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Bosch Emission SystemsModular exhaust-gas systemfor on- and off-highway application

From 2014 on there will be more stringent emission

limits for off-highway engines. Compared with the first

emission regulations, particulate and nitrogen oxide

emissions from engines between 130 and 560 kW, for

instance, will be reduced by more than 90%.

Since the introduction of level 3b/Tier 4 interim in

2011, it has already become impossible to comply

with the limits just by implementing internal engine

measures. These limits require complex exhaust-gas

treatment technology.

BESG has developed a modular exhaust-gas system

for applications like these in engines up to 560 kW.

It consists of a heater stage, a particulate filter as well

as nitrogen-oxide reduction by AdBlue/DEF dosing

and an SCR catalytic converter.

System control and monitoring of the required

sensors can be carried out by a separate control unit

or integrated into an existing control unit.

For engines exceeding 560 kW, BESG develops and

manufactures individual solutions to meet customer

requirements. Development time, validation expenses

and tooling costs are reduced by consequent use of

modern simulation and design tools combined with

the use of standardized components.

The modular exhaust-gas system is individually

adapted to the available installation space of the

particular vehicle or machine.

Particularly in the off-highway sector, diesel engines

are often operated under extreme conditions. Massive

temperature fluctuations or high mechanical stress

caused by vibration make high demands on theexhaust-gas system. During development these

conditions were considered as thoroughly as the

requirement for long service life, robustness and

unrestricted function throughout the program map.

Customer benefits

Enables compliance with next stage of emission

regulations, Tier 4 final and Euro VI

Individual solutions due to modular system

design

Flexible installation even in the most complex

spaces

High robustness and long service life

Short development time

Validation with little effort

Reduced tooling costs

Modular exhaust-gas system

Bosch Emission Systems GmbH & Co. KG (BESG) is

a Bosch affiliate which offers engineering services to

vehicle and engine manufacturers in the on-highway

and off-highway sectors as well as for marine applica-

tions. These services include the design and calibra-

tion of exhaust-gas treatment systems as well as

support for certification.

Apart from the manufacturing and supply of these

certified power packs, BESG also offers enginemanufacturers the professional integration of the

exhaust-gas treatment systems into the vehicle or

machine as a service.

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Bosch Emission Systems

GmbH & Co. KG

Postfach 30 02 20

70442 Stuttgart

Germany

www.besg.com

Printed in Germany

Bosch Emission System GmbH & Co. KG 2012. All rights reserved, also regarding any disposal, exploitation,

reproduction, editing, distribution, as well as in the event of applications for industrial property rights

Design and operating principle

The exhaust-gas system is connected to the turbo-

charger using a flexible pipe section for vibration

absorption.

The particulate filter (DPF) consists of a ceramic

substrate and filters out the soot particles which are

generated during fuel combustion in the diesel engine.

The DPF is regenerated by increasing the exhaust-gas

temperature above 600C to burn off the stored soot

particles. This can either be achieved by internal

engine measures, or by heating the exhaust-gas stream

by injecting diesel fuel which is then oxidized in the

oxidation catalytic converter.

Alternatively the DPF can be regenerated continuously.

This variant burns off the particles using NO2which,

among other things, is generated in the oxidation

catalytic converter upstream of the DPF. The genera-

tion of NO2requires an exhaust-gas temperature of

at least 320C.

The nitrogen oxides (NOx) contained in the exhaust

gas are removed in the SCR catalytic converter

(Selective Catalytic Reduction). Inside the converter

the nitrogen oxides react with ammonia and are

converted into nitrogen (N2) and water. The ammonia

is generated through pyrolysis of a urea-in-water

solution (AdBlue/DEF) injected into the hot exhaust-

gas stream in a mixing section upstream of the SCR

converter. Depending on engine condition, conversion

rates of more than 90% can be achieved.

Bosch Emission Systems | Modular exhaust-gas system for on- and off-highway application

SpecificationOperating fluidsDPF regeneration Lead-free diesel

according to EN590

SCR system Urea-in-water solution

AUS 32/ISO22241

Voltage 12 V, 24 V

Application OnHW, OffHW, Marine

Max. engine power

Modular system 560 kW

Customized system 3 MW

Retrofit solutions All engine sizes

Emission targets Tier 4 final, Euro VI

Bosch: Automotive competence from a single source

Comprehensive range of services and know-how

System and network competence

Innovator and technology leader

Warrantor for quality and dependability

Worldwide presence

Universal partner

DPM for active DPF regeneration

Exhaust-gas system control unit

SCR catalytic converter with Denoxtronic Urea

Dosing System with AdBlue tank, heated hose lines,

and sensors

Diesel particulate filter(DPF) downstream of diesel

oxidation catalytic converter (DOC), with sensors

1

3

2

4

Modules of the exhaust-gas system

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3

4

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