Rajan Wilcox
Diesel fuel is prone to gelling in cold temperatures, which can cause vehicle engines to stop working. Gelling occurs when paraffin wax within the fuel solidifies and bonds together at low temperatures, compromising fuel flow. This process starts at the fuel's cloud point, which is when the fuel appears cloudy due to wax crystallisation. As temperatures continue to drop, the fuel reaches its pour point, where it thickens and can no longer flow properly. Finally, the fuel reaches its gel point, where it has completely solidified and can no longer flow, typically around 10°F to 15°F. Gelling can be prevented by using fuel heaters, fuel additives, or mixing diesel with kerosene, which has a lower gelling point.
Characteristics and Values of Diesel Fuel Gelling
| Characteristics | Values |
|---|---|
| Definition | The crystallization of waxes in diesel fuel in extremely cold weather |
| Appearance | Cloudy or hazy |
| Fuel Type | No. 2 diesel |
| Cloud Point | 14°F or -12°C |
| Pour Point | 6°F to 10°F lower than the cloud point |
| Gel Point | 10°F to 15°F |
| Prevention | Fuel heaters, fuel additives, kerosene, winter-blend fuel |
| Symptoms | Loss of power, engine stops running, vehicle starts but doesn't run continuously |
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What You'll Learn
Gelling vs. icing
Gelling and icing can be a significant concern during winter for diesel vehicles. Gelling occurs when paraffin wax within diesel fuel solidifies and bonds together at extremely low temperatures. This process starts when the fuel hits its cloud point, which is typically around 14°F for No. 2 diesel, giving the fuel a cloudy or hazy appearance. As the temperature continues to drop, the wax particles grow larger and begin to restrict fuel flow. At the pour point, which is usually 6°F to 10°F lower than the cloud point, the fuel thickens and can no longer flow properly. Finally, at the gel point, typically around 10°F to 15°F, the fuel has completely solidified and is unable to flow, clogging fuel lines and filters. This can prevent fuel flow to the engine, rendering it inoperable.
Icing, on the other hand, is caused by the presence of water in the fuel system or storage tank. Water can enter the fuel system through condensation or other means. During cold weather, this water can freeze, leading to icing issues. Icing is more likely to be the cause of vehicle problems when temperatures are near 20 to 30 degrees Fahrenheit.
To prevent gelling, diesel fuel additives such as AFC 805, BOSS All Season Diesel Fuel Additive, or Hot Shot's Secret's EDT+ Winter Defense can be used. These additives contain cold flow improvers that break the waxy bonds into smaller particles, allowing them to pass through filters more easily. Fuel heaters are also effective in maintaining the temperature of the fuel and preventing gelling. Additionally, mixing diesel #1 (kerosene) with diesel #2 or using Diesel 911 can help prevent and reverse gelling.
To avoid icing, proper tank maintenance is essential to remove water droplets before they become an issue during cold weather. Storing your vehicle in a climate-controlled garage can also help prevent icing, although it may increase energy costs.
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How to prevent gelling
Gelling of diesel fuel can be a problem in cold temperatures, as the paraffin wax present in the fuel can solidify, clogging filters and fuel lines. This can prevent fuel flow to the engine, making it impossible for diesel engines to run. To prevent diesel fuel from gelling, here are some measures you can take:
Use Fuel Heaters or Store in Warm Conditions
Fuel heaters are an effective way to keep diesel fuel from gelling as they constantly monitor the temperature of the fuel and adjust heating element temperatures accordingly. If you don't have access to fuel heaters, you can keep your fuel tanks warm by parking your vehicle in a garage or sheltered area. Alternatively, you can use an engine block heater to keep the fuel warm.
Use Winter-Blend Fuel or Fuel Additives
Winter-blend fuels are designed to have a lower gelling point than regular diesel fuel. These blends contain additives that can help prevent the fuel from gelling in cold temperatures. Fuel additives, such as anti-gel and flow improvers, can also be added to your diesel fuel to improve cold-weather performance by lowering the gelling point and enhancing fuel flow. Additives like BOSS All Season Diesel Fuel Additive contain cold flow improvers (CFI) and wax anti-settling agents (WASA) to prevent gelling.
Keep Fuel Tanks Full
Keeping your fuel tanks full helps to reduce condensation, which can prevent water from entering the fuel system. Water can contribute to fuel gelling in cold temperatures.
Use Kerosene or Kerosene-Blended Fuel
Kerosene has a lower gelling point than diesel fuel. You can mix kerosene with diesel fuel to lower its freezing point. However, using kerosene may lead to reduced fuel mileage and efficiency.
Use a Blend of #1 Diesel and #2 Diesel
#1 diesel contains less paraffin and has a lower cloud point than #2 diesel. By blending the two, you can lower the overall cloud point and improve performance in cold temperatures.
Change Fuel Filters
It is recommended to change your fuel filters before cold weather arrives. This can help prevent gelling and improve fuel flow.
By implementing these measures, you can effectively prevent diesel fuel from gelling in cold weather conditions and ensure the reliable operation of your diesel engines.
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How to ungel fuel
Gelling occurs when the paraffin wax in diesel fuel crystallises and thickens, making the fuel gel-like. This can clog the entire fuel system since the fuel solidifies and loses its ability to flow. This usually happens when temperatures fall below 10 to 15 degrees Fahrenheit or below -12 degrees Celsius.
To ungel diesel fuel, follow these steps:
- Move the vehicle to a warmer place, such as a heated garage, to allow the fuel to return to its normal state naturally.
- If you don't have access to a heated space, add a gel-melting formula or anti-gel additive to your tank. Anti-gel additives lower the temperature at which diesel starts to gel and help prevent fuel system blockages. Follow the instructions on the formula you purchase, as the amount of anti-gel required depends on the temperature and specific formula.
- If you have gelled fuel in your lines or filter, remove your fuel filters and fill them with a de-gel formula and diesel fuel. Reinstall the filters and start the engine.
- As a preventative measure, change your fuel filter every winter. Fuel filters collect contaminants that have been filtered out of your fuel. The more contaminants in the filter, the quicker the fuel will gel.
- Fuel heaters are another preventative option, as they constantly monitor the temperature of the fuel and make heating element adjustments to prevent gelling.
It's important to note that gelling is different from icing, which occurs when water is present in the fuel system or bulk storage tank. Icing is the most common diesel fuel issue in the winter months.
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Pour point and cloud point
Gelling is a common issue with diesel fuel during the winter months. This phenomenon occurs due to the crystallization of waxes in the fuel at extremely low temperatures, which can prevent fuel flow to the engine and clog fuel lines and filters. Understanding the cloud point and pour point of diesel fuel is crucial to mitigating these issues.
The cloud point refers to the temperature at which the waxes in diesel fuel start to crystallize, resulting in a cloudy or hazy appearance. For No. 2 diesel, the typical cloud point is around 14°Fahrenheit. As the temperature continues to drop, the waxes crystallize further, leading to significant operational issues. At temperatures between 10°F and 15°F, the waxes will cause the fuel to gel, blocking fuel supply and filters.
The pour point, on the other hand, is the temperature at which diesel fuel loses its ability to flow. This temperature is usually much lower than the cloud point. When diesel reaches its pour point, it becomes extremely difficult for it to pass through the mechanical elements of engines, rendering it useless.
To prevent gelling issues, fuel heaters are often used to maintain the temperature of the fuel in freezing conditions. Additionally, fuel additives are commonly employed to lower the cloud point and improve cold flow characteristics. For example, cold flow improvers (CFI) break down waxy bonds, allowing the fuel to pass through filters more easily. Another additive, the wax anti-settling agent (WASA), prevents wax particles from accumulating at the bottom of tanks.
In an experimental study, researchers found that while the addition of certain additives did not significantly reduce the cloud point, even small amounts of additives caused a substantial decrease in the pour point. Specifically, ethanol was identified as the most effective additive in lowering the pour point, with a 20% ethanol-fuel mixture resulting in a nearly 30° reduction.
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Fuel additives
Gelling is a common issue with diesel fuel during the winter months. This occurs when paraffin wax within the fuel solidifies and bonds together at extremely low temperatures, compromising fuel flow and operational reliability.
Fuel heaters are the most effective way to prevent diesel fuel from gelling, but fuel additives are also a good option. Additives like AFC 805 contain chemical compounds that lower the cloud point of diesel fuel, allowing it to pass through fuel filters at lower temperatures. Cold flow improvers, found in some additives, dissolve the bonds in paraffin wax, breaking the waxy bonds into smaller particles that can pass through filters.
BOSS All Season Diesel Fuel Additive contains a cold flow improver (CFI) and a wax anti-settling agent (WASA). The CFI changes the shape of the paraffin structure, while the WASA keeps the particles suspended in the fuel, preventing them from accumulating at the bottom of the tank. With BOSS, cold weather operability can be extended down to around 0°F.
For temperatures below 0°F, the addition of No. 1 diesel is recommended, as it contains less paraffin and has a cloud point of around -45°F. A blend of 80% No. 2 diesel and 20% No. 1 diesel is often used for extreme low temperatures.
Other fuel additives that can be used to prevent gelling include Diesel 911, Howes Life Line, and Hot Shot’s Secret Diesel Winter Rescue. Diesel 911 can reliquefy gelled fuel, but it does not prevent gelling. Howes Life Line is recommended for cold weather, and Kerosene is also an option, although it may reduce fuel mileage and efficiency. Hot Shot’s Secret Diesel Winter Rescue is a high-quality product that thaws frozen filters and reliquifies gelled diesel, restoring the engine’s full operational capabilities.
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Frequently asked questions
Diesel fuel gelling is the crystallization of waxes in diesel fuel in extremely cold weather.
Diesel fuel gels when temperatures fall below 10 to 15 degrees Fahrenheit or below -12 degrees Celsius. The gelling process starts when the fuel hits the cloud point, which gives it a cloudy appearance. As the temperature continues to drop, the fuel thickens and can no longer flow properly.
Some signs that diesel fuel is starting to gel include a cloudy fuel appearance, white smoke coming from the exhaust when trying to accelerate, and the engine stopping when idle.
To prevent diesel fuel from gelling, you can use fuel heaters, kerosene, or fuel additives. Fuel heaters constantly monitor the temperature of the fuel and adjust accordingly. Kerosene has a lower gelling point than diesel fuel, so it can be mixed with diesel fuel to lower the freezing point. Fuel additives, such as Hot Shot's Secret's EDT+ Winter Defense, can also be used to change the properties of the fuel so it can withstand colder temperatures.
