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Ethanol

Converting Equipment to E85

E85 Equipment Conversion Checklist (PDF 84 KB) Download Adobe Reader

Understanding the issues related to converting existing equipment to E85 (85% ethanol, 15% gasoline) compatibility is important for installing E85 infrastructure. In general, newer petroleum equipment in good condition can be converted for use with E85 in most areas of the country, but the conversion equipment and installation procedure must be "listed" as per the applicable codes. (At this time, "listing" is not available; therefore, a variance by the authorities having jurisdiction is required.) Local and state requirements vary; the project contractor should know local rules.

There are three primary concerns for converting existing equipment to E85 fueling. These are described below:

  • Condition of existing equipment. The existing tank and lines must be clean because the high-alcohol content of E85 will "clean out" and absorb contamination left behind by years of petroleum fuel storage. If the previous fuel used in the equipment was an ethanol-blended gasoline, this might pose less of a concern. Converting diesel equipment might require more thorough cleaning owing to scale in these systems. Some tanks might need to be replaced completely.

  • Compatibility. Older fuel lines and dispenser components might not be compatible with the higher alcohol content of E85 and should be replaced as required. If using an older dispenser, it is advisable to check it monthly regardless of what fuel is used. In some cases, the best decision is to purchase new E85-compatible equipment. Components on newer fueling equipment are often tested by the manufacturer to be "100% methanol or ethanol" compatible and have been used with E85 for several years without incident. Use the online guide developed and maintained by the Petroleum Equipment Institute to search for ethanol-compatible equipment. No compatibility concerns have been reported for steel tanks and E85. According to Sullivan Curran of the Fiberglass Tank and Pipe Institute (National Petroleum News interview, June 2004), single-wall fiberglass tanks might not be appropriate for fuel ethanol concentrations greater than 30%. The same is not true of double-wall fiberglass tanks or fiberglass pipe; however, this should be verified with the supplier.

  • Metering accuracy. If incompatible materials are present within the fuel dispenser and its metering system, the possibility exists for the meter to fail or become less accurate over time. Some manufacturers feel this is a very important concern and will not extend warranties to non-petroleum uses of their dispensers. In a decade of use in E85 pilot markets, dispenser failures have been rare. At retail locations where weights and measures agencies check fuel dispensers, a problem will be discovered during annual testing if not immediately by the station's fuel accounting system.

Although E85 dispenser failures are rare, fuel contamination problems have been uncovered. In nearly every case, these were attributed to poor tank cleaning or a failure to use the proper filters, nozzle, or hose. At a minimum, all E85 fueling systems should use ethanol nozzles, 1- or 2-micron dispenser filters, and ethanol-compatible hose, gaskets, and seals. Underwriters Laboratories now has a listing procedure in place for gaskets and seals.

To learn more, see Step-by-Step Process for Converting a Diesel or Gasoline System to an E85-Compatible System.