Filtering out nano-particles

German company Emitec as developed the PM-Metalit diesel particulate filters which reduce particulate emission by up to 80%, and are easy to retrofit. The company introduced the filters, along with special catalytic converters which ensure trucks meet current emission norms.
Last year, the MAN Nutzfahrzeuge Group, awarded Emitec with one of its annual 10 “Trucknology Supplier” awards for its ability to cut pollution by after-treatment of particulate emissions. Emitec had in collaboration with MAN developed the PM-KAT diesel particulate filter. MAN is the first commercial vehicle manufacturer to use this technology to meet the Euro 4 standard in trucks. The worked together on a retrofit for Euro 3 vehicles for almost all truck models.
The latest engines from MAN feature the combined filter-catalytic converter system. Similar retrofit systems are also available for passenger cars. BMW has been using Emitec filters in series-produced models for some time now and is planning to fit all its diesel-engine vehicles also with wall-flow particulate filters from 2006 onward. The manufacturer is to market retrofit systems for diesel models already on the road.
Emitec was founded in 1986 as a subsidiary of Siemens and GKN. Headquartered in Lohmar, near Bonn, the company is the world’s largest manufacturers of metal substrates for catalytic converters. The benefit of partial flow PM-Metalit filters is that they are virtually maintenance-free and have no impact on fuel consumption. In addition, they are of an open design and do not become blocked. Soot particles are collected in pores of a fleece-like metal foil, where they are continuously combusted by the incoming NO2 at temperatures of around 200 °C.
According to the company, studies show that the new system removes the very finest particles with a diameter of between 20 and 100 nanometers (a millionth of a millimeter), which penetrate deeply into the lungs and therefore pose a particular health hazard. At the same time, an oxidizing catalytic converter – using a new “turbulent” metallic substrate – changes nitrogen oxides into nitrogen dioxide. The latter provides the oxygen required to burn the soot particles and is completely reduced to nitrogen oxide in the process.
One of the products that Emitec is focusing on is its Exhaust Gas Recirculation (EGR) Catalyst, which will 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.
Automotive Industries spoke to Emitec’s managing director, Wolfgang Maus and asked him to tell us about new technologies in the pipe-line.
Maus: Our PM-Metalit “partial flow filter technology” will offer all benefits when Diesel engines will be cleaner and will emit more or less “Nano-Partikulates”. Then this PM-filter concept will offer as a next generation DPF a continuous PM reduction process in competition to those which need active soot regeneration. Also a new approach will be an optimized SCR-System. This will be presented at the forthcoming Commercial Vehicles IAA in Hannover in September 2006. Other novelties like the Pre-Turbo-Metalit or the EGR-Metalit will follow soon.
AI: How has the North American market responded to your products?
Maus: The North American Market has responded very promising to our new product developments. US 2010 legislation requires more efficient and cost effective solutions
Largest growth potential for Emitec we are also seeing already in Asia, especially in India, where we just brought a new plant on stream and in China, Korea and Japan.
AI: What are your plans to expand Emitec’s global reach?
Maus: Globalization offers open markets and in any respect optimal production locations. So on one hand having plants on three continents we now achieved highest production standards with regard to quality, cost and logistics. And this will be completed. Therefore on the other hand – Emitec will continue to build on today’s success which is our specialized engineering service to the auto industry worldwide. And not at least we will continue to create ideas and products vehicle manufacturers most probably will need after 2010.