Shale gas Still a boon to US manufacturing?
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Shale gas Still a boon to US manufacturing? December 2014 With contribution from National Association of Manufacturers and The American Chemistry Council At a glance US shale gas development is maturing swiftly. Its momentous growth is not only changing the country’s energy mix, and affecting energy markets globally. It’s also giving US manufacturing a boost through significant cost savings and jobs creation, according to a PwC analysis.
Introduction Shale gas activity in the US has taken root in the last several years, and its effects on the country’s energy mix and energy independence have progressed beyond prognostication and shaped new realities. The ‘shale effect’ on manufacturing, too, is taking shape—making the US a more attractive locale due to relatively low energy and feedstock costs. This report takes a look at what shale gas has meant for US manufacturing and what may lie on the horizon. The surge in shale gas production and So, what does this all mean for Shale gas revisited consumption in the US has proven a US manufacturing? According to genuine game changer on a number a new analysis by PwC, shale gas of fronts including: strengthening US development could have the following energy security and independence, impacts on US manufacturing overall: and helping trigger a resurgence in • Annual cost savings of $22.3 billion US manufacturing. in 2030 and $34.1 billion in 2040. Indeed, natural gas has altered • 930,000 shale gas-driven the energy landscape in ways few manufacturing jobs created by would have foreseen just five years 2030 and 1.41 million by 2040. ago. Consider just a few milestones reached in large part due to domestic The most likely beneficiaries in a shale gas and oil activity. The US scenario of continued low natural overtook Russia as the world’s largest gas prices and high yields include natural gas producer in 20101, and energy-intensive manufacturing is projected to surpass Saudi Arabia sectors such as metals, as well as those and Russia as the global leader in oil sectors—most notably chemicals production by 2015, according to the and petrochemicals—which use International Energy Agency(IEA).2 natural gas as a feedstock. This Meanwhile, 84% of the country’s report highlights major developments energy demand was met through in the US shale gas industry and domestically produced energy in 2013, analyzes potential impacts on the US up from 69% in 2005,3 as natural gas manufacturing sector. prices in the US fell some 75% over the same period. The US now eyes real prospects of becoming a significant exporter of liquefied natural gas. 1 International Energy Agency statistical database, retrieved on September 22, http://www.iea.org/ statistics/statisticssearch/report/?country=USA&product=naturalgas&year=2010. 2 “U.S. to Be Top Oil Producer by 2015 on Shale, IEA Says”, November 12, 2013. 3 “Domestic production satisfies 84% of total U.S. energy demand in 2013”, retrieved on US Energy Information Agency. http://www.eia.gov/todayinenergy/detail.cfm?id=16511, June 2, 2014. 1 Shale gas: Still a boon in US manufacturing?
US production surges on Shale gas fueling Shale gas production has continued of total US natural gas production.4 America’s rise to rise unabated over the last several The EIA (US Energy Information years. With extraction of US (and Administration) also estimates as global energy Canadian) shale-derived fossil fuels that shale gas represents 32% of all powerhouse being carried out quickly and in high technically recoverable wet natural volume, shale gas persists to change gas in the US.5 Since 2007, shale gas the face of North American energy production and proven reserves have mix. Shale resources comprise 29% of risen steadily (see charts). total US crude oil production and 40% Figure 1: US shale gas proved reserves and production, 2007-2012 What is shale gas (Billion Cubic Feet) and fracking? 131,616 10,371 129,396 Hydraulic fracturing (fracking) is a technology for extracting trapped natural gas or oil through the 97,449 7,994 fracturing of shale rock formations to increase the flow of the natural 5,336 gas or oil, thereby enabling greater 60,644 amounts to be recovered. The 3,110 wells are either drilled vertically 34,428 23,304 2,116 or horizontally and can be done 1,293 to depths of thousands of feet. Fractures are produced by injecting 2007 2008 2009 2010 2011 2012 2007 2008 2009 2010 2011 2012 fluids (containing water, proppant such as sand or ceramic pellets, and Proved Reserves Production chemicals) at high pressure into shale fractures, which are enlarged, Source: “US Crude Oil and Natural Gas Proved Reserves, 2012” EIA, April 2014. http://www.eia.gov/dnav/ng/hist/res_epg0_r5301_nus_bcfa.htm then kept open by the proppant. After the natural gas is extracted to the surface, a ‘fracking’ fluid (or so-called ‘flowback’ or ‘produced Figure 2: Staying low: US natural gas prices 2004-2014 water’, a cocktail of water, sand and Industrial prices at July of each year, (US Dollars per Thousand Cubic Feet) the injected chemicals) then rises to 16 the surface through the wellbore, and is either treated or disposed of. 12 Hydraulic fracturing requires much more water for deeper wells than 8 conventional natural gas drilling. 4 0 2007 2008 2009 2010 2011 2012 2013 2014 Source: US Energy Information Administration database, http://www.eia.gov/dnav/ng/ng_pri_sum_dcu_nus_m.htm 4 Shale oil and shale gas resources are globally abundant, January 2, 2014, EIA website, http://www.eia.gov/todayinenergy/detail.cfm?id=14431. 5 “Technically recoverable shale oil and shale gas resources: an assessment of 137 shale formations in 41 countries outside the United States,” EIA, June 2013. 2
Eyes now cast toward …and on exporting shale Energy infrastructure exporting LNG… gas know-how build-out also likely to Prospects of the US growing into a A number of countries have begun to benefit manufacturers significant exporter of LNG (liquefied examine the production potential of In addition to the shale-linked natural gas) have grown, with a shale formations in their countries. benefits to manufacturers discussed rising pool of companies applying for Poland, for example, has leased out thus far, manufacturers could also permits to export. The Department of shale lands and has drilled 43 test benefit from the considerable volume Energy, Office of Fossils Energy, had shale gas wells as of 2013. Argentina, of infrastructure (e.g., machinery, received 44 applications to export Australia, China, England, Mexico, turbines, pipes) required to meet domestically produced LNG from the Russia, Saudi Arabia, and Turkey natural gas demand—not only in lower 48 states as of October 21, 2014.6 have also explored the potential in the US, but also in other countries— As of October 2014, FERC (Federal their shale formations.9 With rising to ramp up their own natural Energy Regulatory Commission) had global interest in exploiting this gas development. Manufacturers approved four LNG export projects resource, exporting hydraulic drilling supplying products needed for the with 14 additional LNG export projects know-how, technology, and hardware continued build-up of infrastructure proposed to FERC.7 could present significant opportunities required for the extraction and for US energy and oil and gas services distribution of shale gas (not to The timing for US exporters could companies and manufacturers that mention the infrastructure needed likely be very good. Consider that supply them. for exporting LNG in high volume) 32% of China’s natural gas consumed will likely be chief beneficiaries of in 2013 was imported, up from 2% Take China’s push to build a domestic the shale gas boom. Just consider, for in 2006, according to the EIA. The shale gas industry. While its natural example, that in 2013 alone, North country, which is keen on increasing gas production has tripled since 2003, America constructed (or planned its use of natural gas, presently has its foray into shale gas has fallen short for construction of) 41,810 miles 10 regasification terminals. In 2012, of expectations, despite having the of pipeline.12 it was the third-largest natural gas world’s highest technically recoverable importer behind Japan and South shale gas reserves.10 In 2013, China Korea. In 2013, it imported 870 billion became the world’s third-biggest cubic feet (Bcf) of LNG, with 2014 natural gas consumer, following the imports forecast to be even stronger.8 US and Russia, and the International Energy Agency predicts China’s consumption will nearly double by 2019. Due to difficult geology and high extraction costs, however, the country recently nearly halved its 2020 target for domestically developed shale gas.11 6 “Summary of LNG Export Applications” US Department of Energy Fossil Energy Office, website retrieved on November 7, 2014, http://energy.gov/fe/downloads/summary-lng-export-applications-lower-48-states. 7 FERC Authorizes Construction of Cove Point Export Project,” Docket No. CP13-113-000, FERC website, September 29, 2014; http://www.ferc.gov/industries/gas/indus-act/lng/lng-export-proposed.pdf. 8 “Natural gas serves a small, but growing portion of China’s total energy demand,” US Energy Information Administration, August 18, 2014. 9 Shale oil and shale gas resources are globally abundant, January 2, 2014, EIA website, http://www.eia. gov/todayinenergy/detail.cfm?id=14431. 10 “Natural gas serves a small, but growing, portion of China’s total energy demand,” EIA, August 18, 2014. 11 Orcutt, Mike, “China’s Shale Gas Bust,” August 12, 2014. 12 Rita Tubb, “Pipeline & Gas Journal’s 2013 Worldwide Construction Report,” Pipeline & Gas Journal, January 2013, Vol. 240 No. 1. 3 Shale gas: Still a boon in US manufacturing?
Our analysis for this report looked at We estimated, based on our model, Continued low shale how low natural gas prices (largely annual cost savings of $22.3 billion due to increased shale gas resources) in 2030 and $34.1 billion in 2040, gas prices could save could translate into cost savings for assuming a high natural gas recovery US manufacturers US manufacturers through benefits of and low-price scenario were to persist13 over $22 billion using natural gas as an energy source (see chart). Cost savings benefits could and as feedstock for manufacturing potentially be higher if the elasticity of by 2030 (with chemicals industry). While demand is included. These potential manufacturers could also naturally savings are up markedly from a similar benefit from the incremental demand analysis carried out by PwC in 2011, for products needed to extract natural which estimated that manufacturers gas, this benefit was not included in could save up to $11.6 billion annually our analysis. by 2025 and $11.2 billion by 2035 in a high-recovery, low-price scenario.14 In the low shale recovery case (i.e., Figure 3: Natural gas/US manufacturing cost sensitivity analysis 50% less gas is recovered from each Total US manufacturers estimated annual natural gas expenses under high and low shale formation vs. the reference shale gas recovery/price scenarios ($ billion) case), natural gas costs for the $70 manufacturing sector could increase 91% to $46.7 billion, in 2030, and by 60.28 130% to $60.3 billion, in 2040. $60 $34.06 bil. est. annual savings $50 46.66 $22.33 bil. est. $40 annual savings $30 26.22 24.33 $20 15.74 $10 $2.75*/mil $4.25*/mil $8.15*/mil $4.58*/mil $10.53*/mil Btu Btu Btu Btu Btu $0 2012 2030 2040 High recovery/low price Low recovery/high price *Avg. wellhead price Source: EIA, PwC Analysis 13 Note: To arrive at these estimates, we used the annual volume of natural gas consumed by manufacturers from the most recent Manufacturing Energy Consumption Survey (MECS) and estimates of future wellhead gas prices under reference, low and high shale gas recovery scenarios. The most recent MECS indicates that US manufacturers used 5,725 trillion Btu of natural gas (not including natural gas liquids, or NGLs) during 2010 for all purposes. 14 “Shale gas: A renaissance in US manufacturing?” PwC, 2011. 4
We also looked at how shale gas was In particular, we looked at two ways in Shale gas spurring impacting manufacturers through which companies describe such a shale the lens of public disclosures by gas impact: 1) as a source for growth US manufacturing executives in a survey of SEC filings for in demand for their products, and 2) as growth US chemicals, metals, and industrial a feedstock and/or energy benefit. Our manufacturers. Our survey found analysis showed that, over the period a continued rise in the number surveyed, roughly half attributed the of companies commenting to the potential impact of shale gas activity investment community about the on their business as a source of potential for shale gas activity to affect downstream demand, and about half their business. In 2013, we found noted the feedstock/energy benefit that 40 US manufacturing companies (see chart). included shale gas impacts in their public filings, up from 15 in 2011 that we found in a previous PwC analysis.15 Figure 4: Manufacturers’ public disclosure of shale gas impact Number of companies disclosing shale gas impact in SEC filings (2008-2013) 45 40 35 30 21 25 20 20 20 15 10 10 19 5 11 9 2 5 0 1 1 2008 2009 2010 2011 2012 2013 Source of downstream demand Feedstock/energy cost benefit Source: Company SEC filings and PwC analysis 15 “Shale gas: A renaissance in US manufacturing?” PwC, 2011. 5 Shale gas: Still a boon in US manufacturing?
Which manufacturing Chemicals sector benefiting Power costs for US sectors stand to from affordable feedstock industrial sector forecast benefit most? Beyond recognizing the benefits of to remain stable We expect chemicals and low natural gas prices, manufacturers Industrial natural gas prices have fallen metals companies may be the are making moves to take advantage. considerably over the last decade (see greatest beneficiaries among US The American Chemistry Council, for chart). Continued low-price scenario manufacturers. Chemical companies example, reports that as of September could, as our analysis indicates, hold are benefiting from the affordable 2014, it had identified 197 chemicals important implications in cost savings feedstock and low natural gas and plastics projects (new plants, for manufacturers. Going forward, prices, which are helping drive expansions or processes) in the electricity costs for the US industrial investments in expansions and new US—tied to relatively inexpensive sector are forecast to increase annually facilities by companies in this sector. natural gas from shale formations— by an average of just 0.8% through Metals companies and industrial that are worth roughly $125 billion 2040, when 35% of electricity is manufacturers are benefiting from in potential new investment. The forecast to be generated by gas-fired the rising demand for products and Council estimates that this new power plants, up from 16% in 2000, equipment needed for the extraction, investment—of which 64 percent according to the EIA (see chart). distribution, storage, and processing is from companies based outside of natural gas. Energy-intensive the US—could potentially create manufacturing sectors, such as metals over 700,000 jobs by 2023. Most of and cement, may continue to benefit the projects identified are aimed at from relatively low energy prices. increasing production of ethylene, and ethylene derivatives.16 Figure 5: US electricity generation by fuel, 1990-2040 (trillion kilowatt hours per year) History 2012 Projections 6 5 “Thanks to the shale 35% gas production boom, Natural gas 4 the United States is the 16% 30% most attractive place 3 9% Renewables 16% in the world to invest in 12% 19% chemical and plastics Nuclear 16% 2 19% manufacturing. It’s an astonishing gain in 52% 1 Coal competitiveness.”17 37% 32% 3% 1% Oil and other liquids 1% Cal Dooley 0 ACC President and CEO 2000 2010 2020 2030 2040 Source: “AEO2014 Early Release Overview” EIA, http://www.eia.gov/forecasts/aeo/er/early_elecgen.cfm 16 “U.S. Chemical Investment Linked to Shale Gas Reaches $100 Billion,” American Chemistry Council press release, February 20, 2014. 17 Ibid. 6
According to a PwC analysis, we Marcellus basin and Gulf Coast, where Expected natural estimate that the continued shale natural gas prices tend to be lower gas activity in the US will translate because of the lower gas distribution gas effect on into new manufacturing jobs growth, costs. [Please note: The regression manufacturing jobs: contributing 930,000 shale gas-driven model used to arrive at these estimates 1.41 million by 2040 jobs by 2030 and 1.41 million by 2040. is the same used in our 2011 model, These estimates are comparable to using estimates for natural gas prices estimates we carried out in a 2011 under high and low scenarios.] study (1.31 million jobs in 2025 and We must note that these estimates 1.08 million in 2035).18 Indeed, shale- do not include possible jobs growth driven jobs growth has already taken from likely LNG exports, the potential root. A report from the US Conference development of which is still unclear. of Mayors found that energy-intensive It is interesting to note, however, that manufacturing sectors added over the American Petroleum Institute 196,000 jobs from 2010-2012 in the has estimated that LNG exports will country’s metro areas alone, with generate between 7,800 and 76,800 inexpensive natural gas being a main net jobs between 2016 and 2035, driver.19 We see pockets of higher mostly in the manufacturing sectors job growth existing in the regions of tied to refining, petrochemicals, shale gas production, particularly the and chemicals.20 Figure 6: Natural gas/US manufacturing employment sensitivity analysis Estimated change in US manufacturing employment under high and low shale recovery/price scenarios 0.93 mil. est. benefit 1.41 mil. est. benefit to employment to employment $2.75*/mil. $4.25*/mil $8.15*/mil $4.58*/mil $10.53*/mil Btu Btu Btu Btu Btu 2010 2030 2040 High recovery/low price Low recovery/high price *Avg. wellhead price Source: BLS, EIA, PwC Analysis 18 “Shale gas: A renaissance in US manufacturing?” PwC, 2011. 19 “Impact of the Manufacturing Renaissance from Energy Intensive Sources,” US Conference of Mayors, March 20, 2014. 20 “US LNG Exports: Impacts on Energy Markets and the Economy,” ICF, API, May 2013. 7 Shale gas: Still a boon in US manufacturing?
Shale gas wild cards to watch Our estimates are based in part on Insufficient natural gas 349 public natural gas filling stations forecasts of natural gas supplies refueling infrastructure in the US (291 compressed natural and production supplied by the gas and 58 liquefied natural gas), a There still exists the need for the US to IEA. However, there exist other pittance compared to the nation’s some accelerate its natural gas distribution developments and trends that signal, 120,000 gasoline filling stations.21,22 infrastructure in order for natural or potentially could result in, reduced gas prices to be competitive through benefits of shale gas development Redrawing shale gas tax the country, rather than lower prices to US manufacturers. Below are policies: have energy MLPs tending to occur in areas closest some such developments important reached their shelf life? to shale gas production (i.e., the to industry, governmental, and Mid-Atlantic, or near the Marcellus Changes in tax policy could affect public stakeholders as the shale gas formation). Indeed, as more reserves capital investments in shale gas plays phenomenon continues to unfold. are discovered and more wells and alter the investment picture. established in new regions, more In particular, a significant amount Supply exceeding demand, manufacturing regions will stand to of the capital investment in shale unrealized LNG export benefit through lower gas prices. development in the US has been potential powered by master limited partnerships It is possible that there may be periods Natural gas trucking (MLPs), corporate structures that are of over-supply, which could lead to continues to sputter not taxed as corporations and which a slowing of investment in shale gas are exempt of corporate tax on oil Additionally, the impacts of shale development and a reduction in the and gas transportation and storage gas could be amplified if natural gas downstream activity supporting infrastructure.23 were to become a more common that development (e.g., drilling transportation fuel. So far, this is equipment, processing infrastructure, Environmental issues not the case, with natural gas fueled and transport pipes). Over-supply trucks still comprising a tiny fraction The environmental effect of hydraulic could also occur if LNG exports of the country’s fleet. Part of the fracturing, the process used to create are not carried out to the degree reason for the slow development is fractures in shale rock, is still being and at the speed that is potentially the higher price for these vehicles. studied. The primary area of interest possible (as mentioned earlier in But another more basic impediment is the potential for contamination of this report). Over-supply could also to their widespread use is the lack water sources from chemicals used exacerbate the challenge of building of fueling infrastructure. Lower during fracking; several states have out infrastructure in regions that have transportation costs through the use announced moratoria on the process. yet to produce significant amounts of natural gas trucking would likely Increased transparency regarding the of natural gas (e.g., the Mid-Atlantic benefit manufacturers through lower chemicals should help allay concerns. region as it relates to the Marcellus distribution and logistics costs. But, in In addition, the Environmental shale formation). order for this to happen, there would Protection Agency is conducting a need to be a significant growth in the study on the environmental effects of number and network of natural gas hydraulic fracturing, which will likely fueling stations, not to mention new help shape future discourse on the use fleets of natural gas trucks and retro- of this technology. fitting kits. Consider that there are only 21 “Shale gas: A renaissance in US manufacturing?,” PwC, 2011. 22 “U.S. LNG Exports: Impacts on Energy Markets and the Economy,” ICF, API, May 2013 23 “Natural Gas: Tax-favored partnerships have fueled the shale gas boom—will that continue?,” E&E.com, May 29, 2013. 8
The last half-decade has ushered in However, as the industry has Conclusion a larger, and more mature shale gas continued to grow, so has the urgency industry to an extent that there is for all stakeholders—government, potential that the US industry could environmental watchdog groups, become a significant exporter of regulators, educational institutions, natural gas and the technological and private enterprises—to ensure expertise to develop in countries keen that the industry grows with on building their own domestic shale transparency and with a vigorous gas industries. pursuit toward the safety of all processes and technologies deployed. As the shale gas push in the US still Certainly, the natural gas boom has powers on, we estimate that there still already demonstrated that it can be a exists a likelihood that manufacturers bona fide driver of manufacturing in will benefit across a number of fronts, the US and can help the country curb assuming that shale gas is extracted at its carbon footprint and add jobs. But high rates and that natural gas prices these scenarios will likely play out remain relatively low. only so far as the industry can ensure We estimate 1.4 million manufacturing environmental safety, public trust, and jobs added and $34.1 billion in cost common support. savings by 2040 as a result of the For the manufacturing sectors, part benefits to manufacturing through of achieving this will be continuing relatively low energy and feedstock to improve and refine the industry— prices linked to domestic natural gas by, for example, introducing production. Investment in shale gas innovations that cut water use and development, and in manufacturing mitigate air pollution. Indeed, such sectors that benefit from that innovations are already being carried development, continues to pour in. And out. By refining and improving more companies are publicly disclosing shale gas development further, US a link between natural gas production manufacturers may place themselves as a material advantage to their in a position to be even stronger global businesses in SEC filings (40 in 2013 leaders in this technology, on top of compared to 15 in 2010). the benefits shale gas brings the sector described in this report. 9 Shale gas: Still a boon in US manufacturing?
Natural gas/US Natural gas/US Methodology manufacturing cost manufacturing sensitivity analysis employment sensitivity This sensitivity analysis uses the analysis annual volume of natural gas For this natural gas employment consumed by the manufacturing sensitivity analysis, we created a time sector, as well as EIA estimates of series regression which primarily natural gas prices in 2030 and 2040 uses natural gas prices and a binary under low and high shale recovery recession variable to predict domestic scenarios. The low shale recovery manufacturing employment. We then scenario assumes that 50% less gas is used the EIA natural gas recovery/ recovered from each shale formation, price scenario estimates described in which would lead to the higher price our natural gas/US manufacturing estimates in the pink columns in 2030 cost sensitivity analysis to find the and 2040. The high shale recovery predicted difference in manufacturing scenario assumes that 50% more gas is employment under the high recovery/ recovered from each shale formation, low price and low recovery/high price which would lead to the lower price scenarios. Our forecast is that high estimates in the red columns in 2030 shale extraction could result in almost and 2040. If we set aside elasticity of one million extra manufacturing jobs demand, then the difference in annual in the US economy by 2030 and 1.4 natural gas costs to the manufacturing million more by 2040. sector under high vs. low scenarios is over $22 billion by 2030. EIA natural gas spot prices under high and low recovery scenarios are in real (2012) dollars. All other prices are in nominal terms. 10
Robert McCutcheon A special thanks to the National Contributions to this Partner, US Industrial Products Board Member Manufacturing Institute Association of Manufacturers and The American Chemistry Council for their paper were made by and Metals Leader contributions to this report. Niloufar Molavi Partner, US Energy Leader Bobby Bono Partner, US Industrial Manufacturing Leader Michael Portnoy Manufacturing Analyst Thomas Waller US Industrial Products Director Christopher Sulavik Senior Research Fellow Robert McCutcheon Pamela Schlosser To have a deeper conversation Partner, US Industrial Products Leader Partner, US Chemicals Leader about shale gas, please contact: 412 355 2935 419 254 2546 robert.w.mccutcheon@us.pwc.com pamela.schlosser@us.pwc.com Niloufar Molavi Michael Tomera Partner, US Energy Leader Partner, US Metals Leader 713 356 6002 412 355 6095 niloufar.molavi@us.pwc.com michael.tomera@us.pwc.com Bobby Bono Partner, US Industrial Manufacturing Leader 704 350 7993 robert.b.bono@us.pwc.com www.pwc.com © 2014 PwC. All rights reserved.“PwC” and “PwC US” refer to PricewaterhouseCoopers LLP, a Delaware limited liability partnership, which is a member firm of PricewaterhouseCoopers International Limited, each member firm of which is a separate legal entity. This document is for general information purposes only, and should not be used as a substitute for consultation with professional advisors. MW-15-0386. Rr.
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