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 began burrowing into the ground. In the various millennia since, mining has grown into one of many world’s most necessary and widespread commercial enterprises, with operations spread throughout the globe whereas tasked with recovering an nearly inexhaustible listing of priceless commodities.
In reality, based on the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined products were recovered in 2018, up from eleven.three billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian countries accounted for fifty eight % of the 2018 manufacturing, with North America second at 15.1 p.c, adopted 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 probably the most prolific producers, with their total 51.1 p.c of manufacturing greater than the remainder of the world mixed.
This signifies that the mining trade is a powerful one, with solid development expected to continue within the coming years in plenty of regions of the world. It also means that mining operations will continue to depend on pumping applied sciences that offer robust, dependable, and safe service in a quantity of critical liquid-handling operations. This white paper will illustrate why positive displacement air-operated double-diaphragm (AODD) pumps can be the best choice for many of these applications.
THE CHALLENGE
While mining may look like nothing more 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 advanced and sometimes delicate operations that must be performed correctly if the mining operation is to carry out at its highest stage of effectivity.
From a macro standpoint, this requires a pumping technology that may function reliably in harsh and remote locations, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and in addition one that is able to be maintained and repaired simply so 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 selection for use in these circumstances was centrifugal pumps. While centrifugal pumps are capable of create the high move charges which might be required, they’ve numerous operational “pain points” that hamper their use in mining applications: an lack of ability to self-prime or run dry; particular seals wanted to forestall leaks; particular linings needed to deal with solids; excessive motor speeds of as much as 1,800 rpm; and relatively excessive maintenance necessities and costs, particularly when charged with transferring solid-heavy liquids.
Another well-liked alternative has been the progressive cavity pump, however, like centrifugal pumps, they have numerous operational shortcomings. These embody an incapability to consistently deal with liquids with excessive ranges of abrasives, which finally ends up in increased maintenance costs, wear on costly stators and rotors that will ultimately need to be changed, and overall higher buy, working, and repair/replacement costs.
Here are some of the specific liquid-transfer operations that happen in a mine and the ways in which some pump applied sciences can fall brief in satisfying them:
Mine dewatering: Removing excess produced water from the mine is a critical 24/7/365 operation and the water that is recovered is commonly filled with particulates that can be as giant as 0.12 to 0.sixteen inches in measurement. If used on this utility, centrifugal pumps require special materials of development, which could be cost prohibitive, to protect towards impeller put on attributable to the abrasive particles. Centrifugal pumps are additionally not dry-run capable, which adversely impacts their stage of efficiency on this application.
General service: For frequent liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip lines, operate at low speeds whereas still delivering excessive move rates, and be straightforward 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 elements of centrifugal and progressive cavity pumps. This typically calls for a need to use special mechanical seals, which can lead to exorbitant upkeep, restore, and substitute prices.
Press filter: Press filters are used to scrub the liquids that are produced in the mines and, once more, centrifugal pumps can fall quick on this software as a outcome of the solid-laden liquid can injury the pump’s internals until particular, costlier 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 best effectivity level (BEP), resulting in 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, however these are expensive and might negatively affect the cost-effectiveness of the operation.
Product transfer: This is out there in all forms 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 would possibly be required. In each instance, there is the risk that the pump will be compelled to run dry as the truck or storage vessel is emptied, whereas discharge-pressure variation also can generate excessive vibration and radial loads. As previously illustrated, centrifugal pumps can’t run dry, in order that they need protection from this condition or the addition of particular seals. However, all of these upgrades nonetheless can’t totally protect towards a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the best solution in many liquid-handling functions in mining, one pump expertise that has proven to be an optimum choice is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and security for mining personnel and the environment.
AODD pumps are capable of perform effectively in mining purposes as a outcome of their technique of operation permits them to simply handle variable circulate charges and pressures, whereas being dry-run and line-stripping succesful, and nimble sufficient to switch liquids that are shear-sensitive or high-viscosity, as well as slurries laden with rocks, pebbles, and other particulates.
The simple design of the AODD pump options few transferring parts and comparably lower speeds than other pump technologies, which improves reliability and simplifies upkeep, while the pump’s seal-less construction results in 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 can be found in each metallic (most commonly aluminum, ductile iron and forged iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad selection of elastomers can be utilized in the diaphragms, which eliminates many chemical-compatibility considerations.
A extensive number of AODD pump configurations present operational flexibility that may additionally end in optimized performance at many levels. The capacity to function AODD pumps in a wide range of applications, from primary general use to delicate chemical-handling processes, permits operators to more cost-effectively outfit their mines. AODD pumps can also be more price effective to operate, especially those fashions which would possibly be 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 situations discovered within 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 ago, has been devoted to developing applied sciences that meet the needs of mining operations. Today, Wilden provides three AODD pump fashions which are constructed to excel in mining applications, obtainable in ductile iron, cast iron, aluminum, polypropylene and Kynar supplies of building:
Brahma® Series: The Brahma pumps, which characteristic a bolted configuration, have been built to be used in purposes that require the handling of liquids that includes large solids. The Brahma pumps have a unique top-inlet/bottom-discharge circulate orientation and flap valves that permit the passage of large solids with no risk that harm will happen on account of product entrapment or the settling of solids throughout the pump’s inner 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 as much as 60 percent. 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 four Brahma pumps is 166 to 258 gallons per minute at pressures up to a hundred twenty five psi with solids-handling functionality ranging from 2 to 3 inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for lightweight portability. Their design features large internal clearances and flow-through paths for simple passage of enormous solids with no likelihood for clogging. An altered ball/seat check-valve assembly additional permits solids passage, while a polyurethane screen base on the inlet will increase the pump’s durability. 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 rates amongst the six fashions vary from fifty seven gallons per minute to 232 gallons per minute at working pressures up to a hundred twenty five psi. Solids sizes that can be dealt with vary from 1/2 to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps feature clamped or bolted configuration. Their design options completely different chamber materials, including metal and plastics, even Kynar, which is capable of handling high levels of abrasive materials. The Pro-Flo SHIFT can additionally be essentially the most efficient AODD pump in the market, able to reducing up to 60 % air consumption. This makes it the best suited choice for dealing with corrosive and abrasive products in mining processes. The pumps have a product range that goes from 1.5 to 3 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 broad array of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of supplies, corresponding to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. เกจวัดแรงดัน gives customers the widest selection of diaphragms on the market, all of that are capable of offering extended mean time between failure (MTBF) for optimized uptime with decreased upkeep, restore, and alternative prices.
All of these capabilities make AODD pumps the ideal choice for the aforementioned common liquid-handling applications in mining: dewatering, basic service, corrosive-handling, filter press, and daily product switch.
CONCLUSION
In summary, Wilden AODD pumps are the best suited choice for mining functions as a end result of they offer considerable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, along with increased operational security and a discount in maintenance/repair prices that can be incurred by pumps that are not designed to deal with 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 components for sooner, easier, and safer repairs and the lowest variety of spare components to inventory; recent enhancements in materials of building that increase the pump’s MTBF; and improved efficiency by way of using the Pro-Flo SHIFT ADS, which finally ends in quicker product switch with decrease air consumption. Wilden additionally continues to innovate via the development of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which enhance service life and safety while not compromising the handling of challenging liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional supervisor North Latin America for Wilden, a quantity one manufacturer of air-operated double-diaphragm (AODD) pumps. He may be reached at fernando.meneses@psgdover.com. Wilden is a product model of PSG®, a Dover firm. PSG is comprised of several main pump companies, including Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For more data, visit www.wildenpump.com or www.psgdover.com.
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