AEES-14 The Use of Ethanolas an UnmixedFuel for lnternalCombustionEngines by JosephL. Taraba Extension istfor Agricultural Engineering Special GeorgeM. Turner Extensi on Special istf or Agricultural Engineering RobertRazor Undergrad uateStudent,Department of Agricultural Eng ineering Department of Agricultural Engineering University of Kentucky Lexington, Kentucky February1981 U N I V E R S I T Yo f K E N T U C K Y in COLLEGEof AGRICULTURE coogerolion OEPT.of AGRIC.ENGINEERING with COOPERATIVE EXTENSIONSERVICE KENTUCKY DEPARTMENT of ENERGY Preface A committeeof the AgriculturalEngineeringDepartment,Universityof Kentucky,of which the authorsare members,is investigatingthe feasibilityof certainfarmersbecoming e n e r g yi n d e p e n d e nbt y p r o d u c i n gt h e i ro w n e n g i n ef u e l . A part of this investigationconcernsjust how low a proof of ethanolcan be toleratedby internalcombustionenginesfrom severalaspects.Naturally,the lowerthe proofthe easierthe p r o d u c t i o nw i l l b e . This paperdescribesthe resultsof a literaturesearchon the effect of water dilution in ethanolon the combustionprocessin internalcombustionengines. CONTENTS I n t r o d u c t i o .n. . . ... . ... . 3 Proof of EthanolTolerableby InternalCombustionEngines . .. . 3 M e c h a n i c aM l o d i f i c a t i o nR s e q u i r e df o r U s e o f E t h a n o a l s a F u e li n a S l E n g i n e .... 5 e ot hf a n o l a s a F u ei ln a D i e s e lE n g i n e . . . . . 1 0 M e c h a n i c aMl o d i f i c a t i o n s R e q u i r e d f o r U s E C o m p a r i s o n oEf n g i n e P e r f o r m a n c e o n E t h aannodl C o n v e n t i o n F a lu e l s . S a f e t yi n H a n d l i n gE t h a n o l ........11 .. . . 13 D e t e r i o r a t i oonf M a t e r i a l si n C o n t a c tw i t h E t h a n o l. . . . .. ... .. . 14 P o l l u t a nE t m i s s i o n sL e v e l so f E n g i n e sU s i n gE t h a n o l . .. 14 y s i n gE t h a n o l E n g i n eD u r a b i l i t U D e p o s i t si n E n g i n e sU s i n g E t h a n o l .... 16 .. . . . . .. 17 Conclusion ...... 17 Glossaro yf Terms ...... 18 Bibliography..... ......19 In tro d u cti o n T h e u s e o f e t h a n o l( e t h y la l c o h o l )a s a f u e l f o r s p a r ki g n i t e d( S l ) . i n t e r n acl o m b u s t i o ne n g i n e sh a s been evaluatedand consideredsatisfactorysince the early1900s.Today due to the increasingcost of p e t r o l e u ma n d t h e c u r r e n t w o r l d o i l u n c e r t a i n t y , w h i c h m a y g r e a t l ya f f e c tt h e f u t u r e a v a i l a b i l i t yo f p e t r o l e u ms, o m ea l t e r n a t i v feu e l sf o r i n t e r n acl o m b u s t i o ne n g i n e sa r e n e e d e d .E t h a n o li s o n e o f t h e f u e l st h a t h a ss h o w np r o m i s ea sa p e t r o l e u ms u b s t i tute. Today the country of Brazilhas chosena path o f l e s sd e p e n d e n c e o n p e t r o l e u mb y d e v e l o p i n ga n e t h a n o lf u e l t e c h n o l o g y I. n t h e s p r i n go f 1 9 8 0 ,c a r s designedto run exclusivelyon ethanolwereoffered f o r s a l e t o t h e B r a z i l i a np u b l i c . B r a z i l h a s a l s o e n c o u r a g e di t s c i t i z e n st o u s ee t h a n o lb y m a k i n gi t a v a i l a b l et o t h e c o n s u m e ra t h a l f t h e c o s t o f g a s o line. T h i s p a p e r r e v i e w st h e u s e o f e t h a n o l a s a n u n m i x e df u e l f o r i n t e r n a cl o m b u s t i o ne n g i n e s A . nh y d r o u s e t h a n o l ( n o w a t e r p r e s e n t )i s r e q u i r e d w h e nf u e l m i x t u r e sa r em a d ew i t h g a s o l i n eo r d i e s e l f uel.Presenceof greaterthan 1.50/o waterin ethanol w i l l c a u s es e p a r a t i o no f t h e e t h a n o lf r o m t h e p e t r o l e u m f u e l . O n - f a r m p r o d u c t i o no f e t h a n o lw i l l yield ethanolf uel with at least50/o water presentor present. Thus,on-farmethanolf uel up to 50%water p r o d u c t i o n w o u l d n e c e s s i t a t ea d a p t i n g i n t e r n a l c o m b u s t i o ne n g i n e sf o r u s e o f u n m i x e d e t h a n o l fuel. Severalbasicf uel propertiesof ethanolin comoarison to other conventionalfuels need to be noted becauseof theireffectson the use of ethanol a s a f u e l f o r i n t e r n a cl o m b u s t i o ne n g i n e s S . o m eo f t h e f u e lp r o p e r t y c o m p a r i s o nasr es h o w ni n T a b l e1 . C o n v e n t i o n ahl y d r o c a r b o nf u e l s( g a s o l i n ea n d d i e s e l o i l ) c o n t a i n 1 8 , 9 0 0a n d 1 8 , 2 5 0B t u / l b i n c o m p a r i s o nt o e t h a n o l , w h i c h c o n t a i n s 1 1 , 5 0 0 B t u / l b .I n o r d e rt o a c h i e v ee q u i v a l e net n g i n ep o w e r o u t o u t f o r d i f f e r e n tf u e l s t h e r e m u s t b e s i m i l a r e n e r g y i n p u t , a s f u e l . F o r e x a m p l e ,p u r e e t h a n o l c o n t a i n s6 1 % o f t h e e n e r g y o f g a s o l i n ep e r u n i t weight, thereforemore pounds of ethanol are req u i r e d t h a n g a s o l i n ef o r e q u i v a l e net n g i n e p u w e r o u t p u t .l f a n e t h a n o fl u e l c o n t a i n sw a t e r ,w h i c h h a s n o c o m b u s t i o ne n e r g y ,t h e r em u s t b e a n i n c r e a s e d f u e l r a t e t o t h e e n g i n e t o s u p p l y s u f f i c i e n ti n p u t energy. Anotherimportantdifferencebetweenconvent i o n a lf u e l sa n d e t h a n o li s t h e h e a to f v a p o r i z a t i o n . E t h a n o lr e q u i r e s3 6 1 B t u / l b t o v o l a t i l i z ew , hich is a p p r o x i m a t e l y2 . 5 t i m e s t h e h e a t r e q u i r e d p e r p o u n do f g a s o l i n eo r d i e s e fl u e l .W a t e rh a sa h e a to f v a p o r i z a t i o 2n . 7t i m e st h a t o f a l c o h o l . T h e a u t o - i g n i t i o np r o p e r t yo f a f u e l b e c o m e s i m p o r t a n tf o r t h e t y p e e n g i n ei n w h i c h t h e f u e l i s u s e d .T h e o c t a n en u m b e rm e a s u r e st h e r e s i s t a n c e to self-ignition w h i l e t h e c e t a n en u m b e rm e a s u r e s propert h e e a s eo f s e l f - i g n i t i o nL.o w a u t o - i g n i t i o n ( h i g h ties o c t a n en u m b e ra n d l o w c e t a n en u m b e r ) a r ed e s i r a b l e f o r s p a r ki g n i t i o ne n g i n e sE . t h a n oal n d g a s o l i n eb o t h i n d i c a t eh i g h o c t a n ea n d l o w c e t a n e n u m b e r s .B u t d i e s e le n g i n e sr e q u i r ea h i g h a u t o i g n i t i o nv a l u ef u e l ( h i g hc e t a n en u m b e r ,l o w o c t a n e number)w , h i c h d i e s e lf u e l d o e sp o s s e s s . F i n a l l yt h e a i r - fu e l r a t i ot o a c hi e v et h e c o mp l e t e b u r n i n g o f t h e f u e l ( s t o i c h i o m e t r i cA / F r a t i o ) i s 1 4 . 7 : 1' f o rg a s o l i n eb u t o n l y 9 : 1f o r e t h a n o l T . h i sf u e l propertyrequi res carburetor f uel-rateadjustments t o a c h i e v em a x i m u me n g i n ee f f i c i e n c y . Proofof EthanolTolerableby InternalGombustion Engines T h e p r o o f o f a l c o h o lt o l e r a b l eb y a n i n t e r n a l c o m b u s t i o ne n g i n e i s o n e o f t h e m o s t i m p o r t a n t Table 1.-Fuel Properties. Heatof Combusion Btu/lb Gasoline D i e s e lF u e l Ethanol Water - A b b r e v i a t i o n sa r e 18,900 18,250 11,500 Density lb/gal Heat of Vaporization Btu/lb 6.2 7.3 o.o 8.3 d e f i n e da t t h e e n d o f t h e p u b l i c a t i o n . 142 115 361 970 Octane Number Cetane Number Stoichiometric A i r / F u e lR a t i o 77-86 10-30 89 10-20 14.7 15.0 9.0 AE, 20-10 f a c t o r s t h a t m u s t b e c o n s i d e r e di n t h e u s e o f e t h a n o lE . t h a n o il s c o n c e n t r a t e d u r i n gt h e d i s t i l l a t i o n o f a m i x t u r eo f e t h a n o a l n d w a t e r .E a c ht i m e t h e m i x t u r e i s d i s t i l l e d ,i t s p r o o f ( t w o t i m e s t h e p e r c e n t a g ec o n t e n to f t h e a l c o h o li n t h e a l c o h o lw a t e r solution) increases.Therefore, the lower proof ( h i g h e rt h e w a t e r c o n t e n t )e t h a n o l i s c h e a p e rt o p r o d u c e a n d e c o n o m i c a l l ym o r e a t t r a c t i v ea s a o e t r o l e u ms u b s t i t u t e . T h e u s e o f e t h a n o li n a n i n t e r n a lc o m b u s t i o n e n g i n ew i t h a p r o o fa s l o w a s 7 0 h a s b e e nr e p o r t e d ( S c h r o c k ,1 9 7 9 ) . B u t i n a t e s t d o n e o n a 1 9 4 7 P l y m o u t he n g i n ea t w i d e o p e n t h r o t t l e( W O T )w i t h t h e i g n i t i o n ,s p a r kt i m i n g a n d a i r - f u e lr a t i oc a r b u retoradjustedfor maximumpower,and usinghotter s p a r kp l u g s t h a n f o r n o r m a lg a s o l i n eo p e r a t i o n i,t was f ound that as the proof of alcohol decreases, the horsepower and thermal efficiency decrease The results of whilethe f uel consumptionincreases. t h i s t e s ta r e s h o w n i n T a b l e2 ( S c h r o c k 1, 9 7 9 ) . A n o t h e rt e s t o e r f o r m e do n a n O l i v e ri n - l i n es i x c y li n d e re n g i n ew i t h a h e a t e rf o r t h ea ir - fu e l m i x t ur e s h o w e d s l i g h t l y d i f f e r e n tr e s u l t sf o r t h e t h e r m a l e f f i c i e n c yT. h e r e s u l t si n d i c a t e dt h a t a s w a t e rw a s a d d e dt o 2 0 0 p r o o f a l c o h o lt h e t h e r m a le f f i c i e n c y i n c r e a s e du n t i l t h e m i x t u r e w a s 1 8 0 p r o o f , t h e n d e c r e a s e da s i n c r e a s i n ga m o u n t s o f w a t e r w e r e a d d e d .H o w e v e r ,t h e p o w e r o u t p u t o f t h e e n g i n e was maximumat 200 proof (Deardorff,1979). fhese testsindlcate that the higher proof ethanol is a more desirable fuel. But as before, the e c o n o m i c sm u s tc o n s i d e rm o r et h a nj u s tt h ec o s to f t h ef u e l . Lower proof ethapol also has caused some . u r d e t h a n o rl e q u i r e sm o r e h e a t e n g i n ep r o b l e m s P per gallon for vaporizationthan gasolineor diesel f u e l .F u r t h e r t, h e l o w e rt h e p r o o fo f t h e e t h a n o lt h e more Btu of heat per gallon for vaporizationare r e q u i r e db e c a u s eo f t h e h i g h h e a to f v a p o r i z a t i o on f water.Therefore,more heatis neededfor the intake m a n i f o l d( H u n t ,1 9 7 9 ) .I n t h e t w o t e s t sm e n t i o n e d p r e v i o u s l y t, h e f a c t t h a t t h e O l i v e re n g i n e h a d a h e a t e rf o r t h e a i r - f u e lm i x t u r e a n d t h e P l y m o u t h e n g i n ed i d n o t ,m a y h a v ec a u s e dt h e d i s c r e p a n c iyn . u r t h e r l, o w e rp r o o f t h e t h e r m a le f f i c i e n c yr e s u l t s F ethanolfuels (168proof) havealso producedstarti n g p r o b l e m s( H u n t ,1 9 8 0 ) . O i l d i l u t i o nh a s a l s o b e e n r e p o r t e dd u r i n g u s e of lower proof ethanol. ln a test performedon the 1 9 4 7P l y m o u t he n g i n e o, i l d i l u t i o nw a se n c o u n t e r e d w h e nu s i n g7 0 p r o o fe t h a n o lA . t W O T t h ee n g i n er a n s m o o t h l yo n 7 0 p r o o fe t h a n o lb u t w a s i n c o n s i s t e n t i n i t s o o e r a t i o n .B u t u n d e r t h e s es a m e c o n d i t i o n s r u n n i n g t h e e n g i n e f o r o n e h o u r r e s u l t e di n t h e from6 to 8 quarts, c r a n k c a s eo i l v o l u m ei n c r e a s i n g d u e t o t h e d i l u t i o no f t h e o i l b y t h e a l c o h o la n dw a t e r ( S c h r o c k ,1 9 7 9 ) .O i l d i l u t i o nc a n b e o v e r c o m eo r g r e a t l yr e d u c e db y r a i s i n gt h e c o o l i n gw a t e rt e m perature by changing thermostats(Deardorff, 19 7 9 ) . W i t h o u t h e a t a d d i t i o nt o t h e f u e l - a i rm i x t u r e , the temperature o f t h e c h a r g ee n t e r i n gt h e e n g i n e c y l i n d e ri s l o w e r f o r e t h a n o lo r e t h a n o l - w a t efru e l t h a n g a s o l i n e .T h i s r e s u l t s i n a d e n s e r f u e l - a i r charge to the cylinderand a higher volumetric e f f i c i e n c yf o r a n e n g i n ef u e l e d w i t h e t h a n o lo v e r gasoline. Table 2.-Engine Performanceon VariousProof Alcohol. Proof Brake Horsepower 200 190 180 160 140 120 110 100 90 80 70 47.67 46.18 46.67 45.07 45.58 43.60 42.00 42.94 42.35 41.40 34.10 Blend Ethanol Consumption Consumption lb/bhp-hr Gal/hr 6.85 7.53 7.94 9.52 11.33 12.90 14.53 19.00 17.90 20.87 26.70 .944 1.029 1.042 1.127 1.162 1.207 1.278 1.490 1.277 1.341 '1.853 Thermal Efficiencya 21.2 19.4 19.2 t t.o 17.2 to.o 15.6 13.4 15.6 14.9 10.8 a H i g h e r h e a t i nvga l u eu s e db y t h i s s t u d y ( D u c k e t a l 1. ,9 4 5 t)o c a l c u l a t e t h e r m a l e f f i c i e n c y Optimum SparkAdvance 17.5 zu.+ 21.3 27.0 29.0 33.0 35.0 36.0 41.5 47.O 50.0 One interesting fact about the lower proof ethanol is that it may be able to withstandgreater i n c r e a s e si n t h e c o m p r e s s i o nr a t i ot h a n t h e h i g h e r p r o o f ( H u n t ,1 9 8 0 ) .l f t h i s i s t r u e t h e p o w e ro u t p u t a n d t h ee n g i n e e f f i c i e n c y w o u b l de i n c r e a s e fdo r t h e l o w e r o r o o fe t h a n o l . Ethanol is more suitable for use in spark ignition engines than in diesel engines because of ethanol'shigh octanenumber (the octanenumber and the cetane number are inverselyrelated).The c e t a n en u m b e ro f e t h a n o lc a n b e r a i s e db y t h e u s e o f a d d i t i v e s .A m y l n i t r a t e i s a n a d d i t i v et h a t i s popular in the UnitedStates.A 1.50/o mixtureof amyl n i t r a t ei n e t h a n o li n c r e a s e st h e c e t a n en u m b e ro f e t h a n o lb y 1 5 p o i n t s .H o w e v e r ,n o r e p o r t so n t h e p e r f o r m a n c eo f a d i e s e le n g i n eu s i n g e t h a n o la n d a m y l n i t r a t eh a v eb e e nf o u n d ( S c h r o c k 1, 9 7 9 ) . C y c l o h e x a n oils a n a d d i t i v et h a t i s p o p u l a ri n Europe.When it makes up 100/o of a mixture with e t h a n o l ,t h e c e t a n en u m b e r o f e t h a n o l i s c o m p a r a b l et o t h a to f d i e s e fl u e l .A d i e s e el n g i n ec a n b e r u n o n t h i s m i x t u r ew i t h n o m a j o rc h a n g e st o t h ee n g i n e (Schrock,1979). MechanicalModificationsRequiredfor U s e o f Et h a n o la s a F u e l i n a S l E n gine W h e n g a s o l i n et h a t c o n t a i n sm o r e t h a n 2 5 % e t h a n o li s u s e d i n a S l e n g i n e ,s o m e m o d i f i c a t i o n m u s t b e m a d et o t h e e n g i n e( F l o w e r se t a l . , ' 1 9 7 9 ) . T h i s o f c o u r s ei n c l u d e se t h a n o l - w a t ebr l e n d st h a t c o n t a i nn o g a s o l i n eT. h e m o d i f i c a t i o n ds e p e n do n t h e e n g i n ea n d w h a t i s r e q u i r e do f t h e e n g i n e . But before mechanical modifications are undertakenon an engine,a choicemust be madeas to the ease of reversibility of the engine changes. This choice must be based on the availabilityof alcoholfuelf or all anticipatedvehicleuses,fhe cost of the engine modifications, and the expertiserequired to make the engine changes. for increased fuel 3 . m o d i f y i n gt h e c a r b u r e t i o n flow, 4 . h e a t i n gt h e a i r - f u e l m i x t u r et o e n s u r et h e vaporizationof the alcohol,and 5 . u s i n gv a r i o u sm e t h o d st o e n h a n q et h e c o l d s t a r t i n ga b i l i t yo f t h e e n g i n e . SparkTiming A s a g e n e r a lr u l et h e s p a r kt i m i n go f a n e n g i n e m u s tb e a d v a n c e dt o r u n o n e t h a n o l T . h i s i s d o n et o p r o v i d et h e e t h a n o lw i t h e n o u g ht i m e t o c o m p l e t e c o m b u s t i o ns, i n c ee t h a n o lb u r n ss l o w e rt h a n g a s o l i n e .O n e s t u d yr e c o m m e n d e ad d v a n c i n g thetiming a p p r o x i m a t e l2yO o( F l o w e r se t a l . ,1 9 7 9 ) . l n a n o t h e rs t u d y ,d o n e r e c e n t l yi n t h e U n i t e d States,a 1979 Ford Fiestawas modifiedto run on e t h a n o l( A D M C o r p . ,1 9 8 0 ) .I n t h i s t e s t t h e i g n i t i o n timing was changedfrom 12" lo 6' BTC. The i g n i t i o na l s o w a s r e d u c e do n a f o u r - c y l i n d e r1, . 6 l i t e re n g i n eu s e di n a t e s to n e t h a n o li n B r a z i l( P a u l , 1979)T . h e i g n i t i o nt i m e , b e f o r eB T C ,w a s r e d u c e d in the lattertwo tests becauseof the differencesin t h e m o d i f i c a t i o ndso n e t o t h e d i f f e r e n et n g i n e s . T h e s p a r k t i m i n g o f a n e n g i n eo p e r a t i n go n ethanolcan be set two differentways.A tachometer c a n b e h o o k e d u p t o t h e e n g i n ea n d t h e t i m i n g a d j u s t e du n t i l t h e m a x i m u mR P M r e a d i n gi s f o u n d with the engineon fast idle.Anotherway to set the t i m i n g i s t o s t a r t w i t h a n a d v a n c ei n t h e i g n i t i o n . h e n u s ea s t o p t i m i n g o f 4 ' B T C ( M i n g l e ,1 9 7 9 ) T watchto determine the time it takesfor the vehicleto a c c e l e r a t ef r o m 3 0 t o 5 5 m p h i n h i g h g e a r a t f u l l throttle.This procedureis repeatedin 4o of advance i n c r e m e n t su n t i l t h e m i n i m u ma c c e l e r a t i o tni m e i s reached. F r o m t h e d i f f e r e n tc h a n g e sm a d e i n t h e s p a r k timing in the tests reviewedand the procedures usedto set the timing,it can be seenthat thereis no general rule about setting the spark timing for all engines using ethanol as a f uel. The correct settlng of the timing depends on the engine and the other modificationsdone to the engine. lt must be determined by experiment. Reversible Modifications Vacuum Advance T h e f i r s t t y p e so f e n g i n em o d i f i c a t i o nt h a t w i l l be discussed are reversible.The cost is a few h u n d r e dd o l l a r so r l e s sd e p e n d i n go n t h e m o d i f i c a t i o n u n d e r t a k e nA . s i m p l i e d ,t h e s e m o d i f i c a t i o n s can be undonewith relativeeaseto permitoperation o n c o n v e n t i o n af u l e l s .T h e s em o d i f i c a t i o nisn c l u d e : 1 . c h a n g i n gt h e s p a r kt i m i n g , 2 . c h a n g i n gt h e v a c u u ma d v a n c e , C h a n g i n gt h e s e t t i n go f t h e v a c u u ma d v a n c ei s a n o t h e r r e v e r s i b l em o d i f i c a t i o nT. h e v a c u u m a d v a n c ea f f e c t st h e f u e l e c o n o m yo f t h e e n g i n eo p e r a t i n go n e t h a n o lF. r o mF i g u r e1 ,( C h u ie t a l . ,1 9 7 9 i)t i s s h o w nt h a t t h e b e s tf u e l e c o n o m yo n t h e e n g i n e t e s t e do c c u r s w h e n t h e v a c u u ma d v a n c ei s s e t t o g i v e a n a d d i t i o n a l1 0 o o f a d v a n c eo v e r t h e i d l e i g n i t i o nt i m e . V A C U U MA D V A N C E 2.3 LITER ENGINE IOO "h ETHANOL t-? o PRODUCTION lrJ z <l BEST ECONOMY f, ()l T a b l e3 s h o w st h e s er e s u l t su s i n ga n a r b i t r a r y s c a l ef o r t h e f l o a tl e v e la t d i f f e r e n R t P M sa n d o r o o f s o f e t h a n o l .I n t h i st e s ta n i n c r e a s ei n j e t s i z eo f 1 0 t o 150/o wds sufficient,but the conclusionreachedwas that the actualjet sizeneededin the carburetormust be found by experiment. Adjusting the carburetor also adjusts the equivalence r a t i o ,t h a t i s , actual airlfuel ratio stoichiometric air/fuel ratio. T h e e q u i v a l e n c er a t i o a f f e c t st h e f u e l e c o n o m y , t h e r m a le f f i c i e n c ya n d p o w e ro u t p u to f t h e e n g i n e . F i g u r e2 ( U n i v e r s i t yo f S a n t a C l a r a ,1 9 7 8 )s h o w s t h a tt h e f u e le c o n o m yo f a n e n g i n eo p e r a t i n go n 2 0 0 p r o o f e t h a n o li s b e s tw h e n t h e e q u i v a l e n c er a t i oi s a p p r o x i m a t e l y .w Sh, i c hi s i n t h el e a nr e g i o nF. i g u r e 3 ( U n i v e r s i t oy f S a n t aC l a r a ,1 9 7 8 )s h o w st h a tt h i si s a p p r o x i m a t e l yt h e s a m e e q u i v a l e n c er a t i o f o r m a x i m u mt h e r m a le f f i c i e n c yT. h e p o w e ro u t p u t o f a n e n gi n e i s a l s og r e a t e rw h e nt h ee q ui v a l e n c er a t i o i s t h e l e a n r e g i o n ( < 1 0 ) H o w e v e r ,i t s h o u l d b e noted that running an engineon too lean a mixture EU E L E T H A N O LA N DI N D O L E N F URBAN E C O N O MSYI M U L A T E D ( D R I V I N GH O T I 9 7 2 F T P ) CC) F O R DP t NT 0 ( 2 , 3 O O ?34 INTAKE VACUUM (KPA) F i g .1 . - F o r t h e S le n g i n ue s i n g , eo p t i m u m e t h a n oals f u e tl h isf oundto bebelowtheproducforeconomy sparkadvance tion vacuumadvance overthe full rangeof enginein the vacuum thatis related RPM. to engine @ osn ETHANoL O O E MI N D O L E N E ( ) = M A L O I S T R I E U T II O NN OEX 2to (-l-r :) LEAN I F (D Carburelor Modifications o In allof the testsreviewedthe enginesrequired more volume of f uel when operatedon ethanolas compared to operation on gasollne. The correct s t o i c h i o m e t r i ca i r - f u e lm i x t u r ef o r e t h a n o l i s 9 : 1 , w h i l e t h e c o r r e c t m i x t u r e f o r g a s o l i n ei s 1 4 . 7 : 1 ( H u n t ,1 9 7 9 ) T . h e r e a s o nf o r t h e d i f f e r e n c e si n t h e ratiosis that ethanolhasa lowerenergycontentper v o l u m et h a ng a s o l i n e . The f uel-flow increaseis achievedby modifying the carburetor.The generalprocedurefor the fuelf l o w i n c r e a s ei s t o e n l a r g et h e c a r b u r e t o rf u e l j e t d i a m e t e r' 11 / 2 t i m e s .T h i s c a n b e d o n e b y d r i l l i n g o u t t h eo r i g i n ajle t o r r e p l a c i n gt h ej e t .H o w e v e ro, n e r e c e n t s t u d y ( E n g l e m a n ,1 9 8 0 )s h o w e d d i f f e r e n t r e s u l t s .I n u s i n g a s i n g l e - c y l i n d eer n g i n e ,a d j u s t m e n to f t h e c a r b u r e t ofrl o a tw i l l i n c r e a s et h e f l o w o f e t h a n o l .I n c r e a s e df l o w w a s a c h i e v e db e c a u s eo f i n c r e a s e dl i q u i d h e a d a s w e l l a s t h e d i f f e r e n c e si n v a p o r p r e s s u r e s, u r f a c et e n s i o n a n d v i s c o s i t yo f e t h a n o la s c o m p a r e dt o g a s o l i n e . o u RICH t90 J = y = lTO (c.o23) z O U -: U l5o l o.7 o.8 0.9 r.o E o u t v A L E N c En a r r o Q F i g . 2 . - T h e f u e l e c o n o m y f o r a nS l e n g i n eu t i l i z i n ge t h a n o li s higher than one using indolene (a standardgasoline mix) o v e r a l l t e s t e d e q u i v a l e n c er a t i o s u n d e r s i m u l a t e d u r b a n d r i v i n gc o n d i t i o n s . Table 3.-Effect of CarburetorFloat Adiustment on Fuel Flow. Carb Float lndolene 190 Proof 180 Proof 9OORPM 1.0 F u e ll b l h r A/F IHP 2.60'1 11.79 3.47 3.404 8.93 4.51 4.291 9.18 4.20 2.0 F u e ll b l h r A/F IHP 2.484 12.44 4.93 2.984 10.27 3.91 2.874 10.60 3.45 2.6 F u e ll b / h r A/F IHP 2.270 13.50 3.55 2.678 '11.54 (Rough r u n n i n ga n d m i s fi r i n g ) 2.30 1 , 2 0 0R P M 1.0 F u e ll b / h r A/F IHP 2.829 12.72 6.41 4.513 8.09 5.93 4.155 8.50 5.45 2.0 F u e ll b / h r A/F IHP 2.516 14.30 6.43 4.105 9.10 5.58 3.863 8.90 7.17 2.6 F u e ll b / h r A/F IHP 2.410 14.75 6.43 3.862 9.67 5.79 3.749 9.29 4.78 1 , 5 0 0R P M 1.0 F u e ll b / h r A/F IHP 2.996 13.12 6.39 4.947 8.18 6.55 4.884 8.45 6.01 2.0 F u e ll b / h r A/F IHP 2.811 14.05 6.50 4.728 8.71 6.33 4.622 9.23 5.67 2.6 F u e ll b / h r A/F IHP 2.411 16.47 6.23 5.547 8.97 6.08 4.476 9.53 5.57 can resultin burnt valves.A lot of practicalexperi. u n n i n ga n e n g i n e e n c ea t t e s t st o t h i s c o n c l u s i o nR o n a r i c h m i x t u r es t i l l d o e sn o t e l i m i n a t et h e a d v a n t a g eo f e t h a n o lo v e rg a s o l i n ef o r t h e r m a le f f i c i e n c y a n d e c o n o m ya s s e e ni n F i g u r e s2 a n d 3 . PreheatingAir-Fuel Mixture As mentionedpreviously,heatingthe air-ethan o l f u e l m i x t u r e r e q u i r e s2 . 5 t i m e s m o r e h e a t f o r v a p o r i z a t i o nt h a n d o e s g a s o l i n e .F o r t h i s r e a s o n some additionalheat may be desirablefor the airf uel mixturebeforeit entersthe cylinder.Two of the tests reviewedused some additionalheat and two did not. In a test performedin 1948,a gasolinet{actor was modifiedto run on 950/o ethanol(Meyer,1948). In this test the exhaust gases were recycled to providethe extra heat in two differentways. In one part of the test the recycled exhaust gases were m i x e dd i r e c t l y w i t ht h e i n t a k ea i r .T h e o t h e rm e t h o d used was to heat the intake air with the exhaust t h r o u g h a h e a t e x c h a n g e r .T h i s s e c o n d m e t h o d seemedto be more satisfactory. In another test from Brazil the exhaust gases were also recycled to provide more heat for the i n t a k ea i r o n a f o u r - c y l i n d e r1, . 6l i t e re n g i n e( P a u l , 1979). However, in this test it was shown that -- LEAN A n o t h e r s i m p l e c o l d - s t a r ts y s t e m h a s b e e n u s e d .T h i ss y s t e mi ss h o w ni n F i g u r e4 . l t c o n s i s t so f a s e c o n c i a rgya st a n kf o r g a s o l i n e( t h es t a r t i n gf u e l ) , a s e c o n d a r ye l e c t r i cf u e l p u m p ,a n d a t o g g l es w i t c h to engagethe cold-startsystemand needlevalvesto c o m p l e t e l ys h u t o f f t h e c o l d - s t a r ts y s t e m .V o l k s w a g e nh a sc o m eu p w i t h a s i m i l a rc o l d - s t a rst y s t e m . Ir E X A M P L E O F A D U A L -F U E L S Y S T E M o z U S I N G G A S O L I N EA S T H E C O L D -S T A R T I N GF U E L U gto L L U 4. 32 UJ I F o U FUEL FILTER N€EOLE VALVE UAIN FUEL PUMP T- JOINT 50 + (TO POWER) 5 GALLON PROPANE T A N X ( G A S O L I N €) F Q eza PINTO 2,3OO CC ENGINE M B T S P A R KT I M I N G 2 O O OR P M - W O T 0.6 - DSR ETHANOL __- O E M I N D O L E N E( O . 0 6 ) 0.7 0.8 0.9 r.o ELECTRIC FUEL PUMP NEEOLE VALVE F i g . 4 . - T h i s i s a d i a g r a mo f a d u a l J u e ls y s t e mu s i n g g a s o l i n e a s a c o l d - s t a r t i n gf u e l . T h e s y s t e m r e q u i r e sa s e p a r a t e s t o r a g et a n k , f u e l p u m p a n d f u e l f i l t e r . t.l E Q U I V A L E N C ER A T I O, Fig.3.-The indicated thermal efficiency of an Sl engine u s i n ge t h a n o li s h i g h e rt h a n o n e u s i n g i n d o l e n e( a s t a n d a r d g a s o l i n e m i x ) o v e r a l l t e s t e d e q u i v a l e n c er a t i o s a t W O T o f 2 , 0 0 0R P M . p r o b l e m sc a n r e s u l tf r o m e x c e s s i v e l yp r e h e a t i n g t h e i n t a k ea i r . I n t h e e a r l y t e s t st h e i n t a k ea i r w a s e x c e s s i v e l yp r e h e a t e d ,c a u s i n g s e v e r e e n g i n e k n o c k ,r e s u l t i n gi n t h e d e s t r u c t i o n of the engine. Other methods that have been used to overc o m e t h e c o l d - s t a r tp r o b l e m i n c l u d eu s i n g a 3 5 0 w a t t r e s i s t a n c eh e a t e r i n t h e i n t a k e m a n i f o l d ( S c h r o c k ,1 9 7 9 ) ;u s i n g e l e c t r i cg l o w p l u g s i n t h e m a n i f o l d( H u n t ,1 9 7 9 ) o; r u s i n ga n e l e c t r i cs c r e e n g r i d b e t w e e nt h e c a r b u r e t o a r n d i n t a k em a n i f o l dt o h e a t t h e a i r - f u e l m i x t u r e ( H i l l , 1 9 8 0 ) .T h i s l a s t s y s t e mi s s h o w n i n F i g u r e5 . W h e n e v e rc o l d - s t a r t p r o b l e m sa r e e n c o u n t e r e dt,h e d r i v e rt u r n s o n t h e k e yf o r 3 0 s e c o n d st o l e tt h e g r i d w a r m u p .T h e nt h e car is startedas usual. Cold Start Modification S C R E E N - G R I DW A R M U P S Y S T E M O n eo f t h em a i np r o b l e m si n u s i n ge t h a n oiln a n e n g i n ei s l o w t e m p e r a t u r eT.h i sp r o b l e ma r i s e s f r o m t h e f a c t t h a t e t h a n o lr e o u i r e sm o r e h e a tf o r v a o o r i zationthan gasoline.Saturafedethanolvaporsare too lean to ignite below 50"F and starting problems becomesignificant below 40" F (Keller,1979). T h e c o l d - s t a r to r o b l e m w i t h e t h a n o l c a n b e o v e r c o m ei n s e v e r adl i f f e r e n w t a y s .F i r s ti s t h e u s e o f a d d i t i v e sI .n o n e t e s ti t w a s f o u n d t h atth ea d d i t i o n o f 1 0 0 /goa s o l i n et o 2 0 0 p r o o f e t h a n o le x t e n d e dt h e c o l d - s t a r ta b i l i t y f r o m t h e o r i g i n a l4 0 o F d o w n t o t h a tr e p o r t e d l y 3 2 " F ( C h u i ,1 9 7 9 )A. n o t h e ra d d i t i v e h a s g o o d r e s u l t si n o v e r c o m i n gc o l d s t a r t si s e t h e r ( K e l l e r ,1 9 7 9 ) .T h e r e i s c o m m e r c i a l l ya v a i l a b l ea n e t h e r i n j e c t i o ns y s t e m f o r d i e s e l e n g i n e s ( H i l l , 19 8 0 ) . SCREEN GRIO PLAT€ CARAURETOR SCAEEN GRIO PLATE F i g . 5 . - T h i s i s a d i a g r a m o f a c o l d - s t a r ts y s t e m t h a t u s e s a g r i d o f h e a t e rw i r e t o h e a t t h e a i r J u e l m i x t u r e a f t e r i t l e a v e s t h e c a r b u r e t o ra n d b e f o r e e n t e r i n ot h e i n t a k e m a n i f o l d . Another problem encountered with ethanol at very high temperaturesvvasvapor lock. ln one study it was f ound that vaporlock in the f uel pump became a problem at temperaturesabove 173"F (Keller, 1979). I rreversible Modif ications are onesthat Modificationsthat are irreversible are hard to remove. They also are usually more expensive,require more expertise,and can be very hazardouswhen the engine fails. Modificationsin t h i s c a t e g o r yi n c l u d e : 1 . c a m s h a f ct h a n g e , , nd 2 . i n c r e a s i n tgh ee n g i n ec o m p r e s s i o rna t i o a 3. using turbochargersor superchargers. CamshaftChange I n t h e s t u d y o n t h e 1 9 7 9 F o r d F i e s t a( A D M t a sc h a n g e dA . ccording C o r p . ,1 9 8 0 )t h e c a m s h a fw t o t h e s t u d yt h i sw a sd o n et o p r o v i d em o r el o w R P M torque,easierstartingand betterf uel economy.The d e t a i l so f t h i s c h a n g ea n d t h e o t h e r m o d i f i c a t i o n s made are shown in Table4. Table 4.-1979 Ford FiestaSpecifications. Original Modified P r i m a r yF u e l Unleaded Gasoline Ethyl Alcohol- Bore Stroke T o t a lC u b i c I n c h 3.188 3.056 97.6(1,600cc) 3.000 3.056 86.4 (1,416cc) Compression Ratio C a mT i m i n g Intake: Open Close Exhaust Open Close l g n i t i o nT i m i n g (static) 8.6:1 29" (BeforeTDC) 63' (After BDC) 7 1 " ( B e f o r eB D C ) 2 1 " ( A f t e rT D C ) ' 1 2 "( B e f o r e TDC) 12.5:1 16" 540 540 16" c y l i n d e rh a s 1 2 1o f o r c o m b u s t i o na n d e x p a n s i o nt o t a k e p l a c e ,w h i l e t h e e n g i n e m o d i f i e dt o r u n o n e t h a n o lh a d 1 3 2 ' f o r c o m b u s t i o na n d e x p a n s i o nt o take place. Changein CompressionRatio In all of the tests reviewed,the compression ratio was increasedto take advantageof the high octane rating of ethanol to produce more power. One study suggestedincreasingthe compression r a t i ot o s o m e w h e r eb e t w e e n1 0 t o 1 5 : 1( F l o w e r se t al.. 1979).Two of the studiesreviewedf ollowedthis r e c o m m e n d a t i o nT. h e s t u d y o n t h e F o r d F i e s t a ( A D MC o r p . ,1 9 8 0 )i n c r e a s e tdh e c o m p r e s s i o nr a t i o , 979) s t u d y( P a u l 1 f r o m 8 . 6 : 1t o 1 2 . 5 : .1T h e B r a z i l i a n 'l .2:1 1 .'1 . to increasedcompressionratio trom 7 performed the tractor in 1948 The study on ( M e y e r e ta l . ,1 9 4 8 )d i d n o t f o l l o w t h i sr e c o m m e n d a tion. Rather,the compressionratio was increased . h e r e a s o nf o r t h i s r e l a t i v e l y f r o m 6 . 4 : ' 1t o 7 . 3 5 : 1 T l o w e r c o m p r e s s i o nr a t i o w a s t h a t a l l e n g i n ec o m pressionratios at that time were much lower than those of today. The comoressionratiocan be increasedseveral d i f f e r e n tw a y s . T h e y i n c l u d e i n s t a l l i n gd i f f e r e n t p i s t o n s ,s h a v i n gt h e h e a d o r u s i n g a t h i n n e rh e a d g a s k e t .E v e nt h o u g h s o m e o f t h e s em o d i f i c a t i o n s a r e e a s ya n d i n e x p e n s i vteo d o , o n e t h i n g m u s t b e emphasized.The increasein compresslonratiocan damageor even destroy an engine if the other parts of the engine are not strong enough to handle the increasedpower or cylinder pressures. A l l o f t h e t e s t sm e n t i o n e dp r e v i o u s l yi n c r e a s e d the compressionratioto takeadvantageof ethanol's h i g h o c t a n er a t i n gt o i n c r e a s et h e p o w e ro u t p u to f t h e e n g i n e .A n o t h e rw a y t o t a k e a d v a n t a g eo f t h e h i g h o c t a n er a t i n go f e t h a n o lt o i n c r e a s et h e p o w e r o u t p u t o f t h e e n g i n e i s t o r a i s et h e c o m p r e s s i o n p r e s s u r eo f t h e e n g i n e b y t u r b o c h a r g i n gT. a b l e 5 s h o w s t h e t h e o r e t i c a le q u i v a l e n tc o m p r e s s i o n r a t i o s f o r d i f f e r e n ti n c r e a s e si n t h e a i r p r e s s u r e ( G o e r i n g1 , 979). Table 5.-EquivalentCompressionRatiosof Tu rbochargedEngine. o- .180proof(900/o 10o/o water) or 200proofethyl ethylalcohol: alcohol. Otherratiosmavalsobetried. I t i s i n t e r e s t i n gt o n o t e t h a t e v e n t h o u g h t h e i g n i t i o nt i m i n gw a s r e t a r d e di n t h i st e s t ,t h e r ei s s t i l l m o r e t i m e f o r c o m b u s t i o nt o t a k e p l a c ew i t h t h e e t h a n o lT . h i s e x t r at i m e i s n e e d e db e c a u s ee t h a n o l b u r n s s l o w e r t h a n g a s o l i n e .T h e o r i g i n a l e n g i n e Actual compression ratio 7 8 o 10 11 12 Equivalentcompressionratio at boost pressureof: 5 psi 1 0p s i 1 5p s i 8.8 10.0 11.3 12.5 13.8 10.4 11.9 13.4 14.9 16.4 17.9 12.0 13.7 15.5 17.2 18.9 20.6 16n A t u r b o c h a r g e ru s e se x h a u s tg a s e st o d r i v e a t u r b i n e c o n n e c t e dt o a n o t h e rt u r b i n e t h a t f o r c e s o u t s i d ea i r t h r o u g h t h e c a r b u r e t o rT . he air that is f o r c e dt h r o u g ht h e c a r b u r e t ocr a u s e sa n i n c r e a s ei n t h e c o m b u s t i o np r e s s u r e .O n e d r a w b a c ko f t h e t u r b o c h a r g e ri s t h a t t h e e x h a u s t d o e s n o t h a v e e n o u g hp o w e rt o e f f e c t i v e l yr u n t h e s y s t e mu n t i l a r e l a t i v e l hy i g he n g i n eR P Mi s r e a c h e du, s u a l l y2 , 5 0 0 t o 3 , 0 0 0R P M ( L y n c h ,1 9 7 9 ) . S u p e r c h a r g i n go v e r c o m e st h e t u r b o c h a r g e r drawback.A superchargeroperateson the same p r i n c i p l ea s a t u r b o c h a r g e rb u t i n s t e a do f b e i n g d r i v e nb y t h e e x h a u s tg a s e s ,i t r u n s o f f t h e e n g i n e u s i n g a b e l t - d r i v e m e c h a n i s m .T h e r e f o r e , t h e superchargeroperatesat all RPM levels. T h e r ea r ed r a w b a c k si n u s i n ga t u r b o c h a r g eor r nressure s u p e r c h a r g et ro i n c r e a s et h e c o m p r e s s i o p i n o r d e rt o i n c r e a s ep o w e r .O n e i s t h e c o s t .T h e k i t s c u r r e n t l y a v a i l a b l ec o m m e r c i a l l yr a n g e i n p r i c e . h i s m a k e st h e f r o m $ 6 0 0t o $ 1 , 2 0 0( L y n c h ,1 9 7 9 ) T t u r b o c h a r g eor r s u p e r c h a r g ear m a j o r i n v e s t m e n t . T h e o t h e r d r a w b a c k so f t h e s e u n i t s a r e m e c h a n i c a lT . h e i n c r e a s ei n c y l i n d e rp r e s s u r ed u r i n g c o m b u s t i o nm a y c a u s e i n c r e a s e dw e a r o n m a n y e n g i n ep a r t s .H o w e v e r i, n o n e t e s t p e r f o r m e do n a f o u r - c y l i n d eer n g i n e i, t w a sf o u n dt h a ta s l o n ga st h e pressureincreasewas kept moderate(overallpressure of 55 to 60 bars) no harm was done to the b e a r i n g sp, u s h r o d so r c r a n k s h a f(t S p i n d l e r1, 9 7 8 ) . In addition to the increasedpressure there is an increasein the heat neededto be dissipatedfrom t h e e n g i n e .T h e t e s t m e n t i o n e dp r e v i o u s l y( S p i n d l e r ,1 9 7 8 )u s e da s p e c i a ls, t e e lc y l i n d e rh e a dg a s k e t , increasedthe valvestemclearanceto avoid bu rnt o r s t i c k i n gv a l v e sa, n d m o d i f i e dt h e c o o l i n gs y s t e mt o a v o i dp r o b l e m sw i t h t h e c y l i n d e rh e a d c r a c k i n g .l t h a sa l s ob e e nf o u n d t h a t u s i n gb r o n z ev a l v eg u i d e s o v e r c a m et h e v a l v ep r o b l e m s( L y n c h ,1 9 7 9 ) . T h e h i g h a m o u n t o f h e a t d i s s i p a t e df r o m t h e e x h a u s tm a n i f o l da l s o c a u s e dp r o b l e m s( S p i n d l e r , 1 9 7 8 ) .I n i t i a l l yt h e i n c r e a s ei n h e a tc a u s e db o t h t h e e x h a u s tm a n i fo l d a n dt h e t u b i n gu s e dt o r e c y c l et h e exhaustto crack. This problem was overcomeby m o d i f y i n gt h e e x h a u s tm a n i f o l da n d t u b i n g .E v e n t h o u g ht h e r ea r e s e v e r am l e c h a n i c apl r o b l e m sw i t h u s i n gt u r b o c h a r g e rosr s u p e r c h a r g e r tsh, e y a l l c a n be overcomeas they were in this test. O n e f a c t w o r t h m e n t i o n i n gi s t h a tt h e f u e l u s e d i n t h e p r e v i o u s l ym e n t i o n e dt e s t w a s g a s o l i n e . F i g u r e6 ( P y r e ,1 9 3 7 )s h o w st h a ta l c o h o l( 1 9 5p r o o f ) as compared to gasoline,gives more heat to the e x h a u s ta n d l e s sh e a tt o t h e c y l i n d e rw a l l s( c o o l i n g w a t e r )w h e n r u n i n a n e n g i n ew i t h o u tt u r b o c h a r g i n g o r s u p e r c h a r g i n gF. r o mt h i s i t m i g h t b e c o n c l u d e d t h a t o p e r a t i o no n a l c o h o lm i g h td e c r e a s et h e p r o b - 10 lems caused by the increasedheat entering the e n g i n e ,w h i l e i n c r e a s i n gt h e p r o b l e m sc a u s e db y the increasedheat leavingthe engine. ALCOHOL < uJ 50 t. .'1^{',^o, ---/ _ / /- -- 4eetaot To O E EXxHxAaUuSsTr\ -. = I I t -'t" /-'' J - ---"t F 40 ^L - z U r=:----- O E. Hso - --=-4 - z. -----=_- F .ro rHp {---'- -:\_ \ .----r_ -------7 .- _ 420 F I o To cooLrNG ureFA-r- - - F U rto 4 r.o r.t t.2 r.3 E Q U I V A L E N C ER A T I O , O l r F i g .6 . - H e a t d i s t r i b u t i o ni n a n S l e n g i n eu s i n ge t h a n o o g a s o l i n eA. h i g h e rp e r c e n t a goef h e a ti s f o u n di n t h ee x h a u s t a n d i n e n g i n eh o r s e p o w e b r ,u t a l o w e rp e r c e n t a goef h e a ti s f o u n d i n c o o l i n gw a t e rw h e n f u e l e dw i t h e t h a n o lo v e r a l l e o u i v a l e n crea t i o s . A g a i n , a s w i t h t h e c o m p r e s s i o n r a t i o i n c r e a s e ,i f the parts of the engine are not strong enough to handle the increased power, the engine may be damaged or destroyed. M echanicalModificationsRequi r ed for Use of Ethanolas Fuel in a DieselEngine A s m e n t i o n e db e f o r e ,t h e d i e s e le n g i n ei s n o t w e l l - s u i t e dt o t h e u s e o f e t h a n o l .B u t , f o u r b a s i c l n g i n eh a v e a p p r o a c h e st o u s i n ge t h a n o li n a d i e s e e b e e nf o u n d : 1. c o n v e r td i e s e el n g i n et o a h i g hc o m p r e s s i o n , s p a r ki g n i t i o ne n g i n e , 2. modifythe dieselto toleratestraightethanol injection, 3. carburetthe ethanol,and 4 . u s ed u a l i n j e c t i o no f e t h a n o la n d d i e s e fl u e l . s o o n b e c o m m e r c i a l l ya v a i l a b l eb y M & W G e a r C o m p a n y ,G i b s o n C i t y , l l l i n o i s .T h i s s y s t e mu s e s t h e t u r b o c h a r g e rb o o s t t o p r e s s u r i z et h e a l c o h o l f u e l t a n k i n o r d e rt o m e t e rt h e f u e l a s a f u n c t i o no f e n g i n e l o a d .T h e a l c o h o lf u e l i s n o t a d d e d a t l o w l o a d .R e s e a r c hh a s i n d i c a t e dr e d u c e de n g i n ee f f i c i e n c ya t l i g h tl o a d ,b u t i n c r e a s e tdh e r m a el f f i c i e n c y o v e rd i e s e fl u e l m a y o c c u ro n l y a t h e a v yl o a d i n g .I n g e n e r a tl h o u g h ,i t s h o u l db e a s s u m e dt h a t c a r b u r e t i o n o f a l c o h o li n t o a d i e s e le n g i n er e p l a c e sd i e s e l f u e l o n a n e q u a lh e a tc o n t e n tb a s i sw i t h n o c h a n g e i n e f f i c i e n c y( S c h r o c k 1, 9 7 9 ) . T h e r ew a s a d e v e l o p m e not f a n a l t e r n a t i v de i e d u r i n gW W l l i n w h i c h s e l e n g i n ew i t hd u a li n j e c t i o n t h e m a i nf u e l ,a l o wc e t a n er a t e df u e l ,i s i n j e c t e dw i t h t h e a i r i n t o a d i e s e la n d a p i l o t f u e l ,a h i g h c e t a n e f u e l , i s i n j e c t e dn e a r t h e e n d o f t h e c o m p r e s s i o n cycle that ignites,from compressionheat,the total f u e l m i x t ur e ( B r oe t a | . , 1 9 7 7 )S. e eF i gu r e7 . T h e l o w c e t a n em a i n f u e l m a k e su p a p p r o x i m a t e l 7y 0 p e r cent of the total fuel energy.Researcheffortshave u t i l i z e do n l y 2 0 0 p r o o f e t h a n o la s a m a i n f u e l , b u t t h e r es e e m st o b e n o l i m i t a t i o no f u s i n ga n e t h a n o l f uel that has a lower proof. O n e e n g i n et h a t l e n d si t s e l ft o t h i s c o n v e r s i o n t o s p a r ki g n i t i o ni s t h e 8 5 5C u m m i n sD i e s e lE n g i n e ( S c h r o c k ,1 9 7 9 ) .T h e a r e a st h a t r e q u i r em o d i f i c a t i o n i n c l u d e t h e p i s t o n s ,h e a d a s s e m b l y ,i n t a k e m a n i f o l di g n i t i o ns y s t e m c, a r b u r e t oar n d g o v e r n o r . P a r t s a r e a v a i l a b l ef o r t h e c o n v e r s i o n ,b u t t h e e s t i m a t e dm i n i m u m c o s t f o r t h e m o d i f i c a t i o n si s $3,000. f o r t h e m i l i t a r yi,s A m u l t i f u e l e n g i n ed,e v e l o p e d d e s i g n e dt o f u n c t i o nu s i n gf u e l sr a n g i n gf r o md i e s e l o i l t o l o w o c t a n ec o m b a tg a s o l i n eT. h e M A N D i e s e l ( a l s ok n o w na s t h e M e u r e ro r W h i s p e rd i e s e l )h a sa u n i q u e c o m b u s t i o nc h a m b e r d e s i g n t o f u n c t i o n s m o o t h l y u s i n g l o w c e t a n ef u e l s a n d l o w o c t a n e g a s o l i n e( S c h r o c k1, 9 7 9 )T. h i sd i e s e el n g i n ed e s i g n c o u l db e t h e m o s tt o l e r a n ot f m a n u f a c t u r eedn g i n e s t o u s e e t h a n o lw i t h o u t m o d i f i c a t i o nT. h i s e n g i n e was offered for limited agriculture use by InternationalHarvesterand Whitein the last10 years,but i t i s n o t p r e s e n t l ya v a i l a b l e . l n g i n e si s A n o t h e rw a y t o u s ee t h a n o li n d i e s e e to carburee t t h a n o li n t o t h e a i r i n t a k ei n f r o n t o f t h e t u r b o c h a r g e (r S c h r o c k ,1 9 7 9 ) .A k i t t o d o t h i s w i l l D I R E C T I N J E C T I O ND I E S E LE N G I N E U S I N G A L C O H O LA N O P I L O T I N J E C T I O N Compar isonof EnginePer for m anc e on Ethanoland GonventionalF uel s FuelEconomy E L E C T R O N I CF U E I N . ' E C T I O N F OR LIOUID FUEL The volumetric fuel economy of S/ englnes using ethanolas a fuel is not as good as that of the same engines operating on gasoline. The maior reason for this is that ethanol does not contain as much energy per unit volume or per unit weight as gasoline.Pure ethanol (200proof) contains650/o of t h e e n e r g yp e r u n i t v o l u m ea n d 6 1 %o f t h e e n e r g y per unit weight when comparedto gasoline ( S c h r o c k , 1 9 7 9 ) .T h e r e f o r e ,w h e n c o m p a r e d t o g a s o l i n em , o r e e t h a n o li s r e q u i r e dt o d o t h e s a m e work in an engine. T h e a b o v e i s c o n f i r m e di n a l l o f t h e s t u d i e s reviewed.But differenttests give different results d e p e n d i n go n t h e e n g i n ea n d t h e m o d i f i c a t i o n os f the engine.ln a test performedinBrazil,it wasfound t h a t v o l u m e t r i cf u e l c o n s u m p t i o nw a s 5 t o 1 0 0 / o h i g h e rf o r 2 0 0 p r o o f e t h a n o la s c o m p a r e dt o g a s o l i n e ( M u e l l e r ,1 9 7 8 ) .A n o t h e r t e s t , o f w h i c h t h e r e s u l t sa r es h o w ni n F i g u r e8 ( M u e l l e r1, 9 7 8 )s, h o w s t h a tt h e s p e c i ifc e n e r g yc o n s u m p t i o ni n t e r m so f B t u p e r g a l l o ni s a b o u t1 2 o /loo w e ri n a l o w c o m p r e s s i o n e n g i n ea n d 1 5 0 /l o w e ri n a h i g hc o m p r e s s i o e nngine . his implies f o r e t h a n o la s c o m p a r e dt o g a s o l i n e T t h a t h i g h e r c o m p r e s s i o nr a t i o e n g i n e sa r e m o r e '190 e f f i c i e n ti n u s i n g t h e h i g h e r o c t a n e v a l u e o f p r o o fe t h a n o l . I NTAKE EXHAUST ILOT FUEL INJECTION N O Z ZL E F i g .7 . - D u a l i n j e c t o r fsu e la d i e s e l e n g i n eO.n ei n j e c t opr u t s i n 3 0 0 /oof f u e le n e r g ya s a h i g hc e t a n ef u e lt h a ti g n i t e sd u e t o h e a to f c o m p r e s s i o na,n d t h e na s e c o n di n j e c t o rp u t si n t h e r e m a i n d eor f f u e le n e r g ya s l o w c e t a n ef u e l . 11 Table 6.-Fuel Efficiencyol a Six-CylinderEngine. COMPARATIVE SPECIFICENERGY USING CONSUMPTION OF ENGINES N E A T E T H A N O L ( 5 % W A T E R) AND GASOLINE I Gasoline (Original Engine) F u e l ,g a l / h r ( a tm a x i m u m power) HP - h r / g a l Thermal E ff i c i e n c y , + lrJ z = U LC R HCR (t (D o/o E t h a n o lP r o o f 164 186 200 7.44 7.4 T.IJ /.o 6.3 8.82 4.3 11.7 27 260/o 25o/o 27olo lrj z o an sion ratio tor 192 proof ethanol showed an even greaterpower increase.The maximumhorsepower i n c r e a s e d1 8 . 7 o / 0 w,h i l e t h e m a x i m u m t o r q u e i n on ethanol operation (Paul, 1979). creased20.5o/o T h e i n c r e a s ei n p o w e rg a i n e df r o me t h a n o li ss h o w n i n F i g u r e9 ( H u n t ,1 9 8 0 )a s a f u n c t i o no f R P M .I n t h i s t e s tt h e s i x - c y l i n d eer n g i n er u n n i n go n e t h a n o lh a d the compressionratioincreasedfrom 7.5:1to 8.45:1, a reworkedcarburetoranda heatedintakemanifold. (9 = o CE lt -l lrJ o z (J -l LCR. LOW COMPRESSIOR NATIO ENGINE H C R .H I G HC O M P R E S S I O RN ATIO ENGINE F i g . 8 . - T h e c o m p a r i s o no f t h e s p e c i fi c e n e r g yc o n s u m p t i o n o f h i g h c o m p r e s s i o na n d l o w c o m p r e s s i o nS l e n g i n e ss h o w that the ethanolJueled engines require less energy than g a s o l i n e -uf e l e d e n g i n e s .T h e h i g h - c o m p r e s s i o ne n g i n e r e q u i r e s l e s s e n e r g y t h a n t h e l o w - c o m p r e s s i o ng a s o l i n e e n gi n e . As the proofof ethanolincreasesthe volumetric f u e l e c o n o m yi m p r o v e sA. s e x p e c t e dt,h i s i s d u e t o the fact that increasingthe proof increasesthe v o l u m e t r i ce n e r g yc o n t e n to f t h e e t h a n o l .T a b l e 6 ( H u n t ,19 8 0 )i n d i c a t e st h i si n t e r m so f t h e r a n g eo f a v e h i c l eo p e r a t i n go n e t h a n o la s c o m p a r e dt o g a s o l i n e .A f u e l t a n kt h a tw o u l dc a r r ya v e h i c l e2 0 0 m i l e s o n g a s o l i n ew o u l d g o 1 3 5 m i l e s o n 2 0 0 p r o o f e t h a n o l 9, 5 m i l e so n 1 6 0p r o o fe t h a n o a l n d6 0 m i l e s o n 1 2 0p r o o fe t h a n o l( S c h r o c k 1, 9 7 9 ) . Power Output The power output of ethanol was greaterin all of the testsreviewedwhen comparedto gasoline. O n e s t u d y ,w h i c h c o m p a r e d1 9 0p r o o fe t h a n o la n d gasoline,showeda 30/o increasein poweroutput for ethanol at the same compressionratio (Schrock, 19 7 9 ) . Another study that used 7.2:1 compression r a t i of o r g a s o l i n eo p e r a t i o na n d a n 1 1 : 1c o m p r e s - 12 il tt r,7oo RATEDlsOO tpOO R E V O L U T I O N SP E R M I N U T E C Y L I N D E R -2 4 0 C U B I CI N C H E S ) F i g . 9 . - T h e i n d i c a t e dh o r s e p o w e ro f a n S l e n g i n e i n d i c a t e s t h a t t h e e t h a n o l f u e l e d e n g i n e a t a l l p r o o fs w a s h i g h e r t h a n t h e g a s o l i n ee n g i n e a t t h e r a t e d R P M . F i g u r e 1 0 ( U n i v e r s i t yo f S a n t a C l a r a , 1 9 7 8 ) s h o w st h e h o r s e p o w ear s a f u n c t i o no f e q u i v a l e n c e r a t i o f o r b o t h g a s o l i n e a n d c o m m e r c i a lg r a d e e t h a n o l .T h e e n g i n eo p e r a t e do n e t h a n o lu s e d t h e D e r e s s e r a t oI rn d u c t i o nS y s t e m .E t h a n o lf u e l g a v e g r e a t e rb r a k e h o r s e p o w e ri n c o m p a r i s o nt o i n d o l e n e( a s t a n d a r dg a s o l i n e ) . +l LEAN tr g o -) I R I CH 4s .L lrJ (t, (E o -40 UJ I a t e d w i t h p r o l o n g e di n h a l a t i o ni n c l u d ec o u g h i n g , eye irritationand headaches. T h e s t o r a g eo f e t h a n o lm u s t b e h a n d l e dd i f f e r e n t l y fr o m t h a to f g a s o l i n eF. o r m a x i m u ms a f e t ya n d t o r e d u c el o s s e sd u r i n gs t o r a g ee, t h a n o ls h o u l db e s t o r e d i n w h i t e t a n k s i n a s h a d e da r e a .T h e t a n k s relief s h o u l d b e e q u i p p e dw i t h p r e s s u r e - v a c u u m f i ll e rc u p s .N o r u b b e rh o s e so r s e a l ss h o u l db e u s e d w i t h i nt h e s y s t e mi n o r d e rt o a v o i dl e a k sc a u s e db y t h e d e t e r i o r a t i o no f r u b b e r w h e n i n c o n t a c tw i t h e t h a n o l( R i d e re t a l . ,1 9 7 9 ) . E t h a n o il s t o t a l l yd i f f e r e n ft r o m g a s o l i n ei n t h a t i t d o e s m i x w i t h w a t e r . F o r t h i s r e a s o ne t h a n o l s h o u l dn e v e rb e s t o r e di n a t a n k w h e r et h e r ei s a n y w a t e ro r t h e r ee x i s t sa p o s s i b i l i t yo f w a t e rc o m i n g i n t o c o n t a c t w i t h t h e e t h a n o l .T h i s a l s o i n c l u d e s p r o l o n g e de x p o s u r et o h i g h h u m i d i t ya i r . Ethanolburnswith a nearlyinvisibleblue flame, while gasoline or diesel burns with a highly visible yellow or orange tlame. Sometimesthe only det e c t a b l ef e a t u r e o f b u r n i n o e t h a n o l i s t h e h e a t waves. E (D 35 COMPARATIVEPOWER OUTPUT O F E N G I N E SU S I N G N E A T E T H A N O L ( 5 % W A T E R )A N O G A S O L I N E :g 0.70 lrJ z. J tlJ UI 6 F i g . 1 o . - T h e b r a k e h o r s e p o w e ro f a n S l e n g i n e f u e l e d w i t h e t h a n o l i s h i g h e r t h a n e n g i n e sf u e l e d w i t h i n d o l e n eo v e r t h e tested eouivalence ratios at 2.000 RPM. U = .J' , 9 7 8 )t h e p e r c e n t a g e I n F i g u r e1 1 ( M u e l l e r 1 p o w e r i n c r e a s e sa r e s h o w n f o r b o t h a h i g h c o m p r e s s i o nr a t i oe n g i n ea n d a l o w c o m p r e s s i o nr a t i o e n g i n eo p e r a t i n go n 1 9 0p r o o fe t h a n o al s c o m p a r e d . h e e n g i n eo p e r a t i n go n e t h a n o lh a d t o g a s o l i n eT m o d i f i c a t i o n so n t h e c a r b u r e t o r a n d i g n i t i o n system. Sa f e t yi n H a n d l i n gE th a n o l o E L u z o LCR HCR NA T I OE N G I N E L C R . L O W C O M P R E S S I OR H C R ' H I G H C O M P R E S S I ORNA T I OE N G I N E E t h a n o li s n o t h i g h l y t o x i c b u t s o m e d i s c o m forts havebeen known to occur if the fumesare i n h a l e df o r a l o n g p e r i o do f t i m e i n a p o o r l y v e n t i . h e d i s c o m f o r t sa s s o c i l a t e da r e a ( M u e l l e r1, 9 7 8 ) T F i g . 1 1 . - T h e c o m p a r a t i v ep o w e r o u t p u t o f a h i g h a n d a l o w c o m p r e s s i o ne n g i n e f u e l e dw i t h e t h a n o l i s h i g h e r t h a n w h e n f u e l e dw i t h g a s o l i n e . '13 Tabfe 7.-NFPS Hazard ldentificationSignals. Health Methanol Fire Reactivity 1a Ethanol 0 Gasoline a0 safe E x t i n g u i s hA g e n t a l c o h o lf o a m ,C O zo r d r y chemical water.alcoholfoam, CO2or dry chemical f o a m ,C O zo r d r y c h e m i c a l 4 severelyhazardous E t h a n o al l s od i f f e r sf r o m g a s o l i n ei n t h e k i n d o f e x t i n g u i s h i nagg e n tt h a tm a y b e u s e do n i t i n c a s eo f f ire. Listed in Table 7 are the NFPShazardidentific a t i o ns i g n a l sf o r t w o t y p e so f a l c o h o la n d g a s o l i n e ( P a u l ,1 9 7 9 ) . Deterioration of Materiatsin Contactwith Ethanol Ethanol has been found to be corrosive to severalmaterialsthat are exposedwithin the engine or fuel system of the vehicle. ln the fuel system, ethanol has been found to be corroslve to polya' mide filter housings, polyurethane and polyester bonded fiberglass(Schrock, 1979).For this reason it is recommendedthat allhosesand the f uel pump diaphragm be made of neoprene rubber, a material compatiblewith ethanol(Nerpel,1980). Ethanol is also corrosive to metals,such as s t e e l ,a l u m i n u ma n d c o p p e r .T h e e x t e n tt o w h i c h i t corrodes these materials can be shown by an exampleusing the relativecorrosionratesof these m e t a l sw h e n i m m e r s e di n 2 0 0p r o o fe t h a n o al t r o o m et al., 1980).Assuming temperature(Persiantseva a n 8 - g a u g em e t a l( t h i c k n e s os f . 1 2 8i n c h e s )u s e di n a storagetank or a pieceof tubing,it would take the ethanol32 yearsto completelypenetratethe steel, 3 1. 17 y e a r sf o r t h ea l u m i n u ma n d 1 8 2 . 9y e a r sf o r t h e copper. T h e p r o o f o f t h e e t h a n o la l s o i n f l u e n c e st h e corrosion rates of these metals in ethanol. lf the metalsare immersedin 90 proof ethanolinsteadof the 200 proof ethanol, the steel's corrosion rate would increase2.3times,the copperwould increase 1 . 6 t i m e s ,a n d t h e a l u m i n u mw o u l d d e c r e a s e4 . 1 t i m e s( P e r s i a n t s e veat a l . ,1 9 8 0 ) . Temperaturealso affectsthe corrosionrate of metals.lf the temperatureincreasesfrom 80'F to 280"F the corrosionratefor steelin ethanolgoes up f r o m . 0 0 4i n c h e sp e r y e a rt o . 0 5i n c h e sp e r y e a r ,a n i n c r e a s eo f 1 2 . 5t i m e s( P e r r y ,19 7 3 ) . I t s h o u l db e n o t e dt h a tt h e r ei s a n o t h e rp r o b l e m with having aluminum in contact with ethanol. When ethanol and water come into contact with a l u m i n u mt h e y p i c k u p a l u m i n u mo x i d ef o r m i n ga m i l k y w h i t e s l u d g e( S c h n e i d e r1, 9 7 9 ) .l t i s r e c o m m e n d e d t h a t a n y a l u m i n u mt h a t m i g h t c o m e i n contact with the ethanol be replacedbecausethe s l u d g ec o u l d c l o g f i l t e r sa n d f u e l l i n e s . Zinc is also incompatible with ethanol. In one t e s t ,t h e v e h i c l ec o n t a i n e da z i n c - l i n e dg a st a n kt h a t h a d t o b e r e p l a c e dw i t h a s t a i n l e s s t e e lt a n k ( H i l l , 1 9 8 0 )S . t a i n l e s s s t e ei sl k n o w nt o b e h i g h l yr e s i s t a n t to corrosionby ethanoleven at high temperatures. A s a c o n s e q u e n c eo f t h e i n c o m p a t a b i l i t i e s associatedwith ethanol,it is recommendedthat the f ol lowing areasbe checkedf or compatabiIity before r u n n i n ga n e n g i n eo n e t h a n o l( F l o w e r se t a l . ,1 9 7 9 ) : r carburetorfloat, o carburetorneedleand seat, o cdrburetorfilter (plasticgasket), o f u e l f i l t e r( p l a s t i c ) , o fuellines, o f u e l p u m p ( p l a s t i ca n d r u b b e rp a r t s )a n d o f u e lt a n k . PollutantEmissionsLevelsof EnginesUsing Ethanol There are conflictingreportson the effectsof e t h a n o lu s e o n t h e e x h a u s te m i s s i o n so f e n g i n e s . T h e s ec o n f l i c t sr e s u l tm a i n l yf r o m u s i n g d i f f e r e n t e n g i n e sa n d d i f f e r e n tm e t h o d so f e v a l u a t i n gt h e e m i s s i o n s .I n T a b l e 8 ( P a u l , 1 9 7 9 ) t h e e x h a u s t c o m p o s i t i o no f a n e n g i n eo p e r a t i n go n e t h a n o li s s h o w n .T h e e n g i n eh a d a d i s p l a c e m e notf 2 . 3 l i t e r s and a modifiedcarburetor. 14 Table 8.-Exhaust Compositionf rom NeatEthanolbyFTIRSand OtherMethods. Compound Water C a r b o nd i o x i d e C a r b o nm o n o x i d e Heavyhydrocarbons(Cu+1 N i t r i co x i d e N i t r o g e nd i o x i d e N i t r o u so x i d e N i t r o u sa c i d H y d r o g e nc y a n i d e Ammonia S u l f u rd i o x i d e Methane Acetylene Ethylene Ethane Propylene lsobutane Formaldehyde Acetaldehyde F o r m i ca c i d Methanol Ethanol Total NOX Total HC * FTIRS A m o u n ta t 4 Hours (ppm) 1.10. 1.08488. 0.3** 14.4 46.9 0.4 2.4 0.1 0 0.3 8.7*" 4 . 6 "* 26.0 1.8** 0.5** 3.0** 8.8.57.4** 0.6.. 7 . 6 ** 194.-. 63.7 313.3*. Error 0.2 0.2 18.4 14.7 0.6 0.6 0.2 0.2 0.4 o.2 0.4 0.2 0.4 0.9 0.4 '1.8 1.8 0.2 1.6 0.2 0.2 o: A m o u n ta t 26Hours o.52 1.07 490. 0. 4.0 31.5 0.4 2.2 0 0.1 tl 8.8 AA 26.0 1.7 0.6 e6 7.8 55.6 0.2 6.4 168. 37.6 280.0 o/o '. ppm carbon N01 Emissions Unburned Fuel Emissions I t w a sf o u n dt h a tN O Xe m i s s i o n w s e r eg e n e r a l l y l e s sf o r e t h a n o la s c o m p a r e dt o g a s o l i n eT. h i s h e l d t r u e e x c e p ti n t h e v e r y l e a n a n d v e r y r i c h r e g i o n s . F i g u r e1 2 ( U n i v e r s i t yo f S a n t aC l a r a ,1 9 7 8 )p o i n t s t h i s o u t i n g r a p h i c afl o r m . T h e a m o u n t b y w h i c h t h e N O y e m i s s i o n sd e crease varies between tests. One test reported r e d u c t i o no f 5 5 t o 6 0 % u s i n g e t h a n o la t t h e s a m e . n o t h e rt e s t f o u n d e q u i v a l e n c er a t i o ( P a u l ,1 9 7 9 ) A that reductionto be 8 to 12 o/oal the same equival e n c er a t i o( U n i v e r s i toy f S a n t aC l a r a ,1 9 7 8 ) . T h e u n b u r n e df u e l e m i s s i o n sw e r ef o u n dt o b e . n e t e s tw i t h h i g h e rf o r e t h a n o lt h a n f o r g a s o l i n e O t h e s a m ee n g i n e so p e r a t i n ga t t h e s a m ee q u i v a l e n c e ratio, reportedincreasesof 6 to 25 0/o(Universityof S a n t aC l a r a , 1 9 7 8I)n. F i g u r e1 3 ( M u e l l e r1, 9 7 8 ) t h i s i n c r e a s ei s a l s os h o w ne x c e p ti n t h e r i c h r e g i o n . Aldehyde Emissions I t s h o u l d b e n o t e d t h a t a t t h e p r e s e n tt i m e a l d e h y d ee m i s s i o n sa r e n o t f e d e r a l l yr e g u l a t e dB. u t t h e a l d e h y d ee m i s s i o n sf r o m e t h a n o lo p e r a t i o na r e m u c h h i g h e rw h e nc o m p a r e dt o o p e r a t i o no n g a s o l i n e .I n o n e t e s t ,w i t h t h e c a r b u r e t o ar n d d i s t r i b u t o r i ncreasewasf ound (Chu i, 1979).In modified,a 5Oo/o F i g u r e1 4 ( U n i v e r s i toy f S a n t aC l a r a ,1 9 7 8 )a l a r g e r i n c r e a s ei s s h o w n .T h e i n c r e a s es h o w n f r o m t h i s g r a p h r a n g e sf r o m t h r e e t o s i x t i m e s t h e g a s o l i n e C O E mi ssi o n s T h e C O e m i s s i o n s w e rfeo u n dt o b e l o w e r w h e n . ne test o p e r a t i n go n e t h a n o lt h a n w i t h g a s o l i n e O reported that CO emi ssionswere reduced30 to 60 0/o w h e n o p e r a t i n go n e t h a n o a l t t h e s a m ee q u i v a l e n c e ratio (Universityof SantaClara,1978). 15 P I N T O 2 , 3 O OC C E N G I N E M B T S P A R KT I M I N G a O O O R P M- W O T FORDPINTO 2.5 LITER M B T S P A R KT I M I N G 2 0 0 0 R P M, W o T DSR ETHANOL -_-OEMINDOLENE BASIS DATA ON PER-CYLINDER DSR ETHANOL -__OEM INDOLENE r0c r2.o CL (-l t I - to E o o I RICH a z o o z LEAN 8.O 6 a (n 6 I r q u x o z |r 6.O J 4.O U z 4. z o.6 o.7 0.8 o9 LO t.l ?.o o.7 E Q U I V A L E N C ER A T I O , ! [ o.8 0.9 t.o t .I t.2 E O U I V A L E N C EN A T I O , Q F i g .1 3 . - T h e u n b u r n e df u e l e m i s s i o nfsr o m a n S l e n g i n e f u e l e dw i t h e t h a n o la r e e q u i v a l e ntto e n g i n e sf u e l e dw i t h i n d o l e n eT. h e u n b u r n e df u e le m i s s i o nas r eg r e a t e fro r i n d o l e n ew h e nt h e e q u i v a l e n crea t i oi s h i g h e rt h a n1 . 0 . Fig. 12.-The nitrogen oxides emitted f rom an Sl engine f ueled with ethanol and indoleneare nearly equal for all e q u i v a l e n c er a t i o s e x c e p t i n t h e 0 . 9 t o 1 . 0 r a n g e w h e r e t h e e t h a n o lf u e l e de n g i n e se m i t c o n s i d e r a b l yl e s s N O y . o p e r a t i o nv a l u e s O . n e t e s tr e p o r t e dt h a ta s t a n d a r d c a t a l y t i cc o n v e r t e rc a n e l i m i n a t et h e p r o b l e m so f a l d e h y d e m i s s i o n (sH i l l ,1 9 8 0 ) . O n e p r o b l e mp o i n t e do u t i n t h e e m i s s i o n tse s t s w a s t h e m a l d i s t r i b u t i obne t w e e nc y l i n d e r s( f a i l u r e o f f u e l t o d i s t r i b u t ee v e n l ya m o n gc y l i n d e r s r) e s u l t i n g f r o m t h e u s e o f e t h a n o l .l t w a s f o u n d t h a t t h i s p r o b l e m i n c r e a s e dw i t h i n c r e a s i n gv e h i c l es p e e d ( C h u i ,1 9 7 9 ) T . h e m a l d i s t r i b u t i ovna r i e dt h e e m i s s i o n sf r o m o n e c y l i n d e rt o t h e n e x t ,b u t i t i s n o t k n o w nw h a t e f f e c tt h i s o r o b l e mh a s o n o t h e ra r e a s o f e n g i n eo p e r a t i o no n e t h a n o l . the ethanol (Rider et al., 1979). Another study c o n d u c t e dd u r i n g t h e w i n t e r , o n s h o r t t r i p s a n d stop-and-godriving, reporteda 1800/o increasein t h e i r o n w e a r o f t h e e n g i n e p l u s i n c r e a s e do i l v i s c o s i t ya n d a c i dc o n t e n t .l t w e n to n t o s a yt h a t t h e p r o b l e m sa r e n o t s e r i o u sa t h i g h e r a m b i e n tt e m peratures(Schrock,1979). A s m e n t i o n e de a r l i e r ,i n s o m e t e s t st h e i n t a k e a i r o f t h e e n g i n eu s i n ge t h a n o li s p r e h e a t e dl.t w a s f o u n d t h a t w h e n t h e i n t a k ea i r w a s h e a t e de x c e s s i v e l ye n g i n ek n o c k o c c u r r e da n d t h e e n g i n ew a s destroyedT . h e s t u d y r e c o m m e n d e dk e e p i n gt h e t e m p e r a t u ro e f t h e e n g i n ep a r t sb e l o w2 9 0 ' C ( P a u l , 19 7 9 ) . A n o t h e rp r o b l e mm e n t i o n e di n o n e p a p e rw a s t h a t v a l v e r e c e s s i o nm i g h t o c c u r i n o l d e r m o d e l . his e n g r n e so p e r a t i n go n e t h a n o l( S c h r o c k1, 9 7 9 )T p r o b l e mc a n a l s o o c c u r i n o l d e r m o d e l e n g i n e s o p e r a t i n g o n u n l e a d e d g a s o l i n e .T h e p r o b l e m occurs becauseof the absenceof tetraethyllead. N e w m o d e lc a r sa r ee q u i p p e dw i t hv a l v es e a ti n s e r t s t o e l i m i n a t teh i sp r o b l e ml.f t h i sp r o b l e mo c c ur s i t i s r e c o m m e n d e dt h a t v a l v es e a t i n s e r t sb e o l a c e di n E n g i n eD u r a b i l i t y U si n g E th a n o l There see/ns to be some conflict between reportson the effectof ethanolon enginedurability. O n e s t u d y r e p o r t e dn o d o c u m e n t e di n c i d e n c e so f e n g i n ec o r r o s i o nd u e t o e t h a n o lu s e . l t s t a t e dt h a t t o e t h a n o l w a sr e a l l y t h ee n g i n ec o r r o s i o na t t r i b u t e d t h e a r e s u l to f d e n a t u r a not r o t h e ra d d i t i v e su s e di n 16 the headsorthat the headsbe replacedwith a newer model. Friction and wear characteristicsof various f u e l s w e r e t e s t ebdy B a i l y e ta l .( 19 7 9 )i n a c c o r d a n c e with ASTM standards.The lubricationperformance of ethanol was poorer than dieselfuel, but it was s u p e r i o rt o g a s o l i n e . I n d u a l i n j e c t i o nd i e s e le n g i n e s( o n e i n j e c t i n g b o t h e t h a n o la n d d i e s e lf u e l )t h e p r o b l e mo f h e a v y k n o c k o c c u r r e dw h e n t h e i n t a k ea i r w a s h e a t e d excessively.lt was found that at air temperatures a b o v e 2 0 0 " C t h e e t h a n o l s e l f - i g n i t e dd u r i n g t h e compressionstroke (Bro et al.,1977). ( B A N D SI N C L U D E 9 5 % O F ACTUAL DATA POINTS) E MI 2-OO = 0 = =- OEM INDOLENE 0.06 - DSR ETHANOL O.| | oN o Gonclusion Ethanolseemsto be an attractivesubstitutefor o e t r o l e u mf u e l s i n t h e S l i n t e r n a l c o m b u s t i o n e n g i n e .l t s t w o m o s tp o s i t i v eq u a l i t i e sa r et h a t i t c a n b e u s e d i n t o d a y ' se n g i n e sa n d c a n b e m a d ef r o m renewableresources,such as grain.However,there a r e p r o b l e ma r e a si n e t h a n o lu s e ,s o m eo f w h i c ha r e l i s t e di n T a b l e 9 ( S c h r o c k ,1 9 7 9 ) .O t h e r p r o b l e m s with its widescaleuse are its cost, productionand d i s t r i b u t i o nt o t h e p u b l i c . l n s u m m a r y t, h e f o l l o w i n gg e n e r a l i z a t i o ncsa n be made based on the literaturereviewedin this paper: P I N T O A 3 O OC C E N G I N E M B T S P A R KT I M I N G aOOO R PM - ALL LOADS I .L I o u t o f t h e e n g i n e .l t h a s b e e n f o u n d t h a t e t h a n o l , b e i n ga n e x c e l l e nst o l v e n tw , i l l l o o s e nu p g u m sa n d d e p o s i t sa lr e a d yf o r m e di n t h ee n g in e .O n e p r o b l e m w i t h t h i s i s t h a t w h e n e t h a n o li s f i r s t u s e d i n a n e n g i n e ,o n e s h o u l d e x p e c t t h a t s o m e f i l t e r s m a y clog up due to the gums and depositsbeing cleansedfrom the engine.However,afterthe engine i s i n i t i a l l yc l e a n s e dt h e r es h o u l d n o t b e a n y m o r e p r o b l e m sw i t h c l o g g e df i l t e r s ,u n l e s st h e e t h a n o l c o m e s i n t o c o n t a c tw i t h s o m e o f t h e i n c o m o a t i b l e m a t e r i a l sm e n t i o n e de a r l i e r( R i d e re t a l . ,1 9 7 9 ) . r.60 U' I -1LEAI{ U' z 9 I RICH t.? an v, = U lrJ o o. I td 6 J \ \-- 0.40 =\ _____..-_ .-.-i..-- .\ .\ .\ o.70 0.80 0.90 r.o t.l a r t o ,Q E e u r v A L E N cnE F i g . 1 4 . - T h e a l d e h y d ee m i s s i o n s o fa n S l e n g i n e f u e l e dw i t h e t h a n o l s h o w v e r y s i g n i f i c a n ti n c r e a s e sa t l o w e q u i v a l e n c e r a t i o s . W h e n t h e e q u i v a l e n c er a t i o i s g r e a t e r t h a n 0 . 9 t h e e t h a n o lf u e l e de n g i n e a p p r o a c h e s t h ei n d o l e n e fu e l e de n g i n e b u t s t i l l i s s i g n i f i c a n t l yg r e a t e r . D ep o si tsi n E n g i n e s U si n g E th a n o l ln the studies reviewed ethanol has not been found to leave any unfavorable engine deposits. I n o n e s t u d y p r a c t i c a l l yn o c o m b u s t i o nc h a m b e r d e p o s i t sw e r ef o u n d i n a n e n g i n ea f t e r5 0 0 h o u r so f o p e r a t i o no n e t h a n o l ( M e y e re t a l . , 1 9 4 8 ) .I n f a c t e t h a n o ld o e s j u s t t h e o p p o s i t e .l t c l e a n sd e p o s i t s 17 1 ) T h e h i g h e rp r o o fe t h a n o (l ) 1 8 0 ) i s a m o r e s u i t a b l ef u e l f o r t o d a y ' se n g i n e sd u e t o i t s increased power output, increasedvolum e t r i c f u e l e c o n o m y ,a n d t h e a b s e n c eo f d ithlower s o m eo f t h e p r o b l e m sa s s o c i a t e w p r o o fe t h a n o , . 2 ) E t h a n o li s m o r e a d a p t a b l et o u s e i n s p a r k i g n i t i o ne n g i n e st h a n i n d i e s e le n g i n e s . 3 ) W h e ne t h a n o il s u s e di n a S l e n g i n e m , o d i if c a t i o n ss h o u l d b e m a d e t o t h e c a r b u r e t o r , c o m p r e s s i o nr a t i oa n d i g n i t i o nt i m i n g ,a n d someadditionalform of heatmay be needed f o r t h e i n t a k ea i r . 4 ) W h e n c o m p a r e dt o g a s o l i n e ,e t h a n o l d e livers more power, betterfuel economy, h i g h e r t h e r m a l e f f i c i e n c y ,b u t l e s s v o l u m e t r i cf u e l e c o n o m y . 5 ) S o m ea d d i t i o n afl o r m o f h e a to r a s e p a r a t e startingfuel is neededto start engines operatingon ethanolat low temperatures. 6) E t h a n o il s l e s st o x i ct h a ng a s o l i n eb, u t m o r e p r e c a u t i o n sm u s t b e t a k e ni n i t s s t o r a g et o i n s u r ei t s i n i t i a lq u a l i t y . 7 ) E t h a n o l i s c o r r o s i v et o s e v e r a lm a t e r i a l s u s e d i n v e h i c l e s c u r r e n t l y o p e r a t i n go n g a s o l i n eT. h e c o r np a t a b i l i t o y f m a t e r i a l isn a vehicleshould be checked before usinq ethanol. 8) T h e N O X a n d C O e m i s s i o n sa r e l e s s ,a n d t h e u n b u r n e df u e l a n d a l d e h v d ee m i s s i o n s are greater for ethanol as compared to gasoline. 9 ) T h e r e s e e m t o b e n o m a j o r p r o b l e m si n e n g i n ed u r a b i l i t yu s i n ge t h a n o lt h a t c a n n o t be overcomewith minor modifications. 10) There are no unfavorableengine deposits l e f t i n e n g i n e su s i n ge t h a n o l .I n f a c t ,t h e r e are fewer engine depositsthan found from the use of gasoline. Eventhough there are some problemsassociated with its use,ethanolhas been used as a gasolinesubstitutebefore,andtherearenoinsurmounta b l e p r o b l e m st o k e e p i t f r o m b e i n gu s e da g a i n .A greatnumberof barriersexist in the useof unmixed ethanolin dieselenginesbecauseof the low cetane numberforethanol.Tomakeitsusepracticaltoday, there are active research programs around the world investigating these problems. in Engines. Table9.-Summaryol EthanolApplications Approximateo/o Fuel Replaced by Ethanola 200 Proot EthanolVatue Potentialc Problems No . 7 5x g a s o l i n e 1,2,5,7 100 Yes . 6 7x g a s o l i n e 3, 4,7,I Naturag l as lrr engines, old Sl tractors 100 Yes . 7 6x g a s o l i n e 3, 4,7,I C l t r a c t o r sc, o m b i n e s 100 Yes . 5 2x d i e s e l 4,6,7,9 Application Engine 1 ) Ethanol-gasoline mixtures V e h i c l e sa n d o l d e r Sl tractors 2 a ) E t h a n o li n S l S t d .C R V e h i c l e sn, a t u r a lg a s e n g i n e s o, l d S l t r a c t o r s 2 b ) E t h a n o li n Sl HighCR 10 Utilize Low Proof? 3) E t h a n oiln S l c o n v e r t e dd i e s e l s h i g hC R 4) E t h a n o li n d i e s e l s C l t r a c t o r s c; o m b i n e s 100 Yesb . 5 5x d i e s e l 4,5,7,8,10 5) Ethanol-diesel m txtures C l t r a c t o r s c, o m b i n e s 10 No . 5 1x d i e s e l 1,4,6,7,'10 6) Carbureted e t h a n o lC l C l t r a c t o r s ,c o m b i n e s 30 Yes . 5 5x d i e s e l 11 a A s s u m i n g10 0 o /aod o p t i o n Dspeculative c P o t e n t i a lP r o b l e m s 1 - P h a s es e p a r a t i o n 2 = Driveability 3 = V a l v er e c e s s i o n 4 = S t a r t i n g( b e l o w4 0 " F ) 5 - V a p o rl o c k 6 = U n a v a i l a b i l i t yo f r e t r o fi t c o n v e r s i o nh a r d w a r e 7 M a t e r i a l sc o m p a t i b i l i t y 8 I n j e c t o rp u m p l u b r i c a t i o n g - o i l d i l u t i o na t l i g h tl o a d s l 0 C o m b u s t i o nk n o c k 1.1 Inconvenience GLOSSARY OF TERMS A/F BTC Cl DSR <D FTIRS FTP IHP MBT Ml Ml NFPS NOX OEM Sl WOT Air to fuel ratio Beforetop deadcenter C o m p r e s s i oing n i t i o n inductionsystem-sonicflow fuel/airinduction Dresserator Equivalence ratio-actual airlfuel ratio stoichiometric airlfuel ratio Fuoriertransform infraredspectroscopy Federaltest procedure Indicatedhorsepower M i n i m u ms p a r ka d v a n c ef o r b e s tt o r q u e M a l d i s t r i b u t i oi nnd e x O richestcvlinder- leanestcylinder 2 x O average NationalFireProtectionSocietv N i t r o u so x i d e s Originalequipmentmanufacturer S p a r ki g n i t i o n Wide open throtile 18 Bibliogr aphy 1 . A D M C o r o . 1 9 8 0 . C o r n P o w e rF u e l e d 1 9 7 9 F o r d 1 6 . M e y e rA , n d r eJ . a n d R . E . D a v i s1. 9 4 8 D . evelopment o f a P r a c t i c a lM e t h o d o f B u r n i n g A l c o h o l i n a G a s o l i n eT r a c t o r .U n i v e r s i t yo f K e n t u c k y ,L e x i n g ton, Kentucky. 1 7 M i n g l e ,J o h n G . O c t o b e r. '9l 7 9 .C o n v e r t i n gY o ur C a r t o R u n o n A l c o h o lF u e l s .O r e g o nS t a t eU n i v e r s i t y , C o r v a l l i sO, r e g o n . F i e s t aC . e d a rR a p i d s ,l o w a . 2 . B a i l e y , B . K . a n d J . A . R u s s e l .1 9 7 9 . E m e r g e n c y F u e l sC o m p o s i t i o na n d l m p a c t ,P h a s el l F o r m u l a t i o n a n d S c r e e n i n gD i e s e lE m e r g e n c yF u e l s .M E D R e o o r t 1 0 1 . S o u t h w e s t R e s e a r c h I n s t i t u t e .S a n A n t o n i o ,T e x a s . e B r o , K l a u s a n d P . S . P e d e r s o n 1. 9 7 7 .A l t e r n a t i v e D i e s e lE n g i n eF u e l s ;A n E x p e r i m e n t aI ln v e s t i g a t i o n o f M e t h a n o l ,E t h a n o lM e t h a n ea n d A m m o n i a i n a D . l . D i e s e lE n g i n ew i t h P i l o t I n j e c t i o nS. A E P a p e r . a s s e n g ecr a r m e e t i n go f S A E ,D e t r o i t , N o . 7 7 0 7 9 4P Michigan. 1 8 . M o t h e r E a r t h N e w s . 1 9 7 9 .M o t h e r s E x o e r i m e n t a l A l c o h o l - P o w eTr r u c k .M o t h er E a r t hN e w s .S e p t e m b e r l O c t o b e r1 9 7 9 . 1 9 . M u e l l e r A s s o c i a t e s ,I n c . 1 9 7 8 .S t a t u s o f A l c o h o l U t i l i z a t i o nT e c h n o l o g yf o r H i g h w a yT r a n s p o r t a t i o n . D O E C o n t r a c tE C - 7 7 - X - 0 1 - 2 9 2 B 3 .a l t i m o r e ,M a r y land. C h u i .G . K . . R . D . A n d e r s o na n d R . E . B a k e r .1 9 7 9 . B r a z i l i aV n e h i c l eC a l i b r a t i ofno r E t h a n oFl u e l sF. o r d , ichigan. M o t o rC o m p a n y D . e t r o i tM 20. N e r p e l C , h u c k .1 9 8 0 B . o o z eB u r n e r sT, h e D e b u to f t h e A l c o h o l i cA u t o m o b i l e .A D M G a s o h o l N e w s . F e b r u a r y2 7 , 1 9 8 0 . D e a r d o r f f ,T . 1 9 7 9 .O p e r a t i o no f a S p a r k - l g n i t i o n E n g i n ew i t h a R a n g eo f E t h a n o lo n W a t e rM i x t u r e s . l o w a S t a t eU n i v e r s i t yA, m e s ,l o w a . b. 21 P a u l ,J . K . 1 9 7 9 E . t h y lA l c o h o lP r o d u c t i o n andUse a s a M o t o r F u e l . N o y e s D a t a C o r p o r a t i o n .P a r k R i d g e ,N e w J e r s e y . D u c k . J . T . a n d C . S . B r u c e . 1 9 4 5 .U t i l i z a t i o no f N o n - P e t r o l e u mF u e l si n A u t o m o t i v eE n g i n e s N . af/. Bur. Std.,J. Fes 35: 439. 22. P e r r y , C h i l t o n . 1 9 7 3 . C h e m i c a lE n g i n e e r sH a n d b o o k , F i f t h E d i t i o n . M c G r a w - H i l lC o m p a n y , N e w Y o r k ,N e w Y o r k . . asolina E n g e l m a nH, e l m u t hW . 1 9 8 0 G e n dD i s t i l l e d A f c o h o l C o m p a r e di n a n E n g i n e .l n L o o k i n g a t Alcohol Fuel:Farm Productionand Use.Ohio State , o l u m b u s ,O h i o . U n i v e r s i t yE x t e n s i o nS e r v i c e C P e r s i a n t s e v aV,. P . , l . L . R o z e nife l d ,V . E . Z o r n i a ,E . K . E n i k e e va n d M . l . C h a r a e v a1. 9 8 0 .P r o t e c t i o no f M e t a l s , T r a n s a c t i o n so f t h e Z a s h c h i t a M e t a l l o v , J a n u a r y1 9 8 0 .C o n s u l t a n t sB u r e a u ,N e w Y o r k ,N e w York. , i l l i a mJ . a n d C . W . F l o w e r s1. 9 7 9 .E n g i n e 8 . F l o w e r sW M o d i fi c a t i o n sf o r t h e U s e o f A l c o h o l F u e l si n S o a r k l g n i t i o nE n g i n e sN . i c h o l l sS t a t eU n i v e r s i t yT,h i b o d a u x ,L o u i s i a n a . 24 P y e , D . R . 1 9 3 7 .T h e l n t e r n a lC o m b u s t i o nE n g i n e , V o l u m e/ . O x f o r d U n i v e r s i t yP r e s s .L o n d o n , E n g land. 9 . G a l l o p o u l o s ,N i c h o l a s E . A l t e r n a t i v eF u e l s f o r R e c i p r o c a t i n gI n t e r n a lC o m b u s t i o nE n g i n e sA . ltern a t i v e H y d r o c a r b o nF u e l s : C o m b u s t i o n a n d C h e m i c a l K i n e t i c s .P r o g r e s si n A s t r o n a u t i c sa n d Aerona utics. 62 7 4-115. 2 5 R i d e r ,A l l e nR . a n d D . P . S h e l t o n1. 9 7 9 .E t h a n o l - A F u e l f o r A g r i c u l t u r aE l n g i n e s .U n i v e r s i t yo f N e b r a s k a ,L i n c o l n ,N e b r a s k a . . .1 9 5 3 E . l e m e n t s olfn t e r n a lC o m b u s 26. R o g o w s k i , AR t i o n E n g i n e s . M c G r a w - H i l lB o o k C o m p a n y , I n c . N e w Y o r k ,N e w Y o r k . 1 0 .G o e r i n g , C a r r o l l E . 1 9 8 0 . B u r n i n g E t h a n o l i n E n g i n e s l.n L o o k i n ga t A l c o h o l F u e l sF: a r mP r o d u c t i o n a n d U s e . O h i o S t a t e U n i v e r s i t yE x t e n s i o n S e r v i c eC, o l u m b u sO , hio. 1 1 . H i l l , R a y .1 9 8 0 ." A l c o h o lF u e l s - C a n T h e y R e p l a c e Gasoline?"PopularSclence.216:25-34. 2 7 S c h n i e d e rR, o l l i n .1 9 7 9 S . a f e t yf o r E t h a n o P l roduct i o n a n d U t i l i z a t i o nU. n i v e r s i t vo f N e b r a s k aL, i n c o l n ,N e b r a s k a . 28. S c h r o c k ,M a r k D . 1 9 7 9 .U s i n gA l c o h o li n E n g i n e s . K a n s a sS t a t eU n i v e r s i t yM , ansas. , a n h a t t a nK 1 2 . H u n t , D o n n e l lR . 1 9 7 9 .E n g i n e M o d i f i c a t i o nfso r B u r n i n g E t h a n o la s a F u e l .U n i v e r s i t yo f l l l i n o i s , U r b a n a l, l l i n o i s . 12 29. S p i n d l e r W , . 1 9 7 8 .M a t c h i n ga T u r b o c h a r g etro a P a s s e n g eC r a r P e t r o lE n g i n e .C o n f e r e n c eo n T u r b o c h a r g i n ga n d T u r b o c h a r g e r sI.n s t i t u t i o no f M e c h a n i c a l E n g i n e e r s H e a d q u a r t e r s .L o n d o n , E n g l a n dA. p r i l1 8 - 2 9 1 , 978. H u n t , D o n n e l l R . 1 9 8 0 .P e r s o n a lc o r r e s p o n d e n c e . D e p a r t m e not f A g r i c u l t ur a l E ng i n e e rni g , U ni v e r s i t y . r b a n a l. l l i n o i s . o f l l l i n o i sU 1 4 . K e l l e r ,J a m e s L . 1 9 7 9 .A l c o h o l sa s M o t o r F u e l ? Hydrocarbon Processing.58: 127-138. 30. U n i v e r s i t yo f S a n t a C l a r a ,S c h o o l o f E n g i n e e r i n g . 1 9 7 8 .E t h a n o li n M u l t i c y l i n d eAr u t o m o t i v eS l E n g i n e s ;A s t u d yo f P e r fo r m a n c ea n d E m i s s i o n sC h a r a c t e r i s t i cR s e l a t i v teo l n d o l e n ea n d M e t h a n o lD. O E C o n t r a c tE C - 7 8 - C - 0 3 -713 7 .S a n t aC l a r a ,C a l i f o r n i a . Lynch,Craig O. 1979.Alcohol FuelsOur Renewable E n e r g y .B l u e L i g h t P r e s s .C o n c o r d ,C a l i f o r n i a . 19 Office, College of Agriculture, University of Kentucky, Room S-105, Agricultutal Science Building-North, Lexington, Kentucky 40546 lssued in furtherance of Cooperative Extension work, Acts ot May 8 and June 30, 1914, in cooperation with the U.S. Department of Agriculture. Charles E. Barnhart, Director of Cooperative Extension Service, University ot Kentucky College ol Agricullure, Lexington, and Kentucky State University, Frankfort. l s s u e d8 - 8 1 , 1 M ; 1 M - 1 1 - 8 1