Continental Emitec GmbH Business Report FY ended Dec. 2014
Acquired by Continental
-In July 2014, Continental AG acquired 50% shares from GKN for a cash consideration of GBP 46 million, making the Company a wholly-owned subsidiary of Continental AG. Then the Company was integrated into Continental's Powertrain Division. Continental plans to start production of Emitec products by the end of 2014 at its site in Wuhu, China. The products will continue to be traded under the Emitec brand name.
Recent Development Outside Germany
-In September 2012, the Company's first production site in France, Faulquemont officially opened as SCR dosing factory. The former Grundfos NoNOx A/S's factory's operation, bought in 2010, moved to a new production building and expanded by adding a second highly automated production line. The manufacturing output will increase to almost double. The plant currently makes dosing module for heavy-duty trucks; in future the product range will also include modules for vans and passenger cars. (From a press release on September 11, 2012)
Acquisitions
-In September 2010, the Company has acquired the Danish company Grundfos NoNOx A/S. Grundfos NoNOx produces SCR systems for truck and bus diesel engines and its development and production facilities are located in France. By this acquisition, the Company has expanded its product and system range in the field of SCR technology.
Business Partnership
-In November 2010, Emitec Inc., U.S. has signed an agreement with Ford Performance Vehicles (FPV) of Australia to supply catalytic converters. The new catalyst will be used in FPV' s new Boss V8 range of vehicles starting in October 2010, and is also used on the new Euro 4 FPV F6 since June 2010. (From a press release on November 1, 2010)
R&D Facilities
-The Company has research and development facilities in Lohmar and Eisenach, Germany.
Patents
-The Company owns more than 2,700 patents worldwide.
R&D Activities
-At the 2014 IAA Commercial Vehicles exhibition, the Company will display a concept study of an exhaust gas aftertreatment system designed to meet Euro VI standards. The concept study demonstrated a system with both reduced weight and volume, which in turn provides benefits to payload, vehicle design, and fuel efficiency. One feature that the concept introduces is the first instance of the catalytic converter being integrated into the space between the engine and chassis of the commercial vehicle. This was enabled by the flexibility of the company's metal substrates for catalytic converters. The integration improves the efficiency of the system due to reduced heat loss. Other features include Continental's AdBlue diesel exhaust fluid injectors which are configured by the Company for individual commercial vehicle applications, and a dosing system integrated into the AdBlue tank. (From a press release on September 23, 2014)
-In 2012, the Company has focused on SCR applications for emerging markets such as China, Brazil, India, Russia and others. The technologies involved are similar to those that were developed for EU IV and EU V, however there are also challenging conditions such as extreme climate, poor fuel quality and high mechanical stresses and affordable market prices. With its test center in Eisenach the Company is ready to develop them. (From a press release in September, 2012)
Product Development
In-tank urea dosing systems for light- and medium-duty applications
In 2014, the Company announced in-tank urea dosing systems for light- and medium-duty application that it developed with Cummins Emission Solutions. With tank flange pump module design, this system incorporates pipes, lines, tank heating devices and filters along with electric components such as various sensors, dosing control units and wiring harnesses. Other feature includes its being adaptable to multi-tank configurations. The new in-tank urea dosing system will be introduced in mass production in the fourth quarter of 2014 by Cummins Emission Solutions.
In-Tank SCR dosing module
-The SCR dosing module GenIII and GenIV are installed inside of AdBlue tank and very compact. Despite being integrated in the tank, every important component is easy to replace for servicing. The installation size is reduced by 30% comparing previous generation. The nozzles for the AdBlue ammonia fluid have been developed together with the parent company Continental AG. The integrated pump can deliver up to 8 litres per hour (GenIII) or 3 litres per hour (GenIV). A new plant for development and production of SCR systems was opened in Faulquemont (France) at the beginning of 2012. (From a press release in September, 2013)
Catalytic converter with an temperature sensor (Sensorkat)
-Benefit of integrated sensor is not only the compactness but also the time. The sensor reaches its operating temperature in as little as 10 seconds after a engine cold start. Compared to conventional solutions, Sensorkat reduces NOx emission alone by around 40%. Volvo was the first to use the system in their production vehicles for the US market. (From a press release in September, 2013)
Air-assisted AdBlue SCR dosing system (UDA 2 SCR Dosing system)
-The Company has developed the next generation of air-assisted AdBlue SCR dosing system to meet the requirements for the new EURO VI emission standard that will apply to all new trucks from 2013/14. MAN will be the first company to use the system in its new TGX trucks. (From a press release in September, 2012)
Substrates for Catalytic converters for CNG (Compressed Natural Gas) engines
-The Company has developed substrates for three-way catalytic converters or oxidation catalytic converters for commercial vehicles driven by CNG engines. (From a press release in September, 2012)
Heated catalytic converter
-There is renewed demand for heated catalytic converters because of the low exhaust temperatures of modern highly efficient engines or of start/stop system. The Company's new heated catalytic converter is suitable for a wide range of commercial vehicles, from small vans to heavy-duty trucks and high-performance buses. (From a press release in September, 2012)
Lightweight catalysts
-In 2011, the Company reduced the thickness of the catalyst jacket to 0.5mm, while metal jackets in conventional metal catalysts is between 1 and 2mm thick depending on size and application. A jacket with a thickness of 0.5mm has a lower degree of mechanical strength, however it is also much more stress-resistant to rapid temperature changes and thermal shock. The new lightweight catalyst is 10 to 30% lighter than a conventional ones. Its flexural rigidity and inherent stability are up to 65% greater than those of an identical catalyst with a smooth jacket. In addition, lightweight catalysts with vaulted structures are much more durable. The new lightweight catalyst can be combined with all other the Company's products.
New generation of close-coupled catalysts
-In 2008, the Company developed a new generation of close-coupled catalysts that can be fitted close to the turbocharger of light- and medium-duty diesel vehicles. The new close-coupled compact catalyst uses its patented longitudinal structure (LS) foil technology, which creates turbulent flow inside the catalyst and increases efficiency. Due to the more efficient substrate, the required catalyst volume is reduced by approximately one quarter. In a joint development with a European automaker, its new close-coupled compact catalyst will be available in its first light-duty application in summer 2008. (From a press release on Apr 14, 2008)