Fuel Filtration for Modern

Diesel Fuels

National Biodiesel Board Technician Outreach Program

 Today’s Topics

 Changes in modern diesel fuel

 Basics of diesel engine fuel filtration

 Fuel Filter design

 Fuel Filter media

 Fuel quality

 Filter efficiency

 Resources
Changes in modern diesel fuel
 Emissions & air quality driven
 Ultra Low sulfur Diesel
 Low Sulfur Diesel fuel, Off-road
 Biodiesel & Biodiesel Blends
 Non- Biodiesel fuels
 Coal Slurries
 Raw Vegetable Oils and Fats
 Non-Esterified Oils
 Partially Esterified Oils
 Blends With Diesel
 Non Ester Renewable Diesel
Diesel fuel and its injection

Common Rail Diesel and

Unit injection fuel
injectors operate at high
pressures
They are electronically
controlled for optimum
fuel metering and
complete combustion
End goal is cleaner diesel
emissions
Fuel Filter Variation
 Capacity is the measurement (in grams) of the total
amount of containment a filter can retain at a rated
flow and given end-point (restriction).
 Restriction is the pressure drop across the element at a
given flow, temperature, and fluid viscosity.
 The type of media and general filter construction
defines restriction.
Fuel Filter Efficiency
Efficiency is the ability of the filter to remove
particulate (% efficient) at a given micron (size)
 The type of media being used ultimately

defines the filter's efficiency.

 Filter Micron Rating
 What is a micron?
 The common unit of measurement in the filtration
industry is the micron or micrometer.
 One micron equals forty millionths of an inch
(.00004).
 A single human hair is approximately 70
micrometers.
Fuel Filter Media
 Silicone Treated
Cellulose
 Glass and Cellulose Co-
Pleated
 Cellulose and Meltblown
Combination
 The type of media and the
amount (square inches) of
media defines capacity.
 Primary Fuel Filter
 Provides low restriction because it is
mounted on the suction side of the fuel
pump where normally a suction pressure of
only 5-6 pounds per square inch is
available.
 The primary filter protecting the transfer
pump and lightening the load of the
secondary fuel filter (if installed).
 Primary fuel filters typically have a nominal
rating of 10 - 30 microns.
 Not all vehicles have a primary filter
Secondary Fuel Filter
 The secondary fuel filter is designed
to offer full protection to the fuel
injectors.
 It is mounted between the transfer
pump and the injectors.
 Secondary filters tend to see much
higher pressures than primary filters.
 Secondary fuel filters typically have
a nominal rating of 2 - 10 microns.
 Water Separators
 Water flowing at high velocity between highly polished
valve seats and through fine nozzle orifices causes a
wearing action that approaches that of abrasion.
 The presence of water, especially with entrained air and
various fuel components, causes rust and other
chemical corrosion that eats away at the finely mated
surfaces.
 Use chemically treated paper to repel water which then
settles by gravity to the bottom of the filter.
 Accumulated water can be drained from the filter if
equipped with a drain valve or plug.
 Water Separators
 Emulsified water is a problem for both
ULSD and biodiesel
 Traditional media is challenged by both

fuels
 Interfacial Tension

 Fuel Surfactancy

 Fuel/Water emulsion stability

Fuel Quality concerns
 Out of specification
fuel of any kind can
clog filters and
damage internal
components
 Purchase fuel that
has been properly
filtered to meet your
vehicle’s needs
Asphaltenes
 Asphaltene is a by-product of fuel as it oxidizes.
 These particles are generally thought to be in the half
micron - 2-micron range
 Thought to be harmless to the injection system, as they
are soft and deformable.
 As these tiny particles pass through the filter media
they tend to stick to the individual fibers.
 Aphaltenes can be observed in normal fuel filters as a
black, tarry substance on the dirty side of the element
Fuel Filter Maintenance
 Adhere to
manufacturers
recommended
maintenance
 Examine internal filter

media
 How full is the filter?
 Exposure to Air
• Enters through vent pipes and
contains large amounts of
moisture.
• Generally displaces the fuel as
tank is emptied.
• It is not practical to keep air from
entering the tank.
• Will increase the oxidation of fuel.
• Do not store fuels for long periods
of time in partially empty tanks
without stabilizers.
• Consider desiccant dryers.
 Microbial Growth
• Microbes are bacteria or fungus that live and propagate
in fuel at the fuel/water interface.
• Water needed to live—no water, no bugs.
• Hydrocarbons in petrodiesel or biodiesel provide the
food and the water provides the oxygen.
• This environment is needed for living, growth, and
reproduction.
• The filters with microbial contamination often had an
odor different from the normal fuel smell.
 Water Contamination
• ULSD reaches water saturation at approximately 200-300
ppm. More settles to the bottom.

• NREL B20 survey data: same water saturation level as

petrodiesel. More settle to the bottom

• B100 can hold more water, up to 1200 ppm

• Still very small—0.12%, on the same order as gasoline can hold

water. Un-dissolved water settles to the bottom like it does in
petrodiesel tanks.

• While higher than petrodiesel, biodiesel is not water loving (i.e.

hygroscopic) like ethanol is. Most people do not understand this
fact.
 What could I see
in a Diesel Fuel
Filter?

Severe water saturation

High Water Concentration

Icing of the filter
• When there is excess free water in fuel, it can form
ice on the filter and cause filter plugging in cold
temps. A filter which has been plugged but is clean
and new at room temperature indicates that icing is
the likely cause.

• Since the temperatures of engines are warm, any

moisture picked up within the engine can be brought
back to the fuel lines. This moisture can freeze
overnight in low ambient temperatures.

Free water
 What could I see in a
Diesel Fuel
Filter?
• Some of the filters had solid sediment
within the folds and solid particles in
the filter casing.
• Sediment present in the fuel or rust
particles from within the engine can
collect over time and plug the filter
even when there are not necessarily
problems with the fuel.

• Not always related to biodiesel use

This filter had a rust sediment plugging issue, this

substance came back at 99.5% iron
What else could I see in
a Diesel Fuel Filter?
• High level of paraffin material could be
from the way ULSD is processed.
• When the temperature of the fuel is at or
below its cloud point, paraffin material
will precipitate out and collect on the
bottom of the tank.
• When warmed to room temperature the
paraffin wax will turn back into liquid.
• Paraffin build-up does not come from
biodiesel fuel.
What could I see in a Diesel Fuel
Filter?

Glycerin from off

specification biodiesel Other contaminants like
water and sediment
 Oxidation
• Filters with a black and shiny surface
but no microbial growth odor or gel
or sediment indicate they may be
plugged by oxidation build-up.
• Because many newer engines run at
higher temperatures, there may be a
black “asphaltene” petrodiesel type
material collecting on the filter.
• This phenomenon has been seen all
around the country, often in newer
engines.
 Oxidation
• Petrodiesel does not have an oxidation
specification, while B100 and B6 to B20
specs already do.
• Biodiesel can also oxidize, but oxidized
biodiesel manifests itself in acid numbers
which are out of spec
• The acid number for biodiesel will go out of
spec before filter clogging occurs
Troubleshooting Checklist
• Fuel Storage Tank Maintenance – Reduce
exposure to air, water, and microbial growth
• Fuel/Water Separators – Excess water in tank can
cause icing in filters
• Oxidation – Hot fuel return to fuel tank, aged diesel
fuel
• Paraffin Wax – Temperature at or below cloud point
• Recommend regular fuel filter maintenance
 Filtration Resources
•www.biodiesel.org
• Technical Library
• Biodiesel Bulletin
• Educational Videos Available
• Informational Resources
• Technical Resources
• On-line Database & Spec Sheets
•Southwest Research International Filtration
Conference
•Filter Manufacturers Council
http://www.filtercouncil.org/
•Donaldson Filtration
•Society for Automotive Engineers