Statements we make in the following discussion that express a belief,
expectation or intention, as well as those that are not historical fact, are
forward-looking statements made in good faith that are subject to risks,
uncertainties and assumptions. These forward-looking statements are based on our
current beliefs, intentions, and expectations and are not guarantees or
indicators of future performance. Our actual results, performance or
achievements, or industry results, could differ materially from those we express
in the following discussion as a result of a variety of factors, including risks
related to our ability to obtain the
Recent Developments
Reorganization, Chapter 11 Proceedings, and Going Concern
The Debtors filed the Chapter 11 Cases under the Bankruptcy Code on
Since the commencement of the Chapter 11 Cases, each of the Debtors has
continued to operate its business as a "debtor-in-possession" under the
jurisdiction of the
The risks and uncertainties surrounding the Chapter 11 Cases, the defaults under
our Credit Agreement, the depressed condition of the oil and natural gas
industry and broader economic conditions raise substantial doubt as to our
ability to continue as a going concern. Accordingly, the audit report issued by
our independent registered public accounting firm on our financial statements as
of and for the year ended
COVID-19 Update
On
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world, including mandates for many individuals to substantially restrict daily activities and for many businesses to curtail or cease normal operations. To the extent COVID-19 continues or worsens, governments may impose additional similar restrictions.
Due to a combination of geopolitical and COVID-19 pandemic related pressures on the global supply-demand balance for crude oil and related products, commodity prices have significantly declined in recent months, and oil and gas operators, including certain of our customers, have reduced development budgets and activity. Although the full impact of the decline in commodity prices and the COVID-19 pandemic on our business are currently unknown and continue to evolve as of the date of this report, we expect that demand for our products and services will be adversely affected and we may see ongoing operational interruptions, which would adversely affect our business and financial condition. The Company will continue to work with its customers and suppliers to ensure the protection of our collective workforces when and where they interact.
Executive Level Overview
The Company conducts its business within two operating segments: 1) Oilfield and Industrial Technologies and Services and 2) Environmental Technologies and Services.
The Company's Oilfield and Industrial Technologies and Services segment manufactures and sells ceramic technology products and services and base ceramic proppant for both the oilfield and industrial sectors. The products have different technology features and product characteristics, which vary based on the application for which they are intended to be used. The various ceramic products' manufacturing processes are similar.
Oilfield ceramic technology products and base ceramic proppant are manufactured and sold to pressure pumping companies and oil and gas operators for use in the hydraulic fracturing of natural gas and oil wells. Hydraulic fracturing is the most widely used method of increasing production from oil and natural gas wells. The hydraulic fracturing process consists of pumping fluids down a natural gas or oil well at pressures sufficient to create fractures in the hydrocarbon-bearing rock formation. A granular material, called proppant, is suspended and transported in the fluid and fills the fracture, "propping" it open once high-pressure pumping stops. The proppant filled fracture creates a conductive channel through which the hydrocarbons can flow more freely from the formation to the well and then to the surface.
There are three primary types of proppant that can be utilized in the hydraulic fracturing process: sand, resin coated sand and ceramic. Sand is the least expensive proppant, resin-coated sand is more expensive and ceramic proppant is typically the most expensive. We believe the higher initial cost of ceramic proppant is justified by the fact that its use in certain well conditions typically results in an increase in the production rate of oil and natural gas, an increase in the total oil or natural gas that can be recovered from the well and, consequently, an increase in cash flow for the operators of the well. The increased production rates are primarily attributable to the higher strength and more uniform size and shape of ceramic proppant versus alternative materials. During the fourth quarter of 2019, we idled all of our sand operations, and we are currently evaluating alternatives for the sand business.
Through our wholly-owned subsidiary
FracPro provides a suite of stimulation software solutions used for designing fracture treatments and for on-site real-time analysis. Use of FracPro enables our clients to optimize stimulation jobs to enhance oil and gas production. FracPro has been integrated with third-party reservoir simulation software, furthering its reach and utility.
The
Our industrial ceramic technology products are manufactured and sold to industrial companies. These products are designed for use in various industrial technology applications, including but not limited to casting and milling.
We also produce industrial products at our manufacturing facilities for third parties under tolling arrangements. These products so far have been primarily used in industrial, or agricultural applications. We continue to develop additional opportunities within the industrial, agricultural and oil and gas industries to grow revenue, and reduce our plant's slowing and idling costs.
Our Environmental Technologies and Services segment is intended to protect operators' assets, minimize environmental risks, and lower lease operating expense ("LOE"). AGPI, the only subsidiary of ours to operate in this segment, provides spill prevention, containment and countermeasure systems for the oil and gas industry. AGPI uses proprietary technology to make products designed
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to enable its clients to extend the life of their storage assets, reduce the potential for hydrocarbon spills and provide containment of stored materials.
International revenues represented 27% and 19% of total revenues in 2019 and 2018, respectively.
Operating profit margin for our ceramic business is principally impacted by sales volume, product mix, sales price, distribution costs, manufacturing costs, including natural gas, and our production levels as a percentage of our capacity. The level of selling, general and administrative spending, as well as other operating expenses, can also impact operating profit margins.
Critical Accounting Policies
Our Consolidated Financial Statements are prepared in accordance with accounting
principles generally accepted in the
The accompanying financial statements have been prepared assuming that we will
continue as a going concern. The Debtors filed Chapter 11 Cases under the
Bankruptcy Code on
Revenue is recognized when title passes to the customer (generally upon delivery
of products) or at the time services are performed. We generate a significant
portion of our revenues and corresponding accounts receivable from sales to the
petroleum pressure pumping industry and end users. In addition, during 2019, we
generated a significant portion of our revenues and corresponding accounts
receivable from sales to one major customer, an exploration and production
company. However, as of
We value inventory using the weighted average cost method. Assessing the
ultimate realization of inventories requires judgments about future demand and
market conditions. We regularly review inventories to determine if the carrying
value of the inventory exceeds net realizable value and we record an adjustment
to reduce the carrying value to net realizable value, as necessary. Future
changes in demand and market conditions could cause us to be exposed to
additional obsolescence or slow moving inventory. If actual market conditions
are less favorable than those projected by management, lower of cost or net
realizable value adjustments may be required. During the year ended
Income taxes are provided for in accordance with ASC Topic 740, "Income Taxes". This standard takes into account the differences between financial statement treatment and tax treatment of certain transactions. Deferred tax assets ("DTAs") and liabilities ("DTLs") are recognized for the future tax consequences attributable to differences between the financial statement carrying value of existing assets and liabilities and their respective tax bases. Deferred tax assets and liabilities are measured using enacted tax rates expected to apply to taxable income in the years in which those temporary differences are expected to be recovered or settled. The effect of a change in tax rates is recognized as income or expense in the period that includes the enactment date. This calculation requires us to make certain estimates about our future operations. Changes in state, federal and foreign tax laws, as well as changes in the Company's financial condition, could affect these estimates.
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Accounting Standards Codification ("ASC") Topic 740, Income Taxes, provides the carrying value of DTAs should be reduced by the amount not expected to be realized. A company should reduce deferred tax assets by a valuation allowance if, based on the weight of all available evidence, it is no longer more likely than not that some portion or all of the deferred tax assets will be realized. The valuation allowance should be sufficient to reduce the deferred tax asset to the amount that is more likely than not to be realized. ASC 740 requires all available evidence, both positive and negative, be considered to determine whether a valuation allowance for deferred tax assets is needed in the financial statements. Additionally there can be statutory limitations and losses also assessed on the deferred tax assets should certain conditions arise.
We believe it is more likely than not that a portion of our deferred tax assets
will not be realized in the future. Accordingly, we have a
Long-lived assets, which include net property, plant and equipment, goodwill, intangibles and other long-term assets, comprise a significant amount of the Company's total assets. The Company makes judgments and estimates in conjunction with the carrying values of these assets, including amounts to be capitalized, depreciation and amortization methods and useful lives. Additionally, the carrying values of these assets are periodically reviewed for impairment or whenever events or changes in circumstances indicate that the carrying amounts may not be recoverable. An impairment loss is recorded in the period in which it is determined that the carrying amount is not recoverable. This requires the Company to make long-term forecasts of its future revenues and costs related to the assets subject to review. These forecasts require assumptions about demand for the Company's products and services, future market conditions and technological developments. Significant and unanticipated changes to these assumptions could require a provision for impairment in a future period.
Due to worsening market conditions and outlook and the loss of a key customer
during the fourth quarter of 2019, we evaluated essentially all of our
long-lived assets for possible impairment and in doing so recognized an
impairment charge totaling
In addition, the Company identified indicators of impairment relating to our
PicOnyx investment, and as a result recorded an impairment of
The Company evaluated goodwill during the fourth quarter of 2019. The Company
has been marketing for sale all or a portion of the Company to various
parties. As a result of this marketing effort and various indications of
interest, the Company estimated that the fair value of
As of
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sand that does not require the use of a distribution center, as the sand is
trucked directly to the wellsite from the mine. Further, during the third
quarter of 2019, the lease with the third party expired and was not
renewed. Given these developments and the expectation for them to continue
indefinitely, there is no business need for these distribution center assets in
the region. As we do not expect to renew the lease and efforts to locate a
buyer have not been successful, the Company concluded to abandon the assets
and has recorded an impairment of
During the fourth quarter of 2019, we evaluated the carrying value of
inventories and concluded that for certain inventory, the net realizable value
had fallen below its carrying value, and as a result, we recorded a
Low production levels triggered the component of our inventory accounting policy relating to operating at production levels below normal capacity. To determine the amount of production costs that we expense during each period, the Company allocates fixed production overheads to the costs of conversion based on the normal capacity of each production facility, generally considered to be 65% of a facility's stated capacity or higher.
When a production facility operates at normal capacity, all of its fixed production overheads are allocated to costs of conversion of each product manufactured, based on the actual level of production. This determination is made facility-by-facility on a monthly basis in order to calculate the initial measurement value to recognize as cost of goods produced in a month by a given facility.
When a facility's total production in a month drops below 65% of its normal capacity, it is considered to be operating at an abnormally low production level. In such cases, each unit of production receives an allocation of fixed overheads in the amount that would have been allocated at the lower-end of normal capacity. The remaining unallocated excess fixed overhead cost for the facility is recognized as expense in the period and classified as Cost of Sales.
Materials are the only variable component of production. Plant labor and all other overhead costs incurred in the production of the Company's products are either semi-fixed or fixed in nature, therefore all are included in the monthly evaluation of costs allocable to costs of conversion at normal capacity.
The Company maintains a rate for each production facility that represents the
maximum fixed production overhead cost per unit of production allocable to costs
of conversion. The rates are based on an analysis of a recent historical period
considered representative of a normal operating environment in which the
facility operated at normal capacity. The maximum rate is calculated by
recasting the fixed production overhead cost per unit of production on a pro
forma basis as if the facility had operated at the lower-end threshold of its
range of normal capacity, generally 65% of stated capacity. The current rates
are based on 2014 as the representative year. Implied in this method is the
assumption that 2014 production costs relative to sales prices yield a normal
profit margin. A significant, permanent deterioration in the average selling
prices of the Company's products could result in a significant lowering of the
rates, thereby increasing the periodic charge. The most recent period in which
normal capacity was achieved was the year-ended
Results of OperationsNet Loss Percent ($ in thousands) 2019 Change 2018 Net Loss$ (304,201 ) (303 )%$ (75,433 )
For the year ended
Individual components of financial results by reportable operating segment are discussed below.
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Revenues Percent ($ in thousands) 2019 Change 2018 Consolidated revenues$ 161,707 (23 )%$ 210,745
Revenues by operating segment:
Oilfield and Industrial Technologies and Services$ 135,555 (24 )%$ 178,609 Environmental Technologies and Services$ 26,152 (19 )%$ 32,136
Oilfield and Industrial Technologies and Services segment revenues of
Environmental Technologies and Services segment revenues of
Gross (Loss) Profit Percent ($ in thousands) 2019 Change 2018 Consolidated gross loss$ (33,437 ) (47 )%$ (22,689 ) Consolidated as a % of revenues (21 )% (11 )%
Gross (loss) profit by operating segment:
Oilfield and Industrial Technologies and Services$ (36,483 ) (28 )%$ (28,439 ) Oilfield and Industrial Technologies and Services % (27 )% (16 )% Environmental Technologies and Services$ 3,046 (47 )%$ 5,750 Environmental Technologies and Services % 12 % 18 %
Our cost of sales related to our Oilfield and Industrial Technologies and Services segment consists of manufacturing costs, packaging and transportation expenses associated with the delivery of our products to our customers and handling costs related to maintaining finished goods inventory and operating our remote stocking facilities. Variable manufacturing costs include raw materials, while labor, utilities and repair and maintenance supplies are semi-fixed. Fixed manufacturing costs include depreciation, property taxes on production facilities, insurance and factory overhead.
Oilfield and Industrial Technologies and Services segment gross loss for the
year ended
Environmental Technologies and Services segment gross profit for the year ended
Depreciation and amortization was
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Selling, General & Administrative (SG&A) and Other Operating Expenses
Percent ($ in thousands) 2019 Change 2018 Selling, general and administrative expenses (SG&A) (exclusive of depreciation and amortization)$ 39,181 (0 )%$ 39,227 SG&A as a % of revenues 24 % 19 % Depreciation and amortization$ 1,516 (35 )%$ 2,336 Loss on sale of Millen plant $ - (100 )%$ 2,305 Loss on sale of Russian proppant business $ - (100 )%$ 350 Other operating expense (income)$ 224,896 n/m$ (332 )
SG&A by operating segments:
Oilfield and Industrial Technologies and Services$ 36,743 1 %$ 36,491 Oilfield and Industrial Technologies and Services % 27 % 20 % Environmental Technologies and Services$ 2,438 (11 )%$ 2,736 Environmental Technologies and Services % 9 % 9 %
n/m - not meaningful
Oilfield and Industrial Technologies and Services segment SG&A was
Depreciation and amortization was
Income Tax Expense (Benefit) ($ in thousands) 2019 2018 Income Tax (Benefit) Expense$ (2,214 ) $ 892 Effective Income Tax Rate (0.7 )% 1.2 %
Income taxes are not allocated between our operating segments. Consolidated
income tax benefit was
Liquidity and Capital Resources
Overview
At
We estimate our total capital expenditures in 2020 will be less than
Chapter 11 Cases
Since the commencement of the Chapter 11 Cases, each of the Debtors has
continued to operate its business as a "debtor-in-possession" under the
jurisdiction of the
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claims against us that they hold for 100% of the equity interests in Reorganized CARBO and that our existing common stock will be cancelled.
The commencement of the Chapter 11 Cases also constituted an event of default under our Credit Agreement that accelerated our obligations thereunder. Under the Bankruptcy Code, the Supporting Lenders are stayed from taking any action against us as a result of this event of default.
Principal Sources and Uses of Capital Resources
Our principal sources of liquidity consist of (i) cash and cash equivalents; (ii) cash generated from operations; and (iii) following the filing of the Chapter 11 Cases, borrowing capacity under the DIP Facility. Our principal liquidity requirements are currently for: (i) working capital needs; (ii) debt service and (iii) professional fees associated with the Chapter 11 Cases.
Debtor-in-Possession Financing and Exit Facility
On
The Debtors' obligations under the DIP Credit Agreement are secured by first
priority priming liens on substantially all of the Debtors' assets, subject to
certain customary exclusions and carve-outs. Borrowings under the DIP Facility
will mature
Going Concern and Financial Reporting in Reorganization
As a result of our financial condition, the defaults under our Credit Agreement
and the risks and uncertainties surrounding the Chapter 11 Cases, substantial
doubt exists regarding to our ability to continue as a going concern.
Accordingly, the audit report issued by our independent registered public
accounting firm on our financial statements as of and for the year ended
Off-Balance Sheet Arrangements
We had no off-balance sheet arrangements as of
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