Flex Fuel Vehicles in Brazil - Global Bioenergy · ANFAVEA - Brazilian Vehicle Manufacturers...

ANFAVEA - Brazilian Vehicle Manufacturers Association

Flex Fuel Vehicles in Brazil

Henry Joseph Jr.ANFAVEA

Energy & Environment Affairs Commission

Brasília, March 22th, 2013.

ANFAVEA - Brazilian Vehicle Manufacturers Association2

The Brazilian Automobile Industry

Local Manufacturers (2012) - 26 companies

Net Revenue (2011) - US $ 121,3 billions

Investments (1994 ~ 2011) - US $ 61,0 billions

Total Tax Generation (2011) - US $ 31,4 billions

Share of Industrial GDP (2011) - 21,0 %

Employment (direct + indirect) (2011) - 1. 500.000 heads



Production Volume (2002 ~ 2012)

CountryProduction

(2011)

1st China 18.419.000

2nd USA 8.654.000

3rd Japan 8.399.000

4th Germany 6.311.000

5th South Korea 4.657.000

6th India 3.936.000

7th Brazil 3.407.861

8th Mexico 2.680.000

9th Spain 2.354.000

10th France 2.295.000

11th Canada 2.135.000

12th Russia 1.988.000

1.68

4.71

5

2.12

4.17

7

2.35

7.76

3

2.40

3.69

3

2.82

5.27

9

3.05

0.63

1

3.07

6.00

0

3.38

2.14

3

3.40

7.86

1

3.34

2.61

7

0

500.000

1.000.000

1.500.000

2.000.000

2.500.000

3.000.000

3.500.000

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012



Passenger Cars 2.623.704 78,5%

Light Commercials 549.249 16,4%

Trucks 132.820 4,0%

Buses 36.844 1,1%

To Domestic Market 2.900.542 86,8 %

To Export Market 442.075 13,2 %

Locally Produced 3.007.006 79,1 %

Imported 795.065 20,9 %

Imp

ort

ed F

rom

Argentina 349.168 43,9%

South Korea 151.875 19,1%

Mexico 109.033 13,7%

China 61.548 7,7%

Germany 53.016 6,7%

Others 70.425 8,9%

Production Profile (2012) Domestic Market (2012)



Automobile Fleet (2011)

Total Fleet: 34.654.969 vehicles

(5,5 inhabitants / vehicle)

(2 wheel vehicles, tractors and agriculture machinery are not included)


The Brazilian Ethanol Fuel Program

“PROALCOHOL”This energy program was adopted by the Brazilian Government in 1975 due to the

international oil crisis, aiming 2 applications:

1) to blend high volume of ethanol in gasoline (more than 15%);

2) to incentive the development of 100% ethanol fueled engines.

. ALCOOL .

6


High volume content of ethanol in gasoline

Due to the ethanol availability (it’s a byproduct of sugarproduction), experiments with ethanol fueled vehicleswere performed in Brazil since 1920;

In the time of World War (imported oil rationing), gasolineblended with ethanol (up to 5%) was intensely employedin Brazil with good results;

Since then, Brazil has continuously added different levelsof ethanol in gasoline:

1938 ~ 1966 ⇒ 0% to 25%

1966 ~ 1981 ⇒ 10% to 14%

1981 ~ 1982 ⇒ 18% to 22%

1982 ~ today ⇒ 20% to 25%

Officially, the vehicles are certified for 22% ± 1% (E22).

37


100% Ethanol Fueled Vehicles

From 1979 on the Brazilian automobile industry started to offer vehicles adapted to100% ethanol fuel (E100).

At that time, the Brazilian Government also took some measures to incentive theuse of ethanol (fuel price control, subsided loans to ethanol producers, obligationfor all fuel stations to offer ethanol, tax reduction for ethanol fueled vehicles, etc.).

Consequently, the E100 vehicle sales was a big success.

0

100

200

300

400

500

600

700

800

900

1.000

Units

(x 1

.000

)

1979

1980

1981

1982

1983

1984

1985

1986

1987

1988

1989

Ethanol (E100) Gasohol (E15~E25)

1979 to 1989


The PROALCOHOL Crisis

Due to economic problems, in 1987 the ethanol subsides were removed and itsprice became more expensive and closer of gasoline. In 1989, due to the inflationand price control, the ethanol producers decided to export more sugar causing amarket ethanol shortage.

Therefore, the sales of 100% ethanol fueled vehicles were seriously affected.

0

200

400

600

800

1.000

1.200

1.400

1.600

1.800

2.000

Units

(x 1

.000

)

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

Ethanol (E100) Gasohol (E15~E25)

1989 to 1999


Ethanol again?

At the end of 1990s, the ethanol supply was normalized and the price becamestable and cheap;

The “clime changes” became a matter of great concern and the renewable fuelsstarted to be valorized by the media, including ethanol.

So, the customers started to have interest on ethanol again.

1.224

10.947 10.292

18.335

55.961

0

10.000

20.000

30.000

40.000

50.000

60.000

1998 1999 2000 2001 2002

E100 Fueled Vehicles Sales


Flex Fuel Vehicles (FFV)

Introduced in the Brazilian Market in March of 2003.

At this moment: 13 brands and 163 models.

11


The Flex Fuel are designed to be indistinctly fueled with gasoline (E22), ethanol(E100) or any blend of these two fuels. For the customers, it means to choose thefuel at each vehicle filling, according to fuel price, characteristics of quality,performance or even availability.

Through some special electronic sensors, the on-board computer recognizes thefuel and properly adjust the engine combustion parameters, without anyinterference from the driver.

Gasoline Alcohol

Sensors

The Fuel Recognition System

12


Flex Fuel Sales

13

7,5%

87,0%

0,0

20,0

40,0

60,0

80,0

100,0ja

n/03

mai

/03

set/0

3

jan/

04

mai

/04

set/0

4

jan/

05

mai

/05

set/0

5

jan/

06

mai

/06

set/0

6

jan/

07

mai

/07

set/0

7

jan/

08

mai

/08

set/0

8

jan/

09

mai

/09

set/0

9

jan/

10

mai

/10

set/1

0

jan/

11

mai

/11

set/1

1

jan/

12

mai

/12

set/1

2

jan/

13

% E22 Only % E100 Only % Flex Fuel % Diesel

18,3 millions ofFFV sold


The Brazilian Ethanol Fuel

Sugar Cane

Drying

Process

Application:

To use as straight fuel.

(E-100)

Application:

To blend with gasoline.

(E-20 ~ E-25 )

“Anhydrous”Ethylic Alcohol(< 0,7% H2O)

Fermentation&

Distillation

“Hydrous”Ethylic Alcohol(~ 6,8% H2O)

2 different kinds of ethanol:

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The Technology to Use Ethanol Fuel

Technically, the use of ethanol brings some concerns on:

• Compatibility with metallic materials (corrosion);

• Compatibility with plastic or rubber materials (chemical attack);

• High fuel consumption (low energy content);

• Loss of drivability (change of combustion air/fuel ratio);

• Difficulty in the engine cold start (low vapor pressure).

However, it all depends of:

1. Percentage of ethanol blended at gasoline;

2. Ethanol fuel specification and quality;

3. The vehicle technological level (age).

15


Eventual Modifications for Ethanol

EvaporativeEmissionSystem

ColdStart

System

MotorOil

ExhaustPipe

CatalyticConverter

FuelTank

IgnitionSystem

BasicEngine

FuelFilter

FuelPressureDevice

FuelPump

Electronic Fuel Injectionor

Carburetor

IntakeManifold

16


Probably Necessary Modifications

Fuel Ethanol Content

Fu

el Injectio

n 1

stGen

.

Fu

el Pu

mp

1stG

en.

Fu

el Injectio

n 2

nd

Gen

.

Fu

el Pu

mp

2n

dG

en.

Fu

el Pressu

re Device

Fu

el Filter

Ign

ition

System

Evap

orative S

ystem

Fu

el Tank

Catalytic C

on

verter

Basic E

ng

ine

Mo

tor O

il

Intake M

anifo

ld

Exh

aust S

ystem

Co

ld S

tart System

≤ 10%

10 ~ 15%

15 ~ 25%

25 ~ 85%

≥ 85%

- Not Necessary - Probably Necessary

(Otto Cycle Engines)

- - - - - - - - - - - - - - - - - - - For any vehicle - - - - - - - - - - - - - - - - - - -

- - - - - - - - - - - For fleets up to 10 years old - - - - - - - - - - - -

17


Engine and Vehicle components changes

Motor: Higher compression ratio. Valves with new profile and protected against corrosion.

Inlet Manifold: Optimized geometry to reach quickly the ideal temperature after cold start

Fuel supply: Every plastic and metallic parts must resist to Gasoline and also Ethanol.

Catalytic converter: The type and amount of noble metals must be adjusted.

Exhaust system: Internal surface of pipes must be protected against oxidation. The dimension considers high water level inside the pipes.

Ignition system: Different ignition timing for each fuel. Spark plugs with optimized heat value .

18


Engine and Vehicle components modification

Cold start system: As the ethanol does not evaporate at low temperatures, it is necessary a small tank with gasoline for helping cold start.

The additional tank is not necessary with mixtures up to 85% ethanol (E85).

ECU and Software: Additional functions are included to determine ethanol ratio in fuel and calculate fuel injection amount and ignition time.

Fuel filter: Filter element material and its porosity must be arranged.

Pressure regulator: The fuel pressure must be increased. Internal surface must be protected against corrosion.

Fuel injectors and lambda sensor: The fuel injectors must be protected against corrosion. The lambda sensor will determine the air/ fuel ratio for every possible mixture.

Fuel pump: It must provide fuel in higher pressure and flow. Internal components must be protected against corrosion.

19


Evolution in flex vehicles: Electric Cold Start

In 2009, it was introduced the first flexible vehicle produced in Brazil that doesn’tneed the injection of gasoline to support the cold start.

This vehicle has an electrical heater that works integrated with the injectors andwarms the ethanol (when it is necessary), assuring a perfect start of the engineeven at low temperatures.

20


Ethanol Engines: Relative Performance

0

20

40

60

80

100

120

140

160

Power Torque Max Speed Acc Time(0~100 km/h)

Consumption(L/100km)

103,

3 %

102,

1 %

103,

2 %

95,5

%

109,

0 %

110,

0 %

106,

4 %

105,

3 %

89,3

%

144,

0 %

Gasoline 0% Gasohol 22% Ethanol 100%

Three different vehicles of same model, each one adjusted and calibrated to an specific fuel.

21


Fuel Consumption

1,0 L/100km 1,58 L/100km1,09 L/100km

E0

31,65 MJ/L

E22

28,99 MJ/L

E100

20,09 MJ/L

+ 9% + 44%

Energy Content:

Fuel Consumption:

100,0 km 63,3 km91,7 kmAutonomy for 1,0 L:

Ethanol Price must be ≤ 70 % of E22 price

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Thank you

[email protected]

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