Ameer Randolph
Gelling is a common issue with diesel fuel during cold months. It occurs when paraffin wax within the fuel solidifies and bonds together at extremely low temperatures, compromising fuel flow and operational reliability. This can prevent engines from running and cause significant inconvenience and costs for vehicle owners. The phenomenon of gelling is influenced by various factors, including the quality of the fuel, regional climate, and the use of additives. Understanding the causes and prevention methods of diesel gelling is essential for those operating diesel vehicles and equipment in cold environments.
Diesel Fuel Gelling Characteristics and Values Table
| Characteristics | Values |
|---|---|
| Reason for gelling | Crystallization of waxes in diesel fuel in extremely cold weather |
| Appearance | Cloudy or hazy |
| Temperature range | Varies, but typically between -12°C to -15°C or 10°F to 15°F |
| Fuel type | No. 2 diesel |
| Cloud point | 14°F |
| Prevention | Fuel heaters, fuel additives, winter-blend fuel additives (e.g., AFC 805), fuel winterization, fuel additive (e.g., BOSS All Season Diesel Fuel Additive), kerosene, Diesel 911 |
| Common issues | Fuel flow problems, clogged fuel lines/filters, engine issues |
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What You'll Learn
Paraffin wax crystallisation
Gelling is a common issue with diesel fuel during cold months. Diesel fuel contains a small percentage of paraffin wax, which is a mixture of hydrocarbon molecules. In normal operating conditions, paraffin wax remains in its liquid form. However, in extremely cold temperatures, the paraffin wax in diesel fuel can crystallize and solidify, causing the fuel to gel. This can lead to fuel flow issues, clogging of fuel lines and filters, and even render the fuel useless.
Paraffin wax crystallization occurs when the temperature drops below the cloud point of the fuel. The cloud point is the temperature at which the waxes in the fuel start to crystallize and the fuel appears cloudy. For No. 2 diesel, the cloud point is typically around 14°F. As the temperature continues to drop, the wax crystals grow larger and begin to restrict fuel flow. At temperatures between 10°F and 15°F, the waxes will cause the fuel to gel and clog fuel supply and filters. This point is known as the Cold Filter Plugging Point (CFPP), indicating the lowest temperature at which diesel fuel can pass through a 45-micron filter.
To prevent paraffin wax crystallization and diesel fuel gelling, several measures can be taken:
- Fuel heaters or warmers can be integrated into the fuel management system to maintain the fuel at a set temperature, preventing it from reaching the cloud point.
- Fuel additives, such as winter-blend additives like AFC 805, can be used to lower the cloud point of the fuel. These additives contain cold flow improvers that dissolve the bonds in the paraffin wax, allowing the fuel to pass through filters at lower temperatures.
- Using a quality additive like BOSS All Season Diesel Fuel Additive, which contains a cold flow improver (CFI) and a wax anti-settling agent (WASA), can help keep the wax particles suspended in the fuel and prevent them from accumulating at the bottom of the tank.
- Blending No. 2 diesel with No. 1 diesel, which contains less paraffin and has a lower cloud point of around -45°F, can improve cold weather performance. A blend of 80% No. 2 diesel and 20% No. 1 diesel is commonly recommended for extreme low temperatures.
- Proper maintenance of fuel systems and tanks is essential to prevent icing issues, which can also cause operational problems during winter.
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Fuel heaters
Gelling is a common issue with diesel fuel during the winter months. This happens when the paraffin wax within the diesel fuel solidifies and bonds together at extremely low temperatures, compromising fuel flow and operational reliability. Fuel heaters, also known as fuel warmers or engine block heaters, are an effective way to prevent diesel fuel from gelling. These heaters are integrated into the systems that manage the fuel and maintain a set temperature for the stored fuel in freezing conditions.
There are several types of fuel heaters available, each with its own advantages and considerations:
For vehicles that are stored in a garage or left stationary for extended periods, fuel heaters can be used to keep the fuel and engine warm. This includes options such as light bulbs placed under the vehicle, tarps with heaters that blow warm air, and block heaters that connect to the engine to warm the coolant and oil. While these methods are effective in preventing fuel gelling, they require a constant supply of electricity, which can increase energy costs.
For vehicles that are in use and travelling during cold weather, portable fuel heaters or engine block heaters can be utilised. These heaters are designed to maintain the temperature of the fuel system and engine, reducing the risk of gelling. Engine block heaters, in particular, are a practical and energy-efficient solution, as they can keep the engine warm even when the vehicle is not in use.
Fuel Additives
While not a heating solution, fuel additives are another way to prevent diesel fuel gelling. Additives such as AFC 805, BOSS All Season Diesel Fuel Additive, and Howes Life Line contain chemical compounds that lower the cloud point of diesel fuel, allowing it to remain in a liquid state at lower temperatures. These additives can be used in conjunction with fuel heaters for added protection against gelling.
It is important to note that the effectiveness of fuel heaters and additives may vary depending on the specific climate conditions and the composition of the diesel fuel. Additionally, proper vehicle maintenance, such as changing fuel filters before cold weather arrives and maintaining appropriate fuel tank levels, can also help prevent gelling and icing issues.
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Fuel additives
Diesel fuel is prone to "gelling" in extremely cold weather. This is caused by the crystallization of waxes in the fuel, which can prevent fuel flow to the engine and clog fuel lines and filters. This can cause significant operational issues and even render the fuel useless.
To prevent these issues, fuel heaters can be used to maintain the temperature of the fuel. Additionally, fuel additives are a highly effective solution to prevent diesel fuel from gelling. These additives can lower the freezing point of diesel fuel and prevent wax crystallization.
One such additive is BOSS All Season Diesel Fuel Additive, which contains a cold flow improver (CFI) and a wax anti-settling agent (WASA). The CFI changes the structure of the wax, breaking it into smaller particles that can pass through filters. The WASA keeps these particles suspended in the fuel, preventing them from accumulating at the bottom of the tank. With this additive, diesel engines can operate at temperatures as low as 0°F.
Other effective additives include Diesel 911, which can reliquify gelled fuel and de-ice frozen fuel filters. Diesel Fuel Supplement +Cetane Boost is another additive that prevents fuel gelling and protects against fuel-filter icing. It is important to note that while Diesel 911 can resolve existing gelling issues, it does not prevent them. For prevention, Diesel Fuel Supplement +Cetane Boost is recommended.
Kerosene is another option that can be mixed with diesel fuel to lower its freezing point. However, this may result in reduced fuel mileage and efficiency. Newer fuel additives provide a more straightforward and cost-effective solution.
In summary, while diesel fuel gelling can be a significant issue in cold weather, it can be effectively prevented through the use of fuel heaters and fuel additives. These solutions ensure that diesel engines can operate smoothly and reliably, even in extremely low temperatures.
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Cold weather maintenance
Cold weather can cause diesel fuel to gel, which can prevent engines from running. This is due to the crystallization of waxes in the fuel at low temperatures, which can block fuel supply and clog filters. To prevent this, it is recommended to take the following steps as part of your cold-weather maintenance:
Know the Fuel's Pour Point
The pour point is the lowest temperature at which the fuel maintains its flow characteristics. No. 2 diesel has a cloud point of 14°F, at which wax crystallization causes the fuel to appear cloudy. As temperatures drop further, the waxes will cause the fuel to gel at around 10-15°F.
Use Fuel Additives
Winter-blend fuel additives, such as AFC 805, can effectively lower the cloud point of diesel fuel. Additives with cold flow improvers can dissolve the bonds in the wax, allowing the fuel to pass through filters more easily. BOSS All Season Diesel Fuel Additive is another option that contains both a cold flow improver and a wax anti-settling agent to keep wax particles suspended.
Blend with No. 1 Diesel
If temperatures drop below 0°F, consider blending your No. 2 diesel with No. 1 diesel, which contains less paraffin and has a much lower cloud point of around -45°F. A blend of 80% No. 2 diesel and 20% No. 1 diesel is recommended for extreme low temperatures.
Utilize Fuel Heaters
Fuel heaters, also known as fuel warmers or fuel treatment, can be integrated into fuel management systems to maintain the fuel at a set temperature during freezing conditions. This is an effective way to monitor and adjust the temperature of the fuel, preventing it from gelling.
Prevent Icing Issues
Icing is another common issue during winter, caused by water entering the fuel system through condensation. Proper tank maintenance procedures should be followed to remove water droplets and prevent icing before cold weather arrives.
Change Fuel Filters
It is advisable to change fuel filters before the onset of cold weather. If gelling occurs, the filters may become clogged and need to be replaced.
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Icing vs gelling
Gelling and icing are two major concerns with diesel fuel during the winter months. While gelling involves wax crystals, icing manifests as ice crystals. Gelling occurs when paraffin wax within diesel fuel solidifies and bonds together at extremely low temperatures, typically around 10° to 15°F (-12° to -9°C) or lower. This solidification can prevent fuel flow to the engine and clog fuel lines and filters, causing issues with engine performance.
Icing, on the other hand, occurs when water is present in the fuel system. Water can enter the fuel system through condensation or other means. As temperatures drop, this water freezes and can cause issues with fuel flow and engine performance. Icing typically occurs at temperatures near 20° to 30°F, so if vehicle issues occur within this temperature range, icing is likely the culprit rather than gelling.
To prevent gelling, fuel heaters can be used to maintain the fuel at a set temperature. Fuel additives, such as cold flow improvers (CFI) and anti-gel additives, can also be used to break down wax crystals and prevent filter clogs. For extreme low temperatures, blending No. 2 diesel with No. 1 diesel, which contains less paraffin, can help lower the fuel's cloud point.
To prevent icing, regular tank maintenance is important to remove water from the system before cold weather sets in. Additionally, fuel filters should be checked and changed before the arrival of cold weather to ensure they are not clogged with ice crystals.
In summary, gelling and icing are two distinct issues that can affect diesel fuel in cold weather. Gelling is caused by the solidification of wax in the fuel, while icing is caused by water freezing in the fuel system. Both issues can be prevented through proper maintenance and the use of appropriate additives and heaters.
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Frequently asked questions
Gelling is a term used to describe the crystallization of waxes in diesel fuel in extremely cold weather.
Diesel fuel contains paraffin wax, which is a mixture of hydrocarbon molecules. In normal operating conditions, the wax remains in its liquid form. However, in extremely cold temperatures, the wax can solidify and bond together, causing the fuel to gel.
To prevent diesel fuel from gelling, you can use a fuel additive designed for diesel winterization, such as AFC 805 or BOSS All Season Diesel Fuel Additive. Fuel heaters can also be integrated into fuel management systems to maintain the fuel at a set temperature and prevent gelling.
