Ethanol fuel Totally Explained

Everything about Ethanol Fuel totally explained

Ethanol fuel is ethanol (ethyl alcohol), the same type of alcohol found in alcoholic beverages. It can be used as a fuel, mainly as a biofuel alternative to gasoline, and is widely used in cars in Brazil. Because it's easy to manufacture and process, and can be made from very common crops, such as sugar cane and maize (corn), it's an increasingly common alternative to gasoline in some parts of the world. Anhydrous ethanol (ethanol with less than 1% water) can be blended with gasoline in varying quantities up to pure ethanol (E100), and most spark-ignited gasoline style engines will operate well with mixtures of 10% ethanol (E10). Most cars on the road today in the U.S. can run on blends of up to 10% ethanol, and the use of 10% ethanol gasoline is mandated in some cities where harmful levels of auto emissions are possible.
Ethanol can be mass-produced by fermentation of sugar or by hydration of ethylene from petroleum and other sources. Current interest in ethanol mainly lies in bio-ethanol, produced from the starch or sugar in a wide variety of crops, but there has been considerable debate about how useful bio-ethanol will be in replacing fossil fuels in vehicles. Concerns relate to the large amount of arable land required for crops, as well as the energy and pollution balance of the whole cycle of ethanol production. Recent developments with cellulosic ethanol production and commercialization may allay some of these concerns.
According to the International Energy Agency, cellulosic ethanol could allow ethanol fuels to play a much bigger role in the future than previously thought. Cellulosic ethanol offers promise as resistant cellulose fibers, a major component in plant cells walls, can be used to generate ethanol. Dedicated energy crops, such as switchgrass, are also promising cellulose sources that can be produced in many regions of the United States. However, scientists, such as David Pimentel and Tad Patzek say that more fossil energy is needed to produce ethanol than it produces, due to artificial fertilizers and oil used for heating during the fermentation process

Chemistry

During ethanol fermentation, glucose is decomposed into ethanol and carbon dioxide. ť C₆H₁₂O₆ → 2C₂H₆O + 2CO₂

During combustion ethanol reacts with oxygen to produce carbon dioxide, water, and heat: (other air pollutants are also produced when ethanol is burned in the atmosphere rather than in pure oxygen) ť C₂H₆O + 3O₂ → 2CO₂ + 3H₂O

Together, they add up to:
ť C₆H₁₂O₆ + 6O₂ → 6CO₂ + 6H₂O + heat

Sources

Ethanol is considered "renewable" because it's primarily the result of conversion of the sun's energy into usable energy. Creation of ethanol starts with photosynthesis causing the feedstocks such as switchgrass, sugar cane, or corn to grow. These feedstocks are processed into ethanol.
   About 5% of the ethanol produced in the world in 2003 was actually a petroleum product. It is made by the catalytic hydration of ethylene with sulfuric acid as the catalyst. It can also be obtained via ethylene or acetylene, from calcium carbide, coal, oil gas, and other sources. Two million tons of petroleum-derived ethanol are produced annually. The principal suppliers are plants in the United States, Europe, and South Africa. Petroleum derived ethanol (synthetic ethanol) is chemically identical to bio-ethanol and can be differentiated only by radiocarbon dating.
   Bio-ethanol is obtained from the conversion of carbon based feedstock. Agricultural feedstocks are considered renewable because they get energy from the sun using photosynthesis, provided that all minerals required for growth (such as nitrogen and phosphorus) are returned to the land. Ethanol can be produced from a variety of feedstocks such as sugar cane, bagasse, miscanthus, sugar beet, sorghum, grain sorghum, switchgrass, barley, hemp, kenaf, potatoes, sweet potatoes, cassava, sunflower, fruit, molasses, corn, stover, grain, wheat, straw, cotton, other biomass, as well as many types of cellulose waste and harvestings, whichever has the best well-to-wheel assessment.
   Current, first generation processes for the production of ethanol from corn use only a small part of the corn plant: the corn kernels are taken from the corn plant and only the starch, which represents about 50% of the dry kernel mass, is transformed into ethanol. Two types of second generation processes are under development. The first type uses enzymes and yeast to convert the plant cellulose into ethanol while the second type uses pyrolysis to convert the whole plant to either a liquid bio-oil or a syngas. Second generation processes can also be used with plants such as grasses, wood or agricultural waste material such as straw.

Production process

The basic steps for large scale production of ethanol are: microbial (yeast) fermentation of sugars, distillation, dehydration (requirements vary, see Ethanol fuel mixtures, below), and denaturing (optional). Prior to fermentation, some crops require saccharification or hydrolysis of carbohydrates such as cellulose and starch into sugars. Saccharification of cellulose is called cellulolysis (see cellulosic ethanol). Enzymes are used to convert starch into sugar.

Fermentation

Ethanol is produced by microbial fermentation of the sugar. Microbial fermentation will currently only work directly with sugars. Two major components of plants, starch and cellulose, are both made up of sugars, and can in principle be converted to sugars for fermentation. Currently, only the sugar (for example sugar cane) and starch (for example corn) portions can be economically converted. However, there's much activity in the area of cellulosic ethanol, where the cellulose part of a plant is broken down to sugars and subsequently converted to ethanol.

Distillation

For the ethanol to be usable as a fuel, water must be removed. Most of the water is removed by distillation, but the purity is limited to 95-96% due to the formation of a low-boiling water-ethanol azeotrope. The 95.6% m/m (96.5% v/v) ethanol, 4.4% m/m (3.5% v/v) water mixture may be used as a fuel alone, but unlike anhydrous ethanol, is immiscible in gasoline, so the water fraction is typically removed in further treatment in order to burn with in combination with gasoline in gasoline engines.

Dehydration

Currently, the most widely used purification method is a physical absorption process using a molecular sieve, for example, ZEOCHEM Z3-03 (a special 3A molecular sieve for EtOH dehydration). Another method, azeotropic distillation, is achieved by adding the hydrocarbon benzene which also denatures the ethanol (to render it undrinkable for duty purposes). A third method involves use of calcium oxide as a desiccant.

Technology

Ethanol-based engines

Ethanol is most commonly used to power automobiles, though it may be used to power other vehicles, such as farm tractors and airplanes. Ethanol (E100) consumption in an engine is approximately 34% higher than that of gasoline (the energy per volume unit is 34% lower). In general, ethanol-only engines are tuned to give slightly better power and torque output to gasoline-powered engines. In flexible fuel vehicles, the lower compression ratio requires tunings that give the same output when using either gasoline or hydrated ethanol. For maximum use of ethanol's benefits, a much higher compression ratio should be used, which would render that engine unsuitable for gasoline use. When ethanol fuel availability allows high-compression ethanol-only vehicles to be practical, the fuel efficiency of such engines should be equal or greater than current gasoline engines. However, since the energy content (by volume) of ethanol fuel is less than gasoline, a larger volume of ethanol fuel (151%) would still be required to produce the same amount of energy.
   A 2004 MIT study, and an earlier paper published by the Society of Automotive Engineers, describing tests, identify a method to exploit the characteristics of fuel ethanol that's substantially better than mixing it with gasoline. The method presents the possibility of leveraging the use of alcohol to even achieve definite improvement over the cost-effectiveness of hybrid electric. The improvement consists of using dual-fuel direct-injection of pure alcohol (or the azeotrope or E85) and gasoline, in any ratio up to 100% of either, in a turbocharged, high compression-ratio, small-displacement engine having performance similar to an engine having twice the displacement. Each fuel is carried separately, with a much smaller tank for alcohol. The high-compression (which increases efficiency) engine will run on ordinary gasoline under low-power cruise conditions. Alcohol is directly injected into the cylinders (and the gasoline injection simultaneously reduced) only when necessary to suppress ‘knock’ such as when significantly accelerating. Direct cylinder injection raises the already high octane rating of ethanol up to an effective 130. The calculated over-all reduction of gasoline use and CO2 emission is 30%. The consumer cost payback time shows a 4:1 improvement over turbo-diesel and a 5:1 improvement over hybrid. In addition, the problems of water absorption into pre-mixed gasoline (causing phase separation), supply issues of multiple mix ratios and cold-weather starting are avoided.
   Ethanol's higher octane rating allows an increase of an engine's compression ratio for increased thermal efficiency. In one study, complex engine controls and increased exhaust gas recirculation allowed a compression ratio of 19.5 with fuels ranging from neat ethanol to E50. Thermal efficiency up to approximately that for a diesel was achieved. This would result in the MPG (miles per gallon) of a dedicated ethanol vehicle to be about the same as one burning gasoline.
   Engines using fuel with from 30% to 100% ethanol also need a cold-starting system. For E85 fuel at temperatures below 11 °C (52 °F) a cold-starting system is required for reliable starting and to meet EPA emissions standards. However, the EPA doesn't require cold start systems on E85 vehicles. No current production E85 vehicles in the USA are equipped with these cold start systems, and they meet EPA emission guidelines.

Ethanol fuel mixtures

To avoid engine stall due to "slugs" of water in the fuel lines interrupting fuel flow, the fuel must exist as a single phase. The fraction of water that an ethanol-gasoline fuel can contain without phase separation increases with the percentage of ethanol.. This shows, for example, that E30 can have up to about 2% water. If there's more than about 71% ethanol, the remainder can be any proportion of water or gasoline and phase separation won't occur. However, the fuel mileage declines with increased water content. The increased solubility of water with higher ethanol content permits E30 and hydrated ethanol to be put in the same tank since any combination of them always results in a single phase. Somewhat less water is tolerated at lower temperatures. For E10 it's about 0.5% v/v at 70 F and decreases to about 0.23% v/v at -30 F.
In many countries cars are mandated to run on mixtures of ethanol. Brazil requires cars be suitable for a 25% ethanol blend, and has required various mixtures between 22% and 25% ethanol, as of October 2006 23% is required. The United States allows up to 10% blends, and some states require this (or a smaller amount) in all gasoline sold. Other countries have adopted their own requirements. Beginning with the model year 1999, an increasing number of vehicles in the world are manufactured with engines which can run on any fuel from 0% ethanol up to 100% ethanol without modification. Many cars and light trucks (a class containing minivans, SUVs and pickup trucks) are designed to be flexible-fuel vehicles (also called dual-fuel vehicles). In older model years, their engine systems contained alcohol sensors in the fuel and/or oxygen sensors in the exhaust that provide input to the engine control computer to adjust the fuel injection to achieve stochiometric (no residual fuel or free oxygen in the exhaust) air-to-fuel ratio for any fuel mix. In newer models, the alcohol sensors have been removed, with the computer using only oxygen and airflow sensor feedback to estimate alcohol content. The engine control computer can also adjust (advance) the ignition timing to achieve a higher output without pre-ignition when it predicts that higher alcohol percentages are present in the fuel being burned. This method is backed up by advanced knock sensors - used in most high performance gasoline engines regardless if they're designed to use ethanol or not - that detect pre-ignition and detonation.

Fuel economy

In theory, all fuel-driven vehicles have a fuel economy (measured as miles per US gallon, or liters per 100 km) that's directly proportional to the fuel's energy content.In reality, there are many other variables that come in to play that affect the performance of a particular fuel in a particular engine. Ethanol contains approx. 34% less energy per unit volume than gasoline, and therefore in theory, burning pure ethanol in a vehicle will result in a 34% reduction in miles per US gallon, given the same fuel economy, compared to burning pure gasoline. This assumes that the octane ratings of the fuels, and the thus the engine's ability to extract energy from the fuels, are the same. For E10 (10% ethanol and 90% gasoline), the effect is small (~3%) when compared to conventional gasoline, and even smaller (1-2%) when compared to oxygenated and reformulated blends. However, for E85 (85% ethanol), the effect becomes significant. E85 will produce lower mileage than gasoline, and will require more frequent refueling. Actual performance may vary depending on the vehicle. The EPA-rated mileage of current USA flex-fuel vehicles should be considered when making price comparisons, but it must be noted that E85 is a high performance fuel, with an octane rating of about 104, and should be compared to premium. In one estimate Brazil and the United States accounted for 70 percent of all ethanol production, with total world production of 13.5 billion US gallons (40 million tonnes). When accounting just for fuel ethanol production in 2007, the U.S. and Brazil are responsible for 88% of the 13.1 billion gallons total world production. Strong incentives, coupled with other industry development initiatives, are giving rise to fledgling ethanol industries in countries such as Thailand, Colombia, and some Central American countries. Nevertheless, ethanol has yet to make a dent in world oil consumption of approximately 4000 million tonnes/yr (84 million barrels/day).

Further Information

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