Ethanol Considerations and The Future of Aviation Fuels

1. Ethanol Considerationsand The Future of Aviation Fuels

2. The fuels we will use today and in the future will not be the same as the ones we used even last year. Automobile gasoline formulation is changing greatly 100LL will be a fuel of the past, just as leaded automotive gas is today

3. WHAT ARE SOME OF THE REASONS FOR CHANGE?

4. The mandated use of Ethanol has increase greatly in the US and is now being required in European auto gasoline's. There is significant pressure throughout the world to find alternatives to gasoline and jet fuels. There is only one supplier of tetra ethyl lead left in the western world Leaded automotive fuels are no longer used in, North America, Europe, Australia, New Zealand and some parts of South America, Asia and Africa.

5. Starting in 2000 North American , European, Japanese and Korean new car production became exclusively unleaded vehicles. World wide use of 100LL is declining, causing production and distribution costs to rise EPA wants eventual end to use of leaded fuel

6. Last year the government: Removed the oxygenate requirement for reformulated fuels (Meaning Ethanol was no longer mandated in reformulated gasoline) Added a requirement that a minimum amount of ethanol be used gasoline sold in the US The result is that more automotive gasoline contains Ethanol than ever before. One hand gives the other takes away

7. Engines For most non-injected aircraft engines there are nomajor issues. Airframes Most if not all aircraft fuel systems have major issues with fuels containing ethanol. FAA says do not do use it. SAIB CE-07-06 October 27, 2006 What are the Issues with Ethanol?

8. Common misconception that aircraft engines in general have problems with gasoline's that contain ethanol Use of ethanol in gasoline does pose material compatibility issues for some fuel injection components Fuel flow is a significant issue as it must be increased as the amount of ethanol added increases Oil “washing” is a concern particularly for engines that are not operated for extended periods of time. Accumulation of water in engine crankcase an issue for two stroke engines that are not operated often. ENGINES

9. Material compatibility ethanol Vapor Lock Phase separation Water Temperature Octane lost (leading to detonation) Material compatibility with water/ethanol mix Cleaning AIRFRAME

10. Adversely affects the volatility of auto gasoline, which could cause vapor lock. Is corrosive and not compatible with rubber seals and other materials used in aircraft, which could lead to fuel system deterioration and malfunction. Is subject to phase separation, which happens when the fuel cools as an aircraft climbs to higher altitudes. When the alcohol separates from the gasoline, it may carry water that has been held in solution and that cannot be handled by the sediment bowl. Reduces the energy content of fuel. Methanol has approximately 55 percent of the energy content of gasoline, ethanol 73 percent. More alcohol equals reduced range. The FAA cites numerous reasons alcohol and airplanes do not mix. Alcohol:

11. No not think you are OK just because you have not had a problem yet. Except for vapor lock ethanol related issues occur over time Effects of Ethanol takes time

16. Autogas is generally sold with 10% or 85% ethanol. For conventional type certified aircraft testing has indicated that 3% ethanol is the maximum an aircraft system can safely handle. Ethanol

17. Always test for Ethanol Do not store fuel for long periods When you buy it use it Do not store fuel in metal containers If you do not have a sump drain add one Use your sump drains Consider using an aircraft style gascolator Experimental and LSA aircraft can mix 100LL and autogas to reduce percentage of ethanol Follow additional maintenance schedule for ROTAX engines using a leaded fuel What should you do

18. Using a glass or chemical resistant plastic (such as TPX) container, mark ten equally spaced volumes. A graduated cylinder is ideal; however, a non-tapered glass jar, such as a large (quart) olive bottle, will work.  Add one part water (approximately 100 ml) into the container, fill to the first mark, and then add nine parts (approximately 900 ml) of automobile gasoline, fill to the top mark. Shake thoroughly, let stand for 10 minutes or until automobile gasoline is again bright and clear. Mark the apparent level of the line between the automobile gasoline and water. If alcohol is present, the water will absorb it, and the amount of water will appear to increase. Testing for Ethanol

19. Fuel Test Kit (15$ from EAA)

20. When you start talking numbers at the end of the presentation it can be a little confusing. Like 91/97, 98-108 MON, 91 grade, 87 UL mean what, octane, MON, RON, AKI. You know this all get a little confusing. Another question you might face is I have a 912, Rotax says when using 100LL you have increased lead deposits which are bad, what is the lesser of 2 evils, using autogas with alcohol or using 100LL? That is a tough one that you can not answer but I have had that question over the phone. Some of the ultralight/light plane fuel tanks are fiberglass with polyester resin and the alcohol is a real problem for these. Suggestion for those that have no choice but to use alcohol autogas is to completely disassemble and inspect/clean/replace as appropriate, fuel system every 6 months. Another suggestion for 2-cycle engines is to use mineral based oil instead of synthetic based oil. Mineral based oil is typically 50:1 where as synthetic is 100:1, twice as much mineral oil coating internal engine components while the engine is in the hangar. Also, mineral based oil clings better to surfaces, synthetic has lower coefficient of friction and will not cling to part as well, when the engine is in the hangar.

21. Regular autogas will continue to have high levels of ethanol Unleaded Aviation fuels have been developed Market place will drive changes LSA’s are starting to be a market factor Increased use of jets putting pressure on remainder of fleet to transition to unleaded fuel What is in the future

22. ASTM International is involved with writing the new fuel specifications The Coordinating Research Council (CRC) is helping organize basic research on new fuels components Who are the Players

23. The same organizations belong to both ASTM and the CRC fuel groups EAA, FAA, ROTAX, Cessna, Ethyl, ExxonMobil, TEXACO, Philips, AIRBP, and Chevron are currently the most active participants Recently proponents for an Aviation E85 fuel have also become much more engaged

24. Fuel components being examined as a replacement for lead include:-Ethers (MTBE, ETBE)-Amines -MMT (Ethyl corp)-Ethanol

25. AKI, MON, RON, Rich Ratings, 100/130, 80/87, 82UL, 100LL What does all this mean to you? A Short lesson on Numbers

26. HOW MUCH TIME DO WE HAVE UNTIL WE SEE THESE NEW FUELS?

27. No one knows for sure 82 Grade is available 91/98 Grade Aviation Gasoline can be made unleaded Autogas is no longer the safe alternative for the low end of aviation (ultralights, homebuilt, Katana type trainers) 100LL will go away

28. WHAT HAS BEEN DEVELOPED TO DATE?

29. A Swedish refiner is selling 91/97 unleaded aviation gasoline Oil companies have unleaded test fuels available in the 98 to 108 MON range GAMI is developing engines controls they hope will allow the most demanding opposed engines to operate on 91 grade fuel Cessna has successfully developed and flight tested a ETBE fuel. E85 Ethonal based fuel has been STC’ed. EAA, Cessna and ROTAX working on a new 87 UL aviaiton gasoline based on premium autogas.

30. EAA autogas STC website www.aviationfuel.org EAA SPORT PILOT MAGAZINE June 2006 “Power On” Ethanol and Rotax Engines by Phillip Lockwood. References