Guidebook for 

Handling, Storing, &

Dispensing Fuel Ethanol

Prepared for the 

U.S. Department of Energy

by the Center for Transportation Research

Energy Systems Division

Argonne National Laboratory

A L T E R N A T I V E - F U E L V E H I C L E S

M A D E F O R T O M O R R O W . T O D A Y .
Disclaimer

This guidebook was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government

nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately

owned rights. Reference herein to any specific commercial product, process, or service, by trade name, trademark, manufacturer, or otherwise, does

not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views

and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

Argonne National Laboratory is operated by the University of Chicago as part of the

U.S. Department of Energy National Laboratory System under contract No. W-31-109-ENG-38.

Produced in cooperation with the National Ethanol Vehicle Coalition, which is jointly supported by the Governors’ Ethanol Coalition

and the National Corn Growers Association and its affiliated state corn associations.

Publishing support services provided by Information and Publishing Division,

Argonne National Laboratory

FOREWORD

This guidebook is intended as firsthand information for

fuel distributors and retailers who have not had any

experience or formal training with ethanol fuels. The

first three chapters contain information about government regulations, ethanol-fueled vehicles, and fuel

standards, which may also be useful to fleet managers

and ethanol fuel users. The rest of the handbook

addresses material recommendations, parts and

equipment, and handling and delivery of ethanol fuel.

This guidebook has been reviewed by selected 

representatives of vehicle manufacturers, fuel

providers, fleet operators, and Federal and state 

governments, as well as a technical review committee.
1

WHY FUEL ETHANOL? 2

ENERGY POLICY ACT OF 1992 3

ALCOHOL-FUELED VEHICLES 4

PRODUCTION, PROPERTIES, & 

ENVIRONMENTAL IMPACTS 5

Production

Physical Properties

Emissions

E85 FUEL SPECIFICATIONS & STANDARDS 8

ASTM Fuel Standard Specification

Seasonally Adjusted Blend

Hydrocarbons

Fuel Additives

E85 QUALITY ASSURANCE 10

MATERIALS RECOMMENDATIONS 11

FUEL STORAGE & DISPENSING 12

General Dispensing Equipment

Aboveground Fuel-Storage Systems

Underground Fuel-Storage Systems

FUEL TRANSPORT & DELIVERY 14

HANDLING FUEL ETHANOL 15

Visual Inspection

Hydrocarbon Content of the Fuel Ethanol

Electrical Conductivity

TABLE OF CONTENTS

SAFETY PROCEDURES 17

Health Considerations

Fire Safety Considerations

Safety Codes

Appendix A: Comparison of Fuel Properties 19

Appendix B: AAMA Specifications 

for Fuel Ethanol as Dispensed 

to Vehicles 20

Appendix C: Geographical 

Fuel-Marketing Regions 21

Appendix D: E85 Shipping Procedures 23

Appendix E: Method to Determine the Total

Hydrocarbon Content of Alcohol Fuel 24

Appendix F: Material Safety Data Sheet for E85 25

FOR MORE INFORMATION, CALL . . . 27

TROUBLESHOOTER’S GUIDE 29

Table 1 Properties of Fuel Ethanol 7

Table 2 ASTM D 5798 Standard Specification 

for Fuel Ethanol for Automotive SparkIgnition Engines 9

Table 3 First Aid Treatments for Exposure to 

Fuel Ethanol 18
2

Concern about our country’s dependence on foreign petroleum and about the environment has led to

development of alternative fuels in the transportation

sector. By switching to these new fuels and vehicle technologies, fleet owners are leading the way to energy

security and cleaner air. Alcohol fuels* and, in particular,

fuels of ethyl alcohol (also known as ethanol) blended

with gasoline are well-suited for 

replacing gasoline in light-duty vehicles and diesel fuel in trucks and

buses. The other fuel alcohol 

commercially available today is

methanol. Although it sounds similar

to ethanol, it is derived from different

sources, its properties are quite different, and it cannot be used in

place of ethanol. 

Currently, a small amount of

ethanol (10% by volume) is added

to gasoline to increase the octane

rating and to provide oxygen to

decrease tail-pipe emissions of carbon monoxide (CO); the resulting

fuel blend, called gasohol by the public and E10 by the

industry in the United States, is a widely accepted vehicle

fuel. New vehicle technologies have been developed

that can use blends having higher concentrations of

ethanol in gasoline as fuels while achieving reliable, 

low-emission operation. The new flexible-fuel vehicles

operate on blends of up to 85% ethanol (known as E85).

The gasoline in E85 makes the vehicle easier to start in

cold weather and increases the vehicle’s range.

Specifications, technical standards, handling procedures, and refueling equipment for fuel ethanol have

been developing at a rapid pace. Because of the limited

experience with ethanol blends as fuels, research and

data collection from vehicles in the field will be continuing

for some time. Fuel distributors and fuel producers, as well 

as managers responsible for operating these new fleets of

ethanol-powered vehicles, need practical information to

successfully use this renewable alternative fuel.

This guidebook provides accurate

and up-to-date information — based

on proven practices developed by

experienced fuel providers, fleet

managers, and vehicle manufacturers — for successfully using fuel

ethanol in vehicles. Safe and environmentally responsible working procedures and simple tests to assess

fuel quality in the field are presented.

In the near future, as market

conditions demand, vehicles in the

field may need to operate on

blends having ethanol concentrations different from E85. No matter

what the blend, the basic practices for handling and

using fuel ethanol remain the same — you can apply the 

information presented in this guidebook to all expected

new blends.

WHY FUEL ETHANOL?

* Alcohol fuel blends are designated by E for ethanol or M for methanol,

followed by a number representing the percentage of alcohol (by volume) in the blend. The ethanol used in fuel blends is denatured and can

contain up to 5% hydrocarbons (gasoline or gasoline-like additives) before

blending. Additional gasoline is added to the ethanol to make up the

desired percentage in the blend. The fuel E10, or “gasohol,” is 10% denatured ethanol blended with 90% gasoline; E85, commonly called fuel

ethanol, is 70-85% denatured ethanol blended with 30-15% hydrocarbons;

and E100 is 100% denatured ethanol.
3

The Energy Policy Act of 1992 (EPACT) addresses the

energy challenges facing our country as we approach

the next century, including lessening our dependence on

foreign oil. Under this law, the Secretary of Energy is

required to “. . . ensure the availability of those replacement fuels that will have the greatest impact in 

reducing oil imports, improving the health of our Nation’s

economy, and reducing greenhouse gas emissions.”

According to EPACT, alternative

fuels include ethanol, methanol,

and other alcohols; mixtures containing 85% or more by volume of

methanol, ethanol, or other alcohols

with gasoline or other fuels; natural

gas; liquefied petroleum gas; coalderived liquid fuels; hydrogen; fuels

(other than alcohols) derived from

biological materials; electricity; and

any other fuel the Secretary of

Energy determines is substantially

not petroleum.

EPACT established the purchase requirements for

alternative-fueled vehicles (AFVs) for Federal, state government, and fuel-provider fleets. If the Secretary of

Energy determines that EPACT goals will not be met with

only the above requirements, municipal and private 

sector fleets may be required to purchase AFVs. Also

established were tax incentives for purchasing AFVs, for

converting gasoline vehicles to operate on alternative

fuels, and for installing refueling or recharging facilities.

Other state and local financial incentive programs may

be available in your area. For up-to-date information on

these programs or on funding, financing, and incentives,

contact the U.S. Department of Energy (DOE) National

Alternative Fuels Hotline at 800-423-1DOE, the DOE

Alternative Fuels Data Center Internet home page at

http://www.afdc.doe.gov, or your state energy office.

ENERGY POLICY ACT OF 1992
4

To safely and effectively operate your alcohol-fueled

fleet, the vehicles need to be compatible with alcohol

use. Aftermarket conversion of gasoline-powered vehicles to alcohol-fueled vehicles, although possible, is not

recommended because of the changes in component

materials necessary, the high cost, and the need for

extensive engine recalibration. In addition, the lack 

of widespread refueling facilities

makes operating vehicles dedicated to alcohol fuel impractical. 

To resolve refueling infrastructure problems, automakers have

developed vehicles, called flexiblefuel vehicles (FFVs), that can operate on alcohol, gasoline, or any

blend of these fuels up to 85%

alcohol (dedicated to either

methanol blends or denatured

ethanol blends). These vehicles are

designed to use a specific alcohol

fuel, either methanol or denatured

ethanol, and only the alcohol fuel

the vehicle is designed for can be used. Use of methanol

in an ethanol vehicle, and vice-versa, will result in improper

vehicle operation and could cause failure of fuel system

components. Flexible-fuel vehicles manufactured by Ford

are available now in the marketplace. These vehicles are

fully warranted. You may take advantage of government

incentives and credits if you purchase FFVs. Contact the

DOE National Alternative Fuels Hotline (800-423-1DOE), or

your automobile dealer for an up-to-date list of available

vehicles. More information about FFVs can be found on

the DOE Alternative Fuels Data Center Internet home

page at http://www.afdc.doe.gov or by calling the E85

hotline (800-E85-8895). 

Ethanol FFVs are similar to gasoline vehicles. The main

changes are new materials in the fuel management system and special engine calibration. In addition, FFVs

require special lubricating oils and fuel filters. 

Flexible-fuel vehicles are fueled by pumping the fuel

from a storage tank through a dispenser and hose, just like

gasoline-powered vehicles. Differences in the fueling installations are

discussed later in this guidebook

(see Materials Recommendations,

Fuel Storage & Dispensing, and Fuel

Transport & Delivery). Although the

alcohol content of the blend while

it is in the storage tank may be

specified, the alcohol content of

the fuel after it has been dispensed

to the vehicle may be different

because of mixing with any existing

fuel in the vehicle’s tank.

Always follow the recommendations of the manufacturer for

maintenance, lubricants, and

replacement parts for the vehicle. Training on alcoholfueled vehicles is helpful for a fleet’s mechanics, but if the 

specified parts and lubricants are used, routine maintenance can easily be performed.

ALCOHOL-FUELED VEHICLES
5

Production

Ethanol is also known as ethyl alcohol or grain alcohol. Like gasoline, ethanol contains hydrogen and carbon, but ethanol also contains oxygen in its chemical

structure. The oxygen makes ethanol a cleaner burning

fuel than gasoline. It can be produced chemically from

ethylene or biologically from grains,

agricultural wastes, or any material

containing starch or sugar. Because

ethanol can be produced from

crops, it is classified as a renewable

fuel. Today’s ethanol is produced in

the United States mainly from corn

grown in the Midwest. One bushel of

corn (approximately 56 pounds)

produces 2.5 gallons of ethanol.*

Because the gasoline or additives 

in an ethanol blend make the 

ethanol “denatured” (unfit to drink),

blends are exempt from Federal

liquor taxes.

It is a common misconception

that ethanol production consumes as much energy as

the ethanol may offer. Recent research has shown that

producing ethanol from corn creates 24% more energy

than the production process uses. Due to the abundance

of natural gas, propane, and coal, ethanol produced

from these feedstocks has the potential to replace a significant amount of petroleum imports.

Physical Properties

Properties of E85 are listed in Table 1. Ethanol is a flammable, colorless liquid (E100 is clear like water) with a faint

alcohol odor, but ethanol fuel blends have a color that

depends on the color of the gasoline in the blend and

have a gasoline-like odor. One gallon of E85 provides as

much energy as 0.72 gallon of gasoline. A comparison of the properties

of E85 to those of methanol,

ethanol, and gasoline is found in

Appendix A of this guidebook.

Emissions

One of the benefits of using AFVs

is a reduction in the emission of pollutants into the air we breathe. 

In general, the type of emissions

from vehicles using E85 will be similar

to that from gasoline-powered vehicles, but the amount of emissions will

be less. The quantity of pollutants

released depends on how well the

vehicle’s emissions control system captures and burns

emissions and how well the engine is designed and

“tuned” for using fuel ethanol. The emissions control 

systems found on ethanol-powered vehicles manufactured today have been engineered to meet or exceed all

Federal and state emissions control regulations.

PRODUCTION, PROPERTIES, & ENVIRONMENTAL IMPACTS

MORE ➾

* In addition to the ethanol, one bushel of corn produces 12.4 lb of 21%

protein feed, 3 lb of 60% gluten meal, 1.5 lb of corn oil, and 17.0 lb of carbon dioxide (for carbonated soft drinks).
6

PRODUCTION, PROPERTIES, & ENVIRONMENTAL IMPACTS (cont.)

Two types of emissions are released by AFVs: exhaust

and evaporative. Although compliance with Federal 

and state regulations has already resulted in a decrease

in exhaust emissions from gasoline-powered vehicles,

ethanol-fueled vehicles can further reduce pollution from

emissions by a modest, but meaningful, amount.

Compared with gasoline-fueled vehicles, most ethanolfueled vehicles produce lower carbon monoxide (CO)

and carbon dioxide (CO2) emissions and the same or

lower levels of hydrocarbon (HC) and nonmethane

hydrocarbon (NMHC) emissions; nitrogen oxides (NOx)

emissions are about the same or even less. In recent tests,

1996 model Ford Taurus FFVs emitted 50% less NMHC and

35% less CO when running with E85 than when running

with reformulated gasoline (RFG). No change was reported

for NOx. In addition, once at operating temperature, 

the catalytic converter in an ethanol-fueled vehicle is

very efficient at breaking down aldehydes into less harmful chemicals. (Aldehydes are chemical compounds

associated with incomplete combustion of alcohol that

are suspected of being carcinogenic). 

Emissions resulting from fuel evaporation are a potential problem for any vehicle, regardless of the fuel. More

emissions can leak from a vehicle when it is sitting than

when it is operating! The built-up heat in the engine 

compartment, and sometimes even the heat reflected

from the pavement onto the fuel tank, can cause the

most volatile parts of the fuel to boil off and leak into 

the air, causing pollution. E85 has fewer highly volatile

components than gasoline and so has fewer emissions

resulting from evaporation. Ethanol’s low volatility means

that it needs help in igniting at low temperatures — that’s

why gasoline and other hydrocarbons are added to the

fuel. Without hydrocarbons in the blend, an ethanolfueled vehicle may be hard to start when the engine is

cold, especially in wintertime.
7

TABLE 1 PROPERTIES OF FUEL ETHANOL

Property Comment

Vapor density Ethanol vapor, like gasoline vapor, is denser than air and tends to settle 

in low areas. However, ethanol vapor disperses rapidly.

Solubility in water Fuel ethanol will mix with water, but at high enough concentrations of 

water, the ethanol will separate from the gasoline.

Energy content For identical volumes, ethanol contains less energy than gasoline. On 

an energy basis, 1.0 gallon of E85 is equivalent to 0.72 gallon of gasoline.

Flame visibility A fuel ethanol flame is less bright than a gasoline flame but is easily 

visible in daylight.

Specific gravity Pure ethanol and ethanol blends are heavier than gasoline.

Conductivity Ethanol and ethanol blends conduct electricity. Gasoline, by contrast, 

is an electrical insulator.

Stoichiometric fuel-to-air ratio E85 needs more fuel per pound of air than gasoline; therefore, E85 

cannot be used in a conventional vehicle. 

Toxicity Ethanol is less toxic than gasoline or methanol. Carcinogenic compounds

are not present in pure ethanol; however, because gasoline is used in the

blend, E85 is considered to be potentially carcinogenic.

Flammability At low temperature (32 ̊F), E85 vapor is more flammable than gasoline 

vapor. However at normal temperatures, E85 vapor is less flammable 

than gasoline, because of the higher autoignition temperature of E85.
8

Alcohols are more corrosive than gasoline because

they are electrically conductive and may contain 

corrosive impurities. Alcohols may degrade materials that

are commonly used with gasoline or diesel fuel. You 

can reduce the chance for failure or contamination 

of alcohol equipment and systems by selecting proper

materials and by controlling fuel composition. 

The American Society for Testing

and Materials (ASTM) and the

American Automobile Manufacturers

Association (AAMA) have established standards for E85. While the

two standards are similar, only the

ASTM standard (Table 2) is discussed

in this section. For your information, a

copy of the AAMA specification

appears in Appendix B. 

ASTM Fuel Standard Specification

(ASTM D 5798)

The ASTM standard specification for fuel ethanol, designated 

ASTM Ed75-Ed85 (where d stands for

denatured), covers fuel blends for different seasons 

and geographical areas. These specifications, shown in

Table 2, represent the minimum commercial standards

and reflect the consensus of many stakeholders. The

ethanol and hydrocarbon denaturant used in making fuel

ethanol must meet the requirements of ASTM D 4806.

Seasonally Adjusted Blend

The amount of alcohol in the fuel ethanol blend

depends on the geographical fuel-marketing region and

the season. (A complete breakdown by volatility class for

the geographical fuel regions can be found in Appendix C.)

In cold weather, more gasoline is added to the blend to

avoid starting problems. A minimum of 70% by volume 

of alcohol is permitted in the winter blend by the ASTM

fuel standard.

Hydrocarbons

The hydrocarbon(s) blended

into the fuel ethanol must comply

with several of the same standards

as gasoline. The hydrocarbon may

contain ethyl tertiary butylether (ETBE),

methyl tertiary butyl ether (MTBE), or

other aliphatic ethers as blending

components, as is customary for

automobile spark-ignition-engine

fuel. Natural gasoline, commonly

used as the denaturant of fuel

ethanol, is an excellent blend stock

for the hydrocarbon portion of E85.

Fuel Additives

Commercial gasoline contains additives, detergents,

and inhibitors, as well as hydrocarbons. Federal law

requires that the hydrocarbon portion of E85 contain

detergent additives. After blending the gasoline with

denatured alcohol to make E85, any additives that were

in the gasoline are now in the E85 (although at reduced

levels). In some states in the United States, certain 

detergents used in commercial gasoline, such as 

E85 FUEL SPECIFICATIONS & STANDARDS
9

polyisobutylene amine, have performed poorly in FFV

operation. If these additives get into the fuel ethanol, 

precipitation and deposition in the FFV’s fuel system may

TABLE 2 ASTM D 5798 STANDARD SPECIFICATION FOR FUEL ETHANOL (Ed75-Ed85)

FOR AUTOMOTIVE SPARK-IGNITION ENGINES

Property Value for Class Test Method

ASTM volatility class 1 2 3 N/A

Ethanol, plus higher alcohols (minimum, volume %) 79 74 70 ASTM D 5501

Hydrocarbons (including denaturant)/(volume %) 17-21 17-26 17-30 ASTM D 4815

Vapor pressure at 37.8°C

kPa 38-59 48-65 66-83 ASTM D 4953, D 5190, D 5191

psi 5.5-8.5 7.0-9.5 9.5-12.0

Lead (maximum, mg/L) 2.6 2.6 3.9 ASTM D 5059

Phosphorus (maximum, mg/L) 0.3 0.3 0.4 ASTM D 3231

Sulfur (maximum, mg/kg) 210 260 300 ASTM D 3120, D 1266, D 2622

Methanol (maximum, volume %) 0.5 N/A

Higher aliphatic alcohols, C3-C8 (maximum, volume %) 2 N/A

Water (maximum, mass %) 1.0 ASTM E 203

Acidity as acetic acid (maximum, mg/kg) 50 ASTM D 1613

Inorganic chloride (maximum, mg/kg) 1 ASTM D 512, D7988

Total chlorine as chlorides (maximum, mg/kg) 2 ASTM D 4929

Gum, unwashed (maximum, mg/100 mL) 20 ASTM D 381

Gum, solvent-washed (maximum, mg/100 mL) 5.0 ASTM D 381

Copper (maximum, mg/L) 0.07 ASTM D 1688

Appearance Product shall be visibly free of Appearance determined at

suspended or precipitated ambient temperature or 21°C 

contaminants (shall be clear (70°F), whichever is higher.

and bright).

N/A = Not applicable.

result. The best way to avoid this problem is to use natural

gasoline in the E85 blend, if it is available in your area. 
10

Once your E85 refueling station has been installed,

taking simple operational precautions can assure fuel

quality. A periodic check of fuel properties will avoid costly damage to vehicles operating with E85. Some of these

checks may be performed in the field, but others may

require the services of a specialized laboratory. A list of

some of these laboratories may be obtained by calling

the U.S DOE National Alternative

Fuels Hotline (800-423-1DOE).

For a new fuel station, the 

following properties of E85, at a 

minimum, should be checked within

a few days of the start of operation:

✓ Conductivity (see Electrical

Conductivity on page 16),

✓ Unwashed gum content,

✓ Water content, and

✓ Particulate content.

After the refueling station has

reached normal operation, test the fuel periodically. At a

minimum, the following items should be checked every 

1-2 months, depending on how frequently the station is

used. Also, any time you suspect your fuel is contaminated, check these properties: 

✓ Hydrocarbon content (see Hydrocarbon Content of

the Fuel Ethanol on page 16),

✓ Reid vapor pressure,

✓ Water content, and

✓ Acidity.

Because it is possible to perform the conductivity test

and the test for hydrocarbon content in the field, these

tests should be performed more often. More details about

these tests may be found in

Handling Fuel Ethanol (page 15).

If you need to send a fuel sample to a laboratory, you will find

information on shipping procedures

in Appendix D; always remember to

follow the shipper’s requirements for

packaging hazardous materials.

E85 QUALITY ASSURANCE
11

Fuel ethanol, like other liquid fuels, is very easy to contaminate. Certain materials commonly used with gasoline

are totally incompatible with alcohols. When these materials come in contact with ethanol, they may dissolve in

the fuel and damage engine parts, possibly causing

breakdown of the vehicle. Even if parts do not fail, 

running an ethanol-fueled vehicle with contaminated

fuel may cause deposits that could

eventually harm the engine. The

materials and parts presented in this

guidebook have been shown to

perform well with E85.

The supplier providing your

equipment and the contractor

installing it are responsible for using

components compatible with E85 

in your system, but you should be

aware of materials-compatibility

issues in case of problems with 

your customers’ vehicles.

The AAMA has identified materials and equipment that are compatible with E85. Compatibility with E85 means not only

that equipment made from a material will not deteriorate, but also that the quality of the E85 in contact with

that material will not degrade. The AAMA recommends

that the integrity of all components coming into contact

with the fuel be verified by soak testing. Before and after

soak testing the equipment, you should determine the

electrical conductivity, chemical stability, and filterplugging tendencies (presence of particulates and

unwashed gum) of the soak test fuel. In addition, the

AAMA recommends that, when constructing the dispensing site, dissimilar metals that come in contact with the

fuel should not be coupled. (Dissimilar metals are those

that are separated widely in the galvanic series.)

The following sections describe parts and equipment

that are compatible with fuel ethanol. They should be

available from your usual supplier. (Reference to specific

products is for your convenience

and does not constitute endorsement by the U.S. Government.)

Some materials are known to

become degraded by contact with

fuel ethanol blends having high

alcohol concentrations. Zinc, brass,

lead, and aluminum are some of

these sensitive metals. Terne (leadtin-alloy)-plated steel, which is commonly used for gasoline fuel tanks,

and lead-based solder are also

incompatible with fuel ethanol.

Avoid using these metals because of

the possibility of vehicle failure or

fuel contamination. Unplated steel,

stainless steel, black iron, and bronze have shown

acceptable resistance to corrosion by ethanol.

Nonmetallic materials that degrade when in contact

with fuel ethanol include natural rubber, polyurethane,

cork gasket material, leather, polyester-bonded fiberglass

laminate, polyvinyl chloride (PVC), polyamides, and

methyl-methacrylate plastics. Nonmetallic materials 

that have been successfully used with fuel ethanol

include Buna-N, Neoprene rubber, polyethylene, nylon,

polypropylene, nitrile, Viton, and Teflon.

MATERIALS RECOMMENDATIONS
12

The technology for storing and dispensing gasoline

can be applied to alcohol fuels because alcohols and

alcohol blends, like gasoline, are liquid under the pressures and temperatures usually encountered. However,

only E85-compatible materials should be used. Most operating problems with ethanol-fueled vehicles have been

traced to contaminated fuel. Consequently, choosing

the right materials for fuel storage

and dispensing systems and following proper fuel-handling procedures

are crucial for successful operation

of ethanol-fueled vehicles. Although

research and testing of materials is

expected to continue, the parts and

materials discussed here have performed well with E85. They can be

obtained from your usual supplier.

(Reference to specific products is for

your convenience and does not

constitute endorsement by the U.S.

Government.)

E85 can be stored in aboveground or underground installations. Both systems are safe

and practical. Factors like the size of the tank, the space

available, requirements for stationary evaporative emissions, and local safety codes will determine which type of

installation is best for your fleet. 

Important! Before planning any fuel-storage system,

check your local building and fire codes. Fuel ethanol

falls under the same handling and storage requirements

as gasoline within the provisions of National Fire Protection

Agency (NFPA) Standards 30 and 30A (see Safety Codes

on page 18).

General Dispensing Equipment

Dispenser hoses, nozzles, and fitting connectors are

the same for aboveground and underground fuel-storage

systems. The items common to both systems are discussed

in this section. Parts that differ for aboveground and

underground installations are discussed in the specific

sections that follow. Again, your 

supplier can help you obtain E85-

compatible parts and equipment.

Avoid any components made

from zinc, brass, lead, aluminum, or

other soft metals; the ethanol fuel

may cause leaching from such soft 

metals, contaminating the vehicle’s

fuel system and potentially resulting

in poor vehicle performance.

In-Line Filters. A one-micron, inline filter is recommended for fuel

ethanol dispensing equipment. This

size filter will trap most of the debris

and impurities that might be present

in the storage tank and prevent them from being 

transferred to the vehicle during refueling. The CUNO

model 1B2 filter or the Cim-Tek filter have performed well

in fuel ethanol installations.

Dispenser Hoses. The type of hose used for dispensing

E85 depends on the type of vapor recovery in your system. For a Stage II vapor-recovery system, a Goodyear

Maxxim coaxial hose with stainless steel fittings has performed well. For a system without Stage II vapor recovery,

the Goodall Kem Flexpart No. N2494 with stainless steel

end fittings has been successfully used. 

FUEL STORAGE & DISPENSING
13

New research has shown that hoses with nylon inner

liners, especially the Goodyear Nylon Veneer 11, perform

better than Maxxim coaxial hose. However, at the time of

publication of this guidebook, hoses made from Nylon

Veneer 11 are still considered experimental.

When you are specifying materials for your refueling

facility, contact equipment vendors for the latest information and use the components with the highest resistance to deterioration from continuous contact with fuel

alcohols. In some cases, equipment specified for use with

fuel methanol will be available. Because fuel methanol is

even more corrosive than fuel ethanol, components and

materials certified for fuel methanol use will almost always

be acceptable for fuel ethanol use. If you have a choice

of materials, select the ones certified by the manufacturer for fuel methanol to provide an extra measure of insurance against materials compatibility problems.

Nozzles. Aluminum nozzles should not be used with

E85, and nozzles made from any aluminum alloy must be

used with caution. A nickel-plated nozzle is the best

choice; OPW No. 11AP-0492 or Emco Wheathon No.

A2000-451 models will work well.

Fittings and Connectors. All fittings, connectors, and

adapters that will be in contact with the fuel blend should

be made of materials like stainless steel (best choice),

black iron, or bronze to avoid degradation. If aluminum or

brass fittings are used, they must be nickel-plated to avoid

any contact of the bare metal with fuel ethanol.

Piping. The best choice for piping is inexpensive

schedule 40 black iron pipe. If secondary piping is needed, polyethylene pipe (such as the Total Containment

brand) should be used. Do not use conventional zincplated steel piping for fuel ethanol. Galvanized pipe may

be used. Pipe thread sealant, when needed, must be

Teflon tape or Teflon-based pipe-thread compound.

Aboveground Fuel-Storage Systems

Tanks. Several companies manufacture tanks for E85

storage. ConVault, U-Fuel, and Hallmark are the most

commonly mentioned manufacturers. Typical capacities

are 1000 or 2000 gallons. Tanks should be constructed of

cold-finished steel and butt-welded. Do not use any plated metal tanks.

Dispensers. The Tokheim dispenser model No. 785 RC

or No. 7552 (with a No. 898 piston-type meter) and two

different-sized dispensers produced by Gasboy, model

numbers 9152 (1/3 hp) and 9153 (3/4 hp), are some of the

dispensers that have been successfully used. The dispenser must use iron unplated steel or stainless steel in the

fuel path. In the case of vane-type pumps, avoid

impellers made from soft metals (zinc, brass, lead, 

aluminum, etc.). Steel or an engineering polymer having

high chemical resistance (like Torlon) will give excellent

results.

Underground Fuel-Storage Systems

Tanks. Double-walled, low-carbon, cold-finished steel

tanks will be serviceable, but butt-welded tanks are

preferable. Do not use plated-metal tanks. Fiberglass

tanks can be used, but they should be lined with 

chemical-grade rubber to prevent the fuel from contacting

the fiberglass.

Dispensers. The Tokheim dispenser model No. 785 RC

or No. 7552 (with a No. 898 piston-type meter) and two

different-sized dispensers produced by Gasboy, model

numbers 9152 (1/3 hp) and 9153 (3/4 hp), are some of the

dispensers that have been successfully used. The dispenser must use iron, unplated steel, or stainless steel in

the fuel path.
14

Today fuel ethanol is transported by truck from the

producer or distributor to the refueling facility.

Ethanol/gasoline blends cannot use existing petroleum

pipeline systems because of possible contamination by

water and residues from other petroleum products or

incompatibility with the system due to the corrosive properties of alcohols. 

The fuel provider should blend

the fuel ethanol as E85 before distribution, either in the terminal tank or

on the transport truck. Sometimes

the fuel is transported as E100 and

“splash” blended with local gasoline

after delivery. This method is not recommended; however, if you must

splash blend in your area, pour 

the ethanol into the gasoline for

more uniform blending of the two

components.

Although transport and delivery

of fuel are responsibilities of the fuel

provider, fuel retailers need to be

aware of normal operating procedures to avoid fuel contamination or unsafe performance by the fuel provider.

To avoid contamination during transport, the fuel

provider should use a dedicated ethanol container, tank,

or truck constructed only of E85-compatible materials. If a

dedicated ethanol tank is not available, a tank that has

been used only for gasoline transport may be used. Avoid

using tanks that have contained other types of fuels. If

you must use a tank that was not dedicated to ethanol or

gasoline transport, before loading the fuel ethanol, wash

the tank with solvent and allow it to air dry. If the solventwashed tank is steam-dried, condensate will contaminate the fuel ethanol. Since transport trucks deliver 

from the bottom of the tanker compartment, any accumulated water or contaminants will be dispensed into the

storage tank.

FUEL TRANSPORT & DELIVERY
15

Up to this point, you have been told what your equipment supplier should do to make your installation compatible with alcohol fuels and what your fuel provider

should do to deliver uncontaminated fuel ethanol. Now

it’s time to explain how you should handle E85 to keep

your customers’ vehicles operating properly and safely.

As with any other fuel, common

sense should govern handling of fuel

ethanol. The procedures are similar

to those for handling gasoline.

Following the recommendations

below at your installation should

keep your employees and customers safe, prevent contamination

of the fuel, and protect your equipment from degradation. 

✓ Avoid skin or vapor contact

with E85. If you are handling E85,

always wear ethanol-resistant gloves

(such as nitrile gloves). In the event

of contact, seek medical help (also

see Safety Procedures on page 17).

✓ Use only equipment that is recommended for use

with ethanol. Do not use parts or equipment for handling

and dispensing E85 fuel that are designed for use with

other fuels (see pages 11-13).

✓ Be sure that the fuel ethanol is transported and

delivered to you in an ethanol-compatible, dedicated

tank; in a gasoline tank; or, if necessary, in a tank that has

been cleaned by following the recommendations on

page 14.

✓ Do not reuse cans or barrels that have contained

other fuels to store or transport fuel ethanol. Other fuels

can leave residues that may contaminate E85. New containers are always preferable. Dedicate them to fuel

ethanol use!

✓ If your refueling station is used less often than once

a week, recycle the fuel contained

in the hose between the nozzle and

the filter. If E85 is in contact with the

hose material for a long period of

time, the hose may degrade and

become a source for contamination

that cannot be trapped by the filter.

At least weekly, fill a one-gallon E85-

compatible container with fuel from

the nozzle and return the fuel to the

storage tank. (Although a quart

would probably be enough to drain

the hose, draw a gallon to be on the

safe side.)

✓ E85 from your storage tank

should be tested on a regular basis

for appearance, hydrocarbon content, and electrical

conductivity (see the following sections for directions on

how to perform these tests). Put samples to be tested into

alcohol-compatible containers. Stainless steel containers,

steel containers with epoxy liners, or glass containers are

recommended for use in sampling and testing.

Visual Inspection

Visual inspection may be the least expensive and

most efficient way to check for possible contamination of

alcohol fuel. Fuels must be completely clear and free

HANDLING FUEL ETHANOL

MORE ➾
16

from visible particulates. Particulates indicate contamination; if they are found, immediately begin an investigation

into the source of the contamination. 

At least two samples should be visually examined.

Pour one sample of fuel from the dispenser hose into a

quart-sized clear glass container and inspect the liquid.

Remember that this first quart is the fuel that was stored in

the dispenser hose between the nozzle and the filter. If

particulates are found in the first sample, the hose has

begun to degrade. Draw more fuel through the hose into

a compatible container until you are sure you have emptied the hose and are dispensing fuel from the tank. (This

fuel can be returned to the tank later if no particulates

are found in the test sample to be drawn next.) Then draw

another quart sample of fuel into a separate glass container and observe the liquid. If particulates are found in

the second sample, fuel in the tank has become contaminated. If particulates are found in either sample, do not

dispense any fuel until the problem has been identified

and corrected. Contact your fuel provider for assistance.

Hydrocarbon Content of the Fuel Ethanol

If you are experiencing poor vehicle performance,

the hydrocarbon content in the fuel blend may be too

low. The FFVs produced in the United States today have

alcohol sensors as standard equipment, but storage tanks

rarely are equipped with this kind of sensor. Checking the

hydrocarbon content of the fuel in the tank is inexpensive

and fast — use the procedure described in Appendix E.

Check the hydrocarbon content as a standard procedure once every month, after each fuel delivery, or when

drivers report a change in vehicle performance. If the

hydrocarbon content is too high or too low, contact your

fuel provider for assistance.

Remember that the blend you are dispensing from

the storage tank may be different from the blend inside

the vehicle because of mixing with fuel already in the

vehicle tank. If vehicles are experiencing performance

problems, you may need to check the hydrocarbon 

content of the fuel in the vehicle’s tank as well as in the

storage tank.

Electrical Conductivity

The electrical conductivity of the fuel ethanol is 

a measure of the fuel’s quality. High conductivity is a sign 

of corrosivity of the fuel and may indicate the presence 

of metal in the fuel, which could be the result of material

or equipment degradation. If you use fuel whose conductivity is higher than specification, your vehicles will 

not operate properly. A conductivity value of no more

than 500 micro-mhos/meter is recommended (mho 

is sometimes abbreviated as S). If the conductivity reading is outside specification, contact your fuel provider 

for assistance.

Measuring the electrical conductivity of the fuel sample with a conductivity meter is easy. Follow the manufacturer’s instructions. 

Check the AAMA specification for fuel ethanol to

obtain more details about recommended conductivity

meters. Check the fuel’s conductivity every time onequarter of the storage tank has been dispensed or every

two weeks, whichever occurs sooner.

HANDLING FUEL ETHANOL (cont.)
17

✓ Contact medical personnel.

For skin absorption,

✓ Wash the skin with soap and rinse with large quantities of water,

✓ Remove contaminated clothing, and

✓ Contact medical personnel.

For eye absorption,

✓ Flush the eyes with water for at

least 15 minutes and

✓ Contact medical personnel.

For ingestion,

✓ Have the person lie down and 

keep him/her warm,

✓ Do not induce vomiting, and

✓ Contact medical personnel 

immediately.

Fire Safety Considerations

Fuel ethanol fires generally release less heat than

gasoline fires, but any fires should be taken seriously. Use

a CO2, halon, or dry chemical extinguisher that is marked

B, C, BC, or ABC. An alcohol-type or alcohol-resistant

(ARF) foam may be used to effectively combat fuel

ethanol fires. Never use water to control a fire involving

high-concentration fuel ethanol such as E85.

Before constructing any refueling installations, consult

your local Fire Marshall. Regulations governing the safe

SAFETY PROCEDURES

Health Considerations

Treat fuel ethanol with a high degree of respect, just

as you would any fuel. Minimize exposure to the fuel. Just

like gasoline, fuel ethanol is flammable and poisonous,

and may contain additives that are harmful, even in

casual contact. And, do not confuse fuel ethanol 

with alcohol intended for human

consumption — fuel ethanol can

poison and kill you. Never drink fuel

ethanol!

Exposure to fuel ethanol can

occur by breathing its vapors

(inhalation), getting it on the skin or

in the eyes (skin absorption), or accidentally swallowing it (ingestion).

The following symptoms of exposure to fuel ethanol may appear 

immediately:

✓ Dullness of memory and 

concentration;

✓ Impaired motor coordination;

and

✓ Drowsiness, stupor, and finally coma.

Contact medical personnel immediately in cases 

of exposure.

The first-aid treatment needed will depend on the

type of exposure:

For inhalation,

✓ Move away from the vapors to fresh air and

MORE ➾
18

handling of fuel ethanol vary from area to area. Only your

local officials will know the regulations in force in your

locale.

Safety Codes

The safety standards for handling and storing E85 are

the same as those for gasoline. The National Fire

Protection Agency (NFPA) has two standards that apply

to fuel ethanol blends: NFPA 30, “Flammable and

Combustible Liquids Code,” and NFPA 30A, “Automotive

and Marine Service Station Code.” These codes contain

information on refueling facilities, storage, and handling

requirements for all flammable and combustible liquids.

NFPA assigns both ethanol and methanol fuels (including

E100 and M100) to the same class as gasoline. Contact

your local Fire Marshall or the NFPA for copies of these

standards.

A Material Safety Data Sheet (MSDS) for E85 is shown

in Appendix F. 

Symptoms of Exposure

Dullness of memory and concentration

Impaired motor coordination

Drowsiness, stupor, and finally coma

Treatment Compared

Exposure First Aid Treatment to Gasoline Exposure

Inhalation Move away from the vapors to fresh air and contact medical Same

personnel.

Skin absorption Wash the skin with soap and rinse with large quantities of water; Same

remove contaminated clothing; and contact medical personnel.

Eye absorption Flush the eyes with water for at least 15 minutes and contact Same 

medical personnel.

Ingestion Have the person lie down and keep him/her warm; do not induce Different 

vomiting; and contact medical personnel immediately.

TABLE 3 FIRST AID TREATMENTS FOR EXPOSURE TO FUEL ETHANOL

SAFETY PROCEDURES (cont.)
19

APPENDIX A: Comparison of Fuel Properties

Gasoline

Property Methanol Ethanol (87 Octane) E85 

Chemical formula CH3OH C2H5OH C4 to C12 chains *

Main constituents

(% by weight) 38C, 12H, 50O 52C, 13H, 35O 85-88C, 12-15H 57C, 13H, 30O

Octane (R+M)/2 100 98-100 86-94 96

Lower heating value 

(Btu/lb) 8,570 11,500 18,000-19,000 12,500

Gallon equivalent 1.8 1.5 1 1.4

Miles per gallon as 

compared to gasoline 55% 70% – 72%

Relative tank size to 

yield driving range Tank is 1.8 times Tank is 1.5 times 1 Tank is 1.4 times

equivalent to gasoline larger larger larger 

Reid vapor pressure (psi) 4.6 2.3 8-15 6-12

Ignition point

Fuel in air (%) 7-36 3-19 1-8 * Temperature (approx.) (°F) 800 850 495 *

Specific gravity 

(60/60°F) 0.796 0.794 0.72-0.78 0.78

Cold weather starting Poor Poor Good Good

Vehicle power 4% power increase 5% power increase Standard 3-5% power increase

Stoichiometric air/fuel

ratio (by weight) 6.45 9 14.7 10

* Depends on percentage and type of the hydrocarbon fraction.
20

APPENDIX B: AAMA Specifications for Fuel Ethanol (Ed75-Ed85) as

Dispensed to Vehicles (Purged or Unpurged Dispenser)

Property Value for Class Test Method

ASTM volatility class (applications per ASTM D 4814) 1 23 –

Ethanol, plus higher alcohols (minimum, volume %) 79 74 70 ASTM D 5501

Hydrocarbons (including denaturant)/(volume %) 17-21 17-26 17-30 N/A

Vapor pressure at 37.8°C 

kPa 38-59 48-65 66-83 ASTM D 4953, D 5190,

psi 5.5-8.5 7.0-9.5 9.5-12.0 D 5191, D5482

Octane TBD N/A

Higher aliphatic alcohols, C3-C8 (maximum, volume %) 2 ASTM D 5501

Acidity as acetic acid (maximum, mg/kg) 50 ASTM D 1613

Chloride ion (maximum, mg/kg) 1 Ion chromatography

Total chlorine as chlorides (maximum, mg/kg) 2 ASTM D 4929, Method B

Electrical Conductivity (maximum, micro S/m) 500 ASTM D 1125

Gum, unwashed (maximum, mg/100 mL) 20 ASTM D 381

Gum, washed (maximum, mg/100 mL) 5.0 ASTM D 381

Particulates (maximum, mg/L) 0.1 ASTM D 2276

Aluminum (maximum, mg/L) 0.03

Iron (maximum, mg/L) 0.1

Filter plugging TBD N/A

Lead (maximum, mg/L) 2.6 ASTM D 3229

Phosphorus (maximum, mg/L) 0.2 ASTM D 3231

Sulfur (maximum, mg/kg) 50.0 ASTM D 3120, D 1266, D 2622

Water (maximum, mass %) 1.0 ASTM E 203

Denaturant (maximum, %) 5.0 ASTM D 4806

Appearance Product shall be visibly free of Use a strong beam of light

suspended or precipitated aimed diagonally toward 

contaminants (shall be clear the eye and view through 

and bright). a clear glass 250 mL beaker.

N/A = Not applicable.

TBD = To be determined.

ICP-Atomic emission

spectroscopy
21

APPENDIX C: Geographical Fuel-Marketing Regions

Volatility Class by Month

State and Fuel-Marketing Region Jan Feb March April May June July Aug Sept Oct Nov Dec

Alabama 2 2 2 2 2/1 1 1 1 1 1/2 2 2

Alaska

Southern Region 3 3 3 3 3/2 2/1 1 1/2 2/3 3 3 3

South Mainland 3 3 3 3 3/2 2/1 1/2 2 2/3 3 3 3

Arizona

North of 34 lat. & E of 111° long. 3 3 3 3/2 2 2/1 1 1 1/2 2/3 3 3

Remainder south of 34° 2 2 2 2/1 1 1 1 1 1 1/2 2 2

Arkansas 3 3 3/2 2/1 1 1 1 1 1/2 2 2/3 3

California

North Coast 2 2 2 2 2 2/1 1 1 1 1/2 2 2

South Coast 2 2 2 2 2/1 1 1 1 1 1/2 2 2

Southeast 3 3/2 2 2 2/1 1 1 1 1/2 2 2/3 3

Interior 2 2 2 2 2 2/1 1 1 1 1/2 2 2

Colorado

East of 105° longitude 3 3 3 3/2 2 2/1 1 1 1/2 2/3 3 3

West of 105° longitude 3 3 3 3 3/2 2 2/1 1/2 2/3 3 3 3

Connecticut 3 3 3 3/2 2 2/1 1 1 1/2 2 2/3 3

Delaware 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

District of Columbia 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

Florida

North of 29° latitude 2 2 2 2/1 1 1 1 1 1 1/2 2 2

South of 29° latitude 2 2/1 1 1 1 1 1 1 1 1 1/2 2

Georgia 3 3/2 2 2/1 1 1 1 1 1 1/2 2 2/3

Hawaii 1 1 1 1 1 11 1 1 1 1 1

Idaho 3 3 3 3/2 2 2 2/1 1/2 2 2/3 3 3

Illinois

North of 40° latitude 3 3 3 3/2 2 2/1 1 1 1/2 2/3 3 3

South of 40° latitude 3 3 3 3/2 2/1 1 1 1 1/2 2/3 3 3

Indiana 3 3 3 3/2 2/1 1 1 1 1/2 2/3 3 3

Iowa 3 3 3 3/2 2 2/1 1 1 1/2 2/3 3 3

Kansas 3 3 3 3/2 2 2/1 1 1 1/2 2/3 3 3

Kentucky 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

Louisiana 2 2 2 2/1 1 1 1 1 1 1/2 2 2

Maine 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

Maryland 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

Massachusetts 3 3 3 3/2 2 2/1 1 1 1/2 2 2/3 3

Michigan

Lower Peninsula 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

Upper Peninsula 3 3 3 3 3/2 2/1 1 1/2 2 2/3 3 3

MORE ➾
22

APPENDIX C: Geographical Fuel-Marketing Regions (cont.)

Volatility Class by Month

State and Fuel-Marketing Region Jan Feb March April May June July Aug Sept Oct Nov Dec

Minnesota 3 3 3 3 3/2 2/1 1 1/2 2 2/3 3 3

Mississippi 2 2 2 2/1 1 1 1 1 1 1/2 2 2

Missouri 3 3 3 3/2 2/1 1 1 1 1/2 2/3 3 3

Montana 3 3 3 3 3/2 2 2/1 1/2 2/3 3 3 3

Nebraska 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

Nevada

North of 38° latitude 3 3 3 3/2 2 2 2/1 1/2 2 2/3 3 3

South of 38° latitude 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

New Hampshire 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

New Jersey 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

New Mexico

North of 34° latitude 3 3 3 3/2 2 2/1 1 1 1/2 2/3 3 3

South of 34° latitude 3 3 3/2 2/1 1 1 1 1 1 1/2 2/3 3

New York

North of 42° latitude 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

South of 42° latitude 3 3 3 3/2 2/1 1 1 1 1/2 2 2/3 3

North Carolina 3 3 3/2 2 2/1 1 1 1 1/2 2/3 3 3

North Dakota 3 3 3 3 3/2 2/1 1 1/2 2 2/3 3 3

Ohio 3 3 3 3/2 2/1 1 1 1 1/2 2/3 3 3

Oklahoma 3 3 3 3/2 2/1 1 1 1 1/2 2 2/3 3

Oregon

East of 122° longitude 3 3 3 3/2 2 2 2/1 1/2 2 2/3 3 3

West of 122° longitude 3 3/2 2 2 2 2/1 1 1 1/2 2 2 2/3

Pennsylvania

North of 41° latitude 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

South of 41° latitude 3 3 3 3/2 2 2/1 1 1 1/2 2 2/3 3

Rhode Island 3 3 3 3/2 2/1 1 1 1 1/2 2 2/3 3

South Carolina 2 2 2 2/1 1 1 1 1 1 1/2 2 2

South Dakota 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

Tennessee 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

Texas

North of 31° latitude 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

South of 31° latitude 2 2 2 2/1 1 1 1 1 1 1/2 2 2

Utah 3 3 3 3/2 2 2/1 1 1 1/2 2/3 3 3

Vermont 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

Virginia 3 3 3/2 2 2/1 1 1 1 1/2 2 2/3 3

Washington

East of 122° longitude 3 3 3/2 2 2 2/1 1 1 1/2 2/3 3 3

West of 122° longitude 3 3/2 2 2 2 2/1 1 1 1/2 2 2 2/3

West Virginia 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

Wisconsin 3 3 3 3/2 2 2/1 1 1/2 2 2/3 3 3

Wyoming 3 3 3 3 3/2 2 2/1 1/2 2 2/3 3 3
23

To ensure the high quality of your fuel, it may be wise

to send a sample of your fuel ethanol to a laboratory for

analysis. Your fuel provider may be able to recommend a

laboratory in your area that can perform this type of test,

or for a list of laboratories that perform E85 tests, call the

U.S. DOE Alternative Fuels Hotline (800-423-1DOE). To safely

ship a sample of the fuel, follow all of your shipper’s

requirements for hazardous materials. Be sure that the 

following information appears on the outside of the 

package —

DOT Shipping Name:

“Denatured Ethanol (Ethanol and Gasoline)”

Identification Number:

“NA1987”

Diamond Labels: 

Health 2, Flammability 3, Reactivity 0

Label: 

“Flammable Liquid”

Arrow Label:

“This End Up”

A one-gallon container compatible with ethanol is

recommended. The SturdeeSeal UN 4G gasoline combination package is one product on the market that has

been successfully used for this purpose. The combination

package contains a UN-marked one-gallon metal can

with an epoxy phenolic lining, fiberboard, polyethylene

bag, and closing tape. For information on where to

obtain this package, see the section, For More

Information, Call . . . , found at the back of this guidebook.

APPENDIX D: E85 Shipping Procedures
24

This procedure is based on a similar procedure for methanol developed by General

Motors.* Errors in ethanol content of up to 5 percentage points may occur for E85 blended

with gasoline containing detergent additives.

Essential Equipment

50-mL volumetric pipette

100-mL graduated cylinder with stopper

Procedure

1. Use the volumetric pipette to extract exactly 50 mL of fuel and place the fuel in the

graduated cylinder.

2. Add approximately 50 mL of water to the

fuel in the cylinder. (The total volume should

not exceed 100 mL.)

3. Place the stopper in the cylinder, and 

shake the contents vigorously for about 

15 seconds.

4. Loosen the stopper to release the pressure in

the cylinder but do not remove the 

stopper.

5. Tighten the stopper. Place the cylinder

upright on a level surface away from sunlight

and heat sources. Wait 15 minutes. 

If separation of the two layers is not complete, lightly tap the cylinder to encourage

complete separation.

6. Record the level of the top and bottom of

the hydrocarbon layer (upper layer). 

Do this by reading the measurement at the

lowest part of the meniscus at both the top

and bottom of the upper layer. (The meniscus is the curved border [the interface]

between the air and the top of the liquid 

or between the hydrocarbon layer and 

the water layer. See the accompanying

illustration.)

MENISCUS

7. Find the volume (in milliliters) of the upper

layer by subtracting the value at the lower

meniscus from the value at the upper

meniscus.

8. Calculate the ethanol concentration (percent by volume) by this equation:

% ethanol = 98.69 - [1.97 x volume of the

upper layer in milliliters].

9. Calculate the hydrocarbon concentration

(percent by volume) by this equation:

% hydrocarbon = 1.31 + [1.97 x volume of

the upper layer in milliliters].

APPENDIX E: Method to Determine the Total Hydrocarbon

Content of Alcohol Fuel

* “A Simple Method to Determine the Methanol

Content of Methanol Fuels,” Society of Automotive

Engineers paper number 912421 by Scott W. Jorgensen,

Robert L. Furey, and Kevin L. Perry.
25

APPENDIX F: Material Safety Data Sheet for E85

(Reproduce locally) OSHA 174, Sept. 1985

Material Safety Data Sheet

May be used to comply with

OSHA’s Hazard Communication Standard,

29 CFR 1910.1200. Standard must be

consulted for specific requirements.

U.S. Department of Labor

Occupational Safety and Health Administration

(Non-Mandatory Form)

Form Approved

OMB No. 1218-0072

IDENTITY (As Used on Label and List)

Fuel Ethanol Ed85

Note: Blank spaces are not permitted. If any item is not applicable, or no

information is available, the space must be marked to indicate that.

Section I

Manufacturer’s Name

Archer Daniels Midland Company

Emergency Telephone Number

800/424-9300 or 217/424-5200

Address (Number, Street, City, State, and ZIP Code)

4666 Fairies Parkway

Telephone Number for Information

217/362-3980

Decatur, Illinois 62526

Date Prepared

7/5/95

Signature of Preparer (optional)

Section II — Hazardous Ingredients/Identity Information

Hazardous Components (Specific Chemical Identity: Common Name(s)) OSHA PEL ACGIH TLV

Other Limits

Recommended % (optional)

Ethyl Alcohol (200 proof) CAS 0064-17-5 80%

Natural Gasoline CAS 008-006-619 20%

*Benzene CAS-0071-43-2 1ppm 10ppm < 1100ppm

*"A chemical known to the State of

 California to cause cancer"

Section III — Physical/Chemical Characteristics

Boiling Point

96°-170°F

Specific Gravity (H2O = 1)

0.76-0.78

Vapor Pressure (mm Hg.)

340-560

Melting Point

NA

Vapor Density (AIR - 1)

2.0-4.0

Evaporation Rate

(Butyl Acetate = 1)

Not

 Estimated

Solubility in Water

60-70 gm./100ml.

Appearance and Odor

Clear, colorless volatile liquid with an ethereal odor.

Section IV — Fire and Explosion Hazard Data

Flash Point (Method Used)

–20°F to –4°F TCC Flammable LimitsNot estimated LEL1.4 UEL19.0

Extinguishing Media

Carbon dioxide dry chemical, water for small fires. Polar solvent foam for large fires.

Special Fire Fighting Procedures

Use necessary protective equipment and breathing apparatus as would normally be used when

fighting fires where there may be danger of breathing hazardous products of combustion.

Unusual Fire and Explosion Hazards

Flammable liquid.

MORE ➾
26

APPENDIX F: Material Safety Data Sheet for E85 (cont.)

Page 2 * U.S.G.P.O.: 1986-491-529/45775

Section V — Reactivity Data

Stability Unstable Conditions to Avoid

None in normal use. Stable

X

Incompatibility (Materials to Avoid)

May react vigorously with oxidizing materials.

Hazardous Decomposition or Byproducts

Combustion may produce COx, NOx and reactive hydrocarbons. Hazardous

Polymerization

May Occur Conditions to Avoid

None in normal use. Will Not Occur

X

Section VI — Health Hazard Data

Route(s) of Entry: Inhalation?

(A) Skin?(B)

Ingestion?

(C) Health Hazards (Acute and Chronic)

(A) May cause mucous membrane irritation; unconsciousness; coma; respiratory failure and death.

(B) May cause skin irritation as a result of defatting. (C) Moderately toxic (LD50 0.5 to

5 G/Kg), gastrointestinal irritation, vomiting, CNX depression, coma.

Carcinogenicity: NTP?

Not determined

IARC Monographs??

Not determined

OSHA Regulated?

Yes

Signs and Symptoms of Exposure

May cause dizziness, loss of balance and coordination.

Medical Conditions

Generally Aggravated by Exposure Not determined.

Emergency and First Aid Procedures

If swallowed, do not induce vomiting. If inhaled, remove person to fresh air. Give artificial

respiration if breathing has stopped. Call a physician. If splashed in eyes or on skin, flush

immediately with copious amounts of water.

Section VII — Precautions for Safe Handling and Use

Steps to be Taken in Case Material is Released or Spilled

Eliminate all sources of ignition. Small spills should be flushed with large quantities

of water. Large spills should be collected for waste disposal.

Waste Disposal Method

Do not allow to enter sewers where vapors may become ignited. Incinerate in

furnace where permitted under appropriate federal, state & local regulations or dispose of in

a site stipulated for hazardous materials.

Precautions to Be Taken in Handling and Storage

Keep away from heat, sparks, & open flames. Keep container closed. Use with adequate

ventilation. Other Precautions

Use explosion proof electrical equipment and non-sparking tools. Ground electrical

equipment.

Section VIII — Control Measures

Respiratory Protection (Specify Type)

Air supplied mask for high concentrations. Ventilation Local Exhaust

Preferred

Special

None Mechanical (General)

Acceptable OtherNone Protective Gloves

Rubber

Eye Protection

Goggles

Outer Protective Clothing or Equipment

Eye bath and safety shower.

Work/Hygienic Practices

NA
27

General

U.S. Department of Energy

Alternative Fuels Data Center

National Alternative Fuels Hotline

P.O. Box 12316

Arlington, VA 22209

703-528-3500 (User Support Services)

800-423-1DOE (Toll-Free)

e-mail: hotline@afdc.nrel.gov

Governors’ Ethanol Coalition

Nebraska Energy Office

The Atrium, First Floor, 1200 N Street

P.O. Box 95085

Lincoln, NE 68509

402-471-2867

Contact: Robert Harris

National Corn Growers Association

1000 Executive Parkway, Suite 105

St. Louis, MO 63141

314-275-9915

National Ethanol Vehicle Coalition*

1648 Highway 179

Jefferson City, MO 65109

573-635-8445

800-E85-8895

Contact: Phillip Lampert

National Renewable Energy Laboratory

1617 Cole Boulevard

Golden, CO 80401-3393

303-275-4481

Contact: Norm Hinman, Biofuels Program Manager

Renewable Fuels Association

One Massachusetts Avenue, N.W., Suite 820

Washington, DC 20001

202-289-3855

U.S. Environmental Protection Agency

Division of Regulatory Programs & Technology

2565 Plymouth Road

Ann Arbor, MI 48105

313-668-4296

Ethanol Fuel Codes and Safety

National Fire Protection Association

1 Batterymarch Park

P.O. Box 9101

Quincy, MA 02269-9101

617-984-7407

Contact: Ted Lemoff

Standards 

American Automobile Manufacturers Association

1401 H Street, N.W., Suite 900

Washington, DC 20005-2110

202-326-5500

American Society for Testing and Materials

100 Bar Harbor Drive

West Conshohocken, PA 19428-2959

Publication and Customer Service

610-832-9585

Society of Automotive Engineers

400 Commonwealth Drive

Warrendale, PA 15096-0001

412-776-5760

Materials

Convault 

4109 Zeering Road

Denair, CA 95316

209-632-7571

FOR MORE INFORMATION, CALL . . .

MORE ➾ * For the name of a contact nearest your area, call the National Ethanol

Vehicle Coalition at 800-E85-8895.
28

Cuno Separations Systems

50 Kerry Place

Norwood, MA 02062

800-367-6805

EMCO Wheaton

4001 Weston Parkway

Cary, NC 27513

800-285-3626

Gasboy of Canada Ltd.

430-T Industrial Road

London, Ontario, Canada N5V 1T5

519-453-5340

Goodall Rubber Co.

Grover Mill Road, Suite 203

Lawrenceville, NJ 08648

609-799-2000

Goodyear

331 McCarter Hwy

Newark, NJ 07114

201-242-5550

OPW Fueling Components

9393 Princeton-Glendale Road

P.O. Box 405003

Cincinnati, OH 45240-5003

800-947-6976

Tokheim Co.

1123 C Avenue NW

P.O. Box 74062-T

Cedar Rapids, IA 52407

319-362-4847

U-Fuel, Inc.

306 Barstow Street

P.O. Drawer 1511

Eau Claire, WI 54702

715-836-0905

Alternative Fuel Vehicles

Chrysler Corp.

Alternative Fuel Vehicle Sales and Marketing

27777 Franklin Road

Southfield, MI 48034

810-984-3644

Contact: Mike Clement

Ford Motor Co.

Alternative Fuels Program

The American Road

Dearborn, MI 48121

800-ALT-FUEL

General Motors Corp.

Automotive Emissions Control

3044 West Grand Boulevard

Detroit, MI 48202

313-556-7723

Contact: Gerald Barnes, Manager

DOE Alternative Fuels Data Center

National Alternative Fuels Hotline

P.O. Box 12316

Arlington, VA 22209

703-528-3500 (User Support Services)

800-423-1DOE (Toll-Free)

e-mail: hotline@afdc.nrel.gov

Alcohol-Fueled Vehicle Technician Training

Central Community College, Platte Campus

P.O. Box 1027

Columbus, NE 68602-1027

402-562-1280

Contact: Doug Pauley

Containers

Labelmaster

5724 N. Pulaski Road

Chicago, IL 60646-6797

800-621-5808

FOR MORE INFORMATION, CALL . . . (cont.)
29

?

Remember that a vehicle is a complex machine, so

most of the vehicle’s problems are not related to its fuel.

Always follow the directions and recommendations from

the owner’s manual supplied with the vehicle by the

manufacturer.

Problem: Vehicle does not start, idle is irregular, lack of

power — and you suspect that fuel is a contributing factor

Solution:

• Check the hydrocarbon content of the fuel. If your

vehicle is equipped with an alcohol sensor, read the number from your onboard display; if you do not have an

alcohol sensor, refer to Appendix E for directions on how

to measure the hydrocarbon content. Contact your fuel

provider to see how to modify the fuel to get the correct

hydrocarbon content.

• If you have an electrical conductivity meter, check

the conductivity of the fuel. Check all equipment and

material in contact with the fuel for incompatibility and

possible degradation. Contact your fuel provider and

equipment supplier for assistance.

• Check the fuel filter in the vehicle. If deposits are

present, call your fuel provider or the vehicle manufacturer for assistance.

Problem: Fuel sample is not clear and/or particles are 

present in the fuel

Solution:

• The fuel has become contaminated. Check the

refueling facility for materials compatibility problems.

Check for excessive wear or degradation of nozzle, hoses,

filters, etc. Check for possible external sources of contamination (for example, dirt around the nozzle or refueling

valve) and remedy them. Contact your fuel provider and

equipment supplier for assistance.

Problem: Fuel sample electrical conductivity reading is

too high (over 500 micro S/m)

Solution:

• The fuel has become contaminated. Check the

refueling facility for materials compatibility problems.

Check for excessive wear or degradation of nozzle, hoses,

filters, etc. Check for possible external sources of contamination (for example, dirt around the nozzle or refueling

valve) and remedy them. Contact your fuel provider and

equipment supplier for assistance.

Problem: White powdery deposits on the nozzle

Solution:

• Check the nozzle material for compatibility with

ethanol. Contact your equipment supplier or the nozzle

manufacturer for assistance.

Problem: Delivery of the fuel to the vehicle is slow or no

fuel is coming through the nozzle

Solution:

• Check the electrical connection to the fuel pump.

Check the filter to see if it is plugged. Look for possible

causes of material degradation before the filter. Look for

possible external sources of contamination. Contact your

fuel provider or equipment supplier for assistance.

TROUBLESHOOTER’S GUIDE