Ethanol, fuel for CO2 reduction on ICE (Etanol, combustível para redução de CO2 em motores de combustão interna) Dr. Eduardo Tomanik MAHLE Metal Leve S/A MAHLE
Ethanol, fuel for CO2 reduction on ICE CO2 emissions of Future cars Worldwide Interest for ethanol as fuel Some issues of using ethanol as fuel Conclusions Tomanik - SAE Energia Verde - Jun/2012 2
Which will be the future car? Electrical? Hybrid? Hydrogen fuel cell? Low Cost Downsizing? Bio-Fuel PetroSal? We can only be sure that different solutions will exist! Tomanik - SAE Energia Verde - Jun/2012 3
GreenHousegas (GHG) emissions Predictions to 2035 GHG Emissions (gco2e/km) 300 250 200 150 100 50 0 57 194 36 121 32 17 107 110 20 21 21 21 22 24 30 31 SI Current (2008) 160 Well-to-tank Tank-to-wheels Materials 20 67 2035 51 34 89 143 112 SI Turbo SI Diesel HEV PHEV FCV BEV SI: Spark-Ignition HEV: Hybrid Electric Vehicle PHEV:Plug-in Hybrid with 30-mile all electric range FCV:Hydrogen Fuel Cell vehicle BEV: Battery Electric Vehicle Price Increment relative to Gasoline SIE (USD): Turbo SI 700 Diesel 1,700 Hybrid 2,500 Plug-in Hybrid 5,900 Fuel Cell 5,300 Battery Electric 14,400 Source: On the road in 2035 MIT report Jul/2008 Tomanik - SAE Energia Verde - Jun/2012 4
Well to Wheel The complete cycle of emissions Considering the emissions to produce the fuel, use of bio-fuels brings more CO2 reduction than battery electric vehicles. CO2 Emissions (%) 120 100 80 60 40 20 REF. 23% 32% reduction of 36% 49% 77% 81% 0 Standard Gasoline Standard Diesel Gasoline + Hybrid Diesel + Hybrid Battery Electric Vehicle Biodiesel Ethanol Adapted from Mobility 2030: Meeting the challenges to sustainability World Business Council for Sustainable Development - http://www.wbcsd.org/web/mobilitypubs.htm Tomanik - SAE Energia Verde - Jun/2012 5
Car Fuel Worldwide Fleet till in 2030 By 2030, 90% of the cars still will have internal combustion engines. HCCI: Homogeneous Charge Compression Ignition, CAI: Controlled Auto Ignition Fonte: Continental estimativa baseada em EUCAR 2002, SV, VDA, OEM- Feedback, CVA, CSM 11/2010. Tomanik - SAE Energia Verde - Jun/2012 6
Car Fuel consumption in 2035 Source: On the road in 2035 MIT report Jul/2008 Tomanik - SAE Energia Verde - Jun/2012 7
Propriedade Octanagem Ponto de Fulgor PCI [MJ/kg] Calor Latente de Vaporização [kj/kg] Limite de Inflamabilidade(λ) Relação Estequiométrica - Ar Combustível (A/F) Propriedades físico-químicas E22 x E100 Gasolina (E22) [RON] ~ 92 [ C] ~ 25* [MJ/kg] 38 [kj/kg] 380 ~500 [ -] 0.4-1.6 [ -] 13,2 : 1 Etanol (E100) [RON] > 100 [ C] ~ 13* [MJ/kg] 25,2 [kj/kg] 903 [ -] 0.3-2.1 [ -] 9,0: 1 Desafio Motores que operem em condições tão distintas de taxas compressão ideal Valores menores indicam dificuldade de queima (dificuldadeem partida a frio) Manter a eficiência trabalhando com combustíveis diferentes Dificuldadeem partida a frio Valores maiores implicam em dificuldade de inflamar o combustível Controle da queima estratificada (qualidade do combustível) Controle de vazões diferentes pelo injetor Oportunidade Octanagempermite maior taxa de compressão, aumentando assim, a eficiência do motor Dificuldadede queima pode ser resolvida pelo aumento da pressão de injeção na câmara de combustão (~ 200 bar) Aplicação de downsizing acompanhada de sobrealimentação (cargas altas) Valores maiores aumentamo rendimento volumétrico, pois resfriam a câmara de combustão A queima estratificada explora o potencial do etanol de queimar em condiçõesmais pobres Osinjetores DI são mais precisos mesmo em uma maior faixa de operação (> linearidade) Source: Continental Powertrain
International Research on Ethanol ICE Tomanik - SAE Energia Verde - Jun/2012 9
CO2 reduction using Ethanol Schwaderlapp et al., Ethanol and its Potential for Downsized Engine Concepts (FEV and RWTH Aachen University), MTZ Feb 2012 Tomanik - SAE Energia Verde - Jun/2012 10
Ethanol, fuel for CO2 reduction on ICE CO2 emissions of Future cars Worldwide Interest for ethanol as fuel Some issues of using ethanol as fuel Conclusions Tomanik - SAE Energia Verde - Jun/2012 11
Flex fuel engines Some issues(1/3) Engines Higher efficiency More compact engines CO2 Emissions reduction Lower fuel consumption FFE Technology PCP increase (20 to 30%) More fuel injection (+30%) Spark time changed PCU Higher Loads Less lubrication (fuel dilution) Tribological Severity Increased Tomanik - SAE Energia Verde - Jun/2012 12
Flex fuel engines Some issues(2/3) - Ethanol lower lubricity Bearing corrosion -Fuel dilution on cold start -PCP is higher and closer to TDC Bearing corrosion after ethanol usage with a non-appropriated lube oil, Flex-Fuel engine. MAHLE Performance magazine, 2009 Pressure (bar) Gasoline Alcohol PCP (bar) Maximum PCP Gasoline: -E100: 51.5 84 bar @ Ethanol: 70.2 bar @ -E 22: 66 Piston ring spalling 360 450 54 Crank angle (º) Ferrarese et al. Piston Ring Tribological Challenges on the Next Generation offlex-fuelengines SAE2010-01-1529SAEInt.J.Engines,Vol.3, 13 Issue2 Tomanik - SAE Energia Verde - Jun/2012
Flex fuel engines Some issues(3/3) Valve Issues 4 Rodas Gel in thefuel pump Cordeiro; Yoshino SAE 2011-36-0217 Carmakers rethink sustainability approach amid E10 fuel fiasco 14 4Rodas,Nov2009 Tomanik - SAE Energia Verde - Jun/2012 MAHLE
International Research on Ethanol issues Ethanol effects on Lube and Bearings Hikita et al. Ethanol dilution on Lube Schwarze et al. Effect of Ethanol Fuel E85 on Lube Degradation and Wear in SI Engines MTZ 04/2010 MTZ Jun/2012 Tomanik - SAE Energia Verde - Jun/2012 15
Worldwide interest on ethanol as fuel for combustion engines * 109 (2011) USA EPA apud Schwaderlapp et al., Ethanol and its Potential for Downsized Engine Concepts (FEV and RWTH Aachen University), MTZ Feb 2012 Tomanik - SAE Energia Verde - Jun/2012 16
Conclusions A variety of vehicle/engine technologies is expected on the future. While developed countries will demand high efficiency/tech solutions, the growing market will be on developing countries. Considering well to wheel, advanced engines burning bio-fuels have the lowest CO2 emissions. Lower even than full electric vehicles. Ethanol fuel brings both advantages and disadvantages in terms of combustion and tribology. So far, engines are mostly adapted from gasoline engines, not ethanol optimized. More concentrated efforts on R&D are needed to fully explore the ethanol potential as engine fuel. Although pioneer in ethanol, Brazil scientific studies of ethanol as combustion engine fuel are relatively few. Tomanik - SAE Energia Verde - Jun/2012 17 MAHLE
Ethanol, fuel for CO2 reduction on ICE (etanol, combustivel para redução de CO2 em motores de combustão interna) Obrigado Thanks for the attention eduardo.tomanik@br.mahle.com Tomanik - SAE Energia Verde - Jun/2012 18 MAHLE