Composition of production cost of aluminum ingot
Production cost refers to the sum of material data and labor remuneration spent by an enterprise to produce a certain number of certain commodities, that is, the C+V part of the composition of commodity value. Let's first analyze the material consumption cost of aluminum ingots:
There are mainly three kinds of material data consumed by smelters of electrolytic aluminum to produce aluminum ingots: 1? Alumina; 2? Electricity bill; 3? Anode paste (anode carbon block). In addition, there are fluoride salts and so on. , but their cost is very small, generally only 200 ~ 300 yuan is consumed per ton of aluminum ingots. The following mainly analyzes the costs of the above three substances at the recent market price:
1. alumina cost
Generally speaking, it takes 2 tons of alumina to produce 1 ton of aluminum ingot. With more and more manufacturers adopting advanced technology and strengthening technical transformation, at present, most manufacturers consume about 1.93 tons ~ 1.98 tons of alumina to produce one ton of aluminum ingots. Although this ratio will decline with the efforts of various manufacturers, the decline will be very small, which we can understand as a constant. In this way, the price change of alumina determines the cost in this respect. At present, the market price of alumina is maintained at about 265,438+000 yuan. Taking the consumption per ton of aluminum ingot 1.95 tons of aluminum ingot as a constant, it can be calculated that the current consumption of alumina is about 4 100 yuan.
2. Electricity bill
This part of the cost involves two variables, one is the electricity price per kilowatt hour; Another variable is the electricity consumption per ton of aluminum ingot produced. Electrolytic aluminum industry consumes a lot of electricity. Due to the difference of production technology and equipment level, the power consumption per ton of aluminum ingot varies greatly among production enterprises. At present, it is generally between 1.4 million kwh-1.6 million kwh in China. We take the median household electricity consumption of most factories as 15000 kWh, while the average electricity price of domestic electrolytic aluminum manufacturers in recent two years is about 0.34 yuan, so the average electricity price of domestic electrolytic aluminum manufacturers is about 0.34 yuan.
3. Cost of anode carbon block (anode paste)
At present, the types of electrolytic cells in the world are divided into self-baking cells and pre-baking cells. Accordingly, the carbon anode used in the self-baking tank is called anode paste, and the carbon anode used in the pre-baking tank is called anode carbon block. Because anode carbon blocks need to be roasted first, there are many processes, so the price of anode carbon blocks is relatively high. At present, the market price of one ton of anode paste is about 1.400 yuan, while the price of one ton of anode carbon block is about 3000 yuan. For each ton of aluminum ingot produced, the self-baking tank consumes 0.54 ton of anode paste and the pre-baking tank consumes 0.6 ton of carbon block. Based on this, the anode paste cost of one ton aluminum ingot is 770 yuan, and the anode carbon block is 1.800 yuan. We take the average of the two.
To sum up, we can draw that the average social cost of raw materials for producing one ton of aluminum ingots in China is 250 (fluoride salt, etc.). ) +4 100 (alumina cost) +5 100 (electricity fee)+1280 (anode paste cost) = 10730 yuan. This is only the relatively basic direct material cost in the manufacturing cost. An enterprise also has to pay the wages, management expenses, financial expenses and sales expenses of its personnel, and amortize the depreciation expenses, bank loan interest and taxes of the machine workshop. , should be included in the production cost of the enterprise. At present, the cost of domestic enterprises in this respect accounts for about 20% of the total production cost of aluminum ingots. According to the recent market price of aluminum ingots 13400 yuan/ton, the cost in this respect should be around 2680 yuan.
Analysis on the price change of material data in the composition of aluminum ingot production cost
1. Analysis of price change of alumina
In recent years, the price of alumina fluctuates frequently. The higher price appeared at 3,300 yuan in August and September of 1.995, and the lower price once reached around 1.600 yuan. Most of the time, the price hovers between 2,000 yuan and 400 yuan/t.
The price of alumina is determined by its value and influenced by the relationship between supply and demand. There are three methods used in the industrial production of alumina in China: sintering method, mixed system method and Bayer method, of which mixed system method accounts for 69.4%, sintering method accounts for 20.2% and Bayer method accounts for 65,438+00.4%. Their respective unit manufacturing costs are shown in table 1.
According to the weighted average method, the current unit manufacturing cost of alumina in China is about 1453 yuan/ton. If other costs are added, the domestic production cost of alumina is about 1600 yuan/ton. However, more than 90% of alumina production in western countries adopts Bayer process, and its average production cost is about 150 USD/ton. Compared with domestic and foreign markets, alumina in western countries is more competitive, but the price difference is not very big.
After more than 40 years of construction, China has built six alumina production bases (another way of saying it is five alumina bases, because Zhengzhou Aluminum Plant and Zhongchuan Aluminum Plant are both under the jurisdiction of China Great Wall Aluminum Company, so some people regard them as the same base). Its production mode, output 1998, existing capacity and conventional capacity are shown in table 2.
Due to the large investment in alumina industry, long payback period and limited distribution of bauxite resources, local governments are unable or unwilling to invest. Domestic alumina is mainly supplied by six alumina bases, which have basically reached or reached the existing capacity, and some enterprises even exceed the existing capacity design. However, due to limited funds, the two enterprises to be expanded between now and 2000 cannot be completed on schedule in the near future, and the new alumina resources in China are relatively limited. It is estimated that the output of 1999 alumina is 3.65 million tons. However, the domestic aluminum ingot of 1998 has reached 2.42 million tons, and the output of 1999 will not be a problem if it exceeds 2.5 million tons. According to the ratio of 2 tons of alumina per ton of electrolytic aluminum, the demand will exceed 5 million tons, and the domestic alumina 10% will be used in non-metallurgical industries such as medicine and light industry, and the gap between supply and demand of alumina will reach 65,438+. In this way, the price of international alumina and the change of national foreign trade policy will directly affect the price of domestic alumina. As the price of aluminum ingots in the international market is at a low level, and some western aluminum manufacturers have recently announced the suspension or reduction of production, it is expected that the international alumina price will remain at a low level. At the same time, the country will not rashly adopt the policy of raising tariffs based on China's large import volume and its preparation for joining the WTO. On the other hand, in the face of the high production cost of aluminum ingot production enterprises, the national industry authorities will not significantly increase the price of alumina.
2. Analysis of changes in electricity charges
The cost of electricity in China accounts for about 40% of the production cost of aluminum ingots, which is far from 25% in western countries. Today, the international and domestic markets are more and more closely linked. If the proportion of electricity charge to production cost cannot be reduced, it will endanger the survival and development of domestic electrolytic aluminum industry.
One variable involved in electricity cost is unit electricity price. At present, the average electricity price of domestic electrolytic aluminum industry is about 0.34 yuan, which is twice that of foreign counterparts. In the case that the technical equipment level of most domestic production enterprises is difficult to change at once, the faster way to reduce the cost of electricity consumption is to reduce the electricity price. At present, the call for reducing the electricity price in electrolytic aluminum industry is very high, but it involves the power sector and needs the overall arrangement of the state. While hoping that the power sector will reduce the electricity price, many electrolytic aluminum production enterprises actively carry out aluminum-electricity joint ventures, and the whole industry shows the trend that aluminum plants run small power plants, large power plants run small aluminum plants, and electrolytic aluminum plants and power plants share shares with each other.
Another way to reduce the cost of electricity is to reduce the power consumption per unit aluminum ingot. Electrolytic aluminum electrolyzers are divided into self-baking electrolyzers and pre-baking electrolyzers. Compared with them, the self-baking electrolyzer has the characteristics of mature technology, less investment and quick effect. This electrolyzer is widely used in old enterprises and small and medium-sized enterprises newly put into production. At present, half of aluminum ingot production in China is produced by self-baking electrolyzer with relatively backward technology, but this technology has obvious defects: first, flue gas is discharged in the open air, which seriously harms the ecological environment and workers' physical and mental health; Secondly, the technical indicators are backward and the power consumption is high; Third, the output is small and the degree of automation is low. On the contrary, the prebaked tank has the characteristics of less environmental pollution, high technical index, low power consumption and high degree of automation. The power consumption is only once, and the power consumption for producing one ton of aluminum ingots in the prebaked tank is less than that in the self-baked tank 1000 kWh.
3. Analysis of cost change of anode carbon block
With the change of market demand from self-baking bath to pre-baking bath, and the introduction of the policy that self-baking bath is not allowed in recent three years, carbon factories producing anode paste and anode carbon blocks will face the market change that the demand for anode paste is gradually decreasing and the demand for anode carbon blocks is increasing. From this point of view, the cost will increase slightly, but it takes a process to transform the self-baking tank into the pre-baking tank, and at the same time, it needs to face the supply change of expanding the anode carbon block capacity in the carbon plant. The conditions for price increase in a short period of time are not yet available, and the proportion of costs in this area will not change much.