Barry Golsen
Analyst · Eric Stine with Northland Capital Markets
Thanks, Tony. Since Tony covered the financial results I am going to focus on our sales activity, product backlogs where pertinent and market drivers as we see them. I am also going to give you a special update today on activities at our Pryor facility and as a result of that this part of the conference call will be a little bit longer than it usually is.
To start, please turn to Page 9 which shows our 2012 sales mix by the markets we serve. This is approximately the same as the mix for the full year 2011. 2/3 chemical and 1/3 climate control. In our chemical business about half of our sales were nitrogen-based agricultural fertilizers and associated products. The other half was industrial and mining products. In our chemical business, approximately 79% were sales of various heating, ventilation and air conditioning products to commercial and institutional markets. The balance was the sales of geothermal heat pumps for single-family residential applications.
Focusing first on our chemical business, please turn to Page 10. Total sales in the first quarter were $124 million, up 11% over the first quarter of 2011. The largest increase was agricultural products with sales 18% higher than the 2011 level. Industrial sales were up 10% and mining sales were flat.
Turn to Page 11 for sales of our key agricultural products. During the first quarter, tons shipped of UAN were 9% lower than during the 2011 first quarter, while net sales decreased only 6% reflecting higher sales prices per ton. The decrease in tons sold was a result of the planned and unplanned plant downtime at Pryor. UAN shipments from our Cherokee facility actually increased over the first quarter of 2011. Agricultural grade ammonium nitrate, or AN, tons shipped were 22% higher than the first quarter of 2011, and sales were 36% higher, again reflecting higher sales prices. Higher shipments of ag grade ammonium nitrate were driven by more acres of wheat planted than in previous years, a push by ranchers to rebuild depleted forage inventories, better weather conditions and lower than usual starting inventories at the dealer level.
Our sales of ammonia to agricultural markets increased the most dramatically compared to 2011. This was caused by both higher sales prices per ton and more ammonia available to sell from our Pryor facility as a result of curtailed UAN production. As Tony mentioned, ammonia that would normally have been used to product to UAN was sold as fertilizer.
Turning to our industrial and mining products on Page 12. Both sales dollars and tons shipped of nitric acid were above the first quarter 2011 levels, reflecting increased demand. Tons shipped of industrial grade AN were 2% lower than in the 2011 first quarter, primarily due to lower demand for coal as a result of the relatively warm winter and subsequent high inventories of coal. As a result of the contractual arrangements we have in place for the sale of this industrial grade AN, lower sales volumes did not impact our bottom line.
On Page 13 are some price trends for both the feedstocks we use and the key ag products we sell. The cost of natural gas continues to be very low. This is benefitting production cost at our Cherokee and Pryor facilities which use natural gas as their primary feedstock. The conventional wisdom is that natural gas will remain low for some time. The cost of anhydrous ammonia, the feedstock we use at our El Dorado, Arkansas and Bay Town, Texas facilities, although slightly lower than in 2011, continues to be high compared to previous years. Our current read on the market is that ammonia is about $445 per metric ton.
High ammonia prices have increased production costs at our facilities that use ammonia as a feedstock. Most of the products we produce at Bay Town and most of the industrial and mining products produced at El Dorado are sold on a cost plus basis, so high ammonia costs don’t impact our profitability on those sales. However, ag grade ammonium nitrate also produced at El Dorado is sold at spot market prices. We have been fortunate that selling prices of ag grade AN fertilizer are also relatively high, mitigating the impact of high ammonia cost.
While we are on that subject, the chart on the lower right shows pricing for ag grade or high density ammonium nitrate. In April 2012, Southern Plains prices for AN were $445 per ton compared to $360 per ton 12 months earlier. Increased selling prices coupled with lower average ammonia feedstock cost during the first quarter resulted in higher margins on agricultural grade AN than during 2011. If you look at the chart on the lower left, you can see that the Southern Plains price of UAN was $410 per ton this April compared to $345 per ton in April of 2011. Based on current market indicators, we believe that the price is about $425 per ton. However, we are at the high point of the season and we expect prices to decline in the third quarter.
The market for UAN is currently experiencing greater supply than a year ago, but the supply has been outpaced by demand. Other U.S. manufacturers have stepped up production to take advantage of good overall market conditions. Imports had increased earlier this year but have since leveled out.
Focusing on the outlook for the chemical markets we serve, Page 14 lists several indicators for our agricultural products. All of these are favorable. Grain stock-to-use ratios, both worldwide and in the U.S. continue to be low. Planting levels are generally very high. Very high in the case of corn, which the USDA has predicted 96 million acres planted this season, a possible record. Market prices for corn and wheat remain high as well, so farmers are incentivized as to plant and sell more. All of this is creating strong continuing demand for fertilizers.
Finally, low natural gas prices have reduced the cost to manufacture UAN and ammonia at our plants that use it as feedstock. Factoring in the total cost of production, flux rate and distribution, North America is a low cost producer of nitrogen fertilizers. The industry consensus is that the positive fundamentals for the ag business should continue. In addition to general industry drivers, weather can have a significant impact on fertilizer use, demand and prices. So far, weather conditions have been better this year than they were a year ago, but it’s too early to know how the season will turn out.
Taking all these factors into consideration, we continue to be optimistic about our ag business. Please turn to Page 15. As you can see from the chart on this page, a very significant part of our business continues to be industrial and mining products. They are sold primarily to large customers and most are sold pursuant to contractual, cost plus and/or minimum take arrangements. Page 16 contains some market indicators for this area of the business. Most of these indicators forecast growth for the next few years.
Before turning to the climate control business, I would like to take a few minutes to update you on our Pryor chemical operation. Please turn to Page 17. I am going to cover 6 areas in this part of the presentation, including a quick history to bring those new to LSB up to date. An overview of the Pryor facility process flow, which will put the rest of the discussion in context, a review of the plant improvement project we undertook during the first quarter, a detailed description of the current problem with the urea reactor, which is preventing the production of UAN at this time, a description of the fix we have planned for the urea reactor, and finally update you on the status of the additional capacity we are in the process of bringing online following the receipt of permits.
So first let's talk about history. The Pryor facility was originally constructed in 1966. The previous owner made major upgrades to it in 1997 before shutting the facility down in 1999. LSB purchased the plant at a bargain price in 2001 when the previous owner became insolvent. When we bought the plant it was in a shutdown condition and we did not operate it. At that time there was an oversupply of capacity in the United States and natural gas prices were relatively high. So we kept the plant shut down until 2008. By that time, the supply-demand fundamentals for ammonia and UAN in the U.S. had completely changed and the cost of natural gas had come down.
Beginning in 2008 we repaired, staffed and restarted the plant. We achieved the same production of ammonia during the fourth quarter of 2010 followed by sustained production of UAN in the first quarter of 2011. Despite the fact that we did not operate Pryor to its full capacity throughout 2011, it was very profitable, generating an operating profit of $52 million and recouping our investment in the facility. Before we turn the page, the photos on the right hand side of this page show the entire facility, the nitric acid plant, the urea plant and the ammonia reformer. The last 2 we will discuss next.
Now on Page 18 there is a simplified process flow chart of the Pryor facility. It receives natural gas from the pipeline. The natural gas is processed in a plant which produces anhydrous ammonia, referred to as NH3 on the chart. At this point the ammonia can be sold as an end product or further upgraded. Normally, part of the ammonia is upgraded to nitric acid then to ammonia nitrate solution, which is then mixed with urea to produce urea ammonium nitrate, or UAN. Meanwhile, another part of the ammonia is further processed in a special reactor to create urea. That urea is what is blended with the ammonium nitrate solution to create the UAN.
This is a very simplified version of what happens at the Pryor plant, which also creates and uses CO2 during the process and for sale as an end product. The important thing to know about the Pryor plant is that even when the whole plant is operating as it should, it is urea limited. In other words it has the capacity to produce more ammonia than is required to mix with all of the urea it can produce to make UAN. That’s why we originally said that our production target was 325,000 tons per year of UAN plus 60,000 to 90,000 tons of additional ammonia. The extra ammonia can be sold for either industrial or agricultural uses, but at this time most of the ammonia sold from Pryor is being used as fertilizer.
Continuing on Page 18. The target production level for ammonia at the Pryor facility is 700 tons per day before an additional 60,000 tons per year we planned to add and to produce after that addition. However, due to production limitations caused by restrictions in the flow of processed gas to heat exchangers and other mechanical restriction, during 2011 the ammonia plant was unable to sustain production above 500 tons per day. Between January 3 and February 3 of 2012, a planned improvement project was performed at the Pryor facility to correct most of the restrictions and increase in anhydrous ammonia production levels.
Of course, during that 31-day period, the facility was not in production but was gradually restarted after the project was completed. The current production rate of ammonia is approximately 600 tons per day. Our plan is to eventually make other improvements at Pryor to boost ammonia production and reach our target production rate of 700 tons per day. And again this is before the additional 60,000 tons per year capacity. However, at this time we cannot predict when we will achieve that rate.
By now you can see why the urea reactor is critical for the production of UAN. Please turn to Page 19 of the diagram -- for a diagram of that reactor. The urea reactor is a large high-pressure vessel, which is approximately 63.5 feet tall with an outside diameter of about 5 feet and an inside diameter of 4 feet. Ammonia, CO2 and a substance called carbamate enter the reactor and are blended and turbulated inside the reactor at temperatures of 380 degrees Fahrenheit and a pressure of 3200 pounds per square inch. The pressure is so high that the wall of the reactor is almost 7 inches thick. The outer 6.44 inches is comprised of 4 layers of high-strength carbon steel to provide the strength to the vessel.
Because the chemical reaction inside is so corrosive, the reactor has a half-inch thick stainless steel liner. Normal operating pressures are so high in the reactor that the stainless liner actually expands like a balloon against the inner side of the structural steel wall when the plant is operating and contracts when the plant is turned off. This expansion and contraction is stressful. From time to time the stainless steel liner can leak for a number of reasons. So the reactor is equipped with leak detection ports in the carbon steel plates, commonly called weep holes, to indicate when this occurs. They are supposed to indicate the approximate location of the leak so that a visual inspection can be made to determine the exact location and ultimately repair the leak.
Of course, it’s unsafe to operate the reactor with a leak due to the extremely high temperature and pressure and the high corrosion potential of urea to carbon steel. Three weeks after the planned improvement project on the ammonia plant was completed, during a routine visual inspection, fluid was observed coming out of weep holes near the bottom of the reactor. We immediately ceased production and attempted to locate the leak. This took 3 weeks utilizing specialized contractors and inspectors to look for the leak and to make repairs.
After completing that, what we believed was a good repair, and restarting the reactor, fluid continued to emit from the weep holes, indicating that the true cause of the leak had not been found. This procedure was repeated many times and the reactor was subject to several pressure tests of different types. Several different methodologies were employed to try to determine where the leak was. But we were not able to locate the leak. Although we do not know the cause of the leak at this time, we suspect that the liner might have microscopic cracks that only open up under extreme pressure.
After many failed attempts to locate the source of the leak, on April 25 we decided to replace the entire stainless steel liner. This is a very involved project. And again, we are using outside contractors specialized in this kind of work. To begin, the entire reactor vessel must be removed from the urea plant using a 240-ton crane, which must be assembled on site. Now put this in perspective. The reactor is about 6 stories tall. It has to be lifted up by a crane, the entire 6 story tall assembly, and taken out of the plant.
After removal it’s placed horizontally in special cradles fabricated just for this purpose and then it’s opened up. Before repair, the internal components will be removed. Then the old liner will be removed. Before the new liner can be installed, the inside of the carbon steel outer wall must be reconditioned to accept the new liner. This process is very tedious and labor intensive and by itself can take up to 2 weeks depending on the condition of the inside of the outer wall.
Once the reactor is ready, the new liner will be installed in multiple pieces, which are welded together, then the reactor is pressure tested at close to operating pressures. If it passes, the internal components are returned and then the entire reactor is reinstalled in the plant, again using the crane. The entire process can take up to 6 weeks. It’s extremely unfortunate that we experienced this failure at the height of the season for UAN. However, when you are dealing with high-pressure vessels, high temperatures and corrosive materials, you cannot take any chances. Safety and soundness dictate the course of action.
On a more positive note, on May 2 we received the permit to product an additional 60,000 tons per year of ammonia at Pryor. As we discussed in earlier calls, we have already completed repairs to the additional ammonia plants that were allowed before receiving the permit. They are listed on Page 20. In the next few days we will begin trial operation and the debugging process. We expect to be in production before the end of the year. When we have achieved sustained production we will make an announcement. For clarity, we have also included a chart of Pryor’s current capacities, planned capacities after the 60,000 -- the new 60,000 tons per year is brought on line and our target capacities.
Moving on, on Page 21 we have listed our chemical business strategies and some key initiatives for 2012. We reviewed these with you on our last conference call. This page is here for you to reference or for those who were not on the last call.
Turning now to our climate control business, please go to Page 22. And you can see that sales on this page by major product categories which we report in our quarterly filings. Total sales were approximately $63 million, a decrease of about 1% compared to the first quarter of 2011. Compared to that first quarter of 2011 sales of heat pumps were down 4%, fan coils were up 6% and sales of other products were also slightly up. On Page 23, you can see the sales of products sold for use in commercial and institutional buildings were up 1% while sales of our residential products were down 9% compared to last year’s first quarter. Total bookings during the first quarter were 12% lower than the 2011 first quarter. Commercial bookings were 10% lower and bookings of residential products were off by 21%.
Our backlog of product orders at March 31, 2012 was $47.4 million, approximately 19% lower than one year earlier. However, slightly higher than the $44.5 million backlog at 12/31/11. During April, new orders were $20 million and our backlog of product orders at the end of April was approximately $47.6 million. Although our total bookings during the first quarter were slightly higher than the fourth quarter of 2011, the market continues to be soft. The commercial recovery has been slower than previously anticipated and the market for residential products has been severely impacted by the lowest level of new home construction in decades coupled with very low levels of investment in existing homes.
As a reference point, through February, U.S. shipments of residential air source heat pumps were down 24% from the same period in 2011 according to the Air-conditioning, Heating and Refrigeration Institute. Despite the current low level of orders we have maintained our leading market shares for geothermal and water source heat pumps and fan coils. I will discuss the construction outlook in a few minutes. Tony mentioned that the gross margin for the climate control business had declined. We have historically experienced lags between the time we receive material cost increases and when we have been able to pass them through to our customers.
As we said in our last conference call, the market remains extremely competitive and we are not able to predict when we will be able to increase prices to offset recent material price increases. The next few pages of the PowerPoint deal with the market outlook for construction. On Page 24 there is a graph that shows McGraw-Hill’s most recent construction market forecast report, construction forecast for certain commercial and institutional building types. These are the sectors that are the most important to us. They comprised 61% of our total climate control business sales in 2011. As you can see from the graph, these sectors are all forecasted to grow over the next few years. McGraw-Hill is forecasting that in the aggregate they will increase by approximately 3% in 2012 and 87% through 2016.
If this materializes this should benefit all of our commercial and institutional product sales. In addition to watching construction forecast by sector, we also track the Architectural Billings Index which is considered to be an indicator for non-residential construction spending, 9 to 12 months in the future. On Page 25 is a graph of the ABI. An index score of 50 indicates that the architectural billings were approximately the same as the previous month. Any score above 50 indicates growth in billings while any score below 50 indicates a decline in billings. After indicating struggling business conditions for most of 2011, the ABI finally reached positive territory for the last 5 months in a row, landing in a score of 50.4 for January 2012.
Taking all this into consideration, we believe that the general consensus of most economists and construction industry experts is that the recovery in commercial and institutional new construction is finally here, but it will be at a slower rate than previously forecasted. While new construction remains sluggish, renovation and retrofit of existing buildings has been and will continue to be an important market for us. Fortunately, all of our climate control products are well suited for this.
During 2011 and continuing into the first quarter of 2012, 21% of our climate control business sales were geothermal heat pumps used in single family residential applications. Page 26 shows McGraw-Hill’s forecast for single family residential construction starts. McGraw-Hill forecasts that housing starts will increase from about 435,000 in 2011 to 446,000 in 2012, less than a 3% increase. However, to over a million per year in 2015 and 2016. If this occurs, it should benefit our residential geothermal business.
Turning to Page 27, we have listed our climate control business strategies and some key initiatives. Again, these are repeated from our last call and I will not review them again now. However, I would like to discuss one important new product. We recently announced the launch of our new ultra-efficient Trilogy 40 geothermal series heat pumps, with energy efficiency ratios of 40 and ground [air] conditions and 60 at ground-water conditions. These are truly breakthrough products, with efficiencies that far surpass any other heating and air-conditioning product commercially available today. They also include the most advanced array of state of the art features on the market. With the introduction of the Trilogy 40 series, we continue our tradition of technological and market leadership in our climate control business.
Before opening it up for questions, I would like to mention that Tony and I will be at the BMO Farm to Market Conference in New York City on May 15. We hope to see some of you at this event. And I would like, before I turn this, open it for questions, to request that you limit yourself to 3 questions and then if you have more we can recycle through at the end. Thank you very much.