Exhaust gas re-circulation (EGR) is nothing new in automotive circles. Neither is the concept of trying to turn exhaust gas energy and heat into usable power. What is new, however, is using what would otherwise be waste heat to specifically heat up an engine at cold start– and that’s pretty exciting.

“Until a cold engine reaches its optimal operating temperature, it is much less fuel efficient and generates higher emissions,” explains Joe Fadool, President and General Manager of BorgWarner’s Emissions & Thermal Systems department. The company’s new Exhaust Heat Recovery System (EHRS) will get internal combustion engines up to temperature faster than ever before, and help to reduce the NOx and diesel particulate matter (PM) emissions that have caused Volkswagen so much drama in recent years. The makers of the EHRS also claim that it’s able to improve fuel economy by up to 8.5%, a number that probably carries a half-dozen asterisks behind it– but, hey: Better is better.

You can check out the official BorgWarner press release, below, then let us know what you think of the new EHRS in the comments section at the bottom of the page.


BorgWarner Innovation Helps Hybrids Significantly Improve Fuel Efficiency and Reduce Emissions

  • Innovative solution made for HEVs and PHEVs
  • Improves fuel economy by up to 8.5 percent and reduces emissions significantly
  • Combines EGR and WHRS for maximized benefits

Auburn Hills, Michigan — Developed for hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs), BorgWarner’s innovative Exhaust Heat Recovery System (EHRS) will enter production later this year for vehicles from a major North American automaker. By using the heat from exhaust gas which would normally be diverted through the exhaust pipes and wasted, the company’s technology reduces engine warm-up time, enhances efficiency and significantly improves fuel economy and reduces emissions. This cost-effective solution offers compact packaging, low weight and can easily be integrated into existing vehicles.

“Until a cold engine reaches its optimal operating temperature, it is much less fuel efficient and generates higher emissions, which is one of the challenges to master for upcoming emissions regulations. Our EHRS minimizes engine heat up time, helping automakers around the globe meet new and more stringent regulations,” said Joe Fadool, President and General Manager, BorgWarner Emissions & Thermal Systems. “With the EHRS, BorgWarner serves the growing demand for highly efficient solutions to reduce emissions and strengthens its position as a leading supplier of clean technologies.”

Combining an exhaust gas recirculation (EGR) system with a waste heat recovery system (WHRS), BorgWarner leverages its vast experience in heat transfer and exhaust gas aftertatment technologies, such as EGR coolers and valves, enabling the company to offer a superior solution. The EHRS reduces mechanical losses by using the energy conserved within the exhaust gas. During engine cold starts, a valve controls the exhaust gas flow, routing it through a heat exchanger, where the thermal energy of the gas heats up the vehicle’s subsystem fluids. As a result, the engine warms up faster, reducing emissions and improving fuel efficiency. BorgWarner’s low-pressure EGR valve precisely controls the temperatures in the combustion chamber, improving engine efficiency and combustion timing. In addition, the technology reduces carbon monoxide (CO) and nitrogen oxide (NOx) emissions as well as particulate matter (PM).



Source | Images: BorgWarner, via Green Car Congress.