Illustration: sean mccabe; original photo:
renata ursaia
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Silverio Bonfiglioli of Magneti Marelli in Brazil
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The hot asphalt of the test track stretches ahead. I
stomp on the accelerator of the Fiat Siena and shift
swiftly through the gears. The engine roars, the wind
whooshes. A flock of quero-quero birds lazing nearby in
the scorching Brazilian sun shriek in protest.
You’d never know it by looking at this peppy white
sedan—or even by driving it—but it is one special little
vehicle. When it comes to fuel, it is the most flexible
car on earth. The Siena carries both natural gas and a
mixture of gasoline and ethanol. It will burn the
natural gas—the cheapest car fuel in Brazil—while
cruising, and it will switch on the fly to the liquid
fuel mix whenever it needs more power, for example, when
passing another car or going up a hill.
And here’s the best part: you can put any mixture of
gasoline and ethanol into its tank—from 100 percent
gasoline and no ethanol to 100 percent ethanol and no
gasoline. The engine automatically adjusts its ignition
timing and the quantity of fuel injected into the
cylinders on each cycle to get the most power out of
whatever mixture you’ve got while keeping emissions
under control.
Cars that can use different mixes of gasoline and
alcohol have been around for years. And vehicles that
let the driver switch between natural gas and gasoline
aren’t new, either. But one car that can do
both—switching automatically between the fuels and
adjusting its engine to suit an arbitrary
gasoline-alcohol mix—that’s very new indeed.
“The concept is very powerful, and it certainly is
portable,” says William L. Sharfman, an automotive
expert and principal of Sharfman & Co., a strategic
consulting firm in New York City. “Once you have the
concept, it’s probably applicable to other kinds of
fuel.”
What the Experts Say
T.J. RODGERS: Hitler’s Mercedes ran on either
diesel or gasoline. Where’s the
innovation?....Electric cars can already run on
about one‑third of the cost of gasoline and with
much less pollution.
As concerns about high oil prices and greenhouse-gas
emissions drive legislation that is pushing demand for
such alternative fuels as ethanol to record levels in
many countries, the allure of such an engine isn’t hard
to fathom. Sitting next to me, in the passenger seat of
the Siena, automotive engineer Alfredo Silvio Castelli
considers the many fuel mixtures taking hold around the
world and asks, “Why choose one if you can have all of
them?”
Castelli is the head of the experimental laboratory
here at the Brazilian unit of Magneti Marelli, in
Hortolândia, an hour and a half drive from São Paulo.
Marelli, a ¤4 billion subsidiary of the Fiat Group, is
one of the world’s largest manufacturers of automotive
systems, supplying fuel-injection modules, robotized
gearboxes, and onboard electronics to automakers and
racing teams worldwide. Headquartered in Milan, Marelli
has industrial and R&D facilities in 15 other
countries, and it was a team of the company’s engineers
here in Brazil that created the engine controller that
lets the Siena run on multiple fuels.
Fiat recently began selling, in Brazil only, a version
of the Siena with Marelli’s system. The car’s 1.4-liter,
four-cylinder engine has one set of injectors for the
liquid fuel and another for the natural gas. The
liquids are stored in a 48-L conventional tank, the
compressed natural gas in two 6.5‑cubic-meter cylinders
in the trunk. Marelli calls the system TetraFuel; it’s a
reference to the fact that it can run on pure gasoline,
pure ethanol, gasohol (in Brazil, a gasoline mix with 20
percent ethanol), or straight natural gas.
Marelli says that the TetraFuel system lets an average
driver cut fuel expenses by 25 percent to 40 percent
compared with an ordinary gasoline-powered car. Of
course, the savings depend on the relative costs of
ethanol and natural gas—both of which, as it happens,
have been high in North America and Europe lately.
Reductions in carbon dioxide, however, are independent
of market forces. According to tests Marelli conducted,
a TetraFuel car running on ethanol emits, on average,
12 percent less CO2 than when it runs on gasoline; with
natural gas, the reduction reaches 24 percent.
Still, the question hangs like a midafternoon haze
over São Paulo: In an automotive sector that seems
increasingly convinced that its future is in hybrids,
electrics, and even fuel-cell cars, is there room for an
alt-fuel vehicle whose technological breakthroughs are
all in software and electronics rather than in batteries
and ionic membranes?
Without a doubt, the economics are enticing. Consumers
could be liberated from dependence on a single fuel and
its price oscillations. Ethanol, natural gas, and other
alternative fuels could become more attractive despite
their much smaller distribution networks, because
drivers would know they could always turn to gasoline if
they found themselves in a place where they couldn’t get
the other options.
Put it all together and multifuel technology starts
looking like a bridge from petroleum to other possible
technologies and fuels, such as bioethanol from
cellulose waste. And it would let automakers keep making
internal combustion engines, something they’ve gotten
very good at during the past century.
Taking stock of the various electric and partially
electric drivetrains that now dominate automotive
R&D, Silverio Bonfiglioli, president and CEO of
Marelli’s power-train division for North and South
America, says, “Those are alternatives, sure. But not
for now. The alternatives available today at low cost
and large scale are biofuels: ethanol and biodiesel.”