Sand is the world’s most mined material, with about 50 billion tons extracted from lakes, riverbeds, coastlines, and deltas each year, according to the United Nations Environment Programme. Most of the mined sand is used in construction as a component of concrete. Urbanization in China and India is driving construction sand mining in general. Sand used in hydraulic fracturing to prop open fractures has different specifications from construction sand. Frac sand mining is a very small part of sand mining around the world. There are a few deposits around the world of very high-purity quartz (HPQ) that are the purest sand in the world, much purer than frac sand. These are used to make semiconductors. The world’s main HPQ mine is in North Carolina.
Hydraulic fracturing of a well
requires tens of thousands of tons of sand. If, as is common, multiple wells
are hydraulically fractured simultaneously, that means tens of thousands of
tons for each of the wells. That means a few thousand truckloads of sand, about
3600 truckloads on average. Thus, acquiring and delivering the appropriate
grade(s) of sand is a major feature of frac operations.
Important requirements for
frac sand are that it must be pure sand, of the appropriate sizes, rounded, and
have high crush resistance. According to the American Petroleum Institute (API)
standards, frac sand must be more than 99% quartz or silica, must be of one of
four “mesh” sizes, must have a roundness or sphericity of 0.6 or higher, and
must have a crush resistance of 4000-6000 psi. However, SCS Engineers notes
that frac sand generally has a compressive strength ranging from approximately
6,000 pounds per square inch (psi) to 14,000 psi. Frac sand sizes range from
0.1 to 2 mm. The most common size is 0.4 to 0.8 mm. If the sand is subjected to
higher pressures and gets crushed, its permeability, specifically its sand pack
permeability, will be reduced, making the frac job less effective. This is an
important issue in high-pressure formations.
The mined frac sand must then
be washed, dried, and sorted to remove unwanted material, then size-sorted for
job specs. The sand may also be coated with resin to improve crush resistance.
Most frac sand in the U.S.
used to be mined in Western Wisconsin, about 75% according to a 2014 report.
However, according to a 2023 article:
“In 2017, Wisconsin’s 44 active mines accounted for almost
half the nation’s installed frac sand capacity, but this has changed as local
frac sand mining is replacing older fixed base mines. In fact, a significant
amount of total sand proppant demand is now locally sourced.”
Minnesota, Illinois,
Oklahoma, Arkansas, Ohio, Michigan, Nebraska, and Texas are other major
sources. Missouri is also a potential source. The growth of frac sand mining in
Texas has been significant since it is closer to major shale regions. In the
Wisconsin and Minnesota region, the Ordovician-aged St. Peter Sandstone is a
major source of frac sand. The Cambrian-aged Jordan and Wonewoc sands are also
major sources. Where these sands are near the surface is generally where they
are mined. These are open-pit mines where topsoil is stripped away to get to
the sand. Potential environmental and health impacts of frac sand mining
include groundwater pollution due to the loss of topsoil and the risk of
silicosis for sand mine workers – this is a very real and potentially
debilitating health condition that is caused by breathing silica dust and
according to an OSHA report from about ten years ago about 7300 new cases and
200 deaths per year in sand industries occur.
According to the Wisconsin
Sierra Club chapter, there are 128 industrial sand facilities in Wisconsin.
These include mines and processing facilities that crush, wash, and sort the
sand. The sand is transported mainly via rail. Washing the sand requires massive
quantities of water and produces waste with toxic heavy metals that must be
managed. The waste may be sold as a byproduct or put back into the area during
reclamation. Air quality tests often reveal high quantities of silica dust,
sometimes even higher than respirators can handle. State regulators at the
Wisconsin DNR require air monitoring at frac sand mining and processing
sites.
According to the American Oil & Gas Reporter, the U.S. shale industry consumed an estimated 112 million tons of proppant in 2022. That is 50% higher than the maximum of the following graph, which stops in 2019.
The trend has been for finer sand to be used.
According to Expert Market Research:
“The global frac sand market is estimated to be worth
around USD 9.61 Billion in 2024 and is anticipated to grow at a CAGR of 7.50%
between 2025-2034, reaching USD 19.81 Billion by 2034”
According to SCS Engineers, frac sand exploration involves several considerations:
The exploration geologist is interested in several
elements:
1) Characteristics
of the sand in its natural condition (grain size, sphericity, sorting, clay
content, cementation, crush resistance)
2) Distance
to the point of use (transportation is a big consideration)
3) Available
acreage in large tracts
4) Size of
potential deposit
5) Overburden
to be removed (type and amount)
6) Availability
of water.
Geological surveys, mapping,
remote sensing, and satellite data are all used to identify potential frac sand
deposits. After an area is identified, core sampling ensues. After this, the
sand in the cores is analyzed and lab tested for suitable qualities. SCS
Engineers note:
“The most used frac sand comprises round, well-sorted
particles with a median grain size typically falling within the 0.6 to 0.8
millimeters (mm) range, also known as a “20/40 mesh” for the sieve size range.
This type of frac sand is often referred to as “Northern White” sand and has
historically been a preferred choice for hydraulic fracturing due to its
uniformity and roundness. However, many companies are going to finer sands of
100 to 200 mesh. Common frac sand sizes include 40/70, 30/50, 20/40, 100 mesh,
200 mesh, and finer.”
The Innovation of Wet Sand Processing for Frac Sand
Wet sand processing simply
eliminates the drying process, which involves heating and has associated
pollution and carbon emissions, which are also eliminated. It obviously works
best when the frac sand mine is near the point of use. This is limited, but in
places like Texas, it is becoming more common where there are local “in-basin”
frac sand mines, or even hyper-local “in-field” mines less than 15 miles away.
According to the American Oil & Gas Reporter:
“Most mines have dryers to dry the sand from 10%-15%
moisture to <1% moisture. This is largely a relic of the past when sand had
to be shipped long distances by rail, and the need for dryers has been called
into question by industry thought leaders given the nature of in-basin and
in-field mining and the fact that sand is “re-hydrated” once it gets to the
well site. The dryers are the primary driver of energy consumption and
per-ton-cost at the mine.”
A major advantage of wet sand processing is that the wet
sand does not produce dust, which makes it much safer for workers.
In-Basin Frac Sand Resources
While the above discussion
about wet sand processing is interesting, it begs the question: Where are these
local and hyper-local sand resources? The eastern side of the Permian Basin is
one area where they are being developed. According to Motran:
“3,600 truckloads of sand and water alone are needed for
each well completion, not to mention all of the other necessary equipment and
services that take place over a typical multi-week process.”
“Over the last 18 months, over a dozen sand mines have
gone into development/production to support the needs of the hydraulic
fracturing industry. These locations are primarily located on the eastern side
of the Delaware Basin and each has a 500-600 daily load capacity.”
In-basin sand began to be
mined during the oil & gas industry downturn in 2015. Despite its lower
quality, it provides significant cost savings that can make for better well
economics. About 40-50% savings can be had with in-basin sand, and if wet
processing is used, further operational cost reductions and emissions
reductions will occur.
In parts of the Permian Basin, the Hickory Sandstone Member of the Upper Cambrian Riley Formation of the Moore Hollow Group is the major source of local frac sand.
In the SCOOP/STACK basin
in South Central Oklahoma, there is also local in-basin frac sand mining of the
Ordovician Oil Creek Formation.
While I am not sure how much
frac sand today is in-basin and how much comes from the highest quality
deposits in Wisconsin, a snippet from Black Mountain Sand’s website notes:
“In 2015, 75 percent of frac sand used in domestic
production was shipped by truck or rail from mines located in the upper Midwest
– it’s often termed “Northern Sand”. For Permian producers, that meant managing
a 1,200-mile supply chain. By 2019, Northern Sand’s hold on market share is
expected to drop to 38 percent.
They also estimated that by 2022, 40% of all frac sand
mined in the U.S. would be from Permian Basin in-basin mines. In fact, it
appears that was an understatement as locally sourced frac sand is now the
overwhelming trend in the Permian Basin. According to Pipe Exchange:
“The Permian Basin Petroleum Association consulted
Charley McIntyre, director of business development and support services at Cudd
Energy Services, who cited “a significant shift in the supply.”
“The traditional suppliers of sand to the Permian Basin,
primarily a combination of Brady in Central Texas and Northern White Sand from
Wisconsin, have been largely replaced by local and regional sand mines within
the Basin,” McIntyre said. “Current estimates suggest an overwhelming
transition with 96 percent of the sand now being sourced locally or regionally
and marking a stark decline in outside Basin procurement to a mere 4 percent.
“Texas Independent Producers & Royalty Owners
President Ed Longanecker said Atlas Energy Solutions is the biggest Permian
Basin producer with the largest sand reserves.”
“The Basin is uniquely positioned with quality sand
reserves that are optimal for fracking horizontal wells, particularly in the
Winkler Sand Trend between the Midland and Delaware basins,” Longanecker said
from Austin. “These large dune deposits meet the majority of the demand of
Permian Basin operators and that supply is supplemented by smaller and thinner
localized sand deposits that are logistically positioned to service area
operators.”
The Cenozoic Monahans
Formation dune sands in the Permian Basin of West Texas and Southeast New
Mexico are now a major source of Permian Basin frac sand. A 2025 study of frac
sand turbidity compared the Monahans sands to the Northern White sands (NWS) of
Wisconsin and noted that processing out contaminants such as clays and
feldspars is important for the Monahans to improve quality for frac jobs:
“The results of this work indicate that 1) in-basin
sands yield highly variable and generally higher turbidity than mid-continent
sands, 2) both the level and mineral composition of the turbidity itself can
significantly impact the permeability and conductivity of a stimulated
resource, Finally, the differences in the physical features between regional
sands and NWS may require additional investigation of API Standard testing
methodology.”
“While the value of the in-basin Monahans Sands to the
future of Permian Basin unconventional resource development is undisputed,
oilfield operators and industrial sand producers can unlock additional value by
adapting mineral processing and treatments to the specific geology of these
deposits. Versatile, in-process, and down-hole solutions are available to
enhance the performance of fracturing fluids while addressing the inherent
variability of these sand deposits.”
Black Mountain Sand is a
major provider of Winkler Sand located between the Midland and Delaware Basins
in the Permian region.
“In 2018, Black Mountain Sand’s flagship mines opened in
Winkler County, Texas in the heart of the Permian Basin. We now produce 17MM
annual tons of frac sand and serve in 3 distinct regions: Permian Basin, Eagle
Ford Shale, and Oklahoma’s Mid-Continent.”
· Our
facilities boast the largest in-basin mining capacity at 17MM annual tons.
· Our
custom-designed throughput route averages just 2.5 minutes truck fill time with
total time gate-to-gate averaging under 10 minutes.
· We offer
40/70 and 100 Mesh sand.
With savings of $500,000 to
$800,000 per well, it is no exaggeration to say that in-basin frac sand mines
have revitalized Permian Basin economics. Some driver time logistics are shown
below.
Iron Oak’s Kermit mine in
Winkler County has been a major Permian sand source since 2017, with wet sand
processing.
“In 2022, an independent damp sand unit was built
on-site to meet the increasing customer demand for damp sand. The damp sand
product undergoes three wet screening processes prior to being stockpiled on
large drain pads. The damp sand load-out equipment includes a final screening
process on the product as it is loaded into trucks to ensure quality product is
delivered to the customer well sites.”
References:
Frac
sand crushing characteristics and morphology changes under high compressive
stress and implications for sand pack permeability. Wenbo Zheng and Dwayne
Tannant. Canadian Science Publishing. Canadian Geotechnical Journal, May 2016. 53(9):1412-1423.DOI:10.1139/cgj-2016-0045.
(PDF) Frac sand crushing
characteristics and morphology changes under high compressive stress and
implications for sand pack permeability
The messy
business of sand mining explained: A 21st century construction boom is driving
unregulated sand mining around the world - eroding rivers and coastlines,
disrupting ecosystems and hurting livelihoods. Marco Hernandez, Simon Scarr and
Katy Daigle. Reuters. February, 18, 2021. The messy business of sand mining
explained
Sand
Mines in the Permian Basin. Motran. Sand Mines in the Permian Basin –
Motran
Industrial
Sand Mining Overview. Wisconsin Department of Natural Resources. Industrial sand mining overview | |
Wisconsin DNR
Frac
Sand Mining. Sierra Club, Wisconsin Chapter. Frac Sand Mining | Sierra Club
Frac
Sand: Demand, Regulations and Innovations. Diane Samuels. SCS Engineers. December
12, 2023. Frac Sand: Demand, Regulations and
Innovations
An
Overview of Frac Sand Mining. Pontotoc Sand & Stone. An Overview of Frac Sand
Mining | Pontotoc
Frac
Sand Mining. Alyssa Schmid. June 19, 2014. PPT - Frac Sand Mining PowerPoint
Presentation, free download - ID:1986801
Wet
Sand Delivery Method Results In Significant Cost, Emissions Reductions. Kevin
Fisher and Brian Dorfman. Frac Facts. American Oil & Gas Reporter. June
2023. Wet
Sand Delivery Method Significantly Reduces Costs, Emissions
‘Wet
Sand’ Offers Multiple Benefits. Brian Dorfman and Stephen White. American Oil &
Gas Reporter. August 2021. ‘Wet
Sand’ Offers Multiple Benefits
In-Basin
Frac Sand Sweeping the Industry. Shane Le Capitaine and Carrie Carlson. FEECO
International. In-Basin
Frac Sand Sweeping the Industry
2024
frac sand supplies looking good. December 6, 2023. Pipe Exchange. 2024 frac sand
supplies looking good
In-Basin
Frac Sand Mines. Black Mountain Sand. Frac Sand Facilities of
Black Mountain Sand
In-basin
sand report: new winkler mines change frac sand landscape. Westward Global
Energy Group. March 5, 2018. In-basin
sand report: new winkler mines change frac sand landscape - Westwood
Kermit
Sand Mine. Iron Oak Energy Solutions. Kermit Mine -
Iron Oak Energy Solutions
Turbidity
in Frac Sand from Proximity Mines in the Permian Basin: Is it Detrimental to
the Fracture System? D. Anschutz; M. McGill; S. Fleming; C. Landis; T. Cage. Paper
presented at the SPE Hydraulic Fracturing Technology Conference and Exhibition,
The Woodlands, Texas, USA, February 2025. Paper Number: SPE-223580-MS. January
28, 2025. Turbidity
in Frac Sand from Proximity Mines in the Permian Basin: Is it Detrimental to
the Fracture System? | SPE Hydraulic Fracturing Technology Conference and
Exhibition | OnePetro
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