How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is among the world’s oldest industries, tracing its roots back to these prehistoric days when someone grabbed a digging instrument and started burrowing into the bottom. In the many millennia since, mining has grown into one of many world’s most necessary and widespread commercial enterprises, with operations unfold across the globe while tasked with recovering an virtually inexhaustible list of priceless commodities.
In reality, in accordance with 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 eleven.three billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian nations accounted for fifty eight p.c of the 2018 production, with North America second at 15.1 p.c, adopted by Europe (8 percent), Oceania (6.8 percent), Latin America (6.3 percent), and Africa (5.3 percent). Individually, China (23 percent), the United States (12.1 percent), Russia (9.2 percent), and Australia (7.2 percent) had been probably the most prolific producers, with their total fifty one.1 % of production more than the relaxation of the world combined.
This means that the mining business is a robust one, with solid growth anticipated to proceed within the coming years in plenty of regions of the world. It also implies that mining operations will continue to rely on pumping technologies that offer sturdy, dependable, and protected service in a number of critical liquid-handling operations. This white paper will illustrate why constructive displacement air-operated double-diaphragm (AODD) pumps could be the solely option for many of those functions.
THE CHALLENGE
While mining may look like nothing more than a rough-and-tumble operation—holes are dug by heavy equipment or with explosives, opening the hidden ode to access from above—there are, in fact, many advanced and generally delicate operations that should be carried out correctly if the mining operation is to perform at its highest stage of efficiency.
From a macro standpoint, this requires a pumping technology that may function reliably in harsh and distant locations, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and likewise one that is ready to be maintained and repaired just so downtime is lessened. The pumps should even be light sufficient to be manually moved from location to location inside the mine itself.
For a few years, a popular alternative to be used in these circumstances was centrifugal pumps. While centrifugal pumps are in a place to create the high flow rates that are required, they’ve a number of operational “pain points” that hamper their use in mining functions: an inability to self-prime or run dry; particular seals wanted to stop leaks; special linings wanted to deal with solids; excessive motor speeds of as much as 1,800 rpm; and relatively high maintenance requirements and prices, especially when charged with transferring solid-heavy liquids.
Another in style alternative has been the progressive cavity pump, but, like centrifugal pumps, they’ve numerous operational shortcomings. These embody an lack of ability to consistently handle liquids with excessive ranges of abrasives, which ends up in increased maintenance costs, put on on costly stators and rotors that may ultimately have to be changed, and total greater buy, operating, and repair/replacement costs.
Here are a few of the specific liquid-transfer operations that take place in a mine and the ways that some pump technologies can fall brief in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a crucial 24/7/365 operation and the water that’s recovered is usually full of particulates that can be as large as zero.12 to 0.16 inches in measurement. If used in this application, centrifugal pumps require particular materials of construction, which may be cost prohibitive, to protect in opposition to impeller wear brought on by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely impacts their level of efficiency in this utility.
General service: For common liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip lines, function at low speeds whereas nonetheless delivering high flow charges, and be easy to take care of and repair. Centrifugal pumps simply don’t possess these capabilities.
Corrosive liquids: Much like solid-laden liquids, corrosive ones can wreak havoc on the wetted parts of centrifugal and progressive cavity pumps. This usually demands a need to make use of special mechanical seals, which can lead to exorbitant maintenance, restore, and alternative costs.
Press filter: Press filters are used to wash the liquids that are produced within the mines and, once more, centrifugal pumps can fall brief in this application because the solid-laden liquid can harm 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 can drive the centrifugal pump to operate away from its best efficiency point (BEP), leading to excessive vibration and radial loads that may result in shortened service life. A answer to that 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 transfer: This comes in all forms in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy machinery, fresh and fouled water, and any chemical compounds which might be required. In เกจวัดถังแก๊ส , there is the danger that the pump might be compelled to run dry because the truck or storage vessel is emptied, while discharge-pressure variation also can generate high vibration and radial loads. As previously illustrated, centrifugal pumps can’t run dry, so they want protection from this situation or the addition of special seals. However, all of those upgrades nonetheless cannot completely defend against a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the most effective answer in many liquid-handling purposes in mining, one pump technology that has proven to be an optimum alternative is AODD—in terms of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and security for mining personnel and the setting.
AODD pumps are capable of perform effectively in mining functions as a end result of their technique of operation permits them to easily handle variable circulate rates and pressures, while being dry-run and line-stripping capable, and nimble sufficient to switch liquids which are shear-sensitive or high-viscosity, as nicely as slurries laden with rocks, pebbles, and other particulates.
The simple design of the AODD pump options few moving elements and comparably lower speeds than different pump applied sciences, which improves reliability and simplifies maintenance, while the pump’s seal-less construction ends in fewer leaks, which is a important consideration when handling the many hard-to-seal, corrosive, or hazardous liquids which may be prevalent in a mining operation. AODD pumps are available in both metal (most generally aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, whereas a big selection of elastomers can be used in the diaphragms, which eliminates many chemical-compatibility issues.
A extensive variety of AODD pump configurations provide operational flexibility that may also end in optimized performance at many levels. The capacity to function AODD pumps in a broad range of functions, from basic general use to delicate chemical-handling processes, permits operators to more cost-effectively outfit their mines. AODD pumps may also be more value effective to operate, particularly those fashions which are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most basic, AODD pumps excel in the typical rugged and harsh operating conditions discovered in the world’s mines, which reduces breakdown incidents along with corresponding downtime and repair prices.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years ago, has been devoted to creating applied sciences that meet the needs of mining operations. Today, Wilden provides three AODD pump models which are built to excel in mining applications, obtainable in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of building:
Brahma® Series: The Brahma pumps, which characteristic a bolted configuration, have been constructed to be used in functions that require the handling of liquids featuring giant solids. The Brahma pumps have a novel top-inlet/bottom-discharge move orientation and flap valves that permit the passage of large solids with no threat that damage will happen as a end result of product entrapment or the settling of solids throughout the pump’s inside circulate 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 up to 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 four Brahma pumps is 166 to 258 gallons per minute at pressures up to one hundred twenty five psi with solids-handling functionality starting from 2 to 3 inches.
Stallion® Series: The Stallion pumps function a clamped design with carrying handles for lightweight portability. Their design options massive internal clearances and flow-through paths for simple passage of large solids with no chance for clogging. An altered ball/seat check-valve assembly additional allows solids passage, while 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 strong ADS design for the toughest environments. Flow rates amongst the six fashions range from fifty seven gallons per minute to 232 gallons per minute at working pressures as much as a hundred twenty five psi. Solids sizes that might be dealt with vary from 1/2 to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps characteristic clamped or bolted configuration. Their design options totally different chamber materials, including metal and plastics, even Kynar, which is able to dealing with high levels of abrasive supplies. The Pro-Flo SHIFT is also probably the most efficient AODD pump in the market, capable of reducing as much as 60 % air consumption. This makes it the most fitted 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 capable of be outfitted with a huge selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of materials, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range offers users the widest number of diaphragms in the marketplace, all of which are capable of offering extended imply time between failure (MTBF) for optimized uptime with decreased maintenance, repair, and substitute costs.
All of those capabilities make AODD pumps the ideal choice for the aforementioned widespread liquid-handling functions in mining: dewatering, general service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the best option for mining purposes as a result of they offer appreciable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, together with elevated operational safety and a discount in maintenance/repair costs that can be incurred by pumps that aren’t designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform different AODD applied sciences in other vital methods: simple design with the bottom number of parts for faster, easier, and safer repairs and the bottom variety of spare components to stock; recent improvements in materials of development that enhance the pump’s MTBF; and improved efficiency via the usage of the Pro-Flo SHIFT ADS, which finally leads to sooner product switch with lower air consumption. Wilden also continues to innovate through 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 challenging liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional supervisor North Latin America for Wilden, a leading manufacturer of air-operated double-diaphragm (AODD) pumps. He may be reached at fernando.meneses@psgdover.com. Wilden is a product brand of PSG®, a Dover company. PSG is comprised of a number of main pump companies, including Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra info, go to www.wildenpump.com or www.psgdover.com.
Share

Leave a Comment