HVO fuel problems include limited availability and higher cost, feedstock sustainability concerns (e.g. palm oil), cold-weather gelling, storage contamination (water/microbial growth) and compatibility issues with older engines. To avoid them: buy certified HVO, maintain tanks and filters, and test blends on older equipment before switching fully.
Hydrotreated Vegetable Oil (HVO) fuel has become one of the most discussed alternative fuels in recent years. As more businesses and individuals seek eco-friendly solutions to reduce their carbon footprint, HVO has been praised as a renewable diesel substitute that promises cleaner emissions, improved storage stability, and better cold-weather performance. However, while HVO fuel has many benefits, it’s not without its challenges.
This comprehensive guide explores the most common HVO fuel problems, their causes, and how to avoid them. Whether you’re considering switching to HVO or already using it, understanding these issues can help you make more informed decisions and ensure your systems continue to perform efficiently.
What Is HVO Fuel?
HVO fuel, short for Hydrotreated Vegetable Oil, is a synthetic, renewable diesel fuel made from vegetable oils, animal fats, or waste cooking oils. Unlike traditional biodiesel, which is produced by esterification, HVO is produced by hydrogenation. This means the oxygen in the feedstock is removed, leaving a hydrocarbon structure almost identical to fossil diesel.
Because of this, HVO is a “drop-in” fuel, meaning it can be directly substituted for regular diesel without requiring engine modifications. It’s been lauded for reducing greenhouse gas emissions by up to 90% compared to conventional diesel and is often used in fleets, construction machinery, and backup generators.
However, despite these advantages, several practical, technical, and supply-related problems have emerged as HVO fuel gains traction.
Common HVO Fuel Problems
Limited Availability and High Cost
One of the biggest challenges with HVO fuel is its limited availability. While it is becoming more common across the UK, it’s still far less accessible than standard diesel. The infrastructure for refining, storing, and distributing HVO is developing but not yet widespread.
Moreover, the cost of HVO fuel remains significantly higher than that of regular diesel. This is largely due to its production process, which involves high-pressure hydrogen treatment, an expensive, energy-intensive method. Until more producers enter the market and supply scales up, the price gap between HVO and traditional fuels is likely to remain wide.
For businesses managing large fleets or machinery, this can be a serious financial consideration, especially in industries with high fuel consumption.
Feedstock Supply and Sustainability Concerns
While HVO is marketed as a renewable and sustainable fuel, not all HVO sources are equally environmentally friendly. The sustainability of HVO depends heavily on the origin of the feedstock, whether it’s made from waste oils, animal fats, or virgin vegetable oils such as palm oil.
The use of palm oil in HVO production has raised significant ethical and environmental questions. Palm oil plantations have been linked to deforestation, biodiversity loss, and carbon emissions from land-use changes. Although many HVO producers now claim their products are palm oil-free, not all supply chains are transparent.
Buyers must ensure they are sourcing certified sustainable HVO, such as those verified by ISCC (International Sustainability and Carbon Certification).
Cold Weather Performance Issues
While HVO generally performs better than standard biodiesel in cold temperatures, fuel gelling can still occur in extreme conditions. This happens when paraffin wax crystals form in the fuel, clogging filters and preventing the engine from starting.
Although HVO boasts improved cold-flow properties, its Cold Filter Plugging Point (CFPP) varies by manufacturer and batch. In particularly harsh winters, or when stored outdoors, some users have reported problems starting generators or vehicles.
To mitigate this, users should:
- Use winter-grade HVO where possible.
- Ensure fuel storage tanks are insulated or heated.
- Regularly check filters for wax build-up.
Compatibility with Older Engines
Most modern diesel engines are fully compatible with HVO, but older engines may experience problems. Vehicles or generators that are not designed for synthetic fuels may experience issues such as seal degradation or fuel system corrosion.
This is because some older rubber seals and hoses were designed for fossil diesel and may not react well to HVO’s chemical composition. Although HVO is less aggressive than biodiesel, it’s still advisable to check manufacturer recommendations before switching.
For older engines, it’s often best to start with a blend (e.g., 50% HVO and 50% diesel) before fully transitioning to 100% HVO.
Storage and Tank Contamination
HVO is more stable than biodiesel and has a much longer shelf life, typically up to 10 years. However, storage issues can still arise if tanks are not properly maintained.
Water ingress, condensation, and microbial growth (diesel bug) can occur in storage tanks that haven’t been cleaned or inspected regularly. While HVO itself doesn’t support microbial growth as easily as fossil diesel, bacteria can still thrive at the water-fuel interface.
These contaminants can cause blocked filters, injector problems, and reduced fuel efficiency. To avoid this:
- Keep storage tanks clean and sealed.
- Regularly check for water contamination.
- Use fuel additives if necessary.
Supply Chain and Quality Variations
Not all HVO fuel is created equal. Because HVO can be produced from a wide range of feedstocks and manufacturing methods, fuel quality can vary between suppliers.
Differences in refining techniques or hydrogenation quality can lead to inconsistent performance. Some users have reported minor efficiency losses or differences in exhaust odour and smoke levels.
It’s important to buy HVO only from trusted, certified suppliers to ensure fuel purity and consistent performance. Working with reputable energy providers such as 123 Oil can help you avoid quality-related issues.
Misconceptions about Carbon Neutrality
HVO is often advertised as carbon-neutral or net zero, but this can be misleading. While it does significantly reduce emissions compared to fossil diesel, it still produces carbon dioxide when burned.
The key difference is that the carbon released during combustion was originally absorbed by plants or by organic matter used to make the fuel, meaning the cycle is closer to carbon-neutral than that of fossil fuels.
However, this balance can be disrupted if the feedstock involves land-use change or high transportation emissions. Therefore, while HVO is a much cleaner option, it’s not entirely free from environmental impact.
Engine Efficiency and Performance Variations
Although many users report seamless performance when switching to HVO, some have noticed slight variations in fuel efficiency. Because HVO has a slightly lower energy density (around 34 MJ/L) compared to fossil diesel (35.8 MJ/L), engines may consume marginally more HVO to achieve the same power output.
While this difference is often negligible, it can become noticeable in high-usage vehicles or heavy machinery. Fleet managers should closely monitor fuel consumption after switching to ensure accurate budgeting and efficient tracking.
Misfuelling and Blending Issues
HVO can be mixed with regular diesel in any ratio, but inconsistent blending or accidental misfuelling can cause operational issues. For example, blending with other biodiesel types (FAME-based fuels) can reduce HVO’s stability and increase the risk of filter blockages.
To prevent this, users should ensure that fuel tanks are clearly labelled and that only compatible fuels are stored together.
Limited Government Incentives
While the UK government encourages the use of low-carbon fuels, HVO is not yet widely subsidised or incentivised in many sectors. This makes it financially challenging for smaller businesses to adopt the fuel, even if they wish to reduce their carbon footprint.
As renewable fuel policies evolve, there is hope that HVO may become more affordable and accessible through tax reliefs or green energy grants. For now, businesses must weigh the environmental benefits against the higher operational costs.
How to Minimise HVO Fuel Problems
Despite its drawbacks, many of these issues can be managed effectively with the right practices:
- Source high-quality HVO fuel from reputable suppliers.
- Use certified sustainable feedstock (avoid palm oil-based products).
- Maintain storage tanks regularly to prevent contamination.
- Monitor engine performance after switching to detect any early issues.
- Train staff on proper handling and blending procedures.
By taking these precautions, users can enjoy cleaner HVO performance while reducing the likelihood of mechanical or operational disruptions.
Is HVO Fuel Worth It?
For many users, the answer is yes, provided the switch is planned carefully. HVO fuel offers several undeniable benefits: lower emissions, cleaner combustion, longer storage life, and better engine protection. But it’s also more expensive, less available, and still subject to some technical and supply chain challenges.
For organisations committed to sustainability, the long-term benefits often outweigh the costs. However, smaller businesses and private users should assess their usage patterns, budget, and supply access before committing fully.
Final Thoughts
HVO fuel represents a promising step toward a more sustainable energy future. Yet, it’s important to approach it with realistic expectations. It’s not a flawless solution, and understanding its limitations, from cost and supply challenges to compatibility and sustainability, is key to using it effectively.
By partnering with reliable suppliers such as 123 Oil, ensuring proper storage and maintenance, and staying informed about industry developments, you can make the most of this renewable alternative while minimising potential problems.
Frequently Asked Questions
Not usually. HVO is chemically similar to diesel and safe for most modern engines. However, older engines with certain rubber seals or components may experience compatibility issues, so it’s best to consult the manufacturer.
HVO production involves advanced hydrogen treatment and uses sustainable feedstocks, making it more expensive to produce. Limited infrastructure and supply also contribute to the higher price.
HVO has excellent stability and can last up to 10 years if stored properly in clean, sealed tanks. Regular inspections help prevent water or microbial contamination.
No. Sustainability depends on the feedstock. HVO made from waste oils or animal fats is highly sustainable, whereas HVO made from palm oil can cause environmental harm.
Yes. HVO is fully miscible with diesel and can be blended in any ratio. However, ensure consistent blending and avoid mixing it with FAME biodiesel to maintain performance stability.
