The total production of castings in 2017 ended with a slight increase in 2018


Release time:

2018-01-08

Since last year, a considerable number of scattered, disorderly, and poor casting enterprises have been shut down due to various factors such as environmental protection. After entering June this year, a nationwide environmental inspection has put forward higher governance requirements for many casting enterprises. Entering the heating season, many casting enterprises in certain regions need to implement staggered production, which greatly alleviates overcapacity. Especially in non staggered production areas, casting enterprises have seen a significant increase in orders. It is expected that the total production of castings in China will increase slightly in 2017 compared to 47.2 million tons in 2016.

Expected slight increase in total casting production in 2017

 

Since last year, a considerable number of scattered, disorderly, and poor casting enterprises have been shut down due to various factors such as environmental protection. After entering June this year, a nationwide environmental inspection has put forward higher governance requirements for many casting enterprises. Entering the heating season, many casting enterprises in certain regions need to implement staggered production, which greatly alleviates overcapacity. Especially in non staggered production areas, casting enterprises have seen a significant increase in orders. It is expected that the total production of castings in China will increase slightly in 2017 compared to 47.2 million tons in 2016.

From the perspective of various industries, automotive castings account for nearly one-third of China's production of various types of castings. In 2017, the growth of China's automotive industry remained the main contributor to the growth of castings, especially the explosive growth of heavy-duty trucks; At the same time, the trend of lightweight development has also laid the foundation for the strong growth momentum of non-ferrous casting enterprises such as aluminum and magnesium alloys supporting the automotive industry.

In addition, various products such as excavators and loaders in the construction machinery industry have shown a significant recovery growth trend, resulting in a significant increase in the production of castings for construction machinery; The demand for castings for machine tools has slightly increased; Centrifugal cast iron pipes account for over 16% of all types of castings in China. With the rapid development of urban construction, it is expected that the production of centrifugal cast iron pipes will increase by about 10% in 2017; Castings for agricultural machinery and ships have slightly declined.

The comprehensive competitiveness of the industry is constantly improving

The equipment manufacturing industry is the main battlefield for the adjustment of the national industrial structure. Internet plus casting will accelerate the process of China's foundry industry from big to strong. Over the past year, in order to guide the casting industry to attach importance to promoting the transformation of scientific and technological achievements, accelerate the structural adjustment, transformation and upgrading, and innovation driven development of the casting industry, promote the intelligent transformation of enterprises, and enhance the comprehensive competitiveness of the casting industry enterprise market, the China Foundry Association has done a lot of work in policy research, consulting services, scientific and technological quality, international exchanges, digital and intelligent development, group standard formulation, talent cultivation, and other aspects.

Firstly, connect with government departments and implement relevant industrial policies. By coordinating with government departments, actively organizing the revision of the "Guiding Catalogue for Independent Innovation of Major Technical Equipment", the "Special Implementation Plan for Major Technical Equipment", and the solicitation of investment directions in the casting field of the mechanical industry from "Made in China 2025 to 2018"; We have completed the research on the layout of the industry chain and the collection, analysis, and reporting of materials related to the casting industry, such as the selection of the 19th China Patent Award. Actively organize the evaluation of new technologies, materials, and equipment in the industry to encourage enterprises to develop and tackle new products. Such awards as the Material Golden Tripod Award, Equipment Innovation Award, Four New Technologies, High Quality Casting Gold Award, and New Product and New Technology Appraisal have caused a great response in the industry and stimulated the research and development enthusiasm of enterprises.

Secondly, accelerate the layout of intelligent manufacturing and promote industry transformation and upgrading. Compared with industries such as automobiles and machine tools, the overall level of automation and intelligence in the casting industry lags behind, and information technology construction is relatively weak, which brings broad development space for industry transformation and upgrading. In recent years, on the one hand, the National Development and Reform Commission and the Ministry of Industry and Information Technology have supported some intelligent manufacturing special projects in the field of casting. The construction of these projects not only provides a model demonstration for the intelligent transformation of the casting industry, but also injects new growth momentum into the industry's development. On the other hand, due to comprehensive factors such as environmental protection, safety, and rising labor costs, the replacement of machinery and personnel in the casting industry is accelerating, and some eligible enterprises have a high enthusiasm for the construction of digital workshops/intelligent factories.

In September 2017, the China Foundry Association and Ningxia Shared Group National Intelligent Casting Industry Innovation Center led the formation of the China Intelligent Casting Industry Alliance, adhering to the development concept of "professionalism, collaboration, sharing, and win-win". By coordinating intelligent casting technology and industry related resources, actively exploring intelligent solutions in different fields of casting, and creating a Chinese intelligent casting technology industry chain and innovation chain, Promote resource sharing and mutual benefit among alliance members, build an open, shared, online and offline industry service platform, build an industrial ecology of "Internet plus+entrepreneurship and innovation+green intelligent casting", and enhance the overall competitiveness of China's casting industry.

Thirdly, industry progress requires standards to be prioritized. As of now, the China Foundry Association has released a total of 40 group standards that meet market demand, of which eight standards have been selected as part of the 2017 Ministry of Industry and Information Technology's demonstration catalog for the application of 100 group standards. For example, "High purity pig iron for casting" has changed the situation of China importing a large amount of high-purity pig iron, and played an indispensable supporting role in China's independent production of high-end cast iron parts for major technical equipment. China Yizhong uses products that meet this standard to produce nuclear power pressure vessels, while Inner Mongolia Yiji produces key castings for the 99A series main battle tanks.

In addition, China Casting Association and Zoomlion Certification jointly developed and released the group standard "Quality Management System Certification Requirements for Foundry Enterprises", which is a specific embodiment of deepening the implementation of the Implementation Opinions on the Upgrade of Quality Management System Certification issued by the National Certification and Accreditation Administration, and has received widespread praise from enterprises. In view of this, the Certification and Accreditation Administration has issued a plan to develop the "Quality Management System Requirements for Foundry Enterprises in the Machinery Industry" certification industry standard to China United Certification and China Casting Association, and the group standard will soon be transformed into an industry standard.

Fourthly, the international exchange system has a clearer framework. With the BRICS Foundry Federation, the Foundry Industry Working Committee of the "the Belt and Road" Industry and Commerce Association Alliance, the Asia Foundry Forum and the Cross Strait and Hong Kong Foundry Cooperation Forum as the main line, and the international exchange system constructed with bilateral and multilateral exchanges between China and the United States, China Germany, China, Japan and South Korea, China ASEAN, and China EU as the supplement, CICA has played a full role; A number of "the Belt and Road" theme activities and two research topics have provided important industry support for relevant national departments to formulate industrial policies. The solid foundation for the internationalization development of China's casting industry has been laid.

Taking multiple measures to promote industry transformation and upgrading

However, compared with industrialized countries, China's casting industry is still large but not strong, with significant gaps in industrial structure, quality and efficiency, independent innovation capabilities, process equipment, energy resource utilization efficiency, environmental emissions, and other aspects. The task of transformation and upgrading is urgent and arduous: firstly, the problem of structural overcapacity is prominent, with a considerable amount of backward production capacity, and the consistency and stability of key casting quality are poor; Secondly, the ability for independent innovation is weak, and some high-end key castings still cannot meet the development requirements of domestic main engines and major technical equipment; The third is the high consumption of energy resources and pollutant emissions, with high input, high consumption, high emissions, low output, and low efficiency still being prominent. These issues have greatly delayed the process of China's casting industry's transformation from large to strong, and must be resolved as soon as possible.

To provide important support for the innovative development of high-end equipment manufacturing industry, the casting industry must actively respond to challenges, take multiple measures to seize development opportunities, accelerate supply side structural reform, promote the transformation and upgrading of the casting industry, and improve quality and efficiency.

One is to accelerate the transformation and upgrading of the casting industry through laws, regulations, and industrial policies. The current development level of the casting industry is uneven, with a few backbone casting enterprises with advanced process equipment and complete environmental protection equipment, as well as a large number of enterprises that adopt outdated processes, equipment, and inadequate environmental protection governance. To promote the transformation and upgrading of the casting industry, it is necessary to focus on implementing national laws, regulations, and relevant industrial policies, promoting standardized management of the casting industry, and further reducing the number of enterprises, increasing their scale, and enhancing industrial concentration by standardizing, upgrading, and eliminating a batch.

The second is innovative development, promoting the transformation of old and new driving forces, and promoting the improvement of industry quality and efficiency. The current development of the casting industry varies among enterprises, with traditional manual modeling, mechanization, and automation equipment coexisting simultaneously. We need to take advantage of the current increase in environmental protection and labor costs to promote enterprises to accelerate the implementation of machine replacement, further improve equipment automation level, improve production efficiency, and eliminate outdated processes and equipment. At the same time, we need to promote the deep implementation of the integration of industrialization and industrialization in the casting industry, accelerate the promotion and application of computer technology, manufacturing execution systems (MES), industrial robots, additive manufacturing, intelligent logistics management, CAE simulation technology, etc. in casting enterprises, achieve the replacement of robots in key positions, intelligent optimization of key processes in the casting production process, and promote the construction of digital and intelligent casting factories in advantageous enterprises, Especially, we need to vigorously promote the implementation of proven and mature solutions in different fields within the casting industry.

Casting is one of the industries where additive manufacturing technology has been applied for a long time. Different 3D printing technologies have different application ranges. The integration of these technologies with traditional casting processes can create a broader space for industrial applications and may create new casting production models in some complex product fields.

The third is to promote the green development of the casting industry. The sustainable development of the casting industry must take the path of green development. Firstly, in accordance with national environmental and safety regulations, we should accelerate the comprehensive management of environmental protection in casting enterprises. At the same time, we should implement the Industrial Green Development Plan (2016-2020), increase the application of advanced energy-saving and environmental protection technologies, processes, and equipment in the casting field, and accelerate the cultivation of green casting demonstration enterprises, Promote casting enterprises to implement the concept of green casting throughout the entire casting production process, and pursue the development path of low-carbon, recycling, and intensive green casting.

It is expected that the total production of castings will increase slightly in 2018

During the 13th Five Year Plan period, energy conservation, emission reduction, and green manufacturing have become the main themes of China's development. Various industries are focusing on this theme, and environmental governance efforts are unprecedented. Casting, as a fundamental industry for industrial development, is also a key focus of national governance in terms of energy consumption and environmental pollution. According to its own characteristics, the casting industry should achieve energy conservation and emission reduction from a macro perspective and across the entire industry, and should do the following work well:

Firstly, the formulation of pollutant emissions and clean production standards. At present, there is no specific mandatory national standard for pollution emissions in the casting industry. Except for a few regions that implement local or industry standards, strictly speaking, only the older national mandatory standards, the Comprehensive Emission Standard for Air Pollutants (GB16297-1996) and the Emission Standard for Air Pollutants from Industrial Furnaces and Kilns (GB9078-1996), have legal effect on casting enterprises nationwide. The limits of these two standards are no longer suitable for the current needs of air pollution prevention and control work, and multiple industries have introduced industry-specific standards to replace these two standards. Therefore, the development of national standards for air pollution emissions in the casting industry is particularly important. In October of this year, the China Foundry Association has formulated and promulgated the group standard "Emission Limits for Air Pollutants in the Foundry Industry (T/CFA030802-2-2017)", which is believed to be an important foundation for the development of national standards.

Secondly, the preparation of guiding technical documents for air pollution prevention and control. In addition to necessary emission standards, the prevention and control of air pollution in the casting industry also requires guidance documents on the use of environmental protection technology equipment. At present, multiple industries in China have launched the "Best Feasible Technology Guidelines" for pollution prevention and control, which clarify the specific types, effects, and economic applicability of pollution control technologies that can be used in this industry. The Ministry of Environmental Protection has planned to gradually develop better and more feasible technical guidelines for pollution prevention and control for various industries.

Thirdly, strictly implement the system of pollutant discharge permits and total amount control. The pollution discharge permit and total control system is one of the basic systems for environmental protection in China. Enterprises, institutions, and other producers and operators implementing pollution discharge permit management shall discharge pollutants in accordance with the requirements of the pollution discharge permit; Those who have not obtained a pollution discharge permit shall not discharge pollutants. According to the Implementation Plan for the Control of Pollutant Discharge Permits issued by the State Council and the Catalogue of Classified Management of Fixed Pollution Source Discharge Permits (2017 Edition) issued by the Ministry of Environmental Protection, enterprises engaged in the foundry industry are required to obtain a discharge permit and implement key management for enterprises with an annual output of over 100000 tons; At the same time, it is stipulated that the implementation of pollution discharge permit management in the casting industry will be completed before 2020. At present, the Technical Specifications for Application and Issuance of Pollutant Discharge Permits in the casting industry have been included in the 2019 work plan of the Ministry of Environmental Protection, which will greatly promote the transformation and upgrading of the casting industry.

Fourthly, accelerate industrial restructuring and eliminate outdated production capacity. Vigorously promote the access system for the casting industry, and close casting enterprises that do not meet the "Access Conditions for the Casting Industry", which are small-scale, resource damaging, highly polluting, high energy consuming, and do not have safety production conditions. In particular, the effectiveness of air pollution control will be used as a necessary evaluation indicator for market access, and a "one vote veto" system will be implemented. In addition, the structure of China's casting industry will be adjusted as soon as possible to achieve economic scale production. Through industrial adjustment, casting enterprises will develop towards specialization and large-scale development. This is also the only way for casting enterprises to achieve healthy, orderly, and sustainable development.

Looking ahead to the future, in 2018, the casting industry will still face pressure from environmental protection and safety. The "Emission Standards for Air Pollutants in the Foundry Industry" organized and compiled by the China Foundry Association, commissioned by the Ministry of Environmental Protection, will be released and implemented next year, which will provide a basis for enterprise environmental governance. With the strengthening of local government supervision in the casting industry, casting enterprises will accelerate their polarization. A group of casting enterprises with incomplete environmental protection facilities and substandard emissions will exit, while also guiding casting enterprises with environmental standards to further improve. Due to the decrease in the number of enterprises and the staggered production of environmental protection, it is expected that the domestic and international markets will recover better next year than this year. The order situation of casting enterprises in China that can produce normally will continue to increase, and the total production of castings will still increase slightly.

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