OEM Exhaust & Emission Technologies

Transcription

1 OEM Exhaust & Emission Technologies going the extra mile

2 The Dinex Group The Dinex business concept is to develop, manufacture and distribute complete exhaust systems and emission technologies for all commercial vehicles and industrial machinery with diesel engines. Dinex supply complete exhaust systems from turbo to tailpipe for trucks, buses, vans and industrial machines. In addition, Dinex offer a variety of emission technology products for this range of applications. The competence of Dinex includes all processes of development, manufacturing and distribution. Development is based on space envelope requirements or specific customer drawings. Dinex are Europe s leading supplier of exhaust systems and emission technologies for commercial vehicles and industrial machinery and are the only industrial player with its own purchase and manufacturing departments for metal as well as ceramic products. Organisation Dinex are a Danish family owned company with more than 800 employees. The head office and Emission Technology Centre are based in Denmark. The production sites are located in Denmark, Germany, Latvia, UK, Turkey and Russia, with sales and distribution companies situated in Great Britain, Germany, France, Spain, Italy, Poland, Latvia, Russia, Sweden, USA and Turkey. Dinex operate within the Original Equipment Manufacturer (OEM), Original Equipment Spare parts Supply (OES) and Aftermarket segments. In 2009/2010, further production sites are planned in USA and Asia. 2

3 Company History Jorgen and Grethe Dinesen founded Dinex A/S in The founders have retired from daily operations to be active members of the board. Since 2000 Torben Dinesen has been the Managing Director of the Group Investment in new products for the market, as well as expansion of the production platform Establishment of subsidiaries all over Europe with focus on sales and distribution of the programme Global market expansion in Europe, USA and Asia as the next step for the Dinex Group. going the extra mile 3

4 Dinex Competence Complete Exhaust & Emission Systems Clamps A complete new range of low-leakage clamps tight-fit. Insulation techniques Keeping heat inside or outside. 800 degrees inside and 250 outside. Emission technologies Particle filters and SCR cats can be installed into our modular systems. Silencers Lockseamed, stamped or welded units. We supply alu. or stainless steel in 115 different sizes today with own tooling shop. Flex pipes & bellows We work with partners today. In addition, we have developed a lowleakage flex hose for emission applications 2006/07. Exhaust fittings All fittings are made inhouse for complete systems supply. Pipes Bending from 22 mm to mm in alu, or stainless steel. 4

5 SiC structure Vision The vision of the Dinex Group is to become the main supplier of complete exhaust systems and emission technology products to commercial vehicles and industrial off-road machines worldwide. This includes continuous improvement of existing filter media in conjunction with catalytic wash coating (CDPF`s), fuel borne catalysis (FBC) and various options for active regeneration (AR). The R&D Company Dinex Emission Technology A/S, the R&D company of the Group, will facilitate the Dinex vision by cooperating with the best technology providers in the world. They will identify, develop, test and validate the available technology against future emission standards to be applied to diesel engines serving the on-road and off-road market segments. Also it includes effective methods for reducing nitrogen oxides (NOx) by selective catalytic reduction (SCR) and reliable, cost effective exhaust control and monitoring systems to ensure optimal functionality and compliance. going the extra mile 5

6 Customers The OEM customers of Dinex are manufacturers of building machinery, commercial vehicles and buses, i.e.: Off-road segment: Dinex supply Tier 3-4 in the market and is dominant in Europe with 25% market share expanding the programme into emissions for On-road segment: Dinex supply for Euro 3, 4 and 5 to leading manufacturers in Europe and work on several projects for Euro 6 regulations planned to begin in We offer you Own design and test facilities for emission, back pressure and noise. Complete kit supply from turbo to tailpipe. 95% of all parts manufactured in-house including emission parts. Factory platforms in Europe to secure both high and low volumes. The will and energy to serve you with the best solutions. 6

7 Quality, Environment & Product Quality System Being a supplier to both the OEM and OES market requires a high level of quality management. This is why Dinex A/S maintains a quality management system, which is improved and refined regularly, thereby helping to ensure continuous improvements in quality and standards. Dinex A/S has been certificated in accordance with ISO 9001 since 1995 and is now certificated according to the latest third generation of ISO 9001 the ISO 9001:2000 certification. The TS16949 certification is a superstructure within the automotive industry of the ISO 9001 standard, which Dinex have in progress. manufacturing and products in terms of their impact on the environment. Therefore, Dinex A/S documents its environmental initiatives continuously, which makes it easy to evaluate the environmental impact. Since March 2004, Dinex A/S have been certificated in accordance with the ISO standard. This defines the international standard for environmental management. By being certificated to this standard, customers and other interested parties are ensured that Dinex A/S have environmental objectives that are continuously refined and updated, and that environmental action plans are set up and maintained. Environment Part of the quality management is to ensure that Dinex A/S is environmentally conscious by evaluating the company s Dinex deform inner and outer baffles to obtain a stronger construction. Dinex use single pipe from inlet through to outlet, to withstand vibrations. Dinex use in- and outside pipe attachment to support the flex pipe and prevent breakage. Dinex use aluminized silencer bodies and endplates to improve corrosion resistance. Dinex weld all internal parts minimum 50% to resist breaking. Dinex use small radius tooling to bend all types of pipes. Dinex prefer to bend all pipes and to minimize the use of welding. Dinex lock seam 99% of all silencers produced. going the extra mile 7

8 Know-How The sound pressure distribution across the inner surface of a silencer at a single frequency (f = 100 Hz). Product Development More than 50 R&D employees work on developments of exhaust and emission control systems in house. This includes all phases from design, 3-D drawings, flow dynamics and testing at Dinex s Test Lab for noise, back pressure and prototype designs. Design Dinex use SolidWorks - a 3D CAD system programme, which is a major advantage when communicating with customers as exchanging 3D models and drawings etc. is simplified. 2D Drawings Portable Document Format (PDF) 2D DXF/DWG (.DXF,.DWG) TIF image (.TIF) 3D Models/Assembly STEP AP203/214 Initial Graphics Exchange Specification (.IGS) Pro/ENGINEER files (.PRT,.ASM,.XPR,.XAS) In the development phase different methods of calculation are applied, based on theoretical values and experience, as well as information supplied by customers. Information from customers includes: Engine type Engine power Exhaust temperature Exhaust flow Space envelope available Calculations are supported by a CFD analysis using a Comsol Multiphysics system programme, which verifies the design of silencers. All new designs are tested. Test and Documentation The in-house test centre includes a range of engine test benches making it possible to test and document silencer functionality with regards to sound attenuation and back pressure. Sound levels are measured in 1/3-octave frequency intervals from 50 Hz to 8 khz. All tests are carried out according to Dinex standard testing methods or alternatively to customer requirements. The test centre is used as a design tool for R&D purposes, for documentation and quality control. The new test centre can also take the customer vehicle or engine and test and validate products. An Isosurface plot of the sound pressure inside a silencer at a single frequency (f = 2 khz). 8

9 New technology centre established Technology and new R&D Centre Dinex have installed in excess of 25,000 filter systems in Europe and gained huge experience in emission control installations. In line with the new EURO 5 and EURO 6 regulations, Dinex have established Dinex Emission Technology A/S to ensure the required competences within the Group. The new Dinex Technology Centre enables Dinex to develop, test and validate silencers and emission technologies much faster, more flexible and accurate, and in great detail. The Dinex Technology Centre covers 1,400 m² and includes a new m³ - reverberant sound chamber with Brüel & Kjær measurement equipment for even more detailed analysis of noise and vibrations. In addition, the technology centre includes two new Horiba engine dyno s for engines up to 600 kw and a chassis dyno for vehicles up to 18 m and 600 kw. Furthermore, Dinex have invested in a new flexible FTIR analyser for measuring of exhaust gas and air pollution components. The benefit for our customers is an even more professional and scientific approach, resulting in a higher level of development, verification and documentation that will allow Dinex to work with customers to meet tomorrows challenges for exhaust and emission systems. The technology centre includes facilities for development of new technologies and construction, fitting, testing and verification of prototype systems. The Dinex Technology Centre is one of the most modern engine laboratory in Denmark and amongst the best in Europe. Emissions Eastern Europe Euro 2/3 No regulations USA EPA/07 PM EPA/10-12 NOx+PM Europe Euro 4/06 NOx Euro 5/08 NOx Euro 6/10-12 NOx+PM going the extra mile 9

10 How to Decide for a Technology Prior to any installation of filters, an official Dinex partner would always datalog the vehicle under normal driving conditions. In this way, we ensure the optimum basis for choosing the best technology for the particular installation. The datalogging of exhaust gas temperature is done with the Dinex DiNLOG equipment, and results are tracked in a database for future use if needed at a later stage. The unique sleeving and clamping mechanism using the patented Lambda Larsen joints ensure Europe s leading concept in terms of modularity and easy access for maintenance. Fleet owners today require flexibility the Dinex manufacturing methods ensure that the different emission technologies are interchangeable adapting to constant changing challenges in highly competitive markets for fleet owners. With more than 25,000 Dinex installations worldwide, this has proven to be a valid concept! Dinex normally recommends the DiSiC technology for inner city vehicles such as city buses, refuse or distribution vehicles and generally on light vans. The DiPEX technology is more commonly recommended for long route heavy trucks and coaches. For warranty conditions applying to all technologies we refer to our continously updated website. 10

11 Emission Technologies & Brands Being a complete solutions provider, Dinex offer a broad variety of technologies to the market. Addressing environmental as well as legal aspects from development over manufacturing, maintenance to the recycling of the emission products has been taken care of by Dinex or our partners. In other words, the entire life time of the product is considered NOx PM HC CO DiPEX is a coated cordierite DPF, which is applicable to most vehicles on-road as well as in many off-road applications NOx PM HC CO NOx PM HC CO NOx PM HC CO DiSiC is a silicon carbide DPF. This is considered the most durable filter media at all. DiSiC can be used as a coated filter as well as an uncoated media in conjunction with FBC or Active Regeneration (AR). A unique combined DPF and SCR emission exhaust system, which can take typical EURO 2 & 3 vehicles to the level of EURO 5/EEV on the emissions. A Dinex partial filter media, which is commonly used in regions, where the governmental requirements for PM reduction has been set to a reduced level, where closed trap DPF s are not required. A family of high-tech monitoring devices, which ensure continuous monitoring and control of the chosen emission media. The reporting, monitoring and traceability comply with even the toughest governmental and operational requirements. A full concept of fitting, maintenance and recycling has been established European wide. going the extra mile 11

12 Dinex Competitor Measuring ports All Dinex filters have measuring ports for temperature, back pressure as well as opacity. This enables quick and reliable monitoring of performance and operational conditions. Flow Superior bending capabilities avoid Dinex having to weld and ensures optimal flow of exhaust gasses as well as noise reduction. Competitors run the risk of interrupted gas flow due to welding spots. Dinex Pipe bending Dinex can bend pipes from mm in mild, aluminized and stainless steel avoiding welding which will compromise product life time. Other competitors weld product which results in quicker corrosion. Dinex Competitor Material Dinex use predominantly 2.0 mm pipe thickness against competing manufacturers who use mm thickness. System design Dinex design complete kits, which are tested and validated. Both cylindrical and conical inlet and outlet modules are used. Dinex lock seaming capabilities ensure a superior finish and a longer life time. Other competitors weld their products which causes faster corrosion. Competitor Dinex Dinex Competitor 12

13 Stainless steel Dinex use stainless steel materials (of AISI 304 & 409). Inferior materials are excluded as heavily corroded surfaces may compromise the lifetime of a filter. Ferritic stainless steel has 33% lower heat expansion ability ensuring the heat variations on the filter module surface will not lead to cracking and failure. Unique clamps The patented Lambda Larsen joints as well as the high quality body straps ensure gas tight systems with a good fit to any vehicle. Modularity is guaranteed and easy access to the filters allows for maintenance to ensure optimum life time. Competitors using v-clamps with gaskets require more time for servicing. Dinex Competitor Interior design Superior lock seaming techniques ensure a product of the highest quality. All modules are designed with optimum flow and noise reduction features. The design analysis also considers the long life time requirement and vibration resistance of the unit. Other competitors product is spot-welded, which is more prone to loose inner parts as a result of vibrations. Dinex Competitor going the extra mile 13

14 Emission Norms Worldwide Particulate Matter g/kwh 0,200 Japan NST 0,150 EPA 04 Emission information from industry and government sources. Dinex is not responsible for accuracy of data as presented. Euro 3 0,100 0,050 Japan NLT Euro 4 Euro 5 EPA 07 EPA , Euro 5 Euro 4 Euro 3 NOx g/kwh EPA 2010 EPA 07 EPA 04 Japan NLT Japan NST Reduced Taxes (Maut incentive on German highways) A category B category C category Euro 4+5 & EEV class 1 Euro 3+2 Euro 1 and older Euro 5 & EEV class 1 Euro 4+3 Euro 2+1 and older EEV class 1 Euro 5+4 Euro and older A category B category C category 3 axles 0.09 eur 0.11 eur 0.13 eur 4 axles 0.10 eur 0.12 eur 0.13 eur Environmental Zones In addition to the constantly tighter emission norms, many cities start introducing compulsory use of diesel particulate filters in inner city centres or in public transportation. Such zones are established in amongst others Milan, Copenhagen, Stockholm, London, Santiago de Chile, Bologna and Paris. A well functioning DiNOx system installed on an average city bus equipped with a Euro 2 engine can easily save the environment an emission over 700 kg of NOx and 20 kg of particulates per annum. 14

15 DiSiC DiSiC is a registered trademark by Dinex A/S of a silicon carbide (SiC) diesel particulate filter (DPF). The DiSiC filter is designed using a substrate produced and sleeved by Dinex and integrated with the well-know Dinex modular filter systems that use the patented technology of the Lambda- Larsen joints. The DiSiC filter undergoes a manufacturing process where the substrate is hardened in a furnace with temperatures up to 2,400 degrees Celcius. This offers a higher thermal resistance in the filter than is found in most other available DPFs, and allows the DiSIC to withstand an extremely intensive regeneration of particles within a short space of time, even if regeneration has not occurred for a longer period of time. Such a feature is a result of using the DiSiC as a non-coated passive DPF with fuel born catalysts (FBC) as an additive. The requirements to the average operating temperatures are not different to the DiPEX, but the DiSiC technology is designed for vehicles with longer, low temperature driving cycles with few temperature peaks, i.e. refuse vehicles and the like that have the engine idling through longer periods. Min. required temperature profile for a Euro 2 and onwards engine: Peaks of min. 400 C Average min. 220 C Above 250 C 30% Above 300 C 15% Above 350 C 5% Temperatures for EURO 1 must be higher. Peak temperatures of 400 degrees Celsius are required for a minimum of five minutes to start regeneration, and this will be completed after approximately 10 minutes, even if the engine temperature should drop again during this process. Factors other than temperature need to be taken into account. Therefore, the above is no guarantee of the correct functioning of the filter. The DiSiC filters up to 99% ultrafine particles (PM), the same as the DiPEX technology Relative Emission NOx PM HC CO Base Emission NOx PM HC CO DiSiC going the extra mile 15

16 Dosing System The DiSiC system can use Fuel Borne Catalyst (FBC), which must be mixed into the diesel fuel. Depending on customer wishes, this can be dosed centrally at a facility or on an individual vehicle. For the vehicle Dinex offers an advanced dosing system that is easily fitted and connected to the existing diesel pipe line. The dosing system consists of either a 2 litre or 4 litre tank, an ECU to adjust and control the dosing, an injection pump as well as the required wiring loom. The dosing system is available in both 12V and 24V. The additive used with our dosing system and the DiSiC filter can be supplied by Dinex but is also available through a distribution network. We recommend Infineum F7991 which is tested and approved for DiSiC filters. Regardless if used with FBC or as a coated filter, the DiSiC is optimal for use with active regeneration, where Dinex is developing a superior diesel burner solution (green chart below) covering the broadest span of applications possible compared to other known AR strategies. Fuel Borne Catalyst Using additives is always a question of the correct dosing. Dosing too much Advantage: Better regeneration at low temperature Disadvantage: More ash in filter = more frequent cleans Dosing too little Filter will block quicker due to noncatalytic particles. 16

17 Catalysed DiSiC In addition to the uncoated substrates, the DiSiC filter is also offered as an active platinum coated filter with similar applications and operating features as the proven DiPEX system. To offer a wider variety of design and applications the silicon carbide can be configured in round, square and oval shapes and a multitude of sizes, as well as bullet design in centre baffles in silencers. KEY CHARACTERISTICS DiSiC is a registered trademark by Dinex A/S of a silicium carbide (SIC) diesel particulate filter (DPF). The DiSiC filter is designed with a thermal high resistant substrate. Integrated by Dinex with the markets best sleeving for the well-known Dinex modular filter systems. Patented technology of the Lambda- Larsen joints. The filter is designed to replace the silencer. DiSiC is a non-coated passive DPF using fuel born catalysts (FBC) as an additive or a catalytic coated filter. Optimum ash storage capacity. Type of filter technology Unassisted DiPEX /Catalysed DiSiC CRT DiSiC + FBC AR diesel + DOC AR burner C going the extra mile 17

18 DiPEX DiPEX is a registered trademark by Dinex A/S of a Continuous Regenerating Particulate Trap. The DiPEX diesel particulate filter is based on the patented DPX coating technology from ENGELHARD Corporation. Its ceramic honeycomb substrate is integrated into the Dinex modular sleeving design, utilising Lambda-Larsen joints. The DiPEX filter is coated with a combination of a highly active base metal washcoat and a specially formulated Precious Metal coating. The catalyst coating on the filter element effectively lowers the Light Off temperature at which soot particles will combust. Therefore, it promotes continuous and automatic regeneration of the soot particles that have been collected within the filter element. The DIPEX Filter System does not require the use of fuel additives, burners or additional power sources and has no moving parts. Hence, the primary attention required on this system is regular maintenance. Min. required temperature profile for a Euro 2 and onwards engine: Peaks of min. 400 C Average min. 220 C Above 250 C 30% Above 300 C 15% Above 350 C 5% Temperatures for EURO 1 must be higher. Other factors than temperature do need to be taken into account though. Hence, the above is no guarantee for the correct functioning of the filter. On older engines with high raw emissions the DiPEX can be configurated with a base metal coated pre-cat and is therefore suitable for most applications. Relative Emission NOx PM HC CO NOx PM HC CO Base Emission DiPEX 18

19 The design and operating principles of the filter are that the exhaust gas enters multiple channels of the ceramic monolith. Cell plugs at the inlet and outlet end prevent the exhaust gas flowing through the filter. Due to its porous material, the gaseous fraction of the exhaust can pass through the channel walls and exit the filter via the adjacent channels, thereby trapping the Particulate Matter of the diesel emission. 99% of the health-critical ultrafine soot particulates are filtered out. Additionally, Carbon-monoxide (CO) and Hydrocarbon Emissions (HC) are reduced by more than 80%. DiPEX is designed to replace the existing silencer. KEY CHARACTERISTICS DiPEX is a registered trademark of Dinex A/S of a cordierite diesel particulate filter (DPF). Based on the patented DPX coating technology from Engelhard/BASF. Very wide variety of applications Integrated by Dinex with the markets best sleeving for the well-known Dinex modular filter systems. Patented technology of the Lambda-Larsen joints. Available as DPX 1 and DPX 2. Both versions with a number of approvals including VERT. The cordierite substrate used in the DiPEX technology can also be used as an uncoated substrate in CRT replacement applications. Dinex offer a full range of the most common sizes along with the required rings, gaskets and clamps. going the extra mile 19

20 DiNOx - the Euro 5 & 6 Upgrade The DiNOx technology is especially useful in retrofit applications or to shorten the development time for OEM s on engine upgrades. What makes this system unique is the emission reduction in two stages. In the first stage, there is a ceramic filter in which up to 99% of the particulates are collected and catalytically burned. Residual hydrocarbons (HC) and carbon monoxide (CO) are also burnt in the same stage. In the next stage, the amount of NOx in the exhaust gases is measured and the correct amount of urea, known as AdBlue, is injected. In a selective catalytic converter (SCR), the Adblue reacts with NOx to form nitrogen and water and thereby ensure an 80% or above NOx reduction. The system is a stand alone system and does not need information from the engine to get the high conversion rate of NOx. This makes it a system that is very easy to adjust to any kind of diesel engine and application. The result is not only environmental gains but also the visual benefits, since the exhaust smoke, from buses for instance, is almost invisible. The DiNOx system is currently undergoing various laboratory tests but real life installations have so far produced excellent results. The DiNOx DPF part is based on the technologies available from Dinex - DiPEX and DiSiC both with FBC or coated. 20

21 The system is a sensor based technology. Therefore, the amount of NOx in the exhaust stream is measured continuously thus controlling the amount of Adblue (urea) that is injected into the system to optimize NOx reduction and prevent ammonia slip. For special applications Dinex has a system available that works with pure ammonia as reducing agent. Dinex develops and designs the DiNOx system with specific applications to fit any vehicle, and is already successfully operated in several fleets around Europe. Our DiNOx -system primarily consists of: Urea storage tank Urea injection and control system Sensors SCR Catalyst DPF Filter Exhaust pipelines Ecu KEY CHARACTERISTICS Reach Euro 5 EEV emission levels. Gives high efficiency in most applications. Easy to adapt to different engines and applications. Adblue (Urea) Additive. Allow vehicles into city centres. Relative Emission NOx PM HC CO NOx PM HC CO Base Emission DiNOx going the extra mile 21

22 DiCLEAN Dinex has a strong focus on technology development, manufacturing and distribution. We have a wide network of Premier Partners around Europe. These partners are official Dinex sales and service points, where the access to products and maintenance is guaranteed whenever needed. Here the optimum advice is given prior to installation, so the correct technology is applied at all times. Competitive pricing and fast action are key characteristics of our partners, who are regularly trained and educated by Dinex. The full Dinex range is available with these partners including mobile service units to carry out any installation, repair or maintenance on-site if required. All partners are obliged to return filters to Dinex for recycling at the end of the lifetime, to ensure the best for the environment. 22

23 DiNLOG DiNLOG system Transporter system Pumps, sensors, etc. Simple wiring Simple panel DiNLOG GSM/GPRS Advanced panel CAN bus DiNLOG setup tool (pc) NOx sensors An ultimate particulate filter is the after treatment medium to reduce PM. The high efficiency of the filter, however, requires monitoring to ensure an optimum lifetime and working conditions of the filter and thereby the engine. Dinex have developed a very sophisticated data monitoring strategy, which is constantly improved by means of modern data transmission. All Dinex particulate filters and SCR solutions are installed with equipment monitoring temperatures, back pressure and conversion rates in the after treatment system. In this way the vehicle down time for service and maintenance is reduced to an absolute minimum. Furthermore, the monitoring strategy ensures that any Dinex installation complies with governmental requirements for traceability of the performance/efficiency and durability of the installed emission product. With the DiNLOG system comprising of ECU, wiring and panels a complete overview is guaranteed. Integrated DiNTRACKER (historical database) and Transporter (transmitting interfaces) functionalities ensure transparency and the option to remote monitor - as well as remote programme - via GPRS a large number of vehicles via the internet as well as receiving SMS alarms on eventual service needs. Visual panels are available as simple LED versions or more advanced panels. going the extra mile 23

24 Modules and Technologies Dinex supply emission control systems to comply with legislation. It is Dinex defined strategy to manufacture and supply the necessary emission control systems that may be required from the OEM s to comply with present and future legislation. Silicon carbide filters (DiSiC ). Selective Catalytic Reduction (SCR). Combination package between a DPF and a SCR system (DiNOx ). Active regeneration. During the last five years, Dinex have sold more than 25,000 emission control systems to customers all over the world within the retrofit market, but also to the growing OEM market. The product portfolio of emission control systems, which is constantly developed, currently includes six different technologies that apply to different operating conditions and special customer requirements: Diesel oxidation catalysts (DOC). Being a supplier of exhaust systems to the OEM, OES and Aftermarket is a definite advantage of Dinex, as this makes complete kit solution offerings possible. The kit solutions include oval and round filter designs according to space requirement, electronic control units, hose connections, pressure valves, pumping systems and wiring looms etc. Opposite please find a list of standard universal modules for DiPEX, DiSiC, SCR and DiNOx. Catalysed Diesel Particulate filters (DiPEX ). 24

25 Universal Filters & SCR kw Rating Substrate Part no. Part no. Part no. Part no. Part no. Part no. Dim. DiPEX DiSiC filter module DiSiC filter module DiSiC filter module SCR module SCR TASC (Inch) filter module 90 CPSI uncoated 150 CPSI uncoated 150 CPSI coated module x x x x ,5 x x x (10.5x7) (10.5x7) RT 12 x 8 x NA x x x 15 Segm x 15 Segm NA going the extra mile 25

26 Exhaust Silencers All silencer dimensions are designed to optimise sound attenuation and back pressure. Sound attenuation is documented by the Dinex test procedure where the measured db(a) values are supported by 1/3 Octave from 125 Hz to 8000 Hz. Back pressure is kept at an absolute minimum in compliance with engine manufacturers maximum allowable limits. Exhaust silencers in more than 115 different baffle sizes are available in normal mild steel, aluminised steel and stainless steel: Mild steel Mild steel products are finished with either powder coating or heat resistant paint. Aluminised steel Over 90% of all non-stainless silencers are manufactured from aluminised steel. Aluminised steel or alu-zinc steel is a steel type where mild steel is coated with a thin layer of aluminium oxide composition. This type of material is very resistant to corrosion and no additional after-treatment is required. Stainless steel Dinex manufacture stainless steel products from various types of stainless steel, ranging from AISI 304 to AISI 409. Oval Silencer max. length mm ID ID OD DIM Body Body Body DK LV D 158 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

27 Tooling Sizes A B A A A B A B B B A x B A x B A x B A x B A x B 299 x x x x x x x x x x x 598 Oval Silencers A x B 86 x x 285 B 103 x x x x 435 A 123 x x x x x x x x x x x x 398 B B A A x B 143 x x x x x x x x x x x x x x x x 467 A A x B 175 x 295 going the extra mile 27

28 Exhaust Silencers Small Silencers max. length 1000 mm ID Body DIM LV 120 x x x x x x x x x x x x x x x x x 200 B B B Ø Oval Silencers A x B 86 x x x x x x x x 330 A 130 x x x x x x x x x x 398 A 143 x x x x x x x x 333 A x B 228 x x x x x x x x 467 A x B A 175 x 295 Ø109 Ø178 Ø127 Ø184 Ø155 Ø200 Ø173 Ø206 Triangular Silencer A B A x B 203 x 203 B A A x B 158 x

29 Round silencers max. length mm ID ID OD OD DIM Body Body Body Body DK LV D RUS Round Silencers Ø109 Ø121 Ø127 Ø132 Ø151 Ø155 Ø161 Ø173 Ø178 Ø184 Ø200 Ø204 Ø206 Ø208 Ø217 Ø225 Ø237 Ø249 Ø255 Ø262 Ø266 Ø280 Ø284 Ø292 Ø300 Ø320 Ø330 Ø341 Ø350 Ø383 Ø398 Ø400 Ø439 Ø448 Ø451 Ø518 Ø521 Ø going the extra mile 29

30 Pipes Exhaust pipes Dinex manipulate pipe work ranging from Ø32mm all the way up to 152 mm. Bending technologies utilised within Dinex ensure that all pipes are bent without deformation. New boosting technology also gives minimum Centre Line Radius all the way down to one time the diameter (1-D). All bending processes are CNC controlled to ensure optimal repeatability and quality control. Manipulated pipe work is available in normal mild steel, aluminised steel and in stainless steel. Mild steel Very few products are manufactured in mild steel. Mild steel (DC04/P04) is available but need after-treatment by either powder coating or heat resistant paint. Water-cooling and air charge pipes All pipes are internally cleaned with a high-pressured nozzle and dried. They are then capped/plugged to ensure protection against contamination during transit. Available surface treatments Powder coating Wet paint Blue/Yellow/Black Chromate If any other surfaces treatments are required, please contract one of the Dinex design engineers. Other technical options Mounting bracket Flanges for engine Mounting stop for rubber hose. Pipe beading according to DIN for water/air pipe to rubber hose joints. Aluminised steel Aluminised steel is the most frequently used type of steel for exhaust systems. Stainless steel Dinex manipulates primarily stainless steel in AISI 304/AISI 409. Other types of stainless steel are available upon request. 30

31 Bending DIM CLR Comment DK LV D DIM CLR DK LV D TYR Anti Clockwise Anti Clockwise Anti Clockwise Anti Clockwise Anti Clockwise Anti Clockwise Anti Clockwise Anti Clockwise going the extra mile 31

32 Flexible Pipes Dinex use and integrate the highest quality of interlock flexible pipes available on the market. Flexible pipes are used in exhaust systems to absorb engine vibrations, engine movement and heat expansion. Flexible pipes are supplied in various dimensions as an integrated part of an exhaust pipe or as a separate unit connected with clamps. Installation and use Flexible pipes are designed to absorb mainly lateral and angular movements. It is not recommended to use flexible pipes to absorb torsional movement. For this we recommend bellows. Dinex flex pipes are produced from high quality AISI 304 stainless steel. The Dinex flex pipe is an interlocked pipe which is designed to be gas-tight. Correct installation The function of a flex is to compensate and to absorb vibrations in the exhaust system. If the flex pipe is incorrectly installed, by either being compressed, stretched or bent, it will cause a breakage in the flex pipe after only a short usage time. This is due to vibration. The same problem can also occur when using clamps that are not suitable for flex installation, e.g. U-bolts etc. To ensure the correct function and durability of the flex pipe, correct installation is required. Therefore, it is recommended that flex clamps are used and the following 3-step installation procedure is followed: Compress Bend Flatten to mid-position Compress length = 100 % Bending length = % Extensible length = 125 % 32

33 Bellows The bellows are made by taking two or more thin wall steel plates and pressing or rolling them into a bellow form. To design an optimal bellows unit different factors such as heat, axial, torsion, and lateral movements have to be considered as well as the applications where they are used. Please contact a Design Engineer at Dinex to ensure these factors are optimised. Correct installation The function of a bellows is to absorb vibrations and heat expansion in the exhaust system. If a bellows is incorrectly installed by either being compressed, stretched or bent, it will cause a breakage in the bellows pipe after only a short usage time. This is due to vibration. To ensure the optimised function and durability of the bellows correct installation is required. 1 Single bellows, primarily axial movements, smaller vibrations and lateral movements to a small extent. 2 Double bellows where the spacer is made of the same bellows material. Designed for axial as well as lateral movements. Cannot be fitted with guide pipes. 3 Single bellows with external braid. going the extra mile 33

34 Insulated Pipes and Exhaust Insulation Insulation techniques and solutions are mainly required in engine compartments and other high temperature areas where the demand for reduction in surface temperature is of utmost importance. Further, insulation of exhaust systems with various emission technologies is often required to prevent unintended temperature loss ensuring optimal regeneration. The quality of insulation and insulation techniques is excellence and is resistant and durable at even very high temperatures. The integral insulation is always manufactured to the highest degree of reliability, easy to use and fit for purpose. Different insulation techniques are available depending on specific requirements, durability and customer needs. The Dinex Group uses state of the art techniques and production methods to ensure that customer requirements of product performance, durability, and cost effectiveness are met. Integral insulation on exhaust pipes and silencers High temperature resistant insulation (Special stainless steel foil used) Not inflammable Customised design Not sensitive to vibration Optimal heat insulation Sound insulation/attenuation Flexible fitting and can be supplied in segments Oil and water resistant No adverse health implication during manufacturing, transportation and use All products are supplied according to customer specifications and requirements with regards to range of surface temperature reduction, thermal and physical properties. High temperature insulation techniques are supplied as complete technical solutions, fully documented from start of the project to completion. 34

35 Clamps and Fittings Dinex Clamps Ltd. is our competence centre for design of clamps as well as production of high quality clamps. Dinex offer a wide range of products to fit and connect exhaust components. The programme includes flat clamps, DIN Clamps, V-clamps, Flex clamps and U clamps from very simple and cost effective design solutions all the way up to the highest class of products serving the most demanding installations. Dinex Universal Programme Please refer to the Dinex Universal Parts Catalogue. V-connections and V-clamps In general, Dinex recommend the use of V-connections and use of matching V-clamps. ID /OD solutions are only recommended when a certain degree of tolerance is allowed/required (heat expansion, fitting, alignment etc). going the extra mile 35

36 Flex Fit Exhaust Clamps Designed to connect flex to exhaust pipe. Mechanical joints replace spot welds to insure against fatigue failures. Strong, reliable yet lightweight and flexible. No need to separate pipes before clamping. Cylindrical trunnions allow the screws to self-centre to optimise performance. Socket cap screws provide a strong (12.9 grade) yet compact fastener mechanism. Strong clinching superior to spot welding. Simply torque the socket cap screws for fast assembly.* Available for pipe sizes from Ø50 mm to Ø152.4 mm. Available in polished 304 stainless or aluminized steel. Design Features Stepped strap accommodates flex for fast, easy and accurate installation. All fasteners are high strength and coated to provide high corrosion resistance (>700 hours salt spray resistance.)** Tolerates flex size variations of ±2mm on diameter and clamps can be re-tightened because there is no mechanical bridge or stop. 360o force distribution is achieved using a flexible stepped bridging piece. Dinex, low leakage fit. Competitor. Stepped bridging piece provides a 360 force distribution to help seal the joined components whilst still permitting variations in pipe/flex sizes. * Maximum recommended torque = 20Nm. ** In accordance with BS 7479 (ASTM B117) ISO Dinex Aluminized Inox A mm A Inch B mm B Inch 99250/T 99251/T / /T 99258/T / / /T 99265/T / / /T 99269/T / /T 99277/T / /T 99290/T / / /T / /T 99303/T /T 99315/T / / /T / / /T 99328/T /T 99349/T A B 36

37 TightFit Clamps Designed to connect exhausts pipes (with slotted ends). Mechanical joints eliminate spot welds to reduce corrosion and fatigue failures. Strong, reliable yet lightweight and flexible. Cylindrical trunnions allow the screws to self-centre to optimise performance. No loose parts and no need to separate pipes before clamping. Socket cap screws provide a strong (12.9 grade) yet compact fastener mechanism. Simply hook-in then torque the socket cap screw for fast assembly.* Available for pipe sizes from Ø50 mm upwards. Made from high tensile 304 or 409 stainless or aluminized steel. Design Features Strap made from high tensile grade steel to maximise the strength/weight ratio. All material is edge dressed no sharp burrs. Hook-in style trunnion provides a quick method of clamp assembly or removal. No need to remove the cap screw. All fasteners are high strength and coated to provide high corrosion resistance (>700 hours salt spray resistance.)** Straps are made from high tensile 1.2mm thick stainless or 1.5 mm thick aluminized material. Design can tolerate variations in diameter of ±2mm and clamps can be retightened further if necessary. Utilise mechanically clinched joints. * Maximum recommended torque = 30Nm. ** In accordance with BS 7479 (ASTM B117) ISO 3768 Dinex Inox Aluminized B mm B Inch / / / / / / / / / / / / B 25 going the extra mile 37

38 ButtFit Flat Clamps Designed to connect exhaust pipes end to end. Strong, reliable yet lightweight and flexible. No need to separate pipes before clamping. Simply torque the socket cap screws for fast assembly.* Available for pipe sizes from Ø50mm to Ø152.4mm. Made from polished 304 stainless or aluminized steel. Design Features 75mm wide strap accommodates pipes for fast, easy and accurate installation. Bridging piece helps provide a 360 seal around the joined pipes and accommodates pipe tolerance variations. Mechanical joints replace spot welds to insure against fatigue failures. Cylindrical trunnions allow the screws to self-centre to optimise performance, but also reinforce the joint. Socket cap screws provide a strong (12.9 grade) yet compact fastener mechanism. All fasteners are high strength and coated to provide high corrosion resistance (>700 hours salt spray resistance**). * Maximum recommended torque = 25Nm. ** In accordance with BS 7479 (ASTM B117) ISO Dinex Aluminized Inox B mm B Inch 99350/T 99450/T /T 99457/T / / /T 99463/T / /T 99470/T / /T 99476/T /T 99489/T / /T 99502/T / /T 99514/T / /T 99527/T / /T 99553/T B 38

39 HoseFit Clamps Designed to connect rubber hose to pipe. Strong, reliable yet lightweight and flexible. No loose parts and no need to separate hoses or pipes before clamping. Simply hook-in then torque the socket cap screw for fast assembly. Available for hose sizes from Ø50mm upwards. Made from high tensile 304 or 409 stainless steel*. Bridging piece provides a 360o seal whilst still permitting variations in hose size and tension. Mechanical joints on straps replace traditional spot welds to reduce corrosion and fatigue failures. Cylindrical trunnions allow the screws to self-centre to optimise performance. Socket cap screws provide a strong (12.9 grade) yet compact fastener mechanism. All fasteners are high strength and coated to provide high corrosion resistance (>700 hours salt spray resistance**). Design Features Strap made from high tensile grade stainless steel to maximise the strength/ weight ratio. All material is edge dressed no sharp burrs. * Maximum recommended torque as per chart. ** In accordance with BS 7479 (ASTM B117) ISO Dinex Pt No Clamp Range mm Strap Width ***Maximum Torque Nm Min Dia Max Dia B 25 going the extra mile 39

40 VeeFit Premium V-Clamps Designed to connect vee flanges on exhaust pipes and turbos. All material is edge dressed no sharp burrs. Strong, reliable yet lightweight and flexible enough to open around flanges. Hook-in style trunnion provides a quick method of clamp assembly or removal. No need to remove the cap screw. With no loose parts and 360 positioning of the fastener mechanism, easy assembly saves time, no need to separate flanges before clamping. Simply hook-in then torque the socket cap screw for fast assembly.* Available for pipe sizes from Ø50 mm upwards. Made from 304 or 409 stainless steel or premium aluminized steel with >5000hrs salt spray resistance.** Mechanical joints on straps replace spot welds to reduce corrosion and fatigue failures. Cylindrical trunnions allow the screws to self-centre to optimise performance. Socket cap screws provide a strong (12.9 grade) yet compact fastener mechanism. All fasteners are high strength and coated to provide high corrosion resistance (>700 hours salt spray resistance**). Unlike cast clamps, the fabricated construction maximises strength to weight ratios. Design Features Strap made from high tensile grade steel to maximise the strength/weight ratio. Straps are made from high tensile 1.2 mm thick edge dressed stainless. * Maximum recommended torque = 12Nm. ** In accordance with BS 7479 (ASTM B117) ISO Dinex Veefit Premium V-Clamps Inox Alu A mm A Inch B mm B Inch Tip width mm / /4 6.0 mm / /4 2.5 mm mm / mm / mm / mm / mm / mm / mm / / mm mm mm mm / mm A B 20 40

41 Production Production Equipment The manufacturing equipment consists of various CNC-operated machines such as laser pipe and plate cutters, punching machines, pipe bending machines, presses, robots, lock seaming machines etc. The manufacturing facilities are divided into a silencer line and a pipe line. Using an advanced 3D-drawing programme all technical specifications are transferred directly to the manufacturing machines, where the different components are processed, eliminating any risk of human error. The manufacturing equipment and technologies allow Dinex to manufacture pipes in one piece without welding. Silencers are assembled using a lock seaming and expansion technique, making it possible to produce silencers without any outside welding. Production Sites Each site produces its own specific range of items, but can be adapted to produce others when required. Denmark OEM customers and filter production. Germany OEM customers and insulation production. Latvia Aftermarket and OES production. UK Clamps production OEM and aftermarket. Turkey Large scale OEM production and OES volume. Russia Aftermarket and OEM production for Russia. going the extra mile 41

42 Logistics and Central Warehouse Suppliers The main suppliers are manufacturers of steel materials, and are evaluated according to the applied ISO 9001 quality management system. They are expected to be abreast of developments within their product area and contribute to optimisation of Dinex supply chain. To ensure that purchased products apply to specifications, samples of incoming materials are carefully checked. Warehouse The automatic warehouse is 15 meter high and contains in a 3,000 square meter facility 9,700 pallets, which are stored and restored by five fully automatic robots. The automatic warehouse has been implemented with focus on data logging, unambiguous labelling and storage. The efficiency of the warehouse is approximately 6 times higher than the previous manual warehouse. Raw materials, templates and products are transported directly between the production and the warehouse by automatic trucks (AGVs). The warehouse and production systems are linked thereby making it easier for the production operators to call off the required material from the warehouse. Shipment In respect of packaging and preparation for shipment, Dinex is able to comply with specific customer demands relating to branding, wrapping, packing in kits etc. As a standard all Dinex products are steel stamped with product number and provided with a barcode label (EAN13). If the customer has a logistic agreement with Dinex, Dinex will carry a stock of certain products and is able to deliver within 24 hours. 42