Fuel filtration - MAHLE Industry


Fuel filtration - MAHLE Industry




MAHLE : Fuel filtration solutions

The filtration of fuel, particularly when using

heavy oil (DMC), places high demands on the

cleaning efficiency and throughput of the filter.

The COM plus fuel filter is specifically designed

for the large engines sector and is used for

cleaning fuel for big pistons. The COM plus is

based on a proven flush nozzle principle and

enables to be flushed without a pressure drop

and without affecting the efficiency of the process.

The COM plus can be used for all kinds of

highly viscous fuels, including middle distillates

and bio diesel, even at temperatures exceeding

160 ºC. The cleaning and discharging of filtered

solids into the sludge tank is effected without

affecting the throughput rate and the service

pressure by means of an intelligent filter control.

The flush volume is reduced to a minimum by the

geometric volume of the compensator. The COM

plus thus ensures a constantly high efficiency of

the drive unit.



Series MAHLE COM plus MAHLE COM plus with manual by-pass filter and

change-over element


Fully automatic back-flushing filter

with tempered own medium

Fully automatic back-flushing filter

with tempered own medium

Nominal width of connecting flange DN 25–DN 100 DN 25–DN 100

Housing material GGG 40 GGG 40

Service pressure Up to 16 bar Up to 16 bar

Max. service temperature 160 °C (*higher temperatures on request) 160 °C (*higher temperatures on request)

Filter element Pleated single or double insert Pleated single or double insert

Max. filter fineness 10 µm (different filtration ratings) absolute 10 µm (different filtration ratings) absolute

Back-flushing control Differential pressure-dependent; by time interval Differential pressure-dependent; by time interval

Options Integrated heating (steam/thermal oil) Integrated heating (steam/thermal oil)




The medium being filtered flows

at service temperature via the filter

inlet (1) of the heated filter

housing into the filter insert (2) of

the automatic filter. This comprises

a cylindrical single or double

body, in which the pleated wire

cloth cylinders with the specified

filtration fineness are located.

Any particles in the medium are

deposited on the outside of the

inner filter or on the inside of the

outer filter. The cleaned fuel

flows into the clean section and

flows out of the filter housing via

the outlet connection (3). As the

amount of contamination on the

wire cloth increases, the difference

between the inlet pressure

(contaminated side) and outlet

pressure (clean side) also rises.

This differential pressure is measured

by pressure transmitters at

the inlet and outlet and is transmitted

to the filter control. The

programmable logic controller

(PLC) automatically triggers the

back-flushing cycle once a predefined

differential pressure or

time interval is reached.









On reaching a maximum differential

pressure or a preset time,

the cleaning cycle is triggered.

The cleaning nozzle or the filter

insert is set in motion (rotation)

by the gear motor (4). At the

same time, a 3-way flush valve (5)

opens and connects the dirty

side of the compensator to the

flush channel.

While the sludge is sucked into

the dirty side of the compensator

(6), the corresponding

amount of clean, heated fuel is

simultaneously pushed through

the filter mesh at high velocity.

The cleaning process, which

occurs in the opposite direction

to the filtration process, removes

the dirt particles collected on the

filter mesh (7). The filtration process

itself remains uninterrupted.

Upon completion of the

backwashing cycle, the flush

valve closes again, such that the

dirty side is connected back to

the pressure-free sludge tank (8).

To prepare the next cleaning

cycle, the compensator’s drive

slowly empties the dirty side and

simultaneously fills the clean side

with cleaned fuel, with no significant

pressure loss.



Phase 1:



MAHLE Industriefiltration provides customers

with a special innovation for fuel filtration: the

MAHLE COM plus filter combination is the most

reliable way to filter fuel and has the following


None of the medium escapes when the flush

volume is transferred from the clean side of the

compensator to the contaminated side. This

means there is no pressure drop.

MAHLE filters have proved their efficiency and

operational reliability in 10-micron filtration for

many years. The flush volume (filtered medium)

stored in the compensator is kept at operating

temperature until the back-flushing cycle takes


Phase 2:

Back-flushing cycle

The back-flushing process uses the plant’s own

medium (filtered medium) at operating temperature.

This prevents the wire cloth from sticking

together, which can occur in back-flushing processes

conducted with foreign media (e.g.

compressed air) as a result of possible temperature


Due to extensive quality tests (in our own lab

and external labs and institutes), we can guarantee

that in the event of the fuel treatment

system (separator) failing, the MAHLE COM

plus can take over the task of cleaning the

medium for up to 12 hours without the wire

mesh being destroyed.

Phase 3:

Compensator charging

and draining of sludge

into the sludge tank

Furthermore, in exceptional cases the filter can

be started up at bunker temperature – an

increased resistance due to a lower fuel viscosity

can be offset by the MAHLE COM plus.

And in a final step, maintenance of the filter is

quick and simple as only 1 or 2 wire mesh cylinders

have to be replaced.


Performance through cleanliness

The efficiency and profitability of large engines in

the marine industry or in combined heat and

power stations is largely dependent on their continuous

operation. The cleanliness of the fuel that

is supplied to these engines constitutes an extremely

important factor with regard to their service

life. This is because one of the main causes of

defects and failures is the premature wearing of

components as a result of dirt in the system.

The problem here is that the quality and impurity

of diesel on the market varies greatly, ranging

from marine diesel to heavy fuel oil. The worse

the quality, the higher the susceptibility to faults

and the higher the wear rate for the engines.

However, there is a way to counteract this: The

filter performance must be that good that even

diesel of the worst quality can be made eminently

usable. MAHLE supplies fuel filtration systems

that are optimized to deal with the requirements

of large engines. This is particularly important in

the marine industry: MAHLE automatic filtration

systems also operate reliably and safely in fully

automatic operation.



Reliability down to the finest detail

MAHLE fuel filters are particularly suited to proving

their reliability on board. Thanks to their perfect

filtration performance and undisturbed operation,

our products are especially popular in

shipbuilding. However, power stations have also

been using our fuel filtration systems for several


All MAHLE filters and accessories are extremely

robust and boast impressive service lives. They

require minimal maintenance and have a compact

design. MAHLE offers customers an extensive

range of services all over the world. The

company’s extensive network of agents ensures

that customers are helped by competent engineers

and technicians wherever they are. Experienced

service teams are available for commissioning

and maintenance tasks worldwide.



MAHLE Industriefiltration GmbH

Schleifbachweg 45

D-74613 Öhringen

Phone +49 7941 67-0

Fax +49 7941 67-23429



EN 70529563.08/2012

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