Mercedes Mullins
Farmers and other diesel engine operators in cold climates must take steps to ensure their fuel doesn't thicken and clog their engines. This phenomenon is known as fuel gelling, and it occurs when the paraffin wax in diesel fuel crystallizes in cold temperatures. To prevent this, diesel fuel can be blended with additives, kerosene, or lighter fuels like gasoline. Additives, also known as cold-flow improvers, are a popular choice as they are cheaper than kerosene and can lower the operable temperature of diesel fuel by 15-20°F. Kerosene is more commonly used in extremely cold climates, often in combination with additives. Proper blending, regular fuel testing, and tank maintenance are all critical components of a successful winter fuel management strategy.
| Characteristics | Values |
|---|---|
| Mixtures | Kerosene, Winter Additives (Cold-flow Improvers), Gasoline, Biodiesel |
| Additive Functions | Modify wax crystals, prevent clumping and clogging, lower Cold Filter Plugging Point (CFPP), reduce need for kerosene, disperse water, minimize ice formation |
| Additive Products | Diesel Kleen +Cetane Boost, Diesel Fuel Supplement +Cetane Boost, Diesel 9•1•1, Clear-Diesel Fuel & Tank Cleaner, Bio Kleen Diesel Fuel Biocide |
| Other Methods | Fuel polishing, fuel testing, tank maintenance, low-output electric heaters, spill return systems |
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Kerosene blends
Kerosene, also known as #1 diesel fuel oil, is a lighter diesel oil than regular diesel, which is designated as #2 diesel fuel oil. Kerosene has a much better cold filter plugging point (CFPP) than diesel fuel, allowing it to pass through a fuel filter at lower temperatures.
In the winter, kerosene is often blended with diesel fuel to improve cold flow operability. The diesel fuel to kerosene ratio is usually found between 80:20, 70:30, 60:40, or 50:50. For every 10% kerosene blended, the CFPP is lowered by 3 degrees.
However, kerosene contains less lubricity than diesel fuels, which can lead to more wear and tear on engines. To mitigate this, some people add automatic transmission fluid or 2-cycle oil to the kerosene blend.
While kerosene blends can be effective in ensuring winter performance, they add significant costs that may not always be necessary. Winter additives, also known as cold-flow improvers, are a more economical alternative. These additives modify wax crystals in diesel fuel, preventing them from clumping together and clogging filters. They also have water-dispersing properties, helping to minimize the risk of ice formation in fuel tanks.
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Winter additives
Winter diesel fuel, also known as winter diesel, alpine diesel, or winterised diesel, is diesel fuel enhanced with additives to prevent it from gelling in cold weather. Diesel fuel typically begins to gel at temperatures below the cloud point, where wax particles form, giving the fuel a cloudy appearance. This thickens the oil and clogs fuel filters and injectors in engines, causing the engine to stop running.
The use of winter additives is essential for maintaining fuel performance in cold weather and ensuring diesel engines run smoothly. In extremely cold zones, a blend of kerosene may still be required, but the use of additives can reduce the amount of kerosene needed. Proper blending and fuel testing are critical to a successful winter fuel management strategy, and fuel system maintenance plays a crucial role in preventing winter fuel issues.
Some common winter additives include Diesel Kleen +Cetane Boost, which improves diesel performance, and Diesel Fuel Supplement +Cetane Boost, which prevents fuel gelling and protects against fuel-filter icing. Other products such as Diesel 9•1•1 can be used to reliquify gelled fuel and de-ice frozen fuel filters. It is important to note that the use of additives should be done before temperatures drop below zero to ensure effectiveness.
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Fuel testing
To prevent diesel fuel from gelling in cold weather, farmers often blend it with kerosene or winter additives (also known as cold-flow improvers). While kerosene is essential in extremely cold zones, winter additives are more commonly used and are significantly cheaper. These additives modify the wax crystals in diesel fuel, preventing them from clogging filters and allowing the fuel to flow at lower temperatures.
Cetane Number
The cetane number is a crucial indicator of diesel fuel quality. It measures the fuel's ignition quality during compression. Higher cetane numbers result in smoother engine operation, easier cold starts, reduced noise, and lower emissions. The minimum cetane number required by regulation in the United States is 40.
Sulfur Content
Sulfur content in diesel fuel significantly impacts emissions control, engine lubrication, and after-treatment systems. Regulations, such as the EPA's limit of 15 ppm since 2007, aim to reduce sulfur emissions and curb air pollution.
Water and Sediment Content
Testing for water and sediment content is essential to identify contaminants that can accumulate during storage and impact fuel function. Water buildup in tanks, for example, can worsen winter fuel issues and lead to operational problems.
Density and Volatility
While density is not directly defined in ASTM standards, it is governed by the results of other tests, such as distillation and aromaticity. Volatility, on the other hand, is expressed in terms of the temperature at which successive portions of a fuel sample are distilled under controlled heat.
Distillation and Flash Point
Distillation tests determine the temperature at which 90% of the original liquid volume is condensed and collected. The flash point is related to the front-end volatility of the fuel and is the temperature at which the fuel ignites when a flame is applied.
Fuel Dilution
Fuel dilution occurs when raw or unburned fuel mixes with lubricating oil during the combustion cycle. This can be detected through oil analysis and tests such as viscosity measurements and Fourier-transform infrared (FTIR) spectroscopy. Gas chromatography is considered one of the most effective technologies for detecting fuel dilution.
Regular fuel testing is a critical component of a successful winter fuel management strategy, helping to maintain engine performance, prevent operational issues, and ensure the safety and efficiency of diesel fuel.
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Tank maintenance
- Inspect your bulk tank semi-annually and especially before the cold weather hits. If you find sediment, gums, and sludge accumulating in the bottom inch of your tank, have a professional clean it.
- To mitigate condensation in the headspace of the tank (the empty area between the fuel level and the top of the tank), fill your tanks at the end of the day while the engine is still warm.
- If you have a clean and dry air source, use it to prevent condensation from building up inside the tank and to stop corrosion.
- Use particle filtration and water absorption on the way out of the bulk tank to ensure you have the cleanest, driest fuel possible.
- Keep the diesel tank full over winter to prevent condensation inside.
- If you have a plastic tank, ensure there is plenty of silicone grease on your filler cap.
- Use a biocide to keep your diesel tank maintained.
In addition to tank maintenance, it is essential to choose the correct diesel blend and additives to prevent fuel gelling and maintain engine performance in cold weather.
Gelled fuel can be reliquefied using products such as Power Service Diesel 911, which also helps de-ice frozen fuel filters.
Gelled fuel can be prevented by using additives such as Cold-flow Improvers, which modify the structure of wax crystals, allowing them to pass through filters more easily.
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Fuel polishing
To keep their diesel engines running smoothly during winter, farmers have a few options for blending diesel fuel for improved performance in the cold. They can use kerosene, winter additives (also known as cold-flow improvers), or a blend of both. Kerosene is more commonly used in extremely cold regions, while winter additives are more suitable for milder climates.
Now, let's discuss fuel polishing in detail:
Fuel contamination can lead to critical engine damage and even complete engine failure. This contamination can occur at any point in the supply chain or within the storage tank itself. By regularly polishing fuel, facilities can maintain optimal fuel quality and protect their equipment from unexpected downtime and premature wear and tear.
Benefits of Fuel Polishing:
- Prevents engine damage and unexpected shutdowns due to contaminated fuel.
- Extends the lifetime of critical operating equipment within the polishing systems.
- Ensures optimal fuel quality, protecting engines from premature filter clogging.
- Reduces downtime for critical facilities, such as data centers and hospitals, that rely on a consistent fuel supply.
Best Practices for Fuel Polishing:
- Perform fuel analysis before and after fuel polishing to identify and rectify specific contamination issues.
- Use a fine filter of 4 microns absolute or finer to comply with fuel standards.
- Ensure the removal of both free and emulsified water from the fuel flow.
- Choose a fuel polishing system that is self-pumping, self-monitoring, and automatically shuts off in an alarm state to avoid contaminating the fuel tank.
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Frequently asked questions
Farmers can use a variety of products to prevent their diesel fuel from gelling in the cold. These include:
- Winter additives/Cold-flow improvers
- Kerosene
- Power Service Diesel 9•1•1
- Power Service Diesel Kleen +Cetane Boost
- Power Service Diesel Fuel Supplement +Cetane Boost
- Hot Shots
- Alliant
- Stanadyne
- Howes
Winter additives, also known as cold-flow improvers, are added to diesel fuel to prevent the wax crystals that form in cold weather from clumping together and clogging filters. They are a cheaper alternative to kerosene.
Kerosene is a lighter fuel that can be blended with diesel to lower its Cold Filter Plugging Point (CFPP). In extremely cold weather, a blend of kerosene and diesel fuel, combined with additives, may be required for reliable performance.
Diesel 9•1•1 is a product that can be added to diesel fuel to reliquify gelled fuel and de-ice frozen fuel filters.
