Development and production of metallic catalyst substrates (METALIT®) and electrically heated catalysts (EMICAT®) for exhaust aftertreatment
Emitec Technologies GmbH
Lohmar · Hörselberg-Hainich (Eisenach Kindel) · Pune · TokyoNew on Amplifa
This is Emitec Technologies
Emitec Technologies GmbH develops and manufactures metallic catalyst substrates and foil designs for exhaust aftertreatment. The products METALIT® (metal substrates in round, oval, rectangular and honeycomb shapes) and EMICAT® (electrically heated catalysts and discs), as well as filters and complete system solutions, are manufactured for applications ranging from two-wheelers and passenger cars to trucks, off-highway and non-automotive. Core competence is the joining of high-strength materials, in particular steel foils for metallic catalyst substrates. In addition to series production, the company offers system development with CAD concept development, FEM and CFD simulation, emissions calculation and rapid prototyping in metal (cast or metal-printed). The test center in Hörselberg-Hainich provides engine dynamometers, chassis dynamometers, hot-shake component test benches and flow/back-pressure test benches. Customers include major passenger car, truck and motorcycle manufacturers as well as manufacturers of tractors, agricultural machinery, construction machinery, marine engines and diesel locomotives. Production facilities are located in Lohmar and Eisenach (Germany) as well as Pune (India), with subsidiaries in Japan, South Korea, China and the USA.
- Site
- Lohmar
- Processes
- Manufacture of electrically heated catalysts/discs EMICAT®, Exhaust aftertreatment systems and filters (system solutions), FEM calculation / simulation, CFD simulation and flow measurement / back-pressure measurement, Emissions calculation, mass transfer analysis, vibration analysis, shape analysis, material, Engine dynamometer testing (full load, part load, transient, dynamic), Vehicle/chassis dynamometer testing (passenger cars/LD/HDV) with emissions measurement, Hot-shake component testing (thermal shock, hot vibration, low-temperature)
- Materials
- Steel foils (for metallic catalyst substrates), High-strength alloys, Heat-resistant ceramics, Lightweight composite materials, Steel foils
- Certificates
- IATF 16949
- Founded
- 1986
- Employees
- 1000+
- Industries
- Two-wheelers, Passenger cars, Trucks/commercial vehicles, Off-highway, Agricultural machinery, Construction machinery
- 01
System Engineering (CAD, FEM, CFD, emissions calculation)
- 02
Rapid prototyping in metal (cast or metal-printed)
- 03
Foil processing and joining of high-strength steels
- 04
Manufacture of METALIT® metal substrates and EMICAT® heated catalysts
- 05
Assembly of exhaust aftertreatment systems
- 06
Component, engine and vehicle testing at the test center
Materials and Processes
Steel foils
Base material for METALIT® metallic catalyst substrates with turbulence-generating structures and low back pressure.
High-strength alloys
Used in engine components under extreme conditions; developed jointly with materials scientists.
Heat-resistant ceramics
Material development for components with high thermal requirements.
Lightweight composite materials
Weight reduction and improved thermal efficiency.
Sites
Lohmar
DEHeadquarters, production, development
- Lot size
- Series production
- Materials
- Steel foils
Hörselberg-Hainich (Eisenach Kindel)
DEProduction, Test Center
- Lot size
- Series production
- Materials
- Steel foils
- Dynamic engine dynamometers for passenger cars/LD (3 x 230 kW, 2 x 400 kW, 2 of them in a climatic chamber -20 to +35 °C)
- Dynamic engine dynamometers for trucks (400 kW/2500 Nm and 600 kW/4000 Nm, fuel system with 7 fuel types)
- Four-wheel chassis dynamometer passenger cars/LD (153–258 kW, max. 250 km/h, climatic chamber)
- Four-wheel chassis dynamometer trucks (450–600 kW, max. 160 km/h)
- Flow test bench (flow distribution, hot-wire anemometer, up to 3,000 Nm³/h)
- Back-pressure test bench (up to 2,000 Nm³/h, air flow heater 100 °C)
- Hot-shake test bench (burner 200/400 kW, max. 1,200 °C, ±24,000/-12,000 K/min)
- Shaker (35/54 kN, 10–3,000 Hz, ±12 mm)
- Stand-alone exhaust gas measurement systems
Pune
INProduction
- Lot size
- Series production
- Materials
- Steel foils
Tokyo (Minato)
JPSubsidiary
Products and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Forming | – | – | – | – | Steel foils, High-strength alloys |
| Manufacture of electrically heated catalysts/discs EMICAT®Assembly | – | – | – | – | Metal |
| Exhaust aftertreatment systems and filters (system solutions)Assembly | – | – | – | – | – |
| Engineering | – | – | – | – | Metal |
| FEM calculation / simulationEngineering | – | – | – | – | – |
| CFD simulation and flow measurement / back-pressure measurementTesting | – | – | – | – | – |
| Emissions calculation, mass transfer analysis, vibration analysis, shape analysis, materialEngineering | – | – | – | – | – |
| Engine dynamometer testing (full load, part load, transient, dynamic)Testing | – | – | – | – | – |
| Vehicle/chassis dynamometer testing (passenger cars/LD/HDV) with emissions measurementTesting | – | – | – | – | – |
| Hot-shake component testing (thermal shock, hot vibration, low-temperature)Testing | – | – | – | – | – |
| Joining of high-strength materials (focus competence of the company's history)Joining | – | – | – | – | High-strength steels |
9 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Four-wheel chassis dynamometer passenger cars/LD | – | 1 | 153-258 kW, max. 250 km/h; climatic chamber -20°C to +35°C | – | Hörselberg-Hainich (Eisenach Kindel) |
| Four-wheel chassis dynamometer trucks (HDV) | – | 1 | 450-600 kW, max. 160 km/h | – | Hörselberg-Hainich (Eisenach Kindel) |
| Dynamic engine dynamometers passenger cars/LD | – | 5 | 3 x 230 kW and 2 x 400 kW; 2 in climatic chamber (-20° – 35°C) | – | Hörselberg-Hainich (Eisenach Kindel) |
| Dynamic engine dynamometers trucks (HDV) | – | 2 | 1 x 400 kW, max. 2500 Nm, 5000 rpm; 1 x 600 kW, max. 4000 Nm, 4000 rpm; fuel system with 7 tanks | – | Hörselberg-Hainich (Eisenach Kindel) |
| Flow test bench (flow distribution, hot-wire anemometer) | – | 1 | Air volume flow up to max. 3000 Nm³/h | – | Hörselberg-Hainich |
| Back-pressure test bench | – | 1 | Air volume flow up to max. 2000 Nm³/h, air flow heater 100 °C | – | Hörselberg-Hainich |
| Hot-shake test bench (burner) | – | 1 | Power 200 kW / 400 kW; gas mass flow 100-1,500 kg/h; max. 1,200 °C; +/- 24,000 / -12,000 K/min | – | Hörselberg-Hainich |
| Shaker (vibration testing) | – | 1 | Force vector 35 kN / 54 kN; 10-3,000 Hz; amplitude +/- 12 mm | – | Hörselberg-Hainich |
| Stand-alone exhaust gas measurement systems | – | – | – | – | Hörselberg-Hainich |
Additional services
Reference customers
Quality and Testing
The test center in Hörselberg-Hainich offers engine, chassis and component test benches as well as exhaust gas measurement systems capable of detecting the lowest pollutant concentrations in accordance with current and future emissions legislation.
| Evidence | Lohmar | Hörselberg-Hainich (Eisenach Kindel) |
|---|---|---|
| IATF 16949 |
History
- 1929
Joseph Christie Whitney Frazer patents metallic catalyst designs
- 1986
Founded as Emitec Gesellschaft für Emissionstechnologie GmbH, joint venture Siemens/GKN
- 2007
Siemens VDO sold to Continental; 50/50 JV Continental/GKN
- 2014
Continental acquires GKN's shares; Emitec becomes part of the Powertrain division
- 2021
Vitesco Technologies spun off from Continental; Emitec becomes part of Vitesco
- 2023
Carve-out from Vitesco; part of the DUBAG Group; re-founded as Emitec Technologies GmbH