Proppant Prospects for Industrial Minerals Mike O'Driscoll IMFORMED at SME 2015
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Transcript of Proppant Prospects for Industrial Minerals Mike O'Driscoll IMFORMED at SME 2015
Proppant prospects for
industrial minerals
Ceramic proppant supply and demand trends
imformed.com
Networking and knowledge for the industrial minerals business
imformed.com
[email protected] ▪ +44 (0)1372 450 679 ▪ mobile +44 (0)7985 986 255
Mike O’Driscoll Ismene Clarke
imformed.com
[email protected] ▪ +44 (0)1372 450 679 ▪ mobile +44 (0)7985 986 255
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Outline
1. Hydraulic fracturing
2. Proppants
3. Ceramic proppants (CP) & raw materials
4. Trends and developments
5. Outlook
6. Conclusions
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Exploiting unconventional oil and gas resources
Drivers
• Energy demand
Evolution of:
• Horizontal drilling
• Hydraulic fracturing
• Proppants
Source: EIA
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Squeezing out oil and gas from low permeability rocks
Source: Carbo Ceramics
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Pumping water and proppants under high pressure
Propping agent
= “proppant”
Props open
fracture
Permits oil/gas flow
(conductivity)
Drinking water acquifer <1,000ft
(305m)
Target rock formation
6-10,000+ft (1,829-3,048+m),
fractures extend ’00s ft
8,000ft
(2,438m)
Source: original graphic by Al Granberg
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Objectives: reservoir contact + conductivity
Reservoir Contact (Fractures)
Primarily driven by fluid rate and
fluid/proppant volume
Enhanced Flow Capacity (Conductivity)
Primarily driven by the proppant Source: after Mark Chapman, Carbo Ceramics 2014
$!!
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Typical fracturing fluid components
Source: FracFocus
Water up to 98%
Proppants up to 1-2%
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Evolution of hydraulic fracturing
17 March 1949
Duncan, OK
First fracturing by
Halliburton for
Stanolind Oil Co.
Images: Montgomery & Smith 2010
1949
patent filed; excl. licence
Halliburton, Stephens OK, Orchard
TX; 100-150lbs sand, 332 wells;
75% up in output
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Evolution of hydraulic fracturing
Mid-2000s:
• Multiple frac stages/well
• Increased to 4-6m lbs (3,000 st) proppant/well
From 2013
• 40-50 frac stages
• Up to 20m lbs (10,000 st) proppant/well
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1. Hydraulic fracturing
Significant growth in world proppant demand
2014
90bn lbs 2003
5bn lbs
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
2. Proppants
Proppant types
“The ideal proppant is one that has:
• the specific gravity of water,
• the strength of iron,
• and is cheaper than dirt!”
• walnut shells
• silica sand
• alumino-silicates
• fused zirconia
• plastic pellets
• steel shot
• glass beads
• aluminium pellets
• fly ash
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
2. Proppants
Proppant types
Silica sand (“frac sand”, FS):
derived from silica sand
deposits, 99%SiO2
Ceramic proppants (CP): derived
mainly from bauxite and/or kaolin,
>50% Al2O3
Resin coated proppants
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
2. Proppants
Proppant specifications
API RP 19C ; ISO 13503-2
Particle size
90% within specified size ranges, frequently:
12/20# (1700-850 microns) 20/40# (850-425 microns)
40/70# (425-212 microns) 70/140# (212-106 microns)
Particle shape Well-rounded, spherical grains (>0.6 for frac sand, >0.7 for resin
coated sand and ceramic proppants)
Crush resistance Withstand compressive stress 4000-6000 psi (28-42 MPa),
determined at 10% crush material
Acid solubility Limits on acid soluble material (<2% ≥30/50, <3% <30/50, <7%
for resin coated sand or ceramic proppants)
Turbidity Limits on clay (<2 microns) and silt (2 - 63 microns) content,
maximum turbidity 250 FTU (Formazin Turbidity Unit)
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
2. Proppants
Proppant specifications
Source: Krumbein & Sloss 1955
API
≥ 0.6
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
2. Proppants
Proppant market structure
US proppant market 80bn lbs (40m short tons; 36m tonnes)
Silica sand (“frac sand”)
80-90%
Resin coated
proppant 5-10%
Ceramic proppant 5-10%
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
2. Proppants
Proppant market structure
Source: after Carbo Ceramics
COST
$0.25-
0.90/lb
$0.20-
0.30/lb
$0.0135-
0.0675/lb 80-90%
5-10%
5-10%
Estimated US market share
Up to 10,000 psi
Up to 12,500 psi
Up to 15,000+ psi
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
2. Proppants
Selection criteria
• Proppant properties
Strength
Shape
Size
Durability
• Proppant availability
Supply source, quality, and cost
• Fracture treatment
eg. fluid system required, slickwater vs cross-linked fluids and
impact on proppant size
• Conductivity requirements
Desired conductivity
Cost vs benefit, ie. proppant cost set against oil recovery
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Superior performance
Uniform size/shape
enhances conductivity
of proppant pack
Inconsistent sized,
irregular shaped,
tightly packed
grains reduce
conductivity
INCREASED CONDUCTIVITY = IMPROVED EUR, ROI
• Higher cost
• Stronger, more durable
• Uniform density
• Uniform sphericity
• Uniform size
• Higher conductivity
• Superior performance
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
High pressure environments favour ceramic proppants
Source: Carbo Ceramics
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Raw material feedstock
Primary raw materials
• bauxite
• kaolin
• bauxitic kaolin
• bauxite/kaolin blends
Additives:
• diatomite
• titanium dioxide
• chromite
• boron
• magnetite
• magnesia
• manganese oxide
• rare earth oxides
Alternative raw materials
• magnesium silicate
(derived from serpentinite, olivine, dunite)
• andalusite
• metabasalt
• fly ash – cenospheres
• alumina-rich clays
• nanostructured ceramics/glass
• metallurgical slag
• mine tailings
Source: Carbo Ceramics
Carbo Ceramics, Toomsboro, GA, 1,000m lbs/y
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
Bauxite 70% Al2O3 for IDC grade
70% Al2O3, 25.5% SiO2, 0.61% Fe2O3, 3.82% TiO2
55-71% Al2O3, 7-16% SiO2, 1.5-19% Fe2O3, 2.5-3.8%TiO2
Bauxite (calcined)
+Kaolin
+Bayer alumina fines
(dust collector by-product)
82%Al2O3, 7% SiO2 (Australia)
52% Al2O3, 45% SiO2
99% Al2O3
Calcined kaolin (75-90%)
+Calcined diatomaceous earth
(5-10%)
45.60% Al2O3, 51.21% SiO2, 0.96% Fe2O3
4.37% Al2O3, 87.51% SiO2, 1.91% Fe2O3
Bauxite (55%)
+Kaolin (45%; + iron oxide, 7%)
85% Al2O3, 7% Fe2O3
45% Al2O3, 1% Fe2O3
Bauxite/kaolin blend 72% Al2O3 total for IDC grade
Kaolin 48% Al2O3 for LWC grade
45-50% Al2O3; <0.13 S, <1.0% Fe2O3, <1.0% K2O
“Alumina clays” 41.5-49.0% Al2O3 by wt. calcined basis
3. Ceramic proppants
Known specifications: a range chemical compositions
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Grades categorised by density and strength
Grade Density SG Al2O3 % Feedstock
Ultra High
Strength
3.9 >98 Alumina
High Strength 3.5 80-85 Bauxite
Intermediate
Strength
3.2 70-75 Bauxite
Low Strength 2.7 45-50 Kaolin
In general, increasing alumina content is proportional to increasing strength
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Traditional grades
Ceramic proppant
grade examples
(Carbo Ceramics)
LWC
Lightweight
ceramic
proppant
IDC
Intermediate
density
ceramic
proppant
HDC
High density
ceramic
proppant
Raw material kaolin bauxite bauxite
Apparent SG 2.71 3.27 3.56
Bulk Density (g/cm3) 1.57 1.88 2.00
Alumina % 51.0 72.0 83.0
Silica % 45.0 13.0 5.0
Iron % 1.0 10.0 7.0
Titania% 2.0 4.0 3.5
Source: Carbo Ceramics
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
Proppant Feedstock Size Avg.
US$/lb
Volume
(lbs)
Cost
m$/well
Carbo Econoprop kaolin 20/40 $0.32 6,000,000 $1.92
Imerys ProLite LWC kaolin 20/40 $0.32 5,769,231 $1.84
Chinese LWC bauxite 20/40 $0.26 6,230,769 $1.62
Carbo CarboProp bauxite 20/40 $0.42 7,230,769 $3.03
VersaProp ISP bauxite 20/40 $0.42 7,230.769 $3.18
3. Ceramic proppants
Examples of typical cost and consumption in Bakken 2014
Source: Coretrack Ltd
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Raw abrasive bauxite grade feedstock
% Abrasive Refractory Chemical Metallurgical
Al2O3 min. 55.0 min. 59-61.00 min. 55-58.00 50-55.00
SiO2 max. 5.00 max. 1.50-5.50 max. 5-12.00 0-15.00
Fe2O3 max. 6.00 max. 2.00 max. 2.00 5-30.00
TiO2 min.2.50 max. 2.50 0-6.00 0-6.00
Source: Errol Sehnke, USGS, 1995 • Al2O3 content 55-70%; increases with calcination to 85-90%
• not as strict as refractory grade
• flexibility with iron, not critical
• low silica and alkalies (CaO <0.1 to minimise glass phase)
• supply sources: Australia, Brazil, China, Greece, Guinea, Guyana, Italy
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Kaolin feedstock % Calcined kaolin
for LWC
Al2O3 45.60
SiO2 51.21
Fe2O3 0.96
CaO 0.05
MgO 0.07
TiO2 1.86
Na2O 0.07
K2O 0.17
Typically calcined kaolin
with min. 40% Al2O3
Kaolin has been used containing:
45-55% Al2O3
<1.0% Fe2O3
<0.15% K2O
<0.13% S
Kaolins maybe blended with bauxite
and alumina fines prior to sintering
Source: US Patent 2008/0058228
Source: Imerys C-E Minerals mining, Andersonville, GA
Extrusion
Calcining Kiln
Cooling Drum
Milling
Classification
Binder Mixing
Pelletization
Green Pellet Screen
Sintering Kiln
Cooling Drum
Grading Screen
Feedstock
mineral(s)
Proppant
Source: AJ DeCenso, M-I Swaco 2013
Dry process
Calcined ore,
HS grades.
Wet process
Uncalcined ore, IS and LS grades;
slurrying prior to binder mixing;
fluidizer sprays slurry onto seed
particles prior to sintering
Proppant prospects for industrial minerals Ceramic proppants
3. Ceramic proppants
Manufacturing
©IMFORMED 2015 | imformed.com
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Primary sources, production, & raw material feedstock
Company Plant Capacity
(m. lbs/yr) Feedstock
Carbo Ceramics Inc.
Carbo Ceramics Inc. Eufaula, Alabama 275 kaolin
McIntyre, Georgia 275 kaolin & bauxite
Toomsboro, Georgia 1,000 kaolin
Millen, Georgia 250
(+250 Q3 2015) kaolin & bauxite
Carbo Ceramics (China)
Co. Ltd Luoyang, Henan, China 100 kaolin & bauxite
Carbo Ceramics Eurasia Kopeysk, Chelyabinsk,
Russia 100 bauxite
Carbo total 2,000
Saint-Gobain Proppants
Saint-Gobain Proppants Fort Smith, Arkansas 180-200+ bauxite
Bryant, Saline, Arkansas 330 bauxite
closed 2011 Puerto Ordaz, Venezuela 110.2 bauxite
Saint-Gobain Proppants
(Guanghan) Co. Ltd Guanghan, Sichuan, China 198.4 bauxite
S-G total 730
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Primary sources, production, & raw material feedstock
Company Plant Capacity
(m. lbs/yr) Feedstock
Imerys
C-E Minerals Mulcoa Plant 5,
Andersonville, Georgia 220.4 kaolin
(formerly PyraMax
Ceramics LLC) Wrens, Georgia
500
kaolin
Treibacher
Schliefmittel SpA Domodossola, Italy 13-22
bauxite
(?andalusite)
Imerys total 740
Mineração Curimbaba,
Ltda
Pocas de Caldas, Minas
Gerais 661.2 bauxite
Fores LLC Sukhoy Log, Chelyabinsk,
Russia 550
magnesium silicate
from asbestos
mining waste
JSC Borovichi
Refractories Plant
Borovichi, Novgorod,
Russia 440.8 kaolin
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
China: leading producer, modernising
• Total production capacity est. 10bn lbs/y.
Production est. <50%.
• Export market boomed from 2001,
peaked in 2011 at >1m tonnes;
40-50% of output; mostly to USA
• ~100 plants producing ceramic proppants
10% >220m lbs/y
20% 132-220m lbs/y
70% <110m lbs/y
• Feedstock is bauxite (except Carbo Ceramics plant also uses kaolin)
• Located close to bauxite resources: Henan, Guizhou, Shanxi, and Sichuan
• Major players:
Producers >441m lbs/y:
Gongyi Tianxiang Ceramic Proppant Co. Ltd
Hebei Haihua Petroleum Proppants Ltd
Xinmi Wanli Industry Development Co. Ltd.
• Addressing quality and inefficiency issues
Companies investing in modern capacity
Xinmi Wanli Industry Development Co. Ltd
Yangquan Changqing Petroleum Fracturing
Propping Agents Co. Ltd
Luoyang Maide Ceramics Co. Ltd
Yixing Orient Petroleum Proppant Co. Ltd
Source: Bauxite province map Hill & Sehnke 2007
Bauxitic kaolin: Alabama
Bauxite: Arkansas
Kaolin: Georgia Carbo Ceramics, AR, AL
Imerys, GA
Saint-Gobain, AR
Bauxite, Minas Gerais Mineracao Curimbaba, MG
Bauxite: Henan,
Guizhou,
Shanxi, Sichuan ~100 producers
Kaolin:
Novgorod Borovichi,
Novgorod
Serpentinite (MgSiO2):
Sverdlovsk Fores, Chelyabinsk
Bauxite:
Komi Carbo,
Kopeysk
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
3. Ceramic proppants
Primary sources & production: proximity to feedstock deposits
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
January 2015 US plant closures
Saint-Gobain Proppants
Temporarily closed Ft Smith, AR
plant 21 January 2015
$15m upgrades 2010-2011
180-260m lbs/yr cap.
Started 1979 as Norton Proppants
Oxane Materials Inc.
Closed Van Buren, AR plant 23 January 2015.
Developed HS/IS/LW “advanced ceramic proppant”; a sprayed mixed-metal
oxide shell over a hollow sphere – included fly ash in coating; launched 2013
End-2013, production rising 1.8m lbs/month
to 4.0m lbs/month; expected to
produce 40m lbs in 2014 end-2014.
Ultimate objective was 2 x 100m lbs/year
lines at Van Buren.
Source: Fives
Source: Oxane Materials
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Expansions and investments
Curimbaba Group, Brazil
Oil price impact has placed on hold
planned 70,000 tpa (154.2m lbs/yr)
expansion with new plant originally
scheduled end-2015/early 2016
Source: Sintex
Prime Meridian/Hallmark Minerals
Prime Meridian Resources Corp., Canada LOI for 55% stake in
Hallmark Minerals (I) Pvt. Ltd, India
Aims to add 25,000 tpa (55m lbs/yr) to 10,000 tpa (22m lbs/yr) plant using
bauxite/clay blends.
Carbo Ceramics Inc.
Deferred completion of Millen Line 2
(250m lbs) until Q3 2015/2016
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Developing projects
Baltic Ceramics SA
Building initial 60,000 tpa (132m
lbs/y) plant at Lubsko, western
Poland, expected on stream by the
H2 2015.
135,000 tpa (298m lbs/y) full cap.
production.
Feedstock:
• captive 4.8m tonnes high alumina
kaolin resource close to plant
• bauxite from Greece
• kaolin from the Czech Republic
• fly ash from power stations.
Source: Baltic Ceramics SA
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Developing projects
Ecopropp Pty Ltd/Coretrack Ltd
Building 250kg/hr pilot plant using fly ash, at
Clontarf, near Brisbane, Queensland.
Production expected Q2 2015.
“Highly positive” results of testing fly ash-
based proppants at 15,000 psi.
Aim to sell technology licences to third parties
to build satellite plants near coal fired power
stations and oilfields.
Claimed low processing cost factor: Ecopropp
fly ash proppant at US$0.26/lb = US$0.06-
0.18 cheaper than US/Chinese proppants
Source: Ecopprop Pty Ltd
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Developing feedstock projects
Latin Resources Ltd
Developing the Guadalopito heavy minerals project 25km from Chimbote,
northern Peru. Seeking j-v partners.
Contains estimated 14-16m tonnes andalusite; 15m tpa conventional dredge
mining operation envisaged to yield 155,000 tpa andalusite.
Envisage proppant potential with andalusite blended with kaolin or other.
First Bauxite Corp.
Developing Bonasika bauxite deposit
60km south-west of Georgetown,
Guyana.
Evaluating revised plan for bauxite
mining and beneficiation in Guyana;
150,000 tpa calcining and sintering
plant in south Louisiana aimed at
ceramic proppant and refractory
makets. Source: First Bauxite Corp.
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Developing projects: Where did they go?
Shamrock Proppants LLC
In 2013, acquired Mid America Brick & Structural Clay Products plant, Mexico, MO.
Planning started 2013 2x 36.8 tph rotary kilns Wellsville, MO.
Feedstock: own kaolin resource (affiliated with Christy Minerals Inc.)
Applied Minerals Inc.
October 2013 agreement with OPF to
formulate ceramic proppants based on
halloysite clay from AMI’s developing
Dragon Mine, Utah.
March 2014 clay process plant
commissioned
Brownwood Clay Holdings LLC
Since 2011, developing with OPF Enterprises LLC a deposit in Brownwood, TX,
reportedly >10m s.tons inferred resource of “proppant grade clay”.
March 2014 secured property for plant build in Brownwood, but no construction
expected for “a couple more years”.
Source: Applied Minerals Inc.
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Developing projects: Bubbling under?
Kaolin AD, Bulgaria: kaolin Pasek Minerales, Spain: dunite
Source: Pasek Minerales
Source: Kaolin AD
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Ultra High Strength Proppants – clash of the giants
2013: a new upper tier category of ultra-high strength ceramic proppants based
on high-alumina raw materials introduced for ultra-deep wells eg. 30,000 ft in
Lower Tertiary, Gulf of Mexico – offshore fracking a new frontier
Carbo Ceramics
Kryptosphere: >98% Al2O3; 3.9 SG; 0.9 S/R
25#; Feedstock: ?kaolin, Inner Mongolia
High conductivity at 20,000 psi
HD/LD grades
Retrofit of existing plant to produce 250m
lbs/y Kryptosphere LD, on schedule for
completion by end-Q2 2015. Source: Carbo Ceramics
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Ultra High Strength Proppants
CoorsTek Inc.
February 2014: opened 5m lbs/month plant
in Golden, CO; were plans to double cap. in
2015
CeraProp: lightweight, 2.67-2.72 SG; 0.9 S/R
16/30, 20/40, 30/50, 40/70#
Feedstock: kaolin
Saint-Gobain
Titan: 30/50#
Feedstock: bauxite
“World’s only 30k proppant”
Source: CoorsTek
Source: Saint-Gobain
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Innovations
HiWay – Schlumberger
• “Slugs” of proppant
pumped down well
• Synthetic fibres bond
proppants together
• Creates flow-channels
• Enhances conductivity
• Uses 40% less proppant!
Source: Schlumberger
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Innovations
Propel SSP – Fairmount Santrol
• Proppant transport technology
• Proppant coating swells upon contact
with water to form hydrogel layer
• Decreases proppant's effective specific
gravity, eg. 2.6 to 1.3 for frac sand
• Allows proppant to go further and higher
into the formation.
• The increased stimulated reservoir
volume reduces cost per barrel of oil
equivalent
• “solves decades-old problem of
uniformly distributing proppant
throughout the full length of a created
hydraulic fracture”
Unique polymer coating swells to
3x original particle size
Source: Fairmount Santrol
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Innovations
Propynite – Imerys Oilfield Solutions
• Produced in Italy; bauxite feedstock
• Rod-shaped design exhibits strength
and proppant permeability “far in excess
of conventional HSP.”
• Greater fracture conductivity and
flowback control
• Permits high well productivity at closure
stress levels >15,000 psi.
• Higher pack permeability improves the
mobility of the residue from high
viscosity fracturing fluids, and therefore
improves fracture clean-up.
Source: Imerys
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Innovations
In-situ proppant formation – Oil Chem Technologies
• fracturing fluid itself forms the proppant
• little or no material is carried back to be treated or disposed of
• size of proppant can range <1mm - >20 mm by modifying fracturing fluid
composition.
• No polymer is required to suspend the proppant, hence no breakers are
required
• proppants are perfectly spherical particles with hardness equal or
exceeding conventional proppants.
• Highly permeable solid masses can also be formed within the fracture
using hydraulic fluids containing no solids.
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
4. Trends & developments
Proppant application: trend to using more frac sand
• 2013-14 E&P practice of using higher volumes of frac sand, and only “tailing
in” ceramic proppants
• In softer, ductile formations like Eagle Ford, Permian, rock wraps around
proppant reducing conductivity – solution to overload with proppants to plug
short, wide fractures = using more lower cost FS rather than CP
• Major players switched to FS-only in Eagle Ford: EOG, Pioneer, Anadarko,
ConocoPhillips
• EOG also intensive FS use in Bakken wells increased productivity
• Q2 2014; Rosetta Resources Inc. revised completion design in Eagle Ford
by increasing FS volumes against CP volumes = cost savings $0.5m/well or
250-500m lbs CP
• But after initial high well productivity, it declines steeply soon after, therefore
perhaps only a short term solution – CP will always outperform FS
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
1,358 active US land rigs 13/2/15
weekly drop of 98, one of the biggest
declines in the past three decades
Source: Fuel Fix; data based on Baker Hughes, Bloomberg
5. Outlook
Market situation: oil drilling market in doldrums
WTI oil price “jumped”
$1.68 to $52.89/bbl
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
5. Outlook
Cyclical market: a similar recovery to 2008-09 recession?
Source: After Schlumberger Dec 2014
2015-16/17
Proppant prospects for industrial minerals Ceramic proppants
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• most shale operations are profitable at
$70/bbl
• improved efficiencies of drilling and lower
cost prices could result in more shale
projects becoming profitable at $50/bbl [Goldman Sachs: margin of profitability of
majority of shale operations is $45-40/bbl.]
New CEO at Total: Patrick Pouyanne
Speaking at the World Economic Forum,
Switzerland, 22 January 2015
5. Outlook
A cyclical market: higher prices will return
• widespread industry investment cuts may not necessarily be long term:
“There is a natural decline of 5% a year from existing fields around the world.
That means by 2030 more than half of the existing global oil production will
disappear. There is an enormous amount of money that needs to be invested
to get another 50 million barrels per day of new production. The cycle will
come back and higher prices will come back.”
Source: Reuters/Andrew Winning
Proppant prospects for industrial minerals Ceramic proppants
5. Outlook
Demand driver: forecast future for gas + shale gas as source
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Proppant prospects for industrial minerals Ceramic proppants
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5. Outlook
Demand driver: US energy production to 2040: gas 38%
Source: EIA Sept 2014
(quadrillion BTU)
China
USA
5. Outlook
Demand driver: US shale gas contribution to grow to c.50%
Proppant prospects for industrial minerals Ceramic proppants
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China
USA USA Latin
America India
Asia
Australia
Proppant prospects for industrial minerals Ceramic proppants
5. Outlook
Demand driver: regional market growth
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Proppant prospects for industrial minerals Ceramic proppants
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5. Outlook
World proppant consumption: increasing trend – comparison
of research organisation estimates
Research and
Markets
2013
45.12m tons
2019
84.20m tons
($19bn)
10.7% CAGR
BCC Research 2014
$49.0bn
2019
$83.2bn
11.2% CAGR
Grand View
Research
-- 2020
96.03m tons
--
Freedonia 2012
37m tons
2017
65m tons
12% CAGR
Proppant prospects for industrial minerals Ceramic proppants
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5. Outlook
IHS (PacWest Consulting) US onshore proppant demand
20
21
22
23
24
25
26
27
14Q1 14Q2 14Q3 14Q4 15Q1 15Q2 15Q3 15Q4 16Q1 16Q2 16Q3 16Q4
Source: based on 2014 data from IHS (PacWest)
million
lbs
• consumption to rise 2% p.a. through 2016
• from 80bn lbs in 2013 to 111bn lbs in 2016
• most growth in FS
• RCS decline at 5% p.a.
• CP decline at 17% p.a.
Proppant prospects for industrial minerals Ceramic proppants
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5. Outlook
Demand drivers: more horizontal wells, more frac stages,
more proppant consumed per well; up to 16m lbs/well
Source: IHS (Pac West)
5m lbs
10-16m lbs
Proppant prospects for industrial minerals Ceramic proppants
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5. Outlook
Demand driver: pad drilling practice = much reduced footprint
Source: Statoil
Proppant prospects for industrial minerals Ceramic proppants
5. Outlook
Demand driver: world shale gas resource potential
©IMFORMED 2015 | imformed.com
5. Outlook
Regional emerging shale gas markets for proppants in estimated
order of commercial development (ex-onshore USA/Canada)
Proppant prospects for industrial minerals Ceramic proppants
1
1
1
2
2 2
3
3
1 GoM/Mexico - South America - Middle East
2 N. Africa – Australia - China/SEA
3 Europe - Russia
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Proppant prospects for industrial minerals Ceramic proppants
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6. Conclusions • CP are high performance proppants with a premium price
• There are relatively few producers worldwide
• Feedstock raw material traditionally bauxite/kaolin, but new lower cost
alternative raw materials are emerging
• Critical to secure quality material and correct process route/expertise
• Several new players emerging outside USA; many in China
• Established producers have heavily invested in new capacities in recent
years and near term – market climate has cooled some projects for now
• New grades of CP are being developed for a new era of application –
trend to drill more HPHT wells using ultra-high strength CP grades
• Despite competing with low priced FS, CP’s higher performance ensures
future demand
• Long term demand assured by anticipated world gas demand
• Volume consumption improved by more wells, longer laterals, more stages,
greater volumes used per stage and thus per well
• Anticipated growth markets outside USA to evolve at contrasting rates
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
6. Conclusions • CP are high performance proppants with a premium price
• There are relatively few producers worldwide
• Feedstock raw material traditionally bauxite/kaolin, but new lower cost
alternative raw materials are emerging
• Critical to secure quality material and correct process route/expertise
• Several new players emerging outside USA; many in China
• Established producers have heavily invested in new capacities in recent
years and near term – market climate has cooled these projects for now
• New grades of CP are being developed for a new era of application –
trend to drill more HTHP wells
• Despite competing with “dirt” (FS), CP’s high performance ensures future
demand
• Long term demand assured by anticipated world gas demand
• Volume consumption improved by more wells, longer laterals, more stages,
greater volumes used per stage and thus well
• Anticipated growth markets outside USA
Proppant
prospects for
industrial
minerals…are
good!
Proppant prospects for industrial minerals Ceramic proppants
©IMFORMED 2015 | imformed.com
Sponsors Media
Partner
Proppant prospects for industrial minerals Ceramic proppants
Brazilian proppants: Curimbaba Group
past, present, & future
Peter Muira Nakachima, Manager
Research & Development
Curimbaba Group, Brazil
Proppant market demand outlook
Samir Nangia, Principal
IHS (PacWest Consulting Partners), USA
Oilfield minerals: supplying the market
Dave Frattaroli, Chief Commercial Officer
Unimin Energy Solutions, USA
Frac sand: US exploration and
production – where’s it heading?
Mark Zdunczyk
Consultant Geologist, USA
©IMFORMED 2015 | imformed.com
The future of ceramic proppants in the
unconventional shale market
Jack Larry, General Manager
Saint-Gobain Proppants, USA
Chinese proppants supply & markets
Gene Kim, CEO
AM2F Energy Inc., USA
Ceramic proppant development using
fly ash as raw material
Siegfried Konig, Executive Director,
Coretrack Ltd, Australia
Frac sand developments for the
Argentinean shale gas market
Richard Spencer, President & CEO
South American Silica Corp., USA
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Presenting in Proppants session as of 15 February 2015
Thank you for your attention.
If you have any questions or comments,
or would like more information, please contact me.
Proppant prospects for industrial minerals Ceramic proppants
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