Solutions / Multiple JY-G100 Mobile Filters Protect West African Construction Fleet
Mining & Construction
Multiple JY-G100 Mobile Filters Protect West African Construction Fleet
Diesel Purification (Construction Machinery)
Key outcomes
- Reduced Injector Failure Rate: Effectively reduces injector nozzle failure rate
- Improved Equipment Uptime: Effectively increases equipment effective operating time
- Saved Cartridge Consumable Costs: Effectively reduces vehicle-mounted secondary filter cartridge consumable costs
Case Study
Stage 1 ยท Customer Problem
๐ Customer Problem
A large-scale infrastructure construction contractor in a West African country owns over 200 excavators, bulldozers, and loaders, widely distributed across road, mining, and water conservancy project sites. In the West African field environment, diesel quality has always been a challenge for fleet management:
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High Sand/Dust Content
Local diesel easily mixes with fine dust during storage and transport, causing the fuel to appear cloudy.
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HPCR System Sensitivity
Advanced construction machinery uses HPCR engines sensitive to micron-level particles; inferior fuel causes injector seizure and premature fuel pump failure.
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Frequent Downtime Losses
Machinery frequently goes down due to fuel system failures, causing significant delay penalties on time-sensitive projects.
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High Maintenance Costs
Frequent OEM filter replacement and air-freighting precision spare parts from China result in high operating costs.
Stage 2 ยท Fuel Analysis ยท NEW
๐ฌ Fuel Analysis
Fuel sampling from the field fueling vehicles and site storage revealed severe particulate contamination from the dusty West African environment:
| Metric | Before Treatment | After Treatment | Improvement |
|---|
| ISO 4406 Cleanliness | ~24/22/19 | 13/10/7 | 5โ6 levels โ |
| Free Water (ppm) | ~200 | โค50 | 75% โ |
| Visual Appearance | Cloudy, dusty | Clear, bright | โ |
| TAN (mgKOH/g) | 0.20 | 0.08 | 60% โ |
| Particle Composition | Fine dust/sand, mineral particles, wear metals | โฅ99% removed at โฅ5 ฮผm | 99% โ |
Values are representative based on West African field conditions (high ambient dust, open storage, multiple dispersed project sites). The magnetic pre-filter captures ferrous wear metals, while the rigid composite membrane removes fine dust down to the HPCR-safe range.
Stage 3 ยท Solution
๐ ๏ธ Solution & System Configuration
The customer imported multiple JY-G100 mobile diesel filter units in bulk, implementing a mandatory "purify upon fueling" standard. The compact trolley design is placed directly alongside field fueling vehicles, performing final precision filtration before fuel enters machinery tanks.
Model
JY-G100 (Mobile Trolley)
Flow Rate
50 L/min (3 mยณ/h)
Membrane
Polymer Rigid Composite + Magnetic pre-filter (5000 Gs), 5 ฮผm nominal
ฮฒ Value
โฅ200 at rated pore size
Operating Pressure
0.2โ0.4 MPa
Regeneration
Gas-pulse regeneration (brief 5-15 min safety pause)
Explosion-Proof
IP54 industrial enclosure (field mobile)
Deployment
Field fueling vehicles, multi-site parallel
Key design decisions: The 50 L/min flow rate guarantees filtration precision without extending the fueling wait time per machine. The dual-stage magnetic adsorption (5000 Gs) + rigid composite membrane intercepts fine dust and ferrous wear metals while synergistically removing trace free water, ensuring the fuel entering excavator tanks is clean. The compact trolley design follows the fleet across dispersed project sites, enabling multi-device parallel operation.
Stage 4 ยท Results
๐ Quantified Results
~68%
Injector Failure Reduction
50 L/min
Flow Rate per Unit
200+
Fleet Machines Protected
| Metric | Before | After | Improvement |
|---|
| ISO 4406 Cleanliness | ~24/22/19 | 13/10/7 | 5โ6 levels โ |
| Injector Nozzle Failures | Frequent seizure | Significantly reduced | ~68% โ |
| Engine Black Smoke / Power Loss | Frequent | Significantly reduced | โ |
| Annual Fuel System Repair Cost/Unit | High | Significantly decreased | โ |
| OEM Filter Replacement + Air Freight | Frequent, high logistics cost | Eliminated (3-year membrane life) | 100% โ |
After introducing the JY-G100 system, the contractor's fleet performance noticeably improved. The previously frequent engine "black smoke," starting difficulty, and insufficient power phenomena have been significantly reduced. Statistical data shows a significant decrease in annual fuel system repair costs per unit. Currently, these units have become standard equipment at the enterprise's various project sites in West Africa, not only protecting machinery assets but also ensuring the on-time completion of key projects.
Stage 5 ยท Lessons Learned ยท NEW
๐ก Lessons Learned
โ
Key Success Factor
The mandatory "purify upon fueling" standard enforced by deploying multiple JY-G100 mobile units directly alongside field fueling vehicles. Performing final precision filtration immediately before fuel enters the tank โ combined with the compact trolley mobility that follows the fleet across dispersed road, mining, and water conservancy sites โ ensured every machine received clean fuel regardless of location.
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Common Pitfall
West African contractors often cope with dusty, inferior fuel by frequent OEM filter replacement and air-freighting precision spare parts from China. This reactive approach is expensive (high logistics cost, weeks-long delivery) and still allows HPCR injector seizure and fuel pump failure. The zero-consumable membrane design with gas-pulse regeneration eliminates both the consumable dependency and the long spare-parts logistics chain.
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Replication Advice
Directly applicable to all construction fleets operating in dusty, remote, or poor-fuel-quality regions. The 50 L/min flow rate guarantees filtration precision without extending fueling wait time per machine. For fleets of 200+ machines across dispersed sites, deploy one JY-G100 per fueling vehicle; the mobile trolley design scales naturally with fleet distribution and project mobility.
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Customer feedback
West African dust and inferior fuel were our main problems, until we introduced this batch of JY-G100 units. Their mobility is strong, and they work stably in harsh construction site conditions. Now our operators no longer worry about excavators stalling mid-route due to dirty fuel, which is crucial for saving costs and ensuring project schedules.
Mining & Construction
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