Converting Engines, and the E85 Narrative

by Luke Geiver (Ethanol Producer Magazine) Whether Tuomo Isokivijärvi is meeting with venture capitalists in Palo Alto, California, Finland or anywhere else in the world, he’s usually trying to explain how his company’s E85-based conversion kit technology applies to current and future light-duty passenger vehicles. He doesn’t shy away from explaining the limitations of electric vehicles—why EVs alone won’t be able to fulfill the transportation needs of the world anytime soon, despite what many investors have been repeatedly told. And he relays the comparable affordability of the eFlexFuel technology his company, StepOne Tech Ltd., has commercialized over the past decade. Isokivijärvi is quick to explain that adding an eFlexFuel conversion kit to a compatible vehicle achieves the same lifetime emissions reduction as switching to a battery EV—for less than the price of a new smartphone.

Although there are other technology providers offering similar products to StepOne Tech’s eFlexFuel conversion kit, none have taken the steps to push the idea of such ethanol-based technology forward quite like Isokivijärvi. Should it work and catch on, E85 could be heightened to a different status, Isokivijärvi believes, and ethanol’s highest percentage U.S. blend—decades in use and growing, but below full potential—could gain broader appeal as a practical climate solution with the ancillary benefit of saving drivers money at the pump. For that to happen, the collaboration forged, and the progress recently made by StepOne Tech and the U.S. ethanol industry must continue. Here’s what they’ve achieved to date.

Initiating Conversion
Last year, the Renewable Fuels Association purchased a new 2022 Ford Escape plug-in hybrid electric vehicle (PHEV) to display at events across the country. Working with the University of Nebraska’s Husker Motorsports Team, the RFA installed an eFlexFuel conversion kit from StepOne Tech to showcase the capability of the PHEV when fueled with E85. The vehicle is a plug-in hybrid with external charging and an electric motor that powers the vehicle independently from its internal combustion engine (ICE). When the battery is low, ICE capabilities are activated. The electric motor is recharged by regenerative braking during operation. There is an 11-gallon liquid fuel tank, and the range of the vehicle is 420 to 440 miles on a full tank and full charge. The range breakdown starts with 30 to 40 miles on electricity first, followed by 390 to 400 miles on E85. Recharge times vary depending on the power source. On 110v, charge times are typically in the 10 to 11-hour range.

According to the RFA, the association purchased the PHEV and added the E85 conversion kit for several reasons. First, they wanted to prove that low-carbon liquid fuels in combination with hybrid technology can deliver superior environmental performance at a low cost to the consumer. Second, the RFA wanted to show that consumers don't need to sacrifice optionality, convenience or affordability for superior environmental performance. Third, to show what refueling times, refueling locations, vehicle ranges, purchase prices and cost of operation numbers would look like. And, finally, to demonstrate synergies between low-carbon ethanol and electricity. “Ethanol and electricity can be complementary decarbonization solutions,” the RFA stated last year.

In addition to the PHEV roadshow, the RFA has also had the vehicle tested for tailpipe emissions on E10, E85, and splash-blended E30 at the University of California-Riverside’s Center for Environmental Research & Technology. Although tailpipe emissions testing and lifecycle emissions testing is still underway, the results show a significant reduction in NOx emissions with E85, among other findings.

“We expect the study to show that a plug-in hybrid electric FFV running on cleaner, greener E85 can offer comparable or better carbon performance than many battery electric vehicles,” the RFA revealed.

Today, their conversion kits have been used on 55,000-plus vehicles across the world. Their main customers are those focused on engine performance. The octane and power part of E85 is what they’re after. But lately, the emissions piece has been gaining importance.

The California Air Resources Board has granted the company market compliance status for its technology. The tech is already in a half-million Toyotas, and while working with the RFA, the company was recently featured on a popular YouTube video produced by the world’s largest automotive DIY’er, ChrisFix.

eFlexFuel Conversion Tech: What You Get
Included in the eFlexFuel conversion kits, depending on the version ordered, is everything needed for a fully automatic system that can run on E85, gasoline or a combination of the two. Each system is customized to the vehicle with everything included for DIY installation. There are systems for cars and motorcycles. The piggy-back tech doesn’t interfere with the OEM's engine system. Through a smartphone app, the engine can be monitored and run on economy, sport or dynamic modes.

An ethanol sensor is provided that connects to the fuel line and provides real-time ethanol content info. An eFlexFuel control unit, installed to the fuel injectors, controls the fuel injection based on the fuel ethanol content, engine temperature and the fuel injection pulse. The unit maintains perfect air-to-fuel ratios for optimized fuel economy and power output. A thermal sensor, installed on the engine block, provides engine temperature data in real time. (Note: The team at StepOne Tech funded their research for the conversion kit by writing software for other companies).

In addition to the main components, other DIY essentials are supplied, including a user manual with instructions, cable ties, fuel hose, quick couplings, hose clamps and a fuel line release tool. The kit installation on the RFA’s PHEV took roughly an hour. The systems can’t be used on every vehicle, at least not yet, Isokivijärvi says.

The adoption of such technology is taking off in France. And the StepOne Tech team is planning for rapid growth from its current headcount of about 30 employees across the U.S. and Europe.

For those that want to see the cost advantages of installing the system, eFlexFuel has a calculator that allows a user to see how much can be saved over three years of fuel costs and carbon dioxide emissions when a vehicle is converted to E85.

“With our technology, we could move some of these gasoline powered vehicles into this flex fuel category. We could grow that pool bigger and bigger, even though there might be zero factory made flex-fuel vehicles introduced into the market,” he says. Isokivijärvi believes, at the end of the day, there is demand for a solution that can provide the same carbon footprint reduction as a battery-powered EV.

The RFA seems to agree with him, even though testing isn’t yet complete. Low-carbon E85 in combination with hybrid technology can deliver superior environmental performance at a low cost to the consumer, the RFA says. Customers don’t need to sacrifice optionality, convenience or affordability when they choose a PHE/FFV. Vehicles like PHEVs converted to E85 (for less than the cost of a new smartphone) combines the best of both worlds, the RFA says. “Ethanol and electricity can be complementary decarbonization solutions.” READ MORE