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AXI Cleans Fuel Systems By
Simply Running The Engine
Frequent Filter changes and incurring the expense and inconvenience of 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 microbial infestation all contribute to the process of polymerization and stratification of diesel fuel and other hydrocarbons. This results in poor Fuel Quality, and the formation of 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 (evident from black smoke, caused by un-burned fuel, from exhaust), carbon build-up on engine components, and loss of power. As these problems build on each other, these individual symptoms of bad fuel ultimately lead to complete engine failure.
Filters, separators, and centrifuges remove particles and free water from fuel. Biocides, commonly recommended by many mechanics to cure the ills of "algae" in fuel tanks, are really less than effective in the long term control of microbial activity. Neither, however, eliminates fuel instability or sludge buildup in tanks. Biocide treatments aggravate filtration problems by turning bio-sludge into solids. Removal of fuel tanks for cleaning with high pressure washers or steam (a favorite recommendation of equipment dealers) is expensive, takes equipment out-of-service, necessitates the removal and disposal of fuel from tanks, and is likewise ineffective and does not provide a long term solution.
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. The repeated exposure to the heat and pressure of the injection system accelerates this breakdown of fuel quality. Fuel quality and fuel chemistry is affected by transportation, storage tank conditions as well as time, and factors such as oxidation, water in the fuel, microbial contamination (contributing to acid formation), and incompatibility of fuel additive packages with after-market additives, etc. This toxic combination negatively impacts: (i) the filterability of the fuel through filters that become clogged; and (ii) causes a dramatic increase in the size of the fuel droplets emitted from the fuel injector into the combustion chamber. The degraded condition of the fuel, when combined with the injector degradation that occurs over time from the use of the degraded fuel, result in fuel not being completely burned in the combustion chamber and formation of carbon deposits on internal engine components, all evidenced by a noticeable increase in smoke from the exhaust, loss of power, and an increase in fuel consumption. (See "Diesel Fuel & Injector Failures" for additional information)
in the water
in the bottom
of a diesel
Diesel Fuel suffers from a perplexing problem with a natural tendency to degrade over time. This process can begin within six months of the time the fuel leaves the refinery and is aggravated by the high-pressure that fuel is subjected to in todays fuel injection systems. The extreme pressure and heat of these systems results in the agglomeration of asphaltenes present in the fuel, the high carbon content heavy end fuel molecules that are in solution when the fuel exits the refining process. Asphaltene agglomeration leads to the formation of larger and larger clusters and solids, which are very difficult to completely combust. They contribute to the degradation of injector spray patterns as injector orifices become partially or totally blocked. As fuel spray patterns become compromised, combustion of the fuel becomes incomplete, resulting in increased exhaust smoke and carbon build up on internal engine components. These solids grow so large that they will not pass through the filter element. They become part of the polymer and sludge build up plugging the filter.
If you have noticed diesel fuel that has been in storage having an appearance of dark brown or even black, then you have witnessed the agglomeration of this asphaltene component as it comes out of solution. As these clusters increase in size and gain weight, they will drop to the bottom of the fuel tank and, in time, accumulate into a dark mass. If you have inspected a fuel tank and noticed what looks like the bottom of the tank has been painted with roofing tar, then you have seen the result of this fuel degradation process.
AXI does not market or sell the AXI Fuel Conditioner as a gadget that will provide you with a great improvement in fuel economy by simply adding this component to your equipment. That being said, what AXI does sell to its customers is a component that, when added to equipment that suffers from clogged and slimy filters, dark, hazy fuel, floating debris in tanks, sludge build-up in tanks, loss of power and RPM, excessive exhaust smoke, corroded, pitted fuel injectors, or a foul odor emitting from the fuel tank, all symptoms of having "Bad Fuel", the addition of an AXI Fuel Conditioner will reverse the fuel degradation, and with the adoption of a few simple steps to prevent water entry into, and water accumulation in your fuel tank, regular circulation of the stored fuel through the AXI Fuel Conditioner, and performing regular engine maintenance recommended by the equipment manufacturer, your fuel problems will be but a memory, your equipment will run better and last longer.
As long as fuel meets the (ASTM) specifications and engine manufacturer stated requirements, it will perform in your engine and the AXI Fuel Conditioner will not improve upon that. Using fuel that is less than optimal quality negatively impacts engine efficiency and accelerates the process that degrades fuel injectors, causes fuel pump failure, and makes new engines old. AXI Fuel Conditioners are an excellent preventative maintenance step that will keep the fuel in your equipment in optimal condition.
The solution to suspected microbial growth and the results of asphaltene agglomeration in your fuel is the application of AXI Fuel Conditioning Technology. AXI (formerly ALGAE-X) Fuel Conditioners, when installed in-line in your equipment fuel system, will reverse the process of fuel breakdown, prevent microbial growth, restore fuel filterability, enhance combustibility, and prevent clogged filters and tank sludge. Optimizing fuel droplet size results in combustion efficiency, improved filterability and lower operating costs. (For a detailed explanation of how the AXI Fuel Conditioner performs, see the web page "Learn More About Magnetic Fuel Conditioning")
The AXI Fuel Conditioner will also disperse and return to solution the asphaltene clusters the result in stored fuel degradation and return the fuel to a clear and bright appearance, a process sometimes referred to as "Fuel Polishing". (For additional information, see "Diesel Fuel Polishing")
Operating on the principal of induction on the process of combining kinetic and magnetic energy to influence the behavior of electrons, the AXI Fuel Conditioner provides a powerful magnetic field and the flow of fuel provides the kinetic energy. The process of how the AXI Fuel Conditioner makes clear, bright and more combustible fuel as well as restoring degraded fuel and eliminating the effects of microbial contamination is compelling.
As the AXI Fuel Conditioner does not filter the fuel, but treats it as it passes through the unit, there is seldom any reason to suspect that a restriction is in the AXI Fuel Conditioner. However, there are situations where the benefit of circulating your fuel through a magnetic unit has added benefit. Should the AXI Fuel Conditioner be used in a situation where a fuel tank itself is in poor condition, where the tank may be rusted on the inside and rust flakes may be coming loose, the AXI Fuel Conditioner would prevent the sharp metal flakes from progressing to the fuel filter where they may pierce the filter medium and allow unfiltered fuel to proceed to the fuel system. Also, should the source of your fuel be questionable, such as a marine vessel that fuels at island fuel stops with little oversight, or remote mining operations where a supplier may not be reliable, having the AXI Fuel Conditioner installed to stop metal shavings or other ferrous debris that may be the result of maintenance on upstream distribution equipment could be a great benefit.
Should a fuel restriction that cannot be traced to a clogged filter element make the AXI Fuel Conditioner suspect, you can remove the face plate, remove the magnet and wipe it off with a shop rag and replace the magnet and face plate. An extreme example is pictured to the left. A spare parts kit for the AXI Fuel Conditioner includes a new face panel O-Ring and replacement screws to fasten the face plate.
To completely reverse the buildup of particulates and fuel components that have attached themselves to the fuel tank bottom and sides, the fuel system lines, and inside surfaces of engine components, combine the use of the AXI Fuel Conditioner with regular use of AXI Fuel Catalyst and Tank Cleaning Additives. Unlike off-the-shelf additives that lubricate the fuel pump and limit their effectiveness to cleaning the injectors, the AXI Fuel Catalyst and Tank Cleaning Additives reverse the long term buildup of sludge and degraded organic materials that have accumulated over time in the tank bottom, removes carbon buildup from engine components and stops the degradation of fuel injectors caused by the acids and degraded fuel components.
Diesel engines return excess fuel not used for combustion back to the tank. This process results in a continuous re-circulation of the fuel from the tank, to the fuel system, and back to the tank that allows the AXI Fuel Conditioner to continuously maintain the fuel in optimal condition for peak engine performance. The AXI Magnetic Fuel Conditioner, installed in-line in the fuel line before the primary filter, between the tank and primary filter, continuously treats the fuel and keep the entire system clean while the equipment operates.
The type of application where this works ideally is where equipment is used on a daily basis or the engine is run for a period of time at least every couple of weeks. The following is a list of some of the applications where an AXI Fuel Conditioner installed on the fuel line will continuously keep the fuel in optimal condition:
Tractor Trailer rigs
Marine vessels used regularly
Construction Equipment used year around
Mining Equipment used year around
Equipment rented out year-around
Farm equipment used year-around
In applications where the diesel engine is not operated for weeks or months at a time and, as a result, the fuel is not circulated on a regular, extended basis, the fuel will not be treated and the fuel will again deteriorate. The AXI Magnetic Fuel conditioner only does its work when the fuel is circulating. The following are examples of applications where a AXI Fuel Conditioner that is mounted in-line on the fuel feed line to the engine is not appropriate:
Power Generators used only when the primary electricity service fails
Marine vessels that are not used for months over the winter season
Construction Equipment that is special purpose and not used very often
Rental equipment that is rented only occasionally
Farm equipment used seasonally or only during harvest
Trucks or other equipment used to backup front-line equipment
Fuel Tanks that service fuel needs in seasonal operations
For these applications, AXI has designed systems to specifically meet the needs of your application. Equipment that requires periodic Fuel Treatment and Tank Cleaning may be best serviced by a Mobil Tank Cleaning System. AXI has a portable system invaluable for periodic service on tanks over a wide geographic area. These systems can also quickly perform a fuel polishing treatment on equipment while the equipment is under regular periodic service for oil changes, fluid checks, etc. Equipment that is not used year around, or is held in reserve for use only when needed, can be serviced every few months with a fuel polishing regimen that assures that when the equipment is needed, the fuel is in optimal condition and the immediate service desired will be delivered.
Corrosion caused by acids
formed the result of
Diesel Fuel degradation
Larger tank capacity equipment where a dedicated automated system would maintain fuel without the necessity of personnel being involved, such as larger marine vessel and backup generator systems dedicated to maintaining one or more tanks for a single dedicated purpose, an FPS Automated Tank Cleaning and Fuel Treatment System provides excellent service for single tanks dedicated to a specific application or for a multi-tank installation on a yacht that may service multiple power units and one or more generators.
AXI also has a specialty unit for maintaining a fuel supply where alternate power is not available. AXI SMF Automated Tank Cleaning and Fuel Treatment Systems are solar powered systems ideal for fuel supplies that power generators or water pumps in agriculture, mining or similar operations in remote locations.
For cleaning large tanks that service multiple back-up power generators, such as hospitals, fire/police dispatch and emergency service, commercial data centers, or commercial office buildings where the fuel storage tanks are in a centralized location, larger STS Automated Tank Cleaning and Fuel Treatment Systems are available. These systems are mounted in cabinets to protect the components from the weather, have automatic controllers that will start and stop the fuel polishing process on regular, pre-programed intervals, and can be connected to Building Management Systems allowing for centralized control and monitoring of the process.
Prevents clogged Filters
Eliminates Periodic Tank Cleaning
Provides Peak Engine Performance
Lowers Fuel Consumption
More Power—Less Smoke
Extends Life of Engines
Injectors Last Longer
Lowers Operating Cost
Eliminates Costly Toxic Chemicals
Enhancing Safety of Personnel
Protects the Environment
Saves Money, Increases Safety & Reliability
AXI also offers a 12 Portable Tank Cleaning System that is ideal for an individual user or a group of friends that can share the system to perform do-it-yourself fuel system maintenance or for a small maintenance and repair facility that performs various maintenance duties and needs a system that will solve a customers fuel degradation problems, or simply needs a system that can perform fluid transfer duties when the need arises.
Although horsepower and flow rating information for each AXI Magnetic Fuel Conditioner is provided in the table along the left side of this page, the easiest means of choosing the proper size unit of your application is to determine the inside diameter of the fuel line that you intend on mounting the AXI Magnetic Fuel Conditioner on. If the inside diameter of the fuel line is a size for which there is no unit, use the next larger size unit. Using an AXI Magnetic Fuel Conditioner that is smaller than the inside diameter of your fuel line may cause a fuel flow restriction, especially at high rpm operations.
The AXI Magnetic Fuel conditioner is available in all sizes with National Pipe Thread (NPT), commonly used in North America. In portions of the world where British Standard Pipe thread (BSP) is used, you should purchase the correct AXI Magnetic Fuel Conditioner that is listed as equipped with BSP threaded adapters. Please order the appropriate version of the Magnetic Fuel Conditioner needed for the pipe standards in your country. Note that when fulfilling an order for a Magnetic Fuel Conditioner with BSP threads, we will ship an NPT threaded Magnetic Fuel Conditioner with adapters that allow for use of the unit with BSP threaded fittings.
The AXI Magnetic Fuel Conditioner is bi-directional. Either port may be used as the in-port or out-port. They are easily installed in the fuel line between the tank and the primary filter.
First, turn off the engine or circulating pump and close the necessary valves to assure that any cutting of the fuel line does not cause fuel to run from the tank or the engine side of the cut. Install the AXI Magnetic Fuel Conditioner unit in the fuel system exclusively using connectors and fuel line of appropriate diameter, material and quality as recommended by the engine manufacturer. Apply fuel resistant sealant to all connectors and (if applicable) to the bleeder screw on the face of the AXI Magnetic Fuel Conditioner. Check as necessary to make sure all fittings are properly tightened and no air is allowed to be enter the fuel line or the AXI Magnetic fuel conditioner after installation.
Use a pliable, non-hardening, Diesel Fuel Resistant paste or gasket forming sealant on threads. When using Teflon tape make sure it is resistant to diesel fuel and oil as some of these products are primarily designed for water applications.
The AXI Magnetic Fuel Conditioner are mounted either horizontally or vertically, but NOT with the round side of the unit facing down. We recommend to NOT use 90 degree elbows or sharp curves when installing the AXI Magnetic Fuel Conditioner in the fuel line. Properly installed AXI Magnetic Fuel Conditioners will not cause a pressure drop within the recommended flow capacity range.
After installation, check to insure that all connectors are tight and secure. Use bleeder screws (if included on the model being installed) on the AXI Magnetic Fuel Conditioner, as well as on filters and pumps to bleed all air out of the fuel system, and again check for fuel and/or air leaks. Your AXI Magnetic Fuel Conditioner is now ready for a lifetime of trouble-free service.
Fuel travels in a circular path through the IN port of the AXI Magnetic Fuel Conditioner around the treatment chamber to the OUT port. Fuel emerging from the unit has been effectively decontaminated. The AXI Magnetic Fuel Conditioner treat fuels sent down stream to the filter, the engine and via the return line back to the fuel tank.
Under normal operating conditions, with engines returning a sufficient amount of excess fuel not used in combustion back to the tank, the AXI Magnetic Fuel Conditioner will clean the entire system by simply running the engines.
Prior use of biocides will not damage the AXI Magnetic Fuel Conditioner. However, once the system has been completely decontaminated and the AXI Magnetic Fuel Conditioner is properly installed there is no more need for these chemicals. Solids that have formed as a result of using chemicals can be removed from the fuel by filtration or dissolving by use of AXI Diesel Fuel Catalyst. Note that AFC-710 is Tier 4 compliant. Use of AFC-805 is recommended during periods of cold weather.
When engines are not used for longer periods of time, to preserve the integrity of your fuel the use of an AXI Mobile Tank Cleaning System and AXI Diesel Fuel Catalyst is recommended every three to six months, depending on the climate of your location. The AXI Magnetic Fuel Conditioner is a reliable, inexpensive and valuable part a plan to keep your diesel fuel in optimal condition, but if the fuel is not running from the tank, through the AXI Magnetic Fuel Conditioner and eventually back to the tank, than it cannot do its job and the fuel will eventually degrade and become contaminated.
The magnet in your AXI Magnetic Fuel Conditioner is a permanent magnet. The unit is Direct Flow-Through, Self-Cleaning and requires virtually no maintenance. As long as the unit is not abused, dropped, or damaged, the unit will continue to function normally.
At times, metal fuel tanks will rust and ferrous metal type debris may come into a tank from a fuel fill-up or other means. Any metals that can be drawn to a magnet that may enter your fuel line could stick to the magnet. This is not bad in that it will stop any such metal from passing through your filters, damaging pumps and injectors. This will become evident if you develop a fuel restriction and have the resultant loss of power, usually at high rpm. Should this happen, remove the screws from the faceplate, taking care not to damage the O-ring that seals the faceplate to the main body of the unit. Carefully wipe of the magnet with a shop rag and replace it into the body of the unit, and reattach the face plate. Be careful with the magnet in this operation as it is brittle and hitting the magnet on a hard object or dropping the magnet will break the magnet. This breaking of the magnet is not covered under the AXI warranty. Take care to not over-tighten the face plate screws. Bleed the unit if necessary to remove any air.
You may experience after some years of operation a problem with the O-ring degrading and allowing a leak of fuel from around the faceplate. You will note that we sell parts kits for all AXI Magnetic Fuel Conditioners that include a new O-ring and new screws for the use in this maintenance task.
The most important part of fuel maintenance is keeping water from entering your tank, and if water does find its way into the tank, remove is as soon as is practicable.
When fuel is used from a tank, the fuel is replaced with air typically drawn in from the outside of the tank. Moisture and microbes are commonly pulled into the tank with the air. Temperature changes will cause the moisture in the air to condense on the walls of the fuel tank and these droplets of water will eventually find their way to the bottom of the tank. Accumulated water in the tank bottom is the habitat in which the microbes grow. Tanks should be checked at least every sixty (60) days to be assured that water is not accumulating. A Desiccant Fuel Tank Breather presents a good option for preventing water from entering your tank, especially if you are located in a climate with high humidity and wide temperature changes. The Desiccant Tank Breather may be affixed to the vent on the fuel tank providing a simple yet dependable defense against not only particulate contamination from entering the tank, but also moisture in the air from entering the storage or equipment tank.
Water may also enter your tank will fuel fills. This is highly dependent on the attention to tank maintenance practiced by your fuel supplier and other storage facilities upstream from your fuel supplier to the refinery. Some equipment have fuel tanks tucked into confined space and do not provide inspection ports that are easily accessible, nor fill points that allow for access to inspect fuel tank bottoms and determine the presence of water. However, tanks that do have easy access should be equipped with a means of capturing and holding water for removal. The Water Eliminator is a highly effective device that is placed in the bottom of the fuel tank and, when fuel is added, may be removed and inspected to determine if any water has entered the tank and captured by the water eliminator device. It is an easy and cost effective means of being assured that your tank is free of water.
Without a place to reproduce, the microbes will float around and eventually be pulled into the fuel flow and routed through the AXI Magnetic Fuel Conditioner, and the microbes will not reproduce and will not adversely affect your engines efficient operation.