The Idaho National Laboratory (INL) has just completed an extensive study of the benefits and problems with Ultra Low Sulfur Diesel (ULSD) fuel. I am the principle engineer and ULSD engineer for this site. INL uses 3 to 4 million gallons of diesel fuel each year in a large over the road bus fleet, construction equipment and for standby / emergency diesel power generation. I am working to get the study released for public consumption - as soon as it is available I will make it available to this forum.
However, a quick summary will assist:
1) Seal Life.
ULSD Effects on Fuel System Seals
From the Chevron web site on 1-23-07:
Will low sulfur diesel or low aromatics diesel cause fuel system leaks?
The introduction of low sulfur diesel for on-road use in the U. S. was accompanied by fuel system leaks in a very small percentage of vehicles. Investigations into the cause of these leaks suggest that the problem was linked to the change in the aromatics content of the fuel and to seal material and age.
Diesel fuel systems contain "O-rings" and other parts made of elastomeric materials. These elastomers swell slightly when they contact diesel fuel, because they absorb aromatic compounds from the fuel. Exposure to a fuel with a lower aromatics content will result in some of the absorbed aromatics being leached out, causing the elastomer to shrink towards its original size. If the elastomer is still pliable, this shrinkage will not cause a leak. However, if age or service at higher-than-normal temperatures has caused the elastomer to loose its elasticity, a leak could occur. Vehicle owners should be aware that elastomeric parts have finite lives and should be replaced as necessary.
By itself, low sulfur or low aromatics diesel fuel does not cause fuel system leaks. They are caused by the combination of a change from higher to lower aromatics fuel and aged O-rings and elastomeric parts that have lost their elasticity. In 1994 when diesel fuel was changed to the Low Sulfur Diesel (LSD; <500 ppm sulfur) there were a number of IP seal failures due to this change over and the seal material in use at the time. In this area of the country we have not noticed any increase in IP seal failures due to changing to ULSD at either the INL or in commercial pump / diesel repair facitlities.
2) Lubricity
ULSD may not adequately lubricate the diesel engine injector pump due to the changes in refining processes. The ability of diesel fuel to lubricate injector pumps is referred to as lubricity. To compensate for this deficiency, lubricity additives are blended into the fuel at the pipeline terminal when it is loaded onto the transport truck. Lubricity is tested by the pipelines and refineries. A surprising percentage of the ULSD will meet the lubricity requirements without the use of any lubricity additives, however all ULSD is additized prior to delivery. A number of safequards exist at the terminals to ensure that the lubricity additive is added and blended into the transport.
In summary, providing additional additives will probably not help with anything. Aged seals will eventually leak whether the fuel is changed or not. The ULSD will initially clean out the fuel system so expect to change fuel filters a little bit more often.