Fuel Marketers Tools - Convert Existing Infrastructure
Once you have decided to carry E85, you have the option to decide whether you want to convert your existing fueling infrastructure to be compatible with ethanol or install new equipment for E85. Existing equipment that is in good condition and is compatible with ethnaol may be used with a few modifications. Otherwise, you must install new equipment that is able to handle ethanol, an alcohol-based fuel.

Can I Convert My Existing Equipment?

There are three things to consider before you begin converting your existing fueling infrastructure to carry E85:

1. Condition of the existing equipment: Your 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 and diesel fuel storage. If the previous fuel used in the equipment was an ethanol-blended gasoline, this may pose less of a concern. Converting diesel equipment may require more thorough cleaning due to scale that may have built up in these systems.


2. Compatibility: In addition, older fuel lines and dispenser components may not be compatible with the higher alcohol content of E85. Just as with petroleum dispensing systems, vigilance and periodic maintenance checks can help prevent leaks and component failures. If using an older dispenser, it is advisable to check them on a monthly basis regardless of what fuel is used. Components on newer fueling equipment are often tested to be "100% Methanol or Ethanol" compatible and have been used with E85 for several years without incident.
   
   There are no known compatibility concerns with steel tanks and E85. According to Sullivan Curran of the Fiberglass Tank and Pipe Institute (National Petroleum News interview of June 2004), single-wall fiberglass tanks may not be appropriate for fuel ethanol concentrations of greater than 30 percent. The same is not true of double-wall fiberglass tanks or fiberglass pipe; however, this should be verified with your supplier.


3. Metering Accuracy: If incompatible materials are present within the fuel dispenser and its metering system, over time, the possibility exists for the meter to fail or become less accurate. Some manufacturers feel this is a very important concern and will not extend warrantees to non-petroleum uses of their dispensers. In a decade of use in E85 pilot markets, dispenser failures have been rare. If a dispenser meter were to fail, it would lead to more (not less) fuel dispensed than would be registered. 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 non-aluminum nozzles, 1- or 2-micron dispenser filters, and an alcohol compatible hose (e.g. Teflon-coated).

*Information provided by the National Renewable Energy Lab (NREL)

Conversion Process

Given the above conditions, you can convert either a diesel or gasoline pump to handle 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 may have developed during cleaning.

Next, 100 gallons of an ethanol-blended fuel, such as E10 gasoline, can be loaded into the tank and, then, pumped out again. The ethanol-blended fuel will act as a solvent for removing any moisture or stubborn residue. Your tank cleaning company or local fuel suppliers can assist you with disposing of the fuel and residue in accordance with local regulations. If the tank was clean and the fuel specifications have not been adversely effected, the fuel may still be suitable for motor vehicle use.

If additional precautions are warranted, the site operator may 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 disposed. When you add in the first load of E85, it is acceptable to have minor blending with the remaining amounts of gasoline.

If your equipment vendor determines E85 may be pumped through your dispenser, at a minimum, install an E85-compatible non-aluminum nozzle (nickel-plated or steel), compatible breakaways, and a Teflon-lined 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.

*Information provided by the National Renewable Energy Lab (NREL)

Additional Cleaning Techniques

The following techniques are more involved and may be more expensive than the techniques described above, but will ensure quality fueling in your conversion:

1. Optic Sweep: This patented system utilizes 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 Clean Fuel Guys web site for more information about this product.


2. Steam Cleaning: This involves physically entering the tank and steam cleaning the tank and removing sludge. Care must be taken to properly dry the tank.


3. 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.


4. Chemical Solvents: Involves using a solvent to remove scale and debris. Liquid and debris are then pumped from the tank and disposed.

*Information supplied by the U.S. Department of Energy Efficiency and Renewable Energy

Typical Costs

Typically, the cost of the above cleaning steps is less than $2,000, if your pump is E85 compatible. Please note that the National Ethanol Vehicle Coalition can provide pump labeling and point-of-sale materials for E85 fueling stations.

*Information supplied by the U.S. Department of Energy Efficiency and Renewable Energy

For additional tips on equipment conversions, please see the E85 Conversion Checklist provided by the National Ethanol Vehicle Coalition. If you have any questions about converting your fueling infrastructure to be E85-compatible, please contact your equipment provider or contact Clean Fuels Ohio at (614) 292-5443 or at info@cleanfuelsohio.org.

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