1a.Alt-Fuels-Ethanol.pptx alternate fuel for oils

for m.e thermal engineering

1. Ethanol Dr. P.Nanjappa Chetty , Ph.D., VelTech Dr R.R & Dr S.R Technical University 1 Dr. P.Nanjappa Chetty, Ph.D.,

2. Ethanol Program in India The Government of India has mandated 5% ethanol blending in gasoline in 9 states (Uttar Pradesh, Punjab, Haryana, Gujarat, Maharastra, Goa, Karnataka, Andhra Pradesh and Tamil Nadu) and 4 Union Territories (Chandigarh, Daman and Diu, Dadara and Nagar Haveli and Pondicherry). These states and UT’s represent about 70% of gasoline consumption in India. About 350 million liters of anhydrous ethanol (99.9% pure) would be required for 5% blend. For 10% blend, 700 million liters of anhydrous ethanol would be required. 2 Dr. P.Nanjappa Chetty, Ph.D.,

3. Ethanol Program in India (contd..) Experts estimate that India has capacity to produce 3.2 billion liters of ethanol from sugarcane-based molasses The current production is about 1.3 billion liters* * Dec 2002 Figures 3 Dr. P.Nanjappa Chetty, Ph.D.,

4. Alcohol Fuels Low level blend. Upto 5% can be used as oxygenate (as per IS 2796: 2000 - specifications for motor gasoline). Upto 10% vol. Alcohol blend for gasoline vehicles. High level blend. Containing 10-85% vol alcohol blend for gasoline vehicle. Up to 15% alcohol for diesel blend. Generally recommended 5 to 7.5% for optimum emission performance. 4 Dr. P.Nanjappa Chetty, Ph.D.,

5. Ethanol As Automotive Fuel : Advantages Can be used as an oxygenate Higher CR can be used because of high knock resistance of the fuel Higher volumetric efficiency, leading to increased power Higher flame velocity Wider flammability limits 5 Dr. P.Nanjappa Chetty, Ph.D.,

6. Ethanol As Automotive Fuel : Limitations Highly corrosive in nature - it affects badly metallic and non-metallic parts Higher latent heat of vaporization causes cold and hot startability problems Higher Aldehyde emissions Requires large fuel tank capacity due to lower calorific value Higher evaporative emission due to higher RVP 6 Dr. P.Nanjappa Chetty, Ph.D.,

7. Engine Modifications Required for Higher Blends (E15-E95) Development of metal components for anti-corrosion properties Oil seals/rubber components should be made of compatible elastomers (e.g. Viton ) Large fuel passages (jet/injector sizes) for equivalent energy Retarded ignition timing Higher compression ratios 7 Dr. P.Nanjappa Chetty, Ph.D.,

8. Ethanol in Diesel Vehicles Flash point Flammability Material compatibility and durability Storage and handling Drivability 8 Dr. P.Nanjappa Chetty, Ph.D.,

9. E Diesel Specifications and Emissions Diesel ULSD E Diesel Viscosity, 40°C Cst 2.7 2.3 Flash Point, °C 59 < 23 Sulphur content, ppm 47 < 47 CFPP, °C -20 -20 Cloud Point, °C -3 -2 Cetane Number 54 52 1.5% reduction in Nox, 9% increase in HC, 19% reduction in CO, 17% reduction in PM For Best Emission Performance 7.5% ethanol is recommended Source : Akzo Nobel Surface Chemistry AB, Sweden 9 Dr. P.Nanjappa Chetty, Ph.D.,

10. Certification Issues Fuel System Driving range - tank size, fuel economy Fuel indication - % alcohol read out Performance - compression ratio Exhaust emission measurement (Aldehydes) Durability of catalytic converter SHED emissions - permeability, canister volume Reliability - material upgrade, fuel quality Cold and hot startability 10 Dr. P.Nanjappa Chetty, Ph.D.,

11. Certification Issues -Vehicle Fuel System Tank inflammability Flame luminosity Anti-siphon Fueling receptacle for misfueling protection Labeling and procedures for fuel handling 11 Dr. P.Nanjappa Chetty, Ph.D.,

12. Certification issues Emission Exhaust emissions Carbon Monoxide Hydrocarbon (NMOG) Oxides of Nitrogen Particulate Matter (only for diesel vehicle) Evaporative emissions Crankcase emissions 12 Dr. P.Nanjappa Chetty, Ph.D.,

13. NMOG Measurement Total hydrocarbons are measured by FID analyser Methane is measured by methane cutter + FID or by Methane chromatograph Oxygenated hydrocarbons ( aldehydes & ketones ) are analysed by liquid chromotography 13 Dr. P.Nanjappa Chetty, Ph.D.,

14. NMOG Measurement ( Contd …) Total NMOG mass =  Non Methane HC (NMHC) +  oxygenated HCs Reactivity adjusted NMOG = Total NMOG mass x Reactivity adjustment factor 14 Dr. P.Nanjappa Chetty, Ph.D.,

15. Acetaldehyde Sample Collection - Flow Schematic 15 Dr. P.Nanjappa Chetty, Ph.D.,

16. Certification Issues Material Compatibility Corrosion of steel is accelerated by the presence of alcohol's in the fuel because of increased water content. Both methanol and ethanol in gasoline can cause elastomers to swell and lose tensile strength leading to failures of critical. Components such as fuel pumps, accelerator pumps and hoses. 16 Dr. P.Nanjappa Chetty, Ph.D.,

17. Certification Issues Safety Electrical conductivity Higher for alcohol than gasoline Less danger for ignition caused by static change sparking Invisible flame Suitable additives may be added Rules for handling the fuel and instructions for fire fighting Crash safety of vehicles Special rear end collision tests may be required to determine potential safety hazard 17 Dr. P.Nanjappa Chetty, Ph.D.,

18. Material Compatibility Quality of ethanol has a strong influence on its corrosive effects. General corrosion - caused by ionic impurities mainly chloride ion and acetic acid in ethanol even in trace quantities. Dry corrosion - due to ethanol molecule and its polarity , the metals (mg, Pb, and al) are susceptible. Wet corrosion - caused by azeotropic water which oxidizes most metals. As ETOH has strong affinity for water it will absorb moisture when stored. Specially true for tractor/harvester engines. 18 Dr. P.Nanjappa Chetty, Ph.D.,

19. Material Compatibility Corrosion inhibitors added in additive packages (e.G: VCI-705 concentrate, PEC Puranol) have shown promising results. Synthetic ethanol from coal and natural gas are significantly more corrosive in nature. Elastomeric compounds such as seals and o-rings in FIP which tend to swell and stiffen loosing their properties. Resin bonded or resin sealed components are also susceptible to swelling. 19 Dr. P.Nanjappa Chetty, Ph.D.,

20. Engine Durability- Diesel Engines Studies have shown no abnormal wear with 10-15 % ethanol diesel blends. Some engines may be sensitive to lowering of Cetane no & increased ignition delay causing piston erosion. Small injection timing retardation or addition of ignition improvers such as Triethylene glycol Dinitrate (TEGDN), Octyl nitrate have proven to offset the above problem. 20 Dr. P.Nanjappa Chetty, Ph.D.,

21. Engine Durability- Diesel Engines Studies have shown a decrease in injector coking over 460 hrs of testing with 15% ethanol blend whereas significant amounts of coking was found when ordinary diesel with only 20 hrs testing was used. 21 Dr. P.Nanjappa Chetty, Ph.D.,

22. Blend Stability Solubility of ethanol in diesel is dependent on temperature and water content. Lower limit of phase separation is 10°C. Aromatic content affects stability as ethanol's polar nature induces a dipole in benzene ring allowing strong interaction. 22 Dr. P.Nanjappa Chetty, Ph.D.,

23. Blend Stability Emulsifiers: acts to suspend small droplets of ethanol in diesel. Requires heating, stirring steps to generate final blend. Types: detergent, ionic, detergent less. Co-solvent: acts as a bridging agent through molecular compatibility and bonding to produce homogeneous blend. Ethyl acetate is a good co-solvent that ensures complete miscibility down to 0ºC at 1:2 ratio. 23 Dr. P.Nanjappa Chetty, Ph.D.,

24. Blend Stability Additive packages: Pure energy corporation use 2-5% dosage with 15% ethanol. AAE technologies use 1 to 1.25% for 7.7% to 10% blends. Betz-Dearborn use around 2% for 15% ethanol blend. Blends require less additive in summer conditions compared to winter. 24 Dr. P.Nanjappa Chetty, Ph.D.,

25. Blend Viscosity and Lubricity The diesel engine fuel injection systems rely on fuel lubricity for their lubrication. A study showed that blend of dry ethanol to diesel would lead to a considerable reduction in kinematic viscosity. The reduction in viscosity would lead to fuel pump and injector leakage thereby reducing fuel delivery and hence reduction in power output. 25 Dr. P.Nanjappa Chetty, Ph.D.,

26. Summary- Ethanol Ethanol as low level blend, high level blend and E100 can be used as an automotive fuel for better emission performance Material compatibility is a concern for high level blends Special rear end collision tests may be required for ensuring safety 26 Dr. P.Nanjappa Chetty, Ph.D.,

27. Summary – Ethanol (contd.) The drivability, cold and hot startability problems of the vehicle can be addressed by proper engine calibration Infrastructure for distribution of fuel will be required The acetaldehyde emissions are to be measured and can be controlled by catalytic converters 27 Dr. P.Nanjappa Chetty, Ph.D.,

28. Summary – Ethanol (contd.) 10% ethanol blend in gasoline can be tried out which may not require any major modifications in the vehicle. Evaluation Programme is necessary for vehicle performance, emission, safety, material compatibility. 5 to 7% ethanol blend in diesel could be a promising solution for the reducing in-use vehicle emissions especially for PM reduction. 28 Dr. P.Nanjappa Chetty, Ph.D.,

29. Summary – Ethanol (contd.) Study in respect of performance, emission and safety is need to be launched for all types of vehicles. Use of ethanol blend in gasoline and in diesel will help overall economy with the great benefit to rural areas. Standards / procedures for testing and evaluation / certification are to be framed. 29 Dr. P.Nanjappa Chetty, Ph.D.,

30. Summary – Ethanol (contd.) ARAI has already submitted a Joint Project proposal with Vasantdada Sugar Institute to MOPNG for evaluating different alcohol blends in Diesel and Gasoline Indian make Vehicles ranging from Utility, LCV and HCV will be evaluated with 5% and 10% ethanol blends to assess the technology for Performance Emission Durability 30 Dr. P.Nanjappa Chetty, Ph.D.,

31. Thank You……. 31 Dr. P.Nanjappa Chetty, Ph.D.,