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Tag Archives: egr cleaning

Carbon Cleaners, Fuel Addtives, Fuel System Cleaning

Fuel & Carbon Cleaners – What Happens to the Carbon?

March 10, 2015 Andy 7 Comments

Frequently we are asked about fuel-based carbon cleaners. Specifically, what happens to carbon deposits that are removed through the use of fuel cleaners, and can these cleaners damage an engine?

Let’s begin by discussing the first part of that question.

Within the fuel system, you’ll seldom find carbon itself. You will likely discover sludge, gum, varnish, debris, and similar deposits. The fuel filter captures the larger deposits. These and other deposits that have found their way through the fuel system usually are dissolved and dispersed in a controlled and manageable way using dispersal-based detergents. That’s why it is important to use additives at the recommended dosage so that deposit removal is completed in a controlled manner. High-strength fuel system cleaners that carry out this process typically contain a lubricant to ensure the entire system is lubricated during the cleaning procedure. This too, minimizes the risk of any issues.

Most actual carbon formation occurs in the combustion chamber and post-combustion areas. This includes the turbo’s hot side, intake, inlet valves, EGR, catalytic convertor, DPF, and the remainder of the exhaust tract. The reason why carbon remains is that there is insufficient heat to burn it off. Chemically, a liquid hydrocarbon fuel – such as gasoline or diesel – is very similar to the solidified fuel (carbon) it creates. The difference is that a higher temperature must be reached to ignite and burn solid carbons because the flash point has changed.

High-quality fuel detergents, combined with fuel catalyst technology, reduce the threshold temperature at which the carbons can burn, enabling natural engine processes and inherent heat to gradually “burn off” the deposits. This is undoubtedly the case for combustion chamber deposits.

Sometimes there also is a degree of active cleaning from any cleaning chemistry that can survive the combustion process and thus is still active post combustion. However, as described above, most carbon is removed by reducing the temperature at which it can burn.

It is important to note that there also is a natural cleaning mechanism. When the combustion process is of sufficient quality – generally through an efficient fuel system (no injector deposits), good fuel quality (more often than not, only achieved with fuel conditioners), and an engine that is up to full operating temperature – engines are designed to self-manage carbon build-up. The clean(ish) gases will naturally remove carbons to maintain a respectable level.

The issue arises when this equilibrium is broken, and more carbons are deposited than can be naturally removed. This could be due to a flawed engine design, poor fuel quality, fuel system deposits, driving style, failure to let the engine reach the proper temperature, etc., or a combination of these.

This is why catalyst technology is so vital in carbon cleaning and for keeping a system clean. When a catalyst is added to the fuel, it improves the combustion quality to such a degree that it reduces the amount of hydrocarbons created, particularly when the engine is cold. These cleaner gases then work together with the active work the catalyst is doing to reduce the temperature at which these deposits can burn and be removed.

Essentially, a high-end fuel cleaner and carbon remover provide an environment where the combustion quality is much better, and the exhaust gasses are much cleaner. The cleaner exhaust gasses will naturally scavenge and remove carbons from the combustion and the post-combustion areas. The caveat is that this process requires heat. The catalyst will reduce the temperature at which the carbons can be removed and burned off, but it also needs heat.

This is why it is tough for such chemistries to clean the EGR system. The problem is that an EGR and intake are designed to cool recirculating exhaust gasses. Doing so reduces the efficacy of any post-combustion cleaner or chemistry. Unfortunately, this also applies to the rear of the intake valves of direct poor injection engines. Those two areas are challenging to clean because the gasses going through are cooled.

Also, it is difficult to remove existing deposits in these areas. However, by using a high-quality conditioner with the fuel catalyst in both diesel and petrol applications, you’ll at least give the engine and emission control components a much easier life. This is because the engine and emissions systems will have fewer carbons to manage. This results in fewer deposits and hopefully removes the need to use high-strength cleaners or invasive measures to remove carbons manually.

What about the safety of cleaners and the risk of the fuel system or engine damage?

Providing products are used as per the instructions, the risk of any damage is incredibly low. The few rare cases of alleged damage we have witnessed weren’t caused by a product. The product just revealed or exacerbated an underlying mechanical issue with the fuel system.  Still, this is incredibly rare.

Furthermore, manufacturers err on the side of caution, so even if a product is used aggressively or improperly, it is still likely to be safe to use up until a certain point.

To summarise, fuel system deposits are generally dissolved, dispersed, and combusted naturally. Carbon is usually combusted through heat and added fuel-borne catalyst. They are proven safe processes when used correctly and responsibly.

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Carbon Cleaners, EGR Cleaning & Maintenance

Importance of a Clean EGR

August 21, 2013 Andy 2 Comments

The subject of EGR (Exhaust Gas Recirculation) systems comes up often, so I thought it was about time we explained further how a dirty EGR could affect performance, MPG, and exhaust emissions.
With our professional range of cleaners, we are confident that we can resolve a large percentage of the minor poor running issues (hesitation, poor idle, reduced performance, MPG, increased exhaust smoke, etc.) that our customers encounter. So where does that leave the other percentage? From our experience, faulty EGRs (due to deposit accumulation) and faulty sensors (the Mass Airflow being the most common) contribute to many running issues that professional fuel injector cleaners won’t resolve.

What is an EGR valve?

An EGR valve, or exhaust gas recirculation system, is a primary component of an engine’s emissions system on petrol and diesel-powered vehicles. Its purpose is to reduce NOx emissions by recycling a proportion of the combustion gases that normally exit through the exhaust. Recirculating some of the spent exhaust gases back into the engine is one way to reduce these harmful emissions, and this is done by using an Exhaust Recirculation System (EGR). The main component of this system is a valve that returns a proportion of the exhaust gases back into the engine to be mixed with clean air and fuel and then re-combusted.

The recirculated gases can be passed through air or water-type EGR Cooler. This, in turn, reduces the temperature of the gas, which reduces the charge temperature, that leads to an improved quality of combustion and engine power. In the case of a diesel engine, the recirculated proportion of gases can sometimes be as high as 50% under certain operating conditions.

Over time the EGR valve and associated pipework accumulate carbon deposits. These inhibit bypassed exhaust gasses back into the intake and play havoc with the fuelling. Thus we end up with hesitation, reduced MPG, and ironically, excessive emissions, particularly when the EGR is transitioning from open to close and vice versa. Unfortunately, modern electronics do not always recognize a faulty EGR except when the flow is entirely impeded, or there is an electronic fault with the control solenoid/actuator. What happens is that carbon builds up on the EGR valve itself, creating a resistance to the opening and closing of the valve. This vacuum-operated valve sticks and the solenoid that operates the vacuum has to work overtime to produce a sufficient vacuum to open the valve. An excess draw of current then trips the ECU warning light.

Carbon build-up cannot be avoided entirely as there is a natural and strong affinity between hydrocarbons and metal surfaces. The key is maintaining a manageable level of carbon build-up within the system and in quantities, the engine can naturally consume.

It is important to understand why carbon builds up in the first place and where it comes from. Contrary to popular belief, carbon build-up comes not just from fuel but also from engine oil. Oil can bypass engine rings, inlet valves and crankcase breather systems and then polymerise on intake and emission control system components as it recirculates. This creates a porous surface from which other oil vapor and excess hydrocarbons produced from the combustion process can then adhere and create further build-up.

Numerous solutions are now available ranging from aerosol sprays with accompanying fuel cleaner to pressurized detergents that are atomized into the intake and EGR system. The most effective way is a manual clean of the EGR valve and periphery pipework, but this is not always possible without significant labor time. It is also important to note that it is not always the valve that blocks up but the pipe leading from the EGR back into the intake. The hole(s) that leads into the intake are typically tiny and can block up easily. This then backs up to the valve.

Why do fuel cleaners struggle with EGR cleaning?

Fuel cleaning technology has come a long way, and carbon can be removed from most areas of an engine and emissions control system through fuel system cleaners. However, EGRs are notoriously difficult with this method. Here’s why:

There are four types of fuel-based EGR cleaners (1st three are added to the fuel).

1. Low-cost solvent-based cleaners that do very little other than clean the fuel injectors as the chemistry is destroyed during the combustion process.

2. Higher quality fuel system cleaners that use chemistries such as polyether amines to help remove combustion and post-combustion deposits, although most of it Is destroyed during the combustion process.

3. Patented molecules that are activated during the combustion process (rather than destroyed) are then carried in the recirculating gases. These molecules bond with the carbon, acting as a catalyst for its removal.

4. Solvent cleaners that are sprayed into the air intake and circulate through the intake system, EGR, combustion area, and out into the post-combustion areas, including the turbo and EGR again.

Product type 1 is useless. Product type 2 may have some effect if the carbons are mainly fuel related, but this process relies on heat. What happens is that such products improve the quality of the combustion to the degree that the cleaner exhaust gases will naturally scavenge and remove carbon from post-combustion areas. This is more workable in areas such as the turbo, DPF, CAT, etc., as heat is maintained. This cleaning mechanism is effective with HOT clean exhaust gases, but an EGR system is designed to cool the gases, reducing efficacy considerably. Furthermore, there has to be sufficient flow through the EGR system for this process to work. If it is blocked completely, then natural scavenging will not work.

On a side note, fuel additive manufacturers have been careful not to reveal the fact that combustion modification and improvement and the resulting cleaner exhaust gases can naturally remove carbon deposits! I remember one of our long-term test vehicles (Audi S8 4.2 TDI) having exhaust tips cleaner on the inside than on the outside, and I’m not kidding.

Product type 3 is similar to 2 and slightly more effective.  Specific molecules in the fuel additive are dormant and become active during the combustion process. Carried through the recirculating exhaust gases, they bond to carbonaceous deposits. This acts as a catalyst to dissolve/remove the deposits to the combustion area, where they are then burned. However, like with product type 2, this method requires sufficient heat and airflow through the EGR system.

Product type 4 is the most effective as the solvents do not require heat to work and hit the target areas more easily.  Again, if there is substantial oil build-up, then it is much more difficult to remove.

For information on products to clean the EGR system and keep it clean, read our article HERE.

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EGR Cleaning & Maintenance

EGR Cleaning and EGR Cleaners

July 29, 2013 Andy 100 Comments

An EGR valve, or exhaust gas recirculation system is a primary component of an engine’s emissions system on petrol and diesel powered vehicles. Its purpose is to reduce NOx emissions by recycling a proportion of the combustion gases that normally exit through the exhaust. A valve is used to control the flow of gases, which are re-routed through the intake system, where they are re-combusted with fresh intake air and fuel. On a correctly functioning EGR system, this lowers undesirable exhaust emissions.

The problem with these systems, particularly diesel vehicles, is that excess hydrocarbons are produced during the combustion process. These hydrocarbons deposit themselves on the EGR valve and periphery pipework, where the EGR routes back into the intake system. Over time, this clogs and eventually blocks the EGR valve and the associated pipework.

Additional Source of Deposit Build-up!

It is important to note that the carbon buildup in an EGR system and other emission control components is not only from the combustion process. In most cases, it’s a combination of combustion-produced hydrocarbons and deposits from the crankcase oil. This is where many fail to correctly arrest deposit build-up on the EGR after it has been cleaned or replaced. More on this later…

The engine oil can bypass the piston rings, valve stem seals, and crankcase breather system (PCV). That oil is then consumed during the combustion process, but it isn’t fully combusted. The unburned oil and fuel are both recycled and deposited within the EGR. The oil will polymerize onto the metal surfaces due to the strong affinity between oil and metal. This newly formed surface acts as a “sponge” for all other particulates in the recirculating exhaust gases.

You have a combination of bypassed oil and unburned fuel deposited within the EGR system. This turns into a solid, which builds up and clogs the EGR valve and associated pipework, causing faulty operation.

If the EGR valve begins to stick or is blocked up, the solenoid used to operate it will draw more current to open it. The ECU detects that condition and throws an engine warning light.

The symptoms of a faulty EGR include:

Hesitation
Stumbling
Excessive emissions/smoke during acceleration
Engine warning lights

As deposits begin accumulating, this restricts the flow of gases and disturbs the fuel mixture. The ECU expects a certain amount of recirculating gases as the EGR valve transitions from closed to open and visa-versa. These gases are not delivered as anticipated, hence the air/fuel ratio disturbance. This can result in hesitation, stumbling, and excess emissions, particularly during acceleration.
Natural Carbon Removal

Now, there is a natural carbon cleaning mechanism, and most additive manufacturers won’t tell you this. Suppose you’re able to improve the quality of combustion and are thus able to produce cleaner exhaust gases during the combustion process. In that case, these cleaner exhaust gases will naturally scavenge and remove carbon. This is also the case with many emission control components attached to the exhaust system, such as the hot side of the turbocharger, catalytic converter, or a diesel particulate filter.

You can naturally clean these areas. Many additives you see on the market today are essentially just fuel system cleaners and combustion catalysts. They might be promoted and marketed as EGR cleaners, DPF cleaners, and so on, but they’re nothing more than fuel system cleaners. What they do is restore the efficiency of the fuel system and, by doing so, improve the efficiency of the combustion, which reduces hydrocarbon production. In addition, some products contain a fuel catalyst technology that in itself will lower the hydrocarbons produced. You’re left with cleaner exhaust gases, which will help naturally remove the carbon from these mentioned areas. Except for a few products that contain technologies where molecules are activated during combustion (more on this later), such cleaners do not directly clean these areas, as the chemistry is destroyed during the combustion process.

The Problem with Natural Removal and EGR Valves

This natural cleaning mechanism is not always effective when cleaning the EGR system. The reason for this is that when cleaning carbon from your engine, heat is the primary factor. There must be sufficient heat. Heat, combined with the cleaner, recycled exhaust gases, helps remove carbon. The problem with the EGR is that the gases are usually cooled when they reach the valve and the periphery pipework. Therefore, the natural cleaning mechanism is not always as effective with EGRs, so you have to take alternative action.

Alternative Cleaning for EGR Valves and Systems

Unfortunately, the most effective way to clean an EGR is to remove and clean it manually (if you have access to it). You’ll remove the EGR and the periphery pipework. Scrape off as much carbon as you can manually, then use a quality EGR aerosol cleaner to clean the remainder and reassemble the system.

If you don’t have easy access to the EGR valve, you can use an in situ aerosol-based EGR cleaner that you can either spray into the EGR pipework or through the air intake and clean the EGR this way.  However, particularly with diesel engines, you must be very careful. You don’t want to damage the engine. If you’re in doubt, you should let a trained professional carry out this procedure for you.

Once the EGR is clean and operational, it is essential to take the steps necessary to prevent further carbon buildup. While you can never stop it completely, you can maintain a manageable level of carbon that the engine can naturally consume without the deposits becoming excessive. If you were to remove the EGR, you’d be looking for a fine layer of carbon that you can scratch off with your nail. Anything more than that would be considered excessive.

Maintain and Protect

1. Firstly, use a high-quality polyetheramine-based fuel system cleaner and carbon remover to ensure injector and combustion efficiency is restored. Otherwise, you’ll end up with a clogged EGR valve soon after. We recommend Oilsyn Diesel Dr/Petrol Dr or Archoil AR6400-P/AR6400-D MAX.

2. Secondly, you need high-quality engine oil and/or oil additive that helps prevent oil from bypassing the crankcase breather system or piston rings and polymerizing with the EGR system. You must tackle the problem from both the fuel system end and also the crankcase oil. I recommend a high-quality oil additive pack such as Archoil AR9200 or AR9400. These have been shown to prevent polymerization and even remove carbon from these areas in some cases.

3. Thirdly, and particularly if most of your driving is short or start/stop, use a high-quality ongoing fuel additive containing an effective combustion modifier or fuel catalyst. We recommend Oilsyn Diesel Power DNA, Petrol Power DNA, or Archoil AR6900-D MAX / AR6900-P MAX. These will improve the combustion quality and lower the amount of hydrocarbons being produced and thus recycled through the system, especially when the engine is in its warm-up cycle. Most of the time, you’ll only use a little bit of the product at a time, and a single bottle will last for multiple tanks of fuel.

Get Out and Drive

Finally, it’s important to make you aware our view is that most of today’s vehicles are commonly mis-sold. They are simply not designed for the short journeys that many people use them for – around town driving, shopping runs, school runs, etc. If the vehicle is not permitted to get up to temperature frequently, hydrocarbons will inevitably be produced and deposited throughout the system.

Because of the lack of heat, it will be challenging for the engine and the emissions control components to naturally manage carbon within the system. Therefore, using the correct oil, fuel, and fuel additives is essential to keeping the engine running efficiently.

If you require any advice or help, please don’t hesitate to contact us, and a member of my team or I will be pleased to help.

Oilsyn and Archoil products can be purchased from http://www.powerenhancer.co.uk

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