Research and development for the series production

Future catalyst systems will be expected to ensure extended utilisation and guarantee periods and to increase the effectiveness. In order to achieve these goals, the whole spectrum of technical and scientific knowledge must be applied and new methods must be developed. The tasks of Emitec's system engineering are concentrating on the simulation of the catalytic function, on flow and vibration analyses as well as on the testing of components, exhaust-gas systems and vehicles.

Optimisation

At Emitec, special emphasis is placed not only on material developments and strength-optimisation measures for the matrix structures but also on improving production-related processes and on exploiting the existing potential for development in order to increase the conversion rate. Coordinated development programmes, consisting of theoretical and practical investigations, serve to optimise complete catalyst installations.

Measurement of pressure loss and flow distribution

Measurements of the pressure loss and of the flow distribution support the designing of the catalyst installation. Increasing significance is being attached to the best possible utilisation of the available catalyst volume and to the long-term durability.

Simulation of flow and temperature distribution

Computer programs simulate the flow distribution with different catalysor arrangements and operating conditions and, with suitable efforts, they convey, for example, favourable inflow geometry for the effective use of the noble metal coating and allow the assessment of the necessary catalysor volume. Temperature distribution calculations running in parallel to this can convey the effectiveness and the life of the converter.

Comprehensive Test Programs

Beginning with materials development and assessment, prototypes and series components are tested in test bed investigations and road endurance runs in accordance with suitable theoretical calculation and simulation programmes. Among other things, information is gained about durability at high acceleration and extreme temperatures in standardized tests. The applicability to customer specifications is ensured through application-related test steps. Marginal test conditions and test bed results are systematically accommodated to customer and field experiences.

Racing Trials

Racing has become an important test arena for catalytic converter development. The knowledge gained under the extreme stresses of racing make a significant contribution to series development. Motor racing engineers carry out developments without compromise, aiming for victory. For this reason, Emitec Metalit foils have been the first choice from the beginning. The initial use in touring car sport was a joint pioneering work by BMW Alpina and Emitec. In the meantime, catalytic converters have been specified in many racing car series. Formula 3 races with Emitec high performance catalytic converters. Emission detoxification is even in discussion for Formula 1. This is a challenge that Emitec engineers will be glad to accept.