Introduction
 Energy Policy Act (EPAct) of 2005
 Renewable Fuel Standard (RFS)
 7.5 billion gallons renewable fuel in gasoline by
2012
 Expand from 9 billion gallons to 36 billion gallons
 Reductions in GHG emissions
 Encourage development of renewable fuel sector
 Ethanol – recognized alternative fuel with the
immediate potential to reduce consumption of
gasoline
2
Lesson 1:
Introduction to Ethanol
3
Objectives
 Describe what ethanol is and how to identify
it
 Explain the basic history of ethanol
 Describe how ethanol may help public health
 Explain how ethanol may help stimulate the
economy
 Describe what energy security is and how to
use ethanol to attain it
4
Definition of Ethanol
 Ethanol is made from corn, sugarcane,
wheat, other agricultural products
 Ethanol can be formed through:
 Biochemical conversion
 Thermochemical conversion
Figure 1 (left): Sugarcane stalks, a primary source of ethanol. Source: NAFTC.
Figure 2 (right): Sugar beets, another source of ethanol. Source: NAFTC.
5
 Corn = carbohydrate = high in sugars
 Corn = 95% of current U.S. ethanol
production
 Ethanol from cellulose (woody fibers) =
cellulosic ethanol
Figure 3 (left): Corn is a primary feedstock in ethanol production. Source: NAFTC. Figure 4 (right): Wood fibers for
cellulosic ethanol. Source: NREL.
6
Chemical Properties of Ethanol
 Ethyl alcohol – contains hydroxyl group
 Distilled from fermented sugars
 Also known as “grain alcohol”
7
Ethanol Color
 Pure ethanol is colorless
 When mixed with gasoline,
ethanol will take on straw
yellow color
Ethanol Smell
Figure 6: Inspecting a sample of ethanol. Source: NREL.
 Pure ethanol is odorless
 As it is mixed with gasoline, ethanol will begin
to smell like gasoline
8
Figure 5: Ethanol facts and figures. Source: NAFTC.
9
Ethanol Blends
 Gasoline is added to ethanol to:
 Ensure stability of the fuel system
 Improve cold-start characteristics
 Allow first responders to see the flame in case of
a fire
 Most FFVs run on E85
Special Note:
Ethanol-blended fuels currently in the market – whether E10 or E85 – must meet stringent federal and
state tailpipe emission standards.
10
 Ethanol = 35% oxygen by weight
 8.5 million FFVs on U.S. roads today
 E10 can be used in gasoline vehicles with
no modification
Figure 7: E10 blends are found at most fueling stations. Source: NAFTC.
11
Basic History of Ethanol
 First used as a fuel in the late 1800s
 Nicholas Otto used ethanol in 1860
 Henry Ford used ethanol in “Quadricycle”
Figure 8: Nicholas Otto. Source: EIA.
Figure 9: The “Quadricycle” was fueled by ethanol. Source: The
Henry Ford Museum.
12
Did You Know?
Ethanol was used as lamp fuel in the
U.S. as early as 1840, but a tax levied
on industrial alcohol during the Civil
War made this use uneconomical.
The tax was repealed in 1906.
Source: EIA.
13
 Model T could operate on gasoline or
ethanol
 Model T = first FFV in U.S.
 1930s = more than 2,000 ethanol stations
 Reduced petroleum
prices led to its
decline in the 1940s
Figure 10: Ford Model T. Source: NAFTC.
14
Ethanol Today
 All manufacturers approve ethanol
blends up to 10%
 97% of all U.S. gasoline
contains some ethanol
 Common blend for FFVs
= E85
Figure 11: E85 fueling pump. Source: NAFTC.
15
Comparison to Gasoline
 Higher octane rating than conventional
gasoline
 Burns more completely – reduced emissions
 More volatile than conventional gasoline
 Pure ethanol contains no carcinogenic
compounds
16
Did You Know?
The personal care products industry is
one of the largest users of industrial
ethanol, or ethyl alcohol. Hairspray,
mouthwash, aftershave, cologne, and
cleaning products all contain large
amounts of alcohol by volume.
Source: American Coalition for Ethanol, 2011.
17
Basic Properties of Ethanol
 High octane = resistance to auto-ignition
 Lower energy content than conventional
gasoline
 E85 octane = 95; pure ethanol octane = over
99
18
Figure 12: E85 stations by state. Source: AFDC.
19
Why Consider Ethanol?
 Ethanol is:




Renewable
Nontoxic
Biodegradable
Sulfur-free
 Use produces fewer harmful emissions
 Ethanol production = U.S. job
opportunities
 Can be produced from domestic crops
20
Figure 13: Emission reductions by type. Source: DOE Biomass Program
21
Advantages





Energy self-sufficiency
Creation of U.S. jobs
Major reductions in petroleum consumption
Promotion of U.S. agricultural sector
Higher octane rating
22
Figure 14: Ethanol compared to conventional gasoline. Source: Fueleconomy.gov.
23
Ethanol Benefits
 Major benefits to





Health
Environment
Economy
Energy Security
Renewability
24
Health Benefits
 Carbon monoxide emissions are responsible
for up to 20% of smog formation
 Ethanol/ethanol blends burn more completely,
produce fewer carbon monoxide emissions
 Ethanol is nontoxic, water soluble, quickly
biodegradable
 Ethanol use reduces both carbon dioxide and
greenhouse gas emissions
 Ethanol for fuel and distillers grain
25
Did You Know?
The American Lung Association of
Metropolitan Chicago credits ethanolblended reformulate gasoline with
reducing smog-forming emissions by
25% since 1990.
Source: American Coalition for Ethanol.
26
Did You Know?
A bushel of corn weighs 56 pounds
and will produce at least 2.8 gallons
of ethanol and 17 pounds of
distillers grain.
Source: American Coalition for Ethanol.
27
Environmental Benefits
 Ethanol is highly biodegradable
 Ethanol used as vehicle fuel reduces harmful
emissions
 Plants used to create
ethanol absorb carbon
dioxide during growth
 Ethanol does not
contain sulfur
Figure 15: Sugarcane. Source: NAFTC.
28
Did You Know?
Corn ethanol reduces GHGs by 20%
to 52%, while cellulosic ethanol
reduces GHGs by as much as 86%.
Source: U.S. Department of Energy (DOE).
29
Did You Know?
After the sinking of the Bow Mariner off the Virginia
coast in February 2004, the U.S. Coast Guard
officials noted the cargo of 3.2 million gallons of
industrial ethanol had dissipated quickly and did not
pose an environmental threat to humans or marine
life. In contrast, the impacts after the 2010
Deepwater Horizon – BP oil disaster in the Gulf of
Mexico are still being seen and discovered today.
Source: U.S. Department of Energy (DOE).
30
Economic Benefits
 Creation of domestic jobs
 Growth within U.S. agricultural sector
 In 2011, ethanol industry added more than
$42 billion to U.S. GDP, supported more
than 400,000 jobs
31
Energy Security Benefits
 U.S. = one of the greatest exporters of
agricultural products
 About half of U.S. oil used in 2010 was
imported
 Ethanol can be produced from domestic
resources
 Domestic production lessens dependence
on foreign oil
32
Renewable Benefits
 Ethanol’s energy balance
 Ethanol can be produced from renewable biomass
resources
 Biomass resources can be grown within the U.S.
Special Note:
The U.S. Department of Energy and Agriculture’s Billion Ton Study found that we can grow adequate
biomass feedstocks to displace approximately 30% of current gasoline consumption by 2030 on a
sustainable basis – with only modest changes in land use.
33
Did You Know?
For every barrel of ethanol produced
(1 barrel = 42 gallons), 1.34 barrels
of petroleum are displaced at the
refinery.
Source: Information Resources, Inc.
34
Upon completing this lesson, can you:
 Describe what ethanol is and how to identify
it?
 Explain the basic history of ethanol?
 Describe how ethanol may help public health?
 Explain how ethanol may help stimulate the
economy?
 Describe what energy security is and how to
use ethanol to attain it?
35
Test Your Knowledge
1. True or False: Pure ethanol is both
odorless and tasteless.
2. True or False: Henry Ford used ethanol
as a fuel for one of his first automobiles.
3. True or False: All conventional gasolinepowered vehicles can use E10 as a fuel.
4. True or False: Ethanol is made from
sugarcane, corn, and rubbing alcohol.
36
Lesson 2:
Ethanol Manufacturing,
Infrastructure, and
Sustainability
37
Objectives
 Describe what ethanol is made from –
feedstock
 Explain how ethanol is manufactured and
produced
 Describe how ethanol is transported
 Explain how ethanol is distributed
 Describe the sustainability of ethanol – its
future and cost efficiency
38
Renewable Fuel Sources
 The U.S. Department of Energy’s Office of
Energy Efficiency and Renewable Energy
identifies the following as renewable fuels:







Biomass
Geothermal
Hydrogen
Hydropower
Ocean
Solar
Wind
Figure 16: Renewable Fuel Sources. Source: NAFTC.
39
Renewable Fuel Sources
 Feedstock – any preliminary product that
can be made into a fuel
 Biomass – biological or organic matter
available on a renewable basis
 Bioenergy – the fuels that are created as
a result of converting biomass into usable
energy
40
Figure 17:Primary uses of U.S. corn (billions of bushels). Source: USDA National Agricultural Statistics Service.
41
Renewable Fuel Sources
 Corn
 One of America’s most abundant agricultural
products
 Makes up more than 90% of current ethanol
production
 Sugarcane
 High sugar content =
high fuel yield
 Typically grown in South
America and Asia due to
climate
Figure 18: Sugarcane, often grown in Hawaii and South
America, is an ideal feedstock for ethanol. Source: NAFTC.
42
Renewable Fuel Sources
 Grains
 Various grains can be used
to produce ethanol
 Grains do not possess as
much sucrose as other
sources
Figure 19: Various grains are also used to produce
ethanol. Source: NAFTC.
43
Manufacturing and Production
 Agricultural products that are used to
make ethanol are harvested, transported,
fermented, distilled, and delivered
Figure 20: Harvesting sugarcane to produce ethanol. Source: NAFTC.
44
Dry Milling
 Feedstock is ground up, mixed with water
 Mixture (mash)
is heated
 Yeast is added
 Product is distilled
and denatured
Figure 21: Dry milling process. Source: ICM, Inc.
45
Did You Know?
A modern dry-mill ethanol refinery
produces approximately 2.8 gallons of
ethanol and 17 pounds of highly
valuable feed co-products called
distillers grain from one bushel of
corn.
Source: U.S. Department of Energy (DOE).
46
Did You Know?
Carbon dioxide (CO2) is the last
byproduct from dry milling. Soda
companies often buy this byproduct
to use for carbonation in their
beverages.
Source: American Coalition for Ethanol.
47
Transportation and Distribution
 More than 200 plants in U.S. alone
 Most located in Midwest
 Usually not transported
via conventional
pipelines
 Denaturant is
added
 90% transported by
train or truck
Figure 22: Ethanol plant. Source: NAFTC.
48
U.S. Department of Transportation
Placards
 Required on all bulk shipments
 Same handling requirements as conventional
fuels
 Avoid contact with
skin/avoid inhaling
fumes/vapors
Figure 23: Hazard class 3 flammable placard for ethanol. Source: USDOT.
49
Infrastructure
 Ethanol Fueling Stations
 More than 2,500 E85 stations in the U.S. alone
 Nearly all stations use E10 blends
 Ethanol must be kept in tanks
made from certain materials
 Ethanol Fueling Safety
Features
 Ethanol stations utilize
the same features
conventional stations use
Figure 24: Ethanol fueling station pump. Source: NREL.
50
Special Note:
There are many federal and state tax incentives and credits
to encourage the installation of E85 infrastructure and use of
the fuel. For a comprehensive list of these programs, visit the
State and Federal Incentives and Laws section of the AFDC
at: www.afdc.energy.gov/afdc/laws
51
Identifying Ethanol Hazard Placards
 National Fire Protection Agency requirement
 3 = fuel must be preheated before ignition
 1 = fuel may cause slight to moderate
irritation
 0 = fuel poses no reactivity hazards
Figure 25: NFPA 704 hazard placard for ethanol. Source: NFPA.
52
Ethanol Sustainability
 Sustainability
 Continuation with minimal long-term
environmental effects
 Carbon-neutral status
 Cost Efficiency
 Concerns with using corn for fuel production
 Positive energy balance
 Biomass currently available for ethanol
production
53
Did You Know?
Ethanol production utilized the starch in
4.65 billion bushels of corn in 2010 to
produce 32.5 million metric tons of
high quality livestock feed, distillers
grain, and corn gluten feed and meal,
and 13 billion gallons of ethanol.
Source: Renewable Fuels Association.
54
The Future of Ethanol
 97% of all gasoline sold in the U.S. contains
some ethanol
 Vehicles model year 2001 or newer can use
E15 without modification
Special Note:
The Energy Independence and Security Act of 2007 (EISA) requires use of 36
billion gallons of renewable transportation fuels in the U.S. by 2022. Of that
quantity, 16 billion gallons must be cellulosic biofuels. Ethanol from corn is
capped at 15 billion gallons.
55
Upon completing this lesson, can you:
 Describe what ethanol is made from feedstock?
 Explain how ethanol is manufactured and
produced?
 Describe how ethanol is transported?
 Explain how ethanol is distributed?
 Describe the sustainability of ethanol?
56
Test Your Knowledge
1. True or False: In the process of dry milling,
corn or another grain is ground into a flour
or meal and then mixed with water to form
what is called mash.
2. True or False: Ethanol has a negative
energy balance.
3. True or False: E85 fuel can be stored in
the same tanks and dispensed using the
same pumps as conventional gasoline; but
modifications may be necessary.
57
Lesson 3:
Ethanol Vehicles
(Vehicle Technology)
58
Objectives
 Explain the differences between FFVs vehicles
and conventional vehicles
 Describe the components of FFVs
 Describe the performance of FFVs
 Explain how to maintain FFVs
 Describe the FFVs used today
59
Differences Between FFVs and
Conventional Vehicles
 Some modifications may be needed to engine
calibration and fuel management systems
 Main components:




Internal combustion engine (ICE)
Transmission
Drivetrain
Fuel storage system
 Transmission and drivetrain operate
identically
60
FFV Components
 What is a Flexible Fuel Vehicle?
 Run on blends up to E85
 Specialized diagnostics
 Specified engine calibrations
Figure 26 (left): Buick Regal. Source: Buick. Figure 27 (right): Ford F-150. Source: Ford.
61
How Do Flexible Fuel Vehicles Work?
 E85 contains less energy than gasoline
 Vehicle computer must determine appropriate
amount of fuel
Engine Calibration
 Ethanol = higher octane
 Different compression
ratio
 FFV engine = same size
as conventional gasoline
engine
Figure 28: Flexible fuel vehicle engine. Source: NAFTC.
62
Fuel Management Systems
 Ethanol = highly corrosive
 Fuel lines, storage systems, and injectors must
accommodate this nature
 Larger fuel tanks
 Higher octane will reduce engine “knock”
63
FFV Modifications and Conversions
 All gasoline vehicles
 Blends up to E10 are covered by
manufacturer warranties
 E15 for 2001 and newer vehicles
 Ethanol energy density vs. gasoline density
64
Flexible Fuel Vehicle Performance





Comparable to gasoline vehicles
Higher octane
Absorbs moisture
Detergent properties
Higher compression
65
Flexible Fuel Vehicle Safety
 Fuel must be handled with caution
 Transportation and storage = safer than
gasoline
 Less flammable than gasoline
 Water-soluble
 Biodegradable
66
Flexible Fuel Vehicle Maintenance
 Maintenance is the same as with conventional
vehicles
 Check on a regular basis:








Battery
Ignition system
Spark plugs
Coolant
Transmission fluid
Belts
Hoses
Air and fuel filters
67
 FFVs serve many purposes
 USPS switched to FFVs in January 2000
 As of 2010, the USPS FFV fleet consumed
709,937 gallons of E85
Figure 29: Ethanol-fueled public transportation bus. Source: NREL.
68
Flexible Fuel Vehicles in Use Today
 Brazil = more than 10 million FFVs, 33,000
fueling stations
 By 2020, GM plans to have over 20 million
FFVs on roadways worldwide
Figure 30: USPS ethanol-powered vehicle. Source: NREL.
69
Upon completing this lesson, can you:
 Explain the differences between FFVs and
conventional vehicles?
 Describe the components of FFVs?
 Describe the performance of FFVs?
 Explain how to maintain FFVs?
 Describe the FFVs used today?
70
Test Your Knowledge
1.
State two of the main differences between FFVs
and conventional vehicles.
2. What enables FFVs to “read” the fuel blend
being used?
3. True or False: Performance aspects of ethanol
vehicles are comparable to conventional
vehicles.
4. True or False: An ethanol land or water spill
would be relatively harmless since the fuel
would disperse and decompose very quickly.
71