FLEX FUEL PROTOTYPE

1. Context

• Recently, Toyota introduced a groundbreaking prototype in India, the Innova Hycross, featuring a flex-fuel hybrid powertrain.
• This marks a significant milestone as it becomes India's first car with such an option.
• Additionally, Toyota claims it to be the world's first BS6 Stage II-compliant flex-fuel vehicle.
• This move aligns with the Indian government's efforts to promote and deploy this technology commercially, joining countries like Brazil, Canada, and the United States where flex-fuel vehicles are already in use.

2. About the Innovative Hybrid Powertrain

• The Innova Hycross prototype boasts a 2-litre Atkinson Cycle petrol engine combined with an electric motor, mirroring the hybrid version of the standard Hycross model.
• This groundbreaking vehicle can run on petrol with over 20% ethanol blending, in compliance with Indian mandates.
• Remarkably, it maintains performance levels on par with the standard Hycross hybrid, even with ethanol-blended petrol.
• Toyota also asserts that it achieves low carbon emissions when considering the entire well-to-wheel process.
• Moreover, it operates in electric vehicle mode, drawing power from the battery pack for approximately 60% of the time.
• Currently, multiple units of the flex-fuel prototype will undergo testing in India. The upcoming steps encompass further calibration, homologation (certification of roadworthiness), and formal certification.

3. About Flex-Fuel Technology

• Flex-fuel vehicles are designed to run on multiple types of fuel or fuel mixtures, distinguishing them from conventional petrol-only cars.
• Most commonly, these vehicles use a blend of petrol and ethanol or methanol.
• The crucial feature enabling this flexibility is the integration of a fuel mix sensor and an engine control module (ECM) programmed to sense and adjust to various designated fuel ratios.
• This technology facilitates the use of ethanol blends exceeding the standard 20% mix (E20).
• The government has emphasized that promoting flex-fuel engines aligns with the broader strategy of reducing India's reliance on imported crude oil in the medium-to-long term.

Image Source: AFDC

4. Mechanical Modifications for Flex-Fuel Vehicles

• Flex-fuel vehicles share many components with conventional petrol cars, but certain modifications are essential to accommodate different fuel properties.
• These may include adjustments to the fuel pump, fuel injection system, and ECM calibration.
• Additionally, hybrid engines like the one in the Toyota Hycross feature specific enhancements such as separate spark plugs, piston ring tops, valves, and exhaust system catalysts to mitigate corrosion and lower hydrocarbon emissions.

5. Flex-Fuel Pros and Cons

• Ethanol blending in flex-fuel vehicles results in reduced harmful pollutants and decreased oil imports.
• However, it can lead to decreased fuel efficiency, typically experiencing a 4-8% reduction when using ethanol.
• Ethanol blending also poses challenges related to water-intensive source crops, such as sugarcane.

6. Biofuel Policy and Blending Targets

• India's National Biofuel Policy 2018 has set a 2025 target of achieving a 20% blending rate for ethanol in petrol.
• Brazil, a leader in the flex-fuel segment, adjusts fuel blend ratios based on crude oil prices.
• Brazil's vehicular fleet is equipped to handle higher ethanol blends, and the government offers subsidies to bridge the cost gap between ethanol and pure petrol.
• Ethanol blending in India has risen significantly in recent years, contributing to substantial reductions in oil import bills.
• It is estimated that the expected implementation of E20 by April 2025 could result in annual savings of Rs 35,000 crore in India's oil import expenses.

7. Conclusion

• The flex-fuel Innova Hycross prototype is a significant development in India's efforts to reduce its reliance on imported oil.
• The prototype offers the advantages of both a flex-fuel engine and an electric powertrain, which could help to improve fuel efficiency and reduce emissions.