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Algae-X
Cleans Diesel Fuel
Filters & Tanks

Algae-X Magnetic Fuel Conditioner

Clogged Filters, Dirty Tanks?

ALGAE-X Cleans Fuel Systems By
Simply Running The Engine

Frequent Filter changes and cleaning fuel tanks have become acceptable periodic maintenance instead of a warning signal for engine failure. Filter elements should last a thousand hours or more, and injectors some 15,000 hours. However, since diesel fuel is inherently unstable, solids begin to form and the accumulating tank sludge will eventually clog your filters, ruin your injectors and cause engines to smoke.

Fuels and oils are susceptible to natural deterioration, like any other organic fluid. Oxidation, chemical incompatibility, water and microbes all contribute to the process of polymerization and stratification. This results in poor Fuel Quality, tank sludge, bio film and acids. These by-products of the process of fuel breakdown cause clogged filters, corroded injectors, pumps and tanks, incomplete combustion, carbon build-up, smoke, and loss of power, which ultimately leads to complete engine failure.

Fuel Filter Contamination

Filters and centrifuges remove particles and free water, and biocides are used to control microbial activity. Neither, however eliminates fuel instability or sludge buildup, and additive treatment, such as frequently adding biocides to your diesel fuel, aggravates filtration problems by turning bio-sludge into solids. A study by the University of Idaho determined that there could be as much as a 26% degradation in diesel fuel after just 28 days of storage. Diesel engines continuously return fuel not used for combustion back to the tank. Repeated exposure to the heat and pressure of the injection system accelerates the breakdown of fuel quality.

Diesel fuel is inherently unstable. Fuel quality and chemistry are affected by transportation, storage and as a result of factors such as oxidation, water, microbial contamination, incompatible additive packages, etc. The results is a dramatic increase in the size of the fuel droplets, which negatively affect fuel consumption and filterability.

Diesel Fuel Contaminated

The solution is ALGAE-X Fuel Conditioning Technology. ALGAE-X reverses the process of fuel breakdown, restores fuel filterability, enhances combustibility, and prevents clogged filters and tank sludge. Optimizing fuel droplet size results in combustion efficiency, improved filterability and lower operating costs.

ALGAE-X Total Fuel System Management

Diesel engines return excess fuel not used for combustion back to the tank. This enables ALGAE-X, installed in the fuel line before the primary filter, to continuously treat the fuel and keep the entire system clean.

Metal Corrosion

In applications where the diesel engine is not operated for weeks or months at a time and the fuel is not circulated, the fuel will not be treated and the fuel will again deteriorate. For these applications, ALGAE-X designed systems to specifically meet the needs of your application. For large marine and backup generator systems, a wall mounted Tank Cleaning Polishing System provides excellent service. For cleaning large tanks that service multiple back-up power generators, such as hospitals, fire/police dispatch and emergency service or commercial data centers, an automated tank cleaning system is available. Commercial marinas and repair facilities for boat, truck or standby generator repair and service find mobil tank cleaning systems invaluable. We also offer a 12 volt portable tank cleaning system that is ideal for individual users or a group of friends that can share unit to perform do-it-yourself fuel system maintenance.

ALGAE-X Optimal Fuel Quality...

  Prevents clogged Filters and Tank cleaning

  Provides Peak Engine Performance
     LOWER FUEL CONSUMPTION
     MORE POWER—LESS SMOKE

  Extends life of engines, injectors and fuel
     Reducing maintenance & downtime
     Lowering operating cost

  Eliminates costly toxic chemicals
     Enhancing Safety of personnel
     Protecting the environment

  Saves Money, increases Safety and Reliability

Manson Solves H.R. Morris
Fuel Problems with
Algae-X System

Note: Although the following article was first published in 2004 in International Dredging Review, the information provided is still relevant and explains in a clear way how the condition of the fuel you use impacts the engine's operating efficiency and the performance of emissions components now common on newer trucks and other equipment.

Manson Construction Company recently solved emission problems on the 10,000 hp cutterhead dredge H.R. Morris and other vessels by installing Algae-X magnetic fuel conditioners on the diesel engines, and by treating the fuel with AFC-705 fuel catalyst.

"We had a significant reduction of soot in the exhaust, after installing the system", said Marc Stearns, executive vice president and Southern California Manager for Manson. "There had been an oily soot residue on the catalyst blocks in the engine's exhaust treatment system, before installing the fuel conditioners", he said.

"We were in the process of cleaning the blocks again when we installed the Algae-X system," said Rocky Bolin, Manson's Southern California equipment manager. This involved taking all 500 blocks out and wire brushing and vacuuming them one at a time.

Manson's 28-inch cutterhead dredge H.R. Morris

Manson's 28-inch cutterhead dredge H.R. Morris

The company is preparing for the new California emission requirements, that go into effect in 2005, and for more stringent requirements that begin in 2007.

To remove Nitrous Oxides (NOx) from the engine exhaust, and to anticipate the new emission rules, Manson installed selective catalytic reduction (SCR) systems, manufactured by Kaparta of Switzerland, on the 10,000 hp Morris - a million dollar investment for one dredge.

The SCR systems are large steel containers with several walls of foot-long ceramic bricks with a precious metal coating. The bricks have tiny channels for the exhaust to pass through and are stacked to cover the full cross section of the exhaust treatment chamber.

The reaction of the urea injected into the exhaust stream and the coating that functions as the catalyst lowers the nitrous oxide emissions (NOx) when the engines are operating.

The exhaust of each of the four 2600-horsepower Caterpillar engines is connected to an SCR system on deck of the dredge.

Selective Catalytic Reduction (SCR) systems on deck of H.R. Morris

Selective Catalytic Reduction (SCR) systems on deck of H.R. Morris

After the SCR installation, the Manson crew discovered that oily soot deposits on the bricks reduced the effectiveness of the system, and that the carbon clogging the channels restricted the exhaust from escaping through the stacks. This caused back-pressure on the engines that affected the operation of the engines.

Stearns called in the air quality consultant Justis and Associates, and also Bernard Franken at Kaparta the SCR equipment manufacturer, who recommended Algae-X.

Algae-X visited Manson's project in Los Angeles last Spring for the installation of his magnetic fuel treatment system and fuel combustion catalyst on the engines of one of the boats. The results of the initial installation convinced the project managers to install the system on the Morris.

"Since we installed the system, there is no oily soot residue on the catalyst blocks in the SCR," said Stearns. "We are getting a more complete burn; the soot is dry and there is less of it. The ceramic blocks are clean and dry. fuel efficiency went up, and the system requires less cleaning and maintenance," he said.

Algae-X discovered that fuel re-polymerization is the principal cause of insipient solids that retard combustion and ultimately results in sediments and sludge that cause filtration problems and the need for periodic tank cleaning. In 1994, Algae-X started developing systems that improve the filterability and stability of fuel, enhancing the combustion process. The results include increased power output, reduced emissions and eliminating residue and deposits in exhaust treatment systems.

An engine converts fuel to mechanical energy, heat and exhaust. Ideally, the combustion process should convert the hydro-carbon fuel into mechanical energy, CO2 and water.

Algae-X technology conditions fuel in such a way that it reduces the size and mass of the fuel particle so it combusts more efficiently. Burning more of the fuel in the combustion chamber before the exhaust valve opens eliminates carbon deposits, lowers the exhaust temperatures and cleans up emissions. Fuel conditioning is the key to peak engine performance.

Diesel fuels are inherently unstable, and tend to polymerize, forming larger and larger clusters of agglomerating molecules. Fuel filters are telltales of fuel quality, and frequently need to be replaced after only a few hundred operating hours, instead of lasting several thousand. Visually, a beaker of diesel might appear clear and bright, but filters may quickly clog a two or a ten micron filter element, revealing sediment, gums and other waxy deposits.

Modern fuel injection systems have much higher pressures and tighter tolerances, to comply with increasingly stringent air quality regulations. They are very sensitive to the chemical and physical characteristics of the fuel. At the same time, fuel refinery techniques have changed dramatically, producing fuels that have a much shorter shelf life, are less stable, and more prone to polymerization and oxidation, forming acid incipient sediments and eventually tank sludge.

Historically, refineries could convert only about fifty percent of a barrel of crude oil to produce lighter fuels such as diesel, gasoline and kerosene. The remaining fifty percent went to residual oil and other industrial applications. With the advent of catalytic cracking, it is now possible to capture in excess of 90 percent of that same barrel of crude oil in usable fuel products. As a result, today's fuels such as marine gas-oil and diesel are a blend of distilled and cracked products, which are less stable than straight run distillate.

Fuel quality deterioration is already well underway after the fuel's long journey from the refinery storage tanks through pipelines, tankers, barges, tank farms, wholesale and retail vendors. The negative impact on fuels from temperature changes, water, microbial activity, heat and pressure of engines and pumps is often not understood as the cause of engine performance, maintenance and excessive emissions issues. Coking, corrosion, hard carbon deposits, damaged injectors and pumps are symptomatic of poor fuel quality.

Traditional filtration and centrifuge technology are designed to remove inorganic contaminants and free water, but are not effective solutions for the negative impact that polymerization has on the filterability and combustion of fuels and oil. The core of the issue is the condition of the fuel itself, the formation of organic compounds increasing in size and mass, forming insipient solids and sediments.

Another frequently-used remedy that has proven to aggravate filtration and combustion issues is the use of biocides. These dangerous, toxic additives are designed to deal with microbial activity and offer no effective solution for treating sediments, gums or asphaltene deposits that ruin injection systems.

The solution is the application of fuel conditioning technologies that address polymerization -- the natural attraction and bonding of fuel molecules, that form compounds that keep increasing in size and mass, eventually forming the sludge and jelly found in tanks and bunkers all of us in the industry are very familiar with.

FC Series Magnetic Fuel Conditioner

An Algae-X FC Series Magnetic Fuel Conditioner installed on the Morris

Algae-X total fuel system management is based on principles in physics -- the application of magnetic fluid conditioning -- and on chemistry -- the application of combustion catalyst, surfactants and dispersants.

The installation of an Algae-X fuel conditioner in the fuel line between tank and the primary filter will condition the fuel by reducing the size of the fuel particles. This results in improved fuel filterability, combustion and lower emissions. This technology is based on the same principles that make generators and electro motors do their job.

AFC-705, the Algae-X catalyst, chemically affects the surface tension of the fuel constituents. The active catalytic ingredients enhance the combustion process to more completely burn the fuel, preventing and eliminating hard carbon deposits.

The technologies are complementary in addressing the prevention and reversal of fuel polymerization, optimizing fuel droplet size to promote more efficient combustion.

Algae-X incorporates these technologies in total fuel management systems, manufactured in a variety of sizes for different applications. The company builds complete fuel conditioning, filtration and tank cleaning systems. Its mission is providing customers with solutions to lower their overall operating cost while increasing safety, reliability and compliance with clean air regulations. Its focus is on the treatment of fuels, oil and hydraulic fluids.

The Algae-X system worked so well in Morris that Manson also installed it on the clamshell dredges Valhalla and Valkyrie, and the tugs Cub and Pub. Stearns stated that they plan to add the system to other vessels as well.

CLICK ON SCHEMATIC TO ENLARGE

In high-turnover fuel/oil delivery, transportation terminals, and storage systems, the ALGAE-X FC Series Model is installed between the loading dock and the primary filter banks. It preserves the integrity of stored fuel, improves filterability, reverses the process of sludge build up, prevents tank cleaning, and enhances oil/water separation. In long-term storage ALAGAE-X is installed in re-circulating systems to prevent fuel degradation and sludge build up.

Want Better Fuel Efficiency, Lower Emissions, and A Cleaner Burning Diesel Engine?

Review this Test Report that Shows the addition
of an ALGAE-X MFC unit provided a:

  • 13.2% reduction in Hydrocarbon emissions

  • 11.3% reduction in CO emissions

  • 10.8% reduction in NOx emissions

  • 64.7% reduction in particulate emissions

  • 6.4% reduction in fuel consumption

Read this test report
for the whole story.

This is a large 2.6 MB Acrobat Reader (.pdf) file. Please allow adequate time to download.

The addition of ALGAE-X AFC-705 Diesel Fuel Catalyst will enhance and accelerate the tank cleaning process by breaking down, dispersing, and dissolving existing tank sludge and slime, stabilize and restore fuel quality, decontaminate compartments of the tank that are out of reach of the suction line, and eliminates costly tank cleaning and fuel disposal fees. Treatment with the ALGAE-X Magnetic Fuel Conditioner (MFC) completes the process of making the fuel clear, bright, and usable. Utilizing a fuel polishing service that re-circulates the fuel through a fuel polishing system before using the AFC-705 and installation of the MFC is not necessary. Save your money! Use the AFC-705 periodically to provide peak engine performance: removes and prevents carbon build up, improves combustion, lowers fuel consumption, adds lubricity to low sulfur fuel, prevents corrosion of injectors, reduces harmful emissions, and extends equipment life.

ALGAE-X units are self-cleaning and easy to install, have no moving parts, no electrical hookup, and require Zero Maintenance.

ALGAE-X Technology

The ALGAE-X FMC unit operates on the principle of induction on the process of combining kinetic and magnetic energy to influence the behavior of electrons. Algae-X provides a powerful magnetic field and the flow of fuel provides the kinetic energy.

As fuel deteriorates, clusters of fuel components break down and residue begins to accumulate, resulting in dark, hazy fuel with poor combustibility. The increase in size and mass of the fuel breakdown products lead to clogged filters and the build up of tank sludge (algae).

Algae-X dissolves the clusters, stabilizes the fuel, and eliminates tank sludge. The results are Clear & Bright Fuel improved filterability, optimal combustion and clean fuel systems.

The process of how the ALGAE-X Magnetic Fuel Conditioner makes clear, bright and more combustible fuel as well as restoring degraded fuel and eliminating the effects of microbial contamination is compelling.

Click Here to Learn More
of the Process, the Cure,
and the Benefits.

ALGAE-X Series

Click on Picture to Enlarge

LG-X Model*

Port Size

Max flow rate ** (gph)

Weight lbs

HP range (hp)

 

200

1/4"

25

1

200


500

1/2"

20 - 110

2

500


1500

3/4"

50 - 350

3.5

1500


3000

1"

200 - 800

7.5

3000


4000

1 1/2"

1500

32

3000 (and up)


5000

2"

2500

35

3000 (and up)

* Larger capacity equipment for higher flow rates available
Material: Anodized Marine Grade corrosion resistant 6061 Aluminum
**Max recommended flow capacity for engine applications. For recirculating systems double the indicated flow rate.


Magnetic Fuel Conditioner Literature


Articles on Automated Fuel Cleaning

Power Motoryacht Magzine - Magnetic Fuel Conditioning Captain's Log

LG-X Parts Package

O-Ring and Replacement Screws for the Face Plate of ALGAE-X Magnetic Fuel Conditioners

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