What’s Happening with - Steel Founders Society of America Market.pdf · 2017-10-10 · Frac...
Transcript of What’s Happening with - Steel Founders Society of America Market.pdf · 2017-10-10 · Frac...
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What’s Happening with
the Sand Supply?
Sara Joyce
Badger Mining Corporation
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0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
1996 2000 2005 2006 2007 2008 2009 2010 2011
SH
OR
T T
ON
S (
000's
)U S INDUSTRIAL SAND MARKET
Source: U S Geological Survey
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0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
1996 2000 2005 2006 2007 2008 2009 2010
% o
f M
ark
et
U S Silica Sand Market by Tons
Glass Fdy Frac Other
Source: U. S. Geological Survey
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What is Hydraulic Fracturing?• Process which is used to
assist release of natural gas
and oil from rock/shale
• Drill the well
• Case the well
• Perforate the well
• Place Proppant in the well
(fracking!)
• Let oil or gas flow
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Vertical Wells
• Straight down into the
earth
• Wells are perforated
near the well bore
• Use coarse grades
(1630,2040,3050)
• Conventional
Horizontal Wells
• Down, then sideways
• Perforated along
horizontal leg
• Use MUCH more sand
• Use finer sand in natural
gas wells (4070)
• Unconventional
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Frac Consumption has increased
dramatically over the last 5 years due
to the advancement of the horizontal
drilling process which:
• Improves recovery in shale plays
• Reduces environmental footprint
• Makes massive new areas feasible for
exploration and drilling of oil and gas
• Can access hard to reach areas
• Requires up to 5X sand over conventional
• Commonly uses 40x70 grade (similar to 50/55
GFN)
Most activity has been in pursuit of natural gas!
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U S Drilling Activity by Rig Type
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What makes a good proppant:
• High purity
• Round grains
• Two screen
• Crush resistant
• No fines (NTU’s)
• Large quantities
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Industrial Sand Application
Ranges
20x40Conventional
Frac
30x50Conventional
Frac
40x70Horizontal
Frac
50 GFN Foundry
60 GFN Foundry
50x140Horizontal
Frac
Mesh 20 30 40 50 70 100 140 200
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API/ISO SAND SPECIFICATION
Grade 4070 means that 90% of the sand is
below 40 mesh but above the 70 mesh.
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Foundry vs Frac
Grades
0
10
20
30
40
50
PE
RC
EN
T O
N
SIEVE
Fdy 50 GFN
Fdy 55 GFN
Frac 40x70
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0
10
20
30
40
50
60
70
PE
RC
EN
T O
N
SIEVE
Frac 50x140
Fdy 75 GFN
Foundry vs Frac
Grades
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Tons of Frac 4070 vs All Foundry Grades
0.39
0.9
0.69
0.60
0.89
1.23
1.00
0.88
0.78
0.51
0.86
1.07
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
2006 2007 2008 2009 2010 2011
IND
EX
VA
LU
E
4070 FRAC INDEX FDY INDEX (2006 = 100%)
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Where is this going???? • High frac demand to continue
• Average frac sand price remains well above other industrial users
• Suppliers diverting capacity to frac
• Suppliers adjust process to create more frac
• New capacity dedicated entirely to frac
Foundry is 3 – 4 million tons today
0
10,000,000
20,000,000
30,000,000
2000 2006 2011 2016
Frac Tons
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Multiple new suppliers in
western Wisconsin may help
to ease the 4070 shortage!
• 30 + plants
– Many under construction
– 12 proposed new plants
– At least 7 to 15 more that are in the
development stage
– ALL ARE DESIGEND TO PRODUCE
FRAC
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Issues Facing Sand Plants
• Capitalization
• Permits
• Quality/Specifications
• Public Backlash
– Environmental
– Damage to infrastructure
– Hours of operation
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Reduction in 4070 Demand is
Temporary:
• Return of 2007 base industrial demand
• Return of normal winters
• Increased use to generate electricity
• Increased use to fuel fleet vehicles
• Supplement to coarser grades
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US as Exporter!
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Some Good News• The energy industry uses many
different types of castings
– Valves
– Pipes
– Pumps
– Motors
– Heavy Truck
– Mining Equipment
– Drill bits
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More Good News• Reliable suppliers continue to
supply the metal casting industry
• New 4070 suppliers should improve
available supply
• The metal casting industry is busy
and the outlook is good
• Strong energy industry activity
reduces U S import dependence
• Natural gas prices currently very low
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What can be done?• Sand Reclamation
– Advances in technology have resulted in
better processes that work well
– The EPA has dropped classification of
thermal reclaimers as waste incinerators
– Most sand from the Midwest reclaims
better than other areas
– Provides other performance advantages
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What can be done?• Work closely with your supplier
– Advise any increase in requirements
– Advise of any change in performance
– Visit supplier facilities
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Summary
• The sand market will continue to be
affected by supply and demand
imbalances
• Keys to watch:
– Natural gas demand
– Natural gas prices
– Success of new sand suppliers
– Total frac demand
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THANK YOU!