Solutions / Indonesian Mining Site Multiple 40m³/h High-Flow Diesel Purification Systems
Mining & Construction
Indonesian Mining Site Multiple 40m³/h High-Flow Diesel Purification Systems
Diesel Purification (Mining)
Key outcomes
- Reduced Maintenance Costs: Effectively reduces fuel system maintenance costs
- Improved Fleet Availability: Effectively increases the uptime of heavy-duty mining machinery fleets
- Reduced Injector Replacement Costs: Effectively reduces OEM injector replacement costs
Case Study
Stage 1 · Customer Problem
📋 Customer Problem
A large-scale Indonesian open-pit coal mine operates hundreds of heavy-duty dump trucks, large excavators, and high-power generator sets. The tropical environment and B35 biodiesel mandate create compound fuel quality challenges:
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Microbial "Oil Slime" in B35
Indonesia's high humidity causes trace free water in storage tanks. B35 biodiesel blends are prone to microbial growth, producing "oil slime" that clogs filters and injectors.
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Extreme Dust Environment
Open-pit mining generates severe dust. Fine, hard mineral powder enters the diesel system, causing abrasive wear on HPCR precision components.
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Frequent Unplanned Downtime
Mining trucks frequently experienced insufficient power and injector seizure, with unplanned downtime causing significant coal output losses.
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Severe Contamination Levels
Original fuel particle count fluctuated around ISO 24/22/19, far exceeding the ISO 18/16/13 target required by engine manufacturers.
Stage 2 · Fuel Analysis · NEW
🔬 Fuel Analysis
Fuel sampling from the mine's main fuel depot revealed contamination from multiple sources: tropical humidity, B35 biodiesel degradation, and mineral dust ingress:
| Metric | Before Treatment | After Treatment | Improvement |
|---|
| ISO 4406 Cleanliness | ~24/22/19 | 15/13/10 | 4-5 levels ↑ |
| Free Water (ppm) | ~200 | ≤50 | 75% ↓ |
| Visual Appearance | Dark, cloudy with slime deposits | Clear, bright | — |
| B35 Gum Content (mg/100mL) | ~15 | ≤3 | 80% ↓ |
| Particle Composition | Mineral dust, gum, microbial slime | ≥98% removed at ≥5 μm | 98% ↓ |
Values are representative based on Indonesian tropical mining conditions (B35 biodiesel, high humidity, open-pit dust). Post-treatment testing confirmed ISO 15/13/10 compliance with engine manufacturer warranty requirements.
Stage 3 · Solution
🛠️ Solution & System Configuration
The customer configured multiple JY-DX40 industrial-grade purification arrays at the mining area's main fuel depot, with deep filtration customized for B35 biodiesel:
Model
JY-DX40 (Multiple Units)
Flow Rate
40 m³/h per unit
Membrane
Polymer Rigid Composite, 5 μm nominal
β Value
≥200 at rated pore size
B35 Compatibility
Custom deep filtration for gum & mineral powder
Water Removal
Oleophilic-hydrophobic synergistic separation
Regeneration
Gas-pulse regeneration (brief 5-15 min safety pause)
Monitoring
Real-time particle count + differential pressure
Key design decisions: Specially customized polymer deep filter material performs staged interception of gums and fine mineral powder specific to Indonesian B35 biodiesel. Real-time particle count monitoring ensures the filtered fuel continuously meets engine manufacturer standards. The multi-unit deployment provides redundancy for 24/7 mining operations.
Stage 4 · Results
📈 Quantified Results
15/13/10
ISO Cleanliness Achieved
| Metric | Before | After | Improvement |
|---|
| ISO 4406 Cleanliness | ~24/22/19 | 15/13/10 | 4-5 levels ↑ |
| Injector Life | Frequent seizure and wear | Effectively extended | Significant ↑ |
| Filter Cartridge Replacement | Frequent blockage from slime | 0 (3-year membrane life) | 100% eliminated |
| Unplanned Truck Downtime | Frequent power loss & injector seizure | Near-zero | ~85% ↓ |
| Per-Unit Fuel Consumption | Elevated (incomplete combustion) | Reduced | Improved |
By deploying multiple JY-DX40 units, the mining area effectively resolved the fuel quality challenges that had plagued it for years. The purified diesel particle count is stably maintained at ISO 15/13/10. Injector life of heavy-duty trucks has been effectively extended. Due to improved fuel quality, engine combustion is more complete, and per-unit fuel consumption has also been reduced.
Stage 5 · Lessons Learned · NEW
💡 Lessons Learned
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Key Success Factor
The customized deep filtration for B35 biodiesel gums was the critical differentiator. Standard filtration systems cannot handle the adhesive gum and microbial slime characteristic of B35 blends in tropical conditions. The polymer deep filter material performs staged interception — first capturing large gum masses, then removing fine mineral powder through high-precision media.
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Common Pitfall
Mining operations using B35 biodiesel often treat fuel problems as "biodiesel compatibility issues" and attempt to solve them with fuel additives or by switching to lower biodiesel blends. This addresses symptoms, not causes. The root problem is water + microbial growth + gum formation — all of which are eliminated by continuous membrane polishing with synergistic water removal.
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Replication Advice
Directly applicable to all Indonesian mining operations and other tropical-region mines using B20-B35 biodiesel blends (Malaysia, Thailand, Philippines). The multi-unit JY-DX40 array can be scaled for any mine size. For operations transitioning to higher biodiesel blends (B40+), the same membrane platform handles increased gum loads with adjusted regeneration frequency.
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Customer feedback
In Indonesian mining, dust is an unavoidable issue. Jingyuan's 40m³/h purification units effectively ensure our fleet's fuel quality. Its capability to handle biodiesel is outstanding, resolving the fuel viscosity and injector damage issues we previously encountered frequently, and safeguarding our mining progress.
Mining & Construction
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