Some equipment managers are breathing easy about their rate of diesel consumption after equipping engines with a new fuel catalyst. The catalyst helps diesel fuel systems burn diesel more efficiently, decreasing consumption and emissions. And with this year's rise in fuel prices, every drop counts.

The fuel catalyst, made by Rentar, uses a combination of metals to de-cluster the fuel's carbon molecule chains that clump together before combustion. De-clustering the carbon allows more oxygen to bind to the smaller hydrocarbon chains for better combustion. Installing the device onto the fuel line after the fuel pump and before the filters enables a machine to burn fuel more efficiently, the company says. Essentially, this treats the problem of emissions before it's created, unlike exhaust systems and particulate traps.

Rogers Group Equipment Manager Cameron Druyor has tried the unit on 18 machines including haul trucks, wheel loaders and generators. On fuel consumption, he says the average savings are 7.5%. “I had an L330D Volvo wheel loader, which is already a pretty fuel-efficient machine, and I saw a 6% improvement,” he says. The greatest reduction was 32% on a Caterpillar 980C wheel loader. Rentar says the average savings on fuel consumption is between 2% and 20%.

“It's pretty easy to do the math,” Druyor says. “There's a 3309 Terex haul truck that went from 12.8 gallons per hour down to 10. There's 2.8 gallons that you are not buying.” Druyor says it can decrease the most efficient machine's fuel consumption. Both Druyor and Rentar say the $1,495 catalyst has a one-year payback.

Burning more of the fuel means less of it will be released into the atmosphere in the form of particulate matter or black smoke. A study conducted by Olson-Ecologic Engine Laboratories using UDDS-HD, Steady State and New York City bus cycle modes concluded the catalyst reduced emissions of nitrogen oxide 20.6%, sulfates 22.7%, elemental carbon 32%, organic carbon 17.4%, carbon monoxide 4.6%, carbon dioxide 10% and particulate matter 9.4%. These emission reductions were on electronically injected N-14 DD engines.

Rentar also was selected as a member of the Energy Star partnership, backed by the U.S. Environmental Protection Agency and the U.S. Department of Energy, for increasing energy efficiency among businesses. The Mine Safety and Health Administration has performed standard lab tests on the catalyst, but are not releasing the results until Rentar completes other independent tests.

“First and foremost, we are interested in the health of our employees,” Druyor says. “If we get a dollar savings, that's great. We're after trying to reduce our emissions as much as possible. And they do seem to help.” He says there was a noticeable difference when the catalyst was installed on a Cat D399 generator.

It is most effective on older units with mechanical fuel injectors, which burn fuel less efficiently than electronic injectors. Older engines are subject to less environmental regulations, making the need for such devices more important.

And unlike emission technologies, the catalyst has had no effect on the power of the engine. “It has improved if anything,” Druyor says. As the fuel burns more efficiently, more energy is created during combustion. Rentar says the average engine crankcase collects 30% of the exhaust from the combustion chamber, contaminating the engine oil. But by improving combustion with the fuel catalyst, less soot is generated to contaminate the oil.

The unit measures 16 in. long, 2½ in. in diameter and weighs about 3 lb. A heavy-gauge copper cylinder houses the metals that de-cluster the carbon molecules. It processes as much as 300 gpm with JIC 10 fittings on the fuel line — more with larger lines. There is no need to prime the catalyst during installation, and it installs within half an hour, Druyor says. “There's not much to it.”

The fuel catalyst installs on the fuel line after the fuel filters and near the fuel pump. It is important to install the unit as close to the injector pump as possible. The farther the fuel has to travel before combustion, the more likely it is to return to an untreated state with clustered carbon molecules.

The unit requires zero maintenance, Druyor says. The company only recommends 90-day inspections to check for leaks. Druyor says one unit that he installed did leak around the O-rings, but it was replaced immediately under the 10-year warranty. “They said, ‘no problem; we'll give you another one.’ And there were no questions asked.” Rentar also has lease programs.