SupplierBusiness

The Automotive Exhaust and Aftertreatment Report

2013 edition supplierbusiness.com

Sectoral Report

IHS Automotive

2013 edition 2 © 2013 IHS

IHS Automotive SupplierBusiness | The Automotive Exhaust and Aftertreatment Report

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ContentsKey drivers ....................................................................................................................................................................... 8

Fuel economy and CO2 emissions ............................................................................................................................. 8The United States ......................................................................................................................................................... 8The European Union .................................................................................................................................................... 9Japan ......................................................................................................................................................................... 10China ......................................................................................................................................................................... 10Other countries .......................................................................................................................................................... 10

Criterion emissions ................................................................................................................................................... 12Diesel Soot – Particulate Matters ............................................................................................................................... 13Nitrogen oxides (NOx) ................................................................................................................................................ 14Europe ....................................................................................................................................................................... 15Source: DieselNet .......................................................................................................................................................17The United States ........................................................................................................................................................17Japan ......................................................................................................................................................................... 19Other countries .......................................................................................................................................................... 21Medium- and heavy-duty vehicles .............................................................................................................................. 22

Testing regimes .......................................................................................................................................................... 22Platinum Group Metals trends ................................................................................................................................. 24

Exhaust and Aftertreatment Technology ................................................................................................................... 28Three-Way Catalytic converter (TWC) ......................................................................................................................... 31Diesel oxidation catalyst ............................................................................................................................................. 34Exhaust Gas Re-circulation (EGR) .............................................................................................................................. 35NOx reduction ............................................................................................................................................................ 37Selective catalytic reduction (SCR) ............................................................................................................................. 38Lean NOx trap or NOx adsorber catalyst (NAC).......................................................................................................... 41CRT Process .............................................................................................................................................................. 43Particulate reduction .................................................................................................................................................. 44Particulate filters ......................................................................................................................................................... 45Combined particulate and NOx aftertreatment systems ............................................................................................. 47Catalyst Poisoning ..................................................................................................................................................... 50The SCR versus EGR debate ..................................................................................................................................... 50SCR plus EGR for Euro 6 ........................................................................................................................................... 52

Acoustic management .............................................................................................................................................. 52Exhaust heat recovery systems ............................................................................................................................... 54

Thermoelectric generators ......................................................................................................................................... 57The Exhaust and Aftertreatment Systems Market ................................................................................................... 60

The OEM market ........................................................................................................................................................ 60The Aftermarket ......................................................................................................................................................... 63

Supplier Profiles ............................................................................................................................................................ 65Bienes Turgon ............................................................................................................................................................ 65Bosal ............................................................................................................................................................................ 67Boysen ......................................................................................................................................................................... 69Calsonic Kansei ......................................................................................................................................................... 71

2013 edition 3 © 2013 IHS

IHS Automotive SupplierBusiness | The Automotive Exhaust and Aftertreatment Report

Eberspächer ............................................................................................................................................................... 81Emitec ......................................................................................................................................................................... 85Faurecia ...................................................................................................................................................................... 87Futaba ......................................................................................................................................................................... 94Johnson Matthey ....................................................................................................................................................... 96KSPG ........................................................................................................................................................................... 99Magneti Marelli ........................................................................................................................................................ 102Sichuan Bohong Group ........................................................................................................................................... 107Tenneco ..................................................................................................................................................................... 109Umicore ......................................................................................................................................................................115Wahler Verwaltungsgesellschaft mbH ...................................................................................................................118

FiguresFigure 1: Emissions regulation promulgation from different source jurisdictions ............................................... 5Figure 2: The progress of emissions regulations across major markets ................................................................ 6Figure 3: Tenneco’s technology road map for exhaust systems .............................................................................. 7Figure 4: Global CO2 (g/km) progress normalised to NEDC test cycle .................................................................... 8Figure 5: CO2 (g/km) performance and standards in the EU new cars 1994 - 2011 ............................................... 9Figure 6: Fuel economy standards to 2015 for selected countries (US mpg) ........................................................ 10Figure 7: Comparison of different fuel efficiency regulations and test regimes .................................................. 11Figure 8: Global testing procedures and standards ................................................................................................. 11Figure 9: CO reductions in the EU, Japan and the US, 2000 – 2010 ....................................................................... 12Figure 10: An overview of the role of nitrogen oxides in atmospheric chemistry ................................................ 13Figure 11: The structure of particulate matter (PM) ................................................................................................. 13Figure 12: Diesel PM reductions in the EU, Japan and the US, 2000 – 2010 ......................................................... 14Figure 13: NOx reductions in the EU, Japan and the US, 2000 – 2010 ................................................................... 15Figure 14: Euro 5 and 6 emissions regulation implementation roadmap .............................................................. 16Figure 15: US Light duty emissions standards ........................................................................................................ 19Figure 16: Criterion emissions reductions in the EU, the US and Japan, 1992 – 2015 ......................................... 20Figure 17: Emissions standards timetable in selected countries, 2001 – 2010 ..................................................... 22Figure 18: Comparison of different test regimes for EU, US and Japan ................................................................ 23Figure 19: PGM application suitability mix ................................................................................................................ 25Figure 20: Price trends for palladium, platinum and rhodium 1993 to 2011 .......................................................... 26Figure 21: Factors affecting overall PGM demand ................................................................................................... 27Figure 22: Aggregate PGM demand 2003–2012 ........................................................................................................ 27Figure 23: Eberspächer technology road map for exhaust systems ...................................................................... 28Figure 24: A 2012 exhaust system including emissions control, CO2 reduction and acoustic design .............. 29Figure 25: Audi A3 aluminium cylinder head with integrated exhaust manifold ................................................... 30Figure 26: A comparison of exhaust systems 1975 and 2009 .................................................................................. 30Figure 27: The effect of temperature on catalytic converter operation ................................................................ 31Figure 28: Three-way catalytic converter .................................................................................................................. 32Figure 29: A close-coupled catalytic converter, close to the engine for faster light-off, with underfloor cata-lyst and oxygen sensor ................................................................................................................................................ 32Figure 30: The effect of fuel-air mixture on catalytic converter operation ........................................................... 33Figure 31: The construction of an electrically heated TWC .................................................................................... 33Figure 32: The construction of a diesel oxidation catalytic converter .................................................................. 34Figure 33: Exhaust gas recirculation with cooler ..................................................................................................... 35Figure 34: A schematic of an advanced EGR system ............................................................................................... 36Figure 35: Denso’s compact EGR cooler for gasoline engines ............................................................................... 37Figure 36: Selective catalytic reduction schematic ................................................................................................. 38Figure 37: Selective catalytic reduction ..................................................................................................................... 39Figure 38: Delphi’s on-board reformer ....................................................................................................................... 40

2013 edition 4 © 2013 IHS

IHS Automotive SupplierBusiness | The Automotive Exhaust and Aftertreatment Report

Figure 39: Faurecia ASDS unit ..................................................................................................................................... 41Figure 40: A schematic of Faurecia’s ASDS system ................................................................................................. 41Figure 41: Lean NOx trap operating modes ............................................................................................................... 42Figure 42: NOx trap system with ECU control ........................................................................................................... 43Figure 43: Strategies for the minimisation of PM in GDI engines ........................................................................... 44Figure 44: A schematic of a wall-flow DPF ................................................................................................................ 45Figure 45: Mercedes Benz E Class DPF ..................................................................................................................... 46Figure 46: Acicular Mulite process effects in DPF substrate .................................................................................. 47Figure 47: Combined NOx reduction and particulate reduction systems ............................................................. 48Figure 48: Assessment grid for combined NOx reduction and particulate reduction systems ......................... 49Figure 49: Development trends for SCR and LNT technologies ............................................................................. 49Figure 50: A comparison between EGR and SCR technology ................................................................................ 50Figure 51: Eberspächer’s ActiveSound technology integrated with an Audi A6 exhaust system ...................... 53Figure 52: Energy distribution and losses ................................................................................................................. 54Figure 53: Honda Rankine cycle energy recovery system ....................................................................................... 55Figure 54: Electrical power requirements for NEDC and actual customer requirements for various vehicle classes ........................................................................................................................................................................... 56Figure 55: BMW Turbostreamer technology on test and in-situ ............................................................................. 56Figure 56: BMW’s combined EGR TEG unit ............................................................................................................... 58Figure 57: A systematic diagram of a TE module...................................................................................................... 58Figure 58: Skutterudite structures ............................................................................................................................. 59Figure 59: Thermoelectric materials development ................................................................................................... 59Figure 60: Global gasoline and diesel production forecast to 2024 ....................................................................... 60Figure 61: Global gasoline and diesel production forecast by region to 2024 ..................................................... 61Figure 62: Forecast DPF market for light vehicles to 2024 ...................................................................................... 62Figure 63: Exhaust and aftertreatment market for light vehicles value to 2024 ................................................... 63Figure 64: Exhaust and aftertreatment market for light vehicles value by region to 2024 ................................. 63

TablesTable 1: Euro emissions limits for light positive ignition (gasoline) vehicles (g/km) ............................................ 16Table 2: Euro emissions limits for light compression ignition (diesel) vehicles (g/km) ....................................... 16Table 3: Monitoring requirements of California OBD systems ................................................................................ 18Table 4: Japan emissions limits for light gasoline & LPG vehicles (g/km) ............................................................. 20Table 5: Japan emissions limits for light diesel vehicles (g/km) ............................................................................. 20Table 6: Chinese emissions standards for light duty vehicles ................................................................................ 21Table 7: Emissions control strategies ........................................................................................................................ 29Table 8: Reactions in a three- way catalytic converter ............................................................................................ 31Table 9: Cost comparison EGR vs SCR in Europe .................................................................................................... 51