Abstract This study systematically investigates ethanol, butanol, and gasohol blends in a 4-stroke spark-ignition (SI) engine to explore sustainable and efficient fuel alternatives. The research focuses on understanding the interactions between engine performance and emissions while highlighting the combined effects of ethanol and butanol in gasohol formulations. The research methodology involves a comprehensive investigation into the intricate relationship between power generation, emissions, and efficiency by testing fuel blends with varying ethanol and butanol proportions (5 %, 8 %, 10 %, 12 %, and 15 % volume fractions). A range of performance parameters – including Brake Power (BP), Brake Specific Fuel Consumption (BSFC), Mechanical Efficiency (ME), and Exhaust Gas Temperature (EGT) – are assessed using a state-of-the-art experimental setup. Additionally, the study evaluates the environmental impact of each fuel blend by analyzing emissions of CO, CO2, NOx, and HC. The comparative analysis identifies optimal ethanol-butanol ratios that enhance engine performance while reducing emissions. The results indicate that increasing the alcohol content improves power output and mechanical efficiency while lowering carbon emissions. Specifically, the ethanol-butanol blend with a 12 % volume fraction demonstrated a 6.8 % increase in Brake Power and a 9.5 % reduction in CO emissions compared to conventional gasohol. However, higher ethanol content, due to its greater latent heat of vaporization, led to a 4.2 % decrease in NOx emissions but also a slight increase in BSFC by 3.1 %, highlighting the trade-offs in combustion efficiency. This underscores the need for precise engine calibration, including adjustments to spark timing and fuel injection, to maintain optimal combustion characteristics. By examining six distinct fuel compositions, this research provides valuable insights into the trade-offs between performance and emissions in alternative fuel applications. The findings support the transition toward biofuels by demonstrating their potential to enhance efficiency and sustainability. As the automotive industry advances in alternative fuel technologies, this study offers guidance for optimizing ethanol-butanol blends to develop cleaner and more efficient combustion systems.
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