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E85 Fleet Toolkit

Step-by-Step Process for Converting a Petroleum (Diesel or Gasoline) 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 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.

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

Installing E85 Compatible Equipment

If your equipment vendor has a 'listed' conversion kit or determines E85 may be pumped through your dispenser, at a minimum, install an E85-compatible nozzle, breakaways, seals, 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. See more about converting E85 equipment.

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. See the sample E85 station costs section of this toolkit to get more detailed cost estimates. For more information, contact the National Ethanol Vehicle Coalition at: 1-877-485-8595.

Additional Cleaning Techniques

The following techniques are more involved and typically more expensive than what was discussed above:

  • 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.

  • 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.

  • 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. Involves using a solvent to remove scale and debris. Liquid and debris are then pumped from the tank and disposed.

Preparing to Sell E85

When selling E85, it is critical that the dispenser be properly labeled with appropriate decaling including the E85 logo, cautionary statements, and the orange/black Federal Trade Commission sticker. For retail outlets, a price sign will greatly 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. Note that all point-of-sale materials are available through the National Ethanol Vehicle Coalition (NEVC) at: 1-877-485-8595. The NEVC may also be able to assist with station grant information. You can view and order E85 banners, labels, and signs from the NEVC's Web site.

Resources to Assist with the Conversion Process

Determan-Brownie, Incorporated, 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 above ground fuel storage tanks in the upper Midwest. Tanknology is a well-respected company that can conduct system tightness testing to ensure the integrity of your converted system following a tank cleaning. Also, check out the technical assistance section of this toolkit to see how you can get additional assistance with your project.

Please consult your local and state equipment regulations and a trusted equipment vendor when modifying any re-fueling station. Local building and fire codes should be checked before planning any fuel storage system, and your equipment vendor will be the expert in your area. E85 falls under the same handling and storage requirements as gasoline within the provisions of National Fire Protection Association (NFPA) Standards 30 and 30A; additional provisions may be in use in your area.