UPDATED: 10/16/2017 — see Change Log

OWNER: Koch Fertilizer Fort Dodge LLC (Koch Industries Inc)
PROJECT: Ammonia-UAN plant[memberful does_not_have_subscription=”1314-ammonia-industry-annual-subscription,1311-ammonia-industry-monthly-subscription,3338-ammonia-industry-30-day-subscription”]

EXISTING PLANT:
COST (reported): [none given]
JOB CREATION: 70 permanent — see Job Openings [LINK]
START-UP DATE (reported): 1967

CAPACITY	USGS[1]	COMPANY[2]	PERMIT[3]	ADJUSTED[4]
Ammonia	350,000 mtpy	[none given]	[Membership required]	[Membership required]
Units: stpd, stpy, mtpd, mtpy = short/metric tons per day/year. [1] United States Geological Survey (USGS) Mineral Yearbook, Nitrogen gives capacity in metric tons per year, calculated as “engineering design capacity adjusted for 340 days per year of effective production capability,” rounded to three significant digits. Source: most recent year, Table 4: Domestic Producers of Ammonia, http://minerals.usgs.gov/minerals/pubs/commodity/nitrogen/. [2] Koch does not publish capacity information. [3] [Membership required]. Sources: linked below. [4] [Membership required]. See Methodology.

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SUMMARY STATUS:
In operation since 1967. In 2012, Koch Industries announced potential “production enhancements” at this and other sites but, despite completing major expansions at its other sites, there have been no indications of any expansions at Fort Dodge.

EXISTING PLANT:
COST: [none given]
JOB CREATION: 70 permanent — see Job Openings [LINK]
START-UP DATE: 1967

CAPACITY	USGS[1]	COMPANY[2]	PERMIT[3]	ADJUSTED[4]
Ammonia	350,000 mtpy		1,200 stpd 401,500 stpy	364,235 mtpy
UAN			1,800 stpd	596,045 mtpy
Units: stpd, stpy, mtpd, mtpy = short/metric tons per day/year. [1] United States Geological Survey (USGS) Mineral Yearbook, Nitrogen gives capacity in metric tons per year, calculated as “engineering design capacity adjusted for 340 days per year of effective production capability,” rounded to three significant digits. Source: most recent year, Table 4: Domestic Producers of Ammonia, http://minerals.usgs.gov/minerals/pubs/commodity/nitrogen/. [2] Koch has not published capacity information. [3] Permit documents for this site give capacity in short tons per day. Note that the Title V Permit caps annual capacity at 401,500 stpy, which is less than 100% daily capacity. Sources: linked below. [4] Adjusted Capacity is in metric tons per year assuming operations for 365 days per year, based on Permitted Capacity. See Methodology.

FEEDSTOCK: Natural gas
END PRODUCTS: Ammonia, UAN

RESEARCH NOTES:
The Consumers Cooperative Association began operating an ammonia plant in Duncombe, five miles outside Fort Dodge, IA, in 1967. The original plant had a capacity of 600 short tons per day (stpd), using ammonia technology from M.W. Kellogg.

In 1994, under the ownership of Farmland Industries, the plant’s ammonia capacity increased to 900 stpd and then, in 1996, increased to 1,200 stpd. Also in 1996, the UAN plant started up, with a capacity of 1,800 stpd.

Following Farmland’s filing for Chapter 11 bankruptcy protection in 2002, Koch Nitrogen purchased the Fort Dodge plant at auction in 2003, paying $171 million for it and three other plants, including Enid, OK, Dodge City, KS, and Beatrice, NE, and a dozen terminals. A 2005 revamp “restored” the ammonia plant capacity to 1,200 stpd.

Fertilizer is shipped from the site by rail and truck.

In 2012, Koch Industries announced that engineering company Black & Veatch would “help develop” projects across Koch’s North American plants, to increase capacity by “more than two million tons annually,” “through production enhancements and new capacity investments.”

Since then, expansion projects have been confirmed at Brandon, MB, Enid, OK, and Beatrice, NE, but not at Fort Dodge. No future expansions are mentioned in the permit documents available at Iowa DNR.

Koch Industries Inc reorganized its corporate structure: Koch Fertilizer Fort Dodge LLC is now a subsidiary of Koch Fertilizer LLC, which is a subsidiary of Koch Ag & Energy Solutions LLC.[/memberful]

View larger map with all ammonia plants.

ADDRESS: 3162 200th Street, Duncombe, Iowa 50532, United States

WEBSITE: http://www.kochind.com/
WEBSITE: http://www.kochagenergy.com/
WEBSITE: http://www.kochfertilizer.com/

REGULATORY SOURCES:

• USGS: Minerals Yearbook, Nitrogen [RECENT / ARCHIVE]
• EPA Emissions data: Greenhouse Gas Emissions from Large Facilities: Koch Fertilizer Ft. Dodge [LINK]
• Risk Management Plan: Right to Know Network: Koch Fertilizer Fort Dodge [LINK]
• Operating Permit (Title V): Iowa DNR, Draft & Final Operating Permits [LINK] / [PDF]
• Construction Permitting: Iowa DNR: Construction Permit Search by Plant Number [search: 94-01-005] [LINK]
• PSD Permitting: Iowa DNR: Prevention of Significant Deterioration (PSD) Search [search: K for Koch] [LINK]

NEWS SOURCES:

• UNDATED: Koch Industries fact sheet: Fort Dodge, Iowa [PDF]
• 12/05/2013: Koch Industries press release: Koch Fertilizer Announces New Holding Company and Leadership Changes [LINK]
• 02/13/2013: US EPA press release: Koch Nitrogen Company to Pay $380,000 Civil Penalty for Clean Air Act Violations at Facilities in Iowa and Kansas [LINK]
• 10/30/2012: Koch Industries press release: Koch Nitrogen Adding Control Center at Ft. Dodge Plant [LINK]
• 05/14/2012: Koch Industries press release: Koch Fertilizer to Develop Projects for Production Increase [LINK]
• 03/28/2003: Associated Press news story: Koch buys Farmland fertilizer assets [LINK]