If we do not control, 10 to 15 years later, China's largest free forging problem of excess production capacity will gradually appear. According to incomplete statistics, China's existing 8 ~ 185MN forging free liquid (water, oil) in the press more than 500, of which a large hydraulic press 60 ~ 80MN about 10, 120 ~ 185MN for 7. According to rough statistics, at present, China's annual output of large forgings of about 1.4 million tons, while production capacity hydraulic press at 400 million tons.
I am facing a shortage of large forgings and excess production of contradictions
Freedom of our country to produce large forgings for more than 50 years of history, free forging hydraulic press is currently the number, class, large forgings production ranked first in the world, but we have to admit, although we have entered the production of large forgings the ranks of major powers, but it is far from production power, because some of the important high-quality requirements still need to import large forgings. Now the production of large forgings in a "surplus" and "shortage" of the dual pressures of the general oversupply of large forgings, technical content and quality of large forgings demanding, such as level one million kilowatts of thermal power and nuclear power by steam turbine rotor (supercritical , ultra-supercritical), large roller bearings, high temperature and pressure of large thick-walled cylinder, high-powered low-speed marine diesel engine crankshaft, such as combination of forging, we are still in production capacity or can not produce a low state.
10,000 tons of domestic need free forging hydraulic press forging production users are mainly power plants, petrochemical, metallurgy and shipbuilding. Power requirements for large forgings, such as stand-alone for more than 600MW of thermal power, nuclear power by steam turbine rotor, spindle generators, stand-alone for more than 600MW nuclear power station nuclear reactor pressure vessel with evaporator and regulators, more than stand-alone station 500MW turbine shaft, generator axis, a mirror plate, etc.; petro-chemical equipment is large forgings>hydrogenation reactor 4500mm high temperature and high pressure, such as thick-walled cylinder tower, sealed top; mainly metallurgical equipment> Forging1600mm roller bearing, large-diameter work rolls of hot-rolled; > 200,000 dwt ship shafting, rudder stock and high-powered combination of low-speed diesel engine crankshaft; large forging equipment column, column-chip, such as the work cylinder.
I use 10,000 tons of free forging hydraulic press forging production of the major sectors of the demand for large forgings made the following estimates:
Power generation equipment: According to National Energy Board said that the original construction plans of nuclear power by 2020 total installed capacity of 40 million kilowatts, it is adjusted to 100 million kilowatts (completion of 60 million kilowatts, 38 million kilowatts in the building), which deducted before 2008 built, under construction in 8.7 million kilowatts, in the subsequent 12 years to the capacity of one million kilowatts of new stand-alone level 90 PWR nuclear power plant, an annual average of 8 per one million kilowatts of nuclear power generating units to be about 3,000 large forgings tons, the annual total of about 30,000 tons; thermal power, the installed capacity by 2020 will reach 1.5 billion kilowatts, in the subsequent 12 years to increase the capacity of a single 600,000-one million kilowatts of about 350 units (one single 600,000 kilowatts or about 70%), according to Kazakh electricity, power, the East is expected to electricity production capacity of the three groups, each of about 30,000 tons heavy forgings; to hydropower installed capacity in 2020 to reach 300 million kilowatts, in the future 12 years in stand-alone capacity to add more than 500,000 kilowatts of hydropower generating unit 400, the average annual production of 34 units, in large forgings to be 30,000 tons.
Metallurgical equipment: large forgings required for the major is new mill, accessories and consumables roll, roll, now take a variety of about 40 million tons.Xing tai za guncompany's overall technical, add 80MN free forging hydraulic press, an annual output of various roll 150,000 tons (including steel roller about 50,000 tons). At present, a large roller bearing forging, hot rolling work rolls, mainly in a heavy, double production, annual production of about 20,000 tons, according to an annual output of 500 million tons of steel a year to be serious about forging roller bearing 50,000 tons, when 4 million tons of new hydraulic press put into operation, lack of large-scale forging roller bearings will gradually solve the problem.
Petro-chemical equipment: mainly used for large forgings required for oil refining and chemical hydrogenation reactor, such as high temperature and high pressure tower's thick-walled cylinder, head, once the success of coal liquefaction technology, the required reactor cylinder will be more expected a variety of thick-walled cylinder to be about 50,000 tons.
Shipbuilding: a large ocean-going vessels of large forgings is shafting, rudder stock, low-speed high-powered combination of crankshaft, by 2020 the demand for large new ships about 10 million dwt a year, in large forgings required 150,000 tons, of which about 30% 10,000 tons of forging hydraulic press, about 50,000 tons.
Others: such as the heavy forging equipment, mining equipment and other heavy forgings needed in 50,000 tons.
Limited market for high technology companies need to be cautious in
It is understood that domestic original 3 million tons of free forging hydraulic press control system due to structural and backward, can not be a large cylinder forging forgings, forgings to meet certain production, a heavy, double, on the heavy focus on multi-year master in Luoyang of smelting, forging production experience, and supporting facilities in the original basis of the appropriate expansion of the structure of the installation of a new, modern control system 150MN, 160MN, 165MN, 185MN (still manufactured) free forging hydraulic press is appropriate, the 10,000 tons of hydraulic machines production will gradually reduce the import of large forgings, and is expected to export.
Is put into operation the new and upcoming production of 150MN, 160MN, 165MN, 185MN4 Taiwan should be free forging hydraulic press forging with full hydraulic operation of the new machine, can increase its productivity more than 80% per million tons of hydraulic pressure of about 10,000 tons per month forgings. The original 3 120MN forging hydraulic press large annual capacity of about 120,000 ~ 150,000 tons, add 4 million tons of annual production capacity of large forging hydraulic press in more than 400,000 tons.
By the author of the users above estimates, the domestic market to be large in the free forging of about 300,000 ~ 350,000 tons, accounting for the existing 7 million tons of old and new free forging hydraulic press capacity of 60%. Now there are a number of heavy machinery and other businesses on the 10,000 tons of new free forging hydraulic press about 8 units, worth considering.
It is a large freedom in recent years due to tight supply forgings, good sales, so that some enterprises have to invest in new, expanding million tons of free forging hydraulic press forging production, was also supported by some local governments, forming the current disorderly blind, mutual comparison all new large-scale free forging hydraulic press situation.
Also know that some companies need more than 80MN hydraulic press forging market production is limited, because some of the important large forgings domestic product less than or not the production, investment now would like to seize this market, it is necessary to the production of large forgings pacing about the success of the on hold failure on the left. This line of thinking is no good, with bank loans of billions of dollars at stake, after the closure of many companies are doubtful, and ultimately by the loss to the countries and peoples.
Currently has more than 60MN free forging hydraulic press of the private enterprises are non-smelting capacity, the required ingot in the community-wide procurement. More than 50 tons of steel ingots are cold, not only affects the quality of forgings, also increased energy consumption and cost. 10,000 tons in the production of hydraulic forging machine, most are single ingot more than 100 tons, if not hot ingots, forgings can not guarantee the quality of fuel and loss, and increased production costs. If more than one hundred tons of steel ingot from the smelter to the use of heavy users, such as whether to allow the traffic; if they cast ingot smelter built on the need for large electric furnace, ladle refining furnace, vacuum chamber, such as ingot Note, not only investment in large, extra liquid steel how to solve local pollution of the environment whether to allow construction of the smelter, which must take full account of practical problems.
The difficulty of smelting technology more difficult than forging process, because large-scale depends on the quality of the free forging ingot, it is necessary to improve the overall performance of large forgings, the ingredients must be reduced ingot segregation, non-metallic inclusions to change shape, so that harmful gases in steel elements and harmful content the minimum in order to guarantee the quality of large forgings. Now new 4 million tons of free forging hydraulic press structure, parameters and control system is not the skill level difference than abroad, but also the configuration of the level of smelting equipment (ladle refining, vacuum injection ingot) with foreign considerable. However, with a variety of continuously improve the performance of complete sets of equipment for forging a comprehensive indicator of quality have been increased. If in order to reduce carbon dioxide emissions and improve power generation efficiency, the use of ultra-supercritical turbine generator, steam pressure 316kg/cm2, temperature 593 ℃, high temperature steam turbine rotor is necessary to creep fatigue and fracture performance of the new higher steel species; now to steam temperature to 621 ℃, but also to develop new kinds of steel. Forgings for pressure vessels of nuclear power on the higher requirements, in order to minimize the pressure vessel by neutron radiation, so that the container material to reduce toughness and ductility and embrittlement phenomena occur, smelting must be strictly controlled the content of harmful elements, so that the container the volume of material to minimize embrittlement.
Used by the oil refinery hydrocracking reaction pressure vessel forgings, long-term high temperature and high pressure conditions, the requirements of steel with high tensile strength, fracture toughness and resistance to hydrogen corrosion of these materials is not easy to complete the general smelter. Therefore, the new emerging types of steel, an increase of the difficulty of smelting. Refining our level is not high, it is imperative to improve smelting technology as soon as possible, if not high-quality liquid steel smelting, ingot casting not qualified, that is, to a several 300MN forging hydraulic press freedom still can not pass the production of large forgings.
The production of large forgings is a high-tech, high input, high consumption and high pollution industries, together with supporting the project land area, the state should be carried out quickly pipe up macro-control, can no longer allow such reckless expansion of new and disorderly. Production forgings enterprises should focus on species, there must be division of labor, to the direction of specialization, it is necessary to form their own production conditions in accordance with the characteristics of products in order to better development of domestic and foreign markets.
