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Audi tries synthesizing fuel

Tesla is trying to convert the world to the electric car. The Japanese are pushing hydrogen. But Audi, the German carmaker, has a different idea. It’s trying to synthesize fuel from the simplest of elements – water, carbon dioxide and solar energy.

Audi’s research facility in Dresden has produced what the company calls an e-diesel – a net-zero-carbon-footprint fuel made from carbon dioxide and water. The company announced the project to great fanfare on April 21. In May, it unveiled another advance – e-benzine, a fuel that acts just like gasoline.

The two are the latest of a suite of six fuels developed by Audi that behave just like traditional gasoline or diesel, but burn without releasing any sulfur or aromatic hydrocarbons, the stuff that produce air pollution. The fuels also can be labeled as carbon-neutral, since the carbon dioxide they’re removing from the atmosphere perfectly matches the CO2 they put back in when they burn. E-benzine currently derives its carbon from organic material – biofuels made from rapeseed, sunflower oil or corn. But Audi officials say they soon hope to switch to atmospheric carbon dioxide.
“To me, this is a historic moment,” said Marc Delcourt, CEO of Global Bioenergies, the French company that is partnering with Audi on the e-benzine project. “It is the first time that we have produced real gasoline from plants.”

The e-diesel process works like this: Audi begins by splitting water by electrolysis into hydrogen and oxygen. The electricity is provided by wind or solar energy, which makes it completely fossil-fuel free. The oxygen is released into the atmosphere. Meanwhile, Audi filters carbon dioxide out of the atmosphere. The C02 is stripped down to carbon monoxide, and the CO and hydrogen are then mixed together under high pressure to produce a long-chained hydrocarbon that Audi calls “blue crude.” It has all the properties of crude oil and can be refined down to commercial fuels like e-diesel. “We’re thinking we’re bringing green-ness to a field that desperately needs green-ness,” said Rick Bockrath, vice president for chemical engineering at Global Bioenergies. “It’s basically how we’re moving away from an oil-based economy towards something that has a renewable, sustainable future to it.”

Johanna Wanka, Germany’s Minister of Education and Research, attended the ceremony at which the first batch of Audi e-diesel, five liters’ worth, was put into her official car, an Audi A8 3.0 TDI clean diesel Quattro (that’s her in the photo above). “This synthetic diesel, made using CO2, is a huge success for our sustainability research,” she said. “If we can make widespread use of CO2 as a raw material, we will make a crucial contribution to climate protection and the efficient use of resources, and put the fundamentals of the ‘green economy’ in place.”

The product has a 100 octane rating and can be used either as an additive or as a stand-alone fuel. Audi says cars run much smoother on the product because of the lack of aromatic compounds, sulfur and other impurities. It also converts to energy at 70 percent efficiency, which is much better than regular diesels.

Audi’s pilot project in Dresden is currently producing 160 liters of e-diesel per day. Obviously, that isn’t enough to shake the world. But the long-term plan is to scale up to a level that will make the product available to the public. The estimated price will be 1 to 1.5 euros per liter, which comes to about $3.75 per gallon. This would not offer any price advantage in the United States, where diesel is selling at $2.88 per gallon, but it would be competitive in Europe, where diesel currently sells for about 1.4 euros per liter.

The problem with all such inventions, of course, is whether they can scale up at a price that remains competitive. Robert Rapier, the highly respected energy analyst, is skeptical. In a lengthy piece in GreentechMedia, Rapier did a step-by-step analysis, including all the chemical reactions. He concluded that the price is going to be $3.76 per gallon, which would put it above the current price of diesel in the United States, but perhaps not in Europe. But that doesn’t include any price increases that may come with scaling up the process. In addition, several critics have wondered whether solar and wind electricity will be available on a scale capable of supporting such a commercial operation.

“To sum up, can Audi produce fuel from thin air? Sure. There is no question about technical viability,” Rapier wrote. But “The question boils down to economic viability, which appears to be challenging given what has been released about the process.”

All this doesn’t mean Audi shouldn’t continue experimenting. There’s always room for improvement, and there may be other breakthroughs down the road. A carbon tax would also benefit the process, particularly if Audi could be given credit for the carbon it takes out of the atmosphere. There is also the possibility of combining the procedure with a carbon-capture and storage operation at a fossil-fuel plant, where carbon dioxide is currently regarded as a noxious waste material.

A system that would manufacture automotive fuel out of carbon dioxide in the atmosphere would be like the philosopher’s stone of the transport sector. Audi should keep trying.

(Photo credit: Audi)

The journey of a thousand miles, replacement fuels and FFVs

The headlines recently have been terrible — a commercial plane was shot down over the Ukraine, there’s war in the Middle East and more. It makes you wonder, over and over again, about man and woman’s inhumanity to his or her fellow men and women.

While certainly not equal in impact on the world at the present time, I happened to run across one point of light concerning a set of innovations which, in the long run, could positively impact climate change, security and consumer choice issues. It was reflected in a couple of articles describing the partnership between the state of California’s Energy Commission and Cummins Engines to develop an E85-fueled engine that apparently cuts Co2 by up to 80 percent (read it in Fleets and Fuels) in medium-duty trucks.

According to Cummins Engines and the Commission, a relatively small 4-cylinder, 2.8-liter engine has been successfully subjected to 1,000 miles and 1,500 hours of testing. It is now going through validation tests in Sacramento.

The story is a welcome one. Cummins indicates that the engine can generate 250 horsepower and 450 pound-foot of torque using E85. “Using lignocellulosic-derived E85, the powertrain’s efficiency features 75 to 80 percent lower well-to-wheels carbon emissions than gas engines; depending on the drive cycle…Cellulosic E85 is not derived from tilling, fertilizing and harvesting corn…Using corn-derived E85, the high thermal efficiency and power-to-weight ratio of this engine results in 50 to 80 percent lower well-to-wheels carbon emissions compared with the gasoline engine.”

Based on the Cummins documentation, California’s Energy Commission indicates “that successful completion of the project may result in a new market for E85 fuel now dominated by gasoline and diesel in the 19,500 lb. step-van fleet market.” The agency estimates greenhouse-gas savings as great as 69 percent, or 10 to 20 percent using corn based ethanol.

Fortunately, the general principles guiding development of Cummins’ engine may help improve flex-fuel automobiles and grant Americans more confidence in the environmental, price and economic benefits associated with extended use of E85.

Lessons learned may increase the nation’s ability to reduce GHG emissions. Based on what Cummins has done, using smaller engines extends the benefit of E85. Diesel-like cylinder pressures are important. Ethanol’s high-octane rating generates more engine efficiency. Use of state-of-the art sensors for spark ignition and coordination of stop-and-start functions enhances efficiency and reduces emissions. E85 is clearly a safe fuel.

The knowledge gained from the Cummins effort could lead to better flex-fuel vehicles and could support the effort to use increased technology fixes for older, non-flex-fuel cars and FFV twins. Perhaps the biggest benefit from the partnership between California and Cummings relates to the boost it could give to the search for replacement fuels, as well as the myth-busting understanding it could provide consumers about the safety of E85. It is a safe fuel, assuming engine adaptation and software amendment.

Elon Musk’s proposal to share Tesla’s electric-car patents and ideas might at least encourage increased collaboration among FFV makers in Detroit and the potential players in the conversion industry that likely would emerge, subsequent to EPA testing and approval of older vehicles for conversion. Even improved cooperation at the margin would could expand production of new FFV vehicles and expand conversion of older vehicles. For automakers and makers of conversion kits, as well as developers of FFV software technology, successful collaboration would generate larger markets.

Increased use of E85 through conversion of existing cars and the increased production of new FFV vehicles would help meet national and local environmental objectives, reduce gasoline prices and provide consumers with lower fuel costs, apart from gasoline. Both would also reduce dependency on foreign oil. Paraphrasing the poet Robert Frost, while FFVs — new or converted — are on a road less traveled now, as John F. Kennedy indicated, the journey of a thousand miles must begin with one step. The road less traveled now has more replacement-fuel drivers and FFVs than ever. Because of this fact, the journey of a thousand miles toward alternative fuel choices has made progress and, hopefully soon, will move at a faster speed. Success will mean a better quality of life for us all. It’s good news!

Image credit: Wikimedia commons