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Last Updated: Apr 25, 2025 | Study Period: 2024-2030
Exhaust gas recirculation (EGR) is an emission control technique that allows for considerable NOx emission reductions from most diesel engines, ranging from light-duty engines to medium- and heavy-duty engine applications, and even low-speed, two-stroke marine engines.
While NOx reduction is the most prevalent rationale for using EGR in current commercial diesel engines, its potential applicability extends to other areas as well. Some of them include imparting knock resistance and decreasing the requirement for high load fuel enrichment in SI engines, assisting liquid fuel vaporisation in SI engines, and acting as an enabler for closed cycle diesel engines.
Exhaust gas recirculation (EGR) is a good way to reduce NOx emissions from diesel engines. The EGR lowers NOx by decreasing the oxygen content in the combustion chamber and absorbing heat. Several designs, including high- and low-pressure loop EGR, as well as hybrid systems, have been suggested.
EGR is also utilized in gasoline engines to minimize pumping work and improve engine efficiency. In North America, EGR was frequently utilized for NOx management in spark-ignited gasoline passenger vehicle and light-duty truck engines. Some gasoline-powered applications were able to do without EGR after the early 1990s.
Following its introduction in gasoline engines, EGR was later used in diesel passenger vehicles, light-duty trucks, and finally heavy-duty diesel engines.
While heavy-duty diesel applications date back to the 1970s, it was not until the early 2000s that cooled EGR became widely used in heavy-duty diesel engines in North America. Due to the more severe technological hurdles compared to the light-duty application, this heavy-duty application drew the greatest attention to EGR.
To know more about Global Commercial Vehicle EGR Market, read our report
| S No | Overview of Development | Development Detailing | Region of Development | Possible Future Outcomes |
| 1 | MAHLE group has developed new and innovative EGR Technology | The EGR valve of MAHLE combines familiar technologies, such as the electric drive with a direct current motor, the transmission with spur gears and the successfully applied flat-seat valve with a special bent lever solution. In this way, non-linear opening characteristics with low actuating speed and high opening forces are achieved, particularly for small opening cross-sections. As a result, metering is optimized for operational states in which only low exhaust gas recirculation rates are permitted. | Global | This would enhance better Adoption and better technologies harnessing. |
A mix of NOx reduction catalysts and EGR systems is utilized to cope with stringent NOx emission standards. Vehicles in European nations are subjected to severe inspections to ensure that they meet emission regulations.
Similar rules have been enacted in Japan and the United States. Such emission rules are enacted by governments in order to decrease the impact of hazardous gases on human health and the environment. The major goal of these regulations is to minimize NOx and PM emissions from automobile gasoline.
The consumption of global automotive exhaust gas recirculation valves and coolers increased at a double-digit growth rate due to the effects of emission regulations, whereas in China, due to the China IV emission standard, the consumption of automotive exhaust gas recirculation valves increased rapidly in 2014.
The growing use of SCR over EGR systems technology, which has resulted in a decline in the use of EGR systems, may have an influence on the growth of the Global Automotive EGR systems market. Many vehicle manufacturers employ SCR, a technique that uses AdBlue to convert excess NOx emissions into water and nitrogen.
Commercial vehicles are in high demand in the United States. The growing demand for commercial vehicles fuels the market for automotive exhaust gas recirculation (EGR) systems.
The presence of major automotive EGR system manufacturers, which are primarily concentrating on important developments such as expansion, mergers and acquisitions, product introduction, and others, is also driving the region's growth.
Furthermore, the fact that individuals spend the majority of their time inside cars necessitates the use of modern technology such as automotive exhaust gas recirculation (EGR) systems.
The Global EGR Systems Market can be segmented into following categories for further analysis.
The engine EGR system is intended to minimize the quantity of nitrogen oxides generated by the engine during running periods characterized by high combustion temperatures.
When combustion temperatures approach the adiabatic flame temperature, significant quantities of NOx are produced. By cycling tiny quantities of exhaust gases into the intake manifold, where they mix with the incoming air/fuel charge, the EGR system decreases NOx generation.
The most recent technology has been through the changes in circulation and capture methodology used within the EGR Systems of the market.
The System has a focused approach which is to be at a later initiated on a manufacturing stage. In the EGR system exhaust gas is tapped off before the turbine, run through a cooler and mixed with the intake air after the compressor and aftercooler,
This is done with a minimum of disturbance to the pressure balance across the engine by confining a very efficient venturi-mixer unit with a VGT turbocharger. The venturi-mixer is positioned between the aftercooler and the intake manifold and provides a suction power to the EGR gas.
To tackle the possible corrosion within the engine requirements over the vehicles lifetime, some diesel engine manufacturers propose low pressure EGR systems as an alternative to the more conventional high pressure EGR systems.
The exhaust gas flow is recirculated back into the charge air flow downstream from the Charge Air Cooler in high pressure EGR systems (CAC). The recirculated exhaust gas flow is mixed with the charge air flow upstream of the CAC in low pressure systems.
BorgWarner has purchased Dytech ENSA SL, a manufacturer of exhaust gas recirculation (EGR) coolers, EGR tubes, and integrated EGR modules with valves for on- and off-road automotive and commercial vehicle applications. Dytech ENSA employs people and supplies customers such as Renault/Nissan, VW/Audi, Ford, Fiat, Navistar, General Motors, Daimler, PSA, Suzuki, Mahindra & Mahindra, TATA, Ashok Leyland, MAN, and IVECO from locations in Spain, Portugal, and India.
The terms of the agreement were not disclosed.This acquisition is a great strategic fit in terms of both technology and region. Operational and engineering synergies will be achieved by combining ENSA's cooler technology with BorgWarner's technology expertise in engine air management and products such as turbochargers and EGR valves.
Similarly, the acquisition expands BorgWarner's ability to serve clients globally and expands market prospects in both passenger and commercial vehicle applications. In diesel and gasoline-direct injection (GDI) engines, cooled EGR helps lower NOx and particulate matter emissions.
BorgWarner will be able to provide customers comprehensive system solutions, such as an integrated EGR valve, cooler, by-pass valve, and tubes, by combining ENSA's EGR cooler technology with BorgWarner's EGR valve and controls knowledge. BorgWarner's strategic position in addressing the technology problems of optimising the air and exhaust system for lower emissions, higher fuel economy, and performance is strengthened by the acquisition.
DENSO, a global automotive supplier, has created an exhaust gas recirculation (EGR) valve unit, which is a key component of EGR systems that reduces diesel engine emissions. The new unit, which is the world's first to combine an air intake throttle valve and an EGR valve, is half the size of previous models and has fewer components, lowering expenses.
Later this year, the unit will be put in a diesel passenger vehicle that will be offered in Europe. Previously, air intake throttle valves and EGR valves were mounted independently on automobiles.
The amount of air that enters the engine is controlled by the air intake throttle valve, and the amount of exhaust gas that is recirculated into the engine is controlled by the EGR valve. DENSO consolidated the ducts and decreased the connectors by combining the two valves into one unit, resulting in a size reduction of half compared to earlier models.
Because the EGR system must fit into a compact space near the engine, a smaller system allows automakers to design engines with greater freedom.Both the air intake throttle valve and the EGR valve used to require a motor for valve opening and shutting, as well as a sensor to monitor the valve opening and closing angle.
However, because DENSO's new device incorporates the two valves, it only requires one motor and one sensor, lowering the cost.
Tires are the heart and soul to operational mechanism of the EV at all times throughout its life that contributes to being the least expensive conglomerate part onboard the vehicle.
The EVs tyres need to be technologically advanced and better modified through various requirements being fulfilled at all times. the additional weight of any batteries and electric motor is offset by increasing the load-bearing capacity of the tire carcass, as indicated on most tires by an XL symbol on the sidewall.
Energy losses due to tires are of particular concern to EV manufacturers. With rolling resistance accounting for up to 20% of a vehicleâs energy consumption.
BorgWarner is one of the leaders in development of the EGR Modules and Systems with other internal part advancements being carried out under its regularised research and development requirements for the market.
It has developed the electrically actuated EGR valves feature a high actuation force, fast response time, flexible mounting orientations, compact package size and patented anti-contamination / anti-sticking technology.
With their high flow capability, excellent sealing, and corrosion resistance, they operate reliably in the most severe environments, enabling medium- and heavy-duty commercial diesel engines and vehicles to comply with increasingly rigorous global emissions standards. BorgWarner has also pioneered in the development of exhaust gas heat exchangers to meet increasingly strict emissions standards.
Denso Corporation is another major developer and manufacturer of latest technology equipment and is also involved in large scale development of the EGR Systems. In an effort to meet stricter fuel efficiency and exhaust emission regulations worldwide, DENSO Corporation has developed its first EGR cooler for gasoline engines.
The newly developed EGR cooler is 30 percent smaller than the smallest one currently available on the market, while offering equal performance.
This EGR cooler will greatly help reduce the overall EGR system size. It is aimed on the mechanical backgrounds of the vehicles with EGR systems equipped with EGR coolers can potentially increase fuel efficiency by 2 to 3 percent.
An essential part of automobile exhaust gas recirculation (EGR) systems is the BorgWarner EGR Valve. The BorgWarner EGR Valve is a key component in lowering emissions and increasing fuel efficiency in internal combustion engines.
BorgWarner is a top worldwide automotive supplier and designed and manufactures the valve. Recirculating some of the exhaust gases back into the engine's intake manifold is what the EGR system is there to do.
The EGR system aids in lowering the peak combustion temperature, limiting the creation of hazardous nitrogen oxides (NOx), by reintroducing exhaust gases, which contain inert gases, into the combustion chamber.
To do this, a part of the exhaust gas from the exhaust manifold is diverted through the EGR valve and directed to the intake manifold. The BorgWarner EGR Valve has been specifically designed to regulate the flow of exhaust gases entering the engine's intake system.
It functions using data from the engine control unit (ECU) and a number of sensors, assuring the ideal volume of recirculated exhaust gases under any given engine running condition.
This degree of regulation enables efficient emissions reduction while preserving engine efficiency and performance. Modern design elements are incorporated into the BorgWarner EGR Valve to guarantee dependable and effective performance. Utilizing durable materials that can tolerate high temperatures and corrosive exhaust fumes is one such aspect.
To increase the valve's longevity and performance under difficult circumstances, BorgWarner uses heat-resistant coatings and strong metal alloys.
The BorgWarner EGR Valve uses a precisely built actuator system to regulate the flow of exhaust gases. In response to signals from the ECU, this actuator opens or closes the valve as necessary.
The responsiveness and precision of the actuator guarantee accurate control of the EGR flow, enabling optimum engine performance and emissions reduction.
Additionally, BorgWarner EGR Valves go through extensive testing and validation procedures to meet OEM (Original Equipment Manufacturer) criteria and industry standards. These tests, which check for the valves' dependability and durability in actual use, include endurance testing, temperature cycling, vibration testing, and environmental simulations.
Beyond reducing emissions, the BorgWarner EGR Valve has other advantages. The EGR system helps to increase fuel efficiency by recirculating exhaust gases. The amount of fuel required for combustion is decreased because the inert exhaust gases displace some of the oxygen in the combustion chamber.
This reduces carbon dioxide (CO2) emissions and improves fuel efficiency, satisfying environmental concerns as well as legal obligations. The BorgWarner EGR Valve is also used in commercial vehicles like trucks and buses in addition to passenger cars. Larger EGR valves with higher exhaust gas flow rates are frequently needed for these heavy-duty applications.
To address the unique needs of various vehicle types and engine capacities, BorgWarner provides a variety of EGR valve solutions. The BorgWarner EGR Valve, a crucial part of vehicle EGR systems that helps reduce emissions and improve fuel economy.
The BorgWarner EGR Valve is a prime example of how committed BorgWarner is to creating cutting-edge technologies that answer the difficulties of contemporary engine design thanks to its precise engineering, robust construction, and dependable performance.
Automakers and vehicle owners can gain from a dependable and tested option that aids in the development of cleaner and more effective transportation by selecting BorgWarner EGR Valve.
| Sl no | Topic |
| 1 | Market Segmentation |
| 2 | Scope of the report |
| 3 | Abbreviations |
| 4 | Research Methodology |
| 5 | Executive Summary |
| 6 | Introduction |
| 7 | Insights from Industry stakeholders |
| 8 | Cost breakdown of Product by sub-components and average profit margin |
| 9 | Disruptive innovation in the Industry |
| 10 | Technology trends in the Industry |
| 11 | Consumer trends in the industry |
| 12 | Recent Production Milestones |
| 13 | Component Manufacturing in US, EU and China |
| 14 | COVID-19 impact on overall market |
| 15 | COVID-19 impact on Production of components |
| 16 | COVID-19 impact on Point of sale |
| 17 | Market Segmentation, Dynamics and Forecast by Geography, 2024-2030 |
| 18 | Market Segmentation, Dynamics and Forecast by Product Type, 2024-2030 |
| 19 | Market Segmentation, Dynamics and Forecast by Application, 2024-2030 |
| 20 | Market Segmentation, Dynamics and Forecast by End use, 2024-2030 |
| 21 | Product installation rate by OEM, 2023 |
| 22 | Incline/Decline in Average B-2-B selling price in past 5 years |
| 23 | Competition from substitute products |
| 24 | Gross margin and average profitability of suppliers |
| 25 | New product development in past 12 months |
| 26 | M&A in past 12 months |
| 27 | Growth strategy of leading players |
| 28 | Market share of vendors, 2023 |
| 29 | Company Profiles |
| 30 | Unmet needs and opportunity for new suppliers |
| 31 | Conclusion |
| 32 | Appendix |
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