MARINE PORTFOLIO THE 360 EMISSION CONTROL COMPANY EGINE. EGA. SYSTEM SOLUTIONS. TWINTECBAUMOT GROUP

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1 PORTFOLIO MARINE PORTFOLIO MARINE DEVELOPMENT, APPLICATION AND PRODUCTION ALL FROM A SINGLE SOURCE EGINE. EGA. SYSTEM SOLUTIONS. TWINTECBAUMOT GROUP THE 360 EMISSION CONTROL COMPANY

2 FROM POWERTRAIN TO EGA ALL FROM A SINGLE SOURCE COMPANY PORTRAIT Twintec AG is the parent company of TwintecBaumot Group (TBG), a leading supplier in the area of exhaust gas aftertreatment and engine development. In that context, TBG offers its customers high-quality solutions in Design & Engineering and Products & Solutions as well as Testing & Validation Services. TBG applies those products and services across a wide range of industries in the business fields OEM (original equipment), retrofitting, aftermarket (repair, spare parts) and catalytic coating. In so doing, it covers the entire value creation chain for the exhaust gas aftertreatment sector. The market segments include, in particular, on-road Homologation/ Certification Production Exhaust System Development Development of Functionalities Software Development (e.g. cars, trucks and other commercial vehicles), off-road (e.g. construction machinery, agricultural machinery or stationary plant) and miscellaneous applications such as maritime or medical technology. Emission testing Simulation of system functionality Project Management 3Dmeasurements Within its four subsidiaries, TwintecBaumot Group has more than 380 employees and decades of experience in the field of exhaust gas aftertreatment. Acquired in 2015, Kontec GmbH, together with its subsidiary DIF (Die Ideenfabrik GmbH), represents the OEM develop- Validation on engine bench Product Design with CAD/CAE ment arm of the company, offering low-emission engines and exhaust gas aftertreatment systems to well-known original equipment manufacturers. Baumot AG, which was acquired Validation On road / field test FEM in 2014, is one of the leading providers of selective catalytic reduction (SCR) systems as well as active and passive particulate filters in the OEM and retrofitting business sectors. In addition, as a specialist in the development of emissions technology, Twintec Technologie Catalyst testing (light-off, aging and poisoning) CFD GmbH offers its customers innovative solutions for reducing exhaust gas emissions especially in the retrofitting and aftermarket segments. Through Interkat GmbH, TBG has expertise in catalytic coating services, which are offered across a wide range of industries. Strength and durability tests e.g. Hot shake Benchmarking Rapid Prototyping FMEA STRUCTURE TWINTEC AG Holding TWINTEC AG Holding Measurement and Data Acquisition System Integration Exhaust Aftertreatment Set up demonstrator vehicles Electronic Control Unit Samples and prototypes DESIGN & ENGINEERING PRODUCTS & SOLUTIONS TESTING & VALIDATION After treatment calibration Set up engine test benches KONTEC Automotive Engineering GmbH Sustainable Mobility, Engineering, Automotive Services BAUMOT AG Emission Control Products, Retrofit/Aftermarket KONTEC Testing Validation & LAB GmbH Design, Testing & Validation Services KEY KONTEC Maschinenbau Engineering GmbH Ultra Clean Air industrial applications, Industrial Services DIF GmbH Emission control solutions OEM KONTEC Testing Validation & LAB GmbH Lab DEVELOPMENT DESIGN & SIMULATION INTERKAT Katalysatoren GmbH Air Cleaning Catalytic solutions, Coating KONTEC Motorenentwicklungsgesellschaft mbh Test Benches PROTOTYPING APPLICATIONS TESTING 2

3 MOTIVATION NON-ROAD EMISSIONS REGULATIONS AT A GLANCE Marine, offroad, rail and special-purpose vehicle drive systems are subject to very strict and in future even more strict exhaust emission limits relative to nitrogen oxide (NOx) and particulates (PM). For special environmental protection zones (e.g. for marine, national coastal waters, ports, lakes and rivers), legislation imposing significantly stricter regulations is also currently being passed. Systems with emission reductions of 80% and more are available for diesel main engines and auxiliary engines. They consist of robust, maintenance-free metal SCR (selective catalytic reduction) catalytic converters and metal diesel particulate filters (DPFs). CONCEPT DEVELOPMENT In the future, it will be necessary to develop strategies and concepts to comply with future emissions limits (SCR; DPF; CRT for the reduction of nitrogen oxide and particulates with improvement of fuel consumption = CO2 reduction). We are in a position to develop such concepts, and to generate and evaluate the cost/ benefit assessments and risk analyses corresponding to the customer-specific applications. After comparing all possible scenarios, our engineers develop and apply the most effective Exhaust Gas Aftertreatment (EGA) solution. NON-ROAD EMISSION REGULATIONS PM [g/kwh] EGA MEASURES Stage V: NOx 0,4; PM 0,015 PN: 1x10exp12 Stage III A Tier 3 Stage II Tier 2 PM [g/kwh] DPF In-Engine EGR DPF+SCR Stage III A Tier 3 In-Engine Stage II Tier TIER 4 STAGE III B TIER 4i NO [g/kwh] x 0.02 TIER 4 STAGE III B TIER 4i SCR - EGA NO [g/kwh] x Stage II Stage III A Stage III B Stage V Stage V Emission Regulation is coming in 2019 IN THE FUTURE, IT WILL BE IMPOSSIBLE TO COMPLY WITH NEW EXHAUST EMISSIONS LEGISLATION WITHOUT AN EXTERNAL EGA SYSTEM SUCH AS THE BAUMOT BNOx. 4 5

4 MOTIVATION CONSEQUENCES OF STAGE V ORDINANCE FOR DPF AND SCR TECHNOLOGIES In order to comply with the new European Stage V regulations for Non-road vehicles, vehicles of certain power classes which currently do not require a DPF will also have to be equipped with one in the future. MARPOL ANNEX VI NOX EMISSION LIMITS PROPOSED STAGE V EMISSION STANDARDS FOR INLAND WATERWAY VESSELS CATEGORY NET POWER (kw) DATE CO HC A NOx PROPULSION ENGINES CATEGORY IWP PM IWP-v/c B 4.70 B 0.30 B - IWP-v/c B 5.40 B IWP-v/c PN (1/kWh) IWP-v/c IWP-v/c AUXILIARY ENGINES CATEGORY IWA IWA-v/c IWA-v/c A: A = 6.00 for gas engines, B: HC+NOx PROPOSED STAGE V EMISSION STANDARDS FOR NONROAD ENGINES NOx Limit NOx emission limits are set for diesel engines depending on the engine maximum operating speed (n, rpm), as shown in the following Table and Figure. Tier I and Tier II limits are global, while the Tier III standards apply only in NOx Emission Control Areas Rated Engine Speed (rpm) Tier I Tier II (Global) Tier III (NOx Emission Control Areas) CATEGORY IGN. NET POWER (kw) DATE CO HC NOx PM PN (1/kWh) NRE-v/c-1 CI < A,C 7.50 A,C 0.40 B - NRE-v/c-2 CI A,C 7.50 A,C NRE-v/c-3 CI A,C 4.70 A,C NRE-v/c-4 CI A,C 4.70 A,C NRE-v/c-5 All C NRE-v/c-6 All C NRE-v/c-7 All D TIER DATE NOx Limit n < n < 2000 n 2000 Tier I n Tier II n Tier III n A: HC+NOx, B: 0.60 for hand-startable, air-cooled direct injection engines, C: A = 1.10 for gas engines, D: A = 6.00 for gas engines 6 7

5 TECHNICAL SOLUTIONS BAUMOT S TECHNOLOGICAL SOLUTIONS FOR LOWER EMISSIONS DPF-BAB BNOx BAUMOT BNOx SYSTEM With the high-efficiency BNOx SCR system, you will raise your vehicle emissions to the limits of a EURO VI and beyond! In collaboration with global OE customers, the system was developed for series production and expanded under the same, very strict quality standards into a dependable, package space-optimized SCR system. Diesel engines 19 kw will require a DPF as Diesel engines 56 kw will require a DPF a result of the PN limitation. as a result of the PN limitation and also an SCR due to the NOx limits. DPF required: DPF-BA / DPF-BAB SCR required: BNOx-System BAUMOT DPF-BAB SYSTEM Unlike in oxygen oxidation, with the DPF-BAB system the oxidation of the soot begins already at 250 C. Regeneration occurs automatically while the vehicle is in operation. THE BENEFITS AT A GLANCE Reduction of particle emissions by more than 99% Elimination of hydrocarbons (HC) by 87% Reduction of carbon monoxide (CO) by more than 97% Low-maintenance, fully passive system with autonomous regeneration No additives or electric heating required Housing made of corrosion-free, high-temperature resistant, extra-strength stainless steel Long service life due to extremely durable filter construction Permanent recording and monitoring of the filter function with data logger BAUMOT HAS THE ANSWERS TO WORLDWIDE CUSTOMER DEMANDS Reduction of harmful nitrogen oxides through standard SCR systems Use of BAUMOT-patented NH3 generators for operation at low exhaust gas temperatures Combined BNOx system for reducing nitrogen oxide and soot particles The BNOx SCR system comprises the BAUMOT BNOx ammonia generator, which meters the NH3 gas directly into the exhaust gas line. Unlike with conventional SCR systems, this principle of operation eliminates the need for functionally critical hydrolysis in the exhaust gas stream. THE BENEFITS AT A GLANCE The system works at exhaust gas temperatures as low as150 C NOx reduction rates of 99% are possible (test cycles) Real Live Operation NOx emissions are reduced by 94% Less package space is required, compact design No crystallization occurs in the exhaust gas stream at low temperatures 8 9

6 DEVELOPMENT & DESIGN ALWAYS THE RIGHT SOLUTION As a competent partner, we offer you the full spectrum of services ranging from minor tasks for extra credit to the management and implementation of complete development projects. We provide you with solutions which result from the innovative force, dynamism, flexibility and reliability of our employees. Collaborative relationships with our customers are the key to our shared success. We promise only what we can also deliver. Design of drive train and transmission as well as their development Development and adaptation of combustion, supercharging and injection systems Mechanical development tasks for drives and internal combustion engines Development and optimization of emissions aftertreatment and exhaust gas aftertreatment (EGA) systems EGA prototypes, retrofit/optional products for niche markets (e.g. marine) Concepts, studies, and simulation, calculation and construction services Field engineering, service support, and application support as well as approval Consulting, training courses Test stand / manufacturing facilities and special tools OUR QUALIFICATIONS Engineers from mechanical engineering and vehicle construction, vaerospace, mechatronics and many other disciplines Test engineers and technicians Graduate physicists and mathematicians Quality and FMEA specialists Industrial engineers Technical purchasing personnel FROM INSPIRATION TO THE IDEA TO THE FINISHED PRODUCT DESIGN CONSTURCTION CFD, FEM, SIMULATION PROTOTYPING APPLICATION, TESTING 10 11

7 SERVICE PACKAGE THE TwintecBaumot SERVICE PACKAGE With its highly trained staff, TwintecBaumot Group offers a complete service package. It includes, among other things: Installation: You can install the system yourself, but of course you can also rely on our well-trained employees. In that case, our workshops on four-wheels install the system at your premises. On request, your employees can also be trained. Cleaning: Our service package provides a complete cleaning of filters by our partners. This service includes, among other things, the removal, professional cleaning and check of the filter system. That ensures a long live time and a trouble free operation of you EGA System. For highest availability a filter exchange service can be offered which literally eliminates the down time of your machine. PURCHASING ADVICE SO THAT PRICE AND PERFORMANCE ARE BOTH JUST RIGHT TECHNICAL ADVICE SO THAT EVERYTHING IS CLEAR INSTALLATION TEAM SO THAT EVERYTHING WORKS MAINTENANCE TEAM SO THAT IT ALL STAYS THAT WAY Temperature profile: If you have problems determining the temperature profile of the engine you are retrofitting, don t hesitate to contact us. We will be glad to conduct these measurements and evaluate the data for you. Technical consultation: From the handling of your query by our specialists, to the professional integration of the EGA systems, to a customer-based maintenance and cleaning concept, we leave nothing to chance. Whatever your question, we re always glad to provide you with advice and assistance

8 REFERENCES EMISSIONS REDUCTION FOR MOTOR YACHTS International regulations governing exhaust gas standards, limits and environmental protection zones for shipping are becoming increasingly complex and strict and thereby pose an ever greater challenge for shipbuilders and boat manufacturers. The British luxury yacht builder Sunseeker was looking for an emissions reduction solution for its Manhattan 52 motor yacht, so it would comply with the BSO II standard (Bodensee Schifffahrtsordnung) and thereby obtain a permit to operate on Lake Constance. FREE SAILING ON LAKE CONSTANCE Using feasibility and package space studies, our engineers worked in close cooperation with Sunseeker and Volvo Penta to integrate our BAUMOT Marine SCR system in the Manhattan 52 motor yacht. Simulations of exhaust gas back pressure, catalytic converter flows and urea water metering kept costs and risks at a low level. With the BAUMOT Marine SCR system, we were able to reduce NOx emissions by 92% in the cycle, comply with the required exhaust gas standards, and deliver the first Sunseeker OEM-integrated system. NOx downstream Temp downstream SCR catalyst Urea Injector NOx upstream Temp upstream BAUMOT MARINE EXHAUST GAS AFTERTREATMENT TWIN UNIT Exhaust gas aftertreatment system for the Sunseeker Manhattan 52 motor yacht to comply with the BSO II standard 14

9 REFERENCES EMISSIONS REDUCTION FOR LARGE MARINE ENGINES Since January 2016, the IMO MARPOL Tier III standards require an exhaust gas purification system in the Emission Control Areas (ECA). To comply with the NOx limits, special exhaust gas aftertreatment systems based on SCR full extrudates have already been established in advance. These can also be used with the sulfur-containing marine fuels. Based on the engine power ratings of several megawatts, corresponding requirements related to material and stability must be met. For that reason, the systems are designed, manufactured and installed according to the requirements of the classification societies such as ABS or DNV-GL. Optional combination with practice-proven DPF systems also enables the removal of the particles and therefore permits the use of the engines as a genset for the EPA Tier 4 legislation. DPF part with active burner regeneration SCR part with integrated silencer T, pressure T, NOx T, NOx Full-flow burner (MDO-compatible) Wallflow DPF Urea metering Spark arrestor SCR 2 SCR 1 EXHAUST GAS AFTERTREATMENT EGA FOR LARGE MARINE ENGINES SCR and DPF systems for use in the seagoing ship segment with sulfur-containing fuels with integrated silencer 16

10 HIGH QUALITY SOLUTIONS NOT ONLY FOR MARINE APPLICATION POWERUNIT FOR RAILCAR POWERHEAD Together with Stadler Rail AG, we developed a diesel electric train drive unit for EURO IIIB with hybrid function. For this project, Stadler provided us with specifications that our team had to achieve. Based on package space and installation variant studies, including FMEA tests, on-roof installation was identified as the optimal solution: a so-called Hi-Pack. In a subsequent concept study, the performance of the cooling system and the engine/generator were simulated relative to driving requirements, vibration and strength simulations were prepared, and a preliminary design of the exhaust gas aftertreatment system with SCR technology (EURO IIIB) was developed. Our previous industry-specific expertise enabled us to refine the proposed concept further in certain respects. FURTHER DEVELOPMENT Intake-, exhaust gas system; intake-, exhaust stream independent of direction of travel (patented) Development of modular cooling packages with flow through independent of direction of travel Safer maintenance access Cover concept (protection against dirt, snow, ice) Diesel engine Generator Exhaust gas outlet Exhaust gases outlet diesel engine Exhaust gases inlet exhaust gas unit Package space for catalytic converters Air intake filter DRIVE SYSTEMS DIESEL ELECTRIC TRAIN POWER UNIT FOR EURO IIIB WITH HYBRID FUNCTION Concept and design development of the diesel electric power unit for a rail car according to the latest emission legislation EURO IIIB 18

11 HIGH QUALITY SOLUTIONS NOT ONLY FOR MARINE APPLICATION ADDRESSING THE WIDE RANGE OF VARIANTS One of the known problems in the off-road segment is the extremely wide range of engine and exhaust variants. In order to deal with all these different application, each EGA system has to be specifically tailored and designed for the relevant machines, which implicates tremendous development costs. The objective, therefore, was to develop a system which can be used in over 50 different types of vehicle with four different diesel engines (power range: kw), including certification, actual application and vehicle-specific documentation. MODULAR SCR SYSTEM Through the use of standardized and proven components, we were able to develop within 14 months a certified modular off-road EGA system, based on one low-power and one high-power catalytic converter, for an extremely wide range of package space configurations and application areas (US EPA Tier4i, EURO IV and Euro Stage IIIB). Within the framework of the development program, we were responsible not only for the delivery of all prototypes and pre-series production models, but also for the organization and management of the individual components and suppliers. Variable final chamber Slip catalyst SCR catalyst Urea Water metering EXHAUST GAS AFTERTREATMENT MODULAR SCR SYSTEM FOR THE WIDE RANGE OF OFF-ROAD VEHICLE VARIANTS Hydro cat. Pre-combustion chamber Exhaust gas aftertreatment system for over 50 different vehicle types with four different diesel engines 20

12 HIGH QUALITY SOLUTIONS NOT ONLY FOR MARINE APPLICATION STAGE IIIB-COMPLIANT EGA SYSTEM The engines of ZETOR TRACTORS a.s. had previously complied only with the emission standard Stage III A. The objective of the development order was to have their engines meet the latest emissions standard III B, which has been in force since Timing restrictions imposed by imminent pending legislation necessitated a precisely coordinated development plan, in order to ensure that the supplied product, despite limited time, would comply with both our quality standards and those of our customer. Under those constraints, we were able to develop and approve a passive DPF system and to make it ready for series production within a period of just 12 months. MILESTONES 01/12 Calculation and design of a prototype of the EGA system based on OEM data 03/12 Installation of the prototype in a test vehicle for test runs on the dynamometer and analysis of the package space situation with FARO laser 04/12 Field tests with an extremely wide range of load scenarios and subsequent evaluation and analysis 09/12 Final review of all measurement data and drawing and manufacturing of a pre-series production model 12/12 Type approval, on certified test stand 01/13 Serial delivery EXHAUST GAS AFTERTREATMENT EGA SYSTEM FOR TRACTOR SERIES PRODUCTION Development and design of an EGA system for a Stage III A engine for compliance with the Stage III B standard in the shortest possible time frame 22

13 TWINTEC AG TWINTEC TECHNOLOGIE GMBH INTERKAT KATALYSATOREN GMBH BAUMOT AG DIF DIE IDEENFABRIK GMBH KONTEC GMBH A COMPANY OF TwintecBaumot GROUP POWERTRAIN. EAT. SYSTEM SOLUTIONS. EXHAUST AFTERTREATMENT SYSTEMS I CATALYTIC COATING I ON ROAD OEM ENGINEERING I OFF ROAD OEM ENGINEERING I MEASUREMENT AND TESTING TECHNOLOGY I Version: GERMANY TWINTEC TECHNOLOGIE GmbH Eduard-Rhein-Strasse Königswinter P. +49 (0)2244/ F. +49 (0)2244/ info@twintec.de SWITZERLAND BAUMOT AG Thurgauerstrasse Glattpark P. +41(0) F. +41(0) info@baumot.ch