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PSA Group, SOLVAY and SOGEFI have teamed-up to produce the first Plastic Diesel Fuel Filter fully made of recycled polyamide 66, ready for mass-production. This has been achieved by using the brand new plastic compound developed by SOLVAY Engineering Plastics. This material is 100% recycled from airbag wastes, providing a premium material able to stand demanding applications requirements supplied through circular economy, which is quite unusual in automotive industry yet. SOGEFI has used this material through its existing plastic injection process, and tested the parts on extensive bench validation tests. It confirmed that this material is fully compatible with standard injection process, and that all the tests have been passed successfully. Finally, PSA Group has driven the choice of the tested parts: DV engine 1.6l Euro6b application, homologated the material grade and evaluated the whole validation process. A Life Cycle Analysis has been conducted also, demonstrating the benefits.

Stringent emission regulations are forcing combustion efficiency improvement. Therefore Diesel fuel injection pressures have regularly increased in the recent years to meet emission levels. This has made the Fuel Injection Equipments (FIE) more sensitive to fuel contaminants. The control and maintaining of the Diesel fuel cleanliness is therefore a key parameter of its performance and durability. Previously, FIE protection was specified only by the filter efficiency, as defined by the ISO 19438 lab test method. But new specifications have been developed and recommended by, defining only fuel cleanliness level at FIE entrance, no matter the operating conditions or any other considerations. It was therefore needed to investigate fuel contamination sources and dynamic phenomena like vibration and viscosity impact on fuel cleanliness, and link it to acceptable filter efficiency.

Cold weather is a challenge for compression ignition engines. As Diesel fuel creates wax crystals when temperature goes down enough, it comes to plug the fuel filter and the fuel injection system, leading to undesirable effects like loss of power, engine stall after start or even the engine not starting at all. Moreover, it has been shown that FAME Biodiesel has additional negative impacts on vehicle cold flow operability. Despite fuel additives which can support cold conditions, the whole fuel injection system has to be designed to support engine operability in variable environments, meaning also in very cold conditions, with variable fuel qualities. The Diesel Fuel Filter is a key element of the fuel injection system, as it could become to get plugged by wax and deposit formed at cold temperatures. This can generate fuel shortage on the common rail and high pressure fuel injectors. Addressing this filter plugging effect, can be crucial for vehicle operability.