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Trends in Russian Foundry IndustryRevision 2012
Presented by:
Andrew Dibrov,
Vice-President of Russian Association of Foundrymen
“Trends of Foundry Development in Russia”
General data:
1. Territory – 17.100.000 km2
2. Population – 143,7 mln.3. Working force – 80 mln.4. Total number of foundries – about 1.350
“Trends of Foundry Development in Russia”
GDP in Trillions of Dollars (incl. inflation)
0,70,91,11,31,51,71,92,12,32,52,72,9
1998 2000 2002 2004 2006 2008 2010
“Trends of Foundry Development in Russia”
0
20
40
60
80
100
120
0
0,5
1
1,5
2
2,5
3
1998 2000 2002 2004 2006 2008 2010
USD
/Bar
rel
Trill
ions
of U
SDGDP and oil price
GDP in Trillions of Dollars (incl. inflation)Average annual price of Brent oil
“Trends of Foundry Development in Russia”
Structure of GDP
Services and Financing
27%
Industry19%
Trade18%
Natural resources
9%
Construction6%
Agriculture5%
Others16%
Automobile industry – main consumer of castings is 0,8% of GDP
“Trends of Foundry Development in Russia”
Volumes of castings production
02468
10121416
1990 1998 2001 2006 2008 2010
Mln
. ton
n
Total Cast iron Steel Non-ferrous
The biggest volume of production was in 1985 – Russia produced 18,5 mln. tons
In 2011 total 1240 foundries produced 4,3 mln. tonn of castings, Export only about 2%
0100200300400500600700800900
1.000
2003 2004 2005 2006 2007 2008 2009 2010 2011
Import of foundry equipment
Mln. USD
“Trends of Foundry Development in Russia”
“Trends of Foundry Development in Russia”
60%
5%
7%
12%
12%
2% 2% Cars, trucks andtractorsElectrotechnicalindustryHeavy and Energymachine-buildingChemical and oilindustryConstruction industry
Machine-Tool building
Others
Production of castings by sectors in 2011г.
“Trends of Foundry Development in Russia”
Production of cars, thousands pcs
0
200
400
600
800
1000
1200
1400
1600
2006 2007 2008 2009 2010
Russian brends Foreign brends
“Trends of Foundry Development in Russia”
Areas with high quality casting demand:
1. Railway - boogie2. Oil & gas transport – steel valves3. Mining – wear parts, Mn steel4. Defence/military – large steel castings and
AL and Mg castings
Main need is in steel castings!
“Trends of Foundry Development in Russia”
Distribution of castings by alloys in 2011
72%
17%
11%Cast iron
Steel
Non-ferrous
“Trends of Foundry Development in Russia”
Distribution of castings by alloys in 2011
Carbon steel60%
Alloyed steel
40%
Steel – 17%
AL79%
Mg7%
Cu12%
Zn2%
Others0%
Non-ferrous-11%
Grey iron60%
Ductile iron29%
Special11%
Cast iron - 72%
“Trends of Foundry Development in Russia”
Non-ferrous castings production
High-pressure
48%
Low-pressure
32%
Die cast8%
Green sand12%
Aluminium - 79% from total non-
ferrous
Al79%
Mg7%
Cu12%
Zn2%Others
0%
Non-ferrous -11%from total
“Trends of Foundry Development in Russia”
Distribution of foundries by capacity, 1000 t/year50 - 100
2%10 - 50
7%
5 - 1016%
1 - 535%
<140%
“Trends of Foundry Development in Russia”
Level of foundries automatization by q-ty of castings produced on:
24%
30%32%
14%
Automatic lines
Semi-automaticlines
Single machines
Manually
“Trends of Foundry Development in Russia”
54%
2%
44%
Cupola
Arc furnaces
Inductionfurnaces
Melting of cast iron (by q-ty of castings)
0%
10%
20%
30%
40%
50%
60%
70%
80%
Cupolas Induction furmaces Arc furnaces
20052011
Trends in melting for cast iron (by quantity of castings)
“Trends of Foundry Development in Russia”
“Trends of Foundry Development in Russia”
Composition of the melting charge
0
10
20
30
40
50
60
70
Pig iron Iron scrap Steel scrap
%
20042011
Deficit of high quality scrap
0%
10%
20%
30%
40%
50%
60%
70%
80%
Green sand No-bake
20052011
No-bake and green sand moulding
“Trends of Foundry Development in Russia”
Structure of workers in foundry industry
90,0%
9,9% 0,1%
WorkersEngineersR&D
“Trends of Foundry Development in Russia”
Need in new technologies and equipment from abroad
Most perspective directions of development: Production of No-Bake / Core moulds
Production of cold-box cores
Melting in medium frequency induction furnaces and DC arc furnaces
Growth in production of ductile iron and Al alloys as replacement of malleable iron and steel
Building of new foundries and reconstruction of existing, more big corporations
“Trends of Foundry Development in Russia”
Main conclusions: Internal market has big enough value and
tendency to grow, Russia continues to import castings
Low level of export – will not change soon
Growth of expenses for environmental protection
Lack of skilled workers and engineers – high cost of castings
Reduction of number of foundries (only in 2009 – minus 300 foundries)
“Trends of Foundry Development in Russia”
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