Tronox 10K 2005
UNITED
STATES
SECURITIES
AND EXCHANGE COMMISSION
Washington,
D.C. 20549
FORM 10-K
ANNUAL
REPORT PURSUANT TO SECTION 13 OR 15(d) OF
THE
SECURITIES EXCHANGE ACT OF 1934
For
the fiscal year ended December 31, 2005
Commission
file number 1-32669
TRONOX
INCORPORATED
(Exact
Name of Registrant as Specified in its Charter)
Delaware
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20-2868245
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(State
or Other Jurisdiction of
Incorporation
or Organization)
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(I.R.S.
Employer
Identification
Number)
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123 Robert S.
Kerr Avenue, Oklahoma City, Oklahoma 73102
(Address
of principal executive offices)
Registrant’s
telephone number, including area code: (405) 775-5000
Securities
Registered Pursuant to Section 12(b) of the Act:
Title
of Each Class
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Name
of Each Exchange on Which Registered
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Class
A Common Stock, $0.01 par value
Class
B Common Stock, $0.01 par value
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New
York Stock Exchange
New
York Stock Exchange
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No
Securities are Registered Pursuant to Section 12(g) of the
Act.
Indicate
by check mark if the registrant is a well-known seasoned issuer, as defined
in
Rule 405 of the Securities Act.
Yes
o
No
þ
Indicate
by check mark if the registrant is not required to file reports pursuant
to
Section 13 or Section 15(d) of the Act.
Yes
o
No
þ
Indicate
by check mark whether the registrant (1) has filed all reports required to
be
filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during
the
preceding 12 months (or for such shorter period that the registrant was required
to file such reports), and (2) has been subject to such filing requirement
for
the past 90 days.
Yes þ
No
o
Indicate
by check mark if disclosure of delinquent filers pursuant to Item 405 of
Regulation S-K is not contained herein, and will not be contained, to the
best
of registrant’s knowledge, in definitive proxy or information statements
incorporated by reference in Part III of this Form 10-K or any amendment
to this
Form 10-K.
¨
Indicate
by check mark whether the registrant is a large accelerated filer, an
accelerated filer, or a non-accelerated filer (see definition of “accelerated
filer” in Rule 12b-2 under the Exchange Act). (Check one):
Large
accelerated filer o
Accelerated filer o
Non-accelerated filer þ
Indicate
by check mark whether the registrant is a shell company (as defined in Rule
12b-2 of the Exchange Act).
Yes
o
No
þ
The
aggregate market value of the registrant’s voting and non-voting common stock
held by non-affiliates of the registrant (without admitting that any person
whose shares are not included in such calculation is an affiliate) computed
by
reference to the price at which the Class A common stock was last sold on the
New York Stock Exchange on February 28, 2006, was $269.4 million. The registrant
has provided this information as of February 28, 2006, because its common equity
was not publicly traded as of the last business day of its most recently
completed second fiscal quarter.
As
of
February 28, 2006, 17,801,790 shares of the company’s Class A common stock and
22,889,431 shares of the company’s Class B common stock were
outstanding.
Documents
Incorporated by Reference
The
definitive Proxy Statement for the 2006 Annual Meeting of Stockholders, which
will be filed with the Securities and Exchange Commission within 120 days after
December 31, 2005, is incorporated by reference in Part III of this Form
10-K.
Tronox
Incorporated
Form 10-K
Table
of Contents
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PART
I
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Page
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Items
1. and 2.
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Business
and Properties
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1 |
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Item
1A.
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Risk
Factors
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17 |
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Item
1B.
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Unresolved
Staff Comments
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25 |
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Item
3.
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Legal
Proceedings
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26 |
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Item
4.
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Submission
of Matters to a Vote of Security Holders
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27 |
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PART
II
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Item
5.
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Market
for Registrant’s Common Equity and Related Stockholder
Matters
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27 |
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Item
6.
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Selected
Financial Data
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29 |
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Item
7.
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Management’s
Discussion and Analysis of Financial Condition and Results of
Operations
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33 |
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Item
7A.
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Quantitative
and Qualitative Disclosures About Market Risk
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55 |
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Item
8.
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Financial
Statements and Supplementary Data
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58 |
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Item
9.
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Changes
in and Disagreements With Accountants on Accounting and Financial
Disclosure
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107 |
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Item
9A.
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Controls
and Procedures
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107 |
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PART
III
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Item
10.
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Directors
and Executive Officers of the Registrant
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107 |
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Item
11.
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Executive
Compensation
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109 |
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Item
12.
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Security
Ownership of Certain Beneficial Owners and Management and Related
Stockholder Matters
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109 |
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Item
13.
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Certain
Relationships and Related Transactions
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110 |
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Item
14.
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Principal
Accountant Fees and Services
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110 |
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PART
IV
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Item
15.
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Exhibits
and Financial Statement Schedules
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110 |
TRONOX
INCORPORATED
PART
I
Items
1. and 2. Business and
Properties
Tronox
Incorporated, a Delaware corporation, was formed on May 17, 2005, in preparation
for the contribution and transfer by Kerr-McGee Corporation (“Kerr-McGee”) of
certain entities, including those comprising substantially all of its chemical
business (the “Contribution”). The Contribution was completed in November 2005
along with the recapitalization of Tronox, whereby common stock held by
Kerr-McGee converted into approximately 22.9 million shares of Class B common
stock. An initial public offering (“IPO”) of Class A common stock was
subsequently completed on November 28, 2005. Prior to the IPO, Tronox was a
wholly-owned subsidiary of Kerr-McGee. Pursuant to the IPO registration
statement on Form S-1 (File No. 333-125574), Tronox sold approximately 17.5
million shares of its Class A common stock at a price of $14.00 per share.
Pursuant to the terms of the Master Separation Agreement dated November 28,
2005, among Kerr-McGee, Kerr-McGee Worldwide Corporation and the company (the
“MSA”), the net proceeds from the IPO of approximately $224.7 million were
distributed to Kerr-McGee.
Concurrent
with the IPO, the company, through its wholly-owned subsidiaries, issued $350.0
million in aggregate principal amount of 9.5% senior unsecured notes due 2012
and borrowed $200.0 million under a six-year senior secured credit facility.
Pursuant to the terms of the MSA, the company distributed to Kerr-McGee the
net
proceeds from the borrowings of approximately $537.1 million.
Following
the IPO, approximately 43.3% of the total outstanding common stock of Tronox
was
held by the general public and 56.7% was held by Kerr-McGee. The holders of
Class A common stock and Class B common stock have identical rights, except
that
holders of Class A common stock are entitled to one vote per share while holders
of Class B common stock are entitled to six votes per share on all matters
to be
voted on by stockholders. As of December 31, 2005, Kerr-McGee owned all of
the
company’s outstanding Class B common stock, which represented approximately
88.7% of the company’s total voting power.
On
March 8, 2006, Kerr-McGee’s Board of Directors declared a dividend of Tronox’s
Class B common stock owned by Kerr-McGee to its stockholders (the
“Distribution”). The Distribution is expected to be completed on March 30, 2006.
Upon completion of the Distribution, Kerr-McGee will have no ownership or voting
interest in us.
The
terms “Tronox,” “the company,” “we,” “our” and similar terms are used
interchangeably in this annual report to refer to the consolidated group or
to
one or more of the companies that are part of the consolidated group. The
company is primarily engaged in the global production and marketing of titanium
dioxide, a white pigment used in a wide range of products. The company has
in
the past operated or held businesses or properties, or currently holds
properties, that do not relate to the current chemical business, including
businesses involving the treatment of forest products, the production of
ammonium perchlorate, the refining and marketing of petroleum products, offshore
contract drilling, coal mining and the mining, milling and processing of nuclear
materials.
Overview
Tronox
is one of the leading global producers and marketers of titanium dioxide
pigment. We market titanium dioxide pigment under the brand name TRONOX®, and
our pigment segment represented more than 90% of our net sales in 2005. We
are
the world’s third-largest producer and marketer of titanium dioxide based on
reported industry capacity by the leading titanium dioxide producers, and we
have an estimated 13% market share of the $9 billion global market in 2005
based on reported industry sales. Our world-class, high-performance pigment
products are critical components of everyday consumer applications, such as
coatings, plastics and paper, as well as specialty products, such as inks,
foods
and cosmetics. In addition to titanium dioxide, we produce electrolytic
manganese dioxide, sodium chlorate, boron-based and other specialty chemicals.
In 2005, we had net sales of $1.4 billion and net income of $18.8 million.
Based on the country of production, the geographic distribution of our net
sales
was as follows during the last three years:
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2005
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2004
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2003
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(Millions
of dollars)
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United
States
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$
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755.9
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$
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716.8
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$
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646.7
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International
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608.1
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585.0
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511.0
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$
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1,364.0
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$
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1,301.8
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$
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1,157.7
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The
chart below summarizes our 2005 net sales by business segment:
2005
Net Sales by Business Segment
We
have
maintained strong relationships with our customers since our current chemical
operations began in 1964. We focus on providing our customers with world-class
products, end-use market expertise and strong technical service and support.
With more than 2,100 employees worldwide, strategically located manufacturing
facilities and direct sales and technical service organizations in the United
States, Europe and the Asia-Pacific region, we are able to serve our diverse
base of more than 1,100 customers in over 100 countries.
Globally,
including all of the production capacity of the facility operated under our
Tiwest Joint Venture (see "Manufacturing,
Operations and Properties - The Tiwest Joint Venture"),
we
have 517,000 and 107,000 tonnes of aggregate annual chloride and sulfate
titanium dioxide production capacity, respectively. We hold over 200 patents
worldwide, as well as other intellectual property. We have a highly skilled
and
technologically sophisticated workforce.
Competitive
Strengths
We
benefit from a number of competitive strengths, including the
following:
Leading
Market Positions
We
are
the world’s third-largest producer and marketer of titanium dioxide products
based on reported industry capacity by the leading titanium dioxide producers
and the world’s second-largest producer and supplier of titanium dioxide
manufactured via proprietary chloride technology, which we believe is preferred
for many of the largest end-use applications. We estimate that we have a 15%
share of the $5.2 billion global market for the use of titanium dioxide in
coatings, which industry sources consider the largest end-use market. We believe
our leading market positions provide us with a competitive advantage in
retaining existing customers and obtaining new business.
Global
Presence
We
are
one of the few titanium dioxide manufacturers with global operations. We have
production facilities and a sales and marketing presence in the Americas, Europe
and the Asia-Pacific region. In 2005, sales into the Americas accounted for
approximately 48% of our total titanium dioxide net sales, followed by
approximately 31% into Europe and approximately 21% into the Asia-Pacific
region. Our global presence enables us to provide customers in over 100
countries with a reliable source of multiple grades of titanium dioxide. The
diversity of the geographic markets we serve also mitigates our exposure to
regional economic downturns.
Well-Established
Relationships with a Diverse Customer Base
We
sell
our products to a diverse portfolio of customers with whom we have
well-established relationships. Our customer base consists of more than 1,100
customers in over 100 countries and includes market leaders in each of the
major
end-use markets for titanium dioxide. We have supplied each of our top ten
customers with titanium dioxide pigment for over ten years. We work closely
with
our customers to optimize their formulations, thereby enhancing the use of
titanium dioxide in their production processes. This has enabled us to develop
and maintain strong relationships with our customers, resulting in a high
customer retention rate.
Innovative,
High-Performance Products
We
offer innovative, high-performance products for nearly every major titanium
dioxide end-use application, including seven grades of titanium dioxide
(“TiO2”)
for
specialty applications such as inks, catalysts and electro-ceramics. We are
dedicated to continually developing our titanium dioxide products to better
serve our customers and responding to the increasingly stringent demands of
their end-use markets. Our recently introduced products, CR-826 and CR-880,
offer a combination of optical properties, opacity, ease of dispersion and
durability that is valued by customers for a variety of applications. Sales
volume of these high-performance products increased at a compounded annual
growth rate of 29% from 2001 to 2005.
Proprietary
Production Technology
We
are
one of a limited number of producers in the titanium dioxide industry to
hold
the rights to a proprietary chloride process for the production of titanium
dioxide. Approximately 83% of our gross production capacity uses this process
technology, which is the subject of numerous patents worldwide and is utilized
by our highly skilled and technologically sophisticated work force. Titanium
dioxide produced using chloride process technology is preferred for many
of the
largest end-use applications. The chloride production process generates less
waste, uses less energy and is less labor intensive than the sulfate process.
The complexity of developing and operating the chloride process technology
makes
it difficult for others to enter and successfully compete in the chloride
process titanium dioxide industry.
Experienced
Management Team
Our
management team has an average of 23 years of business experience. The diversity
of their business experience provides a broad array of skills that contributes
to the successful execution of our business strategy. Our operations team and
plant managers, who have an average of 27 years of manufacturing experience,
participate in the development and execution of strategies that have resulted
in
production volume growth, production efficiency improvements and cost
reductions. The experience, stability and leadership of our sales organization
have been instrumental in growing sales, developing and maintaining customer
relationships and increasing our market share.
Business
Strategy
We
use
specific and individualized operating measures throughout our organization
to
track and evaluate key metrics. This approach serves as a scorecard to ensure
alignment with, and accountability for, the execution of our strategy, which
includes the following components:
Strong
Customer Focus
We
target our key markets with innovative, high-performance products that provide
enhanced value to our customers at competitive prices. A key component of our
business strategy is to continually enhance our product portfolio with
high-quality, market-driven product development. We design our titanium dioxide
products to satisfy our customers’ specific requirements for their end-use
applications and align our business to respond quickly and efficiently to
changes in market demands. In this regard, and in order to continue meeting
our
customers’ needs, we commercialized a new pigment grade for paper coatings and
developed a new grade for architectural paints in close cooperation with our
customer base. New and enhanced grades for coatings, plastic, paper laminate
and
specialty applications are in the pipeline for introduction in 2006 and
2007.
Technological
Innovation
We
employ customer and end-use market feedback, technological expertise and
fundamental research to create next-generation products and processes. Our
technology development efforts include building value-added properties into
our
titanium dioxide to enhance its performance in our customers’ end-use
applications. Our research and development teams support our future business
strategies, and we manage those teams using disciplined project management
tools
and a team approach to technological development.
Operational
Excellence
We
achieved record production in 2005 through our currently operating facilities,
with fourth- quarter production rates higher than any previous
quarter. This is an exceptional achievement because it occurred while our
Kwinana plant was shut down approximately two weeks due to force majeure
declared by a third-party process gas supplier. This newly demonstrated
capability positions us to meet market growth over the short term
without investing capital for capacity expansion. While we were not able to
offset the rapid increase in energy pricing in 2005 with cost reductions, we
continued to improve our energy consumption across plants through Six
Sigma projects and other continuous improvement activities. We used a
broader spectrum of TiO2
ore
than ever before, while improving the TiO2
yield
through more tightly controlled plant operations.
Maximize
Asset Efficiency
We
optimize our production plan through strategic use of our global facilities
to
save on both transportation and warehousing costs. Our production process is
designed with multiple production lines. As a result, we can remedy issues
with
an individual line without shutting down other lines and idling an entire
facility. We also actively manage production capability across all facilities.
For instance, if one plant’s finishing lines are already at full capacity, that
plant’s unfinished titanium dioxide can be transferred to another plant for
finishing.
Supply
Chain Optimization
We
improve our supply chain efficiency by focusing on reducing both operating
costs
and working capital needs. Our supply chain efforts to lower operating costs
consist of reducing procurement spending, lowering transportation and warehouse
costs and optimizing production scheduling. We actively manage our working
capital by increasing inventory turnover and reducing finished goods and raw
materials inventory without affecting our ability to deliver titanium dioxide
to
our customers.
Organizational
Alignment
Aligning
the efforts of our employees with our business strategies is critical to our
success. To achieve that alignment, we evaluate the performance of our employees
using a balanced scorecard approach. We also invest in training initiatives
that
are directly linked to our business strategies. For instance, approximately
120
of our employees have completed the well-regarded supply chain management
training program at Michigan State University’s Broad Executive School of
Management. We also train our employees in Six Sigma methodology to support
our
operational excellence and asset efficiency strategic objectives.
INDUSTRY
BACKGROUND
We
are
one of the leading global producers and marketers of titanium dioxide pigments.
We also produce a variety of electrolytic and other specialty chemical
products.
Titanium
Dioxide
Titanium
dioxide, or TiO2,
is a
white pigment used in a wide range of products for its exceptional ability
to
impart whiteness, brightness and opacity. TiO2
is a
critical component of everyday applications, such as coatings, plastics and
paper, as well as many specialty products such as inks, foods and cosmetics.
Titanium dioxide is widely considered to be superior to alternative white
pigments in large part due to its hiding power, which is the ability to cover
or
mask other materials effectively and efficiently. For example, titanium
dioxide’s hiding power helps prevent show-through on printed paper materials
(making the materials easier to read) and a high concentration of titanium
dioxide within paints reduces the number of coats needed to cover a surface
effectively. Titanium dioxide is designed, marketed and sold based on specific
end-use applications.
The
global titanium dioxide market is characterized by a small number of large
global producers. In addition to our company, there are four other major
producers: E.I. du Pont de Nemours and Company, Millennium
Chemicals Inc., Huntsman Corporation and Kronos Worldwide, Inc. These
five major producers accounted for approximately 70% of the global market in
2005, according to reports by these producers.
Based
on reported industry sales by the leading titanium dioxide producers, we
estimate that global sales of titanium dioxide in 2005 exceeded 4.3 million
tonnes, generating approximately $9 billion in industry-wide revenues.
Because titanium dioxide is a “quality of life” product, its consumption growth
is closely tied to a given region’s economic health and correlates over time to
the growth in its average gross domestic product. According to industry
estimates, titanium dioxide consumption has been growing at a compounded annual
growth rate of approximately 2.8% over the past decade.
Although
there are other white pigments on the market, we believe that titanium dioxide
has no effective substitute because no other white pigment has the physical
properties for achieving comparable opacity and brightness or can be
incorporated in as cost-effective a manner. In an effort to optimize titanium
dioxide’s cost-to-performance ratio in certain applications, some customers also
use pigment “extenders,” such as synthetic pigments, kaolin clays and calcium
carbonate. We estimate that the impact on our total sales from the use of such
extenders is minimal.
Titanium
Dioxide Outlook
The
global end-use market demand for titanium dioxide is cyclical, which closely
affects its pricing. The period from late 2000 through 2003, for example, was
a
period of unusually weak business conditions attributable to various factors,
including the global economic recession, exceptionally rainy weather conditions
in Europe and the Americas that limited the painting season, and the outbreak
of
SARS in Asia. These factors reduced demand for titanium dioxide, which resulted
in global over supply. The resulting decline in titanium dioxide prices during
this period led several major titanium dioxide producers to reduce production
and working capital levels and to engage in other capacity rationalization
measures.
A
general improvement in global economic conditions in late 2004 drove increased
demand for titanium dioxide. Increased demand, coupled with reduced supply,
led
to price increases in the last half of 2004 and throughout 2005. We believe
that
current industry dynamics show a sustainable improving trend. With no major
plant construction projects commenced, and considering that it typically takes
two to four years to bring on significant new capacity, we expect the current
high capacity utilization rates to continue in the near term. We believe limited
expected capacity additions over the next several years, when combined with
improving demand, will result in increasing margins.
Manufacturing
Titanium Dioxide
Production
Process.
Titanium dioxide pigment is produced using a combination of processes involving
the manufacture of base pigment particles followed by surface treatment, drying
and milling (collectively known as finishing). There are two commercial
production processes in use: the chloride process and the sulfate process.
The
chloride process is a newer technology and has several advantages over the
sulfate process: it generates less waste, uses less energy, is less labor
intensive and permits the direct recycle of a major process chemical, chlorine,
back into the production process. In addition, as described below under
“Types
of Titanium Dioxide,”
titanium dioxide produced using the chloride process is preferred for many
of
the largest end-use applications. As a result, the chloride process currently
accounts for substantially all of the titanium dioxide production capacity
in
North America and approximately 60% of worldwide capacity. Since the late 1980s,
the vast majority of titanium dioxide production capacity that has been built
uses the chloride process.
In
the
chloride process, feedstock ores (titanium slag, synthetic rutile, natural
rutile or ilmenite ores) are reacted with chlorine (the chlorination step)
and
carbon to form titanium tetrachloride (“TiCl4”)
in a
continuous fluid bed reactor. Purification of TiCl4
to
remove other chlorinated products is accomplished using a distillation process.
The purified TiCl4
is
then oxidized in a vapor phase form to produce base pigment particles and
chlorine gas. The latter is recycled back to the chlorination step for reuse.
Base pigment is then typically slurried with water and dispersants prior to
entering the finishing step.
In
the
sulfate process, batch digestion of ilmenite ore or titanium slag is carried
out
with concentrated sulfuric acid to form soluble titanyl sulfate. After treatment
to remove soluble and insoluble impurities and concentration of the titanyl
sulfate, hydrolysis of the liquor forms an insoluble hydrous titanium oxide.
This precipitate is filtered, bleached, washed and calcined to produce a base
pigment that is then forwarded to the finishing step.
The
schematic diagram below illustrates the basic steps of the chloride and sulfate
processes and a representation of a finishing process common to
both.
Titanium
Dioxide Manufacturing Processes
*Only
required for ilmenite feedstock
Types
of Titanium Dioxide.
Commercial production of titanium dioxide results in one of two different
crystal forms, either rutile or anatase. Rutile titanium dioxide is preferred
over anatase titanium dioxide for many of the largest end-use applications,
such
as coatings and plastics, because its higher refractive index imparts better
hiding power at lower quantities than the anatase crystal form. Although rutile
titanium dioxide can be produced using either the chloride process or the
sulfate process, customers often prefer rutile produced using the chloride
process because it typically has a bluer undertone and greater
durability.
Anatase
titanium dioxide can only be produced using the sulfate process and has
applications in paper, rubber, fibers, ceramics, foods and cosmetics. It is
not
recommended for outdoor applications because it is less durable than rutile
titanium dioxide.
Electrolytic
and Other Chemical Products
Battery
Materials
The
battery industry uses electrolytic manganese dioxide (“EMD”) as the active
cathode material for primary (non-rechargeable) batteries and lithium manganese
oxide and lithium vanadium oxide in rechargeable lithium batteries. Battery
applications account for nearly all of the consumption of these
chemicals.
The
primary battery market is composed of alkaline and zinc carbon battery
technologies to address the various power delivery requirements of a multitude
of consumer battery-powered devices. Approximately 85% of market demand in
the
United States is for alkaline batteries, which are higher performing and more
costly than batteries using the older zinc carbon technology. Tronox is a key
supplier of EMD for the alkaline battery market.
EMD
quality requirements for alkaline technology are much more demanding than for
zinc carbon technology and, as a result, alkaline-grade EMD commands a higher
price than zinc carbon-grade EMD. The older zinc carbon technology remains
dominant in developing countries such as China and India. As the economies
of
China and India continue to mature, and the need for more efficient energy
sources develops, we anticipate that the demand for alkaline-grade EMD will
increase.
The
market application for rechargeable lithium batteries is consumer electronics,
in particular cell phones, computers, camcorders and, most recently, power
tools. A combination of improved power delivery performance and lighter weight
has allowed rechargeable lithium technology to displace older lead acid and
nickel cadmium technologies.
Sodium
Chlorate
The
pulp and paper industry accounts for more than 95% of the market demand for
sodium chlorate, which uses it to bleach pulp. Although there are other methods
for bleaching pulp, the chlorine dioxide process is preferred for environmental
reasons. Approximately 60% of North American sodium chlorate production capacity
is located in Canada due to the availability of lower cost hydroelectric power,
which reduces manufacturing costs and ultimately, product prices. However,
we
believe that the proximity of domestic sodium chlorate producers to the major
domestic pulp and paper producers helps offset the lower-cost power advantage
enjoyed by Canadian sodium chlorate producers, through lower transportation
costs.
Boron
Tronox
produces two types of boron specialty chemicals: boron trichloride and elemental
boron. Boron trichloride is a specialty chemical that is used in many products,
including pharmaceuticals, semiconductors, high-performance fibers, specialty
ceramics and epoxies. Elemental boron is a specialty chemical that is used
in
igniter formulations for the defense, pyrotechnic and automotive air bag
industries.
End-Use
Markets and Applications
Titanium
Dioxide
The
major end-use markets for titanium dioxide products, which we sell in the
Americas, Europe and the Asia-Pacific region, are coatings, plastics and paper
and specialty products. The charts below summarize our approximate 2005 net
sales by geography and our approximate 2005 sales volume by end-use
market:
2005
Net Sales by Geography
|
|
2005
Sales Volume by End-Use Market
|
|
|
|
|
|
|
Coatings
End-Use Market.
The
coatings end-use market represents the largest end-use market for titanium
dioxide products and accounts for approximately 60% of overall industry demand,
based on reported industry sales volumes, and 67% of our 2005 sales volume.
Customers in the coatings end-use market demand exceptionally high quality
standards for titanium dioxide, especially with regard to opacity, durability,
tinting strength and brightness. We recognize four sub-markets within the
coatings end-use market based on application, each of which requires different
titanium dioxide formulations. The table below summarizes the sub-markets within
coatings, as well as their applications and primary growth factors:
Sub-Market
|
|
Applications
|
|
Growth
Factors
|
Architectural
|
|
Residential
and commercial paints
|
|
New
and existing housing market and interest rates
|
Industrial
|
|
Appliances,
coil coatings, furniture and maintenance
|
|
Durable
goods spending and environmental regulations
|
Automotive
|
|
Original
equipment manufacture, refinish and electro-coating
|
|
Interest
rates and environmental regulations
|
Specialty
|
|
Marine
and can coatings, packaging and traffic paint
|
|
Fixed
capital spending and government
regulations
|
Plastics
End-Use Market.
The
plastics end-use market accounts for approximately 20% of overall industry
demand for titanium dioxide, based on reported industry sales volumes, and
22%
of our 2005 sales volume. Plastics producers focus on titanium dioxide’s
opacity, durability, color stability and thermal stability. We recognize
four
sub-markets within the plastics market based on application, each of which
requires different titanium dioxide formulations. The table below summarizes
the
sub-markets within plastics, as well as their applications and primary growth
factors:
Sub-Market
|
|
Applications
|
|
Growth
Factors
|
Polyolefins
|
|
Food
packaging, plastic films and agricultural films
|
|
Consumer
non-durable goods spending
|
PVC
|
|
Vinyl
windows, siding, fencing, vinyl leather, roofing and shoes
|
|
Construction
and renovation markets and consumer non-durable goods
spending
|
Engineering
plastics
|
|
Computer
housing, cell phone cases, washing machines and refrigerators
|
|
Consumer
durable goods spending and electronics market
|
Other
plastics
|
|
Roofing
and flooring
|
|
Construction
market and durable goods spending
|
Paper
and Specialty End-Use Market.
The
paper and specialty end-use market accounts for approximately 20% of overall
industry demand for titanium dioxide, based on reported industry sales volumes,
and 11% of our 2005 sales volume. We recognize four sub-markets within paper
and
specialty end-use market based on application, each of which requires different
titanium dioxide formulations. The table below summarizes the sub-markets within
paper and specialty, as well as their applications and primary growth
factors:
Sub-Market
|
|
Applications
|
|
Growth
Factors
|
Paper
and paper laminate
|
|
Filled
paper, coated paper for print media, coated board for beverage container
packaging, wallboard, flooring, cabinets and furniture
|
|
Consumer
non-durable goods spending and construction and renovation
markets
|
Inks
and rubber
|
|
Packaging,
beverage cans, container printing and rubber flooring
|
|
Consumer
non-durable goods spending
|
Food
and pharmaceuticals
|
|
Creams,
sauces, capsules, sun screen, face and body care products
|
|
Consumer
non-durable goods spending
|
Catalysts
and electroceramics
|
|
Anti-pollution
equipment (catalysts) for automobiles and power-generators and production
of capacitors and resistors
|
|
Environmental
regulations and electronics
|
Electrolytic
and Other Chemical Products
Our
other product lines include chemicals for battery materials, sodium chlorate
for
pulp bleaching and boron-based specialty chemicals. The sub-markets for those
products, together with their applications and growth factors, are as
follows:
Product
|
|
Sub-Market
|
|
Applications
|
|
Growth
Factors
|
Battery
materials
|
|
Non-rechargeable
battery materials
|
|
Alkaline
and zinc carbon battery markets
|
|
Consumer
non-durable goods spending
|
Battery
materials
|
|
Rechargeable
battery materials
|
|
Rechargeable
lithium batteries
|
|
Consumer
non-durable goods spending
|
Sodium
Chlorate
|
|
Pulp
and paper industry
|
|
Pulp
bleaching
|
|
Consumer
non-durable goods spending
|
Boron
|
|
Specialty
chemical
|
|
Pharmaceuticals,
semiconductors, high-performance fibers, specialty ceramics and
epoxies
|
|
Consumer
non-durable goods spending
|
Boron
|
|
Defense,
pyrotechnic and air bag industries
|
|
Igniter
formulations
|
|
Consumer
non-durable goods spending
|
Sales
and Marketing
We
supply titanium dioxide to a diverse customer base that includes market leaders
in each of the major end-use markets for titanium dioxide. In 2005, our ten
largest customers represented approximately 35% of our total sales volume and
no
single customer accounted for more than 10% of our total sales volume. In 2005,
approximately 42% of our global production volume was covered by multi-year
supply contracts.
In
addition to price and product quality, we compete on the basis of technical
support and customer service. Our direct sales and technical service
organizations carry out our sales strategy and work together to provide quality
customer service. Our direct sales staff is trained in all of our products
and
applications. Because of the technical requirements of titanium dioxide
applications, our technical service organization and direct sales offices are
supported by a regional customer service staff located in each of our major
geographic markets.
Our
sales and marketing strategy focuses on effective customer management through
the development of strong relationships throughout our company with our
customers. We develop customer relationships and manage customer contact through
our sales team, technical service organization, research and development team,
customer service team, plant operations personnel, supply chain specialists
and
senior management. We believe that multiple points of customer contact
facilitate efficient problem-solving, supply chain support, formula optimization
and product co-development. By developing close relationships with our customers
and providing well-designed products and services, we are a value-added business
partner.
Competitive
Conditions
Titanium
Dioxide
The
global market in which our titanium dioxide business operates is highly
competitive. Worldwide, we believe that we are one of only five companies
(including E.I. du Pont de Nemours and Company, Millennium
Chemicals Inc., Huntsman Corporation and Kronos Worldwide, Inc.) that
use proprietary chloride process technology for production of titanium dioxide
pigment. We estimate that, based on gross sales volumes, these companies
accounted for approximately 70% of the global market share in 2005. We believe
that cost efficiency and product quality, as well as technical and customer
service, are key competitive factors for titanium dioxide
producers.
Titanium
dioxide produced using chloride process technology is preferred for many of
the
largest titanium dioxide end-use applications; however, titanium dioxide
produced using sulfate process technology is preferred for certain specialty
applications. The following charts summarize the estimated market share and
production process mix for the five leading titanium dioxide pigment producers
for fiscal year 2005:
2005
Global Market Share
|
|
2005
Production Process Mix
|
|
|
|
As
of
December 31, 2005, including the total production capacity of our Tiwest
Joint Venture (see “Manufacturing,
Operations and Properties - The Tiwest Joint Venture”),
we
had global production capacity of 624,000 tonnes per year and an approximate
13%
global market share. In addition to the major competitors discussed above,
we
compete with numerous smaller, regional producers, as well as producers in
China
that have expanded their sulfate production capacity during the previous five
years.
Electrolytic
and Other Chemical Products
Electrolytic
Manganese Dioxide.
The
U.S. market accounts for approximately one-third of global demand for EMD,
and
is based on alkaline grade EMD. Tronox is a key supplier to this market and
has
an estimated 8% share of total global capacity. Other significant producers
and
their estimated global capacity shares include Erachem (7%) in the United
States, as well as international producers Delta (17%), Tosoh (15%), Xiangtan
(11%) and Mitsui (7%). The remainder of global capacity is represented by
various Chinese producers.
Sodium
Chlorate.
We
have an estimated 7% share of North American sodium chlorate capacity. Our
significant competitors and their estimated share of North American capacity
are
ERCO (27%), Eka Chemicals (27%), Canexus (19%) and Kemira-Finnish Chemicals
(11%).
Other
Specialties.
For
boron products, we believe that we have the majority of the installed global
capacity for boron trichloride. Other boron production capacity is located
in
Ireland, Japan and Russia.
Manufacturing,
Operations and Properties
Titanium
Dioxide
We
produce titanium dioxide using either the chloride process or the sulfate
process at five production facilities located in four countries. We believe
our
facilities are well situated to serve our global customer base.
Two
of
our facilities are located in the United States, and we have one facility in
each of Australia, Germany and the Netherlands. We own our facilities in Germany
and the Netherlands, and the land under these facilities is held pursuant to
long-term leases. We own our domestic facilities and hold a 50% undivided
interest in our Australian facility. We market and sell all of the titanium
dioxide produced by our Australian facility and share in the profits equally
with our joint venture partner. See “The
Tiwest Joint Venture.”
The
following table summarizes our production capacity as of December 31, 2005,
by location and process:
Titanium
Dioxide Production Capacity
As
of December 31, 2005
(Gross
tonnes per year)
Facility
|
|
Capacity
|
|
Process
|
|
Hamilton,
Mississippi
|
|
|
225,000
|
|
|
Chloride
|
|
Savannah,
Georgia
|
|
|
110,000
|
|
|
Chloride
|
|
Kwinana,
Western Australia
|
|
|
110,000
|
(1) |
|
Chloride
|
|
Botlek,
Netherlands
|
|
|
72,000
|
|
|
Chloride
|
|
Uerdingen,
Germany
|
|
|
107,000
|
|
|
Sulfate
|
|
Total
|
|
|
624,000
|
|
|
|
|
(1)
|
Reflects
100% of the production capacity of the pigment plant, which is owned
50%
by us and 50% by our joint venture
partner.
|
Including
the titanium dioxide produced by our Australian facility, we produced
588,990 tonnes of titanium dioxide in 2005. Including production volumes
from our Savannah sulfate facility that was closed in September 2004, we
produced 602,024 tonnes in 2004, compared to 578,913 tonnes in 2003. Our
average production rates, as a percentage of capacity, were 94%, 91% and 87%,
in
2005, 2004 and 2003, respectively. Over the past five years, production at
our
current facilities increased by approximately 24%, primarily due to
debottlenecking and low cost incremental investments. Our global manufacturing
presence, coupled with our ability to increase capacity incrementally, makes
us
a stable supplier to many of the largest titanium dioxide
consumers.
The
Tiwest Joint Venture
Our
subsidiary, Tronox Western Australia Pty. Ltd., has a 50% undivided
interest in all of the assets that comprise the operations conducted in
Australia under the Tiwest joint venture arrangement and is severally liable
for
50% of associated liabilities. The remaining 50% undivided interest is held
by a
subsidiary of our joint venture partner, Ticor Pty Ltd, which is a subsidiary
of
Kumba Resources Limited. The joint venture partners operate a chloride process
titanium dioxide plant located in Kwinana, Western Australia, as well as a
mining venture in Cooljarloo, Western Australia, and a synthetic rutile
processing facility in Chandala, Western Australia. Under separate marketing
agreements, we have the right to market our partner’s share of the titanium
dioxide produced by the Kwinana facility. For more information regarding our
facility in Kwinana, see “Titanium
Dioxide”
above. For more information regarding the mining venture, see “Heavy
Minerals”
below.
Management.
The
operations associated with the Tiwest joint venture arrangement are governed
by
two committees: a management committee and an operating committee. The operating
committee meets at least monthly and supervises the joint venture’s routine
operations, and the management committee meets at least quarterly and has the
authority to make fundamental corporate decisions and to overrule the operating
committee’s decisions. The committees’ decisions are made by simple majority
approval. If there is an equal number of votes cast for and against a matter
at
an operating committee meeting, the matter is referred to a subsequent meeting.
If at the subsequent meeting, the matter still receives an equal number of
votes
cast on each side, the matter is referred to the management committee. Tronox
Western Australia and Ticor each have the right to appoint half of each
committee’s members.
Heavy
Minerals.
The
joint venture partners mine heavy minerals from 21,036 acres under a long-term
mineral lease from the State of Western Australia, for which each joint venture
partner holds a 50% undivided interest. Our 50% undivided interest in the
properties’ remaining in-place proven and probable reserves is 5.1 million
tonnes of heavy minerals contained in 197 million tonnes of sand averaging
2.6% heavy minerals. The valuable heavy minerals are composed on average of
61.0% ilmenite, 10.0% zircon, 4.6% natural rutile and 3.3% leucoxene, with
the
remaining 21.1% of heavy minerals having no significant value.
Heavy-mineral
concentrate from the mine is processed at a 750,000-tonne per year dry
separation plant, for which each joint venture partner holds a 50% undivided
interest. Some of the recovered ilmenite is upgraded at the nearby synthetic
rutile facility in Chandala, which has a capacity of 225,000 tonnes per year.
Synthetic rutile is a high-grade titanium dioxide feedstock. All of the
synthetic rutile feedstock for the 110,000-tonne per year titanium dioxide
plant
located at Kwinana is provided by the Chandala processing facility. Production
of feedstock in excess of the plant’s requirements is sold to third parties, as
well as to us, for the portion not already owned, as part of the feedstock
requirement for titanium dioxide at our other facilities.
Information
regarding our 50% interest in heavy-mineral reserves, production and average
prices for the three years ended December 31, 2005, is presented in the
following table. Mineral reserves in this table represent the estimated
quantities of proven and probable ore that, under anticipated conditions, may
be
profitably recovered and processed for the extraction of their mineral content.
Future production of these resources depends on many factors, including market
conditions and government regulations. See “Risk
Factors - Fluctuations in costs of our raw materials or our access to supplies
of our raw materials could have an adverse effect on our results of
operations.”
Heavy-Mineral
Reserves, Production and Prices
(Reserves
and production in tonnes)
|
|
2005
|
|
2004
|
|
2003
|
|
Proven
and probable reserves (as of year end)
|
|
|
5,145,000
|
|
|
5,570,000
|
|
|
5,970,000
|
|
Production
|
|
|
300,000
|
|
|
302,000
|
|
|
294,000
|
|
Average
market price (per tonne)
|
|
$
|
182
|
|
$
|
161
|
|
$
|
152
|
|
Electrolytic
and Other Chemical Products
We
produce electrolytic and other chemical products at three domestic facilities,
each of which we own. The following table summarizes our production capacity
as
of December 31, 2005, by location and product.
Electrolytic
and Other Chemical Capacity
As
of December 31, 2005
(Gross
tonnes per year)
Facility
|
|
Capacity
|
|
Product
|
|
Hamilton,
Mississippi
|
|
|
130,000
|
|
|
Sodium
chlorate
|
|
Henderson,
Nevada
|
|
|
27,000
|
|
|
EMD
|
|
Henderson,
Nevada
|
|
|
525
|
|
|
Boron
products
|
|
Soda
Springs, Idaho
|
|
|
300
|
|
|
Lithium
manganese oxide
and lithium vanadium oxide
|
|
Raw
Materials
Titanium
Dioxide
The
primary raw materials that we use to produce titanium dioxide are various types
of titanium-bearing ores, including ilmenite, natural rutile, synthetic rutile,
titanium-bearing slag and leucoxene. We generally purchase ores under multi-year
agreements from a variety of suppliers in Australia, Canada, India, Norway,
South Africa, Ukraine and the United States. We purchase approximately 47%
of
the titanium-bearing ores we require from two suppliers under long-term supply
contracts that expire in 2008 through 2010. Approximately 85% of the synthetic
and natural rutile used by our facilities is obtained from the operations under
the Tiwest joint venture arrangement. See “Manufacturing,
Operations and Properties - The Tiwest Joint Venture.”
We
do not anticipate difficulties obtaining long-term extensions to our existing
supply contracts prior to their expiration. Other significant raw materials
include chlorine and petroleum coke for the chloride process, which we obtain
from many suppliers worldwide, and sulfuric acid for the sulfate process, which
we produce ourselves.
Electrolytic
and Other Chemical Products
The
primary raw material that we use to produce sodium chlorate is sodium chloride,
and for battery materials, manganese ore. We purchase these materials under
multi-year agreements and spot contracts.
Research
and Development
Research
and development is an integral component of our business strategy. Enhancing
our
product portfolio with high-quality, market-focused product development is
key
in driving our business from the customer perspective.
We
have
approximately 70 scientists, chemists, engineers and skilled technicians to
provide the technology (products and processes) for our business. Our product
development personnel have a high level of expertise in the plastics industry
and polymer additives, the coatings industry and formulations, surface
chemistry, material science, analytical chemistry and particle physics. Among
the process technology development group’s highly developed skills are
computational fluid dynamics, process modeling, particle growth physics,
extractive metallurgy, corrosion engineering and thermodynamics. The majority
of
scientists supporting our research and development efforts are located in
Oklahoma City, Oklahoma. Our expenditures for research and development were
approximately $8.4 million in 2005, $6.3 million in 2004 and
$8.0 million in 2003.
New
process developments are focused on increased through-put, control of particle
physical properties and general processing equipment-related issues. Ongoing
development of process technology contributes to cost reduction, enhanced
production flexibility, increased capacity and improved consistency of product
quality.
In
2005, we commercialized a new pigment grade for paper coatings and developed
a
new grade for architectural paints in close cooperation with our customers.
New
and enhanced grades for coatings, plastic, paper laminate and specialty
applications are in the pipeline for introduction in 2006 and 2007.
Patents
and Other Intellectual Property
Patents
held for our products and production processes are important to our long-term
success. We seek patent protection for our technology where competitive
advantage may be obtained by patenting, and file for broad geographic protection
given the global nature of our business. Our proprietary titanium dioxide
technology is the subject of numerous patents worldwide, the substantial
majority of which relate to our chloride products and production
technology.
We
also
rely upon and have taken steps to secure our unpatented proprietary technology,
know-how and other trade secrets. Our proprietary chloride production technology
is an important part of our overall technology position. We are committed to
pursuing technological innovations in order to maintain our competitive
position.
Employees
We
have
approximately 2,110 employees, with approximately 1,210 in the United States,
860 in Europe, 30 in Australia and 10 in other international locations.
Approximately 15% of our employees in the United States are represented by
collective bargaining agreements, and approximately 99% of our employees in
Europe are represented by works’ councils. We consider relations with our
employees to be good.
Government
Regulations and Environmental Matters
General
We
are
subject to extensive regulation by federal, state, local and foreign
governments. Governmental authorities regulate the generation and treatment
of
waste and air emissions at our operations and facilities. At many of our
operations, we also comply with worldwide, voluntary standards such as ISO
9002
for quality management and ISO 14001 for environmental management. ISOs are
standards developed by the International Organization for Standardization,
a
nongovernmental organization that promotes the development of standards and
serves as an external oversight for quality and environmental
issues.
Environmental
Matters
A
variety of laws and regulations relating to environmental protection affect
almost all of our operations. Under these laws, we are or may be required to
obtain or maintain permits or licenses in connection with our operations. In
addition, these laws require us to remove or mitigate the effects on the
environment of the disposal or release of chemical, petroleum, low-level
radioactive and other substances at various sites. Operation of
pollution-control equipment usually entails additional expense. Some
expenditures to reduce the occurrence of releases into the environment may
result in increased efficiency; however, most of these expenditures produce
no
significant increase in production capacity, efficiency or revenue.
The
table below presents environmental related expenditures incurred by the company
for the year ended December 31, 2005, and projections of expenditures for the
next two years. While it is difficult to estimate the total direct and indirect
costs of government environmental regulations, the table below includes our
current estimate of expenditures for the next two years.
|
|
Year
ending December 31,
|
|
|
|
|
|
Estimated
|
|
Estimated
|
|
|
|
2005
|
|
2006
|
|
2007
|
|
|
|
(Millions
of dollars)
|
|
Cash
expenditures of environmental reserves
|
|
$
|
61
|
|
$
|
78
|
|
$
|
47
|
|
Recurring
operating expenses
|
|
|
41
|
|
|
45
|
|
|
43
|
|
Capital
expenditures
|
|
|
11
|
|
|
18
|
|
|
22
|
|
Recurring
operating expenses are expenditures related to the maintenance and operation
of
environmental equipment such as incinerators, waste treatment systems and
pollution control equipment, as well as the cost of materials, energy and
outside services needed to neutralize, process, handle and dispose of current
waste streams at our operating facilities. These expenditures are necessary
to
ensure that current production is handled in an environmentally safe and
effective manner.
We
are
party to a number of legal and administrative proceedings involving
environmental matters or other matters pending in various courts or agencies.
These include proceedings associated with businesses and facilities currently
or
previously owned, operated or used by our affiliates or their predecessors,
and
include claims for personal injuries, property damages, breach of contract,
injury to the environment, including natural resource damages, and
non-compliance with permits. Our current and former operations also involve
management of regulated materials and are subject to various environmental
laws
and regulations. These laws and regulations obligate us to clean up various
sites at which petroleum and other hydrocarbons, chemicals, low-level
radioactive substances or other materials have been contained, disposed of
and/or released. Some of these sites have been designated Superfund sites by
the
U.S. Environmental Protection Agency (“EPA”) pursuant to the Comprehensive
Environmental Response, Compensation, and Liability Act of 1980 (“CERCLA”) and
are listed on the National Priority List.
We
provide for costs related to environmental contingencies when a loss is probable
and the amount is reasonably estimable. It is not possible for us to reliably
estimate the amount and timing of all future expenditures related to
environmental matters because, among other reasons:
· |
Some
sites are in the early stages of investigation, and other sites may
be
identified in the future.
|
· |
Remediation
activities vary significantly in duration, scope and cost from site
to
site depending on the mix of unique site characteristics, applicable
technologies and regulatory agencies involved.
|
· |
Remediation
requirements are difficult to predict at sites where investigations
have
not been completed or final decisions have not been made regarding
remediation requirements, technologies or other factors that bear
on
remediation costs.
|
· |
Environmental
laws frequently impose joint and several liability on all potentially
responsible parties, and it can be difficult to determine the number
and
financial condition of other potentially responsible parties and
their
respective shares of responsibility for remediation
costs.
|
· |
Environmental
laws and regulations, as well as enforcement policies, are continually
changing, and the outcome of court proceedings and discussions with
regulatory agencies are inherently
uncertain.
|
· |
Unanticipated
construction problems and weather conditions can hinder the completion
of
environmental remediation.
|
· |
Some
legal matters are in the early stages of investigation or proceeding
or
their outcomes otherwise may be difficult to predict, and other legal
matters may be identified in the
future.
|
· |
The
inability to implement a planned engineering design or use planned
technologies and excavation methods may require revisions to the
design of
remediation measures, which can delay remediation and increase its
costs.
|
· |
The
identification of additional areas or volumes of contamination and
changes
in costs of labor, equipment and technology generate corresponding
changes
in environmental remediation costs.
|
We
believe that we have reserved adequately for the reasonably estimable costs
of
known contingencies. However, additions to the reserves may be required as
additional information is obtained that enables us to better estimate our
liabilities, including any liabilities at sites now under review. We cannot
reliably estimate the amount of future additions to the reserves at this time.
Additionally, there may be other sites where we have potential liability for
environmental-related matters but for which we do not have sufficient
information to determine that the liability is probable and/or reasonably
estimable. We have not established reserves for such sites.
For
additional discussion of environmental matters, see “Management’s
Discussion and Analysis of Financial Condition and Results of
Operations”
and
Note 22 to the Consolidated and Combined Financial Statements included in
Item 8 of this annual report on Form 10-K.
Item
1A. Risk
Factors
We
are subject to significant liabilities that are in addition to those associated
with our primary business. These liabilities could adversely affect our
financial condition and results of operations and we could suffer losses as
a
result of these liabilities even if our primary business performs well.
We
currently operate our chemical business through our subsidiary, Tronox Worldwide
LLC, and its subsidiaries. Tronox Worldwide LLC, its subsidiaries and their
predecessors have operated a number of businesses in addition to the current
chemical business, including businesses involving the treatment of forest
products, the production of ammonium perchlorate, the refining and marketing
of
petroleum products, offshore contract drilling, coal mining and the mining,
milling and processing of nuclear materials. As a result, we are subject to
significant liabilities that are in addition to those associated with our
primary business, including legal, regulatory and environmental liabilities.
For
example, we have liabilities relating to the remediation of various sites at
which chemicals such as creosote, perchlorate, low-level radioactive substances,
asbestos and other materials have been used or disposed. Our financial condition
and results of operations could be adversely affected by these liabilities.
We
also could suffer losses as a result of these liabilities even if our primary
business performs well. See Note 22 to the Consolidated and Combined
Financial Statements included in Item 8 of this annual report on Form 10-K
for a
discussion of contingencies.
The
costs of compliance with the extensive environmental, health and safety laws
and
regulations to which we are subject or the inability to obtain, update or renew
permits required for the operation of our business could reduce our
profitability or otherwise adversely affect us.
Our
current and former operations involve the generation and management of regulated
materials that are subject to various environmental laws and regulations and
are
dependent on the periodic renewal of permits from various governmental agencies.
The inability to obtain, update or renew permits related to the operation of
our
businesses, or the costs required in order to comply with permit standards,
could have a material adverse affect on us. For example, we currently are
updating permits related to water and air emissions for our facility in Botlek,
Netherlands. Although we do not anticipate any significant difficulties in
obtaining such permits or that any material expenditures will be required,
the
failure to update such permits could have a material adverse effect on our
ability to produce our products and on our results of operations.
In
addition, changes in the laws and regulations to which we are subject, or their
interpretation, or the enactment of new laws and regulations, could result
in
materially increased and unanticipated capital expenditures and compliance
costs. For example, the proposed REACH (Registration, Evaluation and
Authorization of Chemicals) regulatory scheme in the European Union, if
implemented as currently proposed, could adversely affect our European
operations by imposing on us a testing, evaluation and registration program
for
some of the chemicals that we use or produce. At the present time, we are not
able to predict the ultimate cost of compliance with these requirements or
their
effect on our business.
Environmental
laws and regulations obligate us to remediate various sites at which chemicals
such as creosote, perchlorate, low-level radioactive substances, asbestos and
other materials have been disposed of or released. Some of these sites have
been
designated Superfund sites by EPA under the CERCLA. See Note 22 to the
Consolidated and Combined Financial Statements included in Item 8 of this annual
report on Form 10-K for a discussion of these matters. The discovery of
contamination arising from historical industrial operations at some of our
properties has exposed us, and in the future may continue to expose us, to
significant remediation obligations and other damages.
The
actual costs of environmental remediation and restoration could exceed
estimates.
As
of
December 31, 2005, we had reserves in the amount of $223.7 million for
environmental remediation and restoration. We reserve for costs related to
environmental remediation and restoration only when a loss is probable and
the
amount is reasonably estimable. In estimating our environmental liabilities,
including the cost of investigation and remediation at a particular site, we
consider a variety of matters, including, but not limited to, the stage of
the
investigation at the site, the stage of remedial design for the site, the
availability of existing remediation technologies, presently-enacted laws and
regulations and the state of any related legal or administrative investigation
or proceedings. For example, at certain sites we are in the preliminary stages
of our environmental investigation and therefore have reserved for such sites
amounts equal only to the cost of our environmental investigation. The findings
of these site investigations could result in an increase in our reserves for
environmental remediation. While we believe we have established appropriate
reserves for environmental remediation based on the information we currently
know, additions to the reserves may be required as we obtain additional
information that enables us to better estimate our liabilities.
Our
estimates of environmental liabilities at a particular site could increase
significantly as a result of, among other things, changes in laws and
regulations, revisions to the site’s remedial design, unanticipated construction
problems, identification of additional areas or volumes of contamination,
increases in labor, equipment and technology costs, changes in the financial
condition of other potentially responsible parties and the outcome of any
related legal and administrative proceedings to which we are or may become
a
party. For example, in 2004, remediation efforts required by the Nuclear
Regulatory Commission (“NRC”) at our site in Cushing, Oklahoma, identified
additional soil and groundwater impacts that would require assessment and
possible remediation. As a result, in that year we increased our reserves for
environmental remediation with respect to the Cushing site by $10.3 million,
which was part of a total increase in our 2004 environmental reserves of $81.4
million. See “Management’s
Discussion and Analysis of Financial Condition and Results of Operations -
Environmental Matters - Environmental Costs”
and
Note 22 to the Consolidated and Combined Financial Statements included in Item
8
of this annual report on Form 10-K.
In
addition to the sites for which we have established reserves, there may be
other
sites where we have potential liability for environmental matters but for which
we do not have sufficient information to determine that a liability is probable
and reasonably estimable. As we obtain additional information about those sites,
we may determine that reserves for such sites should be established. New
environmental claims also may arise as a result of changes in environmental
laws
and regulations or for other reasons. If new claims arise and losses associated
with those claims become probable and reasonably estimable, we will need to
increase our reserves to reflect those new claims.
As
a
result of the factors described above, it is not possible for us to reliably
estimate the amount and timing of all future expenditures related to
environmental or other contingent matters, and our actual costs related to
such
matters could exceed our current reserves at December 31, 2005. See
“Business
and Properties - Government Regulations and Environmental
Matters”
and
“Legal
Proceedings.”
Hazards
associated with chemical manufacturing could adversely affect our results of
operations.
Due
to
the nature of our business, we are exposed to the hazards associated with
chemical manufacturing and the related storage and transportation of raw
materials, products and wastes. These hazards could lead to an interruption
or
suspension of operations and have an adverse effect on the productivity and
profitability of a particular manufacturing facility or on us as a whole.
Potential hazards include the following:
· |
Piping
and storage tank leaks and ruptures
|
· |
Employee
exposure to hazardous substances
|
· |
Chemical
spills and other discharges or releases of toxic or hazardous substances
or gases
|
There
is also a risk that one or more of our key raw materials or one or more of
our
products may be found to have currently unrecognized toxicological or
health-related impact on the environment or on our customers or employees.
Such
hazards may cause personal injury and loss of life, damage to property and
contamination of the environment, which could lead to government fines or work
stoppage injunctions and lawsuits by injured persons. If such actions are
determined adversely to us, we may have inadequate insurance to cover such
claims, or we may have insufficient cash flow to pay for such claims. Such
outcomes could adversely affect our financial condition and results of
operations.
Violations
or noncompliance with the extensive environmental, health and safety laws and
regulations to which we are subject could result in unanticipated loss or
liability.
Our
operations and production facilities are subject to extensive environmental
and
health and safety laws and regulations at national, international and local
levels in numerous jurisdictions relating to pollution, protection of the
environment, transporting and storing raw materials and finished products and
storing and disposing of hazardous wastes. We may incur substantial costs,
including fines, damages, criminal or civil sanctions and remediation costs,
or
experience interruptions in our operations, for violations arising under these
laws and regulations. In the event of a catastrophic incident involving any
of
the raw materials we use or chemicals we produce, we could incur material costs
as a result of addressing the consequences of such event.
We
are
party to a number of legal and administrative proceedings involving
environmental and other matters pending in various courts and before various
agencies. These include proceedings associated with facilities currently or
previously owned, operated or used by us or our predecessors, and include claims
for personal injuries, property damages, injury to the environment, including
natural resource damages, and non-compliance with permits. Any determination
that one or more of our key raw materials or products, or the materials or
products associated with facilities previously owned, operated or used by us
or
our predecessors, has, or is characterized as having, a toxicological or
health-related impact on our environment, customers or employees could subject
us to additional legal claims. These proceedings and any such additional claims
may be costly and may require a substantial amount of management attention,
which may have an adverse affect on our financial condition and results of
operations. See “Business
and Properties - Government Regulations and Environmental
Matters”
and
“Legal
Proceedings.”
The
amount of our debt could adversely affect our financial condition, limit our
ability to pursue business opportunities, reduce our operating flexibility
or
put us at a competitive disadvantage.
As
of
December 31, 2005, we had $548.0 million of long-term debt and
$489.0 million of stockholders’ equity. Our debt could have important
consequences for us. For instance, it could:
· |
Require
us to use a substantial portion of our cash flow from operations
for debt
service and reduce the availability of our cash flow to fund working
capital, capital expenditures, acquisitions and other general corporate
activities
|
· |
Limit
our ability to obtain financing for working capital, capital expenditures,
acquisitions or other general corporate activities in the future
|
· |
Expose
us to greater interest rate risk because the interest rates on our
senior
secured credit facility will vary
|
· |
Impair
our ability to successfully withstand a downturn in our business
or the
economy in general and place us at a disadvantage relative to our
less-leveraged competitors
|
The
MSA, the senior secured credit facility and the indenture governing the
unsecured notes limit, but do not prohibit, us from incurring additional debt,
and we may incur additional debt in the future. If we incur additional debt,
our
ability to satisfy our debt obligations may become more limited.
The
terms of our senior secured credit facility and our indenture governing the
unsecured notes contain a number of restrictive and financial covenants that
could limit our ability to pay dividends or to operate effectively in the
future. If we are unable to comply with these covenants, our lenders could
accelerate the repayment of our indebtedness.
The
terms of our senior secured credit facility and our indenture governing the
unsecured notes subject us to a number of covenants that impose significant
operating restrictions on us, including on our ability to incur indebtedness
and
liens, make loans and investments, make capital expenditures, sell assets,
engage in mergers, consolidations and acquisitions, enter into transactions
with
affiliates, enter into sale and leaseback transactions, make optional payments
or modifications of the unsecured notes or other material debt, change our
lines
of business and pay dividends on our common stock. We are also required by
the
terms of the senior secured credit facility to comply with financial covenant
ratios. These restrictions could limit our ability to plan for or react to
market conditions or meet capital needs.
A
breach of any of the covenants imposed on us by the terms of our indebtedness,
including the financial covenants in the senior secured credit facility, could
result in a default under such indebtedness. In the event of a default, the
lenders under the revolving credit facility could terminate their commitments
to
us, and they and the lenders of our other indebtedness could accelerate the
repayment of all of our indebtedness. In such case, we may not have sufficient
funds to pay the total amount of accelerated obligations, and our lenders under
the senior secured credit facility could proceed against the collateral securing
the facility. Any acceleration in the repayment of our indebtedness or related
foreclosure could adversely affect our business.
Market
conditions and cyclical factors that adversely affect the demand for the end-use
products that contain our titanium dioxide could adversely affect our
results.
Historically,
regional and world events that negatively affect discretionary spending or
economic conditions generally, such as terrorist attacks, the incidence or
spread of contagious diseases (such as SARS), or other economic, political,
or
public health or safety conditions, have adversely affected demand for the
finished products that contain titanium dioxide and from which we derive
substantially all of our revenue. Events such as these are likely to contribute
to a general reluctance by the public to purchase “quality of life” products,
which could cause a decrease in demand for our chemicals and, as a result,
may
have an adverse effect on our results of operations and financial
condition.
Additionally,
the demand for titanium dioxide during a given year is subject to seasonal
fluctuations. Titanium dioxide sales are generally higher in the second and
third quarters of the year than in the other quarters due in part to the
increase in paint production in the spring to meet demand resulting from the
spring and summer painting season in North America and Europe. We may be
adversely affected by existing or future cyclical changes, and such conditions
may be sustained or further aggravated by anticipated or unanticipated changes
in regional weather conditions. For example, poor weather conditions in a region
can lead to an abbreviated painting season, which can depress consumer sales
of
paint products that use titanium dioxide pigment.
Our
business, financial condition and results of operations could be adversely
affected by global and regional economic downturns and other
conditions.
We
have
significant production, sales and marketing operations throughout the United
States, Europe and the Asia-Pacific region, with more than 1,100 customers
in
over 100 countries. We also purchase many of the raw materials used in the
production of our products in foreign jurisdictions. In 2005, approximately
45%
of our total revenues were generated from production outside of the United
States. Due to these factors, our performance, particularly the performance
of
our pigment segment, is cyclical and tied closely to general economic
conditions, including global gross domestic product. As a result, our business,
financial condition and results of operations are vulnerable to political and
economic conditions affecting global gross domestic product and the countries
in
which we operate. For example, from 2000 through 2003, our business was affected
when the titanium dioxide industry experienced a period of unusually weak
business conditions as a result of a variety of factors, including the global
economic recession, exceptionally rainy weather conditions in Europe and the
Americas, and the outbreak of SARS in Asia. Based on these factors, global
and
regional economic downturns and other conditions may have an adverse effect
on
our financial condition and results of operations.
Our
results of operations may be adversely affected by fluctuations in currency
exchange rates.
The
financial condition and results of operations of our operating entities in
the
European Union, among other jurisdictions, are reported in various foreign
currencies and then translated into U.S. dollars at the applicable exchange
rate
for inclusion in the financial statements. As a result, any appreciation of
the
U.S. dollar against these foreign currencies will have a negative impact on
our
reported sales and operating margin (and conversely, the depreciation of the
dollar against these foreign currencies will have a positive impact). In
addition, our operating entities often need to convert currencies they receive
for our products into currencies in which they purchase raw materials or pay
for
services, which could result in a gain or loss depending on fluctuations in
exchange rates. Because we have significant operations in Europe and Australia,
we are exposed primarily to fluctuations in the euro and the Australian
dollar.
In
the
past, we have sought to minimize our foreign currency translation risk by
engaging in hedging transactions. We may be unable to effectively manage our
foreign currency translation risk, and any volatility in foreign currency
exchange rates may have an adverse effect on our financial condition or results
of operations. For a further discussion of how we manage our foreign currency
risk, see “Quantitative
and Qualitative Disclosure about Market Risk - Foreign Currency Exchange Rate
Risk.”
Our
industry and the end-use markets in which we compete are highly competitive.
This competition may adversely affect our results of operations and operating
cash flows.
Each
of
the markets in which we compete is highly competitive. Competition is based
on a
number of factors such as price, product quality and service. We face
significant competition from major international producers, such as E.I.
du Pont de Nemours and Company, Millennium Chemicals Inc.,
Huntsman Corporation and Kronos Worldwide, Inc., as well as smaller
regional competitors. Our most significant competitors include major chemicals
and materials manufacturers and diversified companies, a number of which have
substantially larger financial resources, staffs and facilities than we do.
The
additional resources and larger staffs and facilities of such competitors may
give them a competitive advantage when responding to market conditions and
capitalizing on operating efficiencies. Increased competition could result
in
reduced sales, which could adversely affect our profitability and operating
cash
flows. See “Business
and Properties - Competitive Conditions.”
In
addition, within the end-use markets in which we compete, competition between
products is intense. We face substantial risk that certain events, such as
new
product development by our competitors, changing customer needs, production
advances for competing products or price changes in raw materials, could cause
our customers to switch to our competitor’s products. If we are unable to
develop and produce or market our products to compete effectively against our
competitors, our results of operations and operating cash flows may
suffer.
Fluctuations
in costs of our raw materials or our access to supplies of our raw materials
could have an adverse effect on our results of
operations.
In
2005, raw materials used in the production of titanium dioxide constituted
approximately 30% of our cost of products sold. Titanium-bearing ores, in
particular, represented more than 18% of our cost of products sold in 2005.
Costs
of many of the raw materials we use may fluctuate widely for a variety of
reasons, including changes in availability, major capacity additions or
reductions or significant facility operating problems. These fluctuations could
negatively affect our operating margins and our profitability. As these costs
rise, our operating expenses likely will increase and could adversely affect
our
business, especially if we are unable to pass price increases in raw materials
through to our customers.
Should
our vendors not be able to meet their contractual obligations or should we
be
otherwise unable to obtain necessary raw materials, we may incur higher costs
for raw materials or may be required to reduce production levels, which may
have
an adverse effect on our financial position, results of operations or liquidity.
For a further discussion, see “Business
and Properties - Raw Materials.”
The
labor and employment laws in many jurisdictions in which we operate are more
restrictive than in the United States. Our relationship with our employees
could
deteriorate, which could adversely affect our
operations.
In
the
United States, approximately 200 employees at our Savannah, Georgia, facility
are members of a union and are subject to a collective bargaining arrangement
that is scheduled to expire in April 2006. Approximately 40% of our
employees are employed outside the United States. In certain of those countries,
such as Australia and the member states of the European Union, labor and
employment laws are more restrictive than in the United States and, in many
cases, grant significant job protection to employees, including rights on
termination of employment. For example, in Germany and the Netherlands, by
law
some of our employees are represented by a works’ council, which subjects us to
employment arrangements very similar to collective bargaining
agreements.
We
are
required to consult with and seek the consent or advice of the unions or works’
councils that represent our employees for certain of our activities. This
requirement could have a significant impact on our flexibility in managing
costs
and responding to market changes. Furthermore, there can be no assurance that
we
will be able to negotiate labor agreements with our unionized employees in
the
future on satisfactory terms. If those employees were to engage in a strike,
work stoppage or other slowdown, or if any of our other employees were to become
unionized, we could experience a significant disruption of our operations or
higher ongoing labor costs, which could adversely affect our financial condition
and results of operations.
Third
parties may claim that our products or processes infringe their intellectual
property rights, which may cause us to pay unexpected litigation costs or
damages or prevent us from making, using, or selling our
products.
Although
currently there are no pending or threatened proceedings or claims relating
to
alleged infringement, misappropriation, or violation of the intellectual
property rights of others, we may be subject to legal proceedings and claims
in
the future in which third parties allege that their patents or other
intellectual property rights are infringed, misappropriated or otherwise
violated by us or by our products or processes. In the event that any such
infringement, misappropriation, or violation of the intellectual property rights
of others is found, we may need to obtain licenses from those parties or
substantially re-engineer our products or processes in order to avoid such
infringement, misappropriation, or violation. We might not be able to obtain
the
necessary licenses on acceptable terms or be able to re-engineer our products
or
processes successfully. Moreover, if we are found by a court of law to infringe,
misappropriate, or otherwise violate the intellectual property rights of others,
we could be required to pay substantial damages or be enjoined from making,
using, or selling the infringing products or technology. We also could be
enjoined from making, using, or selling the allegedly infringing products or
technology pending the final outcome of the suit. Any of the foregoing could
adversely affect our financial condition and results of operations.
If
we are not able to continue our technological innovation and successful
commercial introduction of new products, our profitability could be adversely
affected.
Our
industries and the end-use markets into which we sell our products experience
periodic technological change and product improvement. Our future growth will
depend on our ability to gauge the direction of commercial and technological
progress in key end-use markets and on our ability to fund and successfully
develop, manufacture and market products in such changing end-use markets.
We
must continue to identify, develop and market innovative products or enhance
existing products on a timely basis in order to maintain our profit margins
and
our competitive position. We may not be able to develop new products or
technology, either alone or with third parties, or license intellectual property
rights from third parties on a commercially competitive basis. If we fail to
keep pace with the evolving technological innovations in our end-use markets
on
a competitive basis, our financial condition and results of operations could
be
adversely affected.
If
our intellectual property were compromised or copied by competitors, or if
competitors were to develop similar intellectual property independently, our
results of operations could be negatively affected.
Our
success depends to a significant degree upon our ability to protect and preserve
our intellectual property rights. Although we own and have applied for numerous
patents and trademarks throughout the world, we may have to rely on judicial
enforcement of our patents and other proprietary rights. Our patents and other
intellectual property rights may be challenged, invalidated, circumvented,
rendered unenforceable or otherwise compromised. A failure to protect, defend
or
enforce our intellectual property could have an adverse effect on our financial
condition and results of operations.
We
also
rely upon unpatented proprietary technology, know-how and other trade secrets
to
maintain our competitive position. While it is our policy to enter into
confidentiality agreements with our employees and third parties to protect
our
proprietary expertise and other trade secrets, these agreements may not be
enforceable or, even if legally enforceable, we may not have adequate remedies
for breaches of such agreements. The failure of our patents or confidentiality
agreements to protect our proprietary technology, know-how or trade secrets
could result in significantly lower revenues, reduced profit margins or loss
of
market share.
We
may
be unable to determine when third parties are using our intellectual property
rights without our authorization. We also have licensed certain of our
intellectual property rights to third parties, and we cannot be certain that
our
licensees are using our intellectual property only as authorized by the
applicable license agreement. The undetected or unremedied, unauthorized use
of
our intellectual property rights or the legitimate development or acquisition
of
intellectual property related to our industry by third parties could reduce
or
eliminate any competitive advantage we have as a result of our intellectual
property, adversely affecting our financial condition and results of operations.
If we must take legal action to protect, defend or enforce our intellectual
property rights, any suits or proceedings could result in significant costs
and
diversion of our resources and our management’s attention, and we may not
prevail in any such suits or proceedings. A failure to protect, defend or
enforce our intellectual property rights could have an adverse effect on our
financial condition and results of operations.
We
may need additional capital in the future and may not be able to obtain it
on
favorable terms, if at all.
Our
industry is highly capital intensive and our success depends to a significant
degree on our ability to develop and market innovative products and to update
our facilities and process technology. We may require additional capital in
the
future to finance our future growth and development, implement further marketing
and sales activities, fund our ongoing research and development activities
and
meet our general working capital needs. Our capital requirements will depend
on
many factors, including acceptance of and demand for our products, the extent
to
which we invest in new technology and research and development projects, and
the
status and timing of competitive developments. Additional financing may not
be
available when needed on terms favorable to us or at all. Further, the terms
of
the senior secured credit facility and the indenture governing the unsecured
notes, as well as our MSA with Kerr-McGee, may limit our ability to incur
additional indebtedness or issue additional shares of our common stock. If
we
are unable to obtain adequate funds on acceptable terms, we may be unable to
develop or enhance our products, take advantage of future opportunities or
respond to competitive pressures, which could harm our business.
As
long as Kerr-McGee owns shares of our common stock representing a majority
of
the voting power of our common stock, it will control us and the influence
of
our other stockholders over significant corporate actions will be
limited.
At
December 31, 2005, Kerr-McGee owned all of our Class B common stock, which
represented a majority of the combined voting power of all outstanding classes
of our common stock. Kerr-McGee’s Board of Directors declared a dividend on
March 8, 2006, of Tronox’s Class B common stock to its stockholders, which is
expected to be completed on March 30, 2006. However,
until the Distribution occurs, Kerr-McGee will continue to control us. As a
result, Kerr-McGee is entitled to nominate a majority of our board of directors
and has the ability to control the vote in any election of directors. Kerr-McGee
also has control over our decisions to enter into significant corporate
transactions and, in its capacity as our majority stockholder, has the ability
to prevent any transaction that it does not believe to be in Kerr-McGee’s best
interest. As a result, Kerr-McGee is able to control, directly or indirectly
and
subject to applicable law, all matters affecting us, including the
following:
· |
Any
determination with respect to our business direction and policies,
including the appointment and removal of
officers
|
· |
Any
determinations with respect to mergers, business combinations or
dispositions of assets
|
· |
Compensation
and other human resources policy
decisions
|
· |
Changes
to other agreements that may adversely affect us
|
· |
The
payment of dividends on our common
stock
|
The
interim services provided to us by Kerr-McGee may not be sufficient to meet
our
needs, and we may not be able to replace these services after our agreements
with Kerr-McGee expire.
Historically,
Kerr-McGee performed various corporate functions on our behalf, including the
following:
· |
Employee
benefits management
|
· |
Risk
and claims management
|
· |
Information
management and technology services
|
· |
Office
administration services
|
Following
the IPO, Kerr-McGee has had no obligation to provide any services on our behalf
other than as provided in our transition services agreement with Kerr-McGee.
We
are in the process of creating our own, or engaging third parties to provide,
systems and business functions to replace many of the systems and business
functions Kerr-McGee historically provided us. However, we may not be successful
in implementing these systems and business functions or in transitioning data
from Kerr-McGee’s systems to ours. If we do not have in place our own systems
and business functions or if we do not have agreements with other providers
of
these services when our transition services agreement with Kerr-McGee expires,
we may not be able to effectively operate our business and our profitability
may
be adversely affected.
We
will qualify for, and intend to rely on, exemptions from the New York Stock
Exchange (“NYSE”) corporate governance requirements.
At
December 31, 2005, Kerr-McGee owned all of our Class B common stock, which
represented a majority of the combined voting power of all outstanding classes
of our common stock. Kerr-McGee’s Board of Directors declared a dividend on
March 8, 2006, of Tronox’s Class B common stock to its stockholders, which is
expected to be completed on March 30, 2006. Until the Distribution occurs,
Kerr-McGee will continue to control a majority of the voting power of our
outstanding common stock. As a result and until that time, we are a ‘‘controlled
company’’ within the meaning of the NYSE corporate governance standards. Under
the NYSE rules, a ‘‘controlled company’’ may elect not to comply with the
following corporate governance requirements:
· |
A
majority of independent directors on the board of
directors
|
· |
A
nominating and corporate governance committee composed entirely of
independent directors
|
· |
A
compensation committee composed entirely of independent
directors
|
· |
An
annual performance evaluation of the nominating and corporate governance
and compensation committees
|
Until
such time that we cease to be a “controlled company,” we intend to utilize these
exemptions. As a result, we do not have a majority of independent directors
and
our nominating and corporate governance and compensation committees do not
consist entirely of independent directors. Additionally, we are relying on
a
transition provision for the New York Stock Exchange standards relating to
the
independence of audit committees. That transition provision allows issuers,
such
as us, that have a registration statement under the Securities Act covering
an
IPO of securities to (1) exempt all but one of our audit committee members
from
the independence requirements for 90 days from the effective date of our
registration statement, and (2) exempt a minority of the members of our audit
committee from the independence requirement for one year from the effective
date
of our registration statement.
Our
executive officers and directors may have conflicts of interest because of
their
ownership of common stock of, and other ties to,
Kerr-McGee.
Two
of
our directors (Robert M. Wohleber and J. Michael Rauh) are officers of
Kerr-McGee. These directors will have fiduciary duties to both companies and
may
have conflicts of interest on matters affecting both us and Kerr-McGee, which,
in some circumstances, may have interests adverse to our interests. Mr. Wohleber
and Mr. Rauh each have notified us of their intention to resign from our board
effective upon, and subject to, the completion of the Distribution. In addition,
all of our executive officers and the majority of our directors own common
stock
of Kerr-McGee or options to purchase common stock of Kerr-McGee. Ownership
of
such common stock or options could create, or appear to create, potential
conflicts of interest when directors and officers are faced with decisions
that
could have different implications for Kerr-McGee and us.
Item
1B. Unresolved
Staff Comments
The
company has no outstanding or unresolved Securities and Exchange Commission
(“SEC”) staff comments.
Availability
of Reports and Governance Documents
Tronox
makes available at no cost on its Internet website, www.tronox.com, its Annual
Report on Form 10-K, Quarterly Reports on Form 10-Q, Current Reports on Form
8-K
and any amendments to those reports as soon as reasonably practicable after
the
company electronically files or furnishes such reports to the SEC. Interested
parties should refer to the Investor Relations link on the company’s website. In
addition, the company’s Code of Business Conduct and Ethics, Code of Ethics for
The Chief Executive Officer and Principal Financial Officers and Corporate
Governance Guidelines, all of which were adopted by the company’s Board of
Directors, can be found on the company’s website under the Corporate Governance
link. The company will provide these governance documents in print to any
stockholder who requests them. Any amendment to, or waiver of, any provision
of
the Code of Ethics for the Chief Executive Officer and Principal Financial
Officers and any waiver of the Code of Business Conduct and Ethics for directors
or executive officers will be disclosed on the company’s website under the
Corporate Governance link.
We
confirm, as required by NYSE Rule 303A.12, that we are filing the certifications
required by Section 302 of the Sarbanes-Oxley Act of 2002 as exhibits to this
annual report on Form 10-K.
SPECIAL
NOTE REGARDING FORWARD-LOOKING STATEMENTS
Forward-Looking
Statements
Statements
in this
annual report regarding the company’s or management’s intentions, beliefs or
expectations, or that otherwise speak to future events, are “forward-looking
statements” within the meaning of the U.S. Private Securities Litigation Reform
Act of 1995. These forward-looking statements include those statements preceded
by, followed by or that otherwise include the words “believes,” “will,”
“expects,” “anticipates,” “intends,” “estimates,” “projects,” “target,”
“budget,” “goal,” “plans,” “objective,” “outlook,” “should,” or similar words.
Future results and developments discussed in these statements may be affected
by
numerous factors and risks, such as the accuracy of the assumptions that
underlie the statements, the market value of Tronox’s products, demand for
consumer products for which Tronox’s businesses supply raw materials, the
financial resources of competitors, changes in laws and regulations, the ability
to respond to challenges in international markets, including changes in currency
exchange rates, political or economic conditions in areas where Tronox operates,
trade and regulatory matters, general economic conditions, and other factors
and
risks identified in the company’s U.S. SEC filings. Actual results and
developments may differ materially from those expressed or implied in this
annual report. The company does not undertake to update forward-looking
statements to reflect the impact of circumstances or events that arise after
the
date the forward-looking statement was made. Investors are urged to consider
closely the disclosures and risk factors in this annual report on Form
10-K.
Item
3. Legal
Proceedings
Savannah
Plant Emissions
On
September 8, 2003, the Environmental Protection Division of the Georgia
Department of Natural Resources issued a unilateral Administrative Order to
our
subsidiary, Tronox Pigments (Savannah) Inc., claiming that the Savannah
plant exceeded emission allowances provided for in the facility’s Title V
air permit. On September 19, 2005, the Environmental Protection Division
rescinded the Administrative Order and filed a Withdrawal of Petition for
Hearing on Civil Penalties. Accordingly, the proceeding on administrative
penalties has been dismissed, without prejudice. However, the Environmental
Protection Division’s most recent actions do not resolve the alleged violations,
and representatives of Tronox Pigments (Savannah) Inc., the Environmental
Protection Division and EPA
are
engaged in discussions to resolve the existing air permit disputes and potential
civil penalties. We believe that any penalties related to this matter are not
likely to have a material adverse effect on us.
Flint
Hills Contract
On
October 11, 2004, Kerr-McGee and one of our subsidiaries, Southwestern
Refining Corporation, were named defendants in a lawsuit filed by Flint Hills
Resources, LP. In the lawsuit, which was removed to the U.S. District Court
in
the Southern District of Texas, Corpus Christi division, Flint Hills alleged
that Kerr-McGee and Southwestern Refining Corporation breached certain
environmental representations and warranties contained in the agreement pursuant
to which Southwestern Refining Corporation sold its refinery in Corpus Christi,
Texas, to a predecessor of Flint Hills. Flint Hills claimed damages of
approximately $7.0 million. An agreement to settle the litigation was
executed on January 11, 2006, pursuant to which Southwestern Refining
Corporation paid Flint Hills $1.4 million and the claim was dismissed, with
prejudice.
New
Jersey Wood-Treatment Site
Tronox
LLC was named in 1999 as a potentially responsible party (“PRP”) under CERCLA at
a former wood-treatment site in New Jersey at which EPA is conducting a cleanup.
On April 15, 2005, Tronox LLC and Tronox Worldwide LLC received a letter
from EPA asserting they are liable under CERCLA as a former owner or operator
of
the site and demanding reimbursement of costs expended by EPA at the site.
The
letter made demand for payment of past costs in the amount of approximately
$179 million, plus interest though EPA has informed Tronox LLC that it
expects final project costs will be approximately $236 million, plus possible
other costs and interest. Tronox LLC did not operate the site, which had been
sold to a third party before Tronox LLC succeeded to the interests of a
predecessor owner in the 1960s. The predecessor also did not operate the site,
which had been closed down before it was acquired by the predecessor. Based
on
historical records, there are substantial uncertainties about whether or under
what terms the predecessor assumed liabilities for the site. In addition,
although it appears there may be other PRPs, the company does not know whether
the other PRPs have received similar letters from EPA, whether there are any
defenses to liability available to the other PRPs or whether the other PRPs
have
the financial resources necessary to meet their obligations. The company intends
to vigorously defend against EPA’s demand, though the company expects to have
discussions with EPA that could lead to a settlement or resolution of EPA
demand. No reserve for reimbursement of cleanup costs at the site has been
recorded because it is not possible to reliably estimate the liability, if
any,
the company may have for the site because of the aforementioned defenses and
uncertainties.
Forest
Products
Between
December 31, 2002, and May 2, 2005, approximately 250 lawsuits (filed
on behalf of approximately 5,100 claimants) were filed against Tronox LLC in
connection with the former wood-treatment plant in Columbus, Mississippi.
Substantially all of these lawsuits are pending in the U.S. District Court
for
the Northern District of Mississippi and have been consolidated for pretrial
and
discovery purposes. In addition, a suit filed by the Maranatha Faith Center
against Tronox LLC and Tronox Worldwide LLC on February 18, 2000, relates to
the
former wood-treatment plant in Columbus and is pending in the Circuit Court
of
Lowndes County, Mississippi. Between December 31, 2002, and June 25,
2004, three lawsuits (filed on behalf of approximately 3,300 claimants) were
filed against Tronox LLC in connection with a former wood-treatment plant
located in Hattiesburg, Mississippi. These lawsuits were removed to the U.S.
District Court for the Southern District of Mississippi. Between
September 9, 2004, and December 28, 2005, four lawsuits (filed on behalf of
69 claimants) were filed against Tronox LLC in connection with a former
wood-treatment plant located in Texarkana, Texas. Two of the Texarkana lawsuits
that were filed in Oklahoma (on behalf of 30 claimants) have been dismissed
on
jurisdictional grounds. Between January 3, 2005, and July 26, 2005, 35
lawsuits (filed on behalf of approximately 4,600 claimants) were filed against
Tronox LLC and Tronox Worldwide LLC in connection with the former wood-treatment
plant in Avoca, Pennsylvania. All of these lawsuits seek recovery under a
variety of common law and statutory legal theories for personal injuries and/or
property damages allegedly caused by exposure to and/or release of creosote,
a
chemical used in the wood-treatment process.
In
2003, Tronox LLC entered into a settlement agreement that resolved approximately
1,490 of the Hattiesburg claims, which resulted in aggregate payments by Tronox
LLC of approximately $0.6 million. In December 2005, Tronox LLC entered
into settlement agreements to resolve up to 1,335 of the remaining Hattiesburg
claims and up to 879 of the Columbus claims. The December 2005 settlement
agreements require Tronox LLC to pay up to $2.5 million, of which $1.8 million
was paid in December 2005. In addition, all of the remaining Hattiesburg claims
have been dismissed without prejudice on the bases of failure to pay filing
fees
and failure to disclose information in compliance with court orders. The company
currently believes that the unresolved claims relating to the Columbus,
Hattiesburg, Texarkana and Avoca plants are without substantial merit and is
vigorously defending against them.
For
a
discussion of other legal proceedings and contingencies, including proceedings
related to our environmental liabilities, see Note 22 to the Consolidated
and Combined Financial Statements included in Item 8 of this annual report
on
Form 10-K.
Item
4. Submission of Matters
to a Vote of Security Holders
There
were no matters submitted to a vote of security holders during the fourth
quarter of 2005 subsequent to the IPO.
PART
II
Item
5. Market for
Registrant’s Common Equity and Related Stockholder Matters
On
November 22, 2005, the company’s Class A common stock began trading on the New
York Stock Exchange. As of March 15, 2006, we had 1,017 holders of record of
our
Class A common stock and estimated that approximately 1,050 additional
stockholders held our Class A common stock in street name on that
date.
The
company’s Class B common stock is not currently trading and was held by one
stockholder (Kerr-McGee) as of March 15, 2006.
On
December 19, 2005, Tronox declared a quarterly dividend of five cents per share
for Class A and Class B common stock for the quarter ending March 31, 2006.
There were no quarterly dividends prior to that time.
The
high and low market prices of Tronox Class A common stock for the period from
November 22, 2005, through December 31, 2005, were $14.50 and $11.75,
respectively. As the company began trading on November 22, 2005, market prices
were not applicable items in 2004 or the first three quarters of
2005.
Information
required under Item 201(d) of Regulation S-K relating to the company’s
securities authorized for issuance under equity compensation plans is included
in Item 12 of this annual report on Form 10-K.
Use
of Proceeds
On
November 28, 2005, we completed the initial public offering of our Class A
common stock that was effected through a Registration Statement on Form S-1
(Reg. No. 333-125574) declared effective by the SEC on November 21, 2005. The
net proceeds resulting from the offering of approximately $224.7 million were
distributed to Kerr-McGee.
Item
6.
|
Selected
Financial Data
|
The
following table sets forth selected financial data as of the dates and for
the
periods indicated in such table. The selected statement of operations data
for
the years ended December 31, 2005, 2004, 2003 and 2002, and the balance sheet
data as of December 31, 2005, 2004 and 2003, have been derived from our audited
consolidated and combined financial statements. The selected statement of
operations data for the year ended December 31, 2001, and the balance sheet
data
as of December 31, 2002 and 2001, have been derived from our accounting records
and are unaudited.
|
|
Year
Ended
December 31,
|
|
|
|
2005
|
|
2004
|
|
2003
|
|
2002
|
|
2001
|
|
|
|
(Millions
of dollars, except per share)
|
|
|
|
|
|
Consolidated
and Combined Statement of Operations Data:
|
|
|
|
|
|
|
|
|
|
|
|
Net
sales
|
|
$
|
1,364.0
|
|
$
|
1,301.8
|
|
$
|
1,157.7
|
|
$
|
1,064.3
|
|
$
|
1,022.6
|
|
Cost
of goods sold
|
|
|
1,143.8
|
|
|
1,168.9
|
|
|
1,024.7
|
|
|
949.0
|
|
|
972.5
|
|
Gross
margin
|
|
|
220.2
|
|
|
132.9
|
|
|
133.0
|
|
|
115.3
|
|
|
50.1
|
|
Selling,
general and administrative expenses
|
|
|
115.2
|
|
|
110.1
|
|
|
98.9
|
|
|
84.0
|
|
|
92.2
|
|
Restructuring
charges (1)
|
|
|
—
|
|
|
113.0
|
|
|
61.4
|
|
|
11.8
|
|
|
—
|
|
Provision
for environmental remediation and restoration, net of
reimbursements
|
|
|
17.1
|
|
|
4.6
|
|
|
14.9
|
|
|
14.3
|
|
|
7.7
|
|
|
|
|
87.9
|
|
|
(94.8
|
)
|
|
(42.2
|
)
|
|
5.2
|
|
|
(49.8
|
)
|
Interest
and debt expense
|
|
|
(4.5
|
)
|
|
(0.1
|
)
|
|
(0.1
|
)
|
|
(0.1
|
)
|
|
(0.1
|
)
|
Other
income (expense) (2)
|
|
|
(15.2
|
)
|
|
(25.2
|
)
|
|
(20.5
|
)
|
|
(13.1
|
)
|
|
(39.9
|
)
|
Income
(loss) from continuing operations before income taxes
|
|
|
68.2
|
|
|
(120.1
|
)
|
|
(62.8
|
)
|
|
(8.0
|
)
|
|
(89.8
|
)
|
Income
tax benefit (provision)
|
|
|
(21.8
|
)
|
|
38.3
|
|
|
15.1
|
|
|
(8.3
|
)
|
|
30.7
|
|
Income
(loss) from continuing operations before cumulative effect of change
in
accounting principle
|
|
|
46.4
|
|
|
(81.8
|
)
|
|
(47.7
|
)
|
|
(16.3
|
)
|
|
(59.1
|
)
|
Loss
from discontinued operations, net of income tax benefit
|
|
|
(27.6
|
)
|
|
(45.8
|
)
|
|
(35.8
|
)
|
|
(81.0
|
)
|
|
(49.0
|
)
|
Income
(loss) before cumulative effect of change in accounting
principle
|
|
|
18.8
|
|
|
(127.6
|
)
|
|
(83.5
|
)
|
|
(97.3
|
)
|
|
(108.1
|
)
|
Cumulative
effect of change in accounting principle, net of income tax
|
|
|
—
|
|
|
—
|
|
|
(9.2
|
)
|
|
—
|
|
|
0.7
|
|
Net
income (loss)
|
|
$
|
18.8
|
|
$
|
(127.6
|
)
|
$
|
(92.7
|
)
|
$
|
(97.3
|
)
|
$
|
(107.4
|
)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income
(loss) from continuing operations per
common
share, basic and diluted
|
|
$
|
1.89
|
|
$
|
(3.57
|
)
|
$
|
(2.08
|
)
|
$
|
(0.71
|
)
|
$
|
(2.58
|
)
|
Dividends
declared per common share
|
|
|
0.05
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year
Ended December 31,
|
|
|
|
|
2005
|
|
|
2004
|
|
|
2003
|
|
|
2002
|
|
|
2001
|
|
|
|
|
(Millions
of dollars)
|
|
Consolidated
and Combined Balance Sheet Data:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Working
capital (3)
|
|
$
|
404.4
|
|
$
|
240.2
|
|
$
|
304.5
|
|
$
|
243.6
|
|
$
|
264.5
|
|
Property,
plant and equipment, net
|
|
|
839.7
|
|
|
883.0
|
|
|
961.6
|
|
|
944.9
|
|
|
948.9
|
|
Total
assets (4)
|
|
|
1,758.3
|
|
|
1,595.9
|
|
|
1,809.1
|
|
|
1,733.6
|
|
|
1,628.1
|
|
Noncurrent
liabilities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Long-term
debt (5)
|
|
|
548.0
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
—
|
|
Environmental
remediation and/or restoration
|
|
|
145.9
|
|
|
130.8
|
|
|
135.9
|
|
|
131.4
|
|
|
40.0
|
|
All
other noncurrent liabilities(4)
|
|
|
200.4
|
|
|
215.9
|
|
|
312.2
|
|
|
192.4
|
|
|
209.6
|
|
Total
liabilities (5)
|
|
|
1,269.3
|
|
|
706.0
|
|
|
797.9
|
|
|
671.2
|
|
|
556.7
|
|
Total
business/stockholders’ equity (5)
|
|
|
489.0
|
|
|
889.9
|
|
|
1,011.2
|
|
|
1,062.4
|
|
|
1,071.4
|
|
Supplemental
Information:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Depreciation and
amortization expense
|
|
|
103.1
|
|
|
104.6
|
|
|
106.5
|
|
|
105.7
|
|
|
119.9
|
|
Capital
expenditures
|
|
|
87.6
|
|
|
92.5
|
|
|
99.4
|
|
|
86.7
|
|
|
153.3
|
|
Adjusted
EBITDA (6)
|
|
|
232.0
|
|
|
162.2
|
|
|
160.3
|
|
|
134.5
|
|
|
N/A
|
|
(1)
|
Restructuring
charges in 2004 include costs associated with the shutdown of our
titanium
dioxide pigment sulfate production at our Savannah, Georgia, facility.
Restructuring charges in 2003 include costs associated with the shutdown
of our synthetic rutile plant in Mobile, Alabama, and charges in
connection with a work force reduction program consisting of both
voluntary retirements and involuntary terminations. Restructuring
charges
in 2002 represent a write-down of fixed assets for abandoned engineering
projects.
|
(2)
|
Includes
interest expense allocated to us by Kerr-McGee based on specifically
identified borrowings from Kerr-McGee at Kerr-McGee’s average borrowing
rates. Also includes net foreign currency transaction gain (loss),
equity
in net earnings of equity method investees, loss on accounts receivable
sales and other expenses. See Note 21 to the Consolidated and
Combined Financial Statements included in Item 8 of this annual report
on
Form 10-K.
|
(3)
|
Working
capital is defined as the excess of current assets over current
liabilities.
|
(4) |
Total
assets and all
other noncurrent liabilities do not include the effects of certain
employee benefit obligations and associated plan assets that will
be
assumed upon completion of the Distribution. See “Management’s
Discussion and Analysis of Financial Condition and Results of Operations
-
Critical Accounting Policies.”
|
(5) |
In
the fourth
quarter of 2005, we completed a recapitalization of the company,
whereby
common stock held by Kerr-McGee converted into approximately 22.9
million shares of Class B common stock. Also in the fourth quarter
of 2005, we completed an IPO, whereby approximately 17.5 million
shares
of Class A common stock were issued. All of the net proceeds
from the IPO were distributed to Kerr-McGee. Concurrent with the
IPO, we issued $350.0 million of senior unsecured notes and borrowed
$200.0 million under senior secured credit
facility.
|
(6)
|
EBITDA
represents net income (loss) before net interest expense, income
tax
benefit (provision), and depreciation and amortization expense. Adjusted
EBITDA represents EBITDA as further adjusted to reflect the items
set
forth in the table below, all of which are required in determining
our
compliance with financial covenants under our senior secured credit
facility. See “Management’s
Discussion and Analysis of Financial Condition and Results of Operations
- Financial
Condition and Liquidity.”
|
|
We
have included EBITDA and adjusted EBITDA to provide investors with
a
supplemental measure of our operating performance and information
about
the calculation of some of the financial covenants that are contained
in
our senior secured credit facility. We believe EBITDA is an important
supplemental measure of operating performance because it eliminates
items
that have less bearing on our operating performance and thus highlights
trends in our core business that may not otherwise be apparent when
relying solely on generally accepted accounting principles (“GAAP”)
financial measures. We also believe that securities analysts, investors
and other interested parties frequently use EBITDA in the evaluation
of
issuers, many of which present EBITDA when reporting their results.
Adjusted EBITDA is a material component of the covenants imposed
on us by
the senior secured credit facility. Under the senior secured credit
facility, we are subject to financial covenant ratios that are calculated
by reference to adjusted EBITDA. Non-compliance with the financial
covenants contained in the senior secured credit facility could result
in
a default, an acceleration in the repayment of amounts outstanding,
and a
termination of the lending commitments under the senior secured credit
facility. Any acceleration in the repayment of amounts outstanding
under
the senior secured credit facility would result in a default under
the
indenture governing the unsecured notes. While an event of default
under
the senior secured credit facility or the indenture governing the
unsecured notes is continuing, we would be precluded from, among
other
things, paying dividends on our common stock or borrowing under the
revolving credit facility. For a description of required financial
covenant levels, see “Management’s
Discussion and Analysis of Financial Condition and Results of
Operations
- Financial
Condition and Liquidity.”
Our management also uses EBITDA and adjusted EBITDA in order to facilitate
operating performance comparisons from period to period, prepare
annual
operating budgets and assess our ability to meet our future debt
service,
capital expenditure and working capital requirements and our ability
to
pay dividends on our common stock.
|
EBITDA
and adjusted EBITDA are not presentations made in accordance with generally
accepted accounting principles, or GAAP. As discussed above, we believe that
the
presentation of EBITDA and adjusted EBITDA in this annual report on Form 10-K
is
appropriate. However, when evaluating our results, you should not consider
EBITDA and adjusted EBITDA in isolation of, or as a substitute for, measures
of
our financial performance as determined in accordance with GAAP, such as net
income (loss). EBITDA and adjusted EBITDA have material limitations as
performance measures because they exclude items that are necessary elements
of
our costs and operations. Because other companies may calculate EBITDA and
adjusted EBITDA differently than we do, EBITDA may not be, and adjusted EBITDA
as presented in this annual report on Form 10-K is not, comparable to similarly
titled measures reported by other companies.
The
following table reconciles net income (loss) to EBITDA and adjusted EBITDA
for
the periods presented:
|
|
Year
ended December 31,
|
|
|
|
2005
|
|
2004
|
|
2003
|
|
2002
|
|
|
|
(Millions
of dollars)
|
|
Net
income (loss) (a)
|
|
$
|
18.8
|
|
$
|
(127.6
|
)
|
$
|
(92.7
|
)
|
$
|
(97.3
|
)
|
Interest
and debt expense
|
|
|
4.5
|
|
|
0.1
|
|
|
0.1
|
|
|
0.1
|
|
Net
interest expense on borrowings
with affiliates and interest income (b)
|
|
|
11.9
|
|
|
9.5
|
|
|
8.8
|
|
|
11.1
|
|
Income
tax provision (benefit)
|
|
|
7.0
|
|
|
(63.0
|
)
|
|
(39.3
|
)
|
|
(35.3
|
)
|
Depreciation
and amortization expense
|
|
|
103.1
|
|
|
104.6
|
|
|
106.5
|
|
|
105.7
|
|
EBITDA
|
|
|
145.3
|
|
|
(76.4
|
)
|
|
(16.6
|
)
|
|
(15.7
|
)
|
Savannah
sulfate facility shutdown costs
|
|
|
—
|
|
|
29.0
|
|
|
—
|
|
|
—
|
|
Loss
from discontinued operations (c)
|
|
|
42.4
|
|
|
69.7
|
|
|
51.9
|
|
|
120.1
|
|
Provision
for environmental remediation and restoration, net of
reimbursements
|
|
|
17.1
|
|
|
4.6
|
|
|
14.9
|
|
|
14.3
|
|
Extraordinary,
unusual or non-recurring expenses or losses (d)
|
|
|
—
|
|
|
(0.3
|
)
|
|
47.0
|
|
|
—
|
|
Noncash
changes constituting:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(Gain)
loss on sales of accounts receivable (e)
|
|
|
(0.1
|
)
|
|
8.2
|
|
|
4.8
|
|
|
4.7
|
|
Write-downs
of property, plant and equipment and other assets (f)
|
|
|
9.3
|
|
|
104.8
|
|
|
29.3
|
|
|
18.5
|
|
Impairment
of intangible assets
|
|
|
—
|
|
|
7.4
|
|
|
—
|
|
|
—
|
|
Cumulative
effect of change in accounting principle
|
|
|
—
|
|
|
—
|
|
|
14.1
|
|
|
—
|
|
Provision
for asset retirement obligations
|
|
|
1.4
|
|
|
—
|
|
|
—
|
|
|
—
|
|
Other
items (g)
|
|
|
16.6
|
|
|
15.2
|
|
|
14.9
|
|
|
(7.4
|
)
|
Adjusted
EBITDA
|
|
$
|
232.0
|
|
$
|
162.2
|
|
$
|
160.3
|
|
$
|
134.5
|
|
(a)
|
Net
income (loss) includes operating losses associated with our Savannah
sulfate facility, which was closed in September 2004, of $2.6
million, $17.8 million, $18.6 million and $9.6 million
for the years ended December 31, 2005, 2004, 2003 and 2002,
respectively.
|
(b)
|
Included
as a component of Other income (expense) in the company’s Consolidated and
Combined Statement of Operations. Net interest expense on borrowings
with
affiliates was $14.6 million, $12.1 million, $10.1 million and $12.9
million for the years ended December 31, 2005, 2004, 2003 and 2002,
respectively.
|
(c)
|
Includes
provisions for environmental remediation and restoration, net of
reimbursements, related to our former forest products operations,
thorium
compounds manufacturing, uranium and refining operations of $17.6
million,
$61.5 million, $41.1 million and $61.1 million for
the years ended December 31, 2005, 2004, 2003 and 2002,
respectively.
|
(d)
|
Represents
extraordinary, unusual or non-recurring expenses or losses as defined
within our credit agreement. Includes $25.8 million associated with
the closure of our Mobile, Alabama, facility in 2003 for charges
not
reflected elsewhere and $21.2 million for a work force reduction
program for continuing operations in 2003. See Note 16 to the Consolidated
and Combined Financial Statements included in Item 8 of this annual
report
on Form 10-K.
|
(e)
|
Loss
on the sales of accounts receivable under an asset monetization program,
or a factoring program, comparable to interest
expense.
|
(f)
|
The
2004 amount includes $86.6 million associated with the shutdown of
our Savannah sulfate facility.
|
(g)
|
Includes
noncash stock-based compensation, noncash pension and postretirement
cost
and accretion expense.
|
Item
7. Management’s
Discussion and Analysis of Financial Condition and Results of
Operations
The
following discussion should be read in conjunction with the selected historical
consolidated and combined financial data and the consolidated and combined
financial statements and the related notes included elsewhere in this annual
report on Form 10-K. Except for the historical consolidated and combined
financial information contained herein, the matters discussed below may contain
forward-looking statements that reflect our plans, estimates and beliefs. Our
actual results could differ materially from those discussed in these
forward-looking statements. Factors that could cause or contribute to these
differences include, but are not limited to, those discussed below and elsewhere
in this annual report on Form 10-K, particularly in “Risk
Factors”
and “Special
Note Regarding Forward - Looking Statement.”
Overview
We
are
the world’s third-largest producer and marketer of titanium dioxide based on
reported industry capacity by the leading titanium dioxide producers, and we
have an estimated 13% market share of the $9 billion global market in 2005
based on reported industry sales. We also produce and market electrolytic
manganese dioxide and sodium chlorate, as well as boron-based and other
specialty chemicals. We operate seven production facilities and have direct
sales and technical service organizations in the United States, Europe and
the
Asia-Pacific region. We have approximately 2,110 employees worldwide and more
than 1,100 customers located in over 100 countries. In 2005, we had net sales
of
$1.4 billion, net income of $18.8 million and adjusted EBITDA of
$232.0 million. For a reconciliation of adjusted EBITDA to net income
(loss), see “Selected
Financial Data.”
Our
business has two reportable segments: pigment and electrolytic and other
chemical products. Our pigment segment, which accounted for approximately 93%
of
our net sales in 2005, primarily produces and markets titanium dioxide pigment.
Performance of our pigment segment is cyclical and tied closely to general
economic conditions, including global gross domestic product. Events that
negatively affect discretionary spending also may negatively affect demand
for
finished products that contain titanium dioxide. Our pigment segment also is
affected by seasonal fluctuations in the demand for coatings, the largest
end-use market for titanium dioxide. From 2000 through 2003, the titanium
dioxide industry experienced a period of unusually weak business conditions
as a
result of a variety of factors, including the global economic recession,
exceptionally rainy weather conditions in Europe and the Americas and the
outbreak of SARS in Asia. However, global economic conditions generally improved
in late 2004, driving increased demand, and, in the last half of 2004 and
throughout 2005, increased prices. No major titanium dioxide plant construction
projects have commenced, and we expect the industry’s current high capacity
utilization rates to continue in the near term and believe that industry
dynamics show a sustainable improving trend.
Due
to
the nature of our current and former operations, we have significant
environmental remediation obligations and are subject to legal and regulatory
liabilities. Former operations include, among others, operations involving
the
production of ammonium perchlorate, treatment of forest products, the refining
and marketing of petroleum products, offshore contract drilling, coal mining
and
the mining, milling and processing of nuclear materials. For example, we have
liabilities relating to the remediation of various sites at which chemicals
such
as creosote, perchlorate, low-level radioactive substances, asbestos and other
materials have been used or disposed. As of December 31, 2005, we had reserves
in the amount of $223.7 million for environmental matters and receivables
for reimbursement for such matters of $56.7 million. For the year ended December
31, 2005, we provided $34.7 million (net of reimbursements) for
environmental remediation and restoration costs, of which $17.6 million
related to discontinued operations. We had $61.1 million of expenditures
associated with our environmental remediation projects, and received
$71.4 million in third-party reimbursements in 2005.
Pursuant
to the MSA, Kerr-McGee has agreed to reimburse us for a portion of the
environmental remediation costs we incur and pay after the IPO. The
reimbursement obligation extends to costs incurred at any site associated with
any of our former businesses or operations. With respect to any site for which
a
reserve has been established as of the effective date of the MSA, 50% of the
remediation costs we incur and pay in excess of the reserve amount (after
meeting a $200,000 minimum threshold amount) will be reimbursable by Kerr-McGee,
net of any amounts recovered or, in our reasonable and good faith estimate,
that
will be recovered from third parties. With respect to any site for which a
reserve has not been established as of the effective date of the MSA, 50% of
the
amount of the remediation costs we incur and pay (after meeting a $200,000
minimum threshold amount) will be reimbursable by Kerr-McGee, net of any amounts
recovered or, in our reasonable and good faith estimate, that will be recovered
from third parties. Kerr-McGee is only required to reimburse us for costs we
actually incur and pay during the seven-year period following the IPO, up to
a
maximum aggregate amount of $100 million. Kerr-McGee’s reimbursement
obligation is subject to various other limitations and
restrictions.
Potential
Dilution. Certain
of our employees have participated in Kerr-McGee's long-term incentive plans.
Under these plans, employees received various stock-based compensation awards,
including stock options, restricted stock, stock opportunity grants and
performance units. Other than with regard to employees eligible for retirement
on the effective date of the Distribution, Kerr-McGee unvested stock options
held by our employees on that date will be forfeited and replaced with options
to purchase our Class A common stock. Unvested restricted shares of Kerr-McGee
common stock and unvested Kerr-McGee performance unit awards held by our
employees on that date will be forfeited and replaced with restricted shares
of
our Class A common stock.
The
actual number of shares of our Class A common stock that will be issued in
connection with the forfeiture and subsequent replacement of the Kerr-McGee
stock-based awards on the Distribution date will depend on the per share price
of our Class A common stock and Kerr-McGee's common stock, as well as on the
number of Kerr-McGee stock-based awards held by our employees on that date.
Based on approximately 161,500 unvested Kerr-McGee options, approximately 81,700
restricted shares of Kerr-McGee stock and stock opportunity grants, and
approximately $3.1 million in value of performance unit awards held by our
employees on February 28, 2006, the following number of shares of our Class
A
common stock would be issued in connection with the replacement of awards,
assuming the prices for our Class A common stock and Kerr-McGee's common stock
shown below:
Hypothetical
Kerr-McGee
Common
Stock Price on
Distribution
Date
|
Hypothetical
Tronox Class A Common Stock Price
on
Distribution
Date
|
|
|
$14.00
|
$15.00
|
$16.00
|
$17.00
|
|
|
(Number
of shares)
|
$
90.00
|
1,781,474
|
1,662,709
|
1,558,790
|
1,467,096
|
$100.00
|
1,955,145
|
1,824,802
|
1,710,752
|
1,610,120
|
The
per
share prices of Kerr-McGee common stock and of our Class A common stock set
forth in this table do not necessarily reflect the range of expected prices
on
the Distribution date. The number of shares of our Class A common stock issued
in connection with the conversion or replacement of Kerr-McGee stock-based
awards could vary significantly from the above numbers due to changes in the
relative values of our Class A common stock and Kerr-McGee's common stock.
This
will result in additional potentially dilutive securities.
Basis
of Presentation
The
combined financial statements prior to the Contribution have been derived from
the accounting records of Kerr-McGee, principally representing the Chemical
-
Pigment and Chemical - Other segments of Kerr-McGee, using the historical
results of operations, and historical basis of assets and liabilities of the
subsidiaries that the company did not own but currently owns and the chemical
business the company operates.
Our
Consolidated and Combined Statement of Operations included in Item 8 of this
annual report on Form 10-K includes allocations of costs for corporate functions
historically provided to us by Kerr-McGee prior to the IPO,
including:
General
Corporate Expenses.
Represents costs related to corporate functions such as accounting, tax,
treasury, human resources, legal and information management and technology.
These costs have historically been allocated primarily based on estimated use
of
services as compared to Kerr-McGee’s other businesses. These costs are included
in selling, general and administrative expenses in the consolidated and combined
statement of operations. This allocation ceased at the IPO date and any services
rendered subsequent to that date and the resulting costs are being billed under
the terms of the transition services agreement.
Employee
Benefits and Incentives.
Represents fringe benefit costs and other incentives, including group health
and
welfare benefits, U.S. pension plans, U.S. postretirement health and life plans
and employee stock-based compensation plans. These costs have historically
been
allocated on an active headcount basis for health and welfare benefits,
including U.S. postretirement plans, on the basis of salary for U.S. pension
plans and on a specific identification basis for employee stock-based employee
compensation plans. These costs are included in costs of goods sold, selling,
general and administrative expenses, restructuring charges and loss from
discontinued operations in the consolidated and combined statement of
operations.
Interest
Expense.
Until
the completion of the IPO and the concurrent financing, Kerr-McGee provided
financing to us through cash flows from its other operations and debt incurred.
Although the incurred debt was not allocated to us, a portion of the interest
expense was allocated based on specifically-identified borrowings at
Kerr-McGee’s average borrowing rates. These costs are included in other income
(expense) in the consolidated and combined statement of operations, net of
interest income that was allocated to Kerr-McGee on certain monies we loaned
to
Kerr-McGee. This allocation ceased at the IPO date as Kerr-McGee no longer
provides financing to us.
Expense
allocations from Kerr-McGee reflected in the income (loss) from continuing
operations in our consolidated and combined financial statements were as
follows:
|
|
2005
|
|
2004
|
|
2003
|
|
|
|
(Millions
of dollars)
|
|
General
corporate expenses
|
|
$
|
24.3
|
|
$
|
27.4
|
|
$
|
25.3
|
|
Employee
benefits and incentives (1)
|
|
|
24.0
|
|
|
28.8
|
|
|
35.9
|
|
Interest
expense, net
|
|
|
14.6
|
|
|
12.1
|
|
|
10.1
|
|
(1)
|
Includes
special termination benefits, settlement and curtailment losses of
nil,
$9.1 million and $28.7 million for years 2005, 2004 and 2003,
respectively.
|
These
allocations were based on what were considered to be reasonable reflections
of
the historical utilization levels of these services required in support of
our
business. We currently estimate that general annual corporate expenses may
be
$15.0 million to $20.0 million greater on an annual basis in the future as
a stand-alone company.
Subsequent
to the IPO, the expense allocations for certain corporate services previously
provided by Kerr-McGee ceased, and we began purchasing such services from
Kerr-McGee under the terms of the transition services agreement. Under the
terms
of the transition services agreement, we also receive compensation for services
provided to Kerr-McGee. The net expense charged to us in 2005 was nominal for
the one-month period subsequent to the IPO.
Kerr-McGee
utilized a worldwide centralized approach to cash management and the financing
of its operations, with all related activity between Kerr-McGee and us reflected
as net transfers from Kerr-McGee in our consolidated and combined statement
of
comprehensive income (loss) and business/stockholders’ equity. In connection
with the IPO, the net amount due from us to Kerr-McGee at the closing date
of
the IPO was contributed by Kerr-McGee to us as equity, forming a part of our
continuing equity. Subsequent to the closing of the IPO, amounts due from or
to
Kerr-McGee arising from transactions subsequent to that date are being settled
in cash.
We
believe the assumptions underlying our consolidated and combined financial
statements are reasonable. However, the consolidated and combined financial
statements may not necessarily reflect our future results of operations,
financial position and cash flows or what our results of operations, financial
position and cash flows would have been had we been a stand-alone company during
the periods presented.
Results
of Operations
The
following table summarizes segment operating profit (loss), with reconciliation
to consolidated and combined net income (loss) for each of the last three
years:
|
|
Year
Ended December 31,
|
|
|
|
2005
|
|
2004
|
|
2003
|
|
|
|
(Millions
of dollars)
|
|
Net
sales—
|
|
|
|
|
|
|
|
|
|
|
Pigment
|
|
$
|
1,267.0
|
|
$
|
1,208.4
|
|
$
|
1,078.8
|
|
Electrolytic
and other chemical products
|
|
|
97.0
|
|
|
93.4
|
|
|
78.9
|
|
Total
|
|
$
|
1,364.0
|
|
$
|
1,301.8
|
|
$
|
1,157.7
|
|
Operating
profit (loss)(1)—
|
|
|
|
|
|
|
|
|
|
|
Pigment
|
|
$
|
101.5
|
|
$
|
(86.5
|
)
|
$
|
(15.0
|
)
|
Electrolytic
and other chemical products (2)
|
|
|
(5.9
|
)
|
|
(0.6
|
)
|
|
(22.0
|
)
|
Subtotal
|
|
|
95.6
|
|
|
(87.1
|
)
|
|
(37.0
|
)
|
Expenses
of nonoperating sites (3)
|
|
|
(2.1
|
)
|
|
(5.5
|
)
|
|
(3.6
|
)
|
Provision
for environmental remediation and restoration (3)
|
|
|
(5.6
|
)
|
|
(2.2
|
)
|
|
(1.6
|
)
|
Operating
profit (loss)
|
|
|
87.9
|
|
|
(94.8
|
)
|
|
(42.2
|
)
|
Interest
and debt expense
|
|
|
4.5
|
|
|
0.1
|
|
|
0.1
|
|
Other
income (expense) (4)
|
|
|
(15.2
|
)
|
|
(25.2
|
)
|
|
(20.5
|
)
|
Benefit
(provision) for income taxes
|
|
|
(21.8
|
)
|
|
38.3
|
|
|
15.1
|
|
Income
(loss) from continuing operations
|
|
|
46.4
|
|
|
(81.8
|
)
|
|
(47.7
|
)
|
Discontinued
operations, net of taxes
|
|
|
(27.6
|
)
|
|
(45.8
|
)
|
|
(35.8
|
)
|
Cumulative
effect of change in accounting principle, net of taxes
|
|
|
—
|
|
|
—
|
|
|
(9.2
|
)
|
Net
income (loss)
|
|
$
|
18.8
|
|
$
|
(127.6
|
)
|
$
|
(92.7
|
)
|
(1)
|
Our
management evaluates segment performance based on segment operating
profit
(loss), which represents the results of segment operations before
unallocated costs, such as general expenses and environmental provisions
related to sites no longer in operation, income tax expense or benefit
and
other income (expense). Total operating profit (loss) of both of
our
segments is a non-GAAP financial measure of the company’s performance, as
it excludes general expenses and environmental provisions related
to sites
no longer in operation which are a component of operating profit
(loss),
the most comparable GAAP measure. Our management considers total
operating
profit (loss) of our segments to be an important supplemental measure
of
our operating performance by presenting trends in our core businesses
and
facilities currently in operation. This measure is used by us for
planning
and budgeting purposes and to facilitate period-to-period comparisons
in
operating performance of our reportable segments in the aggregate
by
eliminating items that affect comparability between periods. We believe
that total operating profit (loss) of our segments is useful to investors
because it provides a means to evaluate the operating performance
of our
segments and our company on an ongoing basis using criteria that
are used
by our internal decision makers. Additionally, it highlights operating
trends and aids analytical comparisons. However, total operating
profit
(loss) of our segments has limitations and should not be used as
an
alternative to operating profit (loss), a performance measure determined
in accordance with GAAP, as it excludes certain costs that may affect
our
operating performance in future
periods.
|
(2)
|
Includes
$10.3 million, nil and $11.0 million for the years ended 2005,
2004 and 2003, respectively, of environmental charges, net of
reimbursements, related to ammonium perchlorate at our Henderson
facility.
|
(3)
|
Includes
general expenses and environmental provisions related to various
businesses in which our affiliates are no longer engaged but that
have not
met the criteria for reporting as discontinued
operations.
|
(4)
|
Includes
interest expense allocated to us by Kerr-McGee based on specifically
identified borrowings from Kerr-McGee at Kerr-McGee’s average borrowing
rates.
|
Year
Ended December 31, 2005 Compared to Year Ended December 31,
2004
Net
Sales.
Net
sales increased by $62.2 million, or 4.8%, to $1,364.0 million in 2005
from $1,301.8 million in 2004. The increase was due to an increase in the
pigment segment sales of $58.6 million and an increase in electrolytic and
other chemical product segment sales of $3.6 million, as discussed below
under “Pigment
Segment - Net Sales”
and
“Electrolytic
and Other Chemical Products Segment - Net Sales.”
Gross
Margin.
Gross
margin in 2005 was $220.2 million compared to $132.9 million in 2004. As a
percent of sales, gross margin increased to 16.1% in 2005 from 10.2% in 2004.
The improved margin was primarily due to improved pricing in the pigment segment
realized in 2005 and due to an inventory revaluation charge of $15.6 million
recognized in 2004 in connection with the shutdown of our titanium dioxide
pigment sulfate production at our Savannah, Georgia, facility. (See further
discussion under “Restructuring Charges” below.)
Selling,
General and Administrative Expenses.
Selling, general and administrative expenses increased $5.1 million in 2005
compared to 2004. Selling, general and administrative costs were higher in
2005
compared to 2004, primarily due to an increase in employee incentive
compensation (including stock-based compensation), largely as a result of
improved operating performance for the year.
Restructuring
Charges.
In
2005, we had no restructuring charges. In 2004, we shut down our titanium
dioxide pigment sulfate production at our Savannah, Georgia, facility. Demand
and prices for sulfate anatase pigments, particularly in the paper market,
had
declined in North America consistently during the previous several years. The
decreasing volumes, along with unanticipated environmental and infrastructure
issues discovered after we acquired the facility in 2000, created unacceptable
financial returns for the facility and contributed to the decision to shut
it
down.
Included
in the restructuring charges in 2004 related to the shutdown of the Savannah
facility was $86.6 million of asset write-downs taken in the form of accelerated
depreciation for plant assets, $7.4 million for impairment of intangible assets,
$6.7 million for severance and benefit plan curtailment costs and $6.7 million
for other closure costs. We also recognized an additional $5.6 million of costs
in 2004 in connection with the closure of the synthetic rutile plant in Mobile,
Alabama.
Provision
for Environmental Remediation and Restoration, net of
Reimbursements.
Provision for environmental remediation and restoration, net of reimbursements,
was $17.1 million in 2005 compared to $4.6 million in the same period
of 2004. The net provision in 2005 included $11.3 million related to
remediation of ammonium perchlorate contamination associated with the Henderson,
Nevada, facility. It was determined in 2005 that the groundwater remediation
system at the Henderson facility would need to be operated and maintained over
an extended time period and a provision was added for the closure of an ammonium
perchlorate pond. The provision for environmental remediation and restoration
also included a charge of $5.6 million in 2005 related to remediation of
the former agricultural chemical Jacksonville, Florida, site for soil
remediation and excavation (see “Environmental
Matters - Environmental Costs”
and
Note 22 to the Consolidated and Combined Financial Statements included in
Item 8 of this annual report on Form 10-K).
In
the
first quarter of 2006, we recognized a receivable of $20.5 million as a result
of a settlement of our claim against the United States, which was documented
in
a consent decree approved by the court on January 13, 2006. We received this
reimbursement in February 2006.
Interest
and Debt Expense.
Interest and debt expense to outside parties increased to $4.5 million in 2005
from $0.1 million in 2004. The increase was due to interest on the company’s
unsecured notes and term loan facility that were entered into concurrent with
the IPO in November 2005.
Other
Income (Expense).
Other
expenses, net, decreased $10.0 million from $25.2 million in 2004 to $15.2
million in 2005, primarily due to a lower net fees incurred in connection with
the accounts receivable securitization program that was terminated in April
2005, including a return of estimated fees previously paid in excess of actual
costs incurred. Other expenses were also lower due to a decrease in losses
attributable to changes in the exchange rates for both the euro and the
Australian dollar.
Benefit
(Provision) for Income Taxes.
Our
effective tax rate related to continuing operations for 2005 was 32.0% compared
to 31.9% for 2004. During 2005, we repatriated $131.0 million in
extraordinary dividends under the American Jobs Creation Act of 2004, resulting
in recognition of income tax expense of $4.7 million. Our effective tax
rate was reduced in 2005 by tax benefits and reductions in statutory rates
recognized in foreign jurisdictions. On a stand-alone basis, our pro forma
provision for income taxes related to continuing operations in 2005 would have
been $19.1 million less than that determined under our allocation policy with
Kerr-McGee. This decrease in income taxes was due primarily to income in the
United States that would have been eliminated by our theoretical stand-alone
net
operating loss carryforward, which we would not have previously recognized
as a
deferred tax asset.
Loss
from Discontinued Operations.
The
loss from discontinued operations, net of tax, in 2005 was $27.6 million
compared to $45.8 million in 2004. The loss in 2005 includes $17.7 million
loss,
net of tax, on our former forest products operations, including an environmental
provision of $3.2 million, net of taxes, for additional soil volumes related
to
the Sauget, Illinois, wood-treatment plant and $4.8 million, net of tax, for
litigation expenses. Also included is a $5.2 million environmental
provision, net of taxes, for pond closure, rock placement and surface water
channels at the former Ambrosia Lake, New Mexico, site associated with our
formerly conducted uranium mining and milling operation (see “Environmental
Matters - Environmental Costs”
and
Note 22 to the Consolidated and Combined Financial Statements included in
Item 8 of this annual report on Form 10-K).
Pigment
Segment
Net
Sales.
Net
sales increased $58.6 million, or 4.8%, in 2005 compared to 2004.
Approximately $136.4 million of this increase was due to an increase in
average selling prices of approximately 12%, partially offset by a decrease
in
volumes sold of $77.8 million. Stronger market conditions contributed to the
improvement in pricing while the decline in volume was primarily attributable
to
the shutdown of our sulfate production facility in Savannah, Georgia, in 2004
and due to reduced volumes in the Asia/Pacific region resulting from increased
volumes in the latter part of 2004 in advance of announced price increases
and
an unplanned temporary two-week shutdown of our Australian pigment plant in
the
fourth quarter of 2005 necessitated by a shutdown of our third-party process
gas
supplier. Approximately $4.0 million of the increase in average sales prices
in
2005 was due to the effect of foreign currency exchange rates.
Operating
Profit.
Operating profit in 2005 was $101.5 million, an increase of
$188.0 million over the operating loss of $86.5 million in 2004. In
addition to the
$58.6 million increase in revenues discussed above, the improvement in operating
results in 2005 was primarily attributable to the shutdown provisions incurred
in 2004 of $123.0 million for the sulfate-process titanium dioxide pigment
production at the Savannah, Georgia, facility and $6.8 million of costs incurred
in connection with the continued efforts to close the synthetic rutile plant
in
Mobile, Alabama. These improvements were partially offset by an increase in
selling, general and administrative expenses of $5.0 million over 2004,
primarily due to an increase in employee incentive compensation (including
stock-based compensation), largely as a result of improved operating performance
for the year.
Electrolytic
and Other Chemical Products Segment
Net
Sales.
Net
sales in 2005 were $97.0 million, an increase of $3.6 million compared
to 2004, primarily due to increased sales of electrolytic manganese dioxide
and
lithium manganese oxide. Sales of manganese dioxide increased due to improvement
in both volumes and price, while sales of lithium manganese increased due to
improved volumes.
Operating
Loss.
Operating loss in 2005 was $5.9 million compared with an operating loss of
$0.6 million in 2004. Operating
performance declined primarily due to higher environmental costs of $9.1 million
resulting from a net $11.3 million environmental provision (net of expected
insurance reimbursement of $20.5 million) incurred in the first quarter of
2005,
related primarily to ammonium perchlorate remediation associated with Tronox’s
Henderson, Nevada, operations. Operating results were also impacted by higher
selling, general and administrative expenses of $2.0 million attributable to
increased litigation expenses and an increase in employee incentive compensation
(including stock-based compensation), largely as a result of improved operating
performance for the year. These higher costs were partially offset by $2.1
million lower operating costs in 2005 at Tronox’s Henderson, Nevada, EMD
manufacturing facility which incurred higher costs in 2004 when production
recommenced after being temporarily curtailed in late 2003.
Year
Ended December 31, 2004 Compared to Year Ended December 31,
2003
Net
Sales.
Net
sales increased by $144.1 million, or 12.4%, to $1,301.8 million in
2004 from $1,157.7 million in 2003. The increase was due to increased sales
in the pigment segment of $129.6 million and increased sales in the electrolytic
and other chemical products segment of $14.5 million, as discussed below under
“Pigment
Segment - Net Sales”
and
“Electrolytic
and Other Chemical Products Segment - Net Sales.”
Gross
Margin.
Gross
margin in 2004 was $132.9 million compared to $133.0 million in 2003.
As a percent of sales, gross margin declined to 10.2% in 2004 from 11.5% in
2003. The decline in the gross margin percentage was primarily due to an
inventory revaluation charge of $15.6 million recognized in 2004 in
connection with the shutdown of our titanium dioxide pigment sulfate production
at our Savannah, Georgia, facility (see further discussion under “Restructuring
Charges”
below).
Selling,
General and Administrative Expenses.
Selling, general and administrative expenses increased $11.2 million in
2004 compared to 2003. This increase was due to an increase in employee
incentive compensation related to cash bonuses and restricted stock awards,
additional costs associated with cash settlements of certain qualified benefits
associated with retirements during the year and increased legal
fees.
Restructuring
Charges.
In
2004, we shut down the titanium dioxide pigment sulfate production at our
Savannah, Georgia, facility. Demand and prices for sulfate anatase pigments,
particularly in the paper market, had declined in North America consistently
during the previous several years. The decreasing volumes, along with
unanticipated environmental and infrastructure issues discovered after we
acquired the facility in 2000, created unacceptable financial returns for the
facility and contributed to the decision to shut it down. We expect this
shutdown, once fully implemented, will result in an improvement in segment
operating profit of approximately $15 million annually based on 2004
costs.
Included
in the restructuring charges in 2004 was $86.6 million of asset write-downs
taken in the form of accelerated depreciation for plant assets,
$7.4 million for impairment of intangible assets, $6.7 million for
severance and benefit plan curtailment costs and $6.7 million for other
closure costs. We also recognized an additional $5.6 million of costs in
2004 in connection with the closure of the synthetic rutile plant in Mobile,
Alabama. The 2003 restructuring charges included $38.6 million for shutdown
costs related to the Mobile, Alabama, facility and $22.8 million in
connection with a work force reduction program consisting of both voluntary
retirements and involuntary terminations that reduced our work force by 138
employees.
Provision
for Environmental Remediation and Restoration, net of
Reimbursements.
Provision for environmental remediation and restoration, net of reimbursements,
was $4.6 million in 2004 compared to $14.9 million in 2003. The
decrease in 2004 was primarily due to an $11.0 million provision in 2003
related to ammonium perchlorate at our Henderson, Nevada facility. Our
environmental obligations are discussed in detail under “Environmental
Matters - Environmental Costs”
below
and Note 22 to the Consolidated and Combined Financial Statements included
in Item 8 of this annual report on Form 10-K.
Other
Income (Expense).
Other
expense increased $4.7 million in 2004 compared to 2003, primarily due to a
$3.4 million increased loss on the pigment receivables sold under the asset
monetization program due to increased activity in 2004 and an increase in the
foreign currency losses in 2004 of $1.7 million primarily due to
unfavorable changes in the Australian dollar exchange rates.
Benefit
for Income Taxes.
Our
effective tax rate related to continuing operations was 31.9%, compared with
24.0% in 2003. This rate was based on Kerr-McGee’s tax allocation policy. On a
stand-alone basis, our pro forma provision for income taxes related to
continuing operations in 2004 would have been $44.2 million more than that
determined under our allocation policy with Kerr-McGee. This increase in income
taxes was due primarily to net operating losses in the United States, which
we
would not have been able to utilize on a stand-alone basis.
Loss
from Discontinued Operations.
We
recognized a loss from discontinued operations as a result of our decision
to
dispose of the forest products business and additional environmental provisions
related to other previously discontinued operations of $45.8 million in
2004 and $35.8 million in 2003, net of tax benefit. The increased loss in
2004 was primarily due to additional environmental provisions, net of
reimbursements and taxes, in 2004 related to our former thorium compounds
manufacturing and refining operations of $5.7 million and $5.1 million
net of taxes, respectively.
Cumulative
Effect of Change in Accounting Principle.
We
recognized a charge of $9.2 million (net of income tax benefit of
$4.9 million) in 2003 upon adoption, as of January 1, 2003, of
Financial Accounting Standards Board Statement No. 143 (“FAS
No. 143”), “Accounting
for Asset Retirement Obligations”
related to our Mobile plant, which we expected to close at the date of adoption
of this standard.
Pigment
Segment
Net
Sales.
Net
sales increased $129.6 million, or 12.0%, in 2004 to $1,208.4 million
from $1,078.8 million in 2003. Of the total increase, approximately
$114 million was due to increased sales volumes and approximately
$16 million resulted from an increase in average sales prices. Sales
volumes for 2004 were approximately 9% higher than in the prior year due
primarily to stronger market conditions. Approximately half of the increase
in
average sales prices in 2004 was due to the effect of foreign currency exchange
rates with the remainder due to price increases resulting from improved market
conditions.
Operating
Loss.
The
pigment segment recorded an operating loss of $86.5 million in 2004,
compared with an operating loss of $15.0 million in 2003. The 2004
operating loss was primarily the result of shutdown provisions discussed above
for the sulfate-process titanium dioxide pigment production at the Savannah,
Georgia, facility totaling $123.0 million. Operating results for 2004 also
were negatively impacted by $6.8 million of costs incurred in connection
with the continued efforts to close the synthetic rutile plant in Mobile,
Alabama, compared to a $46.7 million plant closure provision recognized in
2003 for this facility. Additionally, operating results in 2003 were negatively
impacted by a $22.9 million charge for work force reduction and other
compensation costs. These charges had the effect of reducing operating profit
by
$129.8 million in 2004 and $69.6 million in 2003. The increase in
revenues in 2004 resulting from higher volume and sales prices was offset by
an
increase of approximately $132 million in production costs due to higher
volume (approximately $80 million) and costs (approximately
$52 million including the effects of foreign currency exchange rate
changes) and an increase in selling, general and administrative expenses of
approximately $6 million over 2003. Additional information related to the
shutdowns of the Savannah and Mobile facilities is included in Note 16 to
the Consolidated and Combined Financial Statements included in Item 8 of this
annual report on Form 10-K.
Electrolytic
and Other Chemical Products Segment
Net
Sales.
Net
sales increased $14.5 million, or 18.4%, in 2004 to $93.4 million from
$78.9 million in 2003. The increase in net sales resulted primarily from an
increase in electrolytic sales due primarily to the full year of operations
at
our electrolytic manganese dioxide (EMD) manufacturing operation in Henderson,
Nevada (see further discussion under “Operating
Loss”
below).
Operating
Loss.
The
electrolytic and other chemical products segment recorded an operating loss
for
2004 of $0.6 million compared with an operating loss of $22.0 million
in 2003. The improved operating performance was primarily due to the full year
of operations at the EMD facility, lower environmental costs in 2004 of
$9.4 million compared to 2003 and work force reduction and other
compensation charges recognized in 2003 that did not recur in 2004. The 2003
environmental costs incurred related primarily to remediation of ammonium
perchlorate contamination associated with the Henderson, Nevada facility. While
we are no longer producing ammonium perchlorate, we continue to use the property
in our other chemical products business.
During
the third quarter of 2003, our EMD manufacturing operation in Henderson, Nevada,
was placed on standby to reduce inventory levels due to the harmful effect
of
low-priced imports on our EMD business. In response to the pricing activities
of
importing companies, Tronox LLC filed a petition for the imposition of
anti-dumping duties with the U.S. Department of Commerce International Trade
Administration and the U.S. International Trade Commission on July 31,
2003. In its petition, Tronox LLC alleged that manufacturers in certain named
countries export EMD to the United States in violation of U.S. anti-dumping
laws
and requested that the U.S. Department of Commerce apply anti-dumping duties
to
the EMD imported from such countries. The Department of Commerce found probable
cause to believe that manufacturers in the specified countries engaged in
dumping and initiated an anti-dumping investigation with respect to such
manufacturers. Subsequently, demand in the United States for U.S.-produced
EMD
product increased, and the plant resumed operations in December 2003.
Tronox LLC withdrew its anti-dumping petition in February 2004 but
continues to monitor the pricing activities of EMD importers.
Financial
Condition and Liquidity
Concurrent
with the IPO, our wholly-owned subsidiary, Tronox Worldwide LLC, entered into
a
senior secured credit facility. This facility consists of a $200 million
six-year term loan facility and a five-year multicurrency revolving credit
facility of $250 million. This facility is unconditionally and irrevocably
guaranteed by Tronox and Tronox Worldwide LLC’s direct and indirect material
domestic subsidiaries. The facility is secured by a first priority security
interest in certain domestic assets, including certain property and equipment,
inventory and receivables, of Tronox Worldwide LLC and the guarantors of the
senior secured credit facility. The facility is also secured by pledges of
the
equity interest in Tronox Worldwide LLC and Tronox Worldwide LLC’s direct and
indirect domestic subsidiaries and up to 65% of the voting and 100% of the
non-voting equity interests in Tronox Worldwide LLC’s direct foreign
subsidiaries and the direct foreign subsidiaries of the guarantors of the senior
secured credit facility.
The
term loan facility will amortize each year in an amount equal to 1% per year
in
equal quarterly installments for the first five years and in an amount equal
to
95% in equal quarterly installments for the final year.
Interest
on amounts borrowed under the senior secured credit facility is payable, at
the
company’s election, at a base rate or a LIBOR rate, in each case as defined in
the agreement. The initial margin applicable to LIBOR borrowings is 175 basis
points and may vary from 100 to 200 basis points depending on the company’s
credit rating.
The
terms of the credit agreement provide for customary representations and
warranties, affirmative and negative covenants, and events of default. The
company is also required to maintain compliance with the following financial
covenants effective beginning in 2006 (in each case, as defined in the
agreement):
· |
Consolidated
Total Leverage Ratio of no more than
3.75:1
|
· |
Consolidated
Interest Coverage Ratio of at least
2:1
|
· |
Limitation
on Capital Expenditures
|
Although
these financial covenants did not apply at year-end 2005, we were in compliance
with the
leverage and interest coverage ratio at December 31, 2005.
Also
concurrently with the IPO, Tronox Worldwide LLC and Tronox Finance Corp. issued
$350 million in aggregate principal amount of 9½% senior unsecured notes due
2012 in a private offering. These notes are guaranteed by Tronox and Tronox
Worldwide LLC’s material direct and indirect wholly-owned domestic subsidiaries.
Interest on the notes will be payable on June 1 and December 1 of each year,
commencing June 1, 2006. The company has agreed to file a registration statement
with the SEC relating to an offer to exchange the notes and guarantees for
publicly tradable notes and guarantees having substantially identical terms
no
later than April 27, 2006.
Both
the credit facility and the senior unsecured notes have limitations on the
amount of cash dividends that Tronox can pay to its stockholders. These
limitations restrict cash payments of dividends to $5.0 million in the aggregate
in any fiscal quarter and to $13.5 million in the aggregate in any fiscal year.
Prior
to the IPO, we did not have any long-term debt outstanding. This has changed
our
capital structure and long-term commitments significantly from those that
existed prior to the IPO. The following table provides information for the
analysis of our historical financial condition and liquidity:
|
|
December
31,
2005
|
|
December
31,
2004
|
|
December
31,
2003
|
|
|
|
(Millions
of dollars)
|
|
Current
ratio (1)
|
|
|
2.1:1
|
|
|
1.7:1
|
|
|
1.9:1
|
|
Cash
and cash equivalents
|
|
$
|
69.0
|
|
$
|
23.8
|
|
$
|
59.3
|
|
Working
capital (2)
|
|
|
404.4
|
|
|
240.2
|
|
|
304.5
|
|
Total
assets
|
|
|
1,758.3
|
|
|
1,595.9
|
|
|
1,809.1
|
|
Long-term
debt
|
|
|
548.0
|
|
|
-
|
|
|
-
|
|
Business/Stockholders’
equity (3)
|
|
|
489.0
|
|
|
889.9
|
|
|
1,011.2
|
|
(1)
Represents
a ratio of current assets to current liabilities.
(2)
Represents
excess of current assets over current liabilities.
(3)
Upon
completion of the Distribution, we will assume certain employee benefit
obligations and associated trust assets from Kerr-McGee, which will result
in a
reduction of stockholders’ equity by approximately $25 million based on current
estimates.
Overview
Our
primary cash needs will be for working capital, capital expenditures,
environmental cash expenditures and debt service under the senior secured credit
facility and the unsecured notes. We believe that our cash flows from
operations, together with borrowings under our revolving credit facility, will
be sufficient to meet these cash needs for the foreseeable future. However,
our
ability to generate cash is subject to general economic, financial, competitive,
legislative, regulatory and other factors that are beyond our control. If our
cash flows from operations are less than we expect, we may need to raise
additional capital. We may also require additional capital to finance our future
growth and development, implement additional marketing and sales activities,
and
fund our ongoing research and development activities.
Additional
debt or equity financing may not be available when needed on terms favorable
to
us or even available to us at all. We are restricted by the terms of the senior
secured credit facility and the indenture governing the unsecured notes from
incurring additional indebtedness. Under our MSA, prior to the Distribution,
we
may not incur any additional indebtedness (other than under the revolving credit
facility) without Kerr-McGee’s prior consent. While Kerr-McGee owns at least a
majority of our outstanding common stock, we also are restricted from issuing
any shares of our capital stock, or any rights, warrants or options to acquire
our capital stock (other than any shares of our capital stock or options to
acquire our capital stock granted in connection with the performance of
services), if this would cause Kerr-McGee to own less than a majority of our
outstanding common stock (on a fully diluted basis). In these circumstances,
we
also are restricted from issuing any shares of our capital stock if this would
cause Kerr-McGee to own less than 80% of the total voting power of our
outstanding capital stock entitled to vote generally in the election of our
directors and from issuing any shares of non-voting stock. In addition, under
our tax sharing agreement with Kerr-McGee, if we enter into transactions during
the two-year period following the Distribution which results in the issuance
or
acquisition of our shares, and the Internal Revenue Service subsequently
determines that Section 355(e) of the Internal Revenue Code is applicable to
the
Distribution, we will be required to indemnify Kerr-McGee for any resulting
tax
liability incurred by it.
We
have
an interest in The Landwell Company LP (“Landwell”), a limited partnership
formed to market or develop land in the Henderson, Nevada, area. Landwell
entered into an agreement in late 2004 to sell to Centex Homes approximately
2,200 contiguous acres of land in Henderson for eventual use as a new, mixed-use
master planned community. The agreement contains conditions to closing that
are
generally typical in sales of large tracts of undeveloped land. We have been
advised by Landwell’s general partner that closing conditions on a significant
portion of the land under contract are expected to be satisfied in the second
half of 2006. This large parcel under contract, in addition to other parcels
available for sale by Landwell or under contract, are in the vicinity of our
Henderson facility, where we are in the preliminary stage of exploring the
possible sale of 100% owned acreage considered surplus for plant operations.
Land sale proceeds before taxes could be as much as $50 million in 2006. Cash
flows resulting from the above described agreement with Centex Homes, net
of taxes, are required to be used to pay down outstanding debt under our senior
secured credit facility.
In
the
first quarter of 2006, we recognized an environmental reimbursement of $20.5
million as a result of a settlement of our claim against the United States,
which was documented in a consent decree approved by the court on January 13,
2006. We received this reimbursement in February 2006.
Liquidity
and Capital Resources
Prior
to the IPO, we participated in Kerr-McGee’s centralized cash management system
and relied on Kerr-McGee to provide necessary cash financing. Such activities
included cash deposits from our operations which were transferred daily to
Kerr-McGee’s centralized banking system and cash borrowings used to fund our
operations and capital expenditures. The related cash activity between us and
Kerr-McGee has been reflected as net transfers with affiliates within financing
activities in our consolidated and combined statement of cash flows.
Additionally, as discussed below under “Cash
Flows from Operating Activities,”
certain expenditures related to our operations were paid by Kerr-McGee on our
behalf and, therefore, did not affect cash flows from operating, investing
and
financing activities reported in our consolidated and combined statement of
cash
flows. As such, the amounts of cash and cash equivalents, as well as cash flows
from operating, investing and financing activities presented in our consolidated
and combined financial statements are not representative of the amounts that
would have been required or generated by us as a stand-alone
company.
In
connection with our separation from Kerr-McGee, the net amount due from us
to
Kerr-McGee was contributed by Kerr-McGee, forming a part of our continuing
equity. Such net amounts due to Kerr-McGee that were outstanding at the balance
sheet dates prior to our separation have been reflected in our consolidated
and
combined financial statements as a component of owner’s net investment in
equity. Amounts due to or from Kerr-McGee arising from transactions subsequent
to our separation are being settled in cash.
Of
cash
and cash equivalents at December 31, 2005, $25.1 million was held in the
United States and $43.9 million was held in other countries. In 2005,
$131 million of unremitted foreign earnings in Australia were repatriated
as extraordinary dividends, as defined in the American Jobs Creation Act of
2004, and subsequently transferred to Kerr-McGee as part of its centralized
cash
management system.
Until
recently, we had an accounts receivable monetization program, which served
as a
source of liquidity up to a maximum of $165.0 million. This program was
terminated in April 2005, as discussed in “Off-Balance
Sheet Arrangements”
below. Accounts receivable originated after the termination of this program
are
being collected over a longer period, resulting in increased balances of
outstanding receivables and higher current ratio, working capital and total
assets as of December 31, 2005, compared with year-end 2004.
Cash
Flows from Operating Activities.
Cash
flows from operating activities in our consolidated and combined statement
of
cash flows for all periods presented prior to the IPO date exclude certain
expenditures incurred by Kerr-McGee on our behalf, such as income taxes, general
corporate expenses, employee benefits and incentives, and net interest costs.
Therefore, reported amounts are not representative of cash flows from operating
activities we will generate or use as a stand-alone company. For example, cash
flows from operating activities for 2005 and 2004 exclude $27.2 million and
$37.0 million, respectively, paid by Kerr-McGee for income taxes on our behalf.
Additionally, 2005, 2004 and 2003 cash flows from operating activities exclude
$48.0 million, $55.1 million, and $65.8 million, respectively, of
general corporate expenses, employee benefits and incentives, and net interest
costs associated with our present and discontinued operations. While such costs
are reflected in our consolidated and combined statement of operations because
they were allocated to us by Kerr-McGee, they did not result in cash outlays
by
us. As a stand-alone company, we expect costs and expenses of this nature will
require the use of our cash and other sources of liquidity. Additionally, we
expect that our general corporate expenses may be $15 million to
$20 million greater on an annual basis than we have incurred historically,
which will further reduce our cash flows from operating activities as compared
to historical experience. Further, as discussed under “Contractual
Obligations and Commitments”
below, we expect cash requirements associated with employee pension and
postretirement plans to increase following the completion of this
offering.
Cash
flows from operating activities for 2005 were $61.5 million, compared with
cash from operating activities of $190.8 million for 2004. The
$129.3 million decrease in cash flows from operating activities in 2005 was
due primarily to increases in accounts receivable and inventories. As described
under “Off-Balance
Sheet Arrangements
-
Accounts
Receivable Monetization Program”
below, our accounts receivable program was terminated in April 2005. Termination
of the program resulted in an extension of the collection period for accounts
receivable arising from pigment sales compared to the collection period of
receivables prior to program termination. This has had a one-time impact of
reducing our cash flows from operating activities related to the increase in
our
accounts receivable. Cash flows from operating activities also decreased due
to
an increase in inventories at year-end 2005 compared to year-end 2004. This
is
in contrast to the significant decline in inventory levels at year-end 2004
compared to the prior year that was attributable to the shutdown of our sulfate
production facility in Savannah, Georgia, as well as strong demand during the
latter half of 2004. The decrease in cash flows from operating activities caused
by termination of our accounts receivables monetization program and increase
in
inventories was offset by decreased environmental expenditures of $24.1 million
and an increase in environmental cost reimbursements of $20.9
million.
Cash
flows from operating activities for 2004 were $190.8 million, an increase
of $70.4 million compared with cash flows from operating activities for
2003 of $120.4 million. The increase in cash flows from operating
activities in 2004 is attributable primarily to a reduction in inventories,
$35.7 million higher environmental cost reimbursements, $12.7 million
lower expenditures for environmental remediation and restoration and
$35.0 million less cash paid for legal settlements largely related to our
former forest products business. These positive effects on cash flows from
operating activities were partially offset by an unfavorable effect of timing
differences between product sales and collections of trade accounts receivable.
While improved economic conditions resulted in increased sales volumes in late
2004, collection of the related accounts receivable did not occur until
2005.
Cash
Provided by (Used in) Investing Activities.
Net
cash provided by investing activities in 2005 was $83.3 million, an increase
of
$174.7 million from $91.4 million used in investing activities for 2004. The
collection of repurchased accounts receivable that were contributed to us by
Kerr-McGee resulted in an increase of $165.0 million in cash from investing
activities in 2005.
Capital
expenditures in 2005 were $87.6 million, $4.9 million less than the prior year.
Significant projects in 2005 include projects to increase productivity and
enhance product quality. These projects include changes to the Uerdingen,
Germany, pigment facility to convert waste to a saleable product and reduce
raw
material costs, upgrading the oxidation line at the Botlek, Netherlands, pigment
facility and process improvements at the Hamilton, Mississippi, facility to
produce a new grade for use in architectural paints.
Net
cash used in investing activities was $91.4 million in 2004 compared to
$95.7 million in 2003 principally representing capital expenditures.
Significant capital expenditure projects in 2004 included waste management
projects and an automated slurry project at our Hamilton, Mississippi facility
that was begun in 2003. In 2003, significant projects included the Savannah
plant high productivity oxidation line, waste management projects and the
initial phase of the Hamilton plant automated slurry project that was completed
in 2004.
Cash
Used in Financing Activities.
Net
cash used in financing activities was $103.3 million in 2005, $131.1 million
in
2004, and $10.3 million in 2003. In 2005, we completed our IPO by issuing
17.5 million shares of Class A common stock which provided proceeds, net of
issuance costs, of $226.0 million. Concurrent with the IPO, we issued $350.0
million in aggregate principal amount of 9 ½% senior unsecured notes and entered
into a senior secured credit facility consisting of a $200.0 million six-year
term loan facility. Proceeds from the unsecured notes and the term loan facility
provided $539.1 million in cash flow from financing activities in 2005, net
of
debt issuance costs. The net proceeds from our Class A common stock offering,
unsecured notes and term loan facility were distributed to Kerr-McGee in the
amount of $761.8 million. Net transfers to Kerr-McGee were $106.6 million,
$131.1 million and $10.0 million in 2005, 2004 and 2003,
respectively.
Off-Balance
Sheet Arrangements
Accounts
Receivable Monetization Program.
Through April 2005, we sold selected accounts receivable through a
three-year, credit-insurance-backed asset securitization program with a maximum
availability of $165.0 million. Under the terms of the program, selected
qualifying customer accounts receivable were sold monthly to a special-purpose
entity (“SPE”), which in turn sold an undivided ownership interest in the
receivables to a third-party multi-seller commercial paper conduit sponsored
by
an independent financial institution. We sold, and retained an interest in,
excess receivables to the SPE as over-collateralization for the program. Our
retained interest in the SPE’s receivables was classified in trade accounts
receivable in our accompanying Consolidated and Combined Balance Sheet. No
recourse obligations were recorded since we had no obligations for any recourse
actions on the sold receivables.
The
accounts receivable monetization program included ratings downgrade triggers
based on Kerr-McGee’s senior unsecured debt rating. These triggers provide for
program modifications, including a program termination event upon which the
program would effectively liquidate over time and the third-party multi-seller
commercial paper conduit would be repaid with the collections on accounts
receivable sold. In April 2005, Kerr-McGee’s senior unsecured debt was
downgraded, triggering program termination. As opposed to liquidating the
program over time or modifying its terms, Kerr-McGee elected to terminate the
program by repurchasing the then outstanding balance of receivables sold of
$165.0 million, which were then contributed to us.
Other
Arrangements.
We
have entered into agreements that require us to indemnify third parties for
losses related to environmental matters, litigation and other claims. We have
recorded no material obligations in connection with such indemnification
obligations. In addition, pursuant to our MSA with Kerr-McGee, we will be
required to indemnify Kerr-McGee for all costs and expenses incurred by it
arising out of or due to our environmental and other liabilities other than
such
costs and expenses reimbursable by Kerr-McGee pursuant to the MSA. At
December 31, 2005, we had outstanding letters of credit in the amount of
approximately $34.5 million. These letters of credit have been granted to
us by financial institutions to support our environmental clean-up costs and
miscellaneous operational and severance requirements in international locations.
As of March 15, 2006, outstanding letters of credit totaled $40.3
million.
Contractual
Obligations and Commitments
In
the
normal course of business, we enter into operating leases, purchase obligations
and borrowing arrangements. Operating leases primarily consist of rental of
railcars and production equipment. The aggregate future payments under these
borrowings and contracts as of December 31, 2005, are summarized in the
following table:
|
|
Payments
Due By Period
|
|
Type
of Obligation
|
|
Total
|
|
2006
|
|
2007
-2008
|
|
2009
-2010
|
|
After
2010
|
|
|
|
(Millions
of dollars)
|
|
Long-term
debt, including current portion
|
|
$
|
550.0
|
|
$
|
2.0
|
|
$
|
4.0
|
|
$
|
4.0
|
|
$
|
540.0
|
|
Interest
payments on current and long-term
debt
|
|
|
306.7
|
|
|
46.8
|
|
|
92.7
|
|
|
92.2
|
|
|
75.0
|
|
Operating
leases
|
|
|
48.0
|
|
|
7.7
|
|
|
14.2
|
|
|
9.7
|
|
|
16.4
|
|
Purchase
obligations:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Ore
contracts
|
|
|
641.9
|
|
|
162.3
|
|
|
303.2
|
|
|
137.0
|
|
|
39.4
|
|
Other
purchase obligations
|
|
|
360.5
|
|
|
86.5
|
|
|
140.2
|
|
|
95.7
|
|
|
38.1
|
|
Total
|
|
$
|
1,907.1
|
|
$
|
305.3
|
|
$
|
554.3
|
|
$
|
338.6
|
|
$
|
708.9
|
|
We
will
be obligated under an employee benefits agreement with Kerr-McGee to maintain
the Material Features (as defined in the employee benefits agreement) of the
U.S. postretirement plan without change for a period of three years following
the effective date of the Distribution. Based on the actuarially determined
obligations under that plan, we expect contributions to be approximately $10.0
million for each of the next five years.
Environmental
Matters
Current
Businesses
We
are
subject to a broad array of international, federal, state and local laws and
regulations relating to environmental protection. Under these laws, we are
or
may be required to obtain or maintain permits or licenses in connection with
our
operations. In addition, under these laws, we are or may be required to remove
or mitigate the effects on the environment of the disposal or release of
chemical, petroleum, low-level radioactive and other substances at various
sites. Environmental laws and regulations are becoming increasingly stringent,
and compliance costs are significant and will continue to be significant in
the
foreseeable future. There can be no assurance that such laws and regulations
or
any environmental law or regulation enacted in the future is not likely to
have
a material effect on us.
Sites
at which we have environmental responsibilities include sites that have been
designated as Superfund sites by the U.S. EPA pursuant to CERCLA and that are
included on the National Priority List (“NPL”). As of December 31, 2005, we had
received notices that we had been named a PRP with respect to 12 existing EPA
Superfund sites on the NPL that require remediation. We do not consider the
number of sites for which we have been named a PRP to be the determining factor
when considering our overall environmental liability.
Decommissioning
and remediation obligations, and the attendant costs, vary substantially from
site to site and depend on unique site characteristics, available technology
and
the regulatory requirements applicable to each site. Additionally, we may share
liability at some sites with numerous other PRPs, and U.S. law currently imposes
joint and several liability on all PRPs under CERCLA. We are also obligated
to
perform or have performed remediation or remedial investigations and feasibility
studies at sites that have not been designated as Superfund sites by EPA. Such
work frequently is undertaken pursuant to consent orders or other
agreements.
Legacy
Businesses
Historically,
we have engaged in businesses unrelated to our current primary business, such
as
the treatment of forest products, the production of ammonium perchlorate, the
refining and marketing of petroleum products, offshore contract drilling, coal
mining and the mining, milling and processing of nuclear materials. Although
we
are no longer engaged in such businesses, residual obligations with respect
to
certain of these businesses still exist, including obligations related to
compliance with environmental laws and regulations, including the Clean Water
Act, the Clean Air Act, the Atomic Energy Act, CERCLA and the Resource
Conservation and Recovery Act. These laws and regulations require us to
undertake remedial measures at sites of current and former operations or at
sites where waste was disposed. For example, we are required to conduct
decommissioning and environmental remediation at certain refineries, production
and distribution facilities and service stations previously owned or operated
before exiting the refining and marketing business in 1995. We also are required
to conduct decommissioning and remediation activities at sites where we were
involved in the exploration, production, processing or sale of minerals,
including uranium and thorium compounds and at sites where we were involved
in
the production and sale of ammonium perchlorate. Additionally, we are
decommissioning and remediating our former wood-treatment facilities as part
of
our exit from the forest products business. For a description of the
decommissioning and remediation activities in which we currently are engaged,
see “Environmental
Costs”
below
and Note 22 to the Consolidated and Combined Financial Statements included
in Item 8 of this annual report on Form 10-K.
Environmental
Costs
Expenditures
for environmental protection and cleanup for each of the last three years and
for the three-year period ended December 31, 2005, are as
follows:
|
|
Year
Ended December 31,
|
|
|
|
2005
|
|
2004
|
|
2003
|
|
Total
|
|
|
|
(Millions
of dollars)
|
|
Cash
expenditures of environmental reserves
|
|
$
|
61.1
|
|
$
|
85.2
|
|
$
|
97.9
|
|
$
|
244.2
|
|
Recurring
operating expenses
|
|
|
41.4
|
|
|
33.4
|
|
|
33.8
|
|
|
108.6
|
|
Capital
expenditures
|
|
|
10.7
|
|
|
8.6
|
|
|
14.0
|
|
|
33.3
|
|
Recurring
operating expenses are expenditures related to the maintenance and operation
of
environmental equipment such as incinerators, waste treatment systems and
pollution control equipment, as well as the cost of materials, energy and
outside services needed to neutralize, process, handle and dispose of current
waste streams at our operating facilities. These expenditures are necessary
to
ensure that current production is handled in an environmentally safe and
effective manner.
In
addition to past expenditures, reserves have been established for the
remediation and restoration of active and inactive sites where it is probable
that future costs will be incurred and the liability is reasonably estimable.
For environmental sites, we consider a variety of matters when setting reserves,
including the stage of investigation; whether EPA or another relevant agency
has
ordered action or quantified cost; whether we have received an order to conduct
work; whether we participate as a PRP in the Remedial Investigation/Feasibility
Study (RI/FS) process and, if so, how far the RI/FS has progressed; the status
of the record of decision by the relevant agency; the status of site
characterization; the stage of the remedial design; evaluation of existing
remediation technologies; the number and financial condition of other potential
PRPs; and whether we can reasonably evaluate costs based on a remedial design
or
engineering plan.
After
the remediation work has begun, additional accruals or adjustments to costs
may
be made based on any number of developments, including revisions to the remedial
design; unanticipated construction problems; identification of additional areas
or volumes of contamination; inability to implement a planned engineering design
or to use planned technologies and excavation methods; changes in costs of
labor, equipment or technology; any additional or updated engineering and other
studies; and weather conditions. Additional reserves of $69.0 million,
$81.4 million and $88.2 million were added in 2005, 2004 and 2003,
respectively, for active and inactive sites.
As
of
December 31, 2005, our financial reserves for all active and inactive sites
totaled $223.7 million. This includes $69.0 million added to the
reserves in 2005 for active and inactive sites. In the Consolidated and Combined
balance sheet at December 31, 2005, included in Item 8 of this annual
report on Form 10-K, $145.9 million of the total reserve is classified as
noncurrent liabilities-environmental remediation or restoration, and the
remaining $77.8 million is included in accrued liabilities. We believe we
have reserved adequately for the reasonably estimable costs of known
environmental contingencies. However, additional reserves may be required in
the
future due to the previously noted uncertainties.
Pursuant
to the MSA, Kerr-McGee has agreed to reimburse us for a portion of the
environmental remediation costs we incur and pay after the IPO (net of any
cost
reimbursements we expect to recover from insurers, governmental authorities
or
other parties). The reimbursement obligation extends to costs incurred at any
site associated with any of our former businesses or operations.
With
respect to any site for which we have established a reserve as of the effective
date of the MSA, 50% of the remediation costs we incur and pay in excess of
the
reserve amount (after meeting a $200,000 minimum threshold amount) will be
reimbursable by Kerr-McGee, net of any amounts recovered or, in our reasonable
and good faith estimate, that will be recovered from third parties. With respect
to any site for which we have not established a reserve as of the effective
date
of the MSA, 50% of the amount of the remediation costs we incur and pay (after
meeting a $200,000 minimum threshold amount) will be reimbursable by Kerr-McGee,
net of any amounts recovered or, in our reasonable and good faith estimate,
that
will be recovered from third parties.
Kerr-McGee’s
aggregate reimbursement obligation to us cannot exceed $100 million and is
subject to various other limitations and restrictions. For example, Kerr-McGee
is not obligated to reimburse us for amounts we pay to third parties in
connection with tort claims or personal injury lawsuits, or for administrative
fines or civil penalties that we are required to pay. Kerr-McGee’s reimbursement
obligation also is limited to costs that we actually incur and pay within seven
years following the IPO.
The
following table reflects our portion of the known estimated costs of
investigation or remediation that are probable and estimable. The table
summarizes EPA Superfund NPL sites where we have been notified we are a PRP
under CERCLA and other sites for which we had financial reserves recorded at
year-end 2005. In the table, aggregated information is presented for other
sites
(each of which has a remaining reserve balance of less than $3 million).
The reimbursement obligation discussed above applies to each of the sites
specifically identified in the table below. Sites specifically identified in
the
table below are discussed in Note 22 to the Consolidated and Combined
Financial Statements included in Item 8 of this annual report on Form 10-K.
Location
of Site
|
Stage
of Investigation/Remediation
|
Total
Expenditures
Through
December
31, 2005
|
Remaining
Reserve
Balance
at
December
31, 2005
|
Total
|
|
|
(Millions
of dollars)
|
EPA
Superfund sites on NPL
|
|
|
|
|
West
Chicago, Illinois(1)
Vicinity
areas
|
Remediation
of thorium tailings at residential areas and Reed-Keppler Park is
substantially complete. Cleanup of thorium tailings at Kress Creek
and
Sewage Treatment Plant is ongoing.
|
$141
|
$75
|
$216
|
|
|
|
|
|
Milwaukee,
Wisconsin
|
Completed
soil cleanup at former wood-treatment facility and began cleanup
of
offsite tributary creek. Groundwater remediation and cleanup of tributary
creek is continuing.
|
41
|
4
|
45
|
|
|
|
|
|
Lakeview,
Oregon
|
Consolidation
and capping of contaminated soils and neutralization of acidic waters
from
former uranium mining is ongoing.
|
7
|
4
|
11
|
|
|
|
|
|
Soda
Springs, Idaho
|
All
former impoundments of calcine tailings have been closed as required
by a
record of decision (“ROD”). The ROD also requires continuation of
groundwater monitoring. Closure of an additional ten-acre pond, not
a part
of the ROD, will be completed within two years. Duration of groundwater
monitoring is unknown.
|
3
|
3
|
6
|
|
|
|
|
|
Other
sites
|
Sites
where the company has been named a PRP, including landfills, wood-treating
sites, a mine site and an oil recycling refinery. These sites are
in
various stages of investigation/remediation.
|
15
|
—
|
15
|
|
|
207
|
86
|
293
|
Location
of Site
|
Stage
of Investigation/Remediation
|
Total
Expenditures
Through
December
31, 2005
|
Remaining
Reserve
Balance
at
December
31, 2005
|
Total
|
|
|
(Millions
of dollars)
|
Sites
under consent order, license or agreement, not on EPA Superfund
NPL
|
|
|
|
|
West
Chicago, Illinois(1)
Former
manufacturing facility
|
Excavation,
removal and disposal of contaminated soils at former thorium mill
are
substantially complete. The site will be used for moving material
from the
Kress Creek and Sewage Treatment Plant remediation sites. Surface
restoration and groundwater monitoring and remediation are expected
to
continue for approximately ten years.
|
$
447
|
$
12
|
$
459
|
|
|
|
|
|
Cushing,
Oklahoma
|
Excavation,
removal and disposal of thorium and uranium residuals were substantially
completed in 2004. Investigation of and remediation addressing hydrocarbon
contamination is continuing.
|
147
|
12
|
159
|
|
|
|
|
|
Henderson,
Nevada(2)
|
Groundwater
treatment to address ammonium perchlorate contamination is being
conducted
under consent decree with Nevada Department of Environmental
Protection.
|
124
|
37
|
161
|
|
|
|
|
|
Ambrosia
Lake, New Mexico
|
Uranium
mill tailings and selected pond sediments consolidated and capped
onsite.
A request to end groundwater treatment and a decommissioning plan
for
impacted soils are under review by the NRC.
|
28
|
11
|
39
|
|
|
|
|
|
Crescent,
Oklahoma
|
Buildings
and soil decommissioning complete. Evaluating available technologies
to
address limited on-site radionuclide contamination of
groundwater.
|
48
|
7
|
55
|
|
|
|
|
|
Sauget,
Illinois
|
Soil
remediation of wood-treatment related contamination is ongoing. Conducting
groundwater monitoring and evaluating options to remediate sediment
and
surface water.
|
8
|
9
|
17
|
|
|
|
|
|
Location
of Site
|
Stage
of Investigation/Remediation
|
Total
Expenditures
Through
December
31, 2005
|
Remaining
Reserve
Balance
at
December
31, 2005
|
Total
|
|
|
(Millions
of dollars)
|
Sites
under consent order, license or agreement, not on EPA Superfund
NPL
|
|
|
|
|
Hattiesburg,
Mississippi
|
Completed
remediation of process areas at former wood-treatment facility
and
completed most off-site remediation. Off-site remediation to be
completed
when access to certain properties is granted.
|
$
12
|
$
3
|
$
15
|
|
|
|
|
|
Cleveland,
Oklahoma
|
Facility
is dismantled and certain interim remedial measures to address
air, soil,
surface water and groundwater contamination are complete. Design
of
on-site containment cell has been submitted for approval.
|
19
|
4
|
23
|
|
|
|
|
|
Calhoun,
Louisiana
|
Soil
and groundwater remediation of petroleum hydrocarbons at a former
gas
condensate stripping facility is ongoing.
|
22
|
5
|
27
|
|
|
|
|
|
Jacksonville,
Florida
|
Remedial
investigation of a former manufacturing and processing site for
fertilizers, pesticides and herbicides completed. Feasibility study
with
recommended remediation activities expected to be submitted to
EPA in
2006.
|
4
|
6
|
10
|
|
|
|
|
|
Other
sites
|
Sites
related to wood-treatment, chemical production, landfills, mining,
and oil
and gas refining, distribution and marketing. These sites are in
various
stages of investigation/remediation.
|
169
|
32
|
201
|
|
|
1,028
|
138
|
1,166
|
|
Total
|
$1,235
|
$224
|
$1,459
|
(1)
|
Amounts
reported in the table for the West Chicago sites are not reduced
for
actual or expected reimbursement from the U.S. government under Title
X of
the Energy Policy Act of 1992 (Title X), described in Note 22 to the
Consolidated and Combined Financial Statements included in Item 8
of this
annual report on Form 10-K.
|
(2)
|
Amounts
reported in the table for the Henderson, Nevada site are not reduced
for
actual or expected reimbursement from the U.S. government under a
consent
decree settlement nor for expected insurance policy recoveries, described
in Note 22 to the Consolidated and Combined Financial Statements
included in Item 8 of this annual report on Form
10-K.
|
There
may be other sites where we have potential liability for environmental-related
matters but for which we do not have sufficient information to determine that
the liability is probable or reasonably estimable. We have not established
reserves for such sites. One such site involves a former wood treatment plant
in
New Jersey.
Tronox
LLC was named in 1999 as a PRP under CERCLA at a former wood-treatment site
in
New Jersey at which EPA is conducting a cleanup. On April 15, 2005, Tronox
LLC and Tronox Worldwide LLC received a letter from EPA asserting they are
liable under CERCLA as a former owner or operator of the site and demanding
reimbursement of costs expended by EPA at the site. The letter made demand
for
payment of past costs in the amount of approximately $179 million, plus
interest though EPA has informed Tronox LLC that it expects final project costs
will be approximately $236 million, plus possible other costs and interest.
Tronox LLC did not operate the site, which had been sold to a third party before
Tronox LLC succeeded to the interests of a predecessor owner in the 1960s.
The
predecessor also did not operate the site, which had been closed down before
it
was acquired by the predecessor. Based on historical records, there are
substantial uncertainties about whether or under what terms the predecessor
assumed liabilities for the site. In addition, although it appears there may
be
other PRPs, the company does not know whether the other PRPs have received
similar letters from EPA, whether there are any defenses to liability available
to the other PRPs or whether the other PRPs have the financial resources
necessary to meet their obligations. The company intends to vigorously defend
against EPA’s demand, though the company expects to have discussions with EPA
that could lead to a settlement or resolution of EPA’s demand. No reserve for
reimbursement of cleanup costs at the site has been recorded because it is
not
possible to reliably estimate the liability, if any, the company may have for
the site because of the aforementioned defenses and uncertainties.
Critical
Accounting Policies
Preparation
of financial statements in conformity with accounting principles generally
accepted in the United States requires management to make estimates, judgments
and assumptions regarding matters that are inherently uncertain and that
ultimately affect the reported amounts of assets, liabilities, revenues and
expenses, and the disclosure of contingent assets and liabilities. Even so,
the
accounting principles we use generally do not impact our reported cash flows
or
liquidity. Generally, accounting rules do not involve a selection among
alternatives, but involve a selection of the appropriate policies for applying
the basic principles. Interpretation of the existing rules must be done and
judgments made on how the specifics of a given rule apply to us.
The
more significant reporting areas impacted by management’s judgments, estimates
and assumptions are recoverability of long-lived assets, restructuring and
exit
activities, environmental remediation, tax accruals and benefit plans.
Management’s judgments, estimates and assumptions in these areas are based on
information available from both internal and external sources, including
engineers, legal counsel, actuaries, environmental studies and historical
experience in similar matters. Actual results could differ materially from
those
judgments, estimates and assumptions as additional information becomes
known.
The
following description of our critical accounting policies is not intended to
be
an all-inclusive discussion of the uncertainties considered and estimates made
by management in applying accounting principles and policies. Results may vary
significantly if different policies were used or required and if new or
different information becomes known to management.
Long-Lived
Assets
Key
estimates related to long-lived assets include useful lives, recoverability
of
carrying values and existence of any retirement obligations. As a result of
future decisions, such estimates could be significantly modified. The estimated
useful lives of our property, plant and equipment range from three to
40 years and depreciation is recognized on the straight-line basis. Useful
lives are estimated based upon our historical experience, engineering estimates
and industry information. Our estimates include an assumption regarding periodic
maintenance and an appropriate level of annual capital expenditures to maintain
the assets.
Long-lived
assets are evaluated for potential impairment whenever events or changes in
circumstances indicate that carrying value may be greater than future net cash
flows. Such evaluations involve a significant amount of judgment since the
results are based on estimated future events, such as sales prices; costs to
produce the products; the economic and regulatory climates; and other factors.
We cannot predict when or if future impairment charges will be required for
held-for-use assets.
Restructuring
and Exit Activities
We
have
recorded charges in recent periods in connection with closing facilities and
work force reduction programs. These charges are recorded when management
commits to a plan and incurs a liability related to the plan. Estimates for
plant closing include write-down of inventory value, write-down of property,
plant and equipment, any necessary environmental or regulatory costs, contract
termination, asset retirement obligations and severance costs. Estimates for
work force reductions are recorded based on estimates of the number of positions
to be terminated, termination benefits to be provided, estimates of any enhanced
benefits provided under pension and postretirement plans and the period over
which future service will continue, if any. We evaluate the estimates on a
quarterly basis and adjust the reserves when information indicates that the
estimates are above or below the initial estimates. For additional information
regarding work force reduction programs and exit activities, see Note 16 to
the Consolidated and Combined Financial Statements included in Item 8 of this
annual report on Form 10-K. Changes in estimates of provisions for restructuring
and exit activities were not significant over the last three years.
Environmental
Remediation and Other Contingency Reserves
Our
management makes judgments and estimates in accordance with applicable
accounting rules when it establishes reserves for environmental remediation,
litigation and other contingent matters. Provisions for such matters are charged
to expense when it is probable that a liability has been incurred and reasonable
estimates of the liability can be made. Estimates of environmental liabilities,
which include the cost of investigation and remediation, are based on a variety
of matters, including, but not limited to, the stage of investigation, the
stage
of the remedial design, the availability of existing remediation technologies,
presently enacted laws and regulations and the state of any related legal or
administrative investigation or proceedings. In future periods, a number of
factors could significantly change our estimate of environmental remediation
costs, such as changes in laws and regulations, revisions to the remedial
design, unanticipated construction problems, identification of additional areas
or volumes of contamination, and increases in labor, equipment and technology
costs, changes in the financial condition of other potentially responsible
parties and the outcome of any related legal and administrative proceedings
to
which we are or may become a party. Consequently, it is not possible for us
to
reliably estimate the amount and timing of all future expenditures related
to
environmental or other contingent matters and actual costs could exceed our
current reserves.
Before
considering reimbursements of our environmental costs discussed below, we
provided $69.0 million, $81.4 million and $88.2 million pre-tax
for environmental remediation and restoration costs in 2005, 2004 and 2003,
respectively, including provisions of $29.9 million, $75.7 million and
$52.3 million in 2005, 2004 and 2003, respectively, related to former
businesses reflected as a component of loss from discontinued
operations.
To
the
extent costs of investigation and remediation are recoverable from the U.S.
government or Kerr-McGee, and have been incurred or are recoverable under
certain insurance policies or from other parties and such recoveries are deemed
probable, we record a receivable. In considering the probability of receipt,
we
evaluate our historical experience with receipts, as well as our claim
submission experience. At December 31, 2005, estimated recoveries of
environmental costs recorded in the Consolidated and Combined Balance Sheet
totaled $56.7 million. Provisions for environmental remediation and
restoration in the Consolidated and Combined Statement of Operations were
reduced by $34.3 million, $14.2 million and $32.2 million in
2005, 2004 and 2003, respectively, for estimated recoveries, including
recoveries of $12.3 million, $14.2 million and $11.2 million in
2005, 2004 and 2003, respectively, related to former businesses reflected as
a
component of loss from discontinued operations.
For
additional information about contingencies, refer to “Environmental
Matters”
above
and Note 22 to the Consolidated and Combined Financial Statements included
in Item 8 of this annual report on Form 10-K.
Income
Taxes
The
closing of the IPO resulted in the deconsolidation of the company from
Kerr-McGee under U.S. Federal income tax laws. We continued as a member included
in the U.S. Federal consolidated income tax return of Kerr-McGee up to the
deconsolidation date. Prior to the deconsolidation date, we had not been a
party
to a tax-sharing agreement with Kerr-McGee but had consistently followed an
allocation policy whereby Kerr-McGee has allocated its members of the
consolidated return provisions and/or benefits based upon each member’s taxable
income or loss. This allocation methodology resulted in the recognition of
deferred assets and liabilities for the differences between the financial
statement carrying amounts and their respective tax basis, except to the extent
for deferred taxes on income considered to be permanently reinvested in foreign
jurisdictions. Deferred tax assets and liabilities are measured using enacted
tax rates expected to apply to taxable income in the years in which those
temporary differences are expected to be recovered or settled. Kerr-McGee has
allocated current tax benefits to the members of its consolidated return,
including us, that have generated losses that are utilized or expected to be
utilized on the U.S. Federal consolidated income tax return. The income taxes
presented as a result of this allocation methodology are not consistent with
that calculated on a stand-alone tax return basis. In addition, Kerr-McGee
manages its tax position for the benefit of its entire portfolio of businesses,
and its tax strategies are not necessarily reflective of those tax strategies
that we would have followed or will follow as a stand-alone
company.
Upon
closing the IPO and with the deconsolidation, we entered into a tax sharing
agreement with Kerr-McGee that governs Kerr-McGee’s and our respective rights,
responsibilities and obligations with respect to taxes for tax periods ending
in
2005 and prior. Generally, taxes incurred or accrued prior to the IPO that
are
attributable to the business of one party will be borne solely by that party.
In
addition, the tax sharing agreement addresses the allocation of liability for
taxes incurred as a result of restructuring activities undertaken to implement
the separation and distribution. We are required to indemnify Kerr-McGee for
any
tax liability incurred by reason of the Distribution by Kerr-McGee of our
Class B common stock to its stockholders being considered a taxable
transaction to Kerr-McGee as a result of a breach of any of our representations,
warranties or covenants contained in the tax sharing agreement.
Under
U.S. federal income tax laws, we and Kerr-McGee are jointly and severally liable
for Kerr-McGee’s federal income taxes attributable to the periods prior to and
including Kerr-McGee’s current taxable year, which ends on December 31,
2005. If Kerr-McGee fails to pay the taxes attributable to it under the tax
sharing agreement for periods prior to and including its current taxable year,
we could be liable for any part of, including the whole amount of, these tax
liabilities.
Benefit
Plans
U.S.
Plans.
Our
U.S. employees participate in the noncontributory defined benefit retirement
plans and the contributory postretirement plans for health care and life
insurance sponsored by Kerr-McGee. Our consolidated and combined results of
operations reflect costs associated with Kerr-McGee’s U.S. plans which have been
allocated by Kerr-McGee based on salary for defined benefit retirement plans
and
based on active headcount for postretirement plans, but do not reflect assets
and liabilities associated with our employees’ participation in the plans, since
we were not the plan sponsor for the historical periods presented.
Effective
upon completion of the Distribution, we intend to establish a U.S. tax-qualified
defined benefit retirement plan and related trust for our employees and former
employees who participated in Kerr-McGee’s defined benefit retirement plans at
the Distribution date. In connection with our assumption of obligations,
Kerr-McGee will transfer assets from the trust for Kerr-McGee’s defined benefit
retirement plans to the trust we will establish. It is estimated that our
defined benefit obligation for this plan, determined on a plan termination
basis
as set forth in the employee benefits agreement, will be approximately
$435.0 million and will be fully funded at the Distribution
date.
We
also
intend to establish postretirement benefit plans for health care and life
insurance and health and welfare benefits, which we expect will be an unfunded
plan that will have comparable features to the plan currently maintained by
Kerr-McGee. In connection with the establishment of our postretirement plans,
we
estimate that the accumulated benefit obligation relating to all eligible
retired and active vested participants related to us of approximately
$149.0 million will be assumed by us upon completion of the
Distribution.
The
estimated defined benefit obligation and the estimated postretirement health
and
welfare benefit obligation that we will assume has been made based primarily
on
Kerr-McGee plan assumptions as of December 31, 2005, and participant data as
of
January 1, 2006. Trust assets to be transferred were estimated using interest
rate and other assumptions as of February 28, 2006. The assumptions and
participant data will be updated as of the Distribution date and could result
in
a change in the liability assumed and trust assets to be
transferred.
To
measure plan obligations and attribute cost to periods when employee services
are provided, we will form various assumptions related to the newly established
plans, including discount rate, rate of compensation increases, long-term rate
of return, mortality and retirement rates, inflation and health care cost trend
rate, among others. Some of these assumptions are specific to us and our
employee groups covered, and, therefore, are expected to be different from
assumptions formed by Kerr-McGee for its plans. Therefore, application of such
assumptions by us may result in different amounts of net periodic cost (benefit)
recognized in our financial statements in future periods compared to the net
periodic cost (benefit) historically allocated to us by Kerr-McGee (amounts
historically allocated are presented in Note 19 to the Consolidated and
Combined Financial Statements included in Item 8 of this annual report on Form
10-K.) Further, we currently do not reflect any assets or liabilities associated
with Kerr-McGee’s U.S. defined benefit retirement and postretirement
plans.
Foreign
Benefit Plans.
We
currently provide defined benefit retirement plans for employees in Germany
and
the Netherlands and account for these plans in accordance with FAS No. 87,
“Employers’
Accounting for Pensions.”
The
various assumptions used and the attribution of the costs to periods of employee
service are fundamental to the measurement of net periodic cost and pension
obligations associated with the retirement plans.
The
following are considered significant assumptions related to our foreign
retirement plans:
· |
Long-term
rate of return (applies to our plan in the Netherlands
only)
|
· |
Rate
of compensation increases
|
Other
factors considered in developing actuarial valuations include long-term
inflation rates, retirement rates, mortality rates and other factors. Assumed
long-term inflation rates are based on an evaluation of external market
indicators. Retirement rates are based primarily on actual plan experience.
Long-term rate of return assumption for the Netherlands plan is developed
considering the portfolio mix and country-specific economic data that includes
the expected long-term rates of return on local government and corporate bonds.
The discount rate assumption is based on long-term local corporate bond index
rates. We determine rate of compensation increases assumption based on our
long-term plans for compensation increases specific to employee groups covered.
The assumed rate of salary increases includes the effects of merit increases,
promotions and general inflation. Additional information regarding the
significant assumptions relevant to the determination of the net periodic
pension cost and the actuarially determined present value of the benefit
obligations is included in Note 19 to the Consolidated and Combined
Financial Statements included in Item 8 of this annual report on Form
10-K.
Unrecognized
Gains (Losses) and Prior Service Cost - Accounting
standards currently in effect provide for deferring the recognition of certain
gains and losses resulting from changes in actuarial assumptions and from
experience different from that assumed (such as the difference between the
actual and expected return on plan assets). Similarly, a portion of increases
or
reductions in the benefit obligations attributable to plan participants’ prior
service arising from a plan amendment is also deferred. At December 31, 2005,
unrecognized net actuarial losses and unrecognized net prior service gain for
our foreign plans totaled $21.2 million and $1.4 million, respectively.
Following accounting guidance currently in effect, amortization of these
unrecognized items will be included as a component of net periodic cost over
the
remaining service period of plan participants expected to receive benefits
under
the plan. The average amortization periods for unrecognized net actuarial losses
and unrecognized prior service gain as of December 31, 2005, are approximately
11 and 9 years, respectively. The component of the 2006 net periodic cost
related to amortization of unrecognized items for our foreign retirement plans
is estimated to be approximately $1.0 million.
In
connection with the assumption of the obligation for the U.S. retirement and
health and welfare postretirement plans and the associated trust assets, as
discussed above, we will recognize assets and liabilities upon completion of
the
Distribution that will reflect the funded status of our newly-established U.S.
benefit plans, as well as net unrecognized actuarial losses and prior service
cost associated with the assumed benefit obligation. As a result, net periodic
cost in periods subsequent to the Distribution is expected to increase,
reflecting amortization of such unrecognized items.
FASB
Project
- The
Financial Accounting Standards Board (“FASB”) has recently initiated a project
that is expected to result in issuing a new accounting standard later in 2006.
Assuming the provisions of the final standard are consistent with decisions
reached by the FASB to date, the standard will require recognition on the
balance sheet of unrecognized items discussed above, with an offsetting change
in accumulated other comprehensive income (loss) in equity. This initial stage
of the FASB project is not expected to affect the measurement of the net
periodic cost. The result of such accounting policy will be the recognition
on
the balance sheet of the over or (under) funded status of the plans (or the
difference between the benefit obligation and the fair value of plan assets,
if
any).
New/Revised
Accounting Standards
In
November 2004, the FASB issued FAS No. 151, “Inventory Costs - an
Amendment of ARB No. 43, Chapter 4,” which requires that abnormal amounts
of idle facilities cost, freight, handling costs and spoilage be expensed as
incurred and not capitalized as inventory. FAS No. 151 is effective for
inventory costs incurred during fiscal years beginning after June 15, 2005.
The company will adopt the standard effective January 1, 2006. The effect
of adoption is not expected to have a material effect on the company’s financial
position or results of operations.
In
December 2004, the FASB issued Statement No. 123 (revised 2004), “Share-Based
Payment” (“FAS No. 123R”), which replaces FAS No. 123 and supersedes Accounting
Principles Board Opinion (“APB”) No. 25. FAS No. 123R requires all share-based
payments to employees to be recognized in the financial statements based on
their fair values. The company will adopt FAS No. 123R effective January 1,
2006, using the modified prospective method, as permitted by the standard.
The
modified prospective method requires that compensation expense be recorded
for
all unvested share-based compensation awards at the beginning of the first
quarter of adoption. The following provides a summary of some of the
implementation effects of this standard:
· |
Stock-based
compensation expense recognized in the Consolidated and Combined
Statement
of Operations will be higher, reflecting a change in the measurement
basis
of stock options from intrinsic to fair value. The magnitude of the
increase will depend upon the number of options granted and other
factors
affecting fair value.
|
· |
Net
cash flows provided by operating activities will be lower and cash
flows
from financing activities will be higher by the amount of the reduction
in
cash income taxes as a result of tax deductibility of stock options
and
restricted stock awards.
|
In
2005, the FASB initiated a project titled “Postretirement Benefit Obligations
Other than Pensions,” which is expected to result in the issuance of a new
accounting standard later in 2006. The possible effects of the expected standard
on our Consolidated and Combined Balance Sheet are discussed above under
“Critical
Accounting Policies - Benefit Plans - FASB Project.”
Item
7A. Quantitative
and Qualitative Disclosure about Market Risk
We
are
exposed to market risks, including credit risk, from fluctuations in foreign
currency exchange rates and natural gas prices. To reduce the impact of these
risks on earnings and to increase the predictability of cash flows, from time
to
time, we enter into derivative contracts, primarily forward contracts to buy
and
sell foreign currencies. In addition to information included in this section,
see Notes 2 and 12 to the Consolidated and Combined Financial Statements
included in Item 8 of this annual report on Form 10-K.
Foreign
Currency Exchange Rate Risk
The
U.S. dollar is the functional currency for our international operations, except
for our European operations, for which the euro is the functional currency.
Periodically, we enter into forward contracts to buy and sell foreign
currencies. Certain of our contracts for the purchase of Australian dollars
and
the sale of euros have been designated and have qualified as cash flow hedges
of
our anticipated future cash flows related to pigment sales, raw material
purchases and operating costs. These contracts generally have durations of
less
than three years. Changes in the fair value of these contracts are recorded
in
accumulated other comprehensive income (loss) and are recognized in earnings
in
the periods during which the hedged forecasted transactions affect
earnings.
The
following table presents the notional amounts at the contract exchange rates
and
the weighted-average contractual exchange rates for contracts to purchase (sell)
foreign currencies outstanding at year-end 2005 and 2004. All amounts are U.S.
dollar equivalents. The estimated fair value of our foreign currency forward
contracts is based on the year-end forward exchange rates quoted by financial
institutions. At December 31, 2005 and 2004, the net fair value of our
foreign currency forward contracts was an asset of $0.7 million and a liability
of $3.6 million, respectively.
|
Notional
Amount
|
Weighted-
Average
Contract
Rate
|
|
(Millions
of dollars,
except
average contract rates)
|
Open
contracts at December 31, 2005 -
|
|
|
Maturing
in 2006:
|
|
|
Euro
|
$(17)
|
1.2523
|
Australian
dollar
|
5
|
.7539
|
|
|
|
Open
contracts at December 31, 2004 -
|
|
|
Maturing
in 2005:
|
|
|
Euro
|
$(72)
|
1.2998
|
Japanese
yen
|
(1)
|
.0095
|
New
Zealand dollar
|
(1)
|
.6873
|
British
pound sterling
|
(1)
|
1.8043
|
Interest
Rate Risk
We
are
exposed to changes in interest rates, primarily as a result of our debt
obligations. The fair value of our fixed-rate debt is affected by changes in
market interest rates. Our variable-rate debt exposes us to the risk of higher
interest cost if market interest rates increase. Based on the current mix of
variable and fixed-rate debt, we do not expect the impact of changes in interest
rates to be material to our earnings or cash flows.
The
table below presents principal amounts and related interest rates by maturity
date for the company’s debt obligations outstanding at December 31, 2005:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fair
|
|
|
|
|
|
|
|
|
|
|
|
|
|
There-
|
|
|
|
Value
|
|
|
|
2006
|
|
2007
|
|
2008
|
|
2009
|
|
2010
|
|
After
|
|
Total(1)
|
|
12/31/05
|
|
|
|
(Millions
of dollars)
|
|
Fixed-rate
debt -
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Principal
amount
|
|
$
|
-
|
|
$
|
-
|
|
$
|
-
|
|
$
|
-
|
|
$
|
-
|
|
$
|
350.0
|
|
$
|
350.0
|
|
$
|
358.2
|
|
Interest
rate
|
|
|
-
|
%
|
|
-
|
%
|
|
-
|
%
|
|
-
|
%
|
|
-
|
%
|
|
9.50
|
%
|
|
9.50
|
%
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Variable-rate
debt -
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|