Mix – filter – separate
Highly functional modular system for engines with low pressure EGR

MANN+HUMMEL is able to fully exploit its expertise in the design of low pressure exhaust gas recirculation modules (LP-EGR modules). The experts at MANN+HUMMEL have come up with an innovative, highly functional LP-EGR modular system which offers extreme flexibility in adapting functions of a module to the individual specifications and installation space requirements of the customer.

EGR Modular System

Graphics EGR

Low pressure EGR systems make an important contribution towards reducing the emissions of combustion engines. They reduce the NOx emissions of diesel engines and CO2 emissions of petrol engines. These systems are becoming ever more important in view of the future emission legislation.

Functions combined compactly
With its LP-EGR modular system MANN+HUMMEL follows the philosophy to unite the separate functional elements of today in an integrated module, to improve them, and to include new important functions to reduce NOx and COemissions. ‘There are obviously clear advantages of integrating EGR functions in a single compact product’, says Dietmar Talmon-Gros, project manager advanced development thermodynamics.

The modular design is oriented to the system architecture of the customer and designed to meet all his requirements. Modules can include an EGR mixer, condensate separator, EGR filter, integrated intake air throttle or a combined actuation of air and EGR throttling (combi-valve).

EGR mixer
This component directs the recirculated exhaust gas into the clean air path of the intake air. The best possible EGR mixing concept is determined using a decision matrix derived from different mixing concepts. In this respect, the customer together with MANN+HUMMEL evaluates and prioritizes each individual criterion for his application such as the installation space, pressure loss, mixing efficiency and air flow into the turbocharger compressor.

Condensate separator
This element separates condensate droplets formed during cooling of the EGR gas in the LP-EGR cooler and thereby protects the turbocharger compressor from droplet impact. For this MANN+HUMMEL was able to develop a concept which is almost free of pressure loss and has a high separation efficiency.

EGR filter
The EGR filter protects the turbocharger compressor against solid particles in the exhaust gas such as residual dirt or ceramic particles from the diesel particulate filter.

Integrated intake air throttle
The intake air throttle generates a partial pressure gradient to increase the EGR rate when the engine is operating at part load condition. For full throttle operation the intake air throttle is designed to be almost free of pressure loss. The intake air throttle from MANN+HUMMEL integrated into the clean air duct has a considerable cost advantage over other commonly available exhaust gas throttles.

The combi-valve is a combination of an intake air throttle and a low pressure EGR valve. The combi-valve only requires a single actuator for both valve functions and this alone considerably reduces costs. Further advantages of this concept are its compact design and flexible adaptation to ever tighter and more complex available installation space. The MANN+HUMMEL engineers also realized the R&D goals of minimal pressure loss, low internal leakage of the EGR valve, and simple controllability of the valves.

The new low pressure EGR module is made of plastic whereby material requirements vary according to the required function. The temperature range, chemical resistance to condensates and mechanical stability are decisive in the selection of the appropriate plastic.

Based on special analysis, experts establish the ideal pairing of materials and application areas. Thanks to intensive cooperation, the new modular system benefits from the expertise of material suppliers, turbocharger producers and manufacturers of electrical actuators in addition to internal know-how.

Press contact:        Miriam Teige

                                  Phone:          +49 (0) 7141 98 - 3354

                                  Mobile:                      +49 (0) 152 54 70 46 99

                                 E-Mail:           miriam.teige@mann-hummel.com



The MANN+HUMMEL Group is a leading global expert for filtration solutions and development partner and original equipment supplier to the international automotive and mechanical engineering industries. Employing 14,575 people at more than 50 locations worldwide, the company achieved turnover of approx. 2.6 billion euros in 2012. The group's product portfolio includes air filter systems, intake manifold systems, liquid filter systems, cabin filters and plastic components for sound design, so-called symposers, and filter elements for servicing. For general engineering, process engineering and industrial applications the company's product range includes industrial filters and membrane filters for water filtration and filter systems.