Naftosense Launches New Ethanol Leak Detection System

Why Ethanol Leak Detection Matters

Ethanol plays an increasingly important role in modern fuel blends. Oil and gas companies now produce, transport, and store ethanol on a massive scale as they meet government blending mandates and consumer demand for lower-emission gasoline. Unlike traditional hydrocarbons, ethanol mixes easily with water. That simple fact creates a problem. Leaks often escape traditional detection systems because the alcohol dissolves into water rather than separating on the surface like gasoline or diesel.

This challenge presents ethanol handling as a distinct kind of risk. Contaminated groundwater can spread fuel compounds farther and faster when ethanol is present. Regulators take a closer look at these leaks because they can create long-lasting environmental and safety issues. Companies need a reliable way to identify problems before they turn into violations or costly cleanups.

The Role of Ethanol in Fuel Blending

Ethanol provides clear benefits as a fuel additive. It increases octane ratings and helps gasoline burn more completely, reducing some types of tailpipe emissions. It is also widely available, with the United States producing billions of gallons each year, mostly from corn. Oil companies blend it into gasoline at levels ranging from 10 to 15 percent for everyday use, and sometimes higher for specialized applications.

Despite these benefits, ethanol brings new challenges. Higher blends reduce fuel economy and can place stress on engines not designed for them. Production plants release significant amounts of hazardous air pollutants, and large-scale cultivation of corn raises concerns about land use and greenhouse gas emissions. These debates underscore the industry's need to continually improve its environmental performance at every stage, from plant operations to storage tanks.

How Leaks Happen in Transfer and Storage

Ethanol moves from plants to terminals and ultimately into pipelines and trucks. Each step creates opportunities for leaks. Unlike crude oil or refined fuels, ethanol does not stay separate from water. When a tank, pipe, or fitting leaks, the ethanol can dilute into surrounding water sources. Once this happens, most conventional sensors fail to detect the problem because they are designed to spot hydrocarbons floating on water, not alcohol dissolved within it.

That limitation creates blind spots for operators. Undetected leaks can damage aquifers, violate environmental laws, and spark expensive remediation projects. Companies need technology that can distinguish ethanol even when it is diluted in water.

The Naftosense Solution

Naftosense developed a new detection system built specifically for this challenge. The technology ignores the presence of water and zeroes in on ethanol and other alcohols. It works even at 20 percent concentration, which is the level regulators see as a real problem, while anything under 20 percent usually isn’t treated as a threat. This approach gives operators confidence that they can identify issues promptly and take action before minor problems escalate into significant events.

Oil and gas companies now have a tool designed for the realities of ethanol blending. By addressing the weaknesses of conventional leak detection, Naftosense offers a practical solution that supports both regulatory compliance and corporate sustainability goals. Companies that invest in this system can strengthen their safety programs, protect the environment, and build public trust at a time when every gallon of biofuel faces scrutiny.

Looking Ahead

Ethanol will remain a cornerstone of gasoline production for the foreseeable future. As production expands, so do the risks of leaks during transfer, storage, and handling. The companies that succeed in this new era will be those that not only meet blending mandates but also show they can manage the environmental responsibilities that come with them.

Naftosense's ethanol leak detection system arrives at precisely the right moment. It gives producers and refiners a reliable way to manage risk, stay compliant, and demonstrate leadership in an industry that demands both innovation and accountability.

How Polymer Absorption Sensors Revolutionized Leak Detection Systems

Polymer Absorption Sensor technology sits at the center of today’s most reliable hydrocarbon leak detection systems. At its core, PAS uses engineered polymers that selectively absorb hydrocarbons, swell, and trigger an immediate, measurable change—usually electrical or optical. That simple physical principle lets operators spot minor releases early, before they become expensive cleanups or safety incidents.

From materials science to field-hardened sensors

PAS traces its roots to mid-20th-century materials research, when engineers began exploiting polymer swelling to detect target chemicals. By the late 1970s and 1980s, industrial leak detection moved from manual checks and float switches toward polymer-based sensing cables that could monitor long runs continuously. In hydrocarbons, early commercial systems emerged by the late 1990s, with cable designs that used conductive polymers to complete a circuit when exposed to fuels.

Engineers also adapted PAS to fiber optics: a swellable polymer jacket sits over the fiber; when hydrocarbons contact the jacket, it microbends or otherwise alters the fiber enough that an optical time-domain reflectometer identifies the event and its position. That variant proved helpful around liners and buried infrastructure where electrical methods can be inconvenient.

How PAS actually detects leaks

PAS relies on a chemically sensitive polymer layer applied to a cable or probe. Hydrocarbon molecules diffuse into that layer and cause it to swell. Designers translate that swelling into a signal in a few ways. For example, the polymer can bridge electrodes and change resistance, push on an optical fiber and increase attenuation, or shift other measurable properties. Crucially, hydrocarbon-specific polymers let these sensors ignore water and many inorganics, so the system avoids nuisance trips in humid or wet locations.

Modern vendors have toughened the introductory chemistry to work in air, underground soils, standing water, and even icy conditions. They also focus on low cross-sensitivity—responding to butane and heavier hydrocarbons while shrugging off weather and contaminants—so operators can trust alarms during real storms, washdowns, and seasonal swings.

The “digital cable” era: location, addressability, and reuse

The big leap over the past two decades came from digitalization. Instead of a simple alarm loop, PAS cables now integrate with locating modules that pinpoint the leak within about a meter along the cable, making field response faster and cheaper. Many systems also support “addressable” segments—each section carries a microchip ID—so panels can report multiple, simultaneous events and exact locations across extensive facilities. Reusable cable designs further cut lifecycle cost: after cleanup, you put the same cable back in service.

Where PAS thrives

Operators deploy PAS wherever liquid hydrocarbons must never go unnoticed. Along above-ground pipe racks and pump pads, PAS cable is exposed to sun, vibration, and traffic while remaining selective to fuels. Around tank bottoms and sumps, it covers long perimeters and complex geometries. Inside or around double-walled piping, it watches the annulus so any loss triggers an early alert. Refineries, terminals, pipelines, power plants, and airports rely on these systems because they provide continuous coverage with precise location and minimal false alarms.

What changed recently: reliability in the real world

PAS adoption accelerated as vendors solved the field problems that once limited the technology. Newer formulations maintain sensitivity in cold, humid, or flooded environments and deliver fast recovery once you remove the leak source. Qualification programs now validate performance across soils, backfill types, and water bodies, making PAS viable for remote pipelines and harsh climates. Industry studies and field pilots over the past decade—spanning petroleum pipelines to irrigation and groundwater protection—also strengthened operator confidence that PAS can run unattended for long periods while still catching minor releases.

Why PAS fits modern risk and compliance goals

Environmental rules are continually tightening, stakeholders are demanding faster reporting, and CFOs are seeking lower total cost of ownership. PAS answers all three. Distributed cables or compact probes create a continuous sensing “skin” that shrinks detection time and helps prove due diligence. Addressable segments and meter-level location shorten investigation time and excavation scope. Hydrocarbon selectivity reduces nuisance alarms, keeping teams responsive to the alarms that matter. And because digital PAS panels tie into SCADA and cloud dashboards, they fit cleanly into predictive maintenance programs.

The outlook

Expect steady growth as users standardize on mixed architectures: cable for long-run coverage and probes for high-risk points like valves, sumps, and dispensers. The chemistry will continue to improve—faster uptake for light ends, better recovery for heavy crudes, and coatings that resist fouling. On the data side, locating panels and IIoT nodes will push richer diagnostics to enterprise systems, while improved reuse and durability keep lifecycle costs attractive versus single-use or moisture-only cables.

A final word about Naftosense (Dublin, Ohio)

Naftosense designs and manufactures PAS-based leak detection systems that pair hydrocarbon-selective polymer sensors with addressable electronics for fast, precise alarms. The company publishes practical guidance and a current catalog that outlines cable and probe options, reuse expectations, and integration with progressive alarm modules. Based in Dublin, Ohio, Naftosense supports operators that need real-time integrity monitoring in harsh environments—tank farms, terminals, generator rooms, and more—with a focus on reliability, selectivity, and total cost of ownership.

New Naftosense Industrial Leak Detection Catalog – Now Available

Naftosense has just released its latest 12-page catalog, offering a comprehensive look into its industry-leading hydrocarbon leak detection technologies. Designed for engineers, facility operators, and industrial safety professionals, this newly published catalog introduces the most advanced leak detection solutions available today—built to perform in the world's harshest environments.

The new catalog is more than just a product list—it's a roadmap for protecting critical infrastructure. It outlines proven solutions for oil and gas, power generation, marine terminals, chemical processing, and countless other applications where safety, uptime, and environmental responsibility matter most. From pipelines to refineries, tank farms to generator rooms, Naftosense systems detect hydrocarbon leaks with speed, precision, and reliability.

At the heart of Naftosense's innovation is its Polymer Absorption Sensor (PAS) technology, a time-tested method enhanced by innovative control modules and advanced communication protocols. Readers will find detailed product profiles for sensors and cables like the FLD-HSC, FLD-PHD, and FLD-O2W-SP, along with powerful control panels such as the FLD-TSP and FLD-SMP-MB. Each product is purpose-built to deliver early detection, reduce false alarms, and integrate seamlessly with SCADA, PLCs, or cloud-based platforms like Elecsys Connect.

The catalog also highlights Naftosense's commitment to long-term performance with reusable sensors, modular system architecture, and a 10-year standard warranty on all products. Installation, commissioning, maintenance services, and expert engineering support round out a complete leak detection offering that keeps facilities safer and smarter.

Whether you're designing a new facility or retrofitting existing infrastructure, the Naftosense catalog provides the clarity and confidence you need to select the right leak detection system—one that works reliably for decades.

Explore the new catalog today at Naftosense.com or call 614-350-0911 to connect with a leak detection specialist. Protect your people, your assets, and the environment—with Naftosense, not a drop is spilled.

Miniature Leak Detection, Maximum Confidence: A Deep Dive into the Naftosense FLD-HCSP

In today’s industrial landscape, timely detection of hydrocarbon leaks—especially in cramped or hazardous spaces—can mean the difference between operational safety and environmental catastrophe. Enter the Naftosense FLD-HCSP: a miniature, stainless-steel-encased hydrocarbon leak detection probe designed to reliably sniff out crude oil, refined fuels, and vapors, even in the most unforgiving conditions.

What Is the FLD-HCSP?

The FLD-HCSP is a compact, passive hydrocarbon leak detection sensor. Built for high-risk industrial environments, it measures only 3.74 inches (95 mm) in length and 0.59 inches (15 mm) in diameter. Despite its small footprint, this device punches far above its weight class, offering robust performance, minimal maintenance, and quick detection across a broad temperature spectrum—from -40°F to 185°F (-40°C to 85°C).

Naftosense designed this sensor to interface seamlessly with its acquisition modules and intrinsically safe field boxes, making integration into third-party systems straightforward via analog outputs, dry contacts, or serial communications.

Real-World Applications

The FLD-HCSP thrives where space is limited, danger is present, and precision is critical. Common applications include:

• Tank interstitial space monitoring
• Leak detection in dual-wall piping systems
• Detection in sump pits, pump seals, and leak detection wells
• Fuel containment monitoring in retail and downstream facilities
• Rotating equipment (machine shafts, pumps) where conventional sensors may fail

It also excels as a fume or vapor detector, capable of identifying hydrocarbons diffused through soil or air with minimal false alarms—making it ideal for early-stage leak warnings.

Key Features That Set It Apart

1. Fast, Reliable Detection

The FLD-HCSP detects various hydrocarbons in as little as 20 seconds (gasoline and jet fuel) to under 10 minutes(heavy crude), depending on the substance. This speed aligns with or exceeds standards such as FM7745.

2. Reusability and Ease of Maintenance

The sensor is reusable and cleanable, thanks to an optional quick-disconnect jumper cable. This significantly reduces lifecycle costs and supports a rapid return to service after contamination.

3. Total Safety in Hazardous Zones

Designed as a passive element, the FLD-HCSP carries Class I, Division 1, and Zone 0 hazardous location certifications under ATEX, IECEx, and U.S. standards—allowing deployment in the most stringent environments without risk of ignition.

4. Long Operating Life

The materials used in the sensor have undergone natural aging tests, with an expected service life of over 30 years at 104°F (40°C). Naftosense backs this up with a 10-year warranty, providing peace of mind in long-term installations.

5. Harsh Environment Durability

Rated IP68, the FLD-HCSP is fully submersible and suitable for direct burial—critical for leak detection around underground tanks, lines, and containment systems.

Integration and Connectivity

Naftosense simplifies integration with approved analog or digital field modules, enabling users to deploy the probe in either wired or wireless configurations. When paired with intrinsically safe acquisition modules, users can achieve real-time monitoring, alerts, and system-wide diagnostics—all while staying compliant with PHMSA (Pipeline and Hazardous Materials Safety Administration) guidelines.

The sensor supports up to 300 feet (90 meters) of cable distance, offering flexibility in design and layout, especially in retrofits or remote field deployments.

Contact Naftosense

For product inquiries, integration support, or to request a demo, call (614) 350-0911 or visit www.naftosense.com.