supplierbusiness - sae international · diesel soot – particulate ... figure 28: selective...

Automotive Exhaust and Aftertreatment Systems Report

SupplierBusiness

2012 Edition

CONTENTS

Introduction ...................................................................................................... 7

Key drivers ..................................................................................................... 10

Fuel economy and CO2 emissions ................................................................. 10

The United States ...................................................................................... 10

The European Union................................................................................. 12

Japan ........................................................................................................ 12

China........................................................................................................ 12

Other countries ......................................................................................... 13

Noxious emissions and health concerns ........................................................ 14

Diesel Soot – Particulate Matters ............................................................... 17

Nitrogen oxides (NOx) .............................................................................. 19

Europe ...................................................................................................... 21

The United States ...................................................................................... 23

Japan ........................................................................................................ 27

Other countries ......................................................................................... 30

Medium- and heavy-duty vehicles .............................................................. 31

Platinum Group Metals trends...................................................................... 31

Exhaust and after-treatment technology ........................................................... 35

Gasoline engine emissions control ................................................................ 39

Three-Way Catalytic converter (TWC) ...................................................... 39

Exhaust Gas Re-circulation (EGR) ............................................................ 42

Diesel engine emissions control .................................................................... 44

Diesel oxidation catalyst ............................................................................ 44

Selective catalytic reduction ....................................................................... 45

CRT Process ............................................................................................. 52

Diesel particulate filter .............................................................................. 53

Catalyst Poisoning .................................................................................... 56

The SCR versus EGR debate ..................................................................... 56

SCR plus EGR for Euro 6 ......................................................................... 59

Acoustic management ............................................................................... 60

Exhaust heat recovery systems ................................................................... 61

Thermoelectric generators ......................................................................... 65

The exhaust and aftertreatment systems market ............................................... 67

The OEM market ...................................................................................... 67

The Aftermarket ........................................................................................ 72


© IHS Global Limited 3

Supplier Profiles .............................................................................................. 75

Bosal ........................................................................................................ 75

Boysen ...................................................................................................... 78

Calsonic Kansei ........................................................................................ 80

Eberspächer .............................................................................................. 84

Emitec ...................................................................................................... 87

Faurecia .................................................................................................... 89

Futaba ...................................................................................................... 96

Gustav Wahler .......................................................................................... 98

Johnson Matthey .................................................................................... 100

Katcon .................................................................................................... 103

KSPG ..................................................................................................... 105

Magneti Marelli ...................................................................................... 109

Tenneco .................................................................................................. 114

Umicore.................................................................................................. 118

Wescast .................................................................................................. 121

TABLE OF FIGURES

Figure 1: The progress of emissions regulations across major markets ................. 8 Figure 2: Fuel economy standards to 2015 for selected countries (US mpg) ....... 10 Figure 3: International car CO2 emissions standards ......................................... 11 Figure 4: NOx limits in the EU, Japan and the US, 1995 – 2010 (g/kWh) ........ 13 Figure 5: PM limits in the EU, Japan and the US, 1995 – 2010 (g/kWh) .......... 13 Figure 6: Global testing procedures and standards ............................................ 15 Figure 7: An overview of the role of nitrogen oxides in atmospheric chemistry.. 15 Figure 8: HC reductions in the EU, Japan and the US, 2000 – 2010 .................. 16 Figure 9: The structure of particulate matter (PM) ............................................ 17 Figure 10: CO reductions in the EU, Japan and the US, 2000 – 2010 ................ 18 Figure 11: Diesel PM reductions in the EU, Japan and the US, 2000 – 2010 ..... 19 Figure 12: NOx reductions in the EU, Japan and the US, 2000 – 2010 .............. 19 Figure 13: The progress of EU gasoline emissions regulations........................... 21 Figure 14: US Light duty emissions standards ................................................. 26 Figure 15: Criterion emissions reductions in the EU, the US and Japan, 1992 –

2015.......................................................................................................... 28 Figure 16: Emissions standards timetable in selected countries, 2001 – 2010 ..... 30 Figure 17: Price comparison and volatility in Platinum and Palladium 2007 -

2012.......................................................................................................... 32 Figure 18: Tenneco’s technology road map for exhaust systems ........................ 35 Figure 19: A comparison of exhaust systems 1975 and 2009 ............................. 36 Figure 20: A 2012 exhaust system including emissions control, CO2 reduction

and acoustic design ................................................................................... 37 Figure 21: Three-way catalytic converter .......................................................... 38 Figure 22: The effect of fuel-air mixture on catalytic converter operation .......... 40



Figure 23: The effect of temperature on catalytic converter operation ................ 41 Figure 24: The construction of an electrically heated TWC ............................... 42 Figure 25: Exhaust gas recirculation with cooler .............................................. 43 Figure 26: Denso’s compact EGR cooler for gasoline engines ........................... 43 Figure 27: Selective catalytic reduction schematic ............................................ 45 Figure 28: Selective catalytic reduction ............................................................ 46 Figure 29: Faurecia ASDS unit ........................................................................ 48 Figure 30: Delphi’s on-board reformer ............................................................. 49 Figure 31: A schematic of Faurecia’s ASDS system .......................................... 49 Figure 32: Lean NOx trap/ storage catalyst converter (NSC) system ................ 50 Figure 33: NOx trap system with ECU control ................................................. 52 Figure 34: A schematic of a wall-flow DPF ...................................................... 53 Figure 35: Mercedes Benz E Class DPF ........................................................... 54 Figure 36: Acicular Mulite process effects in DPF substrate .............................. 55 Figure 37: A comparison between EGR and SCR technology ........................... 57 Figure 38: Eberspächer’s ActiveSound technology integrated with an Audi A6

exhaust system .......................................................................................... 60 Figure 39: Energy distribution and losses ......................................................... 62 Figure 40: BMW’s combined EGR TEG unit .................................................. 62 Figure 41: Electrical power requirements for NEDC and actual customer

requirements for various vehicle classes ..................................................... 64 Figure 42: BMW Turbostreamer technology on test and in-situ ........................ 64 Figure 43: A systematic diagram of a TE module ............................................. 65 Figure 44: Skutterudite structures .................................................................... 66 Figure 45: Global gasoline and diesel production forecast to 2024 .................... 67 Figure 46: Global gasoline and diesel production forecast by region to 2024..... 68 Figure 47: Forecast PGM use in autocatalysts .................................................. 69 Figure 48: Forecast DPF market for light vehicles to 2024 ................................ 69 Figure 49: Exhaust and aftertreatment market for light vehicles value to 2024 ... 70 Figure 50: Exhaust and aftertreatment market for light vehicles value by region

to 2024 ...................................................................................................... 71



TABLE OF TABLES

Table 1: Euro emissions limits for light positive ignition (gasoline) vehicles (g/km) ...................................................................................................... 22

Table 2: Euro emissions limits for light compression ignition (diesel) vehicles (g/km) ...................................................................................................... 22

Table 3: US emissions standards for light-duty vehicles, to five years/50,000 miles (g/mile) ........................................................................................... 23

Table 4: Monitoring requirements of California OBD systems .......................... 24 Table 5: Japan emissions limits for light gasoline & LPG vehicles (g/km) ......... 27 Table 6: Japan emissions limits for light diesel vehicles (g/km) ......................... 27 Table 7: Chinese emissions standards for light duty vehicles ............................. 29 Table 8: Emissions control strategies ................................................................ 38 Table 9: Reactions in a three- way catalytic converter ....................................... 40 Table 10: Cost comparison EGR vs SCR in Europe ......................................... 59



supplierbusiness - sae international · diesel soot – particulate ... figure 28: selective...

Documents