NGK to Establish New Plant for Ceramic Products for Diesel Automotive Exhaust Gas Purifiers in Poland
March 05, 2012
NGK to ramp up production capacity by 40% by investing 37 billion yen
in six production sites worldwide
NGK Insulators, Ltd. (President: Taro Kato; Headquarters: Nagoya, Japan) has announced its decision to construct a new plant for large-size HONEYCERAM substrates for automobile catalytic converters for use in diesel vehicles at NGK CERAMICS POLSKA Sp. z o.o. (Gliwice, Silesia Province, Poland), a manufacturing subsidiary in Poland. Furthermore, NGK will upgrade production facilities for silicon carbide (SiC) diesel particulate filters (DPFs) at NGK CERAMICS POLSKA.
NGK expects to enter into long-term supply agreements for ceramic products for diesel automotive exhaust gas purifiers with major customers. Accordingly, NGK will ramp up production capacity by investing approximately 37 billion yen in six production sites for ceramics products for automotive exhaust gas purifiers worldwide, including Poland. Through these investments, NGK will successively expand production capacity for ceramic products for cordierite automotive exhaust gas purifiers, with the view to increasing production capacity by around 40% by the end of fiscal 2013.
NGK plans to construct the new large-size HONEYCERAM (LSH) plant on a site adjacent to NGK CERAMICS POLSKA's plant for the production of SiC DPFs for use in passenger cars. Production at the new plant is scheduled to commence in January 2014, with a planned production capacity of units based on a conversion to standard models (8 million units based on conversion to HONEYCERAM). Furthermore, NGK will upgrade some production facilities for SiC DPFs at NGK CERAMICS POLSKA, with the view to increasing production capacity by around 20% by fiscal 2013 compared with the current level.
Demand for ceramic products for exhaust gas purifiers is projected to expand mainly due to stricter diesel exhaust gas regulations worldwide and increased automobile sales volume centered on emerging markets. In response, NGK will establish a framework for the stable supply of ceramic products by executing capital investment of approximately 37 billion yen in production sites worldwide according to trends in each region and product demand. This is also to ensure that NGK fulfills its obligations under long-term supply agreements with major client manufacturers of diesel engines, large vehicles, passenger cars, construction machinery and so forth. Planned production increases at various sites other than Poland and an outline of products are as follows:
Main planned production increases for ceramic products for exhaust gas purifiers (excluding NGK CERAMICS POLSKA)
1. NGK INSULATORS, LTD. Ishikawa Plant (Nomi City, Ishikawa Prefecture)
・Capital investment details: establish new production facilities for LSH and cordierite DPFs
・Start of production: July 2013
2. NGK CERAMICS SUZHOU CO., LTD. (Suzhou, Jiangsu Province, China) Eighth phase of capital investment
・Capital investment details: increase production facilities for HONEYCERAM, LSH, and cordierite DPFs
・Start of production: August 2012
3. NGK CERAMICS MEXICO, S. DE R.L. DE C.V. (Cienega de Flores, State of Nuevo León, Mexico) Second and third phases of capital investment
・Capital investment details: increase production facilities for LSH and cordierite DPFs
・Start of production: March 2013
4. P.T. NGK CERAMICS INDONESIA (Bekasi, West Java Province, Indonesia) Fifth capital investment
・Capital investment details: increase production facilities for HONEYCERAM and LSH
・Start of production: April 2013
5. NGK CERAMICS USA, INC. (Mooresville, North Carolina, U.S.A.) Fifth phase of capital investment
・Capital investment details: increase production facilities for HONEYCERAM
・Start of production: January 2014
Outline of Products
1. HONEYCERAM substrates for automobile catalytic converters for gasoline-powered vehicles
This model of HONEYCERAM is used as a ceramic catalyst carrier for a catalyst that purifies harmful substances, such as hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxide (NOx), in automobile exhaust gas.
2. Large-size HONEYCERAM (LSH) substrates for automobile catalytic converters for diesel vehicles
Made of cordierite, this model of HONEYCERAM is used as a catalyst carrier for an oxidation catalyst that removes particulate matter (PM), and for a selective catalytic reduction (SCR) catalyst that removes nitrogen oxide (NOx) in the diesel exhaust gas of large commercial vehicles such as trucks and buses.
3. Cordierite diesel particulate filters (DPFs)
Cordierite DPFs employ the thin ceramic walls as a filter by alternately closing off the ends of HONEYCERAM. This enables the removal of PM in exhaust gas. Cordierite DPFs are used mainly in trucks and other large vehicles because they are lightweight even in large sizes, given their lower specific gravity than SiC DPFs.
4. Silicon carbide (SiC) diesel particulate filters (DPFs)
SiC DPFs are used mainly in passenger cars because they are more heat resistant, and can capture and incinerate a greater amount of PM than cordierite DPFs.