How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is considered one of the world’s oldest industries, tracing its roots back to these prehistoric days when somebody grabbed a digging instrument and commenced burrowing into the ground. In the various millennia since, mining has grown into one of many world’s most important and widespread business enterprises, with operations spread throughout the globe whereas tasked with recovering an virtually inexhaustible listing of priceless commodities.
In fact, according to the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined merchandise have been recovered in 2018, up from 11.3 billion metric tons in 2000 and practically double the 9.6 billion metric tons in 1985. pressure gauge น้ำมัน accounted for 58 p.c of the 2018 manufacturing, with North America second at 15.1 %, adopted by Europe (8 percent), Oceania (6.8 percent), Latin America (6.3 percent), and Africa (5.three percent). Individually, China (23 percent), the United States (12.1 percent), Russia (9.2 percent), and Australia (7.2 percent) had been essentially the most prolific producers, with their complete fifty one.1 p.c of production more than the the rest of the world combined.
This implies that the mining business is a strong one, with strong growth expected to continue in the coming years in many areas of the world. It additionally signifies that mining operations will proceed to depend on pumping technologies that offer robust, reliable, and secure service in a quantity of crucial liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps can be your finest option for lots of of those functions.
THE CHALLENGE
While mining may look like nothing greater than a rough-and-tumble operation—holes are dug by heavy machinery or with explosives, opening the hidden ode to entry from above—there are, in fact, many complex and typically delicate operations that should be carried out correctly if the mining operation is to perform at its highest degree of effectivity.
From a macro standpoint, this requires a pumping expertise that can function reliably in harsh and distant areas, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive merchandise, and likewise one that is in a position to be maintained and repaired in order that downtime is lessened. The pumps must also be light sufficient to be manually moved from location to location within the mine itself.
For a few years, a popular alternative for use in these circumstances was centrifugal pumps. While centrifugal pumps are capable of create the high move charges that are required, they have a quantity of operational “pain points” that hamper their use in mining applications: an lack of ability to self-prime or run dry; particular seals wanted to prevent leaks; particular linings needed to handle solids; high motor speeds of up to 1,800 rpm; and comparatively high maintenance requirements and costs, especially when charged with transferring solid-heavy liquids.
Another popular choice has been the progressive cavity pump, however, like centrifugal pumps, they have numerous operational shortcomings. These embody an lack of ability to consistently deal with liquids with excessive levels of abrasives, which results in increased upkeep prices, wear on expensive stators and rotors that may ultimately must be changed, and overall higher buy, working, and repair/replacement prices.
Here are a few of the particular liquid-transfer operations that happen in a mine and the ways that some pump technologies can fall short in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a important 24/7/365 operation and the water that is recovered is usually filled with particulates that might be as massive as zero.12 to zero.sixteen inches in measurement. If used on this software, centrifugal pumps require special materials of building, which could be price prohibitive, to guard in opposition to impeller wear brought on by the abrasive particles. Centrifugal pumps are also not dry-run succesful, which adversely affects their stage of efficiency in this software.
General service: For common liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip traces, operate at low speeds while nonetheless delivering high flow rates, and be simple to maintain up and repair. Centrifugal pumps simply do not possess these capabilities.
Corrosive liquids: Much like solid-laden liquids, corrosive ones can wreak havoc on the wetted components of centrifugal and progressive cavity pumps. This typically calls for a need to make use of particular mechanical seals, which might result in exorbitant maintenance, repair, and alternative prices.
Press filter: Press filters are used to clean the liquids which would possibly be produced in the mines and, once more, centrifugal pumps can fall brief on this software because the solid-laden liquid can injury the pump’s internals except special, more expensive supplies of development or linings are used. Also, the character of press-filter operation creates a strong discharge-pressure variation that may pressure the centrifugal pump to operate away from its finest efficiency point (BEP), leading to excessive vibration and radial loads that can result in shortened service life. A solution to this is the incorporation of variable frequency drives (VFDs) and controllers, but these are expensive and might negatively have an effect on the cost-effectiveness of the operation.
Product switch: This is out there in all types in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy equipment, contemporary and fouled water, and any chemical compounds which are required. In each occasion, there is the risk that the pump might be forced to run dry because the truck or storage vessel is emptied, while discharge-pressure variation also can generate excessive vibration and radial masses. As previously illustrated, centrifugal pumps can’t run dry, so that they want protection from this condition or the addition of special seals. However, all of those upgrades still can’t completely shield in opposition to a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the most effective answer in plenty of liquid-handling purposes in mining, one pump technology that has proven to be an optimum selection is AODD—in terms of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and security for mining personnel and the surroundings.
AODD pumps are able to carry out successfully in mining functions because their methodology of operation permits them to simply handle variable flow charges and pressures, whereas being dry-run and line-stripping succesful, and nimble enough to switch liquids which may be shear-sensitive or high-viscosity, as well as slurries laden with rocks, pebbles, and different particulates.
The simple design of the AODD pump options few moving elements and comparably decrease speeds than other pump applied sciences, which improves reliability and simplifies maintenance, whereas the pump’s seal-less building leads to fewer leaks, which is a important consideration when handling the numerous hard-to-seal, corrosive, or hazardous liquids that are prevalent in a mining operation. AODD pumps can be found in each metal (most commonly aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, whereas a extensive selection of elastomers can be utilized in the diaphragms, which eliminates many chemical-compatibility issues.
A broad variety of AODD pump configurations present operational flexibility that may additionally lead to optimized performance at many ranges. The capability to function AODD pumps in a wide range of applications, from primary general use to delicate chemical-handling processes, permits operators to extra cost-effectively outfit their mines. AODD pumps can additionally be less expensive to function, particularly those fashions which would possibly be outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most basic, AODD pumps excel within the typical rugged and harsh working situations found within the world’s mines, which reduces breakdown incidents along with corresponding downtime and restore costs.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years ago, has been dedicated to creating applied sciences that meet the needs of mining operations. Today, Wilden presents three AODD pump models which would possibly be constructed to excel in mining purposes, out there in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of development:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been built for use in purposes that require the handling of liquids that includes giant solids. The Brahma pumps have a novel top-inlet/bottom-discharge circulate orientation and flap valves that permit the passage of large solids with no danger that harm will occur as a outcome of product entrapment or the settling of solids throughout the pump’s inner flow paths. Brahma pumps are available in two models—PS810 (2-inch) and PS1510 (3-inch)—that are outfitted with the revolutionary Pro-Flo® SHIFT ADS, which has been designed to reduce back air consumption by as much as 60 percent. The T810 and T1510 fashions are powered by the Turbo-Flo™ ADS, the industry’s first air motor for AODD pumps. The flow-rate vary for the 4 Brahma pumps is 166 to 258 gallons per minute at pressures as a lot as one hundred twenty five psi with solids-handling capability starting from 2 to three inches.
Stallion® Series: The Stallion pumps characteristic a clamped design with carrying handles for lightweight portability. Their design options giant internal clearances and flow-through paths for simple passage of huge solids with no probability for clogging. An altered ball/seat check-valve meeting further allows solids passage, whereas a polyurethane display base on the inlet increases the pump’s sturdiness. The PS4, PS8, and PS15 (1.5-, 2-, and 3-inch) fashions are powered by a Pro-Flo SHIFT ADS, with the T4, T8, and T15 (1.5-, 2-, and 3-inch) pumps featuring the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the toughest environments. Flow rates amongst the six fashions range from 57 gallons per minute to 232 gallons per minute at working pressures as much as one hundred twenty five psi. Solids sizes that might be handled range from half of to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design options totally different chamber materials, including steel and plastics, even Kynar, which is capable of dealing with high levels of abrasive materials. The Pro-Flo SHIFT can also be the most efficient AODD pump in the market, able to lowering up to 60 % air consumption. This makes it the finest choice for handling corrosive and abrasive products in mining processes. The pumps have a product range that goes from 1.5 to three inches and flows from 2 to 271 gallons per minute.
All of the Brahma, Stallion, and Pro-Flo SHIFT pumps are able to be outfitted with a extensive array of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of materials, such as Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary gives customers the widest choice of diaphragms on the market, all of which are capable of providing extended imply time between failure (MTBF) for optimized uptime with reduced upkeep, repair, and substitute costs.
All of these capabilities make AODD pumps the ideal alternative for the aforementioned frequent liquid-handling functions in mining: dewatering, general service, corrosive-handling, filter press, and every day product switch.
CONCLUSION
In summary, Wilden AODD pumps are the finest option for mining applications as a result of they provide appreciable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead functionality, together with increased operational safety and a discount in maintenance/repair costs that could be incurred by pumps that are not designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform other AODD applied sciences in different significant ways: simple design with the bottom number of components for faster, easier, and safer repairs and the lowest number of spare elements to inventory; current improvements in supplies of building that increase the pump’s MTBF; and improved efficiency via the usage of the Pro-Flo SHIFT ADS, which finally leads to sooner product transfer with decrease air consumption. Wilden additionally continues to innovate by way of the event of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which improve service life and security while not compromising the handling of difficult liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional manager North Latin America for Wilden, a leading producer of air-operated double-diaphragm (AODD) pumps. He can be reached at fernando.meneses@psgdover.com. Wilden is a product brand of PSG®, a Dover firm. PSG is comprised of a number of leading pump companies, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra data, visit www.wildenpump.com or www.psgdover.com.
Share

Leave a Comment