APLINDO. Asosiasi Industri Pengecoran Logam Indonesia

BULETIN APLINDO N0.41/2014, Mei - Juli 2014

APLINDO

Asosiasi Industri Pengecoran Logam Indonesia Gedung Manggala Wanabakti Blok IV Lantai 3 Ruang 303A Jl. Gatot Subroto, Senayan, Jakarta 10270 Telp. 021.573 3832 ; 571 0486; Fax : 021.572 1328

Email : [email protected] Web Site : www.aplindo.web.id

BULETIN - APLINDO No.41/2014

DAFTAR ISI

No. 1. 2.

Uraian Pengantar Redaksi Kenaikkan Tarif Dasar Listrik Kembali Naik

Halaman 2 4

3.

Peraturan Menteri Energi dan Sumber Daya Mineral No.9 tahun 2014 Tentang Tarif Tenaga Listrik Yang Disediakan Oleh Perusahaan Perseroan (Persero) PT Perusahaan Listrik Negara

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4.

Roadmap Hilirisasi Minerba

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5.

Reformulasi Roadmap Pengembangan Industri Besi Baja Berbasis Sumber daya Lokal

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7.

Reformulasi Roadmap Pengembangan Industri Aluminium Berbasis Sumber daya Lokal

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8.

Data Kendaraan Bermotor di Indonesia 1. Data kendaraan bermotor roda 4 2. Data kendaraan bermotor roda 2 (sepeda motor)

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Informasi Umum dan Pameran 1. Website pemerintah yang dapat diakses 2. Website Asosiasi Industri Pengecoran Logam Indonesia 3. Website Himpunan Ahli Pengecoran Logam Indonesia 4. Pameran dan Seminar

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Pengantar Redaksi Pada edisi 41/2014 ini, membahas Kenaikan TDL yang terus berlanjut dan telah dikukuhkan dengan Permen ESDM No.9 tahun 2014 tentang Tarif Tenaga Listrik Yang Disediakan Oleh Perusahaan Perseroan (Persero) PT Perusahaan Listrik Negara sehingga industri tidak memiliki kelonggaran waktu untuk mencicilnya walaupun Kenaikan listrik industri dinaikkan secara bertahap. Dampak kenaikkan ini bagi semua kalangan usaha menyebabkan biaya produksi industri membengkak dan akan mengganggu cash flow perusahaan yang berujung pada kenaikan harga barang atau bahkan PHK bagi sebagian karyawan sebagai konsekuensi kenaikan ongkos produksi dan tentu akan menimpa kinerja industri, menurunkan daya saing, disisi lain Indonesia akan menghadapi Masyarakat Ekonomi Asean 2015. Terkait dengan kebijakan pelarangan ekspor (hilirisasi) atau yang lebih dikenal dengan peningkatan nilai tambah dan sesuai dengan amanat Inpres no.3 tahun 2013 Tentang Percepatan Peningkatan Nilai Tambah Mineral Melalui Pengolahan Dan Pemurnian Di Dalam Negeri, maka Kementerian Perindustrian telah membuat roadmap kebijakan pengembangan industri berbasis mineral logam dan telah dilakukan sosialisasi pada tanggal 8 April 2014 dengan memprioritas 4 jenis industri yaitu industri besi baja; industri aluminium; industri nikel dan industri tembaga. Dalam edisi kini dimuat roadmap alumunium dan roadmap besi baja. Selanjutnya kami mengharapkan agar buletin ini menjadi media antar anggota maupun antar industri pengecoran didalam negeri dan diluar negeri. Harapan kami, seluruh anggota dapat mengisi buletin ini menjadi kenyataan. Redaksi buletin APLINDO menghimbau anggota APLINDO berpartisipasi dalam mengisi tulisan/artikel, data maupun informasi lain yang berhubungan dengan industri pengecoran logam. Naskah tulisan/artikel dapat dikirim ke sekretariat APLINDO, melalui email ataupun fax. Redaksi

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Kenaikkan Tarif Dasar Listrik (TDL) Kembali Naik Sebagaimana kita tahu bahwa Pemerintah baru saja melakukan kebijakan menaikan TDL yang diperkuat dengan Peraturan Menteri Energi dan Sumber Daya Mineral no.9 tahun 2014 tertanggal 1 April 2014 yang menetapkan 2 macam tariff dengan dalih ingin mencabutan subsidi sehingga ada penghematan sebesar Rp. 5 triliun. Bagi pelanggan industri (I-3) berdaya pasang diatas 200 KVA khusus untuk perusahaan berstatus terbuka ditetapkan 8,6 persen per dua bulan sekali dan untuk pelanggan industri (I-4) berdaya pasang di atas 30.000 KVA ditetapkan 13,3 persen per dua bulan sekali sebanyak empat kali dalam 2014 yaitu 1 Mei, 1 Juli, 1 September, dan 1 November 2014 dengan total pada 2014, tarif I3 tbk akan naik 38,9 persen dan I4 naik 64,7 persen. dengan dalih ingin mencabutan subsidi sehingga ada penghematan sebesar Rp. 5 triliun.

Sekarang Pemerintah melalui Kementerian Energi dan Sumber Daya Mineral (ESDM) dan Dewan Perwakilan Rakyat (DPR) kembali menaikkan tarif listrik bagi enam golongan pelanggan rumah tangga dan pelanggan industri I3 non terbuka (tbk) mulai berlaku 1 Juli 2014, dengan alasan menyama-ratakan antara I3 terbuka dan I3 bukan Terbuka dan aka nada penghematan

anggaran subsidi listrik di Anggaran Pendapatan Belanja Negara (APBN) Perubahan 2014 sebesar Rp 8,51 triliun. Berikut daftar enam golongan pelanggan yang mengalami kenaikan tarif listrik mulai 1 Juli 2014: 1. Pelanggan industri I3 non terbuka (tbk) dinaikkan secara bertahap 11,57 persen setiap dua bulan terhitung 1 Juli 2014. Perkiraan penghematan subsidi kenaikan ini sebesar Rp 4,78 triliun. 2. Pelanggan rumah tangga R3 dengan 3.500-5.500 voltampere (VA), naik bertahap 5,7 persen setiap dua bulan mulai 1 Juli 2014. Potensi penghematan subsidi dari kenaikan ini sebesar Rp 370 miliar. 3. Pelanggan pemerintah (P2) dengan daya di atas 200 kilovoltamper (kVA). Kenaikan secara bertahap setiap dua bulan sebesar 5,36 persen mulai 1 Juli 2014. Potensi penghematan subsidi dari kenaikan golongan ini sebesar Rp 100 miliar.

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4. Pelanggan rumah tangga (R1) dengan daya 2.200 VA yang kenaikan bertahap rata-rata 10,43 persen setiap dua bulan. Kenaikan mulai 1 Juli dengan perkiraan penghematan sebesar Rp 990 miliar. 5. Pelanggan penerangan jalan umum (P3) dengan kenaikan bertahap sebesar 10,69 persen setiap dua bulan mulai 1Juli 2014. Potensi penghematan subsidi dari pelanggan ini sebesar Rp 430 miliar. 6. Pelanggan rumah tangga (R1) dengan daya 1.300 VA yang kenaikan bertahap 11,36 persen setiap dua bulan mulai 1 Juli 2014. Dengan potensi penghematan subsidi dari pelanggan ini sebesar Rp 1,84 triliun. Seharusnya Pemerintah lebih memilih kenaikan BBM dengan mengurangi subsidi BBM dibanding dengan TTL, karena kenaikan BBM lebih efisien dan dampaknya tidak luas. Kenaikan TTL dapat mempengaruhi perekonomian Indonesia dan membuat menurunnya penyerapan tenaga kerja karena banyak industri yang mengalami kerugian. Industri merupakan sektor yang paling penting dalam pertumbuhan ekonomi nasional yang dapat menciptakan lapangan kerja, menghasilkan produk yang bisa diekspor, dan bayar pajak. Dengan kenaikan tarif listrik ini, tidak heran jika nantinya banyak industri yang gulung tikar atau memindahkan pabriknya ke negara lain yang biaya produksinya lebih murah. Dengan semakin sedikitrnya lapangan kerja yang dapat menyerap tenaga kerja maka daya beli akan menurun karena tidak ada penghasilan, tentunya akan berpengaruh pada barang yang diproduksi. Bagi kalangan industri kenaikkan ini akan menyebabkan naikknya biaya produksi industri dan akan mengganggu cash flow perusahaan yang berujung pada kenaikan harga barang atau bahkan PHK bagi sebagian karyawan sebagai konsekuensi kenaikan ongkos produksi, termasuk konsekwensi di masyarakat yang berpotensi melemahnya daya beli. Dampak tersebut tentu akan menimpa kinerja industri, melemahkan daya saing, disisi lain Indonesia akan menghadapi Masyarakat Ekonomi Asean 2015.

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Reformulasi Roadmap Pengembangan Industri Nikel Berbasis Sumber daya Lokal Pada edisi 40/2014 telah dibahas reformulasi pengembangan industri besi baja dan industri alumunium berbasis sumber daya lokal yang telah dilakukan oleh Kementerian Perindustrian dalam program hilirisasi industri berbasis migas dan bahan tambang mineral serta peningkatan daya saing industri berbasis sumber daya mineral (SDM) sebagai amanat dari Intruksi Presiden Instruksi Presiden Republik Indonesia Nomor 3 Tahun 2013 Tentang Percepatan Peningkatan Nilai Tambah Mineral Melalui Pengolahan Dan Pemurnian Di Dalam Negeri. Produksi Nikel Ore Indonesia 

Total produksi bijih nikel (Ore) Indonesia pada tahun 2012 adalah sebesar 41 Juta ton, atau setara dengan 320.000 ton Niikel yang terkandung didalam bijih nikel (Ni Metal).

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Indonesia menyumbang sekitar 15% dari produksi bijih nikel dunia atau peringkat kedua setelah Filipina (16%)

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Total Produksi nikel Dunia pada tahun 2012 adalah sebesar 2,1 Juta ton (berdasarkan kandungan nikel didalam Ore)

Produksi Nikel Intermediet

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BULETIN - APLINDO No.41/2014  Selain memproduksi bijih nikel, Indonesia juga memproduksi nikel intermediet/nikel olahan, yaitu berupa feronikel (20% Ni) dan nikel matte (78% Ni)  Kapasitas produksi nikel intermediete Indonesia saat ini adalah sekitar 89.000 ton (ekuivalen dengan 34.900 ton nikel murni) atau hanya sekitar 2% dari kapasitas produksi nikel intermediete Dunia yang sebesar 1,7 juta ton  Semua hasil produksi nikel intermediete Indonesia digunakan untuk diekspor ke luar negeri

Ekspor Bijih Nikel dan Produk Turunannya

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Catatan : Untuk ekspor FeNi ke Belanda, digunakan oleh negara di Eropa Barat. Seperti : Belgia, Swedia, dll yang memiliki industri stainless steel. Sedangkan di Belanda hanya sebagai pelabuhan transit distribusi.

Pohon Industri Nikel

Keterangan : : Ada industri dalam negeri : Belum ada industrinya didalam negeri

: Pengguna Akhir KBLI

: Klasifikasi Baku Lapangan Usaha Indonesia

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BULETIN - APLINDO No.41/2014 Segmen Penggunaan Nikel dan Stainless Steel di Indonesia (2012)

Estimasi Besaran Biaya Investasi Pabrik Pengolahan Nikel Jenis Produk Olahan

Kapasitas Produksi (ton/tahun)

Besaran Investasi (US$/ton)

100.000

2.650 – 3.300

200.000

2.650 – 3.300

50.000

1.200 – 1.500

100.000

1.200 – 1.500

5.500

24.000 – 30.000

15.000

26.600 – 33.300

Nikel Matte

40.000

27.500 – 32.500

Heap Luach

24.500 (Ni = 39%)

20.326

Nikel Pig Iron (NPI)

Crude Ferronikel

Ferronikel

Sumber : Kementerian Enerrgi dan Sumber Daya Mineral, diolah

Estimasi Besaran Biaya Operasi Pabrik Pengolahan Nikel Jenis Produk Olahan Nikel Pig Iron (NPI) Ferronickel Nikel Matte

Besaran Biaya Operasi (US$/ton) 16.500 11.250 11.250 9


HPAL

8.600

Sumber : USAID, Economic Effects of Indonesia Mineral Processing Requirements for Export, 2013 Catatan : Masih perlu dilakukan kajian yang lebih mendalam

Struktur Biaya Smelter Nikel A.

B.

Produk Feronikel dan Nikel Matte NPV IRR Payback Period Nikel Hydroxide NPV IRR Payback Period

Keterangan 639 Juta dollar 20% 8 tahun 284 juta dollar 15% 12 tahun

Keterangan :  NPV adalah arus kas yang diperkirakan pada masa yang akan datang yang didiskonkan pada saat ini.  IRR (Internal Rate of Return) ialah indikator tingkat efisiensi dari suatu investasi.  Payback Period : suatu periode yang diperlukan untuk dapat menutup kembali pengeluaran investasi dengan menggunakan proceed atau net cash flow.

Peningkatan Nilai Tambah Produk Pengolahan Nikel

Sumber : Mineral&Energi, Maret 2013, Tekmira, ESDM Catatan : Perbandingan harga produk turunan nikel tersebut adalah terhadap harga bijih nikel/nickel ore

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BULETIN - APLINDO No.41/2014 Sebaran Potensi Nikel Indonesia

Nikel Province Sumber Daya (juta ton) Cadangan (juta ton) Ore Metal Ore Metal 1 Kalimantan Timur 36,0 0,6 2 Sulawesi Selatan 330,1 4,9 128,7 1,9 3 Sulawesi Tenggara 687,0 10,3 384,1 6,1 4 Sulawesi Tengah 231,1 4,0 94,8 1,2 5 Maluku Utara 795,5 11,4 334,2 8,2 6 Papua Barat 294,4 4,2 241,7 3,5 7 Papua 474,1 5,7 Total 2.849,1 41,8 1.178,7 21,2 Sumber : Statistic Mineral and Coal 2012, diolah

Impor Nikel dan Produk Turunannya

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Sumber : BPS, 2012, diolah

Proyeksi Kebutuhan Stainless Steel Indonesia

Sumber : BPS dan MP3EI, 2012, diolah Asumsi PDB dan Jumlah Penduduk Indonesia berdasarkan MP3EI yaitu : Jumlah PDB Indonesia adalah :2010:$3.005; 2015:$5.300; 2020:$9.000 ; dan 2025:$14.900, sedangkan jumlah penduduk Indonesia yaitu : 2010: 237 Juta Jiwa; 2015 :253 Juta Jiwa; 2020:269 Juta Jiwa: dan 2025:286 Juta Jiwa

Proyeksi Kebutuhan Nikel Indonesia

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Rencana Pembangunan Smelter Nikel Domestik

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BULETIN - APLINDO No.41/2014 Proyeksi Pengembangan Industri Nikel Domestik

Ketersediaan Cadangan Nikel Ore Untuk Produksi Smelter Domestik

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BULETIN - APLINDO No.41/2014 Kebutuhan Bahan Baku Pendukung, Energi dan Investasi Smelter Nikel

Proyeksi Kebutuhan Bahan Baku Pendukung

Proyeksi Kebutuhan Listrik Untuk Smelter Nikel (Kapasitas Terpasang)

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BULETIN - APLINDO No.41/2014 Proyeksi Kebutuhan Investasi Untuk Pembangunan Smelter

Potensi Demand Produksi Olahan Nikel Indonesia

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Teknologi Indonesia Energy-saving seminar The Joint Crediting Mechanism (JCM) and Energy saving by introducing high efficiency induction furnace Energi merupakan kebutuhan dasar dalam pembangunan berkelanjutan oleh Karena itu, energi harus digunakan secara hemat, rasional dan bijaksana agar kebutuhan energi pada masa sekarang dan masa datang dapat terpenuhi. Efisiensi penggunaan energi merupakan salah satu langkah penting yang harus dilakukan baik untuk mengatasi masalah perubahan iklim, masalah krisis energi dan masalah kesinambungan hidup. Terkait penggunaan energi, pemerintah telah mengeluarkan PP No. 70 Tahun 2009 tentang konservasi energi yang mengharuskan pengguna sumber energi dan penggunan energi yang menggunakan energi lebih besar atau sama dengan 6.000 setara ton minyak (TOE) per tahun wajib melakukan konservasi energi melalui manajemen energi dengan menunjuk manager energi. upaya konservasi dan efisiensi energi yang dilakukan dunia usaha tentu saja membutuhkan sejumlah investasi untuk teknologi. Sejalan dengan dengan kebijakan Konservasi Energi dan Pengurangan Emisi CO2 di Sektor Industri, Aplindo bekerjasama dengan PT Fuji Electrik menyelenggarakan “Indonesia Energy-saving seminar” pada tanggal 13 Mei 2014 di Hotel Sahid, Jababeka. Dalam seminar ini ada program bantuan dari Jepang untuk pembelian alat konversi energi untuk industri pengecoran logam (lihat makalah pada halaman berikut)

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Researchers at Missouri S&T analyze methods for improving melting efficiency.

A Global Casting Staff Report This article is based on a research paper, “Increasing Melting Energy Efficiency in Steel Foundries,” presented at the 2012 AFS Metalcasting Congress.

The high temperatures required to melt steel result in significantly higher energy losses in comparison with melting other cast alloys. The energy costs associated with heat losses during melting are significantly higher for steel casting facilities than for those melting other alloys. Today’s steel casting facilities use induction furnaces (IF) and electric arc furnaces (EAF) to melt steel. Siddhartha Biswas, Kent Peaslee and Simon Lekakh of Missouri University of Science & Technology, Rolla, Mo., conducted a benchmarking survey on current energy use among U.S. steel casting facilities. They investigated opportunities for energy improvement through a series of industrial trials involving chemical energy and ladle practice development.

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BULETIN - APLINDO No.41/2014 Background Furnace capacity, power supply, age of equipment, rate of production, melting schedule and operating practice all have major influences on energy consumption. A study of 19 North American steel casting facilities included a combination of historical data and industrial measurements on the type of melting equipment, refractory practices (Fig. 1), energy use and ladle practices. (See Tables 1, 2 and 3.) Table 1. Installation year by type of melting furnace Furnace Type

No.

Average year Installad

Oldest year Installad

Newest year Installad

ALL

58

1977

1938

2003

EAF

24

1980

1938

1977

IF

34

1992

1976

2003

Table 2. Capacities of steel melting furnace Furnace Type

No.

Average Capacity (lb)

Minimum Capacity (lb)

Maximum Capacity (lb)

ALL

58

12.368

400

110.000

EAF

24

26.433

6.000

110.000

IF

34

2.440

400

9.000

Table.3 Energy consumption (Kwh/t) for steel melting Average

Standard Deviation

Minimum

Maximum

58

12.368

400

110.000

24

26.433

6.000

110.000

34

2.440

400

9.000

A multiple regression analysis using commercially available statistics software allowed the researchers to evaluate the influence of the melting furnace (type, size, age and transformer power) and operating parameters such as tap temperature, tap to tap time and furnace productivity on the energy consumption for melting steel. Successful energy management in steel casting facilities is difficult without monitoring energy consumption. Unfortunately, this is an area where the steel casting industri is poorly equipped. Only 38% of EAFs and 15% of IFs in operation are equipped with electric meters for monitoring electric consumption. More than one third of the plants surveyed have no equipment for monitoring their energy consumption during steel melting.

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BULETIN - APLINDO No.41/2014 Multiple regression analyses determined how operating practice variables and equipment type influence the energy consumption in kWh/ton for melting steel. The analysis showed the following independent variables had an influence on the energy consumption for melting steel (from strong to weak influence): 

Increasing “tap temperature” increased energy consumption (strong influence).

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Increasing “tap to tap time” increased energy consumption (strong influence).,

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EAF has lower energy consumption than IF (strong influence).

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Newer equipment decreased energy consumption (strong influence).

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Increasing “furnace capacity” decreased energy consumption (weak influence).

Fig 1. This chart shows the refractory linings used in melting furnaces in the 19 facilities surveyed

In addition to the statistical data collected, operators were asked to report what they considered to be major factors with the greatest influence on energy losses during melting at their facilities. The three most frequently cited were: refractory (75%), scheduling (70%) and casting yield (25%). Procedure The MS & T team visited five metalcasting facilities, observed the melting of several heats and calculated heat balances. Figure 2 shows an example of the heat balance from an electric arc furnace. Supplemental chemical energy is one way to decrease electrical energy consumption and increase the efficiency and productivity of melting steel in EAFs. Many technologies can introduce supplemental chemical energy into the process. Preheating of the scrap charge and using oxyfuel burners can increase melting efficiency of the solid scrap charge. Two supplementary chemical energy methods, post-combustion of CO in the furnace to CO2 and exothermic heat from oxidation reactions to the melt, could increase energy efficiency during the flat bath period.

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Fig. 2. This Sankey diagram (energy flows) depicts melting steel in a 15-ton EAF.

Opportunities to increase energy efficiency are greatest during the superheating and correction period because the electrical energy efficiency drops significantly when heating liquid steel with an open arc in air. A significant portion of the arc energy is reflected from the arc and bath surface to the sidewalls and roof where the energy is lost in heating (and often melting) refractory rather than steel. In addition to using chemical energy, there is a future potential for increasing arc efficiency by utilizing more energy efficient long arcs (higher voltage and lower current) with a foamy slag, to decrease the heat losses by blanketing the arc. In an industrial trial, chemical energy from oxygen combustion of natural gas was introduced in a 4 ton EAF through installation of an oxyfuel burner through the door. Effective combustion of natural gas provides energy to the solid charge during the melting period. The electrical energy consumption was decreased from 480-500 kWh/ton without oxyfuel burners to 400-420 kWh/ton with burners. Direct injection of oxygen by a lance to the solid charge and melted steel can reduce electrical energy consumption by decreasing scrap melting time and direct generation of chemical energy from oxidation reactions in the melt. The introduction of coherent jet has decreased electrical energy consumption 10% and also reduces melt down time 13%.

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BULETIN - APLINDO No.41/2014 Scrap preheating systems, oxyfuel burners and postcombustion of CO require additional capital investment. By comparison, the addition of a material such as SiC, which produces exothermic reactions during the oxygen blow, does not require any capital investment (Fig. 3).

Fig. 3. This Sankey diagram shows the decrease in electrical energy consumption by the addition of chemical energy (0.4% SiC in charge). Because the heat of oxidation reaction is generated within the liquid steel, heat transfer efficiency from exothermic reactions should be nearly 100%. This expected efficiency is much higher than the typical 40% efficiency for post-combustion of CO above the bath. In the study, the amount of exothermic heat generated during oxygen boiling was increased by adding SiC with the solid charge. The energy and operational effects of adding enough SiC with the scrap charge to represent 0.4% to 0.6% of the charge weight was investigated in a 20-ton acid-lined EAF. The addition of SiC reduced electrical energy consumption by 7.1% and increased productivity by nearly 5%. Effective ladle design, preheat practices and use are important for steel casting production. The tap temperature of the liquid steel typically is superheated 250F to 500F (121C to 260C) above the steel’s liquidus to compensate for heat losses during tapping and holding in small ladles with large surface area to volume ratios. In spite of the relatively short time the steel is in contact with the ladle lining, the huge thermal gradients in the lining drive high values of heat flux through the refractory surface. Initial information about heat losses during steel ladling was taken from a survey of steel casting facilities and from industrial measurements at seven plants. The influence of the thermal properties of different ceramic materials typically used for steel ladle linings on heat losses during use was analyzed. From this work, a new type of ladle lining was developed at Missouri University S&T. It was based on porous ceramics with the potential to significantly decrease heat losses and save considerable ladle preheat energy.

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BULETIN - APLINDO No.41/2014 The data collected through the survey and trials was analyzed to determine the factors that were most important to energy losses in the ladle. One of the most important factors was found to be the ladle capacity. The tap temperature was found to be significantly lower for higher capacity ladles. A computational fluid dynamics (CFD) model was used to study the effects of ladle size and validate the industrial measurements. The temperature of the liquid steel at tap typically varies between 2,950F (1,621 C) and 3,200F (1,760C) at steel casting facilities. These temperatures are close to the softening temperature of the complex Al, Ca, Si, and Mg oxide compounds which are often used for ceramic linings. Also, the high rate of chemical reactions between the lining and components of the liquid steel and slag takes place at these temperatures. As a rule, ladles are not fully soaked even when used multiple times and are therefore used under unsteady state heat transfer conditions. Even in cases where the lining is preheated prior to tap, a significant part of the heat energy from the liquid steel accumulates inside the lining during the first 530 minutes after tap. Foundry ladle operations require special ceramic lining materials. A specially designed low density porous alumina castable was introduced. It has very low thermal conductivity and was determined to improve energy efficiency in the ladle (Table 4).

Results and Conclusions Major opportunities for energy savings were identified as:

improvement in scheduling and

decreasing delays while liquid metal is in the furnace; addition of chemical energy for melting steel; and improvement in ladle practice. CFD modeling, and industrial and laboratory trials determined the effects of these changes in reducing electrical power consumption. This data will be used in the future for development of a spreadsheet type model to allow metalcasters to calculate energy usage and melt temperature losses.

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The Future of Light Metal Die Casting Foundries

Fig. 1. Shown are options for application and possible savings in weight when aluminum die cast structural components are used for the body structure of cars. (Source: Bühler, Annual Report 2010)

The optimization of energy consumption and the associated reduction of CO2 emissions are top priorities for our society in the 21st century. In addition, the world’s resources are finite which is why it is important to search for opportunities to use them as efficiently as possible. The governmental regulation of emissions standards for vehicles in particular has led to a paradigm change resulting in the promotion of innovative concepts for light construction. Despite global efforts to reduce the use of non-renewable energy, the worldwide demand for individual mobility has been unrelenting. Independent studies of trends and markets conducted by well-known automobile manufacturers and research institutes have shown this to be true. Optimistic predictions talk about a doubling of production volume for automobiles within the next 20 years, whereby the classic drive technologies will be replaced with new, future-oriented technologies. Regardless, an increased use of light and highly resilient materials is to be expected. Aluminum and magnesium will play a crucial role in this. With the demand for efficiency and sustainability, diecasters have encountered new and recently yet unknown challenges, not least of which is to master the diecasting process and ensure the required level of quality. An overall trend is moving toward more complex components with increased functionality and lower weight at lower costs. In addition to substituting heavy materials such as steel with lighter metals, the use of structural components contributes to reducing the weight of automobiles. This makes it 27


possible to effectively reduce fuel consumption and, as a result, CO2 emissions. However, vehicles running on gasoline or diesel are not the only ones to benefit from lighter construction. Electric or hybrid vehicles also benefit: batteries and additional drive elements such as electric motors increase the weight. This can be compensated for by the strict use of light construction for the bodies of the vehicles. Structural components made of die cast aluminum provide additional options. They play an ever-increasing key role in the construction of new vehicles now and in the future.

Fig. 2. The estimated worldwide production of automobiles (Source: PwC) is compared to the forecast use of materials. (Source: McKinsey, Advanced Industries 2012)

Difficult Challenges The requirements placed on such components are high: particularly in the area of support structures and vehicle bodies, they have to withstand highly dynamic stresses and meet the strict requirements of the vehicle manufacturers in terms of crash safety and joining technology. This requires a consistent, high-level uniform process to be implemented. Only then can the good mechanical properties be reliably maintained. In addition, structural components must be easy to weld, clinch and bond. Despite strict requirements of the automotive industri, production must be cost-efficient. This means the entire diecasting process chain must be carried out and monitored within narrow boundaries—from the selection and handling of the melt through die design and casting technology to clear labeling of each individual casting.

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The Right Process, the Right Plant Engineering Structural components unify the function of many metal component parts, thereby reducing the complexity required for body construction. By integrating many components into a single casting, they continue to become larger and more complex. In order to minimize their weight, wall thicknesses have been reduced from the 2.5-3 mm range to less than 2 mm and are only reinforced according to local requirements. In order to ensure reliable production of such components, having the right process run on machines and systems designed for that process is critical. Thinner wall thicknesses call for shorter die filling times; even larger castings with long flow paths for the molten metal require very accurately dimensioned locking units. In order to fulfill these tasks, very efficient and highly dynamic shot ends with little scattering of the process parameters are required. Hydraulic clamping cylinders directly on the tie-bars allow for each tie-bar to be clamped individually and therefore promote homogenous distribution of the locking force. This results in little flashing or need for post-processing. In addition, the unique control of the casting process in real-time ensures an extraordinarily high degree of reproducibility over the entire production process. Air-Tight and Free of Turbulence To achieve the low vacuum in the cavity that determines the component properties in diecasting, properly designed dies and high-performance die vacuum technology are required. Wear resistance and thermal insulation of the shot sleeve are crucial: they guarantee the tightness of the vacuum system between the shot sleeve and the plunger and reduce the heat loss of the molten metal in the shot sleeve. Turbulence must be reduced for ladling metal from the dosing furnace to ensure the molten metal in the shot sleeve is low in oxide and hydrogen and ready for the next die filling process. Precision in Post-Processing In addition to how the material is molten and die cast, post-processing, thermal treatment and logistics of the components must also be taken into consideration. Errors made when the die releasing agent is applied could increase porosity due to gas which would have a negative effect on the quality of the weld. For this reason, there is a clear trend for such castings toward using a minimum of die releasing agent when spraying. However, this requires the temperature control concept be adjusted for the die inserts in order to dissipate the process energy efficiently. The ejection and extraction of the castings in particular and the subsequent cooling has a significant effect on warping. The large-scale dimensions of structural components present a new challenge for high-volume production: trimming of components in the die casting cell requires large trimming presses and an optimized flow of material for the cast part as well as for recycled materials. A thermal treatment process that is not set correctly could lead to an increase in rejects during production since the required mechanical properties cannot be attained in a reproducible manner.

29


Fig. 3. An example of typical use of the lost core technology is this closed deck motor block to increase the structural strength of highly charged diesel engines. (Source: Volkswagen AG), on the right: salt core insert. Keyword: Lost Core The potential for light construction has been further expanded with a process that has been advanced by pioneers for years: lost core technology. The internal design of a casting can be more complex with geometric undercuts, which allows for a previously unknown component design and a higher degree of functional integration. For example, cylinder crankcases with closed deck construction can take advantage. In this process, the water jacket is formed with a salt core that is flushed out later with water under high pressure. The use of salt cores in a diecasting machine does not pose any problems since, in contrast to sand cores, they are not abrasive and do not cause any wear. This is how components from gravity and sand diecasting can be substituted and produced even more economically with pressure diecasting: pressure die castings are near net-shape and require fewer post-processing steps. Another advantage of the lost core technology is the excellent quality of the surface of the cast wall by the salt core, comparable to the roughness of a diecast component. Lost core is particularly well-suited for manufacturing components for guiding flowing media, such as water and oil. Aluminum castings with salt recesses demonstrate very little flow resistance. When the salt core that determines the internal shape of the component is created, the appropriate salt solution and process parameters play a crucial role. This guarantees the stability of the core while making it possible to extract the core subsequently. The diecasting machine manufacturer becomes the technology partner who supports customers throughout the entire process, from the initial idea to the production stage, and from component design for the salt core application to the die and salt core concept in the die casting process. Keyword: Improving the Efficient Use of Resources Special attention must be paid to the use of energy and materials during diecasting. The die and the gating system play a crucial role here. The melting and holding processes alone use between 50 and 70 percent of the energy required for the entire process. A lot of energy is consumed initially to melt and overheat the metal to then solidify it in the die shortly afterwards and cool and extract the casting. The die temperature control concept plays a critical role in determining the cooling time and, consequently, the cycle time of the casting process. The classic surface cooling by spraying with water-soluble die releasing agents uses up to 50% of the entire cycle—and the same in terms of energy and resources.

30


In turn, the design of the shot system is critical for the amount of material used. Thin-walled castings use the greatest portion of material for the gating proportionally. The material must be returned and melted down again, which results in additional use of energy and, at the same time, loss of material due to slagging. Cost-effectiveness demands sophisticated gating concepts that make it possible to substantially reduce the amount of returns. Consistent optimizing at an early stage of the concept is key to sustainable, economic success. More precise and faster filling and solidifying simulations are created to find the right gating, ventilating and cooling systems. These methods will grow in importance along with the practical experience of the caster. In addition to the material and its solidification and casting properties, post-processing, thermal treatment and logistics of the components are also taken into consideration for the overall analysis. Knowledge of the individual process steps and how they affect costs and function should be learned through well-founded training. The only way to prevent costly mistakes is to have well-trained experts.

Fig. 4. Tools such as Bühler’s «Event Analyzer» support foundries in their strategic optimization of the OEE (Overall Equipment Efficiency). The process data from the die casting machine are analyzed, statistically evaluated and made available to the user as well-founded analyses.

Keyword: Increasing Productivity The best indicator of the productivity of a diecasting cell are uptime and the efficiency of the die casting process, i.e. the number of castings produced per unit of time. However, how can we measure this as objectively as possible? The OEE (Overall Equipment Efficiency) method of measurement was recently recommended throughout the industri and compares the theoretical output capacity and actual capacity of the plant. Of particular interest is the fact that this method of calculation includes the performance of the entire diecasting cell, i.e. the diecasting machine and peripherals, while taking into account the factors of time, velocity and quality in a meaningful and reliable manner. The reliability and uptime of individual components is therefore less important for the output capacity of the diecasting cell. It is

31


much more determined by the weakest link and the interaction of the individual components and sub-processes of the production chain. A clear connection between all components that are relevant to the process is the key to uninterrupted and cost-efficient production. The cell control system of current diecasting machines integrates all the activities of the system peripherals throughout the process in monitoring and documenting the process. Interfaces to higher level systems make it possible to collect, analyze and safeguard all the data in a central location over the long term. Furthermore, they support the operator with a sophisticated diagnosis system in optimizing the entire diecasting process and, therefore, the OEE. The control system logs important information regarding the operating status of the machine and its peripheral equipment, and any alarms that may have been sounded. These logs should then be used actively for continuous improvement of the process and for understanding the most common sources of error. Using specialized software packages, it is possible to evaluate the data as needed. Downtimes can be assigned to corresponding alarms, and any process errors can be identified. This is a key benefit to a diecasting facility: it can increase the productivity and quality of its process in a targeted manner while improving profitability. The challenges of the future for diecasting can be met with new innovative concepts and consistent implementation, along with existing expertise. These challenges are a result of requirements for weight reduction, expanded functionality of components and improved resource and cost efficiency of the castings to be produced. Machine concepts and technologies continuously are being improved. However, as diecasters are confronted with changing processing conditions, they need to rethink how they operate. In order to manufacture components of the highest quality in a cost-efficient manner, all measures must be coordinated individually to meet the different requirements of the component to be produced and the particular production process.

32


Keys to Success in Semi-Permanent Mold Casting Developing a successful, repeatable, reliable process for pouring aluminum into a permanent mold is no simple task. The many variables include metal and mold temperatures, shrink factors, mold coatings, casting cycle times and melt quality. Considering the numerous factors that influence quality and quantity, introducing sand cores to permanent molds only complicates matters.

Figs. 1a-b: A metal ball detent pin (right) and bushing can help lift and set heavy cores (left). Beyond the obvious issues of cost and binder material, a sand core can slow the heat transfer (and extend solidification time for the casting), change shrinkage factors for the casting, introduce potential core coatings and require additional venting for gases in semi-permanent molds—so-called because of the disposable core. Additional issues arise in handling cores, such as trimming, insertion and removal from the metal mold. Sand cores also require added tooling, which includes validation and maintenance. The corebox itself is only one concern. Tooling includes trimming methods, c ore assembly fixtures, transport materials, material handling components and verification fixtures. The core’s effect on dimensional accuracy is a critical consideration for components with tight dimensional requirements. One determination for any given casting part is whether the mold or the sand core will have the more significant influence on dimensional shrinkage. Among the determining factors are the core material, resin percentage, casting size, geometry, wall thickness and whether the core is knocked out after solidification or remains in the casting during cooling. Additionally, some castings may include axisFig. 2: A stripper plate can be used to specific shrink factors. remove core fins and parting lines in higher volume applications

33


Gas and Venting All sand cores generate gas due to binder decomposition when contacting molten metal; the amount depends on the binder system and coating. Various core binders not only generate different amounts of gas, but also show different gas evolution profiles (i.e., when and at what rate gas is released). The gas amount and its evolution rate are affected by binder type, melt temperature, core geometry and processing conditions. Binders that generate more gas need increased venting—in total number and/or size—to allow for proper gassing of the mold cavity. Vents should be placed to ease cleaning of core gas residue. Engineers also must determine if the mold requires active or passive gas venting, that is, if the mold design and filling pattern will push the gas out naturally or a more aggressive vacuum assist is necessary. Gas evolution also can correlate with condensation in the mold cavity. Core Handling and Placement Handling sand cores and placing them into a hot metal mold can be sources of trouble. Some practical suggestions include:

Figs. 3a-b: Large shell cores present unique challenges for aluminum permanent molders. Fig. 3a (left) weighed 46 lbs. (20.9 kg) with 32 in. (81 cm) between core prints. Fig. 3b was 14 in. (35.5 cm) tall, 22 in. (55.9 cm) wide and weighed 20 lbs. (9.1 kg).

Core Positioning: A cold core may fit differently into a cold mold versus a hot one. The core should be positioned in the mold so it’s fully supported during pouring. Core prints should locate the core without constraining it in a way that could lead to fracture. Prints should be easy to clean and discourage residue buildup, which could lead to misalignment. Core prints also must allow for the thickness of the mold core coating and ensure adequate core print clearances. It is important to focus on both halves of the mold and include proper core clearances, at least 0.005–0.015 in. (0.127–0.381 mm) per side. Some metalcasting facilities provide additional close-over clearances of 0.005–0.01 in. (0.127–0.254 mm). Because prints wear excessively, they should be easy to access and repair. Also, since closing the mold will likely shave some sand from the core, prepare for residue in the mold. The core print may be an ideal spot for venting. Because there is no liquid metal surrounding the core print, it provides an easier path for venting core gasses that won’t mark the casting surface.

Core Handling: Handling is a concern with cores that are heavy, fragile, easily contaminated and/or prone to damage resulting in a defective casting. One option includes molding a steel bushing into the core and using a ball detent pin to lift and place the core into the mold (Fig. 1a-1b). Trimming: Hand trimming is an economical approach for low quantities of cores, but trim plates and stripping dies can be helpful (Fig. 2) when dealing with larger volumes or trying to 34


limit hand trimming variability. Automation, including CNC machines and robotics, is another viable option for higher volume cores. Core Coating: The first consideration is to determine if a coating is needed, with the surface finish of the casting around the core the essential factor. Coatings usually are added in areas that require a smoother casting surface finish, or to prevent molten metal penetration issues such as erosion, veining or burn-in-type defects. Coating also can help direct the core gas toward vents. Core Removal: How the core will be removed from the casting and how soon after solidification can affect casting dimensions. Most metalcasting facilities use a combination of vibration, abrasion (e.g., hammers, drills, blasting) and bake-out ovens. Knockout is faster and allows for quicker inspection times. Shot blasting removes final residues after knockout. Large Shell Cores Large shell cores—those weighing more than 10 lbs. (4.54 kg), longer than 24 in. (61 cm) or with a length-to-diameter ratio greater than four (Figs. 3a-3b)—present a special set of challenges, including the potential for core breakage, cracking, distortion and gas-related porosity. When a core is damaged, the casting must undergo excessive cleaning room operations, which can increase costs significantly, or be scrapped entirely. Such damage can be caused by core and molten metal issues such as the pressure of the molten metal on the core, insufficient core strength, excessive metal temperature, thermal shock or mold-related issues like excessively tight core prints. Insufficient shell core curing or improper venting will lead to gas porosity. A majority of issues relating to large shell cores can be resolved with proper engineering controls and continual process review. Here are a few basic steps to deal with large shell cores: Core and Mold Alignment: Maintain proper mold and machine alignment by minimizing contact points in core prints. Establish a formal preventative maintenance program on all permanent mold machines. Use shell core cooling fixtures to maintain dimensional accuracy. Core Integrity: Determine the parameters for optimal resin content to maximize core integrity, wall thickness, cure time, temperature, etc. Ensure the core is cured fully. Gating: Review the gating system to avoid excessive stress on the core. Core Gas: Provide adequate venting for the removal of core gases. Core Strength: Add features as needed to improve strength, such as a tie bar between the legs of a U-shaped core to Fig. 4: The large flat section prevent distortion. Modify the core binder system and change on this 26-in. (66-cm) core the resin composition of the shell core as needed to improve developed cracks regularly. strength. Work with the sand provider on new formulations.

35


Even after implementing these suggestions, large shell cores can remain difficult to use in permanent mold applications. For example, at Wisconsin Aluminum Foundry Co. (WAFCO), Manitowoc, Wis., the large cylindrical core in Figure 3a failed at a 75% rate due to a number of problems. Engineers filled the 46-lb. (20.87-kg) shell core with air-set sand to produce castings, but this process increased both core weight and knockout costs. Similarly, the core in Figure 4, at nearly 26 x 6 in. (66.7 x 15.2 cm), featured a large flat section that developed cracks regularly. While not leading to outright failure, as in the cylindrical core, it required additional inspection to verify the surface finish in the cored casting cavity and extra cleaning room labor to remove flashing caused by broken and cracked cores. WAFCO continues to minimize variation in the core and molding process by working with suppliers to modify sand recipes to improve core integrity, discussing necessary core support prints with clients and avoiding new high risk jobs based on experience. Though networking with other metalcasting facilities is helpful in learning techniques to overcome challenges, large shell cores remain a complex endeavor.

36


Data Kendaraan Bermotor Indonesia 1.

Data Kendaran Roda 4 a. Penjualan Kendaraan roda 4 (unit) tahun 2010-2014 No.

Bulan

1 2 3 4 5 6 7 8 9 10 11 12

Januari Februari Maret April Mei Juni Juli Agustus September Oktober Nopember Desember Total

2010

Penjualan (Unit) 2011 2012 2013

52,831 55,688 65,555 65,232 60,520 70,388 72,100 64,779 49,147 69,160 69,249 70,061 764,710

73,990 76.427 96.718 69,591 86.486 103.278 82,166 87.917 95.996 60,728 87.144 102.257 61,055 95.541 99.697 70,157 101.746 104.268 89,056 102.511 112.178 73,279 76.445 77.964 79,835 102.100 115.974 86,345 106.754 112.039 67,656 103.703 111841 80,325 89.456 97.691 894,183 1.116.230 1.229.901

2014 103.595 111.880 113.096 106.096 97.136 110.560 91.393

733.716

Sumber : Gaikindo

b. Produksi Kendaraan roda 4 (unit) tahun 2010-2014 No.

Bulan

1 2 3 4 5 6 7 8 9 10 11 12


2010 49,818 48,780 57,354 59,493 55,758 65,589 68,306 60,939 44,348 66,262 63,919 61,942 702,508

Produksi (Unit) 2011 2012 2013 70,715 77.036 97.793 63,928 86.469 100.491 74,308 85.507 89.073 54,556 84.426 101.805 54,637 97.367 99.661 64,454 94.400 97.939 83,591 97.330 106.519 69,107 71.113 77.354 77,349 94.488 116.974 81,265 100.298 115.533 64,687 99.168 110.570 79,669 77.955 94.499 838.266 1.065.557 1.208.211

2014 104.728 112.501 123.007 121.114 94.353 117.309 93.610

768.622

Sumber : Gaikindo

37

BULETIN - APLINDO No.41/2014 2.

Data Kendaraan Roda 2 / Sepeda Motor a.

Penjualan sepeda motor 2010-2014

No.

Bulan

1 2 3 4 5 6 7 8 9 10 11 12


Penjualan (Unit) 2010

2011

2012

503,840 540,067 608,142 657,185 641,871 655,363 701,432 734,439 481,619 698,342 656,597 516,751 7,395,648

667,124 613,449 713,672 709,177 709,122 661,304 740,121 681,444 723,906 717,514 643,271 463,431 8,043,535

652.601 670.757 626.689 622.929 619.540 550.468 585.658 433.741 628.739 634.575 627.048 488.841 7.141.586

2013

2014

649.983 580.288 653.357 681.267 657.483 728.820 660.505 729.279 647.215 734.030 661.282 753.789 704.019 539.171 490.824 678.139 717.272 688.527 552.408 7.771.014 4.755.644

sumber : AISI Diolah

b.

Produksi sepeda motor 2010-2014 Produksi (Unit) 2010 2011 2012 2013 2014 1 Januari 515,962 677,356 685.688 662.920 595.636 2 Februari 528,303 621,988 665.570 659.417 659.258 3 Maret 628,967 720,284 606.984 654.760 729.476 4 April 650,001 715,864 619.839 672.370 748.401 5 Mei 636,023 698,427 619.829 644.881 722.192 6 Juni 664,767 645,975 535.621 653.384 761.117 7 Juli 695,974 722,184 577.488 694.492 553.626 8 Agustus 733,021 671,506 428.662 484.428 9 September 476,354 713,061 620.250 683.066 10 Oktober 690,194 725,036 627.352 729.876 11 Nopember 682,363 646,510 625.865 691.115 12 Desember 513,461 446,102 466.573 549.586 Total 7,415,390 8,004,293 7.079.721 7.780.295 4.769.706

No. Bulan

sumber : AISI Diolah

38


Informasi Umum & Pameran

A.

B.

Web site Pemerintah yang dapat diakses : 1.

www.setneg.go.id (Sekretariat Negara)

2.

www.kemenperin.go.id (Kementerian Perindustrian)

3.

www.kemenkeu.go.id (Kementerian Keuangan)

4.

www.kemendag.go.id (Kementerian Perdagangan)

5.

www.beacukai.go.id (Direktorat Bea & Cukai, Kementerian Keuangan)

6.

www.esdm.go.id (Kementerian ESDM)

7.

www.bkpm.go.id (Badan Koordinasi Penanaman Modal)

8.

www.bps.go.id (Biro Pusat Statistik)

Web site Asosiasi Industri Pengecoran Logam Indonesia (APLINDO) Kini APLINDO telah tersedia Web site sendiri : www.aplindo.web.id, mohon dukungan partisipasi aktif Bapak-bapak sekalian dan diharapkan saran, masukan, permasalahan dan perkembangan yang terjadi di industri pengecoran logam di Indonesia. Saran dan masukan anda dapat berupa artikel ke alamat [email protected]

C.

Web site Himpunan Ahli Pengecoran Logam Indonesia Kini HAPLI telah tersedia Web-site sendiri : http://hapli.wordpress.com/ , mohon dukungan partisipasi aktif Bapak-bapak sekalian dan diharapkan saran serta masukan anda berupa artikel sesuai page yang tersedia dalam format *.doc ke alamat [email protected] untuk diupload, ataupun komentar langsung anda pada Blog.

D. Pameran dan Seminar 1.

11 Sep 2014 - 13 Sep 2014 Ankiros/Annofer/Turkcast 2014 Tuyap Centre, Istambul www.ankiros.com/

2.

Korea Metal Week 2014: 16 Sep 2014 - 19 Sep 2014 Kintex, South Korea As the specialised leading international trade fair in Korea, Korea Metal Week provides the best

39


marketplace with the latest technology for suppliers, manufacturers and traders in the metal and machinery industries around the world. www.korea-metal.com 3.

54th International Foundry Conference - Slovenia: 17 Sep 2014 - 19 Sep 2014 Portorož, Slovenia Contact: Mirjam Jan-Blažic, Slovenian Foundrymen Society, email: [email protected] www.drustvo-livarjev.si

4.

Fundiexpo 2014: 24 Sep 2014 - 26 Sep 2014 Cintermex Convention Centre Congress and international exhibition. http://www.fundiexpo2014.com/en/

5.

International Foundry Forum: 26 Sep 2014 - 27 Sep 2014 Venice, Italy www.international-foundry-forum.org

6.

Midest 2014: 4 Nov 2014 - 7 Nov 2014 Paris Nord Villepinte - France MIDEST is a key platform for international suppliers of industrial subcontracting, offering manufacturers, component suppliers and assemblers the chance for face to face meetings with suppliers of solutions in the fields of metals, plastics, electronics or industri services. http://www.midest.com/site/GB,C6374,I6374.htm

7.

Indometal 2014: 11 – 13 Des 2014 A robust intergrated platform for the metal and steel industries JIEXPO, PRJ Kemayoran Jakarta For enquiries, please contact : PT. Wahana Kemala Niaga, telp. +6221.53660804 Fax. +6221.5325587/90 email : [email protected] http://www.indometal.net

8.

27 Feb 2015 - 1 Mar 2015, FEX 2015 Greater Noida, Gautam Buddh Nager, UP, India Alongside 63rd Indian Foundry Congress, IFEX 2015 – 11th edition of International Exhibition on Foundry Technology, Equipment Supplies. www.ifexindia.com

9.

16-20 June 2015 GIFA, METEC, THERMPROCESS and NEWCAST Düsseldorf, Germany Websites: www.gifa.de, www.metec.de, www.thermprocess.de and www.newcast.de.

40

APLINDO. Asosiasi Industri Pengecoran Logam Indonesia

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