Case Study: MPG-6099 System Replaces Endress+Hauser in Indonesian Nickel Mine Wastewater Monitoring with 45 Units Deployed

I. Client Background and Requirements: Environmental Monitoring Challenges in Nickel Hydrometallurgy

Indonesia, the world's largest nickel producer contributing 58% of global nickel output, relies on hydrometallurgical processes (HPAL) for 62% of production. The client, a nickel mining group in Sulawesi, operates 3 high-pressure acid leaching lines producing 28,000 tons/year of nickel-cobalt hydroxide. Its mining wastewater and smelting tailings must comply with Indonesia's Ministry of Environment and Forestry Regulation No.18/2023: pH 6.5-9.0, COD ≤80mg/L, TSS ≤70mg/L, with real-time data transmission to the National Mining Environmental Monitoring Platform.

Previously using Endress+Hauser's Proline series, the client encountered three critical issues over two years of operation:

• Inadequate High-Salinity Resistance: Cl⁻ concentrations up to 15,000mg/L in acidic nickel wastewater caused frequent corrosion of Endress+Hauser pH sensor membranes, resulting in 45-day average lifespan and annual replacement costs exceeding USD 80,000;
• High Maintenance Complexity: Weekly disassembly and cleaning of TSS sensors caused >4-hour data gaps per maintenance, violating the Ministry's "continuous data upload" requirement;
• Flow Measurement Inaccuracy: Severe electrode scaling in high-mineral tailwater led to ±8% monthly error in electromagnetic flowmeters, distorting per-ton water environmental cost calculations.

To align with Indonesia's "Nickel Industry Localization Policy" (2024-2030), the client launched the Sparing Project to procure 45 multi-parameter water quality analysis systems, requiring acid resistance, low maintenance, local service support, and seamless DCS integration. The MPG-6099 system with配套 sensors was selected after technical evaluation.

II. Product Features and Advantages: Technical Breakthroughs for Nickel Mining Conditions

1. Specialized Design for Extreme Operating Conditions

• Acid-Resistant pH Sensor: IOT-485-pH sensor features tantalum electrode and PTFE housing, achieving 180-day lifespan in pH 0-14 environments with Cl⁻ ≤20,000mg/L—4x longer than Endress+Hauser units. Built-in temperature compensation (-5℃~130℃) handles 85℃ smelting wastewater;
• Anti-fouling TSS Monitoring: ZDYG-2087-01QX sensor integrates "high-pressure water冲洗 + air purge" dual-cleaning system (configurable 1-24 hour cycles), maintaining ±2% FS accuracy (0-1000mg/L range) in high-viscosity tailwater;
• Dual-Mode Flow Measurement: BQ-OCFM ultrasonic open channel flowmeters (for Parshall flumes) at discharge points eliminate suspended solids clogging, while BQ-ULF-100W wall-mounted ultrasonic flowmeters provide non-contact measurement in process pipelines (DN50-DN3000) with ≤±1.5% error in DN200 pipes.

2. Lifecycle Cost Advantages

• 38% Lower Procurement Cost: At 62% of Endress+Hauser Proline's price point, 45 units delivered USD 980,000 in capital savings;
• 65% Maintenance Cost Reduction: 320-day MTBF (Mean Time Between Failures) reduces annual maintenance from 12 to 4 times per unit, cutting per-unit annual maintenance costs from USD 18,000 to USD 6,300;
• Zero-Cost Data Integration: Native Profibus-DP protocol compatibility with Siemens PCS7 system eliminates need for additional gateways (Endress+Hauser required USD 4,000 protocol converters per unit).

3. Enhanced Anti-Interference Performance

CODS-3000-01 COD sensor employs UV-visible dual-spectroscopy (254nm/546nm) with algorithmic compensation for heavy metal ion (Ni²⁺, Co²⁺) interference, achieving ≤±5% error in 50-1000mg/L COD range—outperforming Endress+Hauser's >12% error under identical conditions.

III. Performance Outcomes and ROI: From Compliance to Productivity Gains

1. Environmental Monitoring Improvements

Since commissioning in November 2024, the 45 systems have achieved:

• Precision pH Control: Neutralized wastewater pH stabilized at 7.2-8.1 with ≤±0.2 fluctuation—60% improvement over Endress+Hauser's ±0.5 variation;
• Enhanced Pollutant Removal: Real-time monitoring optimized lime dosing, increasing COD removal efficiency from 68% to 91% (effluent: 45-65mg/L); TSS reduced from 95mg/L to 38mg/L, meeting Indonesia's "Green Mine" certification standards;
• 99.9% Data Integrity: 150-day continuous operation without data gaps—5.7% improvement over Endress+Hauser's 94.2%—eliminating USD 50,000/month non-compliance penalties.

2. Total Benefits Exceed USD 6 Million

• Direct Cost Savings: Annual maintenance reduced from USD 810,000 to USD 283,500; sensor replacement costs cut from USD 80,000 to USD 22,000/year;
• Chemical and Energy Optimization: 22% reduction in lime consumption (USD 320,000/year savings); 1.45 million kWh annual electricity savings through flow-optimized pump operation;
• Production Capacity Increase: Maintenance downtime reduced from 72 to 9 hours/year, enabling 350 tons/year additional nickel-cobalt hydroxide production valued at USD 4.2 million.

IV. After-Sales Support: Nickel Mining-Specific Service Infrastructure

To address remote mining site challenges, the supplier established:

• Local Service Team: Kendari-based service center with 5 engineers (including 2 Indonesian technicians) providing 2-hour on-site response;
• On-Site Spare Parts Warehouse: 45 sets of sensors and critical components stocked at client's facility enabling <12-hour emergency replacements—83% faster than Endress+Hauser's 72-hour response;
• Certified Training Program: Customized "acid environment monitoring" training for 30 client technicians, covering anti-corrosion maintenance protocols with 100% pass rate and certificates recognized by the Indonesian Mining Association (APBI).

V. Client Testimonial and Industry Impact

The client's Technical Director stated at IMDEX Indonesia 2025: "The MPG-6099 system resolved our extreme environment monitoring challenges with sensor longevity and data stability exceeding expectations, helping us achieve 'Green Mine' certification 6 months ahead of schedule." As of April 2025, the client has recommended the system to 3 affiliated nickel smelters, generating 62 additional orders.

Indonesia's Ministry of Environment Mining Division Director noted during site inspection: "This system's corrosion resistance and reliability set new standards for HPAL wastewater monitoring, with its 45-unit deployment demonstrating Chinese environmental technology's breakthrough in extreme industrial applications."

Case Insight: Amid surging global demand for nickel in new energy industries, wastewater monitoring has evolved from a regulatory compliance burden to a critical productivity enabler. The MPG-6099's success in replacing Endress+Hauser showcases a winning formula for Chinese high-tech exports: extreme condition specialization + localized service infrastructure.