2

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

Introduction

3

Lesson 1:Introduction to Ethanol

4

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

5

Ethanol is made from corn, sugarcane, wheat, other agricultural products

Ethanol can be formed through: Biochemical conversion Thermochemical conversion

Definition of Ethanol

Figure 1 (left): Sugarcane stalks, a primary source of ethanol. Source: NAFTC. Figure 2 (right): Sugar beets, another source

of ethanol. Source: NAFTC.

6

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.

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Chemical Properties of Ethanol Ethyl alcohol – contains hydroxyl

group Distilled from fermented sugars Also known as “grain alcohol”

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Ethanol Color Pure ethanol is colorless When mixed with gasoline,

ethanol will take on straw yellow color

Ethanol Smell Pure ethanol is odorless As it is mixed with gasoline, ethanol

will begin to smell like gasoline

Figure 6: Inspecting a sample of ethanol. Source: NREL.

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Figure 5: Ethanol facts and figures. Source: NAFTC.

10

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.

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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.

12

First used as a fuel in the late 1800s

Nicholas Otto used ethanol in 1860

Henry Ford used ethanol in “Quadricycle”

Basic History of Ethanol

Figure 8: Nicholas Otto. Source: EIA.

Figure 9: The “Quadricycle” was fueled by ethanol. Source: The Henry Ford Museum.

13

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.

14

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.

15

All manufacturers approve ethanolblends up to 10%

97% of all U.S. gasoline contains some ethanol

Common blend for FFVs = E85

Ethanol Today

Figure 11: E85 fueling pump. Source: NAFTC.

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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

17

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.

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Basic Properties of Ethanol High octane = resistance to auto-

ignition Lower energy content than

conventional gasoline E85 octane = 95; pure ethanol

octane = over 99

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Figure 12: E85 stations by state. Source: AFDC.

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Ethanol is: Renewable Nontoxic Biodegradable Sulfur-free

Use produces fewer harmful emissions Ethanol production = U.S. job

opportunities Can be produced from domestic crops

Why Consider Ethanol?

21

Figure 13: Emission reductions by type. Source: DOE Biomass Program

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Advantages Energy self-sufficiency Creation of U.S. jobs Major reductions in petroleum

consumption Promotion of U.S. agricultural sector Higher octane rating

23

Figure 14: Ethanol compared to conventional gasoline. Source: Fueleconomy.gov.

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Major benefits to Health Environment Economy Energy Security Renewability

Ethanol Benefits

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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

Health Benefits

26

Did You Know?

The American Lung Association of Metropolitan Chicago credits ethanol-blended reformulate gasoline with reducing smog-forming emissions by 25% since 1990.

Source: American Coalition for Ethanol.

27

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.

28

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

Environmental Benefits

Figure 15: Sugarcane. Source: NAFTC.

29

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).

30

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).

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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

Economic Benefits

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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

Energy Security Benefits

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Ethanol’s energy balance Ethanol can be produced from renewable

biomass resources Biomass resources can be grown within

the U.S.

Renewable Benefits

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.

34

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.

35

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?

36

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 gasoline-powered vehicles can use E10 as a fuel.

4. True or False: Ethanol is made from sugarcane, corn, and rubbing alcohol.

Test Your Knowledge

37

Lesson 2:Ethanol Manufacturing,

Infrastructure, and Sustainability

38

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

39

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

Renewable Fuel Sources

Figure 16: Renewable Fuel Sources. Source: NAFTC.

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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

Renewable Fuel Sources

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Figure 17:Primary uses of U.S. corn (billions of bushels). Source: USDA National Agricultural Statistics Service.

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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

Renewable Fuel Sources

Figure 18: Sugarcane, often grown in Hawaii and South America, is an ideal feedstock for

ethanol. Source: NAFTC.

43

Grains Various grains can be used

to produce ethanol Grains do not possess as

much sucrose as other sources

Renewable Fuel Sources

Figure 19: Various grains are also used to produce ethanol. Source: NAFTC.

44

Agricultural products that are used to make ethanol are harvested, transported, fermented, distilled, and delivered

Manufacturing and Production

Figure 20: Harvesting sugarcane to produce ethanol. Source: NAFTC.

45

Figure 21: Dry milling process. Source: ICM, Inc.

Dry Milling Feedstock is ground up, mixed with

water Mixture (mash)

is heated Yeast is added Product is distilled

and denatured

46

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).

47

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.

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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

Transportation and Distribution

Figure 22: Ethanol plant. Source: NAFTC.

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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.

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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

Infrastructure

Figure 24: Ethanol fueling station pump. Source: NREL.

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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

52

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.

53

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

Ethanol Sustainability

54

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.

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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.

56

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?

57

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.

Test Your Knowledge

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Lesson 3:Ethanol Vehicles

(Vehicle Technology)

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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

60

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

Differences Between FFVs and Conventional Vehicles

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What is a Flexible Fuel Vehicle? Run on blends up to E85 Specialized diagnostics Specified engine calibrations

FFV Components

Figure 26 (left): Buick Regal. Source: Buick. Figure 27 (right): Ford F-150. Source: Ford.

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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 gasolineengine Figure 28: Flexible fuel vehicle engine.

Source: NAFTC.

63

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”

64

All gasoline vehicles Blends up to E10 are covered by

manufacturer warranties E15 for 2001 and newer vehicles Ethanol energy density vs.

gasoline density

FFV Modifications and Conversions

65

Comparable to gasoline vehicles Higher octane Absorbs moisture Detergent properties Higher compression

Flexible Fuel Vehicle Performance

66

Fuel must be handled with caution Transportation and storage =

safer than gasoline Less flammable than gasoline Water-soluble Biodegradable

Flexible Fuel Vehicle Safety

67

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

Flexible Fuel Vehicle Maintenance

68

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.

69

Brazil = more than 10 million FFVs, 33,000 fueling stations

By 2020, GM plans to have over 20 million FFVs on roadways worldwide

Flexible Fuel Vehicles in Use Today

Figure 30: USPS ethanol-powered vehicle. Source: NREL.

70

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?

71

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.

Test Your Knowledge