How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is amongst the world’s oldest industries, tracing its roots back to those prehistoric days when somebody grabbed a digging instrument and began burrowing into the bottom. In the numerous millennia since, mining has grown into one of many world’s most essential and widespread industrial enterprises, with operations spread across the globe whereas tasked with recovering an virtually inexhaustible list of valuable commodities.
In reality, in accordance with the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined merchandise were recovered in 2018, up from 11.three billion metric tons in 2000 and almost double the 9.6 billion metric tons in 1985. Asian nations accounted for 58 % of the 2018 production, with North America second at 15.1 percent, followed by Europe (8 percent), Oceania (6.8 percent), Latin America (6.three 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) have been the most prolific producers, with their whole fifty one.1 % of manufacturing more than the the rest of the world combined.
This signifies that the mining trade is a powerful one, with solid growth expected to continue in the coming years in plenty of regions of the world. It additionally signifies that mining operations will continue to rely on pumping applied sciences that offer robust, reliable, and protected service in numerous crucial liquid-handling operations. This white paper will illustrate why positive displacement air-operated double-diaphragm (AODD) pumps could be your finest option for so much of of these functions.
THE CHALLENGE
While mining would possibly appear to be nothing more 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 reality, many advanced and sometimes delicate operations that must be performed correctly if the mining operation is to carry out at its highest stage of efficiency.
From a macro standpoint, this requires a pumping expertise that can function reliably in harsh and distant places, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and likewise one which is ready to be maintained and repaired in order that downtime is lessened. The pumps should even be mild sufficient to be manually moved from location to location throughout the mine itself.
For many years, a popular alternative for use in these conditions was centrifugal pumps. While centrifugal pumps are in a place to create the high circulate charges which are required, they have a number of operational “pain points” that hamper their use in mining functions: an inability to self-prime or run dry; special seals needed to prevent leaks; particular linings needed to handle solids; high motor speeds of as a lot as 1,800 rpm; and comparatively excessive upkeep requirements and prices, especially when charged with transferring solid-heavy liquids.
Another popular selection has been the progressive cavity pump, however, like centrifugal pumps, they’ve a quantity of operational shortcomings. These embrace an lack of ability to consistently handle liquids with excessive ranges of abrasives, which leads to increased upkeep prices, wear on expensive stators and rotors that may eventually must be changed, and overall greater purchase, working, and repair/replacement costs.
Here are a number of the particular liquid-transfer operations that happen in a mine and the ways in which some pump technologies can fall quick in satisfying them:
Mine dewatering: Removing excess produced water from the mine is a important 24/7/365 operation and the water that is recovered is commonly full of particulates that can be as giant as zero.12 to zero.sixteen inches in size. If used on this utility, centrifugal pumps require particular materials of construction, which can be price prohibitive, to protect against impeller put on caused by the abrasive particles. Centrifugal pumps are also not dry-run capable, which adversely impacts their stage of efficiency in this utility.
General service: For widespread liquid-handling functions, you need an easy-to-operate pump that reliably can run dry, strip traces, operate at low speeds whereas nonetheless delivering high move rates, and be simple to keep up and repair. Centrifugal pumps merely do not 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 sometimes demands a necessity to use special mechanical seals, which might result in exorbitant upkeep, restore, and alternative costs.
Press filter: Press filters are used to wash the liquids which might be produced in the mines and, once more, centrifugal pumps can fall short in this utility because the solid-laden liquid can injury the pump’s internals until special, costlier materials of building 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 greatest effectivity level (BEP), resulting in high vibration and radial masses that may result in shortened service life. A answer to this 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 trucks with new and used oil for the heavy machinery, contemporary and fouled water, and any chemicals which are required. In every instance, there may be the chance that the pump will be pressured to run dry because the truck or storage vessel is emptied, whereas discharge-pressure variation can also generate excessive vibration and radial hundreds. As previously illustrated, เกจวัดน้ำยาแอร์refco cannot run dry, so that they want protection from this situation or the addition of particular seals. However, all of these 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 simplest solution in plenty of liquid-handling functions in mining, one pump expertise that has proven to be an optimum alternative is AODD—in terms of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and safety for mining personnel and the surroundings.
AODD pumps are capable of perform successfully in mining functions as a outcome of their methodology of operation allows them to simply handle variable flow rates and pressures, whereas being dry-run and line-stripping succesful, and nimble enough to transfer liquids which would possibly 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 shifting elements and comparably lower speeds than different pump technologies, which improves reliability and simplifies maintenance, whereas the pump’s seal-less construction results in fewer leaks, which is a critical consideration when dealing with the many hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps are available in each metallic (most commonly aluminum, ductile iron and cast iron) and plastic (polypropylene and PVDF) housing constructions, while a huge selection of elastomers can be used within the diaphragms, which eliminates many chemical-compatibility considerations.
A broad variety of AODD pump configurations present operational flexibility that may also end in optimized performance at many levels. The ability to feature AODD pumps in a variety of applications, from primary general use to delicate chemical-handling processes, allows operators to more cost-effectively outfit their mines. AODD pumps can also be less costly to operate, particularly these fashions which are 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 in the world’s mines, which reduces breakdown incidents together with corresponding downtime and restore costs.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping principle sixty-five years in the past, has been devoted to creating technologies that meet the needs of mining operations. Today, Wilden provides three AODD pump models which are constructed to excel in mining functions, available in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of development:
Brahma® Series: The Brahma pumps, which feature a bolted configuration, have been built for use in applications that require the dealing with of liquids that includes large solids. The Brahma pumps have a unique top-inlet/bottom-discharge circulate orientation and flap valves that enable the passage of enormous solids with no risk that injury will happen on account of product entrapment or the settling of solids inside the pump’s inside circulate 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 reduce 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 capability ranging from 2 to 3 inches.
Stallion® Series: The Stallion pumps characteristic a clamped design with carrying handles for lightweight portability. Their design features giant internal clearances and flow-through paths for simple passage of large solids with no probability for clogging. An altered ball/seat check-valve assembly additional enables solids passage, whereas a polyurethane display screen 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 that includes the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the hardest environments. Flow charges amongst the six fashions vary from 57 gallons per minute to 232 gallons per minute at working pressures up to 125 psi. Solids sizes that can be dealt with range from 1/2 to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps feature clamped or bolted configuration. Their design features completely different chamber materials, including steel and plastics, even Kynar, which is capable of dealing with excessive levels of abrasive materials. The Pro-Flo SHIFT can be the most efficient AODD pump out there, able to lowering up to 60 p.c air consumption. This makes it the greatest 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 big selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of supplies, corresponding to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range offers users the widest selection of diaphragms available on the market, all of which are capable of offering prolonged imply time between failure (MTBF) for optimized uptime with reduced upkeep, restore, and substitute costs.
All of those capabilities make AODD pumps the perfect selection for the aforementioned common liquid-handling functions in mining: dewatering, common service, corrosive-handling, filter press, and daily product switch.
CONCLUSION
In summary, Wilden AODD pumps are the best option for mining applications as a outcome of they offer considerable 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 handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform different AODD technologies in different important methods: easy design with the bottom variety of parts for faster, easier, and safer repairs and the bottom number of spare parts to stock; recent improvements in supplies of construction that improve the pump’s MTBF; and improved efficiency by way of using the Pro-Flo SHIFT ADS, which ultimately ends in faster product switch with decrease air consumption. Wilden also continues to innovate by way of the development of the next-generation Chem-Fuse and EZ-Install diaphragms, both of which enhance service life and security while not compromising the dealing with 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 could be reached at fernando.meneses@psgdover.com. Wilden is a product model 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 more info, go to www.wildenpump.com or www.psgdover.com.
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