Emitec Technologies Aggressively Reduce Diesel Impact on Environment

DETROIT, April 11 -- Recognizing the upward trend of growth in clean diesel technology, Emitec Inc. helps lower the environmental impact of diesel engines with its latest range of substrate technology for both OE and retrofit applications. The company delivers innovations such as its new particulate filter and structured turbulent foil substrate solutions that aggressively remove impurities and produce cleaner tail pipe emissions.

Particulate Matter (PM) Filter Catalyst

Developed by Emitec, the PM filter catalyst has the potential to reduce particulate matter up to 80 percent in many applications including trucks, and is particularly effective in capturing even the finest particles. The PM filter catalyst works on the principle of a partial flow filter, diverting a portion of the exhaust gas as it travels down each channel of the substrate through a stainless-steel sintered, fleece fiber material. PM from the exhaust gas is then deposited in the fleece material for oxidation through a combination of heat and nitrogen dioxide (NO2).

In addition, the Emitec PM Filter Catalyst is maintenance free. Due to its open construction design, it cannot become clogged or blocked like traditional wall-flow particle filters and therefore does not require periodic ash cleaning. This is a major advantage from the end customer through to the OEM in terms of total reliability and cost.

The first OE application of the PM Filter Catalyst on MAN's new D20 engine was announced jointly at the 2004 IAA Commercial Vehicles Show in Hannover, Germany. The first OE application in a diesel passenger car followed in the beginning of 2005. Available retrofit applications include diesel passenger cars supplied by major OEMs and trucks through Twin-Tec in Germany.

Structured Foil Substrates

Emitec's new turbulent METALIT(R) substrates constructed from structured foils provide the quantum leap in exhaust gas aftertreatment needed to meet future performance and cost requirements.

-- The Perforated (PE) Design METALIT(R) is made of perforated foil and provides for the possibility of mixing and radial flow within the substrate itself.

-- The Longitudinal Structure (LS) METALIT(R) with a patented "counter- corrugation" enhances the effectiveness of a 200-cpsi substrate to perform like a 400-cpsi substrate.

-- The Mixer (MX) substrate, constructed of foil that re-directs the exhaust gas from one channel to another channel, greatly improves the performance of selective catalytic reduction (SCR) systems and reduces the packaging and length needed between the urea injector and the front face of the hydrolysis catalyst.

All three structured foil substrates take advantage of "turbulent flow" characteristics to enhance performance features like backpressure, efficiency and exhaust gas mixing for optimized catalyst performance.

Nitrogen Oxide (NOx) Absorber and Sensor Catalyst

The NOx Absorber is responsible for the storage of nitrogen oxides prior to converting them by adding hydrocarbons during a regeneration phase. Structured METALIT(R) with LS- and PE-Design permit radial flow and uniform concentration of NOx in the absorber, allowing volume to be reduced. Integrating the NOx sensor into the substrate itself allows for reduced packaging and direct regeneration control.

Pre-Turbo Catalyst(TM)

The Pre-Turbo Catalyst(TM) is fitted very close to the engine before the turbocharger. There, it uses the higher exhaust gas temperatures for effective reduction of pollutants. Adapted coatings are used to cope with the increased maximum temperatures of the exhaust gas close to the combustion chamber. The sturdy Pre-Turbo Catalyst features a small metal substrate, thick walls and larger cells, and is mounted close to the engine, which avoids the heat absorbing issues caused by the turbocharger. The robust design provides high durability and high flow, protecting engine efficiency and performance, while significantly reducing hydrocarbon (HC) and carbon monoxide (CO) emissions.

Exhaust Gas Recirculation (EGR) Catalyst

The EGR catalyst is integrated into the EGR line to protect the heat exchanger from harmful deposits and contamination. The catalyst was developed in anticipation of the potential increase in EGR rates for 2007 through 2010.

SCR-System Mixer

The Emitec Mixer is located in the SCR system as a hydrolysis catalyst and ensures even distribution and conversion of the urea, which is dissolved in water. The mixing device incorporates structured foil technology to mix the exhaust gas in diesel engines with the SCR reductant. The mixer was designed to offer effective mixing in minimum space requirements by incorporating structured corrugated foil with blades to direct the flow of exhaust gas through a perforated, flat foil layer. These patented design features maximize the mixing of the reductant and exhaust gas, allowing for the urea injector to be placed in an optimum position in the exhaust system. The Emitec Mixer is now in mass production for HC-SCR systems produced by a leading retrofit supplier.

SCR-Catalyst System

The SCR-Catalyst System, comprised of the pre-oxidation catalyst, urea hydrolysis catalyst and the actual SCR-Reduction Catalyst, uses ammonia to directly reduce NOx. With this technology, potential NOx reduction rates range from 70 to 90 percent. Using a structured METALIT(R) with LS- and PE- Design, both of which create a turbulence effect, the catalyst volume can be dramatically reduced compared to straight-channel, flow-through catalysts. This dramatic reduction in volume enhances packaging while reducing both weight and cost.

About Emitec

Emitec GmbH is the leading designer and manufacturer of metallic substrates and diesel particulate filters for exhaust aftertreatment and evaporative emissions. Founded in 1986, Emitec is headquartered in Lohmar, Germany and currently holds more than 1,400 international patents. The company's North American operations, Emitec Inc., are headquartered in Auburn Hills, Mich. Manufacturing facilities are located in Fountain Inn, S.C. as well as Lohmar and Eisenach, Germany. Research and development centers are located in Lohmar and Eisenach, Germany.