Emergency Replacement Project for Basket Filters in Australian Mining Company

The customer is a medium-sized mining company in Western Australia, Australia, mainly engaged in iron ore mining and preliminary processing. Its beneficiation plant has a critical water supply pipeline that transports circulating water to the screening equipment. The basket filters installed on the original pipeline have suffered corrosion and leakage due to long-term high-load operation, and urgent replacement is required.

• Equipment failure: The original filter housing was corroded and the seal failed, resulting in severe leakage and affecting production.
• Part mismatch: The original equipment is of a European brand and has been discontinued. Therefore, it is impossible to purchase the same model of spare parts.
• Time is tight: The maintenance shutdown window is only 10 days left, and the replacement must be completed by October 10, 2025.
• On-site conditions: The spacing of the pipe flanges is fixed. The new equipment must exactly match the original installation dimensions; otherwise, a large-scale renovation of the pipeline will be required.

• Size: DN125
• European standard: PN25-AS2129
• Flange to flange distance: 420mm (Must be precisely matched; otherwise, installation will not be possible)
• Filter accuracy: 1.5mm
• Material requirements: 316 stainless steel (The original equipment was made of carbon steel. The customer requests an upgrade to this material to enhance corrosion resistance.)
• Interface requirements: It is necessary to be equipped with an exhaust port and a sewage discharge port to facilitate daily maintenance.
• Sealing material: EPDM, suitable for temperature variations in water

• Quick response and confirmation
  Complete the drawing confirmation within 24 hours based on the parameters provided by the customer.
  Ensure that the center distance of the flange is 180mm, the diameter of the flange hole is 18mm, and the 8 holes are evenly distributed, all of which are exactly in line with the original pipeline.
• Material Upgrade and Structural Optimization
  The cylinder is made of 316 stainless steel, with a diameter of 219mm and a thickness of 4mm. Its corrosion resistance far exceeds that of the original carbon steel equipment.
  The interior of the cylinder is polished to reduce the adhesion of impurities and extend the cleaning cycle.
  The flange surface is engraved with specification markings, facilitating on-site identification and management.
• Function configuration is complete and well-structured.
  Equipped with 3/4" internal thread BSP exhaust and drainage outlets, facilitating system exhaust and impurity discharge.
  Add a 1/2" internal pipe as a backup sewage outlet to enhance maintenance flexibility.
• Production and Logistics
  Emergency order production. Complete the manufacturing of 3 filters within 5 days.
  Use quick-release wooden boxes for overall packaging to ensure safe transportation during long-distance sea voyages.
  Ship the goods from the factory to Zhengzhou before October 10th, and then have the customers arrange air transportation to Australia.

• Seamless replacement: After the new equipment arrives, it perfectly matches the existing pipeline without requiring any modifications. The installation is completed on the same day.
• Performance improvement: The 316 stainless steel material significantly enhances corrosion resistance, and is expected to increase the service life by more than twice.
• Production resumption: After the filter replacement, the pipeline system resumed normal water supply, and the beneficiation line was successfully restarted.
• Facility maintenance: New sewage outlets and exhaust vents have been added. On-site workers have reported that it is now much more convenient for daily cleaning and maintenance.

We originally thought that we couldn't find a suitable replacement equipment, and the production line might have to be shut down for a much longer period. But unexpectedly, the Chinese factory was able to provide completely matched customized products within such a short time, and the material quality was even upgraded. When installing, we simply aligned the holes and there were no problems at all. This cooperation has helped us solve a major problem.