Compatibility Study for Plastic, Elastomeric, and Metallic Fueling Infrastructure Materials Exposed to Aggressive Formulations of Isobutanol-blended Gasoline
The Energy Independence and Security Act (EISA) of 2007 is an omnibus energy policy law designed to move the United States toward greater energy security and independence. A key provision of EISA is the Renewable Fuel Standard (RFS), which requires the nation to use 36 billion gallons per year (BGPY) of renewable fuel in vehicles by 2022. Ethanol is the most widely used renewable fuel, and increasing the allowable ethanol content from 10% to 15% is expected to push renewable fuel consumption to as much as 21 BGPY. Therefore, a large portion of the 36 billion gallon requirement can be met by increasing the ethanol content in gasoline to 15%. However, raising the ethanol content to 15%, by itself, will still not fully meet the RSF requirement, and concerns have been raised that this increase in ethanol may not be entirely compatible with current and legacy materials used in standard gasoline fueling systems. In the summer of 2008, the U.S. Department of Energy (DOE) recognized the need to assess the impact of intermediate blends of ethanol on the fueling infrastructure, specifically those systems located at the fueling station. A short time later (March 2009), Growth Energy (a coalition of ethanol producers and supporters) requested a waiver from the U.S. Environmental Protection Agency (EPA) to allow the use of 15% ethanol in gasoline. In 1981 the EPA approved a waiver (known as the OCTAMIX waiver) that allowed other alcohol types (such as methanol) to be blended with gasoline as long as the resulting fuel blend was substantially similar to gasoline. Another requirement is that the fuel oxygen content cannot exceed 3.7 wt %. Currently, this requirement limits ethanol in gasoline to 10 vol %. The corresponding oxygen equivalent for isobutanol is 16 vol %; therefore, isobutanol offers a pathway towards meeting the RFS requirement by allowing greater biofuel usage than can be achieved by ethanol alone. In fact, the United States has already hit the “blend wall” for ethanol, the point at which virtually all gasoline sold is E10 and no remaining market is left for ethanol, meaning that the country cannot substantially increase ethanol usage unless the EPA allows for higher levels of ethanol or until E85 use is expanded significantly. Butamax Advanced Biofuels, LLC has developed proprietary technologies to convert corn into isobutanol. Much of the infrastructure already existing at ethanol plants can be readily converted to produce isobutanol instead. The focus of this investigation was to compare the compatibility of fueling infrastructure materials (such as elastomers, plastics, and metals) to test fuels representing E10 and E15 and their corresponding oxygen equivalents with isobutanol (iBu16 and iBu24). Butamax sponsored a research project at Oak Ridge National Laboratory (ORNL) to perform empirical studies using aggressive fuel formulations representing 16 and 24% isobutanol. The results contained within this report include a solubility analysis for each material type and fuel formulation and empirical results for elastomers, plastics, and metals. Data obtained from the preceding ethanol compatibility studies on these materials are included for additional interpretation and summary.