Automotive Aluminum - Analysis of Automobile Body Aluminum Sheet Project
Since the beginning of the new century, the automobile industry has been forced by the environmental regulations and global warming to reduce the quality of the car itself. At the moment, the most effective measure to reduce the car's own quality is to make spare parts with as much aluminum as possible, and the full aluminization of the body is a shortcut to do this. Since 2008, industrialized countries have set off a wave of renovation and expansion of new ABS projects. As of 2015, there are 30 projects in the world that have been built and under construction, with a total production capacity of 4,405 kt / a, of which 8 production capacity in China is At 1425 kt/a, the United States is 1810 kt/a, accounting for 41.1% of the world.
Automotive body aluminum sheet is abbreviated as ABS. It is a high-precision aluminum alloy sheet for stamping passenger car body parts. It is 0.8mm~1.8mm thick and ≤2200mm wide. It has the highest technical threshold in 4 kinds of high-precision rolled aluminum products (FRPs). The other three products are aerospace aluminum alloy plates, PS and CTP substrates, and all-aluminum cans. Automobile aluminum sheets can be divided into two categories: ABS is a special type; the other type is a general-purpose board, which means all the strips except ABS, there are thin plates and thick plates, and its performance requirements are lower than ABS.
Strict environmental regulations force the car to be lightweight
The accumulation of greenhouse gases on the earth and the human living environment are severely challenged. One of the main manufacturers of environmental degradation is the exhaust gas emitted by automobiles. In order to protect the environment, since the end of the last century, governments and some organizations have frequently made moves. The EU requires that cars sold in its member countries should reach 90g CO2/km in 2020, and the fuel consumption in 2016 should not exceed 4.5L/(100km). When driving on a city standard road, the car's own quality consumes about 84% of the fuel, and the fuel consumed by the passengers and the trunk is only about 15%. Known as the "country on the wheel", the new federal law of the United States stipulates that the fuel consumption of a car in 2016 must reach 7.6L / (100km), and in 2025 it should be reduced to 4.5L / (100km). Japan stipulates that the fuel consumption of small cars in 2015 should be ≤5.5L/(100km), and the CO2 emissions in 2015 must be 29% lower than that in 2010. At present, 85% of China's gasoline is consumed by various automobiles. 75% of the harmful gases in large cities are emitted by automobiles. The external dependence of PetroChina has exceeded 56.5% in 2011, and China faces an extremely severe resource situation.
This shows how important the role of vehicle lightweighting in energy conservation and emission reduction. The measures for lightweight vehicles are designed, processed and manufactured, but in today's conditions, the first two aspects of "oil and water" are not large, and the replacement of steel with low-density lightweight materials is the most Realistic choices are available in lightweight materials such as aluminum, magnesium, titanium, plastics, and composite materials, but it is most desirable to replace steel with aluminum for a long time to come, and to have the highest price/performance ratio.
Foreign ABS project construction is surging
The rebuilding, expansion and new construction of this round of ABS projects around the world is expected to be basically completed in 2018, with a total production capacity of about 4,400 kt / a, which can meet the needs of the automobile manufacturing industry before 2030. Among them, the United States has the largest production capacity, 8 production enterprises of 1810kt/a; followed by Germany, 410kt/a, 4 production enterprises; Japan third, 200kt/a, 4 production enterprises; the other 6 total production capacity is 560kt /a, respectively: South Korea 120kt/a, Saudi Arabia 120kt/a, Switzerland 80kt/a, France 120kt/a, Belgium 80kt/a, Austria 60kt/a.
In 2011, Alcoa invested $300 million to expand the ABS line at Davenport Works in Iowa. It was completed in December 2013 with a production capacity of 200 kt/a.
At the beginning of 2013, Alcoa invested 275 million US dollars to renovate the ABS production line of the Tennessee rolling mill in Alcoa Town, Tennessee, and converted the original production line of production tanks into ABS strip production line. Completed, production capacity of 150kt / a.
Oswego Works, located in New York State (NY), is a Nobelis Aluminium company that rebuilds the original ABS line of the plant to a capacity of 240kt/a and has two production lines. The production capacity of the strip is 120kt/a, which was put into operation in August 2013. The original leading product of the plant is the can body material.
The Lewisport Rolling Mill is located in Kentucky and is a Novelis Aluminum Company. In 2014, the company decided to invest 350 million yuan to build two wide-width ABS continuous annealing production lines, one new wide-width cold rolling mill and one R&D center with a total production capacity of 220kt/a. It will be put into operation in February 2017 and is globally available. The only company that produces a wide 2300mm ABS.
The United States is building the world's largest ABS plant. American Specialty Alloys plans to build the world's largest automotive aluminum strip plant in the southeastern United States with a total investment of $12 billion and an automotive grade aluminum sheet production capacity of 600 kt/a, which is unprecedented. Construction in phases, the first phase is completed at the end of 2016, and full production will be carried out in June 2017. The biggest attraction of the plant is that it is not only the largest in the world, but also produced by small mills.
Kenlian Aluminium Co., Ltd. is a company specializing in the production of high-precision aluminum strips based in Paris, France. It is a transnational company transformed from the century-old aluminum giants Puji Aluminum (France), Swiss Aluminum and Canadian Aluminum. The industry leader was established by Apollo Global Management, Rio Tinto Mining Group and French Strategic Investment Fund. In November 2014, Kental Aluminium reached an agreement to acquire the Muscle Shoals strip rolling mill in Alabama (AL). After the completion of the acquisition, the plant will be rebuilt and expanded by investing US$750 million by 2022 to increase the production capacity of the hot rolling line from the current 450kt/a to 700kt/a and produce 200kt/a ABS.
Toyota Motor Corporation of Japan and Kobe Steel decided to build an ABS production plant in the southeastern United States with a production capacity of 100 kt/a for the Toyota Camel brand, which is selling well in the United States. The project will be completed in the fall of 2017 and will begin full production in early 2018.
UACJ, in cooperation with Kental Aluminium, invested US$150 million to build an ABS plant in Bowling Green, Kentucky, USA, with a production capacity of 100 kt/a, December 2015, Vol. Strips are off the assembly line. The plant has no production capacity for casting, hot rolling and cold rolling, and cold rolled coils are supplied by other flat rolling products.
Germany is the starting country for the ABS reform and expansion work. The first work was carried out by Novelis Aluminium Company, and then the relevant enterprises in Belgium, Austria, France, Switzerland, etc. have carried out corresponding work, and It has ended in 2012. As of the end of 2014, four companies in Germany can produce ABS with a total production capacity of 410 kt/a.
Natched Aluminium is a Novelis Aluminium company based in Natched, Germany. Production began in 1997 with ABS. After expansion in 2009, the production capacity reached 120 kt/a. The plant has two major features: cold rolled strip blanks are supplied by Alunoff Aluminium Co., Ltd.; in 2002, laser cutting lines were put into production, with 4 cutting machines, and annual production capacity of 1 million pieces can be directly punched into automotive sheet metal parts. The precise size of the blanks optimizes material logistics and reduces the cost of turnover and transportation process waste.
Greven Broy Aluminium Company is a Hydro Aluminium Company, located in Grevenbroy, Germany. It has two ABS production lines: AL1 and AL2. It was put into operation in 2003 and has a total production capacity of 200 kt/a after re-expansion. The AL2 line is dedicated to the production of 6xxx series ABS with high surface quality.
The G?ttingen rolling mill is a Nobelis aluminium company and is expanding its ABS production line, which will be completed in autumn 2015 with a production capacity of 40 kt/a.
The Singen rolling mill in Germany is located in the city of Xingen, Germany. It belongs to the automotive division of Kenlian Aluminium Co., Ltd., with an ABS production capacity of 50 kt/a.
The Austrian non-ferrous metal processing plant is the only aluminium and copper rolling mill in the country, located in Ranshofen. The production of body panels began in 2006 with a modern air-cushion furnace and finishing line with an ABS production capacity of 60 kt/a.
Aleris's Dufir Aluminum Strip Co., Ltd. in Belgium has added a wide-width aluminum strip cold rolling mill (2400mm grade) to meet the automotive company's demand for wide-width aluminum sheets. After this round of expansion, Duffel Aluminium Strip Co., Ltd. can produce the widest ABS in Europe, and its production capacity has also increased significantly. This cold rolling mill was commissioned in the first half of 2013. The company's ABS production capacity is 80kt/a and the maximum width is 2300mm.
The Swiss Schell rolling mill is now a Novelis Aluminium Company. It started to produce ABS in 2000 and has been expanded and expanded to produce 80kt/a.
Newbridges Aluminum Company of France is a United States Kenlian Aluminum Company. It started to produce ABS in the mid-1990s. In 2004, it invested 20 million Euros to rebuild and expand the production line to make its ABS production capacity reach 100kt/a. Different sheet metal parts are made of original five kinds of aluminum alloys: ForalexTM alloy, StrongalexTM alloy, SecureexTM alloy, SurfaxexTM alloy, UltralexTM alloy.
Ma'aden Alcoa is the English abbreviation for Saudi Arabian Mining Company. Saudi Aramco is the most complete modern large-scale comprehensive aluminum enterprise in the past 40 years. It is located in the port town of Alhar, in the eastern part of Saudi Arabia. It will be the world's lowest production cost. A variety of aluminum ingots and aluminum suppliers. In the original design, there was no ABS project. Due to the promising market prospect of ABS, in 2013, it was decided to build an ABS production line with a capacity of 120 kt/a. The company's Alcoa company holds 30% of the shares, but it is responsible for the construction and management of the post-production.
Novelis-Dahan Aluminum Co., Ltd. is located in Seoul, South Korea. The factory is located in Ulsan and Rongzhou. In 2010, the production capacity of flat rolling products was 600kt/a. After extensive renovation and expansion, the production capacity reached 1000kt/a in 2014, among which ABS With a production capacity of 120kt/a, both of them have become the largest single aluminum companies in Asia.
As of 2013, the production capacity of ABS in Japan is estimated to be 200 kt, which is distributed at the Kobe Steel Rolling Plant of Kobe Steel, the Fukui Rolling Mill of Japan Aluminium Company, the Osaka Rolling Plant, and the Nagoya Rolling Mill of Sumitomo Light Metals. The output of the Maoka rolling mill accounts for about 50% of Japan's total production. The developed 5xxx series and 6xxx series ABS alloys have been formed into series. For example, KS5J30 alloy and KS5H32 alloy have been widely used in the Japanese automobile manufacturing industry.
By 2015, the ABS production capacity that has been put into production and under construction abroad is nearly 3,000 kt/a, with the largest in the United States, accounting for 60% of the total capacity, followed by Germany, accounting for 13.8% of the total, and the other seven countries accounting for 26.2%. There are 9 foreign countries that can produce ABS in batches.
Novelis Aluminium is the world's largest producer of flat rolled aluminum products and the largest high-end ABS producer. It has 7 plants in 5 countries (including one in China) with a total production capacity of 940 kt/a. It accounts for 21.3% of the world's total production capacity.
The construction of domestic ABS projects is catching up
As of 2015, China has completed 2 ABS projects and 6 projects under construction, with a total production capacity of 1425 kt/a, accounting for 32.35% of the world's total production capacity of 4405 kt, including 3 wholly foreign-owned enterprises with a total production capacity of 320 kt/a. It accounts for 22.5% of the total domestic production capacity.
On December 21, 2009, there were media reports that the ABS of Southwest Aluminum (Group) Co., Ltd. was successfully launched, opening the first batch of ABS in China. The company has two air-cushion furnace production lines, one was introduced from the United States in the mid-1980s, and the other one was made in China. However, public reports on the mass supply of ABS to major automobile manufacturing companies in Germany, Japan, the United States and South Korea have not yet been seen. . The estimated production capacity is approximately 35 kt/a.
Novelis (China) Aluminum Products Co., Ltd. is located in the National High-tech Development Zone of Changzhou City, Jiangsu Province, covering an area of 4.32 million m2, with an investment of 100 million US dollars and an ABS production capacity of 120 kt/a. It was completed and put into operation on October 21, 2014. The company is only the downstream process of ABS, and the blanks are shipped from Korea. The second phase and the upstream rolling and casting project will be built depending on the market conditions. The company is a wholly-owned company of Novelis Aluminium, and in 2015 it can supply ABS in bulk to the automotive industry.
Kobelco Automotive Aluminum (Tianjin) Co., Ltd. under construction is located in Tianjin Xiqing Economic and Technological Development Zone. It is a wholly-owned enterprise of Kobe Iron and Steel Co., Ltd. with a registered capital of 475 million yuan. The billet is shipped from the Moka rolling mill in Japan. The total investment is 1.15 billion yuan, the ABS production capacity is 100kt/a, and it will be put into operation in the first half of 2016, with 140 employees at full capacity.
Nanshan Aluminum is constructing a 200kt/a high-precision aluminum strip project in phases, with a total investment of 8 billion yuan. The first phase has a 1 (5600mm) +1 (4100mm) + 5 (3000mm) hot rolling line, 2800mm CVC 6Plus stand-alone One non-reversible cold rolling mill and other complete finishing equipment. Product structure: thick plate 80kt/a, thin plate with 120kt/a. The ABS project is divided into three phases: one phase is 120 kt/a, the second phase is 180 kt/a, and the third phase is 300 kt/a. The result is 600 kt / a, becoming the largest producer in Asia, and the United States special alloy company, but the second and third phases can only be considered as the proposed project.
Tianjin Zhongwang Aluminum Industry Co., Ltd. is located in the Auto Parts Industrial Park of Wuqing District, Tianjin, covering an area of 5.5 million m2, with a total investment of 44.6 billion yuan. The total production capacity of plates, belts and foils is 3000 kt/a, starting from the second half of 2015. It has been put into production successively and completed in 2018. The production capacity of ABS is 300kt/a. This is an unprecedented large-scale project in the history of the world aluminum industry, with a total of 10,000 employees.
Tongren Aluminum Industry Co., Ltd. is located in Sanmenxia City, Henan Province. It is a subsidiary of Yimei Coal Group. Now it has built a 1 (4500mm) +1 (3300mm) hot rough-finishing production line.