Katerina Swanson
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, which can prevent fuel flow to the engine and clog fuel lines and filters. This can be avoided with proper maintenance, such as using fuel heaters or fuel additives, and by storing vehicles in climate-controlled garages. The gelling temperature depends on the composition and quality of the fuel, but it typically starts at temperatures below 10 to 15 degrees Fahrenheit or below -12 degrees Celsius.
| Characteristics | Values |
|---|---|
| Temperature | Gelling occurs at extremely low temperatures, typically below 10-15°Fahrenheit or below -12°Celsius. |
| Paraffin Wax Content | Gelling is caused by the crystallization of paraffin wax in diesel fuel. |
| Fuel Type | No. 2 diesel has a higher cloud point (14°F) and is more prone to gelling than No. 1 diesel (-45°F cloud point). |
| Fuel Appearance | A cloudy or hazy appearance indicates that the fuel has reached its cloud point and gelling may occur. |
| Fuel Flow | Gelling can prevent fuel flow to the engine, clogging fuel lines and filters. |
| Engine Performance | Gelling results in a loss of power and compression, causing the engine to stop running, particularly when idling or trying to accelerate. |
| Fuel Additives | Fuel additives, such as BOSS All Season Diesel Fuel Additive, can prevent gelling by modifying the shape of wax particles. |
| Fuel Mixtures | Mixing No. 1 diesel (kerosene) with No. 2 diesel can lower the gelling point of the fuel. |
| Fuel Treatment | Fuel treatments, such as anti-gel or diesel-specific treatments, can prevent gelling in cold conditions. |
| Fuel Storage | Storing vehicles in climate-controlled garages can help prevent gelling, but energy consumption should be considered. |
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What You'll Learn
Paraffin wax crystallisation
Gelling is a common issue with diesel fuel during cold months. It occurs when paraffin wax, which is naturally occurring in No. 2 diesel fuel, solidifies and crystallises at extremely low temperatures. This crystallisation process can clog fuel lines and filters, making it impossible for diesel engines to run.
Paraffin wax, also known as petroleum wax, is a mixture of hydrocarbon molecules. In normal operating conditions, paraffin wax remains in its liquid form. However, when temperatures drop, the wax can start to solidify and crystallise, leading to the gelling of diesel fuel. This typically occurs when temperatures fall below the cloud point of diesel fuel, which is around 14°F for No. 2 diesel. At this temperature, the fuel takes on a cloudy or hazy appearance as the wax crystals begin to form.
As temperatures continue to drop, the wax crystals grow larger and begin to restrict fuel flow. This can lead to significant operational issues, as fuel flow to the engine may be prevented. The fuel will eventually reach its pour point, which is typically 6°F to 10°F lower than the cloud point. At this stage, the fuel thickens and can no longer flow properly.
To prevent paraffin wax crystallisation and diesel fuel gelling, several measures can be taken. One option is to use fuel additives, such as BOSS All Season Diesel Fuel Additive, which contains a cold flow improver (CFI) and a wax anti-settling agent (WASA). These additives modify the shape of the paraffin structure, breaking the waxy bonds into smaller particles that can pass through filters more easily. Additionally, storing vehicles in climate-controlled garages or using kerosene-blended fuel can help prevent gelling by modifying the fuel mixture and lowering the freezing point.
It is important to note that the gelling of diesel fuel can occur at different temperatures depending on the supplier and the treatment of the fuel. Cold snaps can cause fuel to gel, even if it has been treated for colder conditions. Therefore, it is crucial to monitor temperatures and take preventive measures when temperatures start approaching the gelling range, typically around 10°F to 15°F for most diesel fuels.
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Cold weather conditions
Diesel fuel contains paraffin wax, which is a natural petroleum-based wax. In cold weather, this wax thickens and crystallizes, causing the fuel to gel. This usually happens at temperatures below 32°Fahrenheit (0°Celsius), although it can occur at temperatures as high as 40°Fahrenheit (4.4°Celsius) for low-quality fuels.
The first sign of diesel fuel gelling is when the fuel reaches its cloud point, the temperature at which wax crystals begin to form and the fuel becomes cloudy. As the temperature continues to drop, the wax crystals stick together, and the fuel thickens, leading to sluggish acceleration and reduced engine performance. Eventually, the fuel may gel completely, blocking fuel lines and filters and preventing fuel from reaching the engine. This can result in poor engine performance and potential damage to the fuel system.
To prevent diesel fuel gelling in cold weather, there are several measures that can be taken:
- Use winter-specific or winterized diesel fuel, which has a lower gelling temperature.
- Add diesel fuel additives or anti-gel supplements to the fuel to stabilize it and lower the cloud point and gelling point.
- Keep fuel tanks full to minimize condensation and reduce the risk of water collecting, which can lead to frozen fuel.
- Park in a temperature-controlled environment, such as a heated garage, to prevent cold start issues.
- Use an engine block heater to keep the engine and fluids warm, even when the vehicle is not in use.
- In extremely cold temperatures, consider adding kerosene to your diesel fuel at a ratio of 20:80 to prevent gelling while maintaining lubrication.
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Fuel flow issues
Diesel fuel gelling is a common issue in cold weather. Gelling occurs when paraffin wax, which is naturally present in No. 2 diesel fuel, solidifies and bonds together at extremely low temperatures. This solidification can prevent fuel flow to the engine, clogging fuel lines and filters, and making it impossible for diesel engines to run.
The cloud point is the temperature at which the waxes in the fuel crystallize enough to give it a cloudy appearance. For No. 2 diesel, the cloud point is typically around 14°F (-10°C). As the temperature continues to drop, the wax crystals tend to sink to the bottom of the tank, forming a thick layer of dense wax, further compromising fuel flow. At temperatures of 10-15°F (-12°C to -9°C), the fuel will gel and clog the fuel supply and filters. This temperature is known as the Cold Filter Plugging Point (CFPP), indicating the lowest possible temperature that diesel fuel can pass through a 45-micron filter.
To prevent fuel flow issues due to gelling, it is essential to prepare for cold weather conditions. One method is to use fuel additives, such as the BOSS All Season Diesel Fuel Additive, which contains a cold flow improver (CFI) and a wax anti-settling agent (WASA). CFI breaks the waxy bonds into smaller particles, allowing them to pass through filters, while WASA keeps the particles suspended in the fuel, preventing them from accumulating at the bottom of the tank. These additives can extend the operability of diesel fuel down to around 0°F (-18°C).
In more extreme cold temperatures, below 0°F, blending No. 1 diesel, which contains less paraffin, with No. 2 diesel is recommended. A typical blend is 80% No. 2 diesel and 20% No. 1 diesel or 70/30 for extremely low temperatures. Additionally, fuel heaters can be integrated into fuel management systems to maintain a set temperature for the fuel in freezing conditions.
It is worth noting that gelling should not be confused with icing, which is the most common diesel fuel issue in winter. Icing occurs when water is present in the fuel system, usually due to condensation. While gelling and icing can cause similar issues, they require different preventative measures and solutions.
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Icing vs gelling
Gelling and icing are two major concerns with diesel fuel during the winter months. Gelling occurs when paraffin wax, a naturally occurring substance in No. 2 diesel fuel, solidifies and bonds together at extremely low temperatures, typically below 10°F (-12°C). This process is similar to water turning into ice. The wax crystals can clog fuel lines and filters, preventing the fuel from flowing to the engine. This can cause significant operational issues and even render the fuel useless.
On the other hand, icing in diesel fuel occurs due to the presence of water, which can enter the fuel system through condensation or other means. When temperatures drop, water freezes and solidifies, leading to ice crystal formation. Icing typically occurs at temperatures near 20 to 30 degrees Fahrenheit, and it can cause similar issues to gelling, such as clogged filters and reduced fuel flow.
To differentiate between gelling and icing, a visual inspection of the fuel filter can be helpful. If ice crystals are present, then icing is the likely culprit. Additionally, gelling is more common in extremely cold climates, while icing can occur in a wider range of temperatures.
Preventing gelling involves using fuel additives, such as cold flow improvers (CFI) and wax anti-settling agents (WASA), which break down wax crystals and improve fuel flow. Maintaining fuel at a set temperature using fuel heaters or winter-specific diesel fuel can also prevent gelling.
To address icing, proper tank maintenance is crucial, including regularly checking for water accumulation and following recommended procedures to remove it. Using anti-icing additives and de-icing products can also help prevent and resolve icing issues.
In summary, while both gelling and icing can cause operational issues in diesel engines during cold weather, they have distinct causes, appearances, and prevention methods. Gelling is primarily due to wax crystallization at extremely low temperatures, while icing results from water freezing and solidifying at a wider range of temperatures. Understanding these differences can help diesel equipment operators take appropriate preventive measures and maintain functionality during winter.
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Preventing and reversing gelled fuel
Diesel fuel gelling is a common issue during winter or in cold climates. Gelling occurs when the paraffin wax in diesel fuel solidifies and bonds together at extremely low temperatures. This can prevent fuel flow to the engine and clog fuel lines and filters, making it impossible for diesel engines to run.
Preventing Diesel Fuel from Gelling
To prevent diesel fuel from gelling, you can take the following measures:
- Use a winter-blend fuel: These fuels are designed to have a lower gelling point and contain additives that can help prevent the fuel from gelling in cold temperatures.
- Use fuel additives: Additives like anti-gel and flow improvers can improve the cold-weather performance of diesel fuel by lowering the gelling point and improving fuel flow.
- Keep fuel tanks full: A full fuel tank generates less condensation, reducing the risk of water entering the fuel system. Water can contribute to fuel gelling in cold temperatures.
- Keep fuel tanks warm: Park your vehicle in a garage or sheltered area, or use an engine block heater or fuel tank heater to maintain the fuel's temperature.
- Use kerosene: Kerosene has a lower gelling point than diesel fuel. Mixing it with diesel fuel can lower its freezing point. However, this may cause reduced fuel mileage and efficiency.
- Use No. 1 diesel: No. 1 diesel contains less paraffin and has a lower cloud point than No. 2 diesel. Blending it with No. 2 diesel can improve performance in extremely low temperatures.
- Keep fuel tanks covered: Covering the fuel tank can help insulate it and protect the fuel from cold temperatures.
Reversing Gelled Diesel Fuel
If your diesel fuel has already gelled, you can try the following methods to reverse the gelling:
- Warm the fuel system: Move the vehicle to a warmer place or use engine block heaters to raise the temperature of the fuel system.
- Use a diesel fuel anti-gel additive: Additives like Opti-Lube Gel Melt, Diesel 911, or Power Service Winter Diesel Supplement can help dissolve gelled fuel and return it to a liquid state.
- Change the fuel filter: Gelled fuel may have spread to the fuel filter, so replacing it can help resolve the issue.
- Use kerosene: Kerosene can help thaw gelled fuel, but it may take time for it to work through the entire fuel system.
Gelled diesel fuel can be a frustrating issue, but by taking preventive measures and knowing how to reverse gelling, you can keep your diesel engine running smoothly during cold weather.
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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 gels when temperatures fall below 10 to 15 degrees Fahrenheit or below -12 degrees Celsius. However, the exact temperature varies depending on the composition and quality of the fuel.
Some telltale signs include a cloudy fuel appearance, white smoke coming from the exhaust when trying to accelerate, and the engine stopping when idle.
To prevent gelling, you can keep the fuel warm, change its properties to withstand colder temperatures, or use fuel additives. Storing your vehicle in a climate-controlled garage can also help, but it may increase energy costs.
If your fuel has gelled, you can use Diesel 911 to reverse the gelling process. You may also need to replace the fuel filters and treat the tanks to prevent further issues.
