In 2005, we monetized part of our chemicals business through
an initial public offering of the Canexus Income Fund. We have
retained a 61.4% interest in our chemicals business, and we
continue to fully consolidate chemicals in our Consolidated Financial Statements .
Visit Canexus website for more information.
Description of Chemicals Business Our chemicals business manufactures sodium chlorate and
chlor-alkali products (chlorine, caustic soda and muriatic acid)
in Canada and Brazil. This production is sold in North and
South America, with some sodium chlorate distributed in
Asia. Our manufacturing facilities are modern, reliable and
strategically located to capitalize on competitive power costs
or transportation infrastructure to minimize production and
delivery costs. This enables us to have reliable supplies and
low costs—key factors for marketing bleaching chemicals.
Electricity is the most significant operating cost in producing
sodium chlorate and chlor-alkali products, making up over half
our cash costs. Therefore, our current facilities are strategically
located to take advantage of economic power sources.
Our second highest cost is transportation. The proximity of
our manufacturing plants to major customers and competitive
freight rates minimize our transportation costs. Labour is also
a significant manufacturing cost. Approximately 50% of our
workforce is unionized with collective agreements in place
at all of our unionized plants.
To grow value in our chemicals business, we focus on
reducing our costs while maintaining market share, building
a sustainable North American customer base and capturing
new offshore opportunities.
North America The North American pulp and paper industry consumes
approximately 95% of the continent’s sodium chlorate production.
We market our sodium chlorate production to numerous
pulp and paper mills under multi-year contracts that contain
price and volume adjustment provisions. Approximately 32%
of this production is sold in Canada, 61% in the US, and the
rest is marketed offshore.
We are the third-largest manufacturer of sodium chlorate in
North America with four Canadian facilities: Nanaimo, British
Columbia; Bruderheim, Alberta; Brandon, Manitoba; and
Beauharnois, Quebec.
In October 2004, we completed an expansion of our Brandon
plant, increasing capacity to 260,000 tonnes per year. Brandon
is the world’s largest sodium chlorate facility and has one of the
lowest cost structures in the industry, significantly enhancing
our competitive position in North America. In late 2006, we
began another expansion at Brandon which is expected to
increase capacity by 33,000 tonnes per year, by mid 2008.
Our chlor-alkali facility at North Vancouver, British Columbia, manufactures
caustic soda, chlorine and muriatic acid. Almost all of our
caustic soda is consumed by local pulp and paper mills, while
our chlorine is sold to various customers in the polyvinyl chloride,
water purification and petrochemicals industries, primarily in the
United States. In early 2008, a technology conversion project
for the North Vancouver facility was sanctioned. The conversion
project will replace existing diaphragm technology and assets
with newer, proven membrane technology that is expected to be
more cost effective and will expand productive capacity by 35%.
The project is expected to be completed early 2010.

Brazil We entered Brazil in 1999 by acquiring a sodium chlorate plant
and a chlor-alkali plant from Aracruz Cellulose S.A. (Aracruz),
the leading manufacturer of pulp in Brazil. The majority of
the sodium chlorate production is sold to Aracruz under a
long-term sales agreement that expires in 2024. Most of the
chlorine and about 15% of the sodium chlorate production is
sold in the merchant market under shorter-term contracts. In
2002, we completed an expansion at both facilities to meet
Aracruz’s growing needs. The majority of our electricity needs
are supplied by a long-term supply contract in Brazil.
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