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SCHI.OB > SEC Filings for SCHI.OB > Form 10-Q on 10-Nov-2009All Recent SEC Filings

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Form 10-Q for STERLING CHEMICALS INC


10-Nov-2009

Quarterly Report


Item 2. Management's Discussion and Analysis of Financial Condition and Results
of Operations
The following discussion should be read in conjunction with our condensed consolidated financial statements (including the Notes thereto) included in Item 1, Part I of this report.
Business Overview
We are a North American producer of selected petrochemicals used to manufacture a wide array of consumer goods and industrial products. We currently operate in two segments: acetic acid and plasticizers. Each segment has a single customer.
Our acetic acid is used primarily to manufacture vinyl acetate monomer, which is used in a variety of products, including adhesives and surface coatings. Pursuant to our 2008 Amended and Restated Production Agreement, or our Acetic Acid Production Agreement, that extends to 2031, all of our acetic acid production is sold to BP Amoco Chemicals Company, or BP Chemicals. We are BP Chemicals' sole source of acetic acid production in the Americas. BP Chemicals markets all of the acetic acid that we produce and pays us, among other amounts, a portion of the profits derived from its sales of our acetic acid. In addition, BP Chemicals reimburses us for 100% of our fixed and variable costs of production, other than specified indirect costs. We also jointly invest with BP Chemicals in capital expenditures related to our acetic acid facility in the same percentage as the profits from the business we receive from BP Chemicals.
We own and operate one of the lowest cost acetic acid facilities in the world. Our acetic acid facility utilizes BP Chemicals' proprietary "Cativa" carbonylation technology, which we believe offers several advantages over competing production methods, including lower energy requirements and lower fixed and variable costs. Acetic acid production has two major raw material requirements, methanol and carbon monoxide. BP Chemicals, a producer of methanol, supplies 100% of our methanol requirements related to our production of acetic acid. All of our requirements for carbon monoxide are supplied by Praxair Hydrogen Supply, Inc., or Praxair, from a partial oxidation unit constructed by Praxair on land leased from us at our site in Texas City, Texas, or our Texas City facility.
Although slowdowns in the housing and automotive markets over the last year have reduced short-term global demand for vinyl acetate monomer, the largest derivative of acetic acid, annual global production of vinyl acetate monomer is expected to increase from 10.8 billion pounds in 2007 to 14.2 billion pounds in 2013. The North American acetic acid industry tends to sell most of its products through long-term sales agreements having "cost plus" pricing mechanisms, eliminating much of the volatility seen in other petrochemicals products and resulting in more stable and predictable earnings and profit margins.
All of our plasticizers, which are used to make flexible plastics, such as shower curtains, floor coverings, automotive parts and construction materials, are sold to BASF Corporation, or BASF, pursuant to a long-term production agreement that extends until 2013, subject to some early termination rights held by BASF that begin in 2010. Under our agreement with BASF, or our Plasticizers Production Agreement, BASF provides us with most of the required raw materials, markets the plasticizers that we produce and is obligated to make certain fixed quarterly payments to us and reimburse us monthly for our actual production costs and capital expenditures relating to our plasticizers facility. Due to the terms of our Plasticizers Production Agreement, we are not exposed to fluctuations in costs or market conditions. Our Plasticizers Production Agreement was amended in May 2008, after BASF nominated zero pounds of phthalic anhydride, or PA, under the prior version of the agreement due to deteriorating market conditions, which ultimately resulted in the closure of our PA unit, and again in July 2009, to add the use of an additional storage tank by BASF to the facility fee.
On September 17, 2007, we entered into a long-term exclusive styrene supply agreement and a related railcar purchase and sale agreement with NOVA Chemicals Inc., which was subsequently assigned to INEOS NOVA, LLC, or INEOS NOVA. After the supply agreement became effective, INEOS NOVA nominated zero pounds of styrene under the supply agreement for the balance of 2007 and, in response, we exercised our right to terminate the supply agreement and permanently shut down our styrene facility. Under the supply agreement, we were responsible for the closure costs of our styrene facility and are also restricted from reentering the styrene business until November


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2012. The restricted period was initially eight years. However, INEOS NOVA unilaterally reduced the restricted period to five years on April 1, 2008.
We sold substantially all of our remaining styrene inventory during the first quarter of 2008. The process of decommissioning our styrene facility was completed by the end of 2008, and the associated costs incurred for 2008 was $18.9 million. In July 2008, we announced a reduction in work force in order to reduce our staffing to a level appropriate for our existing operations and site development projects. As a result, we reduced our salaried work force by 19 people and our hourly work force by 15 people and recognized and paid $1.4 million of severance costs in 2008. In addition, as a result of our work force reduction, the accrual of defined benefits for all future services of a significant number of employees was eliminated and we recorded a curtailment loss of $1.2 million for our benefit plans in 2008.
We own the acetic acid and plasticizers manufacturing units located at our Texas City facility. We lease a portion of our Texas City facility to Praxair, who constructed a partial oxidation unit on that land. We also lease a portion of our Texas City facility to S&L Cogeneration Company, a 50/50 joint venture between us and Praxair Energy Resources, Inc., or Praxair Energy, who constructed a cogeneration facility on that land. However, because our strategic initiatives under consideration do not require utilization of the steam produced by the cogeneration facility, we and Praxair Energy elected to terminate the joint venture and have amended the joint venture agreement governing S&L Cogeneration Company to extend its term until the later of November 30, 2009 or upon completion of all final audits, and to address several matters related to the sale of the cogeneration facility, the distribution of the joint venture's assets and the termination and winding-up of its affairs. We lease space for our principal offices located in Houston, Texas. Recent Developments
On October 12, 2009, John R. Beaver, our Senior Vice President - Finance and Chief Financial Officer announced his resignation from Sterling, effective as of October 31, 2009. Ms. Carla Stucky, Vice President and Corporate Controller of Sterling, will assume Mr. Beaver's responsibilities as our principal financial officer beginning October 31, 2009 until we engage a new Chief Financial Officer. Ms. Stucky has been our Corporate Controller since December 2007 and has served as one of our Vice Presidents since September 2008. Prior to joining us, Ms. Stucky served as Corporate Controller for Outsource Partners International, Inc. from July 2006 through November 2007, as Director of Finance for Hempel A/S from April 2005 to July 2006, as Assistant Controller for Nabors Industries, Ltd., from April 2003 to March 2005, as Director of Reporting and Corporate Accounting for Live Nation from May 1999 to March 2003, and as an Audit Manager in the audit practice of PricewaterhouseCoopers prior to May 1999.
Under the Restated Certificate of Designations, Preferences, Rights and Limitations of our Series A Convertible Preferred Stock, or our Preferred Stock, the holders of our Preferred Stock have the exclusive right to remove and replace members of our Board of Directors that were elected to our Board of Directors by the holders of our Preferred Stock. On November 6, 2009, the holders of our Preferred Stocked removed Mr. Byron J. Haney as a Director, which also caused Mr. Haney's removal as a member and the Chairman of the Audit Committee of our Board of Directors. Mr. Haney had served as a Director and as Chairman of the Audit Committee of our Board of Directors since December 2002. On November 6, 2009, the holders of our Preferred Stock elected Daniel Fishbane to our Board of Directors, effective as of November 6, 2009, to fill the vacancy resulting from Mr. Haney's removal.
Mr. Fishbane is a Senior Vice President and the Chief Financial Officer of M.D. Sass Investors Services. Inc., or M.D. Sass, the sole owner of Resurgence Asset Management, L.L.C., or Resurgence. Resurgence has beneficial ownership of a substantial majority of the voting power of our equity securities due to its investment and disposition authority over securities owned by its and its affiliates' managed funds and accounts. Currently, Resurgence has beneficial ownership of over 98% of our Preferred Stock and over 55% of our common stock, representing ownership of over 85% of the total voting power of our equity. The holders of our Preferred Stock are entitled to designate a number of our directors roughly proportionate to their overall equity ownership, but in any event not less than a majority of our directors as long as they hold in the aggregate at least 35% of the total voting power of our equity. Results of Operations
Three Months Ended September 30, 2009 Compared to Three Months Ended September 30, 2008
Revenues and income (loss) from continuing operations Our revenues were $27.2 million for the third quarter of 2009, a 36% decrease from the $42.4 million in revenues we recorded for the third quarter of 2008. We had a net loss from continuing operations of $3.0 million for the third quarter of 2009, compared to net income from continuing operations of $3.0 million in the third quarter of 2008.
Revenues from our acetic acid operations were $20.9 million in the third quarter of 2009, a 42% decrease from the $35.8 million in revenues we received from these operations in the third quarter of 2008. This decrease in acetic acid revenues in the third quarter of 2009 was primarily due to a $6.2 million reduction in cost reimbursements from BP Chemicals as a result of lower production and energy costs compared to the third quarter of 2008, a $1.9 million reduction in revenue due to lower acetic acid contribution margin and sales volumes and the inclusion of $6.5 million of revenues in the third quarter of 2008 related to the settlement of a blend gas dispute with BP Chemicals. Gross profit for our acetic acid operations was zero for the third quarter of 2009 compared to a gross profit of $9.6 million for the third quarter of 2008. This decrease in gross profit was primarily due to reduced revenue resulting from lower acetic acid contribution margin and sales volumes discussed above for the three-month period ended


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September 30, 2009 compared to the same period in 2008, as well as the inclusion of $6.5 million in revenues in the third quarter of 2008 related to the settlement of the blend gas dispute with BP Chemicals. In addition, we incurred $0.3 million of project start-up costs in 2009.
Revenues from our plasticizers operations were $6.0 million in the third quarter of 2009, a 9% decrease from the $6.6 million in revenues we received from these operations in the third quarter of 2008. Revenues for the third quarter of 2009 were lower primarily due to decreased cost reimbursements of $0.7 million from BASF as a result of lower energy costs in the third quarter of 2009 compared to the third quarter of 2008. Gross profit from our plasticizers operations was $1.5 million for the third quarter of 2009 compared to $0.4 million for the third quarter of 2008. This increase in gross profit for the third quarter of 2009 was primarily due to favorable economic indices applicable to various components of reimbursable costs under our Plasticizers Production Agreement.
Other gross profit was $0.7 million for the third quarter of 2009 compared to a loss of $0.9 million for the third quarter of 2008. This improvement was primarily due to the reversal of the $1.0 million litigation reserve in the third quarter of 2009.
Selling, general and administrative expenses Our selling, general and administrative expenses were $2.9 million for the third quarter of 2009 compared to $3.7 million for the third quarter of 2008. This decrease was primarily due to a reduction in legal fees resulting from the resolution of various lawsuits that were being litigated during the 2008 period. The amounts stated above for the third quarter of 2009 and 2008 exclude insurance reimbursements of $0.2 million and $0.7 million, respectively, which are recorded in other income.
Impairment of long-lived assets
We recorded zero and $0.8 million for impairment of long-lived assets for the third quarter of 2009 and 2008, respectively. The $0.8 million impairment in the third quarter of 2008 was for the write-down of our turbo generator units as a result of the decision to permanently discontinue use of those units.
Interest income
We recorded $0.1 million of interest income in the third quarter of 2009 compared to $1.0 million in the third quarter of 2008. This decrease was due to lower interest earned on our cash investments in 2009 compared to 2008.
Other income
Our other income was $0.2 million for the third quarter of 2009 compared to $1.5 million for the third quarter of 2008. This decrease in other income for the third quarter of 2009 compared to the third quarter of 2008 was primarily due to a decrease in reimbursements under our insurance policies for legal fees as a result of the resolution of various lawsuits that were being litigated during the 2008 period.
Benefit for income taxes
During the third quarter of 2009, we recorded a net tax benefit of $1.3 million for income taxes from continuing operations, compared to a net tax benefit of less than $0.1 million for income taxes from continuing operations for the third quarter of 2008. The net tax benefit in the third quarter of 2009 was generated by utilizing income in discontinued operations to recognize a portion of the benefit from losses generated in continuing operations. The net tax benefit in the third quarter of 2008 was generated due to a refund of alternative minimum tax. Our continuing operations effective tax rate was 31.1% for the three-month period ended September 30, 2009 compared to an effective tax rate of 3.4% for the period ended September 30, 2008. There was no change to the valuation allowance of $52.0 million.


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Income (loss) from discontinued operations, net of tax During the third quarter of 2009, net income from discontinued operations, net of tax was $1.8 million compared to a net loss from discontinued operations, net of tax, of $1.8 million for the third quarter of 2008. The difference was primarily due to the significant costs we incurred during the third quarter of 2008 to complete the decommissioning of our styrene facility.
Nine Months Ended September 30, 2009 Compared to Nine Months Ended September 30, 2008
Revenues and loss from continuing operations Our revenues were $85.5 million for the nine-month period ended September 30 2009, a 33% decrease from the $128.5 million in revenues we recorded for the nine-month period ended September 30, 2008. We had a net loss from continuing operations of $7.0 million in the first nine months of 2009, compared to a net loss from continuing operations of $2.0 million in the first nine months of 2008.
Revenues from our acetic acid operations were $64.5 million for the nine-month period ended September 30, 2009, a 38% decrease from the $103.9 million in revenues we received from these operations for the nine-month period ended September 30, 2008. This decrease in acetic acid revenues in the first nine months of 2009 compared to the first nine months of 2008 was primarily due to a $23.3 million reduction in cost reimbursements from BP Chemicals due to lower energy costs and reduced production, which resulted from the shutdown of our acetic acid unit in June 2009 for scheduled maintenance. Additionally we had an $8.3 million reduction in revenue resulting from reduced contribution margin and sales volumes for the first nine months of 2009 compared to the first nine months of 2008 and revenues for the first nine months of 2008 included $6.5 million for the blend gas dispute with BP Chemicals. Gross profit from our acetic acid operations was $4.5 million for the first nine months of 2009 compared to $23.1 million for the first nine months of 2008. The $18.6 million decrease in gross profit was primarily due to $8.3 million of reduced revenue resulting from reduced contribution margins and sales volumes discussed above, a $6.5 million decrease related to the settlement of the blend gas dispute in 2008 and increased project start-up costs and overhead expenses in 2009 of $0.9 million and $0.8 million, respectively, compared to 2008.
Revenues from our plasticizers operations were approximately $20.2 million for the nine months ended September 30, 2009, a 16% decrease from the $24.1 million in revenues we received from these operations for the nine months ended September 30, 2008. In the first nine months of 2009, our revenues were lower primarily due to decreased cost reimbursements of $2.5 million resulting from lower energy costs, which were offset by increased revenues of $2.7 million due to reimbursement for the capital project to redesign our process wastewater treatment system. Additionally, our revenues for the nine months ended September 30, 2008 included $3.7 million in cost reimbursements related to the closure of our phthalic anhydride, or PA, unit. Gross profit from our plasticizers operations was $4.2 million for the first nine months of 2009 compared to $3.5 million for the first nine months of 2008. The increase in gross profit for the first nine months of 2009 compared to the first nine months of 2008 was primarily due to favorable economic indices applicable to various components of reimbursable costs under our Plasticizers Production Agreement.
Other gross profit was approximately $0.3 million for the nine months ended September 30, 2009 compared to a loss of $3.3 million for the nine months ended September 30, 2008. This improvement was primarily a result of styrene residual costs incurred in 2008 that were significantly reduced, with the remaining costs being allocated to the acetic acid and plasticizers segments in 2009. Additionally, we reversed the $1.0 million litigation reserve in the third quarter of 2009.
Impairment of long-lived assets
We recorded zero and $7.4 million for impairment of long-lived assets for the nine months ended September 30, 2009 and 2008, respectively. The $7.4 million impairment in the first nine months 2008 was for the $6.6 million write-down of PA assets to zero as a result of the shutdown of our PA unit, and a $0.8 million write-down of our turbo generator units as a result of the decision to permanently discontinue use of those units.


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Interest and debt related expenses
We recorded $12.0 million and $13.1 million of interest and debt related expenses for the nine months ended September 30, 2009 and 2008, respectively. The reduction in interest and debt expense for the nine months ended September 30, 2009 was primarily due to the penalty interest incurred on our Secured Notes in 2008 of $0.3 million and a $0.2 million write-off of debt fees resulting from the reduction of our commitment under our revolving credit facility in the second quarter of 2008.
Interest income
We recorded $0.7 million of interest income for the first nine months of 2009 compared to $3.5 million in the first nine months of 2008. This decrease was due to lower interest earned on our cash investments during the first nine months of 2009 compared to the same period in 2008.
Other income
Our other income was $2.9 million for the first nine months of 2009 compared to $1.5 million for the first nine months of 2008. This increase in other income was primarily due to the receipt of a $1.1 million previously disputed contractual payment in 2009 and a $0.2 million increase in reimbursements of legal fees related to various lawsuits during the first nine months of 2009 compared to the first nine months of 2008.
Benefit for income taxes
During the nine month periods ended September 30, 2009 and 2008, we recorded net tax benefit of $2.5 million and less than $0.1million, respectively, for income taxes from continuing operations. The net tax benefit in the nine-month period ended September 30, 2009, was generated by utilizing income in discontinued operations to recognize a portion of the benefit from losses generated in continuing operations. The net tax benefit in the nine-month period ended September 30, 2008, was generated due to a refund of alternative minimum tax. Our continuing operations effective tax rate was 26.9% for the nine month period ended September 30, 2009, compared to an effective tax rate of 3.4% for the nine month period ended September 30, 2008. For the nine months ended September 30, 2009, there was no change to our valuation allowance of $52.0 million.
Income (loss) from discontinued operations, net of tax During the first nine months of 2009, net income from discontinued operations, net of tax, was $5.4 million compared to a net loss from discontinued operations, net of tax, of $9.8 million for the first nine months of 2008. The difference was primarily due to the significant costs we incurred during the third quarter of 2008 to complete the decommissioning of our styrene facility.
Liquidity and Capital Resources
On March 29, 2007, we completed a private offering of $150 million aggregate principal amount of unregistered 101/4% Senior Secured Notes due 2015, or our Secured Notes, pursuant to a Purchase Agreement among us, Sterling Chemicals Energy, Inc., or Sterling Energy, one of our former wholly-owned subsidiaries, and Jefferies & Company, Inc. and CIBC World Markets Corp., as initial purchasers. In connection with that offering, we entered into an indenture, dated March 29, 2007, among us, Sterling Energy, as guarantor, and U. S. Bank National Association, as trustee and collateral agent. On May 6, 2008, Sterling Energy was merged with and into us. Upon consummation of the merger, Sterling Energy no longer had independent existence and, consequently, our Secured Notes are no longer guaranteed by Sterling Energy. Pursuant to a registration rights agreement among us, Sterling Energy and the initial purchasers, we agreed to exchange our unregistered Secured Notes for a new issue of substantially identical debt securities registered under the Securities Act, to cause the registration statement for the exchange offer to become effective by December 24, 2007, and to complete the exchange offer within 50 days of the effective date of the registration statement. On August 30, 2007, we made an initial filing of the exchange offer registration statement. However, the registration statement was not declared effective by December 24, 2007, and, as a result, the interest rate on our Secured Notes increased by 0.25% per annum on each of December 25, 2007, March 24, 2008 and June 22, 2008. The registration statement was declared effective on August 13, 2008, and the exchange offer was closed on September 19, 2008. As a result, the interest rate on our Secured Notes reverted back to the face amount of 101/4% per annum when the exchange offer closed. The additional interest incurred from


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December 25, 2007 through the closing of the exchange offer was approximately $0.5 million and was paid on April 1 and October 1, 2008.
Our indenture contains affirmative and negative covenants and customary events of default, including payment defaults, breaches of covenants and certain events of bankruptcy, insolvency and reorganization. If an event of default occurs and is continuing, other than an event of default triggered upon certain bankruptcy events, the trustee under our indenture or the holders of at least 25% in principal amount of our outstanding Secured Notes may declare our Secured Notes to be due and payable immediately. Upon an event of default, the trustee may also take actions to foreclose on the collateral securing our outstanding Secured Notes, subject to the terms of an intercreditor agreement dated March 29, 2007, among us, Sterling Energy, the trustee and The CIT Group/Business Credit, Inc, or CIT. Our indenture does not require us to maintain any financial ratios or satisfy any financial maintenance tests. We are currently in compliance with all of the covenants contained in our indenture.
Interest is due on our outstanding Secured Notes on April 1 and October 1 of each year. Our outstanding Secured Notes, which mature on April 1, 2015, are senior secured obligations and rank equally in right of payment with all of our existing and future senior indebtedness. Subject to specified permitted liens, our outstanding Secured Notes are secured (i) on a first priority basis by all of our fixed assets and certain related assets, including, without limitation, all property, plant and equipment and (ii) on a second priority basis by our other assets, including, without limitation, accounts receivable, inventory, capital stock of our domestic restricted subsidiaries, intellectual property, deposit accounts and investment property.
On December 19, 2002, we entered into a Revolving Credit Agreement, or our revolving credit facility, with CIT as administrative agent and a lender, and certain other lenders. Under our revolving credit facility, we and Sterling Energy were co-borrowers and were jointly and severally liable for any indebtedness thereunder. After the merger of Sterling Energy with and into us, Sterling Energy ceased to be a co-borrower under our revolving credit facility. Our revolving credit facility is secured by first priority liens on all of our accounts receivable, inventory and other specified assets. On March 29, 2007, we amended and restated our revolving credit facility to, among other things, extend the term of our revolving credit facility until March 29, 2012, reduce the maximum commitment thereunder to $50 million, make certain changes to the calculation of the borrowing base and lower the interest rates and fees charged thereunder. Borrowings under our revolving credit facility bear interest, at our option, at an annual rate of a base rate plus 0.0% to 0.50% or the LIBOR rate plus 1.50% to 2.25%, depending on our borrowing availability at the time. We are also required to pay an aggregate commitment fee of 0.375% per year (payable monthly) on any unused portion of our revolving credit facility. Available credit under our revolving credit facility is subject to a monthly borrowing base of 70% of eligible accounts receivable plus 65% of eligible inventory. In response to the expected continued lower levels of accounts receivable and inventory, as well as our lesser need for a working capital facility, we reduced our commitment under our revolving credit facility to $25 million on June 30, 2008. On November 7, 2008, we further amended our revolving credit facility to substantially reduce restrictions, subject to minimum liquidity requirements, on investment of cash and other assets, payment of cash dividends, repurchase of debt and equity securities, modification of preferred stock terms, entry into affiliated transactions, disposition of assets and engagement in certain business activities. We paid the administrative agent an amendment fee plus expenses totaling approximately $0.1 million in connection with this amendment.
On November 1, 2009, CIT's parent company, CIT Group Inc., and another CIT Group subsidiary announced that they would proceed with a prepackaged plan of reorganization. CIT and CIT Group's other operating subsidiaries are not . . .

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