Ethanol: the Special Ingredient in BYD's Ground Breaking EV

Electric vehicle pioneer BYD is pushing the boundaries beyond pure battery power, introducing an innovative hybrid system that could mark an evolution in sustainable mobility.

The Chinese manufacturer has developed a plug-in hybrid vehicle specifically engineered to run partly on biofuels, targeting the Brazilian market where ethanol infrastructure is already well-established.

The innovation debuts in the SONG PRO COP30, a special edition vehicle that will be donated to the upcoming UN climate summit in Brazil.

This launch coincides with the official inauguration of BYD's final-assembly line in Camaçari, Brazil, where the SONG PRO is manufactured. It is part of BYD's strategic move towards market-specific solutions as it consolidates its position in the global EV sector.

Biofuel-compatible hybrid technology

The vehicle incorporates DM-i (Dual Mode Intelligent) technology, similar to systems featured in European-market models including the SEAL U DM-i and SEAL 6 DM-i.

According to BYD, the system offers a "predominantly EV driving experience", with the combustion engine functioning primarily as a power generator for the battery, even during hybrid mode operation.

The SONG PRO's 1.5-litre engine is a collaborative effort between Chinese and Brazilian engineers.

The powerplant has been designed to operate on any ratio of petrol and ethanol, Brazil's most widely used green fuel alternative, while maintaining performance and efficiency standards.

Manufacturing milestone achievement

During a ceremony attended by Brazil's President Luiz Inácio Lula da Silva, a SONG PRO COP30 became BYD's 14 millionth new-energy vehicle globally as it rolled off the Camaçari production line.

Thirty examples of the special edition are being donated to COP30, the forthcoming United Nations climate summit in Brazil.

BYD founder and CEO Wang Chuanfu explained: "After two years of effort by more than 100 Chinese and Brazilian engineers, today our 14 millionth vehicle rolls off the production line equipped with the world's first plug-in hybrid engine dedicated to biofuel.

"This is not just a technological breakthrough – it is a green and sustainable solution tailor-made for Brazil."

Mr Wang added: "Two years ago, on a visit to Brazil, I realised the potential of ethanol. We then decided that we would bring our plug-in hybrid technology, but with a flex engine developed by and for this country.

"The car we are delivering today to President Lula is proof that BYD not only invests in Brazil but also co-creates with Brazil unique solutions for the world."

Aggressive production expansion

The Brazilian facility has been operational since July, following a 15-month construction period. The plant can produce 150,000 vehicles annually in its first phase, scaling to 300,000 in later stages, and currently employs more than 1,500 personnel.

The facility is the largest electric vehicle production site in Latin America and BYD's largest manufacturing operation outside Asia.

During discussions with President Lula, Wang confirmed additional investment to expand the factory and double its annual production capacity from the planned 300,000 vehicles to 600,000 units per year.

This expansion could position Brazil as a crucial manufacturing hub for BYD's Americas operations.

Stella Li, Global Executive VP and CEO of BYD for the Americas and Europe, said: "BYD believes in the growth potential of the Brazilian market, has long-term plans for a population that deserves increasingly better vehicles, and will continue to invest to help boost the economy, create jobs, and train the workforce.

"This factory is 100% Brazilian, created so that Brazilians have access to better, more modern, connected, technological and sustainable cars."

Tyler Li, CEO of BYD Brazil, said: "Ethanol is one of Brazil's greatest strategic advantages in the energy transition.

"Incorporating it into our DM-i architecture represents a historic advance: we value the national renewable energy matrix, in addition to offering consumers a vehicle with greater efficiency, lower environmental impact and aligned with the country's energy reality."

In Brazil, BYD has expanded its dealer network to more than 200 stores across all states, capitals and major cities, with plans to reach 250 outlets in early 2026.