SupplierBusiness Automotive Exhaust and Aftertreatment Systems Report 2012 Edition
CONTENTS Introduction... 7 Key drivers... 10 Fuel economy and CO 2 emissions... 10 The United States... 10 The European Union... 12 Japan... 12 China... 12 Other countries... 13 Noxious emissions and health concerns... 14 Diesel Soot Particulate Matters... 17 Nitrogen oxides (NOx)... 19 Europe... 21 The United States... 23 Japan... 27 Other countries... 30 Medium- and heavy-duty vehicles... 31 Platinum Group Metals trends... 31 Exhaust and after-treatment technology... 35 Gasoline engine emissions control... 39 Three-Way Catalytic converter (TWC)... 39 Exhaust Gas Re-circulation (EGR)... 42 Diesel engine emissions control... 44 Diesel oxidation catalyst... 44 Selective catalytic reduction... 45 CRT Process... 52 Diesel particulate filter... 53 Catalyst Poisoning... 56 The SCR versus EGR debate... 56 SCR plus EGR for Euro 6... 59 Acoustic management... 60 Exhaust heat recovery systems... 61 Thermoelectric generators... 65 The exhaust and aftertreatment systems market... 67 The OEM market... 67 The Aftermarket... 72 IHS Global Limited 3
Supplier Profiles... 75 Bosal... 75 Boysen... 78 Calsonic Kansei... 80 Eberspächer... 84 Emitec... 87 Faurecia... 89 Futaba... 96 Gustav Wahler... 98 Johnson Matthey... 100 Katcon... 103 KSPG... 105 Magneti Marelli... 109 Tenneco... 114 Umicore... 118 Wescast... 121 TABLE OF FIGURES Figure 1: The progress of emissions regulations across major markets... 8 Figure 2: Fuel economy standards to 2015 for selected countries (US mpg)... 10 Figure 3: International car CO 2 emissions standards... 11 Figure 4: NOx limits in the EU, Japan and the US, 1995 2010 (g/kwh)... 13 Figure 5: PM limits in the EU, Japan and the US, 1995 2010 (g/kwh)... 13 Figure 6: Global testing procedures and standards... 15 Figure 7: An overview of the role of nitrogen oxides in atmospheric chemistry.. 15 Figure 8: HC reductions in the EU, Japan and the US, 2000 2010... 16 Figure 9: The structure of particulate matter (PM)... 17 Figure 10: CO reductions in the EU, Japan and the US, 2000 2010... 18 Figure 11: Diesel PM reductions in the EU, Japan and the US, 2000 2010... 19 Figure 12: NOx reductions in the EU, Japan and the US, 2000 2010... 19 Figure 13: The progress of EU gasoline emissions regulations... 21 Figure 14: US Light duty emissions standards... 26 Figure 15: Criterion emissions reductions in the EU, the US and Japan, 1992 2015... 28 Figure 16: Emissions standards timetable in selected countries, 2001 2010... 30 Figure 17: Price comparison and volatility in Platinum and Palladium 2007-2012... 32 Figure 18: Tenneco s technology road map for exhaust systems... 35 Figure 19: A comparison of exhaust systems 1975 and 2009... 36 Figure 20: A 2012 exhaust system including emissions control, CO 2 reduction and acoustic design... 37 Figure 21: Three-way catalytic converter... 38 Figure 22: The effect of fuel-air mixture on catalytic converter operation... 40 IHS Global Limited 4
Figure 23: The effect of temperature on catalytic converter operation... 41 Figure 24: The construction of an electrically heated TWC... 42 Figure 25: Exhaust gas recirculation with cooler... 43 Figure 26: Denso s compact EGR cooler for gasoline engines... 43 Figure 27: Selective catalytic reduction schematic... 45 Figure 28: Selective catalytic reduction... 46 Figure 29: Faurecia ASDS unit... 48 Figure 30: Delphi s on-board reformer... 49 Figure 31: A schematic of Faurecia s ASDS system... 49 Figure 32: Lean NOx trap/ storage catalyst converter (NSC) system... 50 Figure 33: NOx trap system with ECU control... 52 Figure 34: A schematic of a wall-flow DPF... 53 Figure 35: Mercedes Benz E Class DPF... 54 Figure 36: Acicular Mulite process effects in DPF substrate... 55 Figure 37: A comparison between EGR and SCR technology... 57 Figure 38: Eberspächer s ActiveSound technology integrated with an Audi A6 exhaust system... 60 Figure 39: Energy distribution and losses... 62 Figure 40: BMW s combined EGR TEG unit... 62 Figure 41: Electrical power requirements for NEDC and actual customer requirements for various vehicle classes... 64 Figure 42: BMW Turbostreamer technology on test and in-situ... 64 Figure 43: A systematic diagram of a TE module... 65 Figure 44: Skutterudite structures... 66 Figure 45: Global gasoline and diesel production forecast to 2024... 67 Figure 46: Global gasoline and diesel production forecast by region to 2024... 68 Figure 47: Forecast PGM use in autocatalysts... 69 Figure 48: Forecast DPF market for light vehicles to 2024... 69 Figure 49: Exhaust and aftertreatment market for light vehicles value to 2024... 70 Figure 50: Exhaust and aftertreatment market for light vehicles value by region to 2024... 71 IHS Global Limited 5
TABLE OF TABLES Table 1: Euro emissions limits for light positive ignition (gasoline) vehicles (g/km)... 22 Table 2: Euro emissions limits for light compression ignition (diesel) vehicles (g/km)... 22 Table 3: US emissions standards for light-duty vehicles, to five years/50,000 miles (g/mile)... 23 Table 4: Monitoring requirements of California OBD systems... 24 Table 5: Japan emissions limits for light gasoline & LPG vehicles (g/km)... 27 Table 6: Japan emissions limits for light diesel vehicles (g/km)... 27 Table 7: Chinese emissions standards for light duty vehicles... 29 Table 8: Emissions control strategies... 38 Table 9: Reactions in a three- way catalytic converter... 40 Table 10: Cost comparison EGR vs SCR in Europe... 59 IHS Global Limited 6