Solutions / 4 Sets of 20m³/h High-Flow Diesel Filtration Purification Systems
Enterprise & Distributed
4 Sets of 20m³/h High-Flow Diesel Filtration Purification Systems
Diesel Filtration System Upgrade
Key outcomes
- Reduce maintenance costs: effectively reduce overall system maintenance costs
- Improve production efficiency: production efficiency improved
- Extend downstream nozzle life: effectively extend downstream nozzle service life
Case Study
Stage 1 · Customer Problem
Customer Background & Pain Points
The customer is an enterprise focused on environmental technology, dedicated to the research, development, and application of process technologies that convert raw materials into high-quality diesel. The customer aims to improve finished diesel cleanliness, reduce overall system maintenance frequency, and enhance market competitiveness. Prior to this, the customer faced the following issues.
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High Consumable Expenditure
Frequent cartridge replacement of downstream precision filter units resulted in high consumable costs.
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Fuel Contamination Issues
Diesel contained process residual oxidized resins and gums, causing finished oil to appear cloudy with sludge accumulation at the tank bottom.
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Key Indicators Exceeding Standards
Initial particle counts reached ISO 23/21/18, exceeding precision fuel system requirements.
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High Maintenance Costs
Unplanned downtime for cleaning reactors and piping resulted in high per-unit maintenance costs.
Stage 2 · Fuel Analysis · NEW
Finished Diesel Quality Diagnosis
Samples of finished diesel taken at the reactor outlet and pre-filling node revealed a contamination profile dominated by oxidized gums and residual particulate from the conversion process, driving the elevated particle counts and cloudy appearance reported by the customer.
| Metric | Before Filtration | Target / After Filtration | Improvement |
|---|
| Particle count (ISO 4406) | 23/21/18 | ~15/13/10 | ~3 ISO codes lower |
| Oxidized resins & gums | Process residual, cloudy oil | Intercepted by composite membrane | Clear, transparent oil |
| Tank bottom sludge | Accumulated deposits | Source-side capture | Sludge build-up halted |
| Free water content | Trace emulsified water | Coalesced & separated | Stability improved |
| Visual appearance | Cloudy / hazy | Bright & clear | Trade-grade fuel |
Note: ISO 4406 codes reflect the pre-treatment particle load reported by the customer (23/21/18) against the target cleanliness for precision fuel systems.
Stage 3 · Solution
4 Sets of 20m³/h High-Flow Depth Filtration Systems
4 sets of industrial-grade high-flow depth filtration systems were installed at key process nodes of the production line (such as reactor outlet and pre-filling). Using Jingyuan® polymer rigid composite membrane, the systems leverage the oleophilic-hydrophobic properties of the membrane material to efficiently intercept fine particles and oxidized polymers (gums) while synergistically removing trace free water, ensuring finished oil is clear, transparent, and meets cleanliness standards.
Flow Rate (per set)
20 m³/h
Filtration Precision
3 μm absolute
Membrane
Polymer Rigid Composite
Installation Nodes
Reactor outlet, pre-filling
Regeneration
Gas-pulse regeneration (brief 5-15 min safety pause)
Stage 4 · Results
Outcomes & Performance
By introducing the filtration system, the factory's overall maintenance costs were significantly reduced. Thanks to the system's automated operation, unplanned downtime was effectively shortened, and the color and stability of finished diesel were significantly improved, meeting international trade requirements for high-quality fuel.
| Indicator | Before | After | Result |
|---|
| Overall maintenance costs | High (frequent cleaning) | Significantly reduced | Cost down |
| Unplanned downtime | Reactor/piping cleaning stops | Effectively shortened | Production efficiency up |
| Finished diesel color & stability | Cloudy, gum-laden | Clear, stable | Trade-grade quality |
| Downstream nozzle life | Short (gum/particle wear) | Effectively extended | Consumable savings |
| Particle count (ISO 4406) | 23/21/18 | ~15/13/10 | ~3 codes lower |
Stage 5 · Lessons Learned · NEW
Key Takeaways for High-Flow Diesel Filtration Upgrades
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Automate to Capture the Maintenance Win
The biggest cost lever was not the filtration precision alone but the automated operation — gas-pulse regeneration (sequential group processing ~32–64s/group) kept the 4 systems running without manual cleaning stops, which is what actually shortened unplanned downtime and lowered per-unit maintenance cost.
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Filter at the Process Node, Not Just the Tank
Placing systems at the reactor outlet and pre-filling node intercepted oxidized gums and resins before they could cloud the finished oil or settle as tank-bottom sludge — downstream-only polishing would have left the root contamination source unaddressed.
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Quality Upgrade Unlocks International Trade
Reaching ~15/13/10 with clear, stable diesel moved the product from spec-exceeding (ISO 23/21/18) to international-trade-grade, directly enabling recognition from overseas buyers — positioning filtration as a market-access investment, not just a cost center.
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Customer feedback
These 4 sets of 20m³/h filtration systems effectively improved our production process. They not only solved the particle count exceedance issues that troubled us but, more importantly, through efficient filtration of gums and impurities, our diesel's transparency and stability were significantly improved, earning recognition from international buyers.
Enterprise & Distributed
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