Alternate Fuels A View into Gasoline Tom Weyenberg
Outline What is gasoline? Ethanol blended gasoline The role of additives Gasoline performance measurements
Point #1: Not All Gasoline is the Same! 140 billion gallons/year in the US ~138 refineries in 48 states Plus bulk gasoline imports Refined from a variety of crude oils US, Canada, Caribbean, Middle East Light/Heavy/Sweet/Sour Using a variety of refinery processes Crude distillation Alkylation Reformation Cracking Gasoline is blended with oxygenates, mainly ethanol
From Well to Wheels Quality is Built In Throughout the Chain Crude Oil Production Crude Oil Transport Refining Fuel Terminal Filling Station Extracted from reservoir Moved by pipeline and/or ship to a refinery Processed into various products Used for storage before use Moved into the vehicle fuel tank Separation of gases and production water Moved to fuel terminal (usually by pipeline) Moved by tanker to filling station tanks
At the Refinery Crude to Gasoline Asphalt 3% Liquified Petroleum 4% Jet Fuel 9% Other Products 12% Crude Oil (42 Gallon Barrel) Diesel and Home Heating 26% Gasoline 46% Products made from a barrel of crude Source: EIA
Pathways to Gasoline Gas and light gasoline Lt. ends plant Liquefied petroleum gas Butanes Light straight run gasoline Crude oil Atmospheric distillation Naphtha Kerosene Diesel Isomerization plant Reformer Alkylation plant Isomerate Reformate Alkylate Gasoli ne AGO Hydrocracker Jet Vacuum Distillation VGO Residuum HCO Catalytic cracker Coker Light Cycle Oil Hydrotreater Dies el Fuel oil Asphalt Coke
At the Terminal Blending Ethanol Ethanol is too corrosive to ship by pipeline, so it is blended into gasoline at the terminal Refineries make gasoline to a specification (BOB) such that addition of fuel grade ethanol at a terminal brings the final gasoline into specification U.S. Gasoline and Ethanol Production 4,000,000 12% Production (Thousands of Barrels) 3,500,000 Ethanol Deposit Control Additives are also added at the terminal 3,000,000 9.3% 9.6% 8% 2,500,000 8.0% 2,000,000 7.0% 6% 1,500,000 Gasoline 4.8% 4% 1,000,000 3.9% 2.9% 2.5% 2% 500,000 2.1% 1.2% 0.8% 1.0% 1.1% 1.1% 1.3% 1.3% 1.5% 0 0% 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Source: 2011 EIA Most gasoline in the US is now blended with 10% ethanol 10% Ethanol Blend (%)
At the Pump Consumer Choices Brand part of what drives consumer choice 100% 90% 80% U.S. Market Share (by product grade) Octane level Regular / Mid / Premium OEM requirement and consumer perception Behind the scenes Quality control Tank hygiene Fuel supplier / f 70% 60% 50% 40% 30% 20% 10% 0% 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Regular Midgrade Premium Source: EIA Most filling stations receive gasoline from a nearby terminal located on a product pipeline. Marketers pulling from a terminal get the same basic gasoline, although additive type and level may be different.
Point #2: Gasoline quality is Highly Regulated Complex patchwork of federal, state and industry specifications: ASTM D4814 12 California CaRFG Phase 3 EPA Tier 2 fuel regulations (Tier 3 proposed) Federal RFS drives ethanol usage, as well as state and local factors, including subsidies and mandates Octane limits set and regulated at state level
Basic Gasoline Specifications Composition Max sulfur Max benzene Max aromatics Max olefins Limits on other elements (lead, manganese, phosphorous) Physical properties Vapor pressure, RVP (varies by season and geography) Distillation and final boiling point Oxygen content (typically from ethanol) Oxidative stability
Point #3: Ethanol blended gasoline is here to stay, the question is how high does the E level go? Point #3A: Ethanol presents some challenges to gasoline performance.
Ethanol Ethanol is a renewable fuel made from high energy density plant sources such as corn and sugar cane Ethanol is a gasoline blending stock (E10 = 10% ethanol blend) Fuel ethanol specifications: ASTM D4806 1a Composition Ethanol Methanol max Denaturant min/max (typically gasoline) Water max Gums max Other elements max (chloride, copper, sulfur) Properties ph acidity
The Ethanol Controversy Green movement meets farm lobby, date, then break up. The case for: Renewable Domestic and good for farm economies Replacement oxygenate for MTBE The case against: Lifecycle Analysis: not as green as you might think LCA Carbon, fertilizer runoff, water use, alternate land use Heavily subsidized: excise tax credits, direct investment, RIN credits Driving up food prices food for fuel 30% lower BTU energy content Performance issues: corrosion, intake valve deposits, hot running, shortened engine life The reality: Approaching 10% ethanol in all gasoline, while E85 remains a niche At the blend wall, yet mandates in Federal RFS to further increase ethanol usage
The E15 Ethanol Outlook EPA has approved E15 for use in MY 2001 and later vehicles Exceptions for motorcycle, off road (i.e. boat, lawnmower) Investigating approval for older vehicles Lawsuits filed Numerous organizations testing, showing engine and fuel system damage from E15 Not allowed in California Marketers are holding off on E15 Liability for damage from mis fueling Fuel station infrastructure limits Expense of blender pumps Source: US EPA The E15 controversy is keeping ethanol and its negative effects high in the consumers mind.
Ethanol Water Tolerance If ethanol blended gasoline becomes contaminated with too much water, phase separation will occur. Example: E10 will phase separate at 0.3% 0.5% water When phase separation occurs, the blend separates into two layers: gasoline on top, ethanol/water on bottom. Phase separation is more likely to occur with: Higher amounts of water contamination Lower temperatures Standard recommendation when phase separation occurs is to remove separated fuel and clean the fuel tank.
Ethanol and Intake Valve Deposits E0 and E10 IVD Comparison in ASTM D5500 BMW Test 4K 16K km intake valve deposit test length Identical base and additized fuels tested with (E10) and without (E0) 10% ethanol Over all comparisons, E10 IVD was significantly higher than E0 E10 IVD 41% higher than E0 >95% confidence The delta was strongest in the same vehicle subset E10 IVD 67% higher than E0 >95% confidence Effective additive can overcome the increased fouling propensity E10 IVD (mg/valve) 350 300 250 200 150 100 50 0 Comparison of E0 and E10 IVD in BMW Tests 0 100 200 300 400 E0 IVD (mg/valve) same vehicle different vehicles
Ethanol and Intake Valve Deposits Highest deposit concerns around E10 E15 Intake Valve Deposits (mg) 350 300 250 200 150 100 50 0 No Additive Desired Deposit Level 0 20 40 60 80 100 Ethanol Content of Fuel (vol %) The impact of ethanol on intake valve deposits has been shown to exhibit a maximum at or around 10% ethanol (E10). However, even E85 and E100 form IVD
Point #4: Deposit control additives are used in all US fuels, at varying levels Deposit Control Additives are used to keep fuel system components clean, which impacts vehicle emissions, fuel economy and performance. By law, all gasoline sold in the US must contain deposit control additive at a minimum performance level. Some fuel marketers use deposit control additives to give higher level performance. Additive packages are formulated with other performance components to protect fuel and provide differentiation.
What s in a typical bulk gasoline additive?
Gasoline Deposit Control Additives Impaired Fuel Flow Poor Cold Start Better Air/Fuel mixing Dirty Decreased Maintenance Clean
Gasoline Deposit Control Additives Dirty Clean Poor Fuel Distribution Better Fuel Atomization Unburned Hydrocarbons Reduced Emissions Loss of Power Improved Fuel Economy
Gasoline Fuels and Additives The Main Performance Levels LAC Required by the US EPA everywhere in the US CARB Required in California TOP TIER Higher performance level recommended by GM, BMW, Honda, Toyota, VW and Audi Differentiated Some marketers use additive levels well above TOP TIER
Gasoline Fuels and Additives Performance Levels LAC Required by the US EPA Using EPA 65 th percentile fuel ASTM D5500 BMW Intake Valve Deposit Test Additized fuel must give <100 mg/valve IVD Using base fuel that gives > 290 mg/valve ASTM D5598 Chrysler Fuel Injector Test less than 5% flow loss CARB California Only US EPA LAC plus Using CARB PIII fuel (tightly specified) ASTM D5500 BMW less than 50 mg IVD ASTM D5500 BMW less than 140% of base fuel Combustion Chamber Deposits (CCD) CARB uses the same IVD test as US EPA s LAC requirement, with a stricter deposit limit and a defined base fuel.
Gasoline Fuels and Additives Performance Levels TOP TIER Developed and recommended by GM, Honda, BMW, Toyota and VW Using fuels specified and severity tested ASTM D6201 Ford Intake Valve Deposit Additized fuel less than 50 mg/valve Using Base fuel >500 mg/valve ASTM D6201 Ford less than 140% of base fuel CCD GM SCPI injector sticking test GM intake valve sticking no harm test To claim TOP TIER all octane levels must meet performance specifications TOP TIER uses four engine/vehicle tests using somewhat more modern engines: 1994 vs. 1985
Point #5: Higher levels of deposit control additives provide real performance benefits to the consumer. Point #5A: CARB gasoline is inbetween EPA LAC and TOP TIER on deposit control performance.
Gasoline Fuels and Additives Performance Levels Deposit Prevention Ranking: EPA LAC < CARB < TOP TIER EPA LAC CARB TOP TIER Requirement Required in U.S. Required in California IVD performance: D5500 (BMW) Base Fuel >290 mg >290 mg D5500 (BMW) Additized <100 mg <50 mg D6201 (Ford 2.3L) Base Fuel D6201 (Ford 2.3L) Additized Additive Treat Rate, expressed as multiple of EPA LAC level Premium differentiated treatment >500 mg <50 mg 1X 1.5 2.0X 2.5 3.0X
Deposit Control Comparison ASTM D6201, Ford 2.3L IVD test Fuels sampled from filling stations: Unleaded regular, 87 Octane Run in industry standard engine test, ASTM D6201 4 th quarter 2012 LAC Gas TOP TIER Gas Differentiated Gas 731 mg 97 mg 9.8 mg
CARB Gasoline Average Properties GRADE AVERAGE 90% EVAP AVERAGE CORRECTED AROMATICS AVERAGE CORRECTED OLEFINS AVERAGE SULFUR (D5453) Deg. F Vol % Vol % ppm wt. National 316.8 25.0 6.8 24.8 CARB 308.3 22.7 3.7 5.8 128 CARB gasoline on average has lower aromatics, olefins and sulfur when compared to other states. Combined with deposit control additive requirements under CARB protocol, on average CARB fuel is better than the national average gasoline treated at LAC level. However, CARB gasoline is not at the TOP TIER level, both in comparing specifications and as proven in testing.
California Market Fuels Test Results ASTM D6201 Ford Intake Valve Deposit Test Location Brand Grade Test Lab Avg. IVD Weight Result (mg) TOP TIER IVD Pass/Fail Limit <50 mg Culver City CA A Regular SWRI 22.2 Pass El Monte CA B Regular SWRI 88.6 Fail Venice CA C Regular SWRI 36.2 Pass Concord CA A Regular Lubrizol 32.4 Pass San Bernardino CA A Regular Lubrizol 116.8 Fail 40% of CARB gasoline samples run in an industry standard engine test did not meet TOP TIER IVD requirements 129
Summary Not all gasoline is the same Gasoline quality is highly regulated Ethanol blended gasoline is here to stay. The question is how high does the E level go? Ethanol causes fuel system issues, some of which can be corrected with additives Deposit control additives are used in all US fuels, at varying levels Deposit control: EPA LAC < CARB < TOP TIER < Differentiated CARB gasoline does make deposits
Contact: Tom Weyenberg The Lubrizol Corporation tom.weyenberg@lubrizol.com 440-347-1301