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The waste heat generated by combustion engines is a precious commodity. Used in the right way, it can help to reduce tailpipe emissions and fuel consumption by a considerable margin. This article takes a brief look at ElroTherm D and energy harvesting, two innovation projects initiated by ElringKlinger’s Shielding Technology division.
Combustion engines are becoming increasingly efficient – a boon to motorists and the environment, but a challenge for automotive suppliers. The catalytic converter, for instance, which is responsible for neutralizing pollutants contained in the exhaust gases, can only work efficiently once it has reached the required operating temperature – and the latter exceeds 200 degrees Celsius. After a cold start, therefore, the objective is to direct the exhaust gas to the catalytic converter without losing an excessive amount of heat. This task is performed particularly well by a new generation of shielding materials launched onto the market by ElringKlinger under the name of ElroTherm D. The shielding material, comprising one layer each of stainless steel and silicate fibers, is fitted to all heat- carrying components – from the exhaust manifold via the turbocharger to the catalytic converter itself. Superior insulation offers other advantages, too. First, consumption is scaled back, as less fuel has to be injected after a cold start. Secondly, ElroTherm D also dampens noise generated in the exhaust system.
Energy is valuable. If it was possible to recycle the waste heat of a combustion engine, one could use this heat as an additional source of energy. As part of a joint project supported by the German Ministry of Education and Research, ElringKlinger is currently assessing a number of pioneering technologies that may contribute greatly to this vision. “Tests already conducted on these innovative shielding systems with integrated functional features have revealed considerable potential for savings at the overall system level,” says Beate Zika-Beyerlein, Head of Development within the Shielding Technology division. Now the objective is to verify the functionality of this new technology with the help of prototypes fitted to an actual combustion engine with the associated exhaust system. The technologies currently undergoing research are particularly interesting for use in electric vehicles (either plug-ins or hybrids), which are being marketed more widely by manufacturers. In this case, the combustion engine only operates temporarily – and emits heat as it cools down.