At Gigonsa, we know that diesel fuel is the heart of many industrial, transport, agricultural, and marine engines. But we also know that there is a silent and often underestimated enemy: water. Below, we explain why we consider water in diesel to be its «worst enemy,» what damage it triggers, and how proper protection can make all the difference.
The Cost of Water Contamination
Industry assessments show that water in diesel fuel can cause a decrease of at least 15% in power and a similar increase in fuel consumption. This leads to increased operating costs, more frequent maintenance, and unexpected downtime.
Corrosion in diesel engine components caused by water contamination
How Water Gets Into Diesel
Diesel fuel is not normally completely free of dissolved water—those small traces in solution—but the real problem begins when that water becomes free or emulsified in the fuel. There are various sources through which water can enter diesel:
- Condensation inside the tank due to temperature changes
- Moisture buildup in humid environments
- Leaks or poorly sealed vents
- Residual water during transport or storage
- Fuel tanks that are not properly maintained
In the Mexican context, for example, where there is abundant humidity, heavy transport, and climates that expose tanks and machinery to demanding conditions, this phenomenon is particularly relevant.
The Damaging Effects of Water in Diesel
Corrosion and Rust
Water in contact with iron, steel, aluminum, and other internal metal components causes corrosion, rust, and surface degradation. According to technical studies, free water combined with acids from the fuel can corrode ferrous and non-ferrous metals, even causing injector failure in less than 300 hours of use. This rust generates particles that circulate in the fuel, pass through filters, and reach injectors or high-pressure pumps, causing abrasive wear and premature failure.
Abrasion
Diesel fuel also acts as a lubricant within the injection system; when water is mixed in, it reduces the viscosity of the lubricating fluid and diminishes the lubricating «cushion» between moving parts. The result is increased abrasive wear. This means that the internal components operate with less protection, accelerating their deterioration.
Pickling, Acid Formation, Pitting
When water is present, fuel can degrade more rapidly, releasing hydrogen sulfide, sulfuric acid, and other acidic byproducts that attack metal surfaces. This pitting and scaling phenomenon has been documented as a direct consequence of the interaction between water, fuel, and metals. Thus, the ingress of water not only generates conventional corrosion but also aggressive chemical wear.
Microbial Contamination
Free water in tanks or lines promotes the proliferation of microorganisms (bacteria, fungi, algae) that produce sludge, acids, and slime, which affect filters, tanks, pipes, and the fuel itself. These microbes act as catalysts for the internal deterioration of the fuel and the injection system.
Crystallization and Ice Blockage
In cold environments, free water can freeze, forming ice crystals that act like hard particles or simply block filters and fuel lines. This type of phenomenon reduces flow, obstructs the system, and can cause unexpected shutdowns.
Condensation formation inside fuel tanks – a major source of water contamination
Loss of Power and Increased Operating Costs
Beyond mechanical damage, the presence of water in fuel directly affects engine performance and, consequently, productivity. Diesel in emulsion or with dissolved water loses calorific value, which translates into a decrease of at least 15% in power and a similar increase in fuel consumption, according to industry assessments.
The simultaneous effects include increased consumption, reduced efficiency, more frequent maintenance, unexpected downtime, and a shorter equipment lifespan. In Mexico, and particularly in industries such as agriculture, transportation, and power generation, these losses can represent significant costs. Furthermore, contamination of fuel or water supplies (as has been observed in areas of Mexico City) exacerbates the situation and increases the risk of widespread failures.
For example, premature failures in injection lines, loss of power, increased pollutant emissions, unscheduled maintenance and, consequently, production stoppages have been recorded.
Prevention Strategies
Prevention is key, and here we present practices that we consider essential to minimize risk:
| Prevention Method | Description | Impact |
|---|---|---|
| Quality Fuel Sources | Ensure fuel comes from reliable sources and is stored properly | Reduces initial contamination risk |
| Tank Maintenance | Keep fuel tanks clean, properly sealed, and limit air/moisture entry | Prevents condensation and external contamination |
| Water Separators | Install filters capable of removing water and emulsions | Protects injection system from water damage |
| Regular Drainage | Regularly drain filters and tanks to remove accumulated free water | Prevents water buildup and microbial growth |
| Fuel Analysis | Perform periodic tests to detect dissolved or free water | Early detection allows proactive measures |
| Cold Climate Measures | Special attention to ice formation in filters or fuel lines | Prevents blockages and system failures |
Our Solution: Gigonsa’s Fuel Purification Technology
At Gigonsa, we are convinced that conventional filtration is no longer sufficient to protect diesel engines from water, moisture, and contaminants. That’s why, through our AK Purifier brand, we offer advanced fuel purification solutions that remove up to 99% of water and sediment at the source, without replaceable filters or costly maintenance.
Our technology is designed for demanding applications: industrial, transportation, marine, agricultural, power generation, and more. Thanks to advanced centrifugation and the robust design of our Classic, Premium, and Agricultural lines, we guarantee a long service life (up to 15 years and up to a lifetime warranty on the Premium line) and ongoing technical support.
AK Purifier not only prevents free water or emulsions from entering the injection system, but also protects the entire fuel system: tanks, pipes, primary filters, pumps, and injectors. As a result, the risk of corrosion, abrasion, microbial growth, and power loss is significantly reduced.
We are proud to support our customers in more than 25 countries and with more than 10,000 installations, backing up our commitment to «Protect the engine. Maximize performance.»
If you operate fleets, agricultural machinery, power generation, or service stations where fuel is critical, we invite you to learn how AK Purifier by Gigonsa can become your strategic ally in removing water and contaminants from diesel.
Advanced fuel purification system protecting diesel engines from water contamination
Water is Indeed Diesel’s Worst Enemy
In conclusion, we state unequivocally that water is diesel’s worst enemy because it attacks the most vulnerable points of the system: the fuel, the tanks, the lines, the injection system, and ultimately the engine. Its presence triggers corrosion, abrasion, microbial growth, blockages from ice or sludge, and a real loss of power and efficiency.
In the Mexican and Latin American environment, where conditions can be more challenging (high humidity, heavy transport, machinery in the field), this threat becomes even more serious. That’s why we operate on the philosophy that prevention is far more cost-effective than repair. Implementing purification systems like AK Purifier isn’t a luxury: it’s a necessity to protect your assets, ensure productivity, reduce costs, and safeguard the environment.
At Gigonsa, we offer over 30 years of experience, 365-day-a-year technical support, and proven technology to give you peace of mind knowing your diesel fuel will be as clean as your engine demands. Don’t let water continue to be a silent sabotage.
Gigonsa — AK Purifier: technology that brings diesel to life.