Catalytic Converter Interest Group (CCIG)
The Catalytic Converter Interest Group was formed several years ago to
further the aims of this very successful export based industry.
The group represents the majority of motor vehicle manufacturers in South Africa, as well as manufacturers of the precious metal catalyst and the companies who fabricate the final catalytic converter assembly. Most of the players in this industry are local subsidiaries of multi-nationals who have made substantial investments in this rapidly growing sector ofthe South African automotive component industry.
The high profile grouping has taken the industry, through the innovation of the Motor Industry Development Programme, to a billion rand a year export business.
To support the industry's success and sustainability the group is workingclosely with government and all stakeholders through the Partnering for Growth strategy to ensure it remains a world competitive industry. All the key critical issues are addressed to maintain the industry as a good investment both for the group and for the country.
The industry is critical to the growth of the stainless steel manufacturing sector in South Africa, consuming 30% of primary material supplied into the domestic market by Columbus.
Auto emission systems in SA
The modern automobile exhaust is a complex system of components increasingly made almost entirely of stainless steel.
The manufacture of automobile emission control systems in South Africa is one of the fastest growing industry sectors in the world. Founded on the growth and development of catalytic converter manufacture, of which South Africa now has in excess of 10% of the world's production, the auto emission industry is now supplying highly sophisticated systems to many of the world's auto companies. Current production of catalytic convertersis now in excess of 10 million units/year.
The South Africa automobile industry has manufacturing plants from most of the world's premium auto manufacturers. These are:
BMW NISSAN MERCEDES VOLKSWAGON
AUDI CHRYSLER FORD VOLVO FIAT
Export of locally manufactured vehicles and components from these companies is supported by the Motor Industry Development Programme, which is attempting to rationalise the model ranges made by local plants, by increasing exports of these models into global markets.
Catalytic converters - SA supplies 10% of world market
The industry's primary source of stainless steel is Columbus Stainless, who currently supply in excess of 30 000 tonnes of stainless steel per annum into the South African auto-exhaust industry, for export around the world.
Columbus is particularly strong in the production of the ferritic grades such as 1.4512 (409) and 1.4509 which are typically used in the manufacture of exhaust systems. This is partly due to Columbus' on-site supply of ferrochrome, the world's lowest electricity costs and their modern, state of the art equipment.
Columbus has the capacity to produce 500 000 tons of stainless steel flat products annually. Their stainless steel has been granted the Ü mark and TUV Rheinland approval, and can be produced to all major international specifications.
Columbus Stainless products
Austenitic
Chromium and nickel based alloys with low carbon contents
Corrosion resistant
Good formability
Good weldability
Withstands extreme temperatures
304/304L
Suitable for corrosive environments
Automotive applications:
-Cone sections on catalytic converter
-Flexible couplings
309/310
High oxidation resistance
Suitable for extreme temperature applications
Automotive applications:
-Cone sections on catalytic converter
316/316L
Suitable for specialised applications
Recommended for tank containers transporting corrosive liquids
316Ti/321
Suitable for components requiring elevated temperature strength and corrosion resistance
Automotive applications:
-Cone sections on catalytic converter
-Flexible couplings
Cromanite(tm)
Alloy with high chromium, manganese and nitrogen content.
Corrosion, impact and wear resistant
High strength
Ferritic
Chromium based with low carbon content
Not subject to high Nickel surcharge fluctuations
Good weldability
Good formability
Corrosion and Oxidation resistance
409
Price competitive
Recommended for automotive components:
Exhaust systems and catalytic converters components
Shells
Blanks
Baffles
Tubing
1.4509
Recommended for high temperature environments of up to 750C
Good creep resistance
Sagging resistance
Automotive applications
Tubular manifolds
Exhaust systems and catalytic converter components
Shells, blanks, baffles and flanges
Tubing
430
Heat resistant
Kitchen and catering equipment
Kitchen sinks
Washtroughs
Cutlery
3CR12
A Columbus Stainless innovation.
Price competitive
Corrosion resistant
Weldable in thicknesses up to 30mm
Automotive applications:
-Flanges
-Hangers
-Brackets Why stainless steel?
The many unique values provided by stainless steels make them powerful candidates in routine materials selection in the light of LCC.
Catalytic converters
Catalytic converters are the largest of the auto component groupings being exported from South Africa and now amount to $500 million/year. The growth of the local catalytic converter industry has been spectacular.
This industry is founded on South Africa's strategic strengths in the key inputs required for catalytic converter manufacture:
1. Platinum Group Metals
South Africa produces in excess of 60% of the world's platinum group metals (PGM's), including platinum, palladium and rhodium, which are the essential catalysts in the converter. Additionally, while South Africa's production levels are high, the country has in excess of 80% of the known reserves of these metals, which makes South Africa the long-term strategic supplier of these products. Five of the world's leading coating companies are now situated in South Africa, using advanced technology to apply PGM coatings to converter monoliths. These are:
* ASEC
* Cateler
* Degussa
* Engelhard
* Johnson Matthey
2. Chromium
South Africa is additionally the home to over 70% of the world's resources of chromium, which is the essential ingredient in the stainless steels used to both house the catalyst and produce modern auto exhausts. This resource base now produces in excess of 50% of the world's ferrochrome and has prompted the development of Columbus Stainless, one of the largest and most modern integrated stainless steel works in the world.
3. Monoliths
Major investments in new manufacturing plants has resulted in this critical component of catalytic converters being made in South Africa by both Corning Inc of USA and NGK of Japan. Discussions are taking place with producers of the metallic monoliths also used in auto catalysts to locate manufacturing plants in South Africa.
Exhaust systems
The growth of catalytic converters has attracted all of the world's major producers of auto exhaust systems to South Africa, and the following organisations all now have manufacturing plants, producing a range of products for export and local consumption.
* Arvin Meritor
* Bosal
* Calsonic
* Cataler
* Eberspächer
* Faurecia
* HJS
* Magnetti Marelli
* Stainless Precision Components
* Tenneco
* Zeuna Starker
While these organisations are often the designers and ultimate exporters of the finished system, there is a wide array of South African and international companies producing the individual components from local manufacturing facilities.
For further information contact:
Brian Potter - CCIG Chairman
Tel.: 082 572 5807
Excerpts: http://sassda.co.za/sectors/catcon.htm
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