How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is doubtless considered one of the world’s oldest industries, tracing its roots again to those prehistoric days when somebody grabbed a digging instrument and commenced burrowing into the ground. In the many millennia since, mining has grown into one of many world’s most important and widespread industrial enterprises, with operations unfold across the globe whereas tasked with recovering an nearly inexhaustible list of useful commodities.
In fact, according to the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined products were recovered in 2018, up from 11.three billion metric tons in 2000 and practically double the 9.6 billion metric tons in 1985. Asian international locations accounted for fifty eight % of the 2018 production, with North America second at 15.1 p.c, followed 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 probably the most prolific producers, with their whole fifty one.1 percent of production more than the the rest of the world combined.
This signifies that the mining trade is a powerful one, with stable development anticipated to proceed in the coming years in lots of regions of the world. pressure gauge 10 bar implies that mining operations will continue to rely on pumping technologies that offer strong, reliable, and safe service in numerous critical liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps can be the greatest choice for so much of of those functions.
THE CHALLENGE

While mining would possibly appear to be nothing greater than a rough-and-tumble operation—holes are dug by heavy equipment or with explosives, opening the hidden ode to entry from above—there are, in fact, many complex and generally delicate operations that have to be performed properly if the mining operation is to perform at its highest stage of efficiency.
From a macro standpoint, this requires a pumping know-how that can operate reliably in harsh and remote areas, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive products, and likewise one that is able to be maintained and repaired just so downtime is lessened. The pumps should also be gentle enough to be manually moved from location to location within the mine itself.
For many years, a popular selection to be used in these conditions was centrifugal pumps. While centrifugal pumps are in a place to create the high flow rates which would possibly be required, they have a variety of operational “pain points” that hamper their use in mining functions: an lack of ability to self-prime or run dry; particular seals wanted to prevent leaks; special linings needed to deal with solids; high motor speeds of as a lot as 1,800 rpm; and comparatively excessive maintenance requirements and costs, especially when charged with transferring solid-heavy liquids.
Another well-liked alternative has been the progressive cavity pump, however, like centrifugal pumps, they’ve a variety of operational shortcomings. These embrace an inability to constantly handle liquids with high ranges of abrasives, which ends up in increased maintenance costs, wear on costly stators and rotors that will ultimately must be replaced, and overall higher purchase, operating, and repair/replacement costs.
Here are a few of the specific liquid-transfer operations that take place in a mine and the ways in which some pump applied sciences can fall quick in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a crucial 24/7/365 operation and the water that is recovered is usually filled with particulates that can be as giant as 0.12 to 0.16 inches in dimension. If used in this application, centrifugal pumps require special materials of building, which can be cost prohibitive, to protect in opposition to impeller wear attributable to the abrasive particles. Centrifugal pumps are also not dry-run capable, which adversely affects their level of performance on this application.
General service: For frequent liquid-handling functions, you want an easy-to-operate pump that reliably can run dry, strip traces, function at low speeds while nonetheless delivering high flow charges, and be straightforward to maintain 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 components of centrifugal and progressive cavity pumps. This sometimes calls for a necessity to make use of special mechanical seals, which may lead to exorbitant maintenance, restore, and alternative prices.
Press filter: Press filters are used to clean the liquids which might be produced in the mines and, once more, centrifugal pumps can fall brief in this application as a outcome of the solid-laden liquid can injury the pump’s internals until special, dearer materials of construction or linings are used. Also, the character of press-filter operation creates a strong discharge-pressure variation that may drive the centrifugal pump to operate away from its best efficiency point (BEP), leading to excessive vibration and radial loads that may lead to shortened service life. A resolution to this is the incorporation of variable frequency drives (VFDs) and controllers, but these are costly and may negatively affect the cost-effectiveness of the operation.
Product switch: This comes in all types in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy machinery, recent and fouled water, and any chemical compounds that are required. In each instance, there is the risk that the pump shall be forced to run dry because the truck or storage vessel is emptied, whereas discharge-pressure variation also can generate excessive vibration and radial masses. As previously illustrated, centrifugal pumps can not run dry, so they need protection from this condition or the addition of particular seals. However, all of these upgrades still cannot completely protect in opposition to a catastrophic failure.
THE SOLUTION

While centrifugal pumps—despite their popularity—have proven to not be the simplest answer in lots of liquid-handling functions in mining, one pump know-how that has confirmed to be an optimum selection is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and security for mining personnel and the surroundings.
AODD pumps are in a position to perform effectively in mining applications as a end result of their technique of operation allows them to easily deal with variable move rates and pressures, whereas being dry-run and line-stripping capable, and nimble enough to switch liquids which may be shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and different particulates.
The easy design of the AODD pump options few shifting parts and comparably lower speeds than other pump applied sciences, which improves reliability and simplifies upkeep, whereas the pump’s seal-less development leads to fewer leaks, which is a crucial consideration when dealing with the various hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps are available in each steel (most generally aluminum, ductile iron and cast iron) and plastic (polypropylene and PVDF) housing constructions, whereas a wide array of elastomers can be utilized in the diaphragms, which eliminates many chemical-compatibility issues.
A extensive number of AODD pump configurations provide operational flexibility that can additionally lead to optimized efficiency at many ranges. digital pressure gauge to characteristic AODD pumps in a variety of functions, from fundamental common use to delicate chemical-handling processes, permits operators to more cost-effectively outfit their mines. AODD pumps can additionally be less costly to function, particularly those fashions that 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 working circumstances 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 principle sixty-five years ago, has been dedicated to developing applied sciences that meet the needs of mining operations. Today, Wilden offers three AODD pump fashions that are constructed to excel in mining applications, available in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of construction:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been constructed to be used in purposes that require the handling of liquids that includes giant solids. The Brahma pumps have a singular top-inlet/bottom-discharge flow orientation and flap valves that allow the passage of huge solids with no threat that injury will happen because 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 scale back air consumption by as much as 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 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 function a clamped design with carrying handles for lightweight portability. Their design features large inside clearances and flow-through paths for straightforward passage of large solids with no likelihood for clogging. An altered ball/seat check-valve meeting further enables solids passage, whereas a polyurethane screen 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 robust ADS design for the hardest environments. Flow charges amongst the six models range from 57 gallons per minute to 232 gallons per minute at working pressures as a lot as one hundred twenty five psi. Solids sizes that might be handled vary from half of to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design options different chamber materials, together with steel and plastics, even Kynar, which is capable of handling excessive ranges of abrasive materials. The Pro-Flo SHIFT can be essentially the most efficient AODD pump out there, capable of decreasing up to 60 p.c air consumption. This makes it the greatest option 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 broad array of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of supplies, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary gives customers the widest number of diaphragms in the marketplace, all of which are able to offering extended mean time between failure (MTBF) for optimized uptime with lowered maintenance, repair, and substitute prices.
All of these capabilities make AODD pumps the perfect selection for the aforementioned common liquid-handling purposes in mining: dewatering, common service, corrosive-handling, filter press, and daily product switch.
CONCLUSION

In abstract, Wilden AODD pumps are the finest option for mining purposes as a end result of they offer appreciable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, together with increased operational security and a discount in maintenance/repair prices that can be incurred by pumps that are not designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform different AODD technologies in other important ways: easy design with the lowest variety of elements for sooner, less complicated, and safer repairs and the lowest number of spare parts to stock; recent enhancements in materials of development that enhance the pump’s MTBF; and improved effectivity by way of the utilization of the Pro-Flo SHIFT ADS, which in the end leads to sooner product transfer with lower 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 quantity one producer 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 firm. PSG is comprised of a quantity of leading pump companies, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For more data, go to www.wildenpump.com or www.psgdover.com.
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