OFFROAD & MARINE

PORTFOLIO OFFROAD & MARINE

DEVELOPMENT, APPLICATION AND PRODUCTION ALL FROM A SINGLE SOURCE

EGINE. EGA. SYSTEM SOLUTIONS.

PORTFOLIO

A COMPANY OF THE

TwintecBaumot GROUP

2

COMPANY PORTRAIT

Twintec AG is the parent company of TwintecBaumot Group (TBG), a leading supplier in the

area of exhaust gas aftertreatment and engine development. In that context, TBG offers its

customers high-quality solutions in Design & Engineering and Products & Solutions as well as

Testing & Validation Services. TBG applies those products and services across a wide range

of industries in the business fields OEM (original equipment), retrofitting, aftermarket (repair,

spare parts) and catalytic coating. In so doing, it covers the entire value creation chain for

the exhaust gas aftertreatment sector. The market segments include, in particular, on-road

(e.g. cars, trucks and other commercial vehicles), off-road (e.g. construction machinery,

agricultural machinery or stationary plant) and miscellaneous applications such as maritime

or medical technology.

Within its four subsidiaries, TwintecBaumot Group has more than 380 employees and deca-

des of experience in the field of exhaust gas aftertreatment. Acquired in 2015, Kontec

GmbH, together with its subsidiary DIF (Die Ideenfabrik GmbH), represents the OEM develop-

ment arm of the company, offering low-emission engines and exhaust gas aftertreatment

systems to well-known original equipment manufacturers. Baumot AG, which was acquired

in 2014, is one of the leading providers of selective catalytic reduction (SCR) systems as

well as active and passive particulate filters in the OEM and retrofitting business sectors.

In addition, as a specialist in the development of emissions technology, Twintec Technologie

GmbH offers its customers innovative solutions for reducing exhaust gas emissions especial-

ly in the retrofitting and aftermarket segments. Through Interkat GmbH, TBG has expertise

in catalytic coating services, which are offered across a wide range of industries.

FROM POWERTRAIN TO EGAALL FROM A SINGLE SOURCE

FMEA

Production

CFD

Exhaust System

Development

Development of

Functionalities

Software Development

Project Management

Product Design with CAD/CAE

Samples and prototypes

ElectronicControl

Unit

RapidPrototyping

Strength and durability tests e.g. Hot shake

Catalyst testing (light-off, aging and poisoning)

Validation on engine bench

3D- measurements

Emission testing

Simulation of system

functionality

Set up demonstrator

vehicles

Set up engine

test benches

After treatment calibration

Measurement and Data

Acquisition

Benchmarking

System Integration Exhaust

Aftertreatment

Homologation/ Certification

FEMValidation �On road / field test

DEVELOPMENT

APPLICATIONS

DESIGN & SIMULATION

TESTING

PROTOTYPING

KEY

STRUCTURETWINTEC AG

HoldingTWINTEC AG

Holding

INTERKAT Katalysatoren GmbH

Air Cleaning Catalytic solutions,Coating

KONTEC Automotive Engineering GmbH

Sustainable Mobility, Engineering, Automotive Services

BAUMOT AG Emission Control Products,

Retrofit/Aftermarket

KONTEC Testing Validation & LAB GmbH

Design, Testing & Validation Services

KONTEC Testing Validation & LAB GmbH

Lab

KONTEC Motoren- entwicklungsgesellschaft mbH

Test Benches

DIF GmbH Emission control solutions

OEM

KONTEC Maschinenbau Engineering GmbH

Ultra Clean Air industrial applications, Industrial Services

DESIGN & ENGINEERING PRODUCTS & SOLUTIONS TESTING & VALIDATION

4 5

DIF - DIE IDEEN FABRIK

MOTIVATION

In the future, it will be necessary to develop strategies and concepts to comply with future

emissions limits (SCR; DPF; CRT for the reduction of nitrogen oxide and particulates with

improvement of fuel consumption = CO2 reduction).

We are in a position to develop such concepts, and to generate and evaluate the cost/

benefit assessments and risk analyses corresponding to the customer-specific applications.

After comparing all possible scenarios, our engineers develop and apply the most effective

solution.

Off-highway, marine, rail and special-purpose vehicle drive systems are subject to very strict

– and in future even more strict – exhaust emission limits relative to nitrogen oxide (NOx)

and particulates (PM). For special environmental protection zones (e.g. for marine, national

coastal waters, ports, lakes and rivers), legislation imposing significantly stricter regulations

is also currently being passed.

Systems with emission reductions of 80% and more are available for diesel main engines

and auxiliary engines. They consist of robust, maintenance-free metal SCR (selective cata-

lytic reduction) catalytic converters and metal diesel particulate filters (DPFs).

OFF-ROAD EMISSIONS REGULATIONS AT A GLANCE

Stage IITier 2

2000

Stage II Stage III BStage III A

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2019

Stage IV

Stage III ATier 3

STAGE III B TIER 4i

Ϟ Stage V Emission Regulation is coming in 2019

0.4 2.0 6.0 NOx [g/kWh]

PM [g/kWh]

4.0

0.02

0.2

0.1

TIER 4

Stag

e V:

NOx

0,4

; PM

0,0

15

PN: 1

x10e

xp12

OFF-ROAD EMISSION REGULATIONS

CONCEPT DEVELOPMENT

IN THE FUTURE, IT WILL BE IMPOSSIBLE TO COMPLY WITH NEW EXHAUST EMISSIONS LEGISLATION WITHOUT AN EXTERNAL EGA SYSTEM SUCH AS DIF BNOx.

Stage IITier 2

Stage III ATier 3

STAGE III B TIER 4i

0.4 2.0 6.0 NOx [g/kWh]

PM [g/kWh]

4.0

0.02

0.2

0.1

TIER 4

EGA MEASURES

In-Engine EGR

DPF+SCR

SCR - EGA

DPF

In-E

ngin

e

6 7

DIF - DIE IDEEN FABRIK

MOTIVATION

• For the first time, a new emissions level also applies for engines

under 19 kW and over 560 kW

• Stage V will go into effect for all engine classes (except 56-130 kW),

and will not be phased in

• The tightening of requirements to Stage V necessitates

a complete change in technology

In order to comply with the new European Stage V regulations for off-road vehicles, vehicles

of certain power classes which currently do not require a DPF will also have to be equipped

with one in the future.

■ Power classes which will have to be equipped with a DPF in the future

CONSEQUENCES OF STAGE V ORDINANCE FOR DPF AND SCR TECHNOLOGIES

STAGE V EXPANDS THE MARKET TREMENDOUSLY

Power class DOC DPF SCR EGR

19-37 kW • ■ •

37-56 kW • ■ •

56-130 kW • ■ • •

130-560 kW • • • •

Power class 2014 2015 2016 2017 2018 2019 2020 2021 2022

<19 kW

Production EnginesNo emission regulations Stage V

CO: 6,6 NOx+HC: 7,5 PM:0,4

on the market Machines

19-37 kW

Production EnginesStage IIIACO: 5,5 Nox+HC: 7,5 PM:0,6

Stage V CO: 5,0 NOx+HC: 4,7 PM:0,015 PN: 1x10˄12

on the market Machines

37-56 kW

Production EnginesStage IIIACO: 5,5 NOx+HC: 7,5 PM:0,6

Stage IIIB CO: 5,0 Nox+HC: 4,7 PM:0,025

Stage V CO: 5,0 NOx+HC: 4,7 PM:0,015 PN: 1x10˄12

on the market Machines

56-130 kW

Production EnginesStage IIIA Stage IIIB

CO: 5,0 Nox+HC: 4,7 PM:0,025Stage IV CO: 5,0 NOx: 0,4 HC: 0,19 PM:0,025

Stage VCO: 5,0 NOx: 0,4 HC: 0,19

PM:0,015 PN: 1x10˄12

on the market MachinesPossible via Flex

130-560 kW

Production EnginesStage IIIB Stage IV

CO: 3,5 Nox:0,4 HC: 0,19 PM:0,025Stage V

CO: 3,5 NOx: 0,4 HC: 0,19 PM:0,015 PN: 1x10˄12

on the market Machines

>560 kW

Production EnginesNo emission regulations Stage V

CO: 3,5 NOx: 0,4 HC: 0,19 PM:0,045

on the market Machines

8 9

Unlike in oxygen oxidation, with the DPF-BAB system the oxidation of the soot begins already

at 250°C. Regeneration occurs automatically while the vehicle is in operation.

THE BENEFITS AT A GLANCE

• Reduction of particle emissions by more than 99%

• Elimination of hydrocarbons (HC) by 87%

• Reduction of carbon monoxide (CO) by more than 97%

• Low-maintenance, fully passive system with autonomous regeneration

• No additives or electric heating required

• Housing made of corrosion-free, high-temperature resistant, extra-strength stainless

steel

• Long service life due to extremely durable filter construction

• Permanent recording and monitoring of the filter function with data logger

DIF DPF-BAB SYSTEM

Diesel engines ≥ 56 kW will require a DPF

as a result of the PN limitation and also an

SCR due to the NOx limits.

SCR required: DIF BNOx-System

Diesel engines ≥ 19 kW will require a DPF as

a result of the PN limitation.

DPF required: DIF DPF-BA / DPF-BAB

• Reduction of harmful nitrogen oxides through standard SCR systems

• Use of DIF-patented NH3 generators for operation at low exhaust gas temperatures

• Combined BNOx system for reducing nitrogen oxide and soot particles

The BNOx SCR system comprises the DIF-BNOx generator (ammonia generator), which me-

ters the NH3 gas directly into the exhaust gas line. Unlike with conventional SCR systems,

this principle of operation eliminates the need for functionally critical hydrolysis in the exhaust

gas stream.

DIF HAS THE ANSWERS TO WORLDWIDE CUSTOMER DEMANDS

DIF BNOx SYSTEM

With the high-efficiency BNOx SCR system, you will raise your vehicle emissions to the li-

mits of a EURO VI and beyond! In collaboration with global OE customers, the system was

developed for series production and expanded under the same, very strict quality standards

into a dependable, package space-optimized SCR system.

THE BENEFITS AT A GLANCE

• The system works at exhaust gas temperatures as low as150°C

• NOx reduction rates of 99% are possible (test cycles)

• “Real Drive” NOx emissions are reduced by 94%

• Less package space is required, compact design

• No crystallization occurs in the exhaust

gas stream at low temperatures

DIF - DIE IDEEN FABRIK

TECHNICAL SOLUTIONS

DIF’S TECHNOLOGICAL SOLUTIONS FOR THE STAGE V ORDINANCE

DPF-BAB BNOx

10 11

BNOx TECHNOLOGY AT A GLANCE

• The area of application of the BNOx system covers the area in which today’s SCR DeNOx

technology reaches it limits, e.g. due to temperature problems, packaging requirements

or the wide range of applications.

• Consequently, the BNOx System is suitable for use in all areas where DeNOx technology

is used to meet emissions requirements, such as on-road, NRMM, industry, rail trans-

portation and shipping.

• That applies to the development of future engine generations in general as well as to the

retrofitting and upgrading of vehicles or existing NRMM fleets.

SUMMARY OF TEST RESULTS FOR THE BNOX SYS-TEM IN DIFFERENT APPLICATIONS

The testsdemonstrate

the exceptionalDeNOx-performance

in a wide range of*DIFFERENT SYSTEM

CONFIGURATIONS

Milbrook Test Cycle

School Bus real drive, Morning start

ISO 8178 C1 (NRSC)*

ISO 8178 C1 (NRSC)*

NRTC (hot)*

NRTC (hot)*

ETC

WHTC combined

WHTC (hot)

0 … 60 % 70 % 80 % 90 % 100 %NOx - Reduction Rate

94 %

93 %

85 %

89 %

87 %

90 %

91 %

84%

92 %

NOx reduction rate performed on test cycles with TDI-engines from 6 L to 11 L

NOx reduction rate (%) in text cycles with TDI engines from 6 - 11 liters

This test illustrates the extraordinarily high DeNOx performance in a broad range of OEM

and retrofit applications.

*Tests were conducted with different system configurations.

Ϟ DeNOx functional performance in all tested applications between 84 and 99%

Ϟ High conversion rates possible with urea injection rates of NH3 / NOx > 1

DIF - DIE IDEEN FABRIK

TECHNICAL SOLUTIONS

EMISSION MEASUREMENT BNOx SYSTEM

Comparison of the emissions of a tractor with and without BNOx-System in 3 measur-

ments with 8 test phases each on the basis of the ISO 8178 C1 test method.

Total nitrogen oxide emissions (NOx) of a tractor with and without BNOx system.

NOx with BNOx (1) NOx with BNOx (2) NOx with BNOx (3)

NOx without BNOx (1) NOx without BNOx (2) NOx without BNOx (3)

NO

x Em

issi

on (

ppm

)

Time [s]

12 13

As a competent partner, we offer you the full spectrum of services ranging from minor tasks

for “extra credit” to the management and implementation of complete development projects.

We provide you with solutions which result from the innovative force, dynamism, flexibility

and reliability of our employees. Collaborative relationships with our customers are the key

to our shared success. We promise only what we can also deliver.

• Design of drive train and transmission as well as their development

• Development and adaptation of combustion, supercharging and injection systems

• Mechanical development tasks for drives and internal combustion engines

• Development and optimization of emissions aftertreatment and exhaust gas aftertreat-

ment (EGA) systems

• EGA prototypes, retrofit/optional products for niche markets (e.g. marine)

• Concepts, studies, and simulation, calculation and construction services

• Field engineering, service support, and application support as well as approval

• Consulting, training courses

• Test stand / manufacturing facilities and special tools

DESIGN CONSTURCTIONCFD, FEM,

SIMULATIONPROTOTYPING

APPLICATION, TESTING

DIF - DIE IDEEN FABRIK

DEVELOPMENT & DESIGN

ALWAYS THE RIGHT SOLUTION

• Engineers from mechanical engineering and vehicle construction,

vaerospace, mechatronics and many other disciplines

• Test engineers and technicians

• Graduate physicists and mathematicians

• Quality and FMEA specialists

• Industrial engineers

• Technical purchasing personnel

OUR QUALIFICATIONS

FROM INSPIRATION TO THE IDEA TO THE FINISHED PRODUCT

14

International regulations governing exhaust gas standards, limits and environmental protec-

tion zones for shipping are becoming increasingly complex and strict – and thereby pose an

ever greater challenge for shipbuilders and boat manufacturers.

The British luxury yacht builder Sunseeker was looking for an emissions reduction solution

for its Manhattan 52 motor yacht, so it would comply with the BSO II standard (Bodensee

Schifffahrtsordnung) and thereby obtain a permit to operate on Lake Constance.

FREE SAILING ON LAKE CONSTANCE

Using feasibility and package space studies, our engineers worked in close cooperation with

Sunseeker and Volvo Penta to integrate our DIF BLUELess SCR system in the Manhattan

52 motor yacht. Simulations of exhaust gas back pressure, catalytic converter flows and

metering kept costs and risks at a low level.

With the DIF BLUELess SCR system, we were able to reduce NOx emissions by 92% in

the cycle, comply with the required exhaust gas standards, and deliver the first Sunseeker

OEM-integrated system.

SCR catalyst

NOx downstream

Injector

Temp downstream

NOx upstream

Temp upstream

EMISSIONS REDUCTION FOR MOTOR YACHTS

DIF BLUELessEXHAUST GAS AFTERTREATMENT TWIN UNIT

Exhaust gas aftertreatment system for the Sunseeker Manhattan 52 motor yacht to comply with the BSO II standard

DIF - DIE IDEEN FABRIK

REFERENCES

16

Together with Stadler Rail AG, we developed a diesel electric train drive unit for EURO IIIB

with hybrid function. For this project, Stadler provided us with specifications that our team

had to achieve. Based on package space and installation variant studies, including FMEA

tests, on-roof installation was identified as the optimal solution: a so-called “Hi-Pack”.

In a subsequent concept study, the performance of the cooling system and the engine/ge-

nerator were simulated relative to driving requirements, vibration and strength simulations

were prepared, and a preliminary design of the exhaust gas aftertreatment system with SCR

technology (EURO IIIB) was developed. Our previous industry-specific expertise enabled us to

refine the proposed concept further in certain respects.

FURTHER DEVELOPMENT

• Intake-, exhaust gas system; intake-, exhaust stream

independent of direction of travel (patented)

• Development of modular cooling packages with flow through

• independent of direction of travel

• Safer maintenance access

• Cover concept (protection against dirt, snow, ice)

Generator

Exhaust gas outlet

Diesel engine

Package space for catalytic converters

Exhaust gases outlet diesel engine Exhaust gases inlet exhaust gas unit

Air intake filter

POWERUNIT FOR RAILCAR POWERHEAD

DRIVE SYSTEMSDIESEL ELECTRIC TRAIN POWER UNIT FOR EURO IIIB WITH HYBRID FUNCTION

Concept and design development of the diesel electric power unit for a rail car according to the latest emission legislation EURO IIIB

DIF - DIE IDEEN FABRIK

REFERENCES

18

One of the known problems in the off-road segment is the extremely wide range of engine

variants. In order to deal with all these different engines, each EGA system has to be speci-

fically tailored and designed for the relevant engine, which implicates tremendous develop-

ment costs.

The objective, therefore, was to develop a system which can be used in over 50 different

types of vehicle with four different diesel engines (power range: 120 - 505 kW), including

certification, actual application and vehicle-specific documentation.

MODULAR SCR SYSTEM

Through the use of standardized and proven components, we were able to develop within 14

months a certified modular off-road EGA system, based on one low-power and one high-po-

wer catalytic converter, for an extremely wide range of package space configurations and

application areas (US EPA Tier4i, EURO IV and Euro Stage IIIB). Within the framework of the

development program, we were responsible not only for the delivery of all prototypes and

pre-series production models, but also for the organization and management of the individual

components and suppliers.

SCR catalyst

Slip catalyst

Variable final chamber

Pre-combustion chamber

UWS metering

Hydro cat.

ADDRESSING THE WIDE RANGE OF VARIANTS

EXHAUST GAS AFTERTREATMENT MODULAR SCR SYSTEM FOR THE WIDE RANGE OF OFF-ROAD VEHICLE VARIANTS

Exhaust gas aftertreatment system for over 50 different vehicle types with four different diesel engines

DIF - DIE IDEEN FABRIK

REFERENCES

20

The engines of ZETOR TRACTORS a.s. had previously complied only with the emission stan-

dard Stage III A. The objective of the development order was to have their engines meet

the latest emissions standard III B, which has been in force since 2012. Timing restrictions

imposed by imminent pending legislation necessitated a precisely coordinated development

plan, in order to ensure that the supplied product, despite limited time, would comply with

both our quality standards and those of our customer. Under those constraints, we were

able to develop and approve a passive DPF system and to make it ready for series production

within a period of just 12 months.

MILESTONES

01/12 Calculation and design of a prototype of the EGA system based on OEM data

03/12 Installation of the prototype in a test vehicle for test runs on the dynamometer and analysis of the package space situation with FARO laser

04/12 Field tests with an extremely wide range of load scenarios and subsequent evaluation and analysis

09/12 Final review of all measurement data and drawing and production of a pre-series production model

12/12 Type approval, on certified test stand

STAGE IIIB-COMPLIANT EGA SYSTEM

EXHAUST GAS AFTERTREATMENT EGA SYSTEM FOR TRACTOR SERIES PRODUCTION

Development and design of an EGA system for a Stage III A engine for compliance with the Stage III B standard in the shortest possible time frame

DIF - DIE IDEEN FABRIK

REFERENCES

22

Since January 2016, the IMO MARPOL Tier III standards require an exhaust gas purification

system in the Emission Control Areas (ECA). To comply with the NOx limits, special exhaust

gas aftertreatment systems based on SCR full extrudates have already been established in

advance. These can also be used with the sulfur-containing marine fuels.

Based on the engine power ratings of several megawatts, corresponding requirements

related to material and stability must be met. For that reason, the systems are designed,

manufactured and installed according to the requirements of the classification societies

such as ABS or DNV-GL.

Optional combination with practice-proven DPF systems also enables the removal of the par-

ticles and therefore permits the use of the engines as a genset for the EPA Tier 4 legislation.

EMISSIONS REDUCTION FOR LARGE MARINE ENGINES

EXHAUST GAS AFTERTREATMENT EGA FOR LARGE MARINE ENGINES

SCR and DPF systems for use in the seagoing ship segment with sulfur-containing fuels with integrated silencer

DIF - DIE IDEEN FABRIK

REFERENCES

SCR 1SCR 2Spark arres-

tor

Wallflow DPF

Full-flow burner

(MDO-compa-tible)

T, pressure

T, NOx

T, NOx

Urea metering

SCR part with integrated silencerDPF part with active burner regeneration

Version: 01

.08

.16

TWINTEC AG

DIF DIE IDEENFABRIK GMBH KONTEC GMBH

TWINTEC TECHNOLOGIE GMBH

BAUMOT AGINTERKAT KATALYSATOREN GMBH

DIF DIE IDEENFABRIK GmbH Otto-Lilienthal-Straße 7 | 88046 Friedrichshafen T. +49 (0) 7541/95358 - 0F. +49 (0) 7541/95358 201www.d-i-f.com | info@d-i-f.com

A COMPANY OF

TwintecBaumot GROUPPOWERTRAIN. EAT. SYSTEM SOLUTIONS.

EXHAUST AFTERTREATMENT SYSTEMS I

CATALYTIC COATING I

ON ROAD OEM ENGINEERING I

OFF ROAD OEM ENGINEERING I

MEASUREMENT AND TESTING TECHNOLOGY I