Solutions / A Southeast Asian Country Mining Engineering Fleet
Mining & Construction
A Southeast Asian Country Mining Engineering Fleet
Vehicle-Mounted Diesel Purification
Key outcomes
- Engine protection return: effectively protect engines and improve ROI
- Reduce fuel system downtime: effectively reduce fuel system downtime failures
- Extend filter cartridge maintenance cycle: original vehicle filter cartridge maintenance cycle effectively extended
Case Study
Stage 1 ยท Customer Problem
๐ Customer Problem
The customer is a core engineering contractor for a large-scale mining project in a Southeast Asian country, managing a modern fleet of over 300 heavy-duty mining dump trucks and excavators. The operating environment is characterized by high temperatures, high humidity, and heavy dust, with demanding requirements for vehicle availability. Under these extreme conditions, the customer faces the "last hundred meters" contamination problem:
๐๏ธ
Uncontrollable Secondary Contamination
Even if main storage tank fuel meets standards, dust and impurities easily enter the vehicle fuel tank during transfer via mobile fueling trucks and open-air fueling.
โ๏ธ
Fragile Precision Components
Heavy-duty truck HPCR injector nozzles are precision components where tiny hard particles cause injection orifice wear or needle valve seizure.
๐
Frequent Failures & Downtime
Insufficient power or engine alarms from dirty fuel force heavy-loaded vehicles to stop on inclines, creating safety hazards and site clearance costs.
๐ฐ
High Maintenance Costs
OEM filter cartridges are overloaded by terminal contamination, requiring frequent replacement across 300+ vehicles, driving up maintenance costs.
Stage 2 ยท Fuel Analysis ยท NEW
๐ฌ Fuel Analysis
Fuel sampling from vehicle fuel tanks after mobile fueling operations revealed the "last hundred meters" contamination effect โ fuel that met standards at the storage tank was significantly degraded by the time it reached vehicle tanks:
| Metric | Before Treatment | After Treatment | Improvement |
|---|
| ISO 4406 Cleanliness | ~22/20/17 | 14/11/8 | 4-5 levels โ |
| Free Water (ppm) | ~160 | โค50 | 69% โ |
| Visual Appearance | Hazy with visible dust particles | Clear, bright | โ |
| TAN (mgKOH/g) | 0.15 | 0.07 | 53% โ |
| Particle Composition | Dust, mineral particles from open-air fueling | โฅ99% removed at โฅ4 ฮผm | 99% โ |
Values reflect terminal-stage contamination during mobile fueling in the dusty mining environment. The vehicle-mounted unit provides a final barrier before fuel enters the engine. Post-treatment ISO 14/11/8 exceeds typical engine manufacturer requirements (ISO 18/16/13), with 4 ฮผm nominal precision selected for vehicle-mounted vibration-resistant deployment.
Stage 3 ยท Solution
๐ ๏ธ Solution & System Configuration
Jingyuan uniformly installed JY-210 vehicle-mounted high-efficiency filtration systems on all 300 engineering vehicles, providing a terminal barrier at the point of fuel entry into each engine:
Model
JY-210 vehicle-mounted filtration system
Membrane
Polymer Rigid Composite, 4 ฮผm nominal
ฮฒ Value
โฅ200 at rated pore size
Deployment
Chassis-mounted on all 300 engineering vehicles
Water Removal
Oleophilic-hydrophobic synergistic separation
Regeneration
Gas-pulse regeneration (brief 5-15 min safety pause)
Function
Terminal barrier โ first line of vehicle fuel system
Monitoring
Real-time alert for cartridge replacement
Key design decisions: The JY-210's compact, robust design was essential for installation in the limited space of heavy-duty truck chassis, with vibration and impact resistance for mining operations. Serving as the first barrier of the vehicle fuel system, it effectively improves diesel cleanliness before it enters the engine. Real-time monitoring alerts drivers to timely cartridge replacement, transforming reactive maintenance into proactive prevention.
Stage 4 ยท Results
๐ Quantified Results
14/11/8
ISO Cleanliness Achieved
~65%
Fuel System Failure Reduction
~50%
OEM Cartridge Life Extension
| Metric | Before | After | Improvement |
|---|
| ISO 4406 Cleanliness | ~22/20/17 | 14/11/8 | 4-5 levels โ |
| Fuel System Failures | Frequent, vehicles stop on inclines | Noticeable decrease | ~65% โ |
| OEM Filter Cartridge Life | Overloaded, frequent replacement | Effectively extended | ~50% โ |
| Unplanned Maintenance Cost | High per vehicle | Effectively reduced per vehicle | โ |
| Vehicle Availability Rate | Affected by fuel system downtime | Noticeably improved | โ |
Through comprehensive coverage of 300 units, the mining area fleet's fuel system failure rate decreased noticeably. The JY-210 effectively intercepted the vast majority of impurities from the fueling chain's terminal end, effectively extending the life of the original vehicle's precision filter cartridges. According to the fleet management system, the annual unplanned maintenance cost per vehicle was effectively reduced, and the total economic benefit across the 300-unit scale was significant.
Stage 5 ยท Lessons Learned ยท NEW
๐ก Lessons Learned
โ
Key Success Factor
Vehicle-mounted deployment was the critical decision for addressing the "last hundred meters" contamination that stationary systems cannot intercept. Even when storage tank fuel meets standards, dust ingress during mobile fueling and open-air transfer degrades fuel quality before it reaches the engine. The compact, vibration-resistant JY-210 design made installation feasible across 300 heavy-duty truck chassis, providing a terminal barrier at the point of use.
โ ๏ธ
Common Pitfall
Mining fleets often rely on OEM filters alone to handle terminal contamination, but in dusty environments these filters overload rapidly. Each OEM filter replacement also introduces contamination risk during the maintenance process. Without a vehicle-mounted pre-filtration barrier, the OEM filter becomes the failure point rather than the protector, leading to frequent replacement across a 300-vehicle fleet โ a massive maintenance burden.
๐
Replication Advice
Directly applicable to all mobile mining fleets with open-air fueling operations. The vehicle-mounted approach is essential where mobile fueling trucks and dust exposure make terminal contamination unavoidable. For large fleets, comprehensive coverage across all vehicles is critical โ partial deployment leaves unprotected vehicles as failure points. Real-time monitoring transforms reactive maintenance into proactive prevention across the fleet.
"
Customer feedback
In our mining area, fuel added to vehicles is frequently contaminated by dust. Installing 300 sets of Jingyuan JY-210 was one of the right decisions in our fleet management. It effectively filters impurities that threaten injector nozzles, ensuring stable engine operation. Our vehicle availability rate has noticeably improved.
Mining & Construction
Get a technical solution