High Octane Fuels, Making Better use of Ethanol
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1 High Octane Fuels, Making Better use of Ethanol Brian West Fuels, Engines, and Emissions Research Center EESI High-Octane Fuels Briefing Washington, DC November 13, 2017 Work supported by DOE Office of Energy Efficiency and Renewable Energy Ag/Auto/Ethanol Workgroup
2 Ethanol is a very effective octane booster ~2/3 rd of octane benefit from first 1/3 rd of ethanol volume percent U.S. EPA opened the door for a high octane ~E30 fuel in Tier 3 rule we allow vehicle manufacturers to request approval for fuel such as a high-octane 30 percent ethanol blend (E30) for vehicles optimized for such fuel Road fuel infrastructure for a midlevel ethanol blend is not trivial (but significantly less complex than many other alternatives) USDA Biofuel Infrastructure Partnership is helping grow number of stations capable of dispensing E25 and higher blends Research Octane Number D4806 Data from Stein, et al., SAE Ethanol Content (vol %) 2 Managed by UT-Battelle for the U.S. Department of Energy
3 Industry and DOE Investing In Programs to Quantify Efficiency and GHG Benefits of High Octane Fuels DOE Work supported by Vehicle Technologies Office Bioenergy Technologies Office Brake Thermal Efficiency (%) RON (E0) CR RON (E30) CR RON (E30) CR12 Industry Cost-Share, Funds-in, and Tech Support Ford General Motors Fiat Chrysler Coordinating Research Council Ag/Auto/Ethanol Workgroup Thermal Efficiency of Ford EcoBoost (data from Sluder, ORNL) Brake Mean Effective Pressure (kpa) Managed by UT-Battelle for the U.S. Department of Energy
4 A New High Octane Fuel Could Make Better Use of Ethanol s Properties, Moving The U.S. Toward Multiple Goals Engine efficiency can be improved with increasing ethanol and octane rating E25-E40 blend in future vehicles can return equivalent tank mileage as E10 in today s comparable vehicles Energy density penalty is linear with increasing ethanol concentration Power and efficiency gains are non-linear Volumetric Fuel Economy Parity means every gallon of ethanol displaces a gallon of gasoline Efficiency/fuel economy benefit to OEM is significant Can help U.S. Comply with Renewable Fuel Standard Legal to use in >20M legacy FFVs REGULAR Today s Octane Numbers PLUS PREMIUM Future: New Regular? HIGH OCTANE FUEL MINIMUM OCTANE RATING RON METHOD 100 Managed by UT-Battelle for the 4 U.S. Department of Energy 4
5 5 A few example results
6 High Octane Vehicle Demonstration Supported by DOE Bioenergy Technologies Office and follow-on work by Ag/Auto/Ethanol Objective: Demonstrate High Octane fuel benefits at the vehicle level Late model vehicle with 2.0 liter, 4-cylinder, turbocharged GDI engine Efficiency gains of 5-10% demonstrated with high-octane mid-level blends Fuel Economy (E0mpg equivalent) E0_equiv mpg CO2 g/mi +8.5% FTP (City Test) -6.6% CO2 Emissions (g/mi) Piston Blank Cadillac ATS equipped with a 2.0 liter turbocharged, direct-injection engine and manual transmission 9.5:1 Production 10.5:1 Prototype 24.0 Baseline E10 Downsped E10 Downsped E30 Factory Setup 10.5:1 Compression Pistons, Downspeeding Range bars denote max and min of multiple tests
7 Ag/Auto/Ethanol Supporting Mini Cooper E25 Demonstration Vehicle Specs: 2.0 liter turbo GDI Factory pistons and drivetrain Why Mini? Owner s manual calls out E25: Tier 3 E10 and Tier 3 E25 fuels High-Octane E25 provides efficiency and performance gains Property Research Octane Number Motor Octane Number Test Method Tier 3 E10 Value Tier 3 E25 Value ASTM D ASTM D AKI (RON+MON)/ Sensitivity RON-MON * Acknowledgement to BMW for informal technical support
8 Downsizing experiments conducted with Mini Cooper on dynamometer using 2006 Dodge Charger test weight and road load. High-octane E25 on aggressive US06 test provides efficiency gain over regular E10. Fuel Economy (E0-equiv. mi/gal) US06 Aggressive Driving Test 2.0 Turbo GDI Mini Cooper Tested at 4500 lb Dodge Charger Test Weight (downsize experiment) 3.6% 2006 Dodge Charger dynamometer settings used with Mini Cooper vehicle to simulate downsizing 24.0 E10 E25 8 Range bars indicate max and min of multiple tests
9 Extreme downsizing can improve fuel economy at the expense of acceleration performance. Mini is 0.4s quicker with high-octane E25 than with E10. With Charger test weight, vehicle considerably slower; high-octane E25 again provides 0.4s quicker acceleration. Aftermarket Power Module increases boost, improves acceleration time by 2.4 s with HO E25 fuel E10-Mini E25-Mini Dodge Charger dynamometer settings used with Mini Cooper to simulate downsizing mph Elapsed Time (s) E10-Charger E25-Charger E25-Charger with Power Module NM Engineering Power Module (PM) intercepts T MAP sensor and increases boost. PM installed by previous owner; PM was disconnected for all tests except these final E25 WOT tests. 6-nm-eng-power-module.html E10 Mini Cooper E25 E10 E25 E25 Dodge Charger Dyno Settings
10 F150 EcoBoost * Currently Under Test * 3.5L Turbocharged V6 Status Baseline testing at ORNL with Tier 3 E10 and E25 ** Complete Piston swap complete Mahle designed, fabricated, and delivered high-compression pistons (target +2.2 CR) More significant CR increase than previous experiments Ford F150 in ORNL Laboratory High Compression Experiments Underway Measurements planned Fuel Economy NMHC/NMOG, CO, NOx emissions PM mass (cold LA4) Acceleration **Same fuels used in Mini Cooper Work supported by Ag/Auto/Ethanol Workgroup Factory 10:1 MAHLE 12.2:1 Ford F150 Pistons 10
11 Factory and High Compression Pistons for Ford EcoBoost Engine from MAHLE Powertrain Factory 10:1 Prototype 12.2:1 11
12 F150 EcoBoost V6 Acceleration: High Octane E25 Provides performance difference over regular E10 in baseline (factory) test condition E10 E25 Acceleration Time (s) to 75 mph 15 to 80 mph 12
13 F150 EcoBoost V6 Particulate Matter: Baseline tests show E25 provides statistically significant reduction in cold start particulate matter over regular E10. Cold portion of test generally produces ~90% of particulate matter in certification test 12 Cold Start PM Baseline (Cold LA4) [mg/mile] FTP Cold-Start PM (mg/mile) E10 E25 Range Bars Show min and max of three measurements
14 Summary High-octane fuels can enable improved vehicle efficiency (in vehicles designed for their use) Vehicle-level demonstrations have shown efficiency gains can more than offset lowered energy density of added ethanol Vehicle efficiency gains of up to 12% demonstrated Improved torque and power can provide performance improvement (or permit smaller engines) Legacy FFVs, turbo GDI engines (Mini Cooper) show improved acceleration, demonstrate potential for OEMs if fuel widely available 14 Managed by UT-Battelle for the U.S. Department of Energy
15 Contact Information Brian West Deputy Director Fuels, Engines, and Emissions Research Center (865) Managed by UT-Battelle for the U.S. Department of Energy
16 Acknowledgements DOE Vehicle Technologies Office DOE Bioenergy Technologies Office Ag/Auto/Ethanol Workgroup National Corn Growers Illinois Corn Marketing Board Missouri Corn Growers Industry Partners and National Lab Peers Fuels, Engines, Emissions Research Center (FEERC) colleagues 16
17 Backup Slides 17 Managed by UT-Battelle for the U.S. Department of Energy
18 Recent Experiments Highlight Efficiency Benefits of High Octane Fuel for SI engines Engines can make more torque and power with higher octane fuel Ethanol is very effective at boosting octane number 87 AKI E0 + 30% Ethanol = 101 RON Fuel Increased torque enables downspeeding and downsizing for improved fuel economy For future vehicles, engine and system efficiency can balance lower energy density of ethanol blends IMEP = data point E0 (9.2:1) Best Efficiency E30 (12:1) Constant Power 101 RON E30 87 AKI E0 E0 (12:1) Engine Speed (RPM) In a high compression research engine, high-octane E30 enables doubling of available torque compared to 87 AKI E0 fuel - Splitter and Szybist, ORNL 18
19 Legacy FFVs Realize Performance Gain with High Octane Mid-Level Ethanol Blends Work supported by DOE Bioenergy Technologies Office Motivation: Measureable performance improvement in legacy FFVs could enable early adoption of High Octane Fuel for Your FFV Tested 4 ethanol tolerant FFVs GMC Sierra Chevrolet Impala Ford F150 Dodge Caravan Prep and Baseline wide open throttle (WOT) test with Regular E10 Prep and WOT test with ~100 RON E30 HIGH OCTANE FUEL For your FFV MINIMUM OCTANE RATING RON METHOD 100 Car and Driver FFV test shows 0.4 second faster 0-60 mph time with E85 Report available: 3 of 4 FFVs show acceleration improvement with E30 19 ORNL s Sierra results with E30 similar to Car and Driver test with E85 If half of FFVs on road today filled up with E25 half the time, nation would consume over halfbillion gallons more ethanol Time (s) MPH to 80 MPH WOT Acceleration Time (GMC Sierra FFV, 12 run average) E10 Regular E seconds 10.1 CR (factory) High Octane E30 RSP E30
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