Understanding thermal management in aftertreatment systems

What is thermal management in an aftertreatment system?

Thermal management is the process of controlling exhaust and catalyst temperatures, so emissions-control technologies operate within their optimal temperature range. Effective thermal management helps maximize catalyst efficiency, support regulatory compliance, and reduce harmful emissions released into the environment.

Advanced aftertreatment technologies reduce emissions and help manufacturers meet increasingly stringent environmental standards. These technologies use catalysts to capture and reduce pollutants from exhaust gases, but their effectiveness depends on precise temperature control.

By maintaining the optimal operating temperature, thermal management enables emissions-control systems to perform efficiently, contributing to cleaner air and improved environmental outcomes.

When did emission regulations start for diesel trucks?

The commercial vehicle industry has worked for decades to lower emissions. Fifty years ago, exhaust aftertreatment technologies didn’t exist. Initially, efforts focused on reducing emissions within the engine through better combustion technology. However, the early 2000s brought tighter regulatory standards, prompting a shift toward exhaust aftertreatment systems to achieve further emissions reductions.

Aftertreatment systems were a big step forward. These systems convert emissions into less harmful forms. However, they need to stay at the right temperature to work effectively, making thermal management a critical component to meet stringent emissions regulations.

Thermal management offerings from Cummins Emissions Solutions

At Cummins Emissions Solutions (CES), we’ve developed advanced thermal management technologies that meet today’s regulatory standards and prepare for future regulations.

Hydrocarbon Dosing

This technology injects small amounts of diesel fuel into the exhaust stream, where the fuel oxidizes and increases the temperature of the exhaust gas and catalytic components. Maintaining these temperatures helps catalytic systems continue operating within their intended performance range.

Hydrocarbon dosing can be especially valuable during low-load engine operation, when exhaust temperatures may otherwise drop below the optimal range required for effective emissions reduction.

Electric Heaters

Another important CES innovation is electric heater technology. We’ve developed electric heaters, including 5 kW and 10 kW versions, to provide rapid and precise temperature control within aftertreatment systems. These heaters are particularly effective during cold starts and in hybrid vehicle applications where immediate thermal activation is critical.

By helping systems reach operating temperature more quickly, electric heaters minimize emissions during startup and improve aftertreatment effectiveness from the earliest stages of operation.

The future of thermal management

The future of thermal management in aftertreatment systems will focus on greater efficiency and emissions reduction. CES technologies already cut emissions by up to 99%, but future regulatory standards will demand even more. Meeting these requirements will require new materials, system integration, and control algorithms to push the boundaries of what’s possible.

As the transportation and manufacturing sectors evolve, CES is committed to staying ahead of the curve. Our team develops solutions that meet future standards and set new benchmarks for sustainability and efficiency. Innovations in thermal management will continue to deliver cleaner, more efficient systems that benefit both the environment and industries.