innovations and highlights - emitec gmbh...innovations and highlights at the 65th iaa in frankfurt...

Press Release 65th IAA Cars September 2013 _____________________________________________________________________________________________________________________

Press enquiries: Emitec Gesellschaft für Emissionstechnologie mbH Hauptstraße 128 53797 Lohmar www.emitec.com

Email: [email protected] Tel.: 0049 (0)2246 109-311 Fax: 0049 (0)2246 109-109

Emitec Cleans Up Engine Emissions: Close-Coupled Catalytic Converters for Petrol and Diesel Engines

Innovations and highlights at the 65th IAA in Frankfurt Since overcoming what were previously thought to be the insurmountable problems of metal

catalytic converter substrates some 26 years ago, Emitec has developed a full range of

components and systems for every conceivable type of application. Different solutions have to

be found just for installation position and space requirement alone. All of Emitec’s metal

substrates are characterised by minimum exhaust back pressure and turbulent flow to fully

exploit the entire catalytic converter cross-section.

Emitec’s very first catalytic converters were designed for close-coupled mounting to petrol

engines. Emitec was by far the first manufacturer in the world to anticipate a development that is

now also catching on with diesel engines. Close-coupled catalytic converters heat up very

quickly after a cold start, not least because of the substrate’s wafer-thin high-temperature steel

foils. The faster the catalytic converter heats up, the fewer pollutants escape into the

environment. Tests have shown that around 80% of pollutants are still being produced during the

cold start phase. With its new EU 5 and 6 diesel engines Volkswagen has been able to

demonstrate that close-coupled oxidation catalytic converters (from Lohmar) and close-coupled

SCR catalytic converter systems offer optimum emission control, making the work of automotive

engineers much easier when it comes to emission reduction.

In addition to its function, the weight of the exhaust system is another important factor in many

applications, especially in motorcycles and sports cars. Emitec’s latest lightweight catalytic

converter has its world premiere in BMW’s R 1200 GS motorcycle. Emitec’s tried and tested

metal substrate catalytic converter is encased in a shell made from only 0.5 mm thick stainless

steel with a bionic and hence very rigid structure. Metal substrates with turbulence-generating

LS (longitudinal) or PE (perforated) structures help save even more weight. This type of high-

performance catalytic converter is now being fitted by BMW. Porsche has been using it for its

Panamera models for some time, so it is likely to catch on with other manufacturers as well.




Increasingly stricter emission limits for petrol and diesel engines require a constant stream of

new solutions for exhaust gas aftertreatment. Accurate monitoring of system processes is

becoming increasingly more important. In response, Emitec upgraded its Sensorkat™, a

catalytic converter with an integrated lambda sensor, for petrol engines, which Volvo had already

been using in vehicles destined for the US market. Sensor catalysts are now also being fitted to

diesel engines. Here, the thermocouple is no longer positioned in front of or behind the catalytic

converter but directly inside the metal substrate where it is able to respond much more quickly to

temperature changes and control fuel injection via the engine management system to change

injection timing and fuel quantities.

Emitec’s metal substrate is uniquely suited to heating cold exhaust gas. First designs were

developed over 20 years ago for the petrol engines of the BMW Alpina 7-Series and then the

BMW AG 7-Series. Because of its great reliability this EMICAT® is the only one of its kind that is

suitable for large-scale production. However, it is an even more essential component for diesel

engines because of their “cold” exhaust gas and it is being brought into series production for the

first time (again!) to preheat the exhaust gas of a V6 turbodiesel during critical driving conditions

before it enters the catalytic converter. These critical conditions occur primarily during

deceleration when there is no combustion and the engine is sending cold air to the catalytic

converter. The intermittent engine cut-offs associated with hybrid vehicles are no less of a

problem. When the combustion engine restarts after a period of electric-only propulsion it

produces cold exhaust gas that has to be preheated. Pre-heating the exhaust gas can also be

useful when the engine restarts during start/stop operations.

Emitec has been working on the reduction of nitrogen oxide in the exhaust gas for many years

and has developed a number of relevant components. Emitec will be presenting the latest,

extremely compact in-tank supply modules for selective catalytic reduction (SCR) at the IAA.

SCR involves the injection of a urea solution into the exhaust system to convert NOx to nitrogen.

The injection quantity is controlled inside the module; Gen III (trucks/NRMM) und Gen IV (cars)

also have fill level and quality sensors. The installation size of the modules is only 0.7 litres,

which makes them significantly smaller than competitors’ products. Both Emitec modules can be

bolted or welded to the inside of the AdBlue tank to protect them against harsh environmental




conditions. Despite being integrated in the tank, every important component is easy to replace

for servicing.

Emitec is also going to present various turbulence-generating metal foil profiles at its stand.

These foils ensure that there is much better contact between the exhaust gas and the catalytic

coating and greater utilisation of the substrate cross-section. Turbulence-generating catalytic

converters currently account for over 50% of Emitec’s deliveries and their share is steadily rising.

Emitec’s stand is also well worth a visit because of the many other exhibits of various sizes,

which demonstrate that Emitec’s metal substrates are not limited to small catalytic converters

alone. Products range from components for mopeds to those for locomotive and ship engines.

We look forward to talking to you when you visit us at stand B32 in hall 5.1 at the IAA in

Frankfurt.

Turbulence-generating PE and LS metal foil profiles

LS-Design

® and EGR filter BMW R 1200 GS system Lightweight catalytic converter

used in the MDB of the VW Group with lightweight catalytic converter




Sensorkat™ Heated catalytic converter

Gen III and Gen IV supply modules for SCR

innovations and highlights - emitec gmbh...innovations and highlights at the 65th iaa in frankfurt...

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