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Prelude to Fuel
This booklet is written in order to share a fair part of the
knowledge that Donaldson has gathered over the years both
in the field as in the laboratories around the world.
By spending between 2 and 3% of Donaldsons annual
turnover on Research & Development (R&D), our technology,
whether it is new media development, filter package or
solution positioning, stands where it is today.
We strive to continue this process and to invest in knowledge
about fuels & oils. Knowledge that will provide us the key to
the solutions of the problems you face today and most likely
tomorrow.
A big impact in fuel and fuel cleanliness is not only the fuel
itself, but also how it is applied in new engine platforms with
advanced common rail injection systems.
The better we understand this continuous change, the more
reliable our solutions and your machines become.
The fuel booklet is written to introduce you to the world of
fuels, a world that like human society is in a continuous mode
of change.
A world that has a profound part of what can be described as
mysterious, for those who are not breathing the science day in
and day out.
On the next 28 pages we will reveal part of the mystery and
show you a glimpse of the near future.
Niko Verhaegen
Development Manager Clean Fuel & Lubricant Solutions
Table of Contents
Fuel Legislation
PM&NOx
CO2
EN590
ISO4406/99
Types of Diesel
Biodiesel
Fuel Chain
Fractional Distillation
Contamination
10
12
14
17
19
20
21
Case Studies
24
FAQ
26
2
Fuel Legislation
Engines have been driving our world, whether it is the engine
in your car/ truck that takes you to your next adventure or the
engine of a ship, plane or train that connects you with your
friends, colleagues or family. Engines have made our big blue
planet smaller at each leap of technology. This technology
path is mostly challenged by legislation.
The engine emissions regulations, whether it is on road (Euro)
or offroad (Tier), are forcing Engine manufacturers to decrease
the emissions and to make better & cleaner engines.
EN590
Before this Directive the European fuel standard EN 590:2009
has incorporated the latest fuel quality requirements.
Products coming from manufacturers of fuel injection
equipment may not meet the expected lifetime performances
and emissions targeted, if the fuel used doesnt respect the
parameters of EN590:2009.
The most important features in terms of cleanliness of the
EN590 standard are:
up to 24mg/kg of total contamination findings 3<x<10
below 200 ppm of water finding 59<x<150
These general parameters will surely be more specified in the
future, but for now are the only cleanliness norms that can
be used.
ISO 4406/99
The International Standard Organization (ISO) has also
developed a cleanliness code that has become a standard, the
ISO 4406/99. This code defines more in details the number of
particles present per milliliter of fluid.
For more info please read section on how clean should fuel be.
Worldwide Fuel Charter
On a more worldwide scale, in 1998
engine manufacturers created the
Worldwide Fuel Charter to set
international standards for fuels. In the
preamble for the 2006 edition it stated
that: advanced ultra-clean engine
and vehicle technologies have begun
to be introduced in some markets and
will continue to be used in increasing
numbers.
These new technologies require the best quality to achieve
their emissions and performance potential. The charter
quotes a requirement for diesel fuel to meet an ISO
18/16/13 cleanliness requirement and on the other hand fuel
manufacturers start working on a fuel that has to be much
cleaner in order to respond to the needs of modern common
rail injector needs.
Types of Diesel
Common Diesel Fuel
It is obtained through the fractional distillation of petroleum
fuel oil and it is generally simpler to refine than gasoline. It
contains hydrocarbons and has a boiling point in the range of
180-360C (360-680F).
Diesel derived from petroleum has a composition of about
75% saturated hydrocarbons and 25% aromatic hydrocarbons.
The chemical formula for this type of fuel is normally C12H23
and goes from C10H20 to C15H28.
Because of recent changes in fuel quality regulations,
additional refining is required to remove sulfur, this has led to
the production of ULSD (Ultra Low Sulfur Diesel) fuel.
If the level of sulfur is high this is harmful for the environment
because sulfur prevents the control of particulate emissions
through catalytic diesel particulate filters, but not only: also
innovative technologies like nitrogen oxide (NOx) absorbers
are unable to reduce emissions.
Another effect of the lowering of sulfur in diesel is the
reduction of fuel lubricity that provokes the increase in the
usage of additives in the fuel to improve lubrication.
Biodiesel
Fuel Chain
Fractional Distillation
Source:
Understanding Biodiesel Fuel
Quality and Performance
By: J.M. Weiksner Sr. P.E.,
Stephen L. Crump Ph.D., and
Thomas L. White Ph.D.
Contamination
Types of contaminants
10
11
40 m
80 m
25 m
100 m
2 m
10 m
100 m
Human hair
80 m
40 m
25 m
Talcum powder
10 m
8 m
Bacteria
2 m
Silt
<5 m
visual test of how clear and bright your fluid is, is not correct
and therefore a so-called patch test is required. The patch test
is a test where a sample of 25 ml of the fluid to be tested is
poured through a membrane with porosities of up to 0.8m,
causing any particle greater than 0.8 to be captured on the
surface of the membrane. This membrane is than visually
inspected under the microscope with a suitable magnification
level.
12
15
ISO 18/16/13
PARTICLES HARMFUL
TO THE COMPONENT
4 6
14
SO 22/21/18
ISO
18/16/13
ISO 18/16/13
Typical
cleanliness of
elivered fluids
Target
Targetrating
ratingforfor
heavy
gear/engine
heavy
gear/
oils oils
engine
ISO
16/14/11
ISO 16/14/11
ISO
ISO 14/13/11
14/13/11
Target
Targetrating
rating
for
forhydraulic/
hydraulic/
transmission
transmissionoils
oils
Target rating
Target
ratingfor
for
diesel fuel
diesel
fuel
16
17
Injection
reservoir
Online
APC*
Down Stream
Test reservoir
pump
Up Stream
pump
Test
Filter
Online
APC*
*A
PC = Liquid Automatic
Particle Counter
ISO 16889
18
Efficiency
1,01
0,99%
19
1,1
9,09%
1,5
33,33%
50,00%
75,00%
80,00%
10
90,00%
20
95,00%
75
98,67%
100
99,00%
200
99,50%
1000
99,90%
2000
99,95%
10000
99,99%
Example:
4(c) =200 signifies that
there are 200 times as
many particles that are 4
m and larger upstream
as downstream. This is
99.5% efficiency.
Example:
4(c) =2000 indicates that
there are 2000 times as
many particles that are 4
m and larger upstream
as downstream. This is
99.95% efficiency.
20
1
Now what to do with the existing machines and tanks...
which have been exposed for years to deliveries of dirty
fuel, atmospheric dirt, water ingression and a lot of other
contamination sources.
The best you can do is to stir you reservoir and use a mobile
filter cart to clean up the bottom of the tank.
The CLEAN.PROTECT.POLISH concept consists of 3
steps of filtration.
1
21
Donaldson Delivers
TM
22
This range is not only for fuels, elements are predefined for
various liquids:
25m Absolute Media element for bulk engine and gear
oil applications.
Target cleanliness ISO 18/16/13
7m Absolute Media element for bulk hydraulic and
transmission applications.
Target cleanliness ISO 16/14/11
4m Absolute Media element for bulk diesel fuel.
Target cleanliness ISO 14/13/11
(Incorporates DERT Donaldson electrostatic reduction technology)
The Spark
We all know what happens when you touch your car on a dry
day after youve driven it right, you get a spark. This is the
result of the build-up of electric charge on your cars surface
caused by the friction with the air. This same effect occurs on
filter media where a non-conductive fluid passes over a nonconductive media causing electric discharges on the media
which can in turn damage your media. Holes of 200-300
(micron) and bigger are created at the tips of the filter media,
preventing only big debris and dead bugs to be captured.
Evidently, your protection is gone at this point.
Donaldson, through R&D, has invested a lot of time and
resources to overcome this
natural phenomenon and
we are more than happy
to state that our DERT
(Donaldson electrostatic
reduction technology) media
is resistant to this effect.
(Hole created by ESD over filter media)
23
Case Studies
Transportation - Clean fuel case study
24
FAQ
Can additive drop-outs be blocked by Donaldson Clean
Solutions range of filters?
Additive drop-outs, forming soft sticky stuff material,
could be provoked by a set of various conditions. The
typical components that lead to drop outs are: bio mix,
additives; temperature fluctuations and the presence of
water.
Most seen in the field today are cases of cold flow
improver, glycerin & corrosion inhibitors drop outs.
Installation of inlet filtration guarantees consistent quality
of product going into the tank and prevents drop outs to
enter.
What is the dirt holding capacity of filters?
Donaldson always stresses the fact that the main aspect
to consider in choosing a filtration unit is the balance of
efficiency, capacity and pressure drop.
There are many factors to consider when it comes to dirtholding capacity: flow, viscosity, system pressure drop,
contaminant properties, etc All these factors have an
impact on the dirt-holding capacity of a filter.
Are particle counters always accurate?
Normally, laser and automated white light particle
counters are used to detect the contamination that
is present in fluids. It may happen that these particle
counters are not accurate and count phantom particles
because of the difficulty in differentiating dirt, water or
additives. Phantom particles count is more present in
fluids blended with additives than in base fluids.
26
27
28
2013 Donaldson
Company, Inc.
Donaldson Company,
Inc. reserves the right
to change or discontinue any model or
specification
30at any
time and without
notice.