Cash Cow

US project seeks to make the family car a cash cow

AFP/Karras Photography-HO – US researchers unveiled this converted Toyota Scion xB, seen here at the annual meeting of the American …

by Karin Zeitvogel – Fri Feb 19, 9:15 am ET

SAN DIEGO, California (AFP) – US researchers unveiled a vehicle Thursday that earns money for its driver instead of guzzling it up in gasoline and maintenance costs.

The converted Toyota Scion xB, shown at the annual meeting of theAmerican Association for the Advancement of Science here, is the firstelectric car to be linked to a power grid and serve as a cash cow.

"This is the first vehicle that's ever been paid to participate in the grid -- the first proof of concept vehicle," Ken Huber, who overseestechnological development at wholesale electricity coordinator PJM Interconnection, told AFP.

The presentation of the box-like, unassuming looking Scion was the researchers' way of introducing the "vehicle-to-grid" (V2G) concept as it begins to gain momentum in the United States and around the world.

V2G projects with hybrid cars that use electricity and gas to store energy in their batteries and feed it back into the power grid are up and running in the United States, and the drive now is to produce all electric vehicles to plug into the power grid.

"This makes the car useful not only when it's being driven, but also when it's parked, as long as you remember to plug it in," said Willett Kempton, who is leading a V2G project at the University of Delaware.

A V2G car is connected via an Internet-over-powerline connection that sends a signal from inside the car's computer to an aggregator's server.

The aggregator acts as the middleman between the car owner and power grid management companies, which are constantly trying to keep electricity output at a constant level.

When the grid needs more power due to a surge in demand, power companies usually draw from traditional power plants, which in the United States are often coal-fired and leave a large carbon footprint.

When V2G becomes more widespread, the power could be drawn from millions of vehicles plugged into sockets in home garages or from commercial fleets, such as the US Postal Service's vans, for a much smaller footprint than that of the power plants.

Grid management companies like PJM Interconnection currently pay around 30 dollars an hour when taking power from a car.

V2G is still a new concept, but it is gaining ground in the United States and Europe.

"Ten years ago, this was just a plan. Today, it's a real project and in 10 years, we'll be producing tens of megawatts of power this way," said Kempton, adding that V2G will readily find applications in countries that are rapidly ramping up reliance on wind and solar energy, such as Denmark and Britain.

Huber said he will be meeting in the coming weeks in Paris with heads of European grid management companies about V2G.

"We're going to try to determine how we can work together on this. It's a technology that is very good at meeting a need we have, and there's growing interest among auto companies to develop V2G vehicles," he added.

AC Propulsion of California has designed an electric drive system for V2G, and car manufacturers including Renault/Nissan, Mitsubishi and BMW are producing all-electric vehicles with an eye on the V2G market.

Wheat Straw

Reducing Petroleum Use by Using Wheat


November 12, 2009

Small changes can make huge difference. Consider a plastic storage bin. By using wheat straw-reinforced plastic rather than 100-percent traditional petroleum products, it is estimated that petroleum use will be reduced by approximately 20,000 and CO2 emissions will be reduced by approximately 30,000 pounds per year.

The first application of the natural fiber-based plastic that contains 20-percent wheat straw bio-filler is on the 2010 Ford Flex's third-row interior storage bins. Ford is already considering using the environmentally-friendly technology in the construction of center-console bins and trays, interior air registers, door trim panel components and armrest liners.

Ford's sustainable materials portfolio also includes soy-based polyurethane seat cushions, seatbacks and headliners; post-industrial recycled yarns for seat fabrics; and post-consumer recycled resins for underbody systems, such as the new engine cam cover on the 2010 Ford "Ford continues to explore and open doors for greener materials that positively impact the environment and work well for customers," said Patrick Berryman, a Ford engineering manager who develops interior trim. "We seized the opportunity to add wheat straw-reinforced plastic as our next sustainable material on the production line, and the storage bin for the Flex was the ideal first application."

Collaborative effort

Ford researchers were approached with the wheat straw-based plastics formulation by the University of Waterloo in Ontario, Canada, as part of the Ontario BioCar Initiative – a multi-university effort between Waterloo, the University of Guelph, University of Toronto and University of Windsor. Ford works closely with the Ontario government-funded project, which is seeking to advance the use of more plant-based materials in the auto and agricultural industries.

The University of Waterloo already had been working with plastics supplier A. Schulman of Akron, Ohio, to perfect the lab formula for use in auto parts, ensuring the material is not only odorless, but also meets industry standards for thermal expansion and degradation, rigidity, moisture absorption and fogging. Less than 18 months after the initial presentation was made to Ford's Biomaterials Group, the wheat straw-reinforced plastic was refined and approved for Flex, which is produced at Ford's Oakville (Ontario) Assembly Complex.

The wheat straw-reinforced resin is the BioCar Initiative's first production-ready application. It demonstrates better dimensional integrity than a non-reinforced plastic and weighs up to 10 percent less than a plastic reinforced with talc or glass.

"Without Ford's driving force and contribution, we would have never been able to move from academia to industry in such lightning speed," said Leonardo Simon, associate professor of chemical engineering at the University of Waterloo. "Seeing this go into production on the Ford Flex is a major accomplishment for the University of Waterloo and the BioCar Initiative."

An interior storage bin may seem like a small start, but it opens the door for more applications, said Dr. Ellen Lee, technical expert, Ford's Plastics Research.

"We see a great deal of potential for other applications since wheat straw has good mechanical properties, can meet our performance and durability specifications, and can further reduce our carbon footprint – all without compromise to the customer."

Abundant waste material put to good use

The case for using wheat straw to reinforce plastics in higher-volume, higher-content applications is strong across many industries. In Ontario alone, where Flex is built, more than 28,000 farmers grow wheat, along with corn and soybeans. Typically, wheat straw, the byproduct of growing and processing wheat, is discarded. Ontario, for example, has some 30 million metric tons of available wheat straw waste at any given time.

"Wheat is everywhere and the straw is in excess," said Lee. "We have found a practical automotive usage for a renewable resource that helps reduce our dependence on petroleum, uses less energy to manufacture, and reduces our carbon footprint. More importantly, it doesn't jeopardize an essential food source."

To date, Ford and its suppliers are working with four southern Ontario farmers for the wheat straw needed to mold the Flex's two interior storage bins.

History in the making

Ford's interest in wheat dates back to the 1920s, when company founder Henry Ford developed a product called Fordite – a mixture of wheat straw, rubber, sulphur, silica and other ingredients – that was used to make steering wheels for Ford cars and trucks. Much of the straw used to produce Fordite came from Henry Ford's Dearborn-area farm.

The company's new-age application for wheat straw joins other bio-based, reclaimed and recycled materials that are in Ford, Lincoln and Mercury vehicles today, including:

• Soy-based polyurethane foams on the seat cushions and seatbacks, now in production on the Ford Mustang, Expedition, F-150, Focus, Escape, Escape Hybrid, Mercury Mariner and Lincoln Navigator and Lincoln MKS. More than 1.5 million Ford, Lincoln and Mercury vehicles on the road today have soy-foam seats, which equates to a reduction in petroleum oil usage of approximately 1.5 million pounds. This year, Ford has expanded its soy-foam portfolio to include the industry's first application of a soy-foam headliner on the 2010 Ford Escape and Mercury Mariner for a 25 percent weight savings over a traditional glass-mat headliner.
  
• Underbody systems, such as aerodynamic shields, splash shields and radiator air deflector shields, made from post-consumer recycled resins such as detergent bottles, tires and battery casings, diverting between 25 and 30 million pounds of plastic from landfills. The newest addition is the engine cam cover on the 3.0-liter V-6 2010 Ford Escape.
  
• 100 percent post-industrial recycled yarns in seat fabrics on vehicles such as the Ford Escape. The 2010 Ford Fusion and Mercury Milan Hybrids feature 85 percent post-industrial yarns and 15 percent solution-dyed yarns. The 100 percent usage represents a 64 percent reduction in energy consumption and a 60 percent reduction in CO2 emissions.
  
• Repurposed nylon carpeting made into nylon resin and molded into cylinder head covers for Ford's 3.0L Duratec engine. The industry's first eco-friendly cylinder head cover is currently found in the 2010 Ford Fusion and Escape vehicles.
  

About the Ontario Bio-Car Initiative

The Ontario Bio-Car Initiative represents a partnership between the automotive industry and the public sector, aimed at accelerating the use of biomass in automotive materials.