Driving Sustainability: On the Road

Focussing on large vehicles, with more than 90% of our production supporting pick-up trucks and long-haul heavy-duty commercial vehicles, we make big climate contributions to big volumes of big vehicles.

Commercial Vehicles

Weight reduction in commercial vehicles enables improved fuel economy, increased payloads, and ultimately, reduced vehicle miles. Every one million Engine Equivalents of SinterCast-CGI heavy-duty engines saves approximately 30,000 tonnes of CO2 per year (How we Calculate: Read more). In the lead-up to 2027 emissions legislation, heavy duty engines are expected to increase operating pressures by 20% and engine efficiency by 10% to meet the new standards. These requirements continue to drive OEMs toward CGI.

According to the Diesel Technology Forum, from 2007 through 2030, current and new designs of heavy-duty engines, many of them using CGI, will save 550 billion litres of fuel and 1.5 billion tonnes of CO2 compared to previous generation trucks. This CO2 savings is equal to taking every passenger vehicle in the US off of the road for one and half years.

Super-Duty Pick-ups

SinterCast-CGI diesel engines provide 20–30% better fuel economy than the nearest available petrol engine and up to 40% better fuel economy when towing. For the average Super-Duty driver, this improved efficiency translates into fuel savings of approximately 1,000 litres per year (every litre of fuel generates approximately 2.5 kg of CO2). In this high volume sector, the SinterCast technology supports the production of more than 1,000 vehicles every day, providing annual savings of approximately one million tonnes of CO2 per year. This CO2 saving is enough to fill one million hot air balloons, and equal to taking 250,000 passenger vehicles off the road.

In the Super-Duty sector, SinterCast CGI contributes to the saving of approximately one million tonnes of CO2 per year; equal to taking 250,000 passenger vehicles off the American roads; enough to fill one million hot air balloons

Full-Size Pick-ups

The SinterCast-CGI 2.7 litre V6 petrol engine is the smallest, lightest and most fuel efficient engine option in the Ford F-150. This efficiency has led to the SinterCast-CGI engine becoming the most popular engine in the most popular vehicle in America.

Source: US Department of Energy website

CGI vs Aluminium

In comparison to aluminum, Compacted Graphite Iron provides advantages related to strength, durability, wear resistance, design freedom, NVH, package size, cost, and manufacturing CO2. Despite these advantages, aluminum cylinder blocks have leveraged weight reduction to make considerable gains in the small, in-line passenger vehicle sector over the last 30 years.

On 28 April 2022, at the Vienna Motor Symposium, Tupy, Ricardo and SinterCast revealed a novel CGI in-line petrol engine concept with the same weight as aluminium. Compatible with biofuels and future net zero fuels, this breakthrough innovation offers the potential for long-term growth opportunities in the small, in-line passenger vehicle sector that accounts for more than 70% of global passenger vehicles, and in hybrid and battery electric range extender applications.

How we Calculate

Commercial Vehicles: Every 100 kg of weight reduction in a commercial vehicle improves fuel economy by 0.1%. For a 13 litre engine, with fuel consumption of 25 litres per 100 kilometres, the use of SinterCast-CGI can reduce weight by approximately 100 kg. This translates to fuel savings of approximately 0.025 litres for every 100 kilometres travelled. With annual mileage of 400,000 km, the CGI weight saving corresponds to a fuel saving of approximately 62.5 litres of fuel per year. Every litre of diesel fuel generates approximately 2.5 kg CO2; accordingly, the CO2 saving is approximately 250 kg per truck per year. With typical 13 litre cylinder block weight of 300 kg and cylinder head weight of 125 kg, there can be 8.5 Engine Equivalents per vehicle. Therefore, one million Engine Equivalents corresponds to approximately 120,000 trucks and approximately 30,000 tonnes per year of saved CO2.

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