How AODD Pumps Can Satisfy All Demands in Mining Operations

เพรสเชอร์เกจ is considered one of the world’s oldest industries, tracing its roots back to these prehistoric days when someone grabbed a digging instrument and began burrowing into the bottom. In ไดอะแฟรม ซีล since, mining has grown into one of many world’s most essential and widespread business enterprises, with operations unfold across the globe whereas tasked with recovering an virtually inexhaustible listing of useful commodities.
In reality, based on 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.three billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian international locations accounted for 58 p.c of the 2018 production, with North America second at 15.1 %, adopted by Europe (8 percent), Oceania (6.eight percent), Latin America (6.three 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) were the most prolific producers, with their total 51.1 p.c of manufacturing more than the rest of the world mixed.
This implies that the mining trade is a robust one, with solid development expected to proceed within the coming years in plenty of areas of the world. It additionally signifies that mining operations will continue to rely on pumping technologies that supply sturdy, reliable, and safe service in a selection of crucial liquid-handling operations. This white paper will illustrate why positive displacement air-operated double-diaphragm (AODD) pumps may be the finest choice for many of these purposes.
THE CHALLENGE

While mining would possibly seem like nothing greater than a rough-and-tumble operation—holes are dug by heavy machinery or with explosives, opening the hidden ode to access from above—there are, in fact, many advanced and sometimes delicate operations that should be carried out properly if the mining operation is to perform at its highest level of efficiency.
From a macro standpoint, this requires a pumping know-how that may function reliably in harsh and distant areas, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and also one which is in a position to be maintained and repaired in order that downtime is lessened. The pumps must also be gentle enough to be manually moved from location to location inside the mine itself.
For many years, a popular alternative to be used in these situations was centrifugal pumps. While centrifugal pumps are in a position to create the excessive move rates which may be required, they have a variety of operational “pain points” that hamper their use in mining applications: an lack of ability to self-prime or run dry; special seals needed to forestall leaks; special linings needed to deal with solids; excessive motor speeds of up to 1,800 rpm; and relatively high maintenance necessities and costs, especially when charged with transferring solid-heavy liquids.
Another popular selection has been the progressive cavity pump, but, like centrifugal pumps, they have a variety of operational shortcomings. These include an incapability to consistently deal with liquids with high levels of abrasives, which ends up in elevated upkeep costs, wear on costly stators and rotors that can finally need to be changed, and overall larger purchase, working, and repair/replacement prices.
Here are a few of the particular 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 filled with particulates that can be as giant as 0.12 to 0.16 inches in measurement. If used in this application, centrifugal pumps require special materials of construction, which can be value prohibitive, to guard in opposition to impeller wear brought on by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely affects their degree of performance on this utility.
General service: For frequent liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip traces, operate at low speeds whereas nonetheless delivering high move charges, and be straightforward to maintain 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 usually demands a need to use special mechanical seals, which can lead to exorbitant upkeep, restore, and replacement costs.
Press filter: Press filters are used to wash the liquids that are produced in the mines and, once more, centrifugal pumps can fall short on this software as a result of the solid-laden liquid can harm the pump’s internals except special, more expensive materials of development or linings are used. Also, the character of press-filter operation creates a powerful discharge-pressure variation that can force the centrifugal pump to operate away from its best effectivity point (BEP), resulting in excessive vibration and radial masses that may lead to shortened service life. A resolution to that is the incorporation of variable frequency drives (VFDs) and controllers, but these are costly and can negatively have an effect on the cost-effectiveness of the operation.
Product switch: This comes in all varieties in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy equipment, recent and fouled water, and any chemicals which are required. In each instance, there is the chance that the pump shall be pressured to run dry as the truck or storage vessel is emptied, while discharge-pressure variation can even generate excessive vibration and radial hundreds. 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 still can not totally defend in opposition to a catastrophic failure.
THE SOLUTION

While centrifugal pumps—despite their popularity—have confirmed to not be the simplest solution in many liquid-handling applications in mining, one pump technology that has proven to be an optimum alternative is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and security for mining personnel and the environment.
AODD pumps are capable of carry out successfully in mining functions because their method of operation allows them to easily deal with variable flow charges and pressures, whereas being dry-run and line-stripping succesful, and nimble enough to transfer liquids that are shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump options few shifting parts and comparably decrease speeds than different pump applied sciences, which improves reliability and simplifies maintenance, while the pump’s seal-less building ends in 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 are available in each metallic (most commonly aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, while a big 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 can additionally end in optimized efficiency at many levels. The capability to characteristic AODD pumps in a variety of purposes, from primary common use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps may also be less costly to function, especially those fashions which would possibly be outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most elementary, AODD pumps excel within the typical rugged and harsh working situations discovered in the world’s mines, which reduces breakdown incidents together with corresponding downtime and repair prices.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years in the past, has been dedicated to creating technologies that meet the wants of mining operations. Today, Wilden presents three AODD pump fashions which are constructed to excel in mining applications, available in ductile iron, cast iron, aluminum, polypropylene and Kynar materials of development:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been constructed for use in functions that require the handling of liquids that includes massive solids. The Brahma pumps have a unique top-inlet/bottom-discharge move orientation and flap valves that enable the passage of large solids with no risk that harm will happen on account of product entrapment or the settling of solids inside the pump’s internal move paths. Brahma pumps can be found 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 scale back air consumption by up to 60 %. The T810 and T1510 models are powered by the Turbo-Flo™ ADS, the industry’s first air motor for AODD pumps. The flow-rate range 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 functionality starting from 2 to 3 inches.
Stallion® Series: The Stallion pumps function a clamped design with carrying handles for light-weight portability. Their design options giant inside clearances and flow-through paths for easy passage of large solids with no likelihood for clogging. An altered ball/seat check-valve assembly further enables solids passage, whereas a polyurethane display base at the inlet will increase the pump’s sturdiness. The PS4, PS8, and PS15 (1.5-, 2-, and 3-inch) models are powered by a Pro-Flo SHIFT ADS, with the T4, T8, and T15 (1.5-, 2-, and 3-inch) pumps that includes the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the hardest environments. Flow rates amongst the six fashions vary from 57 gallons per minute to 232 gallons per minute at working pressures as much as a hundred twenty five psi. Solids sizes that can be handled vary from half of to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps feature clamped or bolted configuration. Their design options different chamber materials, including metallic and plastics, even Kynar, which is capable of dealing with high ranges of abrasive materials. The Pro-Flo SHIFT can additionally be essentially the most efficient AODD pump out there, able to reducing up to 60 % air consumption. This makes it the best 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 in a place 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, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range offers customers the widest selection of diaphragms available on the market, all of that are capable of providing extended imply time between failure (MTBF) for optimized uptime with reduced maintenance, restore, and replacement prices.
All of those capabilities make AODD pumps the best alternative for the aforementioned frequent liquid-handling applications in mining: dewatering, basic service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION

In abstract, Wilden AODD pumps are the best option for mining functions as a outcome of they provide considerable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, together with increased operational safety and a discount in maintenance/repair prices that can be incurred by pumps that aren’t designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform different AODD technologies in different vital ways: simple design with the lowest variety of elements for quicker, simpler, and safer repairs and the lowest number of spare components to inventory; current improvements in supplies of construction that improve the pump’s MTBF; and improved efficiency via the use of the Pro-Flo SHIFT ADS, which ultimately leads to sooner product switch with lower air consumption. Wilden also continues to innovate by way of the event of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which enhance service life and safety whereas not compromising the handling of challenging liquids.
FOR MORE INFORMATION

Fernando Meneses is the regional manager North Latin America for Wilden, a leading manufacturer of air-operated double-diaphragm (AODD) pumps. He could be reached at fernando.meneses@psgdover.com. Wilden is a product brand of PSG®, a Dover firm. PSG is comprised of several leading pump firms, 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.
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