STAINLESS INDIA / VOL. 16, NO.3 PAGE 1

STAINLESS STEEL GOES GLOBAL

The next time you pass by the Mumbai-Pune Road (NH4), you will not miss thehuge ball that rivets your eyeballs at theAkurdi Chowk in PIMPRI CHINCHWAD,Pune. Instead of spraining your neck, getoff the vehicle to have a good look andtake a couple of shots to show it to yourfamily and friends.

This is a huge 15-feet diameter globemade by M/s. Sharp Engineers, Pune,

Continued on page 2

out of stainless steel tubular structurewith laser-cut continents depicted on it.You may go around the globe, try tolocate your city or locate where your nearand dear ones are living around the globe.

The entire Globe made of stainless steelgrade 304 was manufactured using CNCbending machine and specially designedtooling to form and press the continentsout of 3mm thick SS304 sheets. The type

304 stainless steel tubes forming theglobe are of 40mm diameter. Thisstainless work of art is mounted on asuitable pedestal for passersby to havea good look.

Although the globe looks lovely andserves as a landmark, fabricating it wasa huge challenge. Making this hugeglobe was easy (WAS IT REALLYEASY?) compared to the challenge of

Indian Stainless SteelDevelopment Association

L-22/4, Ground Floor, DLF Phase-II, Gurgaon 122 002

Tel :+91-124 4375 501, 502 & 503Fax: +91-124 4375 509

E-mail: nissda@gmail.com, issdastainless@gmail.comWeb: www.stainlessindia.org

STAINLESS INDIAA MAGAZINE PUBLISHED BY

ISSN 0971-9482

SEPTEMBER 2011VOL.16 NO. 3 A Magazine Devoted to Stainless Steel ApplicationsPublished four times a year

STAINLESS INDIA / VOL. 16, NO.3 PAGE 2

Continued from page 1

ISSDA is organizing a series of fiveworkshops this year on the applicationsof stainless steel for the architecture,building & construction (ABC) sector.

Workshops will be held duringDecember 2011 in the following metrocities:

Delhi : 5th Dec, MondayMumbai : 7th Dec, WednesdayBangalore : 8th Dec, ThursdayChennai : 9th Dec, FridayKolkata : 10th Dec, Saturday

Timings : 5:30 to 9.30 pmfollowed by Dinner

Ms Catherine Houska, consultant toNickel Institute will be makingpresentations in these workshops. The

All-India ABC Workshops by Ms Catherine Houska, theworld’s leading expert on stainless steel – New dates

A section of the participants

Workshop on ‘Sustainable Stainless Steel forBuilding & Construction’ held in Pune

Mr Ramesh Gopal (seated) Mr N C Mathur (speaking)

On 17th June 2011, ISSDA organized ahalf-day workshop titled ‘SustainableStainless Steel for Building &Construction’ in Pune. About 70 inviteddelegates and 20 industry participantsfrom member companies participated inthis workshop.

A good number of academics includingstaff and students of schools of

architecture in the city, Public WorksDepartment, Municipalities of Pune,Pimpri & Chinchwad, Cantonment Boardand other government agencies, a coupleof ABC fabricators and builders alsoattended.

This event can definitely be described asa very successful initial foray into Pune.

The International Stainless Steel Forum(ISSF) has granted the first ISSFSustainability Award for Outokumpu.The acknowledgement was received inISSF Annual General Meeting inMadrid, Spain on 22 May 2011. Therecognition was based on Outokumpu’sdetermined actions and greatachievements in reducing waste tolandfill and increasing materialefficiency in Sheffield.

David Martin, chairman of the ISSFHealth & Environment Committeecomments: “Outokumpu’s Sheffieldmelting shop case is an excellentexample of sustainable development.Minimising waste is in everyone’sinterest and this case demonstratessignificant improvements with clearfigures.”

Outokumpu established a sustainablerecovery and re-use route for differentstainless steel waste in Sheffield. Slagwas re-used in the production of asphaltand waste refractory material was usedas a substitute for limestone in thestainless steel making process. Theseactions have led to dramatic reductionin waste to landfill. Since 2007 over80% of all slag has been recovered andre-used as road stone in the asphaltproduction. During 2010 half of allrefractory waste generated on site wasre-used as a lime substitute.

[Extract: Outokumpu press releasedated 26th May, 2011]

Catherine Houska

pressing the continents to the samecurvature as the globe and surfacefinishing after installing on the tubularglobe.

The ‘Globe’ has been adorned byilluminated display signs and has beendrawing attention of everyone passingby. The ‘Globe’ is also protected by asturdy railing system in stainless steeltype 304 to protect it in case of trafficaccidents.

Fabricated and Installed By:

Mr. AMIT AGARWALM/s Sharp EngineersGAT No. 301/1, NanekarwadiChakan, Taluka KhedPune - 410 501. Maharashtra, IndiaTel: +91 2135 320601/2/3Mobile No : 09373 990221www.sharpeng.com

workshops are open to architects,builders, interior designers, engineers,civil authorities, urban planners,infrastructure personnel from airports,highways, sea ports, railways and otherfacilities and stainless steel industrypersonnel.There is no participation fee.For details, please contact ISSDA,nissda@gmail.com

Receives ISSFsustainability award

STAINLESS INDIA / VOL. 16, NO.3 PAGE 3

RAILWAYS TO ENHANCE STAINLESS STEEL COACH PRODUCTIONKalka mail going from Howrah to Delhi,derailed on July 10, 2011 and caused 69passengers dead and around 250 injured.The impact was such that 13 coacheswere thrown off the track, many on topof others, which left them badly mangled.Fire and sparks were seen in the ACcompartments of the train. The train wastravelling at a speed of 110 km/hr at thetime of the accident.

While loss of life and limb in accidentsis most regrettable, rail accidents areplayed up by the media to sell the story.It must however be admitted that railtransport is a relatively safe mode of travelcompared to road, where the annualnumber of victims in the country areeasily 100 times more, but do not comeup in the national news, or hardly amention. This article is about what theIndian Railways are doing to enhancesafety of passengers travelling by train.

The news item that “the casualties in therecent Kalka derailment could have beenmuch less if the train was running onLHB (Linke Hoffmann Bush) coaches”speaks volumes on the advantages ofstainless steel including safety aspects.The modern coaches made of stainlesssteel have more in-built safety features,and can absorb shock and impact ofaccidents more effectively. The sturdyand robust design obviates capsizing ofcoaches in case of accidents.

The importance of stainless steelcoaches has been well recognized by theIndian Railways. The railways plan toswitch over from indigenous ICF-designcoaches to German Technology basedLHB coaches in all mail and expresstrains in a phased manner within the nextfive years i.e. by 2016-17. LHB coachesare designed to minimize fire accidentsas they are equipped with fire retardantquality material and advanced couplers.

This move is aimed at infusing moresafety in train operations.

COACH PRODUCTION – SIGNIFICANTINCREASE IN STAINLESS COACHESPLANNED

The Indian Railways is the largest singlerailway system in the world under asingle owner – the Government of India.It has a fleet of 60,000 coaches, 64,000route kilometers and 220,000 wagons. Itcarries 8 billion people a year, more thanthe total population of the world which isover 6 billion. Metro rail systems areseparate and not included in the abovenumbers.

Out of the 60,000 coaches presently only1,600 coaches are in stainless steel(LHB design). Current and next year planof the railways to enhance the share ofstainless steel coaches is given in thetable below:

2011-12 2012-13

Total Coach 3,650 3,800Production

Stainless Coach 320 800Production

A traditional ICF-design air conditionedcoach made of corten steel costs Rs.1.5 crore each against stainless steelLHB coach costing Rs. 2.5 – 3.0 crores.

The modern coaches are morecomfortable; have a longer life span of35 years because of their high level ofcorrosion resistance against ICF’s 25years. LHB require much lessmaintenance, and also have a 12% - 15%higher passenger capacity that canincrease revenue. Railways areexpecting to enhance productioncapacity of its coach factories to greatly

increase LHB coach production insubsequent years.

It is planned to enhance stainless steelcoach production through the followinginvestments:

1. Rail Coach Factory, Raibareli, UP –Outlay Rs. 2,000 Crores (1,000 LHBcoaches per annum)

2. Rail Coach Factory, Palghat, Kerala– Outlay Rs. 1,000 Crores (600 LHBcoaches per annum)

3. Expansion of Integral Coach Factory,Chennai – Outlay Rs. 240 Crores (300LHB coaches per annum)

In addition, significant investments willbe made for new factories formanufacture of wagons (both stainlessand carbon steel varieties) at five factories– Halida, Guwahati, Bardhman,Bhubneswar & Secunderabad; ElectricalMultiple Units at Kacharapara, WestBengal; Diesel Multiple Units at Sankrail,near Kolkata; locomotives at Marhoura,and Madhepura in Bihar and rail axle atNew Jalpaiguri.

This is part of an overall plan of theGovernment of India to enhanceinfrastructure facilities. Severeconstraints in infrastructure such asroad, rail, water, electricity etc., are seenas the bottleneck pulling down thegrowth of the economy.

Unlike indigenous ICF coaches, whichare prone to capsize or climb on eachother during collision, the LHB coachesdo not get toppled. Apart from restrictingthe speed limit to 105 and 110 kmph onmain line and Rajdhani tracksrespectively, ICF coaches raise safetyconcerns due to a large number ofhanging under-gear parts.

Corten Steel Coach after accident Safer Stainless Steel LHB Coach

STAINLESS INDIA / VOL. 16, NO.3 PAGE 4

World leaders in handrail and balustrade,the Denmark – based Carl F Internationalhas bagged the Chennai InternationalAirport project and also identifiedtremendous growthopportunities in the handrailindustry of India.

Ms. Renu Kathuria –Managing Director of Carl FInternational Pvt Ltd said“We are proud to beassociated with thedevelopment of the ChennaiInternational Airport. Thisclearly endorses ourexpertise in the field ofhandrails and balustrade.The Company has already done the DelhiInternational Airport order for creating andinstalling handrails running about 30 to35 km length. We are poised at aninteresting point on the growth curve andsee this as an opportunity to furtherenhance our association with theaviation infrastructure industry. Carl F

Ms Renu KathuriaManaging Director

ISSDA organized a workshop on‘Stainless Steels in the WaterIndustry’ on Friday, July 22, 2011 at IndiaInternational Centre, New Delhi. Theworkshop was attended by 50participants from a cross section oforganizations related to water industry.The participants included officials fromMCD, NDMC, DDA, Ministry of Coal,Ministry of Water Resources(WAPCOS), Architects, Builders,

Water Treatment Plant Specialists andConsultants etc. The lecture of Mr. DavidJordan, consultant to Nickel Institute,consisted of three sessions on the topicsof i) Stainless Steels in the WaterIndustry, ii) Fabricating Stainless Steeland iii) Water Treatment Plant.Participants were very muchappreciative of the contents of theselectures. The concept of stainless steelplumbing evinced keen interest among

the participants. The display of stainlesssteel plumbing items by JSL wasbefitting to the occasion of the workshop.

Many of the participants requested forhaving a soft copy of the lectures deliveredby Mr. David Jordan and we have sentthem a CD of the PPT of all the threepresentations.

Workshop on Stainless Steels in the Water Industry

David Jordan, Consultant, Nickel InstituteA section of the participants

International is bullish in working acrossindustry segments in the near future.”

Carl F International introduced theconcept of handrails in combination withstainless steel and glass. Apart from itsproducts being associated with the elitelandmarks and buildings for blue – chipclients like the TCS, Cisco, RoyalSundaram, HP, Crisil, Syntel, Turbo

Energy, Techpro Systems and offices ofReliance Group, Carl F International hasalso supplied and installed its handrail& balustrade systems in known Hotelslike Le-Meridien, Radisson, ITC Group ofHotels.The company has worked on theresidences of iconic business people like

Contact details:M/s Carl F International Pvt Ltd,Plot No - C- 239, T.T.C. IndustrialEstate, MIDC, Pawane Village, NaviMumbai - 400705, M:+ 91 9867002356,Tel: + 91- 22 4097 8800 / 01 / 02,27684373 / 77, Fax: 022-27684367http:/www.carlfinternational.com

Bags Chennai International Airport ProjectN . R . N a r a y a n aMurthy, NandanNilekani, besidescelebrities likeChiranjeevi, SachinTendulkar and ShahRukh Khan amongothers.

Stainless steel handrails at T3, I.G.I Airport, Delhi

STAINLESS INDIA / VOL. 16, NO.3 PAGE 5

Rapid urbanization is taking place in Indiadue to migration of populations in searchof a living and other requirements. This isnaturally leading to congestion in urbancentres, both large and small. In anattempt to decongest the roads which arechoking, many cities across India areopting for Mass Rapid Transit Systems(MRTS) similar to the one in Delhi – Thefamous Delhi Metro. These includeBengaluru, Chennai, Hyderabad andMumbai which are on the fast track tocomplete their projects.

The Delhi Metro Rail Corporation hascompleted Phase I & II with 189.63 KMsof rail tracks with 142 stations. Another103.50 KMs are planned in phase III tobe completed by 2016. By 2021, DelhiMetro will have covered more than400 KMs.

Delhi Metro using stainless steel for thecoaches and in stations etc. is very muchappreciated by the people of this city. Dueto increasing passenger traffic, DMRChas made most of the lines 6-coach trains,instead of the 4-coach trains in thebeginning. These will be made 8-coachtrains within two years.

Metro coaches are in 301L grade ofstainless steel because of its strengthresulting in light weight coaches,aesthetics, durability, minimummaintenance, and above all the safety ofpassengers in case of crash or fire. Inmetro stations stainless steel isextensively used in escalators, handrails,benches, advertising panels, ticketingcounters, turn styles etc..

Stainless steel requirement is slated forfurther boost as the following cities have

made their plans to have metro railsystems:• Bangalore Mass Rapid Transit

Limited – 42.3 KMs• Mumbai Metro One Private Limited

– 145.67 KMs• Jaipur Metro Rail Corporation

Limited – 35.15 KMs• Hyderabad Metro Rail Limited –

71.16 KMs• Chennai Metro Rail Project – 43

KMs• Ludhiana Metro Rail Corporation –

28.82 KMs• Lucknow Metro – DPR prepared by

DMRC• Ahmedabad Metro – DPR prepared

by DMRC

There are other cities such as Kochi inKerala, Patna in Bihar, Meerut & Kanpurin Uttar Pradesh which have set theirsights on Metro Rail Systems. To ourknowledge, most of the cities listed

herein have decided to follow Delhi Metroas their role model.

Expecting a rush of cities going in forstainless steel rolling stock andpassenger facilities in stainless steel,apart from Bharat Earth Movers Ltd.(BEML in Bangalore), two overseasstainless steel metro coach makers suchas Alsthom and Bombardier have movedin to the country. While Bombardier hasa plant running near Baroda in Gujarat,Alsthom is expected to set up shop inthe south, along the border areas ofAndhra Pradesh & Tamil Nadu.

The Metro Rail System boost along withthe Indian Railways’ own plan (see anarticle on page 3) for expandingproduction capacity of stainless steelwagons and coaches, and the burgeoningrequirement of automotive exhaustsystem, the transportation sector in Indiawill become a significant share of the useof stainless steel in India within a fewyears.

Transportation Sector to claim a Significant Share of Stainless Steel Usage in IndiaMetro Rail Systems Sprout in Cities Across India

It has been observed that some of the Stainless India magazinesare not getting delivered and being redirected back to us.Readers are requested to provide their changed mailing addressand contact particulars so that they are assured to get‘Stainless India’ magazine regularly.

Attention Readers!

DisclaimerDrawings/photographs of equipment, machinery,products and services in STAINLESS INDIA are forillustrative purposes only and their inclusion does notconstitute or imply any endorsement of the items orthe companies that manufacture or distribute them byISSDA and its staff.

Utmost effort is put into ensuring that there is noinfringement of copyright or IPR. In spite of our bestefforts, sometimes incorrect information creeps in,mainly because we have faith in those who contributearticles / images for us. Any such error, if at all, isdeeply regretted.

Rail Wagons Presentation Available on ISSDA Website

A presentation made by Mr. Ramesh Gopal, Executive Director,ISSDA at Jadavpur University, Kolkata, is now available atwww.stainlessindia.org. The title of the presentation is‘Sustainable Stainless Steel for Wagons’. Click on the icon“What’s New” on the home page.

STAINLESS INDIA / VOL. 16, NO.3 PAGE 6

Biogas typically refers to a gas producedby the biological breakdown of organicmatter in the absence of oxygen. Organicwaste such as dead plant (straws ofcrops like wheat, rice, jowar, bajra, huskof rice etc.), animal material, animaldung, kitchen and human waste etc., canbe converted into a gaseous fuel calledbiogas.

The gases-methane, hydrogen andcarbon monoxide (CO) can becombusted or oxidized with oxygen. Thisenergy release allows biogas to be usedas a fuel. Raw biomass can be used asa fuel in any country for any heatingpurpose, such as cooking.

Nearly 700 million Indians still burnbiomass as the primary source of energyfor cooking in inefficient cookstoves whichburn wood and other agricultural matterand add to air pollution. In addition, it isa source of health problem in kitchenswith insufficient ventilation.

India is the world’s fifth-largest andsecond-fastest-growing producer ofgreenhouse gas emissions. Generatingelectrical power by burning biogas (amixture of methane and carbon dioxideproduced by the bacterial degradation oforganic matter) harnesses thesegreenhouse gases and reduces demandfor fossil fuel-fired generating plants.

The Government is exploring thedevelopment of community-drivenbiomass based resources programs tomeet the basic energy needs of thepopulation in areas where electrificationis not possible, such as remote villages.As a climate change co-benefit, a largescale conversion to biomass-energy candecrease India’s greenhouse gasemissions.

BIOGAS ENERGY POTENTIAL

The Government of India’s Ministry ofNew and Renewable Energy Sources ispreparing a national bio-energy missionto boost power generation from biomass,a renewable energy source abundantlyavailable in India. Surplus biomass inIndia is estimated to be 150 milliontonnes. This could potentially be usedto generate 16 giga watts(16000 MW) ofpower.

During the 12th Five-Year Plan (2012-2017), the Indian Government isenvisaging to facilitate large-scale capital

investments in biomass-fired powerstations. It will provide power for day-to-day requirements of the population,encourage development of ruralenterprises and provide employment toa large number of people in thecountryside. This could also help in thestabilization of electricity grid.

Nearly 70% of the country’s populationlives in villages with marginal access toelectricity. Currently, India has a totalinstalled capacity of 3,000 MW ofbiomass-based power generation. Theministry of new and renewable energy istargeting to double this capacity duringthe 12th Plan (2012-17).

According to some estimates, biomassfrom agro and agro-industrial residuecould potentially generate 25,000 MW ofpower in India. This can be further raisedwith wasteland-based integrated energyplantation and power generationsystems.

Each MW generated from biomassplants would be able to cover about 6,000rural households. The ministry hasearmarked 3,400 crore for the variousincentive schemes under the biomassmission.

POWER GENERATION EQUIPMENT

We present a case study (from ‘NickelMagazine’, volume 23, number 3, June2008) where M/s Capstone TurbineCorporation of Chatsworth, California,U.S.A. installed their first micro turbineto produce biogas energy in Purulia,West Bengal in 2006. Based on thisexperience, they installed few moremicro-turbines at different locations inIndia for generating more biogas energy.The Purulia installation is at a dairy farmand consists of two 30-kilowatt micro-turbine systems, one of which is forbackup. These can run either linked orindependently of the power grid. “Whenthe grid is down, it is connected to thedairy to keep it running”.

The micro-turbines use nickel alloys andstainless steel in components such asthe combustion chamber, spinningturbine, main rotor shaft, recuperatorhousing etc., all of which runcontinuously with minimal maintenance.Austenitic stainless steels are the mostcost-effective material for the systemsthat clean and compress the corrosivebiogas prior to combustion in micro-turbines.

Biogas is mostly methane with hydrogensulphide present as a contaminant. Whenhydrogen sulphide is mixed with water(with which biogas is always 100%saturated), it becomes a weak acid(hydrosulphuric acid). Carbon dioxideforms a mild carbonic acid in thepresence of water. “Biogas is verycorrosive, which is why we use a lot ofstainless steel”.

“Stainless steel has good corrosionresistance to those acids. Predominantlywe use S30400 and S30403, thoughsometimes customers request S31600and S31603, as these are more resistantto corrosion. The S30403 might last 40-50 years whereas the S31603 can last100 years.”

A typical compression and cleaningsystem takes the gas drawn off the topof the sludge in a digester, where manurehas decayed for 20-30 days, andcompresses and cleans it before it isburned. In a simplified description of thisprocess, the gas first passes throughfilters that remove the hydrogen sulphide.These tanks will typically be constructedof stainless steel plate 4.8 or 6.4mmthick and are made to withstand negativepressure. The gas then passes througha compression system, where it is raisedto pressures as high as 8.4 kilogramsper square cm (kg/cm2). The piping usedin this process is typically stainlesssteel. Next it passes through heatexchangers to reduce the temperatureto about 4 °C, forcing more water out ofthe gas. The gas is then re-heated to27 °C, reducing the relative humidity to25%. Subsequently, the gas passes intostainless steel vessels where siloxane,a chemical used in lubricants andpersonal care products, is filtered out.Since siloxane turns into a glass-likesubstance at high temperatures it mustbe removed before the gas is burned.After this step, the biogas is delivered toan end-use device, such as a turbine,internal cubustion engine, or fuel cell.

CONCLUSION:

Given the big plans the Government hasfor use of bio-gas for energy productionin India, austenitic stainless steels havea significant market potential in thissector because they have proved to bethe most cost-effective material for thesystems that clean and compress thecorrosive biogas prior to combustion.

SIGNIFICANT POTENTIAL FOR STAINLESS STEEL IN BIO ENERGY

STAINLESS INDIA / VOL. 16, NO.3 PAGE 7

STAINLESS STEEL IS IDEAL FOR MITIGATING AIR POLLUTION IN COMMERCIAL VEHICLES

THE GOVERNMENT MUST TAKE STRINGENT MEASURES TO CONTROL POLLUTION BY DIESEL COMMERCIAL VEHICLESCommercial vehicles constitute 1.1% of total vehicular population in Delhi, but account for 90% of total vehicular pollution.

Fossil fuel-based vehicles using petroland diesel emit various air pollutants likeCO (carbon monoxide), HC (unburnedhydrocarbons), NOx (nitrogen oxides),SOx (Sulphates) and PM (particulatematter). These pollutants in auto exhaustare responsible for major diseases andare extremely harmful for humans. InDelhi, for instance, one out of every thirdchild is currently suffering from Asthmaand related respiratory diseases.

A study conducted by IIT Delhi in 2007established that even though CNGoperated buses are present in Delhi sincethe year 2000, pollution due to dieselcommercial vehicles is a major sourceof air pollution in the city. Althoughcommercial vehicles constitute only1.1% of the total vehicular population inDelhi, they account for 90% of the totalvehicular pollution in the city. People ofDelhi will distinctly remember the daywhen all diesel based buses were sentoff the road and CNG buses wereintroduced, one could start seeing theblue sky over Delhi. This highlights theeffect of diesel vehicles on the airpollution in cities.

This is not only the case with developingcountry like India; a similar situationprevails in developed countries like USA,Japan, Europe and our close neighbourChina. Pollution is the cause of concernespecially for urban areas in India.

Hence, tight control over the emission ofdiesel commercial vehicles is absolutelyessential all over the country to protectthe health of humans, especially in urbanareas where there is heavy traffic.Through strict emission norms andeffective implementation all across thecountry, we can achieve growth of bothhealth and wealth of India. Stainlesssteels play a very useful role in themitigation of pollution from diesel/petrolpowered vehicles.

Impact of pollutionDiseases caused due to vehicularpollution include Asthma, Alzheimer,Strokes, Pulmonary diseases andirritation in eyes etc., depending upon theexposure to air pollution. This effectivelyshortens the life span of living beings.The effect is much greater in urban areasbecause of higher vehicular population.

A survey has revealed that over 900million people in India are affected by airpollution. The number of prematuredeaths through harmful emission keepson increasing. Deterioration of health isthe major and visible result of airpollutants which has been released byvehicular exhaust.

Given below are the health impacts ofair pollution caused by vehicles:

Oxides of nitrogen (NOx): This gas canmake children susceptible to respiratorydiseases in winters.

Moreover, increased nitrogen loading inwater bodies, particularly coastalestuaries, upsets the chemical balanceof nutrients used by aquatic plants andanimals. Additional nitrogen accelerates“eutrophication,” which leads to oxygendepletion and reduces fish and shellfishpopulations. NOx emission in the air isone of the largest sources of nitrogenpollution in water bodies.

Carbon monoxide (CO): It combineswith haemoglobin to lessen the amountof oxygen that enters our blood throughthe lungs. The binding with otherhaemoglobin in proteins causes changesin the function of the affected organs suchas the brain and the cardiovascularsystem, and also the developing foetus.It can impair our concentration, slow ourreflexes, and make us confused andsleepy.

Sulphur dioxide (SO2) : SO2 in the airis caused due to combustion of fossil

fuels. It can oxidize and form sulphuricacid mist. SO

2 in the air leads to diseases

of the lungs and other lung disorderssuch as wheezing and shortness ofbreath. Long-term effects are moredifficult to ascertain as SO2 is oftencombined with that of SPM.

Suspended Particulate Matter (SPM):Suspended matter consists of dust,fumes, mist and smoke. The mainchemical component of SPM that is ofmajor concern is lead, others beingnickel, arsenic, and those present indiesel exhaust. These particles whenbreathed in, lodge in our lung tissues andcause lung damage and respiratoryproblems

It is important to understand that theabove pollutants are not only affecting thehealth of human beings, but all forms oflife on the planet earth.

Key Factor for Air Pollution –Diesel Commercial VehiclesBoom in industrial and agricultural outputin India, alongwith the favourable policiesof government towards farmers andfactors such as migration of populationtowards urban centres for education,jobs, medical facilities andentrepreneurial opportunities contributeto high density of population in urbancentres. To supply food, vegetables, dairyproducts, clothing and other day-to-dayneeds of urban centres with highpopulation, we need more and morediesel commercial vehicles. This is anecessary evil, which is necessary tofeed India.

Continued on page 9

STAINLESS INDIA / VOL. 16, NO.3 PAGE 8

STAINLESS INDIA / VOL. 16, NO.3 PAGE 9

Emission standards for new heavy-duty diesel engines—applicable to vehicles of GVW > 3,500 kg

Harmful Particulate Matter will be reduced drastically by over 98% if BS-IV norms are implemented throughout the country.

Source : WikipediaEMISSION NORMS - INDIA

In order to reduce harmful emission ofgases from vehicles, including carbondioxide, the governments all over theworld have been taking steps for cleaningthe environment. India has also issuedthe Clean Air Act which is popularlyknown as Bharat Stage in line withEURO norms.

In India, it was in 1991, that the first setof emission norms came into picture for

Continued from page 7

In 2010, Bharat Stage IV (BS-IV) was adopted only in 13 majorcities in India, but the implementation is still not proper.

In India, all on-road vehicles are required to have a valid Pollution under Control(PUC) certificate. However, a significant number of vehicles were already on-road.Poor road conditions and inappropriate maintenance of these vehicles were themain reason of pollution. As of now, each commercial vehicle should undergo anInspection and Certification Programme (I&C) through authorized RTO agencies.However, inadequate training given to independent centres for providing thiscertificate, outdated equipment, and inept tracking system of vehicles are majorflaws in this PUC system till date. This is making the emission norms not capableof controlling the today’s pollution levels.

Anyone can purchase the commercial vehicle from outside these 13 cities anddrive the vehicle in these cities without any check and control on diesel commercialvehicles. The whole purpose of cleaning the air in these cities is being defeatedas the pollution norms are not uniformly applied throughout the country.

As per published data, the sale of diesel commercial vehicle in domestic markethas grown by more than seven times in last 10 years, but emission norms havechanged only twice. This is not enough for the country which is on high growthpath and emission norms needs to be matched along with the changing profile ofdiesel commercial vehicle exhaust volume.

petrol vehicles and the same wasimposed on diesel vehicles in 1992. In1995, the next regulation was extendedto four metro cities (Delhi, Calcutta,Mumbai and Chennai). According to this,it was mandatory to fit catalyticconverters in new petrol passenger carssold. This step was so needed at thattime as “Lead” the highly toxic pollutant,was required to be taken out of petrol.Unleaded fuel was introduced first in

metro cities and then in other 42 majorcities.

One part of the emission is ParticulateMatter (PM) emitted by diesel vehiclesonly, which causes serious damage tohuman beings. PM is considered as mainsource of pollution. In 1996, regulationwas made that there should be cold startemission test for diesel vehicles below3.5 ton GVW (Gross Vehicle Weight).

Comparison of materials for exhaustsystems

As customers, we are concerned aboutthe quality of the vehicle while purchasinga personal vehicle or diesel commercialvehicle. In case of personal vehicles, welook into the aesthetic value, the mileage,the ergonomics, brand value and cost.In diesel commercial vehicles, thecustomer looks for products which havelower maintenance cost, higher loadcarrying capacity and best mileage. Inthe market, exhaust systems with pipesof mild steel, mild steel coated withaluminium and stainless steel are thechoices.

Since the service life of the exhaustsystem has not been defined in theBharat Emission norms, in order toreduce their selling price, manufacturersuse lowest cost materials like mild steelor aluminised steel for their exhaustsystem and provide only one yearwarranty. Their perception is that

Continued on page 11

STAINLESS INDIA / VOL. 16, NO.3 PAGE 10

STAINLESS INDIA / VOL. 16, NO.3 PAGE 11

stainless steel exhaust system is too“costly”. However, when the operational,maintenance and replacement costs tothe customer over the service life of thevehicle, say 8 years, stainless steelsystems prove to be the least cost optionto the user (See Table above).

First and foremost, stainless steels canwithstand high operating temperatures ofthe exhaust system without corrosionover the life of the vehicle. This means(a) the high operating temperatures of theexhausts will maximize the burning of thefuel and will lead to lesser emission ofPM and other harmful gases; (b) Therewill be increased fuel efficiency (read:mileage) (c) There will be no need tochange the exhaust system during thelife of the vehicle; (d) Maintenance costswill be minimal and NO replacements;(e) Because of high corrosion resistance,

thin gauges are used, reducing the weightof the vehicle and further enhancing fuelefficiency. In other words, higher initialoutlay on stainless steel systems giveslife-long benefits and helps keep ourenvironment clean. (f) At the end of servicelife all the stainless steel in the exhausttrain is 100% recycled whereas in thecase of mild steel and aluminised steelthere is a significant loss of material dueto corrosion in service.

The other two options i.e. mild steel andaluminised steel, though appear to be“costing less” initially, are life-long trouble,probably seven replacements and aconstant threat to the environmentthrough leakage of exhaust when in astate of repair (both air and noisepollution), and a big source of pollutionwhen not replaced. When you choosestainless steel, you are minimizing the

EXHAUST TRAIN COMPONENTS

cost and saving the environment. Thechoice is yours!

An exhaust system comprises offollowing components: an exhaustmanifold, front pipe, flexible pipe,catalytical convertor, centre pipe, mainmuffler, and tail end pipe.

Exhaust system has differentialtemperature at its two ends. At the headend it has the highest temperature (900degree centigrade) but at the tail end ithas relatively low temperature (100 – 400degree centigrade). The material forthese parts should be chosen carefullyso that it possesses these temperaturecharacteristics to meet the aim. Differentgrades of stainless steel have thenecessary properties to make asuccessful exhaust system with betterfuel efficiency, excellent oxidation

TableMild Steel Aluminised Steel Stainless Steel

Initial Cost 1 Unit 2 Units 5 Units

High Temperature Low Can perform till 500 deg.C Can perform at higher temperaturesResistance

Maintenance Cost High High Low

Service Life 1 year 1 year 8 - 10 years

Replacements over 7 7 None8 years

Resistance to corrosion Starts at Can resist till the layer is intact but 8 - 10 year of serviceworking temperature immediately layer starts depleting at working

temperature

Life cycle cost High High Low

Mileage Low Low High

MATERIALFACTORS

Continued from page 9

Continued on page 12

STAINLESS INDIA / VOL. 16, NO.3 PAGE 12

On 8th & 9th September, 2011, theWelding Technology Centre of theMetallurgical & Materials EngineeringDepartment of Jadavpur University,Kolkata, in association with ISSDA, helda two-day workshop on ‘Stainless SteelCoach & Wagon Manufacture’. Theworkshop was attended by about 70persons from various units engaged inthe manufacture of stainless steelcoaches and wagons, raw materialsuppliers and vendors of formed parts andsub-assemblies from across India.Welding equipment and consumablessuppliers were also present in significantnumbers and a few students of thedepartment.

The attendance was full even on thesecond day, right till the end of workshopsessions. This is an indication of howvaluable the presentations anddiscussions were to the participants.

Professor T K Pal, coordinator of theWelding Technology Centre did awonderful job of creating this forum forindustry-academia interface where bothmatters of fundamental knowledge ofstainless steel and its joining, as wellas industrial manufacturing matters werediscussed in great detail during the

WORKSHOP ON STAINLESS STEEL ROLLING STOCK AT JADAVPUR UNIVERSITY

course of two days. Practicaldemonstration of joining methods withadvanced equipment was also on display.

The undersigned made a presentation onthe material properties of 409M and itseminent suitability for manufacture ofwagons. An important recommendationmade to railway personnel was that thespecification of IRSM 44/97 (wagons) andCK 201 (for LHB coaches) should bealigned (minimum 0.3% Ni) so that theweldability of IRSM 44/97 is enhanced.Such alignment would enhance thechances of continued use of this gradenot only for open wagons, but also toother categories of wagons. This matterwould be further pursued by ISSDA with

the appropriate organizations of IndianRailway.

On its part, ISSDA also proposed twoimportant things at this workshop whichwere accepted in principle by themanagement of Jadavpur University: (1)Helping with the development of acurriculum for teaching stainless steel asan elective subject for undergraduatestudents in various engineeringdisciplines in the University. (2) Conductjoint workshops with the University inlocations close to the wagon and coachmanufacturing units in Bengal andelsewhere in India to resolve outstandingfabrication problems with the help of theProfessor and other experts.

Participants at the workshop on stainless steel rolling stock

resistance, good formability andweldability with a better aesthetic feel.

Exhaust Train Components:

Manifolds: should have the property tobear high temperature near 900 degreecentigrade, good oxidation resistance,thermal fatigue life and good workabilitybecause of its structure. So the bestsupporting material in the case ofManifolds is 304, 316 or 321 stainlesssteel.

Front Pipe and Flexible Tube: shouldbe able to withstand a temperature of600 – 800 degree centigrade. Goodoxidation resistance is must in this partalso. Grades of stainless steel that arebest fit in these parts of Exhaust systemare: 409L, 436L.

Catalytic Convertor: this includes shelland catalyst carriers. This part ofexhaust system should have the highesttemperature strength, approximately1000 - 1200 degrees centigrade. Also, itshould have the high thermal shockresistance as this is the part which isvery near to engine. Workability andresistance to chloride attack in coastalareas is a must for this part because of

its working. Smart Catalytic convertor canbe made up of these grades of stainlesssteel: 409L, 439, and 441.

Center Pipe: this has relatively lowtemperature (600 degree centigrade) butthe material used to make this shouldhave more corrosion resistance. 409L,439 grades Stainless Steel are the bestfit as a countermeasure against thecorrosion of the inner and outer surfaces.

Main Muffler and Tail End Pipe: thispart has to face the exhaust gascondensation which forms a very highmoist atmosphere inside the muffler. TheTail End Pipe should have its own featureother than oxidation resistance. Thisshould have good exterior as this part isvisible. Thus, ferritic stainless steel like409, 436, and 430 are used for this part.

Conclusion

In view of what has been clarified in thebody of this article, we request theauthorities to consider the followingsuggestions: (a) Strictly implementBS-IV norms for diesel commercialvehicles across the country withoutexception; (b) Make use of stainlesssteel exhaust systems mandatory both

from the point of view of mitigatingpollution and to minimize the cost to thenation in doing so.

Finally, it may be noted that variousgrades of stainless steel for use indifferent sections of the exhaust systemare available indigenously.

Article contributed by:Mr Nimish Goel, Manager - MarketingJSL Stainless Ltd, Jindal Centre, 12Bhikaiji Cama Place, New Delhi 110 066Tel: 91-11-26188340-50Mob: 91-8826287666email:nimish.goel@jindalsteel.com

Editor’s Note : This article explainsthe harmful effects of diesel as a fuelfor IC engines. While a lot of effort ison to mitigate pollution by commercialdiesel vehicles, we see that the numberof privately owned diesel passengercars are drastically increasing. Why?Because diesel is highly subsidised.Private diesel cars do the samedamage as commercial vehicles. Itwould therefore, make a lot of sense ifthe government discourages use ofdiesel vehicles for private use.

Continued from page 11

Edited & Published by Ramesh R. Gopal, for and on behalf of the Indian Stainless Steel Development Association.Printed by : Vee Kay Graphics, D-14/8, Ist Floor, Okhla Indl. Area, Phase-I, New Delhi - 110 020 Phone : 011-26814083/84 E-mail : veekay.graphics@gmail.com