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Ethanol

Step-by-Step Process for Converting a Diesel or Gasoline System to an E85-Compatible System

The following process shows the recommended steps necessary for converting a diesel or gasoline fueling system to an E85-compatible system.

Cleaning and Preparing the Fuel Tanks for E85

First, remaining petroleum fuel should be pumped from the storage tank and system that is to be converted.

Second, all residue from the tank bottom must be cleaned out. Special detail should be paid to tanks that have held diesel fuel to ensure that any remaining diesel is removed. The operator will want to conduct a tightness test on the system to guard against loose fittings or leaks that might have developed during cleaning.

Next, 100 gallons of an ethanol-blended fuel, such as E10, should be loaded into the tank then pumped out again. The ethanol-blended fuel acts as a solvent for removing moisture and stubborn residue. The tank-cleaning company or local fuel suppliers can assist with disposal of the fuel and residue in accordance with local regulations. If the tank was clean and the fuel specifications were not adversely affected, the fuel might still be suitable for motor vehicle use.

If additional precautions are warranted, the site operator might want to circulate another 500 gallons or more of ethanol-blended fuel through the cleaned system. Again, if this fuel meets specifications after circulation, it will remain suitable for motor vehicle use and will not need to be discarded. When the first load of E85 is added, it is acceptable to have minor blending with the remaining gasoline.

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

Installing E85-Compatible Equipment

If the equipment vendor has a "listed" conversion kit, or determines E85 can be pumped through the dispenser, at a minimum install an E85-compatible nozzle, breakaways, seals, and gaskets and a hose with stainless steel ends and fittings. Always use 1- or 2-micron dispenser filters instead of the typical 10-micron filters used with gasoline. Learn more about converting E85 equipment. Use the online guide developed and maintained by the Petroleum Equipment Institute to search for ethanol-compatible equipment.

Typical Costs

Typically, the cost of the abovementioned cleaning steps is less than $2,000 if the pump is E85 compatible. See Sample E85 Station Costs for more detailed cost estimates.

Additional Cleaning Techniques

The following techniques are more involved and might be more expensive than those discussed above:

  • Optic sweep. This patented system uses a fiber optic camera and controllable probe with an extraction device that can visually inspect and clean fuel storage tank bottoms at any fuel level and with no tank downtime. The optic sweep can locate and remove water, sludge, bacteria, rust particles, and sediment while customers continue to pump. Visit the Optic Fuel Clean Web site for more information about this product.

  • Steam cleaning. This involves physically entering the tank, steam cleaning it, and removing sludge. Care must be taken to dry the tank properly.

  • Filter agitator. The agitating device is lowered into the tank. The fuel and any debris are agitated and circulated. A filtration system removes the suspended debris.

  • Chemical solvents. This technique involves using a solvent to remove scale and debris. Liquid and debris are then pumped from the tank and disposed of.

Preparing to Sell E85

When selling E85, it is critical that the dispenser be labeled properly with appropriate decaling, including the E85 logo, cautionary statements, and the orange/black Federal Trade Commission sticker. For retail outlets, a price sign will improve awareness of this new fuel. It is also strongly recommended that E85 nozzle covers, pump toppers, and hose hangtags are used to train and educate drivers using the fueling site.

Resources to Assist with the Conversion Process

Determan-Brownie is a company with experience in tank cleaning for E85 use. Optic Fuel Clean specializes in visual fiber optic fuel inspection and cleaning of underground and aboveground fuel storage tanks in the upper Midwest. Tanknology is a company that can conduct system tightness testing to ensure the integrity of a converted system following tank cleaning. U.S. Department of Energy technical assistance also might be available.

Consult local and state equipment regulations and a trusted equipment vendor when modifying a fueling station. Local building and fire codes should be checked with the help of the equipment vendor. E85 falls under the same handling and storage requirements as gasoline within the provisions of National Fire Protection Association Standards 30 and 30A. Additional provisions might also apply.