Evolution of All-aluminum Trucks in China



Evolution of All-aluminum Trucks in China

All-aluminum trucks refer to those with maximum aluminum parts with current technical support and safety guarantee. In the new century, countries around the world have been sparing no efforts to reduce energy consumption and emission of greenhouse gases and exhaust. Particularly, developed countries in the Europe and North America have drafted and issued national fuel consumption policies with timelines and initiated the research on fuel consumption policy and strategy after 2020.

According to report, in 2017, China consumed over 300 barrels of oil every 3 seconds nationwide, among which 85% were consumed by vehicles and over 75% of urban harmful gases were emitted by vehicles. Currently, vehicle fuel consumption in China is nearly 2 times that of Japan, making vehicle fuel consumption reduction an urgent problem to be solved.

In 2017, China boasted over 3.8 million heavy trucks and about 42 million vans, whose exhaust become the major source of atmospheric pollution. Means of energy saving and emission reduction of vehicles can be summarized into three aspects, i.e. curb weight reduction, engine efficiency improvement and body structure improvement, and the latter two have reached their improvement extreme, while the first still has huge room for improvement.Vehicle curb weight reduction is the key to reduce fuel consumption and improve transport efficiency, while low-density aluminum and aluminum alloy (<2.8g/cm³) is an inherent means to reduce curb weight. For example, the net weight of a standard aluminum semitrailer is 3.5 tons lighter than that of a steel one. Therefore, the aluminum semitrailer can carry goods 3.5 tons more than the steel one, save proportional fuel in case of deadhead and improve vehicle operation and wear. According to available data, it consumes 13.5 Wh power to extract 1 kg primary aluminum, which can replace about 1.7 kg steel in vehicle manufacturing; 1 kg material saving in the vehicle’s life cycle can save about 0.7 kg fuel, which amounts to power saving of about 800 kWh and CO2 reduction of 1,800 kg.

According to the statistics of relevant logistics companies, for an annual operation mileage of 150,000 km, aluminum alloy semitrailer with lighter weight can earn RMB 150,000 - 180,000 more than the steel semitrailer. Although 40% higher in terms of purchase cost than the steel one, the aluminum alloy semitrailer can recover the cost within a year and a half. In 2017, the percentage of aluminum trucks (semitrailers, vans and special-purpose trucks) in Japan and western countries has reached 75%-83%. If the percentage can reach 50% in China, 12 million-ton carrying capacity can be increased, 6.5 million-ton fuel can be saved, and 20 million-ton greenhouse gas emission can be reduced. Based on the data issued by western countries, the life cycle of aluminium alloy tank trucks is about 17.5 years, while those of the stainless steel trucks and steel trucks are about 15 years and 8 years. Moreover, after the aluminium alloy trucks are retired, aluminium scrap can recover 85% of value of the primary aluminium, and the energy consumption of recovery is only 5% of the extraction of primary aluminium, outperforming the steel counterparts.

Based on survey and rough estimate, the percentage of aluminum trucks in China in 2017 is less than 5%, so there is still a long way to go to reach the level of 75%-83% in western countries.

Currently, vehicle lightweight materials mainly include aluminum, magnesium and composite, with aluminum the most cost-effective. According to calculation of relevant test agencies, the use of aluminum in a vehicle can amount to 540 kg, realizing weight reduction of 40%. The traditional vehicle body accounts for 30%-40% of total vehicle weight, making it the major part to be replaced with aluminum alloy. In 2014, the average aluminum consumption in a passenger car in China is only 92 kg, showing a huge gap with 150 kg in western countries, let alone the gap of trucks. The development of aluminum trucks and buses in China is summarized below.

●The first all-aluminum semitrailer

On December 15, 2009, the all-aluminum semitrailer body JINBA E33-621, the first all-aluminum body with full independent intellectual property, was successfully co-developed by Shandong Longkou Conglin Group and Dongfeng Motor Co., Ltd. The aluminum body has a weight of 252 kg, 178 kg lighter than the steel one, realizing weight reduction of 41.4% and fuel saving of >6%. The successful development of JINBA E33-621 can contribute to improve aluminum deep processing capacity and technical level in China, promote the technical progress of the automobile industry, narrow the gap with developed countries, and enhance market competitiveness of innovation capability of self-owned auto brand.

● The first batch of all-aluminum tank trucks

In October 2009, the first batch of all-aluminum tank trucks developed and manufactured by CIMC Vehicles Group under the technical guidance of Alcoa were put into road test in Beijing and Jinan. Compared with traditional stainless steel trucks, the all-aluminum tank trucks realizes weight reduction by 30%, which correspondingly increases payload, improves fuel economy and reduces greenhouse gas emission. Notably, China no longer needs to import all-aluminum tank trucks for aviation gasoline, and the stainless steel trucks used in the past are harmful to the quality of aviation gasoline.

For the first batch of all-aluminum tank trucks, the aluminum plates were manufactured by Alcoa Bohai Aluminum Industries Co., Ltd., Huck branded fasteners were manufactured by Alcoa Fastening System (Suzhou) Co., Ltd., and wheels were Dura-Bright products manufactured by Alcoa-Kofem in Hungary.

Moreover, early in 2007, Alcoa had established strategic partnership with Zhengzhou Ningtong Bus Group. The two parties successfully developed the new-generation eco-friendly and energy-saving bus prototype, which was exhibited at Beijing Olympics 2008 and put into road test, scoring satisfactory results.

●The first aluminum-alloy dump truck in China

In December 2009, lightweight QDZ 3310ZH46W aluminum-alloy dump truck was successfully developed by CNHTC Special-purpose Vehicle Co., Ltd. and passed the evaluation of scientific and technological achievements with independent intellectual property in Shandong Province. With a design length of 8.2 m, effective volume of 33.9m³ and loading weight of <3.8 t, the truck can be widely used to transport coal, cereal and other bulk goods. The truck is featured by light weight (with welded high-strength aluminum alloy plates, 57% lighter than the steel truck), significant ROI, long service life, high recovery value after retirement, and low recycling energy consumption.

●Two aluminum-alloy van semitrailers included in the “Catalogue of Recommended Semitrailers for Road Drop & Pull Transport” issued by Ministry of Transport

On January 15, 2015, CSH 9400XXY and CSH 9402XXY, two three-axis van semitrailers developed by SNTO Truck affiliated to SNTO Group, were granted China CCC certificate and included in the “Catalogue of Recommended Semitrailers for Road Drop & Pull Transport (Version 3.0)” issued by Ministry of Transport.

●15.22 m-long van manufactured by ML Lightweight Auto Co., Ltd.

On September 1, 2017, the 15.22 m-long van manufactured by ML Lightweight Auto Co., Ltd., the joint venture of Nanping Aluminum Co., Ltd. and Nanping Industry Group Co., Ltd., was officially delivered to the user ZTO EXPRESS. The aluminum materials for the van are manufactured by Nanping Aluminum Co., Ltd. Compared with the comparative vans on the market, the van has the following advantages: adopting aluminium alloy profiles with more advanced technology and better performance, higher structural strength and anti-expansion capability, better side wall joint structure, more reliable sealing property; adopting reinforced front wall plates with strong shock resistance in case of braking.

In April 2018, the flexible and intelligent production line built by ML Lightweight Auto Co., Ltd. with an investment of RMB 250 million was officially put into production, with annual production capacity of 1,000 aluminium alloy van bodies and logistics vehicles and industrial output of over RMB 1 billion. Particularly, the total weight of the 15.22 m-long aluminium alloy van body is only 2,990 kg.

●Nanning Yuanzheng all-aluminum new-energy bus project

Launched in March 2015, the project with multiple phases is located in Nanning Yongning District Emerging Industry Park, with a land area of 2000 mu and total investment of RMB 4.8 billion. With a land area of 530 mu and total investment of RMB 1.5 billion, Phase I project has been put into production in 2015, with planned annual capacity of 5,000 all-aluminum new-energy buses and regular buses and 10,000 all-aluminum special-purpose battery electric vehicles. On December 31, 2015, the first all-aluminum new-energy bus officially rolled off the production line in Nanning Yuanzheng Co., Ltd., which boasts the largest all-aluminum new-energy bus project.

●The first eco-friendly aluminium alloy truck body prototype by Nanping Aluminum Co., Ltd.

Nanping Aluminum Co., Ltd. Plate Division successfully delivered to the customer the first eco-friendly aluminium alloy truck body prototype, which is 40% lighter than the traditional steel body. With multiple technical communications and own technical advantages in process design and metal material processing, Nanping Aluminum Co., Ltd. adopted the design proposal of combination of riveting and welding. With both good shock resistance and water tightness, the prototype adopts mid-strength aluminium alloy and special section support, which guarantee strength and safety and effectively control the net weight of body.

●50 Aluminum Travelers developed by Conglin Group travel on road

Aluminum Traveler refers to lightweight aluminium alloy trailer developed by Conglin Group with 3-year development cycle. Over 30% lighter than the steel one in net weight, the aluminum trailer can save fuel by over 20%, i.e. 20 t/a, equivalent to RMB 200,000 saving per year. The extra purchase cost can be recovered in less than two years.

● The largest battery electric bus imported put into service in China

In March 2015, the largest battery electric bus imported by China was officially put into service in Beijing. With maximum passenger capacity of 143 and length of 18 m, the bus interior is spacious and quiet with only weak motor noise. The bus can travel over 100 km per charging, and full charging takes less than 3 hours.

●PetroChina purchased 70 aluminium alloy tank semitrailers in a single order

In February 2016, PetroChina purchased 70 aluminium alloy tank semitrailers in a single order from Liaoning Jinbi Automotive Group Co., Ltd. Mainly used to transport diesel, petrol and LNG, etc., the semitrailers reach national level in all technical indicators and international level in certain indicators.

●Special-purpose aluminium alloy electric vehicles by Nanping Aluminum Co., Ltd.

In June 2016, Nanping Aluminum Co., Ltd. Lightweight Integration Division put into production the all-aluminum body with optimal design and own precision aluminium profiles. It completed the first electric all-aluminum body framework assembly in late April, completed whole assembly and joint with the bodywork in early May, completed the whole joint and fabrication and successfully delivered the first prototype to customer for actual road test in middle May.

In December 2016, the first green and low-carbon vehicle co-developed by Nanping Aluminum Co., Ltd. and Nanping Yanxin Logistics Co., Ltd. in Fujian Province successfully rolled off the production line. The 7.7 m-long all-aluminum logistics vehicle boasts multiple technical innovations and highlights: the total weight is about 1.5 t, over 25% lighter than the steel one; the fuel consumption can reduce by 2-3 L/100 km, equivalent to RMB 35-45/100 km reduction in transport cost; given annual travel mileage of 100,000 km, over RMB 40,000 cost can be saved annually, which is sufficient to cover the extra purchase cost of all-aluminum body, which has multiple advantages as anti-corrosion, easy maintenance and high recycling value.

●The first all-aluminum travel trailer successfully registered for road use

On January 18, 2018, Starship One travel trailer developed by Shanxi Puruilaisi Auto Service Co., Ltd. was successfully registered at Xinzhou City Vehicle Administration. As the first all-aluminum travel trailer in China, Starship One has a size of 5950mmX 2840mm, curb weight of 1.2 t and engine capacity of 1.6 L. With a vintage streamline design, the trailer exterior and interior are made of aircraft-grade aluminum, making it corrosion-resistant, odor-free, lightweight and clean. Moreover, the trailer is equipped with bed, bathroom, air-conditioner, kitchen, etc., which can meet the needs of 3-4 people for outdoor camping, travel and living.

●All-aluminum trailer developed by CHALIECO Trading Co., Ltd. parked at CHALCO Group

Lightweight all-aluminum trailer co-developed by CHALIECO Trading Co., Ltd. and Shandong Xinneng Energy Equipment Manufacturing Co., Ltd. parked in front of the Xizhimen Office Building of CHALCO Group. Characterized by light weight, anti-corrosion, high safety performance, high recovery value, attractive appearance and durability, the trailer is aligned with the development goal of national low-carbon economy, and is expected to become the best choice of replacing steel trailer.

●Sanxing Minghang Special-purpose Vehicle Co., Ltd. becomes one of the largest aluminum vehicle manufacturers in China

As a subsidiary of Shandong Sanxing Group, Sanxing Minghang Special-purpose Vehicle Co., Ltd. is specialized in manufacturing various all-aluminum trailers and tank trucks. Founded in 2014, it has become one of the largest aluminum trailer manufacturers in China. In 2017 alone, dozens of tank trucks were shipped from Qingdao Port to Dubai.

In 2015, based on the original machinery manufacturing foundation, Sanxing Minghang invested about RMB 200 million to purchase advanced laser CNC cutters, CNC tools, robot welders, CNC shearers and other processing equipment, enabling the production scale, precision and automation and annual capacity of 10,000 all-aluminum trailers.

In addition to aluminum tank trucks, Sanxing Minghang also independently developed all-aluminum trailers of different models and payloads, including two-axis and three-axis trailers, semitrailers and plate trailers. In the all-aluminum trailer, the parts and systems other than axle, traction, damping system, tires and braking system are all made of mid-strength, anti-corrosion and high-ductility aluminium alloy. The aluminium alloy materials are manufactured by Yuhang Aluminum Co., Ltd. affiliated to Sanxing Group, and the aluminium alloy semitrailers and tank trucks are manufactured by Sanxing Minghang.

●SNTO aluminium alloy tank trucks are popular in the Middle East

Aluminium alloy tank trucks manufactured by SNTO Truck affiliated to SNTO Group have successfully entered the Middle East in 2015. By June 2016, 300 trucks had been sold in the Middle East. Weld joints have huge impact on the overall strength and leakage resistance of the tank body. The tank trucks manufactured by SNTO Truck are made from high-strength and high-ductility aluminium alloy plates without butt welds. Meanwhile, the frame, subframe and shoulder armor are manufactured by extruded profiles with high strength, stable quality and no fragility. Particularly, the tank trucks manufactured by SNTO Truck have passed the ADR certification.

●The largest aluminium alloy special-purpose vehicle production base Phase I in China put into production

Phase I of aluminium alloy special-purpose vehicle (tank truck, LNG tanker, fire truck, postal service truck, express service truck and sanitary truck, etc.) production project in aluminum processing and deep processing base (planned area of 20km²) in Liaoning Yingkou invested by China Zhongwang Group has been put into production in November 2017. The total investment of the project consisting of two phases is RMB 6 billion, with investment of Phase I of RMB 3 billion and capacity of special-purpose vehicle of 50,000. The sales revenue after the project completion is expected to reach RMB 10 billion, making it the largest aluminium alloy special-purpose vehicle production base in China and best in class worldwide. Currently, the unit price of the truck made from aluminum manufactured by Zhongwang Group is about RMB 200,000, 6 t lighter than the steel one in net weight, equivalent to increase of 6 t in payload.

By 2017, the percentage of aluminum trucks in China will not exceed 5%, a huge gap with 70%-83% in developed countries. China Nonferrous Metals Industry Association has made much efforts in the promotion of aluminum semitrailers and scored remarkable achievements, but the desired objective is yet to be met. The promotion of aluminum in the trucks and buses has huge potential and economic and environmental benefits, and developed countries have set a good example in this regard, what are the reasons behind the gap between actual results and desired objective? Here are the possible reasons: people are not sufficiently aware of the advantages and energy saving and environmental protection benefits of all-aluminum semitrailers and vans, so the publicity and education need to be strengthened; all-aluminum trucks and semitrailers allow no excess of rated load, while steel ones may double the rated load or more, which implies huge economic benefits and high safety risks; laws and regulations regarding energy saving and emission reduction are yet to be improved, a large number of non-compliant steel semitrailers exist in the transport sector, the penalties on overloaded trucks are weak, and the road transport order is yet to be regulated, the state should preferably introduce certain incentives on lightweight aluminum alloy trucks, vigorously encourage the market adoption of aluminum trucks, especially the small vans; the maintenance techniques for aluminum vehicles are more complex, so maintenance network should be established and technicians should be trained. Notably, the number of registered small vans in China in 2017 has exceeded 15 million, but the percentage of aluminum ones is extremely low. Therefore, it is suggested to introduce relevant regulations to set a deadline for fuel economy indicator, so as to urge the manufacturers to significantly reduce net weight of trucks and vans.