
484 |
|
|
|
575 |
|
Actuarial gain |
|
|
(368 |
) |
|
|
(2,518 |
) |
Curtailment loss |
|
|
|
|
|
|
290 |
|
Benefits paid |
|
|
(701 |
) |
|
|
(1,277 |
) |
|
|
|
|
|
|
|
Benefit obligation at end of year |
|
$ |
7,604 |
|
|
$ |
8,144 |
|
|
|
|
|
|
|
|
Funded status |
|
$ |
(7,604 |
) |
|
$ |
(8,144 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Amounts recognized in the balance sheet consist of: |
|
|
|
|
|
|
|
|
Current liabilities |
|
$ |
(690 |
) |
|
$ |
(789 |
) |
Non-current liabilities |
|
|
(6,914 |
) |
|
|
(7,355 |
) |
|
|
|
|
|
|
|
Net amount recognized in financial position |
|
$ |
(7,604 |
) |
|
$ |
(8,144 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Amounts recognized in accumulated other comprehensive income consists
of (pre-tax): |
|
|
|
|
|
|
|
|
Net gain |
|
$ |
760 |
|
|
$ |
391 |
|
Plan amendment/prior service costs |
|
|
20,520 |
|
|
|
22,686 |
|
|
|
|
|
|
|
|
Net amount recognized in accumulated other comprehensive income |
|
$ |
21,280 |
|
|
$ |
23,077 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
Discount rate used to determine benefit obligations |
|
|
5.25 |
% |
|
|
6.25 |
% |
Net periodic plan costs consist of the following components:
56
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Components of net plan costs: |
|
|
|
|
|
|
|
|
Service cost |
|
$ |
45 |
|
|
$ |
55 |
|
Interest cost |
|
|
484 |
|
|
|
575 |
|
Net amortization: |
|
|
|
|
|
|
|
|
Prior service costs |
|
|
(2,164 |
) |
|
|
(2,165 |
) |
|
|
|
|
|
|
|
Net plan benefit |
|
$ |
(1,635 |
) |
|
$ |
(1,535 |
) |
|
|
|
|
|
|
|
Discount rate used to determine periodic cost |
|
|
6.25 |
% |
|
|
6.00 |
% |
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Changes in benefit obligations recognized in
accumulated other comprehensive (loss)
income (pre-tax): |
|
|
|
|
|
|
|
|
Net gain |
|
$ |
368 |
|
|
$ |
2,519 |
|
Amortization of prior service cost |
|
|
(2,164 |
) |
|
|
(2,165 |
) |
|
|
|
|
|
|
|
Total |
|
$ |
(1,796 |
) |
|
$ |
354 |
|
|
|
|
|
|
|
|
The weighted-average annual assumed health care trend rate is assumed to be 9% for 2010.
The rate is assumed to decrease gradually to 4.5% by 2017 and remain level thereafter. Estimated
benefit payments for 2010 are expected to be approximately $0.7 million. The expected amortization of
amounts included in accumulated other comprehensive income as of December 31, 2009 to net benefit
income for 2010 is $2.2 million. Based on enacted plan changes, assumed health care cost trend
rates no longer have a significant effect on the amounts reported for our health care plans. A one
percentage point change in assumed health care trend rates would have the following effects:
|
|
|
|
|
|
|
|
|
|
|
1% Increase |
|
|
1% Decrease |
|
|
|
(Dollars in Thousands) |
|
Effect on total of service and interest cost components |
|
$ |
19 |
|
|
$ |
(17 |
) |
Effect on post-retirement benefit obligation |
|
|
356 |
|
|
|
(319 |
) |
Estimated Future Benefits Payable
We estimate that the future benefits payable over the next ten years under our pension and
other post-retirement benefits as of December 31, 2009 are as follows (in thousands):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other |
|
|
|
|
|
|
Pensions- |
|
|
Pensions- |
|
|
Pensions- |
|
|
Postretirement |
|
|
|
|
|
|
hourly |
|
|
salaried |
|
|
other |
|
|
Benefits |
|
|
Total |
|
2010 |
|
$ |
3,474 |
|
|
$ |
5,174 |
|
|
$ |
209 |
|
|
$ |
690 |
|
|
$ |
9,547 |
|
2011 |
|
|
3,345 |
|
|
|
5,203 |
|
|
|
203 |
|
|
|
687 |
|
|
|
9,438 |
|
2012 |
|
|
3,293 |
|
|
|
5,259 |
|
|
|
196 |
|
|
|
719 |
|
|
|
9,467 |
|
2013 |
|
|
3,294 |
|
|
|
5,219 |
|
|
|
188 |
|
|
|
735 |
|
|
|
9,436 |
|
2014 |
|
|
3,222 |
|
|
|
5,195 |
|
|
|
181 |
|
|
|
739 |
|
|
|
9,337 |
|
2015-2019 |
|
|
16,273 |
|
|
|
26,839 |
|
|
|
779 |
|
|
|
3,510 |
|
|
|
47,401 |
|
Long-term Incentive Plan
On August 7, 2009, our Board of Directors adopted our Long-Term Incentive Plan, or our LTI
Plan. Our LTI Plan provides for the issuance of performance awards to our Chief Executive Officer
and President, our Senior Vice Presidents and other key employees. The purpose of our LTI Plan is
to provide an incentive to our executive
57
officers and other designated employees to contribute to our growth and profitability, to
increase stockholder value and to retain such employees. Performance awards under our LTI Plan may
be payable in the form of cash or other property, and are payable upon the satisfaction of
pre-determined performance goals over performance periods; provided that, with some exceptions, the
recipient remains employed by us on the last day of the performance period for which such recipient
is receiving the award. We expensed $0.2 million in 2009 for the LTI Plan.
Bonus Plan and Gain Sharing Plan
In February 2002, our Board of Directors, upon recommendation of its Compensation Committee,
approved the establishment of a Bonus Plan and a Gain Sharing Plan. The Bonus Plan, which has been
amended several times since its original adoption, is designed to benefit all qualified salaried
employees, while the Gain Sharing Plan is designed to benefit all qualified hourly employees. Both
plans provide our qualified employees the opportunity to earn bonuses depending on, among other
things, our annual financial performance. We expensed $2.1 million and $1.2 million for the years
ended December 31, 2009 and 2008, respectively, in connection with payments under our Bonus Plan
and our Gain Sharing Plan.
Key Employee Protection Plan
On January 26, 2000, we instituted our Key Employee Protection Plan, which has subsequently
been amended several times. We established this plan to help us retain certain of our employees
and motivate them to continue to exert their best efforts on our behalf during periods when we may
be susceptible to a change of control, and to assure their continued dedication and objectivity
during those periods. Our Compensation Committee has designated a select group of management or
highly compensated employees as participants under our Key Employee Protection Plan, and has
established their respective applicable multipliers and other variables for determining benefits.
Our Compensation Committee is also authorized to designate additional management or highly
compensated employees as participants under our Key Employee Protection Plan and set their
applicable multipliers. Our Compensation Committee may also terminate any participants
participation under the plan with 60 days prior notice if it determines that the participant is no
longer one of our key employees.
Under our Key Employee Protection Plan, any participant under the plan that terminates his or
her employment for Good Reason or is terminated by us for any reason other than Misconduct or
Disability within his or her Protection Period is entitled to benefits under the plan. A
participants Protection Period commences 180 days prior to the date on which a specified change of
control occurs and ends either two years or 18 months after the date of that change of control,
depending on the size of the participants applicable multiplier. A participant may also be
entitled to receive payments under this plan in the absence of a change of control if he or she
terminates his or her employment for Good Reason or is terminated by us for any reason other than
Misconduct or Disability, but in these circumstances his or her applicable multiplier is
reduced by 50%. If a participant becomes entitled to benefits under our Key Employee Protection
Plan, we are required to provide the participant with a lump sum cash payment that is determined by
multiplying the participants applicable multiplier by (a) the sum of the participants highest
annual base compensation during the last three years plus (b) the participants targeted bonus for
the year of termination, and then deducting the sum of any other separation, severance or
termination payments made by us to the participant under any other plan or agreement or pursuant to
law.
In addition to the lump sum payment, the participant is entitled to receive any accrued but
unpaid compensation, compensation for unused vacation time and any unpaid vested benefits earned or
accrued under any of our benefit plans (other than qualified plans). Also, for a period of 24
months (including 18 months of COBRA coverage), the participant will continue to be covered by all
of our life, medical and dental insurance plans and programs (other than disability), as long as
the participant makes a timely COBRA election and pays the active employee premiums required under
our plans and programs and by COBRA. In addition, our obligation to continue to provide coverage
under our plans and programs to any participant ends if and when the participant becomes employed
on a full-time basis by a third party which provides the participant with substantially similar
benefits.
If any payment or distribution under our Key Employee Protection Plan to any participant is
subject to excise tax pursuant to Section 4999 of the Internal Revenue Code, the participant is
entitled to receive a gross-up payment from us in an amount such that, after payment by the
participant of all taxes on the gross-up payment, the amount of the gross-up payment remaining is
equal to the excise tax imposed under Section 4999 of the Internal Revenue Code. However, the
maximum amount of any gross-up payment is 25% of (a) the sum of the participants highest
58
annual base compensation during the last three years plus (b) the participants targeted bonus
for the year of payment.
We may terminate our Key Employee Protection Plan at any time and for any reason but any
termination does not become effective as to any participant until 90 days after we give the
participant notice of the termination of the plan. In addition, we may amend our Key Employee
Protection Plan at any time and for any reason, but any amendment that reduces, alters, suspends,
impairs or prejudices the rights or benefits of any participant in any material respect does not
become effective as to that participant until 90 days after we give him or her notice of the
amendment of the plan. No termination of our Key Employee Protection Plan, or any of these types
of amendments to the plan, can be effective with respect to any participant if the termination or
amendment is related to, in anticipation of or during the pendency of a change of control, is for
the purpose of encouraging or facilitating a change of control or is made within 180 days prior to
any change of control. Finally, no termination or amendment of our Key Employee Protection Plan
can affect the rights or benefits of any participant that are accrued under the plan at the time of
termination or amendment or that accrue thereafter on account of a change of control that occurred
prior to the termination or amendment or within 180 days after such termination or amendment. We
expensed $0.3 million and zero in 2009 and 2008, respectively, pursuant to this plan.
Severance Pay Plan
On March 8, 2001, our Board of Directors approved our Severance Pay Plan, which has
subsequently been amended. This plan covers all of our non-unionized employees and was established
to help us retain these employees by assuring them that they will receive some compensation in the
event that their employment is adversely affected in specified ways. Under our Severance Pay Plan,
any participant that terminates his or her employment for Good Reason or is terminated by us for
any reason other than Misconduct or Disability is entitled to benefits under our Severance Pay
Plan. If a participant becomes entitled to benefits under our Severance Pay Plan, we are required
to provide the participant with a lump sum cash payment in an amount equivalent to two weeks of
such participants base salary for each credited year of service, with a maximum payment of one
years base salary. However, certain salary grades are guaranteed a minimum payment of six months
base salary without consideration of credited years of service. The amount of this lump sum
payment is reduced, however, by the amount of any other separation, severance or termination
payments made by us to the participant under any other plan or agreement, including our Key
Employee Protection Plan, or pursuant to law.
In addition to the lump sum payment, for a period of six months after the participants
termination date, the COBRA premium required to be paid by such participant for coverage under our
medical and dental plans may not be increased beyond that required to be paid by active employees
for similar coverage under those plans, as long as the participant makes a timely COBRA election
and pays the active employee premiums required under those plans and otherwise continues to be
eligible for coverage under those plans.
We may terminate or amend our Severance Pay Plan at any time and for any reason but no
termination or amendment of our Severance Pay Plan can affect the rights or benefits of any
participant that are accrued under the plan at the time of termination or amendment. With respect
to continuing operations, we recorded zero expense in 2009 and 2008.
Savings and Investment Plan
Our Eighth Amended and Restated Savings and Investment Plan covers substantially all
employees, including executive officers. This plan is qualified under Section 401(k) of the
Internal Revenue Code. Each participant has the option to defer taxation of a portion of his or
her earnings by directing us to contribute a percentage of such earnings to the plan. A
participant may direct up to a maximum of 100% of eligible earnings to the plan, subject to certain
limitations set forth in the Internal Revenue Code. A participants contributions become
distributable upon the termination of his or her employment. We match 100% of employees
contributions; to the extent such contributions do not exceed 6% of such participants base
compensation (excluding bonuses, profit sharing and similar types of compensation). Our expense
under this plan was $0.9 million and $1.0 million in 2009 and 2008, respectively.
59
Employment Agreement
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. Genovas employment
as our President and Chief Executive Officer is governed by an Employment Agreement, or the
Employment Agreement, dated effective as of May 27, 2008, which was subsequently amended. The
Employment Agreement has a term of three years with automatic one-year extensions each year unless
we or he elect to stop the automatic extensions. The Employment Agreement governs Mr. Genovas
base salary, bonus, incentive plan and other employee benefits as well as severance benefits if his
employment is terminated in specified ways for specified reasons. In addition, when Mr. Genova
signed the Employment Agreement, we granted Mr. Genova options to acquire 120,000 shares of our
common stock at an exercise price of $31.60 per share. These options, which were granted under our
2002 Stock Plan, have a ten-year term and will vest and become exercisable in three equal, annual
installments, with the first installment vesting and becoming exercisable on May 27, 2009 (subject
to Mr. Genovas continued employment with us on each applicable vesting date).
8. Stock-Based Compensation
On December 19, 2002, we adopted our 2002 Stock Plan and reserved 379,747 shares of our common
stock for issuance under the plan (subject to adjustment), which has since been amended, or our
2002 Stock Plan. On December 5, 2008, the Compensation Committee of our Board adopted our Second
Amended and Restated 2002 Stock Plan and it became effective upon approval by the stockholders
during our Annual Meeting of Stockholders held on April 30, 2009. Upon approval by our
stockholders, an additional one million shares of our common stock became available for issuance
under our 2002 Stock Plan and we reserved an additional one million shares of our common stock for
this purpose. Under our 2002 Stock Plan, officers and key employees, as designated by our Board of
Directors, may be issued stock options, stock awards, stock appreciation rights or stock units.
There are currently options to purchase a total of 224,167 shares of our common stock outstanding
under our 2002 Stock Plan, with a weighted average contractual term of ten years, all at an
exercise price of $31.60, and an additional 1,139,747 shares of common stock available for issuance
under our 2002 Stock Plan. The decrease in compensation expense in 2009 is due to an increase in
our estimated forfeiture rate to 38% in 2009 compared to 5% in 2008. The increase in the estimated
forfeiture rate resulted from increased forfeitures of stock options in 2009 and resulted in a
cumulative adjustment of $0.2 million in 2009.
During the second quarter of 2008, we granted 125,000 stock options at a weighted-average
exercise price of $31.60. The fair value of each grant was estimated to be $7.25 on the date of
grant using the Black-Scholes option pricing model with the following weighted-average assumptions:
|
|
|
|
|
|
|
2008 |
|
Expected life (years) |
|
|
7.5 |
|
Expected volatility |
|
|
54.3 |
% |
Expected dividend yield |
|
|
|
|
Risk-free interest rate |
|
|
3.5 |
% |
The cost of employee services received in exchange for a stock-based award is determined
based on the grant-date fair value (with exceptions). That cost is then recognized over the period
during which the employee is required to provide services in exchange for the award (usually the
vesting period).
Any awards granted under our 2002 Stock Plan after December 31, 2005 are being expensed over
the vesting period of the award. The impact to net income and cash flows from operations for our
stock based compensation expense was $0.1 million and $0.3 million for the years ended December 31,
2009 and December 31, 2008, respectively.
A summary of our stock option activity for 2009 is presented below:
60
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted-Average |
|
|
Weighted-Average |
|
|
Aggregate |
|
|
|
|
|
|
|
Exercise |
|
|
Remaining |
|
|
Intrinsic |
|
|
|
Shares |
|
|
Price |
|
|
Contractual Term |
|
|
Value |
|
Outstanding at beginning of year |
|
|
347,500 |
|
|
$ |
31.60 |
|
|
|
|
|
|
|
|
|
Forfeited |
|
|
(123,333 |
) |
|
|
31.60 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Outstanding at end of year |
|
|
224,167 |
|
|
$ |
31.60 |
|
|
5.6 years |
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Options exercisable at end of year |
|
|
144,167 |
|
|
|
|
|
|
2.6 years |
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
A summary of our unvested stock options as of December 31, 2009, and the changes during
the year then ended is presented below:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted-Average |
|
|
|
Outstanding |
|
|
Grant-Date Fair |
|
|
|
Shares |
|
|
Value |
|
Unvested as of December 31, 2008 |
|
|
125,000 |
|
|
$ |
|
|
Vested |
|
|
(41,667 |
) |
|
|
7.25 |
|
Forfeited |
|
|
(3,333 |
) |
|
|
5.76 |
|
|
|
|
|
|
|
|
Unvested as of December 31, 2009 |
|
|
80,000 |
|
|
$ |
7.31 |
|
|
|
|
|
|
|
|
The total fair value of options that vested during the years ended December 31, 2009 and
2008 was $0.3 million and zero, respectively. As of December 31, 2009, there was $0.1 million of
total future compensation expense related to unvested options which are expected to vest. That
cost is expected to be recognized over a weighted average period of 1.4 years.
9. Commitments and Contingencies
Product Contracts:
We have long-term agreements which provide for the dedication of 100% of our production of
acetic acid and plasticizers, each to one customer. See Note 11 for more information.
Environmental Regulations:
Our operating expenditures for environmental matters, primarily waste management and
compliance, were $14.5 million and $15.9 million in 2009 and 2008, respectively. During 2009 and
2008, we spent $1.8 million and $1.1 million, respectively, for environmentally-related capital
projects and anticipate spending approximately $0.3 million for capital projects related to waste
management, incident prevention and environmental compliance during 2010.
On December 13, 2007, the Texas Commission for Environmental Quality, or the TCEQ, issued an
agreed order requiring us to remove all process wastewater from a holding pond at our Texas City
facility in order to prevent discharges during heavy rain events. In order to comply with this
agreed order, we implemented a capital project at a total cost to us of $2.8 million, which
represented the majority of our environmentally-related capital projects in 2008 and 2009.
Legal Proceedings:
On July 5, 2005, Patrick B. McCarthy, an employee of Kinder-Morgan, Inc., or Kinder-Morgan,
was seriously injured at Kinder-Morgans facilities near Cincinnati, Ohio, while attempting to
offload a railcar containing one of our plasticizers products. On October 28, 2005, Mr. McCarthy
and his family filed a suit in the Court of Common Pleas, Hamilton County, Ohio (Case No. A0509
144) against us and six other defendants. During the case, five of the other defendants were
dismissed. The plaintiffs sought in excess of $42 million in alleged compensatory and punitive
damages from the defendants in the aggregate. On May 7, 2009, the jury found that we had not been
negligent in connection with the incident and rendered a take nothing verdict in favor of the
defendants. On June 24, 2009, the plaintiffs filed a motion for judgment notwithstanding the verdict or, in the
alternative, a new trial. On September 4, 2009, the Court denied plaintiffs motion for judgment
notwithstanding the verdict, but granted
61
plaintiffs motion for a new trial. We and the other
remaining defendant timely filed notices of appeal of that order, as well as other orders issued
during the trial. We believe that all, or substantially all, of any liability imposed upon us as a
result of this suit and our related out-of-pocket costs and expenses will be covered by our
insurance policies, subject to a one million deductible, which was met in January 2008. We do not
believe that this incident will have a material adverse effect on our business, financial
condition, results of operations or cash flows, although we cannot guarantee that a material
adverse effect will not occur.
On February 21, 2007, we, several of our benefit plans and the plan administrators for those
plans were sued in a class action suit, Case No. H-07-0625 filed in the United States District
Court, Southern District of Texas, Houston Division. The plaintiffs are seeking to represent a
proposed class of retired employees of Sterling Fibers, Inc., one of our former subsidiaries that
we sold in connection with our emergence from bankruptcy in 2002. The plaintiffs are alleging that
we were not permitted to increase their premiums for retiree medical insurance based on a provision
contained in the asset purchase agreement between us and Cytec Industries Inc. and certain of its
affiliates governing our purchase of our former acrylic fibers business in 1997. During our
bankruptcy case, we specifically rejected this asset purchase agreement and the bankruptcy court
approved that rejection. The plaintiffs are claiming that we violated the terms of the benefit
plans and breached fiduciary duties governed by the Employee Retirement Income Security Act and are
seeking damages, declaratory relief, punitive damages and attorneys fees. A trial for this matter
was held during the second week of November 2009 but the court has not yet as issued a ruling. We
are vigorously defending this action and are unable to state at this time if a loss is probable or
remote and are unable to determine the possible range of loss related to this matter, if any.
On February 4, 2008, we filed a Petition for Declaratory Judgment in the 212th District Court
of Galveston County, Texas (Case No. 08CV0108) against Marathon Petroleum Company LLC, or Marathon,
in connection with a dispute between Marathon and us under a Purchase Agreement for FCC Off-Gas, or
the Off-Gas Purchase Agreement. Under the Off-Gas Purchase Agreement, we purchase an amount of
off-gas each month from Marathon within a stated range at Marathons option. Following the closure
of certain production units at our Texas City facility, our demand for off-gas has been below the
low-end of the stated range. On July 31, 2007, and again on November 19, 2007, we invoked the
undue economic hardship clause of the Off-Gas Purchase Agreement and requested that Marathon enter
into good faith negotiations to modify its terms. After Marathon disputed the applicability of the
economic hardship provision and refused to renegotiate the terms of the Off-Gas Purchase Agreement,
we filed a declaratory judgment action to enforce the terms of the economic hardship provision, and
Marathon filed a counter-claim against us for breach of contract. Marathon contended that
Sterlings failure to take the minimum contract quantities has resulted in damages in the past,
which will continue in the future through the end of the term of the Off-Gas Purchase Agreement on
April 30, 2011. On February 26, 2010, we and Marathon entered into a confidential settlement
agreement with respect to this matter. We do not believe that this matter will have a material
adverse impact on our business, financial condition, results of operations or cash flows, although
a material adverse effect could occur.
We are subject to various other claims and legal actions that arise in the ordinary course of
our business. We do not believe that any of these claims and actions, separately or in the
aggregate, will have a material adverse effect on our business, financial condition, results of
operations or cash flows, although we cannot guarantee that a material adverse effect will not
occur.
As of December 31, 2008, we had a receivable of $1.3 million due from our insurance carriers
for reimbursement of legal costs that exceeded our insurance deductibles and were, therefore,
reimbursable through our insurance carriers. For the year ended December 31, 2009, we incurred
$2.1 million of legal costs that are reimbursable under our insurance policies and received $3.3
million of payments from our insurance carriers, resulting in a receivable balance of $0.1 million
as of December 31, 2009.
10. Leasing Arrangements
Certain of our contractual arrangements with customers and suppliers qualify as leasing
arrangements. These leasing arrangements consist principally of our Acetic Acid Production
Agreement with BP Chemicals, our Plasticizers Production Agreement with BASF and a supply agreement
with Praxair related to the purchase of hydrogen and carbon monoxide. In the fourth quarter of 2009, BASF elected to terminate our
Plasticizers
62
Production Agreement, effective December 31, 2010. The Acetic Acid Production
Agreement expires in 22 years and the Praxair Agreement expires in 7 years. All of these
agreements are classified as operating leases.
The following schedule provides an analysis of the net book value of our plant, property and
equipment under the operating leases to BP Chemicals and BASF as of December 31, 2009 (in
thousands):
|
|
|
|
|
Machinery and equipment |
|
$ |
81,842 |
|
Other |
|
|
1,367 |
|
Less: accumulated depreciation |
|
|
(52,939 |
) |
|
|
|
|
|
|
$ |
30,270 |
|
|
|
|
|
The following is a schedule by year of minimum future rentals to be received for operating
leases with BP Chemicals and BASF, whose operating lease will be terminated effective December 31,
2010, as of December 31, 2009 (in thousands):
|
|
|
|
|
Year ending December 31: |
|
|
|
|
2010 |
|
$ |
8,195 |
|
2011 |
|
|
4,875 |
|
2012 |
|
|
4,875 |
|
2013 |
|
|
4,875 |
|
2014 |
|
|
4,875 |
|
Thereafter |
|
|
7,716 |
|
|
|
|
|
|
|
$ |
35,411 |
|
|
|
|
|
The following schedule shows the composition of revenue derived from the operating leases
with BP Chemicals and BASF, whose operating lease will be terminated effective December 31, 2010,
(in thousands):
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
Minimum rentals |
|
$ |
3,260 |
|
|
$ |
3,200 |
|
Contingent rentals(1) |
|
|
16,742 |
|
|
|
28,634 |
|
|
|
|
|
|
|
|
|
|
$ |
20,002 |
|
|
$ |
31,834 |
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
Contingent rentals are primarily based on profit sharing. |
The following is a schedule by year of future minimum rental payments by us required under the
operating lease with Praxair that has a remaining lease term in excess of one year as of December
31, 2009 (in thousands):
|
|
|
|
|
Year ending December 31: |
|
|
|
|
2010 |
|
$ |
7,751 |
|
2011 |
|
|
7,751 |
|
2012 |
|
|
7,751 |
|
2013 |
|
|
7,751 |
|
2014 |
|
|
7,751 |
|
Thereafter |
|
|
12,272 |
|
|
|
|
|
|
|
$ |
51,027 |
|
|
|
|
|
The following schedule shows the composition of total rental expense for the operating
lease with Praxair (in thousands):
63
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
Minimum rentals |
|
$ |
7,751 |
|
|
$ |
7,751 |
|
Contingent rentals(1) |
|
|
|
|
|
|
216 |
|
|
|
|
|
|
|
|
|
|
$ |
7,751 |
|
|
$ |
7,967 |
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
Contingent rentals are based on carbon monoxide purchases in excess of the
minimum purchase requirement. |
We have entered into various non-cancelable long-term operating leases. Specifically, future
minimum lease commitments for the lease of our corporate offices at December 31, 2009 are as
follows: 2010 $0.3 million; 2011 $0.3 million; 2012 $0.3 million; 2013 $0.2 million and thereafter
zero. Rent expense for our corporate offices was $0.3 million for each of the years ended December
31, 2009 and December 31, 2008, respectively.
11. Operating Segment and Sales Information
As of December 31, 2009, after considering the effects of discontinued operations, we have
reported our operations through two segments: acetic acid and plasticizers. The accounting
policies are the same as those described in Note 1. We use gross profit for reporting the results
of our operating segments and this measure includes all operating items related to the businesses.
There are no sales between segments. The revenues and gross profit (losses) for each of our
reportable operating segments are as follows:
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Revenues: |
|
|
|
|
|
|
|
|
Acetic acid |
|
$ |
87,270 |
|
|
$ |
129,696 |
|
Plasticizers |
|
|
26,044 |
|
|
|
31,030 |
|
Other |
|
|
1,020 |
|
|
|
949 |
|
|
|
|
|
|
|
|
Total |
|
$ |
114,334 |
|
|
$ |
161,675 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Segment gross profit (loss): |
|
|
|
|
|
|
|
|
Acetic acid |
|
$ |
5,521 |
|
|
$ |
28,135 |
|
Plasticizers |
|
|
5,878 |
|
|
|
4,133 |
|
Other(1) |
|
|
(265 |
) |
|
|
(2,122 |
) |
|
|
|
|
|
|
|
Total |
|
|
11,134 |
|
|
|
30,146 |
|
Selling, general and administrative expenses |
|
|
12,875 |
|
|
|
12,331 |
|
Impairment of long-lived assets |
|
|
|
|
|
|
7,403 |
|
Interest and debt related expenses |
|
|
15,767 |
|
|
|
17,175 |
|
Interest income |
|
|
(742 |
) |
|
|
(4,408 |
) |
Other income |
|
|
(3,481 |
) |
|
|
(2,030 |
) |
|
|
|
|
|
|
|
(Loss) income from continuing operations before income tax |
|
$ |
(13,285 |
) |
|
$ |
(325 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Depreciation and amortization expenses: |
|
|
|
|
|
|
|
|
Acetic acid |
|
$ |
7,434 |
|
|
$ |
6,209 |
|
Plasticizers |
|
|
1,306 |
|
|
|
1,724 |
|
Other(2) |
|
|
1,112 |
|
|
|
1,669 |
|
|
|
|
|
|
|
|
Total |
|
$ |
9,852 |
|
|
$ |
9,602 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Capital expenditures: |
|
|
|
|
|
|
|
|
Acetic acid |
|
$ |
5,864 |
|
|
$ |
3,467 |
|
Other plant infrastructure |
|
|
4,665 |
|
|
|
2,950 |
|
|
|
|
|
|
|
|
Total |
|
$ |
10,529 |
|
|
$ |
6,417 |
|
|
|
|
|
|
|
|
64
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Total assets: |
|
|
|
|
|
|
|
|
Acetic acid |
|
$ |
35,362 |
|
|
$ |
40,241 |
|
Plasticizers |
|
|
5,412 |
|
|
|
6,345 |
|
Other(3) |
|
|
179,391 |
|
|
|
218,656 |
|
|
|
|
|
|
|
|
Total |
|
$ |
220,165 |
|
|
$ |
265,242 |
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
Gross loss for Other includes various unallocated corporate charges and
credits. |
|
(2) |
|
Includes depreciation and amortization expenses for discontinued operations of less
than $0.1 million and $0.5 million for the periods ended December 31, 2009 and December 31,
2008, respectively. |
|
(3) |
|
Components of Other are presented in the table below: |
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Other: |
|
|
|
|
|
|
|
|
Corporate: |
|
|
|
|
|
|
|
|
Cash |
|
$ |
123,778 |
|
|
$ |
156,126 |
|
Other |
|
|
17,677 |
|
|
|
20,634 |
|
Plant infrastructure: |
|
|
|
|
|
|
|
|
Property, plant and equipment, net |
|
|
37,912 |
|
|
|
41,730 |
|
Assets of discontinued operations |
|
|
24 |
|
|
|
166 |
|
|
|
|
|
|
|
|
Total |
|
$ |
179,391 |
|
|
$ |
218,656 |
|
|
|
|
|
|
|
|
Sales to major customers constituting 10% or more of total revenues from continuing operations
were as follows (there were no export sales):
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
(Dollars in Thousands) |
|
Major customers: |
|
|
|
|
|
|
|
|
BP Chemicals |
|
$ |
87,270 |
|
|
$ |
129,696 |
|
BASF Corporation |
|
|
26,044 |
|
|
|
31,030 |
|
12. Fair Value Measurements
Fair Value of Financial Instruments
In accordance with the provisions of the Fair Value Measurements and Disclosures Topic of the
ASC, the fair value of our financial instrument has been estimated in accordance with GAAP. The
fair value of our fixed rate long-term debt is estimated based on quoted market prices or prices
quoted from third-party financial institutions. The carrying and fair values of our long-term debt
are as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2009 |
|
|
2008 |
|
|
|
Carrying Value |
|
|
Fair Value |
|
|
Carrying Value |
|
|
Fair Value |
|
10.25% senior
secured notes due
April 2015 |
|
$ |
125,000 |
|
|
$ |
119,400 |
|
|
$ |
150,000 |
|
|
$ |
132,000 |
|
The fair values of our cash equivalents, trade receivables and trade payables approximate
their carrying values due to the short-term nature of these instruments.
Nonrecurring Fair Value Measurements
65
Effective January 1, 2009, fair value measurements were applied with respect to our
nonfinancial assets and liabilities.
We measure certain non-financial assets and liabilities, including
long-lived assets, at fair value on a non-recurring basis. The fair
market value of those assets is determined using Level 3 inputs,
which requires management to make estimates about future cash flows.
Management estimates the amount and timing of future cash flows
based on its experience and knowledge of market factors.
Refer to Note 1 Long-Lived
Assets for additional discussion.
13. Capital Stock
Under our Certificate of Incorporation, we are authorized to issue 100,125,000 shares of
capital stock, consisting of 100,000,000 shares of common stock, par value $0.01 per share, and
125,000 shares of preferred stock, par value $0.01 per share. In December 2002, we made our
initial issuance of 2,825,000 shares of common stock. Subject to applicable law and the provisions
of our Certificate of Incorporation and the indenture governing our Secured Notes, dividends may be
declared on our shares of capital stock at the discretion of our Board of Directors and may be paid
in cash, in property or in shares of our capital stock. In December 2002, we also issued warrants
to purchase, in the aggregate, 949,367 shares of common stock. None of these warrants were
exercised prior to their expiration on December 19, 2008.
14. Series A Convertible Preferred Stock
Under our Certificate of Incorporation, we are authorized to issue 125,000 shares of preferred
stock, par value $0.01 per share. In December 2002, we authorized 25,000 shares and made an
initial issuance of 2,175 shares of our Preferred Stock. Each share of our Preferred Stock is
convertible at the option of the holder thereof at any time into 1,000 shares of our common stock,
subject to adjustments. Our Preferred Stock has a cumulative dividend rate of 4% per quarter of
the liquidation value of the outstanding shares of our Preferred Stock, payable in additional
shares of our Preferred Stock in arrears on the first business day of each calendar quarter. As
shares of our Preferred Stock are convertible into shares of our common stock (currently on a one
to 1,000 share basis), each dividend paid in additional shares of our Preferred Stock has a
dilutive effect on our shares of common stock. Since the initial issuance of our Preferred Stock,
we have issued an additional 4,384.050 shares of our Preferred Stock in dividends (convertible into
4,384,050 shares of our common stock).
Our Preferred Stock carries a liquidation preference of $13,793 per share, subject to
adjustments. We may redeem all or any number of our shares of Preferred Stock at any time after
December 19, 2005, at a redemption price determined in accordance with the Certificate of
Designations, Preferences, Rights and Limitations of our Preferred Stock, provided that the current
equity value of our capital stock issued in December 2002 exceeds specified levels. The holders of
our Preferred Stock may elect to have us redeem all or any of their shares of our Preferred Stock
following a specified change of control at a redemption price equal to the greater of:
|
|
|
the liquidation preference for such shares (plus accrued and unpaid dividends); |
|
|
|
|
in the event of a merger or consolidation, the fair market value of the consideration
that would have been received in such merger or consolidation in respect of the shares of
our common stock into which such shares of our Preferred Stock were convertible immediately
prior to such merger or consolidation had such shares of our Preferred Stock been converted
prior thereto; or |
|
|
|
|
in the event of some other specified change of control, the current market value of the
shares of our common stock into which such shares of our Preferred Stock were convertible
immediately prior to such change of control had such shares of our Preferred Stock been
converted prior thereto (plus accrued and unpaid dividends). |
Given that certain of the redemption features are outside of our control, our Preferred Stock
has been reflected in the consolidated balance sheet as temporary equity.
Our Preferred Stock dividends are recorded at their fair value, at each dividend accrual date.
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 shares of our Preferred Stock being issued
or the fair value of the common stock into which those shares could be converted) and an option component (which is determined using a Black-Scholes Option Pricing
Model). These
66
dividends are subtracted from net income in our consolidated statements of
operations, and added to the balance of 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: |
|
2009 |
|
|
2008 |
|
Risk-free interest rate |
|
|
2.7 |
% |
|
|
1.6 |
% |
Volatility |
|
|
72.2 |
% |
|
|
63.6 |
% |
Dividend yield |
|
|
|
|
|
|
|
|
Expected term |
|
|
5.0 |
|
|
|
5.0 |
|
Our Series A Preferred Stock is not currently redeemable or probable of redemption. If
our Series A Preferred Stock had been redeemed as of December 31, 2009, the redemption amount would
have been approximately $45.9 million. The liquidation value of the outstanding shares of our
Series A Preferred Stock as of December 31, 2009 was $90.5 million.
15. Related Party Transactions
Resurgence Asset Management, L.L.C., or Resurgence, has beneficial ownership of a substantial
majority of the voting power of our equity securities due to its investment and disposition
authority over securities owned by its and its affiliates managed funds and accounts. Currently,
Resurgence has beneficial ownership of 98.3% of our Preferred Stock and 55.3% of our common stock,
representing ownership of over 85% of the total voting power of our equity. Each share of our
Preferred Stock is convertible at the option of the holder thereof at any time into 1,000 shares of
our common stock, subject to adjustments. The holders of our Preferred Stock are entitled to
designate a number of our directors roughly proportionate to their overall equity ownership, but in
any event not less than a majority of our directors as long as they hold in the aggregate at least
35% of the total voting power of our equity. As a result, these holders have the ability to
control our management, policies and financing decisions, elect a majority of our Board and control
the vote on most matters presented to a vote of our stockholders. In addition, our shares of
Preferred Stock, almost all of which are beneficially owned by Resurgence, carry a cumulative
dividend rate of 4% per quarter, payable in additional shares of our Preferred Stock. Each
dividend paid in additional shares of our Preferred Stock has a dilutive effect on our shares of
common stock and increases the percentage of the total voting power of our equity beneficially
owned by Resurgence. Preferred Stock dividends were 952.346 shares and 814.069 shares during 2009
and 2008, respectively. Three of our directors, Messrs. Daniel Fishbane, Karl Schwarzfeld and
Philip Sivin, are currently employed by Resurgence or its affiliates. In addition, two of our
former directors, Steven L. Gidumal and Byron Haney, were employed by Resurgence during the period
they served as directors on our Board. Pursuant to established policies of Resurgence, all
director compensation earned by these directors was paid to Resurgence. During 2009 and 2008, we
paid Resurgence an aggregate amount equal to $148,000 and $201,000, respectively, related to
director compensation for Messrs. Fishbane, Gidumal, Haney, Schwarzfeld and Sivin, along with
reimbursement of an immaterial amount of direct, out-of-pocket expenses incurred in connection with
services as directors.
16. New Accounting Standards
Adoption of Accounting Standards:
In December 2007, the Financial Accounting Standards Board, or FASB, issued Accounting
Standards Codification, or ASC, Topic 805, Business Combinations, or Topic 805. Topic 805
applies to all transactions and other events in which one entity obtains control over one or more
other businesses. Topic 805 provides guidance for fair value measurement and recognition of assets
acquired, liabilities assumed and interests transferred and disclosures required as a result of a
business combination. We implemented Topic 805 effective January 1, 2009, and it had no impact on
our consolidated financial statements.
In December 2007, the FASB issued ASC Topic 810-10-65-1, Consolidation Noncontrolling
Interests in Consolidated Financial Statements; an Amendment of ARB No. 51, or Topic 810-10-65-1.
Topic 810-10-65-1 establishes the accounting and reporting standards for a noncontrolling interest
in a subsidiary and for the deconsolidation of a subsidiary, and clarifies that a noncontrolling
interest in a subsidiary is an ownership interest in the consolidated entity that should be
reported as equity in the consolidated financial statements. Topic 810-10-65-1
requires retroactive adoption of the presentation and disclosure requirements for existing
minority interests and
67
applies prospectively to business combinations for fiscal years beginning
after December 15, 2008. We implemented Topic 810-10-65-1 effective January 1, 2009, and it had no
impact on our consolidated financial statements.
In December 2007, the FASB issued ASC Topic 808, Collaborative Arrangements, or Topic 808.
Topic 808 defines collaborative arrangements and establishes reporting requirements for
transactions between participants in a collaborative arrangement and between participants in the
arrangement and third parties. Topic 808 is effective for financial statements issued for fiscal
years beginning after December 15, 2008, and interim periods within those fiscal years and applies
retrospectively to all prior periods presented for all collaborative arrangements existing as of
the effective date. We implemented Topic 808 effective June 30, 2009, and it had no impact on our
consolidated financial statements.
In March 2008, the FASB issued ASC Topic 815, Derivatives and Hedging, or Topic 815. Topic
815 requires enhanced disclosures about an entitys derivative and hedging activities to provide
users of financial statements with an enhanced understanding of how and why an entity uses
derivative instruments, how derivative instruments and related hedged items are accounted for and
how derivative instruments and related hedged items affect an entitys financial position,
financial performance and cash flows. We implemented Topic 815 effective January 1, 2009, and it
had no impact on our consolidated financial statements.
In December 2008, the FASB issued ASC Topic 715-20-50, Compensation Retirement Benefits,
or Topic 715-20-50. Topic 715-20-50 requires enhanced disclosures about the assets held by defined
benefit pension and other post-retirement plans. The enhanced disclosures required by Topic
715-20-50 are intended to provide users of financial statements with a greater understanding of:
|
|
|
how investment allocation decisions are made, including the factors that are
pertinent to an understanding of investment policies and strategies; |
|
|
|
|
the major categories of plan assets; |
|
|
|
|
the inputs and valuation techniques used to measure the fair value of plan assets; |
|
|
|
|
the effect of fair value measurements using significant unobservable inputs (Level
3) on changes in plan assets for reporting periods; and |
|
|
|
|
significant concentrations of risk within plan assets. |
Topic 715-20-50 is effective for the year ending December 31, 2009. We implemented Topic 715-20-50
for the period ending December 31, 2009, and have enhanced our disclosures to comply with Topic
715-20-50.
In April 2009, the FASB issued ASC Topic 805-20-25-18A, Business Combinations Assets and
Liabilities that Arise from Contingencies, or Topic 805-20-25-18A, which applies to all assets
acquired and all liabilities assumed in a business combination that arise from contingencies.
Topic 805-20-25-18A requires the acquirer to recognize such an asset or liability at the
acquisition date if the acquisition date fair value of that asset or liability can be determined
during the measurement period or, if it cannot be determined during the measurement period, if,
consistent with ASC Topic 450, Contingencies, information available before the end of the
measurement period indicates that it is probable that an asset existed or that a liability had been
incurred at the acquisition date and the amount of the asset or liability can be reasonably
estimated. We implemented ASC Topic 805-20-25-18A effective January 1, 2009, and it had no impact
on our consolidated financial statements.
In April 2009, the FASB issued ASC Topic 825-10-65-1, Financial Instruments Interim
Disclosures about Fair Value of Financial Instruments, or Topic 825-10-65-1. Topic 825-10-65-1
requires the disclosure of the fair value of financial instruments for interim reporting periods of
publicly traded companies as well as for their annual financial statements. Topic 825-10-65-1 is
effective for interim reporting periods ending after June 15, 2009, with early adoption permitted
for periods ending after March 15, 2009. We implemented Topic 825-10-65-1 for the period ending
June 30, 2009, and have enhanced our disclosures to comply with Topic 825-10-65-1.
68
In April 2009, the FASB issued ASC Topic 320-10-65-1, Investments Debt and Equity
Securities Recognition and Presentation of Other-Than-Temporary Impairments, or Topic
320-10-65-1, which provides new guidance on the recognition of other-than-temporary impairments of
investments in debt securities and provides new presentation and disclosure requirements for
other-than-temporary impairments of investments in debt and equity securities. Topic 320-10-65-1
became effective for our quarter ending June 30, 2009. We implemented Topic 320-10-65-1 for the
period ending June 30, 2009, and it had no impact on our consolidated financial statements.
In April 2009, the FASB issued ASC Topic 820-10-65-4, Fair Value Measurements and Disclosures
- Determining Fair Value When the Volume and Level of Activity for the Asset or Liability Have
Significantly Decreased and Identifying Transactions That Are Not Orderly, or Topic 820-10-65-4.
Topic 820-10-65-4 provides additional guidance for estimating fair value in accordance with Topic
820, Fair Value Measurements and Disclosures, when the volume and level of activity for the asset
or liability have significantly decreased. Topic 820-10-65-4 also includes guidance on identifying
circumstances that indicate a transaction is not orderly. Topic 820-10-65-4 became effective for
our quarter ending June 30, 2009. We implemented Topic 820-10-65-4 effective June 30, 2009, and it
had no impact on our consolidated financial statements.
In June 2009, the FASB issued ASC Topic 105, Generally Accepted Accounting Principles, or
Topic 105, which establishes the FASB Accounting Standards CodificationTM, or the
Codification, as the single source of authoritative U.S. GAAP recognized by the FASB to be applied
by nongovernmental entities. Rules and interpretive releases of the Securities and Exchange
Commission, or the SEC, under authority of federal securities laws are also sources of
authoritative U.S. GAAP for SEC registrants. Topic 105 and the Codification are effective for
financial statements issued for interim and annual periods ending after September 15, 2009. We
implemented Topic 105 effective September 30, 2009, and are following the guidance of Topic 105 and
the Codification in applying U.S. GAAP.
In August 2009, the FASB issued Accounting Standards Update, or ASU, No. 2009-05, an amendment
to ASC Topic 820-10, Fair Value Measurements and Disclosures Overall, or ASU No. 2009-05, which
provides guidance on the fair value measurement of liabilities. ASU 2009-05 is effective for the
first reporting period (including interim periods) beginning after its issuance, and is, therefore,
effective for us beginning with the fourth quarter of 2009. We implemented Topic 820-10 for the
period ending December 31, 2009 and it had no impact on our consolidated financial statements.
Future Adoption of Accounting Standards:
In September 2009, the FASB issued ASU No. 2009-12, an amendment to ASC Topic 820-10, Fair
Value Measurements and Disclosures Overall, or ASU No. 2009-12, to provide guidance on the fair
value measurement of investments in certain entities that calculate net asset value per share (or
its equivalent). ASU No. 2009-12 is effective for interim and annual reporting periods ending
after December 15, 2009. We do not believe the implementation of ASU 2009-12 will have a material
impact on our consolidated financial statements.
In January 2010, the FASB issued ASU No. 2010-06, an amendment to ASC Topic 820-10, Fair
Value Measurements and Disclosures (Topic 820): Improving Disclosures about Fair Value
Measurements, or ASU No. 2010-06. ASU No. 2010-06 requires some new disclosures and clarifies
some existing disclosure requirements about fair value measurement as set forth in Codification
Subtopic 820-10. The objective of ASU No. 2010-06 is to improve these disclosures and, thus,
increase the transparency in financial reporting. Specifically, ASU 2010-06 amends Codification
Subtopic 820-10 to now require:
|
|
|
a reporting entity to disclose separately the amounts of significant transfers in and
out of Level 1 and Level 2 fair value measurements and describe the reasons for the
transfers; and |
|
|
|
|
in the reconciliation for fair value measurements using significant unobservable
inputs, a reporting entity to present separately information about purchases, sales,
issuances and settlements. |
In addition, ASU 2010-06 clarifies the requirements of the following existing disclosures:
69
|
|
|
for purposes of reporting fair value measurement for each class of assets and
liabilities, a reporting entity needs to use judgment in determining the appropriate
classes of assets and liabilities; and |
|
|
|
|
a reporting entity should provide disclosures about the valuation techniques and
inputs used to measure fair value for both recurring and nonrecurring fair value
measurements. |
ASU 2010-06 is effective for interim and annual reporting periods beginning after December 15,
2009, except for the disclosures about purchases, sales, issuances and settlements in the roll
forward of activity in Level 3 fair value measurements. Those disclosures are effective for fiscal
years beginning after December 15, 2010 and for interim periods within those fiscal years. Early
application is permitted. We do not believe the implementation of ASU 2010-06 will have a material
impact on our consolidated financial statements.
Item 9. Changes in and Disagreements with Accountants on Accounting and Financial Disclosure
None.
Item 9A(T). Controls and Procedures
Evaluation of Disclosure Controls and Procedures. We maintain disclosure controls and
procedures (as defined in Rule 13a-15(e) of the Securities Exchange Act) designed to provide
reasonable assurance that the information required to be disclosed by us in the reports that we
file or submit under the Exchange Act is recorded, processed, summarized, and reported within the
time periods specified in the SECs rules and forms. These include controls and procedures
designed to ensure that this information is accumulated and communicated to our management,
including our Chief Executive Officer and our Chief Financial Officer, as appropriate to allow
timely decisions regarding required disclosure. Because of its inherent limitations, internal
control over financial reporting may not prevent or detect misstatements. Therefore, even those
systems determined to be effective can provide only reasonable assurance of achieving their control
objectives. Our management, with the participation of our Chief Executive Officer and our Chief
Financial Officer, evaluated the effectiveness of our disclosure controls and procedures as of
December 31, 2009. Based on this evaluation, our Chief Executive Officer and our Chief Financial
Officer have concluded that because of the material weakness
described below, our disclosure controls and procedures were not effective as of
December 31, 2009 at the reasonable assurance level.
Managements Annual Report on Internal Control over Financial Reporting. Our management is
responsible for establishing and maintaining adequate internal control over financial reporting (as
defined in Rule 13a-15(f) of the Exchange Act). Our internal control over financial reporting is a
process designed to provide reasonable assurance regarding the reliability of financial reporting
and the preparation of financial statements for external purposes in accordance with accounting
principles generally accepted in the United States.
Because of its inherent limitations, internal control over financial reporting may not prevent
or detect misstatements. Therefore, even those systems determined to be effective can provide only
reasonable assurance of achieving their control objectives.
Our management, with the participation of our Chief Executive Officer and our Chief Financial
Officer, evaluated the effectiveness of our internal control over financial reporting as of
December 31, 2009. In making this assessment, our management used the criteria set forth by the
Committee of Sponsoring Organizations of the Treadway Commission, or COSO, in Internal
Control-Integrated Framework. Based on this evaluation, our management, with the participation of
the our Chief Executive Officer and our Chief Financial Officer, concluded that, as of December 31,
2009, our internal control over financial reporting was not effective
due to the material weakness described below.
Our management identified a control deficiency that represents a material weakness in our
internal control over financial reporting. The material weaknesses identified by management
resulted from a lack of effective controls over
the review and approval of non-routine transactions. In particular,
the material weakness related to the review and approval of cost
allocation billing corrections. See Note 1 to the Consolidated
Financial Statements.
70
Management is in the process of identifying the remediation actions required to successfully
remediate the identified material weakness in our internal controls over financial reporting, which
will include supplementing our written policies and procedures over non-routine transactions to
formalize the review and approval process between accounting and other applicable personnel. We
anticipate that the remediation actions will be identified and implemented by the end of the second
quarter of 2010.
Notwithstanding our assessment that our internal controls over financial reporting were not
effective and that there was a material weakness as identified in this report, we believe that our
financial statements contained in this report on Form 10-K for the year ended December 31, 2009
accurately present our financial condition, results of operations and cash flows in all material
respects.
This annual report does not include an attestation report of our registered public accounting
firm regarding internal control over financial reporting. Managements report was not subject to
attestation by our registered public accounting firm pursuant to temporary rules of the SEC that
permit us to provide only managements report in this annual report.
Changes in Internal Control over Financial Reporting.
There have been no changes in our internal control over financial reporting for the quarter ended
December 31, 2009, that have materially affected, or are reasonably likely to materially affect,
our internal control over financial reporting.
71
PART III
Item 10. Directors, Executive Officers and Corporate Governance
Reference is made to the information responsive to Item 10 of this Part III contained in our
definitive proxy statement for our 2010 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 11. Executive Compensation
Reference is made to the information responsive to Item 11 of this Part III contained in our
definitive proxy statement for our 2010 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 12. Security Ownership of Certain Beneficial Owners and Management and Related Stockholder
Matters
Reference is made to the information responsive to Item 12 of this Part III contained in our
definitive proxy statement for our 2010 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 13. Certain Relationships and Related Transactions, and Director Independence
Reference is made to the information responsive to Item 13 of this Part III contained in our
definitive proxy statement for our 2010 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 14. Principal Accountant Fees and Services
Reference is made to the information responsive to Item 14 of this Part III contained in our
definitive proxy statement for our 2010 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
72
PART IV
Item 15. Exhibits and Consolidated Financial statement Schedules
|
(a) |
|
Financial Statements, Financial Statement Schedules and Exhibits. |
|
1. |
|
Consolidated Financial Statements. See Item 8. Financial Statements and
Supplementary Data Index to Financial Statements. |
|
|
2. |
|
Consolidated Financial Statement Schedules. All schedules for which provision is
made in Regulation S-X either are not required under the related instruction or are
inapplicable and, therefore, have been omitted. |
|
|
3. |
|
Exhibits. See the Exhibit Index for a list of those exhibits filed herewith,
which index also includes and identifies management contracts or compensatory plans or
arrangements required to be filed as exhibits to this Form 10-K by Item 601(b)(10)(iii)
of Regulation S-K. |
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
3.1
|
|
|
|
Second Amended and Restated Certification of Incorporation of Sterling
Chemicals, Inc. (incorporated herein by reference to Annex A to the
Companys definitive proxy statement on Schedule 14A filed on April 15,
2008). |
|
|
|
|
|
3.1(a)
|
|
|
|
Certificate of Amendment to the Second Amended and Restated Certificate of
Incorporation of Sterling Chemicals, Inc. (incorporated herein by
reference from Exhibit 3.1 to our Quarterly Report on Form 10-Q for the
quarterly period ended March 31, 2009). |
|
|
|
|
|
3.2
|
|
|
|
Restated Certificate of Designations, Preferences, Rights and Limitations
of Series A Convertible Preferred Stock of Sterling Chemicals, Inc.
(incorporated herein by reference from Exhibit 3.2 to our Annual Report on
Form 10-K for the fiscal year ended December 31, 2003). |
|
|
|
|
|
3.3
|
|
|
|
Restated Bylaws of Sterling Chemicals, Inc. (conformed copy) (incorporated
herein by reference from Exhibit 3.3 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.1
|
|
|
|
Tag Along Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc., Resurgence Asset Management, L.L.C. and the Official
Committee of the Unsecured Creditors (incorporated herein by reference
from Exhibit 8 to our Form 8-A filed on December 19, 2002 (SEC File Number
000-50132)). |
|
|
|
|
|
4.2
|
|
|
|
Indenture dated March 29, 2007 by and among Sterling Chemicals, Inc., as
Issuer, Sterling Chemicals Energy, Inc., as Guarantor, and U. S. Bank
National Association, as Trustee and Collateral Agent, governing the 101/4%
Senior Secured Notes due 2015 of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 4.2 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.3
|
|
|
|
Deed of Trust, Assignment of Leases and Rents, Security Agreement and
Fixture Filing dated March 29, 2007 made by Sterling Chemicals, Inc.,
Trustor, to Stanley Keeton, an Individual Trustee, for the benefit of U.
S. Bank National Association, as Collateral Agent, Beneficiary.
(incorporated herein by reference from Exhibit 4.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.4
|
|
|
|
Security Agreement dated as of March 29, 2007 by and among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Assignors, U. S.
Bank National Association, as |
73
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
|
|
|
|
Collateral Agent, and U. S. Bank National
Association, as Indenture Trustee for the benefit of the holders the 101/4%
Senior Secured Notes due 2015 of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 4.4 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.5
|
|
|
|
Pledge Agreement dated as of March 29, 2007 by Sterling Chemicals, Inc.
and Sterling Chemicals Energy, Inc. in favor of U. S. Bank National
Association, as Collateral Agent for the Secured Parties (incorporated
herein by reference from Exhibit 4.5 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.6
|
|
|
|
Registration Rights Agreement dated as of March 29, 2007 by and among
Sterling Chemicals, Inc., as the Company, Sterling Chemicals Energy, Inc.,
as Guarantor, and Jefferies & Company, Inc. and CIBC World Markets Corp.,
as the Initial Purchasers of the 101/4% Senior Secured Notes due 2015 of
Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit
4.6 to our Quarterly Report on Form 10-Q for the quarterly period ended
March 31, 2007). |
|
|
|
|
|
10.1
|
|
|
|
Amended and Restated Revolving Credit Agreement dated as of March 29, 2007
by and among Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc.,
as Borrowers, the various financial institutions as are or may become
parties thereto from time to time, as the Lenders, and The CIT
Group/Business Credit, Inc., as the Administrative Agent for the Lenders,
and Wachovia Bank, National Association, as Documentation Agent
(incorporated herein by reference from Exhibit 10.1 to our Quarterly
Report on Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.1(a)
|
|
|
|
First Amendment to Amended and Restated Revolving Credit Agreement dated
as of November 7, 2008 among Sterling Chemicals, Inc., The CIT
Group/Business Credit, Inc., as the Administrative Agent for the Lenders
and the Lenders (incorporated herein by reference from Exhibit 10.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended September 30,
2008). |
|
|
|
|
|
**10.1(b)
|
|
|
|
Letter dated December 10, 2009 from Sterling Chemicals Inc. electing to
terminate Amended and Restated Revolving Credit Agreement dated March 29,
2007 by and among Sterling Chemicals, Inc. and Sterling Chemicals Energy,
Inc., as Borrowers, the various financial institutions as are or may
become parties thereto from time to time, as the Lenders, and The CIT
Group/Business Credit, Inc., as the Administrative Agent for the Lenders,
and Wachovia Bank, National Association, as Documentation Agent. |
|
|
|
|
|
10.2
|
|
|
|
Amended and Restated Security Agreement dated as of March 29, 2007 made by
Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Grantors,
in favor of The CIT Group/Business Credit, Inc. as Administrative Agent
for the Secured Parties (incorporated herein by reference from Exhibit
10.2 to our Quarterly Report on
Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.3
|
|
|
|
Amended and Restated Pledge Agreement dated as of March 29, 2007 made by
Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc. as Pledgors,
in favor of The CIT Group/Business Credit, Inc., as Administrative Agent
for the Secured Parties (incorporated herein by reference from Exhibit
10.3 to our Quarterly Report on
Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.4
|
|
|
|
Intercreditor Agreement dated as of March 29, 2007 among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Borrowers, The CIT
Group/Business Credit, Inc., as First Lien Collateral Agent, and U. S.
Bank National Association, as Second Lien Collateral Agent (incorporated
herein by reference from Exhibit 10.4 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.5*
|
|
|
|
Second Amended and Restated 2002 Stock Plan (incorporated herein by
reference from Exhibit 10.1 to our Quarterly Report on Form 10-Q for the
quarterly period ended March 31, 2009). |
74
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
10.6*
|
|
|
|
Long-Term Incentive Plan (incorporated herein by reference from Exhibit
10.1 to our Quarterly Report on Form 10-Q for the quarterly period ended
June 30, 2009). |
|
|
|
|
|
**10.7
|
|
|
|
$5,000,000 Revolving Line of Credit for letters of credit from JP Morgan
Chase Bank, N.A. to Sterling Chemicals, Inc. |
|
|
|
|
|
10.8*
|
|
|
|
Fifth Amended and Restated Key Employee Protection Plan (incorporated
herein by reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q
for the quarterly period ended September 30, 2006). |
|
|
|
|
|
**10.8(a)*
|
|
|
|
First Amendment to Fifth Amended and Restated Key Employee Protection Plan. |
|
|
|
|
|
10.9*
|
|
|
|
Fourth Amended and Restated Severance Pay Plan (incorporated herein by
reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q for the
quarterly period September 30, 2009). |
|
|
|
|
|
**10.9(a)*
|
|
|
|
First Amendment to Fourth Amended and Restated Severance Pay Plan. |
|
|
|
|
|
10.10*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Salaried Employees Pension
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly
Report on Form 10-Q for the quarterly period ended September 30, 2006). |
|
|
|
|
|
10.10(a)*
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.7(a) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2006). |
|
|
|
|
|
10.10(b)*
|
|
|
|
Second Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.1 to our Quarterly Report on Form 10-Q for the quarterly period
ended September 30, 2007). |
|
|
|
|
|
10.10(c)*
|
|
|
|
Third Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.8(c) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2007). |
|
|
|
|
|
10.10(d)*
|
|
|
|
Fourth Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.8(d) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2007). |
|
|
|
|
|
10.10(e)*
|
|
|
|
415 Compliance Appendix to Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.8(e) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2008). |
|
|
|
|
|
**10.10(f)*
|
|
|
|
Sixth Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan. |
|
|
|
|
|
10.11*
|
|
|
|
Sterling Chemicals, Inc. Pension Benefit Equalization Plan (incorporated
herein by reference from Exhibit 10.10 to our Registration Statement on
Form S-1 (Registration No. 33-24020)). |
|
|
|
|
|
10.11(a)*
|
|
|
|
First Amendment to Sterling Chemicals, Inc. Pension Benefit Equalization
Plan (incorporated herein by reference from Exhibit 10.9(a) to our Annual
Report on
Form 10-K for the fiscal year ended December 31, 2004). |
|
|
|
|
|
10.12*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Supplemental Employee
Retirement Plan (incorporated herein by reference from Exhibit 10.34 to
our Annual Report on Form 10-K for the fiscal year ended September 30,
1989 (SEC File Number 1-10059)). |
75
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
10.12(a)*
|
|
|
|
First Amendment to Sterling Chemicals, Inc. Amended and Restated
Supplemental Employee Retirement Plan (incorporated herein by reference
from Exhibit 10.10(a) to our Annual Report on Form 10-K for the fiscal
year ended December 31, 2004). |
|
|
|
|
|
10.13
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Hourly Paid Employees
Pension Plan (Effective as of January 1, 2007) (incorporated herein by
reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q for the
quarterly period ended September 30, 2007). |
|
|
|
|
|
10.13(a)
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan (Effective as of January 1, 2007)
(incorporated herein by reference from Exhibit 10.11(a) to our Annual
Report on Form 10-K for the fiscal year ended December 31, 2007). |
|
|
|
|
|
10.13(b)
|
|
|
|
415 Compliance Appendix to Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan. (incorporated herein by reference
from Exhibit 10.11(b) to our Annual Report on Form 10-K for the fiscal
year ended December 31, 2008). |
|
|
|
|
|
**10.13(c)
|
|
|
|
Third Amendment to the Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan. |
|
|
|
|
|
**10.13(d)
|
|
|
|
Fourth Amendment to the Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan. |
|
|
|
|
|
**10.14*
|
|
|
|
Sterling Chemicals, Inc. Savings and Investment Plan. |
|
|
|
|
|
**10.15*
|
|
|
|
2010 Bonus Plan |
|
|
|
|
|
10.16*
|
|
|
|
2009 Bonus Plan (incorporated herein by reference from Exhibit 10.1 to our
Form 8-K filed January 15, 2009). |
|
|
|
|
|
10.17*
|
|
|
|
2008 Bonus Plan (incorporated herein by reference from Exhibit 10.2 to our
Current Report on Form 8-K filed on August 22, 2008). |
|
|
|
|
|
10.18*
|
|
|
|
Sterling Chemicals, Inc. Comprehensive Welfare Benefit Plan (incorporated
herein by reference from Exhibit 10.3 to our Quarterly Report on Form 10-Q
for the quarterly period ended September 30, 2007). |
|
|
|
|
|
10.18(a)*
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Comprehensive Welfare
Benefit Plan (incorporated herein by reference from Exhibit 10.14(a) to
our Annual Report on Form 10-K for the fiscal year ended December 31,
2008). |
|
|
|
|
|
**10.18(b)*
|
|
|
|
Second Amendment to the Sterling Chemicals, Inc. Comprehensive Welfare
Benefit Plan. |
|
|
|
|
|
10.19
|
|
|
|
Articles of Agreement between Sterling Chemicals, Inc., its successors and
assigns, and Texas City, Texas Metal Trades Council, AFL-CIO Texas City,
Texas, May 1, 2007 to May 1, 2012 (incorporated herein by reference from
Exhibit 10.5 to our Quarterly Report on Form 10-Q for the quarterly period
ended March 31, 2007). |
|
|
|
|
|
10.20*
|
|
|
|
Form of Indemnity Agreement between Sterling Chemicals, Inc. and each of
its officers and directors (incorporated herein by reference from Exhibit
10.17 to our Annual Report on Form 10-K for the fiscal year ended
September 30, 1996 (SEC File Number 333-04343-01)). |
|
|
|
|
|
+10.21
|
|
|
|
2008 Amended and Restated Production Agreement dated effective as of
January 1, 2008 between BP Amoco Chemical Company and Sterling Chemicals,
Inc. (incorporated herein by reference from Exhibit 10.1 to our Current
Report on Form 8-K filed on August 22, 2008). |
76
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
+10.22
|
|
|
|
Third Amended and Restated Plasticizers Production Agreement dated
effective as of April 1, 2008 between BASF Corporation and Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 10.1 to our
Current Report on Form 8-K filed on July 25, 2008). |
|
|
|
|
|
+10.22(a)
|
|
|
|
First Amendment to Third Amended and Restated Plasticizers Production
Agreement dated effective as of July 1, 2009 between BASF Corporation and
Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit
10.1 to our Quarterly Report on Form 10-Q for the quarterly period ended
September 30, 2009). |
|
|
|
|
|
10.23
|
|
|
|
License Agreement dated August 1, 1986 between Monsanto Company and
Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit
10.25 to our Registration Statement on Form S-1 (Registration No.
33-24020)). |
|
|
|
|
|
+10.24
|
|
|
|
Agreement for the Exclusive Supply of Styrene by and between Sterling
Chemicals, Inc. and NOVA Chemicals Inc., dated September 17, 2007
(incorporated herein by reference from Exhibit 10.20 to Amendment No. 1 to
our Form S-4 Registration Statement (Registration No. 333-145803)). |
|
|
|
|
|
10.25*
|
|
|
|
Amended and Restated Employment Agreement between Sterling Chemicals, Inc.
and John V. Genova, dated as of June 16, 2009 but retroactively effective
to May 27, 2008 (incorporated herein by reference from Exhibit 10.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended June 30,
2009). |
|
|
|
|
|
**10.25(a)*
|
|
|
|
First Amendment to Amended and Restated Employment Agreement between
Sterling Chemicals, Inc. and John V. Genova. |
|
|
|
|
|
14.1
|
|
|
|
Sterling Chemicals, Inc. Code of Ethics for the Chief Executive Officer
and Senior Financial Officers (incorporated herein by reference from
Exhibit 14.1 to our Quarterly Report on Form 10-Q for the quarterly period
ended June 30, 2003). |
|
|
|
|
|
**21.1
|
|
|
|
Subsidiaries of Sterling Chemicals, Inc. |
|
|
|
|
|
**23.1
|
|
|
|
Consent of Grant Thornton LLP |
|
|
|
|
|
**31.1
|
|
|
|
Rule 13a-14(a) Certification of the Chief Executive Officer |
|
|
|
|
|
**31.2
|
|
|
|
Rule 13a-14(a) Certification of the Principal Financial Officer |
|
|
|
|
|
**32.1
|
|
|
|
Section 1350 Certification of the Chief Executive Officer |
|
|
|
|
|
**32.2
|
|
|
|
Section 1350 Certification of the Principal Financial Officer |
|
|
|
|
|
**99.1
|
|
|
|
Amended and Restated Audit Committee Charter of Sterling Chemicals, Inc. |
|
|
|
|
|
99.2
|
|
|
|
Compensation Committee Charter of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 99.1 to our Quarterly Report on Form 10-Q
for the quarterly period ended September 30, 2006). |
|
|
|
* |
|
Management contracts or compensatory plans or arrangements. |
|
** |
|
Filed or furnished herewith. |
|
+ |
|
Portions of the exhibit have been omitted and filed separately with the Securities and
Exchange Commission pursuant to a request for confidential treatment. |
77
SIGNATURES
Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934,
the registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto
duly authorized.
|
|
|
|
|
|
STERLING CHEMICALS, INC.
(Registrant)
|
|
|
By: |
/s/ JOHN V. GENOVA
|
|
|
|
John V. Genova |
|
|
|
President, Chief Executive Officer and Director |
|
|
|
|
|
|
|
By: |
/s/ DAVID J. COLLINS
|
|
|
|
David J. Collins |
|
|
|
Senior Vice President and Chief Financial Officer
Principal Financial Officer |
|
|
Date: March 24, 2010
Pursuant to the requirements of the Securities and Exchange Act of 1934, this report has been
signed below by the following persons on behalf of the registrant and in the capacities and on the
dates indicated.
|
|
|
|
|
Signature |
|
Title |
|
Date |
|
|
|
|
|
Principal Executive Officer: |
|
|
|
|
|
|
|
|
|
/s/ JOHN V. GENOVA
John V. Genova
|
|
President, Chief Executive Officer and
Director
|
|
March 24, 2010 |
|
|
|
|
|
Principal Financial Officer: |
|
|
|
|
|
|
|
|
|
/s/ DAVID J. COLLINS
David J. Collins
|
|
Senior Vice President and Chief
Financial Officer Principal
Financial Officer
|
|
March 24, 2010 |
|
|
|
|
|
Principal Accounting Officer: |
|
|
|
|
|
|
|
|
|
/s/ CARLA E. STUCKY
Carla E. Stucky
|
|
Vice President and Corporate Controller Principal
Accounting Officer
|
|
March 24, 2010 |
|
|
|
|
|
/s/ RICHARD K. CRUMP
Richard K. Crump
|
|
Director
|
|
March 24, 2010 |
|
|
|
|
|
/s/ JOHN W. GILDEA
John W. Gildea
|
|
Director
|
|
March 24, 2010 |
|
|
|
|
|
/s/ DANIEL M. FISHBANE
Daniel M. Fishbane
|
|
Director
|
|
March 24, 2010 |
|
|
|
|
|
/s/ KARL W. SCHWARZFELD
Karl W. Schwarzfeld
|
|
Director
|
|
March 24, 2010 |
|
|
|
|
|
/s/ PHILIP M. SIVIN
Philip M. Sivin
|
|
Director
|
|
March 24, 2010 |
|
|
|
|
|
/s/ DR. PETER TING KAI WU
Dr. Peter Ting Kai Wu
|
|
Director
|
|
March 24, 2010 |
|
|
|
|
|
/s/ JOHN L. TEEGER
John L. Teeger
|
|
Director
|
|
March 24, 2010 |
78
EXHIBIT INDEX
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
3.1
|
|
|
|
Second Amended and Restated Certification of Incorporation of Sterling
Chemicals, Inc. (incorporated herein by reference to Annex A to the
Companys definitive proxy statement on Schedule 14A filed on April 15,
2008). |
|
|
|
|
|
3.1(a)
|
|
|
|
Certificate of Amendment to the Second Amended and Restated Certificate of
Incorporation of Sterling Chemicals, Inc. (incorporated herein by
reference from Exhibit 3.1 to our Quarterly Report on Form 10-Q for the
quarterly period ended March 31, 2009). |
|
|
|
|
|
3.2
|
|
|
|
Restated Certificate of Designations, Preferences, Rights and Limitations
of Series A Convertible Preferred Stock of Sterling Chemicals, Inc.
(incorporated herein by reference from Exhibit 3.2 to our Annual Report on
Form 10-K for the fiscal year ended December 31, 2003). |
|
|
|
|
|
3.3
|
|
|
|
Restated Bylaws of Sterling Chemicals, Inc. (conformed copy) (incorporated
herein by reference from Exhibit 3.3 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.1
|
|
|
|
Tag Along Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc., Resurgence Asset Management, L.L.C. and the Official
Committee of the Unsecured Creditors (incorporated herein by reference
from Exhibit 8 to our Form 8-A filed on December 19, 2002 (SEC File Number
000-50132)). |
|
|
|
|
|
4.2
|
|
|
|
Indenture dated March 29, 2007 by and among Sterling Chemicals, Inc., as
Issuer, Sterling Chemicals Energy, Inc., as Guarantor, and U. S. Bank
National Association, as Trustee and Collateral Agent, governing the 101/4%
Senior Secured Notes due 2015 of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 4.2 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.3
|
|
|
|
Deed of Trust, Assignment of Leases and Rents, Security Agreement and
Fixture Filing dated March 29, 2007 made by Sterling Chemicals, Inc.,
Trustor, to Stanley Keeton, an Individual Trustee, for the benefit of U.
S. Bank National Association, as Collateral Agent, Beneficiary.
(incorporated herein by reference from Exhibit 4.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.4
|
|
|
|
Security Agreement dated as of March 29, 2007 by and among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Assignors, U. S.
Bank National Association, as Collateral Agent, and U. S. Bank National
Association, as Indenture Trustee for the benefit of the holders the 101/4%
Senior Secured Notes due 2015 of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 4.4 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.5
|
|
|
|
Pledge Agreement dated as of March 29, 2007 by Sterling Chemicals, Inc.
and Sterling Chemicals Energy, Inc. in favor of U. S. Bank National
Association, as Collateral Agent for the Secured Parties (incorporated
herein by reference from Exhibit 4.5 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
4.6
|
|
|
|
Registration Rights Agreement dated as of March 29, 2007 by and among
Sterling Chemicals, Inc., as the Company, Sterling Chemicals Energy, Inc.,
as Guarantor, and Jefferies & Company, Inc. and CIBC World Markets Corp.,
as the Initial Purchasers of the 101/4% Senior Secured Notes due 2015 of
Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit
4.6 to our Quarterly Report on Form 10-Q for the quarterly period ended
March 31, 2007). |
79
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
10.1
|
|
|
|
Amended and Restated Revolving Credit Agreement dated as of March 29, 2007
by and among Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc.,
as Borrowers, the various financial institutions as are or may become
parties thereto from time to time, as the Lenders, and The CIT
Group/Business Credit, Inc., as the Administrative Agent for the Lenders,
and Wachovia Bank, National Association, as Documentation Agent
(incorporated herein by reference from Exhibit 10.1 to our Quarterly
Report on Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.1(a)
|
|
|
|
First Amendment to Amended and Restated Revolving Credit Agreement dated
as of November 7, 2008 among Sterling Chemicals, Inc., The CIT
Group/Business Credit, Inc., as the Administrative Agent for the Lenders
and the Lenders (incorporated herein by reference from Exhibit 10.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended September 30,
2008). |
|
|
|
|
|
**10.1(b)
|
|
|
|
Letter dated December 10, 2009 from Sterling Chemicals Inc. electing to
terminate Amended and Restated Revolving Credit Agreement dated March 29,
2007 by and among Sterling Chemicals, Inc. and Sterling Chemicals Energy,
Inc., as Borrowers, the various financial institutions as are or may
become parties thereto from time to time, as the Lenders, and The CIT
Group/Business Credit, Inc., as the Administrative Agent for the Lenders,
and Wachovia Bank, National Association, as Documentation Agent. |
|
|
|
|
|
10.2
|
|
|
|
Amended and Restated Security Agreement dated as of March 29, 2007 made by
Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Grantors,
in favor of The CIT Group/Business Credit, Inc. as Administrative Agent
for the Secured Parties (incorporated herein by reference from Exhibit
10.2 to our Quarterly Report on
Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.3
|
|
|
|
Amended and Restated Pledge Agreement dated as of March 29, 2007 made by
Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc. as Pledgors,
in favor of The CIT Group/Business Credit, Inc., as Administrative Agent
for the Secured Parties (incorporated herein by reference from Exhibit
10.3 to our Quarterly Report on
Form 10-Q for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.4
|
|
|
|
Intercreditor Agreement dated as of March 29, 2007 among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Borrowers, The CIT
Group/Business Credit, Inc., as First Lien Collateral Agent, and U. S.
Bank National Association, as Second Lien Collateral Agent (incorporated
herein by reference from Exhibit 10.4 to our Quarterly Report on Form 10-Q
for the quarterly period ended March 31, 2007). |
|
|
|
|
|
10.5*
|
|
|
|
Second Amended and Restated 2002 Stock Plan (incorporated herein by
reference from Exhibit 10.1 to our Quarterly Report on Form 10-Q for the
quarterly period ended March 31, 2009). |
|
|
|
|
|
10.6*
|
|
|
|
Long-Term Incentive Plan (incorporated herein by reference from Exhibit
10.1 to our Quarterly Report on Form 10-Q for the quarterly period ended
June 30, 2009). |
|
|
|
|
|
**10.7
|
|
|
|
$5,000,000 Revolving Line of Credit for letters of credit from JP Morgan
Chase Bank, N.A. to Sterling Chemicals, Inc. |
|
|
|
|
|
10.8*
|
|
|
|
Fifth Amended and Restated Key Employee Protection Plan (incorporated
herein by reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q
for the quarterly period ended September 30, 2006). |
|
|
|
|
|
**10.8(a)*
|
|
|
|
First Amendment to Fifth Amended and Restated Key Employee Protection Plan. |
|
|
|
|
|
10.9*
|
|
|
|
Fourth Amended and Restated Severance Pay Plan (incorporated herein by
reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q for the
quarterly period September 30, 2009). |
80
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
**10.9(a)*
|
|
|
|
First Amendment to Fourth Amended and Restated Severance Pay Plan. |
|
|
|
|
|
10.10*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Salaried Employees Pension
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly
Report on Form 10-Q for the quarterly period ended September 30, 2006). |
|
|
|
|
|
10.10(a)*
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.7(a) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2006). |
|
|
|
|
|
10.10(b)*
|
|
|
|
Second Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.1 to our Quarterly Report on Form 10-Q for the quarterly period
ended September 30, 2007). |
|
|
|
|
|
10.10(c)*
|
|
|
|
Third Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.8(c) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2007). |
|
|
|
|
|
10.10(d)*
|
|
|
|
Fourth Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.8(d) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2007). |
|
|
|
|
|
10.10(e)*
|
|
|
|
415 Compliance Appendix to Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan (incorporated herein by reference from
Exhibit 10.8(e) to our Annual Report on Form 10-K for the fiscal year
ended December 31, 2008). |
|
|
|
|
|
**10.10(f)*
|
|
|
|
Sixth Amendment to the Sterling Chemicals, Inc. Amended and Restated
Salaried Employees Pension Plan. |
|
|
|
|
|
10.11*
|
|
|
|
Sterling Chemicals, Inc. Pension Benefit Equalization Plan (incorporated
herein by reference from Exhibit 10.10 to our Registration Statement on
Form S-1 (Registration No. 33-24020)). |
|
|
|
|
|
10.11(a)*
|
|
|
|
First Amendment to Sterling Chemicals, Inc. Pension Benefit Equalization
Plan (incorporated herein by reference from Exhibit 10.9(a) to our Annual
Report on
Form 10-K for the fiscal year ended December 31, 2004). |
|
|
|
|
|
10.12*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Supplemental Employee
Retirement Plan (incorporated herein by reference from Exhibit 10.34 to
our Annual Report on Form 10-K for the fiscal year ended September 30,
1989 (SEC File Number 1-10059)). |
|
|
|
|
|
10.12(a)*
|
|
|
|
First Amendment to Sterling Chemicals, Inc. Amended and Restated
Supplemental Employee Retirement Plan (incorporated herein by reference
from Exhibit 10.10(a) to our Annual Report on Form 10-K for the fiscal
year ended December 31, 2004). |
|
|
|
|
|
10.13
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Hourly Paid Employees
Pension Plan (Effective as of January 1, 2007) (incorporated herein by
reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q for the
quarterly period ended September 30, 2007). |
|
|
|
|
|
10.13(a)
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan (Effective as of January 1, 2007)
(incorporated herein by reference from Exhibit 10.11(a) to our Annual
Report on Form 10-K for the fiscal year ended December 31, 2007). |
|
|
|
|
|
10.13(b)
|
|
|
|
415 Compliance Appendix to Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan. (incorporated herein by reference
from Exhibit 10.11(b) to our Annual Report on Form 10-K for the fiscal
year ended December 31, 2008). |
81
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
**10.13(c)
|
|
|
|
Third Amendment to the Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan. |
|
|
|
|
|
**10.13(d)
|
|
|
|
Fourth Amendment to the Sterling Chemicals, Inc. Amended and Restated
Hourly Paid Employees Pension Plan. |
|
|
|
|
|
**10.14*
|
|
|
|
Sterling Chemicals, Inc. Savings and Investment Plan. |
|
|
|
|
|
**10.15*
|
|
|
|
2010 Bonus Plan |
|
|
|
|
|
10.16*
|
|
|
|
2009 Bonus Plan (incorporated herein by reference from Exhibit 10.1 to our
Form 8-K filed January 15, 2009). |
|
|
|
|
|
10.17*
|
|
|
|
2008 Bonus Plan (incorporated herein by reference from Exhibit 10.2 to our
Current Report on Form 8-K filed on August 22, 2008). |
|
|
|
|
|
10.18*
|
|
|
|
Sterling Chemicals, Inc. Comprehensive Welfare Benefit Plan (incorporated
herein by reference from Exhibit 10.3 to our Quarterly Report on Form 10-Q
for the quarterly period ended September 30, 2007). |
|
|
|
|
|
10.18(a)*
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Comprehensive Welfare
Benefit Plan (incorporated herein by reference from Exhibit 10.14(a) to
our Annual Report on Form 10-K for the fiscal year ended December 31,
2008). |
|
|
|
|
|
**10.18(b)*
|
|
|
|
Second Amendment to the Sterling Chemicals, Inc. Comprehensive Welfare
Benefit Plan. |
|
|
|
|
|
10.19
|
|
|
|
Articles of Agreement between Sterling Chemicals, Inc., its successors and
assigns, and Texas City, Texas Metal Trades Council, AFL-CIO Texas City,
Texas, May 1, 2007 to May 1, 2012 (incorporated herein by reference from
Exhibit 10.5 to our Quarterly Report on Form 10-Q for the quarterly period
ended March 31, 2007). |
|
|
|
|
|
10.20*
|
|
|
|
Form of Indemnity Agreement between Sterling Chemicals, Inc. and each of
its officers and directors (incorporated herein by reference from Exhibit
10.17 to our Annual Report on Form 10-K for the fiscal year ended
September 30, 1996 (SEC File Number 333-04343-01)). |
|
|
|
|
|
+10.21
|
|
|
|
2008 Amended and Restated Production Agreement dated effective as of
January 1, 2008 between BP Amoco Chemical Company and Sterling Chemicals,
Inc. (incorporated herein by reference from Exhibit 10.1 to our Current
Report on Form 8-K filed on August 22, 2008). |
|
|
|
|
|
+10.22
|
|
|
|
Third Amended and Restated Plasticizers Production Agreement dated
effective as of April 1, 2008 between BASF Corporation and Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 10.1 to our
Current Report on Form 8-K filed on July 25, 2008). |
|
|
|
|
|
+10.22(a)
|
|
|
|
First Amendment to Third Amended and Restated Plasticizers Production
Agreement dated effective as of July 1, 2009 between BASF Corporation and
Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit
10.1 to our Quarterly Report on Form 10-Q for the quarterly period ended
September 30, 2009). |
|
|
|
|
|
10.23
|
|
|
|
License Agreement dated August 1, 1986 between Monsanto Company and
Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit
10.25 to our Registration Statement on Form S-1 (Registration No.
33-24020)). |
82
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
+10.24
|
|
|
|
Agreement for the Exclusive Supply of Styrene by and between Sterling
Chemicals, Inc. and NOVA Chemicals Inc., dated September 17, 2007
(incorporated herein by reference from Exhibit 10.20 to Amendment No. 1 to
our Form S-4 Registration Statement (Registration No. 333-145803)). |
|
|
|
|
|
10.25*
|
|
|
|
Amended and Restated Employment Agreement between Sterling Chemicals, Inc.
and John V. Genova, dated as of June 16, 2009 but retroactively effective
to May 27, 2008 (incorporated herein by reference from Exhibit 10.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended June 30,
2009). |
|
|
|
|
|
**10.25(a)*
|
|
|
|
First Amendment to Amended and Restated Employment Agreement between
Sterling Chemicals, Inc. and John V. Genova. |
|
|
|
|
|
14.1
|
|
|
|
Sterling Chemicals, Inc. Code of Ethics for the Chief Executive Officer
and Senior Financial Officers (incorporated herein by reference from
Exhibit 14.1 to our Quarterly Report on Form 10-Q for the quarterly period
ended June 30, 2003). |
|
|
|
|
|
**21.1
|
|
|
|
Subsidiaries of Sterling Chemicals, Inc. |
|
|
|
|
|
**23.1
|
|
|
|
Consent of Grant Thornton LLP |
|
|
|
|
|
**31.1
|
|
|
|
Rule 13a-14(a) Certification of the Chief Executive Officer |
|
|
|
|
|
**31.2
|
|
|
|
Rule 13a-14(a) Certification of the Principal Financial Officer |
|
|
|
|
|
**32.1
|
|
|
|
Section 1350 Certification of the Chief Executive Officer |
|
|
|
|
|
**32.2
|
|
|
|
Section 1350 Certification of the Principal Financial Officer |
|
|
|
|
|
**99.1
|
|
|
|
Amended and Restated Audit Committee Charter of Sterling Chemicals, Inc. |
|
|
|
|
|
99.2
|
|
|
|
Compensation Committee Charter of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 99.1 to our Quarterly Report on Form 10-Q
for the quarterly period ended September 30, 2006). |
|
|
|
* |
|
Management contracts or compensatory plans or arrangements. |
|
** |
|
Filed or furnished herewith. |
|
+ |
|
Portions of the exhibit have been omitted and filed separately with the Securities and
Exchange Commission pursuant to a request for confidential treatment. |
83