Solutions / State-Owned Farm Fueling Station Diesel Polishing (JY-219A)
Mining & Construction
State-Owned Farm Fueling Station Diesel Polishing (JY-219A)
Fine Filtration at the Fuel Dispenser — Drop-in Replacement for the Gas-Oil Separator
Key outcomes
- Nozzle Burnout Cut by 92%: Annual fuel-dispenser nozzle damage dropped from 230 units to just 18 — a dramatic reduction in replacement spend
- Dispenser Vent Spray Eliminated: The chronic fuel-spray-from-vent-pipe fault was reduced to zero, the most welcomed improvement among operators
- 25-Minute Drop-in Installation: The JY-219A directly replaced the original gas-oil separator with excellent interchangeability, minimizing station downtime
- 8-Month Field-Validated Operation: Cleaner fuel noticeably reduced engine exhaust smoke across the 114 tractors and 78 harvesters served by the station
Case Study
Stage 1 · Customer Problem
📋 Customer Problem
A large state-owned farm engaged in scaled-up agricultural cropping operates 114 tractors, 78 harvesters and an on-site diesel fueling station. The station's original gas-oil separator could only remove free water and coarse debris, leaving fine contaminants to pass straight through the dispenser nozzle into machinery tanks — creating a cascade of field failures:
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Severe Nozzle Burnout
Fuel dispenser nozzles were burning out at a rate of 230 units per year. Fine particulates and gums in the diesel abraded and clogged nozzle internals, driving constant replacement and interrupting refueling.
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Excessive Impurities & Gums
Delivered diesel carried high levels of particulate contamination and oxidized gums. The gas-oil separator had no means of capturing sub-micron solids or dissolved/asphaltene gums.
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Dispenser Vent Spray
Contaminant buildup in the separator caused the dispenser's vent pipe to spray fuel outward — a safety, environmental and housekeeping hazard that operators complained about constantly.
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High Maintenance Costs
Repeated nozzle replacement, separator servicing and machine fuel-system repairs consumed a large share of the equipment-management budget, with no end in sight under the existing setup.
Stage 2 · Fuel Analysis · NEW
🔬 Fuel Analysis
Fuel samples drawn from the station dispenser (downstream of the original gas-oil separator) confirmed that the separator was passing fine particulates, gums and free water directly into equipment tanks:
| Metric | Before Treatment | After Treatment | Improvement |
|---|
| ISO 4406 Cleanliness | ~23/21/18 | 14/12/9 | ~9 levels ↑ |
| Free Water (ppm) | ~150 | ≤50 | ~67% ↓ |
| Visual Appearance | Cloudy | Clear, bright | — |
| TAN (mgKOH/g) | ~0.35 | ~0.12 | ~66% ↓ |
| Particle Composition | Large amounts of impurities & gums | Trace | Eliminated |
Values are representative of the farm's on-site station conditions (bulk delivery, short settling time, gas-oil-separator-only treatment). The large ISO jump reflects the JY-219A's 2 μm nominal pore geometry and synergistic water removal at the final delivery point.
Stage 3 · Solution
🛠️ Solution & System Configuration
Jingyuan supplied the JY-219A diesel polisher, installed directly inside the fuel dispenser in place of the original gas-oil separator. The drop-in design delivered true point-of-dispense fine filtration with negligible retrofit effort:
Model
JY-219A Diesel Polisher
Flow Rate
20–40 L/min (single dispenser)
Membrane
Polymer Rigid Composite, 2 μm nominal
β Value
≥200 at rated pore size
Operating Pressure
0.2–0.4 MPa
Installation
Dispenser end, replaces gas-oil separator (25 min)
Water Removal
Oleophilic-hydrophobic synergistic separation
Regeneration
Gas-pulse regeneration (brief 5-15 min safety pause)
Maintenance
Cleanable membrane, ~every 100 tons filtered
Key design decisions: Installing the polisher at the dispenser — the very last component before the nozzle — guarantees that every litre entering a tractor or harvester tank has passed through 2 μm high-efficiency capture, regardless of upstream tank or delivery contamination. The cleanable membrane (cleaned roughly every 100 tons of diesel) eliminates disposable-cartridge procurement, and the gas-oil-separator form factor allowed a 25-minute swap with excellent interchangeability.
Stage 4 · Results
📈 Quantified Results
92%
Nozzle Failure Reduction
| Metric | Before | After | Improvement |
|---|
| Annual Nozzle Damage | 230 units/year | 18 units/year | 92% ↓ |
| Dispenser Vent Spray | Frequent fault | 0 incidents | Eliminated |
| ISO 4406 Cleanliness | ~23/21/18 | 14/12/9 | ~9 levels ↑ |
| Engine Exhaust Smoke | Heavy | Noticeably lighter | Reduced |
| Filter Maintenance | Disposable cartridges | Cleanable membrane (100 t cycle) | Reusable |
Over 8 months of continuous operation, the station recorded only 18 damaged nozzles against a prior baseline of 230 per year, and the vent-pipe spray fault dropped to zero — the improvement operators valued most. Lighter engine exhaust smoke across the served fleet confirmed cleaner combustion downstream of point-of-dispense filtration.
Stage 5 · Lessons Learned · NEW
💡 Lessons Learned
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Key Success Factor
Dispenser-end fine filtration is the decisive intervention point. By polishing diesel at the final delivery point — the nozzle — every drop entering machinery tanks is guaranteed clean, regardless of upstream tank or bulk-delivery contamination. The 2 μm nominal membrane caught the fine particulates and gums the gas-oil separator could never retain, directly cutting nozzle burnout by 92%.
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Common Pitfall
Traditional gas-oil separators are designed only to remove free water and coarse debris; they cannot capture fine particles (sub-5 μm) or oxidized gums. Relying on them as the sole dispenser-stage treatment leaves HPCR fuel systems exposed — the 230-nozzles-per-year burnout rate was the direct evidence of this gap.
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Replication Advice
Directly applicable to all farm self-service fueling stations and agricultural cooperatives running their own diesel dispensers. The gas-oil-separator form factor makes the JY-219A a 25-minute drop-in retrofit with minimal disruption, while the cleanable membrane (100-ton cycle) delivers near-zero consumable cost — ideal for multi-dispenser stations serving large machinery fleets.
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Customer feedback
After installing the Jingyuan JY-219A diesel polisher on our fuel dispenser, we have never had fuel spray out of the vent pipe again — this is what users appreciate most. Removing the original gas-oil separator and fitting this device took only 25 minutes; interchangeability is excellent. After filtration, engine exhaust smoke is noticeably reduced, and nozzle burnouts have dropped sharply.
Mining & Construction
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