Borax has been able to maintain its position as the global market leader, but its primary boric acid plant is operating at full capacity. This plant was built in 1980 to produce 180,000 gross metric tons of boric acid per year. Investments and improvements increased capacity to more than 260,000 tons by the end of 2002, and we applied technological advances to produce another 23,000 tons in 2003. Further capacity expansions are underway, to be completed in 2006.

High in the Argentinian Andes, Borax built a new boric acid plant to recycle tailings - or what was once considered waste - to add another 8,000 tons of production. Despite these efforts, the world still needs more boric acid, and Borax still needs more capacity to meet that demand - and to increase energy efficiency and reduce emissions in the process.

Boric acid production is relatively simple on paper. It involves dissolving ore in dilute sulfuric acid; separating out mud and rocks; cooling down the liquid until crystals of boric acid form; and dewatering, drying and screening those crystals to make the final product.

Increasing boric acid production without increasing emissions and energy use is more complicated. We used computer models to design the most efficient plant configuration, and Life Cycle Assessments to measure environmental performance. Then we reviewed existing equipment - from pipes, pumps and conveyors to crystallizers, dryers and filters - to identify opportunities to heighten capacity and efficiency. For example, adding a vacuum belt filter to improve dewatering made the drying process more efficient, thereby reducing energy requirements.

A new crystallizer has been designed to recover the heat used to dissolve ore. More efficient heat exchangers have also been installed, replacing models that required frequent maintenance. A new gas-fired dryer is also planned to dry more tons of boric acid per unit of energy. Moreover, the dryer will be fitted with an ultra-low NOx burner to reduce air emissions. The new dryer alone will not only increase capacity, it will also decrease global warming potential and energy demand by two and four percent, respectively.

Improving how - and how much - boric acid is produced helps Borax remain competitive. In turn, it allows us to continue contributing to local economies through wages, taxes, support for local businesses and community contributions. The neighboring economy will also benefit from increased activity associated with construction.

Equally important, Borax consulted neighbors as part of its planning process - explaining the short- and long-term effects of increased hauling and dumping, and keeping its commitment to consider the health and safety of its employees and surrounding communities as its first priority.