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INTRODUCTION
Diesel fuel systems require filters to remove unwanted
contaminants in the fuel that can damage the engine
system components. Diesel fuel contaminants come
from a range of sources and include; particles, water,
biological material, wax crystals and asphaltines.
Particles can enter the fuel through the fuel distribution
system, engine wear or combustion byproducts. Water
is typically introduced into the fuel supply by
condensation. Free water in the fuel will promote the
growth of microorganisms. Waxes are an important
component of diesel fuel but they can form crystals as
a result of paraffin precipitation. Asphaltines are
present in all diesel fuel and are long chained
hydrocarbons that are hard, sticky and generally
insoluble.
Particles will cause wear to engine parts and block fuel
injector nozzles.
Water can reduce fuel lubricity
causing seizure of close tolerance parts, increase wear
and promote biological growth. Biogrowth in a fuel
system will result in a slime coating over the surface of
the filter significantly reducing the life. Wax crystals
and asphaltines will plug a fuel filter shortening the life.
Modern fuel injection systems are one of the reasons
that the diesel engine market has grown so rapidly in
Europe. Advances in diesel engine fuel injection
systems have been instrumental in complying with
future emission standards.
Higher pressure fuel
produces a finer mist of fuel, which burns cleaner.
Common rail systems run at higher pressures and
allow more injections per combustion cycle improving
fuel economy, better engine performance and lower
noise. Higher pressure fuel injector systems have
tighter tolerances and require high levels of particulate
filtration and water removal to minimize wear related
failures.
Ultralow sulfur diesel fuel will be mandated for use in
on and off road vehicles in 2007. When low sulfur
diesel was introduced in Europe and California for onhighway vehicles there was widespread damage to
injection systems, including, excessive wear and
failure. New media was needed with increased filter
efficiency, water removal and life to meet the demands
of the new fuel.
FILTER MEDIA
There are many different types of nonwoven
media that can be used for diesel fuel applications.
The media vary by materials of construction,
processing method and performance characteristics.
The two-stage system typically uses an open
coalescing media based on cellulose as the primary
filter. The coalescing filter needs to be emptied on
some periodic basis. The secondary filter typically
uses a finer cellulose or cellulose/glass composite
media for particle removal. The cellulose can be
treated with water repellent chemical for additional
water removal. The one-stage systems use a
multilayer composite structure. The current state of the
art uses a modified polyester meltblown media formed
on or laminated to a cellulose support. The chemical
composition of the meltblown has broad chemical
compatibility and is moderately hydrophobic. The
cellulose media provides physical support to the
meltblown and is generally bonded with a phenolic
resin, which needs to be post cured.
Nonwoven filter media can be classified into two
distinct types based on their method of formation. The
first method is a dry laid process, which includes
carded, needled, spunbond and meltblown media. The
second process uses a wet laid formation, which is
generally done on a paper machine. Each process
produces a media with unique properties that have
advantages in different applications.
NONWOVEN CONSTRUCTION
AirLaid Media
Dry laid processes generally produce media
with nominal ratings that are low cost and have high
dirt holding capacities. Melt Blown media are one of
the most versatile nonwovens for liquid filtration and
will be the sole airlaid product discussed in this paper.
Meltblown media is generally composed of a
continuous network of self-bonded polypropylene,
polyester or nylon microfibers produced with a
controlled fiber uniformity and density. The resulting
media has a uniform porosity, does not shed fibers and
contains no binders, adhesives or surfactants.
Meltblown media have nominal ratings from 1m to
50m and when calendered or laminated into
composites can have sub micron and absolute ratings.
Meltblown media can also be produced using highpurity FDA-acceptable polymers.
Wetlaid Media
Wetlaid media are generally produced on a
paper machine with cellulose, synthetic or glass fibers.
It is common for media to be produced with one or more
fiber types. Wetlaid media can be made with nominal or
absolute filter ratings. They typically contain binders,
which can have poor chemical and thermal resistance
and high extractables when compared to air laid media.
Wetlaid media can also be made using FDA compliant
materials.
Cellulose based media is generally lower cost
with nominal efficiencies above 15 m and low dirt
holding capacity. Cellulose fibers are coarse and flat
which produces a dense, two-dimensional structure with
high-pressure drop.
Figure 2 is a typical wetlaid
cellulose nonwoven media.
Filter Performance
Latex
Melamine
Phenolic
Epoxy
Binder Type