e10vq
UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Form 10-Q
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QUARTERLY REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
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For the quarterly period ended June 30, 2005 |
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OR |
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
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For the transition period
from to |
Commission File Number 000-50132
STERLING CHEMICALS, INC.
(Exact name of Registrant as specified in its charter)
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Delaware
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76-0502785 |
(State or other jurisdiction of
incorporation or organization) |
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(IRS Employer
Identification No.) |
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333 Clay Street, Suite 3600
Houston, Texas 77002-4109
(Address of principal executive offices) |
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(713) 650-3700
(Registrants telephone number,
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 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 is an accelerated
filer (as defined in Rule 12b-2 of the Exchange
Act). Yes o No þ.
APPLICABLE ONLY TO ISSUERS INVOLVED IN BANKRUPTCY PROCEEDINGS
DURING THE PRECEDING FIVE YEARS:
Indicate by check mark whether the registrant has filed all
documents and reports required to be filed by Section 12,
13 or 15(d) of the Securities Exchange Act of 1934 subsequent to
the distribution of securities under a plan confirmed by a
court. Yes þ No o.
As of July 31, 2005, Sterling Chemicals, Inc. had
2,828,474 shares of common stock outstanding.
IMPORTANT INFORMATION REGARDING THIS FORM 10-Q
Unless otherwise indicated, references to we,
us, our and ours in this
Form 10-Q refer collectively to Sterling Chemicals, Inc.
and its wholly-owned subsidiaries.
Readers should consider the following information as they review
this Form 10-Q:
Forward-Looking Statements
Certain written and oral statements made or incorporated by
reference from time to time by us or our representatives are
forward-looking statements within the meaning of
Section 27A of the Securities Act of 1933, as amended, and
Section 21E of the Securities Exchange Act of 1934, as
amended (the Exchange Act). 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 statements about the following
subjects:
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the cyclicality of the petrochemicals industry; |
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current and future industry conditions; |
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the extent and timing of expansions of production capacity of
our products, by us or by our competitors; |
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the potential effects of market and industry conditions and
cyclicality on our business strategy, results of operations or
financial position; |
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the level of expected savings from our cost reduction
initiatives; |
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the adequacy of our liquidity; |
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our environmental management programs and safety initiatives; |
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our market sensitive financial instruments; |
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future uses of and requirements for financial resources; |
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future contractual obligations; |
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future amendments or renewals of existing contractual
relationships; |
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business strategy; |
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growth opportunities; |
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competitive position; |
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expected financial position; |
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future cash flows; |
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future dividends; |
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financing plans; |
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budgets for capital and other expenditures; |
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plans and objectives of management; |
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outcomes of legal proceedings; |
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compliance with applicable laws; and |
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adequacy of insurance or indemnification. |
Such statements are based upon current information and
expectations and inherently are subject to a variety of risks
and uncertainties that could cause actual results to differ
materially from those expected or expressed in forward-looking
statements. Such risks and uncertainties include, among others,
the following:
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the timing and extent of changes in commodity prices; |
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petrochemicals industry production capacity and operating rates; |
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market conditions in the petrochemicals industry, including the
supply-demand balance for our products; |
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competition, including competitive products and pricing
pressures; |
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obsolescence of product lines; |
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the timing and extent of changes in global economic and business
conditions; |
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increases in raw materials and energy costs, including the cost
of natural gas; |
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our ability to obtain raw materials, energy and ocean-going
vessels at acceptable prices, in a timely manner and on
acceptable terms; |
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regulatory initiatives and compliance with governmental
regulations; |
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compliance with environmental laws and regulations; |
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customer preferences; |
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our ability to attract or retain high quality employees; |
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operating hazards attendant to the petrochemicals industry; |
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casualty losses; |
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changes in foreign, political, social and economic conditions; |
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risks of war, military operations, other armed hostilities,
terrorist acts and embargoes; |
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changes in technology, which could require significant capital
expenditures in order to maintain competitiveness; |
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effects of litigation; |
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cost, availability and adequacy of insurance; |
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adequacy of our sources of liquidity; and |
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various other matters, many of which are beyond our control. |
The risks included here are not exhaustive. Other sections of
this report and our other filings with the Securities and
Exchange Commission, including, without limitation, our Annual
Report on Form 10-K for the fiscal year ended
December 31, 2004 (our Annual Report), include
additional factors that could adversely affect our business,
results of operations and financial condition and performance.
See Managements Discussion and Analysis of Financial
Condition and Results of Operations Certain Known
Events, Trends, Uncertainties and Risk Factors contained
in our Annual Report. Given these risks and uncertainties,
investors should not place undue reliance on forward-looking
statements. Forward-looking statements included in this
Form 10-Q speak only as of the date of this Form 10-Q
and are not guarantees of future performance. Although we
believe that the expectations reflected in the forward-looking
statements are reasonable, such expectations may prove to have
been incorrect. All subsequent written and oral forward-looking
statements attributable to us, or persons acting on our behalf,
are expressly qualified in their entirety by these cautionary
statements.
ii
Subsequent Events
All statements contained in this Form 10-Q, including the
forward-looking statements discussed above, are made as of
August 8, 2005, unless those statements are expressly made
as of another date. We disclaim any responsibility for the
accuracy of any information contained in this Form 10-Q to
the extent such information is affected or impacted by events,
circumstances or developments occurring after August 8,
2005 or by the passage of time after such date. Except to the
extent required by applicable securities laws, we expressly
disclaim any obligation or undertaking to release publicly any
updates or revisions to any statement or information contained
in this Form 10-Q, including the forward-looking statements
discussed above, to reflect any change in our expectations with
regard thereto or any change in events, conditions or
circumstances on which any statement or information is based.
Document Summaries
Descriptions of documents and agreements contained in this
Form 10-Q 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 our Annual
Report, other periodic reports we file with the Securities and
Exchange Commission or this Form 10-Q.
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
Securities and Exchange Commission pursuant to
Section 13(a) of the Exchange Act, as well as reports filed
electronically pursuant to Section 16(a) of the Exchange
Act, may be obtained through our website
(http://www.sterlingchemicals.com). Our website provides a
hyperlink to a third-party website where these reports may be
viewed and printed at no cost as soon as reasonably practicable
after we have electronically filed such material with the
Securities and Exchange Commission. The contents of our website
are not, and shall not be deemed to be, incorporated into this
report.
iii
STERLING CHEMICALS, INC.
INDEX
3
PART I.
FINANCIAL INFORMATION
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Item 1. |
Financial Statements |
STERLING CHEMICALS, INC.
CONDENSED CONSOLIDATED STATEMENTS OF OPERATIONS
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Three Months Ended | |
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Six Months Ended | |
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June 30, | |
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June 30, | |
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2005 | |
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2004 | |
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2005 | |
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2004 | |
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(Unaudited) | |
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(Dollars in thousands, except share data) | |
Revenues
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$ |
164,193 |
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$ |
184,905 |
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$ |
379,686 |
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$ |
331,007 |
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Cost of goods sold
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185,935 |
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181,770 |
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395,094 |
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339,471 |
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Gross profit (loss)
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(21,742 |
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3,135 |
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(15,408 |
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(8,464 |
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Selling, general and administrative expenses
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773 |
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3,104 |
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3,946 |
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6,285 |
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Impairment of goodwill
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48,463 |
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48,463 |
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Equity (income) loss from joint venture
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(2,492 |
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530 |
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(5,156 |
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(1,270 |
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Other income
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(700 |
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(700 |
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Interest and debt related expenses, net of interest income
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2,515 |
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2,593 |
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5,498 |
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5,122 |
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Loss from continuing operations before income tax
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(21,838 |
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(51,555 |
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(18,996 |
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(67,064 |
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Benefit for income taxes
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(7,987 |
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(971 |
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(6,951 |
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(6,620 |
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Net loss
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$ |
(13,851 |
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$ |
(50,584 |
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$ |
(12,045 |
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$ |
(60,444 |
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Preferred stock dividends
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1,718 |
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1,468 |
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3,370 |
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2,880 |
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Net loss attributable to common stockholders
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$ |
(15,569 |
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$ |
(52,052 |
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$ |
(15,415 |
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$ |
(63,324 |
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Loss per share of common stock, basic and diluted
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$ |
(5.50 |
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$ |
(18.43 |
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$ |
(5.45 |
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$ |
(22.42 |
) |
Weighted average shares outstanding:
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Basic and diluted
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2,828,474 |
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2,825,000 |
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2,827,104 |
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2,825,000 |
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The accompanying notes are an integral part of the condensed
consolidated financial statements.
4
STERLING CHEMICALS, INC.
CONDENSED CONSOLIDATED BALANCE SHEETS
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June 30, | |
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December 31, | |
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2005 | |
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2004 | |
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(Unaudited) | |
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(Dollars in thousands, | |
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except share data) | |
ASSETS |
Current assets:
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Cash and cash equivalents
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$ |
24,970 |
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$ |
1,901 |
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Accounts receivable, net of allowance of $1,307 and $3,092,
respectively
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66,168 |
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113,074 |
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Inventories, net
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49,813 |
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87,980 |
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Prepaid expenses
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1,128 |
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4,198 |
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Deferred tax asset
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3,561 |
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4,108 |
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Total current assets
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145,640 |
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211,261 |
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Property, plant and equipment, net
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240,254 |
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248,598 |
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Other assets, net
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13,099 |
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13,694 |
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Total assets
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$ |
398,993 |
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$ |
473,553 |
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LIABILITIES AND STOCKHOLDERS EQUITY |
Current liabilities:
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Accounts payable
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$ |
37,803 |
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$ |
67,260 |
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Accrued liabilities
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20,153 |
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23,787 |
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Current portion of long-term debt
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17,684 |
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Total current liabilities
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57,956 |
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108,731 |
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Long-term debt
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100,579 |
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100,579 |
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Deferred tax liability
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20,855 |
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28,407 |
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Deferred credits and other liabilities
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70,119 |
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74,464 |
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Redeemable preferred stock
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44,658 |
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41,289 |
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Commitments and contingencies (Note 5)
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Stockholders equity:
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Common stock, $.01 par value
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28 |
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28 |
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Additional paid-in capital
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196,195 |
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199,408 |
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Accumulated deficit
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(90,431 |
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(78,387 |
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Accumulated other comprehensive loss
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(966 |
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(966 |
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Total stockholders equity
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104,826 |
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120,083 |
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Total liabilities and stockholders equity
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$ |
338,993 |
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$ |
473,553 |
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The accompanying notes are an integral part of the condensed
consolidated financial statements.
5
STERLING CHEMICALS, INC.
CONDENSED CONSOLIDATED STATEMENTS OF CASH FLOWS
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Six Months Ended | |
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June 30, | |
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2005 | |
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2004 | |
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(Unaudited) | |
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(Dollars in thousands) | |
Cash flows from operating activities:
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Net income (loss)
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$ |
(12,045 |
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$ |
(60,444 |
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Adjustments to reconcile net income (loss) to net cash used in
operating activities:
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Depreciation and amortization
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13,284 |
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14,196 |
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Impairment of goodwill
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48,463 |
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Interest amortization
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200 |
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199 |
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Lower-of-cost-or-market adjustment
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215 |
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2,739 |
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Other inventory write-downs
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1,258 |
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Gain on sale of joint venture
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(700 |
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Deferred tax benefit
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(7,005 |
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(6,887 |
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Other
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156 |
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Change in assets/liabilities:
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Accounts receivable
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46,906 |
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12,145 |
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Inventories
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36,694 |
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(12,112 |
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Prepaid expenses
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3,070 |
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3,479 |
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Other assets
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(1,031 |
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(3,393 |
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Accounts payable
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(29,456 |
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(14,521 |
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Accrued liabilities
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(3,217 |
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(1,983 |
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Other liabilities
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(4,345 |
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(269 |
) |
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Net cash provided by (used in) operating activities
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43,984 |
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(18,388 |
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Cash flows used in investing activities:
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Capital expenditures
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(3,514 |
) |
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(6,093 |
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Cash provided by sale of joint venture
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700 |
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Cash used for methanol dismantling
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(417 |
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Net cash used in investing activities
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(3,231 |
) |
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(6,093 |
) |
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Cash flows from financing activities:
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Net repayments on the Revolver
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(17,684 |
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Net decrease in cash and cash equivalents
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23,069 |
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(24,481 |
) |
Cash and cash equivalents beginning of year
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1,901 |
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42,384 |
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Cash and cash equivalents end of period
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$ |
24,970 |
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$ |
17,903 |
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Supplemental disclosures of cash flow information:
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Net interest paid
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$ |
5,903 |
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$ |
5,187 |
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Cash paid for income taxes
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|
55 |
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The accompanying notes are an integral part of the condensed
consolidated financial statements.
6
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS
(Unaudited)
In our opinion, the accompanying unaudited condensed
consolidated financial statements reflect all adjustments
necessary to present fairly our consolidated financial position
and consolidated results of operations for the applicable three
and six-month periods ended June 30, 2005 and 2004 and cash
flows for the six-month periods ended June 30, 2005 and
2004. All such adjustments are of a normal and recurring nature.
The results of operations and cash flows for the periods
presented are not necessarily indicative of the results to be
expected for the full year.
The accompanying unaudited condensed consolidated financial
statements should be, and are assumed to have been, read in
conjunction with the consolidated financial statements and notes
included in our Annual Report on Form 10-K for the fiscal
year ended December 31, 2004 (our Annual
Report). The accompanying condensed consolidated balance
sheet as of December 31, 2004 has been derived from the
audited consolidated balance sheet as of December 31, 2004
included in our Annual Report. The accompanying condensed
consolidated financial statements as of June 30, 2005 and
for the three and six-month periods ended June 30, 2005 and
2004, have been reviewed by Deloitte & Touche LLP, our
independent registered public accounting firm, whose report is
included herein.
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2. |
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). 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 278,500 shares of our common stock
outstanding under our 2002 Stock Plan, all at an exercise price
of $31.60.
We account for our stock-based compensation arrangements using
the intrinsic value method in accordance with the provisions of
Accounting Principles Board Opinion No. 25,
Accounting for Stock Issued to Employees (APB
No. 25), and related interpretations. Under APB
No. 25, if the exercise price of employee stock options
equals or exceeds the market price of the underlying stock on
the date of grant, no compensation expense is recognized. All
stock options issued under our 2002 Stock Plan were granted with
exercise prices at estimated fair value at the time of grant.
Therefore, no compensation expense was recognized under APB
No. 25. During March 2005, two individuals exercised 15,833
options and received 3,474 shares of stock through a
cashless exercise. The cashless exercises required variable
accounting and resulted in compensation expense of
$0.2 million during the first quarter of 2005.
7
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The following table illustrates the effect on our net income
(loss) and income (loss) per share attributable to common
stockholders if compensation costs for stock options issued
under our 2002 Stock Plan had been recorded pursuant to
Statement of Financial Accounting Standards (SFAS)
No. 123, Accounting for Stock-Based
Compensation, for the three and six-months ended
June 30, 2005 and 2004.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Three Months Ended | |
|
Six Months Ended | |
|
|
June 30, | |
|
June 30, | |
|
|
| |
|
| |
|
|
2005 | |
|
2004 | |
|
2005 | |
|
2004 | |
|
|
| |
|
| |
|
| |
|
| |
|
|
(Dollars in thousands, except share data) | |
Net loss attributable to common stockholders, as reported
|
|
$ |
(15,569 |
) |
|
$ |
(52,052 |
) |
|
$ |
(15,415 |
) |
|
$ |
(63,324 |
) |
Add: Stock-based employee compensation expense included in
reported net loss, net of related tax effects
|
|
|
|
|
|
|
|
|
|
|
128 |
|
|
|
|
|
Deduct: Total stock-based employee compensation expense
determined under fair value based method for all awards, net of
related tax effects
|
|
|
110 |
|
|
|
270 |
|
|
|
240 |
|
|
|
702 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pro forma net loss
|
|
$ |
(15,679 |
) |
|
$ |
(52,322 |
) |
|
$ |
(15,527 |
) |
|
$ |
(64,026 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss per share attributable to common stockholders:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As reported
|
|
$ |
(5.50 |
) |
|
$ |
(18.43 |
) |
|
$ |
(5.45 |
) |
|
$ |
(22.42 |
) |
Pro forma
|
|
|
(5.54 |
) |
|
|
(18.52 |
) |
|
|
(5.49 |
) |
|
|
(22.66 |
) |
|
|
|
|
|
|
|
|
|
|
|
June 30, | |
|
December 31, | |
|
|
2005 | |
|
2004 | |
|
|
| |
|
| |
|
|
(Dollars in thousands) | |
Finished products
|
|
$ |
24,598 |
|
|
$ |
63,841 |
|
Raw materials
|
|
|
14,224 |
|
|
|
18,682 |
|
Inventories under exchange agreements
|
|
|
5,751 |
|
|
|
330 |
|
Stores and supplies, net
|
|
|
5,240 |
|
|
|
5,127 |
|
|
|
|
|
|
|
|
|
|
$ |
49,813 |
|
|
$ |
87,980 |
|
|
|
|
|
|
|
|
On December 19, 2002, we issued $94.3 million in
original principal amount of our 10% Senior Secured Notes
due 2007 (our Secured Notes). Our Secured Notes are
senior secured obligations and rank equally in right of payment
with all of our other existing and future senior indebtedness,
and senior in right of payment to all of our existing and future
subordinated indebtedness. Our Secured Notes are guaranteed by
Sterling Chemicals Energy, Inc. (Sterling Energy),
our wholly-owned subsidiary. Sterling Energys guaranty
ranks equally in right of payment with all of its existing and
future senior indebtedness, and senior in right of payment to
all of its existing and future subordinated indebtedness. Our
Secured Notes and Sterling Energys guaranty are secured by
a first priority lien on all of our production facilities and
related assets.
Our Secured Notes bear interest at an annual rate of 10%,
payable semi-annually on June 15 and December 15 of each year.
Until December 19, 2004, we were permitted under certain
circumstances to pay interest on our Secured Notes through the
issuance of additional Secured Notes rather than the payment of
cash at an interest rate of
133/8% per
annum. In December 2003, we made an interest payment on our
Secured Notes at the higher rate through the issuance of
$6.3 million in original principal amount of additional
8
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Secured Notes, increasing the aggregate principal amount of
outstanding Secured Notes to $100.6 million. We made all
other interest payments on our Secured Notes in cash.
We may redeem our Secured Notes at any time at a redemption
price of 100% of the outstanding principal amount thereof plus
accrued and unpaid interest, subject to compliance with the
terms of our Revolving Credit Agreement dated December 19,
2002 with The CIT Group/ Business Credit, Inc., as
administrative agent and a lender, and certain other lenders
(our Revolver). In addition, in the event of a
specified change of control or the sale of our facility in Texas
City, Texas, we are required to offer to repurchase our Secured
Notes at 101% of the outstanding principal amount thereof plus
accrued and unpaid interest. Under certain circumstances, we are
also required to use the proceeds of other asset sales to
repurchase those Secured Notes tendered by the holders of such
notes at a price equal to 100% of the outstanding principal
amount thereof plus accrued and unpaid interest.
The indenture governing our Secured Notes contains numerous
covenants and conditions, including, but not limited to,
restrictions on our ability to incur indebtedness, create liens,
sell assets, make investments, make capital expenditures, engage
in mergers and acquisitions and pay dividends. The indenture
also includes various circumstances and conditions that would,
upon their occurrence and subject in certain cases to notice and
grace periods, create an event of default thereunder. However,
the indenture does not require us to satisfy any financial
ratios or maintenance tests.
On December 19, 2002, we also established our Revolver,
which provides up to $100 million in revolving credit
loans. Our Revolver has an initial term ending on
September 19, 2007. Under our Revolver, we and Sterling
Energy are co-borrowers and are jointly and severally liable for
any indebtedness thereunder. Our Revolver is secured by first
priority liens on all of our accounts receivable, inventory and
other specified assets, as well as all of the issued and
outstanding capital stock of Sterling Energy.
Borrowings under our Revolver bear interest, at our option, at
an annual rate of either the Alternate Base Rate plus 0.75% or
the LIBO Rate (as defined in our Revolver) plus
2.75%. The Alternate Base Rate is equal to the
greater of the Base Rate as announced from time to
time by JPMorgan Chase Bank in New York, New York or
0.50% per annum above the latest Federal Funds
Rate (as defined in our Revolver). The average borrowing
rate under our Revolver for the three and six-months ended
June 30, 2005 was 6.5% and 6.2%, respectively. Under our
Revolver, we are also required to pay an aggregate commitment
fee of 0.50% per year (payable monthly) on any unused
portion of our Revolver. Available credit under our Revolver is
subject to a monthly borrowing base of 85% of eligible accounts
receivable plus the lesser of $50 million and 65% of
eligible inventory. In addition, the borrowing base for our
Revolver must exceed outstanding borrowings thereunder by
$8 million at all times. As of June 30, 2005, total
credit available under our Revolver was limited to
$60 million due to these borrowing base limitations. As of
June 30, 2005, there were no loans outstanding under our
Revolver, and we had $2 million in outstanding letters of
credit issued pursuant to our Revolver. Pursuant to Emerging
Issues Task Force Issue No. 95-22, Balance Sheet
Classification of Borrowings under Revolving Credit Agreements
That Include both a Subjective Acceleration Clause and a
Lock-Box Arrangement, any balances outstanding
pursuant to our Revolver are classified as a current portion of
long-term debt.
Our Revolver contains numerous covenants and conditions,
including, but not limited to, restrictions on our ability to
incur indebtedness, create liens, sell assets, make investments,
make capital expenditures, engage in mergers and acquisitions
and pay dividends. Our Revolver also contains a covenant that
requires us to earn a specified amount of earnings before
interest, income taxes, depreciation and amortization (as
defined in our Revolver) on a monthly basis if, for 15
consecutive days, unused availability under our Revolver plus
cash on hand is less than $20 million. Our Revolver
includes various circumstances and conditions that would, upon
their occurrence and subject in certain cases to notice and
grace periods, create an event of default thereunder.
9
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
|
|
5. |
Commitments and Contingencies |
We have certain long-term agreements that provide for the
dedication of 100% of our production of acetic acid,
plasticizers, sodium cyanide and disodium iminodiacetic acid, or
DSIDA, each to one customer. We also have various sales and
conversion agreements that dedicate significant portions of our
production of styrene to certain customers. Some of these
agreements provide for cost recovery plus an agreed profit
margin based upon market prices. However, we have issued a
notice of termination of our sodium cyanide supply agreement
with E.I du Pont de Nemours & Company (see the
discussion below under Legal Proceedings with
respect to the termination of agreements relating to our
production of acrylonitrile and acrylonitrile derivatives).
|
|
|
Environmental Regulations: |
Our operations involve the handling, production, transportation,
treatment and disposal of materials that are classified as
hazardous or toxic waste 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 can be revoked or modified
for cause or when new or revised environmental requirements are
implemented. Changing and increasingly strict environmental
requirements can affect the manufacture, 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 can 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 generally are operated in compliance with all
applicable environmental and health and safety requirements in
all material respects, we cannot be sure that past practices or
future operations will not result in material claims or
regulatory action, require material environmental expenditures
or result in exposure or injury claims by employees, contractors
and their employees and 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.
We have incurred, and may continue to incur, 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.
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 located in an area that the Environmental
Protection Agency (EPA) has classified as not having
attained the ambient air quality standards for ozone, which is
controlled by direct regulation of volatile organic compounds
and nitrogen oxides. Our Texas City facility is also subject to
the federal governments June 1997 National Ambient Air
Quality Standards, which lowered the ozone and particulate
matter threshold for attainment. The Texas Commission for
Environmental Quality (TCEQ) has imposed strict
requirements on regulated facilities, including our Texas City
facility, to ensure that the air quality control region will
achieve the ambient air quality standards for ozone. Local
authorities also may impose new ozone and particulate matter
standards. Compliance with these stricter standards may
substantially increase our future nitrogen oxides, volatile
organic compounds and particulate matter control costs, the
amount and full impact of which cannot be determined at this
time.
10
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
On December 13, 2002, the TCEQ adopted a revised State
Implementation Plan (SIP) for compliance with the
ozone provisions (1 hour standard) of the Clean Air Act.
The SIP is currently being reviewed by the EPA, which is
expected to make further revisions to these rules. Under the
current SIP, we would be required to reduce emissions of
nitrogen oxides at our Texas City facility by approximately 80%
by the end of 2007. The current SIP rules also require
monitoring of emissions of highly reactive volatile organic
carbons (HRVOCs), such as ethylene and propylene, by
the end of 2005, and may impose a site-wide cap on emissions of
HRVOCs in 2006. Additional control measures may be required as
plans for meeting the 8-hour ozone standard are developed over
the next few years. At the conclusion of its review of the SIP,
the EPA may require further control measures, including possibly
increasing the total amount of reductions of nitrogen oxides
emissions required from 80% to 90%. Based on the SIP as adopted
by the TCEQ, we believe that the total cost of the capital
improvements required to comply with all of these new
regulations will be between $22 million and
$24 million, of which $8.6 million has already been
expended, with $0.4 million spent during the second quarter
of 2005. We anticipate that the balance of these capital
expenditures and other expenses will need to be incurred for the
remainder of 2005 through 2008. Under some of our production
agreements, we will be able to recover a small portion of these
costs from the other parties to these agreements. We are
currently evaluating several alternative methods of reducing
nitrogen oxides emissions at our Texas City facility that would
either require less capital expenditures or result in energy
savings that would, over a period of years, more than offset the
initial capital expenditures. However, alternative methods may
not be available to us or, even if available, such alternative
methods may not reduce the net amount of our required capital
expenditures by a meaningful amount.
On July 16, 2001, Sterling Chemicals Holdings, Inc., and
most of its U.S. subsidiaries, including us (collectively,
the Debtors), filed voluntary petitions for
reorganization under Chapter 11 of the United States
Bankruptcy Code in the U.S. Bankruptcy Court for the
Southern District of Texas. The Debtors plan of
reorganization (our Plan of Reorganization) was
confirmed on November 20, 2002 and, on December 19,
2002, the Debtors emerged from bankruptcy pursuant to the terms
of our Plan of Reorganization. Claims and legal actions against
the Debtors that existed as of the Chapter 11 filing date
are subject to the discharge injunction provided for in our Plan
of Reorganization, and recoveries sought thereon from assets of
the Debtors are subject to the terms of our Plan of
Reorganization. As a general rule, all claims against the
Debtors that sought a recovery from assets of the Debtors
estates have been addressed in the Chapter 11 cases and
have been or will be paid only pursuant to the terms of our Plan
of Reorganization or negotiated settlements. Very few issues
remain outstanding before the Bankruptcy Court, all of which
relate to the allowability or amount of certain claims. We do
not believe that the outcome of any of these issues will have a
material adverse effect on our business, financial position,
results of operations or cash flows, but we cannot guarantee
that result.
In February 2005, we shut down our acrylonitrile and derivative
production facilities due to our inability to obtain adequate
supplies of propylene after our primary contract supplier of
propylene declared force majeure and put us on allocation for
propylene. On January 28, 2005, we sent BP Amoco Chemical
Company (BP Chemicals) and ANEXCO, LLC written
declarations of force majeure under our various acrylonitrile
agreements. BP Chemicals, which previously assigned our
acrylonitrile agreements to O&D USA LLC (d/b/a Innovene
Chemicals) in anticipation of its spin-off of certain of its
chemical businesses, and ANEXCO, LLC (through BP Chemicals)
disputed our right to declare force majeure under these
acrylonitrile agreements. In an effort to both resolve this
issue and improve the possibility of operating our
11
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
acrylonitrile business in a less volatile manner, we entered
into a Separation Agreement with Innovene Chemicals, ANEXCO, LLC
and BP Chemicals on May 31, 2005. Under the Separation
Agreement:
|
|
|
|
|
the force majeure dispute among the parties was settled; |
|
|
|
most of the acrylonitrile-related agreements between the parties
were terminated as of May 31, 2005, including the Amended
and Restated Production Agreement dated March 31, 1998, the
Joint Venture Agreement dated March 31, 1998, the
Acrylonitrile Expanded Relationship and Master Modification
Agreement dated June 19, 2003 and the European Distribution
Agreement dated March 31, 1998; |
|
|
|
we assigned our interest in ANEXCO, LLC to Innovene
Chemicals; and |
|
|
|
we and Innovene Chemicals entered into amended and restated
versions of our acrylonitrile License Agreement and Catalyst
Sales Contract. |
In addition, on May 31, 2005, Innovene Chemicals made a
one-time payment to us of $0.7 million; ANEXCO, LLC made an
initial distribution to us of $4.8 million and we made a
few small payments to Innovene Chemicals and ANEXCO, LLC for
services performed prior to the termination of the agreements.
ANEXCO, LLC made a subsequent distribution to us of
$1.5 million on July 15, 2005, and we expect to
receive a final distribution of between $0.5 and
$1.0 million after the audit of the books and records of
ANEXCO, LLC is completed. If, however, the audit shows that the
distributions we previously received from ANEXCO, LLC exceeded
our equity value in ANEXCO, LLC as of May 31, 2005, we will
refund the difference to ANEXCO, LLC. No other payments were or
are required in connection with the settlement of the force
majeure dispute or the termination of the acrylonitrile-related
agreements.
The Separation Agreement did not impact any other commercial
relationships between any of the parties, such as the acetic
acid production agreement between BP Chemicals and us. In
addition, we expect to continue purchasing raw materials related
to our styrene business from Innovene Chemicals or BP Chemicals.
We are continuing to explore all available options with respect
to our acrylonitrile business and related assets, including, in
particular, modifying our acrylonitrile plant to allow for its
operation in an economic manner at significantly reduced rates
or permanently exiting the business. In the event that we
restart the plant at reduced rates, we would anticipate
utilizing all of the hydrogen cyanide produced from our
acrylonitrile operations to produce DSIDA on behalf of Monsanto.
Consequently, we have provided E.I. du Pont de
Nemours & Company with notice of termination of our
Sodium Cyanide Supply Agreement. There are no early termination
penalties associated with this contract, although we are
contractually obligated to pay for one-half of the total
dismantling costs of the sodium cyanide unit. Our portion of
these costs is estimated to be approximately $0.6 million,
which we accrued during the second quarter of 2005. The
agreement will terminate on February 10, 2006 and, after
that time, we will no longer produce sodium cyanide at our Texas
City facility.
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, would be expected to have a material adverse effect
on any results of operations or financial position.
12
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
|
|
6. |
Pension Plans and Other Postretirement Benefits |
Net periodic pension costs consisted of the following components:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Three Months | |
|
Six Months | |
|
|
Ended | |
|
Ended | |
|
|
June 30, | |
|
June 30, | |
|
|
| |
|
| |
|
|
2005 | |
|
2004 | |
|
2005 | |
|
2004 | |
|
|
| |
|
| |
|
| |
|
| |
|
|
(Dollars in thousands) | |
Service cost
|
|
$ |
202 |
|
|
$ |
904 |
|
|
$ |
404 |
|
|
$ |
1,732 |
|
Interest cost
|
|
|
1,669 |
|
|
|
1,861 |
|
|
|
3,338 |
|
|
|
3,770 |
|
Expected return on plan assets
|
|
|
(1,667 |
) |
|
|
(1,655 |
) |
|
|
(3,334 |
) |
|
|
(2,956 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Net pension costs
|
|
$ |
204 |
|
|
$ |
1,110 |
|
|
$ |
408 |
|
|
$ |
2,546 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other postretirement benefits costs consisted of the following
components:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Three Months | |
|
Six Months | |
|
|
Ended | |
|
Ended | |
|
|
June 30, | |
|
June 30, | |
|
|
| |
|
| |
|
|
2005 | |
|
2004 | |
|
2005 | |
|
2004 | |
|
|
| |
|
| |
|
| |
|
| |
|
|
(Dollars in thousands) | |
Service cost
|
|
$ |
99 |
|
|
$ |
79 |
|
|
$ |
198 |
|
|
$ |
156 |
|
Interest cost
|
|
|
|
|
|
|
397 |
|
|
|
|
|
|
|
788 |
|
Curtailment gain
|
|
|
|
|
|
|
(1,418 |
) |
|
|
|
|
|
|
(1,418 |
) |
Expected return on plan assets
|
|
|
|
|
|
|
(83 |
) |
|
|
|
|
|
|
(164 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Net plan costs
|
|
$ |
99 |
|
|
$ |
(1,025 |
) |
|
$ |
198 |
|
|
$ |
(638 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Effective as of January 1, 2005, we froze all accruals
under our defined benefit pension plan for our salaried
employees, which resulted in a plan curtailment under
SFAS No. 88 Employers Accounting for
Settlement and Curtailments of Defined Benefit Pension Plans and
for Termination Benefits. As a result, we recorded a
pretax curtailment gain of $13 million in the fourth
quarter of 2004. At the time we froze accruals under our defined
benefit pension plan, we also increased the company match for
employee contributions under our 401(k) plan.
In June 2004, we had a reduction in force at our Texas City,
Texas plant. This reduction in force led to a curtailment of our
postretirement benefit plan resulting in a $1.4 million
curtailment gain, with $1.3 million of the gain reflected
in cost of goods sold and $0.1 million reflected in
selling, general and administrative expenses during the quarter
ended June 30, 2004. In addition, we amended our
postretirement medical benefit plan as of June 1, 2004 to
freeze our contribution rates for retiree medical coverage at
2004 levels, increase the prescription drug co-pays of plan
participants by 5% and exclude employees hired after
June 1, 2004 from eligibility for retiree medical benefits.
These amendments reduced our accumulated postretirement benefit
obligation by $9.2 million, which we are amortizing over
the average remaining service period of active plan participants
until they become eligible for full benefits (which is
8.5 years).
|
|
7. |
New Accounting Standards |
In November 2004, the Financial Accounting Standards Board (the
FASB) issued SFAS No. 151, Inventory
Costs an amendment of ARB No. 43,
Chapter 4 (SFAS No. 151), in an
effort to conform U.S. accounting standards for inventories
to International Accounting Standards. SFAS No. 151
requires idle facility expenses, freight, handling costs and
wasted material (spoilage) costs to be recognized as
current-period charges. It also requires that the allocation of
fixed production overheads to the costs of conversion be
13
STERLING CHEMICALS, INC.
NOTES TO CONDENSED CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
based on the normal capacity of the relevant production
facilities. SFAS No. 151 will be effective for
inventory costs incurred during fiscal years beginning after
June 15, 2005. We do not believe that the adoption of
SFAS No. 151 will have a material impact on our
consolidated financial statements.
In December 2004, the FASB issued SFAS No. 123-Revised
2004 (SFAS No. 123(R)), Share-Based
Payment. This statement is a revision of
SFAS No. 123 and supersedes APB No. 25. Under
APB 25, we do not record compensation expense for
stock-based compensation. Under SFAS No. 123(R), we
will be required to measure the cost of employee services
received in exchange for stock-based compensation based on the
grant-date fair value of compensation (with limited exceptions),
with that cost being recognized over the period during which the
employee is required to provide services in exchange for the
award (usually the vesting period). The grant date fair value of
the stock-based compensation will be estimated using an
option-pricing model. Excess tax benefits, as defined in
SFAS No. 123(R), will be recognized as an addition to
paid-in capital. This statement is effective as of the beginning
of the first fiscal year beginning after June 15, 2005. We
are currently in the process of evaluating the impact of
SFAS No. 123(R) on our financial statements, and are
also evaluating different option-pricing models. The pro forma
table in Note 2 of the Notes to the Consolidated Financial
Statements illustrates the effect on net income and earnings per
share if we had applied the fair value recognition provisions of
SFAS No. 123 during the relevant periods using the
Black-Scholes option pricing model.
In March 2005, the Securities and Exchange Commission released
SEC Staff Accounting Bulletin (SAB) No. 107,
Share-Based Payment. SAB No. 107 announces
the position of the staff of the Securities and Exchange
Commission regarding the application of
SFAS No. 123(R). SAB No. 107 contains
interpretive guidance related to the interaction between
SFAS No. 123(R) and certain rules and regulations of
the Securities and Exchange Commission, as well as provides the
staffs views regarding the valuation of share-based
payment arrangements for public companies. SAB No. 107
also highlights the importance of disclosures related to the
accounting for share-based payment transactions. We are
currently evaluating the effect of SAB No. 107 on our
consolidated financial statements.
In March 2005, the FASB issued FASB Interpretation No. 47
(FIN 47), Accounting for Conditional
Asset Retirement Obligations, to clarify the term
conditional asset retirement as used in
SFAS 143, Accounting for Asset Retirement
Obligations. Under FIN 47, a liability for the fair
value of a conditional asset retirement obligation is recognized
when incurred if the fair value of the liability can be
reasonably estimated. Uncertainty about the timing or method of
settlement of a conditional asset retirement obligation would be
factored into the measurement of the liability when sufficient
information exists. This interpretation is effective for fiscal
years ending after December 15, 2005. We do not believe
that the adoption of FIN 47 will have a material impact on
our consolidated financial statements.
In May 2005, the FASB issued SFAS No. 154,
Accounting Changes and Error Corrections a
replacement of APB Opinion No. 20 and FASB Statement
No. 3. This statement changes the accounting for and
reporting of a change in accounting principles. Under
SFAS No. 154, a company that makes a voluntary change
in accounting principles must apply that change retrospectively
to prior period financial statements, unless that application
would be impracticable. SFAS No. 154 is effective for
fiscal years beginning after December 15, 2005.
14
REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM
To the Board of Directors and Stockholders of Sterling
Chemicals, Inc.:
We have reviewed the accompanying condensed consolidated balance
sheet of Sterling Chemicals, Inc. and subsidiaries (the
Company) as of June 30, 2005, and the related
condensed consolidated statements of operations for the three
and six-month periods ended June 30, 2005 and 2004 and cash
flows for the six-month periods ended June 30, 2005 and
2004. These interim financial statements are the responsibility
of the Companys management.
We conducted our reviews in accordance with standards of the
Public Company Accounting Oversight Board (United States). A
review of interim financial information consists principally of
applying analytical procedures to financial data and making
inquiries of persons responsible for financial and accounting
matters. It is substantially less in scope than an audit
conducted in accordance with standards of the Public Company
Accounting Oversight Board (United States), the objective of
which is the expression of an opinion regarding the financial
statements taken as a whole. Accordingly, we do not express such
an opinion.
Based on our reviews, we are not aware of any material
modifications that should be made to such condensed consolidated
financial statements for them to be in conformity with
accounting principles generally accepted in the United States of
America.
We have previously audited, in accordance with the standards of
the Public Company Accounting Oversight Board (United States),
the consolidated balance sheet of the Company as of
December 31, 2004, and the related consolidated statements
of operations, stockholders equity (deficiency in assets),
and cash flows for the year then ended (not presented herein);
and in our report dated February 15, 2005, we expressed an
unqualified opinion on those consolidated financial statements
and included 1) an explanatory paragraph referring to the
application of fresh-start accounting in 2002 in accordance with
the AICPAs Statement of Position 90-7,
Financial Reporting for Entities in Reorganization Under
the Bankruptcy Code, and the lack of comparability of
financial information between periods, and 2) an
explanatory paragraph referring to the Companys change in
fiscal year-end from September 30 to December 31 in
2002. In our opinion, the information set forth in the
accompanying condensed consolidated balance sheet as of
December 31, 2004 is fairly stated, in all material
respects, in relation to the consolidated balance sheet from
which it has been derived.
Houston, Texas
August 8, 2005
15
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Item 2. |
Managements Discussion and Analysis of Financial
Condition and Results of Operations |
The following discussion should be read in conjunction with our
condensed consolidated financial statements (including the Notes
thereto) included in Item 1, Part I of this report.
Business Overview
We are a leading North American producer of selected
petrochemicals used to manufacture a wide array of consumer
goods and industrial products throughout the world. Our primary
products include styrene, acetic acid and acrylonitrile. Styrene
is a commodity chemical used to produce intermediate products
such as polystyrene, expandable polystyrene resins and ABS
plastics, which are used in a wide variety of products such as
household goods, foam cups and containers, disposable food
service items, toys, packaging and other consumer and industrial
products. Approximately 50% of our styrene capacity is committed
for sales in North America under long-standing customer
relationships, and the balance of our capacity is available to
produce styrene for sales throughout the world when market
conditions warrant, including the high growth Asian markets.
Acetic acid is used primarily to produce vinyl acetate monomer,
which is used in a variety of products, including adhesives,
surface coatings and cigarette filters. All of our acetic acid
production is sold to BP Amoco Chemical Company (BP
Chemicals) pursuant to a long-term contract that expires
in 2016. Acrylonitrile is used primarily in apparel, textiles,
ABS plastics, upholstery and automotive parts, and is also used
in a wide variety of other applications. Historically, most of
our acrylonitrile sales were made under several long-term
agreements with BP Chemicals, which previously assigned our
acrylonitrile agreements to O&D USA LLC (d/b/a Innovene
Chemicals) in anticipation of its spin-off of certain of its
chemical businesses. However, in February of 2005, we shut down
our acrylonitrile and derivative production facilities due to
our inability to obtain adequate supplies of propylene after our
primary contract supplier of propylene declared force majeure
and put us on allocation for propylene. Innovene Chemicals and
ANEXCO, LLC (through Innovene Chemicals) disputed our right to
declare force majeure under our acrylonitrile agreements and, on
May 31, 2005, we entered into a Separation Agreement with
Innovene Chemicals, ANEXCO, LLC and BP Chemicals, providing for
the termination of most of our acrylonitrile agreements with
Innovene Chemicals.
Our rated annual production capacity is among the highest in
North America for styrene and acetic acid and is currently among
the highest in North America for acrylonitrile. However, as
noted previously, our acrylonitrile and
acrylonitrile-derivatives products facilities were shut down in
February 2005 and we are considering modifying our acrylonitrile
facility to operate more efficiently at significantly reduced
rates with only two reactors. We are also considering exiting
the acrylonitrile business entirely. We also produce
plasticizers and sodium cyanide at our Texas City facility, and
Monsanto Company (Monsanto) has constructed a
facility to produce disodium iminodiacetic acid
(DSIDA) at our site. 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 (BASF) pursuant to a
long-term contract that expires in 2007. Sodium cyanide and
DSIDA are both produced from hydrogen cyanide, a by-product of
our acrylonitrile production. All of our sodium cyanide, which
is used extensively in gold mining operations, has historically
been sold to E.I. du Pont de Nemours and Company
(DuPont) pursuant to a long standing relationship.
However, on May 10, 2005, we issued a notice of termination
of our sodium cyanide supply agreement with DuPont, which will
become effective on February 10, 2006, and we will not
produce sodium cyanide after that time. DSIDA is an essential
intermediate in the production of Roundup®, a
glyphosate-based herbicide. Monsanto has contractually committed
to start-up their DSIDA facility by mid-2007 and has the option
of starting up the facility earlier than that time. After any
start-up of the DSIDA facility, we will produce DSIDA for
Monsanto under a long-term contract that will extend for at
least 15 years. If we elect to exit the acrylonitrile
business entirely, we will not be able to produce DSIDA.
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 throughout the world. Two of our
products, styrene and acrylonitrile, are commodities and exhibit
wide swings in prices and profit margins based upon current and
anticipated levels of supply and demand. The acetic acid
industry tends to sell most of its products through long term
sales agreements having cost plus
16
pricing mechanisms, which eliminates much of the volatility seen
in other petrochemicals products and results in more stable and
predictable earnings and profit margins. Although exceptions
occasionally occur, as a general rule, if styrene profit margins
are favorable, our overall financial performance is good, but
our overall financial performance suffers when styrene margins
are unfavorable. The markets for styrene and acrylonitrile
roughly follow repetitive cycles, and general trends in the
supply and demand balance for these products may be observed
over time. However, it is difficult, if not impossible, to
definitively predict when market conditions will be favorable or
unfavorable.
The financial performance of each of our products is primarily a
function of sales prices, the cost of raw materials and energy
and sales volumes. While changes in the prices for our products
may be tracked through a variety of sources, a change in price
does not necessarily result in a corresponding change in our
financial performance. When the prices of our products increase
or decrease, our overall financial performance may improve,
decline or stay roughly the same depending upon the extent and
direction of changes in our costs for raw materials and energy
and our production rates. For most of our products, the combined
cost of raw materials and energy resources is far greater than
all other costs of production combined. We use significant
amounts of natural gas as fuel in our production processes, and
the producers of most of our raw materials use significant
amounts of natural gas in their production. As a result, our
production and raw materials costs are significantly influenced
by changes in the price for natural gas. Natural gas and most of
our raw materials are commodities and, consequently, are subject
to wide fluctuations in prices, which can, and often do, move
independently of changes in the prices for our products. Prices
for, and the availability of, natural gas and many of our raw
materials are largely based on regional factors, which can
result in wide disparities in prices in different parts of the
world or shortages or unavailability in some regions at the same
time when these products are plentiful in other parts of the
world. Prices for styrene and acrylonitrile, on the other hand,
tend to be more consistent throughout the world, after taking
into account transportation costs. Consequently, changes in
prices for natural gas and raw materials tend to impact the
margin on our sales rather than the price of our products, with
margins increasing when natural gas and raw materials costs
decline and vice versa. In addition, many producers in
other parts of the world use oil-based processes rather than
natural gas-based processes. Consequently, the relationship
between the price of crude oil and the price of natural gas can
either increase or decrease our competitiveness depending on
their relative values at any particular point in time. Sales
volumes influence our overall financial performance in a variety
of ways. As a general rule, increases in sales volumes will
result in an increase in overall revenues and vice versa,
although this is not necessarily the case since the prices for
some of our products can change dramatically from
month-to-month. More importantly, changes in production rates
impact the average cost per pound of the products produced. If
more pounds are produced, our fixed costs are spread over a
greater number of pounds resulting in a lower average cost to
produce each pound. In addition, our production rates influence
the overall efficiency of our manufacturing unit and affect our
raw materials conversion yields.
Styrene sales prices during the second quarter of 2005 were
approximately the same, on average, as those during the first
quarter of 2005. However, styrene sales prices were steadily
increasing during the first four months of 2005 and then rapidly
decreased during the last two months of the second quarter of
2005 as a result of rapidly decreasing benzene prices. Styrene
sales volumes were essentially the same in both the first and
second quarters of 2005. The rapidly decreasing styrene sales
prices during the second quarter of 2005 contributed to negative
gross margins in styrene for the period as a significant amount
of styrene produced using higher-priced benzene as a raw
material was sold in the ensuing month when styrene sales prices
had decreased. This impact resulted in a reduction in gross
profit (loss) of approximately $15 million during the
quarter.
17
Contract benzene prices experienced significant swings during
the first half of 2005, as depicted in the chart below:
Depending on world market conditions for benzene, contract
pricing may be either higher or lower than spot pricing. As we
purchase a portion of our benzene requirements on a contract
basis and the remainder on a spot basis, the actual prices for
our benzene purchases is not exactly the same as shown in the
table above but our actual benzene costs did follow similar
trends. As the combined cost of raw materials and energy
resources is far greater than the total of all other costs of
styrene production, with the cost of benzene having the greatest
impact on overall styrene manufacturing costs, high benzene
prices have continued to make it difficult for United
States styrene producers to realize meaningful margin
improvements on their styrene sales. Many industry experts had
been forecasting that the balance of supply and demand for
styrene would be favorable for producers over the next year and
a half, especially in the Asian markets. However, global demand
for styrene currently appears weaker than previously projected
by these industry experts and margins on export sales have not
been at levels conducive to consistent participation by North
American styrene producers. We believe that high benzene prices
will continue to have a negative impact on global styrene
demand. If and when styrene market conditions improve, we would
expect to have higher operating rates with incremental
production being sold primarily into the Asian spot market.
Several of our competitors have announced their intention to
build new styrene production units outside the United States
during the late 2006 to 2008 time frame, although it is not
uncommon for announced construction to be delayed or abandoned.
In addition, most of this new capacity is being constructed in
politically unstable regions of the world, such as the Middle
East, which may impact the start-up of this new capacity. If and
when these new units are completed, we would anticipate
difficult market conditions until the additional supply is
absorbed by growth in market demand.
Margins for acetic acid have grown steadily over the past
several years, with our profitability for acetic acid reaching
record levels in 2004 and continuing for the first six months of
2005. The North American acetic acid market is mature and well
developed, with demand being 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 about 50% of total
demand. The acetic acid industry tends to sell most of its
products through long term sales agreements having cost
plus pricing mechanisms, which eliminates much of the
volatility seen in other petrochemicals products and results in
more stable and predictable earnings and profit margins. All of
our acetic acid production is sold to BP Chemicals under a
long-term production agreement that expires in 2016. Under the
production agreement, BP Chemicals markets all of the acetic
acid we produce and pays us, among other amounts, a portion of
the profits earned from their sales of our acetic acid.
In February 2005, we shut down our acrylonitrile and derivative
production facilities due to our inability to obtain adequate
supplies of propylene after our primary contract supplier of
propylene declared force majeure and put us on allocation for
propylene. On January 28, 2005, we sent BP Chemicals and
ANEXCO, LLC written declarations of force majeure under our
various acrylonitrile agreements. BP Chemicals, which previously
assigned our acrylonitrile agreements to Innovene Chemicals in
anticipation of its spin-off of certain of its chemical
businesses, and ANEXCO, LLC (through Innovene Chemicals)
disputed our right to declare force majeure under these
acrylonitrile agreements. In an effort to both resolve this
issue and improve the possibility of operating our acrylonitrile
business in a less volatile manner, we entered into a Separation
18
Agreement with Innovene Chemicals, ANEXCO, LLC and BP Chemicals
on May 31, 2005. Under the Separation Agreement:
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the force majeure dispute among the parties was settled; |
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most of the acrylonitrile-related agreements between the parties
were terminated as of May 31, 2005, including the Amended
and Restated Production Agreement dated March 31, 1998, the
Joint Venture Agreement dated March 31, 1998, the
Acrylonitrile Expanded Relationship and Master Modification
Agreement dated June 19, 2003 and the European Distribution
Agreement dated March 31, 1998; |
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we assigned our interest in ANEXCO, LLC to Innovene
Chemicals; and |
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we and Innovene Chemicals entered into amended and restated
versions of our acrylonitrile License Agreement and Catalyst
Sales Contract. |
In addition, on May 31, 2005, Innovene Chemicals made a
one-time payment to us of $0.7 million, ANEXCO, LLC made an
initial distribution to us of $4.8 million and we made a
few small payments to Innovene Chemicals and ANEXCO, LLC for
services performed prior to the termination of the agreements.
ANEXCO, LLC made a subsequent distribution to us of
$1.5 million on July 15, 2005, and we expect to
receive a final distribution of between $0.5 and
$1.0 million after the audit of the books and records of
ANEXCO, LLC is completed. If, however, the audit shows that the
distributions we previously received from ANEXCO, LLC exceeded
our equity value in ANEXCO, LLC as of May 31, 2005, we will
refund the difference to ANEXCO, LLC. No other payments were or
are required in connection with the settlement of the force
majeure dispute or the termination of the acrylonitrile-related
agreements.
The Separation Agreement did not impact any other commercial
relationships between any of the parties, such as the acetic
acid production agreement between BP Chemicals and us. In
addition, we expect to continue purchasing raw materials related
to our styrene business from Innovene Chemicals or BP Chemicals.
We are continuing to explore all available options with respect
to our acrylonitrile business and related assets, including, in
particular, modifying our acrylonitrile plant to allow for its
operation in an economic manner at significantly reduced rates
or permanently exiting the business. In the event that we
restart the plant at reduced rates, we would anticipate
utilizing all of the hydrogen cyanide produced from our
acrylonitrile operations to produce DSIDA on behalf of Monsanto.
Consequently, we have provided E.I. du Pont de
Nemours & Company with notice of termination of our
Sodium Cyanide Supply Agreement. There are no early termination
penalties associated with this contract, although we are
contractually obligated to pay for one-half of the total
dismantling costs of the sodium cyanide unit. Our portion of
these costs is estimated to be approximately $0.6 million,
which we accrued during the second quarter of 2005. The
agreement will terminate on February 10, 2006 and, after
that time, we will no longer produce sodium cyanide at our Texas
City facility.
Our acrylonitrile and acrylonitrile-derivatives businesses
sustained gross losses of $28 million and $36 million
during 2004 and 2003, respectively. Due to these recurring
losses and the continued difficulties we experienced over the
last few years in securing adequate supplies of propylene, we
have been evaluating our options with respect to these
businesses and are now focusing on two options in particular.
One of these options involves an effort to improve the cost
competitiveness of our acrylonitrile business through major
process changes to our acrylonitrile facilities. As a part of
these changes, we would permanently shut down our least cost
efficient acrylonitrile reactor and operate our two remaining
reactors at minimum rates. If we pursue these process changes,
the total capital cost is estimated to be between
$2 million and $3 million. Alternatively, we are
considering a permanent closure of our acrylonitrile and
acrylonitrile-derivatives facilities. A permanent closure of
these facilities would result in estimated one-time costs of
between $20 million and $25 million. These one-time
costs include payment of contractual obligations, employee
severance and decommissioning costs, among other costs. The
monetization of the working capital associated with our
acrylonitrile business will more than offset these one-time
closure costs. Working capital for our acrylonitrile operations
was reduced by $41 million from the end of February to the
end of June 2005, with remaining working capital being
$5 million. If we proceed with the permanent closure of our
acrylonitrile facilities and related derivative units, we
estimate that between $7 million and $9 million per
year of on-going
19
costs would be allocated to our remaining businesses, primarily
consisting of energy costs and continuing fixed costs currently
charged to our acrylonitrile and derivatives operations. In the
event of a permanent closure of these facilities, we would seek
alternative uses of the space and infrastructure that is
currently associated with the acrylonitrile and
acrylonitrile-derivatives operations.
Results of Operations
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Three Months Ended June 30, 2005 Compared to Three
Months Ended June 30, 2004 |
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Revenues and Net Income (Loss) |
Our revenues were $164 million for the second quarter of
2005, an 11% decrease from the $185 million in revenues we
recorded for the second quarter of 2004. This decrease in
revenues primarily resulted from the continued shutdown of our
acrylonitrile unit during the second quarter of 2005. We
recorded a net loss of $14 million for the second quarter
of 2005, compared to a net loss of $51 million recorded in
the second quarter of 2004. A large portion of our net loss in
the second quarter of 2004 resulted from an impairment of our
goodwill in the amount of $48 million. In addition, styrene
margins were lower during the second quarter of 2005 compared to
the second quarter of 2004 primarily as a result of decreasing
styrene prices. During the second quarter of 2005, we lowered
our plasticizer profit sharing estimate by approximately
$4 million due to a statement we received from BASF
Corporation, who purchases all of our plasticizer production,
showing a lower profit sharing estimate for 2005 and a reduction
of the profit sharing amount we received for 2004. The reduced
profit sharing for both 2005 and 2004 shown in the statements
from BASF Corporation appear to be based on BASF
Corporations overstating inventory values and understating
cost of goods sold during the periods.
Our earnings in the second quarter of 2005 were favorably
impacted by our fixed cost reduction efforts. During the last
half of 2004, we developed an organizational efficiency project
involving the design, development and implementation of uniform
and standardized systems, processes and policies to improve our
production, maintenance, process efficiency, logistics and
materials management and procurement functions. Over the course
of developing this project, we analyzed our organizational
structure, selected an optimum workforce design and staffing
model and identified various production and process efficiency
measures. We expect the combined annual cost savings of our
organizational efficiency project and our other cost savings
initiatives to be approximately $20 million (representing a
15% reduction in our annual fixed costs), with approximately 20%
to 30% of these savings accruing to the benefit of some of our
customers under the cost reimbursement provisions of our
production agreements. During the second quarter of 2005, we
reduced our fixed costs by more than our targeted levels of
reduction. However, our actual future level of savings from our
cost reduction initiatives can be impacted by a variety of
factors, including operating rates of our production units and
sales volumes of our products, and may, consequently, be lower
than our expectations.
Revenues from our styrene operations were $135 million for
the second quarter of 2005, an increase of 22% from the
$111 million in revenues we received from these operations
for the second quarter of 2004. This increase in revenues from
our styrene operations resulted primarily from a 21% increase in
direct sales prices. During the second quarter of 2005, the
prices we paid for benzene and ethylene, the two primary raw
materials required for styrene production, increased 27% and 24%
respectively, from the prices we paid for these materials during
the second quarter of 2004. The average price we paid for
natural gas for the second quarter of 2005 increased 11%
compared to the average price we paid for natural gas during the
second quarter of 2004.
Revenues from our other petrochemicals operations, primarily
acetic acid and plasticizers, were $28 million for the
second quarter of 2005, a slight decrease from the
$30 million in revenues we received from these operations
during the second quarter of 2004. This decrease in revenues
resulted primarily from the decrease in plasticizers revenues
attributable to the statement from BASF Corporation mentioned
above.
Revenues for our acrylonitrile operations were less than
$1 million in the second quarter of 2005 due to the
continued shutdown of our acrylonitrile unit compared to
revenues of $44 million in the second quarter of 2004. In
February 2005, we declared force majeure for our acrylonitrile
and acrylonitrile-derivatives operations
20
in Texas City, Texas due to unavailability of propylene and shut
down our acrylonitrile facilities and sodium cyanide unit (which
uses a by-product of our acrylonitrile operations as a raw
material).
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Selling, General and Administrative (SG&A)
Expenses |
Our SG&A expenses for the second quarter of 2005 were less
than $1 million compared to $3.1 million in SG&A
expenses during the second quarter of 2004. This decrease was
primarily due to a $1.7 million reduction in our allowance
for doubtful accounts resulting from a decrease in total
accounts receivable as well as a decrease in balances with
customers having greater credit risk.
We recorded $0.7 million in other income for the second
quarter of 2005, which consisted of a payment we received from
Innovene Chemicals pursuant to our Separation Agreement with
Innovene Chemicals, ANEXCO, LLC and BP Chemicals.
During the second quarter of 2005, we recorded an
$8 million benefit for income taxes compared to a
$1 million benefit for income taxes for the second quarter
of 2004. This increase was primarily due to an increase in
pre-tax loss, excluding the non-tax deductible impairment of
goodwill charge taken during the second quarter of 2005.
Six Months Ended
June 30, 2005 Compared to Six Months Ended June 30,
2004
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Revenues and Net Income (Loss) |
Our revenues were $380 million for the six-month period
ended June 30, 2005, compared to the $331 million in
revenues we received during the six-month period ended
June 30, 2004. This 15% increase in revenues resulted
primarily from higher sales prices for styrene during the first
two quarters of 2005. We recorded a net loss of $12 million
for the six-month period ended June 30, 2005 compared to a
net loss of $60 million during the six-month period ended
June 30, 2004. This was primarily due to the
$48 million impairment of goodwill that we recorded in the
second quarter of 2004.
Additionally, during the first quarter of 2004, we performed
maintenance turnarounds on both our styrene and acrylonitrile
production facilities resulting in our operating income for the
quarter being reduced by $14 million due to the maintenance
costs associated with these turnarounds. As a part of normal
recurring operations, each of our manufacturing units is
completely shut down from time to time, for a period typically
lasting two to four weeks, to replace catalysts and perform
major maintenance work required to sustain long-term production.
These periods are commonly referred to as
turnarounds or shutdowns. While actual
timing is subject to a number of variables, turnarounds of our
styrene unit typically occur every two to three years and
turnarounds of our acrylonitrile unit typically occur every 18
to 24 months. We expense the costs of turnarounds as the
associated expenses are incurred. As expenses for turnarounds,
especially for our styrene and acrylonitrile units, can be
significant, the impact of turnarounds can be material for
financial reporting periods during which the turnarounds
actually occur.
Revenues from our styrene operations were $285 million for
the six-month period ended June 30, 2005, an increase of
39% from the $205 million in revenues we received from
these operations for the six-month period ended June 30,
2004. This increase in revenues from our styrene operations was
primarily due to an increase in direct sales prices of 27%
during the first two quarters of 2005 compared to those realized
during the first two quarters of 2004. During the first two
quarters of 2005, prices for benzene and ethylene, the two
primary raw materials required for styrene production, increased
48% and 36%, respectively, from the prices we paid for these
products in the first two quarters of 2004. The average price we
paid for natural gas for the first two quarters of 2005
increased 10% from the average price we paid for natural gas
during the first two quarters of 2004.
21
Revenues from our other petrochemicals operations, primarily
acetic acid and plasticizers, were $58 million for both the
six-month period ended June 30, 2005 and the six-month
period ended June 30, 2004.
Revenues from our acrylonitrile operations decreased 47% during
the six-month period ended June 30, 2005 compared to the
six-month period ended June 30, 2004 due to the shutdown of
our acrylonitrile and acrylonitrile-derivative operations in
February 2005.
Our SG&A expenses for the six-month period ended
June 30, 2005 were $4 million compared to the
$6 million in SG&A expenses we recorded for the
six-month period ended June 30, 2004. This decrease was
primarily due to a $1.7 million reduction in our allowance
for doubtful accounts resulting from a decrease in total
accounts receivable as well as a decrease in balances with
customers having greater credit risk.
We recorded $0.7 million in other income for the six-month
period ended June 30, 2005, which consisted of a payment we
received from Innovene Chemicals pursuant to our Separation
Agreement with Innovene Chemicals, ANEXCO, LLC and BP Chemicals.
Liquidity and Capital Resources
On December 19, 2002, we issued $94.3 million in
original principal amount of our Secured Notes. Our Secured
Notes are senior secured obligations and rank equally in right
of payment with all of our other existing and future senior
indebtedness, and senior in right of payment to all of our
existing and future subordinated indebtedness. Our Secured Notes
are guaranteed by Sterling Chemicals Energy, Inc.
(Sterling Energy), one of our wholly owned
subsidiaries. Sterling Energys guaranty ranks equally in
right of payment with all of its existing and future senior
indebtedness, and senior in right of payment to all of its
existing and future subordinated indebtedness. Our Secured Notes
and Sterling Energys guaranty are secured by a first
priority lien on all of our production facilities and related
assets.
Our Secured Notes bear interest at an annual rate of 10%,
payable semi-annually on June 15 and December 15 of each year.
Until December 19, 2004, we were permitted under certain
circumstances to pay interest on our Secured Notes through the
issuance of additional Secured Notes rather than the payment of
cash at an interest rate of
133/8% per
annum. In December 2003, we made an interest payment on our
Secured Notes at the higher rate through the issuance of
$6.3 million in original principal amount of additional
Secured Notes, increasing the aggregate principal amount of
outstanding Secured Notes to $100.6 million. We made all
other interest payments on our Secured Notes in cash. We may
redeem our Secured Notes at any time at a redemption price of
100% of the outstanding principal amount thereof plus accrued
and unpaid interest, subject to compliance with the terms of our
Revolving Credit Agreement dated December 19, 2002 with The
CIT Group/ Business Credit, Inc., as administrative agent and a
lender, and certain other lenders (our Revolver). In
addition, in the event of a specified change of control or the
sale of our facility in Texas City, Texas, we are required to
offer to repurchase our Secured Notes at 101% of the outstanding
principal amount thereof plus accrued and unpaid interest. Under
certain circumstances, we are also required to use the proceeds
of other asset sales to repurchase those Secured Notes tendered
by the holders of such notes at a price equal to 100% of the
outstanding principal amount thereof plus accrued and unpaid
interest.
The indenture governing our Secured Notes contains numerous
covenants and conditions, including, but not limited to,
restrictions on our ability to incur indebtedness, create liens,
sell assets, make investments, make capital expenditures, engage
in mergers and acquisitions and pay dividends. The indenture
also includes various circumstances and conditions that would,
upon their occurrence and subject in certain cases to notice and
grace periods, create an event of default thereunder. However,
the indenture does not require us to satisfy any financial
ratios or maintenance tests.
22
On December 19, 2002, we also established our Revolver,
which provides up to $100 million in revolving credit
loans. Our Revolver has an initial term ending on
September 19, 2007. Under our Revolver, we and Sterling
Energy are co-borrowers and are jointly and severally liable for
any indebtedness thereunder. Our Revolver is secured by first
priority liens on all of our accounts receivable, inventory and
other specified assets, as well as all of the issued and
outstanding capital stock of Sterling Energy.
Borrowings under our Revolver bear interest, at our option, at
an annual rate of either the Alternate Base Rate plus 0.75% or
the LIBO Rate (as defined in our Revolver) plus
2.75%. The Alternate Base Rate is equal to the
greater of the Base Rate as announced from time to
time by JPMorgan Chase Bank in New York, New York or
0.50% per annum above the latest Federal Funds
Rate (as defined in our Revolver). The average borrowing
rate under our Revolver for the three and six-months ended
June 30, 2005 was 6.5% and 6.2%, respectively. Under our
Revolver, we are also required to pay an aggregate commitment
fee of 0.50% per year (payable monthly) on any unused
portion of our Revolver. Available credit under our Revolver is
subject to a monthly borrowing base of 85% of eligible accounts
receivable plus the lesser of $50 million and 65% of
eligible inventory. In addition, the borrowing base for our
Revolver must exceed outstanding borrowings thereunder by
$8 million at all times. As of June 30, 2005, total
credit available under our Revolver was limited to
$60 million due to these borrowing base limitations. As of
June 30, 2005, there were no loans outstanding under our
Revolver, and we had $2 million in outstanding letters of
credit issued pursuant to our Revolver.
Our Revolver contains numerous covenants and conditions,
including, but not limited to, restrictions on our ability to
incur indebtedness, create liens, sell assets, make investments,
make capital expenditures, engage in mergers and acquisitions
and pay dividends. Our Revolver also contains a covenant that
requires us to earn a specified amount of earnings before
interest, income taxes, depreciation and amortization (as
defined in our Revolver) on a monthly basis if, for 15
consecutive days, unused availability under our Revolver plus
cash on hand is less than $20 million. Our Revolver
includes various circumstances and conditions that would, upon
their occurrence and subject in certain cases to notice and
grace periods, create an event of default thereunder.
Our liquidity (i.e., cash and cash equivalents plus total credit
available under our Revolver) was $83 million at
June 30, 2005, an increase of $27 million compared to
our liquidity at December 31, 2004. Our liquidity increased
primarily due to the reduction in working capital that followed
the shutdown of our acrylonitrile facility in February 2005.
Working capital for our acrylonitrile operations was reduced by
$41 million from the end of February to the end of June
2005, with remaining working capital being $5 million. We
believe that our cash on hand, together with credit available
under our Revolver, will be sufficient to meet our short-term
and long-term liquidity needs for the reasonably foreseeable
future, although we cannot give any assurances to that effect.
Our working capital on June 30, 2005 was $88 million,
a decrease of $15 million from our working capital of
$103 million on December 31, 2004. This decrease in
working capital primarily consists of a reduction in our
accounts receivable and inventories, due in large part to the
shutdown of our acrylonitrile unit, and the repayment of
outstanding balances under our Revolver.
Net cash provided by our operations was $44 million for the
six-month period ended June 30, 2005, whereas net cash used
in our operations during the first six months of 2004 was
$18 million. The primary factors impacting our cash flow
from operations are production and sales volumes and the prices
of our raw materials and finished products. See discussion of
these factors in Results of Operations above. In
addition, the working capital associated with our acrylonitrile
business was monetized during the first six months of 2005. Net
cash flow used in our investing activities was $3 million
during the six-month period ended June 30, 2005, whereas we
used $6 million of net cash flow in our investing
activities during the six months ended June 30, 2004, with
the reduction attributable to lower capital expenditures in the
first six months of 2005. Net
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borrowings under our Revolver reduced from $18 million to
zero during the six-month period ended June 30, 2005, while
we had no borrowings under our Revolver during the six-month
period ended June 30, 2004.
Our capital expenditures were $4 million during the
six-month period ended June 30, 2005 and $6 million
during the six-month period ended June 30, 2004. We expect
our capital expenditures for the remainder of 2005 to be between
$5 million and $10 million, primarily for routine
safety, environmental and replacement capital and the
continuation of capital projects related to the reduction of
emissions of nitrogen oxides and highly volatile organic
compounds, as required under the State Implementation Plan
adopted by the Texas Commission for Environmental Quality
related to compliance with the ozone provisions of the Clean Air
Act.
Contractual Cash Obligations
We conducted a review of our contractual cash obligations as of
June 30, 2005, and there have been no material changes from
the significant contractual obligations disclosed in our Annual
Report on Form 10-K for the fiscal year ended
December 31, 2004.
Critical Accounting Policies, Use of Estimates and
Assumptions
The preparation of financial statements in conformity with
generally accepted accounting principles requires management to
make estimates and assumptions that affect the amounts reported
in the condensed consolidated financial statements and related
notes. Actual results could differ from those estimates. On an
ongoing basis, management reviews its estimates, including those
related to the allowance for doubtful accounts, recoverability
of long-lived assets, deferred tax asset valuation allowance,
litigation, environmental liabilities, pension and
post-retirement benefits and various other operating allowances
and accruals, based on currently available information. Changes
in facts and circumstances may alter such estimates and affect
our results of operations and financial position in future
periods. There have been no material changes or developments in
our evaluation of the accounting estimates and the underlying
assumptions or methodologies that we believe to be Critical
Accounting Policies disclosed in our Annual Report on
Form 10-K for the fiscal year ended December 31, 2004.
New Accounting Standards
In November 2004, the Financial Accounting Standards Board (the
FASB) issued SFAS No. 151, Inventory
Costs an amendment of ARB No. 43,
Chapter 4 (SFAS No. 151), in an
effort to conform U.S. accounting standards for inventories
to International Accounting Standards. SFAS No. 151
requires idle facility expenses, freight, handling costs and
wasted material (spoilage) costs to be recognized as
current-period charges. It also requires that the allocation of
fixed production overheads to the costs of conversion be based
on the normal capacity of the relevant production facilities.
SFAS No. 151 will be effective for inventory costs
incurred during fiscal years beginning after June 15, 2005.
We do not believe that the adoption of SFAS No. 151
will have a material impact on our consolidated financial
statements.
In December 2004, the FASB issued SFAS No. 123-Revised
2004 (SFAS No. 123(R)), Share-Based
Payment. This statement is a revision of
SFAS No. 123 and supersedes APB No. 25. Under
APB 25, we do not record compensation expense for
stock-based compensation. Under SFAS No. 123(R), we
will be required to measure the cost of employee services
received in exchange for stock-based compensation based on the
grant-date fair value of compensation (with limited exceptions),
with that cost being recognized over the period during which the
employee is required to provide services in exchange for the
award (usually the vesting period). The grant date fair value of
the stock-based compensation will be estimated using an
option-pricing model. Excess tax benefits, as defined in
SFAS No. 123(R), will be recognized as an addition to
paid-in capital. This statement is effective as of the beginning
of the first fiscal year beginning after June 15, 2005. We
are currently in the process of evaluating the impact of
SFAS No. 123(R) on our financial statements,
24
and are also evaluating different option-pricing models. The pro
forma table in Note 2 of the Notes to the Consolidated
Financial Statements illustrates the effect on net income and
earnings per share if we had applied the fair value recognition
provisions of SFAS No. 123 during the relevant periods
using the Black-Scholes option pricing model.
In March 2005, the Securities and Exchange Commission released
SEC Staff Accounting Bulletin (SAB) No. 107,
Share-Based Payment. SAB No. 107 announces
the position of the staff of the Securities and Exchange
Commission regarding the application of
SFAS No. 123(R). SAB No. 107 contains
interpretive guidance related to the interaction between
SFAS No. 123(R) and certain rules and regulations of
the Securities and Exchange Commission, as well as provides the
staffs views regarding the valuation of share-based
payment arrangements for public companies. SAB No. 107
also highlights the importance of disclosures related to the
accounting for share-based payment transactions. We are
currently evaluating the effect of SAB No. 107 on our
consolidated financial statements.
In March 2005, the FASB issued FASB Interpretation No. 47
(FIN 47), Accounting for Conditional
Asset Retirement Obligations, to clarify the term
conditional asset retirement as used in
SFAS 143, Accounting for Asset Retirement
Obligations. Under FIN 47, a liability for the fair
value of a conditional asset retirement obligation is recognized
when incurred if the fair value of the liability can be
reasonably estimated. Uncertainty about the timing or method of
settlement of a conditional asset retirement obligation would be
factored into the measurement of the liability when sufficient
information exists. This interpretation is effective for fiscal
years ending after December 15, 2005. We do not believe
that the adoption of FIN 47 will have a material impact on
our consolidated financial statements.
In May 2005, the FASB issued SFAS No. 154,
Accounting Changes and Error Corrections a
replacement of APB Opinion No. 20 and FASB Statement
No. 3. This statement changes the accounting for and
reporting of a change in accounting principles. Under
SFAS No. 154, a company that makes a voluntary change
in accounting principles must apply that change retrospectively
to prior period financial statements, unless that application
would be impracticable. SFAS No. 154 is effective for
fiscal years beginning after December 15, 2005.
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Item 3. |
Quantitative and Qualitative Disclosures about Market
Risk |
Our financial results can be affected by volatile changes in raw
materials, natural gas and finished product sales prices.
Borrowings under our Revolver bear interest, at our option, at
an annual rate of either the Alternate Base Rate plus 0.75% or
the LIBO Rate (as defined in our Revolver) plus
2.75%. The Alternate Base Rate is equal to the
greater of the Base Rate as announced from time to
time by JPMorgan Chase Bank in New York, New York or
0.50% per annum above the latest Federal Funds
Rate (as defined in our Revolver). The average borrowing
rate under our Revolver for the three and six-month periods
ended June 30, 2005 was 6.5% and 6.2%, respectively. The
fair value of our Revolver is the same as its carrying value due
to the short-term nature of this financial instrument. Our
Secured Notes bear interest at an annual rate of 10%, payable
semi-annually on June 15 and December 15 of each year. The fair
value of our Secured Notes is based on their quoted price, which
may vary in response to changing interest rates. As of
June 30, 2005, the fair value of the Secured Notes was
$99,573.
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Item 4. |
Controls and Procedures |
We maintain disclosure controls and procedures that are designed
to ensure that information required to be disclosed in our
reports under the Securities Exchange Act of 1934, as amended
(the Exchange Act), is recorded, processed,
summarized and reported within the time periods specified in the
rules and forms of the Securities and Exchange Commission, and
that such information is accumulated and communicated to our
management, including our Chief Executive Officer and Chief
Financial Officer, as appropriate, to allow timely decisions
regarding required disclosure. Management necessarily applied
its judgment in assessing the costs and benefits of such
controls and procedures which, by their nature, can provide only
reasonable assurance regarding managements control
objectives.
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We carried out an evaluation, under the supervision and with the
participation of our management, including our Chief Executive
Officer and Chief Financial Officer, of the effectiveness of the
design and operation of our disclosure controls and procedures
pursuant to Exchange Act Rule 13a-15, as of the end of the
fiscal period covered by this report on Form 10-Q. Based
upon that evaluation, each of our Chief Executive Officer and
our Chief Financial Officer concluded that our disclosure
controls and procedures are effective in timely alerting them to
material information relating to us (including our consolidated
subsidiaries) that is required to be disclosed in our Exchange
Act reports. In connection with our evaluation, no change was
identified in our internal controls over financial reporting
that occurred during the second quarter of 2005 that has
materially affected, or is reasonably likely to materially
affect, our internal controls over financial reporting.
Under the current rules and regulations promulgated by the
Securities and Exchange Commission, beginning with our Annual
Report on Form 10-K for 2006, we will be subject to the
provisions of Section 404 of the Sarbanes-Oxley Act that
require an annual management assessment of our internal controls
over financial reporting and related attestation by our
independent registered public accounting firm.
PART II.
OTHER INFORMATION
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Item 1. |
Legal Proceedings |
The information under Legal Proceedings in
Note 5 to the consolidated financial statements included in
Item 1 of Part I of this report is hereby incorporated
by reference.
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Item 4. |
Submission of Matters to a Vote of Security Holders |
Our Annual Meeting of Stockholders was held on April 15,
2005. At the Annual Meeting:
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eight of our incumbent directors were re-elected; |
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the appointment of Deloitte & Touche LLP as our
independent registered accounting firm for the fiscal year
ending December 31, 2005 was ratified and approved; and |
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an amendment to our Amended and Restated Certificate of
Incorporation to increase the number of our total authorized
shares of capital stock from 10,125,000 to 20,125,000 and to
increase the number of our authorized shares of Common Stock
from 10,000,000 to 20,000,000 was ratified and approved. |
Under the Restated Certificate of Designations, Preferences,
Rights and Limitations of our Preferred Stock, the holders of
our Preferred Stock, voting separately as a class, are entitled
to elect a percentage of our directors determined by the
aggregate amount of shares of our Preferred Stock and our common
stock beneficially owned by Resurgence Asset Management, L.L.C.
and certain permitted transferees. Currently, the holders of our
Preferred Stock are entitled to elect a majority of our
directors. Under our Amended and Restated Certificate of
Incorporation, the holders of our Secured Notes have the
exclusive right, voting separately as a class, to elect one of
our directors until our Secured Notes have been paid in full,
with each holder being entitled to one vote for each $1,000 in
principal amount of our Secured Notes held of record by such
holder. All of our other directors are elected by the holders of
our Preferred Stock and the holders of our common stock, voting
together as a single class. For purposes of class voting, each
share of our Preferred Stock has the right to one vote for each
share of our common stock into which such share is convertible
on the record date for such vote, which was 1,000 shares on
the record date for the Annual Meeting. At the Annual Meeting,
four of our directors were elected by the holders of our
Preferred Stock, three of our directors were elected by the
holders of our Preferred Stock and the holders of our common
stock, voting together as a single
26