EGR cooling from MAHLE Behr USA

Exhaust Gas Recirculation (EGR) Cooling for Gasoline Engines

TROY, Mich. June 17, 2014 – MAHLE Behr USA is developing exhaust gas heat exchangers for gasoline engines to help auto makers meet new fuel-economy and emission standards.

Martin Bauer, development director for engine-mounted compo-nents at MAHLE Behr USA, notes that car makers no longer will be able to meet tighter fuel and emissions requirements for cars and light trucks with engine adjustments alone.

“Exhaust gas recirculation systems now in use on diesel engines are an ideal way for car companies to meet stricter standards by improving fuel economy for gasoline-powered vehicles,” Bauer says.

EGR systems remove air from the vehicle’s main exhaust flow, cooling it in a special heat exchanger and mixing it back into the exhaust system. The cooler exhaust gas lowers combustion temperatures in the engine and helps to improve fuel economy, meet emission legislation and limit engine knock.

Bauer estimates that fuel-economy improvements of up to five percent can be achieved with the addition of EGR technology on most gasoline engines.

MAHLE has been a pioneer in the development of EGR technology, bringing cooled exhaust gas recirculation systems for cars into serial production in 1999. A feature of MAHLE’s exhaust gas heat exchangers is their very high performance density and corrosion resistance.

EGR systems and components are produced at MAHLE facilities in Charleston, South Carolina.

As a leading global development partner for the automotive and engine industry, MAHLE offers unique systems competence in combustion engines and engine peripherals.

With its two business units -- Engine Systems and Components and Filtration and Engine Peripherals -- the MAHLE Group ranks among the auto industry’s top three systems suppliers worldwide. The Behr Group was integrated into the MAHLE Group at the start of 2014; it is now trading as MAHLE Behr and makes up the Thermal Management business unit. Consequently, MAHLE also ranks among the leading OEMs worldwide in vehicle air conditioning and engine cooling.

All of the MAHLE Group’s non-automotive activities are combined in the Industry business unit which encompasses products from the application areas of filtration, thermal management, and large engines for industrial purposes. The Aftermarket business unit serves the independent spare parts market with MAHLE products in OE quality.

MAHLE has a local presence in all major world markets. In 2014, some 64,000 employees at more than 140 production locations are expected to generate sales of around 10 billion euros.

At 10 major research and development centers in Germany, Great Britain, the USA, Brazil, Japan, China and India, more than 4,500 development engineers and technicians are working on forward-looking concepts, products, and systems.

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