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Refill Disposable Propane Tank from a Standard BBQ Cylinder

Refill Disposable Propane Tank from a Standard BBQ Cylinder
I refill my littles 1 pound propane bottles from a big one. I'm going to show you how...
 
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Step 1Safety First & Disclaimer

Disclaimer : Whenever there is propane there is risk. If you decide to refill your propane tanks yourself, you have to understand that you do it at your own risk. These cylinders aren't DOT approved for refilling. This means that you can't take your cylinders to the local propane-equipped service station and have them refilled. That's against the law. And refilled cylinders can't be sold commercially. And commercial operators can't transport refilled cylinders across state lines. There are all sorts of limitations and potential liabilities associated with refilling these cylinders. It's perfectly legal to refill them for personal use, however.

There is some safety precautions that you have to take when refilling your disposable propane cylinders and you will need to handle it properly and observe all the best-practice safety protocols.

#1 Always do the refill process outside.

#2 Never smoke during the entire process.

#3 Be sure there is no open flame in the area.

#4 Wear safety glasses and protection gloves for added safety.

Again, I am not responsible for any accident that can happen when you refill your own disposable propane tank.
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132 comments
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Jan 1, 2010. 2:37 AMjohnsned51 says:
OK, bottom line. I'm a propane supplier and I honestly hate this idea, but I'm also realistic enough to know that people will still do it, whether I like it or not.

#1 Do not, under any circumstances, a cylinder to 100 %! Propane has a high temperature/volume expansion rate. Too full when cold means it pops off when it goes hydrstatic (liquid full @ high pressure). 85% MAXIMUM!!!
#2 propane expands at a ratio of 1 to 270 when it goes from a liquid to vapor. Stack up 270 of those little cylinders in your trunk behind where your kids ride in the car on a good hot day.
#3 There is a technical explanation as to why you find half full 1# cylinders in the forest, I mean besides the fact they are wasteful litterbug jerks.
It goes like this, If you know the physical properties of propane, you know that propane appliances burn propane vapor. At atmospheric pressure propane is a vapor. At -44 degrees it is a "0" pressure liquid. Pressurize propane in a tank and you can keep it liquid at higher temperatures. Think thermodynamics. Small tanks, small volume, gas cools in cylinder faster, chills gas to -44, no vapor, no burn. No burn, must be out of gas, throw away 1/2 full tank. (yes, I've seen it! Over and over!)
Big tank, big  volume,gas cools slower, doesn't get to -44, burn hotter longer

Better yet, just don't do it. state an federal agencies do'nt write rules to "big Brother" us. They may seem misguided sometimes but they really want us tobe safe
Mar 13, 2010. 12:17 PMjcwtexas says:
To johnsend51 : why dont you learn how to write. Your negative comment gave me a headache trying to comprehend what you are trying to say.
Apr 24, 2012. 8:18 PMsconner1 says:
Here's the dummies version:
#1&2
Gasses expand with temperature.
If Nit-wit fills a tank's total volume with liquid gas under pressure, there's no room for it to expand.
Tank bursts.
Ouchy.

#3
As Nit-wit uses the gas in the cylinder quickly, more liquid evaporates cooling the rest of the liquid because of the same physics air conditioners work on.
The rest of the liquid gets so cold that it won't evaporate any more.
Nit-wit discards half full cylinder.
Half full tank has time to warm up again.
Smart guy picks up half full cylinder.
Litter Bad.
Free Propane Good.
Oct 29, 2010. 1:23 AMAfricanMystic says:
Well, Jcwtexas, it's not johnsned51's fault that you can't read and / or have no scientific education. His post was totally readable to me and is not negative. It's informative.

This is a dangerous thing to do. There is a good reason that these cylinders are not rated for refilling. They are designed for 1 use, but are over spec'd for safety. It's that safety margin that you are playing with.

Have you ever seen the sort of explosion and the devastation that one of these can cause, it can easily kill.

So if you’re going to refill, then having more info is very valuable. It could save your life. So if you do not understand the info passed on here, do not refill any cylinders. Or, rather do, and rid the gene pool of yourself.
Nov 17, 2011. 3:32 PMoldtimejewelerguy says:
I agree with AfricanMystic and johnsned51, I have an adaptor for filling the 1 pounders and I am going to toss it - It is much easier and safer and in the long run probably cheaper to just go and buy the 1 pounders on sale at a discount store!
Jul 30, 2011. 11:33 AMsnowluck2345 says:
I don't think this is proper English: His post was totally readable. Legible maybe? or understandable?
Sep 19, 2010. 5:00 PMDodge says:
Read it with a Hank Hill voice. It's easier to understand that way.

Jaykaying, Johnsned51, jkjk...
I actually learned something. Thank you.
Jul 9, 2009. 12:13 PMpmally says:
you know there's a little shrader valve in the side of most of thoes tanks so you can get the AIR out of the tank when your filling it any propane tank has a bleeder valve, that's how you get the tank full even if you had a propane pump to help fill it up
Oct 21, 2011. 3:28 PMJ57ltr says:
It's not a bleeder it is a safety vent for DOT regulations.
Apr 24, 2012. 7:58 PMsconner1 says:
Correct. The valve is to vent excess pressure so the tank won't burst.
The valve may have been used to bleed air on the first factory fill.
But as you use the original fill, propane gas exits only. No air enters the tank.
The "air" in the tank is simply leftover Propane gas at a pressure of approx 1 atmosphere.
To vent this gas is wasteful and you run the risk of overfilling the cylinder too.
What happens then? As the temperature rises the pressure valve releases the extra, wasting more gas.
Apr 24, 2012. 7:43 PMsconner1 says:
Chilling is unnecessary.
Hook up a full tank (under high pressure) to an empty tank (under less pressure relative to the full one) and open the valve between them and the pressures will equalize. Some of the contents of the full tank are forced into the empty one until the pressures are equal. Close the valve and disconnect. Done.
Jul 9, 2009. 6:33 AMrvirag says:
Chilling the cylinder is better than releasing the pressure. Releasing the pressure wastes gas, causes pollution and a fire hazard. Unburned propane is heavier than air, and its release contributes to ozone production, which eventually adds to global warming. Chilling the cylinder is safer and conserves propane gas.
Apr 24, 2012. 7:31 PMsconner1 says:
Ozone in the upper atmosphere protects us from excess UV rays.
Ozone near the ground is called smog.
Ozone is not produced by releasing or burning Propane/LNG.
Ozone is not a greenhouse gas.
Global warming is a political hoax.
Dec 31, 2010. 1:34 PMrangerman2889 says:
It's the lack of ozone that is causing global warming. thats why ozone depleting agents aren't used as propellants in cans anymore.
Jul 9, 2009. 11:11 AMjrsuperstar says:
Haven't you heard.. the earth is now in a cooling cycle.
Jul 9, 2009. 4:59 PMmartynbiker says:
its 96 degrees in my back yatrd at the moment, I live in Los Angeles.... COOLING CYCLE MY HAT! roflmao!
Jul 9, 2009. 8:05 AMmacruadhi says:
Propane is non-toxic, non-caustic and will not create an environmental hazard if released as a liquid or vapor into water or soil. If spilled in large quantity, the only environmental damage that may occur is freezing any organism or plant life in the immediate area.
AND
Propane is not considered a greenhouse gas.
source:http://www.propane101.com/propanegreenenergyfuel.htm

And my addition: Propane occurs naturally in the atmosphere, I believe, much like methane, which is a greenhouse gas.
Jan 15, 2012. 2:23 PMsokamiwohali says:
I beg to differ about your statement...here is a direct quote from your link:

Propane Liquid

Propane exists in its liquid form at or below its boiling point (-44°F) as well as when it stored under pressure. To further explain, if the temperature outside is -45°F, propane will be a liquid and you would be able to pour it out of a bucket. But as soon as the temperature rises to -44°F, the propane begins to boil and thus give off vapor. If the temperature outside is colder than -44°F, propane exists as a liquid. It's still propane but it looks a lot like water while at this cold temperature. It's colorless, odorless and tasteless...but who would take a drink of a any liquid that is 45 degrees below zero? Who would stick their finger in a glass of anything that is 45 degrees below zero? Holding a handful of ice can be quite uncomfortable (or painful) after some time but think how painful it would be if that handful of ice was almost 75 degrees colder.

Because propane boils at a temperature that is over 70 degrees lower than the freezing point of water, it has the ability to freeze skin tissue in a very short period of time (severe frostbite). The temperature properties of liquid propane are such that being aware of possible danger when dealing with propane in its liquid state is extremely important.

Propane Vapor

Propane becomes a vapor at temperatures above -44°F. Similar to water when it boils and gives off steam, propane gives off vapor when it boils. One may refer to propane vapor as "flammable steam" for simplicity. However, for the propane vapor to be ignited, there must be the right mix of air and vapor. Propane vapor is heavier than air and will sink to and collect in the lowest point it can find. If propane is vented to the outside air, it will quickly dissipate with the slightest movement of air. Conversely, if propane is vented into an air tight structure with no air movement, the propane vapor will collect on the floor and rise vertically if more propane is vented into the structure.

This is extremely important to know because if there is a propane leak in a house or building, the propane vapor will seek the lowest possible point where it will collect. Keep in mind that one gallon of propane will produce over 36 cubic feet of vapor and this vapor will settle in the lowest possible place. If the propane vapor level continues to rise, it may ignite if finds a source of ignition. The weight of propane vapor being heavier than that of air is a characteristic of propane gas that needs to be understood by all LP Gas users, not just propane companies and their employees.


 


so this means it is virtually IMPOSSIBLE in temperatures above -44*f  to just "spill" propane. it would evaporate either before OR upon hitting the ground. Propane IS toxic, IS caustic, and DOES pollute (touche though on one point that it is less pollutant by much more than gasoline, but it is still a pollutant), will freeze ANYTHING it touches. THIS DOESNT COUNT WHAT WOULD HAPPEN IF AN ACCIDENTAL SPARK WERE TO COME DOWN ON THE PROPANE!!!

Another thing to note...propane expands to 270X its original volume from a liquid. so you would see a considerable explosion/fireball if you were to ignite it. even hinting that propane is not dangerous is wrong and irresponsible.
Jul 6, 2009. 6:55 AMtwhite101 says:
How about warming it, then releasing the pressure then do this step. This should make more of a vacuum in this tank.
Jun 21, 2011. 5:52 PMGrapeApe226 says:
how about spending the money for a propane tree and extension hoses that attach to your large tank, then you can run your lantern, stove, tent heaters and the like off of your large tank and stop wasting time with this nonsense of collecting small tanks and refiling them. Here is a link, but I'm not advertising lol. look around the net for your best buy. http://www.amazon.com/Texsport-30-Propane-Distribution-Tree/dp/B000P9CZXQ
Jul 28, 2011. 9:42 AMhippydog says:
I have one of the propane trees.. very expensive and can be a pain sometimes..
Jul 28, 2011. 1:53 PMGrapeApe226 says:

Wall*Mart $20

yes you have to have some extension hoses too, I think refilling partial mini tanks is a pain too. you have to weigh the difference in your situation. Everything about camping is a pain except the relaxing by the fire lol

:)
Apr 24, 2012. 7:21 PMsconner1 says:
Not everyone wants to carry a 20 lb tank and plumbing for a overnight backpack outing.
Refilling small cylinders at home makes more sense for some.
Mar 28, 2012. 5:47 PMTizaro says:
this is a dangerous thing to do, if you aren't careful about it
follow the rules and play it safe and go easy and you'll be alright

the only reason i wont do this is because i'm pretty lazy
Mar 10, 2012. 6:49 AMdoooda says:
after lots of experience refilling paintball CO2 tanks, refilling disposable propane canisters seemed simple enough, so I gave it a try . Yes, there's danger from the flammable propane, but if we're careful, it's possible to refill the 1 lb cylinders from a 20 lb tank.
Weighing the small cylinder helped to determine how much propane went into it---only about half its rated capacity, despite chilling it.
As others have noted, the Schrader valve on the little cylinder could be opened during filling, and that would allow more liquid propane to fill the small tank. It's awkward to open the Schrader valve, though, since it needs to be pulled out, rather than pushed in, to vent propane vapor, which would allow enough liquid propane for a complete fill.
For filling paintball canisters with CO2, a big tank with a siphon tube was used, so that liquid CO2 came out the valve---not just vapor. Inverting the 20lb propane tank produced the same effect of dispensing liquid, not gas vapor, but the little tank still needs to be vented, it seems, to allow for a full liquid fill, to the small cylinder's rated 1 lb. capacity.
With CO2, it's possible to arrange a couple of valves that can be opened/closed in sequence, to purge the vapor, and allow liquid fill, but with the brass adapters sold to refill disposable propane cylinders, there's no similar venting /purging option, other than opening the Schrader valve during filling.
Feb 20, 2012. 2:09 AMpres68y says:
Just a comment to try to offset the hysteria about overfilling:
If you're not sure how much is in the bottle (the usual case)
then just take a cup of hot water (or some of your hot coffee)
and slowly pour it over the top of the bottle on one side.
Then quickly (before it cools) run your hand down the side
of the bottle. It will get noticeably cooler at the liquid level.
(the metal is quite thin so it heats/cools rather quickly)
This makes it easier to keep below the magic 80% rule.
At least you can get a good idea how much is in the bottle
before you embark on transferring the liquid without a scale.
-works equally well on a bigger (supply) bottle.
Feb 6, 2012. 12:36 PMbaudeagle says:
FYI, here is a news story about the deadly consequences of refilling non-refillable tanks.

http://minnesota.cbslocal.com/2012/02/06/1-dead-1-injured-in-polk-county-garage-explosion/

Jul 9, 2009. 9:47 AMwtkjd says:
This is illegal in some states - either as a citable infraction or a crime. Be sue to check your local laws before attempting this process.
Jan 24, 2012. 1:34 PMusleatherneck says:
I'm this practice causes cancer in California. :)
Jan 15, 2012. 5:00 PMJeffster says:
Just found this link.... not sure about the availablity of these but it looks like a solution down the road.

http://www.allpropanemowers.com/v.php?pg=232
Oct 21, 2011. 3:23 PMJ57ltr says:
I spent several days with the guys at Worthington, including their production manager and several of their engineers. It is perfectly safe to refill the cylinders as long as you do not exceed the Net weight of the container. Freezing the containers was laughed at and they said its a waste of time. Just take the net weight of an empty container and add the contents (900 something grams comes to mind, check the label). The containers go through many tests, one of which is after they are filled on a rotary filling station they go into a 140* F bath to find any leakers and to make sure they can handle the pressure. I spoke with the production supervisor and he said he filled his own all the time. He even converted his engine driven bike to run on these cylinders.

Jeff
Jul 10, 2009. 9:49 AMpblasman says:
your crazy to even think about refilling these tanks. If you make a mistake, your playing with a small bomb.
Oct 21, 2011. 3:16 PMJ57ltr says:
You know nothing of this so you should consider keeping it to yourself. I have worked with Worthington Cylinder, who supplies most all the tanks discussed here. Even Colman buys from them from Worthington when they cannot keep up with supply.
Jul 10, 2009. 6:01 PMDanish M1Garand says:
Ok, but you drive a car with 30 gallons of one of the most flammable liquids around. Use your head don't try to fill any tank that you don't feel 100% about.
Jul 10, 2009. 10:00 PMKATRAZ says:
I've been refilling small tanks for years and never any problems. When you refill them, you are refilling to a pressure that is
Jul 10, 2009. 11:32 AMmagickaldan says:
Alright Guys if you feel unsafe doing this then DON"T do it thats your choice no one can make it for you. But for others have at it, If there is any data showing this is a bad idea then show it but otherwise shut up about how unsafe it is. How many people have gotten blown up from refilling these bottles? anyone... I'm sure there's alot more people out there that do it. The device for refilling them is sold all over the place so it can't be that dangerous.
Jan 17, 2010. 5:35 PMRJSC says:
Well... I was thinking only in refill one supposedly "non-refilable" baloon hellium tank with compressed air at 10 psi from my air compressor to operate a small air tool for a minute on a remote location. I guess the is no risk using compressed air a 10 psi, but if someone thinks other way, please let me know.
They even seem to be welded.
Sep 14, 2011. 12:32 PMisotopej says:
You will have much better results renting a CO2 tank from a homebrew store, soda supplier, or beer store. One 5lb tank holds a LOT of gas that can run your tools. You just have to get the regulator of course. I'd check ebay.
Aug 22, 2011. 9:55 AMNateHoy says:
I imaging that 10PSI would be pretty safe for some time. Putting plain old air in the tank might accelerate corrosion from inside which you won't see, so you'd have to be cautious with the tank over time.

But it seems to me that you could come up with containers that are a lot more portable and easier to use than a non-refillable helium tank at 10PSI. Those tanks aren't spectacularly heavy, but they weigh more than they need to for a 10PSI application.

A mountain bike tire (not just the tube, you need the tire and rim assembly as well) could easily keep 50-60PSI without strain, weighs a lot less, and can be refilled many times. And you can refill it in the field with a bicycle pump.

Heck, you could probably use a couple of mountain bike tires on a cart that would carry your tools around. Get to the job site, hook your air tool up to one of the tires, drain that one, hook it up to the other, drain that one, then use the bike pump to pump the tires back up as needed (and when you're done, so the cart works properly again).

I realize it probably wouldn't carry a lot of volume, but if you can regulate it to your 10PSI the tire would probably last quite some time starting at 50PSI.
Sep 14, 2011. 12:31 PMisotopej says:
I used to refill the 20lb tanks, and all the new ones have the OPV valve inside. Sometimes the valve would stick and we had to bang the tank on the ground to open it. If I'm not mistaken, the valve closes if you turn the tank upside down so I'm not sure how this would work.

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