Just over three years ago, when California’s Governor announced an executive order allowing only zero-emissions vehicles (ZEVs) to be sold in the state, most media (and probably the governor, regulators, and supporters of the rule) understood “ZEV” to mean battery electric vehicles (BEVs) only.
Although the final rule included plug-in hybrids and hydrogen vehicles, we theorized a standard hybrid, with an internal combustion engine (ICE) powered by E85 could have emissions similar to BEVs. When total lifecycle greenhouse gas (GHG) emissions were tallied, as well as carbon intensity (CI) scoring correctly reflecting CI reductions being achieved by farmers and ethanol producers, a standard hybrid flex-fuel vehicle (FFV) can be a ZEV long before any EV.
The American Coalition for Ethanol (ACE) began testing our theory 10 months after the California executive order, using a hybrid vehicle the U.S. Department of Energy (DOE) identifies as midsized, to avoid naysayers dismissing the results as coming from a specialty vehicle or tiny clown car that would get good mileage on any fuel. We also wanted a vehicle similar in size to the best-selling BEV on the market, the Tesla Model 3 Long Range. We bought a 2019 Ford Fusion Hybrid in July 2021 for $30k to $50k less than the most popular new EVs of the day, and before converting it to the Hybrid Electric Flex-Fuel Vehicle we call “HEFF.”
We filled it with regular gasoline and drove 3,688 miles to establish a real-world regular gasoline use baseline, rather than having to compare our real-world results with fictional best case showroom sticker miles-per-gallon (mpg) and EPA’s emissions estimates based on that mileage. EPA pegged our car at 42 mpg on regular, with lifecycle GHG of 255 grams per mile (g/m). While that’s much better than the 25 mpg and 429 g/m of the non-hybrid Fusion, our pre-transition Fusion hybrid results were just over 34 mpg and around 310 g/m. We also adjusted the “regular gas” number we use for comparison using generally accepted mileage differentials for cold weather, and have periodically run tanks of regular gasoline to recalibrate for winter temps, vehicle age, and battery capacity changes during the demonstration project.
Those results are used to estimate regular gasoline consumption and also when we record flex-fuel purchases, cost, and odometer reading with each fill. We record current regular gas price along with the baseline mileage to make a cost comparison. Although our goal is to demonstrate the low CI capability of a hybrid FFV and durability of a standard engine using flex-fuel, we track fuel expenditures because we know critics will always ask about mileage and cost.
Once we calculate real mileage and CI, we compare the results to the Tesla mentioned above, and depending on where you plug in, EPA estimates the 2019 Tesla 3 Long Range emits 80 to 200 g/m lifecycle GHGs, with a national average of 111, assuming a range of 310 miles per charge. However, unscientific anecdotal Tesla Uber driver estimates told us the actual range is from 225 to 240 miles, and Car and Driver’s more scientific 40,000-mile test confirmed the drivers’ reports, saying the 2019 Tesla 3 Long Range got 80 miles less than the expected 310 miles per charge. Changing Tesla’s range to 230 miles increases its real CO2 number to 110 to 270 g/m in different markets, and boosts the U.S. average to 150 g/m.
Our baseline mpg-establishing journey ended in San Diego in August of 2021, where Pearson Fuels, the nation’s largest E85 distributor, arranged to transform the Fusion to HEFF with an eFlexFuel Plus conversion kit. The app that communicates with the flex-fuel converter provides actual ethanol content of the flex-fuel purchased, since flex-fuel can have 51 to 85 percent ethanol. Since the amount of carbon in gasoline and ethanol is different, we need the breakdown to calculate how many grams of carbon are being burned, and we divide that number by miles traveled to get our CI. We also use the ethanol and gasoline content to calculate BTU content of whatever fuel is in the tank to compare the mileage one should expect given that energy content with actual mileage to judge the effectiveness of the conversion kit.
Recording price, miles and ethanol content of every fuel purchase, and calculating E10 use and cost, after two years and three months and almost 30,000 miles on flex-fuel averaging 72 percent ethanol, produced average lifecycle GHGs of 205 g/m CO2 at 26.2 miles per gallon – not much higher than real Tesla average numbers, and lower than a Tesla 3 in many parts of the country. We calculated regular gas mpg at 32.7, which would’ve emitted 375 g/m CO2. And HEFF (Hybrid Electric Flex-Fuel) chugged 1,135 gallons of E72 versus a calculated 906 gallons regular, but the E72 cost $2,942, compared to $3,183 for gas.
We have been able to calculate some other interesting numbers based on our test results so far. Had we been able to use true E85 – 83 percent ethanol – throughout the test, our emissions number would drop to 181 g/m, and further to 113 g/m if the ethanol was CARB-approved low-CI corn fiber ethanol. Blending low-CI ethanol with renewable naphtha would provide a CI of 71 g/m in our converted Ford Fusion Hybrid – lower than the same size Tesla could achieve plugged in anywhere in the U.S. All the flex-fuel blends just mentioned are real; they have been or are being sold today.
And although the flex-fuel hybrid – even a converted flex-fuel hybrid – is capable of achieving such results, a fact recognized by Toyota and Volkswagen and being put into use in the 2024 model year in Brazil, fuel regulations being adopted in the U.S. simply refuse to acknowledge that reality. Ethanol has been responsible for nearly all the air quality improvements seen in the U.S. in the past 20 years, and its ability to reduce carbon intensity is a proven fact. But people who claim to be interested in reducing carbon pollution are enacting regulations that increase the use of electricity that is still 60 percent fossil fuel generated, over plant-based fuels like ethanol, based on what they hope and believe will be done to make electricity cleaner over the next few decades. They use buzz-phrases like “extending the life of petroleum fuels” and “false climate solution” to avoid dealing with real numbers. Projections of cleaner electricity are assumed to be facts, and scientific facts of cleaner ethanol production are ignored.
The inclusion of plug-in hybrids and hydrogen vehicles in CARB’s final Advanced Clean Cars II rule provides a sliver of hope that regulators will eventually be as concerned about actually reducing CO2 emissions as they are enforcing the electric car solution they prefer and believe in. If environmentalists and regulators are truly interested in reducing carbon emissions, solutions are available today. HEFF is proof. But if you can’t trust HEFF, ask Brazil. Or Toyota. Or Volkswagen.
Ron Lamberty is the chief marketing officer of the American Coalition for Ethanol.
The propulsion challenges facing society are complex and multi-dimensional. Decarbonization is at the core of these challenges and, unfortunately, there is no singular fuel type or technology solution to solve them all. Regardless, the transportation segment requires decarbonization – and it requires it yesterday. This truth and its aggressive timetable are why the internal combustion engine is part of the larger solution to reduce lifecycle carbon emissions to address climate change trends.
Regulating tailpipe carbon will not solve the problem of carbon dioxide alone. Reducing the carbon intensity of electric grids will take time. Electric vehicles and plug-in hybrids are great solutions for certain applications, but also need time to reach critical mass. In the meantime, we continue to rely on liquid fuels for combustion engines in conventional vehicles, hybrids, and plug-in hybrids for many on- and off-road applications. Therefore, low-carbon intensity fuels in conjunction with powertrain electrification/hybridization is needed.
Hybridization and low-lifecycle carbon intensity fuels can work together to contribute to a low-net carbon future. The internal combustion engine is ready to use low- and zero- carbon fuels to quickly move down sustainable fuels pathways, power hybrids, and enable more rapid vehicle electrification.
Any decarbonization strategy needs to utilize longer-term low carbon fuels / renewable fuels. The immediate impact of drop-in alternative fuels on legacy vehicle fleets is too great to be dismissed, especially with an existing delivery infrastructure. Industry and legislators alike need to realize it is not always about net zero. Having low-carbon content across a broad scale has a significant decarbonization impact across all transportation sectors. Low-carbon fuels offer decarbonization benefits today as we prepare for the future.
Stanadyne, a leading global fuel and air management systems supplier, is continuing to develop engine innovations enabling the efficient and economic use of low-carbon and future fuels. This continued investment is necessary, as future fuels are propulsion technology drivers with fuel system challenges still needing solutions. As we head down low-carbon fuel pathways, some fuels are thermodynamically challenging with their lower heating values. This and other characteristics make them challenging to use. Their lubricity and viscosity also can be issues, which affect engine start-stop functions and maintaining high fuel delivery pressures for cleaner combustion.
Consumers, vehicle manufacturers, and propulsion systems providers want diesel performance and total cost of ownership, but with a low-carbon fuel without the shortcomings, difficulties, and reduced range. There is a growing impatience for fuel delivery solutions to be developed. Automakers have stated a need for “hyper-collaboration” with suppliers to develop and implement clean propulsion options to meet state and federal legislation.
There are many technology pathways to achieve low- and net-zero carbon emissions. However, hybrid powertrains powered by low-carbon intensity fuels are one of the fastest tracks to decarbonization development and deployment. Alcohol, hydrogen, propane, compressed natural gas, dimethyl ether (DME) and other sustainable low-carbon intensity fuels can energize these small displacement, high-energy output, high speed engines. High-pressure fuel delivery systems operating at twice the flow help overcome alternative fuels’ low energy content. Many systems already can handle biodiesel and other drop-in renewable fuels currently available in the market.
Powertrain and fuel system innovation are key to a sustainable future. Stanadyne is accelerating engine innovation with its growing portfolio of renewable and future fuel complaint products. Our breakthrough direct injection liquid propane system, hydrogen direct injection design platform, and high-pressure direct injection pump and injector advancements are driving internal combustion engine decarbonization.
A low-carbon approach isn’t exclusive to fuels. Stanadyne takes a lifecycle approach by designing products for remanufacturing to support a circular internal combustion engine economy. More than two decades of remanufacturing expertise at scale and quality has kept 15 million pounds of waste out of landfills.
Advanced internal combustion technology will continue to be a dominant part of the fuel and technology mix for decades to come. New engine designs and fuels, like hydrogen and e-fuels, will drive decarbonization. As zero emission technologies continue to emerge, expect a world where engine technologies and fuels compete, complement, and co-exist.
Michael Hornby is Global Vice President of Product Engineering at Stanadyne
There are many outspoken and polarizing proponents of the various fuels and technologies at play today. This has been the case for several decades now and isn’t likely to disappear anytime soon. Many electric car enthusiasts do not see a future for internal combustion or even hydrogen fuel cell vehicles. Hydrogen proponents point out that fuel cell vehicles make more sense than battery electrics since hydrogen generally offers greater driving range and fuel cell vehicles can be refueled in under five minutes, while battery electrics cannot. Biodiesel enthusiasts point out the obvious benefits of this biofuel and even as this fuel gains momentum, wonder why support isn’t stronger. Natural gas advocates see huge and stable supplies of this clean-burning fuel now and in our future, without the truly significant commitment to natural gas vehicles this should bring. And those behind internal combustion vehicles achieving ever-higher efficiency simply wonder what the fuss is all about when conventional answers are here today.
So in the midst of all this, where are we headed? Simple. In the right direction, of course.
As I was writing about these very fuels and technologies some 25 years ago, it wasn’t lost on me that the competition for dominance in the ‘green’ automotive world of the future would be hard-fought and long, with many twists and turns. As our decades-long focus on the ‘green car’ field has shown us, the state-of-the-art of advanced vehicles in any time frame is ever-changing, which simply means that what may seem to make the most sense now is likely to shift, and at times, shift suddenly. This is a field in flux today, as it was back then.
When Nissan powered its Altra EV back in 1998 as an answer to California’s Zero Emission Vehicle mandate, it turned heads with the first use of a lithium-ion battery in a limited production vehicle, rather than the advanced lead-acid and nickel-metal-hydride batteries used by others. Lithium-ion is now the battery of choice, but will it remain so as breakthrough battery technologies and chemistries are being explored?
Gasoline-electric hybrids currently sell in ever-greater numbers, with plug-in hybrids increasingly joining their ranks. Conventionally-powered vehicles are also evolving with new technologies and strategies eking levels of fuel efficiency that were only thought possible with hybrid powerplants just a few years ago.
What drives efficiency – and by extension determines our future path to the high efficiency, low emission, and more sustainable vehicles desired by consumers and government alike – is textbook evolution. Cars are adapting to meet the changing needs of future mobility and the imperative of improved environmental performance. Some of these evolutionary changes are predictable like lightweighting, improved aerodynamics, friction reduction, and enhanced powertrain efficiencies. Other answers, including the fuels that will ultimately power a new generation of vehicles, will be revealed over time.
So here’s to the cheerleaders who tell us quite vocally that their fuel, technology, or strategy is the answer to our driving future. One of them may be right. But the fact is, the evolutionary winner has yet to be determined.
For most Americans, our transportation choices are limited to the fuels offered at the local gas station. For generations, regular gas stations served our needs pretty well, but America’s transportation needs are changing. Every day we learn about new choices in alternative fuel vehicles, advancements in vehicle efficiency, and new, cleaner types of fuel, so it’s bewildering that gas stations haven’t kept up with these changes. Gas stations today offer a fundamental lack of choices and are no longer in step with the way Americans seek to move about their lives.
With 160,000 fueling locations across America, gas stations outnumber McDonalds, Burger King, Subway, Starbucks, and Taco Bell…combined. But as consumers’ transportation needs change, there is no effort by Big Oil to change with them. Fifty percent of the cars in Big Three showrooms are now capable of being powered by something besides oil. Domestically produced renewable fuels have surpassed imports from Saudi Arabia, and gas consumption is at a 10-year low – yet gas prices remain at all time record levels. Mobility is transforming in other ways with ride sharing, public transit, cycling, and telecommuting all on the rise. Yet still no change in our fueling infrastructure.
At Propel, we have created a new vision for the way gas stations serve the mobility needs of a community, one that meets the changing habits of America’s drivers. Earlier this year, we launched our first ‘Clean Mobility Center’ in Fullerton, California, to offer consumers new, more sustainable, domestic fuel and transportation choices that are more in line with their values, and also reduce our collective impact on the environment while supporting local economies and decreasing our nation’s reliance on foreign oil.
Our Clean Mobility Centers provide a distinctly different customer fueling experience, offering a full range of high performance renewable fuels (Flex Fuel E85, biodiesel) alongside the conventional gasoline that drivers use today. More than 17 million cars on American roads can fuel with something besides oil, and for those that can’t, we provide drivers an opportunity to be part of the solution and a movement towards clean mobility.
With a focus beyond fuel, our Clean Mobility Centers also offer a series of unique, community-friendly features not found at any other gas station in the nation. To maximize fuel economy, we offer free air to fill-up vehicle tires and we have installed bike repair stations so cyclists can tune up and fix bikes along their route. Additionally we have kiosks that provide local bus and other mass transit maps and routes, along with information about rideshare opportunities. Finally, we have two new features at the fueling island: recycling on the go, and the nation’s first carbon offset program, which for only $1 per fill-up allows drivers to offset the carbon emissions from their purchase right at the pump and support local clean energy projects.
Looking forward, as new, even more sustainable fuels and transportation options come to market, we’ll use the infrastructure we’re building today to offer new choices. In fact, we’re actively exploring options such as renewable gasoline and diesel, cellulosic fuels, algae-based fuels, natural gas, EV charging, and car sharing.
Just as we’ve seen in other industries, such as manufacturing labor, fair trade practices, or organic agriculture, consumer choice can be the biggest force for change in our society. At the pump, consumers can now vote with their wallets and choose a fuel company that better aligns with their values and interests. No matter what type of car they drive, consumers can use our new stations and learn about cleaner mobility options along the way. With 160,000 outlets and regular contact with customers, the fueling industry is in a unique position to engage consumers and lead them to a brighter future. So far, though, our industry hasn’t shown much leadership. America’s transportation needs are changing, and we believe it’s time our gas stations changed, too.
Matt Horton is CEO of Propel Fuels, www.propelfuels.com
The development and growth of the U.S. ethanol industry over the course of several decades has had concrete impacts on every day Americans. It is helping more than 400,000 of our friends and neighbors find work or keep the jobs they have. It is putting money back into consumers’ pockets by lowering gas prices by a national average of more than $1.00 and reducing the average American’s household gasoline bill by $1,200. Ethanol is now ten percent of America’s fuel supply and 25 percent of all the motor fuel produced from domestic resources, reducing our dependence on foreign oil and increasing our national security.
America consumes approximately 135-140 billion gallons of gasoline a year. More than 95 percent of those gallons were blended with ethanol, predominantly E10 (10 percent ethanol, 90 percent gasoline). America’s new fuel, E15 (15 percent ethanol, 85 percent gasoline), a cheaper and higher octane fuel than E10, is beginning to gain momentum in the marketplace.
Kansas, Iowa and Nebraska now have E15 being sold to model year 2001 and newer vehicles at a total of nine stations. E15 is approved for more than 65 percent of all vehicles on the road today, which consume about 80 percent of all unleaded fuel sold. Thus far, E15 sales have been nearly 20 percent of all sales at each station offering it today, quickly outpacing traditional premium volumes.
The Renewable Fuels Association (RFA) is working in various states to remove the state level hurdles restricting the sale of E15. There are many fuel retailers and marketers nationwide who have been misinformed on costs, liability, and consumer demand revolving around E15. The RFA continues to correct this information by educating on why they should consider offering E15 and what the benefits are.
This includes the development of an E15 business case that will show impact to the bottom line for retailers considering adding this new product. Through a joint effort of the RFA and the American Coalition for Ethanol (ACE), the Blend Your Own (BYO) Ethanol Campaign is also offering to educate retailers and marketers on E15, MLEBs, E85, and blender pumps through station visits and free online webinars.
The RFA is working diligently with the petroleum industry, gas retailers, automakers, and consumers to ensure E15 is used properly. RFA developed a model Misfueling Mitigation Plan (MMP) as required by the Environmental Protection Agency (EPA) for education and outreach on E15 and focused on the prevention of illegal use of E15 by consumers. This is the only EPA approved MMP and was deemed as sufficient on March 15, 2012. E15 Stakeholders can choose to adopt RFA’s model plan by notifying EPA of their intentions utilizing the RFA’s E15 retail and consumer resources.
Additionally, RFA has developed the E15 Retailer Handbook for evaluating existing infrastructure compatibility, safety and conversion practices, and state specific regulatory requirements. Specifically, the handbook offers guidance regarding: Federal regulatory requirements including blender registration, octane posting, proper pump labeling, compliance with an EPA approved fuel survey and OSHA regulations; state and local fuel and safety regulations; E15 conversion guidelines for fueling infrastructure; retail conversion procedures; E15 fuel specification and properties; transportation and storage requirements; and safety and firefighting procedures.
E15 remains the most tested fuel ever approved by EPA and is perfectly safe and effective for approved engines. Adding this fuel option to the marketplace allows consumers to make the decision of which fuel works best for them and their vehicle. Allowing for additional ethanol-blended fuel use will help to lower gas prices, create domestic jobs, reduce oil dependence, and accelerate the commercialization of new biofuel technologies.
Robert White is Director of Market Development at the Renewable Fuels Association, www.ethanolrfa.org
